User manual KTM 105 XC 2008

[. . . ] OWNER'S MANUAL 2008 85 SX, XC 105 SX, XC 3211224en INTRODUCTION » Now you own a modern motorcycle that you and your youngster will certainly enjoy, provided that you service and maintain it properly. Please insert the serial numbers of the motorcycle below Chassis number Engine number Stamp of dealer All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models. [. . . ] The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks for a harder spring. 40-215 SPRING RATE 35-215 30-215 40 45 50 55 60 65 70 35 Rider weight inclusive gears in kilogram Checking the basic setup of the telescopic fork Front fork 85/105 SX/XC Overview of the telescopic fork springs If your child weights less than 45 kg or more than 55 kg, have your KTM workshop mount suitable fork springs. The type number of the telescopic fork is embossed on the inside of the fork leg. According to our experience, the damping rate of the compression stage can remain unchanged. The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks for a harder spring. 3, 6 N/mm SPRING RATE 3, 4 N/mm 3, 2 N/mm 40 45 50 55 60 65 70 35 Rider weight inclusive gears in kilogram ENGLISH 19 The precise riding sag of the telescopic fork cannot be determined for various reasons. If your telescopic fork bumps frequently (hard end stop during compression), you should install harder fork springs to avoid damaging the telescopic fork and frame. MAINTENANCE WORK ON CHASSIS AND ENGINE » Checking chain tension 5-6 cm Support the motorcycle on the center stand or side stand, respectively. Push the chain upwards from the end of the chain sliding component until the upper part of the chain is tensioned. ­ If the chain is too tight the secondary transmission components (chain, sprockets, bearings of the transmission and of the rear wheel) will be put under additional strain that can, in addition to premature wear, also cause chain breakage. ­ If the chain is not tight enough it can slip off the sprockets and block the rear wheel or damage the engine. ­ In both cases the rider is very likely to lose control of the motorcycle. A ENGLISH 1 20 2 3 Correct chain tension Loosen collar nut [1], loosen lock nuts [2], and turn right and left adjusting screws [3] equally far. Before tightening the collar nut, verify that the chain adjusters [4] are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel. ­ If you don't happen to have a torque wrench at hand, make sure you have the tightening torque corrected by a KTM dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle. ­ Tighten the collar nut with the required torque. 2 3 NOTE: The large adjusting range of the chain adjusters (32mm) allows you to use different secondary ratios in combination with the same chain length. The chain adjusters [4] can be rotated by 180°. 4 Always mount the chain tensioner equally aligned. Chain maintenance (SX) For long chain life, good maintenance is very important. The chain should be cleaned in fireproof solvent regularly and afterwards treated with hot grease or chain spray (Motorex Chainlube 622). Chain maintenance (XC) Maintenance of the O-ring chain is reduced to a minimum. Residual used grease must be removed prior to lubrication (Motorex Chain Clean 611). After drying, use a chain spray specially designed for O-ring chains (Motorex Chainlube 622). No lubrication is allowed to reach the rear tire or the brake disks, otherwise the road adherence and the rear wheel braking effects would be strongly reduced and the motorcycle could easily lose control. When mounting the chain masterlink clip, the closed side of the masterlink clip must point in running direction. Also check sprockets and chain guides for wear, and replace if necessary. MAINTENANCE WORK ON CHASSIS AND ENGINE » General information about KTM disc brakes BRAKE CALIPERS: If the front brake caliper is removed, the screws must be secured with Loctite 243 when mounted and tightened to 25 Nm. BRAKE FLUID RESERVOIRS: The brake fluid reservoirs on front and rear wheel brakes have been designed in such a way that even if the brake pads are worn it is not necessary to top up the brake fluid. If the brake fluid level drops below the minimum level either the brake system has a leak or the brake pads are completely worn. [. . . ] Heavily soiled parts should also be cleaned with the help of a paint brush. ­ Before cleaning with water, plug the exhaust pipe to prevent water ingress. ­ After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Then take a short drive until the engine has reached its operating temperature, and also operate the brakes. [. . . ]