KTM 3214489en Manual

SETUP INSTRUCTIONS 2022
85 SX
Art. no. 3214489en

INTRODUCTION
*3214489en*
3214489en
05/2021
INTRODUCTION
Perform the work described in these setup instructions before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make
changes in the interest of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop
are not specified here. It is assumed that the work will be performed by a fully trained mechanic.
All specifications contained herein are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right
to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc.,
without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop produc-
tion of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from fig-
ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that
does not belong to the regular scope of supply.
© 2021 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission
of the copyright owner.
ISO 9001(12 100 6061)
KTM applies quality assurance processes that lead to the highest possible product quality as
defined in the ISO 9001 international quality management standard.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
85 SX 19/16 (F6001V9)
85 SX 17/14 (F6001V8)

1 MEANS OF REPRESENTATION
2
1.1 Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates a resistance measurement.
Indicates the end of an activity including potential rework.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name®Indicates a protected name.
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
are explained in the glossary.

SETUP 2
3
2.1 Unpacking and setting up the vehicle
E00850-10
–Open the box.
–Remove the cable tie and wooden frame.
Info
An assistant prevents the motorcycle from falling over.
To avoid damaging the motorcycle during the setup,
leave the protective film on the vehicle until you have
finished.
–Remove the separate enclosure and unpack it. Check the sepa-
rate enclosure for completeness.
Info
The procedure for missing components is described in
the Customer Service Manual.
402050-01
–Have a lift stand available.
Lift stand (78929955100)
–Together with an assistant, take the vehicle off the pallet.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
Info
The procedure in the event of transport damage is
described in the Customer Service Manual.
V01038-10
–Loosen screws 1and remove wheel spindle. Jack up the
front wheel into the fork, position it, and insert the wheel spin-
dle.
–Mount and tighten the screw of wheel spindle 2.
Guideline
Screw, front wheel
spindle
M20x1.5 35 Nm (25.8 lbf ft)
–Install front fender. ( p. 8)
–Install the start number plate. ( p. 8)
–Install the shock absorber. ( p. 7)
F02439-10
Warning
Danger of accidents A repaired handlebar poses a
safety risk.
If the handlebar is bent or straightened, the mate-
rial becomes fatigued. The handlebar may break as a
result.
–Change the handlebar if the handlebar is damaged
or bent.
–Position the handlebar.

2 SETUP
4
Info
Make sure the cables and wiring are positioned cor-
rectly.
–Position the handlebar clamps. Mount and tighten the screws
evenly.
Guideline
Screw, handlebar
clamp
M8 20 Nm (14.8 lbf ft)
Info
The markings on the handlebar should be at the center
of the handlebar clamps.
Keep the installed gap widths equal when tightening.
F02440-10
–Position the handlebar cushion and secure with a cable tie.
–Remove the fuel tank. ( p. 9)
F02441-10
–Mount the service hour counter on the holder.
–Feed the service hour counter cable through the recess A
and route it under the wiring harness 3along the frame to
the ignition wire.
Tip
Detach cable holder in the area B.

SETUP 2
5
V01046-01
–Wind the cable for the service hour counter around the ignition
wire, and secure it using cable ties.
–Attach cable holder. Tie excess cable together with a cable tie.
–Install the fuel tank. ( p. 10)
T01611-10
–Position the spring in the hole as shown.
F02442-10
–Position the new footrest and pin.
Spring 4engages in area C.
F02443-10
–Press the spring with special tool 5.
Footrest spring plier (79029083000)
The special tool is applied to area Don the footrest.
–Mount pin 6.
F02444-10
–Mount the washer and splint 7.
–Repeat these steps on the opposite side.
–Mount the frame protector.

2 SETUP
6
F02445-10
–Remove the motorcycle from the lift stand. ( p. 7)
–Operate the hand brake lever several times until the brake lin-
ings are seated correctly against the brake disc.
–Activate the front brake and compress the fork a number of
times forcefully to align the fork legs.
–Tighten screws 8.
Guideline
Screw, fork stub M8 15 Nm (11.1 lbf ft)
–Unpack and mount the KTM PowerParts included in the deliv-
ery (optional).
Info
Read the accompanying KTM PowerParts fitting instruc-
tions.
–Attach the stickers included in the scope of supply (optional).
–Refuel. ( p. 13)
–Position all controls in their exact positions on the handlebar.
Tighten all screws.
–Remove the remaining film, padding, the corrugated card-
board, and the other packaging material.
–Prepare the vehicle according to the specifications in
KTM Dealer.net for handover to the customer.

WORK 3
7
3.1 Raising the motorcycle with a lift stand
Note
Danger of damage The parked vehicle can roll away or fall over.
–Park the vehicle on a firm and level surface.
401942-01
–Raise the motorcycle at the frame underneath the engine.
Lift stand (78929955100)
Neither wheel is in contact with the ground.
–Secure the motorcycle against falling over.
3.2 Removing the motorcycle from the lift stand
Note
Danger of damage The parked vehicle can roll away or fall over.
–Park the vehicle on a firm and level surface.
402001-10
–Remove the motorcycle from the lift stand.
–Remove the lift stand.
–To park the motorcycle, insert plug-in stand 1into the left
side of the wheel spindle.
Info
Remove the plug-in stand before riding.
3.3 Installing the shock absorber
A00044-11
Main work
–Push splash protector 1to the side and position the shock
absorber. Mount and tighten screw 2.
Guideline
Screw, top
shock absorber
M12 60 Nm (44.3 lbf ft)
Loctite®2701™
–Mount and tighten screw 3.
Guideline
Screw, bottom
shock absorber
M12 60 Nm (44.3 lbf ft)
Loctite®2701™
–Attach brake line.
Finishing work
–Remove the motorcycle from the lift stand. ( p. 7)

3 WORK
8
3.4 Installing front fender
V00831-10
Main work
–Position front fender.
–Mount and tighten screws 1.
Guideline
Screw, front fender M6 6 Nm (4.4 lbf ft)
–Mount and tighten screws 2.
Guideline
Screw, front fender M6 6 Nm (4.4 lbf ft)
Finishing work
–Install the start number plate. ( p. 8)
3.5 Installing the start number plate
V00829-10
–Attach the start number plate to the brake line.
–Position the start number plate.
Holding lugs 1engage in the fender.
V00828-10
–Mount and tighten screw 2.
Guideline
Start number plate
screw
M6 4 Nm (3 lbf ft)
3.6 Removing the seat
V00836-10
–Remove screw 1.
–Raise the rear of the seat, pull the seat back, and lift it off.

WORK 3
9
3.7 Mounting the seat
V00837-01
–Mount the front of the seat on the collar bushing of the fuel
tank, lower the seat at the rear, and push the seat forward.
–Make sure that the seat is correctly locked in.
V00836-10
–Mount and tighten screw 1of the seat fixing.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
3.8 Removing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
–Keep fuels correctly in a suitable canister, and out of the reach of children.
Preparatory work
–Remove the seat. ( p. 8)
–Turn tap handle of the fuel tap to the OFF position.

3 WORK
10
V00842-10
Main work
–Pull off the fuel hose.
Info
Remaining fuel may flow out of the fuel hose.
–Remove screws 1.
V00843-10
–Remove screw 2with the rubber bushing.
–Remove the hose from the fuel tank breather.
V00844-10
–Pull both spoilers off laterally from the radiator bracket and lift
off the fuel tank.
3.9 Installing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
–Keep fuels correctly in a suitable canister, and out of the reach of children.

WORK 3
11
Main work
–Check the throttle cable routing. ( p. 11)
V00844-11
–Position the fuel tank and fit the two spoilers to the sides of
the radiator mount.
–Make sure that no cables or throttle cables are trapped or dam-
aged.
V00843-11
–Mount and tighten screw 1with the rubber bushing.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
V00842-11
–Mount and tighten screws 2.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Mount fuel hose.
–Position the fuel tank breather in the steering stem.
Finishing work
–Mount the seat. ( p. 9)
3.10 Checking the throttle cable routing
Warning
Danger of accidents The throttle cable may slip out of the guide if routed incorrectly.
The throttle slide will then no longer be closed and the speed can no longer be controlled.
–Make sure that the throttle cable routing and the play in throttle cable complies with the specifica-
tion.
Preparatory work
–Remove the seat. ( p. 8)
–Turn tap handle of the fuel tap to the OFF position.
–Remove the fuel tank. ( p. 9)

3 WORK
12
S04280-01
Main work
–Check the throttle cable routing.
The throttle cable must be routed along the back of the
handlebar, to the right of the frame, above the fuel tank
bracket, and to the carburetor.
» If the throttle cable is not routed as specified:
–Correct the throttle cable routing.
Finishing work
–Install the fuel tank. ( p. 10)
–Mount the seat. ( p. 9)
3.11 Opening the fuel tank filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
–Keep fuels correctly in a suitable canister, and out of the reach of children.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.

WORK 3
13
S03417-11
–Turn fuel tank filler cap 1counterclockwise and lift it off.
3.12 Closing the fuel tank filler cap
S03418-11
–Mount the fuel tank filler cap and turn it clockwise until the
fuel tank is tightly closed.
Info
Route fuel tank breather hose 1without kinks.
3.13 Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.
–Switch off the engine.
–Open the fuel tank filler cap. ( p. 12)

3 WORK
14
401522-10
–Fill the fuel tank with fuel up to measurement A.
Guideline
Measurement of A35 mm (1.38 in)
Fuel tank capacity,
approx.
5.2 l
(1.37 US gal)
Super unleaded
(98 octane) mixed
with 2-stroke
engine oil (1:40)
( p. 17)
Engine oil, 2-stroke ( p. 17)
–Close the fuel tank filler cap. ( p. 13)

TECHNICAL DATA 4
15
4.1 Chassis tightening torques
Screw, stop button M3 0.4 Nm (0.3 lbf ft)
Screw, carburetor cover M4 2 Nm (1.5 lbf ft)
Screw, fixed grip M4 5 Nm (3.7 lbf ft)
Loctite®243™
Spoke nipple M4.5 5 Nm (3.7 lbf ft)
Remaining nuts, chassis M5 5 Nm (3.7 lbf ft)
Remaining screws, chassis M5 5 Nm (3.7 lbf ft)
Screw, main silencer M5 7 Nm (5.2 lbf ft)
Screw, shock absorber adjusting
ring
M5 5 Nm (3.7 lbf ft)
Nut, push rod, foot brake lever M6 6 Nm (4.4 lbf ft)
Pin, front brake M6 8 Nm (5.9 lbf ft)
Pin, rear brake M6 4 Nm (3 lbf ft)
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft)
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Screw for throttle grip M6 5 Nm (3.7 lbf ft)
Screw, ball joint of push rod on
foot brake cylinder
M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, clutch assembly on handle-
bar
M6 5 Nm (3.7 lbf ft)
Screw, foot brake cylinder M6 10 Nm (7.4 lbf ft)
Screw, front brake assembly on
handlebar
M6 5 Nm (3.7 lbf ft)
Screw, front brake disc M6 14 Nm (10.3 lbf ft)
Loctite®243™
Screw, front fender M6 6 Nm (4.4 lbf ft)
Screw, fuel tank spoiler on radiator M6 6 Nm (4.4 lbf ft)
Screw, ignition coil M6 6.4 Nm (4.72 lbf ft)
Screw, rear brake disc M6 14 Nm (10.3 lbf ft)
Loctite®243™
Start number plate screw M6 4 Nm (3 lbf ft)
Throttle cable wire on carburetor
cover
M6x0.75 3 Nm (2.2 lbf ft)
Nut, rim lock M8 10 Nm (7.4 lbf ft)
Remaining nuts, chassis M8 25 Nm (18.4 lbf ft)
Remaining screws, chassis M8 25 Nm (18.4 lbf ft)
Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft)
Screw, chain sliding piece M8 15 Nm (11.1 lbf ft)
Screw, engine brace M8 25 Nm (18.4 lbf ft)
Loctite®2701™
Screw, engine sprocket cover M8 15 Nm (11.1 lbf ft)
Screw, foot brake lever stop M8 20 Nm (14.8 lbf ft)
Screw, fork stub M8 15 Nm (11.1 lbf ft)
Screw, front brake caliper M8 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft)

4 TECHNICAL DATA
16
Screw, rear brake caliper M8 18 Nm (13.3 lbf ft)
Loctite®243™
Screw, rear sprocket M8 35 Nm (25.8 lbf ft)
Loctite®2701™
Screw, subframe M8 35 Nm (25.8 lbf ft)
Loctite®2701™
Screw, top triple clamp M8 17 Nm (12.5 lbf ft)
Steering stem clamp screw M8 20 Nm (14.8 lbf ft)
Engine carrying screw M10 45 Nm (33.2 lbf ft)
Nut, foot brake lever M10 45 Nm (33.2 lbf ft)
Loctite®243™
Remaining nuts, chassis M10 45 Nm (33.2 lbf ft)
Remaining screws, chassis M10 45 Nm (33.2 lbf ft)
Screw, handlebar support M10 40 Nm (29.5 lbf ft)
Loctite®243™
Screw, bottom shock absorber M12 60 Nm (44.3 lbf ft)
Loctite®2701™
Screw, top shock absorber M12 60 Nm (44.3 lbf ft)
Loctite®2701™
Nut, seat fixing M12x1 20 Nm (14.8 lbf ft)
Nut, swingarm pivot M14x1.5 75 Nm (55.3 lbf ft)
Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft)
Nut, steering stem M20x1.5 10 Nm (7.4 lbf ft)
Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft)

SUBSTANCES 5
17
Engine oil, 2-stroke
Standard/classification
–JASO FD ( p. 18)
Guideline
–Only use high-grade 2-stroke engine oil from a reputable brand.
fully synthetic
Recommended supplier
MOTOREX®
–Cross Power 2T
Super unleaded (ROZ 98 / RON 98 / PON 94)
Standard/classification
–DIN EN 228 (ROZ 98 / RON 98 / PON 94)
Super unleaded (98 octane) mixed with 2-stroke engine oil (1:40)
Standard/classification
–DIN EN 228
–JASO FD ( p. 18) (1:40)
Mixture ratio
1:40 Engine oil, 2-stroke ( p. 17)
Super unleaded (ROZ 98 / RON 98 / PON 94) ( p. 17)
Recommended supplier
MOTOREX®
–Cross Power 2T

6 STANDARDS
18
JASO FD
JASO FD is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of
racing. Thanks to first-rate synthetic esters and specially designed additives, superb combustion is achieved even
under extreme operating conditions.