KTM 85 SX 2017 Manual

SETUP INSTRUCTIONS 2017
85 SX
Art. no. 3213592en

INTRODUCTION 1
*3213592en*
3213592en
09/2016
INTRODUCTION
The work described in these setup instructions must be performed 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 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 production of a particular model without prior notice. KTM accepts no liability for delivery options, devi-
ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not
belong to the regular scope of supply.
© 2016 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)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
5230 Mattighofen, Austria
This document is valid for the following models:
85 SX 19/16 (F6001Q9)
85 SX 17/14 (F6001Q8)

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.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained
in the glossary.

2 SETUP 3
2.1 Unpacking and setting up the vehicle
M00075-11
–Remove the box and the plastic packaging.
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 that the scope of supply is
complete on the basis of the enclosed packing list.
402050-01
–Have a lift stand available.
Lift stand (78929955100)
–Together with an assistant, take the vehicle off the palette.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
201937-10
–Remove the tension belt.
The fork rebounds.
–Remove screw and wheel spindle. Lift the front wheel into the fork, position it,
and insert the wheel spindle.
–Mount and tighten the screw of the wheel spindle.
Guideline
Screw, front wheel spindle M20x1.5 35 Nm
(25.8 lbf ft)
201938-10
–Position the fender. Mount and tighten the screws.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
L02337-01
–Unpack the shock absorber.
–Position the shock absorber. Mount and tighten the screws.
Guideline
Screw, top shock absorber M12 60 Nm
(44.3 lbf ft)
Loctite®2701™
Screw, bottom shock
absorber
M12 60 Nm
(44.3 lbf ft)
Loctite®2701™
The longer screw is used at the bottom.
V00031-10
–Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
–Position the handlebar clamps. Mount and tighten the screws evenly.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)

2 SETUP 4
Info
The markings on the handlebar should be at the center of the handlebar
clamps.
Keep the gap widths equal when tightening.
201941-10
–Position the handlebar cushion and secure with cable ties.
201942-10
–Remove screw with the guide from the start number plate.
–Position the start number plate. Mount and tighten screw .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Info
Ensure the holding lugs engage in the fender.
–Position the brake line and guide. Mount and tighten screw .
L02365-01
–Connect the fuel line to the fuel tap.
800042-10
–Mount the footrests with the springs and pins. Secure the pins using the washers
and cotter pins.
Pliers for footrest spring (58429083000)
201944-10
–Take the vehicle off the work stand.
–Operate the hand brake lever several times until the brake linings are seated cor-
rectly against the brake disc.
–Activate the front brake and compress the fork a number of times forcefully to align
the fork legs.
–Tighten screws .
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
–Refuel. ( p. 7)
–Prepare the vehicle according to the specifications in the KTM Dealer.net for han-
dover to the customer.

3 WORK 5
3.1 Raising the motorcycle with 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.
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.
0
0
11
402001-10
–Remove the motorcycle from the lift stand.
–Remove the lift stand.
–To park the motorcycle, insert plug-in stand into the left side of the wheel spin-
dle.
Info
Remove the plug-in stand before riding.
3.3 Installing the front wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
–Always keep the brake discs free of oil and grease.
–Clean the brake discs with brake cleaner when necessary.
H00935-10
Main work
–Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
–Change the front wheel bearing.
–Clean and grease shaft seal rings and contact surface of the spacers.
Long-life grease ( p. 11)
–Insert the spacers.
S01171-11
–Clean and grease wheel spindle.
Long-life grease ( p. 11)
–Position the front wheel.
The brake linings are correctly positioned.
–Insert wheel spindle.
–Mount and tighten screw .

3 WORK 6
Guideline
Screw, front wheel spindle M20x1.5 35 Nm
(25.8 lbf ft)
–Operate the hand brake lever several times until the brake linings are seated cor-
rectly against the brake disc.
–Remove the motorcycle from the lift stand. ( p. 5)
–Operate the front brake and compress the fork a few times firmly.
The fork legs straighten.
–Tighten screws .
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
Finishing work
–Remove the motorcycle from the lift stand. ( p. 5)
3.4 Installing the front fender
H01366-10
–Position the front fender. Mount and tighten screws .
Guideline
Screw, front fender M6 10 Nm (7.4 lbf ft)
The holding lugs on the fender engage in the start number plate.
3.5 Installing the start number plate
H01365-11
–Position the start number plate. Mount and tighten screw .
Guideline
Start number plate screw M6 4 Nm (3 lbf ft)
The holding lugs on the fender engage in the start number plate.
–Position the brake line and clamp. Mount and tighten screw .
3.6 Opening the 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 refuel 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.

3 WORK 7
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.
Warning
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.
H01345-10
–Turn filler cap counterclockwise and lift it off.
3.7 Closing the filler cap
H01345-11
–Mount filler cap and turn it clockwise until the fuel tank is tightly closed.
Info
Run fuel tank breather hose without kinks.
3.8 Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not refuel 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.

3 WORK 8
Warning
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 filler cap. ( p. 6)
AA
401522-10
–Fill the fuel tank with fuel up to measurement .
Guideline
Measurement of 35 mm (1.38 in)
Fuel tank capac-
ity, approx.
5.0 l
(1.32 US gal)
Super unleaded (98 octane) mixed
with 2-stroke engine oil (1:40)
( p. 10)
Engine oil, 2-stroke ( p. 10)
–Close the filler cap. ( p. 7)

4 TECHNICAL DATA 9
4.1 chassis tightening torques
Spoke nipple M4.5 5 Nm (3.7 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, ball joint of push rod on foot
brake cylinder
M6 10 Nm (7.4 lbf ft) –
Screw, foot brake cylinder M6 10 Nm (7.4 lbf ft) –
Screw, front brake disc M6 14 Nm (10.3 lbf ft) Loctite®243™
Screw, front fender M6 10 Nm (7.4 lbf ft) –
Screw, rear brake disc M6 14 Nm (10.3 lbf ft) Loctite®243™
Screw, throttle grip M6 4.5 Nm (3.32 lbf ft) –
Start number plate screw M6 4 Nm (3 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 of brake caliper M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) –
Screw, fork stub M8 15 Nm (11.1 lbf ft) –
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –
Screw, rear sprocket M8 35 Nm (25.8 lbf ft) Loctite®243™
Screw, subframe M8 30 Nm (22.1 lbf ft) –
Screw, top triple clamp M8 20 Nm (14.8 lbf ft) –
Engine carrying screw M10 45 Nm (33.2 lbf ft) –
Remaining nuts, chassis M10 45 Nm (33.2 lbf ft) –
Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –
Screw, foot brake lever M10 45 Nm (33.2 lbf ft) Loctite®243™
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) –

5 SUBSTANCES 10
Engine oil, 2-stroke
Standard/classification
–JASO FD ( p. 12)
Guideline
–Only use high grade 2-stroke engine oil of 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. 12) (1:40)
Mixture ratio
1:40 Engine oil, 2-stroke ( p. 10)
Super unleaded (ROZ 98 / RON 98 / PON 94) ( p. 10)
Recommended supplier
Motorex®
–Cross Power 2T

6 AUXILIARY SUBSTANCES 11
Long-life grease
Recommended supplier
Motorex®
–Bike Grease 2000

7 STANDARDS 12
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.

*3213592en*
3213592en
09/2016
KTM Sportmotorcycle GmbH
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer/KTM