KTM 85 SX 2021 Manual

SETUP INSTRUCTIONS 2021
85 SX
Art. no. 3214362en

INTRODUCTION
*3214362en*
3214362en
02/2021
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 (F6001U9)
85 SX 17/14 (F6001U8)

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 in the event of 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 spindle.
–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 split pin 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 plastic packaging, corrugated card-
board, and 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.