KTM 85 SX 19/16 2015 Manual

SETUP INSTRUCTIONS 2015

85 SX 19/16

85 SX 17/14

Art. no. 3213191en

INTRODUCTION 1

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.

Print out the current PDI form found on the KTM DEALER.NET.

These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter-

est 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 AG specifically reserves the right to modify or delete technical specifica-

tions, 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, deviations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equip-

ment that does not belong to the regular scope of supply.

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 AG

5230 Mattighofen, Austria

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.

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 (54829055000)

–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 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 screws.

Guideline

Screw, top shock absorber M12 60 Nm

(44.3 lbf ft)

Loctite®243™

Screw, bottom shock

absorber

M12 60 Nm

(44.3 lbf ft)

Loctite®243™

The longer screw is used at the bottom.

L02364-10

–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 a cable binder.

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 of the work stand.

–Activate the hand brake lever numerous times until the brake linings rest 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)

–Print out the current PDI form found on KTM DEALER.NET and perform the delivery

inspection.

3 WORK 5

3.1 Raising the motorcycle with the lift stand

Note

Danger of damage The parked vehicle may roll away or fall over.

–Always place the vehicle on a firm and even surface.

401942-01

–Raise the motorcycle at the frame underneath the engine.

Lift stand (59229055000)

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 may roll away or fall over.

–Always place the vehicle on a firm and even surface.

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 Reduced braking efficiency due to oil or grease on the brake discs.

–Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

L00094-11

Main work

–Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:

–Change the wheel bearing.

–Clean and grease shaft seal rings and bearing surface of the spacers.

Long-life grease ( p. 10)

–Insert the spacers.

L00092-11

–Position the front wheel.

The brake linings are correctly positioned.

–Insert wheel spindle.

–Mount and tighten screw .

Guideline

Screw, front wheel spindle M20x1.5 35 Nm

(25.8 lbf ft)

3 WORK 6

–Operate the hand brake lever several times until the brake linings are lying correctly

against the brake disc.

–Remove the motorcycle from the lift stand. ( p. 5)

–Pull the front wheel brake and push down hard on the fork several times to align

the fork legs.

–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

L02336-10

–Ensure that the spacers are mounted in the fender.

–Position the front fender. Mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

The holding lugs engage.

3.5 Installing the start number plate

L02335-11

–Position the start number plate. Mount and tighten screw .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

The holding lugs engage.

–Position the brake line. Position the clamp. Mount and tighten screw .

3.6 Opening the filler cap

Danger

Fire hazard Fuel is highly flammable.

–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no

fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

–The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

–Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with

the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with

soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.

Store fuel properly in a suitable canister and keep away from children.

Warning

Environmental hazard Improper handling of fuel is a danger to the environment.

–Do not allow fuel to get into the ground water, the ground, or the sewage system.

3 WORK 7

L02321-10

–Turn filler cap counterclockwise and lift it off.

3.7 Closing the filler cap

L02321-11

–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.

–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no

fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

–The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

–Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with

the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with

soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.

Warning

Environmental hazard Improper handling of fuel is a danger to the environment.

–Do not allow fuel to get into the ground water, the ground, or the sewage system.

–Switch off the engine.

–Open the filler cap. ( p. 6)

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. 9)

Engine oil, 2-stroke ( p. 9)

–Close the filler cap. ( p. 7)

4 TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS 8

Spoke nipple M4.5 5 Nm (3.7 lbf ft) –

Rear brake bolt M6 12 Nm (8.9 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, rear brake disc M6 14 Nm (10.3 lbf ft) Loctite®243™

Screw, throttle grip M6 4.5 Nm (3.32 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®243™

Screw, top shock absorber M12 60 Nm (44.3 lbf ft) Loctite®243™

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) –

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