KTM 85 SX 2018 Manual

SETUP INSTRUCTIONS 2018

85 SX

Art. no. 3213739en

INTRODUCTION

*3213739en*

3213739en

06/2017

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 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, deviations from figures and descriptions,

misprints, and other errors. The models portrayed partly contain special equipment 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 assur-

ance processes that lead to the maximum possible quality of the products.

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 (F6001R9)

85 SX 17/14 (F6001R8)

1 MEANS OF REPRESENTATION

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.

2 SETUP

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 that the

scope of supply is complete using the enclosed packing list.

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.

V01038-10

–Loosen screws 1and remove 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 2.

Guideline

Screw, front wheel

spindle

M20x1.5 35 Nm (25.8 lbf ft)

V01039-01

–Position the fender. Mount and tighten the screws.

Guideline

Remaining screws,

chassis

M6 10 Nm (7.4 lbf ft)

V01040-01

–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™

2 SETUP

V01041-01

–Position the handlebar.

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 gap widths equal when tightening.

V01042-01

–Position the handlebar cushion and secure with cable ties.

V01043-01

–Attach the start number plate to the brake line.

V01044-10

–Position the start number plate.

The holding lugs engage in the fender.

–Mount and tighten screw 3.

Guideline

Start number plate

screw

M6 4 Nm (3 lbf ft)

–Remove the fuel tank. ( p. 8)

2 SETUP

V01045-10

–Mount the service hour counter on the holder.

–Feed the service hour counter cable through the hole Aand

route it under the wiring harness 4along the frame to the

ignition wire.

Tip

Detach cable holder in the area B.

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. 9)

T01611-10

–Position the spring in the hole as shown.

V01054-10

–Position the new footrest and pin.

Spring 5engages in area C.

2 SETUP

V01055-10

–Press the spring with special tool 6.

Footrest spring plier (79029083000)

The special tool is applied to area Don the footrest.

–Mount pin 7.

V01056-10

–Mount the washer and split pin 8.

–Repeat these steps on the opposite side.

–Mount the frame protector.

V01047-10

–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 9.

Guideline

Screw, fork stub M8 15 Nm (11.1 lbf ft)

–Refuel. ( p. 12)

–Prepare the vehicle according to the specifications in the

KTM Dealer.net for handover to the customer.

3 WORK

3.1 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.

3.2 Removing the seat

V00836-10

–Remove screw 1.

–Raise the rear of the seat, pull the seat back, and lift it off.

3.3 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 WORK

3.4 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 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.

–Keep fuels correctly in a suitable canister, and out of the reach of children.

Preparatory work

–Remove the seat. ( p. 7)

–Turn the tap handle of the fuel tap to the OFF position.

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.

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