KTM 85 SX 17/14 2021, Owner'S Manual

Page 1: ...OWNER S MANUAL 2021 85 SX Art no 3214206en ...

Page 2: ......

Page 3: ...es 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...

Page 4: ... 7 3 Preparing the vehicle for difficult riding conditions 21 7 4 Preparing the vehicle for riding on dry sand 21 7 5 Preparing the vehicle for riding on wet sand 23 7 6 Preparing vehicle for rides on wet and muddy circuits 24 7 7 Preparing vehicle for high temperatures or slow riding 24 7 8 Preparing the vehicle for low temperatures or snow 25 8 RIDING INSTRUCTIONS 26 8 1 Checks and maintenance m...

Page 5: ...34 Checking the chain tension 63 11 35 Adjusting the chain tension 64 11 36 Checking the chain rear sprocket engine sprocket and chain guide 65 11 37 Checking the frame 67 11 38 Checking the link fork 67 11 39 Checking the throttle cable routing 67 11 40 Checking the rubber grip 68 11 41 Adjusting the basic position of the clutch lever 68 11 42 Checking the fluid level of the hydraulic clutch 69 1...

Page 6: ...il level 105 16 2 Changing the gear oil 105 16 3 Adding the gear oil 106 17 CLEANING CARE 108 17 1 Cleaning the motorcycle 108 18 STORAGE 110 18 1 Storage 110 18 2 Preparing for use after storage 111 19 TROUBLESHOOTING 112 20 TECHNICAL DATA 114 20 1 Engine 114 20 2 Engine tightening torques 114 20 3 Carburetor 116 20 3 1 Basic carburetor setting for sandy surfaces 116 20 3 2 Carburetor tuning 117 ...

Page 7: ...ined experts using the auxiliary tools required 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 the end of an activity including potential rework 1 2 Formats used The typographical formats used in this documen...

Page 8: ...s instruction and all further instructions included carefully The safety instructions are highlighted in the text and are referred to at the relevant passages Info Various information and warning labels are attached in prominent locations on the product described Do not remove any information or warning labels If they are missing you or others may not recognize dangers and may therefore be injured...

Page 9: ...fe operation Danger Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others Do not operate the vehicle if you are not fit to ride due to alcohol drugs or medication Do not operate the vehicle if you are physically or mentally impaired Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure ...

Page 10: ...After disassembly clean the parts that are to be reused and check them for damage and wear Change damaged or worn parts After completing a repair or service work check the operating safety of the vehicle 2 9 Environment If you use your motorcycle responsibly you can ensure that problems and conflicts do not occur To protect the future of the motorcycle sport make sure that you use your motorcycle ...

Page 11: ...m com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly carried out as described in the Owner s Manual An incorrect suspension setting can lead to damage and breakage of chassis components Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces can resul...

Page 12: ...IEW OF VEHICLE 10 4 1 View of vehicle front left example S04272 10 1 Hand brake lever p 14 2 Clutch lever p 14 3 Fuel tank filler cap 4 Air filter box cover 5 Shift lever p 16 6 Choke p 16 7 Fuel tap p 16 ...

Page 13: ...CLE 4 11 4 2 View of vehicle rear right example S04273 10 1 Switch off button p 14 2 Throttle grip p 14 3 Fork part number p 12 4 Foot brake lever p 17 5 Kick starter lever p 17 6 Level viewer for brake fluid rear ...

Page 14: ... right side of the steering head 5 2 Type label 402154 10 Type label 1 is located on the front frame tube 5 3 Engine number 401949 10 The engine number 1 is located on the left side of the engine under the engine sprocket 5 4 Fork part number 401947 10 Fork part number 1 is stamped on the inner side of the axle clamp ...

Page 15: ...SERIAL NUMBERS 5 13 5 5 Shock absorber article number H02222 10 The shock absorber part number 1 is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 16: ... hand brake lever 6 3 Throttle grip S04275 11 Throttle grip 1 is fitted on the right side of the handlebar 6 4 Switch off button S04274 11 Switch off button 1 is fitted on the left side of the handlebar Possible states The switch off button is in the basic position In this position the ignition circuit is closed and the engine can be started The switch off button is pressed In this position the ig...

Page 17: ...onsult 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 ...

Page 18: ...completely 6 8 Choke V00818 10 Choke 1 is fitted on the left side of the carburetor Activating the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel This results in a richer fuel air mixture which is needed for a cold start Info If the engine is warm the choke function must be deacti vated Possible states Choke function activated The choke lever is pu...

Page 19: ...k starter lever can be swiveled Info Before riding swing the kick starter lever inwards towards the engine 6 11 Foot brake lever 401956 10 Foot brake lever 1 is located in front of the right footrest The foot brake lever is used to activate the rear brake 6 12 Plug in stand 402001 10 The support for plug in stand 1 is the left side of the wheel spin dle The plug in stand is used to park the motorc...

Page 20: ... is attached below the seat It shows the total number of service hours of the engine The service hour counter begins counting when the engine is started and stops when the engine is switched off Info The value indicated by the service hour counter cannot be cleared or adjusted ...

Page 21: ...g such as helmet boots gloves as well as trousers and a jacket with protectors on all rides Alway use protective clothing for your child that is in good condition and meets the legal require ments When you ride a motorcycle set an example for your child and wear suitable protective clothing Warning Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling cha...

Page 22: ...er p 78 Before using the vehicle for the first time ensure that the basic settings of the chassis are suitable for the weight of your child Allow your child to become accustomed to the handling of the motorcycle on suitable terrain preferably on a large open meadow Info To give your child a feeling for the brake system start by pushing your child Do not start the engine until your child is able to...

Page 23: ...spect or replace parts before the next scheduled service Clean the air filter and air filter box p 57 Info Check the air filter approx every 30 minutes Check the electrical connector for humidity and corrosion and to ensure it is firmly seated If humidity corrosion or damage is found Clean and dry the connector or change it if necessary Difficult riding conditions are Rides on dry sand p 21 Rides ...

Page 24: ...d immediately with lukewarm water Change the radiator cap M01104 01 Mount the air filter dust cover Air filter dust cover 47206920000 Info Observe the KTM PowerParts fitting instructions M01105 01 Mount the air filter sand cover Air filter sand cover 79006922000 Info Observe the KTM PowerParts fitting instructions M01107 01 Adjust the carburetor jetting and setting Info Your authorized KTM worksho...

Page 25: ... engine or the cooling system are at operat ing temperature Allow the cooling system and the engine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Change the radiator cap M01107 01 Adjust the carburetor jetting and setting Info Your authorized KTM workshop can re...

Page 26: ...lue Warning Danger of scalding During motorcycle oper ation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other cooling system components if the engine or the cooling system are at operat ing temperature Allow the cooling system and the engine to cool down before you open the radiator the radiator hoses or other components of the cooling system In t...

Page 27: ...EPARING FOR USE 7 25 7 8 Preparing the vehicle for low temperatures or snow M01107 01 Adjust the carburetor jetting and setting Info Your authorized KTM workshop can recommend the right carburetor tuning ...

Page 28: ...ion p 87 Check tire pressure p 88 Check the spoke tension p 89 Info The spoke tension must be checked regularly as incor rect spoke tension will strongly impair riding safety Clean the dust boots of the fork legs p 45 Bleed the fork legs p 44 Check the air filter Check the settings of all controls and ensure that they can be operated smoothly Check all screws nuts and hose clamps regularly for tig...

Page 29: ...Warning Danger of accidents If you change down at high engine speed the rear wheel blocks and the engine races Make it clear to your child that he or she must not change into a low gear at high engine speed Info If unusual noises occur while riding stop immediately switch off the engine and contact an authorized KTM workshop First gear is used for starting off and for steep inclines When condition...

Page 30: ...the brake system Explain to your child that he or she must brake carefully several times to dry out and remove dirt from the brake linings and the brake discs On sandy wet or slippery surfaces use the rear brake Always finish braking before you go into a bend Your child should change down to a lower gear appropriate to the road speed Insist that your child take advantage of the braking action of t...

Page 31: ...sition Park the motorcycle on firm ground 8 7 Transporting Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk Do not park the vehicle near to materials which are highly flammable or explosive Allow the vehicle to cool down before covering it 401475 01 Switch o...

Page 32: ...ontact 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 15 401522 10 Fill the fuel tank with fuel up to measurement A Guideline Measurement of A 35 mm 1 38 in Fuel tank capa...

Page 33: ...heck the frame p 67 Check the link fork p 67 Check the fork bearing for play Check the shock absorber heim joint for play Check the tire condition p 87 Check tire pressure p 88 Check the wheel bearing for play Check the wheel hubs Check the rim run out Check the spoke tension p 89 Check the chain rear sprocket engine sprocket and chain guide p 65 Check the chain tension p 63 Grease all moving part...

Page 34: ...s every 12 months Change the front brake fluid Change the rear brake fluid Change the hydraulic clutch fluid p 70 Grease the steering head bearing p 53 Service the fork Perform the shock absorber service Check adjust the carburetor components Change the coolant p 95 Perform minor engine service Check the inlet membrane Check the clutch Under difficult operating conditions Change the piston and che...

Page 35: ... fork springs are no longer required a significant weight advantage is achieved when compared to conventional forks The response on slightly uneven surfaces is significantly improved In normal driving mode suspension is provided exclusively by an air cushion A steel spring is located in the left fork leg as an end stop Info If the fork is frequently overloaded then the air pressure in the fork mus...

Page 36: ...ge affect the compression damping in the low speed range and vice versa 10 4 Adjusting the low speed compression damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized KTM workshop will be glad t...

Page 37: ...er of turns corresponding to the shock absorber type Guideline High speed compression damping Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Info Turn clockwise to increase damping turn counterclock wise to reduce damping 10 6 Adjusting the rebound damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The...

Page 38: ...de cover Note the value as dimension A Finishing work Remove the motorcycle from the lift stand p 44 10 8 Checking the static sag of the shock absorber 400989 10 Measure dimension A of rear wheel unloaded p 36 Hold the motorcycle upright with aid of an assistant Measure the distance between rear axle and fixed point again Note the value as dimension B Info The static sag is the difference between ...

Page 39: ...ion C Info The riding sag is the difference between measurements A and C Check riding sag Riding sag 120 mm 4 72 in If the riding sag differs from the specified measurement Adjust the riding sag p 38 10 10 Adjusting the spring preload of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorber is filled ...

Page 40: ...ned spring length Depending on the static sag and or the riding sag it may be necessary to increase or decrease the spring preload Tighten screw 1 Guideline Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft Finishing work Install the shock absorber p 55 Remove the motorcycle from the lift stand p 44 10 11 Adjusting the riding sag Preparatory work Raise the motorcycle with a lift stand p 44 Re...

Page 41: ...compression the fork air pressure must be increased within the specified values to avoid damage to the fork and frame 10 13 Adjusting the fork air pressure Warning Danger of accidents Modifications to the suspension setting may seriously alter the handling characteris tic Extreme modifications to the suspension setting may cause a serious deterioration in the handling char acteristic and overload ...

Page 42: ...accompanying KTM PowerParts instructions Adjust the air pressure as specified Guideline Air pressure 5 bar 73 psi Gradual changing of the air pressure in steps of 0 2 bar 3 psi Minimum air pressure 4 bar 58 psi Maximum air pressure 8 bar 116 psi Info Never adjust the air pressure to a value outside the stated range Disconnect the fork airpump from the left fork leg When disconnecting excess pressu...

Page 43: ...dard 12 clicks Sport 7 clicks Info Turn clockwise to increase damping turn counterclock wise to reduce damping during compression Mount protection cap 1 10 15 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior S03415 10 Turn red adjusting screw 1 clockwise as far as it will go Info Adjusting screw 1 is located at the upper end of th...

Page 44: ...ndlebar position Warning Danger of accidents A repaired handlebar poses a safety risk If the handlebar is bent or straightened the material becomes fatigued The handlebar may break as a result Change the handlebar if the handlebar is damaged or bent C00249 10 Remove screws 1 Take off the handlebar clamps Remove the handlebar and lay it to one side Info Cover the components to protect them against ...

Page 45: ...TUNING THE CHASSIS 10 43 Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Info Make sure the gap widths are even ...

Page 46: ...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 1 into the left side of the wheel spindle Info Remove the plug in stand before riding 11 3 Bleeding the fork legs Preparatory work Raise the motorcycle with a...

Page 47: ...s keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when nec essary Clean and oil the dust boots and inner fork tubes of both fork legs Universal oil spray p 125 Press the dust boots back into their installation position Remove excess oil Finishing work Install the fork protector p 47 Remove the motorcycle from the lift stand p 44 11 5 Removing the fork legs Prep...

Page 48: ...e pressure and rebound damping is located in the right fork leg V00873 11 Tighten screws 2 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft H00935 15 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change front wheel bearing Clean and grease shaft seal rings 4 and contact surfaces B o...

Page 49: ...stub M8 15 Nm 11 1 lbf ft 11 7 Removing the fork protector V00824 10 Remove screws 1 and take off the clamp Remove screws 2 on the left fork leg Take off the fork pro tector Remove screws 3 on the right fork leg Take off the fork pro tector 11 8 Installing the fork protector V00825 10 Position the fork protector on the right fork leg Mount and tighten screws 1 Guideline Remaining screws chassis M6...

Page 50: ... handlebar cushion V00874 10 Main work Pull fuel tank breather 1 out of the steering stem Loosen screw 2 Remove nut 3 pull off the upper triple clamp with the handlebar in an upward direction and hang it to the side Info Cover the components to protect them against damage Do not kink the cables and lines V00875 10 Remove protective ring 4 Take off the lower triple clamp with the steering stem in a...

Page 51: ... 2 Position protective ring 3 S03451 10 Position the upper triple clamp with the handlebar Mount nut 4 but do not tighten yet S03452 10 Position the fork legs Air bleeder screw 5 of the right fork leg is positioned to the front Valve A of the left fork leg faces the front Info The second milled groove from the top must be flush with the upper edge of the upper triple clamp The air suspension is lo...

Page 52: ...en screw 7 Guideline Steering stem clamp screw M8 20 Nm 14 8 lbf ft S03420 10 Using a plastic hammer tap lightly on the upper triple clamp to avoid stresses Tighten screws 8 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft S03455 10 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change front wheel bearing Clean and grease shaft seal rings 9 and contact sur...

Page 53: ...inishing work Install front fender p 54 Install the start number plate p 53 Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check the steering head bearing play p 51 Remove the motorcycle from the lift stand p 44 Position the handlebar cushion and secure with a cable tie 11 11 Checking the steering head bearing play Warning Danger o...

Page 54: ...ng head bearing and replace if required Finishing work Remove the motorcycle from the lift stand p 44 11 12 Adjusting the steering head bearing play Preparatory work Raise the motorcycle with a lift stand p 44 S03421 10 Main work Pull fuel tank breather 1 out of the steering stem Loosen screws 2 Loosen screw 3 Loosen and retighten nut 4 Guideline Nut steering stem M20x1 5 10 Nm 7 4 lbf ft Using a ...

Page 55: ...ing the start number plate V00827 10 Remove screw 1 Unhook the start number plate from the brake line and remove it 11 15 Installing the start number plate V00829 10 Attach the start number plate to the brake line Position the start number plate Holding lugs 1 engage in the fender V00828 10 Mount and tighten screw 2 Guideline Start number plate screw M6 4 Nm 3 lbf ft ...

Page 56: ...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 53 11 18 Removing the shock absorber Preparatory work Raise the motorcycle with a lift stand p 44 A00044 10 Main work Detach the brake line from the brake line guide Remove screw 1 and lower the rear wheel with the link fork as far as possible without blocking the r...

Page 57: ...m 44 3 lbf ft Loctite 2701 Attach brake line Finishing work Remove the motorcycle from the lift stand p 44 11 20 Removing the seat V00836 10 Remove screw 1 Raise the rear of the seat pull the seat back and lift it off 11 21 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 c...

Page 58: ... intake air has a negative effect on the service life of the engine Dust and dirt will enter the engine without an air filter Never start to use the vehicle without an air filter Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Preparatory work Re...

Page 59: ...over p 56 Remove the air filter p 56 V00838 01 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 124 Info Only press the air filter to dry it never wring it out Oil the dry air filter with a high grade air filter oil Oil for foam air filter p 124 Clean the air filter box Check intake flange for damage and looseness Finishing work ...

Page 60: ...xhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehicle V00841 10 Remove screw 1 Pull off the main silencer from the manifold at exhaust sleeve 2 11 28 Installing the main silencer V00841 11 Mount the main silencer with exhaust sleeve 1 Mount and tighten screw 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 ...

Page 61: ...l is positioned on the right in the direction of travel Slide outer tube over the inner tube with the new glass fiber yarn filling Info Seal the connecting cap 5 to the outer tube with sili cone Mount and tighten the screws Guideline Screw main silencer M5 7 Nm 5 2 lbf ft Finishing work Install the main silencer p 58 11 30 Removing the fuel tank Danger Fire hazard Fuel is highly flammable The fuel...

Page 62: ...ase 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 55 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 2 with the ...

Page 63: ...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 ...

Page 64: ...icants on the tires reduces the road grip Remove lubricants from the tires using a suitable cleaning agent 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 Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease f...

Page 65: ...ts may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Raise the motorcycle with a lift stand p 44 V00863 10 Main work Pull the chain at the end of the chain sliding...

Page 66: ...ycle with a lift stand p 44 Check the chain tension p 63 S04279 10 Main work Loosen nut 1 Loosen nuts 2 Adjust the chain tension by turning adjusting screws 3 left and right Guideline Chain tension 46 49 mm 1 81 1 93 in Turn adjusting screws 3 on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks A The rear wheel is th...

Page 67: ...ther 400987 10 Pull on the top section of the chain with the specified weight A Guideline Weight chain wear measure ment 10 15 kg 22 33 lb Measure distance B of 18 chain rollers in the lower chain section Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance B from 18 chain rollers at the longest chain section 219 mm 8 62 in If dista...

Page 68: ... screws chassis M6 10 Nm 7 4 lbf ft H02310 01 Check the chain sliding piece for wear If the lower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten screw on the chain sliding piece Guideline Screw chain slid ing piece M8 15 Nm 11 1 lbf ft 401760 01 Ch...

Page 69: ... authorized by KTM 11 38 Checking the link fork V00857 01 Check the link fork for damage cracking and deformation If the link fork shows signs of damage cracking or defor mation Change the link fork Info Always replace a damaged link fork Repairing the link fork is not authorized by KTM 11 39 Checking the throttle cable routing Warning Danger of accidents The throttle cable may slip out of the gui...

Page 70: ...and to ensure they are firmly seated If a rubber grip is damaged worn or loose Change and secure the rubber grip Rubber grip adhesive 00062030051 p 125 11 41 Adjusting the basic position of the clutch lever S04274 12 Adjust the basic position of the clutch lever to the size of the rider s hand using adjusting screw 1 Info Turn the adjusting screw clockwise to increase the distance between the clut...

Page 71: ...uid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Info The fluid lev...

Page 72: ... contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations...

Page 73: ... the system until it escapes from open ing A of the master cylinder without bubbles Now and then extract fluid from the master cylinder reservoir to prevent overflow Remove the bleeding syringe Mount and tighten screws bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level below container rim 4 mm 0 16 in Position the cover with the membrane Mount and tighten the screw...

Page 74: ...sting the free travel of the handbrake lever S04283 10 Check the free travel of the hand brake lever p 72 Adjust the free travel of the handbrake lever with adjustment screw 1 Info Turn the adjusting screw clockwise to reduce free travel The pressure point moves away from the handlebar Turn the adjusting screw counterclockwise to increase free travel The pressure point moves towards the han dlebar...

Page 75: ...anger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake system and ensure that nobody drives the vehicle before the problem is eliminated Your authorized KTM workshop will be glad to help Warning Danger of ...

Page 76: ... into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your authorized KTM workshop will be glad to help Note Environmental hazard Hazardous substances cause environmental damage Dispose ...

Page 77: ...ger of accidents Incorrect servicing will cause the brake system to fail Ensure that service work and repairs are performed professionally Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with th...

Page 78: ...homologa tion is not guaranteed In this case the vehicle no longer corresponds to its condition at delivery and the manufacturer warranty shall be void Only use brake linings approved and recommended by KTM Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable reg...

Page 79: ... Position the new brake linings Info Always change the brake linings in pairs Mount pin 6 Info To make it easier to mount the pin push the brake lin ings against the retainer spring Make sure the brake linings and retainer spring are seated correctly Mount cotter pins 4 Position the brake caliper Mount and tighten screws 5 Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 S04284...

Page 80: ...djusting the basic position of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification V00866 10 Detach spring 1 Loosen nut 4 and with push rod 5 turn it back until yo...

Page 81: ...e it easier to see the marking If the brake fluid has dropped below the marking A Add rear brake fluid p 79 12 11 Adding rear brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake sys...

Page 82: ...not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container Preparatory work Check the rear brake linings p 80 A00047 10 Main work Stand the vehicle upright Remove screws 1 Take off the cover with the washer and membrane 2 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 122 Mount the cove...

Page 83: ...ediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your authorized KTM workshop will be glad to help Warning Danger of accidents Oil ...

Page 84: ...e piston back into the basic position and ensure that brake fluid does not flow out of the brake fluid reservoir extracting some if necessary S04288 10 Remove cotter pin 3 Press back the brake linings by slightly tilting the brake caliper laterally on the brake disc Remove pin 4 Remove brake linings 5 and the retainer spring Clean brake caliper Position the retainer spring Position the new brake l...

Page 85: ...56 10 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 122 Mount the cover with the washer and membrane 2 Mount and tighten screws 1 Info Use water to immediately clean up any brake fluid that has overflowed or spilled ...

Page 86: ...scs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Hold the front wheel and remove the wheel spindle Take the front wheel out of the fork Info Do not actuate the hand brake lever when the front wheel is removed H00934 10 Remove spacers 3 13 2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the bra...

Page 87: ...brake linings are correctly positioned Insert the wheel spindle Mount and tighten screw 2 Guideline Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Operate the hand brake lever several times until the brake lin ings are seated correctly against the brake disc Remove the motorcycle from the lift stand p 44 Operate the front brake and compress the fork a few times firmly The fork legs straighten...

Page 88: ...the rear wheel and remove the wheel spindle Take the rear wheel out of the link fork Info Do not operate the foot brake lever when the rear wheel is removed H00936 10 Remove spacers 4 13 4 Installing the rear 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 ...

Page 89: ...ith the same chain length Chain adjusters 3 can be turned by 180 Check the chain tension p 63 Tighten nut 4 Guideline Nut rear wheel spin dle M20x1 5 80 Nm 59 lbf ft Operate the foot brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand p 44 13 5 Checking the tire condition Info Only...

Page 90: ... the year of manu facture KTM recommends that the tires be changed after 5 years at the latest regardless of the actual state of wear If the tires are more than five years old Change the tires 13 6 Checking tire pressure Info Low tire pressure leads to abnormal wear and overheating of the tire Correct tire pressure ensures optimal riding comfort and maximum tire service life 400695 01 Remove prote...

Page 91: ...sult Check spoke tension regularly and in particular on a new vehicle Your authorized KTM workshop will be glad to help 400694 01 Strike each spoke briefly using a screwdriver blade Info The frequency of the sound depends on the spoke length and spoke diameter If you hear different tone frequencies from different spokes of equal length and diameter this is an indica tion of different spoke tension...

Page 92: ...10 The radiator covers are mounted in front of the radiator between the radiator shield and radiator Info Do not use radiator covers in difficult operating conditions The radiator cover keeps the coolant temperature in the correct range Optimal coolant tem perature 60 70 C 140 158 F V00884 10 The radiator covers are installed in front of the radiator depending on the ambient temperature Full radia...

Page 93: ...6 01 Position the corresponding radiator cover p 90 The holding lugs point toward the frame V00886 10 Position left radiator shield 4 Mount and tighten screws 3 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position right radiator shield 2 Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 94: ... radiator the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature Allow the cooling system and the engine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic an...

Page 95: ...ne to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately...

Page 96: ...nty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Condition The engine is cold V00832 11 Position the motorcycle upright Place an appropriate container under the water pump cover Remove screw 1 Take off radiator cap 2 Completely drain the coolant Mou...

Page 97: ...ent ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Allow the engine to warm up and cool down again Check the coolant level p 93 Finishing work Check the cooling system for leaks 14 9 Changing the coolant Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not open th...

Page 98: ... under the water pump cover Remove screw 1 Take off radiator cap 2 Completely drain the coolant Mount and tighten screw 1 with a new seal ring Guideline Position the motorcycle upright Completely fill the radiator with coolant Coolant p 122 V00870 10 Loosen screw 3 until coolant escapes without bubbles Mount and tighten screw 3 Guideline Mount radiator cap 2 Danger Danger of poisoning Exhaust gase...

Page 99: ...s sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Start the engine and let it run at idle speed Move the handle bar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the throttle cable play p 97 15 2 Adjusting the throttle cable play Preparatory work Remo...

Page 100: ...with the throttle slide open full throttle If the insulator of a new spark plug is very light or white after a brief ride at full throttle or if the engine knocks a larger main jet needs to be used If the insulator is dark brown or sooty a smaller main jet needs to be used Needle position POS The needle position has the greatest influence in the mid throttle slide range If the engine stutters when...

Page 101: ...en the throttle slide is 1 8 open the first cylindrical part of the needle the idling jet and the clip position have the greatest influence K00496 01 When the throttle slide is 1 4 open the idling jet and the clip position have the greatest influence The influence of the first cylindrical part of the needle is less When the throttle slide is 1 2 open the position of the needle has the greatest inf...

Page 102: ...075 10 Clip position 1 5 Clip position from above The five possible clip positions are shown here The carburetor tuning depends on the defined ambient and operat ing conditions 15 4 Carburetor idle 402799 10 The idle setting of the carburetor has a big influence on the start ing behavior stable idling and the response to throttle opening This means that an engine with a correctly set idle speed is...

Page 103: ...in to the stop p 16 Idle speed 1 400 1 500 rpm Turn idle air adjusting screw 1 slowly in a clockwise direc tion until the idle speed begins to fall Note the position and turn the idle air adjusting screw slowly counterclockwise until the idle speed again begins to fall Adjust to the point between these two positions with the high est idle speed Info If there is a big engine speed rise reduce the i...

Page 104: ...uel 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...

Page 105: ... Switching the ignition timing map from Soft to Performance Join plug in connector 1 of the ignition timing map adjustment Figure T01480 10 p 103 Performance Higher performance 15 9 Checking the basic position of the shift lever Info When driving the shift lever must not touch the rider s boot when in the basic position When the shift lever keeps touching the boot the transmission will be subject ...

Page 106: ... on the shift shaft in the required position and engage gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle components during the shift procedure Mount and tighten screw 1 with the washers Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 ...

Page 107: ...r oil get very hot when the motorcycle is ridden Wear suitable protective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Drain the g...

Page 108: ...en starting or running the engine in an enclosed space Start the engine and check for leaks Finishing work Check the gear oil level p 105 16 3 Adding the gear oil Info Too little gear oil or poor quality gear oil results in premature wear to the transmission Preparatory work Stand the motorcycle upright on a horizontal surface V00834 10 Main work Remove screw 1 with the seal ring 401955 11 Remove ...

Page 109: ... ing them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Start the engine and check for leaks Finishing work Check the gear oil level p 105 ...

Page 110: ... a long period clean it regularly Avoid direct sunshine when cleaning the motorcycle 401061 01 Close off exhaust system to keep water from entering Remove loose dirt first with a soft jet of water Spray the heavily soiled parts with a normal commercial motor cycle cleaner and clean using a brush Motorcycle cleaner p 124 Info Use warm water containing normal motorcycle cleaner and a soft sponge Nev...

Page 111: ...e After the motorcycle has cooled down lubricate all moving parts and pivot points Clean the chain p 62 Treat bare metal except for brake discs and the exhaust sys tem with a corrosion inhibitor Preserving materials for paints metal and rubber p 124 Treat all plastic parts and powder coated parts with a mild cleaning and care product Special cleaner for glossy and matte paint finishes metal and pl...

Page 112: ... period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 124 Refuel p 29 Clean the motorcycle p 108 Change the gear oil p 105 Check the antifreeze and coolant level p 92 Check tire pressure p 88 Empty the carburetor floa...

Page 113: ...STORAGE 18 111 18 2 Preparing for use after storage 401059 01 Remove the motorcycle from the lift stand p 44 Perform checks and maintenance measures when preparing for use p 26 Take a test ride ...

Page 114: ...Check set the carburetor components Adjusting screws on carburetor distorted Carburetor adjust the idle speed p 101 Spark plug defective Change the spark plug Ignition system defective Check the ignition coil Check the spark plug connector Engine does not speed up Carburetor running over because float needle dirty or worn Check set the carburetor components Loose carburetor jets Check set the carb...

Page 115: ...the engine when standing Radiator fins very dirty Clean the radiator fins Foam formation in cooling sys tem Drain the coolant p 94 Refill with coolant p 94 Damaged cylinder head or cylinder head gasket Check the cylinder head and cylinder head gasket Bent radiator hose Change the radiator hose Incorrect ignition point due to loose stator Adjust the ignition White smoke emission steam in exhaust ga...

Page 116: ...smission claw shifted Transmission ratio 1st gear 11 29 2nd gear 14 28 3rd gear 16 26 4th gear 19 26 5th gear 21 25 6th gear 20 21 Ignition Kokusan 504 Spark plug NGK BR9 ECMVX Spark plug electrode gap 0 60 mm 0 0236 in Cooling Water cooled Starting aid Kick starter 20 2 Engine tightening torques Screw adjusting lever M5x16 6 Nm 4 4 lbf ft Loctite 243 Screw clutch spring retainer M5 6 Nm 4 4 lbf f...

Page 117: ...0 Nm 7 4 lbf ft Screw intermediate clutch cover M6x55 10 Nm 7 4 lbf ft Screw intermediate clutch cover M6x60 10 Nm 7 4 lbf ft Screw kick starter intermediate gear M6 10 Nm 7 4 lbf ft Loctite 243 Screw kick starter stop plate M6 10 Nm 7 4 lbf ft Loctite 243 Screw outer clutch cover M6x25 8 Nm 5 9 lbf ft Screw outer clutch cover M6x55 8 Nm 5 9 lbf ft Screw outer clutch cover M6x60 8 Nm 5 9 lbf ft Sc...

Page 118: ...2 turns Main jet 142 140 145 148 Jet needle NRKC NRJC Idling jet 48 45 50 Throttle slide 3 Choke nozzle 62 20 3 1 Basic carburetor setting for sandy surfaces Idle air adjusting screw 2 turns Idling jet 48 Jet needle NRJ C Needle position 4th position from top Main jet 148 Info If the engine is not running smoothly use a smaller main jet ...

Page 119: ...ICAL DATA 20 117 20 3 2 Carburetor tuning 402814 01 M FT ASL Above sea level TEMP Temperature ASO Open rotations idle air adjusting screw IJ Idling jet NDL Jet needle POS Needle position from top MJ Main jet ...

Page 120: ...front Disc brake with 4 piston brake caliper rear Disc brake with 2 piston brake caliper Brake discs diameter front 240 mm 9 45 in rear 220 mm 8 66 in Brake discs wear limit front 3 5 mm 0 138 in rear 3 7 mm 0 146 in Offroad tire pressure front 1 0 bar 15 psi rear 1 0 bar 15 psi Secondary ratio 85 SX 17 14 13 46 Secondary ratio 85 SX 19 16 13 49 Chain 1 2 x 5 16 Rear sprockets available 44 45 46 4...

Page 121: ...pension XACT 5543 Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Fork length 845 mm 33 27 in Oil capacity external mechanism right 363 10 ml 12 27 0 34 fl oz Fork oil SAE 4 48601166S1 p 123 Oil capacity external mechanism left 100 20 ml 3 38 0 68 fl oz Fork oil SAE 4 48601166S1 p 123 Grease capacity left c...

Page 122: ...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 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 6 Nm 4 4 lbf ft Screw rear brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Start number plate screw M6 4 ...

Page 123: ...ssis 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 ...

Page 124: ... stated see specifications on the container and that has the relevant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for antifreeze protection dilution and miscibility comp...

Page 125: ...ard classification SAE p 126 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties 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 126 1 40 Mixture r...

Page 126: ...r High viscosity grease Recommended supplier SKF LGHB 2 Long life grease Recommended supplier MOTOREX Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX Moto Clean Off road chain spray Recommended supplier MOTOREX Chainlube Offroad Oil for foam air filter Recommended supplier MOTOREX Racing Bio Liquid Power Preserving materials for paints metal and rubber Recommended supplier MOTOREX...

Page 127: ... GRIP GLUE Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Special grease 00062010053 Recommended supplier Klüber Lubrication KLÜBERFOOD NH1 34 401 Universal oil spray Recommended supplier MOTOREX Joker 440 Synthetic ...

Page 128: ...t motorcycle engines the transmission and clutch are lubricated with the same oil The JASO T903 MA2 standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity The viscosity describes only one property of oil and says nothing about quality JASO FD JASO FD is a classificati...

Page 129: ...LIST OF ABBREVIATIONS 24 127 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 130: ...idle 100 idle speed adjusting 101 Carburetor tuning 98 Chain checking 65 cleaning 62 Chain guide checking 65 Chain tension adjusting 64 checking 63 Choke 16 Cleaning 108 109 Clutch fluid level checking 69 fluid level correcting 69 fluid changing 70 Clutch lever 14 basic position adjusting 68 Compression damping fork adjusting 41 Coolant changing 95 draining 94 refilling 94 Coolant level checking 9...

Page 131: ... 103 plug in connector 103 Implied warranty 9 Intended use 6 K Kick starter lever 17 L Link fork checking 67 Lower triple clamp installing 49 removing 48 Lowspeed compression damping shock absorber adjusting 34 M Main silencer glass fiber yarn filling changing 58 installing 58 removing 58 Manufacturer warranty 9 Misuse 6 Motorcycle cleaning 108 lift stand raising with 44 removing from lift stand 4...

Page 132: ...g 26 Steering head bearing greasing 53 Steering head bearing play adjusting 52 checking 51 Storage 110 Switch off button 14 T Technical data capacities 118 carburetor 116 chassis 118 chassis tightening torques 120 engine 114 engine tightening torques 114 fork 119 shock absorber 119 tires 119 Throttle cable play adjusting 97 checking 97 Throttle cable routing checking 67 Throttle grip 14 Tire condi...

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