KTM 85 SX 2019 Owner's Manual
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KTM 85 SX 2019 Owner's Manual

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OWNER'S MANUAL
2019
85 SX
Art. no. 3213846en

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Summary of Contents for KTM 85 SX 2019

  • Page 1 OWNER'S MANUAL 2019 85 SX Art. no. 3213846en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art DEAR KTM CUSTOMER sports motorcycle that will give you and your child enormous pleasure if you service and maintain it accordingly.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Preparing the vehicle for difficult TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 riding conditions ......22 Symbols used ........5 Preparing vehicle for rides on dry Formats used........5 sand ..........22 Preparing vehicle for rides on wet SAFETY ADVICE..........
  • Page 5 TABLE OF CONTENTS 10.15 Adjusting the rebound damping of 11.40 Checking the rubber grip ....66 the fork........... 42 11.41 Adjusting the basic position of the 10.16 Handlebar position......42 clutch lever ........66 10.17 Adjusting the handlebar position ..43 11.42 Checking the fluid level of the hydraulic clutch.......
  • Page 6 TABLE OF CONTENTS 15.4 Carburetor - idle....... 97 Carburetor – adjusting the idle 15.5 speed .......... 98 15.6 Emptying the carburetor float chamber ........99 15.7 Plug-in connector of ignition timing map adjustment......100 15.8 Changing the ignition timing map ..100 15.9 Checking the basic position of the shift lever........

  • Page 7: Means Of Representation 1

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary tools required.

  • Page 8: Safety Advice

    2 SAFETY ADVICE Use definition – intended use This vehicle is designed and built to withstand the normal stresses and strains of competitive use. This vehicle complies with the currently valid regulations and categories of the top international motorsport organizations. Info Only operate the vehicle in closed-off areas remote from public road traffic.

  • Page 9: Tampering Warning

    Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. The vehicle should only be used by trained persons. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.

  • Page 10: Protective Clothing

    – When you ride a motorcycle, set an example for your child and wear suitable protective clothing. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing suitable pro- tective clothing. Work rules Special tools are necessary for certain tasks.

  • Page 11: Important Notes 3

    Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void.
  • Page 12 3 IMPORTANT NOTES A list of authorized KTM dealers can be found on the KTM website. International KTM Website: http://www.ktm.com...

  • Page 13: View Of Vehicle 4

    VIEW OF VEHICLE 4 View of vehicle, front left (example) V01286-10 Hand brake lever ( p. 15) Clutch lever ( p. 15) Filler cap Air filter box cover Shift lever ( p. 17) Choke ( p. 17) Fuel tap ( p.

  • Page 14: View Of Vehicle, Rear Right (Example)

    4 VIEW OF VEHICLE View of vehicle, rear right (example) V01288-10 Kill switch ( p. 15) Throttle grip ( p. 15) Fork part number ( p. 13) Foot brake lever ( p. 18) Kick starter ( p. 18) Level viewer for brake fluid, rear...

  • Page 15: Serial Numbers 5

    SERIAL NUMBERS 5 Chassis number Chassis number is stamped on the right side of the steering head. 401945-10 Type label Type label is located on the front frame tube. 402154-10 Engine number The engine number is located on the left side of the engine under the engine sprocket.

  • Page 16: Shock Absorber Article Number

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

  • Page 17: Controls 6

    CONTROLS 6 Clutch lever Clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. V00811-10 Hand brake lever The hand brake lever is fitted on the right side of the handle- bar. The front brake is engaged using the hand brake lever.

  • Page 18: Opening The Filler Cap

    6 CONTROLS 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. –...

  • Page 19: Fuel Tap

    CONTROLS 6 Fuel tap The fuel tap is on the left side of the fuel tank. Using the tap handle on the fuel tap, you can open or close the fuel supply to the carburetor. Possible states Fuel supply closed OFF – Fuel cannot flow from the fuel tank •...

  • Page 20: Kick Starter

    6 CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.10 Kick starter Kick starter is fitted on the right side of the engine. The kick starter can be swiveled. Info 0 0 1 Before riding, swing the kickstarter inwards towards the...

  • Page 21: Service Hour Counter

    CONTROLS 6 6.13 Service hour counter The service hour counter 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 22: Preparing For Use

    7 PREPARING FOR USE Advice on first use Warning Danger of accidents A lack of physical and mental readiness on the part of the child poses a major risk. Children often underestimate or fail to recognize dangerous situations. – Your child must already be able to ride a bicycle. –...
  • Page 23 When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.

  • Page 24: Running In The Engine

    7 PREPARING FOR USE Running in the engine – During the running-in phase, do not exceed the specified engine performance. Guideline Maximum engine performance During the first 3 operating hours < 70 % During the first 5 operating hours < 100 % –...
  • Page 25 Sand cover for air filter (79006922000) Info See the KTM PowerParts fitting instructions. M01105-01 – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning. – Clean the chain. Chain cleaner ( p. 121) –...

  • Page 26: Preparing Vehicle For Rides On Wet Sand

    In the event of scalding, rinse the area affected immediately with lukewarm water. – Change the radiator cap. – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning. – Clean the chain. Chain cleaner ( p. 121) –...

  • Page 27: Preparing Vehicle For Rides On Wet And Muddy Circuits

    – Make sure that no radiator covers ( p. 88) are installed. – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning. – Clean the motorcycle. ( p. 105) – Straighten bent radiator fins carefully.

  • Page 28: Preparing Vehicle For Low Temperatures Or Snow

    7 PREPARING FOR USE – Check the coolant level. ( p. 91) Preparing vehicle for low temperatures or snow – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning. M01107-01...

  • Page 29: Riding Instructions 8

    RIDING INSTRUCTIONS 8 Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 30: Starting Off

    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. –...

  • Page 31: Applying The Brakes

    Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not allow your child to continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system.

  • Page 32: Transporting

    8 RIDING INSTRUCTIONS Significant damage may be caused if the vehicle rolls away or falls over. The components for parking the vehicle are designed only for the weight of the vehicle. – Park the vehicle on a firm and level surface. –...
  • Page 33 RIDING INSTRUCTIONS 8 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. –...

  • Page 34: Service Schedule

    Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.

  • Page 35: Recommended Work

    Final check: Check the vehicle for operating safety and take a test ride. ○ ● ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval Recommended work...

  • Page 36: 10 Tuning The Chassis

    – As delivered, KTM offroad motorcycles are adjusted for an average rider's weight (with full protective clothing). Guideline Standard rider weight 45 …...

  • Page 37: Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber.

  • Page 38: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber.

  • Page 39: Measuring Rear Wheel Sag Unloaded

    TUNING THE CHASSIS 10 Info Turn clockwise to increase damping; turn counterclock- wise to reduce damping. 10.7 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) Main work – Measure the distance – as vertically as possible – between the rear axle and a fixed point such as a mark on the side cover.

  • Page 40: Checking The Riding Sag Of The Shock Absorber

    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 to help.) Preparatory work –...

  • Page 41: Adjusting The Riding Sag

    TUNING THE CHASSIS 10 Main work – Measure the full spring length while it is under tension and note down the value. – Loosen screw – Turn adjusting ring until the spring is no longer under ten- sion. Holding wrench (90129051000) –...

  • Page 42: Checking The Basic Setting Of The Fork

    10 TUNING THE CHASSIS – Check the static sag of the shock absorber. ( p. 37) – Check the riding sag of the shock absorber. ( p. 38) – Adjust the rebound damping of the shock absorber. ( p. 36) 10.12 Checking the basic setting of the fork Info...

  • Page 43: Adjusting The Compression Damping Of The Fork

    A little air escapes from the fork leg when connecting. Info This is due to the volume of the hose and not due to a defect in the fork pump or the fork. Read the accompanying KTM PowerParts instructions. – Adjust the air pressure as specified. Guideline...

  • Page 44: Adjusting The Rebound Damping Of The Fork

    10 TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclock- wise to reduce damping. – Mount protection cap 10.15 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. – Turn red adjusting screw clockwise as far as it will go.

  • Page 45: Adjusting The Handlebar Position

    TUNING THE CHASSIS 10 10.17 Adjusting the handlebar 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. –...

  • Page 46: 11 Service Work On The Chassis

    11 SERVICE WORK ON THE CHASSIS 11.1 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. – Raise the motorcycle at the frame underneath the engine. Lift stand (78929955100) Neither wheel is in contact with the ground.

  • Page 47: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 11.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) – Remove the fork protector. ( p. 47) Main work – Push dust boots of both fork legs downward.

  • Page 48: Installing The Fork Legs

    11 SERVICE WORK ON THE CHASSIS – Loosen screws . Remove the left fork leg. – Loosen screws . Remove the right fork leg. V00873-10 11.6 Installing the fork legs Main work – Position the fork legs. Air release screw of the right fork leg is positioned to the front.

  • Page 49: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11 11.7 Removing the fork protector – Remove screws and take off the clamp. – Remove screws on the left fork leg. Take off the fork pro- tector. – Remove screws on the right fork leg. Take off the fork pro- tector.

  • Page 50: Installing The Lower Triple Clamp

    11 SERVICE WORK ON THE CHASSIS – Remove protective ring – Take off the lower triple clamp with the steering stem in a downward direction. – Remove the upper steering head bearing. V00875-10 11.10 Installing the lower triple clamp Main work –...
  • Page 51 SERVICE WORK ON THE CHASSIS 11 – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front. Valve of the left fork leg faces the front. Info Grooves are milled into the side of the upper end of the fork legs.

  • Page 52: Checking The Play Of The Steering Head Bearing

    Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam- ages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become damaged over time.

  • Page 53: Greasing The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS 11 Main work – Pull fuel tank breather out of the steering stem. – Loosen screws – Loosen screw – Loosen and retighten nut Guideline Nut, steering stem M20x1.5 10 Nm (7.4 lbf ft) – Using a plastic hammer, tap lightly on the upper triple clamp V00826-10 to avoid stresses.

  • Page 54: Installing The Start Number Plate

    11 SERVICE WORK ON THE CHASSIS 11.15 Installing the start number plate – Attach the start number plate to the brake line. – Position the start number plate. Holding lugs engage in the fender. V00829-10 – Mount and tighten screw Guideline Start number plate 4 Nm (3 lbf ft)

  • Page 55: Removing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 11.18 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) Main work – Detach brake line from the brake line guide. – Remove screw and lower the rear wheel with the swingarm as far as possible without blocking the rear wheel.

  • Page 56: Mounting The Seat

    11 SERVICE WORK ON THE CHASSIS 11.21 Mounting the seat – 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. V00837-01 –...

  • Page 57: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 11.24 Removing the air filter Note Engine damage Unfiltered 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.

  • Page 58: Installing The Air Filter

    11 SERVICE WORK ON THE CHASSIS Finishing work – Install the air filter. p. 56) – Install the air filter box cover. ( p. 54) 11.26 Installing the air filter Main work – Mount the clean air filter on the air filter support. –...

  • Page 59: Installing The Main Silencer

    SERVICE WORK ON THE CHASSIS 11 11.28 Installing the main silencer – Mount the main silencer with rubber sleeve – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00841-11 11.29 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven.

  • Page 60: Removing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS 11.30 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. –...

  • Page 61: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 – Pull both spoilers off laterally from the radiator bracket and lift off the fuel tank. V00844-10 11.31 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. –...

  • Page 62: Checking For Chain Dirt Accumulation

    11 SERVICE WORK ON THE CHASSIS – Mount and tighten screw with the rubber bushing. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00843-11 – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Mount fuel hose.

  • Page 63: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 Info The service life of the chain depends largely on its maintenance. Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) Main work – Rinse off loose dirt with a soft jet of water. –...

  • Page 64: Adjusting The Chain Tension

    11 SERVICE WORK ON THE CHASSIS 11.35 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 65: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

    SERVICE WORK ON THE CHASSIS 11 11.36 Checking the chain, rear sprocket, engine sprocket and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) Main work – Shift the transmission to idle. – Check the chain, rear sprocket and engine sprocket for wear. »...
  • Page 66 11 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with, or below, the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated.

  • Page 67: Checking The Frame

    – Change the swingarm. Info Always change a damaged swingarm. Repair of the swingarm is not authorized by KTM. V00857-01 11.39 Checking the throttle cable routing Warning Danger of accidents The throttle cable may slip out of the guide if routed incorrectly.

  • Page 68: Checking The Rubber Grip

    11 SERVICE WORK ON THE CHASSIS Main work – Check the throttle cable routing. The throttle cable must be routed along the back of the handlebar, to the right of the frame, above the fuel tank bracket, and to the carburetor. »...

  • Page 69: Checking The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS 11 11.42 Checking the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch facing discs. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 70: Changing The Hydraulic Clutch Fluid

    11 SERVICE WORK ON THE CHASSIS Info Clean up overflowed or spilled brake fluid immediately with water. 11.44 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. –...
  • Page 71 SERVICE WORK ON THE CHASSIS 11 – Inject the liquid into the system until it escapes from open- 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.

  • Page 72: 12 Brake System

    Do not make any adjustments while riding! 12.3 Checking the brake discs Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.)

  • Page 73: Checking The Front Brake Fluid Level

    – 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.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 74: Adding Front Brake Fluid

    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.

  • Page 75: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 76 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 77 BRAKE SYSTEM 12 – Remove pin – Take off retainer spring and remove the brake linings. – Clean the brake caliper. – Position new brake linings. Info Always change the brake linings in pairs. – Position retaining spring S01169-10 – Mount pin but do not tighten yet.

  • Page 78: Checking The Free Travel Of Foot Brake Lever

    12 BRAKE SYSTEM 12.8 Checking the free travel of 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.

  • Page 79: Checking The Rear Brake Fluid Level

    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.) – Stand the vehicle upright.

  • Page 80: Checking The Rear Brake Linings

    Clean up overflowed or spilled brake fluid immediately with water. A00047-10 12.12 Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.)

  • Page 81: Changing The Rear Brake Linings

    Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 82 12 BRAKE SYSTEM 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 Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
  • Page 83 BRAKE SYSTEM 12 – Operate the foot brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure point. – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 84: 13 Wheels, Tires

    13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) Main work – Loosen screw by several rotations. – Loosen screws – Press on screw to push the wheel spindle out of the axle clamp.

  • Page 85: Removing The Rear Wheel

    WHEELS, TIRES 13 Main work – 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 and contact surface of the spacers. Long-life grease ( p.

  • Page 86: Installing The Rear Wheel

    13 WHEELS, TIRES Main work – Remove nut – Remove chain adjuster . Pull out wheel spindle enough to allow the rear wheel to be pushed forward. – Push the rear wheel forward as far as possible. Remove the chain from the rear sprocket. Info Cover the components to protect them against damage.

  • Page 87: Checking The Tire Condition

    Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have a major impact on the handling of the motorcy- cle.

  • Page 88: Checking The Tire Air Pressure

    DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. KTM recommends that the tires be changed after 5 H01144-01 years at the latest, regardless of the actual state of wear.

  • Page 89: Checking Spoke Tension

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.) –...

  • Page 90: 14 Cooling System

    14 COOLING SYSTEM 14.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.
  • Page 91 COOLING SYSTEM 14 – Remove screws – Remove right radiator shield – Remove screws – Remove left radiator shield V00886-10 – Position the matching radiator cover ( p. 88). The projections point towards the frame. H02356-01 – Position left radiator shield –...

  • Page 92: Removing The Radiator Cover

    14 COOLING SYSTEM 14.4 Removing the radiator cover Info Only remove left radiator shield if both radiator covers are mounted. – Remove screws – Remove right radiator shield – Remove screws – Remove left radiator shield – Remove corresponding radiator cover. –...

  • Page 93: Checking The Coolant Level

    COOLING SYSTEM 14 – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: –...

  • Page 94: Draining The Coolant

    14 COOLING SYSTEM 14.7 Draining the coolant Warning Danger of scalding During motorcycle operation, 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 operating temperature.
  • Page 95 COOLING SYSTEM 14 Main work – Make sure that screw is tightened. – Position the motorcycle upright. – Take off radiator cap – Completely fill the radiator with coolant. Coolant ( p. 119) V00832-11 – Loosen screw until coolant escapes without bubbles. –...

  • Page 96: 15 Tuning The Engine

    15 TUNING THE ENGINE 15.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip backwards and forwards to ascertain play the throttle cable. Throttle cable play 2 …...

  • Page 97: Carburetor Setting

    TUNING THE ENGINE 15 – Turn adjusting screw in such a way there is throttle cable play in the throttle grip. Guideline Throttle cable play 2 … 3 mm (0.08 … 0.12 in) – Tighten nut – Slide on sleeve 400192-11 Finishing work –...
  • Page 98 15 TUNING THE ENGINE Idling jet IJ The idling jet has the greatest influence in the low to mid throttle slide range. If the engine stutters when idling or accelerating with a partially open throttle slide, a smaller idling jet must be used.

  • Page 99: Carburetor - Idle

    TUNING THE ENGINE 15 402797-01 Column 2 corresponds to a needle in the standard position. Column 1 corresponds to a needle which is half a clip leaner. Column 3 specifies the diameter of the first cylindrical part of the needle. The smaller the diameter of the first cylindrical part of the needle, the richer the carburation.

  • Page 100: Carburetor - Adjusting The Idle Speed

    15 TUNING THE ENGINE Carburetor – adjusting the idle speed 15.5 – Screw in idle air adjusting screw all the way and turn it to the specified basic position. Guideline Idle air adjusting screw open 2 turns – Run the engine until warm. Guideline ≥...

  • Page 101: Emptying The Carburetor Float Chamber

    TUNING THE ENGINE 15 15.6 Emptying the carburetor float chamber 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. –...

  • Page 102: Plug-In Connector Of Ignition Timing Map Adjustment

    15 TUNING THE ENGINE 15.7 Plug-in connector of ignition timing map adjustment Plug-in connector of the ignition timing map adjustment is located on the frame under the fuel tank. Possible states Soft – The plug-in connector of the ignition timing map •...
  • Page 103 TUNING THE ENGINE 15 – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the 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.

  • Page 104: 16 Service Work On The Engine

    16 SERVICE WORK ON THE ENGINE 16.1 Checking the gear oil level Condition The engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Remove screw – Check the gear oil level. Gear oil must not run out of the hole. The gear oil level is at the lower edge of the hole.

  • Page 105: Adding Gear Oil

    SERVICE WORK ON THE ENGINE 16 Guideline Oil drain plug with 20 Nm (14.8 lbf ft) magnet – Remove filler plug and fill up with gear oil. Gear oil 0.50 l Engine oil (0.53 qt.) (15W/50) p. 119) – Mount and tighten filler plug Danger Danger of poisoning Exhaust gases are toxic and inhal- 401955-11...
  • Page 106 16 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 107: Cleaning, Care 17

    CLEANING, CARE 17 17.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...
  • Page 108 17 CLEANING, CARE Info The heat produced causes water at inaccessible loca- tions in the engine and on the brake system to evapo- rate. – Push back the protection caps on the handlebar controls to allow water to evaporate. – After the motorcycle has cooled off, lubricate all moving parts and bearings.

  • Page 109: Storage 18

    99) – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with a lift stand. ( p. 44) – Cover the vehicle with a tarp or similar cover that is permeable to air.

  • Page 110: Preparing For Use After Storage

    18 STORAGE 18.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 44) – Perform checks and maintenance measures when preparing for use. ( p. 27) – Take a test ride. 401059-01...

  • Page 111: Troubleshooting 19

    TROUBLESHOOTING 19 Faults Possible cause Action – Engine turns but does not start Operating error Carry out the start procedure. p. 27) – Motorcycle was out of use for a Empty the carburetor float chamber. long time and there is old fuel p.
  • Page 112 19 TROUBLESHOOTING Faults Possible cause Action – Engine stalls or is popping into Lack of fuel Turn handle of the fuel tap to the the carburetor ONposition. – Refuel. ( p. 30) – Engine takes in bad air Check intake flange and carburetor for tightness.

  • Page 113: Technical Data 20

    TECHNICAL DATA 20 20.1 Engine Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 84.93 cm³ (5.1828 cu in) Stroke 48.95 mm (1.9272 in) Bore 47 mm (1.85 in) Idle speed 1,400 … 1,500 rpm Crankshaft bearing 1 grooved ball bearing / 1 roller bearing Conrod bearing Needle bearing...
  • Page 114 20 TECHNICAL DATA Screw, locking lever 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, power valve stop plate M5x12 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, water pump wheel 6 Nm (4.4 lbf ft) Loctite ® 243™ Coolant drain plug 8 Nm (5.9 lbf ft) Nut, adjusting screw, power valve...

  • Page 115: Carburetor

    TECHNICAL DATA 20 20.3 Carburetor Carburetor type KEIHIN PWK 28 Needle position 3rd position from top Idle air adjusting screw open 2 turns Main jet 142 (140, 145, 148) Jet needle NRKC (NRJC) Idling jet 48 (45, 50) Throttle slide Cold start jet 20.3.1 Basic carburetor setting for sandy surfaces...

  • Page 116: Carburetor Tuning

    20 TECHNICAL DATA 20.3.2 Carburetor tuning 402814-01 M/FT ASL Above sea level TEMP Temperature Open (rotations) idle air adjusting screw Idling jet Jet needle Needle position from top Main jet...

  • Page 117: Capacities

    TECHNICAL DATA 20 20.4 Capacities 20.4.1 Gear oil Gear oil 0.50 l (0.53 qt.) Engine oil (15W/50) ( p. 119) 20.4.2 Coolant Coolant 0.8 l (0.8 qt.) Coolant ( p. 119) 20.4.3 Fuel Fuel tank capacity, approx. 5.2 l (1.37 US gal) Super unleaded (98 octane) mixed with 2-stroke engine oil (1:40) p.

  • Page 118: Tires

    90/100 - 16 M/C 52M TT (85 SX 19/16) MAXXIS MAXX CROSS SI MAXXIS MAXX CROSS SI The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 20.7 Fork Fork article number 43.18.8S.04 Fork...

  • Page 119: Chassis Tightening Torques

    TECHNICAL DATA 20 Standard 15 clicks Sport 12 clicks Spring preload 11 mm (0.43 in) Spring rate Weight of rider: < 45 kg (< 99 lb.) 35 N/mm (200 lb/in) Weight of rider: 45 … 55 kg (99 … 121 lb.) 40 N/mm (228 lb/in) Weight of rider: >...
  • Page 120 20 TECHNICAL DATA Screw, top triple clamp 17 Nm (12.5 lbf ft) Steering stem clamp screw 20 Nm (14.8 lbf ft) Engine carrying screw 45 Nm (33.2 lbf ft) Nut, foot brake lever 45 Nm (33.2 lbf ft) Loctite ® 243™...

  • Page 121: Substances 21

    SUBSTANCES 21 Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 Motorex ®...
  • Page 122 21 SUBSTANCES Recommended supplier Motorex ® – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 123) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

  • Page 123: Auxiliary Substances 22

    Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Grip adhesive (00062030051) Recommended supplier KTM AG – GRIP GLUE High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier Motorex ® –...
  • Page 124 22 AUXILIARY SUBSTANCES Oil for foam air filter Recommended supplier Motorex ® – Racing Bio Liquid Power Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ®...

  • Page 125: Standards 23

    STANDARDS 23 JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 126: 24 List Of Abbreviations

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

  • Page 127: Index

    INDEX Chain tension INDEX adjusting ......62 Accessories ......9 checking .
  • Page 128 INDEX Fork air pressure, adjusting ....40 Lower triple clamp Fork legs installing ......48 basic setting, checking .
  • Page 129 INDEX removing ......53 Tire condition checking ......85 Service .
  • Page 130 *3213846en* 3213846en 01/2018 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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