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85 SX 2021
KTM 85 SX 2021 User Manual
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SERVICE
WORK
ON
THE
ENGINE
16
107
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
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)
108
110
Table of Contents
Default Chapter
4
Table of Contents
4
1 Means of Representation 1
7
Symbols Used
7
Formats Used
7
2 Safety Advice
8
Use Definition - Intended Use
8
Misuse
8
Degrees of Risk and Symbols
8
Tampering Warning
9
Safe Operation
9
Protective Clothing
10
Work Rules
10
Environment
10
Owner's Manual
10
3 Important Notes 3
11
Manufacturer Warranty, Implied Warranty
11
Fuel, Auxiliary Substances
11
Spare Parts, Accessories
11
Service
11
Figures
11
Customer Service
11
4 View of Vehicle
12
View of Vehicle, Front Left (Example)
12
View of Vehicle, Rear Right (Example)
13
5 Serial Numbers
14
Vehicle Identification Number
14
Type Label
14
Engine Number
14
Fork Part Number
14
Shock Absorber Article Number
15
6 Controls
16
Clutch Lever
16
Hand Brake Lever
16
Throttle Grip
16
Switch-Off Button
16
Opening the Fuel Tank Filler Cap
17
Closing the Fuel Tank Filler Cap
17
Fuel Tap
18
Choke
18
Shift Lever
18
Kick Starter Lever
19
Foot Brake Lever
19
Plug-In Stand
19
Service Hour Counter
20
7 Preparing for Use 7
21
Advice on Preparing for First Use
21
Running in the Engine
23
Preparing the Vehicle for Difficult Riding Conditions
23
Preparing the Vehicle for Riding on Dry Sand
23
Preparing the Vehicle for Riding on Wet Sand
25
Preparing Vehicle for Rides on Wet and Muddy Circuits
26
Preparing Vehicle for High Temperatures or Slow Riding
26
Preparing the Vehicle for Low Temperatures or Snow
27
8 Riding Instructions
28
Checks and Maintenance Measures When Preparing for Use
28
Starting the Vehicle
28
Starting off
29
Shifting, Riding
29
Applying the Brakes
30
Stopping, Parking
30
Transporting
31
Refueling
31
9 Service Schedule 9
33
Additional Information
33
Required Work
33
Recommended Work
34
10 Tuning the Chassis 10
35
Checking the Basic Chassis Setting with Rider's Weight
35
Air Suspension XACT 5543
35
Compression Damping of the Shock Absorber
36
Adjusting the Low-Speed Compression Damping of the Shock Absorber
36
Adjusting the High-Speed Compression Damping of the Shock Absorber
37
Adjusting the Rebound Damping of the Shock Absorber
37
Measuring the Dimension of the Rear Wheel Unloaded
38
Checking the Static Sag of the Shock Absorber
38
Checking the Riding Sag of the Shock Absorber
39
Adjusting the Spring Preload of the Shock Absorber
39
Adjusting the Riding Sag
40
Checking the Basic Setting of the Fork
41
Adjusting the Fork Air Pressure
41
Adjusting the Compression Damping of the Fork
43
Adjusting the Rebound Damping of the Fork
43
Handlebar Position
44
Adjusting the Handlebar Position
44
11 Service Work on the Chassis
46
Raising the Motorcycle with a Lift Stand
46
Removing the Motorcycle from the Lift Stand
46
Bleeding the Fork Legs
46
Cleaning the Dust Boots of the Fork Legs
47
Removing the Fork Legs
47
Installing the Fork Legs
48
Removing the Fork Protector
49
Installing the Fork Protector
49
Removing the Lower Triple Clamp
50
Installing the Lower Triple Clamp
51
Checking the Steering Head Bearing Play
53
Adjusting the Steering Head Bearing Play
54
Greasing the Steering Head Bearing
55
Removing the Start Number Plate
55
Installing the Start Number Plate
55
Removing Front Fender
56
Installing Front Fender
56
Removing the Shock Absorber
56
Installing the Shock Absorber
57
Removing the Seat
57
Mounting the Seat
57
Removing the Air Filter Box Cover
58
Installing the Air Filter Box Cover
58
Removing the Air Filter
58
Cleaning the Air Filter and Air Filter Box
59
Installing the Air Filter
59
Removing the Main Silencer
60
Installing the Main Silencer
60
Changing the Glass Fiber Yarn Filling of the Main Silencer
60
Removing the Fuel Tank
61
Installing the Fuel Tank
63
Checking for Chain Dirt Accumulation
64
Cleaning the Chain
64
Checking the Chain Tension
65
Adjusting the Chain Tension
66
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide
67
Checking the Frame
69
Checking the Link Fork
69
Checking the Throttle Cable Routing
69
Checking the Rubber Grip
70
Adjusting the Basic Position of the Clutch Lever
70
Checking the Fluid Level of the Hydraulic Clutch
71
Correcting the Fluid Level of the Hydraulic Clutch
71
Changing the Hydraulic Clutch Fluid
72
12 Brake System
74
Checking the Free Travel of the Hand Brake Lever
74
Adjusting the Free Travel of the Handbrake Lever
74
Checking the Brake Discs
74
Checking the Front Brake Fluid Level
75
Adding the Front Brake Fluid
76
Checking the Front Brake Linings
77
Changing the Brake Linings of the Front Brake
77
Checking the Free Travel of Foot Brake Lever
80
Adjusting the Basic Position of the Foot Brake Lever
80
Checking the Rear Brake Fluid Level
81
Adding Rear Brake Fluid
81
Checking the Rear Brake Linings
82
Changing the Rear Brake Linings
83
13 Wheels, Tires
86
Removing the Front Wheel
86
Installing the Front Wheel
86
Removing the Rear Wheel
87
Installing the Rear Wheel
88
Checking the Tire Condition
89
Checking Tire Pressure
90
Checking Spoke Tension
91
14 Cooling System
92
Radiator Cover
92
Installing the Radiator Cover
92
Removing the Radiator Cover
94
Checking the Antifreeze and Coolant Level
94
Checking the Coolant Level
95
Draining the Coolant
96
Refilling with Coolant
96
Changing the Coolant
97
15 Tuning the Engine 15
99
Checking Throttle Cable Play
99
Adjusting the Throttle Cable Play
99
Carburetor Tuning
100
Carburetor - Idle
102
Carburetor - Adjusting the Idle Speed
103
Emptying the Carburetor Float Chamber
104
Plug-In Connector of Ignition Timing Map Adjustment
105
Changing the Ignition Timing Map
105
Checking the Basic Position of the Shift Lever
105
Adjusting the Basic Position of the Shift Lever
105
16 Service Work on the Engine 16
107
Checking the Gear Oil Level
107
Changing the Gear Oil
107
Adding the Gear Oil
108
17 Cleaning, Care
110
Cleaning the Motorcycle
110
18 Storage
112
Preparing for Use after Storage
113
19 Troubleshooting
114
20 Technical Data
116
Engine
116
Engine Tightening Torques
116
Carburetor
118
Basic Carburetor Setting for Sandy Surfaces
118
Carburetor Tuning
119
Capacities
120
Gear Oil
120
Coolant
120
Fuel
120
Chassis
120
Tires
121
Fork
121
Shock Absorber
121
Chassis Tightening Torques
122
21 Substances
124
22 Auxiliary Substances
126
23 Standards
128
24 List of Abbreviations 24
129
Index
130
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Setup Instructions
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KTM 85 SX 2021 Specifications
General
Brand
KTM
Model
85 SX 2021
Category
Motorcycle
Language
English
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