This document is the "SETUP INSTRUCTIONS 2022" for the KTM 85 SX, with article number 3214489EN, published in May 2021. It serves as a guide for preparing the vehicle for customer delivery, emphasizing the importance of performing all described work before handover. The manual is intended for fully trained mechanics and assumes a basic understanding of general workshop methods and safety rules.
Function Description:
The KTM 85 SX is a motocross motorcycle designed for competitive racing, specifically for younger riders transitioning from smaller bikes. The setup instructions detail the initial assembly and preparation steps required to make the motorcycle ready for use. This includes unpacking, setting up the vehicle, installing key components like the front wheel, handlebars, shock absorber, front fender, and start number plate, as well as preparing the fuel system. The overall function of these instructions is to ensure the motorcycle is correctly assembled, all components are securely fastened to specified torques, and the vehicle is safe and ready for operation according to KTM's quality standards.
Important Technical Specifications:
The manual provides critical tightening torques for various chassis components, which are essential for the safe and reliable operation of the motorcycle. These specifications are categorized by screw/nut type and size (e.g., M3, M4, M4.5, M5, M6, M8, M10, M12, M12x1, M14x1.5, M20x1.5).
Key tightening torques include:
- Screw, stop button (M3): 0.4 Nm (0.3 lbf ft)
- Screw, carburetor cover (M4): 2 Nm (1.5 lbf ft)
- Screw, fixed grip (M4): 5 Nm (3.7 lbf ft) with Loctite®243TM
- Spoke nipple (M4.5): 5 Nm (3.7 lbf ft)
- Remaining nuts/screws, chassis (M5): 5 Nm (3.7 lbf ft)
- Screw, main silencer (M5): 7 Nm (5.2 lbf ft)
- Screw, shock absorber adjusting ring (M5): 5 Nm (3.7 lbf ft)
- Nut, push rod, foot brake lever (M6): 6 Nm (4.4 lbf ft)
- Pin, front brake (M6): 8 Nm (5.9 lbf ft)
- Pin, rear brake (M6): 4 Nm (3 lbf ft)
- Remaining nuts/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) with Loctite®243TM
- Screw, clutch assembly on handlebar (M6): 5 Nm (3.7 lbf ft)
- Screw, foot brake cylinder (M6): 10 Nm (7.4 lbf ft)
- Screw, front brake assembly on handlebar (M6): 5 Nm (3.7 lbf ft)
- Screw, front brake disc (M6): 14 Nm (10.3 lbf ft) with Loctite®243TM
- Screw, front fender (M6): 6 Nm (4.4 lbf ft)
- Screw, fuel tank spoiler on radiator (M6): 6 Nm (4.4 lbf ft)
- Screw, ignition coil (M6): 6.4 Nm (4.72 lbf ft)
- Screw, rear brake disc (M6): 14 Nm (10.3 lbf ft) with Loctite®243TM
- Start number plate screw (M6): 4 Nm (3 lbf ft)
- Throttle cable wire on carburetor cover (M6x0.75): 3 Nm (2.2 lbf ft)
- Nut, rim lock (M8): 10 Nm (7.4 lbf ft)
- Remaining nuts/screws, chassis (M8): 25 Nm (18.4 lbf ft)
- Screw, bottom triple clamp (M8): 15 Nm (11.1 lbf ft)
- Screw, chain sliding piece (M8): 15 Nm (11.1 lbf ft)
- Screw, engine brace (M8): 25 Nm (18.4 lbf ft) with Loctite®2701M
- Screw, engine sprocket cover (M8): 15 Nm (11.1 lbf ft)
- Screw, foot brake lever stop (M8): 20 Nm (14.8 lbf ft)
- Screw, fork stub (M8): 15 Nm (11.1 lbf ft)
- Screw, front brake caliper (M8): 25 Nm (18.4 lbf ft) with Loctite®243TM
- Screw, handlebar clamp (M8): 20 Nm (14.8 lbf ft)
- Screw, rear brake caliper (M8): 18 Nm (13.3 lbf ft) with Loctite®243TM
- Screw, rear sprocket (M8): 35 Nm (25.8 lbf ft) with Loctite®2701M
- Screw, subframe (M8): 35 Nm (25.8 lbf ft) with Loctite®2701M
- Screw, top triple clamp (M8): 17 Nm (12.5 lbf ft)
- Steering stem clamp screw (M8): 20 Nm (14.8 lbf ft)
- Engine carrying screw (M10): 45 Nm (33.2 lbf ft)
- Nut, foot brake lever (M10): 45 Nm (33.2 lbf ft) with Loctite®243TM
- Remaining nuts/screws, chassis (M10): 45 Nm (33.2 lbf ft)
- Screw, handlebar support (M10): 40 Nm (29.5 lbf ft) with Loctite®243TM
- Screw, bottom shock absorber (M12): 60 Nm (44.3 lbf ft) with Loctite®2701M
- Screw, top shock absorber (M12): 60 Nm (44.3 lbf ft) with Loctite®2701M
- Nut, seat fixing (M12x1): 20 Nm (14.8 lbf ft)
- Nut, swingarm pivot (M14x1.5): 75 Nm (55.3 lbf ft)
- Nut, rear wheel spindle (M20x1.5): 80 Nm (59 lbf ft)
- Nut, steering stem (M20x1.5): 10 Nm (7.4 lbf ft)
- Screw, front wheel spindle (M20x1.5): 35 Nm (25.8 lbf ft)
Fuel Specifications:
- Fuel tank capacity, approx.: 5.2 l (1.37 US gal)
- Fuel type: Super unleaded (98 octane) mixed with 2-stroke engine oil (1:40)
- Standard/classification (fuel): DIN EN 228 (ROZ 98 / RON 98 / PON 94)
- Engine oil, 2-stroke: JASO FD (fully synthetic)
- Recommended supplier (fuel/oil): MOTOREX® Cross Power 2T
Usage Features:
The setup instructions guide the user through the initial assembly process, which includes:
- Unpacking and setup: Removing the vehicle from its packaging, using a lift stand (78929955100), and checking for transport damage.
- Front wheel installation: Loosening screws, inserting the wheel spindle, and tightening the screw to 35 Nm (25.8 lbf ft).
- Handlebar positioning: Correctly positioning and tightening handlebar clamps to 20 Nm (14.8 lbf ft), ensuring markings are centered and gaps are equal.
- Service hour counter installation: Mounting the counter, routing its cable through a recess and under the wiring harness to the ignition wire.
- Footrest installation: Positioning the spring, using a footrest spring plier (79029083000) to press the spring, and mounting the pin, washer, and splint.
- Shock absorber installation: Pushing the splash protector, positioning the shock absorber, and tightening screws to 60 Nm (44.3 lbf ft) with Loctite®2701M.
- Front fender and start number plate installation: Mounting these components according to instructions.
- Fuel tank removal/installation: Detailed steps for safely removing and installing the fuel tank, including warnings about fuel flammability and toxicity.
- Throttle cable routing check: Ensuring the throttle cable is correctly routed along the back of the handlebar, to the right of the frame, above the fuel tank bracket, and to the carburetor.
- Refueling: Instructions for opening and closing the fuel tank filler cap, and filling the tank with the specified fuel mixture.
Maintenance Features:
While primarily a setup guide, the document implicitly highlights several maintenance-related features:
- Quality Assurance: KTM applies ISO 9001 quality assurance processes, ensuring high product quality.
- Damage Prevention: Instructions include warnings about potential damage during unpacking and setup, such as preventing the motorcycle from falling over and checking for transport damage.
- Safety Warnings: Extensive warnings are provided regarding the dangers of fuel (fire hazard, poisoning) and the importance of correct handlebar and throttle cable installation to prevent accidents.
- Component Integrity: Emphasis on checking for bent or damaged handlebars (requiring replacement) and ensuring correct seating of brake linings.
- Lubrication/Sealants: Specification of Loctite® for certain screws (e.g., fixed grip, ball joint of push rod on foot brake cylinder, front brake disc, engine brace, bottom/top shock absorber, front/rear brake caliper, handlebar support, rear sprocket, subframe, foot brake lever), indicating critical connections that require thread-locking compounds for secure fastening and to prevent loosening due to vibrations.
- Fuel Handling: Detailed instructions on safe refueling practices, including switching off the engine, avoiding open flames, preventing spills, and proper disposal of fuel.
- Documentation: The manual refers to the Customer Service Manual for procedures related to missing components or transport damage, indicating a broader support system for maintenance and troubleshooting.
- KTM PowerParts: Mention of unpacking and mounting optional KTM PowerParts, implying that the motorcycle is designed to accommodate additional performance or aesthetic upgrades.
The document is structured with clear sections for "Means of Representation," "Setup," and "Work," using symbols and typographical formats to enhance readability and comprehension. It underscores KTM's commitment to providing comprehensive instructions for the proper preparation and initial care of their motorcycles.
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