KTM 85 SX 19 User Manual

OWNER'S MANUAL 2013
85 SX 19/16
85 SX 17/14
Art. no. 3211856en

KTM 85 SX 19 Specifications

General

Transmission	6-speed
Starter	Kickstarter
Engine Type	1-cylinder, 2-stroke engine
Displacement	84.9 cm³
Cooling	Liquid-cooled
Front Suspension	WP XACT 43
Rear Suspension	WP monoshock
Front Brake	Disc brake
Rear Brake	Disc brake
Front Tire	70/100
Rear Tire	90/100
Frame	Chromium-Molybdenum steel
Front Brake Diameter	220 mm
Rear Brake Diameter	190 mm

Summary

Means of Representation

Symbols Used

Explains symbols used in the manual for clarity and warnings.

Formats Used

Describes typographical conventions and their meanings.

Safety Advice

Use Definition - Intended Use

Defines the specific purpose and intended use of KTM sport motorcycles.

Safety Advice

General instructions for safe operation of the vehicle.

Degrees of Risk and Symbols

Explains hazard symbols and their associated risk levels.

Tampering Warning

Warns against modifying noise control systems and specifies prohibited acts.

Safety Advice Continued

Protective Clothing

Emphasizes the importance of wearing appropriate protective gear.

Work Rules

Outlines guidelines for performing maintenance and repair work correctly.

Environment

Discusses responsible use and disposal of fluids and components.

Owner's Manual

Stresses the importance of reading and keeping the manual for proper operation.

Important Notes

Guarantee, Warranty

Details conditions for warranty claims and maintenance requirements.

Operating and Auxiliary Substances

Specifies required fluids, fuels, and their proper handling.

Service

Highlights the importance of regular service for optimal performance and longevity.

View of Vehicle

View of Vehicle, Front Left (Example)

Illustrates and labels key components of the front left view.

View of Vehicle Continued

View of Vehicle, Rear Right (Example)

Illustrates and labels key components of the rear right view.

Serial Numbers

Chassis Number

Shows location of the chassis number for identification.

Type Label

Indicates the location of the vehicle's type label.

Engine Number

Shows where the engine number is stamped.

Controls

Clutch Lever

Describes the clutch lever and its operation.

Hand Brake Lever

Identifies the hand brake lever and its function.

Throttle Grip

Explains the throttle grip's location and use.

Kill Switch

Details the kill switch's function and operating positions.

Controls Continued

Closing the Filler Cap

Explains how to properly close the fuel filler cap.

Fuel Tap

Describes the location and function of the fuel tap.

Controls Continued

Choke

Explains the choke lever's function for cold starts.

Shift Lever

Shows the shift lever and gear positions.

Kick Starter

Describes the kick starter's location and use.

Controls Continued

Plug-in Stand

Explains the use and removal of the plug-in stand for parking.

Preparing for Use

Advice on First Use

Provides critical safety and operational advice for initial use.

Preparing for Use Continued

Running in the Engine

Guides on the proper engine break-in procedure and performance limits.

Preparing the Vehicle for Difficult Riding Conditions

Details specific preparations for various challenging riding environments.

Preparing for Use Continued

Preparing for Rides on Dry Sand

Outlines necessary checks and modifications for riding in dry sand.

Preparing for Rides on Wet Sand

Details preparations for riding in wet sand conditions.

Preparing for Use Continued

Preparing for Rides on Wet and Muddy Surfaces

Provides guidance for riding in wet and muddy terrain.

Preparing for Rides at High Temperature and Slow Speed

Lists preparations for operating in hot conditions and at slow speeds.

Preparing for Use Continued

Preparing for Riding at Low Temperatures or in Snow

Explains preparations for riding in cold weather and snow.

Riding Instructions

Checks and Maintenance Work When Preparing for Use

Lists essential pre-ride checks for safety and operation.

Starting

Details the correct procedure for starting the motorcycle engine.

Riding Instructions Continued

Starting Off

Explains how to begin riding after starting the engine.

Shifting, Riding

Covers gear shifting techniques and general riding advice.

Applying the Brakes

Provides instructions and warnings on effective braking techniques.

Riding Instructions Continued

Stopping, Parking

Guides on how to safely stop and park the motorcycle.

Transport

Offers advice on transporting the motorcycle securely.

Riding Instructions Continued

Refueling

Explains the correct procedure and safety precautions for refueling.

Service Schedule

Service Schedule

Details scheduled maintenance tasks based on operating hours.

Service Schedule Continued

Service Work (as Additional Order)

Lists optional service tasks that can be performed.

Tuning the Chassis

Checking the Basic Chassis Setting with the Rider's Weight

Explains how to adjust the suspension based on rider weight.

Compression Damping of the Shock Absorber

Introduces the concepts of high-speed and low-speed compression damping.

Adjusting the Low-Speed Compression Damping of the Shock Absorber

Provides instructions for adjusting low-speed compression damping.

Tuning the Chassis Continued

Adjusting the High-Speed Compression Damping of the Shock Absorber

Details how to adjust high-speed compression damping.

Adjusting the Rebound Damping of the Shock Absorber

Explains the process for adjusting rebound damping.

Tuning the Chassis Continued

Measuring Rear Wheel Sag Unloaded

Describes how to measure unloaded rear wheel sag.

Checking the Static Sag of the Shock Absorber

Explains how to check static sag and adjust spring preload.

Checking the Riding Sag of the Shock Absorber

Details how to measure riding sag and adjust suspension.

Tuning the Chassis Continued

Adjusting the Spring Preload of the Shock Absorber

Provides step-by-step instructions for adjusting spring preload.

Adjusting the Riding Sag

Explains how to adjust riding sag by selecting springs.

Tuning the Chassis Continued

Checking the Basic Setting of the Fork

Discusses basic fork settings and considerations for spring replacement.

Adjusting the Compression Damping of the Fork

Details how to adjust fork compression damping.

Adjusting the Rebound Damping of the Fork

Explains how to adjust fork rebound damping.

Tuning the Chassis Continued

Handlebar Position

Describes options for adjusting handlebar mounting positions.

Adjusting the Handlebar Position

Provides instructions for adjusting handlebar position and tightening.

Service Work on the Chassis

Raising the Motorcycle with the Lift Stand

Explains how to safely raise the motorcycle for service.

Removing the Motorcycle from the Lift Stand

Guides on safely lowering the motorcycle.

Bleeding the Fork Legs

Details the procedure for bleeding air from the fork legs.

Service Work on the Chassis Continued

Cleaning the Dust Boots of the Fork Legs

Explains how to clean fork dust boots to prevent seal damage.

Removing the Fork Protector

Details how to remove the fork protector.

Installing the Fork Protector

Provides instructions for installing the fork protector.

Service Work on the Chassis Continued

Removing the Fork Legs

Describes the process for removing the front fork legs.

Installing the Fork Legs

Guides on installing the front fork legs correctly.

Service Work on the Chassis Continued

Removing the Lower Triple Clamp

Details the steps to remove the lower triple clamp.

Service Work on the Chassis Continued

Installing the Lower Triple Clamp

Explains how to install the lower triple clamp.

Service Work on the Chassis Continued

Checking the Play of the Steering Head Bearing

Describes how to check for play in the steering head bearing.

Adjusting the Play of the Steering Head Bearing

Provides instructions for adjusting steering head bearing play.

Service Work on the Chassis Continued

Greasing the Steering Head Bearing

Explains how to grease the steering head bearing.

Removing the Start Number Plate

Details the process for removing the start number plate.

Checking the Frame

Guides on inspecting the motorcycle frame for damage.

Service Work on the Chassis Continued

Removing the Shock Absorber

Details how to remove the rear shock absorber.

Installing the Shock Absorber

Guides on installing the rear shock absorber.

Removing the Seat

Explains how to remove the motorcycle seat.

Service Work on the Chassis Continued

Mounting the Seat

Provides instructions for installing the motorcycle seat.

Removing the Air Filter Box Lid

Describes how to remove the air filter box lid.

Installing the Air Filter Box Lid

Guides on installing the air filter box lid.

Service Work on the Chassis Continued

Installing the Air Filter

Provides instructions for installing the air filter.

Cleaning the Air Filter and Air Filter Box

Explains how to clean the air filter and its housing.

Removing the Main Silencer

Details how to remove the main exhaust silencer.

Service Work on the Chassis Continued

Installing the Main Silencer

Guides on installing the main exhaust silencer.

Changing the Glass Fiber Yarn Filling of the Main Silencer

Explains how to replace the silencer's internal packing.

Service Work on the Chassis Continued

Removing the Fuel Tank

Details how to safely remove the fuel tank.

Service Work on the Chassis Continued

Installing the Fuel Tank

Guides on installing the fuel tank.

Checking for Chain Dirt Accumulation

Explains how to check the drive chain for dirt.

Cleaning the Chain

Provides instructions for cleaning the drive chain.

Service Work on the Chassis Continued

Checking the Chain Tension

Describes how to check the drive chain's tension.

Adjusting the Chain Tension

Guides on how to adjust the drive chain tension.

Service Work on the Chassis Continued

Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide

Explains how to inspect the drive chain components for wear.

Service Work on the Chassis Continued

Adjusting the Chain Guide

Details how to adjust the chain guide.

Checking the Frame

Guides on inspecting the motorcycle frame for damage.

Checking the Throttle Cable Routing

Details how to check the throttle cable's routing.

Service Work on the Chassis Continued

Adjusting the Basic Position of the Clutch Lever

Describes how to adjust the clutch lever's position.

Checking the Fluid Level of the Hydraulic Clutch

Explains how to check the hydraulic clutch fluid level.

Service Work on the Chassis Continued

Correcting the Fluid Level of the Hydraulic Clutch

Guides on how to add hydraulic clutch fluid.

Changing the Hydraulic Clutch Fluid

Details the process for changing the hydraulic clutch fluid.

Brake System

Checking the Free Travel of the Hand Brake Lever

Explains how to check and adjust hand brake lever free travel.

Adjusting the Free Travel of the Handbrake Lever

Provides instructions for adjusting hand brake lever free travel.

Checking the Brake Discs

Guides on checking brake disc thickness and condition.

Brake System Continued

Checking Front Brake Fluid Level

Explains how to check the front brake fluid level.

Adding Front Brake Fluid

Guides on adding front brake fluid and safety precautions.

Brake System Continued

Checking the Front Brake Linings

Describes how to check front brake lining thickness and condition.

Changing the Front Brake Linings

Details the process for changing front brake linings.

Brake System Continued

Checking the Free Travel of Foot Brake Lever

Explains how to check foot brake lever free travel.

Adjusting the Basic Position of the Foot Brake Lever

Guides on adjusting the foot brake lever's position.

Brake System Continued

Checking the Rear Brake Fluid Level

Explains how to check the rear brake fluid level.

Adding Rear Brake Fluid

Guides on adding rear brake fluid and safety precautions.

Brake System Continued

Checking the Rear Brake Linings

Describes how to check rear brake lining thickness and condition.

Brake System Continued

Changing the Rear Brake Linings

Details the process for changing rear brake linings.

Wheels, Tires

Removing the Front Wheel

Explains how to remove the front wheel.

Installing the Front Wheel

Guides on installing the front wheel.

Wheels, Tires Continued

Removing the Rear Wheel

Details how to remove the rear wheel.

Installing the Rear Wheel

Guides on installing the rear wheel.

Wheels, Tires Continued

Checking the Tire Condition

Explains how to check tire condition, tread depth, and age.

Wheels, Tires Continued

Checking the Tire Air Pressure

Guides on checking and setting tire air pressure.

Checking the Spoke Tension

Describes how to check and adjust spoke tension.

Cooling System

Cooling System

Provides a basic overview of the cooling system.

Checking the Antifreeze and Coolant Level

Explains how to check coolant and antifreeze levels and warnings.

Checking the Coolant Level

Details the procedure for checking the coolant level.

Cooling System Continued

Draining the Coolant

Guides on how to drain the coolant from the system.

Refilling Coolant

Explains how to refill the cooling system with coolant.

Tuning the Engine

Checking the Play in the Throttle Cable

Explains how to check throttle cable play.

Adjusting the Play in the Throttle Cable

Guides on adjusting throttle cable play.

Carburetor - Idle

Discusses the importance of idle settings and factory values.

Tuning the Engine Continued

Carburetor - Adjusting Idle Speed

Details the procedure for adjusting the engine's idle speed.

Tuning the Engine Continued

Emptying the Carburetor Float Chamber

Explains how to drain the carburetor float chamber.

Checking the Basic Position of the Shift Lever

Guides on checking the shift lever's position relative to the boot.

Adjusting the Basic Position of the Shift Lever

Details how to adjust the shift lever's position.

Maintenance Work on the Engine

Checking the Gear Oil Level

Explains how to check the engine's gear oil level.

Changing the Gear Oil

Outlines the process for changing the gear oil.

Draining the Gear Oil

Guides on draining the gear oil.

Maintenance Work on the Engine Continued

Filling up with Gear Oil

Details how to refill the engine with gear oil.

Adding Gear Oil

Explains how to add gear oil and check for leaks.

Cleaning, Care

Cleaning the Motorcycle

Provides instructions and precautions for cleaning the motorcycle.

Storage

Storage

Details steps for long-term storage of the motorcycle.

Preparing for Use After Storage

Outlines procedures for recommissioning after storage.

Troubleshooting

Engine Turns but Does Not Start

Lists potential causes and actions for starting issues.

Engine Has No Idle

Lists potential causes and actions for idle problems.

Engine Does Not Speed Up

Lists potential causes and actions for acceleration issues.

Troubleshooting Continued

Engine Stalls or is Popping into the Carburetor

Lists potential causes and actions for engine stalling or backfiring.

Engine Overheats

Lists potential causes and actions for engine overheating.

White Smoke Emission (Steam in Exhaust Gas)

Lists potential causes and actions for white smoke.

Technical Data

Engine

Provides specifications for the engine.

Engine Tightening Torques

Lists torque specifications for engine components.

Technical Data Continued

Capacities

Lists fluid capacities for the motorcycle.

Chassis

Provides chassis specifications.

Technical Data Continued

Tires

Lists tire specifications and validity.

Fork

Provides specifications for the front fork.

Technical Data Continued

Shock Absorber

Lists specifications for the rear shock absorber.

Chassis Tightening Torques

Lists torque specifications for chassis components.

Technical Data Continued

Carburetor

Provides carburetor type and settings.

Carburetor Tuning

Details carburetor tuning charts for different conditions.

Substances

2-Stroke Engine Oil

Specifies recommended 2-stroke engine oil types and standards.

Brake Fluid DOT 4 / DOT 5.1

Lists recommended brake fluid types and standards.

Coolant

Specifies recommended coolant types and mixture ratios.

Auxiliary Substances

Air Filter Cleaner

Lists recommended air filter cleaner products.

Chain Cleaner

Lists recommended chain cleaner products.

Fuel Additive

Lists recommended fuel additive products.

Auxiliary Substances Continued

High Viscosity Grease

Lists recommended high viscosity grease.

Long-Life Grease

Lists recommended long-life grease.

Off-Road Chain Spray

Lists recommended off-road chain spray products.

Standards

JASO FC

Explains the JASO FC standard for 2-stroke engine oil.

JASO T903 MA

Explains the JASO T903 MA standard for 4-stroke motorcycle oils.

SAE

Explains SAE viscosity classification for oils.