KTM 85 SX 2020 User Manual (English)

Other manuals for KTM 85 SX 2020

Questions and Answers:

M
Michael DavisJul 29, 2025
Why is my KTM Motorcycle engine overheating?
- C
  clayton16Jul 29, 2025
  If your KTM Motorcycle engine overheats, several factors could be responsible. It might be due to insufficient coolant, so you should check the cooling system for leaks and the coolant level. Insufficient airflow can also cause overheating, so switch off the engine when standing. Dirty radiator fins can be another cause, so ensure you clean them. Other potential issues include foam formation in the cooling system (in this case, drain and refill the coolant), a damaged cylinder head or cylinder head gasket (check these components), a bent radiator hose (replace it), or an incorrect ignition point due to a loose stator (adjust the ignition).
E
Erin AustinAug 5, 2025
What to do if my KTM 85 SX 2020 engine stalls or pops into the carburetor?
- D
  Douglas WilsonAug 5, 2025
  If your KTM Motorcycle engine stalls or pops into the carburetor, it could be due to several reasons. One possibility is a lack of fuel; ensure the fuel tap is in the ON position and refuel if necessary. Another reason might be that the engine is taking in bad air; check the intake flange and carburetor for tightness. Also, a loose or oxidized connector or ignition coil could be the culprit; clean the connector and treat it with contact spray.
V
valerieherreraAug 13, 2025
Why does my KTM 85 SX 2020 emit white smoke (steam) in the exhaust gas?
- D
  David VaughnAug 13, 2025
  White smoke emission from your KTM Motorcycle exhaust gas indicates steam. This could be due to a damaged cylinder head or cylinder head gasket. Therefore, you should check the cylinder head and cylinder head gasket.
T
Tonya LaneAug 21, 2025
Why is gear oil exiting at the vent hose on my KTM Motorcycle?
- E
  Elizabeth GibbsAug 21, 2025
  If gear oil exits at the vent hose of your KTM Motorcycle, it's likely because too much gear oil was added. Check the gear oil level.

KTM 85 SX 2020 Specifications

General

Engine Type	1-cylinder, 2-stroke engine
Displacement	84.9 cm³
Starter	Kickstarter
Transmission	6-speed
Clutch	Wet, multi-disc clutch, Formula hydraulics
Front Brake	Disc brake
Rear Brake	Disc brake
Front Brake Disc Diameter	240 mm
Chain	1/2 x 5/16"
Steering Head Angle	66°
Weight (without fuel)	68 kg
Frame Material	Chrome-molybdenum steel
Bore x Stroke	47 mm x 48.95 mm
Frame Design	Central tube frame, chrome molybdenum steel
Front Suspension	WP XACT USD, 43 mm
Rear Suspension	WP XACT monoshock
Tank Capacity	5.2 liters
Fuel System	Keihin PWK 28
Wheelbase	1, 290 ± 10 mm

Summary

MEANS OF REPRESENTATION

Symbols used

Explains the meaning of symbols used in the manual for clarity.

Formats used

Explains the typographical formats used throughout the document.

SAFETY ADVICE

Use definition – intended use

Defines the intended use of the vehicle and its limitations.

Misuse

Describes what constitutes misuse of the vehicle and potential dangers.

Safety advice

General instructions for safe operation and maintenance.

Degrees of risk and symbols

Explains the risk categories and associated symbols used.

Tampering warning

Warns against tampering with the noise control system and its consequences.

Safe operation

Provides essential guidelines for safe operation of the vehicle.

Protective clothing

Emphasizes the importance of appropriate protective clothing.

Work rules

Outlines rules and procedures for performing work on the vehicle.

Environment

Covers environmental awareness and proper disposal of fluids.

Owner's Manual

Stresses the importance of reading and keeping the owner's manual.

IMPORTANT NOTES

Manufacturer and implied warranty

Details warranty conditions and authorized service requirements.

Fuel, auxiliary substances

Notes on using correct fuels and auxiliary substances.

Spare parts, accessories

Recommends using genuine spare parts and accessories.

Service

Highlights the importance of proper service for wear prevention.

Figures

Notes that figures may depict special equipment.

Customer service

Directs users to KTM dealers for questions.

VIEW OF VEHICLE

View of vehicle, front left (example)

Illustrates and labels components on the front left view.

View of vehicle, rear right (example)

Illustrates and labels components on the rear right view.

SERIAL NUMBERS

Vehicle identification number

Specifies the location of the vehicle identification number.

Type label

Specifies the location of the vehicle's type label.

Engine number

Specifies the location of the engine number.

Fork part number

Specifies the location of the fork part number.

Shock absorber article number

Specifies the location of the shock absorber article number.

CONTROLS

Clutch lever

Describes the clutch lever and its function.

Hand brake lever

Describes the hand brake lever and its function.

Throttle grip

Describes the throttle grip and its function.

Kill switch

Explains the function and states of the kill switch.

Opening the fuel tank filler cap

Details how to open the fuel tank filler cap safely.

Closing the fuel tank filler cap

Details how to close the fuel tank filler cap securely.

Fuel tap

Explains the operation of the fuel tap.

Choke

Describes the choke mechanism and its use.

Shift lever

Describes the location and function of the shift lever.

Kick starter lever

Describes the kick starter lever and its operation.

Foot brake lever

Describes the foot brake lever and its function.

Plug-in stand

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

Service hour counter

Explains the function of the service hour counter.

PREPARING FOR USE

Advice on preparing for first use

Provides essential advice for a child's first use of the motorcycle.

Running in the engine

Details the engine break-in procedure and performance limits.

Preparing the vehicle for difficult riding conditions

Guides on preparing the vehicle for challenging terrain or conditions.

Preparing the vehicle for riding on dry sand

Outlines preparations for riding the vehicle on dry sand.

Preparing the vehicle for riding on wet sand

Outlines preparations for riding the vehicle on wet sand.

Preparing vehicle for rides on wet and muddy circuits

Outlines preparations for riding on wet and muddy circuits.

Preparing vehicle for high temperatures or slow riding

Outlines preparations for high temperatures or slow riding.

Preparing the vehicle for low temperatures or snow

Outlines preparations for low temperatures or snow conditions.

RIDING INSTRUCTIONS

Checks and maintenance measures when preparing for use

Lists essential checks before riding the motorcycle.

Starting the vehicle

Details the procedure for starting the vehicle.

Starting off

Explains how to start moving from a standstill.

Shifting, riding

Guides on shifting gears and general riding techniques.

Applying the brakes

Provides instructions and warnings on using the brakes.

Stopping, parking

Details how to safely stop and park the motorcycle.

Transporting

Provides instructions for safely transporting the motorcycle.

Refueling

Covers the procedure and safety precautions for refueling.

SERVICE SCHEDULE

Additional information

Provides context and notes on service intervals and updates.

Required work

Lists mandatory maintenance tasks and their intervals.

Recommended work

Lists recommended maintenance tasks and their intervals.

TUNING THE CHASSIS

Checking the basic chassis setting with rider's weight

Explains how to set up the chassis based on rider weight.

Air suspension XACT 5543

Details the air suspension system used in the fork.

Compression damping of the shock absorber

Explains compression damping for the shock absorber.

Adjusting the low-speed compression damping of the shock absorber

Guides on adjusting low-speed compression damping.

Adjusting the high-speed compression damping of the shock absorber

Guides on adjusting high-speed compression damping.

Adjusting the rebound damping of the shock absorber

Guides on adjusting rebound damping.

Measuring the dimension of the rear wheel unloaded

Details how to measure rear wheel dimensions.

Checking the static sag of the shock absorber

Explains how to check the static sag of the shock absorber.

Checking the riding sag of the shock absorber

Explains how to check the riding sag of the shock absorber.

Adjusting the spring preload of the shock absorber

Guides on adjusting the shock absorber spring preload.

Adjusting the riding sag

Guides on adjusting the riding sag.

Checking the basic setting of the fork

Explains how to check the fork's basic setting.

Adjusting the fork air pressure

Guides on adjusting the fork's air pressure.

Adjusting the compression damping of the fork

Guides on adjusting fork compression damping.

Adjusting the rebound damping of the fork

Guides on adjusting fork rebound damping.

Handlebar position

Details options for handlebar positioning.

Adjusting the handlebar position

Guides on adjusting the handlebar position for comfort.

SERVICE WORK ON THE CHASSIS

Raising the motorcycle with a lift stand

Explains how to safely raise the motorcycle using a lift stand.

Removing the motorcycle from the lift stand

Details how to safely remove the motorcycle from a lift stand.

Bleeding the fork legs

Guides on bleeding the fork legs.

Cleaning the dust boots of the fork legs

Explains how to clean fork leg dust boots to prevent leaks.

Removing the fork legs

Step-by-step guide to removing the fork legs.

Installing the fork legs

Step-by-step guide to installing the fork legs.

Removing the fork protector

Guides on removing the fork protector.

Installing the fork protector

Guides on installing the fork protector.

Removing the lower triple clamp

Step-by-step instructions for removing the lower triple clamp.

Installing the lower triple clamp

Step-by-step instructions for installing the lower triple clamp.

Checking the steering head bearing play

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

Adjusting the steering head bearing play

Guides on adjusting the steering head bearing play.

Greasing the steering head bearing

Details the procedure for greasing the steering head bearing.

Removing the start number plate

Guides on removing the start number plate.

Installing the start number plate

Guides on installing the start number plate.

Removing front fender

Guides on removing the front fender.

Installing front fender

Guides on installing the front fender.

Removing the shock absorber

Step-by-step guide to removing the shock absorber.

Installing the shock absorber

Step-by-step guide to installing the shock absorber.

Removing the seat

Guides on removing the seat.

Mounting the seat

Guides on mounting the seat.

Removing the air filter box cover

Guides on removing the air filter box cover.

Installing the air filter box cover

Guides on installing the air filter box cover.

Removing the air filter

Guides on removing the air filter.

Cleaning the air filter and air filter box

Details cleaning procedures for the air filter and box.

Installing the air filter

Guides on installing the air filter.

Removing the main silencer

Guides on removing the main silencer.

Installing the main silencer

Guides on installing the main silencer.

Changing the glass fiber yarn filling of the main silencer

Details how to change the exhaust silencer's internal filling.

Removing the fuel tank

Step-by-step guide to removing the fuel tank.

Installing the fuel tank

Step-by-step guide to installing the fuel tank.

Checking for chain dirt accumulation

Explains how to check the chain for dirt buildup.

Cleaning the chain

Details the procedure for cleaning the motorcycle chain.

Checking the chain tension

Explains how to check the chain tension.

Adjusting the chain tension

Guides on adjusting the chain tension correctly.

Checking the chain, rear sprocket, engine sprocket, and chain guide

Details how to check wear on the drive chain and sprockets.

Checking the frame

Guides on checking the frame for cracks or deformation.

Checking the link fork

Guides on checking the link fork for damage or wear.

Checking the throttle cable routing

Explains how to check the throttle cable routing.

Checking the rubber grip

Guides on checking the handlebar rubber grips for wear.

Adjusting the basic position of the clutch lever

Guides on adjusting the clutch lever position for rider comfort.

Checking the fluid level of the hydraulic clutch

Explains how to check the hydraulic clutch fluid level.

Correcting the fluid level of the hydraulic clutch

Guides on how to correct the hydraulic clutch fluid level.

Changing the hydraulic clutch fluid

Details the procedure for changing the hydraulic clutch fluid.

BRAKE SYSTEM

Checking the free travel of the hand brake lever

Explains how to check the free travel of the hand brake lever.

Adjusting the free travel of the handbrake lever

Guides on adjusting the free travel of the handbrake lever.

Checking the brake discs

Details how to inspect the brake discs for wear and damage.

Checking the front brake fluid level

Explains how to check the front brake fluid level.

Adding the front brake fluid

Guides on adding front brake fluid safely.

Checking the front brake linings

Explains how to check the front brake linings for wear.

Changing the brake linings of the front brake

Guides on changing the front brake linings.

Checking the free travel of foot brake lever

Explains how to check the free travel of the foot brake lever.

Adjusting the basic position of the foot brake lever

Guides on adjusting the foot brake lever's basic position.

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 safely.

Checking the rear brake linings

Explains how to check the rear brake linings for wear.

Changing the brake linings of the rear brake

Guides on changing the rear brake linings.

WHEELS, TIRES

Removing the front wheel

Step-by-step guide to removing the front wheel.

Installing the front wheel

Step-by-step guide to installing the front wheel.

Removing the rear wheel

Step-by-step guide to removing the rear wheel.

Installing the rear wheel

Step-by-step guide to installing the rear wheel.

Checking the tire condition

Guides on inspecting tires for wear and damage.

Checking tire pressure

Details how to check and set correct tire pressure.

Checking spoke tension

Explains how to check spoke tension and torque.

COOLING SYSTEM

Cooling system

Overview of the engine's cooling system operation.

Radiator cover

Explains the function and types of radiator covers.

Installing the radiator cover

Guides on installing the radiator covers.

Removing the radiator cover

Guides on removing the radiator covers.

Checking the antifreeze and coolant level

Details how to check antifreeze and coolant levels.

Checking the coolant level

Explains how to check the coolant level in the radiator.

Draining the coolant

Guides on safely draining the coolant.

Refilling with coolant

Guides on refilling the cooling system with coolant.

TUNING THE ENGINE

Checking throttle cable play

Explains how to check the throttle cable play.

Adjusting the throttle cable play

Guides on adjusting the throttle cable play.

Carburetor tuning

Explains the effects of carburetor tuning on engine performance.

Carburetor - idle

Details the influence of idle settings on starting and idling.

Carburetor – adjusting the idle speed

Guides on adjusting the engine's idle speed.

Emptying the carburetor float chamber

Details how to empty the carburetor float chamber.

Plug-in connector of ignition timing map adjustment

Explains the ignition timing map adjustment connector.

Changing the ignition timing map

Guides on switching between ignition timing maps.

Checking the basic position of the shift lever

Explains how to check the shift lever's basic position.

Adjusting the basic position of the shift lever

Guides on adjusting the shift lever's basic position.

SERVICE WORK ON THE ENGINE

Checking the gear oil level

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

Changing the gear oil

Details the procedure for changing the gear oil.

Adding the gear oil

Guides on adding engine gear oil.

CLEANING, CARE

Cleaning the motorcycle

Provides instructions for cleaning the motorcycle.

STORAGE

Storage

Details steps for storing the motorcycle for extended periods.

Preparing for use after storage

Outlines checks and maintenance before using after storage.

TECHNICAL DATA

Engine

Lists engine specifications and technical data.

Engine tightening torques

Provides torque specifications for engine components.

Carburetor

Lists carburetor specifications and settings.

Carburetor tuning

Details carburetor tuning parameters for different conditions.

Capacities

Lists fluid capacities for various systems.

Chassis

Lists chassis specifications and dimensions.

Tires

Lists tire specifications and validity.

Fork

Lists fork specifications and adjustment ranges.

Shock absorber

Lists shock absorber specifications and adjustment ranges.

Chassis tightening torques

Provides torque specifications for chassis components.

SUBSTANCES

Brake fluid DOT 4 / DOT 5.1

Details specifications and recommended suppliers for brake fluid.

Coolant

Details specifications and recommended suppliers for coolant.

Engine oil (15W/50)

Details specifications and recommended suppliers for engine oil.

Engine oil, 2-stroke

Details specifications and recommended suppliers for 2-stroke engine oil.

AUXILIARY SUBSTANCES

Air filter cleaner

Lists recommended air filter cleaner.

Chain cleaner

Lists recommended chain cleaner.

Fuel additive

Lists recommended fuel additive.

High viscosity grease

Lists recommended high viscosity grease.

Long-life grease

Lists recommended long-life grease.

Motorcycle cleaner

Lists recommended motorcycle cleaner.

Off-road chain spray

Lists recommended off-road chain spray.

Oil for foam air filter

Lists recommended oil for foam air filters.

Preserving materials for paints, metal and rubber

Lists recommended products for preserving materials.

STANDARDS

JASO T903 MA2

Explains the JASO T903 MA2 standard for motorcycle oils.

SAE

Explains the SAE viscosity classes for oils.

JASO FD

Explains the JASO FD classification for 2-stroke engine oil.

LIST OF ABBREVIATIONS

Related product manuals