KTM 85SX 2006 User Manual

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KTM-Sportmotorcycle AG

A–5230 Mattighofen

www.ktm.at

KTM Group Partner

85SX

OWNER’S MANUAL 2006

ART. NR. 3.211.71EN

ENGLISH

Table of Contents

Questions and Answers:

T
tylerflynnAug 17, 2025
How to start my KTM Motorcycle if the engine fails to start?
- B
  Brian LopezAug 17, 2025
  If your KTM Motorcycle engine won't start, several factors could be at play. It might be an operating error, such as old fuel in the float chamber, an interrupted fuel supply, or too great an electrode distance. The spark plug could be fouled, or the ignition wire damaged. To resolve this: * Open the fuel tap and replenish fuel, avoiding the choke. * Drain old fuel from the float chamber if the motorcycle hasn't been used in over a week. * Check and clean the carburetor and fuel lines. * Reduce the electrode distance to 0.60 mm, or clean/renew the spark plug. * Inspect the ignition system, including cables and connectors. * Dismantle and clean the carburetor.
T
Thomas SmithAug 20, 2025
Why does my KTM 85SX 2006 engine not have enough power?
- S
  Sarah AveryAug 20, 2025
  Your KTM Motorcycle might lack power due to several reasons: the glass fiber yarn in the silencer could be charred, the air filter might be obstructed, the fuel supply could be partly interrupted, or there could be a loss of compression through a loose spark plug. Also, the exhaust system might be damaged, or the engine may not have enough preignition. To address this: * Replace the silencer filling. * Clean or renew the air filter. * Blow through the fuel pipe and clean the carburetor. * Tighten the spark plug. * Check the exhaust system for damage. * Check and adjust the ignition.
M
michael96Aug 22, 2025
What to do if my KTM 85SX 2006 engine is overheating?
- J
  James AndrewsAug 23, 2025
  If your KTM Motorcycle engine is overheating, it could be due to insufficient liquid in the cooling system, clogged radiator fins, frothing in the cooling system, pinched water hoses, incorrect ignition timing because of loose stator screws, or an incorrect compression ratio. Here's what you should do: * Top up the coolant and bleed the cooling system, checking for leaks. * Clean the radiator fins with a water jet. * Renew the coolant using a branded anti-freeze/anti-corrosive (Motorex Anti-Freeze). * Replace any incorrectly routed hoses. * Readjust the ignition timing and secure the screws with Loctite 243. * Measure and adjust the compression ratio.
L
Linda MarksAug 26, 2025
Why is my KTM 85SX 2006 Motorcycle engine sputtering into the carburetor?
- E
  eleeAug 26, 2025
  If your KTM Motorcycle engine sputters into the carburetor, it may be due to a lack of fuel, a spark plug with an incorrect heat value (ignition by incandescence), or the engine taking in air uncontrollably. To fix this: * Clean the fuel pipes, examine the tank aeration, and clean. * Fit the correct spark plug. * Check the intake flange and carburetor to ensure they are firmly seated.
A
Amanda SmithAug 28, 2025
What causes a KTM 85SX 2006 Motorcycle engine to not rev up and run in a four-stroke cycle?
- T
  Tyler WilsonAug 28, 2025
  If your KTM Motorcycle engine isn't revving up and running in a four-stroke cycle, it could be due to the carburetor overflowing (if the level adjust is too high), a dirty or enlarged float needle seating, or loose carburetor jets. To resolve this: * Clean the carburetor; if necessary, replace the float needle and adjust the level. * Tighten the jets.
J
Jeffrey OrtizAug 31, 2025
What should I do if my KTM 85SX 2006 Motorcycle engine doesn't have enough power due to reed valve issues?
- B
  beth02Aug 31, 2025
  If your KTM Motorcycle engine lacks power and you suspect reed valve issues, the reed paddles might be tensionless or damaged, or the surface of the reed valve housing might be damaged. To address this, replace the reed paddles or the reed valve housing.
J
Julie PriceSep 2, 2025
How do I fix a KTM 85SX 2006 engine that won't idle?
- R
  Rebecca LopezSep 2, 2025
  If your KTM Motorcycle engine won't idle, the idle adjusting screw may be out of adjustment, the ignition system may be damaged or there could be wear. To fix this: * Readjust the idle running or replace the idle adjusting screw. * Examine the ignition system. * Overhaul the engine.
P
Patricia BlackSep 5, 2025
What causes high RPM misfiring in my KTM 85SX 2006?
- J
  Jessica HannaSep 5, 2025
  High RPM misfiring in your KTM Motorcycle can be caused by an incorrect heat range spark plug or a low-quality spark plug, or a loose, corroded, or non-conductive ignition socket connector. To address this: * Refer to the technical data section for the correct spark plug. * Check and seal the ignition socket connector with silicon.
J
John LangSep 8, 2025
Why is my KTM 85SX 2006 Motorcycle emitting white smoke (steam)?
- E
  Eileen LeSep 8, 2025
  If your KTM Motorcycle is emitting white smoke (steam), it's likely due to a leaking cylinder head or O-ring of the cylinder head gasket. To resolve this, check the cylinder head and replace the O-ring.
E
Eduardo RichardsonSep 12, 2025
How to fix water in the transmission oil of my KTM Motorcycle?
- J
  Jeffrey ClarkSep 12, 2025
  If there's water in the transmission oil of your KTM Motorcycle, the shaft seal ring of the water pump is likely defective. To fix this, replace the shaft seal ring of the water pump.

KTM 85SX 2006 Specifications

General

Engine Type	Single-cylinder, 2-stroke
Displacement	84.9 cc
Transmission	6-speed
Cooling	Liquid-cooled
Rear Suspension	WP monoshock
Front Brake	Disc brake
Rear Brake	Disc brake
Starter	Kick
Final Drive	Chain
Seat Height	850 mm
Fuel System	Keihin PWK 28
Ignition	Digital
Front Suspension	WP USD 43 mm
Wheelbase	1, 275 mm
Dry Weight	68 kg
Frame	Steel

Summary

IMPORTANT INFORMATION FOR PARENTS ABOUT SAFE DRIVING

OPERATION INSTRUMENTS - SUSPENSION ADJUSTMENTS

Fork Damping Adjustments

Adjusting compression and rebound damping on the front fork.

Shock Absorber Damping Adjustments

Adjusting compression and rebound damping on the rear shock absorber.

OPERATION INSTRUMENTS - SHOCK ABSORBER DAMPING DETAILS

Advanced Shock Absorber Damping

Detailed adjustment of shock absorber compression damping.

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE

First Ride Instructions

Guidance for the initial riding experience and preparation.

Engine Running-In Procedure

Procedure for breaking in the new engine.

DRIVING INSTRUCTIONS

Pre-Ride Inspection Checklist

Essential checks before starting the motorcycle.

DRIVING INSTRUCTIONS - STARTING AND RIDING

Engine Starting Procedures

Steps for starting cold, warm, and flooded engines.

Starting Off and Shifting/Riding

How to begin riding and shift gears effectively.

DRIVING INSTRUCTIONS - BRAKING AND FUELING

Braking and Stopping Techniques

Safe braking and stopping procedures.

Refueling and Fuel Guidelines

PERIODIC MAINTENANCE SCHEDULE - RIDER CHECKS

Rider-Performed Maintenance Checks

Essential maintenance tasks for the rider to perform regularly.

MAINTENANCE WORK ON CHASSIS AND ENGINE

Steering Head Bearing Adjustment

Procedure for checking and adjusting steering head bearing play.

MAINTENANCE WORK ON CHASSIS AND ENGINE - FORK & SHOCK

Shock Absorber Spring Preload

MAINTENANCE WORK ON CHASSIS AND ENGINE - SUSPENSION SETUP

Basic Suspension Setup for Rider Weight

Setting up suspension components based on rider weight.

MAINTENANCE WORK ON CHASSIS AND ENGINE - FORK & SHOCK SPRINGS

Telescopic Fork Setup and Springs

MAINTENANCE WORK ON CHASSIS AND ENGINE - CHAIN & BRAKES

Chain Tension Check and Adjustment

MAINTENANCE WORK ON CHASSIS AND ENGINE - BRAKE SYSTEM

MAINTENANCE WORK ON CHASSIS AND ENGINE - BRAKE PADS & FLUID

Front Brake Fluid Check and Refill

Front Brake Pad Inspection and Replacement

MAINTENANCE WORK ON CHASSIS AND ENGINE - REAR BRAKES

Rear Brake Pedal and Fluid Checks

MAINTENANCE WORK ON CHASSIS AND ENGINE - WHEEL SERVICE

Front Wheel Removal and Installation

MAINTENANCE WORK ON CHASSIS AND ENGINE - WHEEL & TIRE SERVICE

Rear Wheel Removal and Installation

MAINTENANCE WORK ON CHASSIS AND ENGINE - AIR FILTER & EXHAUST

MAINTENANCE WORK ON CHASSIS AND ENGINE - CLUTCH & CABLES

Hydraulic Clutch Fluid Level Check and Bleeding

MAINTENANCE WORK ON CHASSIS AND ENGINE - COOLING SYSTEM

Cooling System Overview and Checks

MAINTENANCE WORK ON CHASSIS AND ENGINE - CARBURETOR ADJUSTMENT

Carburetor Adjustment and Settings

Information on adjusting carburetor settings for different conditions.

Carburetor Wear and Performance Ranges

MAINTENANCE WORK ON CHASSIS AND ENGINE - FLUIDS AND LUBRICATION

Gear Oil Level Check and Change

TROUBLE SHOOTING

Engine Start and Idle Issues

Troubleshooting engine starting and idle problems.

Engine Power and Performance Issues

Diagnosing and resolving engine power loss and misfiring.

TROUBLE SHOOTING - PERFORMANCE AND FLUID ISSUES

Engine Performance and Overheating Issues

Troubleshooting performance, overheating, and smoke issues.

Transmission Oil Contamination

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