2014 KTM 85 SX Service Repair Manual

2014 KTM 85 SX Service Repair Manual

Online pdf 2014 KTM 85 SX Service Repair Manual

Read this repair manual carefully and thoroughly before beginning work, The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly and properly. This repair manual was written to correspond to the latest state of this series. We reserve the right to make changes in the interest of technical advancement without at the same time updating this repair manual.

We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that the repair work will be performed by a fully trained mechanic.

Ail specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical speciticetions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain speccial equipment that does not belong to the regular scope of supply.

10  KTM 85 SX manual EXHAUST. ...  83
10.1  KTM 85 SX manual Removing the manifold. .    83
10.2  KTM 85 SX manual Installing the manifold. ....   83
10.3  KTM 85 SX manual Removing main silencer. .... 84
10.4  KTM 85 SX manual Installing the main silencer. .....  84
10.5  KTM 85 SX manual Changing the glass fiber yarn filling of the main silencer. .  84

11  KTM 85 SX manual
KTM 85 SX manual AIR FILTER. . 86
11.1  KTM 85 SX manual Removing the air filter box lid. .. 86
11.2  KTM 85 SX manual Installing the air filter box lid. ... 86
11.3  KTM 85 SX manual Sealing the air filter box. ..  86
11.4  KTM 85 SX manual Removing the air filter. ....  86
11.5  KTM 85 SX manual Installing the air filter. .  87
11.6  KTM 85 SX manual Cleaning the air filter and air filter box. .  87 

12  KTM 85 SX manual FUEL TANK, SEAT, TRIM. . 89
12.1  KTM 85 SX manual Opening filler cap. ...   89
12.2  KTM 85 SX manual Closing filler cap. ..  89
12.3  Removing the seat.  89
12.4  KTM 85 SX manual Mounting the seat. .  90
12.5  KTM 85 SX manual Removing the fuel tank. ..... 90
12.6  KTM 85 SX manual Installing the fuel tank. ....  91
12.7  KTM 85 SX manual Changing the fuel screen. .  92
12.8  KTM 85 SX manual Changing the fuel filter. ..... 93
12.9  KTM 85 SX manual Changing the fuel pump. ..  95
12.10  KTM 85 SX manual Checking the fuel pressure.    96 

13  KTM 85 SX manual MASK, FENDER.. . .. 98
13.1  KTM 85 SX manual Removing the front fender. .. 98
13.2  KTM 85 SX manual Installing the front fender.  98
13.3  KTM 85 SX manual Removing headlight mask with headlight. .... 98
13.4  KTM 85 SX manual Refitting the headlight mask with the headlight.  99

14  KTM 85 SX manual WHEELS. ..  100
14.1 KTM 85 SX manual Checking the tire air pressure. . 100
14.2 KTM 85 SX manual Checking the tire condition. ....  100
14.3 KTM 85 SX manual Checking the brake discs. .. 101
14.4 KTM 85 SX manual Checking spoke tension. .  101
14.5  KTM 85 SX manual Front wheel. .  102
14.5.1  KTM 85 SX manual Removing the front wheel. .. 102
14.5.2  KTM 85 SX manual Installing the front wheel. ...  102
14.5.3  KTM 85 SX manual Removing the front brake disc. .... 103
14.5.4  KTM 85 SX manual Installing the front brake disc. .... 103
14.6  KTM 85 SX manual Rear wheel. .... 103
14.6.1  KTM 85 SX manual Removing the rear wheel. ...  103
14.6.2  KTM 85 SX manual Installing the rear wheel. ....  104
14.6.3  KTM 85 SX manual Removing the rear brake disc. ..... 105
14.6.4  KTM 85 SX manual Installing the rear brake disc.  105
14.6.5  KTM 85 SX manual Checking the chain tension. ..  106
14.6.6  KTM 85 SX manual Adjusting the chain tension. .  106
14.6.7  KTM 85 SX manual Checking the chain, rear sprocket, engine sprocket and chain guide. ...  107
14.6.8  KTM 85 SX manual Checking for chain dirt accumulation. ....  109
14.6.9  KTM 85 SX manual Cleaning the chain. ..... 109 

15  KTM 85 SX manual WIRING HARNESS, BATTERY. .... 110
15.1  KTM 85 SX manual Changing the main fuse. .  110
15.2  KTM 85 SX manual Changing the fuses of individual power consumers.  . Ill
15.3  KTM 85 SX manual KTM 85 SX manual Removing the battery. ..... 112
15.4  KTM 85 SX manual Installing the battery.  112
15.5  KTM 85 SX manual Checking the charging voltage. ..  113
15.6  KTM 85 SX manual Checking the quiescent current.  113 

16  KTM 85 SX manual BRAKE SYSTEM.   114
16.1  KTM 85 SX manual Checking the front brake linings. ..... 114
16.2  KTM 85 SX manual Changing the front brake linings. ..... 114
16.3  KTM 85 SX manual Checking free travel of hand brake lever. ... 116
16.4  KTM 85 SX manual Adjusting the basic position of the hand brake lever (XC-W). ..  116
16.5  KTM 85 SX manual Adjusting free travel of hand brake lever (all EXC models). .  116
16.6  KTM 85 SX manual Checking the brake fluid level of the front brake.    117
16.7 KTM 85 SX manual Adding front brake fluid. .  117
16.8 KTM 85 SX manual Changing the front brake fluid. ..  118
16.9 KTM 85 SX manual Checking the rear brake linings.  119
16.10 KTM 85 SX manual Changing the rear brake linings.  119
16.11 KTM 85 SX manual Checking the free travel of foot brake lever. ..... 121
16.12  KTM 85 SX manual Adjusting the basic position of the foot brake lever.    121
16.13  KTM 85 SX manual Checking the rear brake fluid level. .  122
16.14  KTM 85 SX manual Adding rear brake fluid. ..  122
16.15  KTM 85 SX manual Changing the rear brake fluid. . 123 

17  KTM 85 SX manual LIGHTING SYSTEM, INSTRUMENTS. ..  125
17.1  KTM 85 SX manual Checking the headlight setting. .  125
17.2  KTM 85 SX manual Adjusting the headlight range. . 125
17.3  KTM 85 SX manual EXC EU/AUS/USA, XC-W. .. 125
17.3.1  KTM 85 SX manual Speedometer overview. .. 125
17.3.2  KTM 85 SX manual Activation and test. ..... 126
17.3.3  KTM 85 SX manual Setting kilometers or miles. ..  126
17.3.4  KTM 85 SX manual Adjusting the speedometer functions. ... 126
17.3.5 KTM 85 SX manual Setting the clock. . 127
17.3.6 KTM 85 SX manual Setting the wheel circumference. .... 127
17.3.7 KTM 85 SX manual Querying lap time . .....  128
17.4  KTM 85 SX manual EXC SIX DAYS. ...  128
17.4.1  KTM 85 SX manual Speedometer overview. .. 128
17.4.2  KTM 85 SX manual Activation and test. ..... 129
17.4.3 KTM 85 SX Setting kilometers or miles. ..  129
17.4.4 KTM 85 SX Setting the speedometer functions.   129
17.4.5 KTM 85 SX Setting the clock. .  130
17.4.6  KTM 85 SX Activating the additional functions.   130
17.4.7  KTM 85 SX Setting the wheel circumference. .... 131
17.4.8  KTM 85 SX Viewing the lap time. .   131 

18 KTM 85 SX ENGINE. ...  133
18.1  KTM 85 SX Removing the engine.  133
18.2  KTM 85 SX Installing the engine. .  137
18.3  KTM 85 SX Engine disassembly. ..  142
18.3.1  KTM 85 SX Preparations. ..  142
18.3.2  KTM 85 SX Draining the engine oil. . 142
18.3.3  KTM 85 SX Removing the clutch push rod. ...  143
18.3.4  KTM 85 SX Removing the oil filter. .. 143
18.3.5  KTM 85 SX Removing the starter motor. ..  144
18.3.6  KTM 85 SX Removing the kickstarter. ... 144
18.3.7  KTM 85 SX Removing the spark plug. ... 144
18.3.8  KTM 85 SX Removing the valve cover. ... 144
18.3.9  KTM 85 SX Removing the alternator cover. .... 145
18.3.10  KTM 85 SX Positioning the engine at ignition top dead center. . 145
18.3.11  KTM 85 SX Removing the timing chain tensioner. ... 146

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