REPAIR MANUAL 2014 85 SX 19/16 85 SX 17/14 Art. no, 3206166enINTRODUCTION ' Read this repair manual carefully and thoroughly before beginning work The vehicle will only be able to meet the demands placed on it ifthe specified service work is performed regularly and properly This repair manual was written to correspond to the latest state of this model series. We reserve the right to make changes in the interest of technical advancement without updating this repair manual at the same time. 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. Al specifications are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical specifications, 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, devi- ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply. © 2016 KTM Sportmotorcycle GmbH, Mattighoten Austria All rights reserved Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner, TOV the maximum possible quality of the products. 3206166en 03/2016TABLE OF CONTENTS 1 MEANS OF REPRESENTATION 1.1 Symbols used 1.2 Formats used. 2 SAFETY ADVICE. 2.1 Repair Manual 2.2 Safety advice nnn 2.3 Degrees of risk and symbols. 2.4 Workrules. 3. IMPORTANT NOTES. 3.1 Manufacturer and implied warranty 3.2 Operating and auxiliary substances 3.3 Spare parts, accessories ... 3.4 Figures . 4 SERIAL NUMBERS... 4.1 Chassis number 4.2 Type label 43° Engine number 4.4 Fork part number... 4.5. Shock absorber article number. 5 MOTORCYCLE 5.1 Raising the motoreycle withthe lift stand 5.2 Removing the motorcycle from the lift stand 5.3 Starting. 6 FORK, TRIPLE CLAMP owe 6.1 Adjusting the compression damping of the fork u 6.2 Adjusting the rebound damping of the fork... 11 6.3 Bleeding the fork legs. 6.4 Cleaning the dust boots of the fork leg.. 6.5 Removing the fork protector 6.6 Installing the fork protector... 6.7 Removing the fork legs 6.8 Installing the fork legs. 6.9 Servicing the fork . Disassembling the fork legs... 6.10 6.11 Disassembling the cartridge... 6.12 Disassembling the compression holder. 6.13 Checking the fork legs Assembling the compression holder... 614 6.15 Assembling the cartridge 6.16 Assembling the fork lags. 6.17. Greasing the steering head bearing 6.18 Removing the lower triple clamp.. 6.19 Installing the lower triple clamp 6.20 Checking the play of the steering head bearing. reves 30 6.21 Adjusting the steering head bearing play 30 7 HANDLEBAR, CONTROLS. 31 7.1 Adjusting the basic position of the clutch lever... 31 7.2 Checking the outing ofthe throttle cable... 7.3 Checking the play in the throttle cable 7.4 Adjusting the play in the throttle cable. 7.5 Handlebar position 7.6 Adjusting the handlebar position 8 SHOCK ABSORBER, SWINGARM 8.1 Adjusting the high-speed compression damping of the shock absorber. 8.2 Adjusting the low speed compression damping ‘of the stock absorber 8.3 Adjusting the rebound dampingct the shock absorber. 10 a 12 13 8.4 Measuring rear whee! sag unloaded, 8.5 Checking the static sag of the shock absorber. 8.6 Checking the riding sag of the shock absorber... 87 Adjusting the spring preload of the shock AbSOFDET. nnn 8.8 Adjusting the riding sag. 8.9 Removing the shock absorber 8.10 Installing the shock absorber. 8.11 Performing a shock absorber service 8.12 Removing the spring. 8.13 Disassembling the damper.. 8.14 Disassembling the piston rod 8.15 Disassembling the seal ring retainer.. 8.16 Disassembling the rebound adjuster... 8.17 Checking the damper 8.18 Removing the heim joint. 8.19 Installing the heim joint. 8.20 Assembling the rebound adjuster... 8.21 Assembling the seal ring retaine 8.22 Assembling the piston rod... 8.23 Assembling the damper. 8.24 Bleeding and filing the damper 8.25 Filing the damper with nitrogen.. 8.26 _ Installing the spring EXHAUST... 9.1 Removing the manifold 9.2 Installing the manifol .. 9.3 Removing the main silencer. 9.4 Installing the main silencer. 95 Charging tea ry ng of he main silencer. AIR FILTER .. 10.1 Removing the air filter bor cover x. 10.2 103 10.4 Removing the air filter... Cleaning the air filter and air filter box. Installing the air filter. 10.5 Sealing the air filter box 10.6 _ Installing the air filter box cover FUEL TANK, SEAT, TRIM... 11.1 Removing the seat . 11.2 Mounting the seat.. 11.3 Fuel tap.. 11.4 Removing the fuel tank. 11.5 _ Installing the fuel tank MASK, FENDER... 12.1 Removing the front fender 12.2 Installing the front fender 12.3 Removing the start number plate... 12.4 Installing the start number plate WHEELS 13.1 Checking the tire air pressure 13.2 Checking the tire condition 13.3 Checking the brake discs. 13.4 Checking spoke tension 13.5 Front whee. 13.5.1 Removing the front wheel 13.5.2 _ Installing the front wheel 13.6 Rear wheel.. 13.6.1 Removing the rear wheel 13.6.2 Installing the rear wheel... 13.6.3 Checking for chain dirt accumulation. 13.6.4 Cleaning the chain 35 35 36 36 37 7 7 38 38 39 40 AL AZ 42 43 44 45 45 a7 49 51 52 54 54 55 55 55 57 57 57 57 58 58. 58. 59 59 59 59 60 60 62 62 62 62 62 63 63 63 63 64 64 64 65 66 66 66 67 67TABLE OF CONTENTS 4 15 13.6.5 13.6.6 13.6.7 13.68 BRAKE SYSTEM... 141 142 143 44 145 146 147 148 149 14.10 14.11 14.12 14.13, 14.14 ENGINE... 15.1 15.2 153 15.3.1 18.3.2 16.33 15.3.4 15.3.5 15.3.6 15.3.7 15.3.8 15.3.9 15.3.10 153.11 153.12 163.13 153.14 153.15 16.3.16 163.17 153.18 153.19 15.3.20 153.21 15.3.22 153.23 153.24 153.25 153.26 15.3.27 15.3.28 15.3.29 15.4 15.4.1 Checking the chain tension. 68 Checking the chain, rear sprocket, engine sprocket, and chain guide.... Agiusting the chain tension Adjusting the chain guide ‘Checking the free travel of the hand brake VEE re ve 72 Adjusting the fre travel of the handbrake lever... iste Checking front brake fluid level [Adding front brake fluid... ‘Changing the front brake fluid Checking the front brake linings. ‘Changing the front brake linings Checking the free travel of foot brake lever ‘Adjusting the basic position of the foot brake lever . ‘Checking the rear brake fuid level. 73 ‘Adding rear brake fluid Changing the rear brake fluid. Checking the rear brake linings... Changing the rear brake linings Removing the engine. Installing the engine Engine disassembly, . Clamping the engine into the engine assembly stand. Removing the engine sprocket. Removing the clutch push rod. Draining the gear ol. Removing the spark plug Removing the cylinder head. Removing the alternator cover Removing the kick starter. Removing the exhaust control Removing the cylinder. Removing the piston. Removing the rotor. Removing the stato... Removing the spacer. Removing the clutch cover.. Removing the clutch basket. Removing the primary gear. Removing the kick starter shaft. Removing the intermediate kick starter ear. Removing the shift shat. Removing the shift drum locating unit... Removing the locking lever Removing the reed valve housing. Removing the left engine case section ... Removing the shit rails. Removing the shift drum. Removing the shift forks... Removing the transmission shafts. Removing the crankshaft. ‘Working on individual parts... Working on the right section of the engine 15.4.2 Work on the left section of the engine Removing the crankshaft bearing inner OCC ene 7 Installing the crankshaft bearing inner FACE 5 Changing the connecting rod, conrod bearing, and crank pin .. i Checking the crankshaft run-out at the bearing pin. Checkingimeasuring the eyinder Removing the exhaust contro. Checking the exhaust control Installing the exhaust control CChecking/measuring the piston. Checking the piston ring end gap Pistonicylinder - measuring the mounting clearance. Checking the reed valve housing, reed valve, and intake flange. Work on the clutch cover Checking the cluten Checking the shift mechanism. reassembling the shift shaft Disassembling the main shaft. Disassembling the countershaft Checking the transmission Assembling the main shaft. ‘Assembling the countershaft. Checking the kick starter Preassembling the kick starter shat Engine assembly... 15.4.3 15.4.4 15.4.5 15.4.6 15.4.7 15.48 15.4.9 15.4.10 154.11 15.4.12 194.13 154.14 15.4.15 15.4.16 154.17 154.18 15.4.19 15.4.20 15.4.21 15.4.2 15.4.23 15.4.24 15.4.25 155 15.5.1 Installing the crankshaft 15.5.2 Installing the transmission shafts. 15.5.3 Installing the shift forks. 15.5.4 Installing the shift drum 15.5.5 Installing the shift rails. 15.5.6 Installing the left engine case section 15.5.7 Installing the reed valve housing . 15.5.8 Installing the locking lever. 15.5.9 Installing the shift drum locating unit. 15.5.10 Installing the shift shaft 15.5.11 Installing the intermediate kick starter gear, 15.5.12 Installing the kick starter shaft. 15.5.13 Installing the primary gear. 15.5.14 Installing the clutch discs. 15.5.15 Installing the clutch cover... 15.5.16 Installing the spacer. 15.5.17 Installing the stator. 15.5.18 Installing the rotor 15.5.19 Installing the piston 15.5.20 Installing the cylinder 15.5.21 Checking the X-distance 15.5.22 Adjusting the X-distance... 1.5.23 Setting the ignition 155.24 Adjusting the Z-distance. 15.5.25 Installing the kick starter. 18.5.26 Installing the alternator cover. 15.5.27 Installing the cylinder head. 15.5.28 Installing the spark plug. 15.5.29 Installing the oll drain plug... 100 101 101 101 1. 103 103, 103 108 105 107 107 108 108 108 113 14 11s 116 116 7 8 11g 120 120 121 121 121 122 122 122 123 123 124 124 124 124 125 125 128 127 127 128 128 128 129 129 130 130 130 132 132 132 132 133,TABLE OF CONTENTS 16 v7 18 19 20 21 22 23 15.5.30 Installing the clutch push red 15.5.31 Installing the engine sprocket 1.5.32 Removing the engine from the engine assembly stand. . ‘CARBURETOR 16.1 Removing the carburetor. 16.2 Installing the carburetor... 16.3 Disassembling the carburetor. 16.4 Assembling the carburetor 16.5 Checking/setting the carburetor components... . 140 . 140 140 141 16.6 Checking the jet needle.. 16.7 Checking the throttle slide. 16.8 Checking the float needle valve 16.9 Checking the choke slide... 16.10. Checking/adjusting the float level 16.11 Carburetor - adjusting idle speed 16.12. Emptying the carburetor float chamber CLUTCH... 17.1 Checking the fluid level of the hydraulic clutch 17.2. Correcting the uid level ofthe | hyoraue cluteh 17.3. Changing the hydraulic clutch fluid. WATER PUMP, COOLING SYSTEM... 18.1 Draining the coolant... 18.2 Refilling coolant... 18.3 Checking the anttteze and coolant level 18.4 Checking the coolant level LUBRICATION SYSTEM, 19.1 Checking the gear oil level 19.2 Changing the gear oil. 19.3 Draining the gear oil. 19.4 Filling up with gear ol 19.5 Adding gear il IGNITION SYSTEM... 20.1 Checking the ignition system. 20.2 Checking the kill switch.. 20.3 Checking the ignition coil 20.4 Checking the ignition pulse generator 20.5 Checking the spark plug connector 20.6 Checking the CDI controller. 20.7 Checking the power supply... TECHNICAL DATA, 21.1 Engine... . 21.2 Engine tolerance, wear limits 21.3. Engine tightening torques. 21.4 Capacities. mts 21.4.1 Gear 21.4.2 Coolant. 21.43 Fuel... 21.5 Chassis. 21.6 Tires... 21.7 Fork 21.8 Shock absorber. 21.9 Chassis tightening torques 21.10 Carburetor. 21.10.1 Carburetor tuning, CLEANING, CARE 22.1. Cleaning the motorcycle STORAGE. 23.1 Storage . 23.2 Preparing for use ater storage. 133 133 . 133 134 134 135 136 138 139 M1 ui soe 142 143 143 143. ne 18 ve 145 oe 145 ee 145 . 146 147 48 148 148 oe 148 ne 149 149 151 151 . 151 - 152 we 153 . 153 . 154 . 154 156 se 156 - 156 . 187 is 87 187 157 187 se 158, - 158, 159 se 159 - 160 160 161 se 162 - 162 163, ue 163 - 163 24 SERVICE SCHEDULE 24.1 Service schedule. 25 WIRING DIAGRAM..... 25.1 Page 1 of 1... 26 SUBSTANCES 27 RUXILIARY SUBSTANCES... 28 SPECIAL TOOLS... 29° STANDARDS 30._LIST OF ABBREVIATIONS. INDEX 164 164 166 166 168 170 172 180 181 1821 MEANS OF REPRESENTATION 5 At Symbols used ‘The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or @ function). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips. Indicates the result ofa testing step. » v Denotes a voltage measurement. A Denotes @ current measurement. 2 Denotes a resistance measurement. ‘The typographical formats used in this document are explained below. Proprietary name Identifies a proprietary name. Name? Identities a protected name. rand™ Identifies a trademark. Underlined terms, Refer to technical details of the vehicle or indicate technical terms, which are explained in the glossary.2 = SAFETY ADVICE Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you tepair and maintain your vehicle. This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available. ‘A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages. ‘The vehicle has various information and warning labels at prominent locations, Do not remove information/warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured. Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken. Note Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken, Warning Indicates a danger that will ead to environmental damage if the appropriate measures are not taken. ‘Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren- theses. E.g.: bearing puller (15112017000) During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts, In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed, After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts. After you complete the repair or service work, check the operating safety of the vehicle.3 IMPORTANT NOTES 7 (31 Manufacturer and implied warranty ‘The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage ‘caused by tampering with and/or conversions on the vehicle are not covered by the warranty. Additional information on the manufacturer or implied warranty and the procedures involved can be found in the Service & Warranty Booklet. Warning Environmental hazard Improper handling of fuel is a danger to the environment. Do not allow fuel to enter the groundwater, the soil, or the sewage system. Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual. (Only use spare parts and accessories approved andior recommended by KTM. KTM accepts no liability for other products and any resulting damage or loss. ‘The current KTM PowerParts for your vehicle can be found on the KTM website. International KTM Website: inttp-iwnw.ktm.com ‘The figures contained in the manual may depict special equipment. Inthe interest of clarity, some components may be shown disassembled or may not be shown at all. It isnot always necessary to dis- assemble the component to perform the activity in question. Please follow the instructions in the text.4 — SERIAL NUMBERS 8 i Chassis number @ is stamped on te right side ofthe steering head. 401945:10 C Type label @ is located on the front frame tube, 492154: Engine number @ is stamp into the engine case below the carburetor. Fork part number @ is stamped on the inner side of the axle clamp, 401947210 ~~] The shock absorber part number @ is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 401948:105 MOTORCYCLE 5.1 Raising the motoreycle withthe fit stand Note Danger of damage The parked vehicle can roll away ofall over. = Park the vehicle on a firm and level surface, Tit sand TEBPOSESTOOTIT BE) ins Neer el seni ewe Sea he motel opt ing 401942.01 Note Danger of damage The parked vehicle can roll away ofall over. — Park the vehicle on a firm and level surface. ~ Remove the motereyele trom th lift stand. = Remove the lt stand = To park the motoreyle, insert plugin stand @ into the let side of the wheel spn- ae Info ©) Remove the plugin stand before riding -ozt0110 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. Always make sure there is sufficient ventilation when running the engine. Use an effective exhaust extraction system when starting or running the engine in an enclosed space. Note Engine failure High rpm with 2 cold engine negatively impacts the lifespan of the engine. = Ensure that the engine is always warmed up at low engine speeds. Info If the motorcycle is unwilling to star, the cause can be old fuel in the float chamber. The flammable elements of the fuel evaporate after along time of standing. If the float chamber is filled with fresh fuel, the engine starts immediately. The moorycle has been out of use for mre than 1 week = Empty the carburetor float chamber. ("» 9. 142) ~ Turn tap handle @ on the fuel tep to the ON position, (Figure €00462-10"* p. 59) Fuel can fon from the fuel tank othe carburetor ~ Remove the matoreyele fom the stan. = Shit goar to neutral.5 MOTORCYCLE ‘The engine is cold Pull the choke lever out as far as possible. Press the kick starter robustly through its full range. 10 Into Ho not open the throttle