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12

BRAKE SYSTEM

53

12.1

Checking the free travel of the hand brake lever

Warning

Danger of accidents

Brake system failure.

–

If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due
to overheating. Adjust the free travel on hand brake lever according to specifications.

C00474-10

–

Push the hand brake lever forward and check free travel

A

.

Free travel of hand brake lever

≥

3 mm (

≥

0.12 in)

» If the free travel does not meet specifications:

–

Adjust the free travel of the handbrake lever. (

12.2

Adjusting the free travel of the handbrake lever

C00475-10

–

Check the free travel of the hand brake lever. (

–

Adjust the free travel of the handbrake lever with adjustment screw

1

.

Info

Turn the adjustment screw clockwise to reduce free travel. The pressure
point moves away from the handlebar.
Turn the adjustment screw counterclockwise to increase free travel. The
pressure point moves towards the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply force.
Do not make any adjustments while riding!

12.3

Checking the brake discs

Warning

Danger of accidents

Reduced braking efficiency due to worn brake disc(s).

–

Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.)

400257-10

–

Check the thickness of the front and rear brake discs at several places on the disk
to see if it conforms to measurement

A

.

Info

Wear reduces the thickness of the brake disc around the area used by the
brake linings.

Brake discs - wear limit

Front

2.5 mm (0.098 in)

Rear

3.5 mm (0.138 in)

» If the brake disc thickness is less than the specified value:

–

Change the brake disc.

–

Check the front and rear brake discs for damage, cracking and deformation.
» If the brake disc shows signs of damage, cracking, or deformation:

–

Change the brake disc.

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Содержание 85 SX 17/14

Страница 1: ...OWNER S MANUAL 2014 85 SX 19 16 85 SX 17 14 Art no 3213029en...

Страница 2: ......

Страница 3: ...cifica tions 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 part...

Страница 4: ...Compression damping of the shock absorber 26 10 3 Adjusting the low speed compression damping of the shock absorber 26 10 4 Adjusting the high speed compression damping of the shock absorber 27 10 5...

Страница 5: ...nging the rear brake linings x 60 13 WHEELS TIRES 62 13 1 Removing the front wheel x 62 13 2 Installing the front wheel x 62 13 3 Removing the rear wheel x 63 13 4 Installing the rear wheel x 63 13 5...

Страница 6: ...tanding In the interest of your own safety have these jobs performed by an authorized KTM workshop There your motorcycle will be opti mally cared for by specially trained experts using the specialist...

Страница 7: ...that will lead to environmental damage if the appropriate measures are not taken 2 4 Tampering warning Tampering with the noise control system is prohibited Federal law prohibits the following acts or...

Страница 8: ...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 com...

Страница 9: ...PowerParts for your vehicle can be found on the KTM website International KTM Website http www ktm com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the se...

Страница 10: ...W OF VEHICLE 8 4 1 View of vehicle front left example C00459 10 1 Hand brake lever p 11 2 Kill switch p 11 3 Clutch lever p 11 4 Air filter box lid 5 Fuel tap 6 Choke p 13 7 Shift lever p 13 8 Chain g...

Страница 11: ...le C00460 10 1 Filler cap 2 Throttle grip p 11 3 Fork rebound setting 4 Shock absorber rebound adjustment 5 Level viewer for brake fluid rear 6 Shock absorber compression adjustment 7 Kick starter p 1...

Страница 12: ...he front frame tube 5 3 Engine number L00012 10 Engine number 1 is stamp into the engine case below the carburetor 5 4 Fork part number L00050 10 Fork part number 1 is stamped on the inner side of the...

Страница 13: ...f the handlebar Possible states Kill switch in basic position In this position the ignition circuit is closed and the engine can be started Kill switch pressed In this position the ignition circuit is...

Страница 14: ...l hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system L00023 10 Turn filler cap 1 counterclockwise and lift i...

Страница 15: ...e way Choke function deactivated The choke lever is pushed up all the way 6 9 Shift lever L00024 10 Shift lever 1 is mounted on the left side of the engine L00024 11 The gear positions can be seen in...

Страница 16: ...4 6 12 Plug in stand L00022 10 The fixture for plug in stand 1 is located on the frame on the left side of the vehicle The plug in stand is used to park the motorcycle Info Remove the plug in stand be...

Страница 17: ...g Danger of accidents Critical riding behavior due to inappropriate riding Ensure that your child adapts the riding speed to the road conditions and to his or her riding abilities Warning Danger of ac...

Страница 18: ...or half an hour Run the engine in p 16 7 2 Running in the engine During the running in phase do not exceed the specified engine performance Guideline Maximum engine performance During the first 3 oper...

Страница 19: ...otection device for air filter 59006022000 Info See the KTM PowerParts fitting instructions Adjust the carburetor jetting and the setting Info Your authorized KTM workshop can recommend the right carb...

Страница 20: ...air filter Waterproofing device for air filter 59006021000 Info See the KTM PowerParts fitting instructions Adjust the carburetor jetting and the setting Info Your authorized KTM workshop can recomme...

Страница 21: ...hain Chain cleaner p 88 Clean the radiator fins Straighten bent radiator fins carefully Check the coolant level p 66 7 8 Preparing for riding at low temperatures or in snow B00437 01 Fit a rain cover...

Страница 22: ...e fuel supply 8 2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient...

Страница 23: ...e the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Your child should switch off the engine if he or...

Страница 24: ...Note Material damage Damage to or destruction of components due to excessive load The side stand is only designed for the weight of the motorcycle Do no sit on the motorcycle when it is resting on the...

Страница 25: ...el vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physi...

Страница 26: ...Check the fluid level of the hydraulic clutch p 51 Check the front brake fluid level p 54 Check the free travel of the hand brake lever p 53 Check the play of the steering head bearing p 38 Change pis...

Страница 27: ...rder Annually Every 80 operating hours Every 40 operating hours Change the front brake fluid x Change the rear brake fluid x Change the hydraulic clutch fluid x p 51 Grease the steering head bearing x...

Страница 28: ...rear wheel suspension and not to the vehicle speed The high speed setting for example has an effect on the landing after a jump the rear wheel suspension compresses more quickly The low speed setting...

Страница 29: ...mber of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Info Turn clockwise to increase damping turn countercloc...

Страница 30: ...is the difference between measurements A and B Check the static sag Static sag 30 mm 1 18 in If the static sag is less or more than the specified value Adjust the spring preload of the shock absorber...

Страница 31: ...reload Standard 10 mm 0 39 in Info The spring preload is the difference between the relaxed spring length and the tensioned spring length Depending on the static sag and or the riding sag it may be ne...

Страница 32: ...Turn adjusting screws 2 clockwise all the way Info Adjusting screws 2 are located at the bottom end of the fork legs Make the same adjustment on both fork legs Turn counterclockwise by the number of c...

Страница 33: ...kage If the handlebar is bent or straightened it will cause material fatigue and the handlebar can break Always replace handle bar C00249 10 Remove the four screws 1 Remove the handlebar clamp Remove...

Страница 34: ...stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface L00022 10 Remove the motorcycle from the lift stand Remove the lift stand...

Страница 35: ...89 Press the dust boots back into their normal position Remove excess oil Finishing work Remove the motorcycle from the lift stand p 32 11 5 Removing the fork legs x Preparatory work Raise the motorc...

Страница 36: ...Nm 14 8 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft L00047 11 85 SX 17 14 Position brake caliper and mount and tighten screws 4 Guideline Screw of brake caliper M8...

Страница 37: ...ng harness and clamp Mount and tighten screws 3 11 9 Removing the lower triple clamp x Preparatory work Raise the motorcycle with the lift stand p 32 Remove the front wheel x p 62 Remove the fork legs...

Страница 38: ...em Mount the upper steering head bearing Slide on O ring 2 Position protective ring 1 C00252 10 Position the upper triple clamp with the steering Mount nut 3 but do not tighten it yet L00042 11 Positi...

Страница 39: ...r M8 25 Nm 18 4 lbf ft Loctite 243 Position the brake line and clamp Mount and tighten screws 9 85 SX 19 16 Position the brake caliper with spacers and fit and tighten screws 8 Guideline Screw of brak...

Страница 40: ...over the entire steering range The handlebar must be able to move easily over the entire steering range No resting locations should be noticeable If click positions are noticeable Adjust the play of...

Страница 41: ...ber plate L00049 10 Position the start number plate Mount and tighten screw 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft The holding lugs engage Position the brake line and clamp Mount and...

Страница 42: ...plash protector 1 to the side and position the shock absorber Mount and tighten screw 2 Guideline Screw top shock absorber M12 60 Nm 44 3 lbf ft Loctite 243 Mount and tighten screw 3 Guideline Screw b...

Страница 43: ...x Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never ride the vehicle without an air filter since dust and dirt can get into the engine and result...

Страница 44: ...rd Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Do not clean the air filter with...

Страница 45: ...alling the main silencer C00470 11 Mount the main silencer with rubber sleeve 1 Mount and tighten screw 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 30 Changing the glass fiber yarn fil...

Страница 46: ...that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling...

Страница 47: ...an immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children C00472 10 Main work Position the fuel tank Make sure that no cables...

Страница 48: ...necessary Preparatory work Raise the motorcycle with the lift stand p 32 L00060 10 Main work Push the chain at the end of the chain sliding component upwards to measure chain tension A Info Lower cha...

Страница 49: ...e lift stand p 32 11 37 Checking the chain rear sprocket engine sprocket and chain guide Preparatory work Raise the motorcycle with the lift stand p 32 400227 01 Main work Shift gear to neutral Check...

Страница 50: ...with or below the chain sliding piece Change the chain sliding piece x Check the chain sliding piece for tightness If the chain sliding piece is loose Tighten the chain sliding piece Guideline Screw...

Страница 51: ...king or deformation due to a mechanical impact Change the frame x Info A frame that has been damaged due to a mechanical impact must always be changed Repair of the frame is not authorized by KTM 11 4...

Страница 52: ...ly securing the rubber grip Preparatory work Check the rubber grip p 50 401198 01 Main work Secure the rubber grip at two points using the securing wire Securing wire 54812016000 Wire twister forceps...

Страница 53: ...utch fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 Correct the fluid up to level A Guideline Level A fluid level below container rim...

Страница 54: ...nge 4 C00473 10 Inject the liquid into the system until it escapes from opening A of the master cylinder without bubbles To prevent overflow drain fluid occasionally from the master cylinder reservoir...

Страница 55: ...ves away from the handlebar Turn the adjustment screw counterclockwise to increase free travel The pressure point moves towards the handlebar The range of adjustment is limited Turn the adjusting scre...

Страница 56: ...brake system is leaking or that the brake linings are completely worn down Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation...

Страница 57: ...p will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing...

Страница 58: ...e brake fluid reservoir 85 SX 19 16 Remove screws 4 and spacers Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc Carefully pull the brake caliper backwa...

Страница 59: ...rake fluid immediately with water 12 8 Checking the free travel of foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds...

Страница 60: ...the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of th...

Страница 61: ...ontainer Preparatory work Check the rear brake linings p 59 C00480 10 Main work Stand the vehicle upright Remove screws 1 Take off the cover with the washer and membrane 2 Add brake fluid to level A B...

Страница 62: ...m accessory suppliers are often not tested and approved for use on KTM vehicles The construc tion and friction factor of the brake linings and therefore the brake power can differ considerably from th...

Страница 63: ...to mount the pin push the retainer spring down Make sure the retainer spring is seated correctly Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and...

Страница 64: ...ue to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary L00094 11 Main work Check the wheel bearing for damage and we...

Страница 65: ...hdraw the wheel spindle Remove the chain from the rear sprocket Take the rear wheel out of the swingarm Info Do not operate the foot brake when the rear wheel is removed Always lay the wheel down in s...

Страница 66: ...ave a negative effect on handling characteristics The type condition and air pressure of the tires all have a major impact on the handling characteristics of the motorcycle The tires mounted on the fr...

Страница 67: ...rect spoke tension Ensure that the spoke tension is correct Your authorized KTM workshop will be glad to help Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes If the sp...

Страница 68: ...hange clothing that is contaminated with coolant Keep coolant out of reach of children Condition The engine is cold 400243 10 Stand the motorcycle upright on a horizontal surface Remove the radiator c...

Страница 69: ...ater imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swal lowed contact a physician immediately Change clothing that is contamin...

Страница 70: ...rement A above the radiator fins Guideline 10 mm 0 39 in Coolant 1 0 l 1 1 qt Coolant p 86 Coolant mixed ready to use p 86 Mount and tighten bleeder screw 3 Mount the radiator cap Finishing work Take...

Страница 71: ...ctive exhaust extraction system Start the engine and let it idle Move the handlebar to and fro over the entire steer ing range The idle speed should not change If the idle speed changes Adjust the pla...

Страница 72: ...hape and position In the lower range the idle setting affects engine tuning in the upper range it is the main jet If during acceleration with a partially opened throttle slide the engine runs only at...

Страница 73: ...nd always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge i...

Страница 74: ...the basic position of the shift lever x p 72 15 7 Adjusting the basic position of the shift lever x C00277 10 Remove screw 1 and take off shift lever 2 C00276 10 Clean gear teeth A of the shift lever...

Страница 75: ...x 400721 01 Drain the gear oil x p 73 400722 01 Fill up with gear oil x p 74 16 3 Draining the gear oil x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden...

Страница 76: ...r of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run th...

Страница 77: ...nd inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an...

Страница 78: ...containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry vehicle always rinse with water first After rinsing the motorcycle with a gentle spray of water allow...

Страница 79: ...f the new season 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 88 Refuel p 23 Clean the motorcycle p 76 Change the gear oil x...

Страница 80: ...rty or worn Check set the carburetor components Loose carburetor jets Check set the carburetor components Fault in ignition system Check the ignition system x Adjust the ignition x Engine has too litt...

Страница 81: ...r hose x Incorrect ignition point due to loose stator Adjust the ignition x White smoke emission steam in exhaust gas Damaged cylinder head or cylinder head gasket Check the cylinder head or cylinder...

Страница 82: ...ques Stop screw for adjustment cable M4 4 Nm 3 lbf ft Loctite 243 Locking cap screw M5 8 Nm 5 9 lbf ft Screw control flap exhaust control M5 8 Nm 5 9 lbf ft Loctite 243 Screw exhaust control cover M5...

Страница 83: ...ith magnet M10 20 Nm 14 8 lbf ft Primary gear screw M10x1 25 80 Nm 59 lbf ft Loctite 243 Nut rotor M12x1 60 Nm 44 3 lbf ft Nut inner clutch hub M14x1 25 60 Nm 44 3 lbf ft Loctite 243 Spark plug M14x1...

Страница 84: ...401536 01 M FT ASL Above sea level TEMP Temperature ASO Idle air adjusting screw open rotations IJ Idling jet NDL Jet needle POS Needle position from above MJ Main jet The carburetor tuning depends on...

Страница 85: ...cs diameter 85 SX 17 14 Front 220 mm 8 66 in Brake discs diameter 85 SX 19 16 Front 240 mm 9 45 in Brake discs diameter Rear 210 mm 8 27 in Brake discs wear limit Front 2 5 mm 0 098 in Rear 3 5 mm 0 1...

Страница 86: ...ht of rider 45 55 kg 99 121 lb 3 4 N mm 19 4 lb in Weight of rider 55 kg 121 lb 3 6 N mm 20 6 lb in Spring length with preload spacer s 438 mm 17 24 in Fork length 835 mm 32 87 in Fork oil per fork le...

Страница 87: ...t Screw of brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw bottom triple clamp M8 15 Nm 11 1 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw rear spro...

Страница 88: ...ountries with high temperatures Use of low quality antifreeze can lead to corrosion and foam ing KTM recommends Motorex products Mixture ratio Antifreeze protection 25 45 C 13 49 F 50 corrosion inhibi...

Страница 89: ...the container and that possess the corresponding properties Super unleaded ROZ 98 RON 98 PON 94 According to DIN EN 228 ROZ 98 RON 98 PON 94 Super unleaded gasoline 98 octane mixed with 2 stroke engi...

Страница 90: ...s Motorex products Supplier Motorex Protect Shine Fuel additive Guideline KTM recommends Motorex products Supplier Motorex Fuel Stabilizer High viscosity grease Guideline KTM recommends SKF products S...

Страница 91: ...Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean Polish Rubber grip adhesive 00062030051 Supp...

Страница 92: ...om the automobile industry were used for 4 stroke motorcycles because there was no separate motorcycle specifi cation Whereas long service intervals are demanded for automobile engines high performanc...

Страница 93: ...s number 10 Choke 13 Cleaning 76 Clutch fluid level checking 51 fluid level correcting 51 fluid changing 51 Clutch lever 11 basic position adjusting 50 Compression damping fork adjusting 30 Compressio...

Страница 94: ...ks and maintenance work when preparing for use 20 Protective clothing 6 R Rear sprocket checking 47 Rear wheel installing 63 removing 63 Rebound damping fork adjusting 30 shock absorber adjusting 27 R...

Страница 95: ...checking 69 Throttle cable routing checking 49 Throttle grip 11 Tire air pressure checking 65 Tire condition checking 64 Transport 22 Troubleshooting 78 79 Type label 10 U Use definition 5 V View of v...

Страница 96: ...3213029en 3213029en 03 2013 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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