2013 KTM 85 SX 19/16 & 85 SX 17/14 - Precision Maintenance & Repair Manual

KTM 85 SX Owner's Manual - 2013 Edition

This professional technical guide provides the operational framework and maintenance protocols required to sustain the peak performance of the KTM 85 SX competition platform. It integrates vital factory specifications, including a hyper-specific requirement for the 1.8 bar (26 psi) radiator cap rating to manage extreme thermal loads during competitive use. Maintaining this exact pressure threshold is critical for preventing coolant cavitation and ensuring maximum engine uptime under high-stress racing conditions.

System Architecture: Technical Applicability & Chassis Configurations

KTM 85 SX Series (Model Year 2013)

• 85 SX 17/14: Small-wheel configuration utilizing a 17-inch front and 14-inch rear wheel set, optimized for specific rider height and class regulations.
• 85 SX 19/16 (EXCEL R): Big-wheel variant equipped with 19-inch front and 16-inch rear wheels, featuring high-strength Excel R rim components for advanced competition.

Operational Advantages: Performance & Precision

• Maintenance Precision: Factory-verified torque sequences and fluid capacities eliminate component stress and ensure mechanical integrity across the drivetrain and chassis.
• Competition Reliability: Detailed setup instructions for diverse racing environments, including dry sand, wet mud, and high-temperature conditions, optimize vehicle survival and performance.
• Suspension Accuracy: Specific calibration data for WP Suspension components allows for precise chassis tuning based on rider weight and track topography.

Document Metadata

• Print Number: 3211856en
• Document Type: Owner's Manual
• Manufacturer: KTM-Sportmotorcycle AG
• Language: US English

Factory Benchmarks: Calibration & Tolerance Data

Chassis Dynamics & Visual Navigation

• Chassis Component Localization: Comprehensive diagrams for front-left and rear-right vehicle orientations facilitate rapid component identification.
• System Controls: Detailed mapping of the hydraulic clutch, braking interfaces, and Moric Digital 2M1 ignition management.
• Serial Number Indexing: Defined locations for the chassis VIN (steering head), engine ID (crankcase), and WP suspension part numbers.

Table of Contents

• Safety Advice: Intended Use, Risk Degrees, and Safe Operation.
• Serial Numbers: Chassis, Type Label, and Engine Identifiers.
• Controls: Clutch, Braking, Throttle, and Choke Systems.
• Preparing for Use: Run-in Procedures and Difficult Condition Setup.
• Riding Instructions: Starting, Shifting, and Thermal Management.
• Service Schedule: Periodic Maintenance and One-time Intervals.
• Chassis Tuning: Static/Riding Sag, Compression, and Rebound Calibration.
• Maintenance Work: Fork/Shock Service, Chain Drive, and Hydraulic Systems.
• Engine Maintenance: Gear Oil Management and Carburetor Synchronization.
• Technical Data: Engine Specs, Torque Values, and Fluid Capacities.

Operational Limits & Specifications

• Gearbox Lubricant: 0.50 L (0.53 qt) of SAE 15W/50 engine oil (JASO T903 MA).
• Coolant Capacity: 1.0 L (1.1 qt) of 50:50 corrosion inhibitor/distilled water mixture.
• Fuel System: 5.0 L (1.32 US gal) capacity; 98 octane unleaded mixed with 2-stroke oil at a 1:40 ratio.
• Critical Torque (Engine): Oil drain plug with magnet (M10) at 20 Nm (14.8 lbf ft).
• Critical Torque (Chassis): Rear wheel spindle nut (M20x1.5) at 80 Nm (59 lbf ft).
• Ignition Hardware: NGK BR9 ECMVX spark plug with a 0.60 mm (0.0236 in) electrode gap.