KTM 65 SX 2011 Manual

SETUP INSTRUCTIONS 2011

65 SX

Art. no. 3211682en

INTRODUCTION 1

INTRODUCTION

The work described in these setup instructions must be performed before the vehicle is delivered to the customer.

Read the setup instructions in their entirety before beginning work.

Print out the current PDI form found on the KTM DEALER.NET.

These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter-

est of technical advancement without at the same time updating this 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 work will be performed by a fully trained mechanic.

All specifications are non-binding. KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifica-

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 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 spe-

cial equipment that does not belong to the regular scope of delivery.

Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright

owner.

ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead

to the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM-Sportmotorcycle AG

5230 Mattighofen, Austria

MEANS OF REPRESENTATION 2

Symbols used

The symbols used are explained below.

Indicates an expected reaction (e.g., to a work step or a function).

Indicates an unexpected reaction (e.g., to a work step or a function).

Indicates a page reference (more information is provided on the specified page).

Indicates information with more details or tips.

Indicates the result of a testing step.

Indicates a voltage measurement.

Indicates a current measurement.

Indicates a resistance measurement.

Formats used

The typographical and other formats used are explained below.

Specific name Denotes a proper name.

Name®Denotes a protected name.

Brand™ Denotes a brand available on the open market.

SET‑UP 3

2.1Unpacking and setting up the vehicle

700529-01

–Open the box.

Info

To avoid damaging the vehicle during assembly, do not remove the protec-

tive plastic from a part until just before mounting it and leave the plastic

sheeting on the vehicle until work is completed.

–Remove the front wheel, fender, hand protectors, and enclosed package from the

box.

–Remove the separate enclosure and unpack it. Check that the scope of delivery is

complete on the basis of the enclosed packing list.

–Lift the vehicle out of the box with the help of another person.

–Raise the motorcycle with a lift stand. ( p. 4)

–Check the vehicle for transport damage.

700530-01

–Remove screw .

–Loosen screws .

–Remove the wheel spindle.

–Install the front wheel. x( p. 4)

–Remove the protective plastic from the handlebar.

700531-01

–Position the handlebar with handlebar clamps .

–Mount and tighten the screws.

Guideline

Screw, handlebar clamp M8 20 Nm

(14.8 lbf ft)

–Check the handlebar position.

» If the handlebar position is not adjusted as the customer requires:

–Adjust handlebar position. x( p. 5)

–Install the front fender. ( p. 5)

–Check the wiring harness, throttle cables and brake line for free movement and cor-

rect routing.

–Check that all controls on the handlebar are in the correct location and seated

firmly.

800042-10

–Mount the footrests with the springs and bolts. Secure the bolts using the washers

and pins.

Plier for footrest spring (58429083000)

–Fill up with fuel. ( p. 6)

–Print out the current PDI form found on KTM DEALER.NET and perform the delivery

inspection.

WORK 4

3.1Raising the motorcycle with a lift stand

Note

Danger of damage The parked vehicle may roll away or fall over.

–Always place the vehicle on a firm and even surface.

700405-01

–Raise the motorcycle at the frame underneath the engine.

Lift stand (59229055000)

The tires should no longer be in contact with the ground.

–Secure the motorcycle against falling over.

3.2Removing the motorcycle from the lift stand

Note

Danger of damage The parked vehicle may roll away or fall over.

–Always place the vehicle on a firm and even surface.

700406-01

–Remove the motorcycle from the lift stand.

–Remove the lift stand.

–To park the motorcycle, insert plug-in stand into the plug-in stand bracket on

the left side of the vehicle.

Info

Remove the plug-in stand before riding.

3.3Installing the front wheel x

Warning

Danger of accidents Reduced braking efficiency due 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.

700438-01

–Check the wheel bearing for damage and wear.

» If the wheel bearing is broken or worn:

–Change the wheel bearing. x

–Clean and grease wheel spindle .

Long-life grease ( p. 9)

–Lift the front wheel into the fork, position it, and insert wheel spindle .

–Tighten screws .

Guideline

Screw, fork stub M6 10 Nm (7.4 lbf ft)

700436-10

–Mount and tighten screw .

Guideline

Screw, front wheel spindle M10 40 Nm

(29.5 lbf ft)

–Remove the motorcycle from the lift stand. ( p. 4)

WORK 5

700536-01

–Operate the hand brake lever several times until the brake linings are in contact

with the brake disc.

–Loosen screw .

–Pull the front wheel brake and push down hard on the fork several times.

This aligns the fork legs.

–Tighten screws .

Guideline

Screw, fork stub M6 10 Nm (7.4 lbf ft)

3.4Adjusting handlebar position x

Warning

Danger of accidents Handlebar breakage.

–If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle-

bar.

B00375-10

–Remove the four screws . Remove the handlebar clamp. Remove the handlebar

and lay it to one side.

Info

Protect the motorcycle and its attachments from damage by covering them.

Do not bend the cables and lines.

–Remove the two screws . Remove the handlebar support.

–Place the handlebar support in the required position. Mount and tighten the two

screws .

Guideline

Screw, handlebar support M10 40 Nm

(29.5 lbf ft)

Loctite®243™

–Position the handlebar.

Info

Make sure cables and wiring are positioned correctly.

–Position the handlebar clamp. Mount and evenly tighten the four screws .

Guideline

Screw, handlebar clamp M8 20 Nm

(14.8 lbf ft)

Info

Make sure the gap width is even.

3.5Installing the front fender

700415-01

–Position the fender with holding lugs into the drill holes on the start number

plate.

WORK 6

700414-11

–Position the front fender. Mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

3.6Refueling

Danger

Fire hazard Fuel is highly flammable.

–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no

fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

–Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-

diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,

contact a doctor immediately. Change clothing that has come into contact with fuel.

Warning

Environmental 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.

–Switch off the engine.

–Open the filler cap.

400382-10

–Fill the fuel tank with fuel up to measurement .

Guideline

Measurement of 35 mm (1.38 in)

Fuel tank capac-

ity, approx.

3.5 l (3.7 qt.) Super unleaded gasoline, mixed with

2-stroke engine oil (1:60) ( p. 8)

2-stroke engine oil ( p. 8)

–Close the filler cap.

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 7

Spoke nipple M3.5 3 Nm (2.2 lbf ft) –

Remaining nuts, chassis M6 15 Nm (11.1 lbf ft) –

Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –

Screw, ball joint of push rod on foot

brake cylinder

M6 10 Nm (7.4 lbf ft) –

Screw, foot brake cylinder M6 10 Nm (7.4 lbf ft) Loctite®243™

Screw, fork stub M6 10 Nm (7.4 lbf ft) –

Screw, front brake disc M6 14 Nm (10.3 lbf ft) Loctite®243™

Screw, rear brake disc M6 14 Nm (10.3 lbf ft) Loctite®243™

Screw, throttle grip M6 4.5 Nm (3.32 lbf ft) –

Nut, rim lock M8 10 Nm (7.4 lbf ft) –

Remaining nuts, chassis M8 30 Nm (22.1 lbf ft) –

Remaining screws, chassis M8 25 Nm (18.4 lbf ft) –

Screw, bottom triple clamp M8 25 Nm (18.4 lbf ft) –

Screw, brake caliper M8 20 Nm (14.8 lbf ft) Loctite®243™

Screw, engine bracket M8 30 Nm (22.1 lbf ft) –

Screw, foot brake lever M8 25 Nm (18.4 lbf ft) –

Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –

Screw, rear sprocket M8 25 Nm (18.4 lbf ft) Loctite®243™

Screw, side stand fixing M8 40 Nm (29.5 lbf ft) Loctite®243™

Screw, tail piece M8 35 Nm (25.8 lbf ft) Loctite®243™

Screw, top triple clamp M8 25 Nm (18.4 lbf ft) –

Remaining nuts, chassis M10 50 Nm (36.9 lbf ft) –

Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –

Screw, bottom shock absorber M10 45 Nm (33.2 lbf ft) –

Screw, front wheel spindle M10 40 Nm (29.5 lbf ft) –

Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite®243™

Screw, top shock absorber M10 45 Nm (33.2 lbf ft) –

Nut, rear wheel spindle M12x1 40 Nm (29.5 lbf ft) –

Nut, swingarm pivot M12x1 40 Nm (29.5 lbf ft) –

Nut, steering stem M20x1.5 10 Nm (7.4 lbf ft) –

SUBSTANCES 8

2-stroke engine oil

According to

–JASO FC ( p. 10)

Guideline

–Only use high quality 2-stroke engine oil of a well-known brand. KTM recommends Motorex®products.

Fully synthetic

Supplier

Motorex®

–Cross Power 2T

Super unleaded gasoline, mixed with 2-stroke engine oil (1:60)

According to

–DIN EN 228

–JASO FC ( p. 10) (1:60)

Mixture ratio

1:60 2-stroke engine oil ( p. 8)

Super unleaded (ROZ 95 / RON 95 / PON 91)

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