KTM 65 SX 2019 Manual

SETUP INSTRUCTIONS 2019

65 SX

Art. no. 3213963en

INTRODUCTION

*3213963en*

3213963en

05/2018

INTRODUCTION

Perform the work described in these setup instructions before the vehicle is delivered to the customer.

Read the setup instructions in their entirety before beginning work.

These setup instructions were 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 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 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, deviations from figures and descriptions,

misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the

regular scope of supply.

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 assur-

ance processes that lead to the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM Sportmotorcycle GmbH

Stallhofnerstraße 3

5230 Mattighofen, Austria

This document is valid for the following models:

65 SX (F6001S6)

1 MEANS OF REPRESENTATION

1.1 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 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.

Indicates the end of an activity including potential rework.

1.2 Formats used

The typographical formats used in this document are explained below.

Proprietary name Indicates a proprietary name.

Name®Indicates a protected name.

Brand™ Indicates a brand available on the open market.

Underlined terms Refer to technical details of the vehicle or indicate technical terms, which

are explained in the glossary.

SETUP 2

2.1 Unpacking and setting up the vehicle

201951-10

–Open the box.

Info

To avoid damaging the vehicle while setting it up, do

not remove the protective film on each component until

installing the component, and leave it on the vehicle

until work has been completed.

–Remove the front wheel, fender, and the separate enclosure

from the box.

–Remove the separate enclosure and unpack it. Check that the

scope of supply is complete using the enclosed packing list.

–Lift the vehicle out of the box with the assistance of another

person.

–Raise the motorcycle with a lift stand. ( p. 5)

–Check the vehicle for transport damage.

201952-10

–Loosen screws 1.

–Remove the wheel spindle.

–Install front fender. ( p. 10)

–Install the front wheel. ( p. 5)

–Remove the protective film from the handlebar and start num-

ber plate.

K00344-10

–Position the handlebar with handlebar clamps 2.

–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 required by the

customer:

–Adjust the handlebar position. ( p. 6)

–Remove the screw of brake line guide 3. Position the brake

line. Mount the brake line guide again and tighten the screw.

–Check that the controls on the handlebar are correctly posi-

tioned and firmly seated.

–Remove the seat. ( p. 7)

–Remove the fuel tank. ( p. 8)

2 SETUP

E00757-01

–Position the service hour counter and fix it in place using an

adhesive pad.

–Route the cable on the frame and attach it to the ignition wire.

Info

Do not kink or damage the cable.

–Check that the wiring harness, throttle cables, and brake line

have the necessary freedom of movement and are correctly

routed.

–Install the fuel tank. ( p. 9)

–Mount the seat. ( p. 7)

800042-10

–Mount the footrests with the springs and pins. Secure the pins

using the washers and cotter pins.

Footrest spring plier (58429083000)

–Fill up with fuel. ( p. 11)

–Prepare the vehicle according to the specifications in the

KTM Dealer.net for handover to the customer.

WORK 3

3.1 Raising the motorcycle with a lift stand

Note

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

–Park the vehicle on a firm and level surface.

401942-01

–Raise the motorcycle at the frame underneath the engine.

Lift stand (78929955100)

Neither wheel is in contact with the ground.

–Secure the motorcycle against falling over.

3.2 Removing the motorcycle from the lift stand

Note

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

–Park the vehicle on a firm and level surface.

402581-10

–Remove the motorcycle from the lift stand.

–Remove the lift stand.

–To park the motorcycle, insert plug-in stand 1into the plug-

in stand bracket on the left side of the vehicle.

Info

Remove the plug-in stand before riding.

3.3 Installing the front wheel

Warning

Danger of accidents Oil or grease on the brake discs reduces the braking effect.

–Always keep the brake discs free of oil and grease.

–Clean the brake discs with brake cleaner when necessary.

H00935-10

–Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:

–Change front wheel bearing.

–Clean and grease shaft seal rings 1and contact surfaces A

of the spacers.

Long-life grease ( p. 17)

–Insert the spacers.

3 WORK

V00247-10

–Clean and grease wheel spindle 2.

Long-life grease ( p. 17)

–Position the front wheel.

The brake linings are correctly positioned.

–Insert the wheel spindle.

–Tighten screws 3.

Guideline

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

V00219-11

–Mount and tighten screw 4.

Guideline

Screw, front

wheel spindle

M10 40 Nm (29.5 lbf ft)

Loctite®243™

–Remove the motorcycle from the lift stand. ( p. 5)

V00248-10

–Operate the hand brake lever several times until the brake lin-

ings are seated correctly against the brake disc.

–Loosen screws 3.

–Operate the front brake and compress the fork a few times

firmly.

The fork legs straighten.

–Tighten screws 3.

Guideline

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

3.4 Adjusting the handlebar position

Warning

Danger of accidents A repaired handlebar poses a safety risk.

If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a

result.

–Change the handlebar if the handlebar is damaged or bent.

601951-11

–Remove screws 1. Take off the handlebar clamps. Remove

the handlebar and lay it to one side.

Info

Protect the motorcycle and its attachments against

damage by covering them.

Do not kink the cables and lines.

–Remove screws 2. Remove the handlebar support.

–Place the handlebar support in the required position. Mount

and tighten screws 2.

WORK 3

Guideline

Screw, handle-

bar support

M10 40 Nm (29.5 lbf ft)

Loctite®243™

–Position the handlebar.

Info

Make sure the cables and wiring are positioned cor-

rectly.

–Position the handlebar clamps. Mount screws 1and tighten

evenly.

Guideline

Screw, handlebar

clamp

M8 20 Nm (14.8 lbf ft)

Info

Make sure the gap widths are even.

3.5 Removing the seat

H00122-10

–Open quick release 1and raise the rear of the seat.

–Pull back the seat and remove it.

3.6 Mounting the seat

V00208-10

–Hook seat onto screw 1and lower the seat at the rear and

push it forward.

The catch 2hooks into the fuel tank.

H00122-11

–Close quick release 3.

3 WORK

3.7 Removing the fuel tank

Danger

Fire hazard Fuel is highly flammable.

The fuel in the fuel tank expands when warm and can escape if overfilled.

–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.

–Switch off the engine for refueling.

–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.

–If any fuel is spilled, wipe it off immediately.

–Observe the specifications for refueling.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

–Avoid skin, eye and clothing contact with fuel.

–Immediately consult a doctor if you swallow fuel.

–Do not inhale fuel vapors.

–In case of skin contact, rinse the affected area with plenty of water.

–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.

–Change your clothing in case of fuel spills on them.

–Keep fuels correctly in a suitable canister, and out of the reach of children.

Preparatory work

–Remove the seat. ( p. 7)

–Turn the knurled screw on the fuel tap all the way clockwise.

V00213-10

Main work

–Remove screw 1.

V00234-10

–Remove screws 2.

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