KTM 50 SX 2012 Manual

SETUP INSTRUCTIONS 2012
50 SX
50 SX Mini
Art. no. 3211878en

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 specifically 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.
© 2012 KTM-Sportmotorcycle AG, Mattighofen 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.
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 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.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.

SETUP 3
2.1Unpacking and setting up the vehicle
700538-01
–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 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.
–Remove the protective plastic from the handlebar.
700539-01
–Position the handlebar with the 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 the handlebar position. x( p. 4)
–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.
700540-01
–Mount the footrests with the springs and bolts. Secure the bolts using the washers
and pins.
Pliers for footrest spring (58429083000)
(50 SX)
–Install the chain guard. ( p. 5)
–Fill up with fuel. ( p. 5)
(50 SX Mini)
–Fill up with oil. ( p. 6)
–Remove the motorcycle from the lift stand. ( p. 4)
–Rest the vehicle on the plug-in stand.
–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.
601590-01
–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.
601585-10
–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.
3.3Adjusting 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.
0
0
1
1
0
0
22
400564-10
–Remove the four screws 1. Remove the handlebar clamps. 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 2. Remove the handlebar support.
–Place the handlebar support in the required position. Mount and tighten the two
screws 2.
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.

WORK 5
–Position the handlebar clamps. Mount and evenly tighten the four screws 1.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
Info
Make sure the gap width is even.
3.4Installing the chain guard (50 SX)
100816-10
–Position the chain guard. Mount cable binder 1.
Info
The cable binder must be run between chain sliding guard 2and
swingarm 3.
100817-10
–Mount the cable binder at the rear.
–Align the chain guard so that screws Aof the chain guide are visible.
–Tighten the cable binder and cut off the ends.
3.5Refueling
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.
00
0
A
A
400214-10
–Fill the fuel tank with fuel up to measurement A.
Guideline
Measurement of A35 mm (1.38 in)
Fuel tank
capacity, approx.
(50 SX Mini)
2.0 l (2.1 qt.) Super unleaded (ROZ 95/RON 95/PON
91) ( p. 8)
Fuel tank
capacity, approx.
(50 SX)
2.3 l (2.4 qt.) Super unleaded gasoline, mixed with
2-stroke engine oil (1:60) ( p. 8)
–Close the filler cap.

WORK 6
3.6Filling up with oil (50 SX Mini)
Warning
Engine failure If the vehicle is run without 2-stroke oil in the tank, the result is engine failure.
–The oil tank must always be filled up to the MIN mark.
–Switch off the engine.
–Open the oil tank cap.
601586-10
–Fill the oil tank at least up to the MIN mark A.
Guideline
MIN mark Sufficient for a single tank filling
Oil tank contents
ca.
0.2 l (0.2 qt.) 2-stroke engine oil ( p. 8)
–Close the oil tank cap.

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 7
Spoke nipple M3.5 3 Nm (2.2 lbf ft) –
Screw, brake linings M5 8 Nm (5.9 lbf ft) –
Rear brake caliper screw M6 10 Nm (7.4 lbf ft) Loctite®243™
Remaining nuts, chassis M6 10 Nm (7.4 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, chain sliding piece M6 3 Nm (2.2 lbf ft) –
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) –
Screw, rear sprocket M7 15 Nm (11.1 lbf ft) Loctite®243™
Engine carrying screw M8 25 Nm (18.4 lbf ft) –
Nut, foot brake lever M8 22 Nm (16.2 lbf ft) –
Nut, rim lock M8 10 Nm (7.4 lbf ft) –
Remaining nuts, chassis M8 25 Nm (18.4 lbf ft) –
Remaining screws, chassis M8 25 Nm (18.4 lbf ft) –
Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) –
Screw, chain sliding piece M8 15 Nm (11.1 lbf ft) –
Screw, front brake caliper M8 20 Nm (14.8 lbf ft) Loctite®243™
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –
Screw, top triple clamp M8 20 Nm (14.8 lbf ft) –
Front wheel spindle nut M10 40 Nm (29.5 lbf ft) –
Nut, swingarm pivot M10 45 Nm (33.2 lbf ft) –
Remaining nuts, chassis M10 45 Nm (33.2 lbf ft) –
Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –
Screw, bottom shock absorber M10 45 Nm (33.2 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, steering head M20x1.5 No play
≤10 Nm (≤7.4 lbf ft)
–

SUBSTANCES 8
2-stroke engine oil
According to
–JASO FC ( p. 9)
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 (ROZ 95/RON 95/PON 91)
According to
–DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
–Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
–Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).
Super unleaded gasoline, mixed with 2-stroke engine oil (1:60)
According to
–DIN EN 228
–JASO FC ( p. 9) (1:60)
Mixture ratio
1:60 2-stroke engine oil ( p. 8)
Super unleaded (ROZ 95/RON 95/PON 91) ( p. 8)
Supplier
Motorex®
–Cross Power 2T

STANDARDS 9
JASO FC
JASO FC is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first
rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions.

*3211878en*
3211878en
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
02/2012
Photo: Mitterbauer