KTM 50 SX 2015 Manual

SETUP INSTRUCTIONS 2015
50 SX
50 SX Mini
Art. no. 3213189en

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, misprints, and other errors. The models portrayed partly contain special equip-
ment that does not belong to the regular scope of supply.
© 2014 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

1 MEANS OF REPRESENTATION 2
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.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
1.2 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.

2 SETUP 3
2.1 Unpacking and setting up the vehicle
201948-10
–Open the box.
Info
To avoid damaging the vehicle while setting it up, do not remove the protec-
tive film on each component until installing the component, and leave it on
the vehicle until work has been completed.
–Remove the separate enclosure and unpack it. Check that the scope of supply is
complete on the basis of 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. 4)
–Check the vehicle for transport damage.
–Remove the protective film from the handlebar.
201949-10
–Position the handlebar with handlebar clamps.
–Mount and tighten 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. 4)
–Remove the screw of the brake line guide. Position the brake line. Mount the brake
line guide again and tighten the screw.
–Check the wiring harness, cables, and brake line for freedom of movement and cor-
rect routing.
–Check that the controls on the handlebar are correctly positioned and firmly seated.
201950-10
–Mount the footrests with the springs and pins. Secure the pins using the washers
and cotter pins.
Pliers for footrest spring (58429083000)
–Fill up with fuel. ( p. 5)
(50 SX Mini)
–Fill up with oil. ( p. 6)
–Remove the motorcycle from the lift stand. ( p. 4)
–Park the vehicle on the plug-in stand.
–Print out the current PDI form found on KTM DEALER.NET and perform the delivery
inspection.

3 WORK 4
3.1 Raising 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.
101933-01
–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.
3.2 Removing 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.
101931-10
–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.
3.3 Adjusting handlebar position
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
11
0
0
22
400564-10
–Remove the screws . Take off 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 screws . Remove the handlebar support.
–Place the handlebar support in the required position. Fit and tighten the
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.

3 WORK 5
–Position the handlebar clamps. Fit and evenly tighten the screws .
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
Info
Make sure the gap width is even.
3.4 Refueling
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.
–The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel 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 physician immediately. Change clothing that is contaminated 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. ( p. 5)
00
0
AA
400214-10
–Fill the fuel tank with fuel up to measurement .
Guideline
Measurement of 35 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. 9)
Fuel tank
capacity, approx.
(50 SX)
2.3 l (2.4 qt.) Super unleaded (95 octane) mixed
with 2-stroke engine oil (1:60)
( p. 9)
–Close the filler cap. ( p. 6)
3.5 Opening filler cap
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.
–The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel 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 physician immediately. Change clothing that is contaminated with fuel.
Store fuel properly in a suitable canister and keep away from children.
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.

3 WORK 6
601580-10
–Turn the tank cap counterclockwise and pull it up.
3.6 Closing filler cap
601580-11
–Put the tank cap on and turn it clockwise.
Info
Run the fuel tank breather hose without kinks.
3.7 Filling 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. ( p. 6)
102031-10
–Fill the oil tank at least up to the MIN mark .
Guideline
MIN mark Sufficient for a single tank filling
Oil tank contents
ca.
0.2 l (0.2 qt.) Engine oil, 2-stroke ( p. 9)
–Close the oil tank cap. ( p. 7)
3.8 Opening oil tank cap (50 SX Mini)
601582-10
–Turn the oil tank cap counterclockwise and pull it up.

3 WORK 7
3.9 Closing oil tank cap (50 SX Mini)
601582-11
–Put the oil tank cap on and turn it clockwise.
Info
Run the oil tank breather hose without kinks.

4 TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS 8
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) –
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, rear sprocket M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, top triple clamp M8 20 Nm (14.8 lbf ft) –
Front wheel spindle screw 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)
–

5 SUBSTANCES 9
Engine oil, 2-stroke
Standard/classification
–JASO FD ( p. 10)
Guideline
–Only use high grade 2-stroke engine oil of a reputable brand.
Fully synthetic
Recommended supplier
Motorex®
–Cross Power 2T
Super unleaded (ROZ 95/RON 95/PON 91)
Standard/classification
–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 (95 octane) mixed with 2-stroke engine oil (1:60)
Standard/classification
–DIN EN 228
–JASO FD ( p. 10) (1:60)
Mixture ratio
1:60 Engine oil, 2-stroke ( p. 9)
Super unleaded (ROZ 95/RON 95/PON 91) ( p. 9)
Recommended supplier
Motorex®
–Cross Power 2T

6 STANDARDS 10
JASO FD
JASO FD 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.

*3213189en*
3213189en
06/2014
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer/KTM