KTM 50 SX PRO SENIOR LC Manual

SETUP INSTRUCTIONS 2019
50 SX
50 SX Mini
Art. no. 3213868en

INTRODUCTION
*3213868en*
3213868en
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.
© 2018 KTM Sportmotorcycle GmbH, 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 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:
50 SX (F6001S4)
50 SX Mini (F6001S5)

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.
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
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 protective 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 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.
–Remove the protective film from the handlebar.
S00974-10
–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 required by the
customer:
–Adjust the handlebar position. ( p. 5)
–Remove the screw of the brake line guide. 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. 6)
–Remove the fuel tank. ( p. 7)
E00751-01
–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. 8)
–Mount the seat. ( p. 6)

2 SETUP
4
201950-10
–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. 10)
(50 SX Mini)
–Fill up with oil. ( p. 11)
–Remove the motorcycle from the lift stand. ( p. 5)
–Rest the vehicle on the plug-in stand.
–Prepare the vehicle according to the specifications in the
KTM Dealer.net for handover to the customer.

WORK 3
5
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 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.
0
0
11
0
0
22
400564-10
–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.

3 WORK
6
–Place the handlebar support in the required position. Mount
and tighten screws 2.
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.
3.4 Removing the seat
H00066-10
–Open quick release 1and raise the rear of the seat.
–Pull back the seat and remove it.
3.5 Mounting the seat
H01431-10
–Hook the seat onto screw 1, lower the seat at the rear, and
push it forward.
Catch 2hooks into the fuel tank.

WORK 3
7
H00066-11
–Close quick release 3.
3.6 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. 6)
–Turn the knurled screw on the fuel tap all the way clockwise.
R00530-10
Main work
–Remove screw 1.

3 WORK
8
R00531-10
–Raise the fuel tank.
–Pull off fuel hose 2.
Info
Remaining fuel may flow out of the fuel hose.
–Pull fuel tank breather out of the steering stem.
–Take off the fuel tank.
3.7 Installing 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.
Main work
–Check the throttle cable routing. ( p. 12)
R00531-11
–Mount fuel hose 1.