KTM 65 SX 2010 Manual

SETUP INSTRUCTIONS 2010
65 SX
Art. no. 3211569en

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.
© 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, 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 in the following.
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).
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained in the following.
Proprietary name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies 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.
–Jack up the motorcycle. ( 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
3.1Jacking up the motorcycle
700405-01
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
–Jack up the motorcycle underneath the engine.
Work stand (54829055000)
–Secure the motorcycle against falling over.
3.2Removing the motorcycle from the work stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
–Remove the motorcycle from the work stand.
–Remove the work stand.
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
–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 work stand. ( p. 4)
700536-01
–Operate the hand brake lever several times until the brake pads are lying correctly
on the brake disc.
–Loosen screw .
–Pull the front wheel brake and push down hard on the fork several times to align
the fork legs.
–Tighten screws .
Guideline
Screw, fork stub M6 10 Nm (7.4 lbf ft)

WORK 5
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.
0
0
22
0
0
11
400271-10
–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.
700414-11
–Position the front fender. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

WORK 6
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.
AA
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)
–Close the filler cap.

TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS 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, footbrake 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) –
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 pedal 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
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
Super unleaded (ROZ 95 / RON 95 / PON 91)

AUXILIARY SUBSTANCES 9
Long-life grease
Guideline
–KTM recommends Motorex®products.
Supplier
Motorex®
–Fett 2000

STANDARDS 10
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.

*3211569en*
3211569en
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
07/2009 Photo: Mitterbauer