KTM 65 SX 2016 Manual

SETUP INSTRUCTIONS 2016
65 SX
Art. no. 3213431en

INTRODUCTION 1
*3213431en*
3213431en
11/2015
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.
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, devi-
ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not
belong to the regular scope of supply.
© 2015 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 assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
5230 Mattighofen, Austria
This document is valid for the following models:
65 SX (F6001P6)

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.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained
in the glossary.

2 SETUP 3
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 protec-
tive film on each component until installing the component, and leave it on
the vehicle where possible 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 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.
201952-10
–Loosen screws .
–Remove the wheel spindle.
–Install the front fender. ( p. 6)
–Install the front wheel. ( p. 4)
–Remove the protective film from the handlebar and start number plate.
K00344-10
–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 brake line guide . Position the brake line. Mount the brake
line guide again and tighten the screw.
–Check that the wiring harness, throttle cables, and brake line have the necessary
freedom of movement and are correctly routed.
–Check that the controls on the handlebar are correctly positioned and firmly seated.
800042-10
–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. 6)
–Prepare the vehicle according to the specifications in the KTM Dealer.net for han-
dover to the customer.

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.
401942-01
–Raise the motorcycle at the frame underneath the engine.
Lift stand (78929955100)
The wheels must no longer touch 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.
402581-10
–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 Installing the front wheel
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.
601957-11
–Check the wheel bearing for damage and wear.
» If the wheel bearing is broken or worn:
–Change the wheel bearing.
–Clean and grease wheel spindle .
Long-life grease ( p. 10)
–Lift the front wheel into the fork, position it, and insert wheel spindle .
The brake linings are correctly positioned.
–Tighten screws .
Guideline
Screw, fork stub M6 10 Nm (7.4 lbf ft)

3 WORK 5
601956-11
–Mount and tighten screw .
Guideline
Screw, front wheel spindle M10 40 Nm
(29.5 lbf ft)
Loctite®243™
–Remove the motorcycle from the lift stand. ( p. 4)
601958-10
–Operate the hand brake lever several times until the brake linings are in contact
with the brake disc.
–Loosen screws .
–Pull the front wheel brake and push down hard on the fork several times.
This aligns the fork legs.
–Tighten screws .
Guideline
Screw, fork stub M6 10 Nm (7.4 lbf ft)
3.4 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.
601951-11
–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.
–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 WORK 6
3.5 Installing the front fender
H00141-10
–Position the fender with drill holes in the holding lugs on the start number
plate.
The holding lugs engage in the drilled holes.
602674-11
–Position the front fender. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
3.6 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. 7)
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 (95 octane) mixed
with 2-stroke engine oil (1:60)
( p. 9)
Engine oil, 2-stroke ( p. 9)
–Close the filler cap. ( p. 7)

3 WORK 7
3.7 Opening the 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 has been 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.
H00146-10
–Press release button , turn the filler cap counterclockwise, and lift it free.
3.8 Closing the filler cap
H00147-10
–Replace the filler cap and turn clockwise until the release button locks in
place.
Info
Run the fuel tank breather hose without kinks.

4 TECHNICAL DATA 8
4.1 chassis tightening torques
Spoke nipple M3.5 3 Nm (2.2 lbf ft) –
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, foot brake cylinder M6 10 Nm (7.4 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, rear brake lining M6 8 Nm (5.9 lbf ft) –
Screw, throttle grip M6 4.5 Nm (3.32 lbf ft) –
Screw; front brake lining M6 10 Nm (7.4 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, brake caliper M8 20 Nm (14.8 lbf ft) Loctite®243™
Screw, engine bracket M8 30 Nm (22.1 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, steering stem M8 20 Nm (14.8 lbf ft) –
Screw, tail assembly M8 35 Nm (25.8 lbf ft) Loctite®2701™
Screw, top triple clamp M8 20 Nm (14.8 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) Loctite®243™
Screw, foot brake lever M10 35 Nm (25.8 lbf ft) Loctite®243™
Screw, front wheel spindle M10 40 Nm (29.5 lbf ft) Loctite®243™
Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite®243™
Screw, top shock absorber M10 45 Nm (33.2 lbf ft) Loctite®243™
Nut, swingarm pivot M12x1 40 Nm (29.5 lbf ft) –
Nut, rear wheel spindle M14x1.5 40 Nm (29.5 lbf ft) –
Nut, steering stem M20x1.5 10 Nm (7.4 lbf ft) –