KTM 65 SX 2019 Manual

SETUP INSTRUCTIONS 2019
65 SX
Art. no. 3213963en

INTRODUCTION
*3213963en*
3213963en
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:
65 SX (F6001S6)

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
201951-10
–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 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 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.
201952-10
–Loosen screws 1.
–Remove the wheel spindle.
–Install front fender. ( p. 10)
–Install the front wheel. ( p. 5)
–Remove the protective film from the handlebar and start num-
ber plate.
K00344-10
–Position the handlebar with handlebar clamps 2.
–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. 6)
–Remove the screw of brake line guide 3. 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. 7)
–Remove the fuel tank. ( p. 8)

2 SETUP
4
E00757-01
–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. 9)
–Mount the seat. ( p. 7)
800042-10
–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. 11)
–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 Installing the front wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
–Always keep the brake discs free of oil and grease.
–Clean the brake discs with brake cleaner when necessary.
H00935-10
–Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
–Change front wheel bearing.
–Clean and grease shaft seal rings 1and contact surfaces A
of the spacers.
Long-life grease ( p. 17)
–Insert the spacers.

3 WORK
6
V00247-10
–Clean and grease wheel spindle 2.
Long-life grease ( p. 17)
–Position the front wheel.
The brake linings are correctly positioned.
–Insert the wheel spindle.
–Tighten screws 3.
Guideline
Screw, fork stub M6 10 Nm (7.4 lbf ft)
V00219-11
–Mount and tighten screw 4.
Guideline
Screw, front
wheel spindle
M10 40 Nm (29.5 lbf ft)
Loctite®243™
–Remove the motorcycle from the lift stand. ( p. 5)
V00248-10
–Operate the hand brake lever several times until the brake lin-
ings are seated correctly against the brake disc.
–Loosen screws 3.
–Operate the front brake and compress the fork a few times
firmly.
The fork legs straighten.
–Tighten screws 3.
Guideline
Screw, fork stub M6 10 Nm (7.4 lbf ft)
3.4 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.
601951-11
–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.
–Place the handlebar support in the required position. Mount
and tighten screws 2.

WORK 3
7
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.
3.5 Removing the seat
H00122-10
–Open quick release 1and raise the rear of the seat.
–Pull back the seat and remove it.
3.6 Mounting the seat
V00208-10
–Hook seat onto screw 1and lower the seat at the rear and
push it forward.
The catch 2hooks into the fuel tank.
H00122-11
–Close quick release 3.

3 WORK
8
3.7 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. 7)
–Turn the knurled screw on the fuel tap all the way clockwise.
V00213-10
Main work
–Remove screw 1.
V00234-10
–Remove screws 2.

WORK 3
9
K00216-10
–Pull off fuel hose 3.
Info
Remaining fuel may flow out of the fuel hose.
–Pull fuel tank breather out of the steering stem.
–Pull both spoilers off sideways from the radiator bracket and
lift off the fuel tank upward.
3.8 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. 13)
K00216-11
–Position the fuel tank and fit the two spoilers to the sides of
the radiator bracket.
–Make sure that no cables or throttle cables are trapped or dam-
aged.
–Mount fuel hose 1.

3 WORK
10
V00234-10
–Mount and tighten screws 2.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
V00213-11
–Mount and tighten screw 3.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Position the fuel tank breather in the steering stem.
Finishing work
–Mount the seat. ( p. 7)
3.9 Installing front fender
V00206-10
–Position start number plate on the fender.
The holding lugs of the start number plate engage in drill
holes 1of the fender.
V00233-11
–Position fender on the lower triple clamp, mount and tighten
screws 2.
Guideline
Screw, fender M6 6 Nm (4.4 lbf ft)

WORK 3
11
3.10 Refueling
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.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.
–Switch off the engine.
–Open the filler cap. ( p. 12)
AA
400382-10
–Fill the fuel tank with fuel up to measurement A.
Guideline
Measurement of A35 mm (1.38 in)
Fuel tank capacity,
approx.
3.5 l (3.7 qt.) Super unleaded
(95 octane) mixed
with 2-stroke
engine oil (1:60)
( p. 16)
Engine oil, 2-stroke ( p. 16)
–Close the filler cap. ( p. 12)

3 WORK
12
3.11 Opening the filler cap
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.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.
V00189-10
–Press release button 1, turn the filler cap counterclockwise,
and lift it free.
3.12 Closing the filler cap
V00190-10
–Replace the filler cap and turn clockwise until the release but-
ton 1locks in place.
Info
Run the fuel tank breather hose 2without kinks.

WORK 3
13
3.13 Checking the throttle cable routing
Warning
Danger of accidents The throttle cable may slip out of the guide if routed incorrectly.
The throttle slide will then no longer be closed and the speed can no longer be controlled.
–Make sure that the throttle cable routing and the play in throttle cable complies with the specifica-
tion.
Preparatory work
–Remove the seat. ( p. 7)
–Turn the knurled screw on the fuel tap all the way clockwise.
–Remove the fuel tank. ( p. 8)
V00218-01
Main work
–Check the throttle cable routing.
The throttle cable must be routed behind the handlebar,
behind the coolant hose and left on the frame.
» If the throttle cable is not routed as specified:
–Correct the throttle cable routing.
Finishing work
–Install the fuel tank. ( p. 9)
–Mount the seat. ( p. 7)

4 TECHNICAL DATA
14
4.1 Chassis tightening torques
Spoke nipple M3.5 3 Nm (2.2 lbf ft)
Screw, brake line bracket M5 2 Nm (1.5 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)
Loctite®243™
Screw, fender M6 6 Nm (4.4 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, front brake linings M6 10 Nm (7.4 lbf ft)
Screw, rear brake disc M6 14 Nm (10.3 lbf ft)
Loctite®243™
Screw, rear brake lining M6 10 Nm (7.4 lbf ft)
Screw, throttle grip M6 4.5 Nm (3.32 lbf ft)
Start number plate screw M6 4 Nm (3 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, engine bracket M8 30 Nm (22.1 lbf ft)
Loctite®243™
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 brake caliper M8 18 Nm (13.3 lbf ft)
Loctite®243™
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)

TECHNICAL DATA 4
15
Nut, rear wheel spindle M14x1.5 40 Nm (29.5 lbf ft)
Nut, steering stem M20x1.5 10 Nm (7.4 lbf ft)

5 SUBSTANCES
16
Engine oil, 2-stroke
Standard/classification
–JASO FD ( p. 18)
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. 18) (1:60)
Mixture ratio
1:60 Engine oil, 2-stroke ( p. 16)
Super unleaded (ROZ 95/RON 95/PON 91) ( p. 16)
Recommended supplier
Motorex®
–Cross Power 2T

AUXILIARY SUBSTANCES 6
17
Long-life grease
Recommended supplier
Motorex®
–Bike Grease 2000

7 STANDARDS
18
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.