KTM 2014 65 SX Manuel

SETUP INSTRUCTIONS 2014

65 SX

Art. no. 3213088en

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 these setup instructions.

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 supply.

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

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 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 1.

–Remove the wheel spindle.

–Install the front fender. ( p. 5)

–Install the front wheel. x( p. 4)

–Remove the protective film from the handlebar and start number plate.

201953-10

–Position the handlebar with handlebar clamps 2.

–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. x( p. 5)

–Remove the screw of the brake line guide 3. 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.

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)

–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.

601945-01

–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.

602658-10

–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 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.

601957-11

–Check the wheel bearing for damage and wear.

» If the wheel bearing is broken or worn:

–Change the wheel bearing. x

–Clean and grease wheel spindle 1.

Long-life grease ( p. 10)

–Lift the front wheel into the fork, position it, and insert wheel spindle 1.

–Tighten screws 2.

Guideline

Screw, fork stub M6 10 Nm (7.4 lbf ft)

601956-11

–Mount and tighten screw 3.

Guideline

Screw, front wheel spindle M10 40 Nm

(29.5 lbf ft)

–Remove the motorcycle from the lift stand. ( p. 4)

3 WORK 5

601958-10

–Operate the hand brake lever several times until the brake linings are in contact

with the brake disc.

–Loosen screws 2.

–Pull the front wheel brake and push down hard on the fork several times.

This aligns the fork legs.

–Tighten screws 2.

Guideline

Screw, fork stub M6 10 Nm (7.4 lbf ft)

3.4 Adjusting 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.

601951-11

–Remove the four screws 1. Remove 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 two screws 2. Remove the handlebar support.

–Place the handlebar support in the required position. Mount and tighten the two

screws 2.

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. Mount and evenly tighten the four screws 1.

Guideline

Screw, handlebar clamp M8 20 Nm

(14.8 lbf ft)

Info

Make sure the gap width is even.

3.5 Installing the front fender

602675-10

–Position the fender with holding lugs 1into the drill holes on the start number

plate.

3 WORK 6

602674-11

–Position the front fender. Mount and tighten screws 2.

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. 6)

400382-10

–Fill the fuel tank with fuel up to measurement A.

Guideline

Measurement of A35 mm (1.38 in)

Fuel tank capac-

ity, approx.

3.5 l (3.7 qt.) Super unleaded gasoline (95 octane),

mixed with 2-stroke engine oil (1:60)

( p. 9)

2-stroke engine oil ( p. 9)

–Close the filler cap. ( p. 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 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 7

602661-10

–Press release button 1, turn the filler cap counterclockwise, and lift it free.

3.8 Closing the filler cap

602662-10

–Replace the filler cap and turn clockwise until the release button 1locks in place.

Info

Run the fuel tank breather hose 2without kinks.

4 TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS 8

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, throttle grip M6 4.5 Nm (3.32 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, tail piece M8 35 Nm (25.8 lbf ft) Loctite®243™

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) –

Screw, foot brake lever M10 35 Nm (25.8 lbf ft) Loctite®243™

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) –

Table des matières

Autres manuels KTM Moto

KTM

KTM 790 ADVENTURE R 2022 Manuel utilisateur

KTM

KTM 690 Enduro R EU 2013 Manuel de la liste des pièces

KTM

KTM 250 SX-F 2018 Manuel utilisateur

KTM

KTM 125 DUKE 2022 Manuel

KTM

KTM 1290 Super Adventure R EU 2019 Manuel

KTM

KTM 85 SX 19/16 Manuel utilisateur

KTM

KTM 400 EXC FACTORY EDITION EU Manuel utilisateur

KTM

KTM 350 EXC-F SIX DAYS EU Manuel utilisateur

KTM

KTM 790 Adventure R Rally 2020 Manuel utilisateur

KTM

KTM 50 SX PRO SENIOR LC 2002 Guide de l'utilisateur

KTM

KTM 250 EXC-F EU 2010 Manuel utilisateur

KTM

KTM F8475S0 2019 Manuel utilisateur

KTM

KTM Freeride E-XC 2018 Manuel utilisateur

KTM

KTM 125 Duke 2018 Manuel utilisateur

KTM

KTM 450 SX-F 2021 Manuel utilisateur

KTM

KTM 690 Enduro R EU 2012 Mode d'emploi

KTM

KTM 144 SX Manuel utilisateur

KTM

KTM 65 SX 2001 Guide de l'utilisateur

KTM

KTM 1290 Super Duke GT 2019 Manuel

KTM

KTM 390 Adventure 2020 Manuel utilisateur

KTM

KTM 350 EXC-F SIX DAYS EU Manuel

KTM

KTM 990 Supermoto R USA 2010 Manuel utilisateur

KTM

KTM 1290 Super Adventure EU 2015 Manuel

KTM

KTM 1998 400 R Guide de l'utilisateur

Manuels Moto populaires d'autres marques

OHVALE

OHVALE GP-0 Manuel de la liste des pièces

Yamaha

Yamaha Star XV19CTSZ 2009 Manuel utilisateur

HYOSUNG

HYOSUNG ST7 Manuel utilisateur

Husqvarna

Husqvarna FC 250 2016 Manuel utilisateur

Ducati

Ducati SCRAMBLER 800 Manuel d'instructions

MOTO GUZZI

MOTO GUZZI QUOTA 1100 ES Manuel utilisateur

APRILIA

APRILIA ETV MILLE CAPONORD - PART1 02-2001 Manuel utilisateur

Yamaha

Yamaha 2006 YZF-R1V Manuel utilisateur

Fantic

Fantic Enduro 125 Manuel utilisateur

Ducati

Ducati Supersport 750 desmodue Manuel utilisateur

MV Agusta

MV Agusta 2008 F4 312RR 1078 Manuel d'instructions

Yamaha

Yamaha XVS650A Manuel utilisateur

Yamaha

Yamaha YZF-R6T(C) Manuel

Ducati

Ducati 748 monoposto strada Manuel utilisateur

ATK

ATK 1988 250 Manuel utilisateur

Excelsior-HENDERSON

Excelsior-HENDERSON 1999 HCX Manuel utilisateur

Triumph

Triumph Thunderbird Manuel utilisateur

Yamaha

Yamaha 2006 FJR1300A Manuel utilisateur