KTM 50 SX 2024, 50 SX FACTORY EDITION 2024 Manual

Also See for 50 SX 2024:

Setup instructions (29 pages)

Table of Contents

Contents

1 INTRODUCTION
2 MEANS OF REPRESENTATION
- 2.1 Symbols used
- 2.2 Formats used
3 SETUP
- 3.1 Unpacking and setting up the vehicle
4 WORK
5 TECHNICAL SPECIFICATIONS
- 5.1 chassis tightening torques
6 SUBSTANCES
7 AUXILIARY SUBSTANCES
8 Documents / Resources
- 8.1 Download manual

KTM 50 SX 2024, 50 SX FACTORY EDITION 2024 Manual

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 model series. We reserve the right to make modifications in the interest 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 contained herein 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.

MEANS OF REPRESENTATION

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 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.

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

Unpacking and setting up the vehicle

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 cable tie.
Remove the separate enclosure and unpack it. Check the separate enclosure for completeness.
Info
The procedure for missing components is described in the Customer Service Manual.
Lift the vehicle out of the box with the assistance of another person.
Raise the motorcycle with a lift stand.
Check the vehicle for transport damage.
Info
The procedure in the event of transport damage is described in the Customer Service Manual.
Remove the protective film from the handlebar.

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.
Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
Position the handlebar clamp. Align the handlebar using marking . Mount and tighten the screws evenly.
Guideline

Screw, handlebar clamp M8 20 Nm (14.8 lbf ft)

Info
Keep the installed gap widths equal when tightening.
Check the handlebar position.
If the handlebar position is not adjusted as required by the customer:
- Adjust the handlebar position.
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 positioned and firmly seated.
Position the handlebar cushion and secure with a cable tie.
Remove the seat.
Remove the fuel tank.
Position service hour counter and mount it with screws 2.
Guideline

Remaining EJOT PT screws EJOT PT
K60x20 2 Nm (1.5 lbf ft)
Route the cable on the frame and attach it to the ignition wire.
Check that the wiring harness, cables, and brake line have the necessary freedom of movement and are correctly routed.
Install the fuel tank.
Mount the seat.
Mount the footrests with the springs and pins. Secure the pins using the washers and cotter pins.
Check the factory-set frame height.
If the frame height is unsuitable for the rider:
- Adjust the seat height on the shock absorber.
- Adjust the seat height on the fork.
- Adjust the seat height on the frame.
Install the frame protector.
Unpack and mount the KTM PowerParts included in the delivery (optional).
Info
Read the accompanying KTM PowerParts instructions.
Attach the stickers included in the scope of supply (optional).
Turn the knurled screw on the fuel tap all the way counterclockwise.
Refuel.
Remove the remaining film, padding, the corrugated cardboard, and the other packaging material.
Remove the motorcycle from the lift stand.
Prepare the vehicle according to the specifications of the presales inspection for handover to the customer.

WORK

Raising the motorcycle with a lift stand

Note

of damage
The parked vehicle can roll away or fall over.

Park the vehicle on a firm and level surface.

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.

Removing the motorcycle from the lift stand

Note

of damage
The parked vehicle can roll away or fall over.

Park the vehicle on a firm and level surface.

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.

Adjusting the handlebar position

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.

Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side.
Info
Cover the components to protect them against damage. Do not kink the cables and lines.
Remove screws . Take off handlebar supports.
Place handlebar supports in required position. Mount and tighten screws.
Guideline

Screw, handlebar support M10 40 Nm (29.5 lbf ft)
Loctite ® 243™
Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
Position the handlebar clamps. Mount screws and tighten evenly.
Guideline

Screw, handlebar clamp M8 20 Nm (14.8 lbf ft)

Info
Make sure the installed gaps are even.

Removing the seat

Open quick release and raise the rear of the seat.
Pull back the seat and remove it.

Removing the frame protector

Remove the cable ties.
Remove screws with the bushings.
Take off the left frame protector.
Push the right frame protector to the front and take off at the bottom.

Installing the frame protector

Position the left frame protector.
Insert the right frame protector from below and push it to the rear.
Mount screws with the bushings and tighten.
Guideline

Remaining screws, chassis M5 5 Nm (3.7 lbf ft)
Secure the frame protector with cable ties.

Mounting the seat

Hook seat onto screw and lower the seat at the rear and push it forward.
Holding lug hooks into the fuel tank.
Close quick release .

Hook seat onto screw and lower the seat at the rear and push it forward.
Holding lug hooks into the fuel tank.
Close quick release .

Removing the fuel tank

Fire hazard
Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.

Do not fuel 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.

of poisoning
Fuel is harmful to health.

Avoid skin, eye and clothing contact with fuel.
Immediately consult a doctor if you swallow fuel.
Do not inhale fuel vapors.
Rinse the affected area immediately with plenty of water in the event of contact with the skin.
Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
Change your clothing if fuel spills on them.
Keep fuels correctly in a suitable canister, and out of the reach of children.

Preparatory work

Remove the seat.
Turn the knurled screw on the fuel tap all the way clockwise.

Main work

Pull fuel tank breather out of the steering stem.
Remove screw.
Pull off fuel hose .
Info
Remaining fuel may flow out of the fuel hose.
Pull the fuel tank guard out of rubber bushing.
Raise the fuel tank.
Take off the fuel tank.

Installing the fuel tank

Fire hazard
Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.

Do not fuel 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.

of poisoning
Fuel is harmful to health.

Avoid skin, eye and clothing contact with fuel.
Immediately consult a doctor if you swallow fuel.
Do not inhale fuel vapors.
Rinse the affected area immediately with plenty of water in the event of contact with the skin.
Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
Change your clothing if fuel spills on them.
Keep fuels correctly in a suitable canister, and out of the reach of children.

Main work

Position the fuel tank.
Make sure that no cables or throttle cables are trapped or damaged.
Press fuel tank guard into rubber bushing.
Check the throttle cable routing.
Mount and tighten screw.
Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Position the fuel tank breather in the steering stem.
Mount fuel hose .
Turn the knurled screw on the fuel tap all the way counterclockwise.

Finishing work

Mount the seat.

Opening the fuel tank filler cap

Fire hazard
Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.

Do not fuel 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.

of poisoning
Fuel is harmful to health.

Avoid skin, eye and clothing contact with fuel.
Immediately consult a doctor if you swallow fuel.
Do not inhale fuel vapors.
Rinse the affected area immediately with plenty of water in the event of contact with the skin.
Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
Change your clothing if fuel spills on them.
Keep fuels correctly in a suitable canister, and out of the reach of children.

information 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.

Turn fuel tank filler cap 1 counterclockwise and lift it off.

Closing the fuel tank filler cap

Mount the fuel tank filler cap and turn it clockwise until the fuel tank is tightly closed.
Info
Route fuel tank breather hose without kinks.

Refueling

Fire hazard
Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.

Do not fuel 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.

of poisoning
Fuel is harmful to health.

Avoid skin, eye and clothing contact with fuel.
Immediately consult a doctor if you swallow fuel.
Do not inhale fuel vapors.
Rinse the affected area immediately with plenty of water in the event of contact with the skin.
Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
Change your clothing if fuel spills on them.

information 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 fuel tank filler cap.
Fill the fuel tank with fuel up to a maximum of level .
Guideline

Dimension 35 mm (1.38 in)

Fuel tank capacity, approx. 2.3 l (2.4 qt.) Super unleaded (95 octane) mixed with 2-stroke engine oil (1:60)

Close the fuel tank filler cap.

Checking the throttle cable routing

of accidents
The throttle cable can become kinked, trapped or blocked if it is not routed correctly.
If the throttle cable is kinked, trapped or blocked, the speed can no longer be controlled.

Make sure that the throttle cable routing and the play in throttle cable complies with the specification.

Preparatory work

Remove the seat.

Turn the knurled screw on the fuel tap all the way clockwise.
Remove the fuel tank.

Main work

Check the throttle cable routing.
The throttle cable must be routed to the carburetor at the rear of the handlebar, above the fuel tank bracket. It must not be hooked into the handlebar cushion.
» If the throttle cable routing is not as specified:
- Correct the throttle cable routing.

Finishing work

Install the fuel tank.
Mount the seat.

Adjusting the seat height on the shock absorber

of accidents
Modifications to the suspension setting may seriously alter the handling characteristic.

Make sure your child rides slowly to start with after making adjustments in order that he or she can assess the new handling characteristic.

Preparatory work

Raise the motorcycle with a lift stand.

Main work

Hold the rear wheel with the link fork and remove screw
Position the shock absorber according to the required seat height.
Guideline

High seat position A

Low seat position B

Mount and tighten screw
Guideline

Screw, top shock absorber M10 45 Nm (33.2 lbf ft)
Loctite^®243™

Finishing work

Remove the motorcycle from the lift stand.

Adjusting the seat height on the fork

of accidents
Modifications to the suspension setting may seriously alter the handling characteristic.

Make sure your child rides slowly to start with after making adjustments in order that he or she can assess the new handling characteristic.

information Info
The seat height can be infinitely adjusted by pushing the fork legs through. If the seat height is adjusted on the fork, the seat height should also be adjusted on the shock absorber.

Preparatory work

Raise the motorcycle with a lift stand.
Remove the front wheel.

Main work

Loosen screw.
Loosen screw.
Position the fork leg according to the required seat height.
Guideline
Condition
Seat position as low as possible, fork fully inserted

Maximum distance between lower edge of screw cap and upper edge of triple clamp 18 mm (0.71 in)

Condition
Seat position as high as possible, fork pulled out completely
Bottom edge of screw cap closes flush with the upper edge of the triple clamp
Position the fork leg only within the described range.
Tighten screw .
Guideline

Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft)

Tighten screw .
Guideline

Screw, top triple clamp M8 20 Nm (14.8 lbf ft)

Repeat the procedure on the other fork leg.
Guideline
Position both fork legs equally.

Finishing work

Install the front wheel.

Adjusting the seat height on the frame

Preparatory work

Remove the seat.
Turn the knurled screw on the fuel tap all the way clockwise.
Remove the fuel tank.
Remove the right side cover.
Remove main silencer.

Main work

Loosen hose clip .
Remove screws on the right and left side.
Remove subframe with air filter box.
Loosen hose clip and slide the intake snorkel to the desired position.
Guideline

High seat position Position A

Low seat position Position B

Condition
Low seat position

Position subframe in position with screws on the right and left side and tighten.
Guideline

Screw, tail assembly M8 30 Nm (22.1 lbf ft)
Loctite ® 2701™

Condition
High seat position

Position subframe in position with screws on the right and left side and tighten.
Guideline

Screw, tail assembly M8 30 Nm (22.1 lbf ft)
Loctite ® 2701™

Position the intake flange on the carburetor and tighten hose clip .
Guideline

Hose clip, carburetor - 2.8 Nm (2.07 lbf ft)

Condition
High seat position

Make sure that tank extension is fitted to the fuel tank using screws supplied.
Guideline

Tank extension screw EJOT 2 Nm (1.5 lbf ft)

Condition
Low seat position

Make sure that tank extension is removed.

Finishing work

Install the main silencer.
Install the right side cover.
Install the fuel tank.
Mount the seat.

Removing the main silencer

of burns
The exhaust system gets hot when the vehicle is driven.

Allow the exhaust system to cool down before performing any work on the vehicle.

Preparatory work

Remove the right side cover.

Main work

Remove screw .
Pull off the main silencer from the manifold at sleeve .

Installing the main silencer

Main work

Position the main silencer.
Mount the main silencer with sleeve .
Guideline

High seat position A

Low seat position B

Mount and tighten screw .
Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

Finishing work

Install the right side cover.
Mount the seat.

Removing the right side cover

Remove the side cover from the rubber bushings in areas and .
Remove the right side cover.

Installing the right side cover

Main work

Press the right side cover in the area into rubber bushing and press into rubber bushing in area .

Finishing work

Mount the seat.

Removing the front wheel

Preparatory work

Raise the motorcycle with a lift stand.

Main work

Remove screw.
Loosen screws.

of accidents
Damaged brake discs reduce the braking effect.

Always lay the wheel down in such a way that the brake disc is not damaged.

Hold the front wheel and remove the wheel spindle. Take the front wheel out of the fork.
Info
Do not actuate the hand brake lever when the front wheel is removed.
Remove spacers .

Installing the front wheel

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.

Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
- Change front wheel bearing.
Clean and grease the contact surfaces of the spacers.
Long-life grease
Insert the spacers.

Clean and grease the wheel spindle.
Long-life grease
Position the front wheel.
The brake linings are correctly positioned.
Insert the wheel spindle.
Mount and tighten screw .
Guideline

Screw, front wheel spindle M10 40 Nm (29.5 lbf ft)
Loctite ® 243™
Operate the hand brake lever several times until the brake linings are seated correctly against the brake disc.
Remove the motorcycle from the lift stand.
Operate the front brake and compress the fork a few times firmly.
The fork legs straighten.
Tighten screws .
Guideline

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

TECHNICAL SPECIFICATIONS

chassis tightening torques

chassis tightening torques - Table 1

SUBSTANCES

Engine oil, 2-stroke
Standard/classification

JASO FD

Guideline

Only use high-grade 2-stroke engine oil from a reputable brand.
fully synthetic

Recommended supplier
MOTOREX^®

Cross Power 2T

Super unleaded (ROZ 95)
Standard/classification

DIN EN 228 (ROZ 95)

Guideline

Only use super unleaded fuel that matches or is equivalent to the specified standard.
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