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KTM 65 SX manual

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Table of contents for the manual

  • Page 1

    KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at KTM Group Partner 4/2006 FOTO: MITTERBAUER 65 SX OWNER’S MANUAL 2007 ART. NR. 3.211.142 EN ENGLISH[...]

  • Page 2

    ENGLISH 1 INTRODUCTION » Please insert the serial numbers of the motorcycle below Chassis number Engine number Stamp of dealer All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, construc[...]

  • Page 3

    ENGLISH 2 IMPORTANT INFORMATION » INTENDED PURPOSE KTM mini-sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading interna- tional motorcycle associations. OWNER’S MANUAL Please read this manua[...]

  • Page 4

    ENGLISH 3 IMPORTANT INFORMATION » W ARRANTY The service work specified in the "Lubrication and Maintenance Schedule" must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void. No claims can be filed under the warranty for damage or consequential damage caused by manipulat[...]

  • Page 5

    ENGLISH 4 IMPORTANT INFORMATION FOR PARENTS ABOUT SAFE DRIVING » The 65 SX mini motorcycles are off-road motorcycles designed for one person only . They are not allowed on public roads. The vehicle dimensions and components are designed for children from 6 to 10 years of age with a max- imum weight of. 50 kg (22.65 lb) and a maximum height of 160 [...]

  • Page 6

    ENGLISH 5 TABLE OF CONTENTS » Page SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . .6 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 OPERA TION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . .6 Clutch lever . . . . . . . . . . . [...]

  • Page 7

    ENGLISH 6 SERIAL NUMBER LOCATIONS » OPERATION INSTRUMENTS » Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number The engine number is stamped into the engine housing underneath the carburetor . Enter this number in the field on page no 1. Clutch lever [...]

  • Page 8

    ENGLISH 7 OPERATION INSTRUMENTS » Short circuit button The short circuit button [1] turns off the engine. When pressing this button, the ignition circuit is short-circuited. Filler cap T o open it: turn filler cap counter -clockwise. T o close it: put filler cap back on and tighten it by turning it clockwise. Install tank breather hose [2] without[...]

  • Page 9

    ENGLISH 8 OPERATION INSTRUMENTS » Kickstarter The kickstarter is mounted on the right side of the engine. Its upper part can be swivelled. Foot brake pedal The foot brake pedal is located in front of the right foot rest. Its basic posi- tion can be adjusted to your seat position (see maintenance work). Compression damping of shock absorber The deg[...]

  • Page 10

    ENGLISH 9[...]

  • Page 11

    ENGLISH 10 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » Instructions for the first ride – Make sure the work for the „pre-delivery inspection“ was per- formed by your authorized KTM workshop. The DELIVERY CER- TIFICA TE and SERVICE MANUAL will be handed over when you pick up your vehicle. – Before your youngster takes his or her[...]

  • Page 12

    ENGLISH 11 DRIVING INSTRUCTIONS » What you should check before each start When you start off, the motorcycle must be in a perfect technical condition. For safety reasons, you should make it a habit to perform an overall check of your motorcycle before each start. The following checks should be performed: 1 CHECK TRANSMISSION OIL LEVEL. A lack of g[...]

  • Page 13

    ENGLISH 12 DRIVING INSTRUCTIONS » Starting when the engine is cold 1 Open fuel tap [1] . 2 Put the gear in neutral 3 Activate the cold-starting aid (choke) [2] . 4 Leave throttle closed and kick down the kickstarter vigorously all the way . – T o avoid injury when starting the engine, always wear strong bikers boots!Y ou may slip off the kicksta[...]

  • Page 14

    – Driving a cold engine at high speed will reduce the life of the engine. W e recommend to warm the engine up at a medium engine speed for several minutes before switching to full load. – Never have the throttle wide open when changing down to a lower gear . The engine will overrev , damaging the valves. In addi- tion, the rear wheel blocks so [...]

  • Page 15

    ENGLISH 14 PERIODIC MAINTENANCE SCHEDULE » A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! Service every 20 hours once a year Before every race Engine Check transmission oil level z Change transmission oil z Check spark plug, change it if necessary , set electrode gap z Carburetor Check carburetor for a tight fit at intake flange[...]

  • Page 16

    ENGLISH 15 PERIODIC MAINTENANCE SCHEDULE » NOTE: If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced. VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each start after every cleaning for cross country use once a year Check transmission oil level z Ch[...]

  • Page 17

    ENGLISH 16 MAINTENANCE WORK ON CHASSIS AND ENGINE » Checking and adjusting the steering head bearing * Check steering head bearing for play periodically . T o check, put motorcycle on the stand so that the front wheel is off the ground. Now try to move the fork forward and backward. For readjusting, loosen the three clamp screws [1] of the top tri[...]

  • Page 18

    ENGLISH 17 MAINTENANCE WORK ON CHASSIS AND ENGINE » Cleaning the dust sleeves of the telescopic fork The dust-protection bellows [1] are to remove dust and coarse dirt particles from the fork tube. However , after some time, dirt may also get in behind the dust-protection bellows. If this dirt is not removed, the oil sealing rings located behind i[...]

  • Page 19

    ENGLISH 18 MAINTENANCE WORK ON CHASSIS AND ENGINE » Basic suspension setup for the weight of the driver T o achieve maximum handling performance and to prevent the telescopic fork and shock absorber from being damaged, the basic setup of the suspension components must be suitable for your child's weight. At delivery , KTM's 65 SX motorcy[...]

  • Page 20

    ENGLISH 19 MAINTENANCE WORK ON CHASSIS AND ENGINE » Checking chain tension Set the motorcycle on the plug-in stand. Press the chain down on the upper end of the chain sliding component. The distance between the chain and the swing arm should be approx. 3 mm. The lower part of the chain should be tightened. – If the chain is too tight the seconda[...]

  • Page 21

    ENGLISH 20 MAINTENANCE WORK ON CHASSIS AND ENGINE » General information about KTM disc brakes BRAKE CALIPERS: If the front brake caliper is removed, the screws must be secured with Loctite 243 when mounted and tightened to 20 Nm. BRAKE FLUID RESERVOIRS: The brake fluid reservoirs on front and rear wheel brakes have been designed in such a way that[...]

  • Page 22

    ENGLISH 21 MAINTENANCE WORK ON CHASSIS AND ENGINE » Checking/refilling the front brake fluid level* The brake fluid reservoir is combined with the hand brake cylinder on the han- dlebar . T o check the brake fluid level, press the brake pistons back into the basic position. Move the hand brake cylinder in a horizontal position, remove the screws [[...]

  • Page 23

    ENGLISH 22 MAINTENANCE WORK ON CHASSIS AND ENGINE » Replacing the front brake pads * Remove the front wheel (see front wheel chapter). Press brake shoes apart with a suitable screwdriver to put the brake pistons in their basic position. Mount the left brake shoe and fix with screw . Mount the right brake shoe and tighten the screw to 6 Nm. Mount t[...]

  • Page 24

    ENGLISH 23 MAINTENANCE WORK ON CHASSIS AND ENGINE » Checking the rear brake fluid level The reservoir for the rear disk brake is on the right side of the motorcycle on the rear brake cylinder . No air bubble should be visible in inspection glass [A] when the vehicle is parked in a vertical position. If the brake fluid level drops below the upper e[...]

  • Page 25

    ENGLISH 24 MAINTENANCE WORK ON CHASSIS AND ENGINE » Replacing the rear brake pads * Dismount the rear wheel (see „Dismounting the rear wheel“). Press the brake shoes apart with a suitable screwdriver to allow the brake pis- tons to return to their basic position. Remove the locking screw [1] , unscrew the screw [2] and pull the brake shoes out[...]

  • Page 26

    ENGLISH 25 MAINTENANCE WORK ON CHASSIS AND ENGINE » Removing and installing the rear wheel Jack the motorcycle up by the frame. Remove the hexagon nut [1] of the wheel spindle together with the washer [2] and remove the chain adjuster [3] . Hold the rear wheel and pull out the wheel spindle. T urn the rear wheel forwards and take the chain off the[...]

  • Page 27

    ENGLISH 26 MAINTENANCE WORK ON CHASSIS AND ENGINE » Removing the seat By using the quick-release mechanism [1] , the seat can be removed without using tools. T urn the quick-release mechanism about 180° counter clockwise and lift up the rear of the seat. Pull the seat backwards and unhook it from the fixing screw [2] . T o mount the seat, positio[...]

  • Page 28

    ENGLISH 27 MAINTENANCE WORK ON CHASSIS AND ENGINE » Exhaust system * The silencer is filled with glass-fiber yarn for damping. When in use, the glass- fiber yarn becomes loose or coked with oil carbon. This can lead to a power loss and a reduction of the silencer damping. The glass-fiber yarn packing can be replaced in a few easy steps. T o replac[...]

  • Page 29

    ENGLISH 28 MAINTENANCE WORK ON CHASSIS AND ENGINE » Changing the original position of the clutch lever The adjusting screw [1] can be used for individual adjustment of the original position of the clutch lever , thus allowing adjustment to an optimal position for every hand size. T urning the adjusting screw counterclockwise reduces the distance b[...]

  • Page 30

    ENGLISH 29 MAINTENANCE WORK ON CHASSIS AND ENGINE » Carburetor adjustment * Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20° C (68° F), mainly for off-road use and central European premium-g[...]

  • Page 31

    ENGLISH 30 MAINTENANCE WORK ON CHASSIS AND ENGINE » Draining the float chamber of the carburetor Following every wet-cleaning procedure, the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it. W ater in the float chamber leads to engine malfunction. Make sure you do this while the engine[...]

  • Page 32

    ENGLISH 31 TROUBLE SHOOTING » If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error . W e would like to point out that many operations cannot be performed by oneself. In[...]

  • Page 33

    ENGLISH 32 TROUBLE SHOOTING » TROUBLE CAUSE REMEDY Engine has not enough power Reed paddles tensionless or dam- aged, surface of reed valve housing damaged W ear Replace reed paddles or reed valve housing Overhaul engine Engine revs not up and running in four stroke cycle Carburetor overflows if level adjust too high, float needle seating is dirty[...]

  • Page 34

    CLEANING » STORAGE » Clean your motorcycle regularly in order to keep its painted finish looking shiny and new . The best manner would be to use warm water that has been mixed with a commercially available washing detergent and a sponge. Th e hard dirt can be removed before with the help of a soft water jet. Never clean your motorcycle with a hig[...]

  • Page 35

    ENGLISH 34 TECHNICAL SPECIFICATIONS – CHASSIS » CHASSIS 65 SX Frame Central chrome-moly-steel frame Fork telescopic fork (Marzocchi USD Ø 35) Wheel travel front/rear 220 mm (8.7 in) / 270 mm (10.7 in) Rear suspension central shock absorber (WP Suspension) 3614 BA VP Front brake Disc brake Ø 198 mm (7.8 in), 4 piston Rear brake Disc brake Ø 16[...]

  • Page 36

    ENGLISH 35 TECHNICAL SPECIFICATIONS – ENGINE » ENGINE CR-65 Design Liquid cooled single cylinder two-stroke engine with reed valve intake Displacement 64.85 ccm Bore/stroke 45 / 40.8 mm (1.77/1.6 in) Fuel SUPER fuel, research octane no 95, mixed with high grade two-stroke oil Oil/gasoline ratio 1 : 60 when using high grade two-stroke oil (e.g. M[...]

  • Page 37

    ENGLISH 36 TECHNICAL SPECIFICATIONS – ENGINE » TIGHTENING TORQUES – ENGINE Hexagon nut – primary gear M 10 60 Nm Collar nut – flywheel M 10x1,25 40 Nm HH screw – cylinder head M 7 15 Nm Collar nut – cylinder base M 8 25 Nm Hexagon screw – inner clutch hub M 10 Loctite 243 + 60 Nm Screw – clutch M 6 12 Nm Oil drain screw M 8 12 Nm S[...]

  • Page 38

    ENGLISH 37 INDEX » Page Adjusting the free travel at the hand brake lever . . . . . .20 Adjusting the throttle cable . . . . . . . . . . . . . . . . . . . . .28 Basic suspension setup for the weight of the driver . . . .18 Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . . . .27 Braking . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 39

    ENGLISH 38[...]

  • Page 40

    ENGLISH 39[...]

  • Page 41

    ENGLISH 40[...]

  • Page 42

    KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at KTM Group Partner 4/2006 FOTO: MITTERBAUER 65 SX MANUAL DE INSTRUCCIONES 2007 ART. NR. 3.211.142 ES ESPAÑOL[...]