KTM 65 SX (2013) manual

OWNER'S MANUAL 2013 65 SX Art. no. 3211855en[...]

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DEAR KTM CUSTOMER 1 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-ar t sports motorcycle that will give you and your child enormous pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment in riding this vehicle. Enter the serial numbers of your ve[...]

TABLE OF CONTENTS 2 TABLE OF CONTENTS 1 MEANS OF REPRESENTAT ION ............................ ......... 4 1.1 Symbols used ....................................... ............ 4 1.2 Formats used ................................ .................... 4 2 SAFETY ADVICE ...................................... ..................... 5 2.1 Use definition -[...]

TABLE OF CONTENTS 3 12.2 Adjusting the basic position of the hand brake lever ................................... ........................... 48 12.3 Checking brake discs ....................................... 48 12.4 Checking front brake fluid level ........................ 49 12.5 Adding front brake fluid x ............................ .. 49 12.[...]

1 MEANS OF REPRESENTATIO N 4 1.1 Symbols used The symbols used are explained in the following. Indicates an expected reaction (e.g., to a work step or a function). Indicates an unexpected reaction (e.g., to a work step or a function). All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of the [...]

2 SAFETY ADVICE 5 2.1 Use definition - intended use KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply with currently valid regulations and categories of the top international motorsport organizations. Info The motorcycle may only be used in closed off areas remote [...]

2 SAFETY ADVICE 6 Warning Danger of burns   Some vehicle components become very hot when the vehicle is operated. – Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these components to cool down before starting work on them. Only operate the vehicle when it is in perfect technical[...]

3 IMPORTA NT INFORMATION 7 3.1 Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net ; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulatio [...]

4 VIEW OF VEHICLE 8 4.1 View of vehicle, front left (example) 601916-10 1 Hand brake lever ( p. 11) 2 Rebound damping of fork 3 Clutch lever ( p. 11) 4 Quick release for seat lock 5 Fuel tap ( p. 12) 6 Choke ( p. 12) 7 Shift lever ( p. 13) 8 Shock absorber, rebound adjustment[...]

4 VIEW OF VEHICLE 9 4.2 View of vehicle, rear right (example) 601917-10 1 Filler cap 2 Kill switch ( p. 11) 3 Compression damping of fork 4 Throttle grip ( p. 11) 5 Chassis number ( p. 10) 6 Level viewer, rear brake fluid 7 Shock absorber, compression adjustment 8 Foot brake lever ( p. 13) 9 Kickstarter ( p. 13)[...]

5 SERIAL NUMBERS 10 5.1 Chassis number 601932-10 The chassis number 1 is stamped on right of the steering head. 5.2 Engine number 601938-11 The engine number 1 is stamped on the left side of the engine under the engine sprocket. 5.3 Shock absorber part number 601933-10 The shock absorber part number 1 is stamped on the top of the shock absorber abo[...]

6 CONTROL S 11 6.1 Clutch lever C00038-10 The clutch lever 1 is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 6.2 Hand brake lever C00030-10 Hand brake lever 1 is fitted on the right side of the handlebar. The hand brake lever is used to activate the front brake. 6.3 Throttle grip C00027-10 Throt[...]

6 CONTROL S 12 Warning Danger of poisoning   Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi- ately with water and contact a doctor. Wash affected skin areas immediate ly with soap and water. If fuel is swallowed, con- tact a do[...]

6 CONTROL S 13 6.9 Shift lever 601938-10 Shift lever 1 is mounted on the left side of the engine. 601939-10 The gear positions can be seen in the photograph . The neutral or idle position N is between the first and second gears. 6.10 Kickstarter 601941-10 The kickstarter 1 is fitted on the right of the engine. The kickstarter can be swiveled. Info [...]

7 PREPARIN G FOR USE 14 7.1 Advice on first use Warning Danger of accidents   Physical and mental readiness of a child. – Your child must be able to ride a bicycle and must be able to erect the vehicle independently after a fall. In addition, your child must understand the regulations and instructions from you or from other guardians. Do not as[...]

7 PREPARIN G FOR USE 15 – Accustom your child to the handling of the motorcycle on suitable terrain, preferably on a large open meadow. Info To give your child a feel for the brake system, you should push your child at first. Do not start the engine until your child is able to apply the necessary front brake pressure. Initially, let your child dr[...]

8 RIDING INSTRUCTIO NS 16 8.1 Checks and maintenance measures when preparing for use Info Before each use, check the condition of the vehicle and its operating safety. The vehicle must be in perfect technical condition when it is being operated. – Check the gear oil level. ( p. 68) – Check the front brake brake fluid level. ( p. 49) – Check t[...]

8 RIDING INSTRUCTIO NS 17 8.3 Starting off Info The plug-in stand must be removed prior to riding. – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully. 8.4 Shifting, riding Warning Danger of accidents   If you change down at high engine speed, the rear wheel can lock up. – D[...]

8 RIDING INSTRUCTIO NS 18 8.6 Stopping, parking Warning Risk of misappropriation   Usage by unauthorize d persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns   Some vehicle components become very hot when the vehicle is operated. – Do not touch hot c[...]

8 RIDING INSTRUCTIO NS 19 8.8 Refueling Danger Fire hazard   Fue l 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. – Fuel in the fuel tank expands when warm an[...]

9 SERVICE SCHEDUL E 20 9.1 Service schedule S10N S20A S40A S80A J1A Check the front brake linings. ( p. 50) • • • • Check the rear brake linings. ( p. 55) • • • • Check the brake discs. ( p. 48) • • • • Check brake lines for damage and leakage. • • • • Change the sealing sleeves of the foot brake cylinder. x • • [...]

9 SERVICE SCHEDUL E 21 S10N S20A S40A S80A J1A Clean the air filter and air filter box. x ( p. 37) • • • • Change the glass fiber yarn filling of the main silencer. x ( p. 38) • • • Check the screws and nuts for tightness. x • • • • Check/set the carburetor components. x • • • Check idle. x • • • • Final inspecti[...]

10 TUNING THE CHASSIS 22 10.1 Adjusting the compression damping of the fork Info The hydraulic compressio n damping determines the fork suspension behavior. C00002-10 – Turn adjusting screw 1 clockwise all the way. Info Adjusting screw 1 is located at the top end of the right fork leg and is labeled with COM . – Turn back counterclockwi se by t[...]

10 TUNING THE CHASSIS 23 10.4 Adjusting the rebound damping of the shock absorber Caution Danger of accidents   Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) 601944-10 – Turn adjusting scre[...]

10 TUNING THE CHASSIS 24 10.7 Checking the riding sag of the shock absorber 0 0 A A 0 0 C C 400990-10 – Measure distance A of rear wheel unloaded. ( p. 23) – With another person holding the motorcycle, the rider sits down on the saddle in full protective clothing in a normal sitting position (feet on footrests) and bounces up and down a few tim[...]

10 TUNING THE CHASSIS 25 10.9 Adjusting the riding sag x Preliminary work – Raise the motorcycle with a lift stand. ( p. 27) – Remove shock absorber. x ( p. 35) – After removing the shock absorber, clean it thoroughly. B00292-10 Main work – Choose and mount a suitable spring. Guideline Spring rate Weight of rider: < 35 kg (< 77 lb.) 3[...]

10 TUNING THE CHASSIS 26 – 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.[...]

11 SERVICE WORK ON THE CHASSIS 27 11.1 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 wit[...]

11 SERVICE WORK ON THE CHASSIS 28 11.4 Cleaning the dust boots of the fork legs Preliminary work – Raise the motorcycle with a lift stand. ( p. 27) C00025-10 Main work – Push dust boots 1 of both fork legs downwards. Info The dust boots should remove dust and coarse dirt particles from the inside fork tubes. Over time, dirt can penetrate behind[...]

11 SERVICE WORK ON THE CHASSIS 29 C00024-11 – Position the fork protection on the left fork leg. Mount and tighten screws 2 . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) – Position the brake line. Mount clamp 3 . – Mount the screws 4 . 11.7 Removing the fork legs x Preliminary work – Raise the motorcycle with a lift stand. ( p[...]

11 SERVICE WORK ON THE CHASSIS 30 C00006-11 – Position brake caliper, mount and tighten screws 4 . Guideline Screw, brake caliper M8 20 Nm (14.8 lbf ft) Loctite ® 243™ – Position the brake line. Mount the clamp and screws 5 . Final work – Install the front wheel. x ( p. 58) 11.9 Removing the lower triple clamp x Preliminary work – Raise [...]

11 SERVICE WORK ON THE CHASSIS 31 11.10 Installing the lower triple clamp x 0 0 1 1 0 0 2 2 300668-01 Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 83) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. – Check whether the top steering h[...]

11 SERVICE WORK ON THE CHASSIS 32 C00041-10 – Mount and tighten screw 6 . Guideline Screw, top triple clamp M8 20 Nm (14.8 lbf ft) C00042-10 – Mount and tighten screws 7 . Guideline Screw, top triple clamp M8 20 Nm (14.8 lbf ft) B00399-10 – Position brake caliper, mount and tighten screws 8 . Guideline Screw, brake caliper M8 20 Nm (14.8 lbf [...]

11 SERVICE WORK ON THE CHASSIS 33 » If click positions are noticeable: – Adjust the play of the steering head bearing. x ( p. 33) – Check the steering head bearing and replace if required. Final work – Remove the motorcycle from the lift stand. ( p. 27) 11.12 Adjusting the play of the steering head bearing x Preliminary work – Raise the mo[...]

11 SERVICE WORK ON THE CHASSIS 34 11.15 Installing the start number plate 700413-01 – Position the start number plate with the drill holes onto the holding lugs 1 of the fender. B00400-11 – Mount and tighten screw 2 . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) – Position the brake line. Put the clamp on, mount and tighten screw[...]

11 SERVICE WORK ON THE CHASSIS 35 11.18 Removing the shock absorber x Preliminary work – Raise the motorcycle with a lift stand. ( p. 27) 601946-10 Main work – Remove screw 1 and lower the rear wheel with the swingarm as far as possible without blocking the rear wheel. Fix the rear wheel in this position. – Remove screw 2 , push splash protec[...]

11 SERVICE WORK ON THE CHASSIS 36 601952-11 – Close quick release 3 . 11.22 Removing the air filter x Note Engine failure   Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Warning Environmenta[...]

11 SERVICE WORK ON THE CHASSIS 37 11.24 Cleaning the air filter and air filter box x Warning Environmental hazard   Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Do not clean the air filter with fuel or petroleum sin[...]

11 SERVICE WORK ON THE CHASSIS 38 601948-11 – Mount and tighten screw 4 . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) 11.27 Changing the glass fiber yarn filling of the main silencer x Warning Danger of burns   The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot [...]

11 SERVICE WORK ON THE CHASSIS 39 601950-10 Main work – Remove screw 1 . 601954-10 – Remove screws 2 . 601955-11 – Pull off fuel hose 3 . Info Remaining fuel may run out of the fuel hose. – Pull both spoilers off of the side of the radiator bracket and lift off the fuel tank. 11.29 Installing the fuel tank x Danger Fire hazard   Fue l is [...]

11 SERVICE WORK ON THE CHASSIS 40 601954-10 – Mount and tighten screws 2 . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) 601950-11 – Mount and tighten screw 3 . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) – Position the fuel tank breather. Final work – Mount the seat. ( p. 35) 11.30 Removing the chain guard 100815-[...]

11 SERVICE WORK ON THE CHASSIS 41 11.32 Checking chain dirt 400678-01 – Check the chain for coarse dirt accumulat ion. » If the chain is very dirty: – Clean the chain. ( p. 41) 11.33 Cleaning the chain Warning Danger of accidents   Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. War[...]

11 SERVICE WORK ON THE CHASSIS 42 601969-10 Main work – Push the chain at the end of the chain sliding component upward to measure the chain tension A . Info The upper chain section 1 must be taut. Because chain wear is not always even, repeat this measurement at differ- ent chain positions. Chain tension 5… 8 mm (0.2… 0.31 in) » If the chai[...]

11 SERVICE WORK ON THE CHASSIS 43 11.36 Checking the chain, rear sprocket , engine sprocket, and chain guide Preliminary work – Raise the motorcycle with a lift stand. ( p. 27) – Remove the chain guard. ( p. 40) 400227-01 Main work – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket and engine sprocket are worn: ?[...]

11 SERVICE WORK ON THE CHASSIS 44 B00383-10 – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. x – Check the chain sliding piece for tightness. » If the chain sliding piece is loose: – Tighten the chain sliding piece. Guideline[...]

11 SERVICE WORK ON THE CHASSIS 45 Final work – Install the chain guard. ( p. 40) 11.38 Checking the frame x 601599-01 – Check the frame for cracking and deformation. » If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. x Info A frame that has been damaged due to a mechanical impact must always be ch[...]

11 SERVICE WORK ON THE CHASSIS 46 11.42 Additionally securing the rubber grip Preliminary work – Check the rubber grip. ( p. 45) 401198-01 Main work – Secure the rubber grip at two locations with the retaining wire. Securing wire (548120160 00) Wire twister forceps (U6907854) The twisted wire ends face away from the palms and are bent in toward[...]

11 SERVICE WORK ON THE CHASSIS 47 C00044-10 – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws 1 . – Remove cover 2 with diaphragm 3 . 300670-10 – Fill bleeding syringe 4 with the appropriate hydraulic fluid. Bleed syringe (503290500 00) Hydraulic fluid (15) ( p. 82) – On the slave cylinde[...]

12 BRAKE SYSTEM 48 12.1 Checking free travel of hand brake lever Warning Danger of accidents   Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake may fail due to overheating. Adjust the free travel on hand brake lever according to specifications. C00035-10 ?[...]

12 BRAKE SYSTEM 49 12.4 Checking front brake fluid level Warning Danger of accidents   Brake system failure. – If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system is leaking or that the brake linings are completely worn down. Check the brake system and do not continue ri[...]

12 BRAKE SYSTEM 50 Warning Danger of accidents   Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard   Hazardous substances cause environmental damage. – Oil, grease, filter[...]

12 BRAKE SYSTEM 51 C00033-10 Main work – Remove the lock washer 1 . – Remove screw 2 . C00032-01 – Remove the brake linings. – Clean brake caliper and brake caliper support. 12.8 Installing the front brake linings x Warning Danger of accidents   Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake [...]

12 BRAKE SYSTEM 52 12.9 Changing the front brake linings x Warning Skin irritation   Br ake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles. – If brake fluid comes into contact with the eyes, flush the eyes thoroughly with [...]

12 BRAKE SYSTEM 53 601962-10 – Disconnect spring 1 . – Move the foot brake lever back and forth between the end stop and the foot brake cylinder piston bracket and check free travel A . Guideline Free travel of foot brake lever 3… 5 mm (0.12… 0.2 in) » If the free travel does not meet specifications: – Adjust the free travel of the foot [...]

12 BRAKE SYSTEM 54 12.13 Checking rear brake fluid level Warning Danger of accidents   Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) W[...]

12 BRAKE SYSTEM 55 100812-10 – Add brake fluid to level A . Guideline Dimension A (brake fluid level below top edge of container) 10 mm (0.39 in) Brake fluid DOT 4 / DOT 5.1 ( p. 81) – Position the membrane and the cover with the washer. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water. 12.15 Ch[...]

12 BRAKE SYSTEM 56 12.17 Installing the rear brake linings 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. Warning Danger of accidents   Reduced braking efficiency due to use of non-approv[...]

12 BRAKE SYSTEM 57 – Remove the chain guard. ( p. 40) – Remove the rear wheel. x ( p. 59) – Remove the rear brake linings. x ( p. 55) 100811-10 Main work – Remove screws 1 . – Take off cover 2 with washer 3 and membrane 4 . – Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake flu[...]

13 WHEELS, TIRES 58 13.1 Removing the front wheel x Preliminary work – Raise the motorcycle with a lift stand. ( p. 27) 601956-10 Main work – Remove screw 1 . 601957-10 – Loosen screw 2 . – Hold the front wheel and pull out wheel spindle 3 . Take the front wheel out of the fork. Info Do not pull the hand brake lever when the front wheel is [...]

13 WHEELS, TIRES 59 13.3 Removing the rear wheel x Preliminary work – Raise the motorcycle with a lift stand. ( p. 27) – Remove the chain guard. ( p. 40) 700439-01 Main work – Remove nut 1 . – Remove washer 2 and chain adjuster 3 . 100819-10 – Withdraw the wheel spindle 4 only enough to allow the rear wheel to be pushed forward. – Push [...]

13 WHEELS, TIRES 60 13.5 Checking the tire conditio n Info Only mount tires that have been approved and/or recommended by KTM. Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle. The front and rear wheels must be mounted[...]

13 WHEELS, TIRES 61 400694-01 – Briefly strike each spoke with the blade of a screwdriver. Info The frequency of the tone depends on the spoke length and diameter. If you hear different tone frequencies from spokes of the same length and thickness, this is an indication that the spoke tension differs. You should hear a high note. » If the spoke [...]

14 COOLING SYSTEM 62 14.1 Cooling system 601959-10 The water pump 1 in the engine forces the coolant to flow. The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap 2 . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions . 120 °C ([...]

14 COOLING SYSTEM 63 14.3 Checking the coolant level Warning Danger of scalding   During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse i[...]

14 COOLING SYSTEM 64 14.5 Refilling the coolant x Warning Danger of poisoning   Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con- tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, [...]

15 TUNING THE ENGINE 65 15.1 Checking the installation position of the throttle grip 601970-10 – Position the throttle grip so that the surface A is vertical. Info If the throttle grip is tipped forward, the throttle cable will slip out of the guide on the carburetor. The throttle slide can no longer be closed. 15.2 Checking the play in the throt[...]

15 TUNING THE ENGINE 66 15.5 Carburetor - adjusting the idle speed x 601965-10 – Screw in idle air adjusting screw 2 all the way and turn it to the specified basic position. Guideline Idle air adjusting screw Open 3.5 turns – Run the engine until warm. Guideline Warm-up time ≥ 5 min Danger Danger of poisoning   Exhaust gases are toxic and i[...]

15 TUNING THE ENGINE 67 Info Carry out this work with a cold engine. Water in the float chamber results in malfunctioning. Preliminary work – Turn the knurled screw on the fuel tap all the way clockwise. No more fuel flows from the tank to the carburetor. 601966-10 Main work – Place a cloth beneath the carburetor to soak up emerging fuel. – R[...]

16 SERVICE WORK ON THE ENGINE 68 16.1 Checking the gear oil level Info The gear oil level must be checked when the engine is cold. Preliminary work – Stand the motorcycle upright on a horizontal surface. 300661-10 Main work – Remove gear oil level check screw 1 . – Check the gear oil level. A small amount of gear oil should flow out of the ho[...]

16 SERVICE WORK ON THE ENGINE 69 601967-10 Main work – Place a suitable container under the engine. – Remove gear oil drain plug 1 with magnet. – Completely drain the gear oil. – Thoroughly clean the gear oil drain plug with magnet. – Clean the sealing area on the engine. – Mount the gear oil drain plug with magnet and the seal ring and[...]

16 SERVICE WORK ON THE ENGINE 70 Danger Danger of poisoning   Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. – Start the e[...]

17 CLEANING , CARE 71 17.1 Cleaning motorcycle Note Material damage   Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the n[...]

18 STORAGE 72 18.1 Storage Warning Danger of poisoning   Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi- ately with water and contact a doctor. Wash affected skin areas immediate ly with soap and water. If fuel is swallowed, co[...]

19 TROUBLE SHOOTING 73 Faults Pos sible cause Action Engine turns but does not start Operating error – Go through the steps of starting the engine. ( p. 16) Motorcycle was out of use for a long time and there is old fuel in the float chamber – Empty the carburetor float chamber. x ( p. 66) Fuel feed interrupted – Check the fuel tank breather.[...]

19 TROUBLE SHOOTING 74 Faults Pos sible cause Action Engine overheats Radiator fins very dirty – Clean radiator fins. Foam formation in cooling system – Drain the coolant. x ( p. 63) – Refill the coolant. x ( p. 64) Damaged cylinder head or cylinder head gasket – Check the cylinder head or cylinder head gas- ket. Bent radiator hose – Chan[...]

20 TECHNICA L DATA 75 20.1 Engine Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 64.85 cm³ (3.9574 cu in) Stroke 40.8 mm (1.606 in) Bore 45 mm (1.77 in) Idle speed 1,400… 1,500 rpm Control Exhaust control PCEV (Pneumatic Controlled Exhaust Valve) Crankshaft bearing 2 grooved ball bearings Conro[...]

20 TECHNICA L DATA 76 Screw, engine case M6 10 Nm (7.4 lbf ft) – Screw, engine sprocket cover M6 10 Nm (7.4 lbf ft) – Screw, exhaust flange M6 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, gear oil level check M6 6 Nm (4.4 lbf ft) – Screw, intake flange/reed valve housing M6 10 Nm (7.4 lbf ft) – Screw, kickstarter stop piece M6 10 Nm (7.4 lbf[...]

20 TECHNICA L DATA 77 20.3.1 Carburetor tuning 100810-01 M/FT ASL Above sea level TEMP Temperature ASO Idle air adjusting screw open (rotations) IJ Idling jet NDL Jet needle POS Needle position from above MJ Main jet The carburetor tuning depends on the defined ambient and operating conditions.[...]

20 TECHNICA L DATA 78 20.4 Fork Fork part number 07.18.7L.04 Fork WP Suspension USD 35 Compression damping Standard 2 turns Rebound damping Standard 2 turns Spring rate Soft 2.6 N/mm (14.8 lb/in) Medium (standard) 2.8 N/mm (16 lb/in) Hard 3.0 N/mm (17.1 lb/in) Spring length with preload spacer(s) 377.5 mm (14.862 in) Fork length 735 mm (28.94 in) F[...]

20 TECHNICA L DATA 79 Brake discs - wear limits Front 2.5 mm (0.098 in) Rear 2.5 mm (0.098 in) Tire air pressure off road Front 1.0 bar (15 psi) Rear 1.0 bar (15 psi) Secondary drive ratio 14:48 Chain 1/2 x 1/4” O ‑ ring Rear sprockets available 46, 48, 50 Steering head angle 64.5° Wheelbase 1,137 mm (44.76 in) Seat height unloaded 750 mm (29.[...]

20 TECHNICA L DATA 80 Nut, swingarm pivot M12x1 40 Nm (29.5 lbf ft) – Nut, steering stem M20x1.5 10 Nm (7.4 lbf ft) –[...]

21 SUBSTAN CES 81 2-stroke engine oil According to – JASO FC ( p. 85) Guideline – Only use high quality 2-stroke engine oil of a well-known brand. KTM recommends Motorex ® products. Fully synthetic Supplier Motorex ® – Cross Power 2T Brake fluid DOT 4 / DOT 5.1 According to – DOT Guideline – Use only brake fluid that complies with the s[...]

21 SUBSTAN CES 82 Hydraulic fluid (15) According to – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Motorex ® products. Supplier Motorex ® – Hydraulic Fluid 75 Shock absorber oil (SAE 2.5) (50180[...]

22 AUXILIAR Y SUBSTANCES 83 Air filter cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Dirt Bio Remover Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline – KTM recommends Motorex ®[...]

22 AUXILIAR Y SUBSTANCES 84 Paint cleaner and polish for high-gloss and matte finishes , bare metal and plastic surfaces Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Clean & Polish Rubber grip adhesive (00062030051) Supplier KTM-Sportmotorcy cle AG – GRIP GLUE Universal oil spray Guideline – KTM recommends Motor[...]

23 STANDAR DS 85 JASO FC JASO FC 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 combustio n is achieved even under extreme operating conditions. JASO T903 MA Different technical development directions requ[...]

INDEX 86 INDEX A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Air filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Ai[...]

INDEX 87 Gear oil level checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 H Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 48 free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 48 Handlebar position[...]

INDEX 88 W Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Work rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6[...]

*321 185 5en* 3211855en 04/2012 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com Photo: Mitterbauer/KTM[...]