KTM 65 SX 2020 Owner's Manual
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KTM 65 SX 2020 Owner's Manual

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OWNER'S MANUAL
2020
65 SX
Art. no. 3213997en

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Summary of Contents for KTM 65 SX 2020

  • Page 1 OWNER'S MANUAL 2020 65 SX Art. no. 3213997en...
  • Page 3 KTM accepts no liability for delivery options, deviations from fig- ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS RIDING INSTRUCTIONS......22 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 Checks and maintenance measures Symbols used ........5 when preparing for use ..... 22 Formats used........5 Starting the vehicle ......22 SAFETY ADVICE..........6 Starting off........23 Shifting, riding ........
  • Page 5 TABLE OF CONTENTS 11.6 Installing the fork protector....41 12.3 Checking the brake discs ....65 11.7 Removing the fork legs ....41 12.4 Checking the front brake fluid level ... 66 11.8 Installing the fork legs ....42 12.5 Adding the front brake fluid ...
  • Page 6 TABLE OF CONTENTS 19 TROUBLESHOOTING ........99 20 TECHNICAL DATA........101 20.1 Engine .......... 101 20.2 Engine tightening torques ....101 20.3 Carburetor ........103 20.3.1 Carburetor tuning....... 103 20.4 Capacities ........104 20.4.1 Gear oil........104 20.4.2 Coolant ........104 20.4.3 Fuel .........

  • Page 7: Means Of Representation 1

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of the safety of your child, have these jobs performed in an authorized KTM work- shop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required.

  • Page 8: Safety Advice

    2 SAFETY ADVICE Use definition – intended use This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle com- plies with the currently valid regulations and categories of the top international motorsports organizations. Info Only operate this vehicle in closed-off areas remote from public road traffic.

  • Page 9: Tampering Warning

    Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use and in a safe and environmentally compatible manner. The vehicle should only be used by trained persons. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.

  • Page 10: Protective Clothing

    – When you ride a motorcycle, set an example for your child and wear suitable protective clothing. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing suitable pro- tective clothing. Work rules Special tools are necessary for certain tasks.
  • Page 11 SAFETY ADVICE 2 The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. International KTM Website: http://www.ktm.com...

  • Page 12: Important Notes

    Manufacturer and implied warranty The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con- firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

  • Page 13: View Of Vehicle 4

    VIEW OF VEHICLE 4 View of vehicle, front left (example) F02168-10 Hand brake lever ( p. 15) Valve for fork airpump Clutch lever ( p. 15) Quick release for seat lock Shock absorber rebound adjustment Choke ( p. 17) Shift lever ( p.

  • Page 14: View Of Vehicle, Rear Right (Example)

    4 VIEW OF VEHICLE View of vehicle, rear right (example) F02169-10 Fuel tank filler cap Kill switch ( p. 15) Fork rebound adjustment Throttle grip ( p. 15) Vehicle identification number ( p. 13) Kick starter lever ( p. 18) Foot brake lever ( p.

  • Page 15: Serial Numbers 5

    SERIAL NUMBERS 5 Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Type label The type label is located on the front frame tube. 402154-10 Engine number The engine number is located on the left side of the engine under the engine sprocket.

  • Page 16: Shock Absorber Article Number

    5 SERIAL NUMBERS Shock absorber article number The shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the left-hand side. H01141-10...

  • Page 17: Controls 6

    CONTROLS 6 Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. S02397-10 Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The hand brake lever is used to activate the front brake. S02398-10 Throttle grip Throttle grip...

  • Page 18: Opening The Fuel Tank Filler Cap

    6 CONTROLS Opening the fuel tank 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. –...

  • Page 19: Fuel Tap

    CONTROLS 6 Fuel tap Fuel tap is on the left of the fuel tank. Possible states Fuel tap is closed – The knurled screw is turned all the way • clockwise. Fuel cannot flow out of the fuel tank. Fuel tap is open – The knurled screw is turned all the way •...

  • Page 20: Kick Starter Lever

    6 CONTROLS 6.10 Kick starter lever Kick starter lever is fitted on the right side of the engine. The kick starter lever can be swiveled. Info Before riding, swing the kick starter lever inwards towards the engine. 401954-10 6.11 Foot brake lever Foot brake lever is located in front of the right footrest.

  • Page 21: Preparing For Use 7

    PREPARING FOR USE 7 Advice on preparing for first use Warning Danger of accidents A lack of physical and mental readiness on the part of the child poses a major risk. Children often underestimate or fail to recognize dangerous situations. – Your child must already be able to ride a bicycle.
  • Page 22 When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-sales inspection work has been carried out by an authorized KTM workshop. You will receive a delivery certificate when the vehicle is handed over.

  • Page 23: Running In The Engine

    PREPARING FOR USE 7 Running in the engine – During the running-in phase, do not exceed the specified engine performance. Guideline Maximum engine performance During the first 3 operating hours < 70 % During the first 5 operating hours < 100 % –...

  • Page 24: Riding Instructions

    8 RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 25: Starting Off

    Make it clear to your child that he or she must not change into a low gear at high engine speed. Info If unusual noises occur while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off and for steep inclines. –...

  • Page 26: Applying The Brakes

    Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not allow your child to continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system.

  • Page 27: Transporting

    RIDING INSTRUCTIONS 8 Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive. – Allow the vehicle to cool down before covering it. Note Material damage The vehicle may be damaged by incorrect procedure when parking.
  • Page 28 8 RIDING INSTRUCTIONS 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. –...

  • Page 29: Service Schedule 9

    Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.

  • Page 30: Recommended Work

    ● ● Final check: Check the vehicle for safe operation and take a test ride. ○ ● ● ● Make a service entry in the KTM Dealer.net. ○ One-time interval ● Periodic interval Recommended work Every 80 operating hours Every 40 operating hours...

  • Page 31: Tuning The Chassis 10

    TUNING THE CHASSIS 10 10.1 Checking the basic chassis setting with rider's weight Info When adjusting the basic chassis setting, first adjust the shock absorber and then the fork. – For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, link fork and frame, the basic settings of the suspension components must match the rider's weight.

  • Page 32: Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber.

  • Page 33: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber.

  • Page 34: Measuring The Dimension Of The Unloaded Rear Wheel

    10 TUNING THE CHASSIS Info Turn clockwise to increase the damping; turn counter- clockwise to reduce the damping. 10.7 Measuring the dimension of the unloaded rear wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 39) Main work –...

  • Page 35: Checking The Static Sag Of The Shock Absorber

    TUNING THE CHASSIS 10 10.8 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 32) – Hold the motorcycle upright with aid of an assistant. – Measure the distance again between the rear axle and mark- ing SAG on the rear fender using the sag gage.

  • Page 36: Adjusting The Spring Preload Of The Shock Absorber

    Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Preparatory work –...

  • Page 37: Checking The Basic Setting Of The Fork

    TUNING THE CHASSIS 10 Main work – Choose and mount a suitable spring. Guideline Spring rate Weight of rider: 35 kg 35 N/mm (200 lb/in) (77 lb.) Weight of rider: 40 kg 40 N/mm (228 lb/in) (88 lb.) Weight of rider: 45 kg 45 N/mm (257 lb/in) B00292-10 (99 lb.)
  • Page 38 A little air escapes from the fork leg when connecting. Info This is due to the volume of the hose and not due to a defect in the fork airpump or the fork. Read the accompanying KTM PowerParts instructions. – Adjust the air pressure as specified. Guideline...

  • Page 39: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS 10 10.14 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. – Turn adjuster clockwise all the way. Info Adjuster is located at the upper end of the right fork leg.
  • Page 40 10 TUNING THE CHASSIS – 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 .

  • Page 41: Service Work On The Chassis 11

    SERVICE WORK ON THE CHASSIS 11 11.1 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. – Raise the motorcycle at the frame underneath the engine. Lift stand (78929955100) Neither wheel is in contact with the ground.

  • Page 42: Cleaning The Dust Boots Of The Fork Legs

    11 SERVICE WORK ON THE CHASSIS 11.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 39) – Remove the fork protector. ( p. 40) Main work – Push dust boots of both fork legs downward.

  • Page 43: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11 – Remove screws on the right fork leg. Take off the fork pro- tector. V00201-10 11.6 Installing the fork protector – Position fork protector on the right fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis...

  • Page 44: Installing The Fork Legs

    11 SERVICE WORK ON THE CHASSIS – Loosen screws . Remove the left fork leg. – Loosen screws . Remove the right fork leg. V00202-10 11.8 Installing the fork legs Main work – Position the fork legs. Bleeder screws are positioned toward the rear. Info The second milled groove (from the top) must be flush with the upper edge of the upper triple clamp.

  • Page 45: Removing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11 11.9 Removing the lower triple clamp Preparatory work – Raise the motorcycle with a lift stand. ( p. 39) – Remove the front wheel. p. 78) – Remove the fork legs. p. 41) – Remove the start number plate.
  • Page 46 11 SERVICE WORK ON THE CHASSIS – Position the upper triple clamp with the handlebar. – Mount nut , but do not tighten it yet. Guideline Nut, steering head M20x1.5 10 Nm (7.4 lbf ft) H00152-11 – Position the fork legs. Bleeder screws are positioned toward the rear.

  • Page 47: Checking The Steering Head Bearing Play

    Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam- ages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.

  • Page 48: Adjusting The Steering Head Bearing Play

    11 SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable on the steering head bearing. » If there is detectable play: –...

  • Page 49: Greasing The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS 11 11.13 Greasing the steering head bearing – Remove the lower triple clamp. p. 43) – Install the lower triple clamp. p. 43) H02387-01 11.14 Removing the start number plate – Remove screw – Unhook the start number plate from the brake line and remove V00203-10 11.15 Installing the start number plate...

  • Page 50: Removing Front Fender

    11 SERVICE WORK ON THE CHASSIS 11.16 Removing front fender – Remove screws . Take off the front fender. V00233-10 11.17 Installing front fender – Position start number plate on the fender. The holding lugs of the start number plate engage in drill holes of the fender.

  • Page 51: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 11.19 Installing the shock absorber Main work – Push splash protector to the side and position the shock absorber. Mount and tighten screw Guideline Screw, top 45 Nm (33.2 lbf ft) Loctite ® 243™ shock absorber –...

  • Page 52: Removing The Air Filter

    11 SERVICE WORK ON THE CHASSIS 11.22 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter. – Never start to use the vehicle without an air filter. Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 53: Cleaning The Air Filter And Air Filter Box

    SERVICE WORK ON THE CHASSIS 11 11.24 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Do not clean the air filter with fuel or petroleum since these substances attack the foam.

  • Page 54: Installing The Main Silencer

    11 SERVICE WORK ON THE CHASSIS 11.26 Installing the main silencer – Mount the main silencer with rubber sleeve – Position wide collar bushing and narrow collar bushing V00211-10 – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00210-11 11.27...

  • Page 55: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 Finishing work – Install the main silencer. ( p. 52) 11.28 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. –...

  • Page 56: Installing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS – Pull off fuel hose 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.

  • Page 57: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS 11 – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00234-10 – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position the fuel tank breather in the steering stem. V00213-11 Finishing work –...

  • Page 58: Checking The Chain Tension

    11 SERVICE WORK ON THE CHASSIS Info The service life of the chain depends largely on its maintenance. Preparatory work – Raise the motorcycle with a lift stand. ( p. 39) Main work – Rinse off loose dirt with a soft jet of water. –...

  • Page 59: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 11.33 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.
  • Page 60 11 SERVICE WORK ON THE CHASSIS Main work – Shift the transmission into neutral. – Check the chain, rear sprocket, and engine sprocket for wear. » If the chain, rear sprocket or engine sprocket is worn: – Change the drivetrain kit. Info The engine sprocket, rear sprocket, and chain should always be replaced together.
  • Page 61 SERVICE WORK ON THE CHASSIS 11 – 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. – Check that the chain sliding piece is firmly seated.

  • Page 62: Checking The Frame

    – Change the link fork. Info Always replace a damaged link fork. Repairing the link fork is not authorized by KTM. V00216-01 11.37 Checking the throttle cable routing Warning Danger of accidents The throttle cable may slip out of the guide if routed incorrectly.

  • Page 63: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS 11 11.38 Checking the rubber grip – Check the rubber grips on the handlebar for damage, wear, and looseness. » If a rubber grip is damaged, worn, or loose: – Change the rubber grip. Rubber grip adhesive (00062030051) ( p.

  • Page 64: Correcting The Fluid Level Of The Hydraulic Clutch

    11 SERVICE WORK ON THE CHASSIS – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Check the fluid level in viewer » If the fluid has dropped below marking in the level viewer: – Correct the fluid level of the hydraulic clutch.

  • Page 65: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 11 11.43 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. –...
  • Page 66 11 SERVICE WORK ON THE CHASSIS – Inject the liquid into the system only until it emerges from drill hole of the master cylinder without bubbles. – Now and then, extract fluid from the master cylinder reservoir to prevent overflow. –...

  • Page 67: Brake System 12

    Do not make any adjustments while riding. 12.3 Checking the brake discs Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.)

  • Page 68: Checking The Front Brake Fluid Level

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 69: Adding The Front Brake Fluid

    If brake fluid spills on to your clothing, change the clothing. Warning Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)

  • Page 70: Checking The Front Brake Linings

    Immediately clean up any brake fluid that has over- flowed or spilled with water. 12.6 Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.)

  • Page 71: Changing The Brake Linings Of The Front Brake

    Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 72 12 BRAKE SYSTEM Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.

  • Page 73: Checking The Free Travel Of The Foot Brake Lever

    BRAKE SYSTEM 12 – Position the brake caliper. – Mount screw but do not tighten yet. – Operate the hand brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure point.

  • Page 74: Adjusting The Free Travel Of The Foot Brake Lever

    12 BRAKE SYSTEM 12.9 Adjusting the free travel of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.

  • Page 75: Checking The Rear Brake Fluid Level

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.
  • Page 76 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 77: Checking The Rear Brake Linings

    Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 78 12 BRAKE SYSTEM Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
  • Page 79 H00144-01 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.

  • Page 80: 13 Wheels, Tires

    13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 39) Main work – Remove screw V00219-10 – Loosen screws Warning Danger of accidents Damaged brake discs reduce the braking effect. –...

  • Page 81: Removing The Rear Wheel

    WHEELS, TIRES 13 – 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 and contact surfaces of the spacers. Long-life grease ( p.

  • Page 82: Installing The Rear Wheel

    13 WHEELS, TIRES Main work – Remove nut – Take off chain adjuster H00116-10 – Pull out wheel spindle far enough to allow the rear wheel to be pushed forward. – Push the rear wheel forward as far as possible. Remove the chain from the rear sprocket.

  • Page 83: Checking The Tire Condition

    Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcycle.

  • Page 84: Checking Tire Pressure

    DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of H01144-10 wear.

  • Page 85: Checking Spoke Tension

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.) –...

  • Page 86: 14 Cooling System

    14 COOLING SYSTEM 14.1 Cooling system The water pump 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 . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 87: Checking The Coolant Level

    COOLING SYSTEM 14 14.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 88: Refilling With Coolant

    14 COOLING SYSTEM Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...
  • Page 89 COOLING SYSTEM 14 – Move the vehicle into the position shown and prevent it from rolling away. Height difference must be reached. Guideline 50 cm (19.7 in) Height difference Info For all of the air to be able to escape from the cooling system, the vehicle must be raised at the front.

  • Page 90: 15 Tuning The Engine

    15 TUNING THE ENGINE 15.1 Checking throttle cable play – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Throttle cable play 3 …...

  • Page 91: Carburettor - Idle Speed

    TUNING THE ENGINE 15 – Turn barrel adjuster until there is throttle cable play the bottom throttle cable sleeve. Guideline Throttle cable play 3 … 5 mm (0.12 … 0.2 in) – Tighten nut – Slide on sleeve 400192-11 Finishing work –...

  • Page 92: Emptying The Carburetor Float Chamber

    15 TUNING THE ENGINE – Adjust the idle speed with adjusting screw Guideline Choke function deactivated – The choke lever is pushed up all the way to the stop. ( p. 17) Idle speed 1,400 … 1,500 rpm – Turn idle air adjusting screw slowly in a clockwise direc- tion until the idle speed begins to fall.
  • Page 93 TUNING THE ENGINE 15 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. Info Carry out work with a cold engine. Water in the float chamber results in malfunctioning. Preparatory work –...

  • Page 94: 16 Service Work On The Engine

    16 SERVICE WORK ON THE ENGINE 16.1 Checking the gear oil level Condition The engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Remove screw – Check the gear oil level. A small quantity of gear oil must run out of the drilled hole. »...

  • Page 95: Adding The Gear Oil

    SERVICE WORK ON THE ENGINE 16 Info Too little gear oil or poor-quality gear oil results in pre- mature wear to the transmission. – Remove filler plug and fill up with gear oil. Gear oil 0.50 l Engine oil (0.53 qt.) (15W/50) p.
  • Page 96 16 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.

  • Page 97: Cleaning, Care 17

    CLEANING, CARE 17 17.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...
  • Page 98 17 CLEANING, CARE Info The heat produced causes water at inaccessible loca- tions in the engine and on the brake system to evapo- rate. – Push back the protection caps on the handlebar controls to allow water to evaporate. – After the motorcycle has cooled off, lubricate all moving parts and pivot points.

  • Page 99: Storage 18

    82) – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with a lift stand. ( p. 39) – Cover the vehicle with a tarp or similar cover that is permeable to air.

  • Page 100: Preparing For Use After Storage

    18 STORAGE 18.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 39) – Perform checks and maintenance measures when preparing for use. ( p. 22) – Take a test ride. 401059-01...

  • Page 101: Troubleshooting 19

    TROUBLESHOOTING 19 Faults Possible cause Action – Engine turns but does not start Operating error Carry out the start procedure. p. 22) – Motorcycle was out of use for a Empty the carburetor float chamber. long time and there is old fuel p.
  • Page 102 19 TROUBLESHOOTING Faults Possible cause Action – Engine has too little power Fault in ignition system Check the ignition system. – Adjust the ignition. – Diaphragm or reed valve hous- Check the diaphragm and reed valve ing damaged housing. – Noticeable wear Overhaul the engine.

  • Page 103: Technical Data 20

    TECHNICAL DATA 20 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...
  • Page 104 20 TECHNICAL DATA Screw, retaining bracket for return 6 Nm (4.4 lbf ft) Loctite ® 243™ spring of shift shaft Screw, shift drum locating 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, water pump impeller 4 Nm (3 lbf ft) Loctite ®...

  • Page 105: Carburetor

    TECHNICAL DATA 20 Nut, primary gear wheel M14x1.25 40 Nm (29.5 lbf ft) Loctite ® 243™ 20.3 Carburetor Carburetor type MIKUNI TM 24 Needle position 2nd position from top Idle air adjusting screw Open 3.5 turns Main jet Jet needle 5IPL43 (5N17) Idling jet Needle jet...

  • Page 106: Capacities

    20 TECHNICAL DATA Needle position from top Main jet The carburetor tuning depends on the defined ambient and operating conditions. 20.4 Capacities 20.4.1 Gear oil Gear oil 0.50 l (0.53 qt.) Engine oil (15W/50) ( p. 108) 20.4.2 Coolant Coolant 0.55 l (0.58 qt.) Coolant ( p.

  • Page 107: Chassis

    TECHNICAL DATA 20 Sport 0.5 turns Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring preload 5 mm (0.2 in) Spring rate Weight of rider: 35 kg (77 lb.) 35 N/mm (200 lb/in) Weight of rider: 40 kg (88 lb.) 40 N/mm (228 lb/in) Weight of rider: 45 kg (99 lb.) 45 N/mm (257 lb/in)

  • Page 108: Tires

    80/100 - 12 41M TT Maxxis MAXX CROSS SI Maxxis MAXX CROSS SI The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 20.9 Chassis tightening torques Screw, brake line bracket EJOT 1.7 Nm (1.25 lbf ft)
  • Page 109 TECHNICAL DATA 20 Screw, rear sprocket 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, steering stem 20 Nm (14.8 lbf ft) Screw, subframe 35 Nm (25.8 lbf ft) Loctite ® 2701™ Screw, top triple clamp 20 Nm (14.8 lbf ft) Remaining nuts, chassis 45 Nm (33.2 lbf ft) Remaining screws, chassis...

  • Page 110: 21 Substances

    21 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX ®...
  • Page 111 SUBSTANCES 21 Recommended supplier MOTOREX ® – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 112) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

  • Page 112: 22 Auxiliary Substances

    22 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier MOTOREX ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier...
  • Page 113 Preserving materials for paints, metal and rubber Recommended supplier MOTOREX ® – Moto Protect Rubber grip adhesive (00062030051) Recommended supplier KTM AG – GRIP GLUE Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier MOTOREX ® –...

  • Page 114: 23 Standards

    23 STANDARDS JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 115: List Of Abbreviations 24

    LIST OF ABBREVIATIONS 24 Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 116: Index

    INDEX Clutch INDEX fluid level, checking ....61 Accessories ......10 fluid level, correcting .
  • Page 117 INDEX Fuel tank installing ......54 Owner's Manual ......8 removing .
  • Page 118 INDEX Steering head bearing greasing ......47 Steering head bearing play adjusting ......46 checking .
  • Page 119 *3213997en* 3213997en 03/2019 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

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