KTM 65 SX 2006 Owner's Manual
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KTM 65 SX 2006 Owner's Manual

KTM 65 SX 2006 Owner's Manual

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OWNER'S MANUAL
2006
65 SX
ART. NR. 3.211.70 EN

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Summary of Contents for KTM 65 SX 2006

  • Page 1 OWNER’S MANUAL 2006 65 SX ART. NR. 3.211.70 EN...
  • Page 2 KTM may stop man- ufacturing certain models without previous notice. KTM shall not be held liable for any deviations of avail- ability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated mod- els partly contain extra equipment, which is not applied to standard models.
  • Page 3 Please strictly observe the prescribed running-in periods and inspection and maintenance intervals. Compliance with these instructions will significantly prolong the life of your motorcycle. Be sure to have the maintenance work carried out by a KTM workshop to avoid losing your right to claim under the warranty.

  • Page 4: Important Warranty And Guarantee Information

    » IMPORTANT WARRANTY AND GUARANTEE INFORMATION 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.

  • Page 5: Important Information For Parents About Safe Driving

    » 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.

  • Page 6: Table Of Contents

    Chain maintenance ......19 General information about KTM disc brakes ..20 OPERATION INSTRUMENTS .

  • Page 7: Serial Number Locations

    » SERIAL NUMBER LOCATIONS 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.

  • Page 8: Short Circuit Button

    » 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 To open it: turn filler cap counter-clockwise. To close it: put filler cap back on and tighten it by turning it clockwise. Install tank breather hose [2] without kinks.

  • Page 9: Kickstarter

    » 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).

  • Page 11: The Motorcycle

    – Make sure the work for the „pre-delivery inspection“ was per- – HAVE YOUR YOUNGSTER WEAR PROPER PROTECTIVE GEAR WHEN- formed by your authorized KTM workshop. The DELIVERY CER- EVER HE OR SHE RIDES THE MOTORCYCLE: HELMET, EYE PRO- TIFICATE and SERVICE MANUAL will be handed over when you TECTION, CHEST, BACK, ARM AND LEG PROTECTORS, GLOVES pick up your vehicle.

  • Page 12: Driving Instructions

    If the level of brake fluid falls below the minimum value, this indicates a leak in the braking system or completely worn out brake pads. Always have the brake system checked by a KTM workshop to avoid brake failure.

  • Page 13: Starting When The Engine Is Cold

    » 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. –...

  • Page 14: Braking

    NOT FILL THE TANK TO THE TOP. (SEE FIG.) TION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM. DON’T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER. Stopping Brake motorcycle and shift gears to idling. To switch off the engine, depress short circuit switch until the engine stops.

  • Page 15: Periodic Maintenance Schedule

    MAINTENANCE WORK PERFORMED BY YOUR AUTHORIZED KTM WORKSHOP IS NOT A SUBSTITUTE FOR CARE AND MAINTE- NANCE BY THE DRIVER! NOTE: A service hour counter (item no.: SXS05450600) is available from your KTM dealer for strict observance of the service intervals.
  • Page 16 Treat all electric plug-in connections with contact spray Check all screws, nuts, and hose clamps for their tight fit at regular intervals RECOMMENDED INSPECTION OF THE 65 SX ENGINE BY YOUR KTM WORKSHOP (ADDITIONAL ORDER FOR THE KTM’S WORKSHOP) every...

  • Page 17: Maintenance Work On Chassis And Engine

    NO FUEL CAN LEAK FROM THE CARBURETOR OR FUEL TANK. – ONLY USE SPECIAL SCREWS WITH AN APPROPRIATE THREAD LENGTH SUPPLIED BY KTM TO FIX THE SPOILERS ON THE TANK. USING OTHER SCREWS OR LONGER SCREWS CAN CAUSE LEAKS IN THE TANK THROUGH WHICH FUEL CAN FLOW OUT.

  • Page 18: Cleaning The Dust Sleeves Of The Telescopic Fork

    » 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.

  • Page 19: Basic Suspension Setup For The Weight Of The Driver

    To 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 motorcycles are set to accommodate a driver weighing 35 – 45 kg (wear- ing full protective clothing).

  • Page 20: Checking Chain Tension

    Tighten the hexagon nut [1] to 40 Nm. – IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV- IOR OF YOUR MOTORCYCLE.

  • Page 21: General Information About Ktm Disc Brakes

    In this case, consult an authorized KTM dealer immediately. BRAKE FLUID: KTM fills the brake system with „Motorex Brake Fluid DOT 5.1“, one of the best brake fluids currently available. We recommend that you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color. If you do not have any DOT 5.1 for refilling, you may use DOT 4 brake fluid.

  • Page 22: Checking/Refilling The Front Brake Fluid Level

    » 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. To check the brake fluid level, press the brake pistons back into the basic position.

  • Page 23: Replacing The Front Brake Pads

    » 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. Remove the lock washer [1] from the screw as well as fixing screw [2] and take the brake shoes out of the brake caliper.

  • Page 24: Checking The Rear Brake Fluid Level

    » 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.

  • Page 25: Replacing The Rear Brake Pads

    Then tighten clamping screws to a max. torque of 10 Nm. – IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV- IOR OF YOUR MOTORCYCLE.

  • Page 26: Removing And Installing The Rear Wheel

    VENT THE THREAD FROM JAMMING. – IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV- IOR OF YOUR MOTORCYCLE.

  • Page 27: Removing The Seat

    [5] from the filter box. – DO NOT CLEAN FOAM FILTER WITH FUEL OR PETROLEUM SINCE THESE DAM- AGE THE FOAM. KTM RECOMMENDS THE PRODUCTS OF THE COMPANY MOTOREX FOR AIR FILTER MAINTENANCE (BIO DIRT REMOVER AND LIQUID BIO POWER).

  • Page 28: Exhaust System

    Mount the silencer and check the exhaust system for tightness. NOTE: Glass fiber yarn packages are offered by your licensed KTM dealer. THE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUN- NING. TO AVOID BURNS DO NOT START WORK ON THE EXHAUST SYSTEM UNTIL IT HAS PROPERLY COOLED DOWN.

  • Page 29: Changing The Original Position Of The Clutch Lever

    » 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.

  • Page 30: Carburetor Adjustment

    » 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-grade fuel (ROZ 95). Mixing ratio 2-stroke motor oil : super fuel 1:60 .

  • Page 31: Draining The Float Chamber Of The Carburetor

    » 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. Water in the float chamber leads to engine malfunction. Make sure you do this while the engine is cold.

  • Page 32: Trouble Shooting

    We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer.
  • Page 33 » TROUBLE SHOOTING TROUBLE CAUSE REMEDY Engine has not enough power Reed paddles tensionless or dam- Replace reed paddles or reed valve housing aged, surface of reed valve housing damaged Wear Overhaul engine Engine revs not up and running Carburetor overflows if level adjust Clean carburetor, if necessary replace float needle and in four stroke cycle too high, float needle seating is...

  • Page 34: Cleaning

    » CLEANING 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. The hard dirt can be removed before with the help of a soft water jet.

  • Page 35: Technical Specifications - Chassis

    » 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) 3612 BAVP Front brake Disc brake Ø...

  • Page 36: Technical Specifications - Engine

    » 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.
  • Page 37 » 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 15 Nm Collar nut – cylinder base 25 Nm Hexagon screw –...

  • Page 38: Index

    ..20 General information about KTM disc brakes ..20 Adjusting the throttle cable .....28 General tips and warnings for starting the motorcycle .
  • Page 42 KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at...

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