Table of Contents
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Table of Contents
Related Manuals for KTM 65 SX 2001
Summary of Contents for KTM 65 SX 2001
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Page 3: Chassis Number
Chassis number RAME NUMBER Engine number NGINE NUMBER Stamp of dealer TAMP OF DEA KTM S PORTMOTORCYCLE RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT TECHNICAL SPECIFICATIONS COLORS MATERIALS SERVICES OFFERED AND RENDERED AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT... - Page 4 In this spirit, we hope that you and your youngsters will always safely enjoy your motorcycle! KTM Austria’s AG certificate of achievement for its Quality System ISO 9001 is the beginning of an on going total reengineering quality plan for a brighter tomorrow.
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Page 5: Table Of Contents
MAINTENANCE WORK ON CHASSIS AND ENGINE ..12 Checking and adjusting the steering head bearing . . .12 General information about KTM disc brakes ..13 Adjusting of free travel at the hand brake lever ..13... -
Page 6: Important Information On Safe Driving For Parents
IMPORTANT INFORMATION ON SAFE DRIVING FOR PARENTS SX mini motorcycles are off-road motorcycles designed for one person only. They are not allowed on public roads. Motorcycle dimension and components are designed for the following age and weight groups: 65 SX: age 8 - 12 years, maximum weight 50 kg (110 lbs), maximum body height 160 cm (65 in) –... -
Page 7: Serial Number Locations
SERIAL NUMBER LOCATIONS Chassis number The chassis number is located on the type plate on the steering head. Write this number into the field on page no 1. Engine number The engine number is stamped into the engine housing underneath the car- buretor. -
Page 8: Filler Cap
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 without kinks. Refueling, fuel Oil (high-grade two-stroke engine oil; i.e. Shell Advance Racing X) must be mixed with the fuel (ROZ 95) at a mixing ratio of 1:40. -
Page 9: Shift Lever
Shift lever The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located bet- ween first and second gear. 2,3,4,5,6 Kickstarter The kickstarter is mounted on the right side of the engine. Its upper part can be swivelled. -
Page 10: Driving Instructions
LWAYS KEEP IN MIND THAT OTHER PEOPLE FEEL MOLESTED BY EXCES brake pads. Arrange for the braking system to be checked by SIVE NOISE an authorized KTM dealer, as complete failure of the braking system can be expected. Running in Also check the state of the brake hose and the thickness of –... -
Page 11: Starting When Engine Is Warm
Starting when the engine is warm CAUTION 1 Open fuel tap – D RIVING A COLD ENGINE AT HIGH SPEED WILL REDUCE THE LIFE OF THE 2 Put the gear in neutral ENGINE E RECOMMEND TO WARM THE ENGINE UP AT A MEDIUM 3 Open throttle to and kick down kickstarter vigorously ENGINE SPEED FOR SEVERAL MINUTES BEFORE SWITCHING TO FULL... -
Page 12: Periodic Maintenance Schedule
PERIODIC MAINTENANCE 65 SX Service every once a year A washed motorcycle can be checked more quickly which saves money! 20 hours Check transmission oil level Change transmission oil Check spark plug, change it if necessary, set electrode gap Check carburetor for tight fit at intake flange Check intake flange for cracks Check idle setting when engine is warm Check cooling system for leaks, antifreeze protection... - Page 13 VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC Check transmission oil level Check coolant level Check brake fluid level Check brake pads for wear Check brake performance Lubricate and adjust actuating cables and nipples Remove and clean dust sleeves of telescopic fork in regular intervals Clean and lubricate chain, check tension and readjust it if necessary Clean air filter and filter box...
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Page 14: Maintenance Work On Chassis And Engine
MAINTENANCE WORK ON CHASSIS AND ENGINE WARNING ALL MAINTENANCE AND ADJUSTEMENT OPERATIONS THAT ARE MARKED WITH A * REQUIRE SPECIALIST KNO- WLEDGE. FOR YOUR OWN SECURITY, LET THESE TASKS BE CARRIED OUT BY A KTM-DEALER ! CAUTION – W HEN CLEANING THE MOTORCYCLE... -
Page 15: General Information About Ktm Disc Brakes
In this case, consult an authorized KTM dealer immediately. BRAKE FLUID: KTM fills the brake system with ”Shell Advance Brake 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. -
Page 16: Refilling The Front Brake Fluid Reservoir
Refilling front brake fluid reservoir * When the brake fluid falls to the middle of the inspection glass, new brake fluid has to be added. Loosen screws and remove lid and membrane Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm (0.2 in) below the rim with clean brake fluid DOT 5.1 (Shell Advance Brake DOT 5.1). -
Page 17: Changing The Basic Position Of The Brake Pedal
Changing basic position of the brake pedal * The basic setting of the foot brake pedal can be changed by turning the end stop roller . Using the push rod , the free play on the foot brake pedal must be set. Measured on the outside, the foot brake pedal must have 3-5 mm of free play, before the push rod can move the piston in the brake cylinder (to be recognised from the resistance on the foot brake pedal). -
Page 18: Checking The Rear Brake Pads
Checking rear brake pads min. The brake pads can be inspected from the rear. The thickness of the linings 1 mm may not be less than 1 mm (0.04 in). WARNING T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN OTHERWISE THEY COULD LEAD TO BRAKE FAILURE OR YOUR OWN SAFETY ’... -
Page 19: Removing And Installing The Front Wheel
Removing and installing front wheel Jack the motorcycle up by the frame so that the front wheel is suspended above the ground. Undo the hexagon nut and remove it together with the washer. Hold the front wheel and pull out the wheel spindle Carefully take the front wheel out of the fork. -
Page 20: Checking The Chain Tension
Checking chain tension Put the motorcycle on the side stand. Press the chain approx. 3 cm (1.2 in) behind the chain sliding piece up toward the swingarm. In this place, it must be possible without pushing hard to press the chain up to 7 mm (0.3 in) toward the swing arm (see figure). -
Page 21: Tires, Air Pressure
(see photo). A clear tone must be the result. Dull tones are indicators of loose spokes. If necessary, have the spokes retightened and the wheel centered by a KTM dealer. WARNING... -
Page 22: Cleaning Of Air Filter
, swing back and remove air filter plus filter car- rier from the filter box. CAUTION O NOT CLEAN FOAM FILTER WITH FUEL OR PETROLEUM SINCE THESE DAMAGE THE . KTM TWIN AIR FOAM RECOMMENDS THE PRODUCTS OF THE COMPANY FOR AIR FIL TER MAINTENANCE Thoroughly wash the foam filter in special cleaning fluid and allow to dry well. -
Page 23: Adjusting The Idle Speed
Adjusting idle speed * The idle speed can be adjusted with screw Turn the screw clockwise to increase the idle speed. Turn the screw counterclockwise to reduce the idle speed. Checking gear oil level An inspection glass on the left side of the engine allows easy checking of the gear oil level. -
Page 24: Cooling System
Check the exhaust system for leaks. NOTE: Glass fiber yarn packages are offered by your licensed KTM dealer. WARNING HE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUNNING AVOID BURNS... -
Page 25: Carburetor Adjustment
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 tempe- rature 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 1:40 . -
Page 26: 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. CAUTION EVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH... -
Page 27: Technical Data - Chassis
TECHNICAL SPECIFICATIONS – CHASSIS 65 SX 2001 Frame single downtube, split-cradle Fork telescopic fork (Paioli) Wheel travel front/rear 200 mm (8 in) / 230 mm (9.2 in) Rear suspension central shock absorber (White Power) Front brake Disc brake Ø 198 mm (7.8 in), 1 piston Rear brake Disc brake Ø... -
Page 28: Technical Data - Engine
TECHNICAL SPECIFICATIONS - ENGINE 65 SX 2001 Engine CR-63 Design Liquid cooled single cylinder two-stroke engine with reed valve intake Displacement 63,58 ccm Bore/stroke 45 / 40 mm (1,77/1,57 in) Compression ratio 9,1 : 1 Fuel SUPER fuel, research octane no 95, mixed with high grade two stroke oil Oil/gasoline ratio 1 : 40 when using high grade two stroke oil (i.ex. - Page 29 TOLERANCES AND FITTING CLEARANCES Crankshaft run out of crank stud max. 0,050 mm 0,00196 in Conrod bearing radial play max. 0,030 mm 0,00118 in Piston fitting clearance 0,03 - 0,05 mm 0,00118 – 0,00196 in Piston ring end gap max. 0,15 mm 0,00590 in Clutch springs length min.
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