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Related Manuals for KTM 65 XC 2009
Summary of Contents for KTM 65 XC 2009
- Page 1 OWNER'S MANUAL 2009 65 SX 65 XC ART. NO. 3211345en...
- Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors.
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Page 4: Table Of Contents
Important maintenance work to be carried out by an Adjusting the basic position of the foot brake pedal ..41 authorized KTM workshop. (as additional order)....19 Checking rear brake fluid level........42 Performance of urgent inspection and maintenace work Adding rear brake fluid .......... - Page 5 CONTENTS Installing the main silencer ..........51 Removing the glass fiber yarn filling of the main silencer ..............52 Installing the glass fiber yarn filling of the main silencer ..............52 Removing the air filter ..........52 Installing the air filter ..........
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Page 6: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of the safety of your child, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required. -
Page 7: Important Notes
Warranty The work prescribed in the service schedule must be carried out in an authorized KTM workshop only and confirmed in the customer's service record, since otherwise no warranty claims will be honored. No warranty claims can be honored for damage resulting from manipulations and/or alterations to the vehicle. - Page 8 IMPORTANT NOTES Environment Motorcycling is a wonderful sport and we naturally hope that you and your child will be able to enjoy it to the fullest. However, it is a potential problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such problems and conflicts do not have to occur.
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Page 9: View Of Vehicle
VIEW OF VEHICLE View of the vehicle from the left front (example) 300673-10 Clutch lever Filler cap Shift lever Chain guide Choke lever Fuel tap Quick release for seat lock... -
Page 10: View Of The Vehicle From The Right Rear (Example)
VIEW OF VEHICLE View of the vehicle from the right rear (example) 300672-10 Kickstarter Shock absorber compression adjustment Shock absorber rebound adjustment Level viewer for brake fluid, rear Foot brake pedal Fork protector Chassis number Hand brake lever Throttle grip Short circuit button... -
Page 11: Location Of Serial Numbers
LOCATION OF SERIAL NUMBERS Chassis number The chassis number is stamped on right of the steering head. 700390-01 Engine number The engine number is stamped on the left side of the engine under the engine sprocket. 700391-01 Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above ... -
Page 12: Controls
CONTROLS Throttle grip Trottle grip is fitted on the right side of the handlebar. 700408-01 Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 700393-10 Hand brake lever Hand brake lever is fitted on the right side of the handlebar. -
Page 13: Opening Filler Cap
CONTROLS Opening filler cap – Press release button , turn filler cap counterclockwise and lift it free. 700396-01 Closing filler cap – Replace the filler cap and turn clockwise until the release button locks in place. Info Run the fuel tank breather hose without kinks. -
Page 14: Kickstarter
CONTROLS Kickstarter 5.10 The kickstarter is fitted on the right of the engine. The kickstarter can be swiveled. Info Before riding, swing the kickstarter inwards towards the engine. 700403-01 Foot brake pedal 5.11 Foot brake pedal is located in front of the right footrest. ... -
Page 15: General Tips And Hints On Putting Into Operation
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover. -
Page 16: Running In The Engine
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION – 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, you should push your child at first. Do not start the engine until your child can is able to apply the necessary brake pressure. -
Page 17: Riding Instructions
RIDING INSTRUCTIONS Checks before putting into operation Info Make sure that the motorcycle is in a perfect technical condition before use. Info In the interests of riding safety, make it your own and your child's habit to perform a general check before going for a ride. Insist that your child perform the general checks himself or herself. -
Page 18: Starting Up
Do not shift into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines. -
Page 19: Stopping, Parking
RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation Usage by unauthorized 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 get very hot when the machine is driven. –... -
Page 20: Service Schedule
SERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop. S20A S40A Engine • Change the gear oil. p. 55) Check spark plug and replace if required. • • Clean spark plug connectors and check for tightness. -
Page 21: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop. (As Additional Order)
SERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) S20A S40A • Check/set the carburetor components. Check intake membrane for wear. • • Check wear of the clutch lining disc. • •... -
Page 22: Maintenance Work On Chassis And Engine
Adjusting the compression damping of the shock absorber Danger 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 pleased to help.) – Turn adjusting knob counterclockwise all the way. -
Page 23: Measuring Rear Wheel Sag Unloaded
MAINTENANCE WORK ON CHASSIS AND ENGINE Info Turn clockwise to increase damping, turn counterclockwise to reduce sus- pension damping. Measuring rear wheel sag unloaded – Jack up the motorcycle. ( p. 20) – Measure the distance – as vertical as possible – between the rear axle and a fixed point, for example, a mark on the side cover. -
Page 24: Adjusting The Spring Preload Of The Shock Absorber
Adjusting the spring preload of the shock absorber Danger 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 pleased to help.) – Remove shock absorber. -
Page 25: Adjusting The Compression Damping Of The Fork
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the compression damping of the fork 9.11 Info The hydraulic compression damping determines the fork suspension behavior. – Turn adjusting screw clockwise all the way. Info Adjusting screw is located at the top end of the left fork leg and is ... -
Page 26: Adjusting The Fork Overhang
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the fork overhang 9.14 Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications, ride slowly at first to get the feel of the new ride behavior. –... -
Page 27: Cleaning The Dust Boots Of The Fork Legs
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be pleased to help.) Info If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time. -
Page 28: Removing The Fork Legs
MAINTENANCE WORK ON CHASSIS AND ENGINE Guideline Screw, top triple clamp 25 Nm (18.4 lbf ft) – Check play of steering head bearing. ( p. 25) Removing the fork legs 9.19 – Remove the front wheel. p. 45) – Remove screws and take off clamp. -
Page 29: Removing The Fork Protector
MAINTENANCE WORK ON CHASSIS AND ENGINE – Tighten screws Guideline Screw, top triple clamp 25 Nm (18.4 lbf ft) – Tighten screws Guideline Screw, bottom triple clamp 25 Nm (18.4 lbf ft) 300664-11 – Position brake caliper, mount and tighten screws ... -
Page 30: Removing The Lower Triple Clamp
MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the fork protection on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the brake line. Mount clamp – Mount the screws ... -
Page 31: Greasing The Steering Head Bearing
MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the upper triple clamp with the steering. – Mount and tighten screw Guideline Nut, steering stem M20x1.5 10 Nm (7.4 lbf ft) – Position fuel tank breather – Install the front fender. ( p. -
Page 32: Dismounting The Start Number Plate
MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 700414-11 Dismounting the start number plate 9.28 – Remove screw and take off clamp. –... -
Page 33: Adjusting Handlebar Position
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting handlebar position 9.31 Warning Danger of accidents Handlebar breakage. – If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle- bar. – Remove the four screws . -
Page 34: Checking Chain Dirt
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking chain dirt 9.34 – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 32) 400678-01 Cleaning the chain 9.35 Warning Danger of accidents Oil or grease on the tires reduces their grip. –... -
Page 35: Checking The Chain Tension - Installing Rear Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the chain tension - installing rear wheel 9.37 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is over tensioned, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel) are under additional load. -
Page 36: Adjusting Chain Tension - After Checking
MAINTENANCE WORK ON CHASSIS AND ENGINE – Loosen nut – Loosen nuts – Adjust the chain tension by turning the adjusting screws to the left and right. Guideline Chain tension 5… 8 mm (0.2… 0.31 in) Turn adjusting screws equally on the left and right. -
Page 37: Adjusting Basic Position Of Clutch Lever
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting basic position of clutch lever 9.43 – Adjust the basic setting of the clutch lever to the size of your child's hand by turn- ing the adjusting screw Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. -
Page 38: Checking Brake Discs
Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be pleased to help.) – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement ... -
Page 39: Adjusting Basic Position Of Handbrake Lever
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be pleased to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 40: Adding Front Brake Fluid
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be pleased to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 41: Removing Front Brake Linings
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license. -
Page 42: Changing The Front Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be pleased to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 43: Adjusting The Free Travel Of The Foot Brake Pedal
MAINTENANCE WORK ON CHASSIS AND ENGINE – Attach spring Adjusting the free travel of the foot brake pedal 9.56 Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can fail due to overheating. -
Page 44: Checking Rear Brake Fluid Level
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be pleased to help.) – Stand the vehicle upright. -
Page 45: Checking The Rear Brake Linings
Removing rear brake linings 9.61 Warning Danger of accident Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be pleased to help.) – Remove the rear wheel. p. 46) – Remove lock washer ... -
Page 46: Changing The Rear Brake Linings
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license. -
Page 47: Removing The Front Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE – Stand the vehicle upright. – Remove screws – Remove cover with the O-ring and diaphragm – Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir. -
Page 48: Removing The Rear Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount and tighten screw Guideline Screw, front wheel spindle 40 Nm (29.5 lbf ft) – Remove the motorcycle from the work stand. ( p. 20) 700436-10 – Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc. -
Page 49: Checking The Tire Condition
DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufac- ture. KTM recommends that the tires be changed regardless of the actual wear, at the latest after 5 years. »... -
Page 50: Checking Spoke Tension
Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be pleased to help.) Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time. -
Page 51: Cooling System
MAINTENANCE WORK ON CHASSIS AND ENGINE – Close quick release 300633-11 Cooling system 9.73 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 . -
Page 52: Checking The Coolant Level
MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount the radiator cap. Checking the coolant level 9.75 Warning Scalding hazard During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, radiator hoses and other components of the cooling system while the engine is warm. Let the engine and cooling system cool down first. -
Page 53: Refilling Coolant
MAINTENANCE WORK ON CHASSIS AND ENGINE Refilling coolant 9.77 Warning Danger of poisoning Coolants are poisonous and a health hazard. – Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. -
Page 54: Removing The Glass Fiber Yarn Filling Of The Main Silencer
MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount and tighten screw Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 700442-10 Removing the glass fiber yarn filling of the main silencer 9.81 Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. –... -
Page 55: Installing The Air Filter
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the air filter 9.84 – Mount the clean air filter onto the air filter support. – Put in both parts together, position them and fix them with the air filter support Info If the air filter is not correctly mounted, dust and dirt can penetrate into the engine and can cause damage. -
Page 56: Emptying The Carburetor Float Chamber
MAINTENANCE WORK ON CHASSIS AND ENGINE Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon- sciousness and/or death. – When running the engine, always make sure there is sufficient venti- lation, and do not start or run the engine in a closed space without an effective exhaust extraction system. -
Page 57: Checking Gear Oil Level
MAINTENANCE WORK ON CHASSIS AND ENGINE – Place a cloth beneath the carburetor to soak up emerging fuel. – Remove plug – Completely drain the fuel. – Mount and tighten the plug. 700458-01 Checking gear oil level 9.89 Info The gear oil level must be checked when the engine is cold. -
Page 58: Filling Up With Gear Oil
MAINTENANCE WORK ON CHASSIS AND ENGINE Filling up with gear oil 9.92 Info Too little gear oil or poor-quality oil results in premature wear of the transmission. – Remove screw cap and fill up with gear oil. Gear oil 0.50 l (0.53 qt.) Engine oil (15W/50) ( p. -
Page 59: Troubleshooting
TROUBLESHOOTING Faults Possible cause Action – Engine turns but does not start Operating error Go through the steps of starting the engine. p. 15) – Motorcycle was out of use for a long Empty the carburetor float chamber. time and there is old fuel in the float p. - Page 60 TROUBLESHOOTING Faults Possible cause Action – Engine overheats Too little air stream Switch off engine when standing. – Radiator fins very dirty Clean radiator fins. – Foam formation in cooling system Drain the coolant. p. 50) – Refill the coolant. p.
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Page 61: Cleaning
CLEANING Cleaning motorcycle 11.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 62: Storage
Check the tire air pressure. ( p. 47) – The storage place should be dry and not subject to large temperature fluctuations. Info KTM recommends jacking up the motorcycle. – Jack up the motorcycle. ( p. 20) – Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. -
Page 63: Technical Data - Engine
TECHNICAL DATA - 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) Control Exhaust control PCEV Crankshaft bearing 2 grooved ball bearings Conrod bearing Needle bearing Piston pin bearing... -
Page 64: Technical Data - Engine Tightening Torques
TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Bearing retainer, main shafts Loctite 648™ – Nut, exhaust control diaphragm 3 Nm (2.2 lbf ft) ® Screw, clutch line holder 5 Nm (3.7 lbf ft) Loctite 243™ – Screw, diaphragm cover of exhaust 4 Nm (3 lbf ft) control ®... -
Page 65: Technical Data - Carburetor
TECHNICAL DATA - CARBURETOR Carburetor type MIKUNI TM 24 Needle position 2nd position from top Idle air adjusting screw Open 3.5 turns Main jet Jet needle 51 PL 43-2 Idling jet Needle jet Q-O (454) Throttle slide... -
Page 66: Technical Data - Chassis
80/100 - 12 50M TT Pirelli SCORPION MX Mid Soft 32 NHS Pirelli SCORPION MX Mid Soft 32 NHS Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 16.2 Fuel tank capacity, approx. 3.5 l (3.7 qt.) Super unleaded gasoline, mixed with 2-stroke engine oil p. -
Page 67: Technical Data - Fork
TECHNICAL DATA - FORK 17.1 Fork part number 46201000033 Fork Marzocchi Upside down Compression damping Standard 10 clicks Rebound damping Standard 10 clicks Spring rate Weight of rider: 35… 45 kg (77… 99 lb.) 3.4 N/mm (19.4 lb/in) Air chamber length 100±2.5 mm (3.94±0.098 in) Fork length 735 mm (28.94 in) -
Page 68: Technical Data - Shock Absorber
TECHNICAL DATA - SHOCK ABSORBER 18.1 Shock absorber part number 03.18.7E.03 Shock absorber WP Suspension 3614 BAVP Compression damping Comfort 10 clicks Standard 9 clicks Sport 3 clicks Rebound damping Comfort 10 clicks Standard 9 clicks Sport 6 clicks Spring preload Comfort 7 mm (0.28 in) Standard... -
Page 69: Technical Data - Chassis Tightening Torques
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Spoke nipple M3.5 3 Nm (2.2 lbf ft) – Remaining nuts, chassis 15 Nm (11.1 lbf ft) – Remaining screws, chassis 10 Nm (7.4 lbf ft) – Screw, ball joint, push rod on foot- 10 Nm (7.4 lbf ft) brake cylinder ®... -
Page 70: Substances
– Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®... - Page 71 SUBSTANCES Shock absorber oil (SAE 2.5) (50180342S1) According to – SAE ( p. 72) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Super unleaded gasoline, mixed with 2-stroke engine oil According to –...
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Page 72: Auxiliary Substances
AUXILIARY SUBSTANCES Air filter cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Chain cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Cleaning and polishing materials for metal, rubber and plastic Specification –... - Page 73 AUXILIARY SUBSTANCES Oil for foam air filter Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Liquid Bio Power Universal oil spray Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Joker 440 Universal...
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Page 74: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation. -
Page 75: Index
INDEX INDEX Engine Air filter running in ....... . 14 cleaning . - Page 76 INDEX Steering head bearing greasing ....... . . 29 Main silencer Steering head bearing play glass fiber yarn filling, installing .
- Page 77 *3211345en* 3211345en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...