KTM 65 SX 2003 Owner's Manual
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KTM 65 SX 2003 Owner's Manual

KTM 65 SX 2003 Owner's Manual

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Summary of Contents for KTM 65 SX 2003

  • Page 2 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 3 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. For the safety of your child, only use spare parts and accessories approved by KTM.
  • Page 4 The service work specified in the "Lubrication and Maintenance Schedule" must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void. The fuels and lubricants specified in the Owner's Manual or automotive fluids with equivalent specifications must be used in accordance with the mainten- ance schedule.

  • 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 maximum weight of.

  • Page 6: Table Of Contents

    OPERATION INSTRUMENTS ..... .6 General information about KTM disc brakes ..20 Clutch lever ....... .6 Adjusting of free travel at the hand brake lever .

  • 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: 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. Fuel tap The fuel tap is located on the left side of the tank. Opening the fuel tap: Turn the knob all the way to the left.

  • Page 9: Kickstarter

    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). Compression damping of shock absorber The degree of damping of the compression can be adjusted with the knob Turn the knob counterclockwise to increase damping, turn it clockwise to...

  • Page 11: General Tips And Warnings For Starting The Motorcycle

    GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE WARNING Instructions for the first ride – H AVE YOUR YOUNGSTER WEAR PROPER PROTECTIVE GEAR WHENEVER – Verify that your KTM dealer performed the PREPARATION HE OR SHE RIDES THE MOTORCYCLE HELMET EYE PROTECTION CHEST OF VEHICLE jobs (see Customer Service Manual).

  • 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 Engine Is Cold

    Starting when the engine is cold 1 Open fuel tap 2 Put the gear in neutral 3 Activate the cold-starting aid (choke) 4 Leave throttle closed and kick down the kickstarter vigorously all the way. WARNING – T O AVOID INJURY WHEN STARTING THE ENGINE ALWAYS WEAR STRONG BIKERS BOOTS OU MAY SLIP OFF THE KICKSTARTER...

  • Page 14: Braking

    Refueling, fuel CAUTION Oil (high-grade two-stroke engine oil; i.e. Shell Advance Racing X) – D RIVING A COLD ENGINE AT HIGH SPEED WILL REDUCE THE LIFE OF THE must be mixed with the fuel (ROZ 95) at a mixing ratio of 1:40. ENGINE E RECOMMEND TO WARM THE ENGINE UP AT A MEDIUM WARNING...

  • Page 15: Periodic Maintenance Schedule

    PERIODIC MAINTENANCE SCHEDULE 65 SX Service every once a year A clean 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 a tight fit at intake flange Check the intake flange and carburetor connection boot for cracks and tightness Check idle setting when engine is warm...
  • 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 as of 03.2002 65 SX ECOMMENDED INSPECTION OF THE ENGINE BY YOUR WORKSHOP KTM’ ADDITIONAL ORDER FOR THE S WORKSHOP hours hours hours hours...

  • Page 17: Maintenance Work On Chassis And Engine

    ALL MAINTENANCE AND ADJUSTMENT OPERATIONS THAT ARE MARKED WITH AN ASTERISK * REQUIRE SPECIALIST KNOWLEDGE. FOR YOUR OWN SECURITY, LET THESE TASKS BE CARRIED OUT BY A KTM-DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED, SKILLED STAFF.

  • Page 18: Basic Suspension Setup For The Weight Of The Driver

    At delivery, KTM's 65 SX motorcycles are set to accommodate a driver weighing 35 – 45 kg (wearing full protective clothing). If your child's weight exceeds or falls short of this range, you will need to adjust the spring preload for the teles- copic fork and shock absorber accordingly.

  • Page 19: Breather Plug Front Fork

    Breather plug front fork The telescopic fork should be ventilated at regular intervals. Jack up the motorcycle until the front wheel no longer touches the ground. Unscrew vent screws several turns to let any excess pressure escape from the inside of the fork. CAUTION XCESSIVE PRESSURE IN THE INTERIOR OF THE FORK CAN CAUSE LEAKS IN THE FORK YOUR FORK IS LEAKING...

  • Page 20: Changing The Spring Preloading Of The Shock Absorber

    Changing spring preloading of the shock absorber This is easily done. NOTE: Before changing the spring preload note down the basic setting, e.g. how many threads are visible above the adjusting ring. Loosen the locking ring with the hook spanner. Change the spring preload with the adjusting ring and re-tighten the locking ring BASIC SETTING –...

  • 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 ”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 22: Checking Of Brake Fluid Level - Front Brake

    Checking brake fluid level - front brake The brake fluid reservoir is combined with the hand brake cylinder on the handlebar and provided with an inspection glass. When the brake fluid reservoir is in a horizontal position, the brake fluid level should not drop below the "MIN"...

  • Page 23: Replacing The Front Brake Pads

    Replacing the front brake pades* 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 from the screw as well as fixing screw take the brake shoes out of the brake caliper.

  • Page 24: Check The Rear Brake Fluid Level

    Check rear brake fluid level The reservoir for the rear disc brake is located above the carburator. The level of brake fluid may not fall below the “MIN” mark when the vehicle has been left standing upright WARNING F THE BRAKE FLUID LEVEL DROPS BELOW MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN N THIS CASE CONSULT AN...

  • Page 25: Removing And Installing The Front Wheel

    Insert the new brake pads into the brake caliper, position the leaf spring , and secure it with the bolt . By tapping on the bolt, drive it into the brake caliper up to the stop. Reattach locking ring and cover WARNING –...

  • Page 26: Removing And Installing The Rear Wheel

    (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.

  • Page 27: Removing The Seat

    , swing back and remove air filter plus filter carrier 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 FILTER MAINTENANCE Thoroughly wash the foam filter in special cleaning fluid and allow to dry well.

  • Page 28: Exhaust System

    Make sure that the oil does not overflow. The bleeder syringe can be purchased from your KTM dealer.Having completed the bleeding procedure, you have to verify that the oil level in the master cylinder is correct.If necessary, fill up with biodegradable hydraulic oil SAE 10 (e.g.

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

    Changing the original position of the clutch lever The adjusting screw 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. Turning the adjusting screw clockwise reduces the distance between the clutch lever and the handlebar.

  • Page 30: 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 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 1:40 .

  • Page 31: Draining The Float Chamber Of The Carburetor

    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 CAUSE REMEDY Engine has not enough Reed paddles tensionless or damaged, Replace reed paddles or reed valve housing power surface of reed valve housing damaged Wear Overhaul engine Engine revs not up and Carburetor overflows if level adjust Clean carburetor, if necessary replace float needle and adjust running in four stroke too high, float needle seating is level...

  • 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. CAUTION EVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH...

  • Page 35: Technical Data - Chassis

    TECHNICAL SPECIFICATIONS – CHASSIS 65 SX 2003 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 (White Power) Front brake Disc brake Ø 200 mm (7.9 in), 1 piston Rear brake Disc brake Ø...

  • Page 36: Technical Data - Engine

    TECHNICAL SPECIFICATIONS - ENGINE 65 SX 2003 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) 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 (e.g.
  • Page 37 TIGHTENING TORQUES - ENGINE Hexagon nut – primary gear M 10 60 Nm/44 ft.lb Collar nut – flywheel M 10x1,25 40 Nm/30 ft.lb HH screw – cylinder head 15 Nm/11 ft.lb Collar nut – cylinder base 25 Nm/19 ft.lb Hexagon screw – inner clutch hub M 10 Loctite 243 + 60 Nm/44 ft.lb Screw –...

  • Page 38: Index

    Page Page Adjusting of free travel at the hand brake lever....20 General information about KTM disc brakes.......20 Adjusting the throttle cable ..........28 General tips and warnings for starting the motorcYcle ..10 Basic suspension setup for the weight of the driver ....17 Hand brake lever ..............6...

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