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

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OWNER'S MANUAL
2007
65 SX
ART. NR. 3.211.142 EN

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  • Page 1 OWNER’S MANUAL 2007 65 SX ART. NR. 3.211.142 EN...
  • Page 2 KTM may stop manufactur- ing certain models without previous notice. KTM shall not be held liable for any deviations of availabil- ity and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models.

  • Page 3: Important Information

    IMPORTANT INFORMATION INTENDED PURPOSE 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 4: Warranty

    SPARE PARTS, ACCESSORIES For the safety of your child, only use spare parts and accessories approved by KTM. KTM shall not assume any liability for other products or consequential damage resulting from the use of such products.

  • 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

    GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE ......10 Instructions for the first ride .

  • Page 7: Serial Number Locations

    SERIAL NUMBER LOCATIONS OPERATION INSTRUMENTS » 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 2,3,4,5,6 » 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: General Tips And Warnings For Starting The Motorcycle

    GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for the first ride – Make sure the work for the „pre-delivery inspection“ was per- formed by your authorized KTM workshop. The DELIVERY CER- TIFICATE and SERVICE MANUAL will be handed over when you 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

    Always pro- vide adequate ventilation while the engine is running. Do not ride your motorcycle at full load and do not rev up the engine when cold. since the piston warms up and expands faster than the water cooled cylinder, this might cause engine damage.

  • Page 14: Braking

    – In the event that, while your child is riding on the motorcycle, you notice any unusual operation-related noise, your child should stop immediately, turn the engine off, and contact an authorized KTM dealer.

  • Page 15: Periodic Maintenance Schedule

    PERIODIC MAINTENANCE SCHEDULE A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! 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...
  • Page 16 Maintenance work performed by your authorized KTM workshop is not a substitute for care and maintenance 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 17: Maintenance Work On Chassis And Engine

    OFF position - if the motorcycle should fall over, 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

    EXAMPLE: Motorcycle jacked up (dimension A) ..... .430 mm Motorcycle on ground with driver seated (dimension B) ..– 340 mm Sag .

  • Page 20: Checking Chain Tension

    – 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 behavior 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 5 mm min. 1 mm 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

    1 mm 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

    – 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 behavior of your motorcycle.

  • Page 26: Removing And Installing The Rear Wheel

    – 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 behavior of your motorcycle.

  • Page 27: Removing The Seat

    [5] from the filter box. – Do not clean foam filter with fuel or petroleum since these damage the foam. KTM recommends the products of the company Motorex for air fil- ter 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 running. 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 10 mm when engine is cold 3-5 mm 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: Part/Full Throttle Range

    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

    Park the motorcycle straight on a horizontal surface and check the oil level. The oil level must not drop below the „MIN“ mark of the inspection glass. Note: If the motorcycle is not parked properly for the oil level inspection it will not be possible to achieve a reliable result.

  • 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 Engine has not enough power Engine revs not up and running in four stroke cycle High rpm misfiring Engine spluters into the carburetor Engine overheating Emission of white smoke (steam) Excessive oil escapes from transmission breather tube Water in transmission oil »...

  • Page 34: Cleaning

    – After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Then take a short drive until the engine has reached its operating temperature, and also operate the brakes. The heat also causes the water at the inac- cessible parts of the engine and the brakes to evaporate.

  • 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) 3614 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 Collar nut – flywheel HH screw – cylinder head Collar nut – cylinder base Hexagon screw – inner clutch hub Screw – clutch Oil drain screw Screws – clutch cover Kickstarter stop plate Screws –...

  • Page 38: Index

    Fuel tap ........7 Page ..20 General information about KTM disc brakes ..20 General tips and warnings for starting the motorcycle . . .10 ..18 Hand brake lever .
  • Page 42 KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at...

This manual is also suitable for:

65 sx 2007

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