KTM Motorcycle 65 SX User Manual
OWNER’S MANUAL 2007  
65 SX  
ART. NR. 3.211.142 EN  
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INTRODUCTION »  
Now you own a modern motorcycle that you and your youngster will certainly enjoy, provided that you serv-  
ice and maintain it properly.  
Please insert the serial numbers of the motorcycle below  
Chassis number  
Engine number  
1
Stamp of dealer  
All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right  
to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work,  
constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the  
above items, all without previous announcement and without giving reasons. 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.  
© 2006 by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in  
extracts, with written allowance of KTM-SPORTMOTORCYCLE AG, Mattighofen only.  
In accordance with the international quality management ISO 9001 standard, KTM uses  
quality assurance processes that lead to the highest possible product quality.  
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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.  
OWNER’S MANUAL  
Please read this manual thoroughly before letting your youngster ride the motorcycle for the first time.  
This manual contains important information and recommendations that will help you and your youngster  
to operate and handle the motorcycle properly. In the interest of everybody involved, we urge you to pay  
particular attention to instructions and information marked as follows:  
– Ignoring these instructions can be dangerous to life and limb!  
2
– Ignoring these instructions may damage parts of the motorcycle or impair the motorcycle's  
traffic safety!  
This manual contains important information on the operation and maintenance of your new KTM motor-  
cycle. It went to press describing your model’s latest state of development. Nevertheless, the descriptions  
may deviate slightly from the current design as our motorcycles are permanently improved.The Owner's  
Manual is an integral part of the motorcycle and must be handed over to the new owner when the motor-  
cycle is sold.  
SERVICE  
Observance of the service, maintenance and tuning instructions for the engine and chassis specified in  
the Owner's Manual is a prerequisite for faultless operation and the avoidance of premature wear. An  
improperly tuned chassis can lead to damage and breakage of the chassis components (see chapter on  
checking the basic chassis setting).  
The use of the motorcycle under extreme conditions, e.g. on extremely muddy and wet terrain, can lead  
to higher than average wear on components such as the drive train or the brakes. In this case it may  
become necessary to service or replace wear parts before the service limit specified in the maintenance  
schedule has been reached.  
We expressly point out that work marked with an asterisk (*) in the chapter "Maintenance work on the  
chassis and engine" must be performed by a KTM workshop. If maintenance work should become neces-  
sary during a competition, it must be performed by a trained mechanic.  
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.  
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IMPORTANT INFORMATION »  
WARRANTY  
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.  
No claims can be filed under the warranty for damage or consequential damage caused by manipulations  
or conversions to the motorcycle.  
AUTOMOTIVE FLUIDS  
The fuels and lubricants specified in the Owner's Manual or automotive fluids with equivalent specifica-  
tions must be used in accordance with the maintenance schedule.  
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.  
When special needs arise, please contact a KTM dealer, who will seek the assistance of the KTM importer  
if necessary.  
SAFETY  
3
Parents should keep in mind that the safety of their youngsters always depends on the efforts made by  
the parents to ensure that the motorcycle is kept in good working order and only used on safe terrains.  
Nevertheless, driving the motorcycle, like driving any other vehicle, involves a potential risk. Therefore,  
please make sure that all fundamental precautions are taken. Please also read the „INFORMATION ON  
SAFE DRIVING FOR PARENTS“ on page 4.  
TRANSPORT  
When transporting your motorcycle, secure it with elastic straps or other mechanical devices in an upright  
position. Be sure that the fuel tap is closed. If the motorcycle topples over, fuel can flow out of the car-  
buretor or fuel tank.  
ENVIRONMENT  
Riding an off-highway motorcycle is a wonderful form of outdoor recreation and we certainly hope that  
you and your youngsters will enjoy it to the full. However, this enjoyable outdoor activity can cause envi-  
ronmental problems or lead to conflicts with other people. Responsible use of the motorcycle will prevent  
such problems and conflicts. You can contribute to securing the future of motorcycling by making sure  
that you and your youngsters only use the motorcycle within the limits established by the applicable laws,  
making environmental protection one of your top priorities and never violating other people’s rights.  
In this spirit, we hope that you and your youngsters will always safely enjoy your motorcycle!  
KTM-SPORTMOTORCYCLE AG  
5230 MATTIGHOFEN, AUSTRIA  
Attachments: 1 spare parts manual chassis & engine  
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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. 50 kg (22.65 lb) and a maximum height of 160 cm (63.04 in).  
4
– Have your youngster wear proper protective gear whenever he or she rides the motorcycle: helmet, eye  
protection, chest, back, arm and leg protectors, gloves and boots. To set a good example, be sure to  
wear protective gear yourself whenever riding a motorcycle!  
– Adjust the clutch lever and hand brake lever to match your child's hand size (with gloves).  
– Adjust the basic setting of the foot brake pedal to your child's seating position.  
– Before your youngster takes his or her first ride, explain how each of the controls works and check if  
your youngster has understood what you explained. We recommend to review the entire owner’s man-  
ual with your youngster item by item, paying particular attention to the specially marked warnings and  
pointing out the danger of injury.  
– Instruct your youngster about riding and falling techniques, explain how the motorcycle will respond  
to shifting of the rider’s weight, etc.  
– Before starting the motorcycle for the first time check whether the basic fork and shock absorber set-  
tings are suitable for your child's weight (see chapter on checking the basic chassis setting).  
– Before using the motorcycle you should always check all components for proper operation  
(see maintenance schedule). Have your youngster perform these technical checks himself / herself  
as well.  
– Whenever you go for a ride with your youngster, keep in mind that the speed should be adjusted to  
your youngster and not the other way around.  
– Your youngster must understand that all instructions he or she receives from you or any other super-  
vising adult must be followed.  
– Your child must be physically ready to ride a motorcycle. This means that he or she must at least be  
able to ride a bicycle. Being good at sports that require fast reactions is an additional advantage. Your  
youngster should be strong enough to pick up the motorcycle after a fall.  
– Never demand too much of your youngster. Give him or her time to get used to the motorcycle and to  
improve his / her riding skills. Do not even consider letting your youngster participate in a race before  
his / her physical condition, riding skills and motivation have sufficiently developed.  
– Explain to your youngster that he / she should always adjust his / her riding speed to the local condi-  
tions as well as to his / her own riding skills and that excessive speed can cause falls and severe injuries.  
Always keep in mind that youngsters tend to underestimate dangers or fail to recognize them alto-  
gether. The riding speed must be reduced, in particular, on unknown terrain.  
– Never let your youngster ride the motorcycle without supervision. An adult should always be present.  
– The motorcycle is designed for one rider only. Your youngster is not allowed to transport a passenger.  
– When you go for a ride, somebody at home should always know where you are going and when you will  
be back. This makes it easier to send you help, should problems occur.  
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TABLE OF CONTENTS »  
Page  
Page  
Checking chain tension . . . . . . . . . . . . . . . . . . . . . .19  
Correcting chain tension . . . . . . . . . . . . . . . . . . . . .19  
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . .19  
General information about KTM disc brakes . . . . . . .20  
Adjusting the free travel at the hand brake lever . . . .20  
Checking/refilling the front brake fluid level . . . . . . . .21  
Checking front brake pads . . . . . . . . . . . . . . . . . . . .21  
Replacing the front brake pads . . . . . . . . . . . . . . . . .22  
Changing basic position of the brake pedal . . . . . . . . .22  
Checking the rear brake fluid level . . . . . . . . . . . . . .23  
Refilling the rear brake fluid reservoir . . . . . . . . . . . .23  
Checking rear brake pads . . . . . . . . . . . . . . . . . . . . .23  
Replacing the rear brake pads . . . . . . . . . . . . . . . . .24  
Removing and installing front wheel . . . . . . . . . . . . .24  
Removing and installing the rear wheel . . . . . . . . . . .25  
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . .25  
Checking spoke tension . . . . . . . . . . . . . . . . . . . . . .25  
Removing the seat . . . . . . . . . . . . . . . . . . . . . . . . .26  
Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . .26  
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . .27  
Checking the oil level of the hydraulic clutch . . . . . .27  
Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . .27  
Changing the original position of the clutch lever . . . .28  
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . .28  
Checking coolant level . . . . . . . . . . . . . . . . . . . . . . .28  
Adjusting the throttle cable . . . . . . . . . . . . . . . . . . . .28  
Carburetor adjustment . . . . . . . . . . . . . . . . . . . . . . .29  
Draining the float chamber of the carburetor . . . . . . .30  
Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . .30  
Changing gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . .30  
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . .6  
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . .6  
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
Short circuit button . . . . . . . . . . . . . . . . . . . . . . . . . .7  
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7  
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7  
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7  
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7  
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8  
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . .8  
Compression damping of shock absorber . . . . . . . . . . .8  
Rebound damping function of the shock absorber . . . .8  
Plugin-Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8  
5
GENERAL TIPS AND WARNINGS FOR STARTING  
THE MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . .10  
Instructions for the first ride . . . . . . . . . . . . . . . . . .10  
Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10  
DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .11  
What you should check before each start . . . . . . . . .11  
Starting when the engine is cold . . . . . . . . . . . . . . .12  
Starting when the engine is warm . . . . . . . . . . . . . . .12  
What to do when the engine is „flooded“ . . . . . . . . .12  
Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12  
Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . .12  
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
Refueling, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . .14  
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . .31  
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33  
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33  
USE AFTER PERIOD OF STORAGE . . . . . . . . . . . . . . . .33  
TECHNICAL SPECIFICATIONS – CHASSIS . . . . . . . . . . .34  
TECHNICAL SPECIFICATIONS – ENGINE . . . . . . . . . . . .35  
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37  
MAINTENANCE WORK ON CHASSIS AND ENGINE . . . .16  
Checking and adjusting the steering head bearing . . .16  
Breather plug front fork . . . . . . . . . . . . . . . . . . . . . .16  
Cleaning the dust sleeves of the telescopic fork . . . . .17  
How to change the handlebar position . . . . . . . . . . .17  
Changing spring preloading of the shock absorber . . .17  
Basic suspension setup for the weight of the driver . .18  
To determine the sag of the shock absorber . . . . . . . .18  
To determine the sag of the telescopic fork . . . . . . . .18  
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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. Enter this number in the field on page no 1.  
6
OPERATION INSTRUMENTS »  
Clutch lever  
1
The clutch lever [1] is located on the left side of the handlebar. The adjust-  
ing screw [A] is used to change the original position of the clutch lever (see  
maintenance work on chassis and engine).  
The clutch is hydraulically actuated and adjusts itself automatically.  
A
Hand brake lever  
2
The hand brake lever [2] is mounted on the handle bars on the right and actu-  
ates the front wheel brake. The adjusting screw [B] can be used to change  
the basic position of the hand brake lever (see maintenance work on chassis  
and engine).  
B
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OPERATION INSTRUMENTS »  
Short circuit button  
The short circuit button [1] turns off the engine. When pressing this button,  
the ignition circuit is short-circuited.  
1
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.  
2
7
Fuel tap  
The fuel tap [3] is located on the left side of the tank.  
Opening the fuel tap: Turn the knob all the way to the left.  
Closing the fuel tap: Turn the knob all the way to the right.  
3
Choke  
The choke button [4] is located on the left side of the carburetor. Pulling the  
choke button all the way out opens a bore in the carburetor through which  
the engine can take in additional fuel, thus achieving the „rich“ fuel air mix-  
ture needed for cold starting.  
4
Pushing the choke button back in closes the bore in the carburetor.  
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 between  
first and second gear.  
2,3,4,5,6  
N
1
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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).  
8
Compression damping of shock absorber  
The degree of damping of the compression can be adjusted with the knob [1].  
Turning in a clockwise direction will increase the damping, turning in a coun-  
terclockwise direction will decrease the damping.  
1
STANDARD ADJUSTMENT:  
Turn the knob all the way to the stop in a clockwise direction.  
Turn the knob 2 clicks in a counterclockwise direction (= position 3).  
Rebound damping function of the shock absorber  
The damping effect of the rebound damping mechanism can be adjusted by  
levels by means of the setting wheel [2]. Turn the setting wheel clockwise (in)  
to increase and counterclockwise (out) to reduce the damping effect.  
2
STANDARD ADJUSTMENT:  
Position 6 at the mark [A]  
A
Plugin-stand  
A socket is provided on the left side of the frame into which you can plug the  
stand [3].  
3
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9
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GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE »  
Instructions for the first ride  
– Make sure the work for the „pre-delivery inspection“ was per-  
– Have your youngster wear proper protective gear whenever he  
or she rides the motorcycle: helmet, eye protection, chest,  
back, arm and leg protectors, gloves and boots. To set a good  
example, be sure to wear protective gear yourself whenever rid-  
ing a motorcycle!  
– Only use accessory parts recommended by KTM.  
– The front and rear wheel are only allowed to be tired with tires  
that have the same profile type.  
– Your youngster's driving speed should always be adjusted to his/her  
driving skills as well as to the terrain.  
– Your youngster should never be allowed to ride the motorcycle  
without supervision.  
– Replace the helmet visor or goggle glasses early enough. When  
light shines directly on a scratched visor or goggles, you will  
be practically blind.  
– Never leave your motorcycle without supervision as long as the  
engine is running.  
– SX models are designed for one person only. Passengers are  
not allowed.  
– These models do not comply with the regulations and safety  
standards established by the law. Therefore, they are not per-  
mitted on public roads.  
formed by your authorized KTM workshop. The DELIVERY CER-  
TIFICATE and SERVICE MANUAL will be handed over when you  
pick up your vehicle.  
– Before your youngster takes his or her first ride, explain how  
each of the controls works and check if your youngster has under-  
stood what you explained. We recommend to review the entire  
owner’s manual with your youngster item by item, paying par-  
ticular attention to the specially marked warnings and point-  
ing out the danger of injury.  
– Adjust the clutch lever, hand lever and foot brake pedal so your  
child can operate them easily!  
– To prevent injury, teach your youngster the basic riding skills  
on soft ground, e.g. on a meadow or in the garden. Be sure that  
there is room enough to maneuver, and that no other riders are  
close.  
– To ensure that your youngster gets the feel of the hand brake,  
have your youngster operate the hand brake while you push the  
motorcycle. Do not start the engine before your youngster has  
learned to apply hand brake with appropriate pressure.  
– To familiarize your youngster with the operation of the hand  
brake let him or her practice to operate the hand brake while  
you are pushing the motorcycle. Do not start the engine before  
he or she is thoroughly familiar with the use of the hand brake.  
– Initially, your youngster should ride back and forth between two  
persons who help the young rider to stop the motorcycle.  
However, you should also teach your youngster how to stop the  
motorcycle himself/herself.  
10  
– Always keep in mind that other people feel molested by exces-  
sive noise.  
– To improve his/her riding skills, your youngster should practise  
riding the motorcycle standing on the footpegs or to riding at  
the slowest possible speed. Additionally, you can arrange a series  
of obstacles and have your youngster drive around them, etc.  
– Pay attention to the running-in procedure.  
Running in  
– Even very precisely machined sections of engine components  
have rougher surfaces than components which have been slid-  
ing across one another for quite some time. Therefore, every  
engine needs to be broken in. For this reason, during its first  
30 minutes the engine must not be revved up to its perform-  
ance limits.  
– Apply low but changing loads for running-in.  
Do not drive at full load for the first 30 minutes!  
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DRIVING INSTRUCTIONS »  
What you should check before each start  
When you start off, the motorcycle must be in a perfect technical condition.  
For safety reasons, you should make it a habit to perform an overall check of  
your motorcycle before each start.  
The following checks should be performed:  
1
2
3
CHECK TRANSMISSION OIL LEVEL.  
A lack of gear oil leads to premature wear and finally results in destruc-  
tion of the gear wheels.  
FUEL  
Check that there is sufficient fuel in the tank; when closing the filler cap,  
check that the tank venting hose is free of kinks.  
11  
CHAIN  
A loose chain was fall off the chain wheels; an extremely worn chain may  
tear, and insufficient lubrication may result in unnecessary wear of the  
chain and chain wheels.  
4
5
TIRES  
Check for damaged tires. Tires showing cuts or dents must be replaced.  
Also check the air pressure. Insufficient tread and incorrect air pressure  
deteriorate the driving performance.  
BRAKES  
Check the correct functioning of the braking system. Verify that there is  
sufficient brake fluid in the reservoir. The reservoirs have been designed  
in such a way that brake fluid does not need to be refilled even when the  
brake pads are worn. 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.  
Also check the state of the brake hose and the thickness of the brake  
linings.  
Check free travel at the hand brake lever and foot brake lever.  
If the resistance in the hand brake lever feels „spongy“ (too much play), this  
is an indication that something is wrong with the brake system. Don’t let your  
child ride the motorcycle anymore without first having the brake system looked  
over by a KTM dealer.  
6
CABLES  
Check correct setting and easy running of all control cables.  
7
COOLING FLUID  
Check the level of cooling fluid when the engine is cold.  
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DRIVING INSTRUCTIONS »  
Starting when the engine is cold  
1
2
3
4
Open fuel tap [1].  
Put the gear in neutral  
Activate the cold-starting aid (choke) [2].  
Leave throttle closed and kick down the kickstarter vigorously all the way.  
– To avoid injury when starting the engine, always wear strong bikers boots!You  
may slip off the kickstarter, or the engine may kick back if you do not kick  
hart enough.  
– Do not start the engine and allow it to idle in a closed area. Exhaust fumes  
are poisonous and can cause loss of consciousness and death. Always pro-  
vide adequate ventilation while the engine is running.  
1
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. always let engine idle until warm  
or drive it warm at low r.p.m. speeds.  
2
NOTE: If you have trouble starting the motorcycle, this could be due to old  
fuel in the float chamber.The easily inflammable components of the  
new fuels evaporate during longer periods of standstill.When the  
motorcycle has been out of operation for more than a week, it is there-  
fore recommended to drain the old fuel from the float chamber. The  
engine will immediately start off when the float chamber is filled with  
new fuel.  
12  
Starting when the engine is warm  
1
2
3
Open fuel tap  
Put the gear in neutral  
Leave throttle closed and kick down kickstarter vigorously all the way.  
What to do when the engine is „flooded“  
1
2
3
Close fuel tap  
Start engine with full throttle. If necessary, unscrew spark plug and dry it.  
Once the engine is running, open fuel tap again.  
Starting off  
Pull the clutch lever. Put the engine into first gear, slowly release the clutch  
lever and accelerate at the same time.  
Always remove the plug-in [3] stand before your child rides the motorcycle.  
Shifting/Riding  
3
You are now in first gear, referred to as the drive or uphill gear. Depending on  
the conditions (traffic, hill size, etc.), you can shift to a higher gear. Turn down  
the throttle, at the same time pull clutch lever in and shift to the next higher  
gear. Let clutch lever go again and open the throttle. If you turned on the  
choke, make sure you turn it off again as soon as engine is warm.  
When shifting down, use the brakes if necessary and turn down at the same  
time. Pull clutch lever and shift down to the next lower gear. Let the clutch  
lever go slowly and open throttle or shift down again.  
– After falling with the motorcycle, check all its functions thoroughly before  
using it again.  
– A twisted handlebar must always be replaced. Do not adjust the handle-  
bar, it will lose stability.  
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DRIVING INSTRUCTIONS »  
– Driving a cold engine at high speed will reduce the life of the  
engine. We recommend to warm the engine up at a medium  
engine speed for several minutes before switching to full load.  
– Never have the throttle wide open when changing down to a  
lower gear. The engine will overrev, damaging the valves. In addi-  
tion, the rear wheel blocks so that the motorcycle can easily  
get out of control.  
– Close the fuel tap when leaving your vehicle. Otherwise the car-  
buretor may get flooded and fuel will enter the engine.  
– The Plugin- Stand is only designed for the weight of the motor-  
cycle. If you get on your motor-cycle and thus put additional  
weight on the motorcycle, the Plugin- Stand or the frame can  
be damaged or the motorcycle may fall on the side.  
– If the engine runs without throttle during longer downhill travel, Refueling, fuel  
the engine should be accelerated occasionally to ensure that  
it is supplied with sufficient lubricant which is mixed in the  
fuel.  
– 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.  
Unleaded premium gasoline RON 95 mixed with high grade two  
stroke oil. Mixture ratio 1:60. Fuel and engine oil should only be  
mixed immediately before use.  
13  
KTM recommends Motorex Cross Power 2T.  
Gasoline is highly flammable and poisonous. Extreme caution  
should be used when handling gasoline. Never refuel the motor-  
cycle near open flames or burning cigarettes. Always switch off the  
Braking  
Turn off the gas and apply the hand and foot brakes at the same engine before refueling. Be careful not to spill gasoline on the engine  
time. When driving on sandy, wet or slippery ground use mainly or exhaust pipe while the engine is hot. Wipe up spills promptly.  
the rear wheel brake. Always brake with feeling, blocking wheels If gasoline is swallowed or splashed in the eyes, seek a doctor’s  
can cause you to skid or fall. Also change down to lower gears depend- advice immediately.  
ing on your speed.  
– Only use premium-grade gasoline ROZ 95 (USA = Premium RON  
91) mixed with high-grade two-stroke engine oil. Other types  
of gasoline can cause engine failure.  
– Only use known brands of high-grade 2-stroke engine oil (Motorex  
Cross Power 2T).  
– In case of rain, after washing the motorcycle, after rides through  
water and in case of rides on wet off-road tracks, humid or dirty  
brake discs can delay the braking effect. The brakes must be  
pulled until they are dry or clean.  
– Dirty brake discs cause increased tear of brake pads and brake  
discs.  
– When you brake, the brake discs, brake pads, brake caliper and  
brake fluid heat up. The hotter these parts get, the weaker the  
breaking effect. In extreme cases, the entire braking system  
can fail.  
– If the resistance in the hand brake lever or foot brake pedal  
feels „spongy“ (too much give), this is an indication that some-  
thing is wrong with the brake system. Don’t ride your motorcy-  
cle anymore without first having the brake system looked over  
by a KTM dealer.  
– Do not use premixed two-stroke oils, oils for outboard engines  
or normal engine oil to prepare the mixture.  
– Not enough oil or low-grade oil can cause erosion of the pis-  
ton. when Using too much oil, the engine may start smoking  
and foul the spark plug.  
– Fuel expands when its temperature rises. Therefore do not fill  
the tank to the top. (see fig.)  
Stopping  
Brake motorcycle and shift gears to idling. To switch off the engine,  
depress short circuit switch until the engine stops. Close fuel tap.  
40 mm  
Motorcycle engines produce a great amount of heat while  
running. The engine, exhaust pipe, muffler, brake rotors, and shock  
absorbers can become very hot. Do not touch any of these parts  
after starting the motorcycle, and take care to park it where pedes-  
trians are not likely to touch it and get burned.  
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PERIODIC MAINTENANCE SCHEDULE »  
Service  
every  
20 hours  
Before  
every  
race  
65 SX  
2007  
once  
a year  
A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY!  
Check transmission oil level  
z
Change transmission oil  
z
z
z
z
z
z
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  
Check the bleeder hose for damage, kinkless installation and passage  
Check cooling system for leaks, antifreeze protection  
Check exhaust system for leaks and suspension  
z
z
z
z
z
Check actuating cables for damage, smooth operation, and kinkless  
arrangement, and adjust and lubricate  
Check oil level of the clutch master cylinder  
Clean air filter and air filter box  
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
Check brake fluid level, lining thickness, brake discs  
Check brake lines for damage and leaks  
Check the hand and foot brake lever for smooth functioning and free travel and the brakes for proper functioning  
Check screws of brake system for a tight fit  
Check suspension strut and fork for leaks and a proper function  
Check dust bellows  
z
z
14  
z
z
Bleed fork legs  
Check swinging-fork pivot  
z
z
z
Check/adjust steering-head bearing  
Check all chassis screws for a tight fit (fork plates, axle nuts,  
swinging-fork pivot, suspension strut)  
z
z
z
z
z
Check spoke tension and rim joint  
z
z
z
z
z
Check tire condition and inflation pressure  
Check chain, chain wheels, chain wheel, chain joint guides for wear, tight fit, and tension  
Lubricate chain  
Check wheel bearings for play  
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PERIODIC MAINTENANCE SCHEDULE »  
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC  
before  
each  
start  
after  
for cross once  
every  
country  
a
cleaning use  
year  
Check transmission oil level  
z
z
z
z
z
Check coolant level  
Check brake fluid level  
Check brake pads for wear  
Check brake performance  
z
z
Lubricate and adjust actuating gas cable and nipples  
Remove and clean dust sleeves of telescopic fork at regular intervals  
Bleed fork legs regularly  
z
z
z
Clean and lubricate chain, check tension and readjust it if necessary  
Clean air filter and filter box  
z
z
Check tire inflation pressure and wear  
Check fuel line for leaks  
z
z
Drain and clean float chamber  
z
z
z
Verify smooth operation of all controls  
z
Treat exposed metal components (except for the brake and exhaust systems)  
with wax-based anti-corrosion agents  
15  
Treat all electric plug-in connections with contact spray  
z
Check all screws, nuts, and hose clamps for their tight fit at regular intervals  
ADDITIONAL SERVICE WORK TO BE PERFORMED UNDER A SEPARATE ORDER.  
every  
20 hours  
every  
40 hours  
once a  
year  
z
z
z
z
z
z
z
z
z
z
z
z
z
Check the reed-type intake valve for wear  
Check the clutch discs for wear  
Check the length of the clutch springs  
Check the cylinder and piston for wear  
Check the eccentricity of the crankshaft journal  
Check the radial clearance of the conrod bearings  
Check the radial clearance of the piston pin main bearing  
Check the crankshaft main bearing for wear  
Replace the crankshaft bearings and conrod bearings  
Check the entire transmission including roller and bearings for wear  
Perform complete fork maintenance  
z
z
z
z
z
z
z
z
z
Perform complete suspension strut maintenance  
Clean and lubricate the swinging-arm bearing  
Clean and lubricate the steering-head bearing and sealing elements  
Clean and adjust carburator  
Change hydraulic clutch fluid  
Change brake fluid  
NOTE: If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced.  
The kilometer reading for inspection intervals should not exceed 5 hours.  
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.  
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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.  
– When cleaning the motorcycle, do not use a high pressure cleaning unit if possible, otherwise water will penetrate the bearings,  
carburetor, electric connectors, etc.  
– When transporting your KTM, ensure that it is held upright with restraining straps or other mechanical fastening devices and that  
the fuel tap is in the 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.  
– Do not use toothed washers or spring rings with the engine fastening screws, as these work into the frame parts and keep working  
loose. Instead, use self-locking nuts.  
– Let your motorcycle cool down before beginning any maintenance work in order to avoid getting burned.  
– Dispose of Oils, fatty matters, filters, fuels, washing detergents, etc. properly.  
– Under no circumstances may used oil be disposed of in the sewage system or in the open countryside. 1 liter of used oil contam-  
inates 1,000,000 liters of water.  
16  
Checking and adjusting the steering head bearing *  
Check steering head bearing for play periodically. To check, put motorcycle  
on the stand so that the front wheel is off the ground. Now try to move the  
fork forward and backward. For readjusting, loosen the three clamp screws  
[1] of the top triple clamp and turn steering stem bolt clockwise [2] until there  
is no more play. Don’t tighten the steering stem bolt all the way, otherwise  
the bearings will be damaged. With a plastic hammer, lightly rap on the triple  
clamp to release tension. Retighten the three clamp screws to 25 Nm.  
2
If the steering head bearing is not adjusted to be free of play, the motorcycle  
will exhibit unsteady driving characteristics and can get out of control.  
1
1
1
If you drive with play in the steering head bearing for longer periods, the bear-  
ings and subsequently the bearing seats in the frame will be destroyed.  
The steering head bearings should be regreased at least once a year  
(i.e. Motorex Long Term 2000).  
Breather plug front fork  
The telescopic fork should be ventilated at regular intervals. Jack up the motor-  
cycle until the front wheel no longer touches the ground. Unscrew vent screws  
[3] several turns to let any excess pressure escape from the inside of the fork.  
Excessive pressure in the interior of the fork can cause leaks in the fork. If  
your fork is leaking, it is recommended to open the breather plugs before hav-  
ing the seals replaced.  
3
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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. If this dirt is not removed, the oil sealing rings located  
behind it may start to leak.  
Use a screwdriver to lift the dust-protection bellows out of the outer tubes  
and slide them downward.  
1
Clean the dust-protection bellows, outer tubes, and fork tubes thoroughly, and  
oil them thoroughly with Universal oil spray (Motorex Joker 440) or engine  
oil. Then, push the dust-protection bellows into the outer tubes by hand.  
No oil may reach the front tire or the brake disks since this would consider-  
ably reduce the tire's road grip and the braking effect of the front brake.  
17  
How to change the handlebar position  
The handlebar position can be readjusted by 22 mm. Thus, you can put the  
handlebar in the position that is the most convenient for you. The upper triple  
clamp [2] includes 2 bores arranged at a distance of 15 mm (0.6 in) from  
one another. The bores at the handlebar support [3] are offset from the cen-  
ter by 3.5 mm (0.13 in). Accordingly, you can mount the handlebar in 4 dif-  
ferent positions.  
For this purpose, remove screws [4] of the handlebar clamps and screws [5]  
of the handlebar support. Position handlebar support, and tighten screws [5]  
to 40 Nm. Mount handlebar and handlebar clamps, and tighten screws [4]  
to 20 Nm. The gap between the handlebar support and handlebar clamps  
should be the same size in the front and in the rear.  
4
5
The screws [5] must be secured with loctite 243.  
3
3,5 mm  
2
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 [6] with the hook spanner. Change the spring  
preload with the adjusting ring [7] and re-tighten the locking ring [6].  
6
BASIC SETTING – SPRING PRELOAD: 7 mm (0.28 in)  
The damping unit of the shock absorber is filled with high compressed nitro-  
gen. Never try to take the shock absorber apart or to do any maintenance work  
yourself. Severe injuries could be the result.  
7
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
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). If your child's weight exceeds or falls short of this  
range, you will need to adjust the spring preload for the telescopic fork and  
shock absorber accordingly.  
A
To adjust, check the sag of the shock absorber and telescopic fork. The motor-  
cycle should be filled up and your child should be wearing full protective  
clothing.  
To determine the sag of the shock absorber  
– Jack up the motorcycle until the rear wheel no longer touches the ground.  
– Measure the vertical distance between the rear wheel axle and a fixed point  
(e.g. a mark on the side cover) and write it down as dimension A.  
– Place the motorcycle on the ground again.  
– Have your child sit on the motorcycle in a normal seating position (feet  
on the footrests) wearing full protective clothing and bounce up and down  
a few times to allow the rear wheel suspension to become level.  
– Holding your child and the bike, have another person measure the dis-  
tance between the same two points with the load on the motorcycle to  
establish dimension B.  
– The sag is the difference between dimensions A and B.  
B
B
EXAMPLE:  
Motorcycle jacked up (dimension A) . . . . . . . . . . . . . . . . . . . . . .430 mm  
Motorcycle on ground with driver seated (dimension B) . . . . . . .– 340 mm  
Sag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 mm  
18  
The sag should be 90 mm (± 5 mm)  
If the sag is lower, the spring preload of the shock absorber must be reduced,  
if the sag is higher, the spring preload must be increased (see Changing spring  
preloading of the shock absorber).  
To determine the sag of the telescopic fork  
– Jack up the motorcycle until the rear wheel no longer touches the ground.  
– Measure the distance between the upper edge of the slider tube and the  
triple clamp and write it down as dimension C.  
– Have your child sit on the motorcycle in a normal seating position (feet  
on the footrests) wearing full protective clothing, and bounce up and down  
a few times to allow the telescopic fork to become level.  
– Holding your child and the bike, have another person measure the dis-  
tance between the same two points with the load on the motorcycle to  
establish dimension D.  
C
– The sag is the difference between dimensions C and D.  
EXAMPLE:  
Motorcycle jacked up (dimension C) . . . . . . . . . . . . . . . . . . . . . .220 mm  
Motorcycle on ground with driver seated (dimension D) . . . . . . .– 180 mm  
Sag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 mm  
1
The sag should be 45 mm (± 5 mm).  
If the sag is lower, the spring preload of the telescopic fork must be reduced,  
if the sag is higher, the spring preload must be increased.  
The preload on the fork spring is determined by the length of preload spacer  
[1]. If an adjustment is necessary, demount the fork legs, remove the plugs  
and shorten the pretensioning sleeves or replace with longer ones.  
D
D
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
Checking chain tension  
Set the motorcycle on the plug-in stand.  
Press the chain down on the upper end of the chain sliding component.  
The distance between the chain and the swing arm should be approx.  
3 mm. The lower part of the chain should be tightened.  
– If the chain is too tight the secondary transmission components (chain,  
sprockets, bearings of the transmission and of the rear wheel) will be put  
under additional strain that can, in addition to premature wear, also cause  
chain breakage.  
– If the chain is not tight enough it can slip off the sprockets and block the  
rear wheel or damage the engine.  
– In both cases the rider is very likely to lose control of the motorcycle.  
4
Correcting chain tension  
Undo the hexagon nut [1], then undo both counter nuts [2] and turn the left  
and the right tensioning screws [3] equally far. Then retighten the counter  
nuts [2].  
2
Before tightening the hexagon nut [1] make sure that the chain adjuster [4]  
is properly resting against the tensioning screws [3] and that the rear wheel  
is properly aligned with the front wheel.  
3
1
19  
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 behavior of your motorcycle.  
– Tighten the hexagon nut to the required torque. A loose wheel spindle may  
lead to an unstable behavior of your motorcycle.  
3
2
4
Chain maintenance  
For long chain life, good maintenance is very important. The chain should be  
cleaned in fireproof solvent regularly and afterwards treated with hot grease  
or chain spray ( Motorex Chainlube 622).  
No lubrication is allowed to reach the rear tire or the brake disks, otherwise  
the road adherence and the rear wheel braking effects would be strongly reduced  
and the motorcycle could easily lose control.  
When mounting the chain masterlink clip, the closed side of the masterlink  
clip must point in running direction.  
Also check sprockets and chain guides for wear, and replace if necessary.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
General information about KTM disc brakes  
BRAKE CALIPERS:  
If the front brake caliper is removed, the screws must be secured with Loctite  
243 when mounted and tightened to 20 Nm.  
BRAKE FLUID RESERVOIRS:  
The brake fluid reservoirs on front and rear wheel brakes have been  
designed in such a way that even if the brake pads are worn it is not neces-  
sary to top up the brake fluid. If the brake fluid level drops below the mini-  
mum level either the brake system has a leak or the brake pads are completely  
worn. 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. DOT 4  
shown on the lid means minimum standard. However, you should replace it  
as soon as possible by DOT 5.1.  
Have the brake fluid changed at least once annually. If you wash your motor-  
cycle often, the brake fluid should be changed even more frequently. Brake  
fluid tends to absorb water. Therefore, vapor pockets may form in „old“ brake  
fluids even at low temperatures, causing the brake system to fail.  
20  
BRAKE DISCS:  
A
Due to wear, the thickness of the brake disc in the area of the contact  
face [1] of the brake pads decreases. The brake disk must be at least  
2.80 mm thick at the thinnest point [A]. Check the thickness of the brake  
disk at several points.  
– A brake disk worn down to less than 2.80 mm is a safety risk. Have the  
brake disk replaced as soon as it reaches the service limit.  
– Have any repairs on the brake system be performed by a KTM dealer.  
1
Adjusting the free travel at the hand brake lever  
Free travel at the hand brake lever may be readjusted by using adjustment  
screw [2]. In this way, the position of the point of pressure (i.e. the resis-tance  
you feel on the hand brake lever when the brake pads are pressed against the  
brake disc) can be adjusted for any hand size.  
When you press the hand brake lever forwards, you should have at least  
3 mm free travel. Turn the adjusting screw [2] if necessary.  
2
min. 3 mm  
At the hand brake lever, free travel must at least be 3 mm (0.1 in). Only then  
may the piston in the hand brake cylinder be moved (to be recognized by the  
greater resistance of the hand brake lever). If this free travel is not provided,  
pressure will build up in the braking system, and the front-wheel brake may  
fail due to overheating.  
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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. Move the hand brake cylinder in a horizontal position, remove  
the screws [1] and the cover [2] with the diaphragm [3]. The brake fluid level  
should be 5 mm below the upper edge of the reservoir (see drawing), other-  
wise add DOT 5.1 brake fluid (e.g. Motorex Brake Fluid DOT 5.1) up to 5 mm  
below the upper edge of the reservoir.  
Mount the diaphragm, the cover and the screws and actuate the hand brake  
lever until you feel the point of pressure again. Wipe off any overflowing or  
spilled brake fluid with water.  
1
2
3
– Actuate the hand brake lever until you feel the point of pressure again.  
– Never use DOT 5 brake fluid! It is based on silicone oil and of a purple  
color. Seals and brake hoses must be especially adapted to it.  
– Store brake fluid out of reach of children.  
– Brake fluid can cause skin irritation. Avoid contact with skin and eyes. If  
you get brake fluid in your eyes, rinse with plenty of water and consult a  
doctor.  
– Don’t let brake fluid get in contact with paint, it is an effective paint remover.  
– Use only clean brake fluid taken from a tightly sealed container.  
21  
5 mm  
Checking front brake pads  
Inspect the brake pads from in front of the vehicle. The linings must be at  
least 1 mm (0.04 in) thick.  
min.  
1 mm  
At their most worn point brake pad linings should not be thinner than 1 mm  
(0.04 in), otherwise they could lead to brake failure. For your own safety don’t  
put off having your brake pads changed.  
If the brake pads are replaced too late so that the lining is partly or entirely  
worn, the steel components of the brake pad will rub against the brake disc,  
thereby imparing the braking effect and destroying the brake disc.  
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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. Clean brake caliper thoroughly  
with compressed air.  
1
22  
2
Mount the left brake shoe and fix with screw. Mount the right brake shoe and  
tighten the screw to 6 Nm. Mount the lock washer. Align brake shoes, mount  
front wheel (see chapter: Mounting the front wheel).  
– It is very important to keep the brake disk free from oil and fatty matters.  
Otherwise, the braking effect would be strongly reduced.  
– After assembly, check if circlips have been fitted correctly.  
– Having performed any work on the braking system, one must always actu-  
ate the hand brake lever or foot brake lever, respectively so as to ensure  
that the brake pads will lie against the brake disk and the pressure point  
is established.  
– Do not unscrew any other screws on the brake caliper or you will have to  
bleed the brake system.  
Changing basic position of the brake pedal *  
The basic setting of the foot brake pedal can be changed by turning the end  
stop roller [3]. Using the push rod [4], 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 recog-  
nised from the resistance on the foot brake pedal).  
3
If this clearance is missing, pressure accumulates in the braking system and  
the brake pads begin to rub. The braking system overheats and can fail com-  
pletely in extreme cases.  
4
3-5 mm  
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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.  
A
If the brake fluid level drops below the upper edge of the inspection glass,  
this indicates that the brake system is either leaking or the brake shoes com-  
pletely worn.  
Refilling the rear brake fluid reservoir *  
Remove the screws [1] and take off the cover [2] and diaphragm [3].The brake  
pistons must be pushed back to their basic position. Fill DOT 5.1 brake fluid  
(e.g. Motorex Brake Fluid DOT 5.1) up to 10 mm under the upper edge of the  
reservoir.  
Remount the diaphragm, cover and screws and actuate the foot brake lever  
until you feel the point of pressure again. Wipe any overflowing or spilled brake  
fluid off with water.  
1
2
3
– Actuate the foot brake lever until you feel the point of pressure again.  
–
Never use DOT5 brake fluid! It is based on silicone oil and of a purple  
color. Seals and brake hoses must be especially adapted to it.  
23  
– Store brake fluid out of reach of children.  
– Brake fluid can cause skin irritation. Avoid contact with skin and eyes. If  
you get brake fluid in your eyes, rinse with plenty of water and consult a  
doctor.  
– Don’t let brake fluid get in contact with paint, it is an effective paint remover.  
– Use only clean brake fluid taken from a tightly sealed container.  
Checking rear brake pads  
The brake pads can be inspected from the rear. The thickness of the linings  
may not be less than 1 mm (0.04 in).  
min.  
1 mm  
At their most worn point brake pad linings should not be thinner than 1 mm,  
otherwise they could lead to brake failure. For your own safety don’t put off  
having your brake pads changed.  
If the brake pads are replaced too late so that the lining is partly or entirely  
worn, the steel components of the brake pad will rub against the brake disc,  
thereby imparing the braking effect and destroying the brake disc.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
Replacing the rear brake pads *  
Dismount the rear wheel (see „Dismounting the rear wheel“).  
Press the brake shoes apart with a suitable screwdriver to allow the brake pis-  
tons to return to their basic position.  
Remove the locking screw [1], unscrew the screw [2] and pull the brake shoes  
out of the brake caliper.  
2
1
24  
Slide new brake shoes into the brake caliper a fasten with the screw [2].  
Tighten the screw to 4 Nm and mount the locking screw [1].  
Mount the rear wheel and actuate the foot brake lever until you can feel the  
pressure point.  
– It is very important to keep the brake disk free from oil and fatty matters.  
Otherwise, the braking effect would be strongly reduced.  
– After mounting, make sure the retaining bracket is in place.  
– After working on the braking system, one must always actuate the hand  
brake lever or foot brake lever, respectively so as to ensure that the brake  
pads will lie against the brake disk and the pressure point is established.  
Removing and installing front wheel  
To remove the front wheel, jack the motorcycle up on its frame so that the  
front wheel no longer touches the ground.  
Loosen the collar screw [3].  
Loosen the 2 clamping screws [4] on the fork fists.  
Hold the front wheel, pull out the wheel spindle [5].  
Remove front wheel carefully from the fork.  
– Do not operate the hand brake when the front wheel has been dismounted.  
– Make sure the brake disc is always on top when you lay down the wheel,  
otherwise the brake disc can be damaged.  
3
Insert the front wheel in the fork and adjust to the right position.  
Mount the wheel spindle [5] and tighten the clamping screws on the right  
fork leg slightly.Degrease the thread on the collar screw and apply Loctite 243.  
Mount the collar nut and tighten to 40 Nm.  
Take the motorcycle off the stand and bounce the fork hard a few times to  
align the fork legs. 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 behavior of your motorcycle.  
– After mounting the front wheel, keep operating the hand brake until the  
pressure point returns.  
– It is very important to keep the brake disk free from oil and fatty matters,  
otherwise the braking effects would be strongly reduced.  
4
5
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
Removing and installing the rear wheel  
Jack the motorcycle up by the frame.  
Remove the hexagon nut [1] of the wheel spindle together with the washer  
[2] and remove the chain adjuster [3].  
Hold the rear wheel and pull out the wheel spindle.  
Turn the rear wheel forwards and take the chain off the rear sprocket.  
Pull the rear wheel backwards.  
To install the rear wheel reverse the procedure described above.  
Slightly grease the wheel spindle.  
3
1
Before tightening the hexagon nut [1] make sure that the chain adjusters [3]  
are properly resting against the tensioning screws. Additionally, make sure  
that the rear wheel is properly aligned with the front wheel.  
Mount the hexagon nut and tighten to 40 Nm.  
2
– Do not operate the rear brake when the rear wheel has been dismounted.  
– Make sure the brake disc is always on top when you lay down the wheel,  
otherwise the brake disc can be damaged.  
– If the axle is dismounted, clean the thread of the wheel spindle and col-  
lar nut thoroughly and apply a new coat of grease to prevent 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 behavior of your motorcycle.  
– After mounting the rear wheel, keep operating the rear brake until the pres-  
sure point returns.  
25  
– It is very important to keep the brake disk free from oil and fatty matters,  
eitherwise the braking effects would be strongly reduced.  
– Tighten the hexagon nut to the required torque. A loose wheel spindle may  
lead to an unstable behavior of your motorcycle.  
Tires, air pressure  
Tire type, tire condition, and air pressure level affect the way your motorcy-  
cle rides, and they must therefore be checked whenever you are getting ready  
to go anywhere on your motorcycle.  
Tire size can be found in the technical specifications  
Tire condition has to be checked every time you want to ride your motorcycle.  
Before leaving, check tires for punctures and nails or other sharp objects that  
might have become embedded in them.  
Tire pressure should be checked regularly on a „cold“ tire. Proper pressure  
(1.0 bar) ensures optimum driving comfort and extends the life of your tires.  
– Damaged tires must be replaced immediately to protect your youngster.  
– Worn tires can have a negative effect on how the motorcycle performs,  
especially on wet surfaces  
– Tire pressure below the normal level will lead to premature tire wear.  
Checking spoke tension  
The correct spoke tension is very important for the stability of the wheels and  
thus for riding safety. A loose spoke causes the wheel to become unbalanced  
and before long other spokes will have come loose. Check spoke tension, espe-  
cially on a new motorcycle, at regular intervals. For checking, tap on each  
spoke with the blade of a screwdriver (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.  
– Spokes can tear if you continue to ride with them loose. This may lead to  
an unstable handling of your motorcycle.  
– Excessively tensioned spokes may rupture due to local overloading. The  
spokes must be tensioned to 3 Nm.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
Removing the seat  
By using the quick-release mechanism [1], the seat can be removed without  
using tools. Turn the quick-release mechanism about 180° counter  
clockwise and lift up the rear of the seat. Pull the seat backwards and unhook  
it from the fixing screw [2].  
1
To mount the seat, position seat on the fixing screw [2] and tank, push  
forward and fix with the quick release.  
1
2
If not correctly mounted, the seat can slip while you are driving and cause  
you to loose control of your motorcycle.  
26  
Cleaning the air filter *  
To do this, remove the seat and the air filter cover from the air filter box. Unclap  
the filter holder [3], swing back and remove air filter [4] plus filter  
carrier [5] from the filter box.  
4
– 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).  
- Never start your motorcycle without any air filters. Otherwise, dust and  
dirt may penetrate and cause damage and increased wear.  
- Dust and dirt can accumulate and damage the engine if the air filter is  
not mounted correctly.  
3
Thoroughly wash the foam filter in special cleaning fluid and allow to dry well.  
Only press out the filter, do not wring out under any circumstances. Oil the  
dry foam filter with a high grade filter oil. Also clean the air filter box. Check  
carburetor collar [A] for damage and that it is fitted correctly.  
3
4
5
Mount the air filter [4] on the filter support [5]. Grease the front side of the  
filter to improve the seal. Mount the air filter and the filter support in the  
filter box. Make sure they are centered, and lock into place with the filter  
holder [3].  
A
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MAINTENANCE WORK ON CHASSIS AND ENGINE »  
Exhaust system *  
3
The silencer is filled with glass-fiber yarn for damping. When in use, the glass-  
fiber yarn becomes loose or coked with oil carbon. This can lead to a power  
loss and a reduction of the silencer damping. The glass-fiber yarn packing  
can be replaced in a few easy steps.  
4
1
To replace, remove the silencer from the vehicle and mark the position of the  
outer tube [1] to the inner tube [2]. Remove screws [3] and the end cap [4].  
Pull of the outer tube and remove the old glass-fiber yarn packing [5] from  
the inner tube. Thoroughly clean all parts.  
5
To assemble, mount a new glass-fiber yarn packing onto the inner tube (see  
illustration) and slide into the outer tube. Mount end cap and fix with  
screws [1]. Before tightening the screws, turn the outer tube until they match  
the positions you marked. Mount the silencer and check the exhaust system  
for tightness.  
2
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.  
27  
Checking the oil level of the hydraulic clutch  
To check the oil level in the master cylinder of the clutch remove the cover.  
For this purpose, remove screws [6] and cover [7] together with the rubber  
boot [8]. The oil level in the horizontal-standing master cylinder should be  
4 mm below the upper edge.  
6
7
If necessary, add SAE 10 biodegradable hydraulic oil (Motorex Kupplungs-  
fluid 75), available from your authorized KTM workshop.  
8
KTM uses biodegradable, hydraulic mineral oil to actuate the hydraulic  
clutch. Do not mix this oil with any other hydraulic oil. Always use  
original KTM hydraulic oil (available from your authorized KTM workshop) to  
make sure your clutch operates smoothly.  
Bleeding the hydraulic clutch *  
If the clutch lever starts to feel unresponsive, the clutch control system needs  
to be bled. You will need a bleeder syringe (special tool) and biodegradable  
hydraulic oil. Both are available from your KTM dealer.  
9
Turn the handlebar until the master cylinder is in a horizontal position, remove  
the screws [6], the cover [7] and the rubber boot [8].  
Fill the bleeder syringe [9] with biodegradable hydraulic oil (Motorex Kupplungs-  
fluid 75). Remove the bleeder screw [10] from the slave cylinder and mount  
the bleeder syringe. Press oil into the system until the oil runs out of the hole  
[11] in the master cylinder without bubbles. Occasionally extract the oil from  
the master cylinder reservoir to keep it from overflowing.  
10  
After you finish bleeding, remove the bleeder syringe, mount the bleeder screw,  
correct the oil level in the reservoir and mount the cover (see above).  
11  
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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.  
Turning the adjusting screw counterclockwise reduces the distance between  
the clutch lever and the handlebar. Turning the adjusting screw clockwise  
increases the distance between the clutch lever and the handlebar.  
1
Adjustment of the clutch lever position is only possible within certain limits.  
Only turn the adjusting screw manually and never apply excessive force.  
Cooling system  
The water pump [2] in the engine keeps the cooling liquid in circulation.  
The cooling liquid is cooled by the air stream. Therefore, the cooling effect  
is reduced when the traveling speed is reduced. Dirty radiators additionally  
reduce the cooling effect.  
The cooling liquid can be drained by removing the screw [3] on the water-  
pump cover.  
3
Do not remove any cooler hoses or the drain screw when the engine is hot.  
2
28  
A mixture of 50% antifreeze liquid and 50% destilled water is used as coolant.  
However, the antifreeze protection must be at least -25° C (-13° F). This mix-  
ture offers antifreeze protection but also good corrosion protection and should  
therefore not be replaced by pure water.  
For the cooling system, use only with high-grade antifreeze (Motorex Anti-Freeze).  
Using lower-grade antifreeze agents can cause corrosion and coolant foaming.  
Pressure induced by heating of the coolant in the system is controlled by a valve  
in the radiator cap [4]; a water temperature rising up to 120° C (248° F) is admis-  
sible, without fear of problems.  
4
Checking coolant level  
The coolant should be 10 mm (0.4 in) above the radiator fins when the engine  
is cold (see illustr.). In the event of the coolant being drained, always fill and  
bleed the system.  
10 mm  
If possible, always check the level of the cooling liquid when the engine is  
cold. If you have to open the radiator cap when the engine is hot, use a rag  
to cover the cap and open slowly to release pressure.  
when engine is cold  
Adjusting the throttle cable *  
3-5 mm  
There must always be a 3-5 mm (0.1-0.2 in) play in the throttle cable. To  
check this, move back the protective cover [5] on the throttle grip. You must  
be able to lift the outer covering of the cable 3-5 mm from the adjusting screw  
[6] until resistance is felt.  
To adjust, loosen the counternut [7] and turn the adjusting screw accordingly.  
Finally tighten the counternut and slide the protective cover back on.  
To check the correctness of this setting, start the engine, turn the handlebar  
left and right, in both cases as far as it will go. This must not cause any changes  
in idling speed. Otherwise, you will have to increase the backlash of the throt-  
tle cable.  
5
6
7
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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 .  
Basic information of changing the carburetor setting  
Always start out from the original carburetor setting. Essential requirements are a clean air filter system, air-tight exhaust system and  
an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and the jet needle is sufficient and that changes  
to other parts of the carburetor will not greatly affect engine performance.  
RULE OF THUMB: high altitude or high temperatures  
low altitude or low temperatures  
>
>
choose leaner carburetor adjustment  
choose richer carburetor adjustment  
– Only use premium-grade gasoline ROZ 95 (USA = Premium RON 91) mixed with high-grade two-stroke engine oil. Other types of  
gasoline can cause engine failure, and their use will void your warranty.  
– Only use high-grade 2-stroke engine oil of known brands (i. e. Motorex Cross Power 2T).  
– Not enough oil or low-grade oil can cause erosion of the piston. If you use too much oil, the engine can start smoking and foul the  
spark plug.  
– In the case of a leaner adjustment of the carburetor proceed cautiously. Always reduce the jet size in steps of one number to avoid  
overheating and piston seizure.  
NOTE: If the engine does not run properly, despite a changed adjustment look for mechanical faults and check the ignition system.  
Basic information on carburetor wear  
As a result of engine vibrations, the throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause  
carburetor malfunction (e.g. overly rich mixture). Therefore, these parts should be replaced after 1000 hours of using.  
29  
Idling range – A, Adjusting the idle speed  
Operation with closed throttle valve. This range is influenced by the position  
of the air control screw [1] and the air control screw [2]. Only make adjust-  
ments when the engine is hot.  
To this end, slightly increase the idling speed of the engine by means of the  
air control screw. Turning it clockwise produces a higher idling speed and turn-  
ing the screw counterclockwise produces a lower idling speed. Create a round  
and stable engine speed using the air control screw (basic position of the air  
control screw = open by 1 turns). Then adjust to the normal idling speed by  
means of the air control screw.  
1
Opening up – B  
Engine behavior when the throttle opens. The idle jet and the shape of the  
throttle valve influences this range. If, despite good idling-speed and  
part-throttle setting, the engine sputters and smokes when the throttle is fully  
opened and develops its full power not smoothly but suddenly at high  
engine speeds, the mixture to the carburetor will be too rich, the fuel level  
too high or the float needle is leaking.  
Part-throttle range – C  
Operation with partly open throttle valve. This range is only influenced by the  
jet needle (shape and position). The optimum part-throttle setting is  
controlled by the idling setting in the lower range and by the main jet in the  
upper range. If the engine runs on a four-stroke cycle or with reduced power  
when it is accelerated with the throttle partly open, the jet needle must be  
lowered by one notch. If the engine pings, especially when accelerating under  
full power at maximum engine revs, the jet needle should be raised.  
If these faults should occur at the lower end of the part throttle range at a  
four-stroke running, make the idling range leaner; if the engine pings, adjust  
the idling range richer.  
2
Full throttle range – D  
main jet  
D
C
jet needle  
Operation with the throttle fully open (flat out). This range is influenced by  
the main jet and the jet needle. If the porcelain of the new spark plug is found  
to have a very bright or white coating or if the engine rings, after a short dis-  
tance of riding flat out, a larger main jet is required. If the porcelain is dark  
brown or black with soot the main jet must be replaced by a smaller one.  
jet needle  
idling jet  
throttle valve  
B
A
idling jet  
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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. Close the fuel tap and place  
a cloth under the carburetor which is capable of absorbing the leaking fuel.  
Unscrew the plug [1] and clean it with compressed air. Then, mount the plug  
together with the gasket and tighten it to 4 Nm, open fuel tap, and check the  
float chamber for leaks.  
1
Fuel is easily flammable and toxic. When handling fuel, be sure to exercise  
the utmost caution. Never perform any work on the fuel system near of open  
flames or burning cigarettes. Always allow the engine to cool off first.  
Immediately clean up any fuel which may have been spilled. Materials satu-  
rated with fuel are also easily flammable. In case you ingested fuel or fuel  
splashed into your eyes, consult a doctor immediately.  
Dispose of the fuel properly!  
30  
Checking gear oil level  
An inspection glass [2] on the left side of the engine allows easy checking of  
the gear oil level.  
2
Warm up the engine, then turn it off and wait two minutes until the oil has  
flown back into the gearbox case.  
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.  
If necessary add gear oil 20W30 (e.g. Motorex Top Speed 4T 15W50).  
Not enough oil or a poor oil quality lead to premature wear of the  
transmission. Therefore, use only high-quality oils (e.g. Motorex Top Speed  
4T 15W50).  
3
Changing gear oil *  
Before changing the gear oil warm up the engine and park the motorcycle on  
a horizontal surface. Remove the oil drain plug [3] and drain the used oil into  
an appropriate container. Clean the sealing surface. Mount the oil drain plug  
together with its gasket and tighten to 15 Nm.  
Remove the filler plug [4] and add 0.30 l gear oil 20W30 (e.g. Motorex Top  
Speed 4T 15W50). Mount the filler plug and check the engine for leaks.  
Not enough oil or a poor oil quality lead to premature wear of the transmis-  
sion. Therefore, use only high-quality oils (e.g. Motorex Top Speed 4T 15W50).  
4
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TROUBLE SHOOTING »  
If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error  
occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error.  
We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer.  
TROUBLE  
CAUSE  
REMEDY  
Engine fails to start  
Operating error  
Open fuel tap, replenish fuel, do not use choke  
The motorcycle has been out of  
operation for a longer period of  
The easily inflammable components of the new fuels evapo-  
rate during longer periods of standstill.  
time. Therefore old fuel has accu- When the motorcycle has been out of operation for more  
mulated in the float chamber  
than a week, it is therefore recommended to drain the old  
fuel from the float chamber. The engine will immediately  
start off when the float chamber is filled with new fuel.  
Fuel supply interrupted  
Close fuel tap, loosen fuel hose at carburettor, lead into a  
basin and open fuel tap,  
– if fuel leaks out, clean carburettor  
– if no fuel leaks out, check tank ventilation, i.e. clean  
fuel tap  
Electrode distance too great  
Reduce electrode distance (0.60 mm)  
Clean spark plug or renew  
Plug fouled by oil, wet or bridged  
Ignition wire or spark plug  
connector damaged  
Dismount spark plug, connect ignition cable, hold to ground  
(blank place on engine) and actuate kickstarter, a strong  
spark must be produced at the spark plug  
31  
– If no spark is produced, loosen spark plug cap from igni-  
tion cable, hold about 5 mm from ground and actuate  
kickstarter  
– If a spark now occurs, replace spark plug cap  
– If no spark is produced, control ignition system  
Kill button wire or  
short-circuit switch faulty  
Disconnect black coloured cable from short circuit button at  
ignition coil and check ignition spark. If the spark is O.K.  
repair defective part of cable or ignition switch  
Loose ignition cable connectors  
Spark too weak  
Inspect cable connectors  
Examine ignition system  
Water in the carburetor and jets  
blocked  
Dismantle and clean carburetor  
Engine without idle running  
Engine has not enough power  
Idle adjusting screw out of  
adjustment  
Readjust idle running or replace idle adjusting screw  
Ignition system damaged  
Wear  
Examine ignition system  
Overhaul engine  
Charred glass fiber yarn in silencer Renew filling  
Air filter obstructed  
Clean or renew airfilter  
Blow through fuel pipe and clean carburetor  
Fuel supply partly interrupted or  
blocked  
Loss of compression through loose Tighten spark plug  
spark plug  
Exhaust system damaged  
Check exhaust system for damage  
Engine has not enough preignition Check and adjust ignition  
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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  
High rpm misfiring  
too high, float needle seating is  
dirty or enlarged  
adjust level  
Tighten jets  
Loose carburetor jets  
Incorrect heat range spark plug or Refer to technical data section  
low quality spark plug  
Loose, corroded or non conductive Check and seal with silicon  
ignition socket connector  
Engine spluters into the  
carburetor  
Lack of fuel  
Clean fuel pipes, examine tank aeration and clean  
Spark plug with incorrect heat  
value (Ignition by incandescence)  
Fit correct spark plug  
32  
Engine takes air out of control  
Check intake flange and carburettor if firmly setted  
Engine overheating  
Insufficient liquid in cooling  
system  
Top up coolant and bleed cooling system check cooling sys-  
tem for leaks  
Radiator fins clogged  
Clean radiatar fins with water jet  
Frothing in cooling system  
Renew coolant using branded anti-freeze/anti-corrosive  
(Motorex Anti-Freeze)  
Pinched or kinked water hoses  
Replace with correct routed hoses  
Incorrect ignition timing because  
of loose stator screws  
Readjust to correct ignition timing specifications, secure  
screws with Loctite 243  
Incorrect compression ratio  
Measure and adjust compression ratio  
Emission of white smoke  
(steam)  
Cylinder head or O-ring of cylinder Check cylinder head, replace O-ring  
head gasket leaks  
Excessive oil escapes from  
transmission breather tube  
Excessive oil quantity  
in transmission  
Correct transmission oil level  
Water in transmission oil  
Shaft seal ring of the water pump Replace shaft seal ring of the water pump  
defect  
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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.  
Never clean your motorcycle with a high-pressured cleaner or a high-pressured water jet. otherwise the water might run into the elec-  
trical components, connectors, sheathed cables, bearings, carburetor etc. and cause mailfunctions, i.e., lead to the premature destruc-  
tion of these parts.  
– Before cleaning with water, plug the exhaust pipe to prevent water ingress.  
– You should use commercially available detergents to clean the motorcycle. Heavily soiled parts should also be cleaned with the  
help of a paint brush.  
– 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.  
– Slide back the protective covers on the handlebar-mounted instruments so that any water that may have seeped into this part of  
the motorcycle is allowed to evaporate.  
– After the motorcycle has cooled down, oil and grease all the gliding bearing parts. Also treat the chain with a chain spray.  
– To prevent failures in the electric system, you should treat the short circuit button with a contact spray.  
33  
STORAGE »  
If you want to put your motorcycle away for longer periods of time, please observe the following instructions:  
– Clean motorcycle thoroughly (see chapter: CLEANING)  
– Change engine oil (old engine oil contains aggressive contaminations).  
– Check antifreeze and amount of cooling liquid.  
– Let the engine warm up again, close fuel tap and wait until the engine dies off by itself. In this way, the carburetor jets are  
prevented from becoming resin-clogged by the old fuel.  
– Remove spark plug and fill in approx. 5 ccm of engine oil into the cylinder through the opening. Actuate kickstarter 10 times in  
order to distribute the oil onto the cylinder walls and mount the spark plug.  
– Let fuel flow out of tank into an appropriate basin.  
– Correct tire pressure.  
– Lubricate bearing points of the control levers, footrests, etc. as well as the chain.  
– The storage place should be dry and not be subjected to overly great temperature fluctuations.  
– Cover the motorcycle with an air permeable tarpaulin or blanket. Do not use airtight materials, as possible humidity might not be  
able to escape and thereby cause corrosion.  
It would be very bad to let the engine run for a short time during the storage period. The engine would not get warmed up enough and  
the thus developed steam would condense during the combustion process and cause the exhaust to rust.  
USE AFTER PERIOD OF STORAGE  
– Fill up tank with fresh fuel.  
– Check motorcycle as before each start (see driving instructions).  
– Take a short, careful test ride first.  
NOTE: Before you put your motorcycle away for the winter, you should check all parts for their function and wear. Should any  
service jobs, repairs, or any refitting be necessary, you should have them carried out during the off-season (lower workload at  
mechanics' shops). This way, you can avoid the long waiting times at your shop at the beginning of the next biking season.  
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TECHNICAL SPECIFICATIONS – CHASSIS »  
CHASSIS  
65 SX  
Frame  
Central chrome-moly-steel frame  
telescopic fork (Marzocchi USD Ø 35)  
220 mm (8.7 in) / 270 mm (10.7 in)  
central shock absorber (WP Suspension) 3614 BAVP  
Disc brake Ø 198 mm (7.8 in), 4 piston  
Disc brake Ø 160 mm (6.3 in), 2 piston  
Fork  
Wheel travel front/rear  
Rear suspension  
Front brake  
Rear brake  
Tires  
front: Pirelli 60/100-14“ MT32A (29M)  
front / rear: 1,0 bar (14 psi) / 1,0 bar (14 psi)  
3.3 liter (0.87 USgal)  
14 : 50  
rear: Pirelli 80/100-12“ MT320 (50M)  
Air pressure  
Fuel tank capacity  
Final drive ratio  
Chain  
1/2 x 1/4" 112 rolls  
64.5 °  
Steering angle  
Wheel base  
1137 mm (44.7 in)  
750 mm (30 in)  
Seat height, unloaded  
Ground clearance  
Dead weight without fuel  
Rider’s body height  
Rider’s body weight  
Recommended age of rider  
Engine  
290 mm (11.5 in)  
55.6 kg (122.7 lbs)  
max. 160 cm (63 in)  
max 50 kg (22.7 lbs)  
8 to 12 years  
34  
CR-65  
STANDARD ADJUSTMENT – FORK  
STANDARD ADJUSTMENT – SHOCK ABSORBER  
MARZOCCHI USD Ø 35  
3,14 N/mm  
10 mm  
WP 03187C03  
Spring  
Compression adjuster  
Rebound adjuster  
Spring  
3
Preload bushing – length  
Air chamber length  
Fork oil  
6
120 mm  
40-220  
7 mm  
SAE 5  
Spring preload  
TIGHTENING TORQUES – CHASSIS  
Hexagon screw – brake caliper  
Flat head screw – brake discs  
AH screw rear brake pad  
M 8  
Loctite 243 + 20 Nm  
M 6 (10.9)  
M 5  
Loctite 243 + 14 Nm  
4 Nm  
Hexagon nut – front wheel spindle  
Hexagon nut – rear wheel spindle  
Hexagon nut – swingarm bolt  
Clamping screws – upper fork bridge  
Clamping screws – lower fork bridge  
AH screw – handlebar clamp  
Spoke nipple  
M 10  
M 12x1  
M 12x1  
M 8  
40 Nm  
40 Nm  
40 Nm  
25 Nm  
M 8  
25 Nm  
M 8  
20 Nm  
M 3,5  
M 5  
3 Nm  
Other chassis screws  
6 Nm  
M 6  
10 Nm  
M 8  
25 Nm  
M 10  
45 Nm  
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TECHNICAL SPECIFICATIONS – ENGINE »  
ENGINE  
CR-65  
Design  
Liquid cooled single cylinder two-stroke engine with reed valve intake  
64.85 ccm  
Displacement  
Bore/stroke  
Fuel  
45 / 40.8 mm (1.77/1.6 in)  
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. Motorex Cross Power 2T),  
when in doubt, please contact our importer  
Lubrication  
mixture lubrication  
Crankshaft bearing  
Connecting rod bearing  
Piston pin bearing  
Piston rings  
2 deep-groove ball bearing  
needle bearing  
needle bearing  
1 compression ring  
Primary drive  
Clutch  
straight cut spur gears, 23:75 t  
multiple disc clutch in oil bath, hydraulic operated (Motorex Kupplungsfluid 75)  
Transmission  
Gear ratio  
6 speed, claw actuated  
1st gear 13 : 37  
2nd gear 16 : 34  
3rd gear 18 : 31  
4th gear 21 : 30  
5th gear 23 : 28  
35  
6th gear 24 : 26  
Transmission oil  
Ignition system  
Spark plug  
Electrode gap  
Carburetor  
0.30 liter (0.0792 USgal) gear oil (e.g. Motorex Top Speed 4T 15W50)  
Moric Digital 2M1  
NGK BR 8 ECM  
0.60 mm (0.0236 in)  
Mikuni VM 24-505  
Coolant  
0.55 liter (0.145 Usgal), 50% antifreeze, 50% destilled water, at least -25° C (-13° F)  
wet foam type air filter insert  
Air filter  
BASIC CARBURETOR SETTING  
CARBURETOR  
MIKUNI VM 24-505  
Main jet  
200  
864 0-0  
25  
Needle jet  
Idling jet  
Jet needle  
5I14  
IV  
Needle position from top  
Throttle valve  
1.5  
30  
Starting jet  
Air adjustment screw open  
1
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TECHNICAL SPECIFICATIONS – ENGINE »  
TIGHTENING TORQUES – ENGINE  
Hexagon nut – primary gear  
Collar nut – flywheel  
M 10  
M 10x1,25  
M 7  
60 Nm  
40 Nm  
15 Nm  
25 Nm  
Loctite 243 + 60 Nm  
12 Nm  
12 Nm  
8 Nm  
HH screw – cylinder head  
Collar nut – cylinder base  
Hexagon screw – inner clutch hub  
Screw – clutch  
M 8  
M 10  
M 6  
Oil drain screw  
M 8  
Screws – clutch cover  
Kickstarter stop plate  
Screws – stator  
M 6  
M 6  
12 Nm  
2 Nm  
M 4  
Shift drum locating device  
Drain plug – carburetor  
Other screws – engine  
M 6  
12 Nm  
4 Nm  
SW 17  
M 5  
6 Nm  
M 6  
12 Nm  
36  
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INDEX »  
Page  
Page  
General information about KTM disc brakes . . . . . . . . . .20  
General tips and warnings for starting the motorcycle . . .10  
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
How to change the handlebar position . . . . . . . . . . . . . .17  
Instructions for the first ride . . . . . . . . . . . . . . . . . . . .10  
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8  
Maintenance work on chassis and engine . . . . . . . . . . . .16  
Operation instruments . . . . . . . . . . . . . . . . . . . . . . . . . .6  
Periodic maintenance schedule . . . . . . . . . . . . . . . . . . .14  
Plugin- Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8  
Rebound damping function of the shock absorber . . . . . .8  
Refilling the rear brake fluid reservoir . . . . . . . . . . . . . .23  
Refueling, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
Removing and installing front wheel . . . . . . . . . . . . . . .24  
Removing and installing the rear wheel . . . . . . . . . . . . .25  
Removing the seat . . . . . . . . . . . . . . . . . . . . . . . . . . . .26  
Replacing the front brake pads . . . . . . . . . . . . . . . . . . .22  
Replacing the rear brake pads . . . . . . . . . . . . . . . . . . .24  
Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10  
Serial number locations . . . . . . . . . . . . . . . . . . . . . . . . .6  
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7  
Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12  
Short circuit button . . . . . . . . . . . . . . . . . . . . . . . . . . . .7  
Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12  
Starting when the engine is cold . . . . . . . . . . . . . . . . . .12  
Starting when the engine is warm . . . . . . . . . . . . . . . . .12  
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33  
Technical Specifications – Engine . . . . . . . . . . . . . . . . .35  
Technical Specifications – Chassis . . . . . . . . . . . . . . . . .34  
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . .25  
To determine the sag of the shock absorber . . . . . . . . . .18  
Adjusting the free travel at the hand brake lever . . . . . .20  
Adjusting the throttle cable . . . . . . . . . . . . . . . . . . . . .28  
Basic suspension setup for the weight of the driver . . . .18  
Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . . . .27  
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13  
Breather plug front fork . . . . . . . . . . . . . . . . . . . . . . . .16  
Carburetor adjustment . . . . . . . . . . . . . . . . . . . . . . . . .29  
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .19  
Changing basic position of the brake pedal . . . . . . . . . .22  
Changing gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . .30  
Changing spring preloading of the shock absorber . . . . .17  
Changing the original position of the clutch lever . . . . . .28  
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
Checking and adjusting the steering head bearing . . . . .16  
Checking chain tension . . . . . . . . . . . . . . . . . . . . . . . .19  
Checking coolant level . . . . . . . . . . . . . . . . . . . . . . . . .28  
Checking front brake pads . . . . . . . . . . . . . . . . . . . . . .21  
Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . .30  
Checking rear brake pads . . . . . . . . . . . . . . . . . . . . . . .23  
Checking spoke tension . . . . . . . . . . . . . . . . . . . . . . . .25  
Checking the oil level of the hydraulic clutch . . . . . . . .27  
Checking the rear brake fluid level . . . . . . . . . . . . . . . .23  
Checking/refilling the front brake fluid level . . . . . . . . . .21  
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7  
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33  
Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . . . .26  
Cleaning the dust sleeves of the telescopic fork . . . . . . .17  
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
Compression damping of shock absorber . . . . . . . . . . . . .8  
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28  
Correcting chain tension . . . . . . . . . . . . . . . . . . . . . . .19  
Draining the float chamber of the carburetor . . . . . . . . .30  
Driving instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .11  
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27  
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7  
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8  
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7  
37  
To determine the sag of the telescopic fork  
. . . . . . . . .18  
Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31  
Use after period of storage . . . . . . . . . . . . . . . . . . . . . .33  
What to do when the engine is „flooded“ . . . . . . . . . . .12  
What you should check before each start . . . . . . . . . . . .11  
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38  
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39  
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40  
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