60/65 SX
BEDIENUNGSANLEITUNG
OWNERS HANDBOOK MANUEL D’UTILISATION MANUAL DE INSTRUCCIONES
2000
Art.Nr. 320583 10/99
IMPORTANT
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:
WARNING
IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY AND YOUR LIFE.
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CAUTION |
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IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF THE MOTORCYCLE OR THAT THE MOTORCYCLE IS NOT ROAD-SAFE ANYMORE.
Please insert the series numbers of your motorcycle in the boxes below
PLEASE INSERT BELOW THE SERIES NUMBERS OF THE MOTORCYCLE
Frame number |
FRAME |
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NUMBER |
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Engine number |
ENGINE |
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ENGLISH 1
STAMP OF DEALER
Stamp of dealer
ENGLISH 2
Introduction
Now you own a modern motorcycle that you and your youngster will certainly enjoy, provided that you service and maintain it properly. This manual contains important information on the operation and maintenance of your new KTM motorcycle. 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.
Maybe you are one of those riders who have acquired good technical skills and can perform many of the maintenance tasks themselves using the instructions contained in this manual. If this is not the case, please keep in mind that the maintenance tasks marked with an asterisk (*) in the chapter „Maintenance of chassis and engine“ should rather be performed by a KTM dealer to protect you and your youngster.
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. Maintenance work should only be performed by a KTM dealer.
When special needs arise, please contact a KTM dealer, who will seek the assistance of the KTM importer if necessary.
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.
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 environmental 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 Austria’s AG certificate of achievement for its Quality System ISO 9001 is the beginning of an on going total reengineering quality plan for a brighter tomorrow.
KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN, AUSTRIA
Attachments: |
1 spare parts manual chassis |
1 spare parts manual engine |
ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL.
© by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved
INDEX
Page
IMPORTANT INFORMATION ON SAFE DRIVING
FOR PARENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . .5 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . |
. .5 |
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. .5 |
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . |
.5 |
Short circuit button . . . . . . . . . . . . . . . . . . . . . . . . . . |
.5 |
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
.6 |
Refueling, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
.6 |
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
.6 |
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
.6 |
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
.7 |
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
.7 |
Rebound damping function of the shock absorber . . . .7 |
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Compression damping of shock absorber . . . . . . . . . . |
.7 |
Changing the spring preloading of the shock absorber |
. .7 |
DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . .8 What you should check before each start . . . . . . . . . . .8 Instructions for the first ride . . . . . . . . . . . . . . . . . . . . .8 Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Starting when engine is cold . . . . . . . . . . . . . . . . . . . .8 Starting when engine is warm . . . . . . . . . . . . . . . . . . .9 What to do when the engine is „flooded“ . . . . . . . . . .9 Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Shifting, Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . |
. . .10 |
MAINTENANCE WORK ON CHASSIS AND ENGINE . |
. . .11 |
Checking and adjusting the steering head bearing |
. . .11 |
General information about KTM disc brakes . . . . . |
. . .12 |
Adjusting of free travel at the hand brake lever . . . . .12 |
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Checking of brake fluid level - front brake . . . . . . |
. . .12 |
Refilling the front brake fluid reservoir . . . . . . . . . . . |
.13 |
Checking the front brake pads . . . . . . . . . . . . . . . . . . |
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Replacing the front brake pads . . . . . . . . . . . . . . . . . |
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Changing the basic position of the brake pedal . . . . . . |
14 |
Checking the rear brake fluid level . . . . . . . . . . . . . . . |
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Refilling the rear brake fluid reservoir . . . . . . . . . . . . . |
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Checking the rear brake pads . . . . . . . . . . . . . . . . . . . . . |
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Replacing the rear brake pads . . . . . . . . . . . . . . . . . . |
15 |
Removing and installing the front wheel . . . . . . . . . . . |
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Removing and installing the rear wheel . . . . . . . . . . . |
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Checking the chain tension . . . . . . . . . . . . . . . . . . . . |
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Correcting the chain tension . . . . . . . . . . . . . . . . . . . |
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Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . |
17 |
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . |
18 |
Checking spoke tension . . . . . . . . . . . . . . . . . . . . . . . |
18 |
Removal of seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
18 |
Cleaning the dust scrabbers of the telescopic fork . . . . |
18 |
Cleaning of air filter . . . . . . . . . . . . . . . . . . . . . . . . . |
19 |
Adjusting the clutch cable . . . . . . . . . . . . . . . . . . . . . |
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Adjusting the throttle cable . . . . . . . . . . . . . . . . . . . . |
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Adjusting the idle speed . . . . . . . . . . . . . . . . . . . . . . |
20 |
Checking the gear oil level . . . . . . . . . . . . . . . . . . . . . |
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Changing the gear oil . . . . . . . . . . . . . . . . . . . . . . . . |
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Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
21 |
Checking the coolant level . . . . . . . . . . . . . . . . . . . . . |
21 |
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
21 |
Carburetor adjustment . . . . . . . . . . . . . . . . . . . . . . . |
22 |
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
TECHNICAL DATA - CHASSIS . . . . . . . . . . . . . . . . . . . .24
TECHNICAL DATA - ENGINE . . . . . . . . . . . . . . . . . . . . .25
ENGLISH 3
IMPORTANT INFORMATION ON SAFE DRIVING FOR PARENTS
SX mini motorcycles are off-road motorcycles designed for one person only. They are not allowed on public roads.
Motorcycle dimension and components are designed for the following age and weight groups:
60 SX and 65 SX: age 8 - 12 years, maximum weight 50 kg (110 lbs), maximum body height 160 cm (65 in)
ENGLISH |
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Have your youngster wear proper protective gear whenever he or she rides the motorcycle: helmet, eye pro- |
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Instruct your youngster about riding and falling techniques, explain how the motorcycle will respond to shif- |
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tection, chest, back, arm and leg protectors, gloves and boots. To set a good example, be sure to wear pro- |
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tective gear yourself whenever riding a motorcycle! |
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Adjust the hand brake lever to your youngster’s hand size (with gloves). |
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Before your youngster takes his or her first ride, explain how each of the controls works and check if your |
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youngster has understood what you explained. We recommend to review the entire owner’s manual with |
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your youngster item by item, paying particular attention to the specially marked warnings and pointing out |
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the danger of injury. |
ting of the rider’s weight, etc.
4– 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 supervising 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 conditions 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 altogether. 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.
SERIAL NUMBER LOCATIONS
Chassis number
The chassis number is located on the type plate on the steering head. Write this number into the field on page no 1.
Engine number
The engine number is stamped into the engine housing underneath the carburetor. Write this number into the field on page no 1.
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OPERATION INSTRUMENTS |
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Clutch lever |
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10 mm |
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The clutch lever 1 is fitted on the left hand side of the handle bar. When |
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engine is cold, there should allways be a play of 10 mm (0,4 in) at this lever |
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(measured at outer edge). |
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CAUTION |
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IF THERE IS NO PLAY ON THE CLUTCH LEVER, THE CLUTCH WILL START TO SLIP. THE |
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CLUTCH WILL THEN OVERHEAT, DESTROYING THE CLUTCH LININGS. |
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ENGLISH 5
2 |
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Hand brake lever |
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The hand brake lever 2 is mounted on the handle bars on the right and |
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actuates the front wheel brake. |
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WARNING |
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IF THE RESISTANCE IN THE HAND BRAKE LEVER FEELS “SPONGY” (TOO MUCH GIVE), 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.
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Short circuit button |
3 |
The short circuit button 3 turns off the engine. When pressing this button, |
the ignition circuit is short-cicuited. |
ENGLISH 6
2
40 mm
3
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.
Refueling, fuel
Oil (high-grade two-stroke engine oil; i.e. Shell Advance Racing X) must be mixed with the fuel (ROZ 95) at a mixing ratio of 1:40.
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WARNING |
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GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS. EXTREME CAUTION SHOULD BE USED WHEN HANDLING GASOLINE. NEVER REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARETTES. ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELING. BE CAREFUL NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT. WIPE UP SPILLS PROMPTLY. IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES, SEEK A DOCTOR’S ADVICE IMMEDIATELY.
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CAUTION |
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– ONLY USE PREMIUM-GRADE GASOLINE ROZ 95 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 (SHELL ADVANCE RACING X).
–NOT ENOUGH OIL OR LOW-GRADE OIL CAN CAUSE EROSION OF THE PISTON. 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.)
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.
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CAUTION |
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THE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED. IF THE TAP IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL GET INTO THE ENGINE.
Choke
The choke button 1 is located on the left side of the carburetor. Pulling the choke button 1 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 mixture needed for cold starting.
Pushing the choke button back in closes the bore in the carburetor.
2,3,4,5,6
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2
3
4
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.
Kickstarter |
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ENGLISH |
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The kickstarter is mounted on the right side of the engine. Its upper part can |
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be swivelled. |
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WARNING |
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WHEN STARTING THE ENGINE, PUT ON MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES. YOU MAY SLIP OFF THE KICKSTARTER, OR THE ENGINE MAY STRIKE BACK WHEN KICKING NOT VEHEMENTLY ENOUGH.
7
Rebound damping function of the shock absorber
The damping effect of the rebound damping mechanism can be adjusted to 14 different levels by means of the setting wheel 1. Turn the setting wheel clockwise (in) to increase and counterclockwise (out) to reduce the damping effect.
STANDARD SETTING: 6 CLICKS OPEN
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–NEVER TURN THE SETTING WHEEL MORE THAN TWO CLICKS BETWEEN TWO TEST RIDES.
–DO NOT TRY TO DISASSEMBLE THE SHOCK ABSORBER OR TO PERFORM MAINTENAN-
CE WORK YOURSELF. DANGER OF INJURY!
Compression damping of shock absorber
With the knob 2 the degree of damping of the compression can be adjusted to 7 positions. Turn the knob counterclockwise to increase damping, turn it clockwise to reduce damping during rebounding.
STANDARD SETTING: 3
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WARNING |
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– THE DAMPING UNITY OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRESSED NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.
Changing the 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.
Remove the right side cover.
Loosen the locking ring 3 with the hook spanner. Change the spring preload with the adjusting ring 4 and re-tighten the locking ring 3.
BASIC SETTING – SPRING PRELOAD 7 mm (0.3 in)
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