KTM 60SX, 65SX 98-2002 Service Manual

60 SX / 65 SX

REPAIR MANUAL

ENGINE

KTM SPORTMOTORCYCLE AG

5230 Mattighofen Austria www.ktm.at

REPAIR

MANUAL

ENGINE

60 SX/65 SX

1 SERVICE-INFORMATIONS

2 GENERAL INFORMATION

3 REMOVING AND REFITTING ENGINE

4 DISASSEMBLING ENGINE

5 SERVICING INDIVIDUAL COMPONENTS

6 ASSEMBLING ENGINE

7 TROUBLE SHOOTING

8 TECHNICAL SPECIFICATIONS

9 PERIODIC MAINTENANCE SCHEDULE

Remove page (s) Replace by page (s) Insert page (s) after page

2-3 to 2-6 2-3d to 2-6d

3-4 3-4d

4-1 to 4-8 4-1d to 4-9d

5-2 to 5-7 5-2d to 5-7d

6-1 to 6-9 6-1d to 6-10d

7-1 7-1d

7-4 7-4d

8-1 to 8-13 8-1d to 8-12d

9-1 9-1d

9-6 9-6d to 9-8d

IMPORTANT INFORMATION/UPDATING INSTRUCTIONS

To be able to continue using the existing loose-leaf repair instructions, simply print the following pages and insert them in the existing repair instructions:

7, 9, 17-20, 25, 26, 29-38, 41-46, 51-61, 63, 67-81, 83, 89-91

KTM REPAIR MANUAL IN LOOSE-LEAF FORM

STORING THE REPAIR MANUAL IN THE BINDER

– Put the index into the binder. – Put the front page of the repair manual (210x297 mm) into the transparent pocket provided for

this purpose on the outside of the binder.

– Put the spine label (170x45 mm) into the transparent pocket provided for this purpose on the

spine of the binder.

– Put the summary list of contents (150x297 mm) into the transparent pocket provided for this

purpose on the inside of the binder or insert this page on the beginning of the manual.

– Then insert the individual chapters of the manual between the sheets of the index according to

the page number printed in the right bottom corner of each page. Example: page no. 3-5 3 = chapter 3 5 = page 5 All pages with a page number that begins with the digit 3, for example, must be put under the index heading „Chapter 3“.

– Index sheets that have not been marked with a certain chapter are for your personal convenience. T

respective headings can be entered in the list of contents.

EXPLANATION

- UPDATING

Edition 6/2002

This repair manual contains the following supplements:

3.205.46-E Repair Manual 60 SX / 65 SX

Basicversion Modelyear 1998 3/1998

3.205.75-E Updating of Rep.Manual 3.205.46-E

Modelyear 1999 5/1999

3.210.05-E Updating of Rep.Manual 3.205.46-E

Modelyear 2000/2001 2/2001 2000: from engine number B60 000 001

from engine number B65 000 001

2001: from engine number B65 100 001

3.210.36-E Updating of Rep.Manual 3.205.46-E

Modelyear 2002 11/2001 from engine number B65 200 001

3.210.66-E Updating of Rep.Manual 3.205.46-E

Modelyear 2003 6/2002 from engine number B65 300 001

Modification / Updating:

Special tools, technical details model 2003, ignition, measurements with PVA, technical specification, periodic maintenance schedule

INTRODUCTION

This repair manual offers extensiv repair-instructions and is an up-to-date version that describes the latest models of the series. However, the right to modifications in the interest of technical improvement is reserved without updating the current issue of this manual.

A description of general working modes common in work shops has not been included. Safety rules common in the work shop have also not been listed. We take it for granted that the repairs are made by qualified profesionally trained mechanics.

Read through the repair manual before beginning with the repair work.



WARNING



STRICT COMPLIANCE WITH THESE INSTRUCTIONS IS ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB.

CAUTION

NON-COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD TO DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER MOTORCYCLES UNFIT FOR TRAFFIC !

„NOTE” POINTS OUT USEFUL TIPS.

Use only ORIGINAL KTM SPARE PARTS when replacing parts.

The KTM high performance engine is only able to meet user expectations if the maintenance work is performed regularly and professionally.

KTM Austria’s certificate of achievement for its quality system ISO 9001 is the beginning of an ongoing total reengineered quality plan for a brighter tomorrow.

KTM Sportmotorcycle AG

5230 Mattighofen, Austria

All design and assembly modification rights reserved.

REPLY FAX FOR REPAIR MANUALS

We have made every effort to make our repair manuals as accurate as possible but it is always possible for a mistake or two to creep in.

To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us as follows:

If you find any errors or inaccuracies in one of our repair manual – whether these are technical errors, incorrect or unclear repair procedures, tool problems, missing technical data or torques, inaccurate or incorrect translations or wording, etc. – please enter the error(s) in the table below and fax the completed form to us at 0043/7742/6000/5349.

NOTE to table:

– Enter the complete item no. for the repair manual in column 1 (e.g.: 3.210.66-E).

You will find the number on the cover page or in the left margin on each right page of the manual.

– Enter the corresponding page number in the repair manual (e.g.: 5-7c) in column 2.

– Enter the current text (inaccurate or incomplete) in column 3 by quoting or describing the respective

passage of the text. If your text deviates from the text contained in the repair manual, please write your text in German or English if possible.

– Enter the correct text in column 4.

Your corrections will be reviewed and incorporated in the next issue of our repair manual.

Item no. of repair manual Page Current text Correct text

Additional suggestions, requests or comments on our Repair Manuals (in German or English):

Name mechanic/shop foreman Company/work shop

GENERAL INFORMATION

CARBURETOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

BLEEDING OF THE HYDRAULIC CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . .2-3

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

INDEX

Repair manual KTM 60 SX + 65 SX Art.-No. 321066-E

2-1d

2-2d

main jet jet needle

jet needle

idling jet

idling jet throttle valve

Carburetor adjustment

Basic information about the original carburetor setting

The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20° C (68° F), mainly for off-road use and central European premium-grade fuel (ROZ 95). Mixing ratio 2-stroke motor oil : super fuel 1:40 .

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 of other parts of the carburetor will not greatly affect engine performance.

RULE OF THUMB: high altitude or high temperatures  choose leaner carburetor adjustment

low altitude or low temperatures

 choose richer carburetor adjustment



WARNING



–O

NLY USE PREMIUM

-GRADE GASOLINE ROZ 95 MIXED WITH HIGH

-GRADE TWO-STROKE ENGINE OIL

. OTHER TYPES OF GASOLINE CAN CAUSE ENGINE

FAILURE

, AND USE OF SAME WILL VOID YOUR WARRANTY

–ONLY USE HIGH

-GRADE 2-STROKE ENGINE OIL OF KNOWN BRANDS

(I.

E.SHELL ADVANCE R

ACING X).

–N

OT ENOUGH OIL OR LOW

-GRADE OIL CAN CAUSE EROSION OF THE PISTON

. USING TOO MUCH OIL

, THE ENGINE CAN START SMOKING AND FOUL THE

SPARK PLUG

–I

N 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 despite a changed adjustment the engine does not run properly, look for mechanical faults and check the ignition system.

Basic information on carburetor wear

As a result of engine vibrations, 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.

Idling range – A

Operation with closed throttle valve. This range is influenced by the idle adjusting screw

1. Only make adjustments when the engine is hot.

The idling speed can be changed by turning the idle adjusting screw. Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed.

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 then 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.

Full throttle range – D

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 distance 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.

B A

2-3d

Repair manual KTM 60 SX + 65 SX Art.-No. 321066-E

Bleeding of the hydraulic clutch

– For bleeding, the cover of the master cylinder of the clutch needs to

be removed.

– At the slave cylinder of the clutch, remove the bleeder nipple

Instead of, mount the bleeder syringe

2 which is filled with SAE 10

hydraulic oil.

– Refill oil, until oil is discharged from the bore

3 of the master cylinder

in a bubble-free state. Make sure that the oil does not overflow.

CAUTION

KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL

NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS

ALWAYS USE BIODEGRADABLE HYDRAULIC OIL

SAE 10 (e.g. Shell Naturelle

HF-E15) TO FILL UP THE MASTER CYLINDER

. NEVER REFILL WITH MINERAL

HYDRAULIC OIL OR BRAKE FLUID

2-4d

cylinder

ignition

height

140

130

2-5d

Repair manual KTM 60 SX + 65 SX Art.-No. 321066-E

FIG. DESCRIPTION PART NUMBER

1 Engine mounting rack 560.12.001.000

2 Mounting tool for crankshaft 491.12.008.000

3 Bearing puller 151.12.017.000

4 Internal bearing puller 12 - 16 mm 151.12.018.000

5 Loctite 243 blue 6 ccm 6 899 785

6 Puller for flywheel 590.29.021.000

7 Holding spanner for primary gear 490.12.004.000

8 Holding spanner for inner clutch hub 490.12.003.000

9 Holding spanner for flywheel 151.12.021.000

10 Adjusting plate - ignition up to engine number 100 000 460.29.022.000

Adjusting plate - ignition from engine number 100 001 on

461.29.006.000

Adjusting plate - ignition from engine number 300 001 on

461.29.006.100

11 Engine holder for engine 460.29.002.000

12 Bleeding syringe for hydraulic clutch 503.29.050.000

13 Magneto extractor 546.29.009.044

Holding spanner for flywheel 546.29.012.100

2-6d

Clean your motorcycle regularly in order to keep its painted finish looking shiny and new. The best manner would be to use warm water that has been mixed with a commercially available washing detergent and a sponge. The hard dirt can be removed before with the help of a soft water jet.

CAUTION

EVER CLEAN YOUR MOTORCYCLE WITH A HIGH-PRESSURED CLEANER OR A HIGH-PRESSURED WATER JET. OTHERWISE WATER MIGHT RUN INTO ELECTRICAL

COMPONENTS

, CONNECTORS, SHEATHED CABLES, BEARINGS, CARBURETOR ETC. AND CAUSE MAILFUNCTIONS, I.E., LEAD TO THE PREMATURE DESTRUCTION

OF THESE PARTS

–You should use commercially available detergents to clean the motorcycle. Heavily soiled parts should also be cleaned with the

help of a paint brush. – Befor cleaning with water, plug the exhaust pipe to prevent water ingress. –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

inaccessible 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.

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 aggresive 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 kick-starter 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, foot rests, etc. as well as the chain. – The storage place should be dry and not be subject to overly great temperature fluctuations. – Cover the motorcycle with an air permeable tarpaulin or blanket. Do not use non-air-permeable materials, as possible humidity

might not be able to escape and thereby cause corrosion.

CAUTION

T 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.

CLEANING

STORAGE

REMOVING AND REFITTING ENGINE

REMOVING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

REFITTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

INDEX

Repair manual KTM 60 SX + 65 SX Art.-No. 321066-E

3-1d

3-2d

Repair manual KTM 60 SX + 65 SX Art.-No. 321066-E

Removing the engine

Before removing the engine thoroughly clean the entire motorcycle. Let the motorcycle cool down before commencing to remove the engine. Danger of burns!

– Jack the motorcycle up on a stable supporting device. –Turn the quick release device

of the seat (180°), slightly lift the rear

portion of the seat and pull it backwards.

– Close the fuel tap and disconnect the hose from the carburetor.

– Remove the chain joint and take off the chain.

Removing tank and exhaust system up to model 2001

– Undo the three bolts

2 on the left and right side and remove both side

covers.

– Remove the bolts

3 of the left and right tank spoilers.

– Remove the two bolts

together with their washers and lift off the

tank.

– Unhook spring

and remove bolt 6.

3-3d

– Unhook the two springs 1of the exhaust pipe and remove the

nut

– Remove the exhaust pipe from the vehicle.

Removing tank and exhaust system from model 2002 on

– Undo the bolt

and remove.

– Lift of tank together with spoilers.

– Unhook the two springs

of the exhaust pipe.

– Remove the bolt of the front exhaust bracket

– Remove the bolt of the rear exhaust bracket

– Pull exhaust pipe out of the rubber sleeve

, take of the exhaust pipe.

3-4d

Repair manual KTM 60 SX + 65 SX Art.-No. 321066-E

– Loosen the two hose clamps 1and remove the carburetor. – Let the fuel of the float chamber run out into an appropriate basin. – Put the carburetor into a clean cloth and lay it on the air filter box.

– Remove the radiator cap. – Remove drain screw

at the water pump cover and drain cooling

liquid.

– Loosen hose clamp

and disconnect the radiator hose.

Clutch control up to model 2001:

– Push the clutch release lever to front and hook out the clutch cable

Then move the release lever into its original position.

– Hook out the clutch cable at the clutch cable support.

Clutch control from model 2002 on:

– Remove the bolts of the clutch cylinder and take of the clutch

cylinder

– Remove bracket

and hang clutch cylinder aside.

– Disconnect spark plug connector, remove cable tie

and disconnect

the two pin connector

– Loosen hose clamp

and disconnect radiator hose at the cylinder

head.

– Remove the two engine fastening bolts

and swingarm pivot bl.

– Lift the engine out of the frame.

3-5d

Installing the engine

– Lift the engine into the frame and correctly position it. – Slightly grease the swingarm pivot

and insert it but do not tighten

it yet.

– Slightly grease, insert and tighten (25 Nm/19 ft.lb) the two engine

fastening bolts

–Tighten the swingarm pivot (40 Nm/30 ft.lb).

– Connect the two pin connector

and attach the cable to the frame

with a cable tie

. – Mount the spark plug connector on the spark plug. – Put the radiator hose onto the connection device on the cylinder head

and fix it with the hose clamp

Clutch control up to model 2001:

– Hook the clutch cable onto the clutch cable support 6, push the

clutch release lever forwards and hook the clutch cable

onto the clutch release lever. Then move the release lever back into its original position.

– Mount the screw

of the water pump cover with a new seal ring.

– Connect the radiator hose to the water pump and fix it with the hose

clamp

– Use the adjusting screw

on the clutch lever to adjust the clutch cable. The clearance measured at the outer end of the clutch lever must be 10 mm (do not forget to release counter nut

before you

commence). Finally, retighten counter nut

Clutch control from model 2002 on:

– Mount clutch cylinder

and tighten the bolts to 10 Nm (7 ft.lb).

NOTE: two bolts M6x16 are used in position

, one bolt M6x20 in

position

– Mount bracket

and tighten bolt with 10 Nm (7 ft.lb)

10 mm

3-6d

Repair manual KTM 60 SX + 65 SX Art.-No. 321066-E

– Fill approximately 0.30 l of antifreeze into the cooling system, then top

it up with water.

Total capacity: 0.55 l

– Mount the radiator cap

– Insert the rear end of the carburetor into the carburetor connection

boot and the front end into the intake flange.

– Mount and tighten both hose clamps.

Mount tank and exhaust system up to model 2001

– Position the exhaust and hook in the two front springs as well as the

rear spring.

– Use the two bolts to fix the exhaust to the silentblocks.

– Correctly position the tank and fix it with two bolts

and their

washers.

– Mount bolt

on the left and on the right side.

– Mount the left and ride side covers and fix them with 3 bolts

– Connect the fuel hose to the carburetor.

3-7d

Mount tank and exhaust system from model 2002 on

– Push exhaust pipe into the rubber sleeve

1 and tighten the bolt of the

rear exhaust pipe bracket 2.

–Tighten the bolt of the front exhaust pipe bracket

– Hook the spring

– Correctly position the tank and mount the bolt

5 with the tank roller,

tighten the bolt to 10 Nm.

– Connect the fuel hose to the carburetor.

– Mount the chain and the chain joint. When mounting the chain joint

make sure that the closed side of the safety device is facing the moving direction.

– Mount the seat. Make sure that the retaining bracket

is properly

hooked onto the seat. Insert the quick release device

into the

corresponding support and turn it (180 °).

After installing briefly warm up the engine and top up the cooling liquid. If the engine is working properly a short, careful test ride can be taken. After the test ride check the engine and the exhaust system for leaks.

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