KTM 60SX, 65SX 98-2002 Service Manual

4 (5)

60 SX / 65 SX

REPAIR MANUAL ENGINE

KTM SPORTMOTORCYCLE AG

5230 Mattighofen Austria www.ktm.at

60 SX/65 SX

REPAIR

MANUAL

ENGINE

1SERVICE-INFORMATIONS

2GENERAL INFORMATION

3REMOVING AND REFITTING ENGINE

4DISASSEMBLING ENGINE

5SERVICING INDIVIDUAL COMPONENTS

6ASSEMBLING ENGINE

7TROUBLE SHOOTING

8TECHNICAL SPECIFICATIONS

9PERIODIC MAINTENANCE SCHEDULE

10

11

12

13

14

15

16

IM P O RTA N T IN F O R M AT I O N /UP D AT I N G I N S T R U C T I O N S

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

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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. The respective headings can be entered in the list of contents.

EX P L A N AT I O N - UP D AT I N G

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

Edition 6/2002

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.

C by KTM SPORTMOTORCYCLE AG, AUSTRIA

All 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

 

 

2-1d

 

 

 

 

 

GENERAL INFORMATION

2

 

 

 

 

INDEX

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

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

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

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

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

Art.-No. 321066-E

Repair manual KTM 60 SX + 65 SX

2-2d

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 low altitude or low temperatures

choose leaner carburetor adjustment

choose richer carburetor adjustment

 

WARNING

 

– ONLY 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 RACING X).

NOT 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.

– 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 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.

D

C

B A

1

main jet jet needle

jet needle

idling jet throttle valve

idling jet

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.

2-3d

2

1

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 1. 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.

3 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.

Art.-No. 321066-E

Repair manual KTM 60 SX + 65 SX

KTM 60SX, 65SX 98-2002 Service Manual

2-4d

 

 

 

 

 

 

 

 

 

 

2

 

 

 

1

 

 

 

 

 

3

 

4

 

6

 

8

 

9

5

7

 

 

10

 

11

12

 

13

 

 

 

 

 

 

 

 

 

ignition

 

 

 

 

 

cylinder height

 

 

 

 

 

14

 

 

5

17

140

 

 

 

27

 

 

 

 

 

 

 

 

 

 

 

60

 

 

 

 

 

8

 

 

 

 

75

 

 

 

 

15

 

130

 

 

 

 

 

 

 

 

 

50

 

 

 

2-5d

 

 

 

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

 

 

 

 

 

14

Holding spanner for flywheel

546.29.012.100

 

 

 

 

 

Art.-No. 321066-E

Repair manual KTM 60 SX + 65 SX

2-6d

CLEANING

Clean your motorcycle regularly in order to keep its painted finish looking shiny and new.

The best manner would be to use warm water that has been mixed with a commercially available washing detergent and a sponge. The hard dirt can be removed before with the help of a soft water jet.

!

CAUTION

!

NEVER 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.

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 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

!

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.

3-1d

REMOVING AND REFITTING ENGINE 3

INDEX

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

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

Art.-No. 321066-E

Repair manual KTM 60 SX + 65 SX

Art.-No. 321066-E

Repair manual KTM 60 SX + 65 SX

3-2d

Removing the engine

1

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 1 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.

3

2

2

Remove the two bolts 4 together with their washers and lift off the tank.

4

– Unhook spring 5 and remove bolt 6.

5

6

3-3d

2

1

3

4

4

5

6

Unhook the two springs 1 of the exhaust pipe and remove the nut 2.

Remove the exhaust pipe from the vehicle.

Removing tank and exhaust system from model 2002 on

Undo the bolt 3 and remove.

Lift of tank together with spoilers.

– Unhook the two springs 4 of the exhaust pipe.

– Remove the bolt of the front exhaust bracket 5.

Remove the bolt of the rear exhaust bracket 6.

Pull exhaust pipe out of the rubber sleeve 7, take of the exhaust pipe.

7

Art.-No. 321066-E

Repair manual KTM 60 SX + 65 SX

3-4d

– Loosen the two hose clamps 1 and remove the carburetor.

1 1 – 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.

4 – Remove drain screw 2 at the water pump cover and drain cooling liquid.

– Loosen hose clamp 3 and disconnect the radiator hose.

Clutch control up to model 2001:

Push the clutch release lever to front and hook out the clutch cable 4. Then move the release lever into its original position.

Hook out the clutch cable at the clutch cable support.

2

3

Clutch control from model 2002 on:

Remove the bolts of the clutch cylinder and take of the clutch cylinder 5.

Remove bracket 6 and hang clutch cylinder aside.

6

 

 

 

 

 

 

 

 

– Disconnect spark plug connector, remove cable tie 7 and disconnect

 

 

 

 

 

 

 

 

 

 

 

 

 

 

9

 

 

 

 

the two pin connector 8.

 

 

 

 

 

 

 

 

Loosen hose clamp 9 and disconnect radiator hose at the cylinder

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

head.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

11

Remove the two engine fastening bolts bk and swingarm pivot bl.

Lift the engine out of the frame.

10

10

3-5d

4

7

1

5

9

Installing the engine

Lift the engine into the frame and correctly position it.

Slightly grease the swingarm pivot 1 and insert it but do not tighten it yet.

Slightly grease, insert and tighten (25 Nm/19 ft.lb) the two engine fastening bolts 2.

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

Connect the two pin connector 3 and attach the cable to the frame with a cable tie 4.

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 5.

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

Mount the screw 8 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 9.

10

11

15

13

Use the adjusting screw bk 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 bl before you commence). Finally, retighten counter nut bl.

Clutch control from model 2002 on:

Mount clutch cylinder bm and tighten the bolts to 10 Nm (7 ft.lb). NOTE: two bolts M6x16 are used in position bn, one bolt M6x20 in position bo.

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

Art.-No. 321066-E

Repair manual KTM 60 SX + 65 SX

3-6d

1

2

2

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 1.

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 2 and their washers.

 

 

 

– Mount bolt 3 on the left and on the right side.

 

 

 

Mount the left and ride side covers and fix them with 3 bolts 4.

 

4

 

 

 

Connect the fuel hose to the carburetor.

4

3

3-7d

2

1

3

4

5

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 3.

– Hook the spring 4.

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.

7

6

Mount the seat. Make sure that the retaining bracket 6 is properly hooked onto the seat. Insert the quick release device 7 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.

Loading...
+ 64 hidden pages