KTM 65 SX, 60 SX User Manual

OWNERS HANDBOOK

MANUEL D’UTILISATION

MANUAL DE INSTRUCCIONES

Art.Nr. 320583 10/99

2000

60/65

SX

BEDIENUNGSANLEITUNG

ENGLISH

1

Please insert the series numbers of your motorcycle in the boxes below

P

LEASE INSERT BELOW THE SERIES NUMBERS OF THE MOTORCYCLE

FRAME

NUMBER

ENGINE

NUMBER

STAMP OF DEALER

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.

!

CAUTION

!

IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO
PARTS OF THE MOTORCYCLE OR THAT THE MOTORCYCLE IS
NOT ROAD-SAFE ANYMORE.

Frame number

Engine number

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 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

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.

ENGLISH

3

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

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

Checking of brake fluid level - front brake . . . . . . . . .12

Refilling the front brake fluid reservoir . . . . . . . . . . . .13

Checking the front brake pads . . . . . . . . . . . . . . . . . .13

Replacing the front brake pads . . . . . . . . . . . . . . . . .13

Changing the basic position of the brake pedal . . . . . .14

Checking the rear brake fluid level . . . . . . . . . . . . . . .14

Refilling the rear brake fluid reservoir . . . . . . . . . . . . .14

Checking the rear brake pads . . . . . . . . . . . . . . . . . . . . .15

Replacing the rear brake pads . . . . . . . . . . . . . . . . . .15

Removing and installing the front wheel . . . . . . . . . . .16

Removing and installing the rear wheel . . . . . . . . . . .16

Checking the chain tension . . . . . . . . . . . . . . . . . . . .17

Correcting the chain tension . . . . . . . . . . . . . . . . . . .17

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 . . . . . . . . . . . . . . . . . . . . .19

Adjusting the throttle cable . . . . . . . . . . . . . . . . . . . .19

Adjusting the idle speed . . . . . . . . . . . . . . . . . . . . . .20

Checking the gear oil level . . . . . . . . . . . . . . . . . . . . .20

Changing the gear oil . . . . . . . . . . . . . . . . . . . . . . . .20

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

4

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)

– Have your youngster wear proper protective gear whenever he or she rides the motorcycle: helmet, eye pro-

tection, chest, back, arm and leg protectors, gloves and boots. To set a good example, be sure to wear pro-

tective gear yourself whenever riding a motorcycle!
– Adjust the hand brake lever to your youngster’s hand size (with gloves).
– 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 manual 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 shif-

ting of the rider’s weight, etc.
– Before using the motorcycle you should always check all components for proper operation (see maintenan-

ce 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.

IMPORTANT INFORMATION ON SAFE DRIVING FOR PARENTS

ENGLISH

5

10 mm

2

1

3

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.

Clutch lever

The clutch lever 1 is fitted on the left hand side of the handle bar. When
engine is cold, there should allways be a play of 10 mm (0,4 in) at this lever
(measured at outer edge).

!

CAUTION

!

I

F THERE IS NO PLAY ON THE CLUTCH LEVER, THE CLUTCH WILL START TO SLIP. THE

CLUTCH WILL THEN OVERHEAT

, DESTROYING THE CLUTCH LININGS.

Hand brake lever

The hand brake lever 2 is mounted on the handle bars on the right and
actuates the front wheel brake.



WARNING



I

F 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.

Short circuit button

The short circuit button 3 turns off the engine. When pressing this button,
the ignition circuit is short-cicuited.

SERIAL NUMBER LOCATIONS

OPERATION INSTRUMENTS

ENGLISH

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.



WARNING



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

.

W

IPE UP SPILLS PROMPTLY. IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES, SEEK

A DOCTOR

’S ADVICE IMMEDIATELY

.

!

CAUTION

!

–O

NLY USE PREMIUM-GRADE GASOLINE ROZ 95 MIXED WITH HIGH-GRADE TWO-

STROKE ENGINE OIL. OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE.

–O

NLY USE KNOWN BRANDS OF HIGH-GRADE 2-STROKE ENGINE OIL (SHELL ADVANCE

RACING X).

–N

OT ENOUGH OIL OR LOW-GRADE OIL CAN CAUSE EROSION OF THE PISTON. WHEN

U

SING 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.

!

CAUTION

!

T

HE 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.

6

40 mm

2

3

1

ENGLISH

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

The kickstarter is mounted on the right side of the engine. Its upper part can
be swivelled.



WARNING



W

HEN 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

.

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



WARNING



–N

EVER 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



WARNING



–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 prelo-

ad with the adjusting ring

4 and re-tighten the locking ring 3.

BASIC SETTING – SPRING PRELOAD

7 mm (0.3 in)

7

2,3,4,5,6

1

N

1

2

3

4

ENGLISH

8

DRIVING INSTRUCTIONS

– 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.

– To improve his/her riding skills, your youngster should prac-

tise to ride the motorcycle standing on the footpegs or to
ride at the slowest possible speed. Additionally, you can
arrange a series of obstacles and have your youngster drive
around them, etc.

– Pay attention to running-in procedure.



WARNING



– 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.

–ALWAYS KEEP IN MIND THAT OTHER PEOPLE FEEL MOLESTED BY EXCES-

SIVE NOISE.

Running in

– Even very precisely machined sections of engine components

have rougher surfaces than components which have been
sliding across one another for quite some time. Therefore,
every engine needs to be broken in. For this reason, during
its first 5 hours the engine must not be revved up to its per-

formance limits.
– Apply low but changing loads for running-in.
– DO NOT DRIVE AT FULL LOAD FOR THE FIRST 5 HOURS!

Starting when the engine is cold

1 Open fuel tap
2 Put the gear in neutral
3 Activate cold-starting aid (choke)
4 Leave throttle closed or open it no more than

1

/3and kick

down kickstarter vigorously all the way.



WARNING



–T

O AVOID INJURY WHEN STARTING THE ENGINE, ALWAYS WEAR BOOTS!

–D

O NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA.

E

XHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONS-

CIOUSNESS AND DEATH. ALWAYS PROVIDE ADEQUATE VENTILATION

WHILE THE ENGINE IS RUNNING

.

!

CAUTION

!

D

O NOT RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DO NOT REV UP

THE ENGINE WHEN COLD

. SINCE THE PISTON IS 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.

What you should check before each start

When you start off, the motorcycle must be in a perfect
technbical 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 CHECK TRANSMISSION OIL LEVEL.

A lack of gear oil leads to premature wear and finally results
in destruction of the gear wheels.

2 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.

3 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 chain and chain wheels.

4 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.

5 BRAKES

Check 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. Arrange for the braking system to be checked by
an authorized KTM dealer, as complete failure of the braking
system can be expected.
Also check the state of the brake hose and the thickness of
the brake linings.
Check free travel at hand brake lever and foot brake lever.

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.



WARNING



–H

AVE 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 WHE-

NEVER RIDING A MOTORCYCLE

!

–O

NLY USE ACCESSORY PARTS RECOMMENDED BY KTM.

Instructions for the first ride

– Verify that your KTM dealer performed the PREPARATION

OF VEHICLE jobs (see Customer Service Manual).

– 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 manual with your youngster item by item,
paying particular attention to the specially marked warnings
and pointing out the danger of injury.

– Adjust the basic hand brake lever position to your young-

ster's hand size. Your youngster should, of course, wear
gloves!

– 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.

ENGLISH

9

Starting when the engine is warm

1 Open fuel tap
2 Put the gear in neutral
3 Open throttle to

1

/2 and kick down kickstarter vigorously

What to do when the engine is „flooded”

1 Close fuel tap
2 Start engine with full throttle. If necessary, unscrew spark

plug and dry it.

3 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.



WARNING



–BEFORE YOU START OFF, CHECK THAT THE MAIN OR SIDE STAND HAS

BEEN SWUNG RIGHT UP TO THE TOP

. IF THE STAND DRAGS ON THE

FLOOR

, YOU MAY LOSE CONTROL OF YOUR MOTORCYCLE.

Shifting/Riding

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 clutch lever go slowly and open throttle or shift
down again.



WARNING



–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

.

–R

EPLACE THE HELMET VISOR OR GOGGLE GLASSES EARLY ENOUGH.

WHEN LIGHT SHINES DIRECTLY ON A SCRATCHED VISOR OR GOGGLES,

YOU WILL BE PRACTICALLY BLIND.

–A

FTER FALLING WITH THE MOTORCYCLE, CHECK ALL ITS FUNCTIONS

THOROUGHLY BEFORE USING IT AGAIN

.

–A

TWISTED HANDLEBAR MUST ALWAYS BE REPLACED. DO NOT ADJUST

THE HANDLEBAR

, IT WILL LOSE STA-BILITY.

!

CAUTION

!

–D

RIVING 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

ADDITION

,

THE REAR WHEEL BLOCKS SO THAT THE MOTORCYCLE CAN

EASILY GET OUT OF CONTROL

.

–I

F THE ENGINE RUNS WITHOUT THROTTLE DURING LONGER DOWNHILL

TRAVEL

, 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 MOTORCY-

CLE, YOU NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, YOUR

CHILD SHOULD STOP IMMEDIATELY

, TURN THE ENGINE OFF, AND

CONTACT AN AUTHORIZED

KTM DEALER.

Braking

Turn off gas and apply the hand and foot brakes at the same
time. When driving on sandy, wet or slippery ground use main­ly the rear wheel brake. Always brake with feeling, blocking
wheels can cause you to skid or fall. Also change down to lower
gears depending on your speed.



WARNING



–I

N 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

.

–D

IRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND BRAKE

DISCS

.

–W

HEN 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

.

Stopping

Brake motorcycle and shift gears to idling. To switch off the
engine, depress short circuit switch until the engine stops. Close
fuel tap.



WARNING



–NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS

THE ENGINE IS RUNNING

.

–M

OTORCYCLE 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 PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET

BURNED

.

!

CAUTION

!

–C

LOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE. OTHERWISE THE

CARBURETOR MAY GET FLOODED AND FUEL WILL ENTER THE ENGINE

.

–T

HE SIDE STAND IS ONLY DESIGNED FOR THE WEIGHT OF THE

MOTORCYCLE

. IF YOU GET ON YOUR MOTOR-CYCLE AND THUS PUT

ADDITIONAL WEIGHT ON THE MOTORCYCLE

, THE SIDE STAND OR THE

FRAME CAN BE DAMAGED OR THE MOTORCYCLE MAY FALL ON THE

SIDE

.

ENGLISH

10

PERIODIC MAINTENANCE SCHEDULE 60 / 65 SX

Check transmission oil level ●●

Change transmission oil ●

Check spark plug and electrode gap ●

Check carburetor for tight fit on the intake flange ●●

Check intake manifold for leaks and cracks ●

Drain and clean carburetor float chamber ●●

Check idle setting when engine is warm ●

Check air filter, filter box and filter boot ●●

Check sprockets, chain guides and chain for wear ●●

Clean and lube chain ●●

Check chain tension ●●

Check coolant level ●●●

Check quality of antifreeze ●

Check cooling system for leaks - visual inspection ●●●

Check exhaust system for leaks ●

Check exhaust brackets ●●

Check brake fluid level ●●●

Change brake fluid ●

Check thickness of disc brake pads ●●●

Check brake discs for wear and wobbling ●

Check freeplay and operation of hand brake lever and foot brake lever ●●

Inspect condition and installation of brake hose ●●●

Check fork for function and tightness ●●

Service front fork completely ●

Check steering head bearing clearance / adjust ●●

Clean and grease steering head bearings ●

Check shock absorber for function and tightness ●●

Check bearings of swingarm for play ●

Clean and grease bearings of swingarm ●

Check tightness of spokes and rim join ●●

Check wheel bearings for clearance ●●

Check tire condition and air pressure ●●

Check cables for damage, correct instalment and easy working ●●

Lube and adjust cables ●●

Check all screws, nuts and hose clamps for proper tightness ●●

Grease or lube all pivot points and sliding components ●●

before each start

after washing

Service after

20 hours

once a year

KTM
rider

KTM

dealer

09. 99

ENGLISH

11

2

1

4

3

1

2

3

4

Checking and adjusting the steering head bearing *

The steering head bearing should regularly be checked for play. For this pur­pose, jack up the motorcycle by the frame so that the front wheel is in the
air. Now try to move the fork forward and backward. There should be no
play.

Undo the screw of the starting number plate and swing the starting num­ber plate sideways.
Remove the four screws

1

of the handlebar clamps and remove the hand­lebar clamps.
Then swing the handlebar sideways.

Undo the two clamp screws

2

of the top triple clamp and remove the coun-

ter nut

3

. Then remove the top triple clamp.

Then turn the adjusting nut

4

until almost no more play is left, but do not
completely tighten the adjusting nut so as to prevent damaging of the bea­rings. Also keep in mind that the play of the bearings decreases when the
counter nut

3

is tightened. Therefore, once again check the play of the

bearings after tightening the counter nut

3

.
To mount the components reverse the procedure described above.
After mounting the triple clamp lightly tap it with a plastic hammer to pre­vent jamming and tighten the two clamp screws (15 Nm/11 ft.lb).



WARNING



IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY, THE MOTORCY-

CLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL.

!

CAUTION

!

–T

HE HANDLEBAR MUST MOVE EASILY. OTHERWISE THE BEARINGS WILL BE DAMAGED.

–I

F YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS, THE

BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME WILL BE DESTROYED

.

At least once a year, the steering head bearings should be smeared with
waterproof grease.



WARNING



ALL MAINTENANCE AND ADJUSTEMENT OPERATIONS THAT ARE MARKED WITH A *REQUIRE SPECIALIST KNO­WLEDGE. FOR YOUR OWN SECURITY, LET THESE TASKS BE CARRIED OUT BY A KTM-DEALER !

!

CAUTION

!

–W

HEN CLEANING THE MOTORCYCLE, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE, OTHERWISE WATER WILL PENETRATE THE BEARINGS, CAR-

BURETOR, 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

–D

O 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

.

–L

ET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED.

–R

EMOVE OILS, FATTY MATTERS,

FILTERS, FUELS, WASHING DETERGENTS ETC.

ORDERLY.

–U

NDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIZE

. 1 LITER USED OIL CONTAMINATES

1.000.000

LITERS WATER.

MAINTENANCE WORK ON CHASSIS AND ENGINE

ENGLISH

General information about KTM disc brakes

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 necessary
to top up the brake fluid. If the brake fluid level drops below the minimum
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 ”Shell Advance Brake 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. However, you should replace it as soon as possible by DOT 5.1.

BRAKE DISCS:
Due to wear, the thickness of the brake disc in the area of the contact
face

3 of the brake pads decreases. At their thinnest point A, the brake

discs must not be more than 0.40 mm (0,016 in) thinner than the pad's
nominal thickness. Measure the nominal thickness in a location

B outside

the contact face. Check wear in several locations.



WARNING



–B

RAKE DISCS SUFFERING FROM WEAR GREATER THAN 0,40 MM (0,016 IN) CONSTI-

TUTE A SAFETY RISK

. HAVE THE BRAKE DISCS REPLACED IMMEDIATELY AS SOON AS

THEY REACH THE WEAR LIMIT

.

–H

AVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BA A KTM DEALER.

Adjusting of 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 resi-

stance you feel on the hand brake lever when the brake pads are pressed
against the brake disc) can be adjusted for any hand size.

For this purpose, undo the counter nut

1 and twist the adjustment screw

until he desired adjustment is achieved. After the adjustment process retigh­ten the counter nut.

!

CAUTION

!

A

T 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 PROVI-

DED, PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM, AND THE FRONT-WHEEL BRAKE
MAY FAIL DUE TO OVERHEATING

.

Checking of brake fluid level - front brake

The brake fluid reservoir is combined with the hand brake cylinder on the
handlebar and provided with an inspection glass. When the brake fluid
reservoir is in a horizontal position, the brake fluid level should not drop
below the "MIN" mark on the inspection glass.



WARNING



D

ROPPING OF THE BRAKE FLUID LEVEL BELOW THE "MIN" MARK INDICATES LEAKS IN

THE BRAKE SYSTEM OR TOTALLY WORN BRAKE PADS

. IN THIS CASE, IMMEDIATELY

CONTACT A LICENSED

KTM DEALER.

12

1

2

min. 3 mm

DOT

5.1

DOT

5

✓

✕

A

B

3

ENGLISH

13

Refilling the front brake fluid reservoir *

When the brake fluid falls to the middle of the inspection glass, new brake
fluid has to be added.
Loosen screws

3 and remove lid 4 and membrane 5.

Place hand brake cylinder in a horizontal position and fill the brake fluid
reservoir to 5 mm (0.2 in) below the rim with clean brake fluid DOT 5.1
(Shell Advance Brake DOT 5.1). Replace membrane and lid, tighten screws.
Rinse off spilled or overflowing brake fluid with water.



WARNING



–N

EVER 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.

–S

TORE BRAKE FLUID OUT OF REACH OF CHILDREN.

–B

RAKE 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

!

!

CAUTION

!

–

DON’T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE PAINT

REMOVER

.

–U

SE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER

.

Checking the 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.



WARNING



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

.

!

CAUTION

!

I

F THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRE-

LY WORN

, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE

DISC

, THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC.

Replacing front brake pads

– Remove the two screws 1 and take the brake caliper off the brake disc.
– Undo the two pins

2 and take them out of the brake caliper. Then remo-

ve the brake pads by pulling them downwards.

– Before installing the new brake pads push the brake pistons backwards

with an appropriate screwdriver.

– Insert the brake pads into the brake caliper from below and mount two

new pins. Secure both pins by folding up the edges.

– Apply Loctite 242 to the threads of the screws

1 and mount the screws.

Tightening torque: 20 Nm (15 ft.lb).

5 mm

3

4

5

min.

1 mm

1

1

2

ENGLISH

Changing the basic position of the brake pedal *

The basic setting of the foot brake pedal can be changed by turning the end
stop roller 1. Using the push rod 2, 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
recognised from the resistance on the foot brake pedal).

!

CAUTION

!

I

F THIS CLEARANCE IS MISSING, PRESSURE ACCUMULATES IN THE BRAKING SYSTEM AND

THE BRAKE PADS BEGIN TO RUB

. THE BRAKING SYSTEM OVERHEATS AND CAN FAIL

COMPLETELY IN EXTREME CASES

.

Check the rear brake fluid level

The reservoir for the rear disc brake is located above the main brake
cylinder. The level of brake fluid may not fall below the „MIN” mark when
the vehicle has been left standing upright



WARNING



I

F THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS

A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN

. IN THIS CASE, CONSULT AN

AUTHORIZED

KTM DEALER IMMEDIATELY.

Refilling the rear brake fluid reservoir*

When the brake fluid level has dropped to the MIN mark, you need to refill
the brake fluid reservoir. Remove the right side cover.
This is done by first unscrewing the cap

3 and rubber belows 4. Add brake

fluid DOT 5.1 (Shell Advance Brake DOT 5.1) until it reaches the MAX
mark, then screw rubber belows and cap back on. Rinse off spilled or over­flowing brake fluid with water.



WARNING



– 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.

–S

TORE BRAKE FLUID OUT OF REACH OF CHILDREN.

–BRAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND EYES.

I

F YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER AND CONSULT

A DOCTOR

.

!

CAUTION

!

–D

ON’T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE

PAINT REMOVER

.

–U

SE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.

14

3-5mm

1

2

3

4

ENGLISH

15

Checking the 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).



WARNING



A

T 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.

!

CAUTION

!

I

F THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRE-

LY WORN, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE
DISC

, THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC

.

Replacing the rear brake pads *

– Remove the cover 1 and the locking ring 2. Using a punch 3, urge the

bolt out of the brake caliper in an outward direction and remove it
together with the leaf spring

4.

– Pull the brake pads upwards and out of the brake caliper. Clean brake

caliper thoroughly with compressed air.

– Before installing the new brake pads push the brake pistons backwards

with an appropriate screwdriver.

– Insert the new brake pads 5 into the brake caliper, position the leaf

spring

4, and secure it with the bolt 3. By tapping on the bolt, drive

it into the brake caliper up to the stop. Reattach locking ring

2 and

cover

1.



WARNING



–I

T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS

.

O

THERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.

–A

FTER ASSEMBLY, CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY.

–H

AVING PERFORMED ANY WORK ON THE BRAKING SYSTEM, ONE MUST ALWAYS ACTUA

-

TE 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

.

1

2

1

2

3

4

5

min.

1 mm

ENGLISH

16

Removing and installing the front wheel

– Jack the motorcycle up by the frame so that the front wheel is suspen-

ded above the ground.

– Undo the hexagon nut

1 and remove it together with the washer.

– Hold the front wheel and pull out the wheel spindle

2.

– Carefully take the front wheel out of the fork.

!

CAUTION

!

–

D

O 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.

– Lift the front wheel into the fork and correctly position it.
– Mount the wheel spindle

2.

– Mount the washer and the hexagon nut

1 and tighten (50 Nm/37 ft.lb).

– Put the motorcycle back on the ground and operate the front wheel

brake until the working point is reached.



WARNING



–I

F 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.

–A

FTER MOUNTING THE FRONT WHEEL, KEEP OPERATING THE HAND BRAKE UNTIL THE

PRESSURE POINT RETURNS

.

–I

T 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 WITH THE REQUIRED TORQUE

. A LOOSE WHEEL SPIND-

LE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE.

Removing and installing the rear wheel

– Jack the motorcycle up by the frame.
– Remove the hexagon nut

3 of the wheel spindle together with the was-

her

4 and remove the chain adjuster 5.

– 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.
– Before tightening the hexagon nut 3 make sure that the chain adjusters 5

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 with 50 Nm (37 ft.lb).

!

CAUTION

!

–

DO NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED.

–M

AKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL,

OTHERWISE THE BRAKE DISC CAN BE DAMAGED.

–I

F THE AXLE IS DISMOUNTED, CLEAN THE THREAD OF THE WHEEL SPINDLE AND COLLAR

NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE TO PREVENT THE THREAD
FROM JAMMING

.



WARNING



–I

F 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.

–A

FTER MOUNTING THE REAR WHEEL, KEEP OPERATING THE REAR BRAKE UNTIL THE

PRESSURE POINT RETURNS

.

–I

T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS,

EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED.

–T

IGHTEN THE HEXAGON NUT WITH THE REQUIRED TORQUE. A LOOSE WHEEL SPIND-

LE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE.

3

4

5

2

1

ENGLISH

17

Checking the chain tension

– Put the motorcycle on the side stand.
– Press the chain approx. 3 cm (1.2 in) behind the chain sliding piece up

toward the swingarm.

– In this place, it must be possible without pushing hard to press the chain

up to 10 mm (0.4 in) toward the swing arm (see figure). At the same
time, the upper half of the chain must be tense.

– If necessary correct the chain tension.



WARNING



–I

F 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

.

–I

F THE CHAIN IS NOT TIGHT ENOUGH IT CAN SLIP OFF THE SPROCKETS AND BLOCK THE

REAR WHEEL OR DAMAGE THE ENGINE

.

–I

N BOTH CASES THE RIDER IS VERY LIKELY TO LOSE CONTROL OF THE MOTORCYCLE

.

Correcting the 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.

–

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.

– Tighten the hexagon nut

1 with 50 Nm (37 ft.lb).



WARNING



–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

.

–T

IGHTEN THE HEXAGON NUT WITH THE REQUIRED TORQUE

. A LOOSE WHEEL SPIND-

LE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE.

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 (i.e. Shell Advance Bio Chain).



WARNING



N

O LUBRICATION IS ALLOWED TO REACH THE REAR TIRE, EITHERWISE THE ROAD ADHEREN

-

CE WOULD BE STRONGLY REDUCED AND THE MOTORCYCLE COULD EASILY LOSE CONTROL

.

!

CAUTION

!

W

HEN 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.

✓

2

3

2

4

1

3

4

10 mm

ENGLISH

18

Tires, air pressure

Tire type, tire condition, and air pressure level affect the way your motorcy­cle 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 pres-

sure (1.0 bar) ensures optimum driving comfort and extends the life of
your tires.



WARNING



–DAMAGED TIRES MUST BE REPLACED IMMEDIATELY TO PROTECT YOUR YOUNGSTER.
–W

ORN 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, especially on a new motorcycle, in 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.



WARNING



SPOKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE. THIS MAY LEAD TO AN

UNSTABLE HANDLING OF YOUR MOTORCYCLE

.

Removal of seat

By using the quick-release fastener 1, the seat can be removed without
using tools. Turn the quick-release fastener about 180° counter clockwise
and lift up the rear of the seat. Pull the seat backwards and unhook it from
the front fastener screw

2.

When installing the seat, be sure to insert the rear portion of the seat into
the metal clasp

3.

Cleaning the dust scrabbers of the telescopic fork

The dust scrabbers 4 should be cleaned on a regular basis.
For this purpose, use a screwdriver to lever the dust scrabbers out of the sli­der tubes, clean them thoroughly with compressed air, spray the fork tubes
and dust scrabbers with silicon oil and press the scrabbers back into the sli­der tubes.

1

2

1

3

4

ENGLISH

19

Cleaning of air filter*

To do this, remove the seat and the air filter cover from the air filter box.
Unclap the filter holder

1, swing back and remove air filter 2 plus filter car-

rier

3 from the filter box.

!

CAUTION

!

D

O NOT CLEAN FOAM FILTER WITH FUEL OR PETROLEUM SINCE THESE DAMAGE THE

FOAM

. KTM RECOMMENDS THE PRODUCTS OF THE COMPANY PUTOLINE FOR AIR FIL-

TER MAINTENANCE. „ACTION CLEANER“ FOR CLEANING PURPOSES AND „ACTION

F

LUID“ TO OIL THE FOAM FILTER.

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 carburettor collar

A for damage and that it is fitted correctly.

Mount the air filter

2 on the filter support 3. 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 B, and lock into place with the filter
holder

1.

Adjusting the clutch cable

When the engine is cold the play of the clutch lever should be 10 mm (mea­sure play at the outer end of the clutch lever).
To adjust the clutch cable push back the protection cover.
Undo the counter nut

4 and twist the adjustment screw 5 until the desi-

red adjustment is achieved.
After the adjustment process retighten the counter nut

4 and put the pro-

tection cover back into place.

Adjusting the throttle cable *

The play of the throttle cable should be 3-5 mm at all times. To check the
play of the throttle cable push back the protection cover 6 at the throttle
grip. Now it should be possible to pull the outer sleeve of the throttle cable
3-5 mm off the throttle twist grip housing before you begin to feel a slight
resistance.

To adjust the throttle cable undo the counter nut

9 at the carburetor and

twist the adjustment screw

8 until the desired adjustment is achieved. After

the adjustment process retighten the counter nut 9 and make sure the pro­tection cover is properly put back into place.

3-5 mm

2

1

10 mm

4

5

6

8

9

1

2

3

A

ENGLISH

20

Adjusting the idle speed *

The idle speed can be adjusted with screw 1.

Turn the screw clockwise to increase the idle speed.
Turn the screw counterclockwise to reduce the idle speed.

Checking the gear oil level

An inspection glass 2 on the left side of the engine allows easy checking of
the gear oil level.
– 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 engine oil (10W40 (i.ex. Shell Advance Ultra 4).

!

CAUTION

!

N

OT ENOUGH OIL OR A POOR OIL QUALITY LEAD TO PREMATURE WEAR OF THE TRANS-

MISSION. THEREFORE, USE ONLY HIGH-QUALITY OILS (E.G. SHELL ADVANCE ULTRA 4).

Changing the 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 with 15 Nm (11 ft.lb).

Remove the filler plug

4 and add 0.30 l engine oil 10W40 (e.g. Shell

Advance Ultra 4). Mount the filler plug and check the engine for leaks.

!

CAUTION

!

N

OT ENOUGH OIL OR A POOR OIL QUALITY LEAD TO PREMATURE WEAR OF THE TRANS-

MISSION

. THEREFORE, USE ONLY HIGH-QUALITY OILS (E.G. SHELL ADVANCE ULTRA 4).

1

3

4

2

ENGLISH

21

Cooling system

The water pump 1 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.

A mixture of 40% anti freeze liquid and 60% water is used as coolant. How­ever, the anti-freeze protection must be at least -25° C (-13° F). This mix­ture offers anti-freeze protection but also good corrosion protection and
should therefore not be replaced by pure water.

!

CAUTION

!

F

OR THE COOLING SYSTEM, USE ONLY WITH HIGH-GRADE ANTIFREEZE (SHELL ADVANCE

COOLANT). 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 2; a water temperature rising up to 120° C (248° F)
is admissible, without fear of problems.

Checking the 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.



WARNING



I

F POSSIBLE,

ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN 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

.

Exhaust system

The main silencer is filled with glass fiber yarn. Heat, however, causes the
glass fiber yarn filling to disintegrate which can reduce the overall perfor­mance of the motorcycle and the damping effect achieved by the main
silencer. The glass fiber yarn package can easily and quickly be replaced.

Remove the main silencer and take off the 4 screws

3 at the front end of

the main silencer. Then take off the connecting pipe

4.

Undo both hexagon nuts

5 and pull the front closure cap 6 out of the

outer sleeve

8.

Now the silencer cap

7 can be removed together with the glass fiber yarn

package

9, pulling both backwards out of the outer sleeve. Take the old

glass fiber yarn package off the inner exhaust pipe and clean the latter with
a wire brush.

To reassemble the main silencer put the new glass fiber yarn package onto
the inner exhaust pipe (see illustration) and push the inner pipe into the
outer sleeve.
Mount the front closure cap and fasten it with the two hexagon nuts

5.

Then fasten the front exhaust pipe

4 with the 4 screws 3 and mount the

main silencer on the vehicle.
Check the exhaust system for leaks.

NOTE: Glass fiber yarn packages are offered by your licensed KTM dealer.



WARNING



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

.

when engine is cold

10 mm

1

2

3

4

5

8

6

7

7

9

ENGLISH

22

main jet
jet needle

jet needle

idling jet

idling jet
throttle valve

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 1:40 .

Basic information on a change of 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 FAI-

LURE, AND USE OF SAME WILL VOID YOUR WARRANTY

.

–O

NLY USE HIGH-GRADE 2-STROKE ENGINE OIL OF KNOWN BRANDS (I. E.SHELL ADVANCE RACING 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 part­throttle 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.

1

D

C

B
A

ENGLISH

23

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

!

N

EVER 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.

– 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 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 preven-

ted 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, 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.



WARNING



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 have to 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 mechanic at the beginning of the next biking season.

CLEANING

STORAGE

ENGLISH

24

Spring 2,91 N/mm

Preload bushing - length 80 mm

Oil capadity per fork leg

170 ccm

Fork oil SAE 7,5

STANDARD ADJUSTMENT – FORK

WP 0318U706

Compression adjuster 3

Rebound adjuster 6

Spring 40-220

Spring preload 7mm (0.3 in)

S

TANDARDADJUSTMENT

- S

HOCKABSORBER

Frame single downtube, split-cradle

Fork telescopic fork (Paioli)

Wheel travel front/rear 200 mm (8 in) / 230 mm (9.2 in)

Rear suspension central shock absorber (White Power)

Front brake Disc brake Ø 198 mm (7.8 in), 1 piston

Rear brake Disc brake Ø 160 mm (6.3 in), 1 piston

Tyres front: 60/100-14“ rear: 80/100-12“

Air pressure front / rear: 1.0 bar (14 psi) / 1.0 bar (14 psi)

Fuel tank capacity 3.5 liter (0,92 USgal)

Final drive ratio 12 : 46 t

Chain 1/2 x 1/4" (415) 108 rolls

Steering angle 63.5 °

Wheel base 1128 mm (44,4 in)

Seat height, unloaded

740

mm (29,1 in)

Ground clearance 265 mm (10,4 in)

Dead weight without fuel 52 kg (114,8 lbs)

Rider’s body height max. 160 cm (63 in)

Rider’s body weight max 50 kg (22,7 lbs)

Recommended age of rider 8 to 12 years

Engine CR63

TECHNICAL SPECIFICATIONS – CHASSIS 65 SX 2000

Hexagon screw - brake caliper M 8 Loctite 242 + 20 Nm 15 ft.lb.

Flat head screw - brake discs M6 Loctite 242 + 10 Nm 7 ft.lb.

Hexagon nut - front wheel spindle M 12x1 50 Nm 37 ft.lb.

Hexagon nut - rear wheel spindle M 12x1 50 Nm 37 ft.lb.

Hexagon nut - swingarm bolt M 12x1 50 Nm 37 ft.lb.

Clamping screws - upper fork bridge M 8 15 Nm 11 ft.lb.

Clamping screws - lower fork bridge M 8 15 Nm 11 ft.lb.

AH screw - handlebar clamp M 8 20 Nm 15 ft.lb.

Other screws chassis M 5 6 Nm 4,5 ft.lb.

M 6 10 Nm 7 ft.lb.

M 8 25 Nm 18 ft.lb.

M 10 40 Nm 30 ft.lb.

TIGHTENING TORQUES

ENGLISH

25

Engine CR-60 CR-63

Design Liquid cooled single cylinder two-stroke engine with reed valve intake

Displacement 59,41 ccm 63,58 ccm

Bore/stroke 43,5 / 40 mm(1,71/1,57 in) 45 / 40 mm (1,77/1,57 in)

Compression ratio 9,1 : 1

Fuel SUPER fuel, research octane no 95, mixed with high grade two stroke oil

Oil/gasoline ratio 1 : 40 when using high grade two stroke oil (i.ex. Shell Advance Racing X),

when in doubt, please contact xour importer

Lubrication mixture lubrication

Crankshaft bearing 2 deep-groove ball bearing

Connecting rod bearing needle bearing

Piston pin bearing needle bearing

Piston rings 1 compression ring

Primary drive straight cut spur gears, 23:75 t

Transmission 6 speed, claw actuated

Gear ratio 1

st

gear 13 : 37

2

nd

gear 16 : 34

3

rd

gear 18 : 31

4

th

gear 21 : 30

5

th

gear 23 : 28

6thgear 24 : 26

Transmission oil 0,30 liter (0,0792 USgal) engine oil 10W40 (z B. Shell Advance Ultra 4)

Ignition system contactless controlled ignition (Selettra NW21)

Spark plug Champion C 55

Electrode gap 0,60 mm (0,0236 in)

Carburetor Mikuni VM 24

Coolant 0,55 liter (0,145 Usgal), mixture coolant : water = 2 : 1, at least -25° C (-13° F)

Air filter wet foam type air filter insert

TECHNICAL SPECIFICATIONS - ENGINE 60/65 SX 2000

ENGLISH

26

Carburetor Mikuni VM 24

Main jet 200

Needle jet N-8

Idling jet 30

Jet needle 5114-3

Needle position from top III

Throttle valve 2.0

Starting jet 20

BASIC CARBURETOR SETTING

Crankshaft run out of crank stud max. 0,050 mm 0,00196 in

Conrod bearing radial play max. 0,030 mm 0,00118 in

Piston fitting clearance 0,03 - 0,05 mm 0,00118 – 0,00196 in

Piston ring end gap max. 0,15 mm 0,00590 in

Clutch springs length min. 27 mm 1,06 in

Transmission shafts end float 0,10 - 0,20 mm 0,00394 – 0,00787 in

TOLERANCES AND FITTING CLEARANCES

Hexagon nut – primary gear M 10 60 Nm (44 ft.Ib)

Collar nut – flywheel M 10x1,25 40 Nm (30 ft.Ib)

AH screw – cylinder head M 7 15 Nm (11 ft.Ib)

Collar nut – cylinder base M 8 25 Nm (18 ft.Ib)

Hexagon screw – inner clutch hub M 10 Loctite 242 + 60 Nm (44 ft.Ib)

Oil drain screw M 8 12 Nm (9 ft.Ib)

Crankcase and cover bolts M 6 10 Nm (7 ft.Ib)

Other screws – engine M 5 6 Nm (5 ft.Ib)

M 6 10 Nm (7 ft.Ib)

TIGHTENING TORQUES - ENGINE

KTM SPORTMOTORCYCLE AG

5230 Mattighofen

Austria

Internet: http://www.ktm.at