65 SX 2011

SPARE PARTS MANUAL: CHASSIS

ART.NO.: 3CF6001K6EN

ENGLISH
FRONT FORK, TRIPLE CLAMP HANDLEBAR, CONTROLS FRAME

FRONT FORK DISASSEMBLED

SHOCK ABSORBER DISASSEMBLED SWING ARM

SHOCK ABSORBER

EXHAUST SYSTEM
AIR FILTER TANK, SEAT, COVERS

MASK, FENDERS

FRONT WHEEL
REAR WHEEL HAND BRAKE CYLINDER BRAKE CALIPER FRONT
BRAKE CALIPER REAR REAR BRAKE CONTROL

ACCESSORIES KIT

All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models. by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTMSPORTMOTORCYCLE AG, Mattighofen only.
FIG 99 PART NUMBER 0025060306 7819139/C 7538029 7717065/R 7701204AC 7701205AC 7850208AR 7528034 7539032AA 7538038/A 7760069FN/C 7530090/B 7530088/B 7521147/A 7819140/C 7521092/E 7850731/C DESCRIPTION HH COLLAR SCREW M6X30 TX30 SLIDER + AXLE CLAMP CPL. R/S GUIDE RING D=35 FOOT VALVE O-RING D=20,3 SHIM 8,1X23X0,1 PISTON RING D=26 LOWER REBOUND SPRING PLUG R/S CPL. PLUG L/S CPL. LENTIL HEAD SCREW M4X6 O-RING D=3,69, S=1,78 O-RING D=34,6, S=1,78 PIN + O-RING SPRINGS + PRELOAD SLEEVES KIT DUST CAP LOCK WASHER D=51,5 OIL SEAL 35X47X10 WASHER 36X47X3 GUIDE RING 35X15 OUTER TUBE CPL. COMPRESSION DAMPING SHIM SHIM 8,1X23X0,2 SHIM 8,1X21X0,2 SHIM 8,1X18X0,2 PISTON COMPRESSION D=26 PISTON COMPRESSION D=26 SPECIAL NUT M6X1 WITH STEP SLIDER + AXLE CLAMP CPL. L/S SPECIAL NUT M6X1 WITH STEP SHIM 8X12X1,5 AH SCREW DIN0912-M 8X25 SHIM 8,1X23X0,3 FORKOIL EBH16 SAE 7.5 REPAIR-KIT USD 35

094620130 / C094620130

* NEW PART

X AS REQUIRED

FRONT FORK, TRIPLE CLAMP
FIG 5 6* 91 92* 94* PART NUMBER 0025080306 0032100256S 0985050003 DESCRIPTION FRONT FORK USS D035MM 09 HH COLLAR SCREW M6X30 TX30 HH COLLAR SCREW M8X30 TX40 AH-COLLAR SCREW M10X25 ISA45 BOT.TRIPLE CLAMP + FORK TUBE TOP TRIPLE CLAMP HANDLEBAR CLAMP D=22MM 2001 HANDLEBAR SUPPORT 22MM 2T 2000 HH NUT M20X1,5 WS=27 RIGHT COVERING CAP O-RING 40,94X2,62 NBR70 TAPERED ROLLER BEARING 32004X PROTECTION RING 20,1X39X5 O-RING 36,00X3,00 NBR SPECIAL SCREW M6X12,5 WS=8 FORK PROTECTOR SET 65 SX WHITE BRAKE HOSE CLIP HH COLLAR SCREW M5X16 TX30 SELF LOCKING NUT DIN0985-M 5

094620110 / C114620110

HANDLEBAR, CONTROLS
FIG PART NUMBER DESCRIPTION HANDLEBAR 65 SX 2009 THROTTLE GRIP 65SX 09 THROTTLE CABLE 65 SX 2009 GRIP SET DUAL COMPOUND PROTECTION COVER '97 SHORT CIRCUIT BUTTON 02 MASTER CYLINDER CPL. D=9MM 05 CLUTCH LEVER SHORT CPL. 2003 CLUTCH LEVER LONG CPL. 2003 REP.KIT PISTON 9,0MM RAC. 2004 COVER HYD.CLUTCH 2T 2000 RUBBER FOR RESERVOIR '98 SPRING FOR CLUTCH LEVER 03 OIL FOR HYD. CLUTCH 75ML PROTECT.CAP FOR LEVER PERCH'98 LEVER SCREW CPL. 125-200 '98 CLAMP WITH PIN 2000 HH COLLAR SCREW M6X20 TX30 FLAT HEAD SCREW DIN0965-M 4X12 SELF CUTTING RING HYDR.PIPE PIPE KIT FOR HYDR.CLUTCH 65 SX PROTECTION CAP

QTY x x 1 1

094620210 / C094620210
FIG 19 PART NUMBER 46203002000 0019080206S 36003014000 DESCRIPTION FRAME 65 SX "MD09" 09 SELF LOCKING NUT M8 10.9 HH SCREW DIN 931 M8X80 10.9 WASHER DIN0125-A 8,4 HEXAGON NUT DIN0934-M 8 SPECIAL SCREW M8X26 WS=10 ADH. FOIL TRANSP. 80X80 MM 04 FOOTPEG L.+R. CPL. 85 SX 03 FOOT PED L/S EXC SILVER 2000 FOOT PED R/S EXC SILVER 2000 BOLT FOR FOOT PED 03 WASHER DIN0125-A10,5 FOOTREST SPRING L/S & R/S PIN DIN0094-3,2X25 STEEL SUB FRAME 65 SX 2009 FLAT HEAD SCREW M. ISA45 M8X20 CHAIN SLIDING PIECE BELOW 07 HH COLLAR SCREW M8X35 TX40 LOCK WASHER 8MM

094620310 / C094620310

SHOCK ABSORBER DISASSEMBLED
FIG PART NUMBER R308 46810850S9 36120817S93010181S 93010182S 93010183S 36120386 36120781S36120787S 36120799 R309 50180342S1 DESCRIPTION REPAIR-KIT CC-COMPRE.DAMPING CONTROL CPL. MONOSHOCK TOP PART CPL. O-RING NBR 5,28X1,78 SCREW PLUG M5X6 RUBBER CAP "DO NOT OPEN" COUNTERNUT ADJUSTING NUT SPRING 40N/MM 40-220 220MM ORA SPRING 35N/MM 35-220 220MM ORA SPRING 45N/MM 45-220 220MM ORA SPRING RET. H=3, D=14,5 MONOSHOCK BOTTOM PART CPL. PISTON RING 8X1X108,3 ADAPTOR 36MM H26,6 CPL. 07 BUMP RUBBER REPAIR KIT BEARINGS 65 SX 09 SHOCK ABSORBER FLUID 5 LT '03

QTY x x x 1

094620430 / C094620430

SWING ARM

FIG PART NUMBER DESCRIPTION SWING ARM CPL. 65 SX 2008 SELF LOCKING NUT M10 CU WS=14 NEEDLE BUSH HK 2016 SPACER BUSHING 20X26X30X9,7 BUSHING BOX 12X20X36,5 O-RING 16,00X2,00 VITON CHAIN SLID. GUARD FRO. 65SX 02 BUSH FOR CHAINSLIDER GUARD 02 SPECIAL SCREW M 5,0X10 SPECIAL SCREW M 5,0X10 CHAIN GUIDE REAR 60/65 '98 HH COLLAR SCREW M6X40 TX30 SELF LOCKING NUT M6 10.9 CHAIN GUARD 08 CABLE TIE 300/4,8MM BLACK SWINGARM BOLT CPL. 201MM FLAT WASHER DIN0125-A13 HEXAGON NUT DIN0934-M12X1 CHAIN ADJUSTER 60/65 '98 HH SCREW M8X40 WS=10 HEXAGON NUT DIN0934-M 8 RETAIN.CLAMP FOR BRAKE HOSE'96

QTY 2 2

094620490 / C094620490
FIG 3 PART NUMBER 03187E54310086100 DESCRIPTION MONOSHOCK 65SX 2009 HH COLLAR SCREW M10X42 WSSELF LOCKING NUT M10 CU WS=14

094620410 / C104620410

FIG PART NUMBER DESCRIPTION EXHAUST PIPE 65 SX 2009 RUBBER SLEEVE D=21MM/23MM '93 SILENCER 65 SX 2009 ROCKWOOL PREFOMED O-RING 35,00X3,00 VITON TEN.SPRING L=62MM EY.MOVEABLE RANGE CHANGE METAL NUT M6 SWINGELEMENT FOR EXHAUST PIPE HH COLLAR SCREW M6X15 TX30 HH COLLAR SCREW M6X16 TX30 HH COLLAR SCREW M6X45 TX30 BUSHING 7.5X12X28X7.6 EXHAUST BRACKET RUBBER BLACK BUSHING 7.5X12X28X23.6

QTY 1 1

094620510 / C094620510

AIR FILTER

FIG PART NUMBER DESCRIPTION AIR FILTER FILTER BOW 65 SX 2009 EJOT PT SCREW K60X20 WS=6 CARBURETOR CONN. BOOT 65 SX 09 HOSE CLAMP 45-65MM FILTER CARRIER '97 AIR FILTER BOW PANEL 65SX 2009 HH COLLAR SCREW M6X25 TX30 COLLARED BUSHING 65SX 09 AIR FILTER BOX 65 SX 09 SPECIAL SCREW T60 6X30 WS=6 SPACER BUSHING 03

094620610 / C094620610

TANK, SEAT, COVERS
FIG 15* 18 PART NUMBER 4620701303330 78007008044X0025060126 46208054000X4C 0025060206 DESCRIPTION FUEL TANK CPL. 65 SX 2009 TANK PLUG ORANGE/BLACK FUEL COCK CPL. SMALL RALLYE'96 O-RING 1,78x10,82x14,38 2-013 EJOT PT SCREW K60X20 WS=6 FUEL PREFORMED HOSE 65 SX 2009 YDNAC-CLAMP 10107 10MM PVC-HOSE 5,6X10X270MM COLLAR SCREW M6X27 TX TANK BUSHING 07 SEAT 65 SX 2009 QUICK RELEASE CPL. 50 SXR '97 TANK ROLLER 12X26X12 '98 HH COLLAR SCREW M6X12 TX30 SPOILERSET EJOT PT SCREW K60X20 ALU WS=6 BUSH FOR SPOILER 6X11X16X5 MM HH COLLAR SCREW M6X20 TX30

094620710 / C114620710

FIG 1* 2* 7* PART NUMBER 46208010000X0017060203 DESCRIPTION START NUMBER PLATE BRAKE HOSE GUIDE EJOT PT SCREW K60X20 ALU WS=6 HH COLLAR SCREW M6X10 TX30 FENDER FRONT 65 SX 2010 HH COLLAR SCREW M6X13 TX30 REAR PART QUICK RELEASE LATCHPLATE SHEET MET.SCR.DIN7981- 3,5X16 SPLASH PROTECTION 65 SX 2009 SPECIAL SCREW T60 6X30 WS=6 SPACER BUSHING 03 EJOT PT SCREW K60X20 WS=6

094620810 / C114620810

FIG 1* PART NUMBER 46208091300 DESCRIPTION DISPLACEM. DECAL 65 SX 2011

104620830 / C114620830

FIG 48 PART NUMBER 50310090050 DESCRIPTION FRONT WHEEL-SP 65 SX 09 FR.WHEEL HUB CPL. SILVER 2006 SPACER BUSH L/S 65SX 04 SPACER BUSH R/S 65SX 04 BEARING SPACER TUBE GR.BALL BEAR. 6003-2RSH/C3HMTF % RIM BAND 14" RIM FRONT 14"X1,6 BLACK 2009 SPOKE NIPPEL M3,BRAKE DISC FRONT 65 SX 09 SPECIAL SCREW M6X16 WS=8 10.9 SELF LOCKING NUT M6 10.9 SPOKE M3,5X145MM SPOKE M3,5X149MM AXLE FRONT 65SX 2002 PLUG SFL13 HH COLLAR SCREW M10X20 WS=17 RIM LOCK CPL. 2004 NUT FOR WHEEL HOLDER '96

094620910 / C094620910

REAR WHEEL
FIG 56 PART NUMBER 50310090050 DESCRIPTION REAR WHEEL-SP 65 SX 09 REAR WHEEL HUB CPL.60/RIM REAR 12"X1,6 BLACK 2009 SPOKE NIPPEL M3,GR.BALL BEAR. 6003-2RSH/C3HMTF GR.BALL BEAR. 6203-2RSHC3HMTF BEAR.SPACER TUBE REAR SX 60/65 SPECIAL SCREW M6X16 WS=8 10.9 SPACER BUSH R/S SX 60/SPACER BUSH L/S SX 60/SPOKE 3X136 C. 150 SPOKE 3X129 C. 161 FLAT HEAD SCREW DIN7991-M 8X25 SELF LOCKING NUT M8 10.9 REAR SPROCKET 46-T REAR SPROCKET 48-T REAR SPROCKET 50-T AXLE REAR 213MM M12X1 RIM BAND 12" BRAKE DISC REAR 65 SX 09 WASHER 20X12,2X2 HEXAGON NUT 12X1 WS19 NUT DIN917-M12X1 CHAIN 1/2X1/4" 65 SX CONNECTING LINK 1/2X1/4" RIM LOCK VM1 (1,60") NUT FOR WHEEL HOLDER '96

QTY x x x 1 1

094621010 / C094621010

HAND BRAKE CYLINDER

FIG PART NUMBER DESCRIPTION HAND BRAKE CYL. CPL. 11MM 03 BRAKE LEVER LOOSE 85 SX 2003 CYLINDER COVER CPL. FRONT 2003 PROTECTION COVER 85 SX 2003 CLAMP FOR BRAKE CYLINDER 2003 SCREW+BUSHING+NUT 03 ADJUSTING SCREW CPL. 85 SX 03 REP.SET PISTON FRONT D=11MM BALL+SPRING+SPRING GUIDE 03 BRAKE HOSE FRONT 65 SX 2004 O-RING 8,00X1,00 FORMULA SELF LOCKING NUT M6 10.9 HH COLLAR SCREW M6X20 TX30 HH COLLAR SCREW M6X30 TX30 HOLLOW SCREW BRAKE CYLINDER 03 BRAKE FLUID DOT5.1 0,25L

094621310 / C094621310

BRAKE CALIPER FRONT
FIG 85 PART NUMBER 46113125000 DESCRIPTION BRAKE HOSE FRONT 65 SX 2004 O-RING 8,00X1,00 FORMULA REPAIR KIT BRAKEPISTON BRAKE CALIPER FR. CPL.85 SX 03 RETAINING SPRING 65 SX BLEEDER SCREW M6 CAP FOR BLEEDER SCREW O-RING 10X1 EPDM HOLLOW SCREW M8X38,8 BRAKE PAD SET FRONT 2002 AH SCREW DIN0912-M 6X28 HH COLLAR SCREW M8X30 TX40 REPAIR KIT SEAL RING 2002 TAB WASHER DIN6799-RA 4,0 AH SCREW + CIRCLIP 2002

094621360 / C094621360

BRAKE CALIPER REAR
FIG 90 PART NUMBER 47013090200 DESCRIPTION RETAINING SPRING 65 SX CAP FOR BLEEDER SCREW REPAIR KIT BRAKEPISTON HOLLOW SCREW REAR 85 SX 2003 HOLLOW SCREW REAR 85 SX 2003 HH COLLAR SCREW M8X20 TX40 HH COLLAR SCREW M8X40 TX40 BRAKE HOSE REAR 65 SX 09 O-RING 8,00X1,00 FORMULA O-RING 10X1 EPDM BRAKE CALIPER REAR CPL.65SX 09 REPAIR KIT SEAL RING REAR 03 AH SCREW + CIRCLIP 85/105 TAB WASHER DIN6799-RA 4,0 BRAKE CALIPER SUPPORT BLEEDER SCREW M8X1 BRAKE PADS REAR SINTER 85SX 08

094621390 / C094621390

REAR BRAKE CONTROL
FIG 5 6* 80 PART NUMBER 54630044000 0032100406S 00062030000 DESCRIPTION FOOT BRAKE LEVER 65SX CPL. STEP PLATE FOR BRAKE LEVER HH COLLAR SCREW M5X12 TX30 BALL BEARING 6000/C3 COLLAR NUT M10 WS=13 AH-COLLAR SCREW M10X40 ISA45 SPECIAL SCREW M8X26 WS=10 COLLAR NUT M8 WS=10 RETURN SPRING FOR BRAKE LEVER SWIVEL HEAD KAHH COLLAR SCREW M6X20 TX30 HEXAGON NUT DIN0934-M 6 PRESSURE ROD 85 SX 06 HH COLLAR SCREW M6X16 TX30 FOOT BRAKE CYL.R. CPL. D=REP. SET PISTON REAR D=CYLINDER COVER REAR 85 SX 03 GASKET CYLINDER COVER REAR 03 HOLLOW SCREW BRAKE CYLINDER 03 AH.SCREW DIN0912-M 4X10 BRAKE HOSE REAR 65 SX 09 O-RING 8,00X1,00 FORMULA BRAKE FLUID DOT5.1 0,25L

094621330 / C114621330

FIG 1* 1 1* 1* PART NUMBER 46208010000X3211594EN 322000 3CF6001K6EN 3CM080208KEN DESCRIPTION HH COLLAR SCREW M6X13 TX30 DOCUMENTS BAG 2006 KTM BALLPOINT PEN ORANGE CABLE TIE 200/3,6MM BLACK FENDER FRONT 65 SX 2010 FOOTPEG L.+R. CPL. 85 SX 03 OWN.MANUAL 65 SX 2011 SAFETY BROCHURES SPORTMINICYC. SPC CHASSIS 65SX 2011 SPC ENGINE 65SX 2011 TOOL KIT 65 SX 09 PLUG IN STAND SX HOOK WRENCH FOR SHOCK ABSORBER T-WRENCH WS=6/8/10 TX=45 B&F WRENCH SW=17/21/27/32 B&F SPARK PLUG WRENCH

094622001 / C114622000

SPARE PARTS MANUAL: ENGINE

ART.NO.: 3CM080208KEN

SPECIAL TOOLS
CRANKSHAFT, PISTON REED VALVE CASE ENGINE CASE
CLUTCH COVER CYLINDER, CYLINDER HEAD

CARBURETOR

CLUTCH

TRANSMISSION KICKSTARTER

SHIFTING MECHANISM

COOLING SYSTEM

WATER PUMP

IGNITION SYSTEM

FIG PART NUMBER T106S 46229090000 DESCRIPTION UNIVERSAL MOUNTING RACK LIFT STAND SX/EXC GEAR SEGMENT CPL. HOUSING SEPARATING TOOL CPL. PRESS. TOOL F. CRANKSHAFT RETAIN. ARM F. ENG. WORK STAND PRE LOAD KEY 4681 STEEL GROUND PLATE SUPPORT ENGINE BASE CPL. ADJUSTING PLATE 65 SX 2003 PRESS. TOOL SPARK PLUG WRENCH 16MM 1/2INCH MAGNETIC PULLER M 27X1 KOKUSAN CLUTCH HOLDER PRESS OUT PLATE CRANKSHAFT FEELER GAUGE SET HOLD. SPANNER ROTOR 2K-1/2/3/4 %SPRING HOOK PEAK VOLTAGE ADAPTER 01 PROTECTION CAP CRANKSHAFT

094622910 / C094622910

CRANKSHAFT, PISTON
FIG PART NUMBER I 46230007000 II 46030030500 DESCRIPTION HH NUT 14X1,25X7 WS=22 STOP DISK 15,2X25,7X1 PRIMARY PINION LOOSE WOODRUFF KEY DIN6888 4X5X13 SH.SEAL RING 30X47X7 BSL VITON GROOVED BALL BEAR.20X52X15 NTN SPACER WASHER - CRANKSHAFT O-RING 16,00X2,00 VITON NEEDLE BEAR.PISTONPIN 12X15X17 CRANKSHAFT CPL. WOODRUFF KEY DIN6888-3X5X13 SEAL SHAFT RING 20X35X6 BTSL CONNECT. ROD REPAIR SET PISTON CPL. I PISTON CPL. II PISTON PIN 12X38 CIRCLIP 09 PISTON RING 45MM 65CCM

QTY 1 x x 1

094623060 / C094623060

REED VALVE CASE

FIG PART NUMBER DESCRIPTION GASKET MEMBRAN CASE MEMBRANE CASE CPL. V-VORCE MEMBRANE INTAKE FLANGE HH COLLAR SCREW M6X20 TX30 CLAMP 25-40 SGT 4

QTY 4 1

094623070 / C094623070

ENGINE CASE

FIG PART NUMBER DESCRIPTION ENGINE CASE CPL. + CONTR.SLIDE ENGINE CASE GASKET OILDRAIN PLUG W.MAG. M 12X1,5 CU-SEAL RING DIN7603-12X18X1,5 DOWEL 12X9X14,5 DOWEL 17/12.1/9.5 DOWEL 10X8,2X10 STUD DIN0835-M 8X35 10.9 STUD M8X41 RETAINING PLATE HH COLLAR SCREW M6X10 TX30 CHAIN SPROCKET GUARD HH COLLAR SCREW M6X30 TX30 CU-SEAL RING DIN7603-6X10X1 VACUUM CONECTION M6/3MM '97 PVC-HOSE 4X6MM GASKET SET 65 SX 2009 HH COLLAR SCREW M6X55 TX30 HH COLLAR SCREW M6X40 TX30 HH COLLAR SCREW M6X30 TX30 HH COLLAR SCREW M6X8 TX30 YDNAC-CLAMP 10068 (6,8MM)

094623010 / C114623010

CLUTCH COVER

FIG 5 6* 7 8* 22 PART NUMBER 0025060556 DESCRIPTION CLUTCH COVER OUTSIDE GASKET - CLUTCH OUTER COVER RETAINING PLATE PLUG CPL. M24X3 O-RING 19,00X3,00 NBR INNER CLUTCH COVER DOWEL 9,8 X 7 X 10 GASKET - CLUTCH INNER COVER HH COLLAR SCREW M6X25 TX30 HH COLLAR SCREW M6X20 TX30 HH COLLAR SCREW M6X55 TX30

094623020 / C114623020

CYLINDER, CYLINDER HEAD
FIG 44 PART NUMBER 0603061001 DESCRIPTION CYL. HEAD BOLT M 7X30 WS=10 CU-SEAL RING DIN7603- 7,3X12X1 CYLINDER HEAD CYLINDER HEAD GASKET COLLAR NUT M8 WS=10 CYLINDER PIN DIN6325- 4X10 CYLINDER + PISTON CYLINDER BASE GASKET 0,2 MM CYLINDER BASE GASKET 0,4 MM CYLINDER BASE GASKET 0,5 MM CYLINDER BASE GASKET 0,6MM EXHAUST PIPE FLANGE GASKET EXHAUST FLANGE BRACKET FOR SPRINGHOLDER HH COLLAR SCREW M6X30 TX30 COLLAR SCREW M5X12 ISA30 BRAKE CABLE CLAMP RSGU 9/12 RETAINING PLATE CLUTCHHOSE SELF LOCKING NUT DIN0985-M 5 VACUUM CONECTION M6/3MM '97 CLAMP MINI 1 HOSE VENTILATION CPL. HH COLLAR SCREW M5X12 TX30 CLOSING COVER SELF LOCKING NUT DIN0985-M 5 MEMBRANE FLANGE EXHAUST CONTROL O-RING 31X1,5 NBR 70 O-RING 15,00X1,50 VITON ADJ. SPRING - EXHAUST CONTROL CONTROL SLIDE CPL. AH SCREW DIN 912 M 5X8 AH SCREW DIN6912 M6X30 8.8 CU-SEAL RING DIN7603-6X10X1

QTY 1 x x x x 1 1

104623050 / C114623050
FIG 45 PART NUMBER 0603050901 DESCRIPTION COPPERT GASKET 5X9X1
FIG 16 PART NUMBER 46231094000 DESCRIPTION ADJUSTING SCREW MIKUNI SPRING IDLE ADJUST SCREW SPRING THROTTLE VALVE MIKUNI 2.5 NEEDLE VALVE CPL. 2.5 JET NEEDLE MIKUNI 5IPL43-2 MAIN JET HOLDER MIKUNI MAIN JET 195 MAIN JET 200 MAIN JET 205 MAIN JET 210 MAIN JET 215 MAIN JET 220 MAIN JET 225 MAIN JET IDLING JET IDLE JET 10 MIKUNI IDLING JET 15 MIKUNI IDLING JET 20 MIKUNI IDLING JET 25 MIKUNI CARBURETOR 65 SX 2009 CHOKE + LEVER CPL. GASKET SET MIKUNI FLOAT BODY + SCREW + GASKET FLOAT + PIN PVC-HOSE 3X5MM ADJUSTER SCREW
QTY 1 x x x x x x x x x x x x x 1

094623110 / C094623110

FIG 20 PART NUMBER 46232015000 DESCRIPTION FLAT HEAD DIN7991-M 6X20 SPRING RETAINER 25X63,5X2 CLUTCH SPRING KIT CLUTCH HUB LINING DISK KIT INTERMEDIATE DISK STEEL CLUTCH PRESSURE CAP STOP DISC 17,2X32X1,5 PRIMARY DRIVE WITH CLUTCH CAGE FLAT HEAD SCREW ISO7380 M6X16 FLAT HEAD SCREW ISO7380 M6X20 BLEEDER SCREW WITH CAP OUTPUT CYL. WITH BLEEDER SCREW O-RING 30,00X1,50 NBR 70 GASKET FOR SLAVE CYLINDER PRESSURE PIECE CPL. HH COLLAR SCREW M10X20 % NEEDLE BEARING K 22X26X10 A INNER RING WITH COLLAR

094623210 / C094623210

TRANSMISSION
FIG 26 PART NUMBER 0912050083 DESCRIPTION COUNTERSHAFT MAIN SHAFT 13-T IDLER GEAR 1.G. SLIDING GEAR 5.G. IDLER GEAR 4.G IDLER GEAR 3.G SLIDING GEAR 6.G. IDLER GEAR 2.G IDLER GEAR 5.G. SLIDING GEAR 3/4. G IDLER GEAR 6.G. SOLID GEAR 2.G NEEDLE BUSH NK1212 STOP DISK 12,1X25X1 NEEDLE BEARING 14X18X8 CIRCLIP DIN 471 20X1,2 LOCK RING GROOVED BALL BEARING 20X42X12 O-RING 20X2 VITON SHAFT SEAL RING 26X35X6BSL NB DISANCESPACER F. SPROCKET CHAIN SPROCKET 13-T. CHAIN SPROCKET 14-T. CIRCLIP AS20X1,75 BALL BEARING 98203 KSE C3 WASHER DIN9021-A 5,3 AH SCREW DIN 912 M 5X8

QTY 1 x 1

094623310 / C094623310

KICKSTARTER

FIG 21 PART NUMBER 46233053016 DESCRIPTION SPROCKET SCREW-AH M8X20 WS=6 WASHER 8MM GALVANIZED KICKSTARTER CPL. SPACER SLEEVE SHAFT SEAL RING 17X28X6B NBR STOP DISK 17,2X24X1 DRIVING HUB 125/200'98 KICKSTARTER SPRING 2,6MM '98 CIRCLIP DIN0471-17X1 KICKSTART. GEAR 28-T 05 KICKSTARTER SHAFT 125/200'98 KICKSTARTER RATCHET THRUST WASHER DIN0988-16X22X1 SPRING 1,4MM '98 HH COLLAR SCREW M6X16 TX30 STOP MET.SHEET 4MM 125/200'98 COVER PLATE BEARING PIN IDLER GEAR INTERMEDIATE STARTING GEAR

094623390 / C094623390

FIG 39 PART NUMBER 0025050206 DESCRIPTION HH COLLAR SCREW M5X12 TX30 SHIFTING SHAFT FENDER RET. PL. SHIFT SHAFT CPL. LOCK WASHER DIN0471-14X1 STOP DISK 14X30X1 RETURN SPRING 03 SPRING GUIDE TENSIONING SPRING 0,8MM STOP DISK 12,1X25X1 NEEDLE BEARING 12X18XSHAFT SEAL RING 12X20X5 B SHIFTING LEVER CPL. STEEL WASHER 6,4X17X3 SPECIAL SCREW M6X16 WS=8 10.9 PRESSURE SPRING 0,9MM SHIFTING RAIL COUNTER SHAFT SHIFTING RAIL MAIN SHAFT NEEDLE ROLLER ZRB 6X10 SHIFT FORK MAIN SHAFT SHIFT FORK COUNTERSHAFT R/S SHIFT FORK COUNTERSHAFT Ll/S AH SCREW DIN6912 M6X30 8.8 SHIFT DRUM LOCATING CPL. BALL BEARING 6805 C3 JR SHIFT ROLLER CPL. BALL BEARING 6903 C4 LOCKING LEVER SPRING 03 SLEEVE FOR LOCKING LEVER LOCATING LEVER CPL. 08 WASHER DIN7349-5X15X2 HH COLLAR SCREW M5X20 TX30

094623410 / C114623410

FIG 11 PART NUMBER 55007016001 DESCRIPTION RADIATOR L/S 65 SX 2009 RADIATOR R/S 65SX 2009 RUBBER SLEEVE D=12MM RADIATOR CAP 50 LC 1,0 BAR COLLAR SCREW M6X12 TX RADIATOR PROTECTOR 65 SX 2009 RADIATOR HOSE CPL.+Y-CONNECT. RADIATOR CONNECTOR TOP PREFORMED HOSE 65SX RAD.L/S HOSE CLAMP NORMA 12/22 PVC-HOSE 7X10 PER METER

094623530 / C094623530

FIG PART NUMBER DESCRIPTION HH COLLAR SCREW M6X8 TX30 CU-SEAL RING DIN7603-6X10X1 HH COLLAR SCREW M6X50 TX30 HH COLLAR SCREW M6X12 TX30 WATERPUMP COVER WATER PUMP COVER GASKET DOWEL 9,8 X 7 X 10 HH COLLAR SCREW M 5X12 WS=6 WATER PUMP WHEEL 07 SHAFT SEAL RING 8X24X7 A DUO WATER PUMP SHAFT BALL BEARING 6000/C3 DRIVE WHEEL GROOVED BALL BEAR. 608 2RS C3

094623510 / C114623510

FIG 16 PART NUMBER 0025060206 DESCRIPTION WIRING HARNESS CDI 65 SX CDI 65 SX 2009 RUBBER BR. DIGI.BOX 65SX IGNITIONCOIL "IG5128" HH COLLAR SCREW M6X16 SPARK PLUG CONNECTOR SPARK PLUG LR8B O-RING 12,00X3,0 VITON 75 STATOR HH COLLAR SCREW M5X16 ROTOR LOCKING RING VSK 12 COLLAR NUT M12X1 R/S IGNITION COVER HH COLLAR SCREW M6X2003 TX30

OWNER'S MANUAL 2009

65 SX 65 XC

ART. NO. 3211345en

DEAR KTM CUSTOMER

Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you and your child enormous pleasure if you service and maintain it accordingly. We wish you great pleasure riding the vehicle!
Enter the serial numbers of your vehicle below. Chassis number ( p. 9) Dealer's stamp

Engine number (

The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing development and design can, however, not be completely excluded. All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery.
2009 by KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
ISO 9001(6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products. Issued by: TV Management Service KTM-Sportmotorcycle AG 5230 Mattighofen, Austria

CONTENTS

2 Removing the fork legs... Installing the fork legs.. Removing the fork protector.. Installing the fork protector.. Removing the lower triple clamp.. Installing the lower triple clamp.. Greasing the steering head bearing.. Dismounting the front fender.. Installing the front fender.. Dismounting the start number plate.. Installing the start number plate.. Handlebar position... Adjusting handlebar position.. Checking the play in the throttle cable.. Adjusting the play in the throttle cable.. Checking chain dirt.. Cleaning the chain.. Checking the chain tension.. Checking the chain tension - installing rear wheel. Checking rear sprocket / engine sprocket for wear. Adjusting the chain tension.. Adjusting chain tension - after checking. Adjusting chain tension - installing rear wheel. Adjusting the chain guide.. Adjusting basic position of clutch lever.. Checking the fluid level of hydraulic clutch.. Changing the hydraulic clutch fluid.. Checking brake discs... Checking free play of hand brake lever.. Adjusting basic position of handbrake lever.. Checking the front brake fluid level.. Adding front brake fluid.. Checking the front brake linings.. Removing front brake linings.. Installing the front brake linings.. Changing the front brake linings.. Checking the free travel of the foot brake lever.. Adjusting the free travel of the foot brake pedal. Adjusting the basic position of the foot brake pedal.. Checking rear brake fluid level.. Adding rear brake fluid... Checking the rear brake linings.. Removing rear brake linings.. Installing the rear brake linings.. Changing the rear brake linings.. Removing the front wheel.. Installing the front wheel.. Removing the rear wheel.. Installing the rear wheel.. Checking the tire condition.. Checking tire air pressure.. Checking spoke tension.. Removing the seat.. Mounting the seat.. Cooling system.. Checking the antifreeze and coolant level. Checking the coolant level... Draining the coolant.. Refilling coolant.. Glass fiber yarn filling of main silencer.. Removing main silencer..

Grades of risks

Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.

Warning

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.

Owner's manual

Carefully read this owner's manual in its entirety together with your child before letting your child ride the motorcycle for the first time. It contains a lot of information and tips to help you and your child operate and handle the motorcycle. Only then will you find out how to customize the motorcycle ideally for your child's use and how to protect your child from injury. The owner's manual also contains important information on servicing the motorcycle. The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.

VIEW OF VEHICLE

View of the vehicle from the left front (example)

300673-10

Clutch lever Filler cap Shift lever Chain guide Choke lever Fuel tap Quick release for seat lock
View of the vehicle from the right rear (example)

300672-10

Kickstarter Shock absorber compression adjustment Shock absorber rebound adjustment Level viewer for brake fluid, rear Foot brake pedal Fork protector Chassis number Hand brake lever Throttle grip Short circuit button
LOCATION OF SERIAL NUMBERS

Chassis number

The chassis number is stamped on right of the steering head.

700390-01

Engine number
The engine number is stamped on the left side of the engine under the engine sprocket.

700391-01

Shock absorber part number
The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side.

700392-01

CONTROLS

Throttle grip

Trottle grip is fitted on the right side of the handlebar.

700408-01

Clutch lever

Environmental hazardImproper handling of fuel is a danger to the environment. Do not allow fuel to get into the ground water, the ground, or the sewage system. Switch off the engine. Open the filler cap. ( Guideline Measurement of 35 mm (1.38 in) 3.5 l (3.7 qt.) p. 11) Super unleaded gasoline, mixed with 2-stroke engine oil ( p. 69) p. 11) Fill the fuel tank with fuel up to measurement.
Fuel tank capacity, approx. Close the filler cap. (

400214-10

SERVICE SCHEDULE
Important maintenance work to be carried out by an authorized KTM workshop.
S20A Engine Change the gear oil.

S40A

p. 55)
Check spark plug and replace if required.
Clean spark plug connectors and check for tightness. Check engine mounting screws for tightness. Carburetor
Check intake flange and carburetor connection boots for cracks and leakage. Check idle. Check vent hoses for damage and routing without sharp bends.

Attachments

Check the cooling system for leakage. Check the antifreeze and coolant level. ( p. 49) p. 35) p. 38) p. 43) p. 37) p. 42) p. 36) p. 40) Check exhaust system for leakage and looseness. Check throttle cables for damage, smooth operation and routing without sharp bends. Check the fluid level of the hydraulic clutch. ( Clean the air filter.

p. 53)

Brakes

Check the front brake linings. ( Check the rear brake linings. ( Check the brake discs. ( p. 36)
Check the front brake fluid level. ( Check the rear brake fluid level. (
Check brake lines for damage and leakage. Check the free play of the hand brake lever. ( Check the free travel of the foot brake lever. ( Check the function of the brake system. Check screws and guide bolts of brake system for tightness. Chassis Check shock absorber and fork for leakage and functioning. Clean the dust boots of the fork legs. ( Bleed fork legs. ( p. 24) p. 25) p. 47) p. 47) p. 32) Check swingarm bearing. Check play of steering head bearing. ( Check all screws to see if they are tight. Wheels Check the spoke tension. ( Check rim run-out. Check the tire condition. ( Check the tire air pressure. ( Check the chain wear. Check the chain tension. ( Clean the chain. ( p. 32) p. 48) p. 25)

Check wheel bearing for play. Clean and grease adjusting screws of chain adjuster. S20A: every 20 service hours S40A: every 40 service hours
Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)
S20A Check/set the carburetor components. Check intake membrane for wear.

S40A

x Check wear of the clutch lining disc. x Check clutch spring length. x Check cylinder and piston for wear. x x
Check exhaust control for functioning and smooth operation, clean. Change the spring of the exhaust control. Check the seating of the piston pin.
x Check main bearing of the crankshaft. x
Check radial clearance of conrod bearing.
x Change crankshafts and conrod bearings. x Fully check the transmission. x Carry out a complete fork service. x Carry out a complete shock absorber service. x Clean and lubricate swingarm bearing. x Grease the steering head bearing. x ( p. 29) Change the glass fiber yarn filling of the main silencer. x Change the hydraulic clutch fluid. x ( p. 35) Change the front brake fluid. x Change the rear brake fluid. x
S20A: every 20 service hours S40A: every 40 service hours J1A: annually
Performance of urgent inspection and maintenace work by the supervisory individual.
NB1A Check the gear oil level. ( p. 55) p. 37) p. 42) p. 38) p. 43) p. 25) p. 32) p. 33) p. 53) p. 47) p. 47) p. 50) Check the front brake fluid level. ( Check the rear brake fluid level. ( Check the front brake linings. ( Check the rear brake linings. ( Check and adjust throttle cables. Bleed fork legs. ( Clean the chain. ( p. 24) p. 32) Clean the dust boots of the fork legs. ( Check the chain tension. ( Check the chain wear. Check rear sprocket / engine sprocket for wear. ( Clean the air filter.
Check the tire air pressure. ( Check the tire condition. ( Check the coolant level. (
Empty the carburetor float chamber. Check braking.
Check all controls for smooth operation. Check all screws, nuts and hose clamps regularly for tightness. NB1A: Depending on conditions of use according to requirements.
MAINTENANCE WORK ON CHASSIS AND ENGINE
Jacking up the motorcycle
Danger of damageThe parked vehicle can roll away or fall over. Always place the vehicle on a firm and even surface.
Jack up the motorcycle underneath the engine. Work stand (54829055000)

700405-01

Secure the motorcycle against falling over.
Removing the motorcycle from the work stand
Danger of damageThe parked vehicle can roll away or fall over.
Always place the vehicle on a firm and even surface. Remove the motorcycle from the work stand. Remove the work stand.

The riding sag is the difference between measurements and. Check the riding sag. Riding sag 90 mm (3.54 in)

400222-10

If the riding sag differs from the specified measurement: Adjust the riding sag.
Adjusting the spring preload of the shock absorber
Danger of accidentsDisassembly of pressurized parts can lead to injury. The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be pleased to help.) Remove shock absorber.
After removing the shock absorber, clean it thoroughly. Measure the full spring length while it is under tension and note down the value. Loosen lock ring. Turn adjusting ring until the spring is no longer under tension. Combination wrench (50329080000) Hook wrench (T106S)

700449-01

Measure the overall spring length when not under tension. Tighten the spring by turning adjusting ring to measurement. Guideline Spring preload Comfort Standard Sport 7 mm (0.28 in) 7 mm (0.28 in) 7 mm (0.28 in)
The spring preload is the difference between the relaxed spring length and the tensioned spring length. Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload. Tighten lock ring. Install the shock absorber.
Removing the shock absorber
Jack up the motorcycle. ( p. 20) Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel. Fix the rear wheel in this position. Remove screw , push splash protector to the side, and remove the shock absorber.

700416-10

Installing shock absorber
Push splash protector to the side and position the shock absorber. Mount and tighten screw. Guideline Screw, top shock absorber Mount and tighten screw. Guideline Screw, bottom shock absorber

700416-11

45 Nm (33.2 lbf ft)

M10 p. 20)

Remove the motorcycle from the work stand. (
Adjusting the compression damping of the fork
The hydraulic compression damping determines the fork suspension behavior. Turn adjusting screw clockwise all the way.
Adjusting screw is located at the top end of the left fork leg and is labeled with a C. Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Compression damping

700450-01

Standard

10 clicks

Adjusting the rebound damping of the fork
The hydraulic rebound damping determines the fork suspension behavior. Turn adjusting screw clockwise all the way.
Adjusting screw is located at the top end of the right fork leg and is labeled with an R. Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Rebound damping

700451-01

Vehicle level
Danger of accidentsModifications to the suspension settings can seriously alter the vehicle's ride behavior. Following modifications, ride slowly at first to get the feel of the new ride behavior.

700414-11

Dismounting the start number plate
Remove screw and take off clamp. Remove screw. Remove the start number plate.

700412-10

Installing the start number plate
Position the start number plate with the drill holes onto the holding lugs of the fender.

700413-01

Mount and tighten screw. Guideline Remaining screws, chassis MNm (7.4 lbf ft)
Position the brake line. Put the clamp on, mount and tighten screw.

700411-10

Handlebar position
On the upper triple clamp, there are 2 holes at a distance of to each other. Distance between holes 15 mm (0.59 in)
The holes on the handlebar support are placed at a distance of from the center.

400271-11

Distance between holes

3.5 mm (0.138 in)

The handlebar supports can be mounted in 4 different positions.
Adjusting handlebar position
Danger of accidentsHandlebar breakage. If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handlebar.
Remove the four screws. Remove the handlebar clamp. Remove the handlebar and lay it to one side.
Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines.

400271-10

Remove the two screws. Remove the handlebar support. Place the handlebar support in the required position. Mount and tighten the two screws. Guideline Screw, handlebar support MNm (29.5 lbf ft) Loctite 243

Position the handlebar.

Make sure cables and wiring are positioned correctly. Position the handlebar clamp. Mount and evenly tighten the four screws. Guideline Screw, handlebar clamp MNm (14.8 lbf ft)
Make sure the gap width is even.
Checking the play in the throttle cable
Move the handlebar to the straight-ahead position. Push back bellows. It must be possible to raise the outer casing of the throttle cable away from the adjusting screw by distance without encountering a resistance. Play in gas throttle cable mm (0.12 0.2 in)
If the throttle cable play does not meet specifications: Adjust the play in the throttle cable.

p. 31)

700453-10
Push on bellows. Check the throttle grip for smooth operation.
Adjusting the play in the throttle cable
Move the handlebar to the straight-ahead position. Push back bellows. Loosen nut. Turn adjusting screw in as far as possible. Turn the adjusting screw so that there is play at the outer casing of the throttle cable. Guideline Play in gas throttle cable mm (0.12 0.2 in) Tighten the nut. Push on bellows. Check the throttle grip for smooth operation.

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container! Jack up the motorcycle. ( Remove screws. Remove the cover with O-ring and diaphragm. Add brake fluid to the top edge of the level viewer. Brake fluid DOT 4 / DOT 5.1 (

700422-01

Position the cover with the O-ring and diaphragm.
Clean up overflowed or spilt brake fluid immediately with water. Mount and tighten the screws.
Checking the rear brake linings

700424-01

If the minimum thickness is less than specified: Change the rear brake linings.

p. 44)

Check the brake linings for damage and cracking. If damage or wear is encountered: Change the rear brake linings. p. 44)
Removing rear brake linings
Danger of accidentBrake system failure. Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be pleased to help.) Remove the rear wheel. Remove lock washer. Remove screw.

p. 46)

700428-01

700430-01

Installing the rear brake linings
Danger of accidentsReduced braking efficiency due to use of non-approved brake linings.
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid. Check the brake discs. ( Insert the brake linings. p. 36)
Mount screw. Mount lock washer. Install the rear wheel.
Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a pressure point.

700429-01

Changing the rear brake linings
Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container! Remove the rear brake linings.

p. 43)

Stand the vehicle upright. Remove screws. Remove cover with the O-ring and diaphragm. Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir. Install the rear brake linings.

p. 43) p. 68)

Add brake fluid to the top edge of the level viewer. Brake fluid DOT 4 / DOT 5.1 (

Removing the front wheel

Jack up the motorcycle. ( Remove screw. p. 20)

Remove screws of locking cap. Remove locking cap and outer tube. Pull the glass fiber yarn filling from the inner tube. Clean the parts that are to be reinstalled.

700443-01

Installing the glass fiber yarn filling of the main silencer
Slide the glass fiber yarn filling over the inner tube. Slide the outer tube over the glass fiber yarn filling. Insert the locking cap into the outer tube. Mount the screws with toothed wheels and tighten. Guideline Remaining screws, chassis M6 p. 51) 10 Nm (7.4 lbf ft)

700443-10

Install the main silencer. (

Removing the air filter

Engine failureUnfiltered intake air has a negative effect on the service life of the engine. Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.
Environmental hazardHazardous substances cause environmental damage. Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Remove the seat. ( p. 48)
Unhook the air filter holder and swing it to the side. Remove the air filter with the air filter support. Remove the air filter from the air filter support.

700441-01

Installing the air filter
Mount the clean air filter onto the air filter support. Put in both parts together, position them and fix them with the air filter support.
If the air filter is not correctly mounted, dust and dirt can penetrate into the engine and can cause damage.

Mount the seat. (

p. 48)

Cleaning air filter

Do not clean the air filter with fuel or petroleum since these substances attack the foam. Remove the air filter. Air filter cleaner (

p. 52)

Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.
Only press the air filter to dry it, never wring it out. Oil the dry air filter with a high/quality filter oil. Oil for foam air filter (

p. 71)

Clean the air filter box. Check carburetor connection boot for damage and tightness. Install the air filter.

Carburetor - idle

The idle setting of the carburetor has a big influence on the starting behavior, stable idling and the response to throttle opening. That means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly.
The carburetor and its components are subject to increased wear caused by engine vibration. Wear can result in malfunctioning. The idle speed is adjusted with adjusting screw. The idle mixture is adjusted with idle air adjusting screw.

Fault in ignition system Short-circuit cable in cable harness frayed, short-circuit button defective Socket connector or ignition coil is loose or oxidized Water in carburetor or jets blocked Engine has no idle Idling jet blocked Adjusting screws on carburetor distorted Spark plug defective Ignition system defective Engine does not speed up Carburetor running over because float needle dirty or worn Loose carburetor jets Fault in ignition system Engine has too little power Fuel feed interrupted

Check the ignition system. Adjust the ignition.
Check the short circuit button.
Clean the socket connector and treat it with contact spray. Check/set the carburetor components. Check/set the carburetor components. Carburetor - adjust the idle speed. ( p. 53) Change spark plug. Check the ignition coil.
Check the spark plug connector.
Check/set the carburetor components.
x Check/set the carburetor components. x Check the ignition system. x Adjust the ignition. x
Check the fuel tank breather. Clean the fuel tap. Check/set the carburetor components. Clean the air filter.
Air filter very dirty Exhaust system leaky, deformed or too little glass fiber yarn filling in main silencer Fault in ignition system Diaphragm or reed valve housing damaged Noticeable wear Engine stalls or is popping into the carburetor Lack of fuel
Check exhaust system for damage. Change the glass fiber yarn filling of the main silencer.
Check the diaphragm and reed valve housing. Overhaul the engine. Turn the knurled screw on the fuel tap all the way counterclockwise. Fill up with fuel. ( p. 17) Check the intake flange and carburetor for tightness. Clean the socket connector and treat it with contact spray. Check the cooling system for leakage. Check the coolant level. ( p. 50)
Engine takes in bad air Socket connector or ignition coil is loose or oxidized Engine overheats Too little coolant in cooling system
Faults Engine overheats Possible cause Too little air stream Radiator fins very dirty Foam formation in cooling system Damaged cylinder head or cylinder head gasket Bent radiator hose Incorrect ignition point due to loose stator White smoke emission (steam in exhaust gas) Gear oil exits at the vent hose Water in the gear oil Damaged cylinder head or cylinder head gasket Too much gear oil added Damaged shaft seal ring or water pump Action Switch off engine when standing. Clean radiator fins. Drain the coolant. Refill the coolant.

x( x( x

p. 50) p. 51)
Check the cylinder head or cylinder head gasket. Change the radiator hose. Adjust the ignition.
Check the cylinder head or cylinder head gasket. Check the gear oil level. ( Check the shaft seal ring and water pump.

CLEANING

Cleaning motorcycle
Material damageDamage and destruction of components by high-pressure cleaning equipment. Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts.
If you clean the motorcycle regularly, its value and appearance are maintained over a long period. Avoid direct sunshine on the motorcycle during cleaning. Before you clean the motorcycle, seal the exhaust system to prevent penetration by water. First remove coarse dirt particles with a gentle water spray. Spray very dirty areas with a normal motorcycle cleaner and then clean with a brush. Motorcycle cleaner ( p. 70)
Use warm water containing normal motorcycle cleaner and a soft sponge. After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly. Empty the carburetor float chamber.
Danger of accidentsReduced braking efficiency due to wet or dirty brakes. Clean or dry dirty or wet brakes by riding and braking gently.
After cleaning, let your child ride the vehicle a short distance until the engine warms up and the brakes are dried.
The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate. Push back the protection covers on the handlebar instruments to allow water to evaporate. After the motorcycle has cooled off, oil or grease all moving parts and bearings. Clean the chain. ( p. 32) p. 70) Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials. Cleaning and polishing materials for metal, rubber and plastic ( Treat all painted parts with a mild paint polish. High-luster polish for paint ( p. 70)
To prevent electrical problems, treat electric contacts and switches with contact spray. Contact spray ( p. 70)

STORAGE

Storage
If you want to garage the motorcycle for a longer period, take the following actions. Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season. Clean the motorcycle. ( Change the gear oil. p. 59) p. 55) p. 49) p. 54)
Check the antifreeze and coolant level. ( Empty the carburetor float chamber. Check the tire air pressure. (

Drain the fuel from the tank into a suitable container.

p. 47)

The storage place should be dry and not subject to large temperature fluctuations.
KTM recommends jacking up the motorcycle. Jack up the motorcycle. ( p. 20)
Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.
Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust.
Putting into operation after storage
Remove the motorcycle from the work stand. ( Fill up with fuel. ( Take a test ride. p. 17) p. 15) Checks before putting into operation. (

TECHNICAL DATA - ENGINE

Design Displacement Stroke Bore Control Crankshaft bearing Conrod bearing Piston pin bearing Pistons Piston rings Engine lubrication Primary transmission Clutch Gearbox Transmission ratio 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Ignition Spark plug Spark plug electrode gap Cooling Starting aid 13:37 16:34 18:31 21:30 23:28 24:26 AET digital NGK LR 8 B 0.60 mm (0.0236 in) Water-cooled Kickstarter 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control 64.85 cm (3.9574 cu in) 40.8 mm (1.606 in) 45 mm (1.77 in) Exhaust control PCEV 2 grooved ball bearings Needle bearing Needle bearing Aluminum cast 1 rectangular ring Mixture oil lubrication 23:75 straight cut spur gear Multidisc clutch in oil bath/hydraulically activated 6-gear, claw shifted

Capacity - gear oil

Gear oil

0.50 l (0.53 qt.)

Engine oil (15W/50) (

Capacity - coolant

Coolant

Coolant (

p. 68) p. 68)
TECHNICAL DATA - ENGINE TIGHTENING TORQUES
Bearing retainer, main shafts Nut, exhaust control diaphragm Screw, clutch line holder Screw, diaphragm cover of exhaust control Screw, ignition system/stator Screw, reed valve housing of exhaust control Screw, retaining bracket for return spring of shift shaft Screw, shift drum locating Screw, water pump wheel Bearing retainer, shift drum Drain plug, water pump cover Exhaust control, lower part of control valve Screw, clutch intermediate cover Screw, clutch slave cylinder Screw, clutch springs Screw, engine housing Screw, engine sprocket cover Screw, exhaust flange Screw, gear oil level check Screw, generator cover Screw, intake flange/reed valve housing Screw, kickstarter stop piece Screw, outer clutch cover Screw, reed valve housing of exhaust control Screw, shift drum locating Screw, shift lever Screw, water pump cover Vacuum connection/vent connection Screw, cylinder head Nuts, cylinder base Screw, kickstarter Stud, cylinder base (left section of the engine case) Stud, cylinder base (left section of the engine case) Screw, inner clutch hub Spark plug Nut, rotor Oil drain plug with magnet Nut, primary gear M5 M5 M5 M5 M5 M5 M5 M5 M5 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M7 M8 M8 MNm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 6 Nm (4.4 lbf ft) 8 Nm (5.9 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 14 Nm (10.3 lbf ft) 8 Nm (5.9 lbf ft) 5 Nm (3.7 lbf ft) 18 Nm (13.3 lbf ft) 20 Nm (14.8 lbf ft) 25 Nm (18.4 lbf ft) Tightening sequence: screw in until it projects by 27 mm (1.063 in) Tightening sequence: screw in until it projects by 29 mm (1.142 in) 60 Nm (44.3 lbf ft) Nm (7.4 8.9 lbf ft) 50 Nm (36.9 lbf ft) 20 Nm (14.8 lbf ft) 40 Nm (29.5 lbf ft) 3 Nm (2.2 lbf ft) 5 Nm (3.7 lbf ft) 4 Nm (3 lbf ft) 5 Nm (3.7 lbf ft) 5 Nm (3.7 lbf ft) 6 Nm (4.4 lbf ft) 6 Nm (4.4 lbf ft) 5 Nm (3.7 lbf ft) 8 Nm (5.9 lbf ft) 6 Nm (4.4 lbf ft) Loctite 648 Loctite 243 Loctite 222 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243

03.18.7E.03 WP Suspension 3614 BAVP 10 clicks 9 clicks 3 clicks 10 clicks 9 clicks 6 clicks 7 mm (0.28 in) 7 mm (0.28 in) 7 mm (0.28 in) 35 N/mm (200 lb/in) 40 N/mm (228 lb/in) 45 N/mm (257 lb/in) 220 mm (8.66 in) 10 bar (145 psi) 12 mm (0.47 in) 90 mm (3.54 in) 347 mm (13.66 in) Shock absorber oil (SAE 2.5) (50180342S1) ( p. 69)
03.18.7E.05 WP Suspension 3614 BAVP 10 clicks 9 clicks 3 clicks 10 clicks 9 clicks 6 clicks 7 mm (0.28 in) 7 mm (0.28 in) 7 mm (0.28 in) 35 N/mm (200 lb/in) 40 N/mm (228 lb/in) 45 N/mm (257 lb/in) 220 mm (8.66 in) 10 bar (145 psi) 12 mm (0.47 in) 90 mm (3.54 in) 347 mm (13.66 in) Shock absorber oil (SAE 2.5) (50180342S1) ( p. 69)
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES
Spoke nipple Remaining nuts, chassis Remaining screws, chassis Screw, ball joint, push rod on footbrake cylinder Screw, footbrake cylinder Screw, fork stub Screw, front brake disc Screw, rear brake disc Screw, throttle grip Nut, rim lock Remaining nuts, chassis Remaining screws, chassis Screw, bottom triple clamp Screw, brake caliper Screw, engine bracket Screw, foot brake pedal Screw, handlebar clamp Screw, rear sprocket Screw, side stand fixing Screw, tail piece Screw, top triple clamp Remaining nuts, chassis Remaining screws, chassis Screw, bottom shock absorber Screw, front wheel spindle Screw, handlebar support Screw, top shock absorber Nut, rear wheel spindle Nut, swingarm pivot Nut, steering stem M3.5 M6 M6 M6 M6 M6 M6 M6 M6 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M10 M10 M10 M10 M10 M10 M12x1 M12x1 M20x1.Nm (2.2 lbf ft) 15 Nm (11.1 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 14 Nm (10.3 lbf ft) 14 Nm (10.3 lbf ft) 4.5 Nm (3.32 lbf ft) 10 Nm (7.4 lbf ft) 30 Nm (22.1 lbf ft) 25 Nm (18.4 lbf ft) 25 Nm (18.4 lbf ft) 20 Nm (14.8 lbf ft) 30 Nm (22.1 lbf ft) 25 Nm (18.4 lbf ft) 20 Nm (14.8 lbf ft) 25 Nm (18.4 lbf ft) 40 Nm (29.5 lbf ft) 35 Nm (25.8 lbf ft) 25 Nm (18.4 lbf ft) 50 Nm (36.9 lbf ft) 45 Nm (33.2 lbf ft) 45 Nm (33.2 lbf ft) 40 Nm (29.5 lbf ft) 40 Nm (29.5 lbf ft) 45 Nm (33.2 lbf ft) 40 Nm (29.5 lbf ft) 40 Nm (29.5 lbf ft) 10 Nm (7.4 lbf ft) Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243 Loctite 243

SUBSTANCES

Brake fluid DOT 4 / DOT 5.1

According to DOT

Guideline Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5.1
Guideline Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foaming. KTM recommends Motorex products. Mixture ratio Antifreeze protection: C (F) 50 % corrosion inhibitor/antifreeze 50 % distilled water

Chain guide adjusting. 34 Chain tension adjusting. 33 checking. 32 Chassis number. 9 Choke. 11 Cleaning. 59 Clutch fluid level, checking. 35 fluid, changing. 35 Clutch lever. 10 adjusting basic position. 35 Compression damping fork, adjusting. 23 shock absorber, adjusting. 20 Coolant draining. 50 refilling. 51 Coolant level checking. 49-50 Cooling system. 49
Gear oil level checking. 55 H Hand brake lever. 10 basic position, adjusting. 37 free travel, checking. 36 Handlebar position. 30 adjusting. 31 K Kickstarter L Lower triple clamp installing. 28 removing. 28. 12
M Main silencer glass fiber yarn filling, installing glass fiber yarn filling, removing installing. removing. Motorcycle cleaning O Owner's manual General information P Play in throttle cable adjusting. 31 checking. 31 Plug-in stand. 12 Putting into operation advice on first use. 13 after storage. 60 checks before putting into operation. 15 R Rear sprocket / engine sprocket checking for wear. 33 Rear wheel installing. 46 removing. 46 Rebound damping fork, adjusting. 23 shock absorber, adjusting. 20 S Seat mounting. 48 removing. 48 Service schedule. 18-19 Shift lever. 11 Shock absorber installing. removing. riding sag, checking static sag, checking. 21 21. 12. 5. 6. 51 51
74 Steering head bearing greasing. 29 Steering head bearing play adjusting. 25 checking. 25 Storage T Technical data carburetor. chassis. chassis tightening torques engine. engine tightening torques fork. shock absorber. 66. 60

Maintenance. 5. 59

Throttle grip. 10 Tire air pressure checking. 47 Tire condition checking. 47 Transport. 5 Troubleshooting. 57-58 U Use definition V Vehicle level. 23 View of vehicle left front. 7 right rear. 8 W Warranty. 5 Work rules. 5.. 5
Shock absorber part number Short circuit button. Side stand. Spare parts, accessories.
Spoke tension checking. 48 Spring preload shock absorber, adjusting. 22
Start number plate installing. 30 removing. 30 Starting. 15

*3211345en*

3211345en
01/2009 Photo: Mitterbauer
KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com