KTM 65 SX 2003 Owner'S Manual Download

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Art.Nr

. 3.210.47 04/2002

OWNER’S MANUAL

MANUALE D’USO

MANUEL D’UTILISA

TION

MANUAL DE INSTRUCCIONES

2003

BEDIENUNGSANLEITUNG

Summary of Contents for 65 SX 2003

Page 1: ...Art Nr 3 210 47 04 2002 65 SX OWNER S MANUAL MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES 2003 BEDIENUNGSANLEITUNG...

Page 2: ...FORMATION MARKED AS FOLLOWS WARNING IGNORING THESE INSTRUCTIONS CAN BE DANGEROUS TO LIFE AND LIMB CAUTION IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE MOTORCYCLE OR IMPAIR THE MOTORCYCLE S TRAF...

Page 3: ...g from the use of such products 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...

Page 4: ...must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void The fuels and lubricants specified in the Owner s Manual or automotive flui...

Page 5: ...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 o...

Page 6: ...nge the handlebar position 18 Page Changing the spring preloading of the shock absorber 19 Checking the chain tension 19 Correcting the chain tension 19 Chain maintenance 19 General information about...

Page 7: ...he clutch lever 1 is located on the left side of the handlebar The adjusting screw A is used to change the original position of the clutch lever see maintenance work on chassis and engine Hand brake l...

Page 8: ...the right Choke The choke button 3 is located on the left side of the carburetor Pulling the choke button 3 all the way out opens a bore in the carburetor through which the engine can take in additio...

Page 9: ...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 Rebound damping function of the s...

Page 10: ...ENGLISH 9...

Page 11: ...n to the specially marked warnings and pointing out the danger of injury Adjust the clutch lever hand lever and foot brake pedal so your child can operate them easily To prevent injury teach your youn...

Page 12: ...ncorrect air pressure deteriorate the driving performance 5 BRAKES Check the correct functioning of the braking system Verify that there is sufficient brake fluid in the reservoir The reservoirs have...

Page 13: ...ay 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 Pul...

Page 14: ...ycle and shift gears to idling To switch off the engine depress short circuit switch until the engine stops Close fuel tap WARNING MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUNNING THE E...

Page 15: ...vel lining thickness brake discs Check brake lines for damage and leaks Check functiuon adjust smooth operation free travel of handbrake levers Check screws of brake system for a tight fit Check suspe...

Page 16: ...ons with contact spray Check all screws nuts and hose clamps for their tight fit at regular intervals for cross country use once a year after every cleaning before each start as of 03 2002 RECOMMENDED...

Page 17: ...SECURITY LET THESE TASKS BE CARRIED OUT BY A KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED SKILLED STAFF CAUTION WHEN CLEANING THE MOTORCYCLE DO NOT USE A HIG...

Page 18: ...motorcycle to establish dimension B The sag is the difference between dimensions A and B EXAMPLE Motorcycle jacked up dimension A 430 mm Motorcycle on ground with driver seated dimension B 340 mm Sag...

Page 19: ...and slide them downward Clean dust protection bellows outer tubes and fork tubes thoroughly and oil them thoroughly with silicone spray or engine oil Then push dust pro tection bellows into the outer...

Page 20: ...counter nuts 4 and turn the left and the right tensioning screws 5 equally far Then retighten the counter nuts 4 Before tightening the hexagon nut 3 make sure that the chain adjuster 6 is properly re...

Page 21: ...VAPOR POCKETS MAY FORM IN OLD BRAKE FLUIDS EVEN AT LOW TEMPERATURES CAUSING THE BRAKE SYSTEM TO FAIL BRAKE DISCS Due to wear the thickness of the brake disc in the area of the contact face 1 of the br...

Page 22: ...lled or overflowing brake fluid with water WARNING NEVER 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 STORE BRAKE FLUI...

Page 23: ...TED CORRECTLY HAVING PERFORMED ANY WORK ON THE BRAKING SYSTEM ONE MUST ALWAYS ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER RESPECTIVELY SO AS TO ENSU RE THAT THE BRAKE PADS WILL LIE AGAINST THE BR...

Page 24: ...HOSES MUST BE ESPECIALLY ADAPTED TO IT STORE BRAKE FLUID OUT OF REACH OF CHILDREN BRAKE FLUID CAN CAUSE SKIN IRRITATION AVOID CONTACT WITH SKIN AND EYES IF YOU GET BRAKE FLUID IN YOUR EYES RINSE WITH...

Page 25: ...of the wheel spindle Remove front wheel carefully from the fork CAUTION DO NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN DISMOUNTED MAKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY D...

Page 26: ...UT TO THE REQUIRED TORQUE A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE Tires air pressure Tire type tire condition and air pressure level affect the way your motorcy cle r...

Page 27: ...carrier 5 from the filter box CAUTION DO NOT CLEAN FOAM FILTER WITH FUEL OR PETROLEUM SINCE THESE DAMAGE THE FOAM KTM RECOMMENDS THE PRODUCTS OF THE COMPANY TWIN AIR FOR AIR FILTER MAINTENANCE Thorou...

Page 28: ...dge If necessary fill up with biodegradable hydraulic oil SAE 10 e g Shell Naturelle HF E15 Biodegradable hydraulic oil is available from your KTM dealer 50ml CAUTION KTM USES BIODEGRADABLE HYDRAULIC...

Page 29: ...water CAUTION FOR 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 o...

Page 30: ...should be replaced after 1000 hours of using Idling range A Adjusting the idle speed Operation with closed throttle valve This range is influenced by the idle adjusting screw 1 Only make adjustments w...

Page 31: ...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...

Page 32: ...ced at the spark plug If no spark is produced loosen spark plug cap from ignition cable hold about 5 mm from ground and actuate kickstarter If a spark now occurs replace spark plug cap If no spark is...

Page 33: ...water hoses Incorrect ignition timing because of loose stator screws Incorrect compression ratio Cylinder head or O ring of cylinder head gasket leaks Excessive oil quantity in transmissi on Shaft sea...

Page 34: ...observe the following instructions Clean motorcycle thoroughly see chapter CLEANING Change engine oil old engine oil contains aggressive contaminations Check antifreeze and amount of cooling liquid L...

Page 35: ...ter 0 92 USgal Final drive ratio 14 50 t Chain 1 2 x 1 4 415 108 rolls Steering angle 63 8 Wheel base 1137 mm 44 7 in Seat height unloaded 750 mm 30 in Ground clearance 290 mm 11 5 in Dead weight with...

Page 36: ...drive straight cut spur gears 23 75 t Clutch multiple disc clutch in oil bath hydraulic operated Shell HF E15 Transmission 6 speed claw actuated Gear ratio 1st gear 13 37 2nd gear 16 34 3rd gear 18 3...

Page 37: ...Nm 19 ft lb Hexagon screw inner clutch hub M 10 Loctite 243 60 Nm 44 ft lb Screw clutch M 6 12 Nm 9 ft lb Oil drain screw M 8 12 Nm 9 ft lb Screws clutch cover M 6 8 Nm 6 ft lb Kickstarter stop plate...

Page 38: ...chamber of the carburetor 30 Driving instructions 11 Engine number 6 Exhaust system 27 Filler cap 7 Foot brake pedal 8 Fuel tap 7 Page General information about KTM disc brakes 20 General tips and war...

Page 39: ...ENGLISH 38...

Page 40: ...KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria Internet www ktm at 321047...

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