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KTM 65 SX 2009, Repair Manual, Page: 114 / 135

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KTM 65 SX 2009 Repair Manual Download Page 114

TECHNICAL DATA - FORK

112

29.1

SX

Fork part number

46201000033

Fork

Marzocchi

Upside down

Compression damping

Standard

10 clicks

Rebound damping

Standard

10 clicks

Spring rate

Weight of rider: 35… 45 kg (77… 99 lb.)

3.4 N/mm (19.4 lb/in)

Air chamber length

100±2.5 mm (3.94±0.098 in)

Fork length

735 mm (28.94 in)

Fork oil

Fork oil (SAE 5) (

p. 120)

29.2

XC

Fork part number

46201000133

Fork

Marzocchi

Upside down

Compression damping

Standard

10 clicks

Rebound damping

Standard

10 clicks

Spring rate

Weight of rider: 35… 45 kg (77… 99 lb.)

3.4 N/mm (19.4 lb/in)

Air chamber length

100±2.5 mm (3.94±0.098 in)

Fork length

735 mm (28.94 in)

Fork oil

Fork oil (SAE 5) (

p. 120)

PartShark.com 

877-999-5686

Summary of Contents for 65 SX 2009

Page 1: ...REPAIR MANUAL 2009 65 SX 65 XC Article no 3206061en P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 2: ...P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 3: ...fy or delete technical specifica tions 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...

Page 4: ...lling the front fender 28 Dismounting the start number plate 28 Installing the start number plate 28 09 FRONT WHEEL 30 Removing the front wheel 30 Installing the front wheel 30 Checking the tire condi...

Page 5: ...g the rotor 78 Installing the piston 79 Installing the cylinder 79 Checking the X distance 80 Setting the X distance 80 Adjusting the ignition 81 Installing the generator cover 81 Installing the dista...

Page 6: ...be carried out by an authorized KTM workshop 116 Important maintenance work to be carried out by an authorized KTM workshop as additional order 117 WIRING DIAGRAM 118 Wiring diagram 118 SUBSTANCES 120...

Page 7: ...ted reaction e g of a work step or a function Identifies a page reference more information is provided on the specified page Formats used The typographical and other formats used are explained below P...

Page 8: ...ts that are to be reused after disassembly must be cleaned and checked for damage and wear Change damaged or worn parts After repair and maintenance ensure that the vehicle is roadworthy Notes warning...

Page 9: ...e engine in a closed space without an effective exhaust extraction system Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always warm up...

Page 10: ...ebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior 700451 01 Turn adjusting screw clockwise all the way Info Adjusting screw is located at the top en...

Page 11: ...e and clean them with brake cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray p 123 Press the dust boots back into their normal position Rem...

Page 12: ...right fork leg 4 8 Installing the fork legs Warning Danger of accidents Modifications to the chassis can seriously alter the vehicle s handling characteristics Following modifications ride slowly at f...

Page 13: ...ing characteristics 700534 01 Loosen screws on the lower triple clamp Loosen screw on the upper triple clamp Info Loosen the screws to the point where the fork leg can be moved without damaging it Mak...

Page 14: ...Remove the upper steering head bearing 4 11 Installing the lower triple clamp 0 0 1 1 0 0 2 2 300668 01 Clean the bearing and sealing elements check for damage and grease Long life grease p 122 Inser...

Page 15: ...ged after time Jack up the motorcycle p 7 400387 10 Move the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel No play should be noticeable in the steer...

Page 16: ...01 FORK TRIPLE CLAMP 14 Fully tighten screw Guideline Screw top triple clamp M8 25 Nm 18 4 lbf ft Check play of steering head bearing p 13 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 17: ...y in gas Bowden cable 3 5 mm 0 12 0 2 in If the gas Bowden cable play does not meet specifications Adjust the play in the gas Bowden cable p 15 Push bellows on Check the throttle grip for smooth opera...

Page 18: ...Remove the handlebar support Place the handlebar support in the required position Mount and tighten the two screws Guideline Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Info Position the...

Page 19: ...nger Danger of accidents The shock absorber is under high pressure The shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any main tenance on i...

Page 20: ...hild wearing a full set of protective clothing on the motorcycle in the normal sitting position feet on the footrests Your child should bounce up and down several times so that the rear wheel suspensi...

Page 21: ...he riding sag Remove shock absorber p 19 After removing the shock absorber clean it thoroughly Choose and mount a suitable spring Guideline Spring rate Weight of rider 35 kg 77 lb 35 N mm 200 lb in We...

Page 22: ...the side and position the shock absorber Mount and tighten screw Guideline Screw top shock absorber M10 45 Nm 33 2 lbf ft Mount and tighten screw Guideline Screw bottom shock absorber M10 45 Nm 33 2 l...

Page 23: ...0 Remove springs Spring hooks 50305017000 p 126 300630 10 Remove screw 300635 10 Unscrew hose clip and pull off the hose 300631 10 Remove screw Remove the exhaust manifold 7 2 Installing the exhaust m...

Page 24: ...ft 7 3 Removing main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down Do not touch hot components 700442 01 Remove sc...

Page 25: ...system to cool down Do not touch hot components Remove the main silencer p 22 700443 01 Remove screws of locking cap Remove locking cap and outer tube Pull the glass fiber yarn filling from the inner...

Page 26: ...ts together position them and fix them with the air filter support Info If the air filter is not correctly mounted dust and dirt can penetrate into the engine and can cause damage Mount the seat p 25...

Page 27: ...pilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See specifications on filling up with fuel Warning Danger of poisoning Fuel is poisonous and a he...

Page 28: ...with fuel Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immedi at...

Page 29: ...EL TANK SEAT TRIM 27 300626 11 Mount and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the fuel tank breather Mount the seat p 25 P a r t S h a r k c o m 8 7 7 9 9 9 5...

Page 30: ...te 700414 11 Position the front fender Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 10 3 Dismounting the start number plate 700412 10 Remove screw and take off clamp...

Page 31: ...FENDER 29 700411 10 Mount and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line Put the clamp on mount and tighten screw P a r t S h a r k c o m 8 7 7 9 9 9...

Page 32: ...ease and clean them with brake cleaner when necessary 700438 01 Clean and grease wheel spindle Long life grease p 122 Lift the front wheel into the fork position it and insert wheel spindle Tighten sc...

Page 33: ...overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life 700434 01 Remove the dust cap Check the tire air pressure when the tires are cold Tire ai...

Page 34: ...which leads to more loose spokes in a short time If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle 700435 01 To check sp...

Page 35: ...brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary 700440 11 Clean and grease wheel spindle Long life grease p 122 Lift the rear wheel into...

Page 36: ...hain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bear...

Page 37: ...procket engine sprocket for wear 400227 01 Check rear sprocket engine sprocket for wear If the rear sprocket engine sprocket are worn Replace rear sprocket engine sprocket Info When fitting the chain...

Page 38: ...sting screws equally on the left and right Check that the rear wheel is aligned with the front wheel Tighten nuts Make sure that the chain adjusters are fitted correctly on the adjusting screws Tighte...

Page 39: ...ding Check the free play of the hand brake lever p 37 13 3 Checking the front brake fluid level Warning Danger of accidents Brake system failure If the brake fluid level falls below the MIN mark this...

Page 40: ...oughly with water and contact a doctor immediately Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan in an a...

Page 41: ...per and brake caliper support 13 7 Installing the front brake linings Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and gr...

Page 42: ...spose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals...

Page 43: ...overheating Adjust free travel on foot brake pedal according to specifications 700535 01 Detach the spring Loosen nut Turn back push rod until free travel is at a maximum Guideline Free play at foot b...

Page 44: ...ke system failure If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Have the brake system checked in an authorized KTM workshop a...

Page 45: ...linings Worn brake linings should be replaced immediately in an authorized KTM workshop 700424 01 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness...

Page 46: ...unt screw Mount lock washer Install the rear wheel p 33 Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a pressure point 13 17 Changing the rear brak...

Page 47: ...e that no brake fluid overflows from the brake fluid reservoir Install the rear brake linings p 44 Add brake fluid to the top edge of the level viewer Brake fluid DOT 4 DOT 5 1 p 120 Position the cove...

Page 48: ...ng it to one side Info Do not kink the clutch line Do not activate the clutch lever while the clutch slave cylinder is not installed 300638 10 Remove screw Disconnect spring Remove screw Maneuver the...

Page 49: ...10 Remove nut Remove the swingarm pivot 300645 10 Lift out the engine from the side Info Pull the link fork back slightly It is useful to have an assistant help you with this step Ensure that the mot...

Page 50: ...linder M6 10 Nm 7 4 lbf ft 300637 11 Position the clutch slave cylinder with the seal Mount and tighten screws Guideline Screw clutch slave cylin der M6 10 Nm 7 4 lbf ft Loctite 243 Position the clutc...

Page 51: ...8 25 Nm 18 4 lbf ft 300640 11 Slide the carburetor into the intake flange Position and tighten hose clamp 300636 10 Mount the radiator hoses Position and tighten the hose clamps Install the exhaust ma...

Page 52: ...29001060 p 124 15 2 Removing the clutch pressure piece 300770 10 Remove the clutch pressure piece 15 3 Removing the oil drain plug 300746 10 Remove the oil drain plug with magnet and the seal ring Com...

Page 53: ...e diaphragm 300750 10 Remove screws Remove the reed valve housing of the exhaust control 300751 10 Remove spring 300752 10 Remove O rings 15 6 Removing the cylinder head 300753 10 Alternately loosen s...

Page 54: ...the clutch line holder Carefully slide the cylinder up and take it off Take off the cylinder base gasket Remove the dowels 15 9 Removing the piston 300758 10 Remove piston pin retainer Remove the pis...

Page 55: ...300764 10 Remove screws Remove the generator cover Remove the gasket 15 13 Removing the rotor 300766 10 Hold the rotor in place with special tool Holding spanner 54629012100 p 127 Remove nut with the...

Page 56: ...ver 300773 10 Remove screws Take off the water pump cover Remove the gasket and dowels 15 17 Removing the clutch cover 300772 10 Remove screws Take off the clutch cover Info Ensure that the kickstarte...

Page 57: ...ment 46229081000 p 125 Loosen nut of the primary gear and remove it with the washer 300778 10 Take off the outer clutch hub 300779 10 Remove needle bearing and collar bushing 15 19 Removing the primar...

Page 58: ...ith the washer Remove screw Remove the retaining bracket 15 22 Removing the shift shaft 300786 10 Push sliding plate away from the shift drum locating Remove shift shaft with the washer 15 23 Removing...

Page 59: ...tion of the engine case up and remove the screw connection of the engine holder 300935 10 Mount special tool Protective cap 46229090000 p 126 300938 10 Mount the special tool Extractor 45229048000 p 1...

Page 60: ...e sure not to misplace the shift rollers Remove shift drum 15 29 Removing the shift forks 300797 10 Take shift forks out of the shift grooves Info Make sure not to misplace the shift rollers 15 30 Rem...

Page 61: ...ISASSEMBLING THE ENGINE 59 15 31 Removing the crankshaft 300800 10 Warm up the crankshaft bearing Guideline 60 C 140 F Remove crankshaft 300801 10 Remove O ring P a r t S h a r k c o m 8 7 7 9 9 9 5 6...

Page 62: ...ecessary use a suitable press drift to push the bearing from the inside to the outside all the way to the stop or so it is flush Info Bearing of the water pump must be pressed from the outside to the...

Page 63: ...re that the engine case section is level to prevent damage Only press the bearings in via the outer ring otherwise the bearings will be damaged when they are pressed in Press crankshaft seal ring from...

Page 64: ...rank web out of the special tool and check that the connecting rod can move freely 300837 10 Measure axial clearance between the stop disk and the crank webs with the spe cial tool Feeler gauge 590290...

Page 65: ...ess out the bearing of the water pump shaft with a suitable tool Info Support the clutch cover when pressing out 16 6 Installing the water pump 300811 11 Press in the bearing of the water pump shaft w...

Page 66: ...ce is damaged Change the piston and if necessary the cylinder Check that the piston ring moves smoothly in the piston ring groove If the piston ring is stiff Clean the piston ring groove Tip Use an ol...

Page 67: ...er mounting clearance New condition 0 060 0 085 mm 0 00236 0 00335 in Wear limit 0 10 mm 0 0039 in 16 10 Checking the piston ring end gap 0 0 B B 400542 10 Remove the piston ring from the piston Place...

Page 68: ...Change all clutch springs Check the contact surface of inner clutch hub for damage and wear If there is damage or wear Change the inner clutch hub Check the contact surfaces of the clutch facing discs...

Page 69: ...ange the clutch pressure cap Check spring retainer for damage and wear If there is damage or wear Change the spring retainer 16 14 Premounting the clutch 300815 10 Oil the clutch discs well Beginning...

Page 70: ...rn Change the shift roller Check springs of the shift rails for damage and wear If the spring is broken or worn Change the spring of the shift rail Check the shift rail on a flat surface for run out I...

Page 71: ...op disk and second gear fixed gear Remove the sixth gear idler gear Remove lock ring Remove the third fourth gear sliding gear Remove lock ring Remove the fifth gear idler gear 16 18 Assembling the ma...

Page 72: ...very repair job Oil all parts carefully before assembling Check the transmission p 71 0 0 bl bl 0 0 9 9 0 0 bk bk 0 0 8 8 0 0 7 7 0 0 6 6 0 5 0 0 4 4 0 3 0 0 2 2 0 0 1 1 300801 02 Fix the countershaft...

Page 73: ...r pair Check the shift dogs of idler gears and fixed gears for damage and wear If there is damage or wear Change the idler fixed gear pair Check the tooth faces of idler gears and fixed gears for dama...

Page 74: ...10 Mount kickstarter ratchet wheel Marking is offset from hole by 180 300857 10 Mount washer 300858 10 Mount starter wheel 300861 10 Mount washer and lock ring 300859 10 Position the spring and hook...

Page 75: ...of the engine case Mount the dowels 17 2 Installing the transmission shafts 300799 10 Oil all bearing Engine oil 15W 50 p 120 Assemble the two transmission shafts and slide them into the bearing seats...

Page 76: ...c essary Info Do not tighten the engine case sections using the screws Mount screws and tighten them after all screws of the left engine case section are mounted Guideline Screw engine housing M6x55 1...

Page 77: ...00788 10 Press locking lever down and position shift drum locating Info The flat surfaces of the shift drum locating are not symmetric 300787 11 Release the locking lever Mount and tighten screw Guide...

Page 78: ...hift shaft M5 6 Nm 4 4 lbf ft Loctite 243 17 12 Installing the kickstarter shaft 300784 10 Premount the kickstarter shaft p 72 Mount the premounted kickstarter shaft with the washer Hook in kickstarte...

Page 79: ...ft Loctite 243 300776 11 Mount washer 300775 11 Premount the clutch p 67 Position the clutch pack Hold the clutch in place with special tool Clutch holder 49012003000 p 126 Mount and tighten screw Gui...

Page 80: ...er M6 8 Nm 5 9 lbf ft 17 17 Installing the kickstarter 300771 10 Position the kickstarter Mount and tighten screw with the washer Guideline Screw kickstarter M8 25 Nm 18 4 lbf ft Loctite 243 17 18 Ins...

Page 81: ...gine case opening with a cloth Position the piston pin retainer in the 6 o clock or 12 o clock position Ensure that the piston pin retainer is correctly seated on both sides Remove the cloth 17 21 Ins...

Page 82: ...and overheats 300826 10 Apply special tool to the cylinder Adjustment gauge 46129006100 p 124 Info Apply the special tool with label cylinder height onto the cylinder Position the piston at top dead c...

Page 83: ...t clockwise until the upper edge of the piston rests against the special tool 300818 10 Turn the stator until markings are aligned 300823 10 Tighten screws Guideline Screw ignition system stator M5 5...

Page 84: ...the chamfer facing inward 17 27 Installing the engine sprocket 300761 10 Slide on the engine sprocket with the collar facing the engine Mount lock ring 17 28 Installing the exhaust control valve 3008...

Page 85: ...ten screws Guideline Screw reed valve housing of exhaust control M5 5 Nm 3 7 lbf ft Mount and tighten screws Guideline Screw reed valve housing of exhaust control M6 10 Nm 7 4 lbf ft 300749 11 Positio...

Page 86: ...in plug 300746 10 Mount and tighten the oil drain plug with magnet and the new seal ring Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft 17 33 Installing the clutch pressure piece 30077...

Page 87: ...rew 300864 10 Remove screw Swing up the tail piece Info Pay attention to the carburetor connection boot 300865 10 Unscrew hose clip Pull the carburetor out of the intake flange 300866 10 Remove screws...

Page 88: ...carburetor 300868 11 Attach throttle cable 300867 11 Position plastic lock Position the throttle slide spring 300866 11 Position the throttle slide and throttle slide cover Mount and tighten screws G...

Page 89: ...ite 243 300862 11 Tighten hose clip Install the main silencer p 22 Install the fuel tank p 26 Check play in the gas Bowden cable p 15 Carburetor adjust the idle speed p 93 18 3 Disassembling the carbu...

Page 90: ...10 Remove screw Remove the valve seat of the float needle valve with the lock washer 300875 10 Remove idling jet 300876 10 Note the setting of the idle air adjusting screw Remove the idle air adjusti...

Page 91: ...ecure the choke slide with the lock washer 300944 11 Mount the speed adjusting screw with the spring and O ring 300876 11 Alternative 1 Mount idle air adjusting screw with the spring Set the idle air...

Page 92: ...in the recess 300872 11 Mount and tighten main jet with the washer Guideline Main jet M5x0 75 2 Nm 1 5 lbf ft 300871 11 Position the float needle valve and float Mount fulcrum pin Check set the float...

Page 93: ...throttle slide p 92 Check the float needle valve p 92 Check the choke slide p 92 Assemble the carburetor p 89 18 6 Checking the jet needle Condition The jet needle has been removed 300877 10 Check th...

Page 94: ...ooth operation If the choke slide is difficult to move or is dirty Clean the choke slide and check its activation Carburetor cleaner p 122 Check the piston of the choke slide for damage and wear If th...

Page 95: ...If you can turn the idle air adjusting screw to the end without any change of engine speed you need to install a smaller idling jet After changing the idling jet start from the beginning with the adj...

Page 96: ...on the fuel tap all the way clockwise No more fuel flows from the tank to the carburetor 700458 01 Place a cloth beneath the opening to soak up emerging fuel Info Water in the float chamber results in...

Page 97: ...fluid batteries etc according to regulations Info The fluid level rises with increasing wear of the clutch lining disc 300669 10 Move the clutch fluid reservoir mounted on the handlebar to a horizont...

Page 98: ...ith a new seal ring Guideline Drain plug water pump cover M6 6 Nm 4 4 lbf ft 20 2 Refilling coolant Warning Danger of poisoning Coolants are poisonous and a health hazard Avoid contact between coolant...

Page 99: ...or cap 20 4 Checking the coolant level Warning Scalding hazard During motorcycle operation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other componen...

Page 100: ...35 WATER PUMP COOLING SYSTEM 98 Mount the radiator cap P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 101: ...ng and gloves If you scald yourself hold the affected area under cold water immediately Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cle...

Page 102: ...or poor quality oil results in premature wear of the transmission 300661 10 Remove gear oil level check screw 300660 11 Remove screw cap Stand the vehicle upright Add gear oil until it flows out of th...

Page 103: ...e ignition coil Check the ignition coil p 103 Info The CDI controller cannot be tested using simple tools but requires an ignition test bench Check the ignition pulse generator p 102 300886 10 Mount t...

Page 104: ...ess Change the ignition pulse generator On the cable harness side of plug FD measure pin 2 against ground Resistance If the measured value does not equal the specified value Check the wiring harness C...

Page 105: ...5 Checking the spark plug connector 300884 10 Measure the removed spark plug connector with a multimeter Spark plug connector Resistance at 20 C 68 F 4 3 5 7 k If the displayed value does not equal th...

Page 106: ...tool to the multimeter Peak voltage adapter 58429042000 p 127 Info When using the peak voltage adapter the measurement range of the multi meter must be set to DCV Place the red measuring lead of the...

Page 107: ...retor components p 91 Adjusting screws on carburetor dis torted Carburetor adjust the idle speed p 93 Fault in ignition system Check the ignition system p 101 Adjust the ignition Ignition system defec...

Page 108: ...y dirty Clean radiator fins Foam formation in cooling system Drain the coolant p 96 Refill the coolant p 96 Damaged cylinder head or cylinder head gasket Check the cylinder head or cylinder head gas k...

Page 109: ...oil lubrication Primary transmission 23 75 straight cut spur gear Clutch Multidisc clutch in oil bath hydraulically activated Gearbox 6 gear claw shifted Transmission ratio 1st gear 13 37 2nd gear 16...

Page 110: ...clearance New condition 0 060 0 085 mm 0 00236 0 00335 in Wear limit 0 10 mm 0 0039 in Piston ring end gap 0 60 mm 0 0236 in Clutch facing disc thickness 2 6 2 7 mm 0 102 0 106 in Clutch spring length...

Page 111: ...ctite 243 Screw gear oil level check M6 6 Nm 4 4 lbf ft Screw generator cover M6 8 Nm 5 9 lbf ft Screw intake flange reed valve housing M6 10 Nm 7 4 lbf ft Screw kickstarter stop piece M6 10 Nm 7 4 lb...

Page 112: ...uretor type MIKUNI TM 24 Needle position 2nd position from top Idle air adjusting screw Open 3 5 turns Main jet 210 Jet needle 51 PL 43 2 Idling jet 20 Needle jet Q O 454 Throttle slide 2 5 P a r t S...

Page 113: ...15 psi Rear 1 0 bar 15 psi Secondary drive ratio 14 50 Chain 1 2 x 1 4 O ring Rear sprockets available 46 48 50 Steering head angle 64 5 Wheelbase 1 137 mm 44 76 in Seat height unloaded 750 mm 29 53...

Page 114: ...length 100 2 5 mm 3 94 0 098 in Fork length 735 mm 28 94 in Fork oil Fork oil SAE 5 p 120 29 2 XC Fork part number 46201000133 Fork Marzocchi Upside down Compression damping Standard 10 clicks Rebound...

Page 115: ...n Fitted length 347 mm 13 66 in Shock absorber oil Shock absorber oil SAE 2 5 50180342S1 p 121 30 2 XC Shock absorber part number 03 18 7E 05 Shock absorber WP Suspension 3614 BAVP Compression damping...

Page 116: ...ake caliper M8 20 Nm 14 8 lbf ft Loctite 243 Screw engine bracket M8 30 Nm 22 1 lbf ft Screw foot brake pedal M8 25 Nm 18 4 lbf ft Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw rear sprocket M8 25...

Page 117: ...ycle cleaner p 122 Info 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 flo...

Page 118: ...eck the rear brake linings p 43 Check the brake discs p 31 Check the front brake fluid level p 37 Check the rear brake fluid level p 42 Check brake lines for damage and leakage Check the free play of...

Page 119: ...of the piston pin Check main bearing of the crankshaft Check radial clearance of conrod bearing Change crankshafts and conrod bearings Fully check the transmission Carry out a complete fork service C...

Page 120: ...NG DIAGRAM 118 34 1 Wiring diagram 1 3 2 4 5 6 8 7 9 0 1 1 1 2 1 2 1 D F 1 A 1 L 1 F B 1 A B 1 S G 4 E C 4 A C 2 4 1 3 1 G 1 2 2 4 5 6 1 3 7 6 4 7 5 3 300807 01 P a r t S h a r k c o m 8 7 7 9 9 9 5 6...

Page 121: ...19 Components A1 CDI controller G1 Generator L1 Ignition coil S1 Short circuit button Cable colors 1 Brown 2 White blue 3 White blue 4 Blue 5 Blue yellow 6 Red 7 White red P a r t S h a r k c o m 8 7...

Page 122: ...torex Anti Freeze Engine oil 15W 50 According to JASO T903 MA p 129 SAE p 129 15W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and tha...

Page 123: ...ith the specified standards see specifications on the container and that possess the corresponding properties Super unleaded gasoline mixed with 2 stroke engine oil According to DIN EN 228 JASO FC p 1...

Page 124: ...aterials for metal rubber and plastic Specification KTM recommends Motorex products Supplier Motorex Protect Shine 645 Contact spray Specification KTM recommends Motorex products Supplier Motorex Accu...

Page 125: ...Supplier Motorex Chain Lube 622 Oil for foam air filter Specification KTM recommends Motorex products Supplier Motorex Twin Air Liquid Bio Power Universal oil spray Specification KTM recommends Motore...

Page 126: ...29006100 Screw connection for engine work stand 400576 01 Art no 46229001060 Holder of engine work stand 300673 01 Art no 46229001070 Crankshaft pressing device 300850 10 Art no 46229008000 Feature Sp...

Page 127: ...941 10 Art no 46229008001 Cover crankshaft pressing device 300942 10 Art no 46229008002 Anchor plate 300939 10 Art no 46229047002 Press plate 300849 10 Art no 46229047050 Gear segment 300670 01 Art no...

Page 128: ...46229090000 Clutch holder 300887 10 Art no 49012003000 Spring hooks 400363 01 Art no 50305017000 Pressing device crankshaft complete 300940 10 Art no 50329047000 Bleed syringe 400058 01 Art no 503290...

Page 129: ...09044 Holding spanner 300676 01 Art no 54629012100 Work stand 500071 01 Art no 54829055000 Peak voltage adapter 400083 01 Art no 58429042000 Feeler gauge 25 20 30 15 10 12 5 3 5 400110 01 Art no 59029...

Page 130: ...SPECIAL TOOLS 128 Spark plug wrench 300888 10 Art no 60029073000 Engine work stand 200306 01 Art no 61229001000 Hook wrench 300576 10 Art no T106S P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

Page 131: ...he gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive E...

Page 132: ...2 Brake fluid level front brake checking 37 rear brake checking 42 Brake linings front brake linings changing 40 front brake checking 39 front brake installing 39 front brake removing 39 rear brake ch...

Page 133: ...bling 69 transmission checking 71 water pump installing 63 water pump removing 63 Exhaust manifold installing 21 removing 21 F Float level checking setting 92 Float needle valve checking 92 Foot brake...

Page 134: ...sories 6 Spark plug connector checking 103 Spoke tension checking 32 Spring preload shock absorber adjusting 18 Start number plate installing 28 removing 28 Starting 7 Steering head bearing greasing 1...

Page 135: ...3206061en 3206061en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 08 2008 Photo Mitterbauer P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6...

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