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KTM 65 SX 2012, Owner'S Manual

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KTM 65 SX 2012 Owner'S Manual Download Page 51

BRAKES

49

Info

Never use DOT 5 brake fluid! It is silicone-based and purple in color. 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 front brake linings.

x

(

p. 47)

C00031-10

–

Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

–

Remove screws

.

–

Remove cover

with membrane

.

–

Press the brake piston back to its basic position and make sure that no brake fluid
overflows from the brake fluid reservoir.

–

Install the front brake linings.

x

(

p. 48)

–

Correct the brake fluid level.
Guideline

Brake fluid level under top level of con-
tainer

5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 (

p. 79)

–

Position the cover with the membrane. Mount and tighten the screws.

Info

Clean up overflowed or spilt brake fluid immediately with water.

11.10

Checking the free travel of the foot brake lever

Warning

Danger of accidents

 

Brake system failure.

–

If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust free travel on foot brake lever according to specifications.

B00401-10

–

Disconnect spring

.

–

Move the foot brake lever back and forth between the end stop and the foot brake
cylinder piston bracket and check free travel

.

Guideline

Free travel of foot brake lever

3… 5 mm (0.12… 0.2 in)

» If the free travel does not meet specifications:

–

Adjust the free travel of the foot brake lever.

x

(

p. 49)

–

Attach spring

.

11.11

Adjusting the free travel of the foot brake lever

x

Warning

Danger of accidents

 

Brake system failure.

–

If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust free travel on foot brake lever according to specifications.

B00402-10

–

Detach the spring.

–

Loosen nut

.

–

Turn push rod

until clearance

is created.

Guideline

Free travel of foot brake lever

3… 5 mm (0.12… 0.2 in)

–

Hold push rod

and tighten nut

.

–

Attach the spring.

Summary of Contents for 65 SX 2012

Page 1: ...OWNER S MANUAL 2012 65 SX Art no 3211712en...

Page 2: ......

Page 3: ...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 stop production of a particular...

Page 4: ...ering head bearing x 32 Dismounting the start number plate 32 Installing the start number plate 32 Dismounting the front fender 32 Installing the front fender 33 Removing the shock absorber x 33 Insta...

Page 5: ...float chamber x 63 MAINTENANCE WORK ON THE ENGINE 64 Checking the gear oil level 64 Changing the gear oil x 64 Draining the gear oil x 64 Filling up with gear oil x 65 Adding gear oil x 65 CLEANING CA...

Page 6: ...standing In the interest of the safety of your child have these jobs done in an authorized KTM workshop There your motorcycle will be serviced optimally by specially trained experts using the speciali...

Page 7: ...and greases according to specifications as listed in the owner s manual Spare parts accessories For your own safety only use spare parts and accessory products that have been approved and or recommend...

Page 8: ...ent 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 Caution Identifies a danger...

Page 9: ...the vehicle from the left front example C00016 10 1 Hand brake lever p 10 2 Clutch lever p 10 3 Quick release for seat lock 4 Front brake caliper 5 Fuel tap p 11 6 Choke p 11 7 Shift lever p 12 8 Shoc...

Page 10: ...the right rear example C00017 10 1 Filler cap 2 Kill switch p 10 3 Throttle grip p 10 4 Chassis number p 9 5 Rear brake caliper 6 Level viewer for brake fluid rear 7 Shock absorber compression adjustm...

Page 11: ...e steering head 4 2 Engine number 700391 01 The engine number is stamped on the left side of the engine under the engine sprocket 4 3 Shock absorber part number 700392 01 The shock absorber part numbe...

Page 12: ...on running engine will not start 5 5 Opening the filler cap Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine...

Page 13: ...ank Possible states Fuel tap is closed The knurled screw is turned all the way clockwise Fuel cannot flow out of the fuel tank Fuel tap is open The knurled screw is turned all the way counterclockwise...

Page 14: ...ight of the engine The kickstarter can be swiveled Info Before riding swing the kickstarter inwards towards the engine 5 11 Foot brake lever 700400 01 Foot brake lever is located in front of the right...

Page 15: ...ning Danger of accidents Critical riding behavior due to inappropriate riding Ensure that your child adjusts the riding speed to the road conditions and to his or her riding abilities Warning Danger o...

Page 16: ...nd in a standing position to get a better feeling for the vehicle Do not let your child ride on terrain that exceed your child s capabilities and experience Your child should hold the handlebar firmly...

Page 17: ...the fuel supply 7 2 Starting Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is suff...

Page 18: ...ake and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Your child should switch off the engi...

Page 19: ...tral Press and hold the kill switch while the engine is idling until the engine stops Turn the knurled screw on the fuel tap all the way clockwise Park the motorcycle on firm ground 7 7 Refueling Dang...

Page 20: ...RIDING INSTRUCTIONS 18 Close the filler cap p 11...

Page 21: ...parts e g hand levers chain and check for smooth opera tion x Change the hydraulic clutch fluid x p 44 Check the fluid level of the hydraulic clutch p 44 Change the front brake fluid x Check the front...

Page 22: ...ews and nuts for tightness x Check set the carburetor components x Check idle x Final inspection check the vehicle for operating safety and take a test ride Create a service entry in the KTM DEALER NE...

Page 23: ...wise all the way Info Adjusting screw is located at the top end of the left fork leg and is labeled with a REB Turn back counterclockwise by the number of clicks corresponding to the fork type Guideli...

Page 24: ...sag unloaded Raise the motorcycle with a lift stand p 26 0 0 A A 400988 10 Measure the distance as vertical as possible between the rear axle and a fixed point for example a mark on the side cover Mak...

Page 25: ...dents Disassembly 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 glad to help R...

Page 26: ...e 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 Distance between holes 3 5 mm 0 138 in The handlebar supports can...

Page 27: ...TUNING THE CHASSIS 25 Position the handlebar clamp Mount and evenly tighten the four screws Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Info Make sure the gap width is even...

Page 28: ...lug in stand bracket on the left side of the vehicle Info Remove the plug in stand before riding 10 3 Bleeding fork legs Raise the motorcycle with a lift stand p 26 C00007 10 Remove bleeder screws bri...

Page 29: ...clamp Remove screw on the left fork leg Take off the fork protector C00022 11 Remove screw on the right fork leg Take off the fork protector 10 6 Installing the fork protector x C00022 10 Position th...

Page 30: ...ter the vehicle s ride behavior Following modifications ride slowly at first to get the feel of the new ride behavior C00007 10 Position the fork legs Info The upper milled groove in the fork leg must...

Page 31: ...end the cables and lines C00009 10 Remove protective ring Remove the lower triple clamp with the steering stem Remove the upper steering head bearing 10 10 Installing the lower triple clamp x 0 0 1 1...

Page 32: ...C00041 10 Mount and tighten screw Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft C00042 10 Mount and tighten screws Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft B00399 10 Position bra...

Page 33: ...ad bearing x p 31 Move the handlebar to and fro over the entire steering range The handlebar must be able to move easily over the entire steering range No resting locations should be noticeable If cli...

Page 34: ...ake off clamp Remove screw Remove the start number plate 10 15 Installing the start number plate 700413 01 Position the start number plate with the drill holes onto the holding lugs of the fender B004...

Page 35: ...he swingarm 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 10 19 Installing shock a...

Page 36: ...ce dust and dirt can get into the engine and result in increased wear Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc shou...

Page 37: ...ter with fuel or petroleum since these substances attack the foam Remove the air filter x p 34 Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner...

Page 38: ...er tube Slide the outer tube over the glass fiber yarn filling Insert the locking cap into the outer tube Mount and tighten the screws with the toothed washers Guideline Remaining screws chassis M6 10...

Page 39: ...n up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health hazar...

Page 40: ...breather Mount the seat p 34 10 30 Removing the chain guard 100815 10 Remove cable binder Take off the chain guard 10 31 Installing the chain guard 100816 10 Position the chain guard Mount cable bind...

Page 41: ...ed in applicable regulations Info The service life of the chain depends largely on its maintenance 400725 01 Clean the chain regularly and then treat with chain spray Chain cleaner p 81 Off road chain...

Page 42: ...heck the chain tension and correct if neces sary Raise the motorcycle with a lift stand p 26 Remove the chain guard p 38 Check the chain tension p 39 700452 10 Loosen nut Loosen nuts Adjust the chain...

Page 43: ...ine sprocket cover Guideline Screw engine sprocket cover M6 10 Nm 7 4 lbf ft B00382 01 Check the chain sliding guard for wear If the lower edge of the chain pins is in line with or below the chain sli...

Page 44: ...uide can be adjusted on small sprockets Remove the chain guard p 38 700459 01 Loosen screw Position the chain guide Tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Install the cha...

Page 45: ...itionally securing the rubber grip Check the rubber grip p 43 401198 01 Secure the rubber grip at two locations with the retaining wire Securing wire 54812016000 Wire twister forceps U6907854 The twis...

Page 46: ...cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info The fluid level rises with increasing wear of the clutch lining disc C00044 10 Move the clutch fluid reserv...

Page 47: ...he hand brake lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar The range of adjustment is limited Turn the adju...

Page 48: ...ne based and purple in color 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 f...

Page 49: ...o a horizontal position Remove screws Remove cover with membrane Correct the brake fluid level Guideline Brake fluid level under top level of con tainer 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 79 Posi...

Page 50: ...ranty is no longer valid Check the brake discs p 45 C00032 01 Insert the brake linings Info Ensure that the brake linings are correctly positioned in the retaining spring C00034 10 Mount and tighten s...

Page 51: ...the foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to ov...

Page 52: ...nuts chassis M8 25 Nm 18 4 lbf ft Check the free travel of the foot brake lever p 49 Guideline Free travel of foot brake lever 3 5 mm 0 12 0 2 in If the free travel at the foot brake lever does not m...

Page 53: ...brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners...

Page 54: ...move lock washer Remove screw 700430 01 Remove the brake linings Clean brake caliper and brake caliper support 11 17 Installing the rear brake linings x Warning Danger of accidents Reduced braking eff...

Page 55: ...ely Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will...

Page 56: ...e Dimension brake fluid level below top edge of container 10 mm 0 39 in Brake fluid DOT 4 DOT 5 1 p 79 Position the membrane and the cover with the washer Mount and tighten the screws Info Clean up ov...

Page 57: ...with brake cleaner when necessary 700438 01 Check the wheel bearing for damage and wear If the wheel bearing is broken or worn Change the wheel bearing x Clean and grease wheel spindle Long life grea...

Page 58: ...lways keep the brake discs free of oil and grease and clean them with brake cleaner when necessary 100819 11 Check the wheel bearing for damage and wear If the wheel bearing is broken or worn Change t...

Page 59: ...its of the DOT marking The first two digits refer to the week of manufacture and last two digits refer to the year of manufac ture KTM recommends that the tires be changed after 5 years at the latest...

Page 60: ...eter If you hear different tone frequencies from spokes of the same length and thickness this is an indication that the spoke tension differs You should hear a high note If the spoke tension differs C...

Page 61: ...immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediate...

Page 62: ...vel does not meet specifications Correct the coolant level Alternative 1 Coolant p 79 Alternative 2 Coolant mixed ready to use p 79 Mount the radiator cap 13 4 Draining the coolant x Warning Danger of...

Page 63: ...ned Stand the vehicle upright Add coolant to level Guideline Level above the radiator fins 10 mm 0 39 in Coolant 0 55 l 0 58 qt Coolant p 79 Coolant mixed ready to use p 79 0 0 A A 0 0 B B 400677 11 P...

Page 64: ...rburetor 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 i...

Page 65: ...ne first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See the...

Page 66: ...4 lbf ft 15 2 Changing the gear oil x 400721 01 Drain the gear oil x p 64 400722 01 Fill up with gear oil x p 65 15 3 Draining the gear oil x Warning Danger of scalding Engine oil and gear oil get ver...

Page 67: ...make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight Check...

Page 68: ...MAINTENANCE WORK ON THE ENGINE 66 Start the engine and check that it is oil tight...

Page 69: ...an with a brush Motorcycle cleaner p 81 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 Emp...

Page 70: ...op waiting times at the start of the new season Clean the motorcycle p 67 Change the gear oil x p 64 Check the antifreeze and coolant level p 59 Drain the fuel from the tank into a suitable container...

Page 71: ...heck the spark plug connector x Engine does not speed up Carburetor running over because float needle dirty or worn Check set the carburetor components x Loose carburetor jets Check set the carburetor...

Page 72: ...or cylinder head gas ket Bent radiator hose Change the radiator hose x Incorrect ignition point due to loose stator Adjust the ignition x White smoke emission steam in exhaust gas Damaged cylinder he...

Page 73: ...ngular ring Engine lubrication Mixture oil lubrication Primary transmission 23 75 straight cut spur gear Clutch Multidisc clutch in oil bath hydraulically activated Gearbox 6 gear claw shifted Transmi...

Page 74: ...level check M6 6 Nm 4 4 lbf ft Screw intake flange reed valve housing M6 10 Nm 7 4 lbf ft Screw kickstarter stop piece M6 10 Nm 7 4 lbf ft Loctite 243 Screw outer clutch cover M6 10 Nm 7 4 lbf ft Scre...

Page 75: ...position from top Idle air adjusting screw Open 3 5 turns Main jet 210 Jet needle 5IPL43 Idling jet 20 Needle jet Q O 454 Throttle slide 2 5 21 2 Carburetor configuration 100810 01 M FT ASL Above sea...

Page 76: ...TECHNICAL DATA CARBURETOR 74 POS Needle position from above MJ Main jet The carburetor configuration depends on the defined ambient and operating conditions...

Page 77: ...Standard 2 turns Rebound damping Standard 2 turns Spring rate Soft 2 6 N mm 14 8 lb in Medium standard 2 8 N mm 16 lb in Hard 3 0 N mm 17 1 lb in Spring length with preload spacer s 337 5 mm 13 287 i...

Page 78: ...d 12 clicks Spring preload Standard 7 mm 0 28 in Spring rate Weight of rider 35 kg 77 lb 35 N mm 200 lb in Weight of rider 35 45 kg 77 99 lb 40 N mm 228 lb in Weight of rider 45 kg 99 lb 45 N mm 257 l...

Page 79: ...Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi Secondary drive ratio 14 48 Chain 1 2 x 1 4 O ring Rear sprockets available 46 48 50 Steering head angle 64 5 Wheelbase 1 137 mm 44...

Page 80: ...tom triple clamp M8 15 Nm 11 1 lbf ft Screw brake caliper M8 20 Nm 14 8 lbf ft Loctite 243 Screw engine bracket M8 30 Nm 22 1 lbf ft Screw foot brake lever M8 35 Nm 25 8 lbf ft Loctite 243 Screw handl...

Page 81: ...es Use of low quality antifreeze can lead to corrosion and foam ing KTM recommends Motorex products Mixture ratio Antifreeze protection 25 45 C 13 49 F 50 corrosion inhibitor antifreeze 50 distilled w...

Page 82: ...ons on the container and that possess the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches...

Page 83: ...oducts Supplier Motorex Protect Shine High viscosity grease Guideline KTM recommends SKF products Supplier SKF LGHB 2 Long life grease Guideline KTM recommends Motorex products Supplier Motorex Bike G...

Page 84: ...AUXILIARY SUBSTANCES 82 Rubber grip adhesive 00062030051 Supplier KTM Sportmotorcycle AG GRIP GLUE Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Synthetic...

Page 85: ...the automobile industry were used for 4 stroke motorcycles because there was no separate motorcycle specifi cation Whereas long service intervals are demanded for automobile engines high performance...

Page 86: ...Choke 11 Cleaning 67 Clutch fluid level checking 44 fluid changing 44 Clutch lever 10 basic position adjusting 43 Compression damping fork adjusting 21 shock absorber adjusting 21 Coolant draining 60...

Page 87: ...adjusting 24 Rubber grip checking 43 securing 43 S Seat mounting 34 removing 33 Service 5 Service schedule 19 20 Shift lever 12 Shock absorber installing 33 removing 33 riding sag checking 23 spring p...

Page 88: ...3211712en 3211712en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 04 2011 Photo Mitterbauer...

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