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ENGLISH

20

General information about KTM disc brakes

BRAKE CALIPERS:
If the front brake caliper is removed, the screws must be secured with
Loctite 243 when mounted and tightened to 20 Nm.

BRAKE FLUID RESERVOIRS:
The brake fluid reservoirs on front and rear wheel brakes have been 
designed in such a way that even if the brake pads are worn it is not neces-
sary to top up the brake fluid. If the brake fluid level drops below the mini-
mum level either the brake system has a leak or the brake pads are com-
pletely worn. In this case, consult an authorized KTM dealer immediately.

BRAKE FLUID:
KTM fills the brake system with ”Shell Advance Brake DOT 5.1”, one of the
best brake fluids currently available. We recommend that you continue to
use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color.
If you do not have any DOT 5.1 for refilling, you may use DOT 4 brake
fluid. DOT 4 shown on the lid means minimum standard. However, you
should replace it as soon as possible by DOT 5.1.

WARNING

H

AVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY

. I

F YOU WASH YOUR

MOTORCYCLE OFTEN

THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE FREQUENTLY

.

B

RAKE FLUID TENDS TO ABSORB WATER

. T

HEREFORE

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 brake pads decreases. At their thinnest point 

A

, the brake

discs must not be more than 0.40 mm (0.016 in) thinner than the pad's
nominal thickness. Measure the nominal thickness in a location 

B

outside

the contact face. Check wear in several locations.

WARNING

– B

RAKE DISCS SUFFERING FROM WEAR GREATER THAN

0.40 

MM

(0.016 

IN

CONSTI

-

TUTE A SAFETY RISK

. H

AVE THE BRAKE DISCS REPLACED IMMEDIATELY AS SOON AS

THEY REACH THE WEAR LIMIT

.

– H

AVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BY A

KTM 

DEALER

.

Adjusting free travel of the hand brake lever

Free travel of the hand brake lever may be readjusted by using the adjust-
ment screw 

2

. In this way, the position of the point of pressure (i.e. the

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

!

CAUTION

!

A

T THE HAND BRAKE LEVER

FREE TRAVEL MUST AT LEAST BE

MM

(0.1 

IN

). O

NLY THEN

MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED

(

TO BE RECOGNIZED BY THE

GREATER RESISTANCE OF THE HAND BRAKE LEVER

). I

F THIS FREE TRAVEL IS NOT

PROVIDED

PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM

AND THE FRONT

-

WHEEL

BRAKE MAY FAIL DUE TO OVERHEATING

.

min. 3 mm

DOT

5.1

DOT

5

2

A
B

1

Содержание 65 SX 2003

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 10: ...ENGLISH 9...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 39: ...ENGLISH 38...

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

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