Owner's Manual 2006

OWNER’S MANUAL 2006

65 SX

ART. NR. 3.211.70EN ENGLISH IMPORTANT extracts, withwrittenallowance ofKTM-SPORTMOTORCYCLE AG,Mattighofen only. © 2005byKTM-SPORTMOTORCYCLE AG,MattighofenAUSTRIA;All rightsreserved;Reprint,alsoin els partlycontainextraequipment,whichisnotappliedtostandard models. ability and/ortodeliver, illustrations,descriptions,printingand/or othererrors.Theillustratedmod- ufacturing certainmodelswithoutpreviousnotice.KTMshall notbeheldliableforanydeviationsofavail- of theaboveitems,allwithoutpreviousannouncementand without givingreasons.KTMmaystopman- ice work,constructions,equipmentandthelikesoastoadapt themtolocalconditionsorcancelany right tomodifyanyequipment,technicalspecifications,prices, colors,shapes,materials,services,serv- AGparticularlyreservesthe All informationcontainediswithoutobligation.KTM-SPORTMOTORCYCLE Stamp ofdealer Engine number Chassis number Please inserttheserialnumbersofyourmotorcycleinboxesbelow tion markedasfollows: In theinterestofeverybodyinvolved,weurgeyoutopayparticularattentioninstructionsandinforma- to operateandhandlethemotorcycleproperly. This manualcontainsimportantinformationandrecommendationsthatwillhelpyouyouryoungster Please readthismanualthoroughlybeforelettingyouryoungsterridethemotorcycleforfirsttime. IGNORINGTHESEINSTRUCTIONSMAY DAMAGEPARTS OFTHEMOTORCYCLEORIMPAIR THEMOTOR- – IGNORINGTHESEINSTRUCTIONSCANBEDANGEROUSTOLIFE ANDLIMB. – CYCLE’S TRAFFICSAFETY. »

1 ENGLISH » Attachments: spare parts manual Now you own a modern motorcycle that you and your youngster will certainly enjoy, provided that you serv- provided enjoy, youngster will certainly that you and your a modern motorcycle Now you own operation and mainte- information on the contains important This manual it properly. ice and maintain latest state of development. your model’s motorcycle. It went to press describing nance of your new KTM current design as our motorcycles are perma- may deviate slightly from the Nevertheless, the descriptions the motorcycle and must be handed over to Owner's Manual is an integral part of the nently improved.The motorcycle is sold. new owner when the chas- in the chapter "Maintenance work on the out that work marked with an asterisk expressly point We maintenance work should become necessary be performed by a KTM workshop. If sis and engine" must it must be performed by a trained mechanic. during a competition, and inspection and maintenance intervals. the prescribed running-in periods Please strictly observe significantly prolong the life of your motorcycle. Compliance with these instructions will out by a KTM workshop to avoid losing your right to claim Be sure to have the maintenance work carried under the warranty. parts and accessories approved by KTM. KTM shall not assume For the safety of your child, only use spare damage resulting from the use of such products. any liability for other products or consequential who will seek the assistance of the KTM importer a KTM dealer, When special needs arise, please contact if necessary. of their youngsters always depends on the efforts made SHOULD KEEP IN MIND that the safety PARENTS is kept in good working order and only used on safe terrains. by the parents to ensure that the motorcycle driving any other vehicle, involves a potential risk. Therefore, Nevertheless, driving the motorcycle, like ON precautions are taken. Please also read the „INFORMATION please make sure that all fundamental on page 4. SAFE DRIVING FOR PARENTS“ form of outdoor recreation and we certainly hope that you Riding an off-highway motorcycle is a wonderful this enjoyable outdoor activity can cause environ- However, and your youngsters will enjoy it to the full. other people. Responsible use of the motorcycle will prevent mental problems or lead to conflicts with to securing the future of motorcycling by making sure can contribute such problems and conflicts. You by the applicable laws, that you and your youngsters only use the motorcycle within the limits established rights. people’s making environmental protection one of your top priorities and never violating other motorcycle! In this spirit, we hope that you and your youngsters will always safely enjoy your AG KTM-SPORTMOTORCYCLE AUSTRIA 5230 MATTIGHOFEN, INTRODUCTION INTRODUCTION

ENGLISH 2 IMPORTANT WARRANTYANDGUARANTEEINFORMATION has beenreached. necessary toserviceorreplacewearpartsbeforethelimitspecifiedinmaintenanceschedule to higherthanaveragewearoncomponentssuchasthedrivetrainorbrakes.Inthiscaseitmaybecome The useofthemotorcycleunderextremeconditions,e.g.onextremelymuddyandwetterrain,canlead or conversionstothemotorcycle. No claimscanbefiledunderthewarrantyfordamageorconsequentialcausedbymanipulations tions mustbeusedinaccordancewiththemaintenanceschedule. The fuelsandlubricantsspecifiedintheOwner'sManualorautomotivefluidswithequivalentspecifica- workshop andrecordedintheservicemanualotherwiseclaimsunderwarrantyshallbecomevoid. The serviceworkspecifiedinthe„LubricationandMaintenanceSchedule“mustbeperformedbyaKTM ing thebasicchassissetting). erly tunedchassiscanleadtodamageandbreakageofthecomponents(seechapteroncheck- the Owner'sManualisaprerequisiteforfaultlessoperationandavoidanceofprematurewear. Animprop- Observance oftheservice,maintenanceandtuninginstructionsforenginechassisspecifiedin tional motorcycleassociations. The motorcyclescomplywiththeregulationsandcategoriescurrentlyineffectleadinginterna- use incompetitions. KTM mini-sportsmotorcyclesaredesignedandconstructedtoresisttheusualweartearofnormal quality assuranceprocessesthatleadtothehighestpossible productquality. In accordancewiththeinternationalqualitymanagementISO 9001standard,KTMuses »

3 ENGLISH » protection, chest, back, arm and leg protectors, gloves and boots. To set a good example, be sure to set a good gloves and boots. To protection, chest, back, arm and leg protectors, a motorcycle! wear protective gear yourself whenever riding man- the entire owner’s recommend to review explained. We your youngster has understood what you particular attention to the specially marked warnings and ual with your youngster item by item, paying pointing out the danger of injury. weight, etc. to shifting of the rider’s (see chapter on checking the basic chassis setting). tings are suitable for your child's weight (see maintenance schedule). Have your youngster perform these technical checks himself / herself as well. your youngster and not the other way around. vising adult must be followed. advantage. Your able to ride a bicycle. Being good at sports that require fast reactions is an additional youngster should be strong enough to pick up the motorcycle after a fall. in a race before improve his / her riding skills. Do not even consider letting your youngster participate his / her physical condition, riding skills and motivation have sufficiently developed. and severe injuries. tions as well as to his / her own riding skills and that excessive speed can cause falls recognize them alto- Always keep in mind that youngsters tend to underestimate dangers or fail to on unknown terrain. The riding speed must be reduced, in particular, gether. be back. This makes it easier to send you help, should problems occur. – eye wear proper protective gear whenever he or she rides the motorcycle: helmet, Have your youngster – lever and hand brake lever to match your child's hand size (with gloves). Adjust the clutch –setting of the foot brake pedal to your child's seating position. Adjust the basic – if takes his or her first ride, explain how each of the controls works and check Before your youngster – about riding and falling techniques, explain how the motorcycle will respond Instruct your youngster – set- motorcycle for the first time check whether the basic fork and shock absorber Before starting the – you should always check all components for proper operation Before using the motorcycle – that the speed should be adjusted to keep in mind Whenever you go for a ride with your youngster, – receives from you or any other super- youngster must understand that all instructions he or she Your – means that he or she must at least be child must be physically ready to ride a motorcycle. This Your – to get used to the motorcycle and to Give him or her time Never demand too much of your youngster. – his / her riding speed to the local condi- Explain to your youngster that he / she should always adjust – An adult should always be present. Never let your youngster ride the motorcycle without supervision. – youngster is not allowed to transport a passenger. Your The motorcycle is designed for one rider only. – know where you are going and when you will When you go for a ride, somebody at home should always The 65 SX They are not allowed motorcycles designed for one person only. mini motorcycles are off-road on public roads. are designed for children from 6 to 10 years of age with a max- The vehicle dimensions and components maximum height of 160 cm (63.04 in). imum weight of. 50 kg (22.65 lb) and a IMPORTANT INFORMATION FOR PARENTS ABOUT SAFE DRIVING DRIVING SAFE ABOUT PARENTS FOR INFORMATION IMPORTANT

ENGLISH 4 ANEAC OKO HSI N NIE. . . .16 MAINTENANCE WORKONCHASSISANDENGINE ..14 SCHEDULE MAINTENANCE PERIODIC ..11 INSTRUCTIONS DRIVING ..10 MOTORCYCLE THE GENERAL TIPSANDWARNINGS FORSTARTING ..6 OPERATIONINSTRUMENTS . ..6 LOCATIONS NUMBER SERIAL AL FCONTENTS OF TABLE odtrietesgo h eecpcfr ..18 fork telescopic the of Tosag the determine . ..18 absorber shock the of Tosag the determine . .18 Basic suspensionsetupforthe weightofthedriver . . .17 Changing springpreloadingof theshockabsorber ..17 position handlebar the change to How . . . . Cleaning thedustsleevesof telescopicfork .17 ..16 fork front plug Breather . . .16 Checking andadjustingthesteeringheadbearing ..13 fuel Refueling, . ..13 Stopping ..13 Braking ..12 Shifting/Riding ..12 off Starting ..12 „flooded“ is engine the when do to What ..12 warm is engine the when Starting ..12 cold is engine the when Starting ..11 start each before check should you What . . .10 in Running ..10 ride first the for Instructions ..8 Plugin-Stand . . . .8 Rebound dampingfunctionoftheshockabsorber ..8 absorber shock of damping Compression ..8 pedal brake Foot ..8 Kickstarter ..7 lever Shift ..7 Choke ..7 tap Fuel . . .7 cap Filler ..7 button circuit Short ..6 lever brake Hand . . .6 lever Clutch ..6 number Engine ..6 number Chassis » Page INDEX . . . ..37 INDEX . ..35 SPECIFICATIONSTECHNICAL ENGINE – . .34 SPECIFICATIONSTECHNICAL CHASSIS – ..33 STORAGE OF PERIOD AFTER USE ..33 STORAGE ..33 CLEANING ..31 SHOOTING TROUBLE hnigga i ..30 oil gear Changing ..30 level oil gear Checking ..30 carburetor the of chamber float the Draining ..29 adjustment Carburetor ..28 cable throttle the Adjusting ..28 level coolant Checking ..28 system Cooling . . Changing theoriginalpositionofclutchlever . .28 . ..27 clutch hydraulic the of Bleeding ...... 27 Checking theoillevelofhydraulicclutch ..27 system Exhaust ..26 filter air the Cleaning ..26 seat the Removing . . .25 tension spoke Checking ..25 Tires,pressure air ..25 wheel rear the installing and Removing ..24 wheel front installing and Removing ..24 pads brake rear the Replacing ..23 pads brake rear Checking ..23 reservoir fluid brake rear the Refilling ..23 level fluid brake rear the Checking ..22 pedal brake the of position basic Changing ..22 pads brake front the Replacing ..21 pads brake front Checking ..21 level fluid brake front the Checking/refilling . . . .20 Adjusting thefreetravelathandbrakelever ..20 brakes disc KTM about information General ..19 maintenance Chain ..19 tension chain Correcting ..19 tension chain Checking Page

5 ENGLISH can be used to change [B] is mounted on the handle bars on the right and actu- [2] is located on the left side of the handlebar. The adjust- is located on the left side of the handlebar. [1] is used to change the original position of the clutch lever (see [A] maintenance work on chassis and engine). The clutch is hydraulically actuated and adjusts itself automatically. The hand brake lever the basic position of the hand brake lever (see maintenance work on chassis and engine). Clutch lever The clutch lever ing screw Hand brake lever The chassis number is stamped on the right side of the steering head tube. of the steering head on the right side number is stamped The chassis on page no 1. number in the field Enter this Engine number underneath the is stamped into the engine housing The engine number in the field on page no 1. Enter this number carburetor. Chassis number ates the front wheel brake. The adjusting screw » » 1 B A 2 OPERATION INSTRUMENTS OPERATION INSTRUMENTS SERIAL NUMBER LOCATIONS LOCATIONS NUMBER SERIAL

ENGLISH 6 OPERATION INSTRUMENTS 4 N 3 2,3,4,5,6 1 1 2 » Fuel tap Install tankbreatherhose To closeit: To openit: Filler cap the ignitioncircuitisshort-circuited. The shortcircuitbutton Short circuitbutton first andsecondgear. gears isshownintheillustration.Neutral,oridlespeed, locatedbetween The shiftleverismountedontheleftsideofengine. positionofthe Shift lever Pushing thechokebuttonbackinclosesborecarburetor. ture neededforcoldstarting. the enginecantakeinadditionalfuel,thusachieving„rich“fuelairmix- choke buttonallthewayoutopensaboreincarburetorthroughwhich The chokebutton Choke Closing thefueltap: Opening thefueltap: The fueltap put fillercapbackonandtightenitbyturningclockwise. turn fillercapcounter-clockwise. [3] is locatedontheleftsideoftank. [4] is locatedontheleftsideofcarburetor. Pullingthe Turn theknoballwaytoright. Turn theknoballwaytoleft. [1] [2] turns offtheengine.Whenpressingthisbutton, without kinks.

7 ENGLISH . [1] . Turn the setting wheel clockwise (in) . Turn [2] [A] . [3] to increase and counterclockwise (out) to reduce the damping effect. ADJUSTMENT: STANDARD Position 6 at the mark Turning in a clockwise direction will increase the damping, turning in a coun- Turning damping. terclockwise direction will decrease the ADJUSTMENT: STANDARD the knob all the way to the stop in a clockwise direction. Turn the knob 2 clicks in a counterclockwise direction (= position 3). Turn A socket is provided on the left side of the frame into which you can plug the stand The degree of damping of the compression can be adjusted with the knob The degree of damping of the compression Rebound damping function of the shock absorber The damping effect of the rebound damping mechanism can be adjusted by levels by means of the setting wheel Plugin-stand The kickstarter is mounted on the right side of the engine. Its upper part can engine. Its upper part the right side of the is mounted on The kickstarter be swivelled. Foot brake pedal Its basic posi- is located in front of the right foot rest. The foot brake pedal work). to your seat position (see maintenance tion can be adjusted Compression damping of shock absorber Kickstarter » 1 3 2 A OPERATION INSTRUMENTS INSTRUMENTS OPERATION

ENGLISH 8 9 ENGLISH » EVER HE OR SHE RIDES THE MOTORCYCLE: HELMET, EYE PRO- EYE THE MOTORCYCLE: HELMET, EVER HE OR SHE RIDES BACK, ARM AND LEG PROTECTORS, GLOVES TECTION, CHEST, SURE TO WEAR PRO- AND BOOTS. TO SET A GOOD EXAMPLE, BE A MOTORCYCLE! TECTIVE GEAR YOURSELF WHENEVER RIDING THE SAME PROFILE TYPE. HAVE WITH TIRES THAT TO THE TERRAIN. TO HIS/HER DRIVING SKILLS AS WELL AS MOTORCYCLE WITHOUT SUPERVISION. VISOR OR GOG- ON A SCRATCHED WHEN LIGHT SHINES DIRECTLY BLIND. GLES, YOU WILL BE PRACTICALLY LONG AS THE ENGINE IS RUNNING. ARE NOT ALLOWED. THEREFORE, BY THE LAW. ESTABLISHED SAFETY STANDARDS THEY ARE NOT PERMITTED ON PUBLIC ROADS. EXCESSIVE NOISE. – GEAR WHEN- YOUR YOUNGSTER WEAR PROPER PROTECTIVE HAVE – RECOMMENDED BY KTM. PARTS USE ACCESSORY ONLY – ALLOWED TO BE TIRED THE FRONT AND REAR WHEEL ARE ONLY – BE ADJUSTED YOUR YOUNGSTER'S DRIVING SPEED SHOULD ALWAYS – RIDE THE YOUR YOUNGSTER SHOULD NEVER BE ALLOWED TO – ENOUGH. EARLY REPLACE THE HELMET VISOR OR GOGGLE GLASSES – AS YOUR MOTORCYCLE WITHOUT SUPERVISION NEVER LEAVE – PASSENGERS PERSON ONLY. SX MODELS ARE DESIGNED FOR ONE – AND WITH THE REGULATIONS THESE MODELS DO NOT COMPLY – MOLESTED BY OTHER PEOPLE FEEL IN MIND THAT KEEP ALWAYS have rougher surfaces than components which have been slid- ing across one another for quite some time. Therefore, every engine needs to be broken in. For this reason, during its first 30 minutes the engine must not be revved up to its performance limits. formed by your authorized KTM workshop. The DELIVERY CER- KTM workshop. The DELIVERY formed by your authorized MANUAL will be handed over when you and SERVICE TIFICATE pick up your vehicle. youngster has under- each of the controls works and check if your recommend to review the entire stood what you explained. We item, paying par- manual with your youngster item by owner’s warnings and point- ticular attention to the specially marked ing out the danger of injury. child can operate them easily! garden. Be sure that on soft ground, e.g. on a meadow or in the no other riders are and that there is room enough to maneuver, close. while you push the have your youngster operate the hand brake your youngster has motorcycle. Do not start the engine before pressure. learned to apply hand brake with appropriate the hand brake while brake let him or her practice to operate the engine before you are pushing the motorcycle. Do not start of the hand brake. he or she is thoroughly familiar with the use stop the motorcycle. persons who help the young rider to how to stop the you should also teach your youngster However, motorcycle himself/herself. riding the motorcycle standing on the footpegs or to riding at you can arrange a series the slowest possible speed. Additionally, of obstacles and have your youngster drive around them, etc. – Apply low but changing loads for running-in. – Even very precisely machined sections of engine components – inspection“ was per- Make sure the work for the „pre-delivery – takes his or her first ride, explain how Before your youngster – hand lever and foot brake pedal so your lever, Adjust the clutch – skills teach your youngster the basic riding prevent injury, To –brake, ensure that your youngster gets the feel of the hand To – familiarize your youngster with the operation of the hand To –two your youngster should ride back and forth between Initially, – riding skills, your youngster should practise improve his/her To – Pay attention to the running-in procedure. GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE MOTORCYCLE THE STARTING FOR WARNINGS AND TIPS GENERAL DO NOT DRIVE AT FULL LOAD FOR THE FIRST 30 MINUTES! DO NOT DRIVE AT Running in Instructions for the first ride Instructions for the

ENGLISH 10 DRIVING INSTRUCTIONS » 5 BRAKES 4 TIRES 3 CHAIN 2 FUEL CHECKTRANSMISSIONOILLEVEL. 1 The followingchecksshouldbeperformed: your motorcyclebeforeeachstart. For safetyreasons,youshouldmakeitahabittoperformanoverallcheckof When youstartoff,themotorcyclemustbeinaperfecttechnicalcondition. What youshouldcheckbeforeeachstart 7 COOLING FLUID 6 CABLES FIRST HAVING THEBRAKESYSTEMLOOKEDOVERBYAKTMDEALER. SYSTEM. DON’TLETYOURCHILDRIDETHEMOTORCYCLEANYMORE WITHOUT PLAY), THISISANINDICATION THAT SOMETHINGISWRONGWITHTHEBRAKE IF THERESISTANCE INTHEHANDBRAKELEVERFEELS„SPONGY“(TOO MUCH Check freetravelatthehandbrakeleverandfootlever. linings. Also checkthestateofbrakehoseandthickness to avoidbrakefailure. brake pads.AlwayshavethesystemcheckedbyaKTMworkshop value, thisindicatesaleakinthebrakingsystemorcompletelywornout brake padsareworn.Iftheleveloffluidfallsbelowminimum in suchawaythatbrakefluiddoesnotneedtoberefilledevenwhenthe sufficient brakefluidinthereservoir. Thereservoirshavebeendesigned Check thecorrectfunctioningofbrakingsystem.Verify thatthereis deteriorate thedrivingperformance. Also checktheairpressure.Insufficienttreadandincorrectpressure Check fordamagedtires.Tires showingcutsordentsmustbereplaced. chain andwheels. tear, andinsufficientlubricationmayresultinunnecessarywearofthe A loosechainwasfalloffthewheels;anextremelywornmay check thatthetankventinghoseisfreeofkinks. Check thatthereissufficientfuelinthetank;whenclosingfillercap, tion ofthegearwheels. A lackofgearoilleadstoprematurewearandfinallyresultsindestruc- Check thelevelofcoolingfluidwhenengineiscold. Check correctsettingandeasyrunningofallcontrolcables.

11 ENGLISH . [2] STAND BEFORE YOUR CHILD RIDES THE MOTOR- STAND [3] . [1] fuel in the float chamber.The easily inflammable components of the easily inflammable fuel in the float chamber.The of standstill.When the new fuels evaporate during longer periods than a week, it is there- motorcycle has been out of operation for more The from the float chamber. fore recommended to drain the old fuel float chamber is filled with engine will immediately start off when the new fuel. OUGHLY BEFORE USING IT AGAIN. OUGHLY HANDLEBAR, IT WILL LOSE STABILITY. ERS BOOTS!YOU MAY SLIP OFF THE KICKSTARTER, OR THE ENGINE MAY KICK MAY OR THE ENGINE OFF THE KICKSTARTER, SLIP ERS BOOTS!YOU MAY ENOUGH. KICK HART BACK IF YOU DO NOT CONSCIOUS- POISONOUS AND CAN CAUSE LOSS OF EXHAUST FUMES ARE THE WHILE VENTILATION ADEQUATE PROVIDE ALWAYS NESS AND DEATH. ENGINE IS RUNNING. Start engine with full throttle. If necessary, unscrew spark plug and dry it. Start engine with full throttle. If necessary, – CHECK ALL ITS FUNCTIONS THOR- WITH THE MOTORCYCLE, AFTER FALLING – BE REPLACED. DO NOT ADJUST THE A TWISTED HANDLEBAR MUST ALWAYS – WEAR STRONG BIK- ALWAYS THE ENGINE, WHEN STARTING INJURY TO AVOID –IT TO IDLE IN A CLOSED AREA. THE ENGINE AND ALLOW NOT START DO DO NOT RIDE YOUR MOTORCYCLE AT FULL LOAD AND DO NOT REV UP THE ENGINE FULL LOAD AND DO NOT AT DO NOT RIDE YOUR MOTORCYCLE THAN THE FASTER UP AND EXPANDS THE PISTON WARMS WHEN COLD. SINCE LET CAUSE ENGINE DAMAGE. ALWAYS COOLED CYLINDER, THIS MIGHT WATER SPEEDS. LOW R.P.M. AT OR DRIVE IT WARM ENGINE IDLE UNTIL WARM What to do when the engine is „flooded“ 1 Close fuel tap 2 3 Once the engine is running, open fuel tap again. Starting off slowly release the clutch Put the engine into first gear, Pull the clutch lever. lever and accelerate at the same time. REMOVE THE PLUG-IN ALWAYS CYCLE. Shifting/Riding Depending on referred to as the drive or uphill gear. are now in first gear, You down Turn the conditions (traffic, hill size, etc.), you can shift to a higher gear. the throttle, at the same time pull clutch lever in and shift to the next higher Let clutch lever go again and open the throttle. If you turned on the gear. choke, make sure you turn it off again as soon as engine is warm. When shifting down, use the brakes if necessary and turn down at the same Let the clutch time. Pull clutch lever and shift down to the next lower gear. lever go slowly and open throttle or shift down again. 1 tap Open fuel 2 in neutral Put the gear 3 cold-starting aid (choke) Activate the 4 vigorously all the way. down the kickstarter closed and kick Leave throttle NOTE: starting the motorcycle, this could be due to old If you have trouble Starting when the engine is warm 1 Open fuel tap 2 Put the gear in neutral 3 the way. Leave throttle closed and kick down kickstarter vigorously all Starting when the engine is cold the engine Starting when » 3 1 2 DRIVING INSTRUCTIONS INSTRUCTIONS DRIVING

ENGLISH 12 DRIVING INSTRUCTIONS »

– DRIVING A COLD ENGINE AT HIGH SPEED WILL REDUCE THE LIFE – CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE. OTHERWISE OF THE ENGINE. WE RECOMMEND TO WARM THE ENGINE UP AT THE CARBURETOR MAY GET FLOODED AND FUEL WILL ENTER A MEDIUM ENGINE SPEED FOR SEVERAL MINUTES BEFORE SWITCH- THE ENGINE. ING TO FULL LOAD. – THE PLUGIN- STAND IS ONLY DESIGNED FOR THE WEIGHT OF THE – NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN MOTORCYCLE. IF YOU GET ON YOUR MOTOR-CYCLE AND THUS PUT TO A LOWER GEAR. THE ENGINE WILL OVERREV, DAMAGING THE ADDITIONAL WEIGHT ON THE MOTORCYCLE, THE PLUGIN- STAND VALVES. IN ADDITION, THE REAR WHEEL BLOCKS SO THAT THE OR THE FRAME CAN BE DAMAGED OR THE MOTORCYCLE MAY MOTORCYCLE CAN EASILY GET OUT OF CONTROL. FALL ON THE SIDE. – IF THE ENGINE RUNS WITHOUT THROTTLE DURING LONGER ENGLISH DOWNHILL TRAVEL, THE ENGINE SHOULD BE ACCELERATED OCCA- Refueling, fuel SIONALLY TO ENSURE THAT IT IS SUPPLIED WITH SUFFICIENT Unleaded premium gasoline RON 95 mixed with high grade two LUBRICANT WHICH IS MIXED IN THE FUEL. – IN THE EVENT THAT, WHILE YOUR CHILD IS RIDING ON THE MOTOR- stroke oil. Mixture ratio 1:60. Fuel and engine oil should only be 13 CYCLE, YOU NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, mixed immediately before use. YOUR CHILD SHOULD STOP IMMEDIATELY, TURN THE ENGINE OFF, KTM recommends Motorex Cross Power 2T. AND CONTACT AN AUTHORIZED KTM DEALER. Braking GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS. EXTREME CAU- TION SHOULD BE USED WHEN HANDLING GASOLINE. NEVER REFUEL Turn off the gas and apply the hand and foot brakes at the same THE MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARETTES. time. When driving on sandy, wet or slippery ground use mainly ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELING. BE CAREFUL the rear wheel brake. Always brake with feeling, blocking wheels NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE can cause you to skid or fall. Also change down to lower gears depend- THE ENGINE IS HOT. WIPE UP SPILLS PROMPTLY. IF GASOLINE IS SWAL- ing on your speed. LOWED OR SPLASHED IN THE EYES, SEEK A DOCTOR’S ADVICE IMME- DIATELY.

– IN CASE OF RAIN, AFTER WASHING THE MOTORCYCLE, AFTER RIDES THROUGH WATER AND IN CASE OF RIDES ON WET OFF-ROAD – ONLY USE PREMIUM-GRADE GASOLINE ROZ 95 (USA = PREMIUM TRACKS, HUMID OR DIRTY BRAKE DISCS CAN DELAY THE BRAK- RON 91) MIXED WITH HIGH-GRADE TWO-STROKE ENGINE OIL. ING EFFECT. THE BRAKES MUST BE PULLED UNTIL THEY ARE DRY OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE. OR CLEAN. – ONLY USE KNOWN BRANDS OF HIGH-GRADE 2-STROKE ENGINE – DIRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND OIL (MOTOREX CROSS POWER 2T). BRAKE DISCS. – DO NOT USE PREMIXED TWO-STROKE OILS, OILS FOR OUTBOARD – WHEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE ENGINES OR NORMAL ENGINE OIL TO PREPARE THE MIXTURE. CALIPER AND BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS – NOT ENOUGH OIL OR LOW-GRADE OIL CAN CAUSE EROSION OF GET, THE WEAKER THE BREAKING EFFECT. IN EXTREME CASES, THE PISTON. WHEN USING TOO MUCH OIL, THE ENGINE MAY THE ENTIRE BRAKING SYSTEM CAN FAIL. START SMOKING AND FOUL THE SPARK PLUG. – IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE – FUEL EXPANDS WHEN ITS TEMPERATURE RISES. THEREFORE DO PEDAL FEELS „SPONGY“ (TOO MUCH GIVE), THIS IS AN INDICA- NOT FILL THE TANK TO THE TOP. (SEE FIG.) TION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM. DON’T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER. Stopping Brake motorcycle and shift gears to idling. To switch off the engine, depress short circuit switch until the engine stops. Close fuel tap. 40 mm

MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUNNING. THE ENGINE, EXHAUST PIPE, MUFFLER, BRAKE ROTORS, AND SHOCK ABSORBERS CAN BECOME VERY HOT. DO NOT TOUCH ANY OF THESE PARTS AFTER STARTING THE MOTORCYCLE, AND TAKE CARE TO PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET BURNED. z z z z z z z z z z z z z z z z z z C/H C/H C/H C/H C/H C/H C/H after every race once a year z z z z once a year z z z z z z z z z z z z z z z z z z z z z z z Service every 20 hours ing 2006 65 SX » OMPETITION) C OBBY USE H intervals.

Check wheel bearings for play Check chain, chain wheels, chain wheel, chain joint guides for wear, tight fit, and tension chain joint guides for wear, Check chain, chain wheels, chain wheel, Lubricate chain swinging-fork pivot, suspension strut) Check spoke tension and rim joint Check tire condition and inflation pressure Check swinging-fork pivot Check/adjust steering-head bearing plates, axle nuts, Check all chassis screws for a tight fit (fork Check dust bellows Bleed fork legs Check the hand and foot brake lever for smooth functioning and free travel and the brakes for proper function Check the hand and foot brake lever for smooth fit Check screws of brake system for a tight and a proper function Check suspension strut and fork for leaks Clean air filter and air filter box brake discs Check brake fluid level, lining thickness, Check brake lines for damage and leaks arrangement, and adjust and lubricate arrangement, and adjust Check oil level of the clutch master cylinder Check cooling system for leaks, antifreeze protection Check cooling system for leaks and suspension Check exhaust system kinkless for damage, smooth operation, and Check actuating cables Check the intake flange and carburetor connection boot for cracks and tightness and carburetor connection boot for Check the intake flange engine is warm Check idle setting when passage for damage, kinkless installation and Check the bleeder hose Check spark plug, change it if necessary, set electrode gap set electrode it if necessary, Check spark plug, change a tight fit at intake flange Check carburetor for Check transmission oil level Check transmission oil Change transmission A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! CHECKED MORE QUICKLY CAN BE A CLEAN MOTORCYCLE

Wheels Chassis Brakes Add-on-parts Carburetor Engine = FOR OFFROAD = FOR COMPETITIVE OFFROAD RACING ( Change brake fluid Clean and adjust carburator Change hydraulic clutch fluid Perform complete suspension strut maintenance Clean and lubricate the swinging-arm bearing Clean and lubricate the steering-head bearing and sealing elements Perform complete fork maintenance IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED NOTE: KTM dealer for strict observance of the service A service hour counter (item no.: SXS05450600) is available from your THE KILOMETER READING FOR INSPECTION INTERVALS SHOULD NOT EXCEED 5 HOURS. SHOULD NOT EXCEED THE KILOMETER READING FOR INSPECTION INTERVALS IS NOT A SUBSTITUTE FOR CARE AND MAINTE- MAINTENANCE WORK PERFORMED BY YOUR AUTHORIZED KTM WORKSHOP NANCE BY THE DRIVER! H C PERIODIC MAINTENANCE SCHEDULE SCHEDULE MAINTENANCE PERIODIC

ENGLISH 14 MUST BEREPLACED. NOTE: IFTHEINSPECTIONESTABLISHES THAT PERMISSIBLE TOLERANCESAREEXCEEDED,THERESPECTIVECOMPONENTS PERIODIC MAINTENANCESCHEDULE Check theentiretransmissionincludingrollerandbearingsfor wear Replace thecrankshaftbearingsandconrod Check thecrankshaftmainbearingforwear Check theradialclearanceofpistonpinmainbearing Check theradialclearanceofconrodbearings Check theeccentricityofcrankshaftjournal Check thecylinderandpistonforwear Check thelengthofclutchsprings Check theclutchdiscsforwear Check thereed-typeintakevalveforwear (ADDITIONAL ORDERFORTHEKTM’SWORKSHOP) RECOMMENDED INSPECTIONOFTHE65SXENGINEBYYOURKTMWORKSHOP Check allscrews,nuts,andhoseclampsfortheirtightfitatregularintervals Treat allelectricplug-inconnectionswithcontactspray with wax-basedanti-corrosionagents Treat exposedmetalcomponents(exceptforthebrakeandexhaustsystems) Verify smoothoperationofallcontrols Drain andcleanfloatchamber Check fuellineforleaks Check tireinflationpressureandwear Clean airfilterandbox Clean andlubricatechain,checktensionreadjustitifnecessary Bleed forklegsregularly Remove andcleandustsleevesoftelescopicforkatregularintervals Lubricate andadjustactuatinggascablenipples Check brakeperformance Check brakepadsforwear Check brakefluidlevel Check coolantlevel Check transmissionoillevel VITAL CHECKSANDCAREPROCEDURESTOBECONDUCTEDBYTHEOWNERORMECHANIC » start each before z z z z z z z z 20 hours every cleaning every after z z z z z z z z z z z z z z use country for cross z z z z 40 hours every year a once z z z z z z z z

15 ENGLISH until there [2] » several turns to let any excess pressure escape from the inside of the fork. of the top triple clamp and turn steering stem bolt clockwise of the top triple clamp and turn steering stem The telescopic fork should be ventilated at regular intervals. Jack up the motorcycle until the front wheel no longer touches the ground. Unscrew vent screws [3] EXCESSIVE PRESSURE IN THE INTERIOR OF THE FORK CAN CAUSE LEAKS IN THE FORK. IF YOUR FORK IS LEAKING, IT IS RECOMMENDED TO OPEN THE BREATHER THE SEALS REPLACED. PLUGS BEFORE HAVING Check steering head bearing for play periodically. To check, put motorcycle To Check steering head bearing for play periodically. off the ground. Now try to move the on the stand so that the front wheel is loosen the three clamp screws fork forward and backward. For readjusting, [1] THE ADJUSTED TO BE FREE OF PLAY, IF THE STEERING HEAD BEARING IS NOT CHARACTERISTICS AND CAN GET MOTORCYCLE WILL EXHIBIT UNSTEADY DRIVING OUT OF CONTROL. IN THE STEERING HEAD BEARING FOR LONGER PERI- IF YOU DRIVE WITH PLAY IN THE FRAME THE BEARING SEATS ODS, THE BEARINGS AND SUBSEQUENTLY WILL BE DESTROYED. The steering head bearings should be regreased at least once a year 2000). (i.e. Motorex Long Term Breather plug front fork Checking and adjusting the steering head bearing * Checking and adjusting the steering is no more play. Don’t tighten the steering stem bolt all the way, otherwise steering stem bolt all the way, Don’t tighten the is no more play. lightly rap on the triple a plastic hammer, the bearings will be damaged. With three clamp screws to 20 Nm. clamp to release tension. Retighten the 2 3 1 1 1 ICAL FASTENING DEVICES AND THAT THE FUEL TAP IS IN THE OFF POSITION - IF THE MOTORCYCLE SHOULD FALL OVER, SHOULD FALL IS IN THE OFF POSITION - IF THE MOTORCYCLE TAP THE FUEL DEVICES AND THAT ICAL FASTENING TANK. FROM THE CARBURETOR OR FUEL NO FUEL CAN LEAK FUEL CAN FLOW THROUGH WHICH LEAKS IN THE TANK OR LONGER SCREWS CAN CAUSE USING OTHER SCREWS TANK. OUT. NUTS. AND KEEP WORKING LOOSE. INSTEAD, USE SELF-LOCKING FRAME PARTS 1,000,000 LITERS OF WATER. 1 LITER OF USED OIL CONTAMINATES WILL PENETRATE THE BEARINGS, CARBURETOR, ELECTRIC CONNECTORS, ETC. THE BEARINGS, CARBURETOR, ELECTRIC WILL PENETRATE – OR OTHER MECHAN- WITH RESTRAINING STRAPS IT IS HELD UPRIGHT KTM, ENSURE THAT YOUR WHEN TRANSPORTING – ON THE SUPPLIED BY KTM TO FIX THE SPOILERS THREAD LENGTH AN APPROPRIATE USE SPECIAL SCREWS WITH ONLY – THESE WORK INTO THE SCREWS, AS FASTENING OR SPRING RINGS WITH THE ENGINE DO NOT USE TOOTHED WASHERS – GETTING BURNED. BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID LET YOUR MOTORCYCLE COOL DOWN – ETC. PROPERLY. DETERGENTS, FUELS, WASHING FILTERS, MATTERS, FATTY DISPOSE OF OILS, – SYSTEM OR IN THE OPEN COUNTRYSIDE. USED OIL BE DISPOSED OF IN THE SEWAGE MAY UNDER NO CIRCUMSTANCES – WATER UNIT IF POSSIBLE, OTHERWISE DO NOT USE A HIGH PRESSURE CLEANING WHEN CLEANING THE MOTORCYCLE, MAINTENANCE WORK ON CHASSIS AND ENGINE ENGINE AND CHASSIS ON WORK MAINTENANCE ALL MAINTENANCE AND ADJUSTMENT OPERATIONS THAT ARE MARKED WITH AN ASTERISK * REQUIRE SPECIALIST KNOWL- * REQUIRE SPECIALIST WITH AN ASTERISK ARE MARKED THAT OPERATIONS AND ADJUSTMENT ALL MAINTENANCE MOTORCYCLE WILL WHERE YOUR OUT BY A KTM-DEALER BE CARRIED TASKS LET THESE YOUR OWN SECURITY, EDGE. FOR STAFF. SKILLED QUALIFIED, APPROPRIATELY BY SERVICED BE OPTIMALLY

ENGLISH 16 MAINTENANCE WORKONCHASSISANDENGINE 2 5

7 15 mm 3 1 3,5 mm 6 4 should bethesamesizeinfrontandrear. to 20Nm.Thegapbetweenthehandlebarsupportandclamps to 40Nm.Mounthandlebarandclamps,tightenscrews of thehandlebarsupport.Positionsupport,andtightenscrews How tochangethehandlebarposition THE FRONTBRAKE. CONSIDERABLY REDUCETHETIRE'SROADGRIPANDBRAKINGEFFECTOF NO OILMAY REACHTHEFRONTTIREORBRAKEDISKSSINCETHISWOULD oil. Then,pushthedust-protectionbellowsintooutertubesbyhand. oil themthoroughlywithUniversalspray(MotorexJoker440)orengine Clean thedust-protectionbellows,outertubes,andforktubesthoroughly, and and slidethemdownward. Use ascrewdrivertoliftthedust-protectionbellowsoutofoutertubes behind itmaystarttoleak. dust-protection bellows.Ifthisdirtisnotremoved,theoilsealingringslocated from theforktube.However, aftersometime,dirtmayalsogetinbehindthe The dust-protectionbellows Cleaning thedustsleevesoftelescopicfork RESULT. DO ANYMAINTENANCE WORKYOURSELF. SEVEREINJURIES COULDBETHE PRESSED NITROGEN. NEVERTRY TOTAKE THESHOCKABSORBERAPART ORTO THE DAMPING UNIT OFTHESHOCKABSORBER ISFILLEDWITHHIGHCOM- BASIC SETTING–SPRINGPRELOAD: 7mm(0.28in) preload withtheadjustingring Loosen thelockingring Beforechangingthespringpreloadnotedownbasicsetting,e.g. NOTE: This iseasilydone. Changing springpreloadingoftheshockabsorber THE SCREWS For thispurpose,removescrews ferent positions. ter by3.5mm(0.13in).Accordingly, youcanmountthehandlebarin4dif- one another. Theboresatthehandlebarsupport clamp handlebar inthepositionthatismostconvenientforyou.Theuppertriple The handlebarpositioncanbereadjustedby22mm.Thus,youputthe [2] how manythreadsarevisibleabovetheadjustingring. includes 2boresarrangedatadistanceof15mm(0.6in)from [5] MUST BESECUREDWITHLOCTITE243. [6] [1] with thehookspanner. Changethe spring [7] are toremovedustandcoarsedirtparticles [4] » and re-tightenthelockingring of thehandlebarclampsandscrews [3] are offsetfromthecen- [6] . [4] [5] [5]

17 ENGLISH – 160 mm – 340 mm ...... D) B) n n » triple clamp and write it down as dimension C. triple clamp and write it down as dimension and bounce up and down on the footrests) wearing full protective clothing, to become level. a few times to allow the telescopic fork tance between the same two points with the load on the motorcycle to establish dimension D. (e.g. a mark on the side cover) and write it down as dimension A. cover) and write it down as dimension (e.g. a mark on the side up and down full protective clothing and bounce on the footrests) wearing to become level. a few times to allow the rear wheel suspension the load on the motorcycle to tance between the same two points with establish dimension B. . If an adjustment is necessary, demount the fork legs, remove the plugs . If an adjustment is necessary, – longer touches the ground. Jack up the motorcycle until the rear wheel no – between the upper edge of the slider tube and the Measure the distance – motorcycle in a normal seating position (feet Have your child sit on the – Holding your child and the bike, have another person measure the dis- – The sag is the difference between dimensions C and D. – ground. the rear wheel no longer touches the Jack up the motorcycle until – wheel axle and a fixed point the vertical distance between the rear Measure – again. Place the motorcycle on the ground – seating position (feet child sit on the motorcycle in a normal Have your – another person measure the dis- Holding your child and the bike, have – between dimensions A and B. The sag is the difference To determine the sag of the telescopic fork To determine the sag of the telescopic EXAMPLE: Motorcycle jacked up (dimension C) ...... 200 mm ...... Motorcycle on ground with driver seated (dimensio Sag ...... 40 mm ...... The sag should be 45 mm (± 5 mm). the spring preload of the telescopic fork must be reduced, If the sag is lower, the spring preload must be increased. if the sag is higher, The preload on the fork spring is determined by the length of preload spacer [1] and shorten the pretensioning sleeves or replace with longer ones. To achieve maximum handling performance and to prevent the telescopic fork prevent the telescopic performance and to maximum handling achieve To setup of the suspension damaged, the basic absorber from being and shock KTM's 65 At delivery, for your child's weight. must be suitable components (wear- 35 – 45 kg a driver weighing are set to accommodate SX motorcycles of this or falls short your child's weight exceeds clothing). If ing full protective and for the telescopic fork the spring preload will need to adjust range, you shock absorber accordingly. fork. The motor- sag of the shock absorber and telescopic adjust, check the To full protective up and your child should be wearing cycle should be filled clothing. sag of the shock absorber To determine the EXAMPLE: Motorcycle jacked up (dimension A) ...... 430 mm (dimensio Motorcycle on ground with driver seated Sag . . . .90 mm ...... The sag should be 90 mm (± 5 mm) shock absorber must be reduced, the spring preload of the If the sag is lower, increased (see Changing spring the spring preload must be if the sag is higher, preloading of the shock absorber). Basic suspension setup for the weight of the driver the weight of the setup for Basic suspension B A B

A D

C C 1 MAINTENANCE WORK ON CHASSIS AND ENGINE ENGINE AND CHASSIS ON WORK MAINTENANCE

ENGLISH 18 MAINTENANCE WORKONCHASSISANDENGINE 4 1 2

3 3 mm 3 3 4 2 nuts Tighten thehexagonnut is properlyalignedwiththefrontwheel. is properlyrestingagainstthetensioningscrews Before tighteningthehexagonnut and therighttensioningscrews Undo thehexagonnut Correcting chaintension 3 mm.Thelowerpartofthechainshouldbetightened. The distancebetweenthechainandswingarmshouldbeapprox. Press thechaindownonupperendofslidingcomponent. Set themotorcycleonplug-instand. Checking chaintension Also checksprocketsandchainguidesforwear, andreplaceifnecessary. TERLINK CLIPMUSTPOINTINRUNNINGDIRECTION. WHEN MOUNTINGTHECHAINMASTERLINKCLIP, THECLOSEDSIDEOFMAS- CONTROL. WOULD BESTRONGLY REDUCEDANDTHE MOTORCYCLECOULDEASILY LOSE OTHERWISE THEROADADHERENCEANDREARWHEELBRAKINGEFFECTS NO LUBRICATION ISALLOWEDTOREACHTHEREARTIREORBRAKEDISKS, or chainspray(MotorexChainlube622). cleaned infireproofsolventregularlyandafterwardstreatedwithhotgrease For longchainlife,goodmaintenanceisveryimportant.Theshouldbe Chain maintenance TIGHTENTHEHEXAGONNUTTOREQUIREDTORQUE.ALOOSEWHEEL – IFYOUDON’THAPPENTOHAVE ATORQUE WRENCHAT HAND,MAKESURE – INBOTHCASESTHERIDERISVERY LIKELY TOLOSECONTROLOFTHEMOTOR- – IFTHECHAINISNOTTIGHTENOUGHITCANSLIPOFFSPROCKETSAND – IFTHECHAINISTOOTIGHTSECONDARY TRANSMISSIONCOMPONENTS – SPINDLE MAY LEADTOANUNSTABLE BEHAVIOR OFYOURMOTORCYCLE. IOR OFYOURMOTORCYCLE. AS POSSIBLE.ALOOSEAXLEMAY LEADTOANUNSTABLE DRIVINGBEHAV- YOU HAVE THETIGHTENINGTORQUECORRECTEDBYAKTMDEALERASSOON CYCLE. BLOCK THEREARWHEELORDAMAGEENGINE. TO PREMATURE WEAR,ALSOCAUSECHAINBREAKAGE. WHEEL) WILLBEPUTUNDERADDITIONALSTRAINTHAT CAN,INADDITION (CHAIN, SPROCKETS,BEARINGSOFTHETRANSMISSIONANDREAR [2] . [1] [1] , thenundobothcounternuts to 40Nm. [3] » [1] equally far. Thenretightenthecounter make surethatthechainadjuster [3] and thattherearwheel [2] and turntheleft [4]

19 ENGLISH if necessary. [2] . Check the thickness of the brake [A] » of the brake pads decreases. The brake disk must be at least of the brake pads decreases. The brake . In this way, the position of the point of pressure (i.e. the resis-tance . In this way, [2] [1] THE BRAKE DISK REPLACED AS SOON AS IT REACHES THE SERVICE LIMIT. IT REACHES THE SERVICE THE BRAKE DISK REPLACED AS SOON AS DEALER. – IS A SAFETY RISK. HAVE A BRAKE DISK WORN DOWN TO LESS THAN 2.80 MM – BY A KTM ON THE BRAKE SYSTEM BE PERFORMED ANY REPAIRS HAVE 2.80 mm thick at the thinnest point you feel on the hand brake lever when the brake pads are pressed against the brake disc) can be adjusted for any hand size. When you press the hand brake lever forwards, you should have at least the adjusting screw 3 mm free travel. Turn disk at several points. BRAKE DISCS: disc in the area of the contact the thickness of the brake Due to wear, face Adjusting the free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw (0.1 IN). LEAST BE 3 MM MUST AT FREE TRAVEL THE HAND BRAKE LEVER, AT THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED (TO BE THEN MAY ONLY OF THE HAND BRAKE LEVER). IF THIS RESISTANCE RECOGNIZED BY THE GREATER IS NOT PROVIDED, PRESSURE WILL BUILD UP IN THE BRAKING FREE TRAVEL OVERHEATING. DUE TO FAIL BRAKE MAY SYSTEM, AND THE FRONT-WHEEL BRAKE CALIPERS: be secured with Loctite the screws must brake caliper is removed, If the front to 20 Nm. mounted and tightened 243 when RESERVOIRS: BRAKE FLUID have been on front and rear wheel brakes The brake fluid reservoirs it is not neces- that even if the brake pads are worn designed in such a way below the mini- fluid. If the brake fluid level drops sary to top up the brake are completely brake system has a leak or the brake pads mum level either the an authorized KTM dealer immediately. worn. In this case, consult BRAKE FLUID: 5.1“, one of the system with „Motorex Brake Fluid DOT KTM fills the brake you continue to use recommend that available. We best brake fluids currently If you color. is based on glycol ether and of an amber it. DOT 5.1 brake fluid may use DOT 4 brake fluid. DOT 4 do not have any DOT 5.1 for refilling, you you should replace it However, shown on the lid means minimum standard. as soon as possible by DOT 5.1. YOUR IF YOU WASH ONCE ANNUALLY. LEAST THE BRAKE FLUID CHANGED AT HAVE BE CHANGED EVEN MORE FRE- MOTORCYCLE OFTEN, THE BRAKE FLUID SHOULD POCK- THEREFORE, VAPOR BRAKE FLUID TENDS TO ABSORB WATER. QUENTLY. CAUS- LOW TEMPERATURES, AT FORM IN „OLD“ BRAKE FLUIDS EVEN ETS MAY ING THE BRAKE SYSTEM TO FAIL. General information about KTM about General information disc brakes A min. 3 mm 1 2 MAINTENANCE WORK ON CHASSIS AND ENGINE ENGINE AND CHASSIS ON WORK MAINTENANCE

ENGLISH 20 MAINTENANCE WORKONCHASSISANDENGINE 1 mm min. 2 3 5 mm 1 spilled brakefluidwithwater. lever untilyoufeelthepointofpressureagain.Wipe offanyoverflowingor Mount thediaphragm,coverandscrewsactuatehandbrake below theupperedgeofreservoir. wise addDOT5.1brakefluid(e.g.MotorexBrakeFluid5.1)upto5mm should be5mmbelowtheupperedgeofreservoir(seedrawing),other- the screws basic position.Movethehandbrakecylinderinahorizontalposition,remove dlebar. To checkthebrakefluidlevel,presspistonsbackinto The brakefluidreservoiriscombinedwiththehandcylinderonhan- Checking/refilling thefrontbrakefluidlevel* DESTROYING THEBRAKEDISC. AGAINST THEBRAKEDISC,THEREBYIMPARING THEBRAKINGEFFECTAND OR ENTIRELY WORN,THESTEELCOMPONENTS OFTHEBRAKEPAD WILLRUB IF THEBRAKEPADS AREREPLACEDTOOLATE SO THAT THELININGISPARTLY YOUR OWNSAFETYDON’TPUTOFFHAVING YOURBRAKEPADS CHANGED. THAN 1MM(0.04IN),OTHERWISE THEYCOULD LEAD TOBRAKEFAILURE. FOR AT THEIRMOSTWORNPOINTBRAKEPAD LININGSSHOULDNOTBETHINNER least 1mm(0.04in)thick. Inspect thebrakepadsfrominfrontofvehicle.Theliningsmustbeat Checking frontbrakepads USEONLY CLEANBRAKEFLUIDTAKEN FROMATIGHTLY SEALEDCONTAINER. – DON’TLETBRAKEFLUIDGETINCONTACT WITHPAINT, ITISANEFFECTIVE – BRAKEFLUIDCANCAUSESKINIRRITATION. AVOID CONTACT WITHSKINAND – STOREBRAKEFLUIDOUTOFREACHCHILDREN. – NEVERUSEDOT5BRAKEFLUID!ITISBASEDONSILICONEOILANDOFA – ACTUATE THEHANDBRAKELEVERUNTILYOUFEELPOINTOFPRESSURE – PAINT REMOVER. AND CONSULT ADOCTOR. EYES. IFYOUGETBRAKEFLUIDINYOUREYES,RINSEWITHPLENTYOFWATER TO IT. PURPLE COLOR.SEALSANDBRAKEHOSESMUSTBEESPECIALLY ADAPTED AGAIN. [1] and thecover [2] with thediaphragm » [3] . Thebrakefluidlevel

21 ENGLISH and [2] , the free play on the foot brake pedal [4] » from the screw as well as fixing screw from the screw as well [1] . Using the push rod [3] MATTERS. OTHERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED. THE BRAKING EFFECT WOULD BE STRONGLY OTHERWISE, MATTERS. OR FOOT BRAKE LEVER, RESPEC- THE HAND BRAKE LEVER ACTUATE ALWAYS WILL LIE AGAINST THE BRAKE THE BRAKE PADS SO AS TO ENSURE THAT TIVELY DISK AND THE PRESSURE POINT IS ESTABLISHED. TO BLEED THE BRAKE SYSTEM. HAVE – TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY IMPORTANT IT IS VERY – BEEN FITTED CORRECTLY. CHECK IF CIRCLIPS HAVE AFTER ASSEMBLY, – SYSTEM, ONE MUST PERFORMED ANY WORK ON THE BRAKING HAVING – THE BRAKE CALIPER OR YOU WILL DO NOT UNSCREW ANY OTHER SCREWS ON must be set. Measured on the outside, the foot brake pedal must have 3-5 mm of free play before the push rod can move the piston in the brake cylinder (to be recog- nised from the resistance on the foot brake pedal). The basic setting of the foot brake pedal can be changed by turning the end stop roller IN THE BRAKING SYS- IF THIS CLEARANCE IS MISSING, PRESSURE ACCUMULATES BEGIN TO RUB. THE BRAKING SYSTEM OVERHEATS TEM AND THE BRAKE PADS IN EXTREME CASES. COMPLETELY AND CAN FAIL Mount the left brake shoe and fix with screw. Mount the right brake shoe and Mount the left brake shoe and fix with screw. Align brake shoes, mount tighten the screw to 6 Nm. Mount the lock washer. front wheel (see chapter: Mounting the front wheel). Changing basic position of the brake pedal * Remove the front wheel (see front wheel chapter). front wheel (see front Remove the to put the brake pistons suitable screwdriver shoes apart with a Press brake position. in their basic Remove the lock washer Replacing the front brake pads * the front brake Replacing take the brake shoes out of the brake caliper. Clean brake caliper thoroughly Clean brake caliper out of the brake caliper. take the brake shoes with compressed air. 3-5 mm 2 1 3 4 MAINTENANCE WORK ON CHASSIS AND ENGINE ENGINE AND CHASSIS ON WORK MAINTENANCE

ENGLISH 22 MAINTENANCE WORKONCHASSISANDENGINE 1 mm min. 2 A 3 1 parked inaverticalposition. fluid offwithwater. until youfeelthepointofpressureagain.Wipe anyoverflowingorspilledbrake Remount thediaphragm,coverandscrewsactuatefootbrakelever reservoir. (e.g. MotorexBrakeFluidDOT5.1)upto15mmundertheupperedgeof pistons mustbepushedbacktotheirbasicposition.FillDOT5.1brakefluid Remove thescrews Refilling therearbrakefluidreservoir* THE BRAKESHOESCOMPLETELY WORN. TION GLASS,THISINDICATES THAT THEBRAKESYSTEMISEITHERLEAKINGOR IF THEBRAKEFLUIDLEVELDROPSBELOWUPPEREDGEOFINSPEC- No airbubbleshouldbevisibleininspectionglass the rearbrakecylinder. The reservoirforthereardiskbrakeisonrightsideofmotorcycle Checking therearbrakefluidlevel DESTROYING THEBRAKEDISC. AGAINST THEBRAKEDISC,THEREBYIMPARING THEBRAKINGEFFECTAND OR ENTIRELY WORN,THESTEELCOMPONENTS OFTHEBRAKEPAD WILLRUB IF THEBRAKEPADS AREREPLACEDTOOLATE SO THAT THELININGISPARTLY SAFETY DON’TPUTOFFHAVING YOURBRAKEPADS CHANGED. THAN 1MM,OTHERWISE THEYCOULDLEADTOBRAKE FAILURE. FORYOUROWN AT THEIRMOSTWORNPOINTBRAKEPAD LININGSSHOULDNOTBETHINNER may notbelessthan1mm(0.04in). The brakepadscanbeinspectedfromtherear. Thethicknessofthelinings Checking rearbrakepads USEONLY CLEAN BRAKEFLUIDTAKEN FROMATIGHTLY SEALEDCONTAINER. – DON’TLETBRAKEFLUIDGETINCONTACT WITHPAINT, ITISANEFFECTIVE – BRAKEFLUIDCANCAUSESKINIRRITATION. AVOID CONTACT WITHSKINAND – STOREBRAKEFLUIDOUTOFREACHCHILDREN. – – ACTUATE THEFOOTBRAKELEVERUNTILYOUFEELPOINTOFPRESSURE – PLE COLOR.SEALSANDBRAKEHOSESMUSTBEESPECIALLY ADAPTEDTOIT. NEVER USEDOT5BRAKEFLUID!ITISBASEDONSILICONEOILANDOFAPUR- PAINT REMOVER. AND CONSULT ADOCTOR. EYES. IFYOUGETBRAKEFLUIDINYOUREYES,RINSEWITHPLENTYOFWATER AGAIN. [1] and takeoffthecover » [2] and diaphragm [A] when thevehicleis [3] .The brake

23 ENGLISH . [2] . [1] and pull the brake shoes . [2] [5] on the fork fists. » [4] and tighten the clamping screws on the right , unscrew the screw . [5] [1] [3] YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON YOU HAVE DRIVING BEHAV- LEAD TO AN UNSTABLE AS POSSIBLE. A LOOSE AXLE MAY IOR OF YOUR MOTORCYCLE. UNTIL THE PRESSURE POINT RETURNS. REDUCED. BE STRONGLY THE BRAKING EFFECTS WOULD OTHERWISE MATTERS, MATTERS. OTHERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED. BE STRONGLY THE BRAKING EFFECT WOULD OTHERWISE, MATTERS. SO AS TO ENSURE RESPECTIVELY HAND BRAKE LEVER OR FOOT BRAKE LEVER, WILL LIE AGAINST THE BRAKE DISK AND THE PRES- THE BRAKE PADS THAT SURE POINT IS ESTABLISHED. DISMOUNTED. THE BRAKE DISC CAN BE DAMAGED. WHEEL, OTHERWISE – HAND, MAKE SURE A TORQUE WRENCH AT IF YOU DON’T HAPPEN TO HAVE – THE HAND BRAKE AFTER MOUNTING THE FRONT WHEEL, KEEP OPERATING – TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY IMPORTANT IT IS VERY – OIL AND FATTY TO KEEP THE BRAKE DISK FREE FROM IMPORTANT IT IS VERY – IS IN PLACE. BRACKET AFTER MOUNTING, MAKE SURE THE RETAINING – THE ACTUATE SYSTEM, ONE MUST ALWAYS AFTER WORKING ON THE BRAKING – THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN DO NOT OPERATE – DOWN THE ON TOP WHEN YOU LAY MAKE SURE THE BRAKE DISC IS ALWAYS Tighten the screw to 4 Nm and mount the locking screw Tighten out of the brake caliper. a fasten with the screw Slide new brake shoes into the brake caliper brake lever until you can feel the Mount the rear wheel and actuate the foot pressure point. Remove front wheel carefully from the fork. Removing and installing front wheel up on its frame so that the remove the front wheel, jack the motorcycle To front wheel no longer touches the ground. Loosen the collar screw Insert the front wheel in the fork and adjust to the right position. Mount the wheel spindle the thread on the collar screw and apply Loctite 243. fork leg slightly.Degrease Mount the collar nut and tighten to 40 Nm. bounce the fork hard a few times to the motorcycle off the stand and Take align the fork legs. Then tighten clamping screws to a max. torque of 10 Nm. Dismount the rear wheel (see „Dismounting the rear wheel“). „Dismounting the rear the rear wheel (see Dismount pis- to allow the brake a suitable screwdriver shoes apart with Press the brake to their basic position. tons to return screw Remove the locking Loosen the 2 clamping screws Hold the front wheel, pull out the wheel spindle Replacing the rear brake pads * the rear brake pads Replacing 4 2 3 1 5 MAINTENANCE WORK ON CHASSIS AND ENGINE ENGINE AND CHASSIS ON WORK MAINTENANCE

ENGLISH 24 MAINTENANCE WORKONCHASSISANDENGINE 3 2 1 Before tighteningthehexagonnut Slightly greasethewheelspindle. To installtherearwheelreverseproceduredescribedabove. Pull therearwheelbackwards. Turn therearwheelforwardsandtakechainoffsprocket. Hold therearwheelandpulloutspindle. [2] Mount thehexagonnutandtightento40Nm. that therearwheelisproperlyalignedwithfrontwheel. are properlyrestingagainstthetensioningscrews.Additionally, makesure Remove thehexagonnut Jack themotorcycleupbyframe. Removing andinstallingtherearwheel eihee n h he etrdb T dealer. retightened andthewheelcentered byaKTM result. Dulltonesareindicators ofloosespokes.Ifnecessary, havethe spokes spoke withthebladeofascrewdriver (seephoto).Acleartonemustbethe cially onanewmotorcycle,atregularintervals.Forchecking, taponeach and beforelongotherspokeswillhavecomeloose.Checkspoke tension,espe- thus forridingsafety. Aloosespokecauses thewheeltobecomeunbalanced The correctspoketensionisveryimportantforthestabilityof thewheelsand Checking spoketension (1.0 bar)ensuresoptimumdrivingcomfortandextendsthelifeofyourtires. Tire pressureshouldbecheckedregularlyona„cold“tire.Proper might havebecomeembeddedinthem. Before leaving,checktiresforpuncturesandnailsorothersharpobjectsthat Tire conditionhastobecheckedeverytimeyouwantrideyourmotorcycle. Tire sizecanbefoundinthetechnicalspecifications to goanywhereonyourmotorcycle. cle rides,andtheymustthereforebecheckedwheneveryouaregettingready Tire type,tirecondition,andairpressurelevelaffectthewayyourmotorcy- Tires, airpressure TIGHTENTHEHEXAGONNUTTOREQUIREDTORQUE.ALOOSEWHEEL – ITISVERY IMPORTANT TOKEEPTHEBRAKEDISKFREEFROMOILANDFATTY – AFTERMOUNTINGTHEREARWHEEL,KEEPOPERATING THEREARBRAKEUNTIL – IFYOUDON’THAPPENTOHAVE ATORQUEWRENCHAT HAND,MAKESURE – IFTHEAXLEISDISMOUNTED,CLEANTHREADOFWHEELSPINDLE – MAKESURETHEBRAKEDISCISALWAYS ONTOPWHEN YOULAY DOWNTHE – DONOTOPERATE THEREARBRAKEWHENWHEELHASBEENDIS- – EXCESSIVELY TENSIONEDSPOKES MAY RUPTURE DUETOLOCALOVERLOAD- – SPOKES CANTEARIFYOUCONTINUETORIDEWITHTHEMLOOSE. THIS MAY – TIREPRESSUREBELOWTHENORMALLEVELWILLLEADTOPREMATURE TIRE – WORNTIRESCANHAVE ANEGATIVE EFFECTONHOWTHEMOTORCYCLEPER- – DAMAGED TIRESMUSTBEREPLACEDIMMEDIATELY TOPROTECTYOUR – SPINDLE MAY LEADTOANUNSTABLE BEHAVIOR OFYOURMOTORCYCLE. MATTERS, EITHERWISE THEBRAKINGEFFECTSWOULDBESTRONGLY REDUCED. THE PRESSUREPOINTRETURNS. IOR OFYOURMOTORCYCLE. AS POSSIBLE.ALOOSEAXLEMAY LEADTOANUNSTABLE DRIVINGBEHAV- YOU HAVE THETIGHTENINGTORQUECORRECTEDBYAKTMDEALERASSOON VENT THETHREADFROMJAMMING. AND COLLARNUTTHOROUGHLY ANDAPPLY ANEWCOAT OFGREASE TOPRE- WHEEL, OTHERWISE THEBRAKEDISCCANBEDAMAGED. MOUNTED. ING. THESPOKES MUSTBETENSIONEDTO3-4 NM. LEAD TOANUNSTABLE HANDLINGOF YOURMOTORCYCLE. WEAR. FORMS, ESPECIALLY ONWETSURFACES YOUNGSTER. and removethechainadjuster [1] of thewheelspindletogetherwithwasher » [1] [3] . make surethatthechainadjusters [3]

25 ENGLISH plus filter [4] and tank, push [2] . Grease the front side of the [5] , the seat can be removed without , the seat [1] » . [2] on the filter support , swing back and remove air filter for damage and that it is fitted correctly. [4] [3] [A] from the filter box. . [5] [3] AGE THE FOAM. KTM RECOMMENDS THE PRODUCTS OF THE COMPANY AGE THE FOAM. KTM RECOMMENDS THE REMOVER AND LIQUID MAINTENANCE (BIO DIRT MOTOREX FOR AIR FILTER BIO POWER). AND CAUSE DAMAGE AND INCREASED WEAR. PENETRATE MAY DUST AND DIRT TER IS NOT MOUNTED CORRECTLY. – WITH FUEL OR PETROLEUM SINCE THESE DAM- DO NOT CLEAN FOAM FILTER – OTHERWISE, AIR FILTERS. YOUR MOTORCYCLE WITHOUT ANY NEVER START – THE ENGINE IF THE AIR FIL- AND DAMAGE CAN ACCUMULATE DUST AND DIRT carrier using tools. Turn the quick-release mechanism about 180° counter about 180° mechanism the quick-release Turn using tools. backwards and unhook the seat. Pull the seat and lift up the rear of clockwise fixing screw it from the position seat on the fixing screw mount the seat, To the quick release. forward and fix with To do this, remove the seat and the air filter cover from the air filter box. Unclap To the filter holder Thoroughly wash the foam filter in special cleaning fluid and allow to dry well. do not wring out under any circumstances. Oil the Only press out the filter, dry foam filter with a high grade filter oil. Also clean the air filter box. Check carburetor collar By using the quick-release mechanism quick-release mechanism By using the WHILE YOU ARE DRIVING AND CAN SLIP MOUNTED, THE SEAT IF NOT CORRECTLY MOTORCYCLE. CAUSE YOU TO LOOSE CONTROL OF YOUR Cleaning the air filter * Mount the air filter filter to improve the seal. Mount the air filter and the filter support in the filter box. Make sure they are centered, and lock into place with the filter holder Removing the seat Removing 1 4 3 3 4 2 A 1 5 MAINTENANCE WORK ON CHASSIS AND ENGINE ENGINE AND CHASSIS ON WORK MAINTENANCE

ENGLISH 26 MAINTENANCE WORKONCHASSISANDENGINE 2 7 1 8 10 4 9 3 5 11 6 fluid 75),availablefromyourauthorizedKTMworkshop. If necessary, addSAE10biodegradablehydraulicoil(MotorexKupplungs- 4 mmbelowtheupperedge. boot correct theoillevelinreservoirandmountcover(see above). After youfinishbleeding,removethebleedersyringe,mount bleederscrew, the mastercylinderreservoirtokeepitfromoverflowing. [11] the bleedersyringe.Pressoilintosystemuntilruns outofthehole fluid 75).Removethebleederscrew Fill thebleedersyringe Checking theoillevelofhydraulicclutch IT HASPROPERLY COOLEDDOWN. NING. TOAVOID BURNSDONOTSTART WORKONTHEEXHAUSTSYSTEMUNTIL THE EXHAUSTSYSTEMBECOMESVERY HOTWHILETHEMOTORCYCLEISRUN- outer tube To replace,removethesilencerfromvehicleandmarkpositionof can bereplacedinafeweasysteps. loss andareductionofthesilencerdamping.Theglass-fiberyarnpacking fiber yarnbecomeslooseorcokedwithoilcarbon.Thiscanleadtoapower The silencerisfilledwithglass-fiberyarnfordamping.Wheninuse,theglass- Exhaust system* the screws Turn thehandlebaruntilmastercylinderisinahorizontalposition,remove hydraulic oil.BothareavailablefromyourKTMdealer. to bebled.You willneedableedersyringe(specialtool)andbiodegradable If theclutchleverstartstofeelunresponsive,controlsystemneeds Bleeding thehydraulicclutch* NEVER REFILLWITHBRAKEFLUID. SHOP) TOMAKESUREYOURCLUTCHOPERATES SMOOTHLY. ORIGINAL KTMHYDRAULICOIL(AVAILABLE FROMYOURAUTHORIZEDKTMWORK- CLUTCH. DONOTMIXTHISOILWITHANYOTHERHYDRAULICOIL.ALWAYS USE KTM USESBIODEGRADABLE,HYDRAULICMINERALOILTOACTUATE THEHYDRAULIC For thispurpose,removescrews To checktheoillevelinmastercylinderofclutchremovecover. NOTE: GlassfiberyarnpackagesareofferedbyyourlicensedKTMdealer. for tightness. the positionsyoumarked.Mountsilencerandcheckexhaustsystem screws illustration) andslideintotheoutertube.Mountendcapfixwith To assemble,mountanewglass-fiberyarnpackingontotheinnertube(see the innertube.Thoroughlycleanallparts. Pull oftheoutertubeandremoveoldglass-fiberyarnpacking in themastercylinderwithoutbubbles.Occasionallyextract the oilfrom [8] [1] . Theoillevelinthehorizontal-standingmastercylindershouldbe . Beforetighteningthescrews,turnoutertubeuntiltheymatch [1] [6] , thecover to theinnertube [9] with biodegradablehydraulicoil(MotorexKupplungs- [7] and therubberboot [2] [6] » . Removescrews [10] and cover from theslavecylinderandmount [7] [8] together withtherubber [3] . and theendcap [5] from [4] .

27 ENGLISH on the water- [3] on the throttle grip. You must on the throttle grip. You [5] and turn the adjusting screw accordingly. » [7] ; a water temperature rising up to 120° C (248° ; a water temperature rising up to 120° [4] can be used for individual adjustment of the original for individual adjustment can be used in the engine keeps the cooling liquid in circulation. in the engine keeps [1] [2] until resistance is felt. be able to lift the outer covering of the cable 3-5 mm from the adjusting screw [6] adjust, loosen the counternut To Finally tighten the counternut and slide the protective cover back on. start the engine, turn the handlebar check the correctness of this setting, To left and right, in both cases as far as it will go. This must not cause any changes in idling speed. Otherwise, you will have to increase the backlash of the throttle cable. There must always be a 3-5 mm (0.1-0.2 in) play in the throttle cable. To check this, move back the protective cover FOR THE COOLING SYSTEM, USE ONLY WITH HIGH-GRADE ANTIFREEZE (MOTOREX FOR THE COOLING SYSTEM, USE ONLY AGENTS CAN CAUSE CORRO- ANTI-FREEZE). USING LOWER-GRADE ANTIFREEZE SION AND COOLANT FOAMING. in the system is controlled by a Pressure induced by heating of the coolant valve in the radiator cap F) is admissible, without fear of problems. Checking coolant level The coolant should be 10 mm (0.4 in) above the radiator fins when the engine In the event of the coolant being drained, always fill and is cold (see illustr.). bleed the system. CHECK THE LEVEL OF THE COOLING LIQUID WHEN THE IF POSSIBLE, ALWAYS CAP WHEN THE ENGINE TO OPEN THE RADIATOR ENGINE IS COLD. IF YOU HAVE TO RELEASE PRES- USE A RAG TO COVER THE CAP AND OPEN SLOWLY IS HOT, SURE. Adjusting the throttle cable * The adjusting screw The adjusting to an optimal position allowing adjustment thus the clutch lever, position of size. for every hand the distance between reduces adjusting screw counterclockwise the Turning adjusting screw clockwise the Turning lever and the handlebar. the clutch the handlebar. the clutch lever and the distance between increases POSSIBLE WITHIN CER- CLUTCH LEVER POSITION IS ONLY ADJUSTMENT OF THE AND NEVER APPLY TURN THE ADJUSTING SCREW MANUALLY LIMITS. ONLY TAIN EXCESSIVE FORCE. Cooling system The water pump cooling effect cooled by the air stream. Therefore, the The cooling liquid is additionally traveling speed is reduced. Dirty radiators is reduced when the reduce the cooling effect. the screw The cooling liquid can be drained by removing pump cover. DRAIN SCREW WHEN THE ENGINE DO NOT REMOVE ANY COOLER HOSES OR THE IS HOT. destilled water is used as coolant. A mixture of 50% antifreeze liquid and 50% at least -25° C (-13° F). This mix- the antifreeze protection must be However, good corrosion protection and should ture offers antifreeze protection but also therefore not be replaced by pure water. Changing the original position of the clutch lever of the clutch the original position Changing 4 2 3-5 mm 1 7 10 mm when engine is cold 6 3 5 MAINTENANCE WORK ON CHASSIS AND ENGINE ENGINE AND CHASSIS ON WORK MAINTENANCE

ENGLISH 28 carburetor malfunction(e.g.overlyrichmixture).Therefore,thesepartsshouldbereplacedafter1000hoursofusing. As aresultofenginevibrations,thethrottlevalve,jetneedle,andneedlearesubjectedtoincreasedwear. Thiswearmay Basic informationoncarburetorwear Iftheenginedoesnotrunproperly, despite achangedadjustmentlookformechanicalfaultsandchecktheignitionsystem NOTE: chooseleanercarburetoradjustment > highaltitudeortemperatures RULE OFTHUMB: to otherpartsofthecarburetorwillnotgreatlyaffectengineperformance. an intactcarburetor. Experiencehasshownthatadjustingthemainjet,idlingjetandneedleissufficienttha Always startoutfromtheoriginalcarburetorsetting.Essentialrequirementsareacleanairfiltersystem,air-tight exhaust Basic informationofchangingthecarburetorsetting Mixing ratio2-strokemotoroil:superfuel1:60. temperature ofapprox.20°C(68°F),mainlyforoff-roaduseandcentralEuropeanpremium-gradefuel(ROZ95). The originalcarburetorsettingwasadaptedforanaltitudeofapprox.500meters(1600ft.)abovesealevel,andtheambient Basic informationontheoriginalcarburetorsetting Carburetor adjustment* MAINTENANCE WORKONCHASSISANDENGINE INTHECASEOFALEANERADJUSTMENTCARBURETORPROCEEDCAUTIOUSLY. ALWAYS REDUCETHEJETSIZEINSTEPSOFONE – NOTENOUGHOILORLOW-GRADE OILCANCAUSEEROSIONOFTHEPISTON.IFYOUUSETOOMUCHOIL,ENGINESTART SMOK- – MOTOREXCROSSPOWER2T). ONLY USEHIGH-GRADE2-STROKEENGINEOILOFKNOWNBRANDS(I.E. – ONLY USEPREMIUM-GRADEGASOLINEROZ95(USA=PREMIUMRON91)MIXEDWITHHIGH-GRADETWO-STROKEENGINEOIL.OTHER – NUMBER TOAVOID OVERHEATING ANDPISTONSEIZURE. ING ANDFOULTHESPARK PLUG. TYPES OFGASOLINECANCAUSEENGINEFAILURE, ANDTHEIRUSE WILLVOIDYOURWARRANTY.

B A o liueo o eprtrs>chooserichercarburetoradjustment > low altitudeortemperatures 1 idling jet throttle valve idling jet jet needle jet needle main jet 2 Idling range–A,Adjustingtheidlespeed brown orblackwithsootthemain jetmustbereplacedbyasmallerone. tance ofridingflatout,alarger mainjetisrequired.Iftheporcelaindark to haveaverybrightorwhitecoating oriftheenginerings,afterashortdis- the mainjetandneedle.Ifporcelainofnewspark plugisfound Operation withthethrottlefullyopen(flatout).Thisrange is influencedby Full throttlerange–D the idlingrangericher. four-stroke running,maketheidlingrange leaner;iftheenginepings,adjust If thesefaultsshouldoccuratthelowerendofpartthrottle rangeata full poweratmaximumenginerevs,thejetneedleshouldbe raised. lowered byonenotch.Iftheenginepings,especiallywhenaccelerating under when itisacceleratedwiththethrottlepartlyopen,jet needlemustbe upper range.Iftheenginerunsonafour-stroke cycleorwithreducedpower controlled bytheidlingsettinginlowerrangeand mainjetinthe jet needle(shapeandposition).Theoptimumpart-throttle settingis Operation withpartlyopenthrottlevalve.Thisrangeisonlyinfluencedbythe Part-throttle range–C too highorthefloatneedleisleaking. engine speeds,themixturetocarburetorwillbetoorich,fuellevel opened anddevelopsitsfullpowernotsmoothlybutsuddenlyathigh part-throttle setting,theenginesputtersandsmokeswhenthrottleisfully throttle valveinfluencesthisrange.If,despitegoodidling-speedand Engine behaviorwhenthethrottleopens.Theidlejetandshapeof Opening up–B of theaircontrolscrew Operation withclosedthrottlevalve.Thisrangeisinfluencedbytheposition means oftheaircontrolscrew. control screw=openby1turns).Thenadjusttothenormalidlingspeed and stableenginespeedusingtheaircontrolscrew(basicpositionof ing thescrewcounterclockwiseproducesaloweridlingspeed.Createround air controlscrew. Turning itclockwiseproducesahigheridlingspeedandturn- To thisend,slightlyincreasetheidlingspeedofenginebymeans ments whentheengineishot. [1] and theaircontrolscrew » [2] . Onlymakeadjust- system and t changes cause .

29 ENGLISH and drain the used oil into [3] » and add 0.30 l gear oil 20W30 (e.g. Motorex Top on the left side of the engine allows easy checking of on the left side of the engine allows easy [4] and clean it with compressed air. Then, mount the plug it with compressed air. and clean [2] [1] Speed 4T 15W50). Mount the filler plug and check the engine for leaks. the gear oil level. up the engine, then turn it off and wait two minutes until the oil has Warm flown back into the gearbox case. surface and check the oil level. Park the motorcycle straight on a horizontal mark of the inspection glass. The oil level must not drop below the „MIN“ for the oil level inspection it Note: If the motorcycle is not parked properly result. will not be possible to achieve a reliable Speed 4T Top If necessary add gear oil 20W30 (e.g. Motorex 15W50). WEAR OF THE NOT ENOUGH OIL OR A POOR OIL QUALITY LEAD TO PREMATURE HIGH-QUALITY OILS (E.G. MOTOREX TOP TRANSMISSION. THEREFORE, USE ONLY SPEED 4T 15W50). An inspection glass WEAR OF THE LEAD TO PREMATURE NOT ENOUGH OIL OR A POOR OIL QUALITY HIGH-QUALITY OILS (E.G. MOTOREX TOP TRANSMISSION. THEREFORE, USE ONLY SPEED 4T 15W50). Changing gear oil * Before changing the gear oil warm up the engine and park the motorcycle on a horizontal surface. Remove the oil drain plug Remove the filler plug Following every wet-cleaning procedure, the float chamber of the carburetor the float every wet-cleaning procedure, Following into may have penetrated any water that drained in order to remove should be malfunction. leads to engine in the float chamber it. Water place the fuel tap and engine is cold. Close you do this while the Make sure fuel. the leaking is capable of absorbing the carburetor which a cloth under plug Unscrew the and check the and tighten it to 4 Nm, open fuel tap, together with the gasket float chamber for leaks. FUEL, BE SURE TO FLAMMABLE AND TOXIC. WHEN HANDLING FUEL IS EASILY THE FUEL SYS- CAUTION. NEVER PERFORM ANY WORK ON EXERCISE THE UTMOST THE ENGINE ALLOW OR BURNING CIGARETTES. ALWAYS TEM NEAR OF OPEN FLAMES BEEN HAVE ANY FUEL WHICH MAY CLEAN UP IMMEDIATELY TO COOL OFF FIRST. IN FLAMMABLE. ARE ALSO EASILY WITH FUEL SATURATED SPILLED. MATERIALS A CONSULT FUEL OR FUEL SPLASHED INTO YOUR EYES, CASE YOU INGESTED DOCTOR IMMEDIATELY. PROPERLY! DISPOSE OF THE FUEL Checking gear oil level Clean the sealing surface. Mount the oil drain plug an appropriate container. together with its gasket and tighten to 15 Nm. Draining the float chamber of the carburetor the float chamber Draining 3 1 2 4 MAINTENANCE WORK ON CHASSIS AND ENGINE ENGINE AND CHASSIS ON WORK MAINTENANCE

ENGLISH 30 We wouldliketopointoutthatmanyoperationscannotbeperformedbyoneself.Incaseofuncertainty, pleasecontactaKTM-de occur nevertheless,weadviseyoutousethetroubleshootingchartinorderfindcauseoferror. If youletthespecifiedmaintenanceworkonyourmotorcyclebecarriedout,disturbancescanhardlyexpected.Shouldanerr TROUBLE SHOOTING Engine failstostart TROUBLE Engine hasnotenoughpower Engine withoutidlerunning blocked Water inthecarburetorandjets Spark tooweak Loose ignitioncableconnectors short-circuit switchfaulty Kill buttonwireor connector damaged Ignition wireorsparkplug Plug fouledbyoil,wetorbridged Electrode distancetoogreat Fuel supplyinterrupted mulated inthefloatchamber time. Thereforeoldfuelhasaccu- operation foralongerperiodof The motorcyclehasbeenoutof Operating error CAUSE Wear Ignition systemdamaged adjustment Idle adjustingscrewoutof Engine hasnotenoughpreignition Exhaust systemdamaged spark plug Loss ofcompressionthroughloose blocked Fuel supplypartlyinterruptedor Air filterobstructed Charred glassfiberyarninsilencer » Dismantle andcleancarburetor Examine ignitionsystem Inspect cableconnectors repair defectivepartofcableorignitionswitch ignition coilandcheckspark.IfthesparkisO.K. Disconnect blackcolouredcablefromshortcircuitbuttonat spark mustbeproducedattheplug (blank placeonengine)andactuatekickstarter, astrong Dismount sparkplug,connectignitioncable,holdtoground Clean sparkplugorrenew Reduce electrodedistance(0.60mm) basin andopenfueltap, Close fueltap,loosenhoseatcarburettor, leadintoa start offwhenthefloatchamberisfilledwithnewfuel. fuel fromthefloatchamber. Theenginewillimmediately than aweek,itisthereforerecommendedtodraintheold When themotorcyclehasbeenoutofoperationformore rate duringlongerperiodsofstandstill. The easilyinflammablecomponentsofthenewfuelsevapo- Open fueltap,replenishfuel,donotusechoke REMEDY Check andadjustignition Check exhaustsystemfordamage Tighten sparkplug Blow throughfuelpipeandcleancarburetor Clean orrenewairfilter Renew filling Overhaul engine Examine ignitionsystem Readjust idlerunningorreplaceadjustingscrew Ifnosparkisproduced,controlignitionsystem – Ifasparknowoccurs,replaceplugcap – Ifnosparkisproduced,loosenplugcapfromigni- – ifnofuelleaksout,checktankventilation,i.e.clean – iffuelleaksout,cleancarburettor – kickstarter tion cable,holdabout5mmfromgroundandactuate fuel tap aler. or

31 ENGLISH Top up coolant and bleed cooling system check cooling sys- Top tem for leaks Clean radiatar fins with water jet Renew coolant using branded anti-freeze/anti-corrosive (Motorex Anti-Freeze) Replace with correct routed hoses secure Readjust to correct ignition timing specifications, screws with Loctite 243 Measure and adjust compression ratio Check cylinder head, replace O-ring Correct transmission oil level Replace shaft seal ring of the water pump REMEDY valve housing paddles or reed Replace reed Overhaul engine replace float needle and if necessary Clean carburetor, adjust level jets Tighten section Refer to technical data silicon Check and seal with and clean Clean fuel pipes, examine tank aeration Fit correct spark plug setted Check intake flange and carburettor if firmly » Shaft seal ring of the water pump defect Cylinder head or O-ring of cylinder head gasket leaks Excessive oil quantity in transmission Insufficient liquid in cooling system Radiator fins clogged Frothing in cooling system Pinched or kinked water hoses Incorrect ignition timing because of loose stator screws Incorrect compression ratio Carburetor overflows if level adjust Carburetor overflows seating is too high, float needle dirty or enlarged Loose carburetor jets spark plug or Incorrect heat range low quality spark plug conductive Loose, corroded or non ignition socket connector Lack of fuel Spark plug with incorrect heat value (Ignition by incandescence) Engine takes air out of control CAUSE tensionless or dam- Reed paddles of reed valve housing aged, surface damaged Wear Water in transmission oil Water Emission of white smoke (steam) Excessive oil escapes from transmission breather tube Engine overheating Engine spluters into the carburetor High rpm misfiring Engine revs not up and running Engine revs not up and in four stroke cycle Engine has not enough power Engine has TROUBLE TROUBLE SHOOTING SHOOTING TROUBLE

ENGLISH 32 CLEANING » Clean your motorcycle regularly in order to keep its painted finish looking shiny and new. The best manner would be to use warm water that has been mixed with a commercially available washing detergent and a sponge. The hard dirt can be removed before with the help of a soft water jet.

NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH-PRESSURED CLEANER OR A HIGH-PRESSURED WATER JET. OTHERWISE THE WATER MIGHT RUN INTO THE ELECTRICAL COMPONENTS, CONNECTORS, SHEATHED CABLES, BEARINGS, CARBURETOR ETC. AND CAUSE MAILFUNCTIONS, I.E., LEAD TO THE PREMATURE DESTRUCTION OF THESE PARTS.

– Before cleaning with water, plug the exhaust pipe to prevent water ingress. – You should use commercially available detergents to clean the motorcycle. Heavily soiled parts should also be cleaned with the help of a paint brush. – After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Then take a short drive until the engine has reached its operating temperature, and also operate the brakes. The heat also causes the water at the inac- cessible parts of the engine and the brakes to evaporate. – Slide back the protective covers on the handlebar-mounted instruments so that any water that may have seeped into this part of the motorcycle is allowed to evaporate. – After the motorcycle has cooled down, oil and grease all the gliding bearing parts. Also treat the chain with a chain spray. – To prevent failures in the electric system, you should treat the short circuit button with a contact spray. ENGLISH

STORAGE » If you want to put your motorcycle away for longer periods of time, please 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. – Let the engine warm up again, close fuel tap and wait until the engine dies off by itself. In this way, the carburetor jets are prevented from becoming resin-clogged by the old fuel. – Remove spark plug and fill in approx. 5 ccm of engine oil into the cylinder through the opening. Actuate kickstarter 10 times in order to distribute the oil onto the cylinder walls and mount the spark plug. – Let fuel flow out of tank into an appropriate basin. – Correct tire pressure. – Lubricate bearing points of the control levers, footrests, etc. as well as the chain. – The storage place should be dry and not be subjected to overly great temperature fluctuations. – Cover the motorcycle with an air permeable tarpaulin or blanket. Do not use airtight materials, as possible humidity might not be able to escape and thereby cause corrosion.

IT WOULD BE VERY BAD TO LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD. THE ENGINE WOULD NOT GET WARMED UP ENOUGH AND THE THUS DEVELOPED STEAM WOULD CONDENSE DURING THE COMBUSTION PROCESS AND CAUSE THE EXHAUST TO RUST.

USE AFTER PERIOD OF STORAGE – Fill up tank with fresh fuel. – Check motorcycle as before each start (see driving instructions). – Take a short, careful test ride first.

NOTE: Before you put your motorcycle away for the winter, you should check all parts for their function and wear. Should any service jobs, repairs, or any refitting be necessary, you should have them carried out during the off-season (lower workload at mechanics' shops). This way, you can avoid the long waiting times at your shop at the beginning of the next biking season. WP 03187B03 3 6 40-220 7 mm 45 Nm Loctite 243 + 20 Nm Loctite 243 + 10 Nm 4 Nm 40 Nm 40 Nm 40 Nm 20 Nm 10 Nm 20 Nm 3-4 Nm 6 Nm 10 Nm 25 Nm » STANDARD ADJUSTMENT – SHOCK ABSORBER Compression adjuster Rebound adjuster Spring Spring preload M 8 M 3,5 M 5 M 6 M 8 M 10 M 8 M 6 M 5 M 10 M 12x1 M 12x1 M 8 M 6 SAE 5 MARZOCCHI USD Ø 35 3,14 N/mm 10 mm 120 mm max. 160 cm (63 in) max 50 kg (22.7 lbs) 8 to 12 years CR-65 Disc brake Ø 160 mm (6.3 in), 2 piston Disc brake Ø 160 mm rear: 80/100-12“ (MT320) front: 60/100-14“ (MT32A) (14 psi) / 1,0 bar (14 psi) front / rear: 1,0 bar 3.3 liter (0.87 USgal) 14 : 50 1/2 x 1/4" 112 rolls 64.5 ° 1137 mm (44.7 in) 750 mm (30 in) 290 mm (11.5 in) 55.6 kg (122.7 lbs) 65 SX frame Central chrome-moly-steel Ø 35) fork (Marzocchi USD telescopic in) (8.7 in) / 270 mm (10.7 220 mm 3612 BAVP absorber (WP Suspension) central shock (7.8 in), 4 piston Disc brake Ø 198 mm STANDARD ADJUSTMENT – FORK Spoke nipple Other chassis screws Clamping screws – lower fork bridge AH screw – handlebar clamp Hexagon nut – rear wheel spindle Hexagon nut – swingarm bolt Clamping screws – upper fork bridge Flat head screw – brake discs AH screw rear brake pad Hexagon nut – front wheel spindle TIGHTENING TORQUES – CHASSIS Hexagon screw – brake caliper Air chamber length Fork oil Spring Preload bushing – length Rider’s body weight Rider’s Recommended age of rider Engine Ground clearance Dead weight without fuel body height Rider’s Wheel base Seat height, unloaded Final drive ratio Chain Steering angle Tires Air pressure Fuel tank capacity Front brake Rear brake Fork front/rear Wheel travel Rear suspension CHASSIS Frame TECHNICAL SPECIFICATIONS – CHASSIS – CHASSIS SPECIFICATIONS TECHNICAL

ENGLISH 34 TECHNICAL SPECIFICATIONS–ENGINE Air adjustmentscrewopen Starting jet Throttle valve Needle positionfromtop Jet needle Idling jet Needle jet Main jet CARBURETOR BASIC CARBURETORSETTING Air filter Coolant Carburetor Electrode gap Spark plug Ignition system Transmission oil Gear ratio Transmission Clutch Primary drive Piston rings Piston pinbearing Connecting rodbearing Crankshaft bearing Lubrication Oil/gasoline ratio Fuel Bore/stroke Displacement Design ENGINE wet foamtypeairfilterinsert 0.55 liter(0.145Usgal),50%antifreeze,destilledwater, atleast-25°C(-13°F) Mikuni VM24-505 0.60 mm(0.0236in) NGK BR8ECM Moric Digital2M1 0.30 liter(0.0792USgal)gearoil(e.g.MotorexTop Speed4T15W50) 6th gear24:26 5th gear23:28 4th gear21:30 3rd gear18:31 2nd gear16:34 1st gear13:37 6 speed,clawactuated multiple discclutchinoilbath,hydraulicoperated(MotorexKupplungsfluid75) straight cutspurgears,23:75t 1 compressionring needle bearing needle bearing 2 deep-grooveballbearing mixture lubrication when indoubt,pleasecontactourimporter 1 :60whenusinghighgradetwo-strokeoil(e.g.MotorexCrossPower2T), SUPER fuel,researchoctaneno95,mixedwithhighgradetwo-strokeoil 45 /40.8mm(1.77/1.6in) 64.85 ccm Liquid cooledsinglecylindertwo-strokeenginewithreedvalveintake CR-65 1 30 1.5 IV 5I14 25 864 0-0 200 MIKUNI VM24-505 »

35 ENGLISH 60 Nm 40 Nm 15 Nm 25 Nm Loctite 243 + 60 Nm 12 Nm 12 Nm 8 Nm 12 Nm 2 Nm 12 Nm 4 Nm 6 Nm 12 Nm » M 6 M 8 M 6 M 6 M 4 M 6 SW 17 M 5 M 6 M 10 M 10x1,25 M 7 M 8 M 10 Other screws – engine Screws – stator device Shift drum locating Drain plug – carburetor Oil drain screw Screws – clutch cover Kickstarter stop plate Hexagon screw – inner clutch hub Hexagon screw – inner Screw – clutch Collar nut – flywheel Collar nut – cylinder head HH screw – cylinder base Collar nut TIGHTENING TORQUES – ENGINE TIGHTENING – primary gear Hexagon nut TECHNICAL SPECIFICATIONS – ENGINE – ENGINE SPECIFICATIONS TECHNICAL

ENGLISH 36 ultp . . . . .7 tap Fuel . . ..8 pedal brake Foot . . .7 cap Filler ..27 system Exhaust ..6 number Engine ..11 instructions Driving ..30 carburetor the of chamber float the Draining ..19 tension chain Correcting ..28 system Cooling . .8 absorber shock of damping Compression ..6 lever Clutch . . . . . Cleaning thedustsleevesoftelescopicfork . .17 ..26 filter air the Cleaning ..33 Cleaning . . .7 Choke ..21 level fluid brake front the Checking/refilling ..23 level fluid brake rear the Checking ..27 clutch hydraulic the of level oil the Checking ..25 tension spoke Checking ..23 pads brake rear Checking ..30 level oil gear Checking ..21 pads brake front Checking ..28 level coolant Checking ..19 tension chain Checking . . . . .16 Checking andadjustingthesteeringheadbearing . ..6 number Chassis . . . Changing theoriginalpositionofclutchlever . . .28 . . . . .17 Changing springpreloadingoftheshockabsorber . . .30 oil gear Changing ..22 pedal brake the of position basic Changing ..19 maintenance Chain ..29 adjustment Carburetor ..16 fork front plug Breather ..13 Braking ..27 clutch hydraulic the of Bleeding . . . .18 Basic suspensionsetupfortheweightofdriver ..28 cable throttle the Adjusting ...... 20 Adjusting thefreetravelathandbrakelever INDEX » Page What you should check before each start . ..11 start each before check should you What . ..12 „flooded“ is engine the when do to What ..33 storage of period after Use . ..31 Troubleshooting ..18 fork telescopic the of Tosag the determine ..18 absorber shock the of Tosag the determine ..25 Tires,pressure air ..34 TechnicalChassis – Specifications ..35 Engine – TechnicalSpecifications . ..33 Storage ..13 Stopping ..12 warm is engine the when Starting ..12 cold is engine the when Starting . ..12 off Starting ..7 button circuit Short ..12 Shifting/Riding . . .7 lever Shift ..6 locations number Serial ..10 in Running ..24 pads brake rear the Replacing ..22 pads brake front the Replacing . . .26 seat the Removing ..25 wheel rear the installing and Removing ..24 wheel front installing and Removing ..13 fuel Refueling, ..23 reservoir fluid brake rear the Refilling ...... 8 Rebound dampingfunctionoftheshockabsorber ..8 Stand Plugin- ..14 schedule maintenance Periodic ..6 instruments Operation ..16 engine and chassis on work Maintenance ..8 Kickstarter ..10 ride first the for Instructions ..17 position handlebar the change to How ..6 lever brake Hand . . .10 General tipsandwarningsforstartingthemotorcycle ..20 brakes disc KTM about information General Page

37 ENGLISH ENGLISH 38 39 ENGLISH ENGLISH 40 4/2005 FOTO: MITTERBAUER

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