KTM 65 SX 2001 User guide

OWNERS HANDBOOK
MANUEL D’UTILISATION
MANUAL DE INSTRUCCIONES
Art.Nr. 320595 9/2000
2001
65 SX
BEDIENUNGSANLEITUNG

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2
Please insert the series numbers of your motorcycle in the boxes below
PLEASE INSERT BELOW THE SERIES NUMBERS OF THE MOTORCYCLE
FRAME NUMBER
ENGINE NUMBER
STAMP
OF DEA-
LER
IMPORTANT
PLEASE READ THIS MANUAL THOROUGHLY BEFORE LETTING YOUR
YOUNGSTER RIDE THE MOTORCYCLE FOR THE FIRST TIME. THIS MANUAL
CONTAINS IMPORTANT INFORMATION AND RECOMMENDATIONS THAT
WILL HELP YOU AND YOUR YOUNGSTER TO OPERATE AND HANDLE THE
MOTORCYCLE PROPERLY.
IN THE INTEREST OF EVERYBODY INVOLVED, WE URGE YOU TO PAY PARTI-
CULAR ATTENTION TO INSTRUCTIONS AND INFORMATION MARKED AS
FOLLOWS:

WARNING

IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY
AND YOUR LIFE.
!
CAUTION
!
IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO
PARTS OF THE MOTORCYCLE OR THAT THE MOTORCYCLE IS
NOT ROAD-SAFE ANYMORE.
Chassis number
Engine number
Stamp of dealer
KTM S
PORTMOTORCYCLE AG RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT , TECHNICAL SPECIFICATIONS , COLORS ,
MATERIALS , SERVICES OFFERED AND RENDERED , AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT
PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS
, OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTI -
TUTING THEM WITH OTHERS . I T SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS
ANNOUNCEMENT
. I N THE EVENT OF SUCH MODIFICATIONS , PLEASE ASK YOUR LOCAL KTM DEALER FOR INFORMATION .
W
E SHALL NOT BE HELD LIABLE FOR ANY PRINTING ERRORS .

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3
Introduction
Now you own a modern motorcycle that you and your youngster will certainly enjoy, provided
that you service and maintain it properly. This manual contains important information on the
operation and maintenance of your new KTM motorcycle. It went to press describing your
model’s latest state of development. Nevertheless, the descriptions may deviate slightly from the
current design as our motorcycles are permanently improved.
Maybe you are one of those riders who have acquired good technical skills and can perform
many of the maintenance tasks themselves using the instructions contained in this manual. If this
is not the case, please keep in mind that the maintenance tasks marked with an asterisk (*) in
the chapter „Maintenance of chassis and engine“ should rather be performed by a KTM dealer
to protect you and your youngster.
Please strictly observe the prescribed running-in periods and inspection and maintenance inter-
vals. Compliance with these instructions will significantly prolong the life of your motorcycle.
Maintenance work should only be performed by a KTM dealer.
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 youngsters always depends on the
efforts made by the parents to ensure that the motorcycle is kept in good working order and
only used on safe terrains. Nevertheless, driving the motorcycle, like driving any other vehicle,
involves a potential risk. Therefore, please make sure that all fundamental precautions are taken.
Please also read the „INFORMATION ON SAFE DRIVING FOR PARENTS“ on page 4.
Riding an off-highway motorcycle is a wonderful form of outdoor recreation and we certainly
hope that you and your youngsters will enjoy it to the full. However, this enjoyable outdoor
activity can cause environmental problems or lead to conflicts with other people. Responsible use
of the motorcycle will prevent such problems and conflicts. You can contribute to securing the
future of motorcycling by making sure that you and your youngsters only use the motorcycle
within the limits established by the applicable laws, making environmental protection one of
your top priorities and never violating other people’s rights.
In this spirit, we hope that you and your youngsters will always safely enjoy your motorcycle!
KTM SPORTMOTORCYCLE AG
5230 MATTIGHOFEN, AUSTRIA
Attachments : 1 spare parts manual chassis 1 spare parts manual engine
ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL.
©by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved
KTM Austria’s AG certificate of achievement for its Quality System ISO 9001 is the beginning of an on going
total reengineering quality plan for a brighter tomorrow.

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4
INDEX
Page
IMPORTANT INFORMATION ON SAFE DRIVING
FOR PARENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . .5
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . .5
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Short circuit button . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Refueling, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Rebound damping function of the shock absorber . . . .7
Compression damping of shock absorber . . . . . . . . . . .7
Changing the spring preloading of the shock absorber . . 7
DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . .8
What you should check before each start . . . . . . . . . . .8
Instructions for the first ride . . . . . . . . . . . . . . . . . . . . .8
Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Starting when engine is cold . . . . . . . . . . . . . . . . . . . .8
Starting when engine is warm . . . . . . . . . . . . . . . . . . .9
What to do when the engine is „flooded“ . . . . . . . . . .9
Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Shifting, Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . .10
MAINTENANCE WORK ON CHASSIS AND ENGINE . . . .12
Checking and adjusting the steering head bearing . . .12
General information about KTM disc brakes . . . . . . . .13
Adjusting of free travel at the hand brake lever . . . . .13
Checking of brake fluid level - front brake . . . . . . . . .13
Refilling the front brake fluid reservoir . . . . . . . . . . . .14
Checking the front brake pads . . . . . . . . . . . . . . . . . .14
Replacing the front brake pads . . . . . . . . . . . . . . . . .14
Changing the basic position of the brake pedal . . . . . .15
Checking the rear brake fluid level . . . . . . . . . . . . . . .15
Refilling the rear brake fluid reservoir . . . . . . . . . . . . .15
Checking the rear brake pads . . . . . . . . . . . . . . . . . . . . .16
Replacing the rear brake pads . . . . . . . . . . . . . . . . . .16
Removing and installing the front wheel . . . . . . . . . . .17
Removing and installing the rear wheel . . . . . . . . . . .17
Checking the chain tension . . . . . . . . . . . . . . . . . . . .18
Correcting the chain tension . . . . . . . . . . . . . . . . . . .18
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .18
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Checking spoke tension . . . . . . . . . . . . . . . . . . . . . . .19
Removal of seat . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Cleaning the dust scrabbers of the telescopic fork . . . .19
Cleaning of air filter . . . . . . . . . . . . . . . . . . . . . . . . .20
Adjusting the clutch cable . . . . . . . . . . . . . . . . . . . . .20
Adjusting the throttle cable . . . . . . . . . . . . . . . . . . . .20
Adjusting the idle speed . . . . . . . . . . . . . . . . . . . . . .21
Checking the gear oil level . . . . . . . . . . . . . . . . . . . . .21
Changing the gear oil . . . . . . . . . . . . . . . . . . . . . . . .21
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Checking the coolant level . . . . . . . . . . . . . . . . . . . . .22
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Carburetor adjustment . . . . . . . . . . . . . . . . . . . . . . .23
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
TECHNICAL DATA - CHASSIS . . . . . . . . . . . . . . . . . . . .25
TECHNICAL DATA - ENGINE . . . . . . . . . . . . . . . . . . . . .26