KTM 65 SX 2001 User guide

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

ENGLISH
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 .

ENGLISH
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.

ENGLISH
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

ENGLISH
5
SX mini motorcycles are off-road motorcycles designed for one person only. They are not allowed on public
roads.
Motorcycle dimension and components are designed for the following age and weight groups:
65 SX: age 8 - 12 years, maximum weight 50 kg (110 lbs), maximum body height 160 cm (65 in)
– Have your youngster wear proper protective gear whenever he or she rides the motorcycle: helmet, eye pro-
tection, chest, back, arm and leg protectors, gloves and boots. To set a good example, be sure to wear pro-
tective gear yourself whenever riding a motorcycle!
– Adjust the hand brake lever to your youngster’s hand size (with gloves).
– Before your youngster takes his or her first ride, explain how each of the controls works and check if your
youngster has understood what you explained. We recommend to review the entire owner’s manual with
your youngster item by item, paying particular attention to the specially marked warnings and pointing out
the danger of injury.
– Instruct your youngster about riding and falling techniques, explain how the motorcycle will respond to shif-
ting of the rider’s weight, etc.
– Before using the motorcycle you should always check all components for proper operation (see maintenan-
ce schedule). Have your youngster perform these technical checks himself / herself as well.
– Whenever you go for a ride with your youngster, keep in mind that the speed should be adjusted to your
youngster and not the other way around.
– Your youngster must understand that all instructions he or she receives from you or any other supervising
adult must be followed.
– Your child must be physically ready to ride a motorcycle. This means that he or she must at least be able to
ride a bicycle. Being good at sports that require fast reactions is an additional advantage. Your youngster
should be strong enough to pick up the motorcycle after a fall.
– Never demand too much of your youngster. Give him or her time to get used to the motorcycle and to
improve his / her riding skills. Do not even consider letting your youngster participate in a race before his /
her physical condition, riding skills and motivation have sufficiently developed.
– Explain to your youngster that he / she should always adjust his / her riding speed to the local conditions
as well as to his / her own riding skills and that excessive speed can cause falls and severe injuries. Always
keep in mind that youngsters tend to underestimate dangers or fail to recognize them altogether. The riding
speed must be reduced, in particular, on unknown terrain.
– Never let your youngster ride the motorcycle without supervision. An adult should always be present.
– The motorcycle is designed for one rider only. Your youngster is not allowed to transport a passenger.
– When you go for a ride, somebody at home should always know where you are going and when you will
be back. This makes it easier to send you help, should problems occur.
IMPORTANT INFORMATION ON SAFE DRIVING FOR PARENTS

ENGLISH
6
10 mm
1
3
Chassis number
The chassis number is located on the type plate on the steering head. Write
this number into the field on page no 1.
Engine number
The engine number is stamped into the engine housing underneath the car-
buretor. Write this number into the field on page no 1.
Clutch lever
The clutch lever 1is fitted on the left hand side of the handle bar. When
engine is cold, there should allways be a play of 10 mm (0,4 in) at this lever
(measured at outer edge).
!
CAUTION
!
IF THERE IS NO PLAY ON THE CLUTCH LEVER, THE CLUTCH WILL START TO SLIP. THE
CLUTCH WILL THEN OVERHEAT, DESTROYING THE CLUTCH LININGS.
Hand brake lever
The hand brake lever 2is mounted on the handle bars on the right and
actuates the front wheel brake.

WARNING

IF THE RESISTANCE IN THE HAND BRAKE LEVER FEELS “SPONGY” (TOO MUCH GIVE), THIS
IS AN INDICATION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM. DON’T LET
YOUR CHILD RIDE THE MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE
SYSTEM LOOKED OVER BY A KTM DEALER.
Short circuit button
The short circuit button 3turns off the engine. When pressing this button,
the ignition circuit is short-cicuited.
SERIAL NUMBER LOCATIONS
OPERATION INSTRUMENTS
2

ENGLISH
7
Filler cap
To open it: turn filler cap counter-clockwise.
To close it: put filler cap back on and tighten it by turning it clockwise.
Install tank breather hose 1without kinks.
Refueling, fuel
Oil (high-grade two-stroke engine oil; i.e. Shell Advance Racing X) must be
mixed with the fuel (ROZ 95) at a mixing ratio of 1:40.

WARNING

GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS. EXTREME CAUTION SHOULD BE USED
WHEN HANDLING GASOLINE. NEVER REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR
BURNING CIGARETTES. ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELING. BE CAREFUL
NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT.
WIPE UP SPILLS PROMPTLY. IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES, SEEK
A DOCTOR’S ADVICE IMMEDIATELY.
!
CAUTION
!
–O
NLY USE PREMIUM-GRADE GASOLINE ROZ 95 MIXED WITH HIGH-GRADE TWO-
STROKE ENGINE OIL. OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE.
–ONLY USE KNOWN BRANDS OF HIGH-GRADE 2-STROKE ENGINE OIL (SHELL ADVANCE
RACING X).
–N
OT ENOUGH OIL OR LOW-GRADE OIL CAN CAUSE EROSION OF THE PISTON. WHEN
U
SING TOO MUCH OIL , THE ENGINE MAY START SMOKING AND FOUL THE SPARK PLUG .
–FUEL EXPANDS WHEN ITS TEMPERATURE RISES. THEREFORE DO NOT FILL THE TANK TO
THE TOP. (SEE FIG.)
Fuel tap
The fuel tap 2is located on the left side of the tank.
Opening the fuel tap:Turn the knob all the way to the left.
Closing the fuel tap: Turn the knob all the way to the right.
!
CAUTION
!
THE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED. IF THE TAP
IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL GET INTO THE ENGINE.
Choke
The choke button 3is located on the left side of the carburetor. Pulling the
choke button 3all the way out opens a bore in the carburetor through
which the engine can take in additional fuel, thus achieving the "rich" fuel
air mixture needed for cold starting.
Pushing the choke button back in closes the bore in the carburetor.
40 mm
2
3
1

ENGLISH
8
Shift lever
The shift lever is mounted on the left side of the engine. The position of the
gears is shown in the illustration. Neutral, or the idle speed, is located bet-
ween first and second gear.
Kickstarter
The kickstarter is mounted on the right side of the engine. Its upper part can
be swivelled.

WARNING

W HEN STARTING THE ENGINE , PUT ON MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES .
YOU MAY SLIP OFF THE KICKSTARTER, OR THE ENGINE MAY STRIKE BACK WHEN KICKING
NOT VEHEMENTLY ENOUGH.
Rebound damping function of the shock absorber
The damping effect of the rebound damping mechanism can be adjusted to
14 different levels by means of the setting wheel 1. Turn the setting wheel
clockwise (in) to increase and counterclockwise (out) to reduce the damping
effect.
STANDARD SETTING: 6 CLICKS OPEN

WARNING

–NEVER TURN THE SETTING WHEEL MORE THAN TWO CLICKS BETWEEN TWO TEST RIDES.
–D
O NOT TRY TO DISASSEMBLE THE SHOCK ABSORBER OR TO PERFORM MAINTENAN-
CE WORK YOURSELF. DANGER OF INJURY!
Compression damping of shock absorber
With the knob 2the degree of damping of the compression can be adju-
sted to 7 positions. Turn the knob counterclockwise to increase damping,
turn it clockwise to reduce damping during rebounding.
STANDARD SETTING: 3

WARNING

–T
HE DAMPING UNITY OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRESSED
NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY
MAINTENANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.
Changing spring preloading of the shock absorber
This is easily done.
NOTE:
Before changing the spring preload note down the basic setting, e.g. how
many threads are visible above the adjusting ring.
Remove the right side cover.
Loosen the locking ring 3with the hook spanner. Change
the spring prelo-
ad with the adjusting ring 4and re-tighten the locking ring 3.
BASIC SETTING – SPRING PRELOAD
7 mm (0.3 in)
2,3,4,5,6
1
N
1
3
4
2

ENGLISH
9
DRIVING INSTRUCTIONS
– To ensure that your youngster gets the feel of the hand
brake, have your youngster operate the hand brake while
you push the motorcycle. Do not start the engine before
your youngster has learned to apply hand brake with appro-
priate pressure.
– To familiarize your youngster with the operation of the hand
brake let him or her practice to operate the hand brake while
you are pushing the motorcycle. Do not start the engine
before he or she is thoroughly familiar with the use of the
hand brake.
– Initially, your youngster should ride back and forth between
two persons who help the young rider to stop the motorcy-
cle. However, you should also teach your youngster how to
stop the motorcycle himself/herself.
– To improve his/her riding skills, your youngster should prac-
tise to ride the motorcycle standing on the footpegs or to
ride at the slowest possible speed. Additionally, you can
arrange a series of obstacles and have your youngster drive
around them, etc.
– Pay attention to running-in procedure.

WARNING

– SX MODELS ARE DESIGNED FOR ONE PERSON ONLY. PASSENGERS ARE
NOT ALLOWED.
–T
HESE MODELS DO NOT COMPLY WITH THE REGULATIONS AND SAFETY
STANDARDS ESTABLISHED BY THE LAW. THEREFORE, THEY ARE NOT PER-
MITTED ON PUBLIC ROADS.
–A
LWAYS KEEP IN MIND THAT OTHER PEOPLE FEEL MOLESTED BY EXCES-
SIVE NOISE.
Running in
– Even very precisely machined sections of engine components
have rougher surfaces than components which have been
sliding across one another for quite some time. Therefore,
every engine needs to be broken in. For this reason, during
its first 5 hours the engine must not be revved up to its per-
formance limits.
– Apply low but changing loads for running-in.
– DO NOT DRIVE AT FULL LOAD FOR THE FIRST 5 HOURS!
Starting when the engine is cold
1 Open fuel tap
2 Put the gear in neutral
3 Activate cold-starting aid (choke)
4 Leave throttle closed or open it no more than 1
/3and kick
down kickstarter vigorously all the way.

WARNING

–T
O AVOID INJURY WHEN STARTING THE ENGINE, ALWAYS WEAR
STRONG BIKERS BOOTS!
–D
O NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA.
EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONS-
CIOUSNESS AND DEATH. ALWAYS PROVIDE ADEQUATE VENTILATION
WHILE THE ENGINE IS RUNNING.
!
CAUTION
!
DO NOT RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DO NOT REV UP
THE ENGINE WHEN COLD. SINCE THE PISTON IS WARMS UP AND EXPANDS
FASTER THAN THE WATER COOLED CYLINDER, THIS MIGHT CAUSE ENGINE
DAMAGE. ALWAYS LET ENGINE IDLE UNTIL WARM OR DRIVE IT WARM AT
LOW R.P.M. SPEEDS.
What you should check before each start
When you start off, the motorcycle must be in a perfect
technbical condition. For safety reasons, you should make it a
habit to perform an overall check of your motorcycle before
each start.
The following checks should be performed:
1 CHECK TRANSMISSION OIL LEVEL.
A lack of gear oil leads to premature wear and finally results
in destruction of the gear wheels.
2 FUEL
Check that there is sufficient fuel in the tank; when closing the
filler cap, check that the tank venting hose is free of kinks.
3 CHAIN
A loose chain was fall off the chain wheels; an extremely
worn chain may tear, and insufficient lubrication may result
in unnecessary wear of chain and chain wheels.
4 TIRES
Check for damaged tires. Tires showing cuts or dents must
be replaced. Also check the air pressure. Insufficient tread
and incorrect air pressure deteriorate the driving performance.
5 BRAKES
Check correct functioning of the braking system. Verify that
there is sufficient brake fluid in the reservoir. The reservoirs
have been designed in such a way that brake fluid does not
need to be refilled even when the brake pads are worn. If the
level of brake fluid falls below the minimum value, this indi-
cates a leak in the braking system or completely worn out
brake pads. Arrange for the braking system to be checked by
an authorized KTM dealer, as complete failure of the braking
system can be expected.
Also check the state of the brake hose and the thickness of
the brake linings.
Check free travel at hand brake lever and foot brake lever.
6 CABLES
Check correct setting and easy running of all control cables.
7 COOLING FLUID
Check the level of cooling fluid when the engine is cold.

WARNING

–H
AVE YOUR YOUNGSTER WEAR PROPER PROTECTIVE GEAR WHENEVER
HE OR SHE RIDES THE MOTORCYCLE: HELMET, EYE PROTECTION, CHEST,
BACK, ARM AND LEG PROTECTORS, GLOVES AND BOOTS. TO SET A
GOOD EXAMPLE, BE SURE TO WEAR PROTECTIVE GEAR YOURSELF WHE-
NEVER RIDING A MOTORCYCLE!
–O
NLY USE ACCESSORY PARTS RECOMMENDED BY KTM.
Instructions for the first ride
– Verify that your KTM dealer performed the PREPARATION
OF VEHICLE jobs (see Customer Service Manual).
– Before your youngster takes his or her first ride, explain how
each of the controls works and check if your youngster has
understood what you explained. We recommend to review
the entire owner’s manual with your youngster item by item,
paying particular attention to the specially marked warnings
and pointing out the danger of injury.
– Adjust the basic hand brake lever position to your young-
ster's hand size. Your youngster should, of course, wear
gloves!
– To prevent injury, teach your youngster the basic riding skills
on soft ground, e.g. on a meadow or in the garden. Be sure
that there is room enough to maneuver, and that no other
riders are close.

ENGLISH
10
Starting when the engine is warm
1 Open fuel tap
2 Put the gear in neutral
3 Open throttle to 1
/2and kick down kickstarter vigorously
What to do when the engine is „flooded”
1 Close fuel tap
2 Start engine with full throttle. If necessary, unscrew spark
plug and dry it.
3 Once the engine is running, open fuel tap again.
Starting off
Pull the clutch lever. Put the engine into first gear, slowly relea-
se the clutch lever and accelerate at the same time.

WARNING

BEFORE YOU START OFF, CHECK THAT THE MAIN OR SIDE STAND HAS BEEN
SWUNG RIGHT UP TO THE TOP. IF THE STAND DRAGS ON THE FLOOR, YOU
MAY LOSE CONTROL OF YOUR MOTORCYCLE.
Shifting/Riding
You are now in first gear, referred to as the drive or uphill gear.
Depending on the conditions (traffic, hill size, etc.), you can
shift to a higher gear. Turn down the throttle, at the same time
pull clutch lever in and shift to the next higher gear. Let clutch
lever go again and open the throttle. If you turned on the
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 time. Pull clutch lever and shift down to the next
lower gear. Let clutch lever go slowly and open throttle or shift
down again.

WARNING

–Y
OUR YOUNGSTER'S DRIVING SPEED SHOULD ALWAYS BE ADJUSTED TO
HIS/HER DRIVING SKILLS AS WELL AS TO THE TERRAIN.
–Y
OUR YOUNGSTER SHOULD NEVER BE ALLOWED TO RIDE THE
MOTORCYCLE WITHOUT SUPERVISION.
–R
EPLACE THE HELMET VISOR OR GOGGLE GLASSES EARLY ENOUGH.
WHEN LIGHT SHINES DIRECTLY ON A SCRATCHED VISOR OR GOGGLES,
YOU WILL BE PRACTICALLY BLIND.
–A
FTER FALLING WITH THE MOTORCYCLE, CHECK ALL ITS FUNCTIONS
THOROUGHLY BEFORE USING IT AGAIN.
–A
TWISTED HANDLEBAR MUST ALWAYS BE REPLACED. DO NOT ADJUST
THE HANDLEBAR, IT WILL LOSE STA-BILITY.
!
CAUTION
!
–D
RIVING A COLD ENGINE AT HIGH SPEED WILL REDUCE THE LIFE OF THE
ENGINE. WE RECOMMEND TO WARM THE ENGINE UP AT A MEDIUM
ENGINE SPEED FOR SEVERAL MINUTES BEFORE SWITCHING TO FULL
LOAD.
–N
EVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A
LOWER GEAR. THE ENGINE WILL OVERREV, DAMAGING THE VALVES. IN
ADDITION, THE REAR WHEEL BLOCKS SO THAT THE MOTORCYCLE CAN
EASILY GET OUT OF CONTROL.
–I
F THE ENGINE RUNS WITHOUT THROTTLE DURING LONGER DOWNHILL
TRAVEL, THE ENGINE SHOULD BE ACCELERATED OCCASIONALLY TO
ENSURE THAT IT IS SUPPLIED WITH SUFFICIENT LUBRICANT WHICH IS
MIXED IN THE FUEL.
–I
N THE EVENT THAT, WHILE YOUR CHILD IS RIDING ON THE MOTORCY-
CLE, YOU NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, YOUR
CHILD SHOULD STOP IMMEDIATELY, TURN THE ENGINE OFF, AND
CONTACT AN AUTHORIZED KTM DEALER.
Braking
Turn off gas and apply the hand and foot brakes at the same
time. When driving on sandy, wet or slippery ground use main-
ly the rear wheel brake. Always brake with feeling, blocking
wheels can cause you to skid or fall. Also change down to lower
gears depending on your speed.

WARNING

–IN CASE OF RAIN, AFTER WASHING THE MOTORCYCLE, AFTER RIDES
THROUGH WATER AND IN CASE OF RIDES ON WET OFF-ROAD TRACKS,
HUMID OR DIRTY BRAKE DISCS CAN DELAY THE BRAKING EFFECT. THE
BRAKES MUST BE PULLED UNTIL THEY ARE DRY OR CLEAN.
–D
IRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND BRAKE
DISCS.
–W
HEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE CALIPER AND
BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS GET, THE WEAKER THE
BREAKING EFFECT. IN EXTREME CASES, THE ENTIRE BRAKING SYSTEM CAN
FAIL.
Stopping
Brake motorcycle and shift gears to idling. To switch off the
engine, depress short circuit switch until the engine stops. Close
fuel tap.

WARNING

–N
EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS
THE ENGINE IS RUNNING.
–M
OTORCYCLE 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.
!
CAUTION
!
–C
LOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE. OTHERWISE THE
CARBURETOR MAY GET FLOODED AND FUEL WILL ENTER THE ENGINE.
–T
HE SIDE STAND IS ONLY DESIGNED FOR THE WEIGHT OF THE
MOTORCYCLE. IF YOU GET ON YOUR MOTOR-CYCLE AND THUS PUT
ADDITIONAL WEIGHT ON THE MOTORCYCLE, THE SIDE STAND OR THE
FRAME CAN BE DAMAGED OR THE MOTORCYCLE MAY FALL ON THE
SIDE.

ENGLISH
11
PERIODIC MAINTENANCE Service
every
20 hours once a year
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
A washed motorcycle can be checked more quickly which saves money!
Check transmission oil level ●
Change transmission oil ●
Check spark plug, change it if necessary, set electrode gap ●
Check carburetor for tight fit at intake flange ●
Check intake flange for cracks ●
Check idle setting when engine is warm ●
Check cooling system for leaks, antifreeze protection ●
Check exhaust system for leaks and suspension ●
Check actuating cables for damage, smooth operation, and kink-less ●
arrangement, and adjust and lubricate
Clean air filter and air filter box ●
Check brake fluid level, lining thickness, brake discs ●
Check brake lines for damage and leaks ●
Check/adjust smooth operation, free travel of handbrake levers ●
Check screws of brake system for tight fit ●
Check suspension strut and fork for leaks and proper function ●
Check swinging-fork pivot ●
Check/adjust steering-head bearing ●
Check all chassis screws for tight fit (fork plates, axle nuts, ●
swinging-fork pivot, suspension strut)
Scheck spoke tension and rim join ●
Check tire condition and inflation pressure ●
Check chain, chain wheels, chain wheel guides for wear, tight fit, and tension ●
Lubricate chain ●
Check wheel bearings for play ●
IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER
Drain and clean the carburetor's float chamber ●
Perform complete fork maintenance ●
Perform complete suspension strut maintenance ●
Clean and lubricate the swinging-arm bearing ●
Clean and lubricate the steering-head bearing and sealing elements ●
Change brake fluid ●
WHEELS CHASSIS BREAKS
ADD-ON-PARTS
ENGINE
65 SX
once a year
CARBURETOR

ENGLISH
12
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC
Check transmission oil level ●
Check coolant level ●
Check brake fluid level ●
Check brake pads for wear ●
Check brake performance ●●
Lubricate and adjust actuating cables and nipples ●
Remove and clean dust sleeves of telescopic fork in regular intervals ●
Clean and lubricate chain, check tension and readjust it if necessary ●●
Clean air filter and filter box ●
Check tire inflation pressure and wear ●
Check fuel line for leaks ●
Drain and clean float chamber ●
Verify smooth operation of all controls ●
Treat exposed metal components (except for the brake and exhaust systems) ●
with wax-based anti-corrosion agents
Check all screws, nuts, and hose clamps for their tight fit in regular intervals ●
for cross country use once a year after every cleaning
before each start

ENGLISH
13
2
1
4
3
1
2
3
4
Checking and adjusting the steering head bearing *
The steering head bearing should regularly be checked for play. For this pur-
pose, jack up the motorcycle by the frame so that the front wheel is in the
air. Now try to move the fork forward and backward. There should be no
play.
Undo the screw of the starting number plate and swing the starting num-
ber plate sideways.
Remove the four screws 1of the handlebar clamps and remove the hand-
lebar clamps.
Then swing the handlebar sideways.
Undo the two clamp screws 2of the top triple clamp and remove the coun-
ter nut 3. Then remove the top triple clamp.
Then turn the adjusting nut 4until almost no more play is left, but do not
completely tighten the adjusting nut so as to prevent damaging of the bea-
rings. Also keep in mind that the play of the bearings decreases when the
counter nut 3is tightened. Therefore, once again check the play of the
bearings after tightening the counter nut 3.
To mount the components reverse the procedure described above.
After mounting the triple clamp lightly tap it with a plastic hammer to pre-
vent jamming and tighten the two clamp screws (15 Nm/11 ft.lb).

WARNING

IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY, THE MOTORCY-
CLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL.
!
CAUTION
!
–T
HE HANDLEBAR MUST MOVE EASILY. OTHERWISE THE BEARINGS WILL BE DAMAGED.
–I
F YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS, THE
BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME WILL BE DESTROYED
.
At least once a year, the steering head bearings should be smeared with
waterproof grease.

WARNING

ALL MAINTENANCE AND ADJUSTEMENT OPERATIONS THAT ARE MARKED WITH A *REQUIRE SPECIALIST KNO-
WLEDGE. FOR YOUR OWN SECURITY, LET THESE TASKS BE CARRIED OUT BY A KTM-DEALER !
!
CAUTION
!
–W
HEN CLEANING THE MOTORCYCLE, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE, OTHERWISE WATER WILL PENETRATE THE BEARINGS, CAR-
BURETOR, ELECTRIC CONNECTORS ETC.
–W
HEN TRANSPORTING YOUR KTM, ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING DEVICES AND THAT
THE FUEL TAP IS IN THE OFF POSITION - IF THE MOTORCYCLE SHOULD FALL OVER, NO FUEL CAN LEAK FROM THE CARBURETOR OR FUEL TANK
–DO NOT USE TOOTHED WASHERS OR SPRING RINGS WITH THE ENGINE FASTENING SCREWS, AS THESE WORK INTO THE FRAME PARTS AND KEEP WORKING
LOOSE. INSTEAD, USE SELF-LOCKING NUTS.
–L
ET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED.
–R
EMOVE OILS, FATTY MATTERS, FILTERS, FUELS, WASHING DETERGENTS ETC. ORDERLY.
–U
NDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIZE. 1 LITER USED OIL CONTAMINATES
1.000.000 LITERS WATER.
MAINTENANCE WORK ON CHASSIS AND ENGINE

ENGLISH
14
General information about KTM disc brakes
BRAKE FLUID RESERVOIRS:
The brake fluid reservoirs on front and rear wheel brakes have been desi-
gned in such a way that even if the brake pads are worn it is not necessary
to top up the brake fluid. If the brake fluid level drops below the minimum
level either the brake system has a leak or the brake pads are completely
worn.
In this case, consult an authorized KTM dealer immediately.
BRAKE FLUID:
KTM fills the brake system with ”Shell Advance Brake DOT 5.1”, one of the
best brake fluids currently available. We recommend that you continue to
use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color.
If you do not have any DOT 5.1 for refilling, you may use DOT 4 brake
fluid. DOT 4 shown on the lid means minimum standard. However, you
should replace it as soon as possible by DOT 5.1.
BRAKE DISCS:
Due to wear, the thickness of the brake disc in the area of the contact
face 1of the brake pads decreases. At their thinnest point A, the brake
discs must not be more than 0.40 mm (0,016 in) thinner than the pad's
nominal thickness. Measure the nominal thickness in a location Boutside
the contact face. Check wear in several locations.

WARNING

–BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0,40 MM (0,016 IN) CONSTI-
TUTE A SAFETY RISK. HAVE THE BRAKE DISCS REPLACED IMMEDIATELY AS SOON AS
THEY REACH THE WEAR LIMIT.
–HAVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BA A KTM DEALER.
Adjusting free travel of the hand brake lever
Free travel at the hand brake lever may be readjusted by using adjustment
screw 2. In this way, the position of the point of pressure (i.e., the resi-
stance you feel on the hand brake lever when the brake pads are pressed
against the brake disc) can be adjusted for any hand size.
!
CAUTION
!
AT THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM (0.1 IN). ONLY THEN
MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED (TO BE RECOGNIZED BY THE
GREATER RESISTANCE OF THE HAND BRAKE LEVER). IF THIS FREE TRAVEL IS NOT PROVI-
DED, PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM, AND THE FRONT-WHEEL BRAKE
MAY FAIL DUE TO OVERHEATING.
Checking brake fluid level - front brake
The brake fluid reservoir is combined with the hand brake cylinder on the
handlebar and provided with an inspection glass. When the brake fluid
reservoir is in a horizontal position, the brake fluid level should not drop
below the "MIN" mark on the inspection glass.

WARNING

DROPPING OF THE BRAKE FLUID LEVEL BELOW THE "MIN" MARK INDICATES LEAKS IN
THE BRAKE SYSTEM OR TOTALLY WORN BRAKE PADS. IN THIS CASE, IMMEDIATELY
CONTACT A LICENSED KTM DEALER.
DOT
5.1 DOT
5
✓✕
A
B
2min. 3 mm
1

ENGLISH
15
Refilling front brake fluid reservoir *
When the brake fluid falls to the middle of the inspection glass, new brake
fluid has to be added.
Loosen screws 1and remove lid 2and membrane 3.
Place hand brake cylinder in a horizontal position and fill the brake fluid
reservoir to 5 mm (0.2 in) below the rim with clean brake fluid DOT 5.1
(Shell Advance Brake DOT 5.1). Replace membrane and lid, tighten screws.
Rinse off spilled or overflowing brake fluid with water.

WARNING

–N
EVER USE DOT 5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PURPLE
COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT.
–S
TORE BRAKE FLUID OUT OF REACH OF CHILDREN.
–B
RAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND EYES. IF
YOU
GET BRAKE FLUID IN YOUR EYES
, RINSE WITH PLENTY OF WATER AND CONSULT A
DOCTOR
!
!
CAUTION
!
– DON’T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE PAINT
REMOVER.
–U
SE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.
Checking front brake pads
Inspect the brake pads from in front of the vehicle. The linings must be at
least 1 mm (0.04 in) thick.

WARNING

AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM,
OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN SAFETY DON’T PUT
OFF HAVING YOUR BRAKE PADS CHANGED.
!
CAUTION
!
IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRE-
LY WORN, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE
DISC, THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC.
Replacing front brake pads
Remove the two screws 4and take the brake caliper off the brake disc.
Undo the two pins 5and take them out of the brake caliper. Then remove
the brake pads by pulling them downwards.
Before installing the new brake pads push the brake pistons backwards with
an appropriate screwdriver.
Insert the brake pads into the brake caliper from below and mount two new
pins. Secure both pins by folding up the edges.
Apply Loctite 243 to the threads of the screws 4and mount the screws.
Tightening torque: 20 Nm (15 ft.lb).
5 mm
11
2
3
4
5
min.
1 mm

ENGLISH
16
Changing basic position of the brake pedal *
The basic setting of the foot brake pedal can be changed by turning the end
stop roller 1. Using the push rod 2, the free play on the foot brake pedal
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
recognised from the resistance on the foot brake pedal).
!
CAUTION
!
IF THIS CLEARANCE IS MISSING, PRESSURE ACCUMULATES IN THE BRAKING SYSTEM AND
THE BRAKE PADS BEGIN TO RUB. THE BRAKING SYSTEM OVERHEATS AND CAN FAIL
COMPLETELY IN EXTREME CASES.
Check rear brake fluid level
The reservoir for the rear disc brake is located above the main brake
cylinder. The level of brake fluid may not fall below the „MIN” mark when
the vehicle has been left standing upright

WARNING

IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS
A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN. IN THIS CASE, CONSULT AN
AUTHORIZED KTM DEALER IMMEDIATELY.
Refilling rear brake fluid reservoir*
When the brake fluid level has dropped to the MIN mark, you need to refill
the brake fluid reservoir.
Remove the right side cover.
This is done by first unscrewing the cap 3and rubber belows 4.
Add brake fluid DOT 5.1 (Shell Advance Brake DOT 5.1) until it reaches the
MAX mark, then screw rubber belows and cap back on. Rinse off spilled or
overflowing brake fluid with water.

WARNING

– NEVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PURPLE
COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT.
–STORE BRAKE FLUID OUT OF REACH OF CHILDREN.
–B
RAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND EYES.
IF YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER AND CONSULT
A DOCTOR.!
CAUTION
!
–D
ON’T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE
PAINT REMOVER.
–U
SE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.
3-5mm
1
2
3
4

ENGLISH
17
Checking rear brake pads
The brake pads can be inspected from the rear. The thickness of the linings
may not be less than 1 mm (0.04 in).

WARNING

AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN
1 MM, OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN SAFETY
DON’T PUT OFF HAVING YOUR BRAKE PADS CHANGED.
!
CAUTION
!
IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRE-
LY WORN, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE
DISC, THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC.
Replacing rear brake pads *
Remove the cover 1and the locking ring 2. Using a punch 3, urge the
bolt out of the brake caliper in an outward direction and remove it together
with the leaf spring 4.
Pull the brake pads upwards and out of the brake caliper. Clean brake cali-
per thoroughly with compressed air.
Before installing the new brake pads push the brake pistons backwards with
an appropriate screwdriver.
Insert the new brake pads 5into the brake caliper, position the leaf spring
4, and secure it with the bolt 3. By tapping on the bolt, drive it into the
brake caliper up to the stop. Reattach locking ring 2and cover 1.

WARNING

–IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS.
OTHERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.
–A
FTER ASSEMBLY, CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY.
–H AVING PERFORMED ANY WORK ON THE BRAKING SYSTEM , ONE MUST ALWAYS ACTUA -
TE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER , RESPECTIVELY SO AS TO ENSURE
THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS
ESTABLISHED
.
12
1
2
3
45
min.
1 mm

ENGLISH
18
Removing and installing front wheel
Jack the motorcycle up by the frame so that the front wheel is suspended
above the ground.
Undo the hexagon nut 1and remove it together with the washer.
Hold the front wheel and pull out the wheel spindle 2.
Carefully take the front wheel out of the fork.
!
CAUTION
!
–
D O NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN DISMOUNTED .
–MAKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL,
OTHERWISE THE BRAKE DISC CAN BE DAMAGED.
Lift the front wheel into the fork and correctly position it.
Mount the wheel spindle 2.
Mount the washer and the hexagon nut 1and tighten (50 Nm/37 ft.lb).
Put the motorcycle back on the ground and operate the front wheel brake
until the working point is reached.

WARNING

–I
F YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE
THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A
LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE.
–A
FTER MOUNTING THE FRONT WHEEL, KEEP OPERATING THE HAND BRAKE UNTIL THE
PRESSURE POINT RETURNS.
–I
T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS,
EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED.
–T
IGHTEN THE HEXAGON NUT WITH THE REQUIRED TORQUE. A LOOSE WHEEL SPIND-
LE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE.
Removing and installing rear wheel
Jack the motorcycle up by the frame.
Remove the hexagon nut 3of the wheel spindle together with the washer
4and remove the chain adjuster 5.
Hold the rear wheel and pull out the wheel spindle.
Turn the rear wheel forwards and take the chain off the rear sprocket.
Pull the rear wheel backwards.
To install the rear wheel reverse the procedure described above.
Slightly grease the wheel spindle.
Before tightening the hexagon nut 3make sure that the chain adjusters 5
are properly resting against the tensioning screws. Additionally, make sure
that the rear wheel is properly aligned with the front wheel.
Mount the hexagon nut and tighten with 50 Nm (37 ft.lb).
!
CAUTION
!
– DO NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED.
–M
AKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL,
OTHERWISE THE BRAKE DISC CAN BE DAMAGED.
–I
F THE AXLE IS DISMOUNTED, CLEAN THE THREAD OF THE WHEEL SPINDLE AND COLLAR
NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE TO PREVENT THE THREAD
FROM JAMMING.

WARNING

–I
F YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE
THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A
LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE.
–A
FTER MOUNTING THE REAR WHEEL, KEEP OPERATING THE REAR BRAKE UNTIL THE
PRESSURE POINT RETURNS.
–I
T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS,
EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED.
–TIGHTEN THE HEXAGON NUT WITH THE REQUIRED TORQUE. A LOOSE WHEEL SPIND-
LE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE.
3
4
5
1
2

ENGLISH
19
Checking chain tension
Put the motorcycle on the side stand.
Press the chain approx. 3 cm (1.2 in) behind the chain sliding piece up
toward the swingarm.
In this place, it must be possible without pushing hard to press the chain up
to 7 mm (0.3 in) toward the swing arm (see figure). At the same time, the
upper half of the chain must be tense.
If necessary correct the chain tension.

WARNING

–I
F THE CHAIN IS TOO TIGHT THE SECONDARY TRANSMISSION COMPONENTS (CHAIN,
SPROCKETS, BEARINGS OF THE TRANSMISSION AND OF THE REAR WHEEL) WILL BE PUT
UNDER ADDITIONAL STRAIN THAT CAN, IN ADDITION TO PREMATURE WEAR, ALSO
CAUSE CHAIN BREAKAGE.
–I
F THE CHAIN IS NOT TIGHT ENOUGH IT CAN SLIP OFF THE SPROCKETS AND BLOCK THE
REAR WHEEL OR DAMAGE THE ENGINE.
–I
N BOTH CASES THE RIDER IS VERY LIKELY TO LOSE CONTROL OF THE MOTORCYCLE.
Correcting chain tension
Undo the hexagon nut 1, then undo both counter nuts 2and turn the left
and the right tensioning screws 3equally far. Then retighten the counter
nuts 2.
Before tightening the hexagon nut 1make sure that the chain adjuster
4is properly resting against the tensioning screws 3and that the rear
wheel is properly aligned with the front wheel.
Tighten the hexagon nut 1with 50 Nm (37 ft.lb).

WARNING

–I
F YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE
THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A
LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE.
–T
IGHTEN THE HEXAGON NUT WITH THE REQUIRED TORQUE. A LOOSE WHEEL SPIND-
LE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE.
Chain maintenance
For long chain life, good maintenance is very important. The chain should
be cleaned in fireproof solvent regularly and afterwards treated with hot
grease or chain spray (i.e. Shell Advance Bio Chain).

WARNING

N O LUBRICATION IS ALLOWED TO REACH THE REAR TIRE , EITHERWISE THE ROAD ADHEREN -
CE WOULD BE STRONGLY REDUCED AND THE MOTORCYCLE COULD EASILY LOSE CONTROL .
!
CAUTION
!
WHEN MOUNTING THE CHAIN MASTERLINK CLIP, THE CLOSED SIDE OF THE MASTERLINK
CLIP MUST POINT IN RUNNING DIRECTION.
Also check sprockets and chain guides for wear, and replace if necessary.
✓
23
2
4
13
4
7 mm