KTM 65 SX 2003 User manual

Art.Nr. 3.210.47 04/2002
65 SX
OWNER’S MANUAL
MANUALE D’USO
MANUEL D’UTILISATION
MANUAL DE INSTRUCCIONES
2003
BEDIENUNGSANLEITUNG

ENGLISH
1
Please insert the serial 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 BE DANGEROUS TO LIFE
AND LIMB.
!
CAUTION
!
IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE
MOTORCYCLE OR IMPAIR THE MOTORCYCLE’S TRAFFIC
SAFETY.
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
PRIOR NOTICE AND WITHOUT GIVING REASONS
, OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTITUTING THEM
WITH OTHERS
. I TSHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS ANNOUNCE -
MENT . I NTHE EVENT OF SUCH MODIFICATIONS , PLEASE ASK YOUR LOCAL KTM DEALER FOR INFORMATION .

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2
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 descrip-
tions may deviate slightly from the current design as our motorcycles are permanently
improved.The Owner's Manual is an integral part of the motorcycle and must be han-
ded over to the new owner when the motorcycle is sold.
We expressly point out that work marked with an asterisk in the chapter "Maintenance
work on the chassis and engine" must be performed by a KTM workshop. If mainten-
ance work should become necessary during a competition, it must be performed by a
trained mechanic.
Please strictly observe the prescribed running-in periods and inspection and maintenan-
ce intervals. Compliance with these instructions will significantly prolong the life of your
motorcycle.
Be sure to have the maintenance work carried out by a KTM workshop to avoid losing
your right to claim under the warranty.
For the safety of your child, only use spare parts and accessories approved by KTM.
KTM shall not assume any liability for other products or consequential damage resul-
ting from the use of such products.
When special needs arise, please contact a KTM dealer, who will seek the assistance of
the KTM importer if necessary.
PARENTS SHOULD KEEP IN MIND that the safety of their youngsters always depends
on the efforts made by the parents to ensure that the motorcycle is kept in good wor-
king order and only used on safe terrains. Nevertheless, driving the motorcycle, like dri-
ving any other vehicle, involves a potential risk. Therefore, please make sure that all fun-
damental precautions are taken. Please also read the „INFORMATION ON SAFE DRI-
VING 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 con-
flicts. 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 appli-
cable laws, making environmental protection one of your top priorities and never viola-
ting 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 & engine
ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL.
©by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved

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3
IMPORTANT WARRANTY AND
GUARANTEE INFORMATIONE
KTM mini-sports motorcycles are designed and constructed to resist the usual
wear and tear of normal use in competitions.
The motorcycles comply with the regulations and categories currently in effect
with the leading international motorcycle associations.
Observance of the service, maintenance and tuning instructions for the engi-
ne and chassis specified in the Owner's Manual is a prerequisite for faultless
operation and the avoidance of premature wear. An improperly tuned chassis
can lead to damage and breakage of the chassis components (see chapter on
checking the basic chassis setting).
The service work specified in the "Lubrication and Maintenance Schedule"
must be performed by a KTM workshop and recorded in the service manual
otherwise claims under the warranty shall become void.
The fuels and lubricants specified in the Owner's Manual or automotive fluids
with equivalent specifications must be used in accordance with the mainten-
ance schedule.
No claims can be filed under the warranty for damage or consequential dama-
ge caused by manipulations or conversions to the motorcycle.
The use of the motorcycle under extreme conditions, e.g. on extremely
muddy and wet terrain, can lead to higher than average wear on components
such as the drive train or the brakes. In this case it may become necessary to
service or replace wear parts before the service limit specified in the mainten-
ance schedule has been reached.
In accordance with the international quality management
ISO 9001 standard, KTM uses quality assurance processes
that lead to the highest possible product quality.

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4
The 65 SX mini motorcycles are off-road motorcycles designed for one person only. They are not allowed on
public roads.
The vehicle dimensions and components are designed for children from 6 to 10 years of age with a maximum
weight of. 50 kg (22,65 lb) and a maximum height of 160 cm.(63,04 in)
–Have 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 whenever riding a motorcycle!
–Adjust the clutch lever and hand brake lever to match your child's hand size (with gloves).
–Adjust the basic setting of the foot brake pedal to your child's seating position.
–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
shifting of the rider’s weight, etc.
–Before starting the motorcycle for the first time check whether the basic fork and shock absorber settings are
suitable for your child's weight (see chapter on checking the basic chassis setting)
–Before using the motorcycle you should always check all components for proper operation
(see maintenance 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 FOR PARENTS ABOUT SAFE DRIVING

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5
TABLE OF CONTENTS
Page
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . .6
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . .6
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Short circuit button . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Compression damping of shock absorber . . . . . . . . . . .8
Rebound damping function of the shock absorber . . . .8
Plugin-Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
GENERAL TIPS AND WARNINGS FOR STARTING THE
MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Instructions for the first ride . . . . . . . . . . . . . . . . . . . .10
Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .11
What you should check before each start . . . . . . . . . .11
Starting when engine is cold . . . . . . . . . . . . . . . . . . .12
Starting when engine is warm . . . . . . . . . . . . . . . . . .12
What to do when the engine is “flooded“ . . . . . . . . .12
Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Shifting, Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Refueling, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . .14
MAINTENANCE WORK ON CHASSIS AND ENGINE . . . .16
Checking and adjusting the steering head bearing . . .16
Basic suspension setup for the weight of the driver . . .17
To determine the sag of the shock absorber . . . . . . . .17
To determine the sag of the telescopic fork . . . . . . . .17
Breather plug front fork . . . . . . . . . . . . . . . . . . . . . . .18
Cleaning the dust scrabbers of the telescopic fork . . . .18
How to change the handlebar position . . . . . . . . . . . .18
Page
Changing the spring preloading of the shock absorber .
19
Checking the chain tension . . . . . . . . . . . . . . . . . . . .19
Correcting the chain tension . . . . . . . . . . . . . . . . . . .19
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .19
General information about KTM disc brakes . . . . . . . .20
Adjusting of free travel at the hand brake lever . . . . .20
Checking of brake fluid level - front brake . . . . . . . . .21
Refilling the front brake fluid reservoir . . . . . . . . . . . .21
Checking the front brake pads . . . . . . . . . . . . . . . . . .21
Replacing the front brake pads . . . . . . . . . . . . . . . . .22
Changing the basic position of the brake pedal . . . . . .22
Check the rear brake fluid level . . . . . . . . . . . . . . . . .23
Refilling the rear brake fluid reservoir . . . . . . . . . . . . .23
Checking the rear brake pads . . . . . . . . . . . . . . . . . . . . .23
Replacing the rear brake pads . . . . . . . . . . . . . . . . . .23
Removing and installing the front wheel . . . . . . . . . . .24
Removing and installing the rear wheel . . . . . . . . . . .25
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Checking the spoke tension . . . . . . . . . . . . . . . . . . . .25
Removing the seat . . . . . . . . . . . . . . . . . . . . . . . . . .26
Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . . .26
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Checking the oil level of the hydraulic clutch . . . . . . .27
Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . . .27
Changing the original position of the clutch lever . . . .28
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Checking the coolant level . . . . . . . . . . . . . . . . . . . . .28
Adjusting the throttle cable . . . . . . . . . . . . . . . . . . . .28
Carburetor adjustment . . . . . . . . . . . . . . . . . . . . . . .29
Draining the float chamber of the carburetor . . . . . . .30
Checking the gear oil level . . . . . . . . . . . . . . . . . . . . .30
Changing the gear oil . . . . . . . . . . . . . . . . . . . . . . . .30
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .31
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
TECHNICAL DATA - CHASSIS . . . . . . . . . . . . . . . . . . . .34
TECHNICAL DATA - ENGINE . . . . . . . . . . . . . . . . . . . . .35
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

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6
Chassis number
The chassis number is stamped on the right side of the steering head tube.
Enter this number in the field on page no 1.
Engine number
The engine number is stamped into the engine housing underneath the
carburetor. Enter this number in the field on page no 1.
Clutch lever
The clutch lever 1is located on the left side of the handlebar. The adjusting
screw Ais used to change the original position of the clutch lever (see
maintenance work on chassis and engine).
Hand brake lever
The hand brake lever 2is mounted on the handle bars on the right and
actuates the front wheel brake.
Short circuit button
The short circuit button 3turns off the engine. When pressing this button,
the ignition circuit is short-circuited.
SERIAL NUMBER LOCATIONS
OPERATION INSTRUMENTS
1
3
2
A

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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.
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.
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.
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.
2,3,4,5,6
1
N
2
3
1

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8
Kickstarter
The kickstarter is mounted on the right side of the engine. Its upper part can
be swivelled.
Foot brake pedal
The foot brake pedal is located in front of the right foot rest. Its basic posi-
tion can be adjusted to your seat position (see maintenance work).
Compression damping of shock absorber
The degree of damping of the compression can be adjusted with the knob 1.
Turn the knob counterclockwise to increase damping, turn it clockwise to
reduce damping during rebounding.
STANDARD SETTING: 3

WARNING

THE DAMPING UNIT 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.
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 2. Turn the setting wheel clockwise
(in) to increase and counterclockwise (out) to reduce the damping effect.
STANDARD SETTING: 6 CLICKS OPEN

WARNING

–N
EVER TURN THE SETTING WHEEL MORE THAN TWO CLICKS BETWEEN TWO TEST RIDES.
–D
ONOT TRY TO DISASSEMBLE THE SHOCK ABSORBER OR TO PERFORM
MAINTENANCE WORK YOURSELF. DANGER OF INJURY!
Plugin- Stand
A socket is provided on the right side of the frame into which you can plug
the stand 3.
2
3
1

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9

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10
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE

WARNING

–HAVE 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
WHENEVER RIDING A MOTORCYCLE!
–O
NLY USE ACCESSORY PARTS RECOMMENDED BY KTM.
–T
HE FRONT AND REAR WHEEL ARE ONLY ALLOWED TO BE TIRED WITH
TIRES THAT HAVE THE SAME PROFILE TYPE.
–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.
–NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS
THE ENGINE IS RUNNING.

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.
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 clutch lever, hand lever and foot brake pedal so
your child can operate them easily!
–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.
–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 riding the motorcycle standing on the footpegs or to
riding at the slowest possible speed. Additionally, you can
arrange a series of obstacles and have your youngster drive
around them, etc.
–Pay attention to the running-in procedure.
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 30 minutes the engine must not be revved up to its
performance limits.
–Apply low but changing loads for running-in.
–
DO NOT DRIVE AT FULL LOAD FOR THE FIRST 30 MINUTES!

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11
DRIVING INSTRUCTIONS
What you should check before each start
When you start off, the motorcycle must be in a perfect technical 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 destruc-
tion 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 the
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 the 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 indicates a leak in the braking system or completely worn out
brake pads. Always have the brake system checked by a KTM workshop
to avoid brake failure.
Also check the state of the brake hose and the thickness of the brake
linings.
Check free travel at the hand brake lever and foot brake lever.

WARNING

IFTHE RESISTANCE IN THE HAND BRAKE LEVER FEELS “SPONGY” (TOO MUCH PLAY),
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.
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.

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12
Starting when the engine is cold
1 Open fuel tap 1.
2 Put the gear in neutral
3Activate the cold-starting aid (choke)2.
4 Leave throttle closed and kick down the kickstarter vigorously all the way.

WARNING

–T
OAVOID INJURY WHEN STARTING THE ENGINE, ALWAYS WEAR STRONG BIKERS
BOOTS!YOU MAY SLIP OFF THE KICKSTARTER, OR THE ENGINE MAY KICK BACK IF YOU
DO NOT KICK HART ENOUGH.
–D
ONOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA. EXHAUST
FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH.
ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING.
!
CAUTION
!
DONOT RIDE YOUR MOTORCYCLE AT FULL LOAD AND DO NOT REV UP THE ENGINE WHEN
COLD. SINCE THE PISTON 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.
Starting when the engine is warm
1 Open fuel tap
2 Put the gear in neutral
3 Leave throttle closed and kick down kickstarter vigorously all the way.
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 release the clutch
lever and accelerate at the same time.

WARNING

ALWAYS REMOVE THE PLUG-IN 3STAND BEFORE YOUR CHILD RIDES THE 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 the clutch
lever go slowly and open throttle or shift down again.

WARNING

–A
FTER FALLING WITH THE MOTORCYCLE, CHECK ALL ITS FUNCTIONS THOROUGHLY
BEFORE USING IT AGAIN.
–A
TWISTED HANDLEBAR MUST ALWAYS BE REPLACED. DONOT ADJUST THE HANDLEB-
AR, IT WILL LOSE STABILITY.
1
2
3

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13
!
CAUTION
!
–D
RIVING A COLD ENGINE AT HIGH SPEED WILL REDUCE THE LIFE OF THE
ENGINE. WERECOMMEND TO WARM THE ENGINE UP AT A MEDIUM
ENGINE SPEED FOR SEVERAL MINUTES BEFORE SWITCHING TO FULL
LOAD.
–NEVER 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
FTHE 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
NTHE 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 the gas and apply the hand and foot brakes at the
same time. When driving on sandy, wet or slippery ground use
mainly 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

–I
N 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. INEXTREME 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

MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE
RUNNING. THE ENGINE, EXHAUST PIPE, MUFFLER, BRAKE ROTORS, AND
SHOCK ABSORBERS CAN BECOME VERY HOT. DONOT 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.
–THE PLUGIN- STAND IS ONLY DESIGNED FOR THE WEIGHT OF THE
MOTORCYCLE. IFYOU GET ON YOUR MOTOR-CYCLE AND THUS PUT
ADDITIONAL WEIGHT ON THE MOTORCYCLE, THE PLUGIN- STAND OR
THE FRAME CAN BE DAMAGED OR THE MOTORCYCLE MAY FALL ON THE
SIDE.
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. BECAREFUL NOT TO SPILL
GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT.
WIPE UP SPILLS PROMPTLY. IFGASOLINE IS SWALLOWED OR SPLASHED IN
THE EYES, SEEK A DOCTOR’SADVICE 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.
–O
NLY 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 SMO -
KING AND FOUL THE SPARK PLUG .
–FUEL EXPANDS WHEN ITS TEMPERATURE RISES. THEREFORE DO NOT FILL
THE TANK TO THE TOP. (SEE FIG.)
40 mm

ENGLISH
14
PERIODIC MAINTENANCE SCHEDULE
Service
every
20 hours
once a year
M AINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER !
A clean 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 a tight fit at intake flange ●
Check the intake flange and carburetor connection boot for cracks and tightness ●
Check idle setting when engine is warm ●
Check the bleeder hose for damage, kinkless installation and passage ●
Check cooling system for leaks, antifreeze protection ●
Check exhaust system for leaks and suspension ●
Check actuating cables for damage, smooth operation, and kinkless ●
arrangement, and adjust and lubricate
Check oil level of the clutch master cylinder ●
Clean air filter and air filter box ●
Check brake fluid level, lining thickness, brake discs ●
Check brake lines for damage and leaks ●
Check functiuon/adjust smooth operation, free travel of handbrake levers ●
Check screws of brake system for a tight fit ●
Check suspension strut and fork for leaks and a proper function ●
Clean dust bellows ●
Bleed fork legs ●
Check swinging-fork pivot ●
Check/adjust steering-head bearing ●
Check all chassis screws for a tight fit (fork plates, axle nuts, ●
swinging-fork pivot, suspension strut)
Check spoke tension and rim joint ●
Check tire condition and inflation pressure ●
Check chain, chain wheels, chain wheel, chain joint 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
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 ●
Clean and adjust carburator ●
Change hydrulic clutch fluid ●
Change brake fluid ●
WHEELS CHASSIS BREAKS
ADD-ON-PARTS
ENGINE
65 SX
once a year
CARBURETOR

ENGLISH
15
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 ga scable and nipples ●
Remove and clean dust sleeves of telescopic fork at regular intervals ●
Bleed fork legs regularly ●
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
Treat all electric plug-in connections with contact spray ●
Check all screws, nuts, and hose clamps for their tight fit at regular intervals ●
for cross country use once a year after every cleaning
before each start
as of 03.2002
RECOMMENDED INSPECTION OF THE 65 SX ENGINE BY YOUR KTM WORKSHOP
( ADDITIONAL ORDER FOR THE KTM’SWORKSHOP)
Check the reed-type intake valve for wear ●●●●●●
Check the clutch shoes for wear ●●●●●●
Check the length of the clutch springs ●●●●●●
Check the cylinder and piston for wear ●●●●●●
Check the eccentricity of the crankshaft journal ●●●●●●
Check the radial clearance of the conrod bearings ●●●
Check the radial clearance of the piston pin main bearing ●●●
Check the crankshaft main bearing for wear ●●●
Replace the crankshaft bearings and conrod bearings ●●●
Check the entire transmission including roller and bearings for wear ●●●
30
hours
45
hours
60
hours
90
hours
120
hours
135
hours
NOTE: IFTHE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED, THE RESPECTIVE COMPONENTS MUST BE REPLACED.

ENGLISH
16
Checking and adjusting the steering head bearing *
Check steering head bearing for play periodically. To check, put motorcycle
on the stand so that the front wheel is off the ground. Now try to move the
fork forward and backward. For readjusting, loosen the three clamp screws1
of the top triple clamp and turn steering stem bolt clockwise 2until there is
no more play. Don’t tighten the steering stem bolt all the way, otherwise the
bearings will be damaged. With a plastic hammer, lightly rap on the triple
clamp to release tension. Retighten the three clamp screws to 20 Nm.

WARNING

IFTHE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY, THE MOTORCYCLE
WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL.
!
CAUTION
!
IFYOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS, THE
BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME WILL BE DESTROYED.
The steering head bearings should be regreased at least once a year
(i.e. Shell Advance Grease).

WARNING

ALL MAINTENANCE AND ADJUSTMENT OPERATIONS THAT ARE MARKED WITH AN ASTERISK *REQUIRE
SPECIALIST KNOWLEDGE. FOR YOUR OWN SECURITY, LET THESE TASKS BE CARRIED OUT BY A KTM-DEALER
WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED, SKILLED STAFF.
!
CAUTION
!
–WHEN CLEANING THE MOTORCYCLE, DO NOT USE A 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
–ONLY USE SPECIAL SCREWS WITH AN APPROPRIATE THREAD LENGTH SUPPLIED BY KTM TO FIX THE SPOILERS ON THE TANK. USING OTHER SCREWS OR
LONGER SCREWS CAN CAUSE LEAKS IN THE TANK THROUGH WHICH FUEL CAN FLOW OUT.
–D
ONOT 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.
–LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED.
–D
ISPOSE OF OILS, FATTY MATTERS, FILTERS, FUELS, WASHING DETERGENTS, ETC. PROPERLY.
–U
NDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIDE. 1 LITER OF USED OIL CONTAMINA-
TES 1,000,000 LITERS OF WATER.
MAINTENANCE WORK ON CHASSIS AND ENGINE
2
1

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

ENGLISH
18
Breather plug front fork
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 1several turns to let any excess pressure escape from the
inside of the fork.
!
CAUTION
!
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 PLUGS BEFORE
HAVING THE SEALS REPLACED.
Cleaning the dust sleeves of the telescopic fork
The dust-protection bellows 2are to remove dust and coarse dirt particles
from the fork tube. However, after some time, dirt may also get in behind
the dust-protection bellows. If this dirt is not removed, the oil sealing rings
located behind it may start to leak.
Use a screwdriver to lift the dust-protection bellows out of the outer tubes
and slide them downward.
Clean dust-protection bellows, outer tubes, and fork tubes thoroughly, and
oil them thoroughly with silicone spray or engine oil. Then, push dust-pro-
tection bellows into the outer tubes by hand.
How to change the handlebar position
The handlebar position can be readjusted by 22 mm. Thus, you can put the
handlebar in the position that is the most convenient for you. The upper tri-
ple clamp 3includes 2 bores arranged at a distance of 15 mm (0.6 in) from
one another. The bores at the handlebar support 4are offset from the cen-
ter by 3.5 mm (0.13 in). Accordingly, you can mount the handlebar in
4 different positions.
For this purpose, remove screws 5of the handlebar clamps and screws 6
of the handlebar support. Position handlebar support, and tighten screws 6
to 40 Nm. Mount handlebar and handlebar clamps, and tighten screws 5
to 20 Nm. The gap between the handlebar support and handlebar clamps
should be the same size in the front and in the rear.

WARNING

THE SCREWS 6MUST BE SECURED WITH LOCTITE 243.
2
1
3
4
5
6
15 mm
3,5 mm

ENGLISH
19
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.
Loosen the locking ring 1with the hook spanner. Change
the spring
preload with the adjusting ring 2and re-tighten the locking ring 1.
BASIC SETTING – SPRING PRELOAD
7 mm (0.3 in)
Checking chain tension
Set the motorcycle on the plug-in stand.
Press the chain down on the upper end of the chain sliding component.
The distance between the chain and the swing arm should be approx. 3mm.
The lower part of the chain should be tightened.

WARNING

–I
FTHE 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
FTHE CHAIN IS NOT TIGHT ENOUGH IT CAN SLIP OFF THE SPROCKETS AND BLOCK THE
REAR WHEEL OR DAMAGE THE ENGINE.
–I
NBOTH CASES THE RIDER IS VERY LIKELY TO LOSE CONTROL OF THE MOTORCYCLE.
Correcting chain tension
Undo the hexagon nut 3, then undo both counter nuts 4and turn the left
and the right tensioning screws 5equally far. Then retighten the counter
nuts 4.
Before tightening the hexagon nut 3make sure that the chain adjuster
6is properly resting against the tensioning screws 5and that the rear
wheel is properly aligned with the front wheel.
Tighten the hexagon nut 3to 50 Nm.

WARNING

–I
FYOU 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 TO THE REQUIRED TORQUE. A LOOSE WHEEL SPINDLE
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 ( Shell Advance Bio Chain).

WARNING

NOLUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISKS, OTHER-
WISE THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS 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.
✓
4
3
4
3 mm
1
2
5
6
5
6