KTM 65 SX 2017 User manual

OWNER'S MANUAL 2017
65 SX
Art. no. 3213470en

DEAR KTM CUSTOMER 1
*3213470en*
3213470en
03/2016
DEAR KTM CUSTOMER
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you and your child enormous pleasure if you service and maintain it accordingly.
We hope you enjoy your new vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( p. 10) Dealer's stamp
Engine number ( p. 10)
The Owner's Manual contained the latest information for this model series at the time of going to print. Minor differences due to develop-
ments in design cannot be ruled out completely.
All specifications are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical specifications,
prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to
local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, devi-
ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not
belong to the regular scope of supply.
© 2016 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
5230 Mattighofen, Austria
This document is valid for the following models:
65 SX (F6001Q6)

TABLE OF CONTENTS 2
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ..................................... 4
1.1 Symbols used ................................................... 4
1.2 Formats used.................................................... 4
2 SAFETY ADVICE........................................................... 5
2.1 Use definition - intended use ............................. 5
2.2 Safety advice.................................................... 5
2.3 Degrees of risk and symbols ............................... 5
2.4 Tampering warning............................................ 5
2.5 Safe operation .................................................. 5
2.6 Protective clothing ............................................ 6
2.7 Work rules........................................................ 6
2.8 Environment..................................................... 6
2.9 Owner's Manual ................................................ 6
3 IMPORTANT NOTES..................................................... 7
3.1 Manufacturer and implied warranty..................... 7
3.2 Operating and auxiliary substances ..................... 7
3.3 Spare parts, accessories .................................... 7
3.4 Service ............................................................ 7
3.5 Figures ............................................................ 7
3.6 Customer service............................................... 7
4 VIEW OF VEHICLE ....................................................... 8
4.1 View of vehicle, front left (example) .................... 8
4.2 View of vehicle, rear right (example) ................... 9
5 SERIAL NUMBERS .................................................... 10
5.1 Chassis number .............................................. 10
5.2 Engine number ............................................... 10
5.3 Shock absorber article number ......................... 10
6 CONTROLS................................................................ 11
6.1 Clutch lever.................................................... 11
6.2 Hand brake lever............................................. 11
6.3 Throttle grip ................................................... 11
6.4 Kill switch...................................................... 11
6.5 Opening the filler cap...................................... 11
6.6 Closing the filler cap ....................................... 12
6.7 Fuel tap ......................................................... 12
6.8 Choke ............................................................ 12
6.9 Shift lever ...................................................... 13
6.10 Kick starter .................................................... 13
6.11 Foot brake lever .............................................. 13
6.12 Plug-in stand.................................................. 13
7 PREPARING FOR USE................................................ 14
7.1 Advice on first use .......................................... 14
7.2 Running in the engine ..................................... 15
8 RIDING INSTRUCTIONS............................................. 16
8.1 Checks and maintenance measures when
preparing for use............................................. 16
8.2 Starting.......................................................... 16
8.3 Starting off..................................................... 17
8.4 Shifting, riding ............................................... 17
8.5 Applying the brakes......................................... 17
8.6 Stopping, parking............................................ 18
8.7 Transport ....................................................... 18
8.8 Refueling ....................................................... 19
9 SERVICE SCHEDULE ................................................. 20
9.1 Additional information..................................... 20
9.2 Required work ................................................ 20
9.3 Recommended work ........................................ 21
10 TUNING THE CHASSIS .............................................. 22
10.1 Checking the basic chassis setting with the
rider's weight.................................................. 22
10.2 Air suspension AER 35.................................... 22
10.3 Compression damping of the shock absorber...... 22
10.4 Adjusting the low-speed compression damping
of the shock absorber ...................................... 23
10.5 Adjusting the high-speed compression
damping of the shock absorber......................... 23
10.6 Adjusting the rebound damping of the shock
absorber......................................................... 24
10.7 Measuring rear wheel sag unloaded................... 24
10.8 Checking the static sag of the shock absorber.... 24
10.9 Checking the riding sag of the shock absorber.... 25
10.10 Adjusting the spring preload of the shock
absorber ..................................................... 25
10.11 Adjusting the riding sag ............................... 26
10.12 Checking the basic setting of the fork ............... 26
10.13 Adjusting the fork air pressure.......................... 26
10.14 Adjusting the rebound damping of the fork ........ 27
10.15 Handlebar position.......................................... 28
10.16 Adjusting handlebar position ........................ 28
11 SERVICE WORK ON THE CHASSIS.............................. 29
11.1 Raising the motorcycle with a lift stand............. 29
11.2 Removing the motorcycle from the lift stand...... 29
11.3 Bleeding the fork legs...................................... 29
11.4 Cleaning the dust boots of the fork legs............. 30
11.5 Removing the fork protector ............................. 30
11.6 Installing the fork protector.............................. 30
11.7 Removing the fork legs ................................. 31
11.8 Installing the fork legs ................................. 31
11.9 Removing the lower triple clamp ................... 32
11.10 Installing the lower triple clamp .................... 33
11.11 Checking play of steering head bearing ............. 34
11.12 Adjusting the steering head bearing play ........ 35
11.13 Greasing the steering head bearing ................ 35
11.14 Removing the start number plate...................... 35
11.15 Installing the start number plate....................... 36
11.16 Dismounting the front fender ........................... 36
11.17 Installing the front fender ................................ 36
11.18 Removing the shock absorber ....................... 37
11.19 Installing shock absorber .............................. 37
11.20 Removing the seat .......................................... 37
11.21 Mounting the seat........................................... 37
11.22 Removing the air filter ................................. 38
11.23 Installing the air filter .................................. 38
11.24 Cleaning the air filter and air filter box .......... 39
11.25 Removing main silencer................................... 39
11.26 Installing the main silencer.............................. 39
11.27 Changing the glass fiber yarn filling of the
main silencer .............................................. 40
11.28 Removing the fuel tank ................................ 40
11.29 Installing the fuel tank ................................. 41
11.30 Checking the chain for dirt............................... 42
11.31 Cleaning the chain .......................................... 42
11.32 Checking the chain tension .............................. 43
11.33 Adjusting the chain tension.............................. 43
11.34 Checking the chain, rear sprocket, engine
sprocket, and chain guide................................ 44
11.35 Checking the frame ..................................... 46
11.36 Checking the swingarm ................................ 46
11.37 Checking the throttle cable routing ................... 46
11.38 Checking the rubber grip ................................. 47
11.39 Additionally securing the rubber grip................. 47
11.40 Adjusting basic position of clutch lever ............. 47
11.41 Checking the fluid level of the hydraulic
clutch............................................................ 47

TABLE OF CONTENTS 3
11.42 Correcting the fluid level of the hydraulic
clutch............................................................ 48
11.43 Changing the hydraulic clutch fluid ............... 48
12 BRAKE SYSTEM ........................................................ 50
12.1 Checking free travel of hand brake lever ............ 50
12.2 Adjusting the basic position of the hand brake
lever .............................................................. 50
12.3 Checking the brake discs ................................. 50
12.4 Checking the front brake fluid level .................. 51
12.5 Adding front brake fluid ............................... 52
12.6 Checking the front brake linings ....................... 53
12.7 Changing the front brake linings ................... 53
12.8 Checking the free travel of the foot brake
lever .............................................................. 55
12.9 Adjusting the free travel of the foot brake
lever ........................................................... 56
12.10 Adjusting the basic position of the foot brake
lever ........................................................... 56
12.11 Checking rear brake fluid level ......................... 57
12.12 Adding rear brake fluid ................................ 57
12.13 Checking the rear brake linings ........................ 58
12.14 Changing the rear brake linings ..................... 58
13 WHEELS, TIRES ........................................................ 61
13.1 Removing the front wheel ............................. 61
13.2 Installing the front wheel ............................. 61
13.3 Removing the rear wheel .............................. 62
13.4 Installing the rear wheel ............................... 63
13.5 Checking the tire condition .............................. 64
13.6 Checking tire air pressure ................................ 64
13.7 Checking spoke tension ................................... 64
14 COOLING SYSTEM ..................................................... 66
14.1 Cooling system ............................................... 66
14.2 Checking the antifreeze and coolant level.......... 66
14.3 Checking the coolant level ............................... 67
14.4 Draining the coolant .................................... 67
14.5 Refilling with coolant ................................... 68
15 TUNING THE ENGINE................................................ 69
15.1 Checking the play in the throttle cable .............. 69
15.2 Adjusting the play in the throttle cable .......... 69
15.3 Carburetor - idle.............................................. 70
15.4 Carburetor - adjusting the idle speed ............. 70
15.5 Emptying the carburetor float chamber .......... 71
16 SERVICE WORK ON THE ENGINE ............................... 72
16.1 Checking the gear oil level ............................... 72
16.2 Changing the gear oil ................................... 72
16.3 Adding gear oil ............................................ 73
17 CLEANING, CARE ...................................................... 74
17.1 Cleaning motorcycle ........................................ 74
18 STORAGE.................................................................. 75
18.1 Storage .......................................................... 75
18.2 Preparing for use after storage.......................... 75
19 TROUBLESHOOTING ................................................. 76
20 TECHNICAL DATA...................................................... 78
20.1 Engine ........................................................... 78
20.2 Engine tightening torques ................................ 78
20.3 Carburetor...................................................... 79
20.3.1 Carburetor tuning........................................ 80
20.4 Capacities ...................................................... 81
20.4.1 Gear oil...................................................... 81
20.4.2 Coolant ...................................................... 81
20.4.3 Fuel .......................................................... 81
20.5 Fork............................................................... 81
20.6 Shock absorber............................................... 81
20.7 Chassis .......................................................... 82
20.8 Tires.............................................................. 82
20.9 Chassis tightening torques ............................... 83
21 SUBSTANCES ........................................................... 84
22 AUXILIARY SUBSTANCES .......................................... 86
23 STANDARDS ............................................................. 88
INDEX .............................................................................. 89

1 MEANS OF REPRESENTATION 4
1.1 Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of
the safety of your child, have these jobs performed in an authorized KTM workshop. There, your motorcycle will
be optimally cared for by specially trained experts using the specialist tools required.
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name®Indicates a protected name.
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained
in the glossary.

2 SAFETY ADVICE 5
2.1 Use definition - intended use
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com-
ply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle may only be used in closed off areas remote from public road traffic.
2.2 Safety advice
A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety
instructions are highlighted in the text and are referred to at the relevant passages.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If
they are missing, you or others may not recognize dangers and may therefore be injured.
2.3 Degrees of risk and symbols
Danger
Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are
not taken.
Warning
Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
2.4 Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device
or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate
purchaser or while it is in use, or
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases.
2 Removal or puncturing of parts of the intake system.
3 Lack of proper maintenance.
4 Replacing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manu-
facturer.
2.5 Safe operation
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
–Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
–Do not operate the vehicle if you are physically or mentally impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
–Always make sure there is sufficient ventilation when running the engine.
–Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

2 SAFETY ADVICE 6
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
–Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle
parts have cooled down.
–Let the vehicle parts cool down before you perform any work on the vehicle.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use and in a safe and environmen-
tally compatible manner.
The vehicle should only be used by trained persons.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
2.6 Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
–Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all
rides.
–Always wear protective clothing that is in good condition and meets the legal regulations.
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.
2.7 Work rules
Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren-
theses. E.g.: bearing puller (15112017000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.
2.8 Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcy-
cle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the
respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that
pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.
2.9 Owner's Manual
It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains
useful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to cus-
tomize the vehicle ideally for your own use and how you can protect yourself from injury.
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed.
If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.
The Owner's Manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold.

3 IMPORTANT NOTES 7
3.1 Manufacturer and implied warranty
The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the
Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage
caused by tampering with and/or conversions on the vehicle are not covered by the warranty.
Additional information on the manufacturer or implied warranty and the procedures involved can be found in the Service & Warranty
Booklet.
3.2 Operating and auxiliary substances
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.
3.3 Spare parts, accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them
installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized KTM dealer will be glad
to advise you.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4 Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the engine and
chassis is properly carried out as described in the Owner's Manual. Incorrect adjustment and tuning of the engine and chassis can
lead to damage and breakage of components.
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can lead to considerably more rapid wear
of components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or
replace parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a
much longer service life for your motorcycle.
3.5 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to dis-
assemble the component to perform the activity in question. Please follow the instructions in the text.
3.6 Customer service
Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.
A list of authorized KTM dealers can be found on the KTM website.
International KTM Website: http://www.ktm.com

4 VIEW OF VEHICLE 8
4.1 View of vehicle, front left (example)
V00239-10
1 Hand brake lever ( p. 11)
2 Valve for fork airpump
3 Clutch lever ( p. 11)
4 Quick release for seat lock
5 Shift lever ( p. 13)
6 Choke ( p. 12)
7 Fuel tap ( p. 12)