User Guide for KTM 65 SX and Workshop Manual

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 wish you a lot of enjoyment in riding this vehicle.

Enter the serial numbers of your vehicle below.

• Chassis number
• Engine number 

The owner's manual contained the latest information for this model at the time of going to print. Slight deviations resulting from continuing development and design can, however, not be completely excluded.

All specifications are non-binding. KTM Sportmotorcycle AG 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, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

KTM 65 SX 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 manufacturer.

Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use and in a safe and environmentally 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.

RIDING INSTRUCTIONS
Checks and maintenance measures when preparing for use
Before each use, check the condition of the vehicle and its operating safety. The vehicle must be in perfect technical condition when it is being operated.

• Check the gear oil level.
• Check the front brake fluid level.
• Check the rear brake fluid level.
• Check the front brake linings.
• Check the rear brake linings.
• Check the brake system function.
• Check the coolant level.
• Check the chain dirt accumulation.
• Check the chain, rear sprocket, engine sprocket, and chain guide.
• Check the chain tension.
• Check the tire condition.
• Check the tire air pressure.
• Check the spoke tension.
• Clean the dust boots of the fork legs.
• Bleed fork legs.
• Check the air filter.
• Check the settings of all controls and ensure that they can be operated smoothly.
• Check all screws, nuts and hose clamps regularly for tightness.
• Check the fuel supply

Engine has been out of use for more than 1 week

1. Empty the carburetor float chamber.
2. Turn the knurled screw on the fuel tap all the way counterclockwise. Fuel can flow from the fuel tank to the carburetor.
3. Remove the motorcycle from the stand.
4. Shift gear to neutral.

If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines.

• When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.
• If the choke function was activated, deactivate it after the engine has warmed up.
• When you reach maximum speed after fully opening the throttle, turn back the throttle to about ¾ of its range. The speed hardly drops, but the fuel consumption falls considerably.
• You should always open the throttle only as much as the engine can handle abruptly opening the throttle increases fuel consumption.
• To shift down, brake and close the throttle at the same time.
• Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again.
• Youshould switch off the engine if he or she expects to be standing for a long time.

KTM 65 SX Service schedule
Check the front brake linings. 
Check the rear brake linings. 
Check the brake discs. 
Change the sealing sleeves of the foot brake cylinder.
Change the rear brake fluid.
Check the rear brake fluid level. 
Check the free travel of the foot brake lever. 
Check the frame and swingarm.
Check swingarm bearing.
Check the heim joints on the upper and lower shock absorbers.
Service the fork.
Service the shock absorber.
Check the tire condition. 
Check the tire air pressure. 
Check wheel bearing for play.
Check the wheel hubs.
Check rim run-out.x 
Check the spoke tension. 
Check the chain, rear sprocket, engine sprocket, and chain guide. 
Check the chain tension. 
Lubricate all moving partshand levers, chain, ... and check for smooth operation.x 
Change the hydraulic clutch fluid.
Check the fluid level of the hydraulic clutch. 
Change the front brake fluid.
Check the front brake fluid level. 
Check the free travel of the hand brake lever. 
Grease the steering head bearing.
Check play of steering head bearing. 
Change the spring of the exhaust control.
Change the piston.
Change the connecting rod, conrod bearing and crank pin.
Change the crankshaft bearing.
Check the transmission and shift mechanism.
Change all engine bearings.
Change the gear oil. 
Check the gear oil level.
Change the spark plug.
Change the spark plug connector.
Check the cylinder and piston.
Check the intake membrane.
Check the exhaust control for functioning and smooth operation.
Check the clutch.
Check all hoses (e. g. fuel, cooling, bleeding, drainage) and sleeves for tearing, tightness and correct routing.x