KTM 65 SX 2009 Repair Manual
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KTM 65 SX 2009 Repair Manual

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REPAIR MANUAL
2009
65 SX
65 XC
Article no. 3206061en

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Summary of Contents for KTM 65 SX 2009

  • Page 1 REPAIR MANUAL 2009 65 SX 65 XC Article no. 3206061en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors.

  • Page 4: Table Of Contents

    CONTENTS 09/FRONT WHEEL ............30 CONTENTS MEANS OF REPRESENTATION ..........5 Removing the front wheel ..........30 IMPORTANT NOTES ............6 Installing the front wheel..........30 MOTORCYCLE..............7 Checking the tire condition..........31 Jacking up the motorcycle ..........7 Checking tire air pressure ..........31 Removing the motorcycle from the work stand....
  • Page 5 CONTENTS Removing the intermediate kickstarter gear...... 56 Installing the engine sprocket ......... 82 Removing the shift shaft ..........56 Installing the exhaust control valve........82 Removing the shift drum locating........56 Installing the cylinder head ..........82 Removing the locking lever ..........56 Installing the exhaust control..........
  • Page 6 SERVICE SCHEDULE............116 Important maintenance work to be carried out by an authorized KTM workshop..........116 Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)....117 WIRING DIAGRAM ............118 Wiring diagram............118 SUBSTANCES..............120 AUXILIARY SUBSTANCES..........

  • Page 7: Means Of Representation

    MEANS OF REPRESENTATION Symbols used The symbols used are explained 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). Identifies a page reference (more information is provided on the specified page). Formats used The typographical and other formats used are explained below.

  • Page 8: Important Notes

    Warranty The work prescribed in the service schedule must be carried out in an authorized KTM workshop only and confirmed in the customer's service record, since otherwise no warranty claims will be honored. No warranty claims can be honored for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 9: Motorcycle

    MOTORCYCLE Jacking up the motorcycle Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. – Jack up the motorcycle underneath the engine. Work stand (54829055000) ( p.

  • Page 10: 01/Fork, Triple Clamp

    01/FORK, TRIPLE CLAMP Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn adjusting screw clockwise all the way.  Info Adjusting screw is located at the top end of the left fork leg and is ...

  • Page 11: Cleaning The Dust Boots Of The Fork Legs

    01/FORK, TRIPLE CLAMP Cleaning the dust boots of the fork legs – Jack up the motorcycle. ( p. 7) – Push dust boots of both fork legs downwards.  Info The dust boots should remove dust and coarse dirt particles from the fork tubes.

  • Page 12: Removing The Fork Legs

    01/FORK, TRIPLE CLAMP – Position the fork protection on the left fork leg. Mount and tighten screws  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the brake line. Mount clamp  – Mount the screws  700433-01 Removing the fork legs –...

  • Page 13: Adjusting The Fork Overhang

    01/FORK, TRIPLE CLAMP – Tighten screws  Guideline Screw, top triple clamp 25 Nm (18.4 lbf ft) – Tighten screws  Guideline Screw, bottom triple clamp 25 Nm (18.4 lbf ft) 300664-11 – Position brake caliper, mount and tighten screws ...

  • Page 14: Removing The Lower Triple Clamp

    01/FORK, TRIPLE CLAMP Removing the lower triple clamp 4.10 – Remove the fork legs. ( p. 10) – Dismount the start number plate. ( p. 28) – Dismount the front fender. ( p. 28) – Remove fuel tank breather  –...

  • Page 15: Greasing The Steering Head Bearing

    Danger of accidents Unsafe riding behavior due to incorrect steering head bearing play. – The steering head bearing play should be adjusted immediately in an authorized KTM workshop. Info If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time.
  • Page 16 01/FORK, TRIPLE CLAMP – Fully tighten screw  Guideline Screw, top triple clamp 25 Nm (18.4 lbf ft) – Check play of steering head bearing. ( p. 13)

  • Page 17: 02/Handlebar, Controls And Instruments

    02/HANDLEBAR, CONTROLS AND INSTRUMENTS Adjusting basic position of clutch lever – Adjust the basic setting of the clutch lever to the size of your child's hand by turn- ing the adjusting screw  Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.

  • Page 18: Adjusting Handlebar Position

    02/HANDLEBAR, CONTROLS AND INSTRUMENTS Adjusting handlebar position – Remove the four screws . Remove the handlebar clamp. Remove the handlebar  0 0 1 and lay it to one side. 0 0 2 Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines.

  • Page 19: 04/Shock Absorber, Swingarm

    04/SHOCK ABSORBER, SWINGARM Adjusting the compression damping of the shock absorber Danger Danger of accidents The shock absorber is under high pressure. – The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main- tenance on it yourself.

  • Page 20: Checking The Static Sag Of The Shock Absorber

    04/SHOCK ABSORBER, SWINGARM Checking the static sag of the shock absorber – Measure distance of rear wheel unloaded. ( p. 17)  – Ask someone to help you by holding the motorcycle upright. – Measure the distance between the rear axle and the fixed point again. 0 0 A –...

  • Page 21: Adjusting The Riding Sag

    04/SHOCK ABSORBER, SWINGARM – Measure the full spring length while it is under tension and note down the value. – Loosen lock ring  – Turn adjusting ring until the spring is no longer under tension.  Combination wrench (50329080000) Hook wrench (T106S) ( p.

  • Page 22: Installing Shock Absorber

    04/SHOCK ABSORBER, SWINGARM Installing shock absorber – Push splash protector to the side and position the shock absorber. Mount and  tighten screw  Guideline Screw, top shock absorber 45 Nm (33.2 lbf ft) – Mount and tighten screw  Guideline Screw, bottom shock absorber 45 Nm...

  • Page 23: 05/Exhaust

    05/EXHAUST Removing the exhaust manifold Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. – Remove springs  Spring hooks (50305017000) ( p.

  • Page 24: Removing Main Silencer

    05/EXHAUST – Mount and tighten screw  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 300630-10 – Position the exhaust control hose. – Position and tighten hose clamp  300635-10 – Mount and tighten screws  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 300631-10 Removing main silencer...

  • Page 25: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    05/EXHAUST – Mount and tighten screw  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 700442-10 Changing the glass fiber yarn filling of the main silencer – Remove the glass fiber yarn filling of the main silencer. ( p. 23) –...

  • Page 26: 06/Air Filter

    06/AIR FILTER Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 27: 07/Fuel Tank, Seat, Trim

    07/FUEL TANK, SEAT, TRIM Removing the seat – Open quick release and raise the rear of the seat.  – Pull back the seat and remove it. 300633-10 Mounting the seat – Hook the seat onto screw and lower the seat at the rear while pushing it forward. ...

  • Page 28: Installing The Fuel Tank

    07/FUEL TANK, SEAT, TRIM – Remove screws  300627-10 – Pull off fuel hose  Info Remaining fuel may run out of the fuel hose. – Pull both spoilers off of the side of the radiator bracket and lift off the fuel tank. 300628-10 Installing the fuel tank Danger...
  • Page 29 07/FUEL TANK, SEAT, TRIM – Mount and tighten screw  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the fuel tank breather. – Mount the seat. ( p. 25) 300626-11...

  • Page 30: 08/Mask, Fender

    08/MASK, FENDER Dismounting the front fender 10.1 – Remove screws . Remove the front fender.  700414-10 Installing the front fender 10.2 – Position the fender with holding lugs into the drill holes on the start number  plate. 700415-01 –...
  • Page 31 08/MASK, FENDER – Mount and tighten screw  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the brake line. Put the clamp on, mount and tighten screw  700411-10...

  • Page 32: 09/Front Wheel

    09/FRONT WHEEL Removing the front wheel 11.1 – Jack up the motorcycle. ( p. 7) – Remove screw  700436-01 – Loosen screw  – Hold the front wheel and pull out wheel spindle . Take the front wheel out of the ...

  • Page 33: Checking The Tire Condition

    Warning Danger of accidents Reduced braking due to worn brake discs. – Worn brake discs should be replaced immediately in an authorized KTM workshop. – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement ...

  • Page 34: Checking Spoke Tension

    Danger of accidents Unstable riding behavior due to loose spokes. – If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop. Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.

  • Page 35: 10/Rear Wheel

    10/REAR WHEEL Removing the rear wheel 12.1 – Jack up the motorcycle. ( p. 7) – Remove nut  – Remove washer and chain adjuster   700439-01 – Withdraw the wheel spindle only enough to allow the rear wheel to be pushed ...

  • Page 36: Checking Chain Dirt

    10/REAR WHEEL Checking chain dirt 12.3 – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 34) 800012-10 Cleaning the chain 12.4 Warning Danger of accidents Oil or grease on the tires reduces their grip. –...

  • Page 37: Checking The Chain Tension - Installing Rear Wheel

    10/REAR WHEEL Checking the chain tension - installing rear wheel 12.6 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel) are under additional load.

  • Page 38: Adjusting Chain Tension - After Checking

    10/REAR WHEEL – Loosen nut  – Loosen nuts  – Adjust the chain tension by turning the adjusting screws to the left and right.  Guideline Chain tension 5… 8 mm (0.2… 0.31 in) Turn adjusting screws equally on the left and right. Check that the rear wheel ...

  • Page 39: 13/Brake System

    If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –...

  • Page 40: Adding Front Brake Fluid

    If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –...

  • Page 41: Checking The Front Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

  • Page 42: Changing The Front Brake Linings

    If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –...

  • Page 43: Checking The Free Travel Of The Foot Brake Lever

    13/BRAKE SYSTEM Checking the free travel of the foot brake lever 13.9 Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can fail due to overheating.

  • Page 44: Checking Rear Brake Fluid Level

    Have the brake system checked in an authorized KTM workshop, and do not ride any further. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. – Stand the vehicle upright. –...

  • Page 45: Checking Rear Brake Linings

    700424-01 Removing rear brake linings 13.15 Warning Danger of accidents Improper brake maintenance and repair. – Always have your brake system maintained and repaired in an authorized KTM workshop. – Remove the rear wheel. ( p. 33) – Remove lock washer ...

  • Page 46: Installing The Rear Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
  • Page 47 13/BRAKE SYSTEM – Stand the vehicle upright. – Remove screws  – Remove cover with the O-ring and diaphragm   – Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir. –...

  • Page 48: 30/Engine

    30/ENGINE Removing the engine 14.1 – Jack up the motorcycle. ( p. 7) – Dismount the fuel tank. ( p. 25) – Drain the coolant. ( p. 96) – Remove the exhaust manifold. ( p. 21) – Loosen the hose clamps. Detach the radiator hoses. 300636-10 –...

  • Page 49: Installing The Engine

    30/ENGINE – Remove screws  – Remove screw  – Take off the engine sprocket cover. 300641-10 – Remove screw  – Take off the shift lever. – Remove connecting link of the chain.  – Remove the chain. 300642-10 –...
  • Page 50 30/ENGINE – Mount the screws with nuts , but do not tighten them yet.  300643-11 – Mount and tighten nut  Guideline Nut, swingarm pivot M12x1 40 Nm (29.5 lbf ft) – Tighten nuts  Guideline Screw, engine bracket 30 Nm (22.1 lbf ft) 300644-11...
  • Page 51 30/ENGINE – Mount the chain. – Connect the chain with connecting link  – Position the shift lever. – Mount and tighten screw with the washers.  Guideline Screw, shift lever 14 Nm Loctite ® 243™ (10.3 lbf ft) 300642-11 –...

  • Page 52: 30/Disassembling The Engine

    30/DISASSEMBLING THE ENGINE Clamping the engine into the engine work stand 15.1 – Mount special tool on engine work stand   Engine work stand (61229001000) ( p. 128) Holder of engine work stand (46229001070) ( p. 124) – Mount the engine. Screw connection for engine work stand (46229001060) ( p.

  • Page 53: Removing The Cylinder Head

    30/DISASSEMBLING THE ENGINE – Remove nut  Info If the shaft of the exhaust control turns, raise the diaphragm and hold the shaft in place. – Remove the diaphragm. 300749-10 – Remove screws  – Remove the reed valve housing of the exhaust control. 300750-10 –...

  • Page 54: Removing The Exhaust Control Valve

    30/DISASSEMBLING THE ENGINE Removing the exhaust control valve 15.7 – Remove exhaust control valve  300828-10 Removing the cylinder 15.8 – Remove nuts on both sides.  Info Be careful not to misplace the clutch line holder. – Carefully slide the cylinder up and take it off. –...

  • Page 55: Removing The Distance Bushing

    30/DISASSEMBLING THE ENGINE Removing the distance bushing 15.11 – Remove distance bushing of the countershaft.  300762-10 – Remove O-ring  300763-10 Removing the generator cover 15.12 – Remove screws . Remove the generator cover.  – Remove the gasket. 300764-10 Removing the rotor 15.13...

  • Page 56: Removing The Stator

    30/DISASSEMBLING THE ENGINE Removing the stator 15.14 – Remove cable support sleeve out of the engine case.  – Remove screw  – Take out the stator. 300769-10 Removing the kickstarter 15.15 – Remove screw with the washer.  – Take off the kickstarter.

  • Page 57: Removing The Primary Gear

    30/DISASSEMBLING THE ENGINE – Remove washer  300776-10 – Hold the outer clutch hub in place with special tool  Gear segment (46229081000) ( p. 125) – Loosen nut of the primary gear and remove it with the washer.  300777-10 –...

  • Page 58: Removing The Kickstarter Shaft

    30/DISASSEMBLING THE ENGINE Removing the kickstarter shaft 15.20 – Detach kickstarter spring  – Remove kickstarter shaft  Info Turn the kickstarter shaft slightly to the left. – Remove washer  300785-10 Removing the intermediate kickstarter gear 15.21 – Remove lock ring ...

  • Page 59: Removing The Reed Valve Housing

    30/DISASSEMBLING THE ENGINE Removing the reed valve housing 15.25 – Remove screws  – Take off the intake flange. 300790-10 – Remove reed valve housing  – Remove the gasket. 300791-11 Removing the left engine case section 15.26 – Remove screws ...

  • Page 60: Removing The Shift Rails

    30/DISASSEMBLING THE ENGINE – Remove engine case gasket  300794-10 Removing the shift rails 15.27 – Remove shift rails with the springs.  300795-10 Removing the shift drum 15.28 – Swing shift forks to one side.  Info Make sure not to misplace the shift rollers. –...

  • Page 61: Removing The Crankshaft

    30/DISASSEMBLING THE ENGINE Removing the crankshaft 15.31 – Warm up the crankshaft bearing. Guideline 60 °C (140 °F) – Remove crankshaft  300800-10 – Remove O-ring  300801-10...

  • Page 62: 30/Engine - Work On Individual Parts

    30/ENGINE - WORK ON INDIVIDUAL PARTS Work on the right section of the engine case 16.1 – Pull the dowels out of the engine case. – Remove crankshaft seal ring  – Remove bearing retainer  – Remove bearing retainer ...

  • Page 63: Work On The Left Section Of The Engine Case

    30/ENGINE - WORK ON INDIVIDUAL PARTS Work on the left section of the engine case 16.2 – Pull the dowels out of the engine case. – Remove crankshaft seal ring  – Remove shaft seal ring of the countershaft.  –...

  • Page 64: Checking The Crankshaft Run-Out On The Bearing Pin

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Mount stop disks , bearing and connecting rod   Info Oil the bearing thoroughly. 300834-10 – Position special tool on the press.  Pressing device, crankshaft, complete (50329047000) ( p. 126) Anchor plate (46229047002) ( p.

  • Page 65: Removing The Water Pump

    30/ENGINE - WORK ON INDIVIDUAL PARTS Removing the water pump 16.5 – Remove water pump drive gear  300809-10 – Hold shaft in place and remove screw   – Take off the water pump impeller. Info If the water pump impeller cannot be removed, the water pump shaft can be pressed out toward the inside.

  • Page 66: Checking/Measuring The Cylinder

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Mount drive gear  300809-11 Checking/measuring the cylinder 16.7 – Check the cylinder bearing surface for damage. » If the cylinder bearing surface is damaged: – Change the cylinder and piston. – Measure the cylinder diameter at several locations on the axes using a ...

  • Page 67: Determining The Piston/Cylinder Mounting Clearance

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Measure the piston at a distance from the piston head, at right angles to the pis-  ton pin. Guideline Distance 32.0 mm (1.26 in) 0 0 A  Piston - diameter Size 1 44.955…...

  • Page 68: Disassembling The Clutch

    30/ENGINE - WORK ON INDIVIDUAL PARTS Disassembling the clutch 16.12 – Remove screws  – Take off the spring retainer. 300812-10 – Remove the springs. – Take off inner clutch hub  300813-10 – Take off clutch discs from the clutch pressure cap. ...

  • Page 69: Premounting The Clutch

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Check the thickness of clutch facing discs  Clutch facing disc - thickness 2.6… 2.7 mm (0.102… 0.106 in) » If the clutch facing disc does not meet specifications: – Change all clutch facing discs. –...

  • Page 70: Checking The Shift Mechanism

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the shift mechanism 16.15 – Check shift forks on leaf for damage and wear (visual inspection).   » If there is damage or wear: 0 0 7 – Change the shift fork and the idler/fixed gear pair. –...

  • Page 71: Preassembling The Shift Shaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS Preassembling the shift shaft 16.16 – Fix the short end of the shift shaft in a vise. 0 0 5 0 0 2 Guideline Use soft jaws. 0 0 6 – Mount preload spring ...

  • Page 72: Dismantling The Countershaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Finally, check all gear wheels for smooth operation. Dismantling the countershaft 16.19 0 0 1 0 0 2 0 0 4 0 0 6 0 0 b l 0 0 8 0 0 b k 0 0 3 0 0 5 0 0 7...

  • Page 73: Checking The Transmission

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the transmission 16.21 – Disassemble the main shaft. ( p. 69) – Dismantle the countershaft. ( p. 70) 300802-01 – Check needle bearing for damage and wear.  » If there is damage or wear: –...

  • Page 74: Premounting The Kickstarter Shaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS Premounting the kickstarter shaft 16.22 – Mount kickstarter ratchet wheel  Marking is offset from hole by 180°.   300856-10 – Mount washer  300857-10 – Mount starter wheel  300858-10 – Mount washer and lock ring ...

  • Page 75: 30/Assembling The Engine

    30/ASSEMBLING THE ENGINE Installing the crankshaft 17.1 – Position the right section of the engine case in the engine work stand. Engine work stand (61229001000) ( p. 128) Holder of engine work stand (46229001070) ( p. 124) – Warm up the crankshaft bearing. Guideline 60 °C (140 °F) –...

  • Page 76: Installing The Shift Rails

    30/ASSEMBLING THE ENGINE Installing the shift rails 17.5 – Install shift rails together with the upper and lower springs.  Fix the springs in the shift rails with grease. 300795-10 Installing the left engine case section 17.6 – Mount engine case gasket ...

  • Page 77: Installing The Locking Lever

    30/ASSEMBLING THE ENGINE – Position the intake flange. – Mount and tighten screws  Guideline Screw, intake flange/reed valve housing 10 Nm (7.4 lbf ft) 300790-11 Installing the locking lever 17.8 – Position locking lever with sleeve and spring  ...

  • Page 78: Installing The Intermediate Kickstarter Gear

    30/ASSEMBLING THE ENGINE Installing the intermediate kickstarter gear 17.11 – Position intermediate kickstart gear with the washer.  – Mount lock ring  – Position the retaining bracket. – Mount and tighten screw  Guideline Loctite ® 243™ Screw, retaining bracket 6 Nm for return spring of shift (4.4 lbf ft)

  • Page 79: Installing The Clutch Cover

    30/ASSEMBLING THE ENGINE – Mount the outer clutch hub. 300778-10 – Hold the outer clutch hub in place with special tool  Gear segment (46229081000) ( p. 125) – Mount and tighten the washer and nut of the primary gear. ...

  • Page 80: Mounting The Water Pump Cover

    30/ASSEMBLING THE ENGINE – Position the clutch cover. Mount and tighten screws  Guideline Screw, clutch intermediate cover 10 Nm (7.4 lbf ft) Info Do not forget the spring hanger. 300772-11 Mounting the water pump cover 17.16 – Mount the gasket and dowels. –...

  • Page 81: Installing The Piston

    30/ASSEMBLING THE ENGINE – Hold the rotor in place with the special tool. Holding spanner (54629012100) ( p. 127) – Mount the washer and nut . Tighten nut.  Guideline Nut, rotor M10x1.25 50 Nm (36.9 lbf ft) 300766-11 Installing the piston 17.20 –...

  • Page 82: Checking The X-Distance

    30/ASSEMBLING THE ENGINE – Mount nuts on both sides and tighten in a crisscross pattern.  Guideline Nuts, cylinder base 20 Nm (14.8 lbf ft) Info Be careful not to forget the clutch line holder. 300825-10 Checking the X-distance 17.22 Info The X-distance is the distance defined for the piston protrusion, when the cylinder is clamped down and the piston is at top dead center.

  • Page 83: Adjusting The Ignition

    30/ASSEMBLING THE ENGINE Adjusting the ignition 17.24 – Position the piston at bottom dead center. – Apply special tool to the cylinder.  Adjustment gauge (46129006100) ( p. 124) Info Apply the special tool with label ignition onto the cylinder. –...

  • Page 84: Installing The Distance Bushing

    30/ASSEMBLING THE ENGINE Installing the distance bushing 17.26 – Lubricate the shaft seal ring prior to installation. Long-life grease ( p. 122) – Mount O-ring  300763-11 – Mount distance bushing with the chamfer facing inward.  300762-11 Installing the engine sprocket 17.27 –...

  • Page 85: Installing The Exhaust Control

    30/ASSEMBLING THE ENGINE – Mount the cylinder head. Mount screws with the washers and tighten in a criss-  cross pattern. Guideline Screw, cylinder head 18 Nm (13.3 lbf ft) Info Always use new screws and washers. 300753-10 Installing the exhaust control 17.30 –...

  • Page 86: Installing The Spark Plug

    30/ASSEMBLING THE ENGINE Installing the spark plug 17.31 – Mount and tighten spark plug  Guideline Spark plug M10x1 10… 12 Nm (7.4… 8.9 lbf ft) Spark plug wrench (60029073000) ( p. 128) 300747-10 Installing the oil drain plug 17.32 –...

  • Page 87: 31/Carburetor

    31/CARBURETOR Removing the carburetor 18.1 – Dismount the fuel tank. ( p. 25) – Remove the main silencer. ( p. 22) – Unscrew hose clip  300862-10 – Loosen screw  300863-10 – Remove screw  – Swing up the tail piece. Info Pay attention to the carburetor connection boot.

  • Page 88: Installing The Carburetor

    31/CARBURETOR – Pull back the throttle slide spring and plastic lock  300867-10 – Detach throttle cable  – Remove the throttle slide. 300868-10 Installing the carburetor 18.2 – Attach throttle cable  300868-11 – Position plastic lock  – Position the throttle slide spring.

  • Page 89: Disassembling The Carburetor

    31/CARBURETOR – Position the tail piece. – Position the carburetor connection boot. – Mount and tighten screws  Guideline Screw, tail piece 35 Nm Loctite ® 243™ (25.8 lbf ft) 300864-11 – Tighten screws  Guideline Screw, tail piece 35 Nm Loctite ®...
  • Page 90 31/CARBURETOR – Remove main jet with the washer.  300872-10 – Press needle jet out of the carburetor in the direction of the venturi tube.  300873-10 – Remove screw  – Remove the valve seat of the float needle valve with the lock washer. 300874-10 –...

  • Page 91: Assembling The Carburetor

    31/CARBURETOR – Remove idle speed adjusting screw with the spring and O-ring.  300944-10 – Remove screws  – Remove the jet needle with the spring retainer. 300878-10 Assembling the carburetor 18.4 – Position the choke slide with the choke lever. –...
  • Page 92 31/CARBURETOR – Position the seat of the float needle valve with the lock washer. – Mount and tighten screw  Guideline Other screws, carburetor 2 Nm (1.5 lbf ft) 300874-11 – Position needle jet in the carburetor.  The pin engages in the recess. 300873-11 –...

  • Page 93: Checking/Setting The Carburetor Components

    31/CARBURETOR – Position the jet needle with the spring retainer in the throttle slide. – Mount and tighten screws  – Install the carburetor. ( p. 86) 300878-10 Checking/setting the carburetor components 18.5 300881-01 – Disassemble the carburetor. ( p. 87) –...

  • Page 94: Checking The Throttle Slide

    31/CARBURETOR Checking the throttle slide 18.7 Condition The throttle slide has been removed. – Check the throttle slide for damage and wear. » If the throttle slide is damaged or worn: – Change the throttle slide. 300879-10 Checking the float needle valve 18.8 Condition The float needle valve is removed.

  • Page 95: Carburetor - Adjusting The Idle Speed

    31/CARBURETOR Carburetor - adjusting the idle speed 18.11 – Screw in idle air adjusting screw all the way and turn it to the specified basic  position. Guideline Idle air adjusting screw Open 3.5 turns – Run the engine until warm. Guideline ≥...
  • Page 96 31/CARBURETOR Info Carry out this work with a cold engine. – Turn the knurled screw on the fuel tap all the way clockwise. No more fuel flows from the tank to the carburetor. – Place a cloth beneath the opening to soak up emerging fuel. Info Water in the float chamber results in malfunctioning.

  • Page 97: 32/Clutch

    32/CLUTCH Checking the fluid level of hydraulic clutch 19.1 Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...

  • Page 98: 35/Water Pump, Cooling System

    35/WATER PUMP, COOLING SYSTEM Draining the coolant 20.1 Warning Scalding hazard During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other components of the cooling system when the engine is hot. Allow the engine and radiator to cool down.

  • Page 99: Checking The Coolant Level

    35/WATER PUMP, COOLING SYSTEM Warning Danger of poisoning Coolants are poisonous and a health hazard. – Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately.
  • Page 100 35/WATER PUMP, COOLING SYSTEM – Mount the radiator cap.

  • Page 101: 38/Lubrication System

    38/LUBRICATION SYSTEM Checking gear oil level 21.1 Info The gear oil level must be checked when the engine is cold. – Stand the motorcycle upright on a horizontal surface. – Remove gear oil level check screw . Stand the vehicle upright. ...

  • Page 102: Adding Gear Oil

    38/LUBRICATION SYSTEM – Remove the screw cap and fill up with gear oil.  Gear oil 0.50 l (0.53 qt.) Engine oil (15W/50) ( p. 120) – Mount and tighten screw cap  Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon- sciousness and/or death.

  • Page 103: 39/Ignition System

    39/IGNITION SYSTEM Checking the ignition system 22.1 Warning Risk of injury The ignition system is under high voltage. – To avoid the danger of an electric shock, do not touch metal parts and the ends of the connection cable during and imme- diately after measuring.

  • Page 104: Checking The Ignition Pulse Generator

    39/IGNITION SYSTEM – Activate the short circuit button. On the cable harness side of plug FD, measure pin 8 against ground. 0 Ω Resistance - short circuit button con- firmed » If the displayed value does not equal the specification: –...

  • Page 105: Checking The Spark Plug Connector

    39/IGNITION SYSTEM – On the cable harness side of plug FD, measure pin 7 against ground. ∞ Resistance » If the measured value does not equal the specified value: – Check the wiring harness. – Change the generator. – On the cable harness side of plug FD, measure pin 9 against ground. ∞...
  • Page 106 39/IGNITION SYSTEM – On the component side, measure the connection of the ignition coil against the high voltage output. Ignition coil Resistance of secondary winding 5… 7.5 kΩ at: 20 °C (68 °F) » If the measured value does not equal the specified value: –...

  • Page 107: Troubleshooting

    TROUBLESHOOTING Faults Possible cause Action – Engine turns but does not start Operating error Go through the steps of starting the engine. p. 7) – Motorcycle was out of use for a long Empty the carburetor float chamber. ( p. 93) time and there is old fuel in the float chamber –...
  • Page 108 TROUBLESHOOTING Faults Possible cause Action – Engine stalls or is popping into the Engine takes in bad air Check the intake flange and carburetor for carburetor tightness. – Socket connector or ignition coil is Clean the socket connector and treat it with loose or oxidized contact spray.

  • Page 109: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 64.85 cm³ (3.9574 cu in) Stroke 40.8 mm (1.606 in) Bore 45 mm (1.77 in) Control Exhaust control PCEV Crankshaft bearing 2 grooved ball bearings Conrod bearing Needle bearing Piston pin bearing...

  • Page 110: Technical Data - Tolerance, Wear Limits Of Engine

    TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE X-distance (distance from adjusting gauge to piston) 0… 0.10 mm (0… 0.0039 in) Piston - diameter Size 1 44.955… 44.965 mm (1.76988… 1.77027 in) Size 2 44.965… 44.975 mm (1.77027… 1.77067 in) Cylinder - bore diameter Size A 45.025…...

  • Page 111: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Bearing retainer, main shafts Loctite 648™ – Nut, exhaust control diaphragm 3 Nm (2.2 lbf ft) ® Screw, clutch line holder 5 Nm (3.7 lbf ft) Loctite 243™ – Screw, diaphragm cover of exhaust 4 Nm (3 lbf ft) control ®...

  • Page 112: Technical Data - Carburetor

    TECHNICAL DATA - CARBURETOR Carburetor type MIKUNI TM 24 Needle position 2nd position from top Idle air adjusting screw Open 3.5 turns Main jet Jet needle 51 PL 43-2 Idling jet Needle jet Q-O (454) Throttle slide...

  • Page 113: Technical Data - Chassis

    80/100 - 12 50M TT Pirelli SCORPION MX Mid Soft 32 NHS Pirelli SCORPION MX Mid Soft 32 NHS Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 28.2 Fuel tank capacity, approx. 3.5 l (3.7 qt.) Super unleaded gasoline, mixed with 2-stroke engine oil p.

  • Page 114: Technical Data - Fork

    TECHNICAL DATA - FORK 29.1 Fork part number 46201000033 Fork Marzocchi Upside down Compression damping Standard 10 clicks Rebound damping Standard 10 clicks Spring rate Weight of rider: 35… 45 kg (77… 99 lb.) 3.4 N/mm (19.4 lb/in) Air chamber length 100±2.5 mm (3.94±0.098 in) Fork length 735 mm (28.94 in)

  • Page 115: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER 30.1 Shock absorber part number 03.18.7E.03 Shock absorber WP Suspension 3614 BAVP Compression damping Comfort 10 clicks Standard 9 clicks Sport 3 clicks Rebound damping Comfort 10 clicks Standard 9 clicks Sport 6 clicks Spring preload Comfort 7 mm (0.28 in) Standard...

  • Page 116: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Spoke nipple M3.5 3 Nm (2.2 lbf ft) – Remaining nuts, chassis 15 Nm (11.1 lbf ft) – Remaining screws, chassis 10 Nm (7.4 lbf ft) – Screw, ball joint, push rod on foot- 10 Nm (7.4 lbf ft) brake cylinder ®...

  • Page 117: Cleaning/Conservation

    CLEANING/CONSERVATION Cleaning motorcycle 32.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, plug connectors, Bowden cables and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 118: Service Schedule

    SERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop. 33.1 S20A S40A Engine Change the gear oil. ( p. 99) • Check spark plug and replace if required. • • Clean spark plug connectors and check for tightness.

  • Page 119: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop. (As Additional Order)

    SERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) 33.2 S20A S40A Check/set the carburetor components. ( p. 91) • Check intake membrane for wear. • • Check wear of the clutch lining disc.

  • Page 120: Wiring Diagram

    WIRING DIAGRAM Wiring diagram 34.1 300807-01...
  • Page 121 WIRING DIAGRAM Components CDI controller Generator Ignition coil Short circuit button Cable colors Brown White-blue White-blue Blue Blue-yellow White-red...

  • Page 122: Substances

    – Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 123 SUBSTANCES Shock absorber oil (SAE 2.5) (50180342S1) According to – SAE ( p. 129) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Super unleaded gasoline, mixed with 2-stroke engine oil According to –...

  • Page 124: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Carburetor cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Carburetor Chain cleaner Specification – ®...
  • Page 125 AUXILIARY SUBSTANCES Offroad chain spray Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Lube 622 Oil for foam air filter Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Liquid Bio Power...

  • Page 126: Special Tools

    SPECIAL TOOLS Extractor Art. no.: 45229048000 300937-10 Adjustment gauge Art. no.: 46129006100 300889-10 Screw connection for engine work stand Art. no.: 46229001060 400576-01 Holder of engine work stand Art. no.: 46229001070 300673-01 Crankshaft pressing device Art. no.: 46229008000 Feature Special tool consists of 46229008001 and 46229008002. 300850-10...
  • Page 127 SPECIAL TOOLS Bushing, crankshaft pressing device Art. no.: 46229008001 300941-10 Cover, crankshaft pressing device Art. no.: 46229008002 300942-10 Anchor plate Art. no.: 46229047002 300939-10 Press plate Art. no.: 46229047050 300849-10 Gear segment Art. no.: 46229081000 300670-01...
  • Page 128 SPECIAL TOOLS Protective cap Art. no.: 46229090000 300936-10 Clutch holder Art. no.: 49012003000 300887-10 Spring hooks Art. no.: 50305017000 400363-01 Pressing device, crankshaft, complete Art. no.: 50329047000 300940-10 Bleed syringe Art. no.: 50329050000 400058-01...
  • Page 129 SPECIAL TOOLS Extractor Art. no.: 54629009044 400036-01 Holding spanner Art. no.: 54629012100 300676-01 Work stand Art. no.: 54829055000 500071-01 Peak voltage adapter Art. no.: 58429042000 400083-01 Feeler gauge Art. no.: 59029041100 400110-01...
  • Page 130 SPECIAL TOOLS Spark plug wrench Art. no.: 60029073000 300888-10 Engine work stand Art. no.: 61229001000 200306-01 Hook wrench Art. no.: T106S 300576-10...

  • Page 131: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation.

  • Page 132: Index

    INDEX rear brake, installing ......44 INDEX rear brake, removing ......43 Air filter cleaning .
  • Page 133 INDEX primary gear, removing ..... . . 55 Fork protector reed valve housing, removing ....57 installing .
  • Page 134 INDEX Tire air pressure checking ....... . . 31 Play in gas Bowden cable Tire condition adjusting .
  • Page 135 *3206061en* 3206061en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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