KTM 60 SX /65 SX ENGINE REPAIR MANUAL – PDF DOWNLOAD
FILE DETAILS:
KTM 60 SX /65 SX ENGINE REPAIR MANUAL – PDF DOWNLOAD
Language :English
Pages :92
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
KTM 60 SX /65 SX ENGINE REPAIR MANUAL – PDF DOWNLOAD
KTM REPAIR MANUAL IN LOOSE-LEAF FORM
STORING THE REPAIR MANUAL IN THE BINDER
– Put the index into the binder.
– Put the front page of the repair manual (210×297 mm) into the transparent pocket provided for
this purpose on the outside of the binder.
– Put the spine label (170×45 mm) into the transparent pocket provided for this purpose on the
spine of the binder.
– Put the summary list of contents (150×297 mm) into the transparent pocket provided for this
purpose on the inside of the binder or insert this page on the beginning of the manual.
– Then insert the individual chapters of the manual between the sheets of the index according to
the page number printed in the right bottom corner of each page.
Example: page no. 3-5 3 = chapter 3 5 = page 5
All pages with a page number that begins with the digit 3, for example, must be put under the
index heading „Chapter 3“.
– Index sheets that have not been marked with a certain chapter are for your personal convenience. The
respective headings can be entered in the list of contents.
INTRODUCTION
- This repair manual offers extensiv repair-instructions and is an up-to-date version that describes the latest models of the series.
- However, the right to modifications in the interest of technical improvement is reserved without updating the current issue of this manual.
- A description of general working modes common in work shops has not been included. Safety rules common in the work shop have also not been listed.
- We take it for granted that the repairs are made by qualified profesionally trained mechanics. Read through the repair manual before beginning with the repair work
TABLE OF CONTENTS:
KTM 60 SX /65 SX ENGINE REPAIR MANUAL – PDF DOWNLOAD
HOME 0
NOTES AND PREFACE 1
Title page and file spine 1
Important information 7
Updating instructions 7
Explanation update 9
Introduction 11
Reply fax for repair manuals 13
TABLE OF CONTENTS 5
SERVICE-INFORMATIONS 0
GENERAL INFORMATION 15
CARBURETOR ADJUSTMENT 16
BLEEDING OF THE HYDRAULIC CLUTCH 17
SPECIAL TOOLS 18
CLEANING 20
STORAGE 20
REMOVING AND REFITTING ENGINE 21
REMOVING ENGINE 23
REFITTING ENGINE 26
DISASSEMBLING ENGINE 29
CLAMP THE ENGINE INTO THE MOUNTING RACK, REMOVING OF KICKSTARTER AND SHIFT LEVER 31
DRAINING GEAR OIL 31
DISMOUNT OF CYLINDER HEAD, CYLINDER AND PISTON 31
DISMANTLE THE WATER PUMP 32
REMOVE THE CLUTCH COVER 32
DISMANTLE CLUTCH 33
PRIMARY DRIVE 33
REMOVE KICKSTARTER SHAFT 34
REMOVE SHIFT SHAFT AND SHIFTING MECHANISM 34
REMOVE INTAKE FLANGE AND REED VALVE HOUSING 35
REMOVE IGNITION SYSTEM UP TO MODEL 2002 35
REMOVE IGNITION SYSTEM FROM MODEL 2003 36
REMOVING THE ENGINE SPROCKET 37
SEPARATING THE HOUSING HALVES 37
REMOVING THE TRANSMISSION SHAFTS 37
REMOVING THE CRANKSHAFT OF THE ENGINE HOUSING 38
SERVICING INDIVIDUAL COMPONENTS 39
WORKS ON THE LEFT HOUSING HALF 41
WORKS ON THE RIGHT HOUSING HALF 42
MEASURING THE CRANKSHAFT 43
WORKS ON THE CLUTCH COVER 43
DISMANTLING AND CHECKING THE WATER PUMP 44
CHECKING THE PISTON 45
PISTON RING END GAP 45
MEASURING PISTON AND CYLINDER, PISTON FITTING CLEARANCE 45
REED VALVE HOUSING, INTAKE FLANGE 46
DISASSEMBLING THE SHIFTING SHAFT 47
SHIFTING MECHANISM – CHECKING PARTS FOR WEAR 47
PREASSEMBLING THE SHIFTING SHAFT 47
CLUTCH – CHECKING PARTS FOR WEAR 48
PREASSEMBLING THE DISC PACKAGE 48
PREASSEMBLE AND ASSEMBLE THE CLUTCH RELEASE 49
PREASSEMBLING THE KICKSTARTER SHAFT 49
TRANSMISSION – CHECKING PARTS FOR WEAR 50
ASSEMBLING THE MAIN SHAFT 50
ASSEMBLING THE COUNTER SHAFT 50
ASSEMBLING ENGINE 51
INSERTING THE CRANKSHAFT 53
MOUNT TRANSMISSION AND SHIFT MECHANISM 53
ASSEMBLING THE ENGINE HOUSING 54
MOUNT KICKSTARTER SHAFT 54
MOUNT SHIFT MECHANISM AND SHIFT SHAFT 55
ASSEMBLE CLUTCH 55
MOUNT PRIMARY DRIVE 56
MOUNT RATCHET GEAR, PRELOAD THE KICKSTARTER SHAFT 56
MOUNT CLUTCH COVER 56
MOUNT THE ENGINE SPROCKET 57
MOUNT REED VALVE HOUSING AND INKTAKE FLANGE 57
MOUNT PISTON AND CYLINDER 58
ADJUSTING DIMENSION „X“ 58
IGNITION, ADJUSTING THE IGNITION UP TO MODEL 2002 59
IGNITION, ADJUSTING THE IGNITION FROM MODEL 2003 60
MOUNT CYLINDER HEAD 61
MOUNT KICKSTARTER 61
MOUNT IGNITION COVER 61
FILLING GEAR OIL 61
TROUBLE SHOOTING 63
TROUBLE SHOOTING 65
RESISTOR VALUES OF THE IGNITION SYSTEM 67
MEASUREMENT WITH PEAK VOLTAGE ADAPTER 68
TECHNICAL SPECIFICATIONS 69
MODEL 1998/99 – ENGINE 71
MODEL 1998/99 – CHASSIS 72
MODEL 2000 – ENGINE 73
MODEL 2000 – CHASSIS 74
MODEL 2001 – ENGINE 75
MODEL 2001 – CHASSIS 76
MODEL 2002 – ENGINE 77
MODEL 2002 – CHASSIS 78
MODEL 2003 – ENGINE 79
MODEL 2003 – CHASSIS 80
TOLERANCES AND FITTING CLEARANCES 81
TIGHTENING TORQUES – ENGINE 81
TIGHTENING TORQUES – CHASSIS 81
PERIODIC MAINTENANCE SCHEDULE 83
MODEL 1998 85
MODEL 2001 86
MODEL 2002 88
MODEL 2003 90
S.M 13/3/2025
