KTM 60 SX 65 SXC Engine Repair Manual – PDF DOWNLOAD

Description

KTM 60 SX 65 SXC Engine Repair Manual – PDF DOWNLOAD

DESCRIPTION:

KTM 60 SX 65 SXC Engine Repair Manual – PDF DOWNLOAD

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.

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.

TABLE OF CONTENTS:

KTM 60 SX 65 SXC 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

IMAGES PREVIEW OF THE MANUAL:

KTM 60 SX 65 SXC ENGINE REPAIR MANUAL – PDF DOWNLOAD:

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

S.V