REPAIR MANUAL 2014 65 SX Art. no. 3206165enINTRODUCTION ' Read this repair manual carefully and thoroughly before beginning work The vehicle will only be able to meet the demands placed on it ifthe specified service work is performed regularly and properly This repair manual was written to correspond to the latest state of this model series. We reserve the right to make changes in the interest of technical advancement without updating this repair manual at the same time. We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here. It is assumed that the repair work will be performed by a fully trained mechanic. Al 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. © 2015 KTM Sportmotorcycle GmbH, Mattighoten 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, TOV the maximum possible quality of the products. 3206165en o72015TABLE OF CONTENTS 1 MEANS OF REPRESENTATION Ll 12 2 SAFETY ADVICE. 241 2.2 23 24 25 26 27 3. IMPORTANT NOTES. sen 31 4 SERIAL NUMBERS... aa 42 43 5 MOTORCYCLE .. 61 5.2 53 6 FORK, 61 62 63 64 65 66 67 68 63 6.10 611 6.12 6.13 14 6.18 6.16 617 6.18 6.19 6.20 7 HANDLEBAR, CONTROLS. 7a 72 73 74 75 78 8 SHOCK ABSORBER, SWINGARM 81 82 83 a4 85 86 87 Symbols used Formats used. Guarantee, warranty Operating and auxiliary substances. Spare parts, accessories. Work rules Satety advice. Degrees of risk and symbols. Repair Manual Figures . Chassis number Engine number Shock absorber part number Raising the motorcycle witha lift stand. Remaving the motorcycle from the lift stand Starting. TRIPLE CLAMP ‘Adjusting the compression damping of the for oo sone 12 Adjusting the rebound damping ofthe fork... 12 Bleeding fork legs 12 Cleaning the dust boots of the fork legs. 13 Remaving the fork protector. Installing the fork protector... Removing the fork legs Installing the fork legs. Servicing the fork . Disassembling the fork legs. Disassembling the piston rod .. Checking the fork legs. Changing the pilot bushing... ‘Assembling the piston rod, Assembling the fork legs... sci Greasing the steering head bearing... on 28 Removing the lover triple clamp. 25 Installing the lower tripe clamp Checking play of steering head bearing Acsting he pay ofthe steering head bearing. ‘Adjusting basic position of clutch lever. Checking the play in the throttle cable Checking the routing of the throttle cable... 29 ‘Adjusting the play in the throttle cable... Handlebar position ‘Adjusting handlebar position Adjusting the compression damping of the ‘shock absorber 32 ‘Adjusting the rebound damping of the shock absorber, sovnee 32 Measuring rear wheel sag unloaded. . 32 Checking the static sag of the shock absorber... 33 Checking the riding sag of the shock absorber... 33 ‘jing te ing prod oft shock AbSODET ree Adjusting the viding se. 10 ul 12 13 4 BB Removing the shock absorber. 8.9 Installing shock absorber 8.10 Servicing the shock absorber. 8.11 Removing the spring... 8.12 Disassembling the damper... 8.13 Disassembling the piston rod 8.14 Checking the damper B.15 Removing the heim joint. 8.16 Installing the heim joint. 8.17 Assembling the piston rod... 8.18 Assembling the damper. 8.19 Bleeding and filling the damper 8.20 Filling the damper with nitrogen 8.21 Installing the spring 8.22 Removing the chain guard 8.23 _ Installing the chain guard EXHAUST. 9.1 Removing the exhaust manifold 9.2 Installing the exhaust manifold 9.3 Removing main silencer. 9.4 Installing the main silencer... 8.5 Changing the glass fiber yarn filing of the main silencer. AIR FILTER. 10.1. Removing the air iter. 10.2 Installing the air filter 10.3 Cleaning te ar filter and air filter box. FUEL TANK, SEAT, TRIM. 11.1 Removing the seat 11.2 Mounting the seat... 11.3 Dismounting the fuel tank... 11.4 _ Installing the fuel tank MASK, FENDER 12.1 _Dismounting the front fender 12.2 _ Installing the front fender 12.3. Dismounting the star number plate 12.4 Installing the start number plate. WHEELS 13.1 Checking tire air pressure. 13.2. Checking the tire condition 13.3 Checking brake discs. 13.4 Checking spoke tension. 13.5 Front whee! 13.5.1 Removing the front wheel. 13.5.2 Installing the front wheel. 13.6 Rear wheel.. 13.6.1 Removing the tear whee! 13.6.2 Installing the rear wheel 13.6.3 Checking chain dit... 13.6.4 Cleaning the chain 13.6.5 Checking the chain tension... 13.6.6 Checking the chain, rear sprocket, engine sprocket, and chain guide. 13.6.7 Adjusting the chain tension 13.6.8 Adjusting the chain guide. BRAKE SYSTEM 14.1 Checking free travel of hand brake lever 14.2. Adjusting the basic position ofthe hand brake lever : Checking front brake fluid level ‘Adding front brake fluid. Changing the front brake fluid... 143 144 145 35 35 35 36 36 37 38 39 40 al 42. 43 47 a7 a7 48 43 49 49 50 51 51 51 51 53 53 53 53 . 54 56 56 56 56 58 58 58. 58. 59 59 59 60 . 60 . 60 61 62 62 62 63 65 65 66 66 66 66 67 68.TABLE OF CONTENTS 146 147 148 149 14.10 ‘Checking the front brake linings. Remaving front brake linings. Installing the front brake linings Changing the front brake linings.. ’ heckng the free travel ofthe fot bake Adjusting the free travel ofthe foot brake lever... 141 14.12 lever... Checking rear brake fui level. ‘Adding rear brake fluid .. Changing the rear brake fluid. Checking the rear brake linings Removing rear brake linings 14.18 Installing the rear brake linings 14.19. Changing the rear brake linings. 15. ENGINE 15.1 Removing the engine. 15.2 Installing the engine... 15.3 Engine disassembly... 15.3.1 Clamping the engine into the engine ‘work stand Removing the clutch pressure piece. Removing the oil drain plug... Removing the spark plug Removing the exhaust control Removing the cylinder head. Removing the exhaust control valve Removing the cylinder. Removing the piston .. Removing the engine sprocket. Removing the spacer. Removing the alternator cover Removing the rotor. Removing the stator Removing the kickstarter... Removing the water pump cover: Removing the clutch cover... Removing the outer clutch hub Removing the primary gear... Removing the kickstarter shaft. Removing the intermediate kickstarter gear Removing the shift shatt. Removing the shift drum locating Removing the locking lever... Removing the reed valve housing Removing the left engine case section Removing the shift rail. Removing the shift drum Removing the shift fork... 1.3.30 Removing the transmission shaft 15.3.31 Removing the crankshaft... 15.4 work on individual parts. 14.13 1414 14.15 14.16 14.17 16.3.2 15.3.3 15.3.4 15.3.5 15.3.6 15.37 15.38 15.3.9 153.10 153.11 153.12 153.13 15.314 153.15 153.16 153.17 153.18 153.19 15.3.20 153.21 163.22 153.23 153.24 153.25 153.26 153.27 153.28 153.29 15.4.1 Work on the right section of the engine case. i : 15.4.2 Work on the left section of the engine case. 15.4.3 Changing the connecting rod, conrad bearing, and crank pin 15.4.4 Checking the crankshaft run-out on the bearing pin... es 15.4.5 Removing the water pump . ‘Adjusting the basic position of the foot brake SSSELERLRRERES n 90 20 90 - 90 91 a1 a1 92 16 15.4.6 15.4.7 15.4.8 15.4.9 Installing the water pump. Checking/measuring the cylinder Checking/reasuring the piston... Determining the pistoweylinder ‘mounting Clearance... Checking the piston ring end gap. Checking the reed valve housing, dipvaan and intake flange. a Disassembling the clutch.. Checking the clutch. Premounting the clutch. Checking the shift mechanism. reassembling the shift shaft Disassembling the main shaft. ‘Assembling the main shaft, Dismantling the countershaft Assembling the countershatt. Checking the transmission Premounting the kickstarter shaft... Engine assembly 164.10 154.11 18.4.12 154.13 154.14 15.4.15, 154.16 154.17 154.18 15.4.19 15.4.20 154.21 15.4.22 15.5 15.5.1 Installing the crankshat. 15.5.2 Installing the transmission shafts 15.5.3 Installing the shift forks. 15.5.4 Installing the shift drum 15.5.5 Installing the shift rails. 15.5.6 Installing the left engine case section 15.5.7 Installing the reed valve housing . 15.5.8 Installing the locking lever. 15.5.9 Installing the shift drum locating. 15.5.10 Installing the shift shaft 15.5.1 Installing the intermediate kickstarter BOOT sissies 15.5.12 Installing the kickstarter shaft 15.5.13 Installing the primary gear. 15.5.14 Installing the outer clutch hub. 15.5.15 Installing the clutch cover 15.5.16 Mounting the water pump cover. 15.5.17 Installing the kickstarter 155.18 Installing the stator. 15.5.19 Installing the rotor. 15.5.20 Installing the piston 15.5.21 Installing the cylinder. 15.8.22 Checking the X-distance 15.5.23 Setting the Xdistance.... 15.5.24 Adjusting the ignition 15.5.25 Installing the alternator cover. 15.5.26 Installing the spacer... 15.5.27 Installing the engine sprocket . 15.5.28 Installing the exhaust control valve 15.5.29 Installing the cylinder head. 15.5.30 Installing the exhaust control 15.5.31 Installing the spark plug. 15.5.32 Installing the oil drain plug... 15.5.33 Installing the clutch pressure piece ..... 15.5.34 Removing the engine from the universal mounting rack . CARBURETOR 16.1 Removing the carburetor. 16.2 _ Installing the carburetor 16.3 Disassembling the carburetor. 16.4 Assembling the carburetor 16.5. Checking/setting the carburetor components. seve 102 1. 104 oa 95 95 96 96 97 97 98 98 99 100 100 101 101 102 105 105 105 105 105 106 106 106 107 107 107 sve 108, 1» 108 108 108 109 110 110 110 1. 110 a 1 112 12 113 113 113 114 14 4 115 16 116 116 16 uy u7 18 ug 121 123TABLE OF CONTENTS 7 18 19 20 2 22 23 24 25 26 a7 28 29 INDEX... 16.6 Checking the jet needle. 16.7 Checking the throttle slide 16.8 Checking the float needle valve 16.9 Checking the choke slide. 16.10. Checking/setting the float level. 16.11 Carburetor - adjusting the idle speed . 16.12. Emptying the carburetor float chamber CLUTCH, 17.1 Checking the fluid level of the hydraulic clutch 17.2. Changing the tydraulic clutch fuis WATER PUMP, COOLING SYSTEM 18.1 Draining the coolant... 18.2 Refilling the coolant, 18.3 Checking the antieeze and coolant level. 18.4 Checking the coolant level LUBRICATION SYSTEM... 19.1 Checking the gear oil level 19.2 Changing the gear oil 19.3 Draining the gear oil. 19.4 Filling up with gear oll 19.5 Adding gear oil IGNITION SYSTEM. 20.1 Checking the ignition system... 20.2 Checking the kill switch.. 20.3 Checking the ignition pulse generator 20.4 Checking the alternator... 20.5 Checking the spark plug connector 20.6 Checking the CDI controller 20.7 Checking the ignition coil TECHNICAL DATA. 21.1 Engine 21.2 Engine tolerance, wear limits 21.3 engine tightening torques 21.4 carburetor 21.4.1 Carburetor tuning 21.5 capacities 21.5.1 Gear all 21.5.2 Coolant. 21.5.3 Fuel 21.6 Chassis... 21.7 Fork 21.8 shock absorber 21.9 chassis tightening torques... CLEANING/PROTECTIVE TREATMENT. 22.1 Cleaning motorcycle... STORAGE. 23.1 Storage . 23.2 Preparing for use after storage. SERVICE SCHEDULE 24.1 Service schedule... WIRING DIAGRAM 25.1 Wiring diagram SUBSTANCES .. ‘AUXILIARY SUBSTANCES SPECIAL TOOLS STANDARDS - 126 124 124 se 128 . 128 125, 125 127 ss 27 127 128 ne 128 128 129 129 we 131 131 131 oe 131 . 132 132 134 ne 134 . 134 138 135 - 136 136 . 136 se 138 . 138 138 . 139 140 140 ne 141 we 141 141 141 ve WL 142 142 .1d2 vo 18 me 144 145 oe 145 145 146 . 146 vn 148, oe 148 se 180 se 152 . 154 164 1651 MEANS OF REPRESENTATION 5 ‘The meaning of specific symbols is described below. V Indicates an expected reaction (e.g. of a work step or a function). xX Indicates an unexpected reaction (e.g. of a work step or @ function). - Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips. Indicates the result ofa testing step. » v Denotes a voltage measurement. A Denotes @ current measurement. 2 Denotes a resistance measurement. ‘The typographical formats used in this document are explained below. Proprietary name Identifies a proprietary name. Name? Identities a protected name. rand™ Identifies a trademark. Underlined terms, Refer to technical details of the vehicle or indicate technical terms, which are explained in the glossary.2 = SAFETY ADVICE 21 Guarantee, warranty ‘The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM Dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- fered for damage resulting from manipulations endior alterations to the vehicle. Additional information on the guarantee or warranty and the procedures involved can be found in the Service & Warranty Booklet. Warning Environmental hazard Improper handling of fuel is a danger to the environment. = Do not allow fuel to get into the ground water, the ground, or the sewage system. Use the operating and auxiliary substances (such as fuel and lubricants) as specified in the manuel. Only use spare parts and accessories approved andior recommended by KTM. KTM accepts no liability for other products and any resulting damage or loss. ‘The current KTM PowerParts for your vehicle can be found on the KTM website International KTM Website: hntto:iwmw.ktm.com ‘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. 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 T 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 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 = SAFETY ADVICE 7 2 Repair Mama Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you tepair and maintain your vehicle. This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available.3 IMPORTANT NOTES 8 BA ges ‘The figures contained in the manual may depict special equipment. Inthe interest of clarity, some components may be shown disassembled or may not be shown at all. It isnot always necessary to dis- assemble the component to perform the activity in question, Please follow the instructions in the text,4 — SERIAL NUMBERS HO 401945:10 401949:10 \ 401948:10 The chassis number @ is stamped onthe right side of the steering head “The engine number @ is located onthe let side ofthe engine under the engine Sprocket The shock abscrber part number @) is stamped onthe top pet ofthe shock absorber above the adjusting fing onthe engine side5 MOTORCYCLE 10 5:1 Raising the motorcycle with atit'stand Note Danger of damage The parked vehicle may roll away or fall over. = Always place the vehicle on a firm and even surface, = Raise the motorcycle at the frame underneath the engine. Lift stand (78929955100) (* p. 159) ins Te vets mt oleic te ad = Secure the motorcycle against falling over. 401942.01 Note Danger of damage The parked vehicle may roll away or fall over. ~ Always place the vehicle on a firm and even surface. = Remove the motoreycle from the lift stand. = Remove the lift stand. ~ To park the motoreyele, insert plugin stand @ into the plugin stand bracket on the let side ofthe vehicle. ‘= Info ©) ©) Remove the plugin stand before riding 40258110 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness andlor death — When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. Note Engine failure High engine speeds in cold engines have a negative effect on the service life ofthe engine. = Always warm up the engine at low engine speeds. Info If the motorcycle is unwilling to star, the cause can be old fuel in the float chamber. The flammable elements of the fuel ‘evaporate after a long time of standing. If the float chamber is filled with fresh fuel, the engine starts immediately. Engine has been out of use for more than 1 week = Empty the carburetor float chamber. (© p. 126) Turn the knurled screw on the fuel tap all the way counterclockwise, ‘ Fuel can flow from the fuel tank to the carburetor. = Remove the motorcycle from the stand, — Shift gear to neutral5 MOTORCYCLE ‘The engine is cold Push the choke lever down all the way. Forcefully step on the kickstarter, pushing it all the way down. u" Into Ho not open the throttle