KTM 65 SX 2006 User Manual (English)

Richard PerkinsAug 5, 2025

Why does my KTM 65 SX 2006 engine has not enough power?

B
Brittany WhiteAug 5, 2025
If your KTM Motorcycle engine lacks power, the glass fiber yarn in the silencer might be charred, requiring you to replace the filling. The air filter could be obstructed, so clean or replace it. A partially interrupted or blocked fuel supply could also be the problem, in that case blow through the fuel pipe and clean the carburetor. Ensure the spark plug is tight to prevent compression loss. Inspect the exhaust system for any damage. Finally, check and adjust the ignition if the engine lacks sufficient preignition.

KTM 65 SX 2006 Specifications

General

Transmission	6-speed
Fuel System	Carburetor
Rear Suspension	WP mono shock
Front Brake	Disc brake
Rear Brake	Disc brake
Cooling	Liquid cooled
Fuel Tank Capacity	3.5 l
Final Drive	Chain
Front Suspension Diameter	35 mm
Engine Type	Single-cylinder, 2-stroke
Bore x Stroke	45 mm x 40.8 mm
Front Suspension	WP USD
Starter	Kick
Carburetor	Dell'Orto

Summary

Serial Number Locations

Chassis Number

The chassis number is stamped on the right side of the steering head tube.

Operation Instruments

Clutch Lever

The clutch lever [1] is located on the left handlebar. Adjusting screw [A] changes position.

Fuel Tap

The fuel tap [3] is on the left of the tank. Turn knob left to open, right to close.

Choke

The choke button [4] is on the left of the carburetor. Pulling provides extra fuel for cold starting.

Kickstarter

The kickstarter is on the right of the engine. Its upper part can be swivelled.

Foot Brake Pedal

Located in front of the right foot rest. Basic position can be adjusted to seating position.

Compression Damping of Shock Absorber

Damping adjusted by knob [1]. Clockwise increases, counterclockwise decreases damping.

General Tips and Warnings for Starting the Motorcycle

Instructions for the First Ride

Ensure pre-delivery inspection. Explain controls, practice on soft ground, teach hand brake use.

Running In

Engine requires break-in. Do not rev to limits for first 30 minutes. Apply low, changing loads.

Driving Instructions

What You Should Check Before Each Start

Perform overall check: transmission oil, fuel, chain, tires, brakes, cables, cooling fluid.

Starting When the Engine is Cold

Open fuel tap, neutral gear, activate choke [2], kickstarter vigorously.

Starting Off

Pull clutch, engage first gear, release clutch slowly while accelerating.

Shifting/Riding

Shift gears by pulling clutch, reducing throttle, and shifting. Downshift using brakes and clutch.

Braking

Turn off gas, apply hand/foot brakes. Use rear wheel on slippery ground. Brake with feeling.

Stopping

Brake, shift to neutral, use short circuit switch to stop. Close fuel tap.

Refueling, Fuel

Use premium gasoline RON 95 mixed with high-grade two-stroke oil (1:60). Mix immediately before use.

Maintenance Work on Chassis and Engine

Checking and Adjusting the Steering Head Bearing *

Check for play. Loosen clamp screws [1], turn bolt [2] clockwise. Retighten screws to 20 Nm.

Cleaning the Dust Sleeves of the Telescopic Fork

Lift dust-protection bellows [1], slide down. Clean bellows, tubes, oil them.

How to Change the Handlebar Position

Handlebar position adjustable by 22 mm. Uses 4 different positions via offset bores.

Changing Spring Preloading of the Shock Absorber

Loosen locking ring [6], turn adjusting ring [7] to change preload. Basic setting: 7 mm.

Basic Suspension Setup for the Weight of the Driver

Setup must suit rider's weight. Check sag of shock absorber and telescopic fork.

To Determine the Sag of the Shock Absorber

Measure distance between rear wheel axle and fixed point, with and without load.

Checking Chain Tension

Press chain down. Distance should be approx. 3 mm. Check chain and swing arm.

Correcting Chain Tension

Undo hexagon nut [1], counter nuts [2]. Turn tensioning screws [3] equally. Tighten nut to 40 Nm.

General Information About KTM Disc Brakes

Covers brake calipers, fluid reservoirs, fluid type, and disc thickness.

Adjusting the Free Travel at the Hand Brake Lever

Adjust free travel using screw [2]. Should be at least 3 mm. Avoid overheating.

Checking/Refilling the Front Brake Fluid Level*

Check level via inspection glass. Add DOT 5.1 fluid if below 5 mm from edge. Actuate lever.

Checking Front Brake Pads

Inspect pads. Linings must be at least 1 mm thick. Replace if worn.

Replacing the Front Brake Pads *

Remove front wheel. Press pistons back. Remove screws [1], [2], shoes. Clean caliper.

Changing Basic Position of the Brake Pedal *

Adjust end stop roller [3]. Free play must be 3-5 mm. Prevents rubbing.

Checking the Rear Brake Fluid Level

Check level in reservoir via inspection glass [A]. Indicates leaks or worn pads.

Refilling the Rear Brake Fluid Reservoir *

Remove cover [2]. Fill DOT 5.1 fluid up to 15 mm below edge. Actuate lever.

Checking Rear Brake Pads

Inspect pads from rear. Linings must be at least 1 mm thick. Replace if worn.

Replacing the Rear Brake Pads *

Dismount rear wheel. Press brake shoes apart. Remove screws [1], [2], shoes. Tighten screw to 4 Nm.

Removing and Installing Front Wheel

Jack up bike. Loosen screws [3], [4]. Pull spindle [5]. Carefully remove wheel from fork.

Removing and Installing the Rear Wheel

Jack up bike. Remove nut [1], washer [2], chain adjuster [3]. Pull spindle. Reverse for install.

Tires, Air Pressure

Check tire type, condition, and pressure. Proper pressure (1.0 bar) ensures comfort and tire life.

Removing the Seat

Use quick-release mechanism [1] to remove seat. Turn about 180° counter-clockwise, lift rear, pull backwards.

Cleaning the Air Filter *

Remove seat, cover. Unclap holder [3], remove filter [4]. Wash in special fluid, dry, oil.

Exhaust System *

Replace glass-fiber yarn packing. Remove silencer, screws [3], cap [4]. Clean parts.

Checking the Oil Level of the Hydraulic Clutch

Remove cover [7]. Oil level should be 4 mm below upper edge of reservoir.

Changing the Original Position of the Clutch Lever

Adjusting screw [1] allows adjustment to optimal position. Turn counterclockwise to reduce distance.

Checking Coolant Level

Coolant should be 10 mm above radiator fins when engine is cold. Always fill and bleed.

Adjusting the Throttle Cable *

Ensure 3-5 mm play. Move protective cover [5]. Loosen counternut [7] and adjust screw [6].

Carburetor Adjustment *

Original setting adapted for 500m altitude, 20°C. Use premium fuel, 1:60 oil ratio.

Idling Range - A, Adjusting the Idle Speed

Adjust idle speed with air control screw [1] and [2] when engine is hot.

Draining the Float Chamber of the Carburetor

Drain float chamber to remove water after cleaning. Unscrew plug [1], clean, tighten to 4 Nm.

Checking Gear Oil Level

Check level via inspection glass [2] on engine. Oil must not drop below MIN mark.

Changing Gear Oil *

Warm engine, drain oil via plug [3]. Add 0.30 I gear oil 20W30 via filler plug [4].

KTM 65 SX 2006 User Manual

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