KTM 65 SX 2009 Repair Manual

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REPAIR MANUAL 2009

65 SX

65 XC

Article no. 3206061en

PartShark.com

877-999-5686

Table of Contents

Table of Contents4
Means of Representation7
Important Notes8
Motorcycle9
- Jacking up the Motorcycle9
- Removing the Motorcycle from the Work Stand9
- Starting9
01/Fork, Triple Clamp10
- Adjusting the Compression Damping of the Fork10
- Adjusting the Rebound Damping of the Fork10
- Bleeding Fork Legs10
- Cleaning the Dust Boots of the Fork Legs11
- Removing the Fork Protector11
- Installing the Fork Protector11
- Removing the Fork Legs12
- Installing the Fork Legs12
- Adjusting the Fork Overhang13
- Removing the Lower Triple Clamp14
- Installing the Lower Triple Clamp14
- Greasing the Steering Head Bearing15
- Checking Play of Steering Head Bearing15
- Adjusting Play of Steering Head Bearing15
02/Handlebar, Controls and Instruments17
- Adjusting Basic Position of Clutch Lever17
- Checking Play in Gas Bowden Cable17
- Adjusting Play in Gas Bowden Cable17
- Handlebar Position17
- Adjusting Handlebar Position18
04/Shock Absorber, Swingarm19
- Adjusting the Compression Damping of the Shock Absorber19
- Adjusting the Rebound Damping of the Shock Absorber19
- Measuring Rear Wheel Sag Unloaded19
- Checking the Static Sag of the Shock Absorber20
- Checking the Riding Sag of the Shock Absorber20
- Adjusting the Spring Preload of the Shock Absorber20
- Adjusting the Riding Sag21
- Removing the Shock Absorber21
- Installing Shock Absorber22
05/Exhaust23
- Removing the Exhaust Manifold23
- Installing the Exhaust Manifold23
- Removing Main Silencer24
- Installing the Main Silencer24
- Changing the Glass Fiber Yarn Filling of the Main Silencer25
- Removing the Glass Fiber Yarn Filling of the Main Silencer25
- Installing the Glass Fiber Yarn Filling of the Main Silencer25
06/Air Filter26
- Removing the Air Filter26
- Installing the Air Filter26
- Cleaning Air Filter26
07/Fuel Tank, Seat, Trim27
- Removing the Seat27
- Mounting the Seat27
- Dismounting the Fuel Tank27
- Installing the Fuel Tank28
08/Mask, Fender30
- Dismounting the Front Fender30
- Installing the Front Fender30
- Dismounting the Start Number Plate30
- Installing the Start Number Plate30
09/Front Wheel32
- Removing the Front Wheel32
- Installing the Front Wheel32
- Checking the Tire Condition33
- Checking Tire Air Pressure33
- Checking Brake Discs33
- Checking Spoke Tension34
10/Rear Wheel35
- Removing the Rear Wheel35
- Installing the Rear Wheel35
- Checking Chain Dirt36
- Cleaning the Chain36
- Checking the Chain Tension36
- Checking the Chain Tension - Installing Rear Wheel37
- Checking Rear Sprocket / Engine Sprocket for Wear37
- Adjusting the Chain Tension37
- Adjusting Chain Tension - after Checking38
- Adjusting Chain Tension - Installing Rear Wheel38
- Adjusting the Chain Guide38
13/Brake System39
- Checking Free Play of Hand Brake Lever39
- Adjusting Basic Position of Handbrake Lever39
- Checking the Front Brake Fluid Level39
- Adding Front Brake Fluid40
- Checking the Front Brake Linings41
- Removing Front Brake Linings41
- Installing the Front Brake Linings41
- Changing the Front Brake Linings42
- Checking the Free Travel of the Foot Brake Lever43
- Adjusting the Free Travel of the Foot Brake Pedal43
- Adjusting the Basic Position of the Foot Brake Pedal43
- Checking Rear Brake Fluid Level44
- Adding Rear Brake Fluid44
- Checking Rear Brake Linings45
- Removing Rear Brake Linings45
- Installing the Rear Brake Linings46
- Changing the Rear Brake Linings46
30/Engine48
- Removing the Engine48
- Installing the Engine49
30/Disassembling the Engine52
- Clamping the Engine into the Engine Work Stand52
  - Removing the Clutch Pressure Piece52
- Removing the Oil Drain Plug52
- Removing the Spark Plug52
- Removing the Exhaust Control52
- Removing the Cylinder Head53
- Removing the Exhaust Control Valve54
- Removing the Cylinder54
- Removing the Piston54
- Removing the Engine Sprocket54
- Removing the Distance Bushing55
- Removing the Generator Cover55
- Removing the Rotor55
- Removing the Stator56
- Removing the Kickstarter56
- Removing the Water Pump Cover56
- Removing the Clutch Cover56
- Removing the Outer Clutch Hub56
- Removing the Primary Gear57
- Removing the Kickstarter Shaft58
- Removing the Intermediate Kickstarter Gear58
- Removing the Shift Shaft58
- Removing the Shift Drum Locating58
- Removing the Locking Lever58
- Removing the Reed Valve Housing59
- Removing the Left Engine Case Section59
- Removing the Shift Rails60
- Removing the Shift Drum60
- Removing the Shift Forks60
- Removing the Transmission Shaft60
- Removing the Crankshaft61
30/Engine - Work on Individual Parts62
- Work on the Right Section of the Engine Case62
- Work on the Left Section of the Engine Case63
- Changing the Conrod Bearing63
- Checking the Crankshaft Run-Out on the Bearing Pin64
- Removing the Water Pump65
- Installing the Water Pump65
- Checking/Measuring the Cylinder66
- Checking/Measuring the Piston66
- Determining the Piston/Cylinder Mounting Clearance67
- Checking the Piston Ring End Gap67
- Checking the Reed Valve Housing, Diaphragm and Intake Flange67
- Disassembling the Clutch68
- Checking the Clutch68
- Premounting the Clutch69
- Checking the Shift Mechanism70
- Preassembling the Shift Shaft71
- Disassembling the Main Shaft71
- Assembling the Main Shaft71
- Dismantling the Countershaft72
- Assembling the Countershaft72
- Checking the Transmission73
- Premounting the Kickstarter Shaft74
30/Assembling the Engine75
- Installing the Crankshaft75
- Installing the Transmission Shafts75
- Installing the Shift Forks75
- Installing the Shift Drum75
- Installing the Shift Rails76
- Installing the Left Engine Case Section76
- Installing the Reed Valve Housing76
- Installing the Locking Lever77
- Installing the Shift Drum Locating77
- Installing the Shift Shaft77
- Installing the Intermediate Kickstarter Gear78
- Installing the Kickstarter Shaft78
- Installing the Primary Gear78
- Installing the Outer Clutch Hub78
- Installing the Clutch Cover79
- Mounting the Water Pump Cover80
- Installing the Kickstarter80
- Installing the Stator80
- Installing the Rotor80
- Installing the Piston81
- Installing the Cylinder81
- Checking the X-Distance82
- Setting the X-Distance82
- Adjusting the Ignition83
- Installing the Generator Cover83
- Installing the Distance Bushing84
- Installing the Engine Sprocket84
- Installing the Exhaust Control Valve84
- Installing the Cylinder Head84
- Installing the Exhaust Control85
- Installing the Spark Plug86
- Installing the Oil Drain Plug86
- Installing the Clutch Pressure Piece86
- Removing the Engine from the Universal Mounting Rack86
31/Carburetor87
- Removing the Carburetor87
- Installing the Carburetor88
- Disassembling the Carburetor89
- Assembling the Carburetor91
- Checking/Setting the Carburetor Components93
- Checking the Jet Needle93
- Checking the Throttle Slide94
- Checking the Float Needle Valve94
- Checking the Choke Slide94
- Checking/Setting the Float Level94
- Carburetor - Adjusting the Idle Speed95
- Emptying the Carburetor Float Chamber95
32/Clutch97
- Checking the Fluid Level of Hydraulic Clutch97
- Changing the Hydraulic Clutch Fluid97
35/Water Pump, Cooling System98
- Draining the Coolant98
- Refilling Coolant98
- Checking the Antifreeze and Coolant Level98
- Checking the Coolant Level99
38/Lubrication System101
- Checking Gear Oil Level101
- Changing the Gear Oil101
- Draining the Gear Oil101
- Filling up with Gear Oil101
- Adding Gear Oil102
39/Ignition System103
- Checking the Ignition System103
- Checking the Short Circuit Button103
- Checking the Ignition Pulse Generator104
- Checking the Generator104
- Checking the Spark Plug Connector105
- Checking the CDI Controller105
  - Checking the Ignition Coil105
Troubleshooting107
Technical Data - Engine109
- Capacity - Gear Oil109
- Capacity - Coolant109
Technical Data - Tolerance, Wear Limits of Engine110
Technical Data - Engine Tightening Torques111
Technical Data - Carburetor112
Technical Data - Chassis113
- Tires113
- Capacity - Fuel113
Technical Data - Fork114
Technical Data - Shock Absorber115
Technical Data - Chassis Tightening Torques116
Cleaning/Conservation117
- Cleaning Motorcycle117
Service Schedule118
- Important Maintenance Work to be Carried out by an Authorized KTM Workshop118
- Important Maintenance Work to be Carried out by an Authorized KTM Workshop. (as Additional Order)119
Wiring Diagram120
Substances122
Auxiliary Substances124
Special Tools126
Standards131
Index132

Other manuals for KTM 65 SX 2009

Owner's Manual77 pages

Questions and Answers:

M
Michael LyonsJul 27, 2025
What to do if my KTM 65 SX 2009 engine turns but does not start?
- S
  schneidermichaelJul 27, 2025
  If your KTM Motorcycle engine turns but doesn't start, several factors could be at play. Start by checking the fuel tank breather and cleaning the fuel tap to ensure uninterrupted fuel feed. Also, inspect and, if necessary, clean or replace the spark plug if it's oily or wet. Adjust the plug gap to 0.60 mm (0.0236 in) if it's too wide. It's also worth checking the carburetor components.
J
John JohnsonAug 6, 2025
Why does my KTM 65 SX 2009 engine have no idle?
- M
  Matthew MoranAug 7, 2025
  If your KTM Motorcycle engine has no idle, it could be due to several reasons. The idling jet might be blocked, in which case you should check and set the carburetor components. The adjusting screws on the carburetor could be distorted; adjust the idle speed of the carburetor. A fault in the ignition system can also cause this issue, so you may need to check the ignition system and adjust the ignition. Another potential cause is a defective ignition system, so check the ignition coil and the spark plug connector.
B
brownjoshuaAug 15, 2025
What to do if my KTM 65 SX 2009 Motorcycle engine does not speed up?
- D
  David LeeAug 15, 2025
  If your KTM Motorcycle engine does not speed up, one potential cause is a carburetor running over because the float needle is dirty or worn. In this case, you should check and set the carburetor components. Another possibility is loose carburetor jets, which also requires checking and setting the carburetor components. It could also be a fault in the ignition system, so you may need to check the ignition system and adjust the ignition.

KTM 65 SX 2009 Specifications

General

Brand	KTM
Model	65 SX 2009
Category	Motorcycle
Language	English

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