KTM 65 XC 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

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