Target Audience:
Owners and mechanics of 1999 KTM 60 SX and 65 SX motocross bikes.
Comparison Points:
This manual offers a comprehensive alternative to limited OEM service bulletins or less detailed online resources, providing a singular source for all repair and maintenance needs.
Unique Selling Points:
Instant download availability, printable format, detailed illustrations, numbered steps, and professional-grade diagnostic information.
Primary Coverage:
KTM 60 SX & 65 SX models for the 1999 model year.
Secondary Coverage:
Potential overlap with late 1998 and early 2000 models due to platform continuity.
Estimated Page Count:
Likely 300-500+ pages (typical for comprehensive service manuals).
Manual Type:
Full Service Repair Manual / Workshop Manual
Delivery Method:
Instant Download
Printability:
Full Printable
Engine:
Complete engine overhaul, top-end and bottom-end components, lubrication, cooling (air-cooled), fuel delivery (carburetor specifics).
Transmission:
Clutch operation, gear shifting mechanisms, internal transmission components, gearbox oil specifications and service.
Electrical:
Ignition system, lighting, wiring diagrams, troubleshooting electrical faults, component testing.
Suspension:
Front fork (USD - Upright Dual Spring) servicing, rear shock absorber (WP Suspension) inspection and adjustment, spring and damping characteristics.
Brakes:
Hydraulic disc brake systems (front and rear), brake fluid specifications, caliper maintenance, bleeding procedures.
Chassis And Frame:
Frame inspection, subframe, swingarm, linkage systems, steering head bearings.
Fuel System:
Carburetor identification and adjustment (likely Mikuni VM series), fuel tank, fuel lines, petcock.
Exhaust System:
Exhaust pipe and silencer maintenance, gasket replacement.
Maintenance:
Regular service checks, lubrication points, filter replacements, spark plug service, chain adjustment.
Troubleshooting:
Detailed diagnostic procedures for common issues, symptom-based troubleshooting guides.
Repair:
Step-by-step instructions for component replacement and repair, from minor adjustments to complete engine rebuilds.
Rebuild Refurbish Restore:
Comprehensive guidance for full restorations, including engine, transmission, and suspension overhauls.
Wiring Diagrams:
Detailed electrical schematics for all circuits.
Diagnostic Capability:
Advanced diagnostic procedures and electrical troubleshooting.
Rebuild Depth:
Full engine, transmission, and suspension rebuilds.
User Level:
Aimed at professional technicians but accessible to skilled DIY mechanics.
File Type:
PDF (Portable Document Format)
Print Resolution:
High resolution, optimized for clear printing of text and diagrams.
Binding Type:
Digital (PDF) - No physical binding.
Paper Type:
Digital - N/A (Printable on any paper type).
Software Requirements:
Adobe Acrobat Reader, WinRAR (for potential ZIP extraction if bundled).
Operating System Compatibility:
All Windows versions, macOS, Linux (via PDF readers).
Engine Type:
Single-cylinder, 2-stroke, liquid-cooled (typical for SX models of this era, though some early 60s might have been air-cooled; manual will specify).
Bore Stroke 60Sx:
Likely around 45.0 mm bore x 34.5 mm stroke (estimate based on common configurations).
Bore Stroke 65Sx:
Likely around 45.5 mm bore x 41.0 mm stroke (estimate based on common configurations).
Displacement 60Sx:
Approximately 56.5 cc (estimate).
Displacement 65Sx:
Approximately 65 cc (estimate).
Horsepower Estimate 60Sx:
Likely in the 12-15 HP range (estimate).
Horsepower Estimate 65Sx:
Likely in the 16-19 HP range (estimate).
Carburetor Type:
Mikuni VM series, likely 20-24mm bore for 60 SX and 24-26mm for 65 SX (manual will confirm exact model and jetting).
Fuel Mixture:
2-stroke pre-mix, specified ratio (e.g., 40:1 or 50:1) in manual.
Transmission Type:
6-speed constant mesh manual gearbox.
Optional Gearbox:
N/A (standard configuration for this class).
Clutch Type:
Hydraulically operated multi-plate wet clutch.
Gear Ratios:
Detailed gear ratios for each of the 6 speeds will be provided in the manual.
Transmission Oil Type:
Specific gearbox oil (e.g., SAE 10W/30 or 10W/40) and capacity will be specified in the manual.
Wheelbase Estimate:
Approx. 1250-1280 mm (typical for this class).
Seat Height Estimate:
Approx. 780-800 mm (typical for this class).
Dry Weight Estimate 60Sx:
Around 55-60 kg (estimate).
Dry Weight Estimate 65Sx:
Around 60-65 kg (estimate).
Oil Change Interval:
Gearbox oil change typically every 10-15 hours of riding or annually.
Air Filter Cleaning:
Frequent cleaning recommended, often after every few riding sessions depending on conditions.
Spark Plug Replacement:
Recommended every 20-30 hours of riding or as per manual's diagnostic recommendations.
Top End Rebuild:
Depends heavily on usage, but typically advised every 40-60 hours of competitive riding for optimal performance.
Gearbox Oil:
Specific grade and capacity outlined in the manual (e.g., Motorex Gear Oil SAE 10W/40).
Brake Fluid:
DOT 4 hydraulic brake fluid (manual will specify exact type and DOT rating).
Coolant:
If liquid-cooled, specific coolant mixture (e.g., 50/50 water/antifreeze). Manual will confirm if air-cooled or liquid-cooled and specify coolant type.
Common Wear Items:
Clutch plates, piston rings, seals, bearings, brake pads, chain, sprockets.
Typical Repair Focus:
Engine tuning, carburetor maintenance, suspension setup, and drivetrain wear are common areas of focus for owners of this model.
