KTM 60 SX 65 SX 1998-2002 Repair Service Manual

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Basic Information Identification Make: KTM Model: 60 SX / 65 SX Model Years Covered: 1998, 1999, 2000, 2001, 2002 Introduction Market Position Target Audience: Primarily professional technicians, but also DIY...

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Type: Motorcycle

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Sku: 54614

Tags: 1998 1999 2000 2001 2002 60 60 SX 65 SX KTM Motorcycle Motorcycles

Product variants

Description

Basic Information
Identification
Make:	KTM
Model:	60 SX / 65 SX
Model Years Covered:	1998, 1999, 2000, 2001, 2002

Introduction
Market Position
Target Audience:	Primarily professional technicians, but also DIY mechanics with basic mechanical/electrical knowledge.
Competitive Analysis
Value Proposition:	Provides factory-level service information for essential maintenance and repair, often unavailable in retail stores.
Key Features
Instructional Style:	Step-by-step guidance, teaching factory-trained technician methods.
Manual Scope:	Covers topics typically found in both factory service and owner's manuals.

Manual Details
Coverage Areas
Coverage:	Complete Repair and Service for KTM 60 SX and 65 SX models from 1998-2002.
Page Count
Page Count:	Not specified, but described as comprehensive.
Manual Type
Manual Type:	Repair Service Manual / Workshop Manual
Language
Language:	English
Format
File Format:	PDF

Manual Coverage
Systems Covered
Engine Service:	Detailed procedures for engine disassembly, assembly, maintenance, and troubleshooting.
Transmission Service:	Covers transmission maintenance, repair, and component servicing.
Chassis And Suspension:	Includes guidance on suspension adjustment, maintenance, and component replacement.
Electrical System:	Details on electrical components, wiring diagrams, and troubleshooting electrical issues.
Braking System:	Covers brake maintenance, fluid replacement, and component servicing.
Cooling System:	Information on coolant maintenance and related system checks.
Procedures Included
Preventative Maintenance:	Step-by-step guidance on routine maintenance tasks to ensure longevity and performance.
Troubleshooting:	Comprehensive diagnostic procedures for identifying and resolving common and uncommon issues.
Disassembly And Assembly:	Detailed instructions for taking apart and reassembling various vehicle components.
Cleaning And Reinstallation:	Guidance on proper cleaning and reinstallation of parts after servicing.
Technical Depth
Depth Level:	Suitable for professional technicians and advanced DIY mechanics with basic electrical and mechanical knowledge.

Manual Specifications
File Format
Print Quality:	Full Printable. Allows for printing of all pages.
Zoom Capability:	YES. Allows for zooming in and out for detailed viewing of illustrations and text.
Binding Type
Binding Type:	Digital Download (PDF). No physical binding.
Paper Type
Paper Type:	Not applicable for digital format, but printable pages are intended for standard paper.
Delivery
Delivery Method:	Instant Download
Requirements
Software Requirements:	Adobe PDF Reader & WinZip (for extraction if zipped)
Compatibility:	All Versions of Windows & Mac

Engine Specifications
Primary Engine
Engine Type 60 Sx:	Single-cylinder, 2-stroke, liquid-cooled (specific displacement for 60cc class).
Engine Type 65 Sx:	Single-cylinder, 2-stroke, liquid-cooled, reed valve induction (specific displacement for 65cc class, e.g., 64.93 cc).
Performance
Bore X Stroke Typical 65 Sx:	Approx. 43.5 mm x 43.7 mm (exact specs will be in manual).
Horsepower Estimate 65 Sx:	Typically in the range of 15-20 HP depending on tuning and year (manual will have precise figures).
Fuel System
Carburetor Type Typical:	Likely a Dell'Orto or Keihin carburetor (e.g., PHBG series or similar).
Fuel Type:	Pre-mix gasoline, typically 95-100 octane recommended.
Ignition System
Ignition Type:	Digital CDI (Capacitor Discharge Ignition).

Transmission
Standard
Transmission Type:	6-speed manual transmission.
Features
Clutch Type:	Wet multi-plate clutch.
Transmission Fluid Type:	Dedicated transmission oil (e.g., SAE 75W/80W or SAE 10W/30 motorcycle-specific oil, manual will specify exact grade and capacity).

Dimensions
Weights
Dry Weight 65 Sx:	Typically around 55-60 kg (121-132 lbs) (exact spec in manual).
Seat Height 65 Sx:	Around 780-820 mm (30.7-32.3 inches) (exact spec in manual).
Ground Clearance 65 Sx:	Approximately 250-300 mm (9.8-11.8 inches) (exact spec in manual).

Safety Features
Ratings
Safety Standards:	Designed for off-road competition, adhering to FIM and AMA standards for youth motocross.
Active Features
Braking System Front:	Hydraulic disc brake with caliper and rotor (specific sizes in manual).
Braking System Rear:	Hydraulic disc brake with caliper and rotor (specific sizes in manual).
Passive Features
Frame Construction:	Chromoly steel frame for strength and rigidity.

Technology Features
Infotainment
Infotainment Features:	Basic motocross bike; no infotainment system, typically features only essential controls.
Driver Assistance
Driver Assistance Systems:	No electronic driver assistance systems; performance relies on rider skill and mechanical setup.
Connectivity
Connectivity Features:	No connectivity features.

Maintenance
Service Intervals
Oil Change Interval:	Transmission oil change recommended every 15-25 hours of riding or annually, depending on usage intensity (specific interval in manual).
Air Filter Cleaning:	Frequent cleaning (every few rides) and periodic replacement are critical for 2-stroke engines.
Spark Plug Replacement:	Recommended at specified hour intervals or as needed based on condition (manual will provide type and interval).
Fluid Specifications
Coolant Type:	Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water (manual will specify exact type and capacity).
Brake Fluid Type:	DOT 4 hydraulic brake fluid (manual will specify exact type and change interval).
Known Issues
Carburetor Tuning:	Proper jetting is crucial for optimal performance and reliability, can be sensitive to altitude and temperature.
Clutch Wear:	Clutch plates can wear over time, especially under heavy use; manual covers inspection and replacement.
Engine Top End:	Piston rings and cylinder wear are common maintenance items for 2-stroke engines; manual provides rebuild procedures.

Vehicle History
Brand Heritage
Ktm Legacy:	KTM has a long-standing reputation in off-road and motorsport, known for its 'Ready to Race' philosophy.
Model Evolution
Sx Lineage:	The SX line represents KTM's dedicated motocross and off-road competition bikes for youth riders.
Production
Manufacturing Location:	Typically manufactured in Austria.

Awards & Recognition
Recognitions
Model Recognition:	The KTM 65 SX is a highly competitive and popular model in its class, often winning championships in youth motocross racing.