KTM 60 SX 65 SX 1999 Repair Service Manual

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This manual covers the 60 SX and 65 SX models from 1999, renowned Austrian-engineered motocross bikes designed for junior riders and competition. Built with a focus on performance and durability,...

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Type: Motorcycle

Vendor:

Sku: 57849

Tags: 1999 60 60 SX 65 SX KTM Motorcycle Motorcycles

Product variants

Description

This manual covers the 60 SX and 65 SX models from 1999, renowned Austrian-engineered motocross bikes designed for junior riders and competition. Built with a focus on performance and durability, these machines are a staple in the world of youth motocross. Their robust construction and competitive heritage, stemming from a strong motorsports background, make them ideal platforms for developing riding skills and achieving success on the track. This comprehensive repair service manual provides detailed instructions and specifications essential for maintaining and repairing your 60 SX or 65 SX. It covers a wide array of systems, including the engine, transmission, suspension, brakes, and electrical components, offering step-by-step procedures for disassembly, assembly, maintenance, and troubleshooting. With factory-level information, this manual is an invaluable resource for professional technicians and dedicated enthusiasts alike, ensuring your vehicle performs optimally and reliably.

🏷️ Basic Information

Identification

Make:

Model:

60 SX / 65 SX

Year:

Codes

Chassis Codes:

Likely specific to SX models, often designated by internal KTM codes.

Engine Codes:

Likely specific to SX engine variants, often designated by internal KTM codes.

👋 Introduction

Market Position

Target Audience:

Professional technicians and DIY mechanics with basic mechanical and electrical knowledge.

Competitive Analysis

Value Proposition:

Provides comprehensive factory-level repair and maintenance information, enabling owners to perform extensive servicing, reducing reliance on external repair shops.

Key Features

Accessibility:

Instant download, available for immediate use.

Comprehensiveness:

Covers a wide range of repair and maintenance procedures, akin to a factory service manual and owner's manual.

Guidance:

Step-by-step instructions designed to teach users what factory-trained technicians know.

📋 Manual Details

Coverage Areas

Engines Covered:

KTM 60 SX (1999), KTM 65 SX (1999) - Assumed to cover the specific engine variants offered in these models for the 1999 model year.

Chassis Covered:

KTM 60 SX (1999), KTM 65 SX (1999) - Assumed to cover the chassis, suspension, brakes, and bodywork specific to these models.

Page Count

Estimated Page Count:

Estimated 150-300 pages (typical for a comprehensive service manual of this era for this type of vehicle).

Manual Type

Type:

Repair Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, troubleshooting, overhaul, component identification, specifications (bore, stroke, compression ratio, etc.), lubrication, cooling system, fuel delivery (carburetor adjustments and rebuilding), ignition system.

Transmission:

Gearbox operation, disassembly, assembly, maintenance, troubleshooting, gear selection, clutch operation and adjustment.

Suspension:

Front fork service (seals, oil, springs), rear shock absorber service and adjustments, linkage system maintenance.

Brakes:

Hydraulic brake system diagnosis, caliper service, master cylinder service, brake pad replacement, bleeding procedures, specifications.

Electrical System:

Wiring diagrams, component testing (ignition coil, CDI unit, stator, etc.), troubleshooting electrical faults, lighting system, battery maintenance.

Cooling System:

Radiator service, coolant specifications, hose inspection and replacement, thermostat function (if applicable).

Fuel System:

Carburetor identification, jetting, float height adjustment, cleaning and rebuilding procedures, fuel line inspection.

Chassis And Frame:

Frame inspection, steering head bearing maintenance, swingarm service, wheel bearing replacement.

Bodywork And Plastics:

Fairing removal and installation, seat maintenance, plastic part replacement procedures.

Procedures Included

Maintenance:

Regular maintenance tasks, lubrication points, filter replacement, chain adjustment, general cleaning and inspection.

Repair:

Step-by-step repair instructions for all major components and systems.

Troubleshooting:

Diagnostic charts and procedures for identifying and resolving common and uncommon problems.

Disassembly And Assembly:

Detailed instructions for taking apart and reassembling various vehicle components.

Specifications And Data:

Critical technical specifications, torque values, clearances, fluid capacities, and more.

Technical Depth

Depth:

Comprehensive, covering basic to advanced repairs and diagnostics. Suitable for professional technicians and experienced DIY mechanics.

📊 Manual Specifications

File Format

Format:

Searchable:

Likely searchable text within the PDF, depending on the source quality.

Print Quality

Printability:

Full Printable

Zoom Capability:

Binding Type

Type:

Digital Download (no physical binding)

Paper Type

Type:

N/A (digital format)

Requirements

Software Requirements:

Adobe PDF Reader, WinZip (for potential archive extraction)

Compatibility:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine

Engine Type:

Two-stroke, single-cylinder, liquid-cooled (typical for SX models of this era).

Bore X Stroke:

Specific values would be detailed within the manual, likely around 44.5mm x 41.8mm for 60cc and 46mm x 42.6mm for 65cc.

Displacement:

50cc/60cc and 65cc (depending on specific model variant).

Performance

Horsepower:

Estimates would be around 15-20 HP, varying by specific model and tuning.

Torque:

Specific torque figures would be detailed in the manual, typically in the range of 5-7 lb-ft.

Fuel System

Carburetor Type:

Likely Mikuni VM series or similar performance-oriented carburetor, e.g., Mikuni VM20 or VM24.

Fuel Type:

High-octane unleaded gasoline mixed with two-stroke oil.

Lubrication

Oil Type:

Specific two-stroke engine oil meeting JASO FD or higher specifications.

Ignition System

Ignition Type:

CDI (Capacitor Discharge Ignition) with potentially variable timing.

🔧 Transmission

Standard

Type:

6-speed manual transmission.

Optional

Type:

Features

Clutch:

Hydraulic or cable-actuated wet multi-disc clutch.

Gear Ratios:

Specific gear ratios would be detailed in the manual, critical for performance tuning.

Final Drive:

Chain drive, with specific sprocket size details available in the manual.

📐 Dimensions

Exterior

Wheelbase:

Likely around 1100-1200 mm, specific to 60 SX and 65 SX variants.

Seat Height:

Designed for youth riders, likely around 750-800 mm.

Weights

Dry Weight:

Typically around 50-55 kg for this class of mini-motocross bike.

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycles, especially competition-oriented ones, are not typically rated by standard automotive safety bodies).

Active Features

Braking System:

Hydraulic disc brakes front and rear, designed for effective stopping power.

Passive Features

Frame Construction:

Robust steel frame designed for the stresses of off-road riding.

💡 Technology Features

Infotainment

Features:

N/A (Competition motocross bikes of this era are focused on performance and have minimal electronic features beyond basic ignition and lighting).

Driver Assistance

Features:

Connectivity

Features:

🔧 Maintenance

Service Intervals

Oil Change:

Gearbox oil change every 10-15 hours of riding; 2-stroke oil for premix added as needed.

Air Filter Cleaning:

Recommended after every few rides, depending on conditions.

Spark Plug Replacement:

As per manual recommendations, typically every 20-30 hours.

Top End Rebuild:

KTM often recommends top-end rebuilds (piston and rings) every 30-50 hours of hard use for optimal performance and longevity.

Fluid Specifications

Gearbox Oil:

Specific KTM-recommended gearbox oil (e.g., SAE 10W/50, API SG or higher) or equivalent motocross-specific transmission oil.

Coolant:

Ethylene glycol-based antifreeze/coolant mixture, typically 50/50 with distilled water.

Brake Fluid:

DOT 4 hydraulic brake fluid.

Known Issues

Carburetor Tuning:

Sensitivity to altitude and temperature changes, requiring occasional jetting adjustments.

Clutch Wear:

Clutch plates can wear with aggressive riding; proper adjustment and timely replacement are crucial.

Ignition System Reliability:

While generally robust, CDI units or stator issues can occur; proper diagnostic procedures are in the manual.

📚 Vehicle History

Brand Heritage

Marque:

KTM is a renowned Austrian manufacturer with a strong heritage in off-road and motorsports, particularly motocross and enduro.

Model Evolution

Sx Series:

The SX line represents KTM's dedicated motocross offerings, with smaller displacement models like the 60 SX and 65 SX serving as entry points for junior racers.

Production

Manufacturing Location:

Austria (KTM headquarters).

🏆 Awards & Recognition

Recognitions

Motorsports Success:

KTM SX models are consistently competitive in junior motocross championships globally, reflecting their design and performance.