2009 KTM 65 SX XC Service Repair Manual

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Basic Information Identification Make: KTM Model: 65 SX / XC Year: 2009 Product Name: 2009 KTM 65 SX XC Service Repair Manual PDF Download Manual Title: 2009 KTM 65 SX...

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Sku: 87208

Tags: 2009 65 SX 65 XC KTM Misc Motorcycle Motorcycles

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Description

Basic Information
Identification
Make:	KTM
Model:	65 SX / XC
Year:	2009
Product Name:	2009 KTM 65 SX XC Service Repair Manual PDF Download
Manual Title:	2009 KTM 65 SX XC Service Repair Manual

Introduction
Market Position
Category:	Youth Motocross / Off-road Competition
Competitive Analysis
Competitors:	Yamaha YZ65, Honda CRF65, Suzuki RM65 (historically), Kawasaki KX65
Key Features
Vehicle Focus:	Performance-oriented, championship-winning platform for junior racers
Manual Value:	Essential for proper maintenance and repair to ensure optimal performance and longevity

Manual Details
Coverage Areas
Overall Coverage:	All models and all repairs A-Z
Specificity:	Specific to model, not generic
Page Count
Estimated Pages:	300+
Manual Type
Type:	Service Repair Manual
Target Audience:	Technicians at dealerships
Content Type:	Official factory service manual
Language
Language:	English
Format
Format:	PDF Download

Manual Coverage
Systems Covered
Engine Mechanical:	Complete engine assembly, disassembly, inspection, and repair
Fuel System:	Carburetor tuning, fuel pump, fuel lines, fuel tank maintenance
Cooling System:	Radiator, water pump, coolant flow, temperature regulation
Ignition System:	Spark plug, ignition coil, CDI unit, timing
Exhaust System:	Exhaust pipe, muffler, sealing
Transmission Drivetrain:	Clutch operation, gear shifting mechanism, gearbox components, chain and sprockets
Suspension Front:	Fork maintenance, seal replacement, oil levels, spring rates, adjustments
Suspension Rear:	Shock absorber servicing, linkage maintenance, bearing checks
Brakes Front:	Brake caliper, master cylinder, brake fluid, pad replacement, bleeding procedures
Brakes Rear:	Brake caliper, master cylinder, brake fluid, pad replacement, bleeding procedures
Wheels Tires:	Wheel bearing inspection, spoke tensioning, tire selection and fitting
Electrical System:	Wiring diagrams, lighting, battery maintenance, stator and regulator/rectifier checks
Frame Chassis:	Frame inspection, steering head bearing maintenance, subframe checks
Bodywork:	Plastic panel removal and installation, seat maintenance
Procedures Included
Scheduled Maintenance:	Detailed maintenance schedules and procedures
Troubleshooting:	Diagnostic flowcharts for common problems and malfunctions
Repair Procedures:	Step-by-step instructions for all component repairs and replacements
Rebuilds:	Complete engine and gearbox rebuild procedures
Adjustments:	Carburetor, clutch, throttle, and brake adjustments
Torque Specifications:	All critical bolt and nut torque values
Technical Depth
Depth:	Comprehensive, covering basic maintenance to complete engine rebuilds
Diagnostic Capabilities:	Includes diagnostic trees and fault finding methods

Manual Specifications
File Format
Format:	PDF
Searchable:	Yes, text-searchable
Print Quality
Quality:	High-resolution, suitable for printing
Binding Type
Binding:	N/A (Digital PDF)
Paper Type
Paper:	N/A (Digital PDF)

Engine Specifications
Primary Engine
Type:	Single-cylinder, two-stroke
Displacement:	65 cc
Bore X Stroke:	43.5 mm x 43.8 mm
Cooling:	Liquid-cooled
Ignition:	Digital CDI
Carburetor:	Dell'Orto PHBG 19 BS
Power Output Estimated:	Approx. 16-18 HP (dependent on tuning and exhaust)
Fuel System
Fuel Type:	Unleaded gasoline with 2-stroke oil mix (e.g., 50:1 ratio)
Fuel Delivery:	Carburetor

Transmission
Standard
Type:	6-speed constant mesh
Clutch:	Hydraulically operated multi-disc clutch
Features
Gear Ratios:	Specific ratios detailed in manual (e.g., 1st: 2.833, 2nd: 1.933, 3rd: 1.400, 4th: 1.136, 5th: 0.917, 6th: 0.750)
Final Drive:	Chain drive

Dimensions
Exterior
Wheelbase:	1160 mm (approx.)
Seat Height:	760 mm (approx.)
Weights
Dry Weight:	53 kg (approx.)

Safety Features
Ratings
Crash Safety:	N/A (Designed for off-road competition, not road use)
Active Features
Brakes:	Hydraulic disc brakes front and rear
Passive Features
Chassis Design:	Robust frame designed for high stress and impact resistance

Technology Features
Infotainment
Features:	N/A (Focus on racing performance, no infotainment systems)
Driver Assistance
Features:	N/A (Focus on racing performance)

Maintenance
Service Intervals
Oil Change Engine:	Every 10-15 hours of riding (or as specified in manual)
Air Filter Cleaning:	After every few rides, or as needed depending on conditions
Spark Plug Inspection:	Every 10-15 hours
Top End Rebuild:	Varies greatly with use and maintenance, typically 30-60 hours for piston/rings.
Fluid Specifications
Engine Oil:	Specific 2-stroke premix oil, e.g., Motorex Cross Power 2T
Transmission Oil:	KTM recommends specific gear oil, e.g., Motorex Gear Oil 10W/40 or SAE 80
Coolant:	KTM Antifreeze/Coolant (or equivalent quality coolant with corrosion inhibitors, typically a 50/50 mix with distilled water)
Brake Fluid:	DOT 4
Known Issues
Common Wear Items:	Piston rings, clutch plates, wheel bearings, fork seals, chain and sprockets.
Carburetor Tuning:	Can be sensitive to altitude and temperature; requires regular cleaning and adjustment for optimal performance.
2 Stroke Engine Care:	Requires meticulous attention to air filter cleanliness, correct fuel/oil mixture, and regular top-end maintenance.

Vehicle History
Brand Heritage
Brand Focus:	KTM is renowned for its off-road racing heritage and performance-oriented motorcycles.
Model Evolution
Lineage:	The 65 SX is part of KTM's long-standing commitment to developing competitive youth motocross bikes.
Updates 2009:	While specific major changes for 2009 are minor, continuous refinement in suspension, chassis, and engine tuning are typical for KTM's development cycle.
Production
Manufacturing Location:	Austria (KTM AG)

Awards & Recognition
Recognitions
Racing Success:	KTM 65 SX models are consistently ridden to victory in national and regional junior motocross championships worldwide.