Category:
High-performance youth motocross competition motorcycle
Competitors:
Yamaha YZ65, Honda CRF65R, Suzuki RM65, Kawasaki KX65
Engine Type:
Liquid-cooled, 2-stroke single-cylinder, specifically designed for motocross racing
Suspension Brand:
High-quality WP Suspension components for superior handling and adjustability
Chassis:
Lightweight and strong chromoly steel frame designed for agility and rider control
Manual Utility:
Provides technicians and owners with the exact information needed to maintain peak performance and ensure longevity of the high-strung racing engine.
Engine:
Complete overhaul, disassembly, assembly, tuning, performance, components (cylinder, piston, crankshaft, connecting rod, bearings, seals)
Control System:
Throttle, clutch, brake levers, shift lever operation and adjustment
Mechanical:
General mechanical principles, torque specifications, fasteners
Fuel Service:
Carburetor service, jetting, fuel lines, fuel tank maintenance, fuel filter replacement
Emission Control:
Relevant emission systems and compliance for the model year (if applicable to off-road regulations)
Intake Exhaust Cooling:
Airbox, reed valve assembly, exhaust pipe, muffler, radiator, coolant system maintenance
Lube:
Two-stroke pre-mix ratio, gearbox oil specifications and change intervals
Ignition Starting Charging:
Ignition system components (CDI, stator, spark plug), charging system (if applicable), troubleshooting electrical issues
Clutch:
Clutch assembly, plates, springs, hydraulic clutch system maintenance and bleeding
Transmission:
Gearbox disassembly, inspection, assembly, shift drum and forks, gear ratios
Suspension:
Front fork (WP) disassembly, service, fluid levels, seals, rear shock absorber (WP) service, spring rates, damping adjustments
Wheels Tires:
Wheel bearing service, spoke tensioning, tire changing, recommended tire pressures
Brake Control:
Brake lever, pedal operation, hydraulic brake system (front and rear), fluid type and replacement
Brake System:
Brake caliper service, pad replacement, rotor inspection, brake line maintenance
Steering:
Steering head bearing service, adjustment, handlebar replacement
Electrical:
Wiring schematics, component testing, lighting (if applicable), horn, kill switch
Bodywork:
Fairings, seat, fuel tank cover, fender removal and installation
Maintenance:
Regular service checks, pre-ride inspections, post-race maintenance, cleaning procedures
Repair:
Component-level repairs for all listed systems, from minor adjustments to major overhauls
Diagnostics:
Troubleshooting guides for common problems, diagnostic flowcharts
Tuning:
Carburetor tuning, suspension adjustment, engine performance optimization
Special Tools:
Identification and usage of KTM-specific or recommended special tools for various procedures
Depth:
Factory-level, comprehensive, detailed step-by-step instructions with diagrams and illustrations for complete repair
Diagrams Illustrations:
Includes step-by-step instructions, diagrams, illustrations, and wiring schematics for complete repair.
Compatibility:
All Versions of Windows and Mac
Accessibility:
Easy-to-use PDF, no need to flip through multiple books
Printability:
Yes, all pages are printable
Image Enhancement:
Ability to blow up images and print enlarged copies
Binding:
Digital (PDF), no physical binding
Paper Type Implication:
N/A (Digital format, user prints on desired paper type)
Software:
Adobe PDF Reader and Winzip (or equivalent unzipping software) are required and available for free download.
Type:
Liquid-cooled, 2-stroke, single cylinder
Bore X Stroke:
43.5 mm x 43.8 mm (Typical for this model, confirm in manual)
Horsepower:
Approximately 10-12 HP (approximate, official figures may vary based on tuning)
Torque:
Not typically published for this class, but optimized for high-RPM power delivery
Carburetor:
Keihin PWK 28 (typical specification, confirm in manual)
Fuel Type:
Unleaded gasoline with a specific two-stroke oil pre-mix ratio (e.g., 40:1 or 50:1, consult manual for exact specification)
Gearbox Oil Type:
SAE 10W/40 high-quality motorcycle transmission oil (confirm viscosity and API rating in manual)
Engine Rebuild Interval:
Highly dependent on usage and rider skill; typically requires top-end rebuilds (piston, rings) every 20-40 hours of aggressive use, full rebuilds less frequently. Consult manual for specific recommendations.
Gearbox Oil Change:
Recommended every 10-15 hours of operation or annually, whichever comes first.
Air Filter Cleaning:
After every ride or as conditions dictate, critical for engine longevity.
Coolant:
Permanent anti-freeze/anti-corrosion coolant (e.g., Motorex Coolant M3.0) or equivalent, mixed with distilled water.
Brake Fluid:
DOT 4 brake fluid (confirm in manual).
Common Wear Items:
Piston rings, spark plugs, clutch plates, wheel bearings, steering head bearings, suspension seals, chain and sprockets.
Common Tuning Challenges:
Correct carburetor jetting for ambient conditions, clutch engagement adjustment, suspension setup for rider weight and track conditions.
