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: KTM Model: 60 SX / 65 SX Year: 1999 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: PDF Searchable: Likely searchable text within the PDF, depending on the source quality. Print Quality Printability: Full Printable Zoom Capability: YES 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: N/A Features Clutch: Hydraulic or cable-actuated wet multi-disc clutch. Gear Ratios: Specific gear ratios...