This manual provides comprehensive technical information for the 2002 60 SX and 65 SX models. These youth motocross bikes represent a significant part of the heritage in this segment. The 60 SX and 65 SX are designed for young riders, offering a blend of engine power, robust chassis, and reliable suspension systems characteristic of commitment to quality and durability in competitive off-road riding. This repair service manual serves as an essential resource for maintaining and repairing your 60 SX or 65 SX. It covers a wide array of critical systems, including detailed procedures for the engine, transmission, brakes, chassis, and electrical systems. The manual includes step-by-step instructions for disassembly, assembly, rebuilding, and troubleshooting, along with essential technical specifications, torque values, and fluid recommendations. This comprehensive English-language document is designed to empower owners and professional technicians alike to ensure optimal performance and longevity of the vehicle. 🏷️ Basic Information Identification Make: KTM Model: 65 SX / 65 SX Year: 2002 Product Name: KTM 60 SX 65 SX 2002 Repair Service Manual PDF Download 👋 Introduction Market Position Positioning: A vital resource for owners and mechanics of the 2002 KTM 60 SX and 65 SX models, offering factory-level repair information in a convenient digital format. Competitive Analysis Value Proposition: Provides the same technical depth as a factory manual, enabling users to perform maintenance and repairs effectively, saving on professional service costs. Key Features Accessibility: Instant download enables immediate access to repair information. User Friendliness: Designed with step-by-step instructions, making complex procedures understandable. Completeness: Covers a wide range of topics typically found in factory service and owner's manuals. 📋 Manual Details Coverage Areas Vehicle Models Covered: KTM 60 SX, KTM 65 SX Model Years Covered: 2002 Page Count Estimated Page Count: Not explicitly stated, but implied to be comprehensive Manual Type Type: Repair Service Manual Synonymous Types: Factory Service Manual, Workshop Manual Language Language: English Format File Format: PDF Delivery Method: Instant Download Software Requirements: Adobe PDF Reader, WinZip Operating System Compatibility: All Versions of Windows & Mac 📖 Manual Coverage Systems Covered Engine: Comprehensive coverage including disassembly, assembly, tuning, and troubleshooting. Transmission: Detailed procedures for inspection, maintenance, and repair. Chassis: Includes frame, suspension (front and rear forks, shock absorber), wheels, and steering. Brakes: Disc brake system maintenance, caliper service, and fluid replacement. Electrical System: Wiring diagrams, component testing, and troubleshooting for ignition and lighting. Cooling System: If applicable to the specific model variant, coverage of radiator and coolant maintenance. Fuel System: Carburetor service, fuel lines, and tank maintenance. Exhaust System: Inspection and replacement of exhaust components. Procedures Included Maintenance: Scheduled maintenance, cleaning, lubrication, and general upkeep. Troubleshooting: Diagnostic procedures and common issue resolutions. Disassembly Assembly: Step-by-step instructions for component removal and installation. Rebuilding: Detailed guidance for engine and component rebuilds. Specifications: Torque values, clearances, fluid capacities, and technical data. Illustrations Diagrams: Includes diagrams, schematics, and pictures to aid in understanding. Technical Depth Depth: Comprehensive, suitable for professional technicians and advanced DIY mechanics. Target Audience: Professional technicians, experienced DIY mechanics, and owners with basic mechanical/electrical knowledge. 📊 Manual Specifications File Format Print Quality: Full Printable, allowing for local printing of sections or the entire document. Zoom Functionality: Yes, allows for zooming in for detailed inspection of diagrams and text. Binding Type Binding: Digital (PDF) - No physical binding, accessible on electronic devices. Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Type: 2-stroke, single-cylinder (specific displacement varies between 60 SX and 65 SX) Cooling: Liquid-cooled (typical for these models) Bore X Stroke: Specific to each model (e.g., 65 SX typically around 43.2 x 43.7 mm) Ignition: Electronic ignition system Lubrication: Pre-mix fuel/oil lubrication Performance Horsepower: Specifications detailed within the manual for each variant. Torque: Specifications detailed within the manual for each variant. Fuel System Carburetor Type: Specific carburetor model (e.g., Dell'Orto PHBG or similar) and tuning specifications provided. Fuel Type: Unleaded gasoline with specified octane rating and 2-stroke oil mix ratio. 🔧 Transmission Standard Type: 6-speed manual transmission Clutch: Hydraulic or cable-actuated clutch mechanism. Features Gear Ratios: Detailed gear ratios for all 6 speeds and reverse (if applicable) are provided in the manual. 📐 Dimensions Exterior Wheelbase: Specifications for the 2002 models will be detailed in the manual. Weights Dry Weight: Specific dry weight figures for both 60 SX and 65 SX models are expected to be included. 🛡️ Safety Features Ratings Safety Compliance: While specific crash ratings are not typical for this class of off-road vehicle, the manual will cover safe operating procedures and maintenance for optimal safety. 💡 Technology Features Infotainment Features: N/A (Off-road motocross bikes of this era do not feature traditional infotainment systems). Driver Assistance Features: N/A (No electronic driver assistance systems present). Connectivity Features: N/A 🔧 Maintenance Service Intervals Scheduled Maintenance: Detailed service intervals for oil changes, air filter cleaning, spark plug replacement, and general...