This manual covers the 65 SX and 60 SX models from 2002. As part of the performance-oriented off-road motocross line, these motorcycles are engineered for young riders and competitive racing. Known for their robust construction and agile handling, these motorcycles have a strong heritage in motorsports, with the SX line consistently demonstrating success in motocross competition. These models feature a liquid-cooled, two-stroke, single-cylinder engine, a 6-speed manual transmission with a wet multi-plate clutch, and hydraulic disc brakes front and rear, all built upon a high-strength steel perimeter frame for optimal rider protection and chassis rigidity. This comprehensive service repair manual provides detailed information for maintaining and repairing your 65 SX or 60 SX. It covers a wide range of essential systems, including complete engine overhauls, fuel and ignition systems, transmission, suspension, brakes, wheels, and the electrical and frame components. The manual offers professional-level diagnostic guides, step-by-step repair instructions, and rebuilding procedures for the engine and gearbox. Additionally, it details regular maintenance schedules, fluid specifications, and common wear items, making it an indispensable resource for professional technicians and advanced DIY mechanics aiming to keep these performance off-road motorcycles in peak condition. 🏷️ Basic Information Identification Make: KTM Model: 65 SX / 60 SX Year: 2002 Codes Engine Code Variant 1: 144SX (likely referring to the 65cc class, often referred to internally or by engine size in mm bore) Engine Code Variant 2: 134SX (likely referring to the 60cc class, often referred to internally or by engine size in mm bore) 👋 Introduction Market Position Product Category: Performance Off-Road Motorcycles (Mini Motocross) Competitive Analysis Competitors 2002: Yamaha YZ65, Suzuki RM65, Honda CR65 (if applicable, though Honda's smaller models varied in displacement) Key Features Manual Delivery Method: Instant Download Cost Benefit: Eliminates shipping costs and waiting time 📋 Manual Details Coverage Areas Primary Coverage: Full Service Repair and Maintenance Page Count Estimated Page Count: Likely 200-400 pages (typical for a comprehensive service manual of this era, exact count not specified but implied by depth) Manual Type Type: Full Service Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, disassembly, assembly, tuning, lubrication, cooling system Fuel System: Carburetor identification, adjustment, cleaning, rebuilding; fuel tank, fuel lines Ignition System: Ignition timing, spark plug specifications, coil, CDI unit troubleshooting Transmission: Clutch operation, adjustment, rebuild; gearbox disassembly and assembly Suspension: Front fork service, seal replacement, oil levels and types; rear shock absorber inspection and service Brakes: Front and rear brake system inspection, hydraulic fluid, caliper service, master cylinder service Wheels And Tires: Tire pressure recommendations, wheel bearing inspection and replacement, spoke tensioning Electrical System: Wiring diagrams, troubleshooting electrical faults, component testing (lights, horn if applicable) Frame And Bodywork: Chassis inspection, seat removal, fuel tank removal/installation, handlebar maintenance Procedures Included Maintenance: Regular service intervals, oil changes, filter replacements, chain adjustment Troubleshooting: Step-by-step diagnostic guides for common problems Repair: Detailed instructions for component disassembly, repair, and reassembly Rebuild: Comprehensive guides for engine and gearbox rebuilding Reconditioning: Guidance on restoring worn or damaged components Technical Depth Depth: Detailed, professional-level diagnostics and repair procedures Target Audience: Professional technicians and advanced DIY mechanics 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Full Printable Binding Type Binding Method: Digital (PDF download), no physical binding Paper Type Digital Format: Electronic document, no paper type specified Requirements Software Requirements: Adobe PDF Reader, WinRAR Compatibility: All versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, single-cylinder Bore X Stroke 60Sx: Approximately 44.5mm x 41.8mm (estimation based on typical 60cc two-stroke configurations) Bore X Stroke 65Sx: Approximately 45mm x 41.8mm (estimation based on typical 65cc two-stroke configurations) Cooling System: Liquid-cooled Performance Horsepower Estimated: Approx. 15-18 HP (typical for this class in 2002) Torque Estimated: Not explicitly stated, but indicative of strong mid-range power delivery Fuel System Carburetor Model Likely: Mikuni VM series (e.g., VM24SS or similar) or Keihin PWK Fuel Type: Unleaded gasoline with pre-mix (2-stroke oil) 🔧 Transmission Standard Transmission Type: 6-speed manual constant mesh Optional Clutch Type: Wet multi-plate clutch Features Gear Ratios: Specific ratios are detailed within the manual. 📐 Dimensions Exterior Wheelbase: Detailed within the manual. Seat Height: Detailed within the manual. Weights Dry Weight: Approximately 50-55 kg (110-121 lbs) depending on exact model and equipment. 🛡️ Safety Features Ratings Safety Certifications: Not applicable to off-road motorcycles in the same manner as street vehicles. Active Features Braking System: Hydraulic disc brakes front and rear Passive Features Frame Construction: High-strength steel perimeter frame for rider protection and chassis rigidity. 💡 Technology Features Infotainment Features: Not applicable (purely competition-focused off-road motorcycle). Driver Assistance Features: Not applicable. 🔧 Maintenance Service Intervals Oil Change Engine: Every 5-10 hours of riding (typical for racing engines) Air Filter Cleaning: After every few rides or as needed based on conditions Spark Plug Replacement: As...