This manual covers the 2009 65 SX and 65 XC models, designed as entry-level performance motocross and off-road competition bikes for young riders. Embodying a 'Ready to Race' philosophy, these models feature lightweight design, powerful 65cc two-stroke engines, and high-quality components aimed at competitive performance. With a 6-speed transmission and hydraulic disc brakes, the 65 SX and XC are built for agility and control on the track and trails, continuing a strong heritage in youth motorsports. This comprehensive 168-page service and repair manual provides detailed information for technicians and owners. It covers all essential aspects of the vehicles, including engine teardown and assembly, fuel and lubrication systems, electrical troubleshooting, chassis components, and suspension servicing. The manual includes periodic maintenance schedules, tune-up procedures, engine rebuild steps, brake and suspension service guides, and detailed troubleshooting diagnostics. It is written in English and is presented in a printable format. 🏷️ Basic Information Identification Make: KTM Model: 65 XC Year: 2009 Product Type: Service Repair Manual 👋 Introduction Market Position Market Niche: Entry-level performance motocross and off-road competition bikes for young riders. Competitive Analysis Competitors: Primary competitors include Yamaha YZ65, Honda CRF65R, and Kawasaki KX65. Key Features Vehicle Philosophy: KTM's 'Ready to Race' philosophy, emphasizing lightweight design, powerful engines, and high-quality components for competitive performance. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service and repair information for 2009 KTM 65 SX and XC models. Page Count Page Count: 168 pages Manual Type Manual Type: Professional Technician Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed coverage of the 65cc two-stroke engine, including teardown, assembly, and troubleshooting. Fuel System: Carburetor adjustment, cleaning, fuel pump, and fuel tank servicing. Lubrication System: Oil mixing ratios, oil pump operation, and lubrication circuit servicing. Electrical System: Ignition system, lighting, battery, wiring diagrams, and troubleshooting of electrical faults. Chassis: Frame, suspension (front forks and rear shock absorber), steering, wheels, and brakes. Procedures Included Periodic Maintenance: Scheduled maintenance checks, lubrication, and filter replacements. Tune Up Procedures: Spark plug inspection and replacement, carburetor tuning, and general performance adjustments. Engine Repair: Piston and cylinder inspection/replacement, crankshaft and connecting rod servicing, clutch and gearbox maintenance. Suspension Servicing: Fork seal replacement, oil changes, shock absorber adjustments, and linkage bearing service. Brake Servicing: Brake pad replacement, caliper maintenance, brake fluid bleeding, and hydraulic system checks. Troubleshooting: Step-by-step diagnostic procedures for common mechanical and electrical issues. Technical Depth Depth: Detailed, in-depth coverage suitable for professional technicians, including torque specifications, clearances, and rebuild procedures. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: Printable (Yes) Binding Type Binding Type: Digital Download (no physical binding) Paper Type Paper Type: N/A (Digital format) Compatibility Compatibility: Compatible with Windows and Mac operating systems. Requirements Software Requirements: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Type: 65cc Liquid-Cooled, Single-Cylinder, Two-Stroke Bore X Stroke: 43.5 mm x 43.0 mm Carburetor: Keihin PWK 28 (standard specification, may vary slightly) Performance Horsepower Estimate: Approximately 14-16 HP (actual output varies with tuning and condition) Torque Estimate: Approximately 7-8 lb-ft (actual output varies with tuning and condition) Fuel System Fuel Type: Unleaded Gasoline (91 octane or higher recommended) Oil Mixture: 50:1 ratio with high-quality 2-stroke premix oil (e.g., Motorex, Castrol) 🔧 Transmission Standard Transmission Type: 6-Speed Constant Mesh Features Clutch Type: Hydraulically Operated Multi-Plate Wet Clutch Gearbox Oil Spec: KTM recommends specific gearbox oil (e.g., Motorex Gear Oil 10W/40 or equivalent) 📐 Dimensions Exterior Wheelbase: Approx. 1,160 mm (45.7 inches) Seat Height: Approx. 745 mm (29.3 inches) Weights Dry Weight: Approx. 52 kg (114.6 lbs) 🛡️ Safety Features Ratings Safety Focus: Designed for off-road competition; safety features primarily relate to rider control and braking effectiveness. Active Features Brakes: Hydraulic Disc Brakes (Front and Rear) Suspension Damping: Adjustable suspension components for optimal control and handling. 💡 Technology Features Infotainment Infotainment System: Not applicable to this model; focused on performance and rider control. Driver Assistance Rider Aids: No electronic rider aids (e.g., traction control, ABS) on this model. Performance is purely mechanical. 🔧 Maintenance Service Intervals Oil Change Frequency: Gearbox oil change every 10-15 hours of riding. Clutch fluid check/flush as per manual. Air Filter Cleaning: Clean air filter after every few rides, depending on conditions. Replacement as needed. Spark Plug Service: Inspect and clean/gap spark plug every 5-10 hours; replace as needed. Top End Rebuild: Top-end rebuild (piston, rings, cylinder inspection) typically recommended every 30-50 hours of competitive use, depending on rider and conditions. Fluid Specifications Fork Oil Type: Specific fork oil viscosity (e.g., WP Suspension Fluid 5W or equivalent) as detailed in the manual. Coolant Type: Mixture of distilled water and appropriate antifreeze/coolant (e.g., 50/50). Known Issues Common Wear Items: Clutch plates, piston rings, chain and sprockets, wheel bearings, and suspension seals are common wear items requiring regular inspection and replacement. Carburetor Tuning: Carburetor...