This manual covers the 65SX and 65 XC models from the 2009 model year. An Austrian manufacturer renowned for its high-performance off-road and racing motorcycles, engineered these bikes for junior motocross and cross-country riding. The 65SX is specifically designed for competitive motocross racing, while the 65XC is optimized for general off-road and cross-country use. These models are characterized by their potent 65cc liquid-cooled, 2-stroke engines, robust chromoly steel perimeter frames, and capable suspension systems, all contributing to their reputation for performance and durability in their class. This comprehensive Factory Service Repair Workshop Manual, provided in English, offers detailed guidance for owners, home mechanics, and professional technicians. It encompasses a wide array of critical information, including complete engine disassembly and assembly, fuel and ignition system servicing, transmission and clutch procedures, suspension and brake system maintenance, and electrical system diagnostics. The manual includes step-by-step instructions supported by hundreds of detailed photos and exploded diagrams, covering everything from routine scheduled maintenance and lubrication to in-depth troubleshooting, repair, and complete rebuild procedures for all major components. 🏷️ Basic Information Identification Make: KTM Model: 65SX / 65 XC Year: 2009 👋 Introduction Market Position Target Audience: Owners, home mechanics, and professional technicians for the KTM 65SX/XC Purpose: To provide comprehensive guidance for repair, maintenance, and troubleshooting Competitive Analysis Value Proposition: Full factory documentation, detailed visuals, lifetime access at a single price point Key Features Visual Aid: Hundreds of detailed photos and diagrams for clarity Completeness: Covers all repair, servicing, and troubleshooting procedures 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Workshop Manual Language: English Format: PDF (Downloadable) Page Count: Hundreds of Pages 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, troubleshooting, and overhaul Fuel System: Carburetor service, fuel tank, fuel lines, fuel pump (if applicable) Ignition System: CDI, spark plug, wiring diagrams Cooling System: Radiator, hoses, coolant specifications and procedures Transmission: Clutch operation, gearbox disassembly and assembly, gear oil specifications Suspension: Front fork service, rear shock absorber service, internal components, adjustments Brakes: Hydraulic brake system, caliper service, master cylinder, brake fluid specifications Electrical System: Wiring diagrams, component testing, battery, lighting Chassis And Frame: Frame inspection, steering head bearing service Bodywork And Plastics: Fairing removal and installation, seat, handlebars Procedures Included Maintenance: Scheduled maintenance, routine inspections, lubrication points Troubleshooting: Diagnostic procedures for common and uncommon issues, symptom analysis Repair: Step-by-step repair instructions for all major components and systems Rebuild: Detailed procedures for engine and gearbox rebuilds Diagnostics: Systematic diagnostic flowcharts and component testing methods Technical Depth Depth Level: Comprehensive (from basic maintenance to complete overhaul and advanced diagnostics) Instruction Style: Step-by-step instructions with detailed photos and exploded diagrams 📊 Manual Specifications File Format Compatibility: Windows and MAC compatible Portability: Usable on unlimited computers Licensing: Lifetime usage, no expiry dates or renewal fees Printing: Printable pages (single or entire manual) Searchability: Likely searchable text-based PDF (standard for professional manuals) ⚙️ Engine Specifications Primary Engine Type: 2-stroke single-cylinder Displacement: 65cc Bore X Stroke: 43.5mm x 43.8mm (typical for this class) Cooling System: Liquid-cooled Performance Horsepower Approx: Approx. 15-18 HP (stock, varies with tuning) Torque Approx: Approx. 8-10 Nm (stock, varies with tuning) Fuel System Carburetor: Keihin PWK 28 (common specification) Fuel Type: Unleaded gasoline with 2-stroke oil mix Lubrication Mixing Ratio: 50:1 or 40:1 with high-quality 2-stroke oil (refer to manual for exact specification) 🔧 Transmission Standard Type: 6-speed manual transmission Clutch Type: Wet multi-plate clutch Features Gear Ratios: Specific ratios detailed within the manual Gear Oil Type: Specific transmission oil (e.g., SAE 10W/30, refer to manual for exact specification) Gear Oil Capacity: Specific capacity detailed within the manual 📐 Dimensions Exterior Wheelbase: Approx. 1150mm (refer to manual for exact figure) Seat Height: Approx. 770mm (refer to manual for exact figure) Weights Dry Weight: Approx. 60 kg (refer to manual for exact figure) 🛡️ Safety Features Active Features Brakes Front: Hydraulic disc brake Brakes Rear: Hydraulic disc brake Passive Features Frame Construction: Chromoly steel perimeter frame (standard for KTM SX models) 💡 Technology Features Infotainment Features: N/A (Performance-oriented off-road motorcycle, no infotainment features) Driver Assistance Features: N/A (Performance-oriented off-road motorcycle, no driver assistance systems) 🔧 Maintenance Service Intervals Oil Change Frequency: As per manual recommendations (typically after specific riding hours or events) Air Filter Cleaning: Frequent cleaning recommended, especially in dusty conditions Spark Plug Replacement: As per manual recommendations Fluid Specifications Coolant: Specific coolant mixture (e.g., distilled water and anti-freeze, refer to manual) Brake Fluid: DOT 4 brake fluid (typical for hydraulic systems, confirm with manual) Known Issues Common Wear Items: Clutch plates, piston rings, chain and sprockets, fork seals, brake pads Performance Tuning: Tuning for optimal performance requires detailed knowledge of jetting, exhaust, and porting, all covered by the manual 📚 Vehicle History Brand Heritage Manufacturer: KTM Sportmotorcycle AG (Austria) Specialty: Renowned for off-road and racing motorcycles Model Evolution Segment: Mini-motocross / Junior...