This manual covers the 1999 60 SX and 65 SX models, representing a strong heritage in off-road and motocross racing. Designed for younger and intermediate riders, these bikes are built with a focus on performance and durability, featuring a chromoly steel frame and advanced suspension systems. The 60 SX, suitable for younger riders with its smaller engine, and the 65 SX, geared towards intermediate riders with a slightly larger displacement, both embody a commitment to the junior motocross market, offering robust engineering for competitive riding. This comprehensive service and repair manual provides detailed instructions for the maintenance, troubleshooting, and repair of your 60 SX or 65 SX. It covers all essential systems, including the engine, transmission, brakes, suspension, and electrical components, with step-by-step procedures, diagnostic guidance, and detailed wiring diagrams. This resource is invaluable for owners and technicians seeking to maintain the optimal performance and longevity of these motocross machines, offering a singular source for all repair and maintenance needs. 🏷️ Basic Information Identification Make: KTM Model: 60 SX / 65 SX Year: 1999 Generation Generation Code: KTM SX Generation 1 (Pre-2000s) Codes Model Variant Codes: 60 SX (younger rider/smaller engine), 65 SX (intermediate rider/larger engine) 👋 Introduction Market Position Target Audience: Owners and mechanics of 1999 KTM 60 SX and 65 SX motocross bikes. Competitive Analysis Comparison Points: This manual offers a comprehensive alternative to limited OEM service bulletins or less detailed online resources, providing a singular source for all repair and maintenance needs. Key Features Unique Selling Points: Instant download availability, printable format, detailed illustrations, numbered steps, and professional-grade diagnostic information. 📋 Manual Details Coverage Areas Primary Coverage: KTM 60 SX & 65 SX models for the 1999 model year. Secondary Coverage: Potential overlap with late 1998 and early 2000 models due to platform continuity. Page Count Estimated Page Count: Likely 300-500+ pages (typical for comprehensive service manuals). Manual Type Manual Type: Full Service Repair Manual / Workshop Manual Language Language: English Format File Format: PDF Delivery Method: Instant Download Printability: Full Printable 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, top-end and bottom-end components, lubrication, cooling (air-cooled), fuel delivery (carburetor specifics). Transmission: Clutch operation, gear shifting mechanisms, internal transmission components, gearbox oil specifications and service. Electrical: Ignition system, lighting, wiring diagrams, troubleshooting electrical faults, component testing. Suspension: Front fork (USD - Upright Dual Spring) servicing, rear shock absorber (WP Suspension) inspection and adjustment, spring and damping characteristics. Brakes: Hydraulic disc brake systems (front and rear), brake fluid specifications, caliper maintenance, bleeding procedures. Chassis And Frame: Frame inspection, subframe, swingarm, linkage systems, steering head bearings. Fuel System: Carburetor identification and adjustment (likely Mikuni VM series), fuel tank, fuel lines, petcock. Exhaust System: Exhaust pipe and silencer maintenance, gasket replacement. Procedures Included Maintenance: Regular service checks, lubrication points, filter replacements, spark plug service, chain adjustment. Troubleshooting: Detailed diagnostic procedures for common issues, symptom-based troubleshooting guides. Repair: Step-by-step instructions for component replacement and repair, from minor adjustments to complete engine rebuilds. Rebuild Refurbish Restore: Comprehensive guidance for full restorations, including engine, transmission, and suspension overhauls. Wiring Diagrams: Detailed electrical schematics for all circuits. Technical Depth Diagnostic Capability: Advanced diagnostic procedures and electrical troubleshooting. Rebuild Depth: Full engine, transmission, and suspension rebuilds. User Level: Aimed at professional technicians but accessible to skilled DIY mechanics. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Print Quality Print Resolution: High resolution, optimized for clear printing of text and diagrams. Binding Type Binding Type: Digital (PDF) - No physical binding. Paper Type Paper Type: Digital - N/A (Printable on any paper type). Requirements Software Requirements: Adobe Acrobat Reader, WinRAR (for potential ZIP extraction if bundled). Operating System Compatibility: All Windows versions, macOS, Linux (via PDF readers). ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 2-stroke, liquid-cooled (typical for SX models of this era, though some early 60s might have been air-cooled; manual will specify). Bore Stroke 60Sx: Likely around 45.0 mm bore x 34.5 mm stroke (estimate based on common configurations). Bore Stroke 65Sx: Likely around 45.5 mm bore x 41.0 mm stroke (estimate based on common configurations). Displacement 60Sx: Approximately 56.5 cc (estimate). Displacement 65Sx: Approximately 65 cc (estimate). Performance Horsepower Estimate 60Sx: Likely in the 12-15 HP range (estimate). Horsepower Estimate 65Sx: Likely in the 16-19 HP range (estimate). Fuel System Carburetor Type: Mikuni VM series, likely 20-24mm bore for 60 SX and 24-26mm for 65 SX (manual will confirm exact model and jetting). Fuel Mixture: 2-stroke pre-mix, specified ratio (e.g., 40:1 or 50:1) in manual. 🔧 Transmission Standard Transmission Type: 6-speed constant mesh manual gearbox. Optional Optional Gearbox: N/A (standard configuration for this class). Features Clutch Type: Hydraulically operated multi-plate wet clutch. Gear Ratios: Detailed gear ratios for each of the 6 speeds will be provided in the manual. Transmission Oil Type: Specific gearbox oil (e.g., SAE 10W/30...