This manual covers the 60 SX and 65 SX off-road motorcycles produced between 1998 and 2002. These motocross bikes are renowned for their robust engineering, lightweight design, and agile handling, making them ideal for junior riders and competitive racing. Austrian heritage in off-road sports is reflected in the performance and durability engineered into these models, providing a solid foundation for developing riding skills. This comprehensive service manual provides detailed instructions for the repair and maintenance of your 60 SX / 65 SX. It covers all essential systems, including the engine, fuel system, transmission, drivetrain, suspension, brakes, and electrical system. You will find step-by-step procedures for routine maintenance, disassembly and assembly, troubleshooting, and rebuilding components. Technical specifications, torque values, fluid types, and wiring diagrams are also included, offering the necessary information for both professional technicians and dedicated enthusiasts to keep these machines in optimal condition. 🏷️ Basic Information Identification Make: KTM Model: 60 SX / 65 SX Model Years: 1998, 1999, 2000, 2001, 2002 Codes Vehicle Type: Off-road Motorcycle (Motocross) 👋 Introduction Market Position Target Audience: Professional technicians and DIY mechanics with basic mechanical and electrical knowledge Competitive Analysis Comparison To Paper: Provides the same comprehensive information as a factory paper manual, with the added benefit of instant download and digital access Key Features Instant Access: Immediate availability for download, allowing for prompt repairs Step By Step Guidance: Detailed, sequential instructions mirroring factory training Comprehensive Data: Covers all aspects of maintenance and repair, typically found in factory service and owner's manuals 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive repair and maintenance Secondary Coverage: Troubleshooting, diagnostics, specifications Page Count Estimated Pages: Likely 200-400+ pages (typical for factory-level repair manuals) Manual Type Type: Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Engine disassembly, assembly, inspection, tuning, lubrication, cooling system Fuel System: Carburetor (model specific, e.g., Keihin PWK), fuel tank, fuel lines, fuel filter Transmission: Gearbox disassembly, assembly, shifting mechanism, clutch operation Drivetrain: Chain and sprockets, rear hub, wheel bearings Suspension: Front fork (e.g., WP Suspension), rear shock absorber, linkage (if applicable), bushings, seals Brakes: Front and rear brake systems (hydraulic disc), caliper service, master cylinder, brake fluid specifications Electrical System: Ignition system (CDI), lighting (if applicable), wiring diagrams, battery, spark plug specifications Chassis Frame: Frame inspection, steering head bearings, swingarm, footpegs Bodywork Trim: Plastics, seat, handlebars, controls Procedures Included Routine Maintenance: Oil changes, filter cleaning/replacement, chain lubrication, brake adjustments, air filter service Disassembly Assembly: Complete step-by-step guides for all major components Troubleshooting: Diagnosis of common problems, symptom-based troubleshooting charts Rebuilds: Engine top-end and bottom-end rebuilds, suspension fork rebuilds Cleaning Lubrication: Specific procedures and recommended lubricants for various parts Specifications Data: Torque values, clearances, fluid capacities, tuning parameters Technical Depth Depth: Advanced diagnostic and repair procedures suitable for professional technicians and experienced DIY enthusiasts 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Print Quality Printable: Full Printable Zoom Functionality: YES (Allows zooming for detailed viewing of diagrams and text) Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Requirements Software: Adobe PDF Reader, WinZip (for extraction) Compatibility: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: 2-Stroke Single Cylinder Displacement 60Sx: Approximately 57.7cc Displacement 65Sx: Approximately 64.9cc Cooling System: Liquid-Cooled Fuel System Carburetor Examples: Keihin PWK (specific sizes vary by year and model) Fuel Type: Unleaded Gasoline mixed with 2-stroke oil (premix ratio specified in manual) Performance Horsepower Range: Estimated 15-20+ HP (varies by model and tuning) Torque: Specific torque figures will be detailed in the manual 🔧 Transmission Standard Type: 6-Speed Manual Features Clutch: Hydraulic Clutch Operation (typical for this era KTM) Gear Ratios: Detailed gear ratios will be provided within the manual Transmission Fluid: Specific ATF (Automatic Transmission Fluid) type and quantity detailed in manual 📐 Dimensions Exterior Wheelbase: Varies by model year, typically around 1200-1250 mm Weights Dry Weight: Approximately 55-60 kg (without fluids) 🛡️ Safety Features Ratings Crash Test Results: N/A (Off-road vehicles are not typically rated by consumer safety organizations like NHTSA or Euro NCAP) Active Features Braking System: Hydraulic Disc Brakes (Front and Rear) for effective stopping power Passive Features Frame Construction: Chromoly Steel Frame providing strength and rigidity 💡 Technology Features Infotainment Features: N/A (Focus is on performance and basic functionality for off-road riding) Driver Assistance Features: N/A 🔧 Maintenance Service Intervals Oil Change Engine: Refer to manual for specific intervals based on operating hours or mileage Air Filter Cleaning: Frequent cleaning recommended, especially in dusty conditions (e.g., after every few rides) Chain Maintenance: Regular cleaning, lubrication, and tension adjustment (check before every ride) Spark Plug Inspection: Recommended inspection and gap check at regular intervals (e.g., 20-30 hours) Fluid Specifications Brake Fluid: DOT 4 recommended (verify exact specification in manual) Coolant: Ethylene glycol-based coolant (50/50 mix with...