2012r Repair manual.pdf

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REPAIR MANUAL
2012
65 SX
Art. no. 3206114en
INTRODUCTION
Read this repair manual carefully and thoroughly before beginning work.
INTRODUCTION
1
Only use
ORIGINAL KTM SPARE PARTS.
The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly and properly.
This repair manual was written to correspond to the latest state of this series. We reserve the right to make changes in the interest of
technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that the repair work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not belong to the regular scope of delivery.
© 2011 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS
TABLE OF CONTENTS
2
Removing main silencer .................................................
Installing the main silencer ............................................
Changing the glass fiber yarn filling of the main silencer ...
06/AIR FILTER..................................................................
Removing the air filter ...................................................
Installing the air filter ....................................................
Cleaning the air filter and air filter box ............................
07/FUEL TANK, SEAT, TRIM..............................................
Removing the seat .........................................................
Mounting the seat .........................................................
Dismounting the fuel tank ..............................................
Installing the fuel tank ...................................................
08/MASK, FENDER ...........................................................
Dismounting the front fender ..........................................
Installing the front fender...............................................
Dismounting the start number plate ................................
Installing the start number plate .....................................
09/FRONT WHEEL ............................................................
Removing the front wheel ...............................................
Installing the front wheel................................................
Checking the tire condition.............................................
Checking tire air pressure ...............................................
Checking brake discs .....................................................
Checking spoke tension..................................................
10/REAR WHEEL ..............................................................
Removing the rear wheel ................................................
Installing the rear wheel .................................................
Checking chain dirt .......................................................
Cleaning the chain.........................................................
Checking the chain tension ............................................
Checking the chain, rear sprocket, engine sprocket, and
chain guide...................................................................
Adjusting the chain tension ............................................
Adjusting the chain guide...............................................
13/BRAKE SYSTEM...........................................................
Checking free travel of hand brake lever...........................
Adjusting the basic position of the hand brake lever..........
Checking front brake fluid level.......................................
Adding front brake fluid .................................................
Changing the front brake fluid ........................................
Checking the front brake linings......................................
Removing front brake linings ..........................................
Installing the front brake linings .....................................
Changing the front brake linings .....................................
Checking the free travel of the foot brake lever .................
Adjusting the free travel of the foot brake lever.................
Adjusting the basic position of the foot brake lever ...........
Checking rear brake fluid level........................................
Adding rear brake fluid ..................................................
Changing the rear brake fluid..........................................
Checking the rear brake linings .......................................
Removing rear brake linings............................................
Installing the rear brake linings.......................................
Changing the rear brake linings.......................................
30/ENGINE.......................................................................
Removing the engine .....................................................
Installing the engine ......................................................
30/DISASSEMBLING THE ENGINE.....................................
Clamping the engine into the engine work stand ...............
Removing the clutch pressure piece ................................
Removing the oil drain plug............................................
Removing the spark plug ................................................
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MEANS OF REPRESENTATION ............................................ 5
IMPORTANT NOTES ............................................................ 6
MOTORCYCLE..................................................................... 7
Raising the motorcycle with a lift stand ............................. 7
Removing the motorcycle from the lift stand ...................... 7
Starting .......................................................................... 7
01/FORK, TRIPLE CLAMP.................................................... 9
Adjusting the compression damping of the fork .................. 9
Adjusting the rebound damping of the fork......................... 9
Bleeding fork legs............................................................ 9
Cleaning the dust boots of the fork legs ........................... 10
Removing the fork protector............................................ 10
Installing the fork protector ............................................ 10
Removing the fork legs................................................... 11
Installing the fork legs ................................................... 11
Servicing the fork .......................................................... 12
Disassembling the fork legs ............................................ 12
Disassembling the piston rod .......................................... 15
Checking the fork legs.................................................... 16
Changing the pilot bushing............................................. 17
Assembling the piston rod .............................................. 18
Assembling the fork legs ................................................ 19
Greasing the steering head bearing.................................. 22
Removing the lower triple clamp ..................................... 22
Installing the lower triple clamp...................................... 23
Checking play of steering head bearing ............................ 24
Adjusting the play of the steering head bearing ................ 25
02/HANDLEBAR, CONTROLS, AND INSTRUMENTS............. 26
Adjusting basic position of clutch lever............................ 26
Checking the play in the throttle cable............................. 26
Adjusting the play in the throttle cable ............................ 26
Handlebar position ........................................................ 26
Adjusting handlebar position .......................................... 26
04/SHOCK ABSORBER, SWINGARM................................... 28
Adjusting the compression damping of the shock
absorber ....................................................................... 28
Adjusting the rebound damping of the shock absorber....... 28
Measuring rear wheel sag unloaded ................................. 28
Checking the static sag of the shock absorber .................. 29
Checking the riding sag of the shock absorber .................. 29
Adjusting the spring preload of the shock absorber ........... 29
Adjusting the riding sag ................................................. 30
Removing the shock absorber ......................................... 31
Installing shock absorber................................................ 31
Servicing the shock absorber .......................................... 31
Removing the spring ...................................................... 32
Disassembling the damper ............................................. 32
Disassembling the piston rod .......................................... 33
Checking the damper ..................................................... 34
Removing the heim joint ................................................ 35
Installing the heim joint ................................................. 36
Assembling the piston rod .............................................. 37
Assembling the damper.................................................. 38
Bleeding and filling the damper ...................................... 39
Filling the damper with nitrogen ..................................... 42
Installing the spring....................................................... 43
Removing the chain guard .............................................. 43
Installing the chain guard............................................... 43
05/EXHAUST .................................................................... 44
Removing the exhaust manifold ...................................... 44
Installing the exhaust manifold ....................................... 44
TABLE OF CONTENTS
Removing the exhaust control ......................................... 78
Removing the cylinder head............................................ 79
Removing the exhaust control valve ................................. 80
Removing the cylinder ................................................... 80
Removing the piston ...................................................... 80
Removing the engine sprocket ........................................ 80
Removing the spacer ..................................................... 81
Removing the alternator cover......................................... 81
Removing the rotor ........................................................ 81
Removing the stator....................................................... 82
Removing the kickstarter ................................................ 82
Removing the water pump cover ..................................... 82
Removing the clutch cover ............................................. 82
Removing the outer clutch hub ....................................... 82
Removing the primary gear ............................................. 83
Removing the kickstarter shaft........................................ 84
Removing the intermediate kickstarter gear...................... 84
Removing the shift shaft ................................................ 84
Removing the shift drum locating.................................... 84
Removing the locking lever ............................................. 84
Removing the reed valve housing .................................... 85
Removing the left engine case section ............................. 85
Removing the shift rails ................................................. 86
Removing the shift drum ................................................ 86
Removing the shift forks ................................................ 86
Removing the transmission shaft..................................... 86
Removing the crankshaft ................................................ 87
30/ENGINE - WORK ON INDIVIDUAL PARTS....................... 88
Work on the right section of the engine case .................... 88
Work on the left section of the engine case ...................... 89
Changing the connecting rod, conrod bearing, and crank
pin............................................................................... 89
Checking the crankshaft run-out on the bearing pin .......... 91
Removing the water pump .............................................. 91
Installing the water pump............................................... 91
Checking/measuring the cylinder..................................... 92
Checking/measuring the piston ....................................... 92
Determining the piston/cylinder mounting clearance ......... 93
Checking the piston ring end gap .................................... 93
Checking the reed valve housing, diaphragm and intake
flange........................................................................... 94
Disassembling the clutch ............................................... 94
Checking the clutch....................................................... 95
Premounting the clutch.................................................. 95
Checking the shift mechanism ........................................ 96
Preassembling the shift shaft.......................................... 97
Disassembling the main shaft ......................................... 97
Assembling the main shaft ............................................. 98
Dismantling the countershaft.......................................... 98
Assembling the countershaft........................................... 99
Checking the transmission.............................................. 99
Premounting the kickstarter shaft.................................. 101
30/ASSEMBLING THE ENGINE ........................................ 102
Installing the crankshaft............................................... 102
Installing the transmission shafts .................................. 102
Installing the shift forks ............................................... 102
Installing the shift drum............................................... 102
Installing the shift rails ................................................ 103
Installing the left engine case section............................ 103
Installing the reed valve housing ................................... 103
Installing the locking lever............................................ 104
Installing the shift drum locating .................................. 104
Installing the shift shaft ...............................................
Installing the intermediate kickstarter gear.....................
Installing the kickstarter shaft ......................................
Installing the primary gear............................................
Installing the outer clutch hub......................................
Installing the clutch cover ............................................
Mounting the water pump cover ....................................
Installing the kickstarter...............................................
Installing the stator .....................................................
Installing the rotor .......................................................
Installing the piston.....................................................
Installing the cylinder ..................................................
Checking the X-distance...............................................
Setting the X-distance..................................................
Adjusting the ignition...................................................
Installing the alternator cover .......................................
Installing the spacer ....................................................
Installing the engine sprocket .......................................
Installing the exhaust control valve................................
Installing the cylinder head ..........................................
Installing the exhaust control........................................
Installing the spark plug...............................................
Installing the oil drain plug...........................................
Installing the clutch pressure piece ...............................
Removing the engine from the universal mounting
rack ...........................................................................
31/CARBURETOR ...........................................................
Removing the carburetor ..............................................
Installing the carburetor ...............................................
Disassembling the carburetor........................................
Assembling the carburetor ............................................
Checking/setting the carburetor components ..................
Checking the jet needle................................................
Checking the throttle slide............................................
Checking the float needle valve.....................................
Checking the choke slide..............................................
Checking/setting the float level .....................................
Carburetor - adjusting the idle speed .............................
Emptying the carburetor float chamber ..........................
32/CLUTCH ....................................................................
Checking the fluid level of hydraulic clutch....................
Changing the hydraulic clutch fluid ...............................
35/WATER PUMP, COOLING SYSTEM ..............................
Draining the coolant ....................................................
Refilling the coolant ....................................................
Checking the antifreeze and coolant level ......................
Checking the coolant level............................................
38/LUBRICATION SYSTEM ..............................................
Checking the gear oil level............................................
Changing the gear oil ...................................................
Draining the gear oil ....................................................
Filling up with gear oil .................................................
Adding gear oil ............................................................
39/IGNITION SYSTEM .....................................................
Checking the ignition system ........................................
Checking the kill switch ...............................................
Checking the ignition pulse generator ............................
Checking the alternator ................................................
Checking the spark plug connector................................
Checking the CDI controller ..........................................
Checking the ignition coil.............................................
TROUBLESHOOTING.......................................................
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