spare parts manual: chassis · air filter box 12x tank, seat, cover 13x mask, fenders 14x decal 15x...

65 SX 2008

SPARE PARTS MANUAL: CHASSIS

ART.NO.: 3CF6001H6EN

EN

GLIS

H

INDEX 65 SX 2008

FRONT FORK

3x

FRONT FORK DISASSEMBLED

4x

HANDLEBAR, CONTROLS

6x

FRAME, SUBFRAME

7x

SWING ARM

8x

MONOSHOCK DISASSEMBLED

9x

EXHAUST SYSTEM

11x

AIR FILTER BOX

12x

TANK, SEAT, COVER

13x

MASK, FENDERS

14x

DECAL

15x

FRONT WHEEL

16x

1

INDEX 65 SX 2008

REAR WHEEL

17x

HAND BRAKE CYLINDER

18x

REAR BRAKE CONTROL

19x

BRAKE CALIPER FRONT

20x

BRAKE CALIPER REAR

21x

ACCESSORIES KIT

22x

x

x

x

All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical

specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local

conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing

certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations,

descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models.

© by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTM-

SPORTMOTORCYCLE AG, Mattighofen only.

2

65 SX 2008

FIG PART NUMBER DESCRIPTION QTY

1 7631210/F FORK LEG L/S USD 35 1

2 7631209/F FORK LEG R/S USD 35 1

5 0025080306 HH COLLAR SCREW M8X30 TX40 9

6 0912100250 AH SCREW DIN6912-M10X25,10.9,L 2

31 77051116 BOT.TRIPLE CLAMP + FORK TUBE 1

34 7501478 TOP TRIPLE CLAMP 1

38 50301038000 HANDLEBAR CLAMP D=22MM 2001 2

39 59001039000 HANDLEBAR SUPPORT 22MM 2T 2000 1

42 59030029000 HH NUT M20X1,5 WS=27 RIGHT 1

43 49001086000 COVERING CAP 1

44 0770021300 O-RING 40,94X2,62 NBR70 1

45 49001081000 TAPERED ROLLER BEARING 32004X 2

46 46001086000 PROTECTION RING 20,1X39X5 1

47 0770360030 O-RING 36,00X3,00 NBR 1

91 59001092050 SPECIAL SCREW M6X12,5 WS=8 6

92 46101092000 FORK PROTECTION L/S 65SX 2002 1

93 46101093000 FORK PROTECTION R/S 65SX 2002 1

94 54601085000 BRAKE HOSE CLAMP MARZOCCHI'95 1

95 0025050166 HH COLLAR SCREW M5X16 TX30 2

96 0985050003 SELF LOCKING NUT DIN0985-M 5 2

084610110 / C084610112

* NEW PART

X AS REQUIRED

3

FRONT FORK

65 SX 2008


1* 0025060306 HH COLLAR SCREW M6X30 TX30 2

2 7819139/C SLIDER + AXLE CLAMP CPL. R/S 1

3 7538029 GUIDE RING D=35 2

4 7717065/R FOOT VALVE 2

5 7528005 O-RING D=20,3 2

6 7521092/D SPECIAL NUT M6X1 WITH STEP 1

7 7517217 REED VALVE 22X8,1X0,1 4

8 7530097/B PISTON REBOUND D=26 1

9 7524163 PISTON RING D=26 1

11 75141087 LOWER REBOUND SPRING 2

13 75321033 PIN 8X30 2

14 75181140/R TUBE BODY R/S 1

15 7523224 STOP RING 10X1 2

16 75181153 GUIDE BUSH 6,4X12X12 2

17 7521005 SPECIAL NUT 2

18 78031082 REBOUND CPL. 1

19 7701196 PLUG CPL. 2

20 7850208AR LENTIL HEAD SCREW M4X6 2

21 7528180 O-RING D=3,69, S=1,78 2

22 7528008 O-RING D=34,6, S=1,78 2

24 7850728 SPRINGS + PRELOAD SLEEVES KIT 1

25 7533167 DUST CAP 2

26 7523236 LOCK WASHER D=51,5 2

27 7528034 OIL SEAL 35X47X10 2

28 7539032AA WASHER 36X47X3 2

29 7538038/A GUIDE RING 35X15 2

30 7760069FN/C OUTER TUBE CPL. 2

33 7514077 TOP REBOUND SPRING 2

35 78031083 COMPRESSION CPL. 1

36 75181139/R TUBE BODY L/S 1

38 7535099 COMPRESSION DAMPING SHIM 1

39 7517028 SHIM 8,1X23X0,2 1

39 7517039 SHIM 8,1X22X0,2 1

39 7517060 SHIM 8,1X22X0,3 1

40 7530090/B PISTON COMPRESSION D=26 1

42 7521147/A SPECIAL NUT M6X1 WITH STEP 1

084610130 / C084610130

* NEW PART

X AS REQUIRED

4


65 SX 2008


43 7819140/C SLIDER + AXLE CLAMP CPL. L/S 1

44 7309651/R COMPRESSION CARTRIDGE CPL. 1

45 7309652/R * REBOUND CARTRIDGE CPL. 1

46 7522061 SHIM 8X12X1,5 2

47 0912080253 AH SCREW DIN0912-M 8X25 2

48 7517044 SHIM 8,1X23X0,3 2

90 7550013 FORKOIL EBH16 SAE 7.5 1

99 7850731/C REPAIR-KIT USD 35 1

084610130 / C084610130

* NEW PART

X AS REQUIRED

5


65 SX 2008


1 46102001200 HANDLEBAR 65 SX 2005 1

2 46102010000 THROTTLE GRIP W.COVER 65 SX 02 1

3 46102091000 THROTTLE CABLE DOMINO 65 SX 02 1

4 50202021000 GRIPP SET 1

6 46002012000 SPACER BUSHING 21,5X28X7,5 1

7 50302020000 PROTECTION COVER '97 1

9 50311089200 SHORT CIRCUIT BUTTON 02 1

30 46102030100 MASTER CYLINDER CPL. D=9MM 05 1

31 54602031000 CLUTCH LEVER SHORT CPL. 2003 1

31 59002031000 CLUTCH LEVER LONG CPL. 2003 x

32 59002032100 REP.KIT PISTON 9,0MM RAC. 2004 1

33 50302033100 COVER HYD.CLUTCH 2T 2000 1

34 50302034000 RUBBER FOR RESERVOIR '98 1

35 59002035000 SPRING FOR CLUTCH LEVER 03 1

36 50302036200 OIL FOR HYD. CLUTCH 75ML 1

37 50302037000 PROTECT.CAP FOR LEVER PERCH'98 1

38 50302038000 LEVER SCREW CPL. 125-200 '98 1

39 50302030150 CLAMP WITH PIN 2000 1


44 0965040123 FLAT HEAD SCREW DIN0965-M 4X12 2

62 50332063050 SELF CUTTING RING HYDR.PIPE x

63 46132063000 PIPE KIT FOR HYDR.CLUTCH 65 SX 1

64 54002016000 PROTECTION CAP 1

084610210 / C084610210

* NEW PART

X AS REQUIRED

6

HANDLEBAR, CONTROLS

65 SX 2008


1 4610300120030 FRAME 65 SX "MD6R" bl. 2007 1

2 46103002044 SUB FRAME 65 SX 2002 1

3 58711054050 METAMOLL FOR BATTERY BRACKET 2

4 54606004000 PLUG 37MM 2

5 0017060203 EJOT PT SCREW K60X20 WS=6 2

7 0934080003 HEXAGON NUT DIN0934-M 8 4

8 54610052000 SPROCKET SCREW-AH M8X20 WS=6 2

9 54510052100 SPROCKET SCREW-AH M8X26 WS=6 2

11 0125080003 WASHER DIN0125-A 8,4 2

12 54310086200 SELF LOCKING NUT M8 10.9 2

13 59001037000 SPECIAL SCREW M8X26 WS=10 2

15 0931080805 HH SCREW DIN 931 M8X80 10.9 2

20 50203053000 CHAIN ROLL D=30MM 1

21 74003021000 BUSHING 8.2 X 12 X 6 1

22 0625006087 GROOVED BALL BEAR. 608 2RS C3 2

23 36003014000 LOCK WASHER 8MM 2


27 4610304013390A FOOTREST L.+R. CPL. 65 SX 03 x

28 54803044000 BOLT FOR FOOT PED 03 2

29 54603041000 FOOTREST SPRING L/S & R/S 2

30 0125100003 WASHER DIN0125-A10,5 2

31 0094032253 PIN DIN0094-3,2X25 STEEL 2

32 5460304010090 FOOT PED L/S SILVER '98 1

33 59003041050 FOOT PED R/S EXC SILVER 2000 1

40 50303002182 PLUG-IN CAP SW14 99 2

084610311 / C084610311

* NEW PART

X AS REQUIRED

7

FRAME, SUBFRAME

65 SX 2008


1* 46104030144 SWING ARM CPL. 65 SX 2008 1

2* 03187D03 MONOSHOCK 65SX 2008 1

3 54603097000 NEEDLE BUSH HK 2016 2

4 46004030070 SPACER BUSHING 20X26X30X9,7 4

6 46004030071 BUSHING BOX 12X20X36,5 2

7 0770160021 O-RING 16,00X2,00 VITON 4

10 46104066000 CHAIN SLID. GUARD FRO. 65SX 02 1

11 46104066050 BUSH FOR CHAIN SLIDER GUARD 02 1

12 0010050103 SPECIAL SCREW M 5,0X10 2

13 0009050103 SPECIAL SCREW M 5,0X10 2

14 46007066000 CHAIN GUIDE REAR 60/65 '98 1



21 0931100453 HH SCREW DIN0931-M10X45 2

22 0125100003 WASHER DIN0125-A10,5 2

23 54310086100 SELF LOCKING NUT M10 CU WS=14 2

24 46012024000 HOOK WRENCH FOR SHOCK ABSORBER 1

25 46004037000 SWINGARM BOLT 201MM M12X1 1

26 0125120003 FLAT WASHER DIN0125-A13 2

28 0917120103 NUT DIN917-M12X1 2

30 46010083000 CHAIN ADJUSTER 60/65 '98 2

31* 50203030090 HH SCREW M8X40 WS=10 2

32* 0934080003 HEXAGON NUT DIN0934-M 8 2

35 54611076100 RETAIN.CLAMP FOR BRAKE HOSE'96 2

084610411 / C084610411

* NEW PART

X AS REQUIRED

8

SWING ARM

65 SX 2008


1 46811525 SHOCK ABS. BOTTOM L=46 1

2 36120586S PISTON ROD D=14, L=126 1

3 46811401S NEEDLE CPL. D=4, L=142 1

4 46811222 O-RING 36X0,5 1

5 46811263 WASHER 1

6 46811261 PIN 4X35 1

7 46811262 ADJ. KNOB D=41 1

10 46811221 O-RING 35X3 1

11 46811367 INTERMEDIATO RING H=4 1

12 46811268 CIRCLIP 22X1,2 1

13 46811259 NEEDLE SEAT 5X17,25 1

16 46811076 ADAPTOR BUSH KGW 10X20 2

17 46811027 BUSHING KGW 1525 2

18 46811077 ADAPTOR BUSH KGW 10X22 2

19 46811050 SEAL KGW 4

22 36120135 BUMP RUBBER WP65 RED 1

23 36120650 SCREW CAP M37,65 STEEL 1

24 46811044 DUST SEAL 1424 1

25 36120064 O-RING NBR 29,74X3,53 1

26 36120522S1 ADAPTER CPL. D=36 H=20,5 1

27 36120469 SHIM 28,5X14X2 1

30 36120726 SHOCK ABSORB.CASE PGB KGW H=33 1

31 0770380020 O-RING 38,00X2,00 NBR 70 SH 3

32 36120137 TUBE L=167 1

33 36120019 THREADED BUSH L=70 BLACK 1

34 36120467 PROTECTION SLEEVE L=40 1

41 36120015 COUNTERNUT 1

42 36120418 ADJUSTING NUT 1

43 40540015 CIRCLIP 38X1,5 1

45 46810893 O-RING NBR 5,28X1,78 1

46 36120151 SCREW PLUG M5X6 1

47 93010181S SPRING 40N/MM 40-220 220MM ORA 1

47 93010182S SPRING 35N/MM 35-220 220MM ORA x

47 93010183S SPRING 45N/MM 45-220 220MM ORA x

48 36120386 SPRING RET. H=3, D=14,5 1

49 46811208 RUBBER CAP "DO NOT OPEN" 1

084610430 / C084610430

* NEW PART

X AS REQUIRED

9


65 SX 2008


50 50180342S1 SHOCK ABSORBER FLUID 5 LT '03 1

60 36120557 REBOUND BUSH H=5,6 1

75 36120603 PISTON 6+6XD=5,5/3,5 BA 1

77 36120040 PISTON RING 8X1X108,3 1

78 46811267 BUSHING 6X9X3 1

79 46811251 BLEED SCREW M 4X6 1

80 36120604 SHIM D10XD22X2,5 1

81 40540450 SHIM 6X9,5X0,3 1

82 40540403 SHIM 6X18X0,1 4

83 36120605S2 PISTON ROD NUT CPL. H=15,2 1

85 36120631 RESERVOIR SCREW L=98 GREY 1

86 36120024 SEPARATION PISTON D=42 1

87 36120466 O-RING VITON 32X5 1

88 46810022 PISTON RING 3,9X1,5X124 1

89 36120552 SCREW FOR RESERVOIR CAP M5 1

90 46810850S7 CC-COMPRE.DAMPING CONTROL CPL. 1

91 46810334 LOCK WASHER JV24 1

92 46810333 STEEL-BALL D=4,75 1

93 50180131S ADJUSTING KNOB CC-MECH. CPL. 1

94 50180095 BLEED PLUG R 1/8 1

084610430 / C084610430

* NEW PART

X AS REQUIRED

10


65 SX 2008


1 46105007000 EXHAUST PIPE 65 SX 2002 1

2 46105079100 MAIN SILENCER 65 SX 2006 1

3 45105079056 ROCKWOOL PREFOMED 50 2002 1

110 GRAMM TOTAL WEIGHT

4 54605057000 RUBBER SLEEVE D=21MM/23MM '93 1

5 50305016000 TEN.SPRING L=62MM EY.MOVEABLE 2

6 0770350030 O-RING 35,00X3,00 VITON 1



9 54603048100 RANGE CHANGE METAL NUT M6 3

10 50305012000 SWINGELEMENT FOR EXHAUST PIPE 2

11 54605068000 EXHAUST BRACKET RUBBER BLACK 1

12 54605069000 BUSHING 7,5X12X28X7,8 '96 2


14 0137060003 SPRING WASHER DIN0137-B 6 1

084610511 / C084610511

* NEW PART

X AS REQUIRED

11

EXHAUST SYSTEM

65 SX 2008


1* 46106001000 A AIR FILTER BOX 65XC 2008 1

2 58406015100 AIRFILTER 1

3 58406016000 FILTER CARRIER '97 1

5 46006010000 SPLASH PROTECTOR 60/65 SX '98 1

6 46106017000 HOLDING HANGER FOR FILTER 2002 1

7 46006026000 CARBURETOR CONNECTING BOOT 1

10 46005058000 HOSE CLAMP 40-60MM 1

11 45007027000 HOSE CLAMP 32-50MM W=5MM 1


20 46106006000 BUSH FOR SPLASH PROTECTOR 2002 2

084610611 / C084610611

* NEW PART

X AS REQUIRED

12

AIR FILTER BOX

65 SX 2008


3 4610701300030 FUEL TANK CPL. 65 SX bl. 2007 1

4 46107040200 SEAT 65 SX 2005 1

5 50307014000 TANK ROLLER 12X26X12 '98 3

6* 4610805000004A SPOILER L/S WITH DECAL 08 1

6* 4610805100004A SPOILER R/S WITH DECAL 08 1



9 50332095200 TUBE RUBBER 6X9 DVOH 200MM 1

10 49007008044 FILLER CAP CPL. SMALL 1

14 55007006200 O-RING 11X1,8 NBR 70 1

15 58507003000 FUEL COCK CPL. SMALL RALLYE'96 1

25 45007040051 QUICK RELEASE CPL. 50 SXR '97 1

37 45107011000 TANK SCREW MINI 50 2001 1

48 58007117000 YDNAC-CLAMP 10107 10MM 2

49 50307016000 FUEL PREFORMED HOSE SX 2001 1

084610710 / C084610711

* NEW PART

X AS REQUIRED

13

TANK, SEAT, COVER

65 SX 2008


1 4610800700004 START NUMBER PLATE 65SX 2002 1


3 4610801300004 REAR PART 65 SX ORANGE 2003 1

4 45007040050 QUICK RELEASE LATCHPLATE 1

5 72210079000 BUCKET 2


7 0981350163 SHEET MET.SCR.DIN7981- 3,5X16 2


9 4610801000004 FENDER FRONT 65SX 2002 1

10 59003001099 METAMOLL 90X45X3MM 03 1

084610810 / C084610810

* NEW PART

X AS REQUIRED

14

MASK, FENDERS

65 SX 2008


1* 46108099600 SPOILER DECAL L/S+R/S 65 SX 08 1

2* 46108092600 DECAL 65 SX 2008 1

084610830 / C084610830

* NEW PART

X AS REQUIRED

15

DECAL

65 SX 2008


1* 46109001544 FRONT WHEEL-SP 1,6X14" ALU ´08 1

2 46109010144 FR.WHEEL HUB CPL. SILVER 2006 1

3 46009014000 SPACER BUSH L/S 65SX 04 1

4 46009013000 SPACER BUSH R/S 65SX 04 1

9 0625060037 GR.BALL BEAR. 6003-2RSH/C3HMTF 2

23 46009073000 RIM BAND 14" 1

30 46109070100 RIM FRONT 1,6X14" ALU 2008 1

31 46009072100 SPOKE NIPPEL M3,5 2001 32

36 46109060000 BRAKE DISC FRONT 65 SX 2004 1

40 59009062016 SPECIAL SCREW M6X16 WS=8 10.9 3


42 46009071000 SPOKE M3,5X145MM 16

43 46009171000 SPOKE M3,5X149MM 16

44 46109081000 AXLE FRONT 65SX 2002 1

45 55009086000 PLUG SFL13 1

46 49032011000 HH COLLAR SCREW M10X20 WS=17 1

47* 45110090000 RIM LOCK CPL. 2004 1

48* 50310090050 NUT FOR WHEEL HOLDER '96 1

084610910 / C084610910

* NEW PART

X AS REQUIRED

16

FRONT WHEEL

65 SX 2008


1* 46110001344 REAR WHEEL SP 1,6X12" ALU 08 1

2 46010010144 REAR WHEEL HUB CPL.60/65 2000 1

7 46110070000 RIM REAR 1,6X12" ALU 2007 1

8 46009072100 SPOKE NIPPEL M3,5 2001 32

9 0625060037 GR.BALL BEAR. 6003-2RSH/C3HMTF 2

10 0625062032 GR.BALL BEAR. 6203-2RSHC3HMTF 1

12 59009062013 SPECIAL SCREW M6X13 WS=8 10.9 4

13 46010013000 SPACER BUSH R/S SX 60/65 2000 1

14 46010014000 SPACER BUSH L/S SX 60/65 2000 1

15 46010071100 SPOKE 3X140X4MM-161° 16

16 46010171100 SPOKE 3X132X5MM-150° 16



19 46010051046 REAR SPROCKET 46-T x

19 46010051048 REAR SPROCKET 48-T x

19 46010051050 REAR SPROCKET 50-T 1

22 46010085100 AXLE REAR 213MM M12X1 1

23 46010073000 RIM BAND 12" 1

30* 46110060200 BRAKE DISC 65SX 2008 1

47 0125120003 FLAT WASHER DIN0125-A13 2

49 0917120103 NUT DIN917-M12X1 2

50 46110165112 CHAIN 1/2X1/4" 1

51 46110166000 CONNECTING LINK 1/2X1/4" 1

55 51009100100 RIM LOCK VM1 (1,60") 1

56 50310090050 NUT FOR WHEEL HOLDER '96 1

084611010 / C084611011

* NEW PART

X AS REQUIRED

17

REAR WHEEL

65 SX 2008


1 47013001000 HAND BRAKE CYL. CPL. 11MM 03 1

2 47013002000 BRAKE LEVER LOOSE 85 SX 2003 1

3 47013003000 CYLINDER COVER CPL. FRONT 2003 1

4 47013004000 PROTECTION COVER 85 SX 2003 1

5 47013005000 CLAMP FOR BRAKE CYLINDER 2003 1

6 47013006000 SCREW+BUSHING+NUT 03 1

7 47013007000 ADJUSTING SCREW CPL. 85 SX 03 1

8 47013008000 REP.SET PISTON FRONT D=11MM 1

9 47013009000 BALL+SPRING+SPRING GUIDE 03 1

10 46113010100 BRAKE HOSE FRONT 65 SX 2004 1

13 0770080019 O-RING 8,00X1,00 EPDM 2




25 47013025000 HOLLOW SCREW BRAKE CYLINDER 03 1

80* 00062030000 BRAKE FLUID DOT5.1 0,25L 1

084611310 / C084611310

* NEW PART

X AS REQUIRED

18

HAND BRAKE CYLINDER

65 SX 2008




43 0934060003 HEXAGON NUT DIN0934-M 6 1


47 0991060203 FLAT H.SCREW DIN7991-M6X20 8.8 1

48 58303063000 BRAKE LEVER STOP '93 1

49 0797060003 TOOTH LOCK WASH. DIN6797-A 6,4 1

50 46003060233 BRAKE PEDAL LEVER CPL 2000 1

52 54603062000 RETURN SPRING FOR BRAKE LEVER 1

55 54603069000 SWIVEL HEAD M6 FOOT BRAKE LEV. 1

56 54603068000 PRESSURE ROD ALU 250 '90 1

60 46113060000 REAR BRAKE CYL. 50+65 04 1

61 47013061000 REP. SET PISTON REAR D=11 2003 1

62 47013062000 CYLINDER COVER REAR 85 SX 03 1

63 47013063000 GASKET CYLINDER COVER REAR 03 1

65 46113325000 HOLLOW SCREW M6 1

66 0912040103 AH.SCREW DIN0912-M 4X10 2

70 46113070000 BRAKE HOSE REAR 65 SX 04 1

71 0770060019 O-RING 6,00X1,00 2

80 00062030000 BRAKE FLUID DOT5.1 0,25L 1

084611330 / C084611330

* NEW PART

X AS REQUIRED

19

REAR BRAKE CONTROL

65 SX 2008


10 46113010100 BRAKE HOSE FRONT 65 SX 2004 1

11 0770080019 O-RING 8,00X1,00 EPDM 2

14 46113019050 REPAIR KIT BRAKEPISTON 1

15 47013015000 BRAKE CALIPER FR. CPL.85 SX 03 1

18 46113018000 RETAINING SPRING 65 SX 1

20 47013020000 BLEEDER SCREW M6 1

21 47013021000 CAP FOR BLEEDER SCREW 1

23 0770100019 O-RING 10X1 EPDM 1

25 47013125000 HOLLOW SCREW M8X38,8 1

30 46113030000 BRAKE PAD SET FRONT 2002 1

70 0912060283 AH SCREW DIN0912-M 6X28 2


81 46113019000 REPAIR KIT SEAL RING 2002 1

83 0799040009 TAB WASHER DIN6799-RA 4,0 1

85 46113125000 AH SCREW + CIRCLIP 2002 1

084611360 / C084611360

* NEW PART

X AS REQUIRED

20

BRAKE CALIPER FRONT

65 SX 2008


18 45113018000 RETAINING SPRING 50 LC 1

25 46113225000 HOLLOW SCREW CPL. 1

26 0912050163 AH SCREW DIN0912-M 5X16 1



50 45119050000 BLEEDER INJECTION-SET 50-65 1

70 46113070000 BRAKE HOSE REAR 65 SX 04 1

71 0770060019 O-RING 6,00X1,00 2

72 0770080019 O-RING 8,00X1,00 EPDM 1

79 45113019100 REPAIR KIT BRAKEPISTON 1

80 46113080000 BRAKE CALIPER REAR CPL.65SX 04 1

81 0770022020 O-RING 22X2X2 EPDM 2

82 45113225000 AH SCREW + CIRCLIP 50/65 04 1

83 0799025000 TAB WASHER DIN6799 RS2,5 1

90* 46113030100 BRAKE PAD SET REAR 65SX 2008 1

084511390 / C084611390

* NEW PART

X AS REQUIRED

21

BRAKE CALIPER REAR

65 SX 2008


0 312305 DOCUMENTS BAG 2006 1

0 312313 KTM BALLPOINT ORANGE 1

0 3210039 CUSTOMER WELCOME LETTER 1

0 45131023070 MAIN JET 70 DELLORTO 1

1 3211223 OWN.MAN. 65 SX/ XC 2008 1

1 322000 SAFETY BROCHURES SPORTMINICYC. 1

1 3CF6001H6EN SPM CHASSIS 65 SX 2008 1

1 3CM080208HEN SPC ENGINE 65 SX 2008 1

29* 46129099000 BORDTOOL 65SX 2008 1

30* 47003020000 PLUG IN STAND SX 85 2003 1

34 60029070200 T-WRENCH WS=6/8/10 TX=45 B&F 1

36 45129072000 SPARK PLUG WRENCH 1

084612010 / C084612010

* NEW PART

X AS REQUIRED

22

ACCESSORIES KIT

65 SX 2008

SPARE PARTS MANUAL: ENGINE

ART.NO.: 3CM080208HEN

EN

GLIS

H

INDEX 65 SX 2008

SPECIAL TOOLS

3x

ENGINE CASE

4x

CYLINDER

5x

CRANKSHAFT, PISTON

6x

CARBURETOR

7x

CLUTCH

9x

TRANSMISSION

10x

KICK STARTER

11x

SHIFTING MECHANISM

12x

COOLING SYSTEM

13x

IGNITION SYSTEM

14x

x

1

INDEX 65 SX 2008

x

x

x

x

x

x

x

x

x

All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical

specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local

conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing

certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations,

descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models.

© by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTM-

SPORTMOTORCYCLE AG, Mattighofen only.

2

65 SX 2008


1 56012001044 UNIVERSAL MOUNTING RACK CPL. 1

2 49112008000 MOUNTING TOOL 1

3 15112017000 BUSHING EXTRACTOR 1

4 15112018000 INTERN.BEAR.PULLER 12-16 MM 1

5 6899785 LOCTITE 243 BLUE 6CCM 1

6 54629009044 MAGNETIC PULLER M 27X1 KOKUSAN 1

7 49012004000 HOLDER FOR PRIMARY WHEEL 1

9 15112021000 HOLDING WRENCH FOR ROTOR 1

10 46129006100 ADJUSTING PLATE 65 SX 2003 1

11 46029002000 ENGINE BRACKET FOR 60/65 CCM 1

084612910 / C084612910

* NEW PART

X AS REQUIRED

3

SPECIAL TOOLS

65 SX 2008


1 46030000344 ENGINE CASE CPL. 65 SX 2007 1

3 46030001200 CLUTCH COVER CPL. 65 SX 2002 1

5 45135052000 WATER PUMP COVER 50 LC 2002 1

6 58030020000 PLUG M 24X3 1

7 51030022000 ANGLE PIECE 90 DEGREE M10X1 1

10 46030039000 ENGINE CASE GASKET 60/65 1

11 46030025000 CLUTCH COVER GASKET INSIDE 1

15 45135053000 GASKET WATER PUMP COVER 02 1

16 46030021100 OIL DRAIN PLUG M10 WS=13 1

17 49030095000 LENS TYPE GN 540 1

19 46033068000 PRESS IN BUSH KICKSTARTER 65SX 1

22 46032059100 RELEASE LEVER 65 SX 2002 1

23 0770160030 O-RING 16,00X3,00 NBR 70 1

24 46033067000 SPECIAL SCREW 65 SX 1

25 46033067100 WASHER F. SPECIAL SCREW 65 SX 1

26 46030023100 DOWEL 17X15 1

27 46030023000 DOWEL 12X14,5 1

28 46030024000 DOWEL 9X15 1

29 0603101420 COPPER GASKET 10,2X14X2 MM 01 1

33 0015060103 HH COLLAR SCREW M 6X10 WS=8 1

34 0603061001 CU-SEAL RING DIN7603-6X10X1 1

40 31007007001 PVC-HOSE 5 X 8 MM x


42 44011076100 CABLE TIE 100/2,5MM BLACK x

43 0912060404 AH SCREW DIN0912-M 6X40 A2 1

44 0912060453 AH SCREW DIN0912-M 6X45 4

45 0912060303 AH SCREW DIN0912-M 6X30 4

46 0912060253 AH SCREW DIN0912-M 6X25 6

50 46030099100 GASKET SET CPL. 65 SX 2002 1

084613010 / C084613010

* NEW PART

X AS REQUIRED

4

ENGINE CASE

65 SX 2008


1 46030005600 CYLINDER W.PISTON 45MM 65SX 03 1

2 46030006700 CYLINDERHEAD 65 SX 2003 1

3 46035027000 PRE-FORM.HOSE CYL.-CLUTCH COV. 1

4 46030035020 CYLINDER BASE GASKET 0,2 MM x




6 46030046000 EXHAUST GASKET 60/65 CCM 1

10 46030037000 O-RING 94,97X1,78 1

11 46030036000 O-RING 53,7X1,78 VITON 1

16 46030043000 STUD M8X41 3

17 46030043100 STUD M8X44 1

18 46030045000 COLLAR NUT M8 WS=10 4

20 10001020000 HOSE CLAMP GEMI 16-27 2

21 31001027000 HOSE CLAMP 32-52MM D5 1

22 46030079100 CYLINDERHEADSCR.HH-M7X38 2003 5

23 50230032010 CU-SEAL RING 7,3 X 12 X 0,5 5


35 46036040100 EXHAUST FLANGE 65 SX 2002 1


49 46030049000 INTAKE VALVE GASKET 1

50 46030050000 INTAKE FLANGE 1

51 46030051144 MEMBRANE HOUSING CPL.65SX 2001 1

52 46030052000 MEMBRANE LOOSE 60/65 CCM 2


55 45130023000 DOWEL 7X9X10 2

084613040 / C084613040

* NEW PART

X AS REQUIRED

5

CYLINDER

65 SX 2008


1 46030007500 A PISTON CPL. 45MM "A/B" 65'98 x

1 46030007500 C PISTON CPL. 45MM "C/D" 65'98 x

1 46030007500 E PISTON CPL. 45MM "E/F" 65'98 x

3 46030033000 PISTON PIN 12X38 1

4 46030030500 PISTON RING 45MM 65CCM 1

5 45130074000 CIRCLIP 2001 2

10* 46130018000 CRANKSHAFT CPL. STROKE 40,8 07 1

11 46030015100 CONN.ROD REPAIR SET 65 SX 2003 1

12 46030082200 GROOVED BALL BEAR.20X52X15 NTN 2

14 47030076100 SEAL SHAFT RING 20X35X6 BTSL 2

17 46030034000 NEEDLE BEAR.PISTONPIN 12X15X17 1

18 46030078100 LOCKING WASHER 14X20X1 x

UNTIL ENGINE NO. B65 5000874

18 47033040000 STOP DISC 15X25X1 x

FROM ENGINE NO. B65 5000875

19 46030029100 HH-NUT M14X1,25X5 '99 1

20 46035056100 SHAFT SEAL RING 10X18X4 1

21 46035057000 WATER PUMP BEARING 10X19X5 1

22 46035058000 WA.PU.BEAR. 10X19X5 DOUBLELIP 1

23* 45135054100 WATER PUMP SHAFT 50 LC 2007 1

24 46035055100 WATER PUMP WHEEL 60/65 '99 1

25 0471090010 CIRCLIP DIN0471- 9X1 1

26 50230029012 LOCKING RING VSK 12 1

27 49030021000 COLLAR NUT M12X1 R/S 1

28 45135058000 SPRING FOR WATER PUMP SHAFT 04 1

29 0888030050 WOODRUFF KEY DIN6888-3X5X13 1

084613060 / C084613060

* NEW PART

X AS REQUIRED

6

CRANKSHAFT, PISTON

65 SX 2008


1 46131001000 CARBURETOR MIKUNI VM24-505 04 1

2 46031011000 FLOAT BODY 5-1 VM24 1

3 45031008000 PIN 2,5X27 1

4 46131020000 NEEDLE VALVE CPL. VM24 1

5 46031018000 GASKET NEEDLE VALVE 9,1X12X0,5 1

6 45031023185 MAIN JET 185 x

6 45031023190 MAIN JET 190 x

6 45031023195 MAIN JET 195 x

6 45031023200 MAIN JET 200 1

6 45031023205 MAIN JET 205 x

7 46031074000 BUFFLE 1

8 46131021000 NEEDLE JET 864 0-0 1

9 45031034200 JET NEEDLE MIKUNI 5I14 1

10 45031007025 IDLING JET 25 MIKUNI 1

11 45031010100 GASKET FLOAT BOWL 1

12 46031009000 FLOAT VM24 1

13 52031137001 PVC-HOSE 3X5MM x

14 52031137001 PVC-HOSE 3X5MM x

15 45031015100 SPRING MIKUNI 1

16 46031019000 THROTTLE VALVE SCREW M6X30 1

17 46031043000 O-RING 17,5X1,4 1

18 45031014016 LINTIL HEAD SCREW M4X16 (SET) 1

20 46131035000 THROTTLE VALVE 1.5 1

21 46031032000 HOLDING WASHER 1

22 45031045000 SPRING 1

23 46031014000 PLUG SCREW M16 WS=17 1

24 57031525000 ADJUSTMENT SCREW M6X0,75 1

25 45031026000 HH-NUT M6X0,75 1

26 46031027000 CARBURETOR COVER VM24 1

27 46031048044 COLD STARTER KNOB CPL. VM24 1

28 46031030000 THROTTLE VALVE SPRING VM24 1

31 46031081000 BRACKET FOR BREATHER HOSE 1

33 46131017000 ADJUSTING SCREW MIKUNI 1

34 45031015000 SPRING 1

35 46131032000 WASHER ADJUSTING SCREW 1

36 46131033000 O-RING ADJUSTING SCREW 1

084613110 / C084613110

* NEW PART

X AS REQUIRED

7

CARBURETOR

65 SX 2008



084613110 / C084613110

* NEW PART

X AS REQUIRED

8

CARBURETOR

65 SX 2008


1 46032000144 PRIM.DR.W.CLUTCH HUB 23:75 '99 1

3 46032003000 PRESSURE CAP 60/65 CCM '98 1

4 46032010000 INTERMEDIATE DISK STEEL 5

5 46032011000 LINING DISK 6

6 46032002000 INNER CLUTCH HUB 60/65 CCM '98 1

10 46032006000 SPRING RETAINER 25X63,5X2 1

11 46032008000 CARRIER FOR AXIAL BEARING 1

12 49032012000 STOP DISK 17,2X30X1,5 2

15 46032015000 INNER RING 22X17X20,5 1

20 46032056000 AXIAL BEARING 6X19X2 1

21 46032054100 PRESSURE PIECE 65 SX 2002 1

22 46132019000 HH COLLAR SCREW M10X20 1

23 46032005100 CLUTCH SPRING REINFORCED 60/65 6

L=27,5 D=2,1

24 0991060203 FLAT H.SCREW DIN7991-M6X20 8.8 6

25 0471006007 CIRCLIP DIN0471-6X0,7 1



61 59032061044 OUTPUT CYLINDER CPL. 2003 1

64 54732064000 BLEEDER SCREW WITH CAP 1

67 0770300015 O-RING 30,00X1,50 NBR 70 1

69 59032066000 PISTON WITH O-RING AND BALL 03 1

75 50329050000 VENT INJEKTION HYDR. CLUTCH 1

084613210 / C084613210

* NEW PART

X AS REQUIRED

9

CLUTCH

65 SX 2008


1 46033011100 IDLER GEAR 2ND GEAR 65 SX 2002 1

2 46033012200 SLIDING GEAR 6TH GEAR 65 SX 02 1

3 46033013100 IDLER GEAR 3RD GEAR 65 SX 2002 1

4 46033014100 IDLER GEAR 4TH GEAR 65 SX 2002 1

5 46033015200 SLIDING GEAR 5TH GEAR 65 SX 02 1

6 46033016200 IDLER GEAR 1ST GEAR 65 SX 2002 1

7 46033002100 COUNTER SHAFT 65SX 2001 1

8 46033001000 MAIN SHAFT 13-T 1


10 46033008200 SLIDING GEAR 3RD/4TH G.65SX 02 1


12 46033010000 SOLID GEAR 2ND GEAR 16-T 1

15 46033029013 SPROCKET 13-T 60/65 x

15 46033029014 SPROCKET 14-T 65 SX 2002 1

16 46033030000 DISTANCE BUSHING SPROCKET 1

17 46033031000 O-RING 18,77X1,78 1

18 0760263560 SHAFT SEAL RING 26X35X6 1

19 46033028000 GROOVED BALL BEARING 20X42X12 1

20 49033091000 CIRCLIP AS20X1,75 4

22 46033020000 NEEDLE BEARING 14X18X8 1

23 46033023000 SPECIAL SCREW M6X10 1

24 49033013000 STOP DISK 12,1X25X1 2

25 46033026000 NEEDLE BEARING NK12 12X19X12 2

28 46033022000 CIRCLIP WS=17X1,2 2

29 46033025000 GROOVED BALL BEAR.SKF98203/C3 1

084613310 / C084613310

* NEW PART

X AS REQUIRED

10

TRANSMISSION

65 SX 2008


1 46133070000 KICKSTARTER ALU 65 SX 2003 1

2 0760142460 SHAFT SEAL RING 14X24X6 B 1

4 46033056000 RATCHET GEAR SPRING 1

5 46030078100 LOCKING WASHER 14X20X1 1

6 46033052000 RATCHET GEAR 1

7 46033069000 STOP PLATE 1

8 46033050000 KICKSTARTER SHAFT 1

9 46033051000 STARTING GEAR 29-T 1

10 46033054000 KICKSTARTER SPRING 1

11 46033055000 DRIVING HUB 1

12 46033053000 INTERMEDIATE GEAR 18-T 1




084613390 / C084613390

* NEW PART

X AS REQUIRED

11

KICK STARTER

65 SX 2008


1 46034031100 SHIFT LEVER COL. 65 SX 2001 1

2 46034020100 SHIFT RAIL 2001 1

3 46034002100 SHIFT FORK COUNTERSHAFT R/S 1

4 46034019100 SHIFT RAIL 10X72MM 2001 1

5 46034001100 SHIFT FORK MAIN SHAFT 2001 1

6 46034012300 SHIFT ROLLER 65 SX 2001 1

7 46034019052 SPRING SHIFT RAIL 2001 4

8 46034005044 SHIFT SHAFT CPL. 1

9 50334018100 SHIFTING ROLLER 6X8X5,2 3

10 46034091100 SPACER WASHER-SET 2001 1

0,2/0,5/0,6 MM

11 46034015100 SHIFT DRUM LOCATING 60/65 2000 1


13 46034002200 SHIFT FORK COUNT. 2.3.GEAR 1

14 46034023100 LOCKING LEVER SPRING 2001 1

15 46034024100 LOCKING LEVER CPL. 65 SX 2002 1

16 0471100010 CIRCLIP DIN0471-10X1 1

17 0625618050 BALL BEARING 61805 C3 2

20 0760122050 SHAFT SEAL RING 12X20X5 B 1

22 46034027000 NEEDLE BEARING 12X18X12 2002 1

24 46034014000 RETURN SPRING 1

25 46034009000 PRESSURE SPRING SLIDER PLATE 1



084613410 / C084613410

* NEW PART

X AS REQUIRED

12

SHIFTING MECHANISM

65 SX 2008


1 46135008000 RADIATOR 65SX 2002 1

2 58035016000 RADIATOR CAP SMALL 20,3 PSI 1

4 5453503400030 RADIATOR PROTECTOR L/S bl. 65 1

6 50235033300 SNAP-NUT HOLDER M6 KP142 2

8 46135026000 PREFORMED HOSE CYL.-RADI. 2002 1

10 46135027000 PREFORMED HOSE WAPU-RADI. 2002 1

13 31007107001 PVC-HOSE 6X9 MM PER METER x


18 0021060003 WASHER DIN9021-A 6,4 3

19 41001052000 RUBBER SLEEVE D=12MM 3

20 42013037200 HOSE CLAMP GEMI 12/22 4



084613530 / C084613530

* NEW PART

X AS REQUIRED

13

COOLING SYSTEM

65 SX 2008


1 46030002100 IGNITION COVER 65 SX 2003 1


3 46139002100 IGNITION CPL. 65 SX 2003 1


5 46139012000 RUBBER FOR IGNITION COVER 2003 2

7 46139095000 WIRING HARNESS 65 SX 2003 1

8 46139031100 ELECTRONIC BOX 65 SX 2006 1

9 46139030000 RUBBER BR. DIGI.BOX 65SX 2003 1

10 47039090000 SPARK PLUG CAP NGK REINFORC.04 1

11 54331093410 SPARK PLUG NGK BR8ECM 1

12 46139006100 IGNITION COIL CPL. 65 SX 2003 1


084613910 / C084613910

* NEW PART

X AS REQUIRED

14

IGNITION SYSTEM

spare parts manual: chassis · air filter box 12x tank, seat, cover 13x mask, fenders 14x decal 15x...

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