65 SX 2009

SPARE PARTS MANUAL: CHASSIS

ENGLISH

ART.NO.: 3CF6001I6EN

65 SX 2009

INDEX

FRONT FORK, TRIPLE CLAMP

FRONT FORK DISASSEMBLED

3x
SHOCK ABSORBER

4x
SHOCK ABSORBER DISASSEMBLED

7x
AIR FILTER

FRAME

5x
SWING ARM

8x
TANK, SEAT, COVER

11x
1

HANDLEBAR, CONTROLS

EXHAUST SYSTEM

9x
MASK, FENDERS

12x

6x

10x
DECAL

13x

14x

65 SX 2009

INDEX
FRONT WHEEL

REAR WHEEL

15x
BRAKE CALIPER FRONT

HAND BRAKE CYLINDER

16x
BRAKE CALIPER REAR

19x

REAR BRAKE CONTROL

17x

18x

21x

ACCESSORIES KIT

20x

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
KTMSPORTMOTORCYCLE AG, Mattighofen only.

x
2

FRONT FORK, TRIPLE CLAMP

65 SX 2009
FIG
1
2
5
6
31
34
38
39
42
43
44
45
46
47
91
92
93
94
95
96

PART NUMBER
46201000033
0025060306
0025080306
0912100250
77051116
7501478
50301038000
59001039000
59030029000
49001086000
0770021300
49001081000
46001086000
0770360030
59001092050
46101092000
46101093000
54601085000
0025050166
0985050003

094620110 / C094620110

DESCRIPTION
FRONT FORK USS D035MM
09
HH COLLAR SCREW M6X30 TX30
HH COLLAR SCREW M8X30 TX40
AH SCREW DIN6912-M10X25,10.9,L
BOT.TRIPLE CLAMP + FORK TUBE
TOP TRIPLE CLAMP
HANDLEBAR CLAMP D=22MM 2001
HANDLEBAR SUPPORT 22MM 2T 2000
HH NUT M20X1,5 WS=27 RIGHT
COVERING CAP
O-RING 40,94X2,62 NBR70
TAPERED ROLLER BEARING 32004X
PROTECTION RING 20,1X39X5
O-RING 36,00X3,00 NBR
SPECIAL SCREW M6X12,5 WS=8
FORK PROTECTION L/S 65SX 2002
FORK PROTECTION R/S 65SX 2002
BRAKE HOSE CLAMP MARZOCCHI'95
HH COLLAR SCREW M5X16 TX30
SELF LOCKING NUT DIN0985-M 5

* NEW PART

QTY
1
2
9
2
1
1
2
1
1
1
1
2
1
1
6
1
1
1
2
2

X AS REQUIRED

FRONT FORK DISASSEMBLED

65 SX 2009
FIG
1
2
3
4
5
7
9
11
18
19
20
21
22
23
24
25
26
27
28
29
30
38
39
39
39
40
42
43
46
47
48
90
99

PART NUMBER
0025060306
7819139/C
7538029
7717065/R
7528005
7517082
7524163
75141087
7701204AC
7701205AC
7850208AR
7528180
7528008
7850652
7850728
7533167
7523236
7528034
7539032AA
7538038/A
7760069FN/C
7535099
7517028
7517057
7517074
7530090/B
7521147/A
7819140/C
7522061
0912080253
7517044
7550013
7850731/C

094620130 / C094620130

DESCRIPTION
HH COLLAR SCREW M6X30 TX30
SLIDER + AXLE CLAMP CPL. R/S
GUIDE RING D=35
FOOT VALVE
O-RING D=20,3
SHIM 8,1X23X0,1
PISTON RING D=26
LOWER REBOUND SPRING
PLUG R/S CPL.
PLUG L/S CPL.
LENTIL HEAD SCREW M4X6
O-RING D=3,69, S=1,78
O-RING D=34,6, S=1,78
PIN + O-RING
SPRINGS + PRELOAD SLEEVES KIT
DUST CAP
LOCK WASHER D=51,5
OIL SEAL 35X47X10
WASHER 36X47X3
GUIDE RING 35X15
OUTER TUBE CPL.
COMPRESSION DAMPING SHIM
SHIM 8,1X23X0,2
SHIM 8,1X21X0,2
SHIM 8,1X18X0,2
PISTON COMPRESSION D=26
SPECIAL NUT M6X1 WITH STEP
SLIDER + AXLE CLAMP CPL. L/S
SHIM 8X12X1,5
AH SCREW DIN0912-M 8X25
SHIM 8,1X23X0,3
FORKOIL EBH16 SAE 7.5
REPAIR-KIT USD 35

* NEW PART

QTY
2
1
2
2
2
4
1
2
1
1
2
2
2
2
1
2
2
2
2
2
2
1
1
1
1
1
1
1
2
2
2
1
1

X AS REQUIRED

HANDLEBAR, CONTROLS

65 SX 2009
FIG
1
2
3
4
7
9
30
31
31
32
33
34
35
36
37
38
39
41
44
62
63
64

PART NUMBER
46202001000
46202010000
46202091000
63002021100
50302020000
50311089200
46102030100
54602031000
59002031000
59002032100
50302033100
50302034000
59002035000
50302036200
50302037000
50302038000
50302030150
0025060206
0965040123
50332063050
46132063000
54002016000

094620210 / C094620210

DESCRIPTION
HANDLEBAR 65 SX
2009
THROTTLE GRIP 65SX
09
THROTTLE CABLE 65 SX 2009
GRIP SET DUAL COMPOUND
PROTECTION COVER '97
SHORT CIRCUIT BUTTON
02
MASTER CYLINDER CPL. D=9MM 05
CLUTCH LEVER SHORT CPL. 2003
CLUTCH LEVER LONG CPL. 2003
REP.KIT PISTON 9,0MM RAC. 2004
COVER HYD.CLUTCH 2T 2000
RUBBER FOR RESERVOIR '98
SPRING FOR CLUTCH LEVER 03
OIL FOR HYD. CLUTCH 75ML
PROTECT.CAP FOR LEVER PERCH'98
LEVER SCREW CPL. 125-200 '98
CLAMP WITH PIN
2000
HH COLLAR SCREW M6X20 TX30
FLAT HEAD SCREW DIN0965-M 4X12
SELF CUTTING RING HYDR.PIPE
PIPE KIT FOR HYDR.CLUTCH 65 SX
PROTECTION CAP

* NEW PART

QTY
1
1
1
1
1
1
1
1
x
1
1
1
1
1
1
1
1
1
2
x
1
1

X AS REQUIRED

FRAME

65 SX 2009
FIG
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

PART NUMBER
4620300104430
54310086200
0931080805
0125080003
0934080003
59001037000
50307012000
4700304003390
59003040050
59003041050
54803044000
0125100003
54603041000
0094032253
46203002000
0019080206S
77303053000
0025080356
36003014000

094620310 / C094620310

DESCRIPTION
FRAME 65 SX "MD09"
09
SELF LOCKING NUT M8
10.9
HH SCREW DIN 931 M8X80 10.9
WASHER DIN0125-A 8,4
HEXAGON NUT DIN0934-M 8
SPECIAL SCREW M8X26 WS=10
ADH. FOIL TRANSP. 80X80 MM 04
FOOTPEG L.+R. CPL. 85 SX 03
FOOT PED L/S EXC SILVER 2000
FOOT PED R/S EXC SILVER 2000
BOLT FOR FOOT PED
03
WASHER DIN0125-A10,5
FOOTREST SPRING L/S & R/S
PIN DIN0094-3,2X25 STEEL
SUB FRAME 65 SX
2009
FLAT HEAD SCREW M. ISA45 M8X20
CHAIN SLIDING PIECE BELOW 07
HH COLLAR SCREW M8X35 TX40
LOCK WASHER 8MM

* NEW PART

QTY
1
2
2
2
2
2
2
1
1
1
2
2
2
2
1
4
1
1
1

X AS REQUIRED

SHOCK ABSORBER

65 SX 2009
FIG
1
2
3

PART NUMBER
03187E03
69004089000
54310086100

094620410 / C094620410

DESCRIPTION
MONOSHOCK 65SX
2009
HH COLLAR SCREW M10X42 WS13 08
SELF LOCKING NUT M10 CU WS=14

* NEW PART

QTY
1
2
1

X AS REQUIRED

SHOCK ABSORBER DISASSEMBLED

FIG
1
2
3
4
5
6
7
8
9
9
9
10
11
12
13
14
15
16

65 SX 2009
PART NUMBER
R308
46810850S9
36120817S1
46810893
36120151
46811208
36120015
36120418
93010181S
93010182S
93010183S
36120386
36120781S5
36120040
36120787S
36120799
R309
50180342S1

094620430 / C094620430

DESCRIPTION
REPAIR-KIT
CC-COMPRE.DAMPING CONTROL CPL.
MONOSHOCK TOP PART CPL.
O-RING NBR 5,28X1,78
SCREW PLUG M5X6
RUBBER CAP "DO NOT OPEN"
COUNTERNUT
ADJUSTING NUT
SPRING 40N/MM 40-220 220MM ORA
SPRING 35N/MM 35-220 220MM ORA
SPRING 45N/MM 45-220 220MM ORA
SPRING RET. H=3, D=14,5
MONOSHOCK BOTTOM PART CPL.
PISTON RING 8X1X108,3
ADAPTOR 36MM H26,6 CPL. 07
BUMP RUBBER
REPAIR KIT BEARINGS 65 SX 09
SHOCK ABSORBER FLUID 5 LT '03

* NEW PART

QTY
1
1
1
1
1
1
1
1
x
x
x
1
1
1
1
1
2
1

X AS REQUIRED

SWING ARM

65 SX 2009
FIG
1
2
3
4
6
7
10
11
12
13
14
15
16
17
18
25
26
29
30
31
32
35

PART NUMBER
46104030144
54310086100
54603097000
46004030070
46004030071
0770160021
46104066000
69004060050
0010050103
0009050103
46007066000
0025060406
56509064100
46104061000
44011076305
46204037033
0125120003
0934120103
46010083000
50203030090
0934080003
54611076100

094620490 / C094620490

DESCRIPTION
SWING ARM CPL. 65 SX 2008
SELF LOCKING NUT M10 CU WS=14
NEEDLE BUSH HK 2016
SPACER BUSHING 20X26X30X9,7
BUSHING BOX 12X20X36,5
O-RING 16,00X2,00 VITON
CHAIN SLID. GUARD FRO. 65SX 02
BUSHING CHAIN GUARD
08
SPECIAL SCREW M 5,0X10
SPECIAL SCREW M 5,0X10
CHAIN GUIDE REAR 60/65 '98
HH COLLAR SCREW M6X40 TX30
SELF LOCKING NUT M6
10.9
CHAIN GUARD
08
CABLE TIE 300/4,8MM BLACK
SWINGARM BOLT CPL. 201MM
FLAT WASHER DIN0125-A13
HEXAGON NUT DIN0934-M12X1
CHAIN ADJUSTER 60/65 '98
HH SCREW M8X40
WS=10
HEXAGON NUT DIN0934-M 8
RETAIN.CLAMP FOR BRAKE HOSE'96

* NEW PART

QTY
1
1
2
4
2
4
1
1
1
3
1
2
2
1
2
1
1
1
2
2
2
2

X AS REQUIRED

EXHAUST SYSTEM

65 SX 2009
FIG
1
2
3
4
5
6
7
8
9
10
11
12
13
14

PART NUMBER
46205007000
54605057000
46205079000
45105079056
0770350030
50305016000
54603048100
50305012000
0024060156
0025060166
0025060456
54605069000
54605068000
46205069000

094620510 / C094620510

10

DESCRIPTION
EXHAUST PIPE 65 SX
2009
RUBBER SLEEVE D=21MM/23MM '93
SILENCER 65 SX
2009
ROCKWOOL PREFOMED 50 2002
O-RING 35,00X3,00 VITON
TEN.SPRING L=62MM EY.MOVEABLE
RANGE CHANGE METAL NUT M6
SWINGELEMENT FOR EXHAUST PIPE
HH COLLAR SCREW M6X15 TX30
HH COLLAR SCREW M6X16 TX30
HH COLLAR SCREW M6X45 TX30
BUSHING 7,5X12X28X7,8 '96
EXHAUST BRACKET RUBBER BLACK
COLLAR BUSHING

* NEW PART

QTY
1
1
1
1
2
2
2
2
2
2
1
1
1
1

X AS REQUIRED

AIR FILTER

65 SX 2009
FIG
1
2
3
4
5
6
7
8
9
10
11
12

PART NUMBER
58406015100
46206017000
0017060203
46206026000
78006027000
58406016000
46206017050
0025060256
46208013010
4620600100030
0017060303
54808020000

094620610 / C094620610

11

DESCRIPTION
AIR FILTER
FILTER BOW 65 SX
2009
EJOT PT SCREW K60X20 WS=6
CARBURETOR CONN. BOOT 65 SX 09
HOSE CLAMP 45-65MM
FILTER CARRIER
'97
AIR FILTER BOW PANEL 65SX 2009
HH COLLAR SCREW M6X25 TX30
COLLARED BUSHING 65SX
09
AIR FILTER BOX 65 SX
09
SPECIAL SCREW T60 6X30 WS=6
SPACER BUSHING
03

* NEW PART

QTY
1
1
5
1
1
1
1
2
2
1
2
2

X AS REQUIRED

TANK, SEAT, COVER

65 SX 2009
FIG
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

PART NUMBER
4620701303330
78007008044
58507003000
55007006200
0017060203
46207016000
58007117000
78007000270
0024060273
77307026000
46207040000
45007040051
50307014000
0025060126
4620805400030A
0017060204
50308052000
0025060206

094620710 / C094620710

12

DESCRIPTION
FUEL TANK CPL. 65 SX 2009
TANK PLUG CPL. EXC
08
FUEL COCK CPL. SMALL RALLYE'96
O-RING 11X1,8 NBR 70
EJOT PT SCREW K60X20 WS=6
FUEL PREFORMED HOSE 65 SX 2009
YDNAC-CLAMP 10107 10MM
PVC-HOSE 5,6X10X270MM
COLLAR SCREW M6X27
TX
TANK BUSHING
07
SEAT 65 SX
2009
QUICK RELEASE CPL. 50 SXR '97
TANK ROLLER 12X26X12
'98
HH COLLAR SCREW M6X12 TX30
SPOILER SET BLACK 65SX/XC 09
EJOT PT SCREW K60X20 ALU WS=6
BUSH FOR SPOILER 6X11X16X5 MM
HH COLLAR SCREW M6X20 TX30

* NEW PART

QTY
1
1
1
1
2
1
2
1
1
1
1
1
3
2
1
8
2
2

X AS REQUIRED

MASK, FENDERS

65 SX 2009
FIG
1
2
3
4
5
6
7
8
9
10
11
12
13

PART NUMBER
4620800700004
46208022000
0017060204
0024060106
4620801000004
0024060136
4620801300004
45007040050
0981350163
46206010000
0017060303
54808020000
0017060203

094620810 / C094620810

13

DESCRIPTION
START NUMBER PLATE 65 SX 2009
BRAKE HOSE GUIDE 65 SX 09
EJOT PT SCREW K60X20 ALU WS=6
HH COLLAR SCREW M6X10 TX30
FENDER FRONT 65 SX
2009
HH COLLAR SCREW M6X13 TX30
REAR PART 65 SX ORANGE 2009
QUICK RELEASE LATCHPLATE
SHEET MET.SCR.DIN7981- 3,5X16
SPLASH PROTECTION 65 SX 2009
SPECIAL SCREW T60 6X30 WS=6
SPACER BUSHING
03
EJOT PT SCREW K60X20 WS=6

* NEW PART

QTY
1
1
1
1
1
4
1
1
2
1
2
2
1

X AS REQUIRED

DECAL

65 SX 2009
FIG
1

PART NUMBER
46208091000

094620830 / C094620830

14

DESCRIPTION
DISPLACEME. DECAL 65 SX 2009

QTY
1

* NEW PART

X AS REQUIRED

FRONT WHEEL

65 SX 2009
FIG
1
2
3
4
9
23
30
31
36
40
41
42
43
44
45
46
47
48

PART NUMBER
46209001044
46109010144
46009014000
46009013000
0625060037
46009073000
4620907000030
46009072100
46209060000
59009062016
56509064100
46009071000
46009171000
46109081000
55009086000
49032011000
45110090000
50310090050

094620910 / C094620910

15

DESCRIPTION
FRONT WHEEL-SP 65 SX
09
FR.WHEEL HUB CPL. SILVER 2006
SPACER BUSH L/S 65SX
04
SPACER BUSH R/S 65SX
04
GR.BALL BEAR. 6003-2RSH/C3HMTF
RIM BAND 14"
RIM FRONT 14"X1,6 BLACK 2009
SPOKE NIPPEL M3,5
2001
BRAKE DISC FRONT 65 SX 09
SPECIAL SCREW M6X16 WS=8 10.9
SELF LOCKING NUT M6
10.9
SPOKE M3,5X145MM
SPOKE M3,5X149MM
AXLE FRONT 65SX
2002
PLUG SFL13
HH COLLAR SCREW M10X20 WS=17
RIM LOCK CPL.
2004
NUT FOR WHEEL HOLDER
'96

* NEW PART

QTY
1
1
1
1
2
1
1
32
1
3
3
16
16
1
1
1
1
1

X AS REQUIRED

REAR WHEEL

65 SX 2009
FIG
1
2
7
8
9
10
11
12
13
14
15
16
17
18
19
19
19
22
23
30
47
48
49
50
51
55
56

PART NUMBER
46210001044
46010010144
4621007000030
46009072100
0625060037
0625062032
46010011000
59009062016
46010013000
46010014000
46210071136
46210071129
0991080253
54310086200
46010051046
46010051048
46010051050
46010085100
45109073100
46210060000
45010081062
45010081061
0917120103
46110165112
46110166000
51009100100
50310090050

094621010 / C094621010

16

DESCRIPTION
REAR WHEEL-SP 65 SX
09
REAR WHEEL HUB CPL.60/65 2000
RIM REAR 12"X1,6 BLACK 2009
SPOKE NIPPEL M3,5
2001
GR.BALL BEAR. 6003-2RSH/C3HMTF
GR.BALL BEAR. 6203-2RSHC3HMTF
BEAR.SPACER TUBE REAR SX 60/65
SPECIAL SCREW M6X16 WS=8 10.9
SPACER BUSH R/S SX 60/65 2000
SPACER BUSH L/S SX 60/65 2000
SPOKE 3X136 C. 150
SPOKE 3X129 C. 161
FLAT HEAD SCREW DIN7991-M 8X25
SELF LOCKING NUT M8
10.9
REAR SPROCKET 46-T
REAR SPROCKET 48-T
REAR SPROCKET 50-T
AXLE REAR 213MM M12X1
RIM BAND 12"
BRAKE DISC REAR 65 SX 09
WASHER 20X12,2X2
HEXAGON NUT 12X1 WS19
NUT DIN917-M12X1
CHAIN 1/2X1/4" 65 SX
CONNECTING LINK 1/2X1/4"
RIM LOCK VM1 (1,60")
NUT FOR WHEEL HOLDER
'96

* NEW PART

QTY
1
1
1
32
2
1
1
4
1
1
16
16
5
5
x
x
x
1
1
1
2
1
1
1
1
1
1

X AS REQUIRED

HAND BRAKE CYLINDER

65 SX 2009
FIG
1
2
3
4
5
6
7
8
9
10
13
16
20
22
25
80

PART NUMBER
47013001000
47013002000
47013003000
47013004000
47013005000
47013006000
47013007000
47013008000
47013009000
46113010100
0770080019
56509064100
0025060206
0025060306
47013025000
00062030000

094621310 / C094621310

17

DESCRIPTION
HAND BRAKE CYL. CPL. 11MM 03
BRAKE LEVER LOOSE 85 SX 2003
CYLINDER COVER CPL. FRONT 2003
PROTECTION COVER 85 SX 2003
CLAMP FOR BRAKE CYLINDER 2003
SCREW+BUSHING+NUT
03
ADJUSTING SCREW CPL. 85 SX 03
REP.SET PISTON FRONT D=11MM
BALL+SPRING+SPRING GUIDE 03
BRAKE HOSE FRONT 65 SX 2004
O-RING 8,00X1,00 FORMULA
SELF LOCKING NUT M6
10.9
HH COLLAR SCREW M6X20 TX30
HH COLLAR SCREW M6X30 TX30
HOLLOW SCREW BRAKE CYLINDER 03
BRAKE FLUID DOT5.1 0,25L

* NEW PART

QTY
1
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1

X AS REQUIRED

REAR BRAKE CONTROL

65 SX 2009
FIG
1
2
3
4
5
6
7
8
9
10
11
12
13
14
60
61
62
63
65
66
70
71
80

PART NUMBER
46213050044
54813051000
0025050126
0625060001
54630044000
0912100406
59001037000
46030045000
54603062000
54813055000
0015060203
0934060003
47013056100
0025060166
47013060300
47013061100
47013062000
47013063000
47013025000
0912040103
46213070000
0770080019
00062030000

094621330 / C094621330

18

DESCRIPTION
FOOT BRAKE LEVER 65SX CPL.
STEP PLATE FOR BRAKE LEVER
HH COLLAR SCREW M5X12 TX30
BALL BEARING 6000/C3
COLLAR NUT M10
WS=13
AH SCREW DIN6912 M10X40 10.9
SPECIAL SCREW M8X26 WS=10
COLLAR NUT M8 WS=10
RETURN SPRING FOR BRAKE LEVER
SWIVEL HEAD KA6
03
HH COLLAR SCREW M 6X20 WS=8
HEXAGON NUT DIN0934-M 6
PRESSURE ROD 85 SX
06
HH COLLAR SCREW M6X16 TX30
FOOT BRAKE CYL.R. CPL. D=12 05
REP. SET PISTON REAR D=12 2004
CYLINDER COVER REAR 85 SX 03
GASKET CYLINDER COVER REAR 03
HOLLOW SCREW BRAKE CYLINDER 03
AH.SCREW DIN0912-M 4X10
BRAKE HOSE REAR 65 SX
09
O-RING 8,00X1,00 FORMULA
BRAKE FLUID DOT5.1 0,25L

* NEW PART

QTY
1
1
2
2
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
2
1

X AS REQUIRED

BRAKE CALIPER FRONT

65 SX 2009
FIG
10
11
14
15
18
20
21
23
25
30
70
75
81
83
85

PART NUMBER
46113010100
0770080019
46113019050
47013015000
46113018000
47013020000
47013021000
0770100019
47013125000
46113030000
0912060283
0025080306
46113019000
0799040009
46113125000

094621360 / C094621360

19

DESCRIPTION
BRAKE HOSE FRONT 65 SX 2004
O-RING 8,00X1,00 FORMULA
REPAIR KIT BRAKEPISTON
BRAKE CALIPER FR. CPL.85 SX 03
RETAINING SPRING 65 SX
BLEEDER SCREW M6
CAP FOR BLEEDER SCREW
O-RING 10X1 EPDM
HOLLOW SCREW M8X38,8
BRAKE PAD SET FRONT
2002
AH SCREW DIN0912-M 6X28
HH COLLAR SCREW M8X30 TX40
REPAIR KIT SEAL RING 2002
TAB WASHER DIN6799-RA 4,0
AH SCREW + CIRCLIP
2002

* NEW PART

QTY
1
2
1
1
1
1
1
1
1
1
2
2
1
1
1

X AS REQUIRED

BRAKE CALIPER REAR

65 SX 2009
FIG
18
21
22
25
26
30
31
70
71
72
80
81
82
83
84
85
90

PART NUMBER
46113018000
47013021000
47013083100
47013225000
47013325000
0025080206
0025080406
46213070000
0770080019
0770100019
46213080000
47013081000
47013425000
0799040009
46213075000
47013085000
47013090200

094621390 / C094621390

20

DESCRIPTION
RETAINING SPRING 65 SX
CAP FOR BLEEDER SCREW
REPAIR KIT BRAKEPISTON
HOLLOW SCREW REAR 85 SX 2003
HOLLOW SCREW REAR 85 SX 2003
HH COLLAR SCREW M8X20 TX40
HH COLLAR SCREW M8X40 TX40
BRAKE HOSE REAR 65 SX
09
O-RING 8,00X1,00 FORMULA
O-RING 10X1 EPDM
BRAKE CALIPER REAR CPL.65SX 09
REPAIR KIT SEAL RING REAR 03
AH SCREW + CIRCLIP 85/105
TAB WASHER DIN6799-RA 4,0
BRAKE CALIPER SUPPORT
BLEEDER SCREW M8X1
BRAKE PADS REAR SINTER 85SX 08

* NEW PART

QTY
1
1
1
1
1
1
1
1
3
2
1
1
1
1
1
1
1

X AS REQUIRED

ACCESSORIES KIT

65 SX 2009
FIG
0
0
0
0
0
0
1
1
1
1
29
30
31
34
35
36

PART NUMBER
0024060136
312305
312313
44011076200
4620801000004
4700304003390
3211345EN
322000
3CF6001I6EN
3CM080208IEN
46229099000
47003020000
46012024000
60029070200
50329080100
45229073000

094622001 / C094622001

21

DESCRIPTION
HH COLLAR SCREW M6X13 TX30
DOCUMENTS BAG
2006
KTM BALLPOINT ORANGE
CABLE TIE 200/3,6MM BLACK
FENDER FRONT 65 SX
2009
FOOTPEG L.+R. CPL. 85 SX 03
OWNERS MANUAL 65SX/XC 2009
SAFETY BROCHURES SPORTMINICYC.
SPM CHASSIS 65 SX MINI 2009
SPM ENGINE 65 SX
2009
TOOL KIT 65 SX
09
PLUG IN STAND SX 85 2003
HOOK WRENCH FOR SHOCK ABSORBER
T-WRENCH WS=6/8/10 TX=45 B&F
WRENCH SW=17/21/27/32 B&F
SPARK PLUG WRENCH

* NEW PART

QTY
4
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1

X AS REQUIRED

NOTICE

65 SX 2009

NOTICE

65 SX 2009

NOTICE

65 SX 2009

*3CF6001I6EN*
3CF6001I6EN

8/2008
Art.Nr.: 3CF6001I6EN

KTM Group Partner

KTM-Sportmotorcycle AG
A-5230 Mattighofen
www.ktm.at

65 SX 2009
SPARE PARTS MANUAL: ENGINE

ENGLISH

ART.NO.: 3CM080208IEN

65 SX 2009

INDEX
ENGINE CASE

CLUTCH COVER

3x
REED VALVE CASE

4x
CARBURETOR

8x
KICKSTARTER

CRANKSHAFT, PISTON

5x
CLUTCH

9x
SHIFTING MECHANISM

12x
1

CYLINDER, CYLINDER HEAD

TRANSMISSION

10x
WATER PUMP

13x

7x

11x
COOLING SYSTEM

14x

15x

65 SX 2009

INDEX
IGNITION SYSTEM

16x

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
KTMSPORTMOTORCYCLE AG, Mattighofen only.

x
2

ENGINE CASE

65 SX 2009
FIG
1
2
3
4
5
6
7
8
9
12
13
14
15
16
17
18
19
20
21
22
23
24

PART NUMBER
46230000033
46230039000
58030021000
58038022000
46230024000
58330023000
46230023000
0835080355
46030043000
54634049000
0025060086
46230060000
0025060306
0603061001
58336020190
31007007101
46230099000
0025060556
0025060406
0025060306
0025060086
45230089000

094623010 / C094623010

DESCRIPTION
ENGINE CASE CPL. WITH BEARING
ENGINE CASE GASKET
OILDRAIN PLUG W.MAG. M 12X1,5
CU-SEAL RING DIN7603-12X18X1,5
DOWEL 12X9X14,5
DOWEL 17 X 14 X 9,5
DOWEL 10X8,2X10
STUD DIN0835-M 8X35
10.9
STUD M8X41
RETAINING PLATE
HH COLLAR SCREW M6X8 TX30
CHAIN SPROCKET GUARD
HH COLLAR SCREW M6X30 TX30
CU-SEAL RING DIN7603-6X10X1
VACUUM CONECTION M6/3MM '97
PVC-HOSE 4X6MM
GASKET SET 65 SX
2009
HH COLLAR SCREW M6X55 TX30
HH COLLAR SCREW M6X40 TX30
HH COLLAR SCREW M6X30 TX30
HH COLLAR SCREW M6X8 TX30
YDNAC-CLAMP 10068 (6,8MM)

* NEW PART

QTY
1
1
1
1
1
1
2
2
2
1
1
1
3
1
1
1
1
5
2
3
1
1

X AS REQUIRED

CLUTCH COVER

65 SX 2009
FIG
1
2
3
4
5
6
7
8
20
21
22

PART NUMBER
46230026000
46230027000
51005074000
58030020100
0770191015
46230001000
49030090000
46230025000
0025060256
0025060206
0025060506

094623020 / C094623020

DESCRIPTION
CLUTCH COVER OUTSIDE
GASKET - CLUTCH OUTER COVER
RETAINING PLATE
PLUG CPL. M24X3
O-RING 19,00X3,00 NBR
INNER CLUTCH COVER
DOWEL 9,8 X 7 X 10
CLUTCH COVER GASKET INSIDE
HH COLLAR SCREW M6X25 TX30
HH COLLAR SCREW M6X20 TX30
HH COLLAR SCREW M6X50 TX30

* NEW PART

QTY
1
1
1
1
1
1
3
1
6
2
2

X AS REQUIRED

CYLINDER, CYLINDER HEAD

65 SX 2009
FIG
1
2
3
4
5
6
7
8
8
8
8
9
10
11
12
13
14
15
16
17
18
19
30
31
32
33
34
35
36
37
38
40
41
42
43
44

PART NUMBER
50330079000
50230032010
46230006000
45230036000
46030045000
0325040100
46230038000
46230035020
46230035040
46230035050
46230035060
46205004000
46205003000
46205003050
0025060306
0025050106
45001070000
46232060050
0985050003
58336020190
42013037000
45237014000
46237036044
0025050126
46237035000
0985050003
46237013000
46237011000
0770030015
0770150151
46237074000
46237017000
46237020000
0912050083
0984060302
0603061001

094623050 / C094623050

DESCRIPTION
CYL. HEAD BOLT M 7X30 WS=10
CU-SEAL RING 7,3 X 12 X 0,5
CYLINDER HEAD
CYLINDER HEAD GASKET
COLLAR NUT M8 WS=10
CYLINDER PIN DIN6325- 4X10
CYLINDER + PISTON
CYLINDER BASE GASKET 0,2 MM
CYLINDER BASE GASKET 0,4 MM
CYLINDER BASE GASKET 0,5 MM
CYLINDER BASE GASKET 0,6MM
EXHAUST PIPE FLANGE GASKET
EXHAUST FLANGE
BRACKET FOR SPRINGHOLDER
HH COLLAR SCREW M6X30 TX30
COLLAR SCREW M5X12 ISA30
BRAKE CABLE CLAMP RSGU 9/12
RETAINING PLATE CLUTCHHOSE
SELF LOCKING NUT DIN0985-M 5
VACUUM CONECTION M6/3MM '97
CLAMP MINI 1
HOSE
VENTILATION CPL.
HH COLLAR SCREW M5X12 TX30
CLOSING COVER
SELF LOCKING NUT DIN0985-M 5
MEMBRANE
FLANGE EXHAUST CONTROL
O-RING 31X1,5 NBR 70
O-RING 15,00X1,50 VITON
ADJ. SPRING - EXHAUST CONTROL
CONTROL SLIDE SHAFT
CONTROL SLIDE BOTTOM PART
AH SCREW DIN 912 M 5X8
AH SCREW DIN6912 M 6X30
CU-SEAL RING DIN7603-6X10X1

* NEW PART

QTY
4
4
1
1
4
2
1
x
x
x
x
1
1
1
3
1
1
1
1
1
2
1
1
3
1
1
1
1
2
1
1
1
1
1
1
1

X AS REQUIRED

CYLINDER, CYLINDER HEAD

65 SX 2009
FIG
45

PART NUMBER
0603050901

094623050 / C094623050

DESCRIPTION
COPPERT GASKET 5X9X1

QTY
1

* NEW PART

X AS REQUIRED

CRANKSHAFT, PISTON

65 SX 2009
FIG
1
2
3
4
5
6
7
8
9
10
11
12
14
15
15
16
17
18

PART NUMBER
46030029000
83061015000
46232023023
0888040050
0760304772
46030082200
46230016000
0770160021
46030034000
46230018000
0888030050
47030076100
46230015000
46230007000 I
46230007000 II
46030033000
45130074000
46030030500

094623060 / C094623060

DESCRIPTION
HH NUT 14X1,25X7 WS=22
STOP DISK 15,2X25,7X1
PRIMARY PINION LOOSE
WOODRUFF KEY DIN6888 4X5X13
SH.SEAL RING 30X47X7 BSL VITON
GROOVED BALL BEAR.20X52X15 NTN
SPACER WASHER - CRANKSHAFT
O-RING 16,00X2,00 VITON
NEEDLE BEAR.PISTONPIN 12X15X17
CRANKSHAFT CPL.
WOODRUFF KEY DIN6888-3X5X13
SEAL SHAFT RING 20X35X6 BTSL
CONNECT. ROD REPAIR SET
PISTON CPL. I
PISTON CPL. II
PISTON PIN 12X38
CIRCLIP
2001
PISTON RING 45MM 65CCM

* NEW PART

QTY
1
1
1
1
1
2
1
1
1
1
1
1
1
x
x
1
2
1

X AS REQUIRED

REED VALVE CASE

65 SX 2009
FIG
1
2
3
4
5
6

PART NUMBER
46230049000
46230051044
46230052000
46230050000
0025060206
10001120000

094623070 / C094623070

DESCRIPTION
GASKET MEMBRAN CASE
MEMBRANE CASE CPL. V-VORCE
MEMBRANE
INTAKE FLANGE
HH COLLAR SCREW M6X20 TX30
CLAMP 25-40 SGT 4

* NEW PART

QTY
1
1
4
1
4
1

X AS REQUIRED

CARBURETOR

65 SX 2009
FIG
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

PART NUMBER
46131017000
45031015200
45031015000
46231035000
46231020000
46231034000
46231034100
45031023210
45031007020
46231001044
46231048044
46231099000
46231011044
46231009044
52031137001

094623110 / C094623110

DESCRIPTION
ADJUSTING SCREW MIKUNI
SPRING IDLE ADJUST SCREW
SPRING
THROTTLE VALVE MIKUNI 2.5
NEEDLE VALVE CPL. 2.5
JET NEEDLE MIKUNI 5IPL43-2
JET NEEDLE OUTER MIKUNI
MAIN JET 210
IDLING JET 20 MIKUNI
CARBURETOR 65 SX
2009
CHOKE + LEVER CPL.
GASKET SET MIKUNI
FLOAT BODY + SCREW + GASKET
FLOAT + PIN
PVC-HOSE 3X5MM

* NEW PART

QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

X AS REQUIRED

CLUTCH

65 SX 2009
FIG
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

PART NUMBER
0991060202
46032006000
46232005000
46232002000
46032011000
46032010000
46232003000
46232012000
46232000044
0738060161
0738060201
54732064000
59032061044
59032066000
0770300015
59032065000
46232057000
46132019000

094623210 / C094623210

10

DESCRIPTION
FLAT HEAD DIN7991-M 6X20
SPRING RETAINER 25X63,5X2
CLUTCH SPRING
CLUTCH HUB
LINING DISK
INTERMEDIATE DISK STEEL
CLUTCH PRESSURE CAP
STOP DISC 17,2X32X1,5
PRIMARY DRIVE WITH CLUTCH CAGE
FLAT HEAD SCREW ISO7380 M6X16
FLAT HEAD SCREW ISO7380 M6X20
BLEEDER SCREW WITH CAP
OUTPUT CYLINDER CPL. 27MM 2003
PISTON + O-RING + BALL 27MM
O-RING 30,00X1,50 NBR 70
GASKET FOR SLAVE CYLINDER
PRESSURE PIECE CPL.
HH COLLAR SCREW M10X20

* NEW PART

QTY
6
1
6
1
6
5
1
1
1
2
1
1
1
1
1
1
1
1

X AS REQUIRED

TRANSMISSION

65 SX 2009
FIG
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
22
23
24
25
26

PART NUMBER
46233010000
46233001000
46233011000
46233015000
46233014000
46233013000
46233016000
46233012000
46233005000
46233003000
46233006000
46233002000
0618121912
49033013000
46033020000
46233091000
46233022000
46033028000
0770020020
0760263561
46233030000
46233029013
46233029014
49033091000
0625982030
0021050003
0912050083

094623310 / C094623310

11

DESCRIPTION
COUNTERSHAFT
MAIN SHAFT 13-T
IDLER GEAR 1.G.
SLIDING GEAR 5.G.
IDLER GEAR 4.G
IDLER GEAR 3.G
SLIDING GEAR 6.G.
IDLER GEAR 2.G
IDLER GEAR 5.G.
SLIDING GEAR 3/4. G
IDLER GEAR 6.G.
SOLID GEAR 2.G
NEEDLE BUSH NK1212
STOP DISK 12,1X25X1
NEEDLE BEARING 14X18X8
CIRCLIP DIN 471 20X1,2
LOCK RING
GROOVED BALL BEARING 20X42X12
O-RING 20X2 VITON
SHAFT SEAL RING 26X35X6BSL NB
DISANCESPACER F. SPROCKET
CHAIN SPROCKET 13-T.
CHAIN SPROCKET 14-T.
CIRCLIP AS20X1,75
* BALL BEARING 98203 KSE C3
WASHER DIN9021-A 5,3
AH SCREW DIN 912 M 5X8

* NEW PART

QTY
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
3
2
1
1
1
1
x
1
1
1
1
1

X AS REQUIRED

KICKSTARTER

65 SX 2009
FIG
1
2
3
4
5
6
7
8
9
11
13
14
15
16
17
18
19
20
21

PART NUMBER
0019080206S
54633037000
46233036044
46233038000
0760172860
50333030000
50333055000
50333054000
0471170010
77033051000
50333050000
50333052000
0988162210
50333056000
0025060166
50333069000
46233069001
46233018000
46233053016

094623390 / C094623390

12

DESCRIPTION
FLAT HEAD SCREW M. ISA45 M8X20
WASHER 8MM GALVANIZED
KICKSTARTER CPL.
SPACER SLEEVE
SHAFT SEAL RING 17X28X6B NBR
STOP DISK 17,2X24X1
DRIVING HUB
125/200'98
KICKSTARTER SPRING 2,6MM '98
CIRCLIP DIN0471-17X1
KICKSTART. GEAR 28-T
05
KICKSTARTER SHAFT 125/200'98
KICKSTARTER RATCHET
THRUST WASHER DIN0988-16X22X1
SPRING 1,4MM
'98
HH COLLAR SCREW M6X16 TX30
STOP MET.SHEET 4MM 125/200'98
COVER PLATE
BEARING PIN IDLER GEAR
INTERMEDIATE STARTING GEAR

* NEW PART

QTY
1
1
1
1
1
3
1
1
2
1
1
1
1
1
2
1
1
1
1

X AS REQUIRED

SHIFTING MECHANISM

65 SX 2009
FIG
1
2
3
4
5
6
7
8
9
10
11
12
13
14
18
19
20
21
22
23
24
30
31
32
33
34
35
36
37
38
39

PART NUMBER
0025050126
46234005010
46234005044
0471140100
54634050000
54834014000
54634020000
56534013100
49033013000
46034027000
0760122050
46234031044
50232050001
59009062016
58038023200
46234019000
46234020000
0402061000
46234001000
46234002000
46234003000
0012060303
46234015044
0625068050
46234012033
0625069034
54834023000
54634052300
50334024144
0349000050
0025050206

094623410 / C094623410

13

DESCRIPTION
HH COLLAR SCREW M5X12 TX30
SHIFT SHAFTSPRING RETAIN.PLATE
SHIFT SHAFT CPL.
LOCK WASHER DIN0471-14X1
STOP DISK 14X30X1
RETURN SPRING
03
SPRING GUIDE
TENSIONING SPRING 0,8MM
STOP DISK 12,1X25X1
NEEDLE BEARING 12X18X12 2002
SHAFT SEAL RING 12X20X5 B
SHIFTING LEVER CPL.
STEEL WASHER 6,4X17X3
SPECIAL SCREW M6X16 WS=8 10.9
PRESSURE SPRING 0,9MM
SHIFTING RAIL COUNTER SHAFT
SHIFTING RAIL MAIN SHAFT
NEEDLE ROLLER ZRB 6X10
SHIFT FORK MAIN SHAFT
SHIFT FORK COUNTERSHAFT R/S
SHIFT FORK COUNTERSHAFT Ll/S
AH SCREW DIN6912 M6X30 8.8
SHIFT DRUM LOCATING CPL.
BALL BEARING 6805 C4 NTN JAPAN
SHIFT ROLLER CPL.
BALL BEARING 6903 C4
LOCKING LEVER SPRING
03
SLEEVE FOR LOCKING LEVER
LOCATING LEVER CPL.
08
WASHER DIN7349-5X15X2
HH COLLAR SCREW M5X20 TX30

* NEW PART

QTY
1
1
1
1
1
1
1
1
1
2
1
1
1
1
4
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1

X AS REQUIRED

WATER PUMP

65 SX 2009
FIG
1
2
3
4
5
6
7
8
9
10
11
12
13
14

PART NUMBER
0025060086
0603061001
0025060506
0025060126
45235052000
45235053000
49030090000
0014050123
54835005000
0760082472
50335054050
0625060001
45235054028
0625006087

094623510 / C094623510

14

DESCRIPTION
HH COLLAR SCREW M6X8 TX30
CU-SEAL RING DIN7603-6X10X1
HH COLLAR SCREW M6X50 TX30
HH COLLAR SCREW M6X12 TX30
WATERPUMP COVER
WATER PUMP COVER GASKET
DOWEL 9,8 X 7 X 10
HH COLLAR SCREW M 5X12 WS=6
WATER PUMP WHEEL
07
SHAFT SEAL RING 8X24X7 A DUO
WATER PUMP SHAFT 125/200'98
BALL BEARING 6000/C3
DRIVE WHEEL
GROOVED BALL BEAR. 608 2RS C3

* NEW PART

QTY
1
1
2
1
1
1
2
1
1
1
1
1
1
1

X AS REQUIRED

COOLING SYSTEM

65 SX 2009
FIG
1
2
3
4
5
6
7
8
9
10
11

PART NUMBER
46235007000
46235008000
41001052000
45135009000
0024060123
46235034000
46235025033
46235025000
46235022000
42013037300
60035067001

094623530 / C094623530

15

DESCRIPTION
RADIATOR L/S 65 SX
2009
RADIATOR R/S 65SX
2009
RUBBER SLEEVE D=12MM
RADIATOR CAP 50 LC 1,0 BAR
COLLAR SCREW M6X12
TX
RADIATOR PROTECTOR 65 SX 2009
RADIATOR HOSE CPL.+Y-CONNECT.
RADIATOR CONNECTOR TOP
PREFORMED HOSE 65SX RAD.L/S
HOSE CLAMP NORMA 12/22
HOSE 6X10 EPDM
03

* NEW PART

QTY
1
1
4
1
4
2
1
1
1
7
x

X AS REQUIRED

IGNITION SYSTEM

65 SX 2009
FIG
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

PART NUMBER
46239095000
46239031000
46139030000
50339006000
0025060166
46239090000
45239093000
0770012030
46239004000
0025050166
46239005000
50230029012
49030021000
46230040000
46230002000
0025060206

094623910 / C094623910

16

DESCRIPTION
WIRING HARNESS CDI 65 SX
CDI 65 SX
2009
RUBBER BR. DIGI.BOX 65SX
% IGNI.COIL KOKU. IG5127
HH COLLAR SCREW M6X16
SPARK PLUG CONNECTOR
SPARK PLUG LR8B
O-RING 12,00X3,0 VITON 75
STATOR
HH COLLAR SCREW M5X16
ROTOR
LOCKING RING VSK 12
COLLAR NUT M12X1 R/S
IGNITION COVER GASKET
IGNITION COVER
HH COLLAR SCREW M6X20

2009
2003
TX30

TX30

TX30

* NEW PART

QTY
1
1
1
1
2
1
1
1
1
3
1
1
1
1
1
3

X AS REQUIRED

*3CM080208IEN*
3CM080208IEN

8/2008
Art.Nr.: 3CM080208IEN

KTM Group Partner

KTM-Sportmotorcycle AG
A-5230 Mattighofen
www.ktm.at