maintenance work on chassis and engine

OWNER'S MANUAL

2009

50 SX

50 SX Junior

50 SX Mini

ART. NO. 3211344en

DEAR KTM CUSTOMER

DEAR KTM CUSTOMER

Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you and your child enormous pleasure if you service and maintain it accordingly.

We wish you great pleasure riding the vehicle!

1

Enter the serial numbers of your vehicle below.

Chassis number ( p. 9)

Dealer's stamp

Engine number ( p. 9)

The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing development and design can, however, not be completely excluded.

All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications, 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 printing and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery.

© 2008 by KTM-Sportmotorcycle AG, Mattighofen Austria

All rights reserved

Reproduction, even in part, 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

CONTENTS

CONTENTS

MEANS OF REPRESENTATION ............................................ 4

IMPORTANT NOTES ............................................................ 5

VIEW OF VEHICLE............................................................... 7

View of the vehicle from the left front (example)................. 7

View of the vehicle from the right rear (example) ................ 8

LOCATION OF SERIAL NUMBERS ........................................ 9

Chassis number............................................................... 9

Engine number................................................................ 9

Shock absorber part number............................................. 9

CONTROLS ....................................................................... 10

Throttle grip.................................................................. 10

Hand brake lever ........................................................... 10

Short circuit button ....................................................... 10

Fuel tap........................................................................ 10

Opening filler cap.......................................................... 10

Closing filler cap ........................................................... 11

Opening oil tank cap (50 SX Mini) .................................. 11

Closing oil tank cap (50 SX Mini).................................... 11

Choke (50 SX)............................................................... 11

Choke (50 SX Junior, 50 SX Mini)................................... 11

Kickstarter.................................................................... 12

Foot brake pedal ........................................................... 12

Plug-in stand ................................................................ 12

GENERAL TIPS AND HINTS ON PUTTING INTO

OPERATION...................................................................... 13

Advice on first use......................................................... 13

Running in the engine.................................................... 14

RIDING INSTRUCTIONS .................................................... 15

Checks before putting into operation ............................... 15

Starting ........................................................................ 15

Starting up ................................................................... 16

Shifting, riding.............................................................. 16

Braking ........................................................................ 16

Stopping, parking .......................................................... 16

Refueling...................................................................... 17

Filling up with oil (50 SX Mini) ....................................... 17

SERVICE SCHEDULE......................................................... 19

Important maintenance work to be carried out by an authorized KTM workshop. ............................................. 19

Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)................ 20

Performance of urgent inspection and care work by the supervisory individual. ................................................... 20

MAINTENANCE WORK ON CHASSIS AND ENGINE.............. 21

Jacking up the motorcycle .............................................. 21

Removing the motorcycle from the work stand.................. 21

Adjusting the rebound damping of the shock absorber....... 21

Measuring rear wheel sag unloaded ................................. 21

Checking the static sag of the shock absorber .................. 22

Adjusting the spring preload of the shock absorber

Removing the shock absorber

x

...... 22

x

..................................... 23

Installing shock absorber x

........................................... 23

Vehicle level ................................................................. 23

Adjusting upper fork projection x .................................. 24

Adjusting seat height x ................................................ 24

Cleaning dust boots of fork legs ...................................... 24

Checking play of steering head bearing............................ 25

Adjusting play of steering head bearing

Removing the fork legs

x ....................... 25

x .............................................. 27

Installing the fork legs x ............................................... 27

Removing the lower triple clamp x ................................ 28

Installing the lower triple clamp x

................................. 29

Greasing the steering head bearing x ............................. 30

Dismounting the front fender .......................................... 30

Installing the front fender............................................... 30

Dismount the start number plate..................................... 31

Installing the start number plate ..................................... 31

Handlebar position ........................................................ 31

Adjusting handlebar position x

...................................... 32

Checking play in gas Bowden cable ................................. 32

Adjusting play in gas Bowden cable x

............................ 32

Checking chain dirt ....................................................... 33

Cleaning the chain......................................................... 33

Checking the chain tension ............................................ 33

Checking the chain tension - installing rear wheel............. 34

Checking rear sprocket / engine sprocket for wear ............. 34

Adjusting chain tension.................................................. 34

Adjusting chain tension - after checking .......................... 35

Adjusting chain tension - installing rear wheel.................. 35

Adjusting the chain guide x

.......................................... 35

Checking brake discs ..................................................... 36

Checking play of handbrake lever .................................... 36

Adjusting play of handbrake lever.................................... 36

Adjusting basic position of handbrake lever...................... 36

Checking front brake fluid level....................................... 37

Adding front brake fluid x

............................................ 37

Checking the front brake linings...................................... 38

Removing front brake linings x ..................................... 38

Installing the front brake linings x ................................. 39

Changing the front brake linings x ................................. 39

Checking free play of foot brake lever .............................. 40

Adjusting basic position of foot brake pedal x

................ 40

Checking rear brake fluid level........................................ 41

Adding rear brake fluid x .............................................. 41

Checking rear brake linings ............................................ 42

Removing rear brake linings x

....................................... 42

Installing the rear brake linings

Changing the rear brake linings

x

.................................. 42

x

.................................. 43

Removing front wheel x

................................................ 44

Installing the front wheel

Removing rear wheel

x

........................................... 44

x

................................................. 45

Installing the rear wheel x

............................................ 45

Tire condition checking.................................................. 45

Checking tire air pressure............................................... 46

Checking spoke tension.................................................. 46

Removing the seat ......................................................... 46

Mounting the seat ......................................................... 47

Cooling system .............................................................. 47

Checking antifreeze and coolant level .............................. 47

Checking the coolant level.............................................. 48

Draining the coolant

Refilling coolant

x

.................................................. 48

x

....................................................... 49

Removing main silencer ................................................. 49

Installing the main silencer ............................................ 50

Glass fiber yarn filling of main silencer ............................ 50

Removing the glass fiber yarn filling of the main silencer x ................................................................... 50

Installing the glass fiber yarn filling of the main silencer x

................................................................... 50

Removing the air filter

Installing the air filter

Cleaning air filter x

............................................... 51 x

............................................... 51 x

...................................................... 51

2

CONTENTS

Carburetor - idle (50 SX) ................................................ 52

Carburetor - idle (50 SX Junior, 50 SX Mini) .................... 52

Carburetor - adjusting idle

Carburetor - adjusting idle

x

(50 SX) ............................. 52

x

(50 SX Junior,

50 SX Mini) .................................................................. 53

Checking oil level (50 SX Mini)....................................... 54

Bleeding the oil pump x

(50 SX Mini) ........................... 54

Checking gear oil level ................................................... 55

Changing the gear oil

Draining the gear oil x

................................................ 55 x ................................................. 55

Filling up with gear oil

Adding gear oil x .............................................. 56 x ......................................................... 56

Checking clutch engagement speed

Adjusting clutch engagement speed x ............................ 57 x ........................... 57

Removing centrifugal clutch

Fitting centrifugal clutch

x ...................................... 57

x ........................................... 58

Checking/measuring clutch x ........................................ 59

Dismantling centrifugal clutch x ................................... 59

Assembling centrifugal clutch x .................................... 59

TROUBLESHOOTING......................................................... 61

CLEANING........................................................................ 63

Cleaning motorcycle ...................................................... 63

STORAGE ......................................................................... 64

Storage......................................................................... 64

Putting into operation after storage ................................. 64

TECHNICAL DATA - ENGINE.............................................. 65

Capacity - gear oil.......................................................... 65

Capacity - coolant.......................................................... 65

TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 66

TECHNICAL DATA - CARBURETOR..................................... 67

50 SX........................................................................... 67

50 SX Junior................................................................. 67

50 SX Mini ................................................................... 67

TECHNICAL DATA - CHASSIS ............................................ 68

Tires ............................................................................ 69

Capacity - fuel............................................................... 69

TECHNICAL DATA - FORK.................................................. 70

50 SX........................................................................... 70

50 SX Junior................................................................. 70

50 SX Mini ................................................................... 70

TECHNICAL DATA - SHOCK ABSORBER ............................. 71

50 SX........................................................................... 71

50 SX Junior................................................................. 71

50 SX Mini ................................................................... 71

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ........ 72

SUBSTANCES................................................................... 73

AUXILIARY SUBSTANCES.................................................. 75

STANDARDS..................................................................... 77

INDEX .............................................................................. 78

3

MEANS OF REPRESENTATION

Symbols used

The symbols used are explained in the following.

Indicates an expected reaction (e.g. of a work step or a function).

Indicates an unexpected reaction (e.g. of a work step or a function).

All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.

Identifies a page reference (more information is provided on the specified page).

Formats used

The typographical and other formats used are explained in the following.

Proper name

Identifies a proper name.

Name

®

Identifies a protected name.

Brand™

Identifies a brand in merchandise traffic.

4

IMPORTANT NOTES

Use definition

KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations.

Info

The motorcycle must be used only in closed off areas remote from public road traffic.

Maintenance

A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of components.

Using the motorcycle in extreme conditions such as very muddy or wet terrain can lead to above-average wear of components such as the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached.

Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle.

Warranty

The work prescribed in the service schedule must be carried out in an authorized KTM workshop only and confirmed in the customer's service record, since otherwise no warranty claims will be honored. No warranty claims can be honored for damage resulting from manipulations and/or alterations to the vehicle.

Fuel, oils, etc.

You should use the fuels, oils and greases according to specifications as listed in the owner's manual.

Spare parts, accessories

For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them installed in an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.

The current KTM PowerParts for your vehicle can be found on the KTM website.

International KTM Website: http://www.ktm.com

Work rules

During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals, seal rings, O-rings, pins, lock washers) must be replaced by new parts.

If a thread locker is used for the screw connections (e.g.

Loctite

®

), follow the specific manufacturer instructions regarding its use.

Parts that are to be reused after disassembly must be cleaned and checked for damage and wear. Change damaged or worn parts.

After repair and maintenance, ensure that the vehicle is roadworthy.

Transport

Note

Danger of damage The parked vehicle can roll away or fall over.

– Always place the vehicle on a firm and even surface.

Note

Fire hazard Some vehicle components get very hot when the machine is driven.

– Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is still warm from being run. Always let the vehicle cool first.

– Switch off the engine.

– Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

5

IMPORTANT NOTES

Environment

Motorcycling is a wonderful sport and we naturally hope that you and your child will be able to enjoy it to the fullest. However, it is a potential problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that your child uses the motorcycle legally, display environmental consciousness, and respect the rights of others.

Notes/warnings

Pay close attention to the notes/warning.

Info

Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured.

Grades of risks

Danger

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.

Warning

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Note

Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Warning

Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.

Owner's manual

– Carefully read this owner's manual in its entirety together with your child before letting your child ride the motorcycle for the first time. It contains a lot of information and tips to help you and your child operate and handle the motorcycle. Only then will you find out how to customize the motorcycle ideally for your child's use and how to protect your child from injury. The owner's manual also contains important information on servicing the motorcycle.

– The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.

6

VIEW OF VEHICLE

3.1

View of the vehicle from the left front (example)

7

6

7

4

5

1

2

3

Hand brake lever

Filler cap

Fuel tap

Quick release for seat lock

Shock absorber compression adjustment

Chain guide

Plug-in stand

700526-01

VIEW OF VEHICLE

3.2

View of the vehicle from the right rear (example)

8

4

5

6

1

2

3

Short circuit button

Chassis number

Throttle grip

Level viewer for brake fluid, rear

Foot brake pedal

Kickstarter

700527-01

LOCATION OF SERIAL NUMBERS

4.1

Chassis number

The chassis number

 is stamped on right of the steering head.

9

4.2

Engine number

700460-01

The engine number sprocket.

 is stamped on the left side of the engine under the engine

4.3

Shock absorber part number

700461-01

The shock absorber part number

 the adjusting ring towards the rear.

is stamped on the top of the shock absorber above

700469-01

CONTROLS

5.1

Throttle grip

Trottle grip

 is fitted on the right side of the handlebar.

5.2

Hand brake lever

700470-01

Hand brake lever

 is fitted on the right side of the handlebar.

The hand brake lever is used to activate the front brake.

5.4

5.5

5.3

Short circuit button

Fuel tap

Opening filler cap

700471-01

Short circuit button

 is fitted on the left side of the handlebar.

Possible states

• Short circuit button in basic position – In this position, the ignition circuit is closed, and the engine can be started.

• Short circuit button pressed – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.

700462-01

Fuel tap

 is on the left of the fuel tank.

Possible states

• Fuel tap is closed – The knurled screw is turned all the way clockwise. Fuel cannot flow out of the fuel tank.

• Fuel tap is open – The knurled screw is turned all the way counterclockwise. Fuel can flow out of the fuel tank.

700463-01

– Turn the tank cap

 counterclockwise and pull it up.

10

700465-10

CONTROLS

5.6

Closing filler cap

– Put the tank cap on and turn it clockwise.

Info

Run the fuel tank breather hose

 without kinks.

700465-11

5.7

Opening oil tank cap (50 SX Mini)

– Turn the oil tank cap

 counterclockwise and pull it up.

700517-01

5.8

Closing oil tank cap (50 SX Mini)

– Put the oil tank cap on and turn it clockwise.

Info

Run the oil tank breather hose

 without kinks.

700517-10

5.9

Choke (50 SX)

Choke lever

 is fitted on the left side of the carburetor.

Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.

Info

If the engine is warm, the choke function must be deactivated.

700464-01

Possible states

• Choke function activated – The choke lever is in the upper position. The O-ring is visible.

• Choke function deactivated – The choke lever is in the lower position. No O-ring is visible.

5.10

Choke (50 SX Junior, 50 SX Mini)

Choke lever

 is fitted on the right side of the carburetor.

Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.

Info

If the engine is warm, the choke function must be deactivated.

700519-01

Possible states

• Choke function activated – The choke lever is pushed up all the way.

• Choke function deactivated – The choke lever is pushed down all the way.

11

CONTROLS

5.11

Kickstarter

5.12

Foot brake pedal

The kickstarter

 is fitted on the right of the engine.

The kickstarter can be swiveled.

Info

Before riding, swing the kickstarter inwards towards the engine.

700472-01

Foot brake pedal

 is located in front of the right footrest.

The foot brake pedal is used to activate the rear brake.

12

5.13

Plug-in stand

700473-01

700474-01

Note



To park the motorcycle, insert the plug-in stand on the left of the vehicle.

 in the support for the plug-in stand

Info

Remove the plug-in stand before riding.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION

13

6.1

Advice on first use

Warning

Danger of accidents Physical and mental readiness of a child.

– Your child must be able to ride a bicycle and must be able to erect the vehicle independently after a fall. In addition, your child must understand the regulations and instructions from you or from other guardians. Do not ask too much of your child; participation in a race should not be considered until your child's stamina, riding techniques and motivation are at the necessary levels. Children often underestimate or fail to recognize dangerous situations; make it clear to your child that it should not, under any circumstances, operate the vehicle without supervision and that your child may only drive at speeds that are commensurate with the child's riding abilities and the road conditions.

– Only let your child ride on the vehicle if it is physically and mentally ready to operate the vehicle.

Warning

Risk of injury Missing or poor protective clothing present an increased safety risk.

– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the motorcycle. You and your child should always used protective clothing that is in good condition and meets the legal requirements. When you ride a motorcycle, set an example for your child and wear suitable protective clothing.

Warning

Danger of crashing Impairment of riding behavior due to different tire tread patterns on front and rear wheels.

– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.

Warning

Danger of accidents Critical riding behavior due to inappropriate riding.

– Ensure that your child adjusts the riding speed to the road conditions and to his or her riding abilities.

Warning

Danger of accidents Accident risk caused by presence of a passenger.

– Your vehicle is not designed to carry passengers. Do not ride with a passenger.

Warning

Danger of accidents Brake system failure.

– If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating.

Ensure that your child raises his or her foot from the foot brake pedal when the child does not want to brake.

Warning

Danger of accidents Destruction of chassis components.

– Do not exceed the maximum allowable rider weight.

Warning

Risk of misappropriation Usage by unauthorized persons.

– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.

Info

When using your motorcycle, remember that others may feel disturbed by excessive noise.

– Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.

You receive a delivery certificate and the service record at vehicle handover.

– Carefully read the entire owner's manual together with your child before going for the first ride.

Info

Pay special attention to the safety warnings and injury risks.

Explain to your child the techniques of riding and falling, e.g. how shifting weight can influence handling characteristics.

– Familiarize your child with the controls.

– Adjust the basic position of the handbrake lever. ( p. 36)

– Adjust the basic position of the foot brake pedal.

x

( p. 40)

– Before using the vehicle for the first time, ensure that the basic settings of the chassis are suitable for the weight of your child.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION

– Accustom your child to the handling of the motorcycle on suitable terrain, preferably on a large open meadow.

Info

To give your child a feel for the brake, you should push your child at first. Do not start the engine until your child can is able to apply the necessary brake pressure.

Initially, let your child drive to another person who can help your child stop and turn.

– Erect obstacles for your child to navigate around to accustom your child to handling the vehicle.

– Your child should also try to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.

– Do not let your child ride on terrain that exceed your child's capabilities and experience.

– Your child should hold the handlebar firmly with both hands and keep his or her feet on the footrests when riding.

– Do not exceed the maximum allowable rider weight.

Requirement

Maximum rider weight

Maximum rider size

< 35 kg (< 77 lb.)

< 130 cm (< 51.2 in)

– Run the engine in. ( p. 14)

6.2

Running in the engine

– During the running-in phase, do not exceed the specified engine performance.

Requirement

Maximum engine performance

During the first 3 service hours

During the first 5 service hours

< 70 %

< 100 %

– Avoid fully opening the throttle!

14

RIDING INSTRUCTIONS

7.1

Checks before putting into operation

Info

Make sure that the motorcycle is in a perfect technical condition before use.

Info

In the interests of riding safety, make it your own and your child's habit to perform a general check before going for a ride.

Insist that your child perform the general checks himself or herself.

– Check the gear oil level. ( p. 55)

(50 SX Mini)

– Check the oil level. ( p. 54)

– Check the chain tension. ( p. 33)

– Check the chain dirt accumulation. ( p. 33)

– Check the tire condition. ( p. 45)

– Check the tire air pressure. ( p. 46)

– Check the front brake brake fluid level. ( p. 37)

– Check the rear brake fluid level. ( p. 41)

– Check the front brake linings. ( p. 38)

– Check the rear brake linings. ( p. 42)

– Check the function of the brake system.

– Check the coolant level. ( p. 48)

– Check the settings of all controls and ensure that they can be operated smoothly.

– Check the functioning of the electrical equipment.

7.2

Starting

Danger

Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death.

– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space without an effective exhaust extraction system.

Note

Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.

– Always warm up the engine at low engine speeds.

15

Info

If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel evaporate after a long time of standing.

If the float chamber is filled with fresh fuel, the engine starts immediately.

– Turn the knurled screw on the fuel tap all the way counterclockwise.

Fuel can flow from the fuel tank to the carburetor.

– Remove the motorcycle from the stand.

The engine is cold

(50 SX)

– Pull up the choke lever as far as possible and turn it max. ¼ of a turn.

(50 SX Junior, 50 SX Mini)

– Push the choke lever up all the way.

– Forcefully step on the kickstarter, pushing it all the way forward.

Info

Do not open the throttle.


7.3

Starting up

Info

The plug-in stand must be removed before you start your journey.

– Open the throttle carefully.

7.4

Shifting, riding

Info

If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.

– If the choke function was activated, deactivate it after the engine has warmed up.

– When you reach maximum speed after fully opening the throttle, turn back the throttle to about ¾ of its range. The speed hardly drops, but the fuel consumption falls considerably.

– Your child should always open the throttle only as much as the engine can handle – abruptly opening the throttle increases fuel consumption.

– Your child should switch off the engine if he or she expects to be standing for a long time.

Requirement

≥ 2 min

7.5

Braking

Warning

Danger of accidents If you brake too hard, the wheels can lock.

– Adapt your braking to the traffic situation and the road conditions.

Warning

Danger of accidents Reduced braking caused by spongy pressure point of front or rear brake.

– Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Danger of accidents Reduced braking due to wet or dirty brakes.

– Clean or dry dirty or wet brakes by riding and braking gently.

– On sandy, wet or slippery surfaces, use the rear brake.

– Braking should always be completed before you go into a bend.

7.6

Stopping, parking

Warning

Risk of misappropriation Usage by unauthorized persons.

– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.

Warning

Danger of burns Some vehicle components get very hot when the machine is driven.

– Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these components to cool down before starting work on them.

Note



Note

Fire hazard Some vehicle components get very hot when the machine is driven.

– Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is still warm from being run. Always let the vehicle cool first.

16


17

Note

Material damage Damage and destruction of components due to excessive load.

– The plug-in stand is designed for the weight of the motorcycle only. You or your child should not sit on the motorcycle when it is standing on the plug-in stand. The plug-in stand and/or the frame could be damaged and the motorcycle could fall over.

– Brake the motorcycle.

– Press and hold the short circuit button while the engine is idling until the engine stops.

– Turn the knurled screw on the fuel tap all the way clockwise.

– Park the motorcycle on firm ground.

7.7

Refueling

Danger

Fire hazard Fuel can easily catch fire.

– Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel.

Warning

Environmental hazard Improper handling of fuel is a danger to the environment.

– Do not allow fuel to get into the ground water, the ground, or the sewage system.

400214-10


– Open the filler cap. ( p. 10)

– Fill the fuel tank with fuel up to measurement



.

Requirement

Measurement of



35 mm (1.38 in)

Super unleaded (ROZ 95 / RON 95 /

PON 91) ( p. 74)

Fuel tank capacity, approx.

(50 SX Mini)

Fuel tank capacity, approx. (50 SX,

50 SX Junior)

2.0 l (2.1 qt.)

2.3 l (2.4 qt.)

– Close the filler cap. ( p. 11)

Super unleaded gasoline, mixed with

2-stroke engine oil ( p. 74)

7.8

Filling up with oil (50 SX Mini)

Warning

Engine failure If the vehicle is run without 2-stroke oil in the tank, the result is engine failure.

– The oil tank must always be filled up to the MIN mark.


– Open the oil tank cap. ( p. 11)


– Fill the oil tank at least up to the MIN mark



.

Requirement

MIN mark Sufficient for a single tank filling


Oil tank contents ca.

0.2 l (0.2 qt.)

– Close the oil tank cap. ( p. 11)

700518-01

18

SERVICE SCHEDULE

8.1

Important maintenance work to be carried out by an authorized KTM workshop.

Engine

Carburetor

Attachments

Brakes

Chassis

Wheels

Change the gear oil.

x

( p. 55)

Check spark plug and replace if required.

x

Clean spark plug connectors and check for tightness.

x

Check engine mounting screws for tightness.

Check the clutch engagement speed.

x

( p. 57)

Check intake flange and carburetor connection boots for cracks and leakage.

Check idle.

Check vent hoses for damage and routing without sharp bends.

Check the cooling system for leakage.

Check the antifreeze and coolant level. ( p. 47)

Check exhaust system for leakage and looseness.

Check Bowden cables for damage, smooth operation and routing without sharp bends.

Clean the air filter.

x

( p. 51)

Check the front brake linings. ( p. 38)

Check the rear brake linings. ( p. 42)

Check the brake discs. ( p. 36)

Check the front brake brake fluid level. ( p. 37)

Check the rear brake fluid level. ( p. 41)

Check brake lines for damage and leakage.

Check the free play of the hand brake lever.

Check the free play of the foot brake lever. ( p. 40)

Check the function of the brake system.

Check screws and guide bolts of brake system for tightness.

Check shock absorber and fork for leakage and functioning.

x

Clean dust boots of fork legs. ( p. 24)

Bleed fork legs.

Check swingarm bearing.

Check play of steering head bearing. ( p. 25)

Check all screws to see if they are tight.

Check the spoke tension. ( p. 46)

Check rim run-out.

Check the tire condition. ( p. 45)

Check the tire air pressure. ( p. 46)

Check the chain wear.

Check the chain tension. ( p. 33)

Clean the chain. ( p. 33)

Check wheel bearing for play.

Clean and grease adjusting screws of chain adjuster.

S20A: Every 20 service hours


•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

S20A

•

•

•

•

•

S40A

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

19

SERVICE SCHEDULE

8.2

Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)

S20A

Clean and adjust carburetor.

x

Check intake membrane for wear.

Checking wear of clutch linings.

x x

Checking wear of clutch drum.

x

Check cylinder and piston for wear.

x

Check the seating of the piston pin.

x

Check main bearing of the crankshaft.

x

Check radial clearance of conrod bearing.

x

Change crankshafts and conrod bearings.

x

Carry out a complete fork service.

x

Carry out a complete shock absorber service.

x

Clean and lubricate swingarm bearing.

x

Grease the steering head bearing.

x

( p. 30)

Change glass fiber yarn filling of main silencer.

x

Change the front brake fluid.

x

Change the rear brake fluid.

x



J1A: annually

•

•

•

•

•

•

•

•

S40A

•

•

•

•

•

•

•

•

•

8.3

Performance of urgent inspection and care work by the supervisory individual.

J1A

•

•

•

•

•

•

•

20

Check the gear oil level. ( p. 55)

Check the front brake brake fluid level. ( p. 37)

Check the rear brake fluid level. ( p. 41)

Check the front brake linings. ( p. 38)

Check the rear brake linings. ( p. 42)

Check and adjust Bowden cables.

Bleed fork legs.

Clean dust boots of fork legs. ( p. 24)

Clean the chain. ( p. 33)

Check the chain tension. ( p. 33)

Check the chain wear.

Check rear sprocket / engine sprocket for wear. ( p. 34)

Clean the air filter.

x

( p. 51)

Check the tire air pressure. ( p. 46)

Check the tire condition. ( p. 45)

Check the coolant level. ( p. 48)

Check all controls for smooth operation.

Check braking.

Check all screws, nuts and hose clamps regularly for tightness.

NB1A: Depending on conditions of use according to requirements.

•

•

•

•

•

•

•

•

•

•

NB1A

•

•

•

•

•

•

•

•

•

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.1

Jacking up the motorcycle

Note



– Jack up the motorcycle underneath the engine.

Work stand (54829055000)

– Secure the motorcycle against falling over.

700475-01

9.2

Removing the motorcycle from the work stand

Note



– Remove the motorcycle from the work stand.

– Remove the work stand.

9.3

Adjusting the rebound damping of the shock absorber

Danger

Danger of accidents The shock absorber is under high pressure.

– The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any maintenance on it yourself.

700476-01

– Turn adjusting screw

 clockwise to the last perceptible click.

– Turn back counterclockwise by the number of clicks corresponding to the shock absorber type.

Requirement

Rebound damping (50 SX)

Standard

Rebound damping (50 SX Junior)

Standard

Rebound damping (50 SX Mini)

Standard

10 clicks

12 clicks

12 clicks

Info

Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

9.4

Measuring rear wheel sag unloaded

– Jack up the motorcycle. ( p. 21)

– Measure the distance – as vertical as possible – between the rear axle and a fixed point, for example, a mark on the side cover.

– Make a note of the value as measurement



.

– Remove the motorcycle from the work stand. ( p. 21)

21

400220-10


9.5

Checking the static sag of the shock absorber

– Measure distance



of rear wheel unloaded. ( p. 21)

– Ask someone to help you by holding the motorcycle upright.

– Measure the distance between the rear axle and the fixed point again.

– Make a note of the value as measurement



.

Info

The static sag is the difference between measurements

 and



.

– Check the static sag.

Static sag (50 SX)

Static sag (50 SX Junior)

Static sag (50 SX Mini)

20 mm (0.79 in)

20 mm (0.79 in)

10 mm (0.39 in)

» If the static sag is less or more than the specified value:

– Adjust the spring preload of the shock absorber.

x

( p. 22)

22

400221-10

9.6

Adjusting the spring preload of the shock absorber

x

Danger

Danger of accidents The shock absorber is under high pressure.

– The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any maintenance on it yourself.

700506-01

– Remove shock absorber.

x

( p. 23)

– After removing the shock absorber, clean it thoroughly.

– Measure the full spring length while it is under tension and note down the value.

– Loosen lock ring



.

– Turn adjusting ring

 until the spring is no longer under tension.

Combination wrench (50329080000)

Hook wrench (T106S)

– Measure the overall spring length when not under tension.

– Tighten the spring by turning adjusting ring

 to measurement.

Requirement

Spring preload (50 SX)

Standard

Spring preload (50 SX Junior)

Standard

Spring preload (50 SX Mini)

Standard

3 mm (0.12 in)

5 mm (0.2 in)

5 mm (0.2 in)

Info

Measure is the difference between the relaxed spring length and the tensioned spring length.

Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload.

– Tighten lock ring



.

– Installing shock absorber.

x

( p. 23)


9.7

Removing the shock absorber

x


– Remove screw

 and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel. Fix the rear wheel in this position.

– Remove screw absorber.



, push splash protector

 to the side, and remove the shock

23

9.8

Installing shock absorber

x

700477-01

700477-11

– Push splash protector tighten screw



.

Requirement

 to the side and position the shock absorber. Mount and

Screw, top shock absorber M10 45 Nm

(33.2 lbf ft)

– Mount and tighten screw



.

Requirement

Screw, bottom shock absorber M10 45 Nm

(33.2 lbf ft)


9.9

Vehicle level

Warning

Danger of accidents Modifications to the chassis can seriously alter the vehicle's handling characteristics.

– Following modifications, ride slowly at first to get the feel of the new handling characteristics.

The level of the vehicle can be adjusted at the front at the fork leg clamp and at the rear by positioning the shock absorber.

The upper fork projection can be adjusted to the individual size of the child. In the lower position position





(standard), the fork is pushed through as far as possible. In the higher

, the cone is flush with the upper triple clamp.

Upper fork projection over the upper triple clamp

10… 17 mm (0.39… 0.67 in)

700523-10

The seat height can be adjusted to the individual size of the child. The shock absorber can be mounted at two different drill holes in the frame.

Difference between lower

(standard) and high position



 seat

25 mm (0.98 in)

700521-01


9.10

Adjusting upper fork projection

x

Warning



700524-01

– Loosen the screws

– Loosen the screw

 of the lower triple clamp.

 of the upper triple clamp.

Info

Loosen the screws enough to avoid damaging the fork legs when adjusting.

Make the adjustments first on one fork leg and then on the other.

– Adjust the upper fork projection over the upper triple clamp.

Requirement

10… 17 mm (0.39… 0.67 in)

– Tighten screw

Requirement



.

Screw, top triple clamp M8 25 Nm

(18.4 lbf ft)

– Fully tighten screw



.

Requirement

Screw, bottom triple clamp M6

– Repeat the adjustment on the other form leg.

10 Nm (7.4 lbf ft)

Info

The adjustments to the vehicle level at the fork legs must be identical on both sides.

9.11

Adjusting seat height

x

Warning



– Remove shock absorber.

x

( p. 23)

– Position the shock absorber according to the required seat height.

Requirement

Low seat position (standard)



High seat position



– Installing shock absorber.

x

( p. 23)

24

700521-01

9.12

Cleaning dust boots of fork legs


– Push dust boots

 of both fork legs upwards.

Info

The dust boots should remove dust and coarse dirt particles from the fork tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak.

700478-11


25

Warning

Danger of accidents Reduced braking due to oil or grease on the brake discs.

– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

– Clean and oil the dust boots and inner fork tube of both fork legs.

Universal oil spray ( p. 76)

– Press the dust boots back into their normal position.

– Remove excess oil.


9.13

Checking play of steering head bearing

Warning

Danger of accidents Unsafe riding behavior due to incorrect steering head bearing play.

– The steering head bearing play should be adjusted immediately in an authorized KTM workshop.

Info

If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time.

400387-10


– Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel.

No play should be noticeable in the steering head bearing.

» If there is noticeable play present:

– Adjust play of the steering head bearing.

x ( p. 25)

– Move the handlebar to and fro over the entire steering range.

The handlebar must be able to move easily over the entire steering range. No resting locations should be noticeable.

» If click positions are noticeable:

– Adjust play of the steering head bearing.

x ( p. 25)

– Check the steering head bearing and replace if required.


9.14

Adjusting play of steering head bearing

x


– Remove the fork legs.

x

( p. 27)

– Remove the fuel tank breather



.

– Remove screws



.

– Remove the handlebar clamp.

– Remove the handlebar and lay it to one side.

Info

Protect the motorcycle and its attachments from damage by covering them.

Do not bend the cables and lines.

300736-10


– Remove screws



.

– Take off the handlebar support.

300737-10

– Remove nut



.

– Take off the upper triple clamp.

300738-11

– Tighten nut



.

Requirement

Steering head nut M20x1.5

10 Nm (7.4 lbf ft)

300739-10

– Position the upper triple clamp.

– Mount nut



, but do not tighten it yet.

Requirement

Nut, steering stem M20x1.5

300738-11

– Install the fork legs.

– Tighten nut



.

x

( p. 27)

Requirement

Nut, steering stem

– Position the handlebar support.

– Mount and tighten screws



.

Requirement

Screw, handlebar support M10

M20x1.5

40 Nm

(29.5 lbf ft)

30 Nm

(22.1 lbf ft)

30 Nm

(22.1 lbf ft)

Loctite ® 243™

300742-11

– Position the handlebar with the handlebar clamps.




.

– Position the fuel tank breather



.

– Check play of steering head bearing. ( p. 25)

– Check the cable harness, bowden cables and brake line for freedom of movement and routing.


300743-11

26


9.15

Removing the fork legs

x

– Remove front wheel.

x

( p. 44)

– Dismount the start number plate. ( p. 31)

– Remove screws

 and take off clamp.

300731-10

– Remove the screws

 with the washers and take off the brake caliper.

– Hang the brake caliper and the brake line loosely to the side.

300732-10

– Loosen screw

– Loosen screw



. Remove the left fork leg.



. Remove the right fork leg.

9.16

Installing the fork legs

x

300733-10

– Position the fork leg.

– Adjust the upper fork projection

Requirement

Upper fork projection



.

10… 17 mm (0.39… 0.67 in)

300734-10

– Tighten screw

Requirement



.

Screw, top triple clamp




.

Requirement

Screw, bottom triple clamp

300733-11

M8

M6

25 Nm

(18.4 lbf ft)

10 Nm (7.4 lbf ft)

27


– Position the brake caliper, fit and tighten the screws

 together with the washers.

Requirement

Screw, front brake caliper M8 20 Nm

(14.8 lbf ft)

Loctite ® 243™

28

300732-11

– Position the brake line. Put the clamp on, and mount and tighten screws

– Install the start number plate. ( p. 31)

– Install the front wheel.

x ( p. 44)



.

300731-11

9.17

Removing the lower triple clamp

x

– Remove the fork legs.

x ( p. 27)

– Dismount the front fender. ( p. 30)

– Remove the fuel tank breather



.

– Remove screws



.

– Remove the handlebar clamp.

– Remove the handlebar and lay it to one side.

Info



300736-10

– Remove screws



.

– Take off the handlebar support.

300737-10

– Remove nut



.

– Take off the upper triple clamp.

300738-11


– Remove nut



.

29

300739-10

– Remove protector ring



.

– Remove the lower triple clamp with the steering stem.

– Remove the upper steering head bearing.

300740-10

9.18

Installing the lower triple clamp

x

– Clean the bearing and sealing elements, check for damage, and grease.

Long-life grease ( p. 75)

– Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

Info

Check that the O-rings of the steering head seals are correctly positioned.

400563-01

– Push on protective ring

– Mount and tighten nut





.

.

Requirement

Steering head nut M20x1.5

10 Nm (7.4 lbf ft)

300739-11

– Position the upper triple clamp.

– Mount nut




Requirement

Nut, steering stem M20x1.5

30 Nm

(22.1 lbf ft)

300738-10

– Position the fork legs.

– Tighten screw



.

Requirement

Screw, top triple clamp M8

300741-10




.

Requirement


– Repeat the operation on the opposite side.

M6

25 Nm

(18.4 lbf ft)

10 Nm (7.4 lbf ft)


– Tighten nut



.

Requirement

Nut, steering stem

– Position the handlebar support.




.

Requirement

Screw, handlebar support M10

M20x1.5

40 Nm

(29.5 lbf ft)

30 Nm

(22.1 lbf ft)

Loctite ® 243™

30

300742-10

– Position the handlebar with the handlebar clamps.




.

– Position the fuel tank breather



.

– Install the front fender. ( p. 30)

– Install the fork legs.

x

( p. 27)

– Check the cable harness, bowden cables and brake line for freedom of movement and routing.

– Check play of steering head bearing. ( p. 25)

300743-10

9.19

Greasing the steering head bearing

x

– Remove the lower triple clamp.

– Install the lower triple clamp.

x

( p. 28)

x ( p. 29)

9.20

Dismounting the front fender

400563-01

– Remove screws



. Remove the front fender.

9.21

Installing the front fender

700479-10

– Position the fender with holding lugs plate.

 into the drill holes on the start number

700480-01


– Position the front fender. Mount and tighten screws



.

Requirement

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

31

700479-11

9.22

Dismount the start number plate

– Remove screw

– Remove screw

 and take off clamp.



. Remove the start number plate.

700466-01

9.23

Installing the start number plate

– Position the start number plate with the drill holes onto the holding lugs fender.

 of the

700467-01




.

Requirement


– Position the brake line. Put the clamp on, mount and tighten screw



.

9.24

Handlebar position

700468-01

400565-10

On the upper triple clamp, there are 2 holes at a distance of

 to each other.

Distance

 between holes 15 mm (0.59 in)

The holes on the handlebar support are placed at a distance of

 from the center.

Distance

 between holes 3.5 mm (0.138 in)

The handlebar supports can be mounted in 4 different positions.


32

9.25

Adjusting handlebar position

x

400564-10

– Remove the four screws and lay it to one side.



. Remove the handlebar clamp. Remove the handlebar

Info



– Remove the two screws



. Remove the handlebar support.

– Place the handlebar support in the required position. Mount and tighten the two screws



.

Requirement

Screw, handlebar support M10 40 Nm

(29.5 lbf ft)

Loctite ® 243™

Info

Position the left and right handlebar supports evenly.

– Position the handlebar.

Info

Make sure cables and wiring are positioned correctly.

– Position the handlebar clamp. Mount and evenly tighten the four screws



.

Requirement

Screw, handlebar clamp M8 20 Nm

(14.8 lbf ft)

Info

Make sure the gap width is even.

9.26

Checking play in gas Bowden cable

– Move the handlebar to the straight-ahead position.

– Push back bellows



.

– It must be possible to raise the outer casing of the gas Bowden cable away from the adjusting screw by distance

 without encountering a resistance.

Play in gas Bowden cable 3… 5 mm (0.12… 0.2 in)

» If the gas Bowden cable play does not meet specifications:

– Adjust the play in the gas Bowden cable.

– Push bellows



x ( p. 32)

on. Check the throttle grip for smooth operation.

700481-10

9.27

Adjusting play in gas Bowden cable

x

700481-11

– Move the handlebar to the straight-ahead position.

– Push back bellows



.

– Loosen nut



. Turn adjusting screw

 in as far as possible.

– Turn the adjusting screw so that there is play in the gas Bowden cable at the gas

Bowden cable casing.

Requirement

Play in gas Bowden cable 3… 5 mm (0.12… 0.2 in)

– Tighten nut.

– Push bellows

 on. Check the throttle grip for smooth operation.

– Check play in the gas Bowden cable. ( p. 32)


9.28

Checking chain dirt

– Check the chain for coarse dirt accumulation.

» If the chain is very dirty:

– Clean the chain. ( p. 33)

33

800012-10

9.29

Cleaning the chain

Warning

Danger of accidents Oil or grease on the tires reduces their grip.

– Remove oil and grease with a suitable cleaning material.

Warning



Warning

Environmental hazard Problem materials cause environmental damage.

– Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

The service life of the chain depends largely on its maintenance.

– Clean the chain regularly and then treat with chain spray.

Chain cleaner ( p. 75)

Offroad chain spray ( p. 75)

9.30

Checking the chain tension

Warning

Danger of accidents Danger caused by incorrect chain tension.

– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary.

700483-01


– Push the chain at the end of the chain sliding component upwards to measure the chain tension



.

Info

The upper chain section

 must be taut.

Because chain wear is not always even, repeat this measurement at different chain positions.

Chain tension

≥ 3 mm (≥ 0.12 in)

» If the chain tension does not meet specifications:

– Adjusting chain tension - after checking. ( p. 35)



34

9.31

Checking the chain tension - installing rear wheel

Warning



– Make sure that the chain adjuster supports are fitted correctly on the adjusting screws.

– Push the chain at the end of the chain sliding component downwards to measure the chain tension



.

Info

Lower chain section

 must be taut.


700483-01

Chain tension

≥ 3 mm (≥ 0.12 in)

» If the chain tension does not meet specifications:

– Adjust the chain tension when installing the rear wheel. ( p. 35)

9.32

Checking rear sprocket / engine sprocket for wear

– Check rear sprocket / engine sprocket for wear.

» If the rear sprocket / engine sprocket are worn:

– Replace rear sprocket / engine sprocket.

400227-01

Info

When fitting the chain joint, always make sure that the closed side of the joint faces forward (riding direction).

The engine sprocket, rear sprocket and chain should always be replaced together.

– Check the chain guide for tightness and wear.

9.33

Adjusting chain tension

Warning




– Push the chain at the end of the chain sliding component downwards to measure the chain tension



.

Info

Lower chain section

 must be taut.


700483-01


700484-11

– Loosen nut



.

– Adjust the chain tension by turning the adjusting screws

 left and right.

Requirement

Chain tension

≥ 3 mm (≥ 0.12 in)

Turn adjusting screws

 equally on the left and right. Check that the rear wheel is aligned with the front wheel.

– Make sure that the chain adjuster supports screws



.

– Tighten nut



.

Requirement

 are fitted correctly on the adjusting

Nut, rear wheel spindle M12x1 40 Nm

(29.5 lbf ft)


9.34

Adjusting chain tension - after checking

– Loosen nut



.


 left and right.

Requirement

Chain tension

≥ 3 mm (≥ 0.12 in)


 equally on the left and right. Check that the rear wheel is aligned with the front wheel.

700484-10

– Make sure that the chain adjuster supports screws



.

– Tighten nut



.

Requirement

 are fitted correctly on the adjusting


(29.5 lbf ft)

9.35

Adjusting chain tension - installing rear wheel


 left and right.

Requirement

Chain tension

≥ 3 mm (≥ 0.12 in)


 equally on the left and right. Check that the rear wheel is aligned with the front wheel.

35

700484-12

9.36

Adjusting the chain guide

x

Info

The size of the chain wheel varies with the number of teeth. The chain guide can be adjusted on small sprockets.

– Loosen screw



.

– Position the chain guide.

– Tighten screw.

Requirement


700485-01


9.37

Checking brake discs

Warning

Danger of accidents Reduced braking due to worn brake discs.

– Worn brake discs should be replaced immediately in an authorized KTM workshop.

400257-10

– Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement



.

Info

Wear reduces the thickness of the brake disc around the area used by the brake linings.

Brake discs - wear limits front

Rear

2.2 mm (0.087 in)

2.2 mm (0.087 in)

» If the brake disc thickness is less than the specified value:

– Change the brake disc.

– Check the front and rear brake discs for damage, cracking and deformation.

» If the brake disk exhibits damage, cracking or deformation:

– Change the brake disc.

9.38

Checking play of handbrake lever

– Push the hand brake lever forwards and check free play



.

Play at handbrake lever 3… 5 mm (0.12… 0.2 in)

» If the play does not meet specifications:

– Adjust the play of the handbrake lever. ( p. 36)

36

700486-01

9.39

Adjusting play of handbrake lever

– Adjust the play of the handbrake lever with the adjustment screw

Requirement



.

Play at handbrake lever 3… 5 mm (0.12… 0.2 in)

– Check the play of the handbrake lever. ( p. 36)

700487-01

9.40

Adjusting basic position of handbrake lever

– Adjust the basic setting of the hand brake lever to the size of your child's hand by turning adjusting screw



.

700528-01

Info

Turn the adjusting screw clockwise to increase the distance between the handbrake lever and the handlebar.

Turn the adjusting screw counterclockwise to decrease the distance between the handbrake lever and the handlebar.

The range of adjustment is limited.

– Check the play of the handbrake lever. ( p. 36)


9.41

Checking front brake fluid level

Warning


– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.

Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Skin irritations Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.

– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking due to old brake fluid.

– Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning



37

Info

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for

DOT 5 brake fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!

Use only clean brake fluid from a sealed container!

700497-01

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

– Remove screws



.

– Remove cover

 with membrane



.

– The brake fluid level may not drop below marking is level.

 when the brake fluid reservoir

Measurement of



5 mm (0.2 in)

» If the brake fluid has dropped below marking



:

– Add front brake fluid.

x

( p. 37)

– Position the cover with the membrane. Mount and tighten the screws.

Info

Clean up overflowed or spilt brake fluid immediately with water.

9.42

Adding front brake fluid

x

Warning




Warning




Warning



Warning




Info


DOT 5 brake fluid.



700497-01


– Remove screws



.

– Remove cover

 with membrane

– Add brake fluid to level



.



.

Requirement

Measurement of



5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 ( p. 73)


Info


9.43

Checking the front brake linings

Warning

Danger of accidents Reduced braking due to worn brake linings.

– Worn brake linings should be replaced immediately in an authorized KTM workshop.

– Check the brake linings for minimum thickness



.

Minimum thickness



≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

– Change the front brake linings.

x

( p. 39)

38

700498-01

9.44

Removing front brake linings

x

Warning

Danger of accidents Improper brake maintenance and repair.

– Always have your brake system maintained and repaired in an authorized KTM workshop.

– Remove front wheel.

x

( p. 44)

– Remove the lock washer



.

– Remove screw



.

700499-01


– Remove the brake linings.

– Clean brake caliper and brake caliper support.

39

700500-01

9.45

Installing the front brake linings

x

Warning



Warning

Danger of accidents Reduced braking due to use of non-approved brake linings.

– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

– Check the brake discs. ( p. 36)

– Insert the brake linings.

Info

Ensure that the brake linings are correctly positioned in the holding spring.

700500-01

– Mount screw



.

– Mount lock washer.

– Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot.

700501-01

9.46

Changing the front brake linings

x

Warning




Warning



Warning




Info


DOT 5 brake fluid.



700497-01

– Remove the front brake linings.

x

( p. 38)


– Remove screws

– Remove cover



.

 with membrane



.

– Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir.

– Install the front brake linings.

– Add brake fluid to level



.

x

( p. 39)

Requirement

Measurement of



5 mm (0.2 in)



Info


9.47

Checking free play of foot brake lever

Warning


– If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can fail due to overheating. Adjust free travel on foot brake pedal according to specifications.

– Disconnect spring



.

– Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free play



.

Requirement

Free play at foot brake lever 3… 5 mm (0.12… 0.2 in)

» If the free travel does not meet specifications:

– Adjust the basic position of the foot brake pedal.

– Reconnect spring



.

x

( p. 40)

700488-01

9.48

Adjusting basic position of foot brake pedal

x

Warning


– If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can fail due to overheating. Adjust free travel on foot brake pedal according to specifications.

700489-01

– Disconnect spring.

– Loosen nut



.

– Turn back the push rod

 until the maximum free travel is available.

– To adjust the basic position of the footbrake pedal for individual requirements, loosen the screw tion.

 and turn the eccentric brake lever stop

 to a suitable posi-

Requirement

Free play at foot brake lever 3… 5 mm (0.12… 0.2 in)

– Hold the push rod

– Reconnect spring.

 and tighten the nut



.

40


9.49

Checking rear brake fluid level

Warning




Warning



– Stand the vehicle upright.

– Check the brake fluid level in the viewer



.

» When in the viewer

 an air bubble is visible:

– Add rear brake fluid.

x

( p. 41)

41

700490-01

9.50

Adding rear brake fluid

x

Warning




Warning




Warning



Warning



Info


DOT 5 brake fluid.



700422-01


– Remove screws



.

– Take off the cover with the metal ring

 and membrane

– Add brake fluid to the top edge of the level viewer.



.


– Position the cover with the metal ring and membrane.

Info


– Mount and tighten screws.


9.51

Checking rear brake linings

Warning

Danger of accidents Reduced braking due to worn brake linings.

– Worn brake linings should be replaced immediately in an authorized KTM workshop.

– Check the brake linings for minimum thickness



.

Minimum thickness



≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

– Change the rear brake linings.

x

( p. 43)

700491-01

9.52

Removing rear brake linings

x

Warning

Danger of accidents Improper brake maintenance and repair.

– Always have your brake system maintained and repaired in an authorized KTM workshop.

– Remove the rear wheel.

– Remove the lock washer

x

( p. 45)



.

– Remove screw



.

42

700492-01

– Remove the brake linings.

– Clean brake caliper and brake caliper support.

700493-01

9.53

Installing the rear brake linings

x

Warning



Warning

Danger of accidents Reduced braking due to use of non-approved brake linings.

– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

– Check the brake discs. ( p. 36)


– Insert the brake linings.

Info

Ensure that the brake linings are correctly positioned in the holding spring.

43

700493-10

– Mount screw



.

– Mount lock washer



.

– Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot.

700494-01

9.54

Changing the rear brake linings

x

Warning




Warning



Warning



Info


DOT 5 brake fluid.



700422-01

– Remove the rear brake linings.

x

( p. 42)


– Remove screws



.

– Take off the cover with the metal ring

 and membrane



.

– Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir.

– Install the rear brake linings.

x

( p. 42)

– Add brake fluid to the top edge of the level viewer.


– Position the cover with the metal ring and membrane.

Info


– Mount and tighten screws.


9.55

Removing front wheel

x


– Remove nut

 with washer.

44

700502-01

– Hold the front wheel and pull out the wheel spindle front wheel out of the fork.

 with the washer



. Take the

Info

Do not pull the hand brake lever when the front wheel is removed.

Always lay the wheel down in such a way that the brake disc is not damaged.

700503-01

9.56

Installing the front wheel

x

Warning



– Clean and grease wheel spindle



.


– Lift the front wheel into the fork, position it, and insert wheel spindle washer



.

 with

700503-10

700502-10

– Position washer



.


Requirement



.

Front wheel spindle nut M12x1 40 Nm

(29.5 lbf ft)


– Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc.


9.57

Removing rear wheel

x

700495-01


– Remove nut



.

– Remove the washer



.

– Pull out the wheel spindle

 with the washer



.

– Remove the chain from the rear sprocket.

– Take the rear wheel out of the swing arm.

Info

Do not operate the foot brake when the rear wheel is removed.

Always lay the wheel down in such a way that the brake disc is not damaged.

9.58

Installing the rear wheel

x

Warning



700496-01

– Clean and grease wheel spindle



.


– Lift the rear wheel into the swingarm and place the chain on the rear sprocket.

– Insert the wheel spindle

 with the washer



.

– Position washer



. Mount nut




– Check chain tension when installing the rear wheel. ( p. 34)

– Make sure that the chain adjuster supports are fitted correctly on the adjusting screws.

– Tighten nut



.

Requirement


(29.5 lbf ft)

– Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot.


9.59

Tire condition checking

Info

Only mount tires approved and/or recommended by KTM.

Other tires could have a negative effect on riding behavior.

The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.

The front and rear wheels must be fitted with tires with similar profiles.

Worn tires have a negative effect on riding behavior, especially on wet surfaces.

– Check the front and rear tires for cuts, impacted foreign bodies and other damage.

» if the tires exhibit cuts, impacted foreign bodies or other damage:

– Change the tire.

– Check the depth of the tread.

Info

Note local national regulations concerning the minimum tread depth.

≥ 2 mm (≥ 0.08 in)

Minimum tread depth

» If the minimum tread depth is insufficient:

– Change the tire.

45


9.60

Checking tire air pressure

Info

Low tire air pressure leads to abnormal wear and overheating of the tire.

Correct tire air pressure ensures optimal riding comfort and maximum tire service life.

700507-01

– Remove the dust cap.

– Check the tire air pressure when the tires are cold.

Tire air pressure off road front

Rear

1.0 bar (15 psi)

1.0 bar (15 psi)

» If the tire pressure does not meet specifications:

– Correct the tire pressure.

– Mount the dust cap

9.61

Checking spoke tension

Warning

Danger of accidents Unstable riding behavior due to loose spokes.

– If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop.

46

Info

A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.

If the spokes are too tight, they can break due to local overload.

Check the spoke tension regularly, especially on a new motorcycle.

– To check spoke tension, tap each spoke with a screwdriver.

Requirement

You should hear a high note.

Spoke nipple M3.5

3 Nm (2.2 lbf ft)

Info

If you hear different tone frequencies from different spokes, this is an indication of different spoke tensions.

700508-01

9.62

Removing the seat

– Open quick release

 and raise the rear of the seat.

– Pull back the seat and remove it.

300611-10


9.63

Mounting the seat

47

– Hook the seat onto screw

 and lower the seat at the rear while pushing it forward.

Projection

 hooks into the fuel tank.

300612-10

– Close quick release



.

300611-11

9.64

Cooling system

The water pump



The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap in the engine forces the coolant to flow.



. The specified coolant temperature is therefore permissible without danger of function problems.

120 °C (248 °F)

Cooling is effected by the air stream.

The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect.

700509-01

9.65

Checking antifreeze and coolant level

Warning

Scalding hazard During motorcycle operation, the coolant gets very hot and is under pressure.

– Do not open the radiator, the radiator hoses or other components of the cooling system when the engine is hot. Allow the engine and radiator to cool down. If you are scalded, hold the affected part under cold water immediately.

Warning

Danger of poisoning Coolants are poisonous and a health hazard.

– Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

– Stand the motorcycle upright on a horizontal surface.

– Remove radiator cap



.

– Check antifreeze of coolant.

−25… −45 °C (−13… −49 °F)

» If the antifreeze of the coolant does not meet specifications:

– Correct antifreeze of coolant.

700510-01


400243-10

– Check the coolant level in the radiator.

Coolant level

 above radiator fins.

10 mm (0.39 in)

» If the level of the coolant does not meet specifications:

– Correct the coolant level.

Alternatively 1

Coolant ( p. 73)

Alternatively 2

Coolant (mixed ready to use) ( p. 73)

– Mount the radiator cap.

9.66

Checking the coolant level

Warning



Warning



400243-10


– Remove the radiator cap.

– Check the coolant level in the radiator.

Coolant level

 above radiator fins.

10 mm (0.39 in)

» If the level of the coolant does not meet specifications:

– Correct the coolant level.

Alternatively 1

Coolant ( p. 73)

Alternatively 2



9.67

Draining the coolant

x

Warning



Warning



48



– Place a suitable container under the engine.

– Remove screw



. Remove the radiator cap.

– Completely drain the coolant.


 with a new seal ring.

Requirement

Screw, water pump cover M6 10 Nm (7.4 lbf ft)

300617-10

9.68

Refilling coolant

x

Warning



700511-01

– Make sure that the screw


 is tightened.

– Pour coolant in up to measurement

 above the radiator fins.

Requirement

10 mm (0.39 in)

Coolant 0.5 l (0.5 qt.)

Coolant ( p. 73)



– Make a short test ride.


9.69

Removing main silencer

Warning

Danger of burns The exhaust system gets very hot when the vehicle is driven.

– Allow the exhaust system to cool down. Do not touch hot components.

– Remove screw

– Remove screw



.



.

49

700512-01

– Pull the main silencer off of the manifold at the rubber sleeve



.

700513-10


9.70

Installing the main silencer

– Position the main silencer.

– Mount the main silencer with the rubber sleeve

– Mount the silentblock with the screw



.

Requirement



.

Remaining screws, chassis M6

700513-01

– Position the collar sleeves.




.

Requirement

Remaining screws, chassis M6

10 Nm (7.4 lbf ft)

10 Nm (7.4 lbf ft)

50

700512-10

9.71

Glass fiber yarn filling of main silencer

The main silencer is filled with glass fiber yarn.

Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out".

Not only is the noise level higher, the performance characteristic changes.

9.72

Removing the glass fiber yarn filling of the main silencer

x

Warning

Danger of burns The exhaust system gets very hot when the vehicle is driven.

– Allow the exhaust system to cool down. Do not touch hot components.

– Remove the main silencer. ( p. 49)

– Remove screws

 of locking cap



. Remove locking cap and outer tube



.

– Pull the glass fiber yarn filling

 from the inner tube.

– Clean the parts that are to be reinstalled.

700514-01

9.73

Installing the glass fiber yarn filling of the main silencer

x

– Slide the glass fiber yarn filling

– Slide the outer tube



 over the inner tube.

over the glass fiber yarn filling.

– Insert the locking cap wheels and tighten.

 into the outer tube. Mount the screws

 with toothed

Requirement


– Install the main silencer. ( p. 50)

700514-10


9.74

Removing the air filter

x

Note

Engine failure Unfiltered intake air has a negative effect on the service life of the engine.

– Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.

Warning



– Remove the seat. ( p. 46)

– Press the rear holding lugs

 together slightly and swing the air filer cover upward.

Pull out the front holding lug and take off the air filter cover.

– Take off the air filter.

51

700504-01

9.75

Installing the air filter

x

– Position the clean air filter.

– Position the rear holding lug. Lower the air filter cover and allow the front holding lug

 to snap in.

Info

If the air filter is not correctly mounted, dust and dirt can penetrate into the engine and can cause damage.

– Mount the seat. ( p. 47)

700505-01

9.76

Cleaning air filter

x

Warning



Info

Do not clean the air filter with fuel or petroleum since these substances attack the foam.

– Remove the air filter.

x

( p. 51)

– Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.

Air filter cleaner ( p. 75)

Info

Only press the air filter to dry it, never wring it out.

– Oil the dry air filter with a high/quality filter oil.

Oil for foam air filter ( p. 76)

– Clean the air filter box.

– Check carburetor connection boot for damage and tightness.

– Install the air filter.

x

( p. 51)


9.77

Carburetor - idle (50 SX)

The idle setting of the carburetor has a big influence on the starting behavior, stable idling and the response to throttle opening. That means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly.

Info

The carburetor and its components are subject to increased wear caused by engine vibration. Wear can result in malfunctioning.

700520-01

The idle speed is adjusted with the idle adjustment screw



.

The idle mixture is adjusted with the idle mixture adjustment screw



.

9.78

Carburetor - idle (50 SX Junior, 50 SX Mini)

The idle setting of the carburetor has a big influence on the starting behavior, stable idling and the response to throttle opening. That means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly.

Info

The carburetor and its components are subject to increased wear caused by engine vibration. Wear can result in malfunctioning.

700522-01

The idle speed is adjusted with the adjustment screw



.

The idle mixture is adjusted with the idle mixture adjustment screw



.

9.79

Carburetor - adjusting idle

x

(50 SX)

700520-01

– Screw in the idle adjusting screw setting.

Requirement

Idle mixture adjusting screw

 until it stops and then to the prescribed basic

Open 3 turns

– Run the engine until warm.

Requirement

Warm-up time

≥ 5 min

Danger



– Adjust the idle speed with the adjusting screw

Requirement



.

Choke function deactivated – The choke lever is in the lower position. No O-ring

is visible. ( p. 11)

Idle speed 1,400… 1,500 rpm

– Turn the idle adjusting screw

 slowly until the idle speed begins to fall.

– Note the position and turn the idle adjusting screw slowly counterclockwise until the idle speed falls.

52


53

– Adjust to the point between these two positions with the highest idle speed.

Info

If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps.

If the procedure described here does not lead to satisfactory results, the cause may be a wrongly dimensioned idling jet.

If you can turn the idle adjusting screw to the end without any change of engine speed, you have to install a smaller idling jet.

After changing the idling jet, start from the beginning with the adjusting steps.

Following extreme air temperature or altitude changes, adjust the idle speed again.

9.80

Carburetor - adjusting idle

x


– Screw in the idle mixture adjusting screw scribed basic setting.

 until it stops and then turn to the pre-

Requirement

(50 SX Junior)

Idle air adjustment screw

Open 3.5 turns

700522-01

(50 SX Mini)


Open

– Run the engine until warm.

Requirement

Warm-up time

1 turn

≥ 5 min

Danger



– Adjust the idle speed with the adjusting screw

Requirement



.

Choke function deactivated – The choke lever is pushed down all the way.

( p. 11)

Idle speed 1,400… 1,500 rpm

– Turn the idle mixture adjusting screw begins to fall.

 clockwise slowly until the idle speed

– Note the position and turn the idle mixture adjusting screw counterclockwise slowly until the idle speed falls.

– Adjust to the point between these two positions with the highest idle speed.

Info

If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps.

If the procedure described here does not lead to satisfactory results, the cause may be a wrongly dimensioned idling jet.

If you can turn the idle mixture adjusting screw to the end without any change of engine speed, you have to install a smaller idling jet.

After changing the idling jet, start from the beginning with the adjusting steps.

Following extreme air temperature or altitude changes, adjust the idle speed again.


9.81

Checking oil level (50 SX Mini)


– Check the level of the oil in the oil tank.

For one fuel tank filling, the oil tank must be filled at least up to tje MIN mark



.

» If the oil level does not meet specifications:

– Fill up with oil. ( p. 17)

700518-01

9.82

Bleeding the oil pump

x

(50 SX Mini)

– Pull off the oil line



.

54

300650-10

– Fill the oil line with a syringe.


300652-10

– Connect the oil line



.

300650-10

– Remove screws



.

– Take off the oil pump.

– Pull off the oil line

 at the curburetor.

300651-10


– Turn the oil pump gear oil line



.

 counterclockwise until oil escapes bubble-free from the

55

300653-10

– Connect the oil line



– Position the oil pump.

.




.

Requirement

Screw, oil pump M5 6 Nm (4.4 lbf ft)

300651-10

9.83

Checking gear oil level

Info

The gear oil level must be checked when the engine is cold.

700525-01


Condition

Engine is cold.

– Remove gear oil level check screw

– Check the gear oil level.



. Stand the vehicle upright.

A small amount of gear oil should flow out.

» If no gear oil flows out:

– Add gear oil.

x

( p. 56)

– Mount and tighten the gear oil level check screw.

Requirement

Screw, gear oil level check M6 10 Nm

(7.4 lbf ft)

9.84

Changing the gear oil

x

– Drain the gear oil.

– Fill up with gear oil.

x

( p. 55)

x

( p. 56)

9.85

Draining the gear oil

x

Warning

Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven.

– Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning



Info

Drain the gear oil only when the engine is warm.

– Stand the motorcycle on its side stand on a horizontal surface.


700515-01

– Place a suitable container under the engine.

– Remove the gear oil drain plug with magnet



.

– Completely drain the gear oil.

– Thoroughly clean gear oil drain plug with magnet

– Clean the sealing area on the engine.

– Mount the gear oil drain plug with magnet





.

and the seal ring and tighten it.

Requirement

Oil drain plug with magnet M12x1.5

20 Nm

(14.8 lbf ft)

9.86

Filling up with gear oil

x

Info

Too little gear oil or poor-quality oil results in premature wear of the transmission.

700516-01

– Remove the screw cap

 and fill up with gear oil.

Gear oil 0.20 l (0.21 qt.)

Gear oil (ATF Dexron 3) ( p. 73)

– Mount and tighten screw cap



.

Danger



– Start the engine and check that it is oil-tight.


9.87

Adding gear oil

x

Info

Too little gear oil or poor-quality oil results in premature wear of the transmission.

– Remove gear oil level check screw



.

56

700525-01

300660-11

– Remove screw cap



. Stand the vehicle upright.

– Add gear oil until it flows out of the bore of the gear oil level screw.


– Mount and tighten the gear oil level check screw.

Requirement

Screw, gear oil level check M6

– Mount and tighten screw cap



.

10 Nm (7.4 lbf ft)


Danger



– Start the engine and check that it is oil-tight.

9.88

Checking clutch engagement speed

x

– Connect the special tool



.

Tachometer (45129075000)

300658-10

Danger



– Start the engine.

– Open the throttle slowly until the clutch begins to engage.

– Read the engine speed.

Clutch engagement speed 7,200… 7,500 rpm

» if the specified value is not met:

– Adjust the clutch engagement speed.

x

( p. 57)

9.89

Adjusting clutch engagement speed

x

– Check the clutch engagement speed.

– Use the correct washer x

( p. 57)

– Remove the centrifugal clutch.

– Dismantle the centrifugal clutch.

x

( p. 57)

x ( p. 59)

 for the measured value.

Requirement

A washer 0.2 mm (0.0079 in) thick changes the clutch engagement speed by ca.:

100 rpm

300666-01

Info

The spacer

 of 1.7 mm (0.0669 in) must always be present.

Inserting the washer

 raises the clutch engagement speed.

Removing the washer

 lowers the clutch engagement speed.

– Assemble the centrifugal clutch.

x ( p. 59)

– Fit the centrifugal clutch.

x

( p. 58)


x

( p. 57)

9.90

Removing centrifugal clutch

x

– Remove nut



.

– Disconnect spring



.

– Take off the footbrake pedal.

57

300654-10


– Lay the motorcycle on its side.

– Remove screws



.

– Take off the clutch cover.

300655-10

– Hold the clutch drum using the special tool



.

Holding spanner (54629012100)

– Remove screw



.

– Remove the clutch drum.

300656-10

– Take off the centrifugal clutch



.

9.91

Fitting centrifugal clutch

x

300657-10

– Position the centrifugal clutch



.

300657-11

– Position the clutch drum.

– Hold the clutch drum using the special tool




.

Requirement



.

Screw, clutch drum M8 30 Nm

(22.1 lbf ft)

Loctite ® 243™

300656-11

– Position the clutch cover with the seal.




.

Requirement

Screw, clutch cover M6 10 Nm (7.4 lbf ft)

300655-11

58


– Position the footbrake pedal.




.

Requirement

Remaining nuts, chassis M8

– Mount the spring



.



x

( p. 57)

300654-11

9.92

Checking/measuring clutch

x

300610-10

30 Nm

(22.1 lbf ft)

Condition

Centrifugal clutch removed.

– Measure clutch.

Requirement

Clutch lining height

≥ 98.00 mm (≥ 3.8583 in)

» if the specified value is not met:

– Replace the clutch linings.

– Dismantle the centrifugal clutch.

– Check clutch linings for damage.

x

( p. 59)

» If the clutch linings are damaged:

– Replace the clutch linings.

– Assemble the centrifugal clutch.

x ( p. 59)

9.93

Dismantling centrifugal clutch

x

Condition


– Loosen the screws

 using the special tool.

Mortise key (45229021000)

59

300513-10

– Remove the screw

 with the spacer

 and spring



.

Info

The washer

 is used for adjusting the clutch engagement speed and does not have to be removed.

– Take off the clutch lining



.

– Repeat the work on the other clutch linings.

300514-10

9.94

Assembling centrifugal clutch

x

Condition



– Position the clutch lining

– Fit the screw





.

with the spacer

 and spring



.

Info

The washer

 is used for adjusting the clutch engagement speed and must be included in the clutch lining assembly identically for all linings, according to the clutch engagement speed.

– Repeat the work on the other clutch linings.

60

300514-11

– Tighten the screws

Requirement

 using the special tool.

Screw, clutch spring M6

Mortise key (45229021000)

7 Nm (5.2 lbf ft)

300513-11

TROUBLESHOOTING

Faults

Engine turns but does not start

Engine has no idle

Engine does not speed up

Engine has too little power

Engine stalls or is popping into the carburetor

Possible cause

Operating error

Motorcycle was out of use for a long time and there is old fuel in the float chamber

Fuel feed interrupted

Engine flooded

Spark plug oily or wet

Electrode distance (plug gap) of spark plug too wide

Fault in ignition system

Short-circuit cable in cable harness frayed, short-circuit button defective

Socket connector or ignition coil is loose or oxidized

Water in carburetor or jets blocked

Idling jet blocked

Adjusting screws on carburetor distorted

Spark plug defective

Ignition system defective

Noticeable wear

Carburetor running over because float needle dirty or worn

Loose carburetor jets


Fuel feed interrupted

Air filter very dirty

Exhaust system leaky, deformed or too little glass fiber yarn filling in main silencer


Reed paddles or reed valve housing is damaged

Noticeable wear

Clutch engagement speed too low or too high

Lack of fuel

Action

– Go through the steps of starting the engine.

( p. 15)

– Empty the carburetor float chamber.

x

– Check the fuel tank breather.

– Clean the fuel tap.

– Check/set the carburetor components.

x

– Clean and dry the spark plug, or change it if necessary.

– Clean and dry the spark plug, or change it if necessary.

– Adjust the plug gap.

Requirement

Spark plug electrode gap

0.60 mm (0.0236 in)

– Check the ignition system.

x

– Check the wiring harness. (visual check)

– Check the electrical system.

– Clean the socket connector and treat it with contact spray.



x x

(50 SX)

– Carburetor - adjust the idle speed.

( p. 52)


– Carburetor - adjust the idle speed.

( p. 53)

– Change spark plug.

x x

– Check the ignition coil.

x

– Check the spark plug connector.

x

– Overhaul the engine.


x


x


x


x

– Check the fuel tank breather.

– Clean the fuel tap.


x

– Clean the air filter.

x

( p. 51)

– Check exhaust system for damage.

– Change glass fiber yarn filling of main silencer.

x


x


x

– Check the reed paddles and reed valve housing.

– Overhaul the engine.


( p. 57)

x

– Turn the knurled screw on the fuel tap all the way counterclockwise.

– Fill up with fuel. ( p. 17)

61

TROUBLESHOOTING

Faults

Engine stalls or is popping into the carburetor

Engine overheats

White smoke emission (steam in exhaust gas)

Gear oil exits at the vent hose

Water in the gear oil

Possible cause

Engine takes in bad air

Socket connector or ignition coil is loose or oxidized

Too little coolant in cooling system

Too little air stream

Radiator fins very dirty

Foam formation in cooling system

Bent radiator hose

Incorrect ignition point due to loose stator

Damaged cylinder head or cylinder head gasket

Too much gear oil added

Damaged shaft seal ring or water pump

Action

– Check rubber sleeves and carburetor for tightness.

– Clean the socket connector and treat it with contact spray.

– Check the cooling system for leakage.


– Switch off engine when standing.

– Clean radiator fins.

– Drain the coolant.

x ( p. 48)

– Refill the coolant.

x

( p. 49)

– Change the radiator hose.

x

– Adjust the ignition point.

– Tighten the stator screws.

– Check the cylinder head or cylinder head gasket.


– Check the shaft seal ring and water pump.

62

CLEANING

11.1

Cleaning motorcycle

Note

Material damage Damage and destruction of components by high-pressure cleaning equipment.

– Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, plug connectors, Bowden cables and bearings, etc., and can damage or destroy these parts.

Warning



63

Info

If you clean the motorcycle regularly, its value and appearance are maintained over a long period.

Avoid direct sunshine on the motorcycle during cleaning.

– Before you clean the motorcycle, seal the exhaust system to prevent penetration by water.

– First remove coarse dirt particles with a gentle water spray.

– Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush.

Motorcycle cleaner ( p. 75)

Info

Use warm water containing normal motorcycle cleaner and a soft sponge.

– After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly.

Warning

Danger of accidents Reduced braking due to wet or dirty brakes.

– Clean or dry dirty or wet brakes by riding and braking gently.

– After cleaning, let your child ride the vehicle a short distance until the engine warms up and the brakes are dried.

Info

The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.

– Push back the protection covers on the handlebar instruments to allow water to evaporate.

– After the motorcycle has cooled off, oil or grease all moving parts and bearings.

– Clean the chain. ( p. 33)

– Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.

Cleaning and polishing materials for metal, rubber and plastic ( p. 75)

– Treat all painted parts with a mild paint polish.

High-luster polish for paint ( p. 75)

– To prevent electrical problems, treat electric contacts and switches with contact spray.

Contact spray ( p. 75)

STORAGE

64

12.1

Storage

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.

Info

If you want to garage the motorcycle for a longer period, take the following actions.

Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season.

– Clean the motorcycle. ( p. 63)

– Change the gear oil.

x ( p. 55)

– Check the antifreeze and coolant level. ( p. 47)

– Drain the fuel from the tank into a suitable container.

– Check the tire air pressure. ( p. 46)

– The storage place should be dry and not subject to large temperature fluctuations.

Info

KTM recommends jacking up the motorcycle.


– Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.

Info

Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust.

12.2

Putting into operation after storage


– Fill up with fuel. ( p. 17)

– Checks before putting into operation. ( p. 15)

– Take a test ride.

TECHNICAL DATA - ENGINE

Design

Displacement

Stroke

Bore

Crankshaft bearing

Conrod bearing

Piston pin bearing

Pistons

Piston rings

Engine lubrication (50 SX, 50 SX Junior)

Engine lubrication (50 SX Mini)

Primary transmission

Clutch

Gearbox

Transmission ratio

Ignition

Spark plug

Spark plug electrode gap

Cooling

Starting aid

13.1

Capacity - gear oil

Gear oil 0.20 l (0.21 qt.)

13.2

Capacity - coolant

Coolant 0.5 l (0.5 qt.)

1-cylinder 2-stroke engine, water-cooled, with reed intake

49.0 cm³ (2.99 cu in)

40 mm (1.57 in)

39.5 mm (1.555 in)

2 grooved ball bearings

Needle bearing

Needle bearing

Aluminum cast

1 rectangular ring

Mixture oil lubrication

Separate lubrication

61:33 straight cut spur gear

3-lining automatic clutch on the main shaft / centrifugal force

Rigid 1-stage reduction gear

19:42

SELETTRA 2p D36

NGK CR 8 HSA

0.60 mm (0.0236 in)

Water-cooled

Kickstarter

65


Coolant ( p. 73)


TECHNICAL DATA - ENGINE TIGHTENING TORQUES

Screw, bearing retainer

Screw, kickstarter

Screw, oil pump (50 SX Mini)

Screw, stator clamp

Screw, water pump wheel

Bleeder flange, engine case

Screw generator cover

Screw, clutch cover

Screw, clutch spring

Screw, engine housing

Screw, engine sprocket cover

Screw, exhaust flange

Screw, gear oil level check

Screw, ignition coil

Screw, intake flange

Screw, water pump cover

Screw, cyliner head

Nuts, cylinder base

Screw, clutch drum

Stud bolt, cylinder base

Spark plug

Nut, primary gear

Nut, rotor

Oil drain plug with magnet

M5

M5

M5

M5

M5

M6

M6

M6

M6

M6

M7

M8

M6

M6

M6

M6

M6

M6

M8

M8

M10x1

M10x1.25

M10x1.25

M12x1.5

5 Nm (3.7 lbf ft)

6 Nm (4.4 lbf ft)

6 Nm (4.4 lbf ft)

6 Nm (4.4 lbf ft)

5 Nm (3.7 lbf ft)

5 Nm (3.7 lbf ft)

6 Nm (4.4 lbf ft)

10 Nm (7.4 lbf ft)

7 Nm (5.2 lbf ft)

10 Nm (7.4 lbf ft)

10 Nm (7.4 lbf ft)

10 Nm (7.4 lbf ft)

10 Nm (7.4 lbf ft)

5 Nm (3.7 lbf ft)

5 Nm (3.7 lbf ft)

10 Nm (7.4 lbf ft)

18 Nm (13.3 lbf ft)

20 Nm (14.8 lbf ft)

30 Nm (22.1 lbf ft)

10 Nm (7.4 lbf ft)

10… 12 Nm (7.4…

8.9 lbf ft)

40 Nm (29.5 lbf ft)

15 Nm (11.1 lbf ft)

20 Nm (14.8 lbf ft)

–

Loctite

®

243™

–

–

Loctite

®

243™

Loctite

®

243™

–

–

–

–

–

–

–

–

Loctite

®

243™

–

–

–

Loctite

®

243™

–

–

Loctite

®

243™

–

–

66

TECHNICAL DATA - CARBURETOR

15.1

50 SX

Carburetor type

Needle position

Idle mixture adjusting screw

Open

Main jet

Jet needle

Idling jet

Needle jet

Throttle slide

Cold start jet

15.2

50 SX Junior

Carburetor type

Needle position


Open

Main jet

Jet needle

Idling jet

Needle jet

Throttle slide

Cold start jet

15.3

50 SX Mini

Carburetor type

Needle position


Open

Main jet

Jet needle

Idling jet

Needle jet

Throttle slide

Cold start jet

DellÒrto PHBG 19BS

3rd position from top

3 turns

85

W9

58

260AU

60

60

DellÒrto PHVA 14DS

3rd position from top

3.5 turns

70

A10

45

211FA

40

60

DellÒrto PHVA 12XS

4th position from top

1 turn

60

A10

35

211FA

40

60

67

TECHNICAL DATA - CHASSIS

Frame

Fork

Shock absorber

Suspension travel (50 SX) front

Rear

Suspension travel (50 SX Junior) front

Rear

Suspension travel (50 SX Mini) front

Rear

Fork offset

Brake system front

Rear

Brake disc diameters front

Rear

Brake discs - wear limits front

Rear

Tire air pressure off road front

Rear

Secondary drive ratio (50 SX)

Secondary drive ratio (50 SX Junior)

Secondary drive ratio (50 SX Mini)

Chain

Rear sprockets available

Steering head angle (50 SX)

Steering head angle (50 SX Junior, 50 SX Mini)

Wheelbase (50 SX)

Wheelbase (50 SX Junior)

Wheelbase (50 SX Mini)

Seat height unloaded (50 SX)

Seat height unloaded (50 SX Junior)

Seat height unloaded (50 SX Mini)

Ground clearance unloaded (50 SX)

Ground clearance unloaded (50 SX Junior)

Ground clearance unloaded (50 SX Mini)

Weight without fuel, approx. (50 SX)

Weight without fuel, approx. (50 SX Junior, 50 SX Mini)

68

Central tube frame of chrome molybdenum steel tubing, powdercoated

Marzocchi

WP Suspension 3614 BAEM

185 mm (7.28 in)

185 mm (7.28 in)

140 mm (5.51 in)

205 mm (8.07 in)

110 mm (4.33 in)

171 mm (6.73 in)

14 mm (0.55 in)

Disc brake, brake caliper, fixed

Disc brake, brake caliper, fixed

160 mm (6.3 in)

140 mm (5.51 in)

2.2 mm (0.087 in)

2.2 mm (0.087 in)

1.0 bar (15 psi)

1.0 bar (15 psi)

11:40

10:40

10:42

1/2 x 3/16”

38, 39, 40, 41, 42

66°

67.4°

1,032 mm (40.63 in)

910 mm (35.83 in)

914 mm (35.98 in)

684 mm (26.93 in)

607 mm (23.9 in)

558 mm (21.97 in)

252 mm (9.92 in)

220 mm (8.66 in)

184 mm (7.24 in)

39.8 kg (87.7 lb.)

39.0 kg (86 lb.)

TECHNICAL DATA - CHASSIS

16.1

Tires

Validity

(50 SX)

(50 SX Junior, 50 SX Mini)

Front tire

60/100 - 12 36M TT

Pirelli SCORPION MX Mid Soft 32 NHS

2.50 - 10 33J TT


Additional information is available in the Service section under: http://www.ktm.com

16.2

Capacity - fuel


(50 SX, 50 SX Junior)


(50 SX Mini)

2.3 l (2.4 qt.)

2.0 l (2.1 qt.)

Rear tire

2.75 - 10 37J TT


2.75 - 10 37J TT


Super unleaded gasoline, mixed with 2-stroke engine oil

( p. 74)

Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. 74)

69

TECHNICAL DATA - FORK

17.1

50 SX

Fork

Spring rate

Weight of rider: 25… 35 kg (55… 77 lb.)

Air chamber length

Fork length

Fork oil

17.2

50 SX Junior

Fork

Spring rate


Air chamber length

Fork length

Fork oil

17.3

50 SX Mini

Fork

Spring rate


Air chamber length

Fork length

Fork oil

Marzocchi

2 N/mm (11 lb/in)

100±2.5 mm (3.94±0.098 in)

692 mm (27.24 in)

Fork oil (SAE 7.5) ( p. 73)

Marzocchi

2 N/mm (11 lb/in)

100±2.5 mm (3.94±0.098 in)

607 mm (23.9 in)


Marzocchi

2 N/mm (11 lb/in)

100±2.5 mm (3.94±0.098 in)

578 mm (22.76 in)


70

TECHNICAL DATA - SHOCK ABSORBER

18.1

50 SX

Shock absorber

Rebound damping

Standard

Spring preload

Standard

Spring rate


Spring length

Gas pressure

Static sag

Fitted length

18.2

50 SX Junior

Shock absorber

Rebound damping

Standard

Spring preload

Standard

Spring rate


Spring length

Gas pressure

Static sag

Fitted length

18.3

50 SX Mini

Shock absorber

Rebound damping

Standard

Spring preload

Standard

Spring rate


Spring length

Gas pressure

Static sag

Fitted length


10 clicks

3 mm (0.12 in)

35 N/mm (200 lb/in)

130 mm (5.12 in)

10 bar (145 psi)

20 mm (0.79 in)

275 mm (10.83 in)


12 clicks

5 mm (0.2 in)

75 N/mm (428 lb/in)

130 mm (5.12 in)

10 bar (145 psi)

20 mm (0.79 in)

255 mm (10.04 in)


12 clicks

5 mm (0.2 in)

75 N/mm (428 lb/in)

120 mm (4.72 in)

10 bar (145 psi)

10 mm (0.39 in)

245 mm (9.65 in)

71

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES

Spoke nipple

Rear brake caliper screw

Remaining nuts, chassis

Screw, ball joint, push rod on footbrake cylinder


Screw, front brake disc

Screw, rear brake disc

Screw, rear sprocket

Engine carrying screw

Nut, rim lock


Remaining screws, chassis

Screw, front brake caliper

Screw, handlebar clamp

Screw, top triple clamp

Nut, swingarm pivot


Remaining screws, chassis

Screw, bottom shock absorber

Screw, handlebar support

Screw, top shock absorber

Front wheel spindle nut

Nut, rear wheel spindle

Nut, steering stem

Steering head nut

M3.5

M6

M6

M6

M8

M8

M10

M10

M10

M10

M10

M10

M12x1

M12x1

M20x1.5

M20x1.5

M6

M6

M6

M7

M8

M8

M8

M8

M8

3 Nm (2.2 lbf ft)

10 Nm (7.4 lbf ft)

15 Nm (11.1 lbf ft)

10 Nm (7.4 lbf ft)

10 Nm (7.4 lbf ft)

15 Nm (11.1 lbf ft)

15 Nm (11.1 lbf ft)

15 Nm (11.1 lbf ft)

25 Nm (18.4 lbf ft)

10 Nm (7.4 lbf ft)

30 Nm (22.1 lbf ft)

25 Nm (18.4 lbf ft)

20 Nm (14.8 lbf ft)

20 Nm (14.8 lbf ft)

25 Nm (18.4 lbf ft)

45 Nm (33.2 lbf ft)

50 Nm (36.9 lbf ft)

45 Nm (33.2 lbf ft)

45 Nm (33.2 lbf ft)

40 Nm (29.5 lbf ft)

45 Nm (33.2 lbf ft)

40 Nm (29.5 lbf ft)

40 Nm (29.5 lbf ft)

30 Nm (22.1 lbf ft)

10 Nm (7.4 lbf ft)

–

Loctite

®

243™

–

–

–

Loctite

®

243™

Loctite

®

243™

Loctite

®

243™

–

–

–

–

Loctite

®

243™

–

–

–

–

–

–

–

–

–

–

Loctite

®

–

243™

72

SUBSTANCES

2-stroke engine oil

According to

– JASO FC ( p. 77)

Guideline

– Only use high quality 2-stroke engine oil of a well-known brand. KTM recommends Motorex

®

products.

Fully synthetic

Supplier

Motorex

®

– Cross Power 2T

Brake fluid DOT 4 / DOT 5.1

According to

– DOT

Guideline

– Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Castrol and Motorex

®

products.

Supplier

Castrol

– RESPONSE BRAKE FLUID SUPER DOT 4

Motorex

®

– Brake Fluid DOT 5.1

Coolant

Guideline

– Use only suitable coolant (in countries with high temperatures also). Use of low-quality antifreeze can lead to corrosion and foaming. KTM recommends

Motorex

®

products.

Mixture ratio

Antifreeze protection: −25… −45 °C (−13…

−49 °F)

50 % Corrosion/antifreeze

50 % Distilled water

Coolant (mixed ready to use)

Antifreeze

Supplier

Motorex

®

– Anti Freeze

−40 °C (−40 °F)

Fork oil (SAE 7.5)

According to

– SAE ( p. 77) (SAE 7.5)

Guideline

– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends

Motorex

®

products.

Supplier

Motorex

®

– Racing Fork Oil

Gear oil (ATF Dexron 3)

According to

– Dexron III (ATF Dexron 3)

Guideline

– Use only ATF gear oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends

Motorex

®

products.

Supplier

Motorex

®

– ATF Dexron 3

73

SUBSTANCES

Super unleaded (ROZ 95 / RON 95 / PON 91)

According to

– DIN EN 228 (ROZ 95 / RON 95 / PON 91)

Super unleaded gasoline, mixed with 2-stroke engine oil

According to

– DIN EN 228

– JASO FC ( p. 77)

Mixture ratio

1:60


Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. 74)

74

AUXILIARY SUBSTANCES

Air filter cleaner

Specification

– KTM recommends Motorex

®

products.

Supplier

Motorex

®

– Twin Air Dirt Bio Remover

Chain cleaner

Specification


®

products.

Supplier

Motorex

®

– Chain Clean 611

Cleaning and polishing materials for metal, rubber and plastic

Specification


®

products.

Supplier

Motorex

®

– Protect & Shine 645

Contact spray

Specification


®

products.

Supplier

Motorex

®

– Accu Contact

High-luster polish for paint

Specification


®

products.

Supplier

Motorex

®

– Moto Polish

Long-life grease

Specification


®

products.

Supplier

Motorex

®

– Fett 2000

Motorcycle cleaner

Specification


®

products.

Supplier

Motorex

®

– Moto Clean 900

Offroad chain spray

Specification


®

products.

Supplier

Motorex

®

– Chain Lube 622

75

AUXILIARY SUBSTANCES

Oil for foam air filter

Specification


®

products.

Supplier

Motorex

®

– Twin Air Liquid Bio Power

Universal oil spray

Specification


®

products.

Supplier

Motorex

®

– Joker 440 Universal

76

STANDARDS

JASO FC

JASO FC is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions.

SAE

The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity. The viscosity describes only one property of oil and says nothing about quality.

77

INDEX

78

INDEX

A

Air filter

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Antifreeze

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

B

Brake discs

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Brake fluid

front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 37

rear brake, adding

. . . . . . . . . . . . . . . . . . . . . . . . . . 41

Brake fluid level

front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 37

rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 41

Brake linings

front brake, changing . . . . . . . . . . . . . . . . . . . . . . . . 39

front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 38

front brake, installing . . . . . . . . . . . . . . . . . . . . . . . . 39

front brake, removing . . . . . . . . . . . . . . . . . . . . . . . . 38

rear brake, changing . . . . . . . . . . . . . . . . . . . . . . . . . 43

rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 42 rear brake, installing . . . . . . . . . . . . . . . . . . . . . . . . . 42 rear brake, removing . . . . . . . . . . . . . . . . . . . . . . . . . 42

C

Carburetor

adjusting idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-53

idle

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Centrifugal clutch

adjusting clutch engagement speed . . . . . . . . . . . . . . . 57 checking clutch engagement speed . . . . . . . . . . . . . . . 57

fitting centrifugal clutch . . . . . . . . . . . . . . . . . . . . . . 58

removing centrifugal clutch . . . . . . . . . . . . . . . . . . . . 57

Chain

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Chain guide

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Chain tension

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Choke

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Coolant

draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Coolant level

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47-48

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

D

Dust boots

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

E

Engine

running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Engine - work on individual parts

assembling centrifugal clutch . . . . . . . . . . . . . . . . . . . 59 checking/measuring clutch . . . . . . . . . . . . . . . . . . . . . 59 dismantling centrifugal clutch . . . . . . . . . . . . . . . . . . 59

Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

F

Filler cap

closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Filling up

fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 40 free play, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Fork legs

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Front fender


Front wheel


Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

G

Gear oil

adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Gear oil level

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Gear oil screen

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

H

Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 36 adjusting play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 checking play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Handlebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

K

Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

L

Lower triple clamp

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

INDEX

79

M

Main silencer

glass fiber yarn filling, installing . . . . . . . . . . . . . . . . . 50 glass fiber yarn filling, removing . . . . . . . . . . . . . . . . . 50 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Motorcycle

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

O

Oil level

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Oil pump

bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Oil tank cap

closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Owner's manual

General information . . . . . . . . . . . . . . . . . . . . . . . . . . 6

P

Play in gas Bowden cable

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Plug-in stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Putting into operation

advice on first use

. . . . . . . . . . . . . . . . . . . . . . . . . . 13

after storage

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

checks before putting into operation . . . . . . . . . . . . . . 15

R

Rear sprocket / engine sprocket

checking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Rear wheel


Rebound damping

shock absorber, adjusting

. . . . . . . . . . . . . . . . . . . . . 21

S

Seat

mounting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Seat height

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20

Shock absorber


static sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 22

Shock absorber part number . . . . . . . . . . . . . . . . . . . . . . . . 9

Short circuit button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Spare parts, accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Spoke tension

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Spring preload

shock absorber, adjusting

. . . . . . . . . . . . . . . . . . . . . 22

Start number plate


Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Steering head bearing

greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Steering head bearing play

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Storage

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

T

Technical data

carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68-69

chassis tightening torques . . . . . . . . . . . . . . . . . . . . . 72

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

engine tightening torques

. . . . . . . . . . . . . . . . . . . . . 66

fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Throttle grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Tire air pressure

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Tire condition

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-62

U

Upper fork projection

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Use definition

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

V

Vehicle level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

View of vehicle

left front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

right rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

W

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Work rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

*3211344en*

3211344en

KTM-Sportmotorcycle AG

5230 Mattighofen/Austria

http://www.ktm.com

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