IMPORTANT

PLEASE READ THIS MANUAL THOROUGHLY BEFORE LETTING YOUR

YOUNGSTER RIDE THE MOTORCYCLE FOR THE FIRST TIME. THIS MANUAL

CONTAINS IMPORTANT INFORMATION AND RECOMMENDATIONS THAT

WILL HELP YOU AND YOUR YOUNGSTER TO OPERATE AND HANDLE THE

MOTORCYCLE PROPERLY.

IN THE INTEREST OF EVERYBODY INVOLVED, WE URGE YOU TO PAY PARTI-

CULAR ATTENTION TO INSTRUCTIONS AND INFORMATION MARKED AS

FOLLOWS:

WARNING

IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY

AND YOUR LIFE.

!

CAUTION !

IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO

PARTS OF THE MOTORCYCLE OR THAT THE MOTORCYCLE IS

NOT ROAD-SAFE ANYMORE.

Please insert below the series numbers of the motorcycle

Frame number

Engine number

1

Stamp of dealer

KTM S

PORTMOTORCYCLE

AG

RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT

,

TECHNICAL SPECIFICATIONS

,

COLORS

,

MATERIALS , SERVICES OFFERED AND RENDERED , AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT

PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS , OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTI -

TUTING THEM WITH OTHERS

. I

T SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS

ANNOUNCEMENT

. I

N THE EVENT OF SUCH MODIFICATIONS

,

PLEASE ASK YOUR LOCAL

KTM

DEALER FOR INFORMATION

.

W E SHALL NOT BE HELD LIABLE FOR ANY PRINTING ERRORS .

2

Introduction

Now you own a modern motorcycle that you and your youngster will certainly enjoy, provided that you service and maintain it properly. This manual contains important information on the operation and maintenance of your new KTM motorcycle. It went to press describing your model’s latest state of development. Nevertheless, the descriptions may deviate slightly from the current design as our motorcycles are permanently improved.

Maybe you are one of those riders who have acquired good technical skills and can perform many of the maintenance tasks themselves using the instructions contained in this manual. If this is not the case, please keep in mind that the maintenance tasks marked with an asterisk (*) in the chapter „Maintenance of chassis and engine“ should rather be performed by a KTM dealer to protect you and your youngster.

Please strictly observe the prescribed running-in periods and inspection and maintenance intervals. Compliance with these instructions will significantly prolong the life of your motorcycle.

Maintenance work should only be performed by a KTM dealer.

When special needs arise, please contact a KTM dealer, who will seek the assistance of the KTM importer if necessary.

PARENTS SHOULD KEEP IN MIND that the safety of their youngsters always depends on the efforts made by the parents to ensure that the motorcycle is kept in good working order and only used on safe terrains. Nevertheless, driving the motorcycle, like driving any other vehicle, involves a potential risk. Therefore, please make sure that all fundamental precautions are taken.

Please also read the „INFORMATION ON SAFE DRIVING FOR PARENTS“ on page 4.

Riding an off-highway motorcycle is a wonderful form of outdoor recreation and we certainly hope that you and your youngsters will enjoy it to the full. However, this enjoyable outdoor activity can cause environmental problems or lead to conflicts with other people. Responsible use of the motorcycle will prevent such problems and conflicts. You can contribute to securing the future of motorcycling by making sure that you and your youngsters only use the motorcycle within the limits established by the applicable laws, making environmental protection one of your top priorities and never violating other people’s rights.

In this spirit, we hope that you and your youngsters will always safely enjoy your motorcycle!

KTM Austria’s certificate of achievement for its Quality System ISO 9001 is the beginning of an on-going total re-engineering quality plan for a brighter tomorrow.

KTM SPORTMOTORCYCLE AG

5230 MATTIGHOFEN, AUSTRIA

1 spare parts manual chassis 1 spare parts manual engine Attachments:

ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL.

© by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved

INDEX

Page

IMPORTANT INFORMATION ON SAFE DRIVING FOR PARENTS ............4

SERIAL NUMBER LOCATIONS ..................................................................5

Chassis number .....................................................................................5

Engine number, engine type..................................................................5

OPERATION INSTRUMENTS .....................................................................5

Throttle grip ..........................................................................................5

Right hand brake lever ..........................................................................5

Short circuit button................................................................................6

Left hand brake lever ............................................................................6

Filler cap................................................................................................6

Refueling, fuel .......................................................................................6

Fuel tap .................................................................................................7

Choke (Dell’orto carburetor SHA 1412).................................................7

Choke (Mikuni carburetor VM18-144)..................................................7

Choke (Mikuni carburetor VM20-352)..................................................7

Kickstarter .............................................................................................7

DRIVING INSTRUCTIONS..........................................................................8

What you should check before each start..............................................8

Instructions for the first ride ..................................................................8

Running in.............................................................................................8

Starting when engine is cold..................................................................8

Starting when engine is warm ...............................................................9

What to do when the engine is „flooded“ ............................................9

Starting off ............................................................................................9

Driving ..................................................................................................9

Braking ..................................................................................................9

Stopping................................................................................................9

PERIODIC MAINTENANCE SCHEDULE ...................................................10

MAINTENANCE WORK ON CHASSIS AND ENGINE ...............................11

Checking and adjusting the steering head bearing ..............................11

Cleaning the dust scrabbers of the telcopic fork ..................................11

Telescopic fork maintenance................................................................12

Telescopic fork maintenance................................................................12

Check chain tension ............................................................................13

Correct chain tension...........................................................................13

Chain maintenance..............................................................................13

Adjusting the front wheel brake cable .................................................14

Checking the front brake linings for wear............................................14

Adjusting the rear wheel brake cable...................................................14

Checking the rear brake linings for wear .............................................14

Drum brake maintenance ....................................................................14

Removing and mounting the front wheel............................................15

Removing and mounting the rear wheel .............................................15

Tires, air pressure.................................................................................15

Checking spoke tension.......................................................................15

Removing the seat...............................................................................16

Cleaning the air filter...........................................................................16

Adjusting the throttle cable .................................................................16

Adjusting the idle speed ......................................................................17

Checking the gear oil level ..................................................................17

Changing the gear oil..........................................................................18

Changing the seat hight ......................................................................18

TECHNICAL DATA - ENGINE...................................................................19

TECHNICAL DATA - CHASSIS .................................................................20

3

IMPORTANT INFORMATION ON SAFE DRIVING FOR PARENTS

4

KTM mini motorcycles are off-road motorcycles designed for one person only. They are not allowed on public roads.

Motorcycle dimensions and components are designed for the following age and weight groups:

50 MINI ADVENTURE / 50 SX JUNIOR / 50 JR ADVENTURE:

Age 4 - 6 years, maximum weight 35 kg (78 lbs), maximum body height 130 cm (51 in)

50 SX SENIOR / 50 SR ADVENTURE:

Age 7 - 8 years, maximum weight 35 kg (78 lbs), maximum body height 130 cm (51 in)

– Have your youngster wear proper protective gear whenever he or she rides the motorcycle: helmet, eye protection, chest, back, arm and leg protectors, gloves and boots. To set a good example, be sure to wear protective gear yourself whenever riding a motorcycle!

– Adjust the hand brake levers to your youngster’s hand size (with gloves).

– Before your youngster takes his or her first ride, explain how each of the controls works and check if your youngster has understood what you explained. We recommend to review the entire owner’s manual with your youngster item by item, paying particular attention to the specially marked warnings and pointing out the danger of injury.

– Instruct your youngster about riding and falling techniques, explain how the motorcycle will respond to shifting of the rider’s weight, etc.

– Before using the motorcycle you should always check all components for proper operation (see mainenance schedule). Have your youngster perform these technical checks himself / herself as well.

– Whenever you go for a ride with your youngster, keep in mind that the speed should be adjusted to your youngster and not the other way around.

– Your youngster must understand that all instructions he or she receives from you or any other supervising adult must be followed.

– Your child must be physically ready to ride a motorcycle. This means that he or she must at least be able to ride a bicycle. Being good at sports that require fast reactions is an additional advantage. Your youngster should be strong enough to pick up the motorcycle after a fall.

– Never demand too much of your youngster. Give him or her time to get used to the motorcycle and to improve his / her riding skills. Do not even consider letting your youngster participate in a race before his / her physical condition, riding skills and motivation have sufficiently developed.

– Explain to your youngster that he / she should always adjust his / her riding speed to the local conditions as well as to his / her own riding skills and that excessive speed can cause falls and severe injuries. Always keep in mind that youngsters tend to underestimate dangers or fail to recognize them altogether. The riding speed must be reduced, in particular, on unknown terrain.

– Never let your youngster ride the motorcycle without supervision. An adult should always be present.

– The motorcycle is designed for one rider only. Your youngster is not allowed to transport a passenger.

– When you go for a ride, somebody at home should always know where you are going and when you will be back. This makes it easier to send you help, should problems occur.

1

SERIAL NUMBER LOCATIONS

Chassis number

The chassis number is located on the type plate on the steering head. Write this number into the field on page no 1.

Engine number

The engine number is stamped into the right half of the engine case next to the kickstarter. Write this number into the relevant area on page 1.

Engine typ

Motorcycle typ Engine typ

50 Mini Adventure ...........................S5-E

50 SX Junior / JR Adventure ............S5-GS

50 SX Senior / SR Adventure ...........S5-GS 5

OPERATION INSTRUMENTS

Throttle grip

The throttle grip is located on the right side of the handlebar. It is used to reduce the engine speed and, thus, the driving speed.

Right hand brake lever

The right hand brake lever is used to operate the front wheel brake via a control cable.

Use stud 1 to adjust the basic position of the hand brake lever to your youngster's hand size.

!

CAUTION !

A

FTER CHANGING THE BASIC POSITION OF THE HAND BRAKE LEVER

,

ALWAYS CHECK IF THE

FRONT WHEEL IS TURNING EASILY

. I

F THIS IS NOT THE CASE

,

READJUST THE BRAKE

CONTROL CABLE

.

6

Short circuit button

The short circuit button 1 turns off the engine. When pressing this button, the ignition circuit is short-cicuited.

1

2

Left hand brake lever

The left hand brake lever is used to operate the rear wheel brake via a control cable.

Use stud 2 to adjust the basic position of the hand brake lever to your youngster's hand size.

!

CAUTION !

A

FTER CHANGING THE BASIC POSITION OF THE HAND BRAKE LEVER

,

ALWAYS CHECK IF THE

REAR WHEEL IS TURNING EASILY

. I

F THIS IS NOT THE CASE

,

READJUST THE BRAKE

CONTROL CABLE

.

Filler cap

To open it: turn filler cap counter-clockwise.

To close it: put filler cap back on and tighten it by turning it clockwise.

Install tank breather hose 3 without kinks.

3

40 mm

Refueling, fuel

Oil (high-grade two-stroke engine oil) must be mixed with the fuel

(ROZ 95) at a mixing ratio of 1:40.

WARNING

G

ASOLINE IS HIGHLY FLAMMABLE AND POISONOUS

. E

XTREME CAUTION SHOULD BE USED

WHEN HANDLING GASOLINE

. N

EVER REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR

BURNING CIGARETTES

. A

LWAYS SWITCH OFF THE ENGINE BEFORE REFUELING

. B

E CAREFUL

NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT

.

W

IPE UP SPILLS PROMPTLY

. I

F GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES

,

SEEK

A DOCTOR

’

S ADVICE IMMEDIATELY

.

!

CAUTION !

– O NLY USE PREMIUM GRADE GASOLINE ROZ 95 MIXED WITH HIGH GRADE TWO -

STROKE ENGINE OIL . O THER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE .

– O NLY USE KNOWN BRANDS OF HIGH GRADE 2STROKE ENGINE OIL (S HELL A DVANCE

R ACING X).

– N OT ENOUGH OIL OR LOW GRADE OIL CAN CAUSE EROSION OF THE PISTON . WHEN

U SING TOO MUCH OIL , THE ENGINE MAY START SMOKING AND FOUL THE SPARK PLUG .

– F UEL EXPANDS WHEN ITS TEMPERATURE RISES . T HEREFORE DO NOT FILL THE TANK TO

THE TOP . ( SEE FIG .)

4

1

2

3

Fuel tap

The fuel tap 1 is located at the front of the motorcycle on the left side of the tank.

Opening the fuel tap: Turn the knob all the way to the left.

Closing the fuel tap: Turn the knob all the way to the right.

!

CAUTION !

T HE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED . I F THE TAP

IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL GET INTO THE ENGINE .

Choke (Dell'Orto carburetor SHA 1412)

The choke lever 2 is located on the right side of the carburetor. Squeezing and engaging the choke lever reduces the air intake of the carburetor, thus achieving the "rich" fuel air mixture needed for cold starting.

To restore the choke lever to its original position, thus deactivating the choke, briefly open the throttle all the way.

Choke (Mikuni carburetor VM18-144 / VM 16-519)

The choke lever 3 is located on the left side of the carburetor. Squeezing the lever opens a bore in the carburetor through which the engine can take in additional fuel, thus achieving the "rich" fuel air mixture needed for cold starting.

To close the bore in the carburetor simply pull the choke lever upwards into the original position.

7

Choke (Mikuni carburetor VM20-364)

When pulling the choke knob 4 fully outwards, a bore is opened in the carburetor. Through this bore the engine can take in additional fuel. This encoure the rich fuel-air mixture, that is needed for a cold start.

When pressing the choke knob downward in the carburetor, the bore is closed again.

Kickstarter

The kickstarter is mounted on the right side of the engine. Its upper part can be swivelled.

WARNING

W HEN STARTING THE ENGINE , PUT ON MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES .

Y OU MAY SLIP OFF THE KICKSTARTER , OR THE ENGINE MAY STRIKE BACK WHEN KICKING

NOT VEHEMENTLY ENOUGH .

DRIVING INSTRUCTIONS

8

What you should check before each start

When you start off, the motorcycle must be in a perfect technbical condition. For safety reasons, you should make it a habit to perform an overall check of your motorcycle before each start.

The following checks should be performed:

1 CHECK TRANSMISSION OIL LEVEL.

A lack of gear oil leads to premature wear and finally results in destruction of the gear wheels.

2 FUEL

Check that there is sufficient fuel in the tank; when closing the filler cap, check that the tank venting hose is free of kinks.

3 CHAIN

A loose chain was fall off the chain wheels; an extremely worn chain may tear, and insufficient lubrication may result in unnecessary wear of chain and chain wheels.

4 TIRES

Check for damaged tyres. Tires showing cuts or dents must be replaced. Also check the air pressure. Insufficient tread and incorrect air pressure deteriorate the driving performance.

5 BRAKES

Check the brakes for proper adjustment and correct operation.

6 Throttle cable

Check the throttle cable for proper adjustment and smooth operation.

WARNING

– H AVE YOUR YOUNGSTER WEAR PROPER PROTECTIVE GEAR WHENEVER

HE OR SHE RIDES THE MOTORCYCLE : HELMET , EYE PROTECTION , CHEST ,

BACK , ARM AND LEG PROTECTORS , GLOVES AND BOOTS . T O SET A

GOOD EXAMPLE , BE SURE TO WEAR PROTECTIVE GEAR YOURSELF

WHENEVER RIDING A MOTORCYCLE !

– O NLY USE ACCESSORY PARTS RECOMMENDED BY KTM.

Instructions for the first ride

– Verify that your KTM dealer performed the PREPARATION

OF VEHICLE jobs (see Customer Service Manual).

– Before your youngster takes his or her first ride, explain how each of the controls works and check if your youngster has understood what you explained. We recommend to review the entire owner’s manual with your youngster item by item, paying particular attention to the specially marked warnings and pointing out the danger of injury.

– Adjust the basic hand brake lever position to your youngster's hand size. Your youngster should, of course, wear gloves!

– To prevent injury, teach your youngster the basic riding skills on soft ground, e.g. on a meadow or in the garden. Be sure that there is room enough to maneuver, and that no other riders are close.

– To ensure that your youngster gets the feel of the brakes, have your youngster operate the brakes while you push the motorcycle. Do not start the engine before your youngster has learned to apply both brakes with appropriate pressure.

– Now your youngster must get the feel of the throttle. Start the engine, hold the motorcycle and have your youngster slowly open the throttle. Then, your youngster can take his/her first ride. Initially, your youngster should ride back and forth between two persons who help the young rider to stop the motorcycle. However, you should also teach your youngster how to stop the motorcycle himself/herself.

– To improve his/her riding skills, your youngster should practise to ride the motorcycle standing on the footpegs or to ride at the slowest possible speed. Additionally, you can arrange a series of obstacles and have your youngster drive around them, etc.

– Tell your youngster to look 3-10 m ahead, depending on the speed, to recognize and avoid obstacles. When riding through curves, the rider should also look far ahead into the curve.

WARNING

– KTM MINI MODELS ARE DESIGNED FOR ONE PERSON ONLY .

P ASSENGERS ARE NOT ALLOWED .

– T HESE MODELS DO NOT COMPLY WITH THE REGULATIONS AND SAFETY

STANDARDS ESTABLISHED BY THE LAW . T HEREFORE , THEY ARE NOT

PERMITTED ON PUBLIC ROADS .

– A LWAYS KEEP IN MIND THAT OTHER PEOPLE FEEL MOLESTED BY

EXCESSIVE NOISE .

Running in

– E

VEN VERY PRECISELY MACHINED SECTIONS OF ENGINE COMPONENTS

HAVE ROUGHER SURFACES THAN COMPONENTS WHICH HAVE BEEN SLI

-

DING ACROSS ONE ANOTHER FOR QUITE SOME TIME

. T

HEREFORE

,

EVERY ENGINE NEEDS TO BE BROKEN IN

. F

OR THIS REASON

,

DURING ITS

FIRST

5

HOURS THE ENGINE MUST NOT BE REVVED UP TO ITS PERFOR

-

MANCE LIMITS

.

–

APPLY LOW BUT CHANGING LOADS FOR RUNNING

-

IN

.

– DO NOT DRIVE AT FULL LOAD FOR THE FIRST 5 HOURS!

Starting when the engine is cold

1 Open fuel tap

2 Operate the choke

3 Swing the side stand all the way up.

4 Squeeze both brake levers.

5 Operate the kickstarter, depressing it all the way, without opening the throttle.

WARNING

– T O AVOID INJURY WHEN STARTING THE ENGINE , ALWAYS WEAR BOOTS !

– W HEN STARTING THE ENGINE , ALWAYS KEEP THE BRAKE LEVERS SQUEE -

ZED . A S SOON AS THE ENGINE IS RUNNING , SLOWLY RELEASE THE BRAKE

LEVERS . A N ACTIVATED CHOKE INCREASES THE IDLE SPEED OF THE ENGI -

NE , THE CENTRIFUGAL CLUTCH THUS BEGINNING TO ENGAGE .

T HEREFORE , THE MOTORCYCLE CAN BEGIN TO MOVE WHEN THE BRAKE

LEVERS ARE RELEASED .

– T HE MOTORCYCLE HAS A CENTRIFUGAL CLUTCH . T HE MOTORCYCLE

BEGINS TO MOVE AS SOON AS THE THROTTLE IS OPENED .

– D O NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA .

E XHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONS -

CIOUSNESS AND DEATH . A LWAYS PROVIDE ADEQUATE VENTILATION

WHILE THE ENGINE IS RUNNING .

Starting when the engine is warm

1 Open fuel tap

2 Swing the side stand all the way up.

3 Squeeze both brake levers.

4 Operate the kickstarter, depressing it all the way, without opening the throttle.

What to do when the engine is „flooded”

1 Close fuel tap

2 Squeeze both brake levers.

3 Start engine with full throttle. If necessary, unscrew spark plug and dry it.

4 Once the engine is running, open fuel tap again.

!

CAUTION !

– D RIVING A COLD ENGINE AT HIGH SPEED WILL REDUCE THE LIFE OF THE

ENGINE . W E RECOMMEND TO WARM THE ENGINE UP AT A MEDIUM

ENGINE SPEED FOR SEVERAL MINUTES BEFORE SWITCHING TO FULL

LOAD .

– W HILE YOUR ALLOW THE ENGINE TO WARM UP , NEVER LET YOUR

MOTORCYCLE REST ON ITS SIDESTAND IN AN INCLINED POSITION ( SEE

PHOTO ). T HIS INCLINED POSITION MIGHT CAUSE ENGINE FAILURE .

– I N THE EVENT THAT , WHILE YOUR CHILD IS RIDING ON THE MOTORCY -

CLE , YOU NOTICE ANY UNUSUAL OPERATION RELATED NOISE , YOUR

CHILD SHOULD STOP IMMEDIATELY , TURN THE ENGINE OFF , AND

CONTACT AN AUTHORIZED KTM DEALER .

9

Starting off

Slowly release the brake lever while simultaneously opening the throttle.

WARNING

B

EFORE YOU START OFF

,

CHECK THAT THE SIDE STAND HAS BEEN SWUNG

RIGHT UP TO THE TOP

. I

F THE STAND DRAGS ON THE FLOOR

,

YOU MAY

LOSE CONTROL OF YOUR MOTORCYCLE

.

O.K.

DON’T

Driving

The engine speed, and thus the driving speed, are regulated by the throttle grip.

The choke must always be deactivated as soon as the engine has warmed up.

If your motorcycle has a Dell'orto carburetor, briefly open the throttle all the way to restore the choke lever to its original position.

If your motorcycle has a Mikuni carburetor, pull the choke lever into the original position.

WARNING

– Y OUR CHILD SHOULD NEVER DRIVE FASTER THAN ITS SKILLS AND THE

TERRAIN PERMIT .

– N EVER LET YOUR CHILD DRIVE ITS MOTORCYCLE UNCHAPERONED .

– W HEN THE ENGINE SPEED DROPS TO THE LEVEL AT WHICH THE CENTRI -

FUGAL CLUTCH DISENGAGES , BRAKING WITH THE ENGINE IS NO LON -

GER POSSIBLE AND THE MOTORCYCLE CAN ONLY BE SLOWED DOWN

USING THE BRAKES .

– R EPLACE THE HELMET VISOR OR GOGGLE GLASSES EARLY ENOUGH .

W HEN LIGHT SHINES DIRECTLY ON A SCRATCHED VISOR OR GOGGLES ,

YOU WILL BE PRACTICALLY BLIND .

– A FTER FALLING WITH THE MOTORCYCLE , CHECK ALL ITS FUNCTIONS

THOROUGHLY BEFORE USING IT AGAIN .

– A BENT HANDLEBAR MUST ALWAYS BE REPLACED . N EVER TRY TO

STRAIGHTEN THE HANDLEBAR BECAUSE THIS WILL CAUSE IT TO LOSE ITS

STABILITY .

Braking

Close the throttle and squeeze both brake levers simultaneously. On sandy, wet or slippery terrain the rear wheel brake should be preferred. The brakes should always be operated carefully as locking wheels can cause skidding or falls.

WARNING

B RAKE DRUM AND LININGS HEAT UP DURING BRAKE OPERATION , THUS

REDUCING THE EFFECT OF THE BRAKES .

Stopping

Reduce the speed. Immediately before the motorcycle comes to a stop, put the left foot down. To turn off the engine, press the short circuit button until the engine stops. Close the fuel tap.

WARNING

– N EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS

THE ENGINE IS RUNNING .

– M OTORCYCLES PRODUCE GREAT HEAT DURING OPERATION .

T HEREFORE , KEEP IN MIND THAT THE ENGINE , THE EXHAUST SYSTEM

AND THE BRAKES CAN HEAT UP CONSIDERABLY . M AKE SURE THAT THESE

PARTS ARE NOT TOUCHED AND ALWAYS TAKE CARE , WHEN PARKING

THE MOTORCYCLE , THAT OTHER PERSONS WILL NOT BURN THEMSELVES .

!

CAUTION !

C

LOSE THE FUEL TAP WHEN LEAVING THE MOTORCYCLE

. O

THERWISE THE

CARBURETOR MAY GET FLOODED AND FUEL WILL ENTER THE ENGINE

.

PERIODIC MAINTENANCE SCHEDULE

50 Mini Adventure

50 SX Junior

50 JR Adventure

50 SX Senior

50 RS Adventure

7. 99

KTM rider

10

Check transmission oil level

Change transmission oil

Check spark plug and electrode gap

Check carburetor for tight fit on the intake flange

Drain and clean carburetor float chamber

Check idle setting when engine is warm

Check air filter, filter box and filter boot

Check sprockets, chain guides and chain for wear

Clean and lube chain

Check chain tension

Check exhaust system for leaks

Check exhaust brackets

Check brake lining thickness

Check brake drums

Check freeplay and operation of hand brake levers

Check fork for function and tightness

Service front fork completely

Check steering head bearing clearance / adjust

Clean and grease steering head bearings

Check shock absorber for function and tightness

Check bearings of swingarm for play

Clean and grease bearings of swingarm

Check tightness of spokes and rim join

Check wheel bearings for clearance

Check tire condition and air pressure

Check cables for damage, correct instalment and easy working

Lube and adjust cables

Check all screws, nuts and hose clamps for proper tightness

Grease or lube all pivot points and sliding components

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

KTM dealer

●

●

●

●

●

●

●

●

●

●

●

●

●

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MAINTENANCE WORK ON CHASSIS AND ENGINE

WARNING

MAINTENANCE WORK AND ADJUSTMENTS MARKED WITH AN ASTERISK (*) MUST BE PERFOR-

MED BY AN EXPERT. TO PROTECT YOUR YOUNGSTER, ALWAYS HAVE SUCH WORK PERFORMED

BY A SPECIALIZED KTM DEALER.

!

CAUTION !

– W HEN CLEANING THE MOTORCYCLE , DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE , OTHERWISE WATER WILL PENETRATE THE

BEARINGS , CARBURETOR , ELECTRIC CONNECTORS ETC .

– W HEN TRANSPORTING YOUR MOTORCYCLE , SECURE IT WITH ELASTIC STRAPS OR OTHER MECHANICAL DEVICES IN AN UPRIGHT POSITION .

B E SURE THAT THE FUEL TAP IS CLOSED . I F THE MOTORCYCLE TOPPLES OVER , FUEL CAN FLOW OUT OF THE CARBURETOR OR FUEL TANK .

– D O NOT USE TOOTHED WASHERS OR SPRING RINGS WITH THE ENGINE FASTENING SCREWS , AS THESE WORK INTO THE FRAME PARTS AND KEEP

WORKING LOOSE . I NSTEAD , USE SELF LOCKING NUTS .

– L ET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED .

– R EMOVE O ILS , FATTY MATTERS , FILTERS , FUELS , WASHING DETERGENTS ETC . ORDERLY .

– U NDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIZE . 1 LITER USED OIL

CONTAMINATES 1.000.000 LITERS WATER .

2

3

2

1

1

Checking and adjusting the steering head bearing *

The steering head bearing should regularly be checked for play. For this purpose, jack up the motorcycle by the frame so that the front wheel is in the air. Now try to move the fork forward and backward. There should be no play. For readjustment, release the two clamp screws 1 of the top triple clamp and the counter nut 2 . Turn the adjusting nut 3 until almost no play is left. Do not tighten the adjusting nut! Tightening the adjusting nut can damage the bearings! Keep in mind that tightening the counter nut 2 reduces the play of the bearing. Slightly tap the top triple clamp with a rubber hammer to prevent jamming. Then tighten the 2 clamp screws with

15 Nm (11 ft.lb).

WARNING

I F THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY , THE MOTORCY -

CLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL .

!

CAUTION !

– T

HE HANDLEBAR MUST MOVE EASILY

. O

THERWISE THE BEARINGS WILL BE DAMAGED

.

– I

F YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS

,

THE

BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME WILL BE DESTROYED

.

At least once a year, the steering head bearings should be smeared with waterproof grease.

11

3

Cleaning the dust scrabbers of the telescopic fork

The dust scrabbers 4 should be cleaned on a regular basis.

For this purpose, use a screwdriver to lever the dust scrabbers out of the slider tubes, clean them thoroughly with compressed air, spray the fork tubes and dust scrabbers with silicon oil and press the scrabbers back into the slider tubes.

4

12

3

1

2

Telescopic fork maintenance (50 Mini Adventure) *

The telescopic fork must be serviced at least once a year:

– Jack up the motorcycle by the frame to take the weight off the front wheel.

– Remove the front wheel and the brake cable guide.

– Release the clamp screws 1 at the triple clamps and pull the fork legs downwards out of the triple clamps.

– Clamp the fork leg into a vise (use protective jaws) and remove the plugs 2 .

– Take the preload spacer and the spring out of the fork tube.

– Remove screws 3 at the underside of the slider tubes and pull the fork tubes out of the slider tubes.

– Remove the dust scrabbers 4 .

4

– Thoroughly clean all parts and check for wear.

– Grease gaskets and springs and reassemble the telescopic fork.

– Tighten the screws at the underside of the slider tubes with 30 Nm

(22 ft.lb).

– Insert the fork legs into the triple clamps (the fork tube must be flush with the top triple clamp) and tighten the clamp screws with 15 Nm

(11 ft.lb).

– Mount the front wheel.

Changing the telescopic fork oil *

(50 SX Junior, 50 JR Adventure, 50 SX Senior, 50 SR Adventure)

– Remove front wheel and fork legs (see above).

– Remove plugs, preload spacers and springs.

– Drain the fork oil into an appropriate container.

– Clean the dust scrabbers.

– Fill the fork tubes with new fork oil (SAE 7.5)

50 SX Junior, 50 JR Adventure: 150 ccm per fork tube

50 SX Senior, 50 SR Adventure: 160 ccm per fork tube

– Insert springs and preload spacers into the fork tube.

– Check and grease O-rings and mount the plugs.

– Mount fork legs and front wheel (see above), then mount the cable guide.

B

Check chain tension

– Put the motorcycle on the sidestand.

– Check the chain tension approximately in the middle between the two chain guides A and B . In this area, the chain should easily move approximately 10 mm (0.4 in) upward and downward.

– If necessary, correct chain tension.

WARNING

– I F CHAIN TENSION IS TOO GREAT , PARTS WITHIN THE SECONDARY TRANSMISSION

( CHAIN , CHAIN WHEELS , GEAR BOX AND REAR WHEEL BEARINGS ) WILL BE SUBJECTED

TO UNNECESSARY STRESS , RESULTING IN PREMATURE WEAR AND EVEN CHAIN BREAKAGE .

– T OO MUCH SLACK IN THE CHAIN , ON THE OTHER HAND , CAN RESULT IN THE CHAIN

JUMPING OFF THE CHAIN WHEELS . I F THIS HAPPENS , THE CHAIN COULD ALSO BLOCK

THE REAR WHEEL OR DAMAGE THE ENGINE .

– I N EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE .

A

10 mm

1

2

3

Correct chain tension

– Release the hexagon nut of the wheel spindle the right hexagon nut 2 equally far.

1 and turn the left and

– Before tightening the hexagon nut of the wheel spindle with 30 Nm

(22 ft.lb), ensure that the supporting plates 3 are resting against the swing arm. Additionally, check that the rear wheel is aligned with the front wheel.

13

3

2

✓

Chain maintenance

For long chain life, good maintenance is very important. Chains without

O-rings should be cleaned in fireproof solvent regularly and afterwards treated with hot grease or chain spray (Shell Advance Bio Chain).

WARNING

K

EEP THE REAR WHEEL FREE OF GREASE

! G

REASE ON THE REAR WHEEL WILL SIGNIFICANTLY

REDUCE THE GRIP OF THE REAR TIRE AND THE MOTORCYCLE COULD EASILY GET OUT OF CONTROL

.

!

CAUTION !

W HEN MOUNTING THE CHAIN MASTERLINK CLIP , THE CLOSED SIDE OF THE MASTERLINK

CLIP MUST POINT IN RUNNING DIRECTION .

Also check sprockets and chain guides for wear, and replace if necessary.

14

6

10 -15 mm

2

3 min 50 mm

1

Adjusting the front wheel brake cable

The hand brake lever should travel between 10 and 15 mm (0.4-0.6 in) before the front wheel is actually slowed down.

To adjust the brake control cable, use either the adjusting screw hand brake lever or the adjusting screw

1 at the

2 at the brake backing plate. Before commencing to adjust the cable, always release the counter nut 3 .

Afterwards, the counter nut must be retightened.

!

CAUTION !

A FTER ADJUSTING THE CABLE , ALWAYS CHECK IF THE WHEEL TURNS SMOOTHLY .

3

Checking the front brake linings for wear

The brake linings must be replaced when the distance between the hub brake lever and the cable support, measured with the brake lever squeezed, is less than 50 mm (2 in) (see illustration).

!

CAUTION !

I F THE BRAKE LININGS ARE REPLACED TOO LATE , I .

E . WHEN THE LINING IS PARTLY OR

FULLY WORN AWAY , THE METAL SHOES WILL RUB AGAINST THE BRAKE DRUM , THUS

REDUCING THE BRAKING EFFECT AND DESTROYING THE BRAKE DRUM .

4

10 -15 mm

Adjusting the rear wheel brake cable

The hand brake lever should travel between 10 and 15 mm (0.4-0.6 in) before the rear wheel is actually slowed down.

To adjust the brake control cable, use eigher the adjusting screw 4 at the hand brake lever or the adjusting screw 5 at the brake backing plate. Before commencing to adjust the cable, always release the counter nut 6 .

Afterwards, the counter nut must be retightened.

!

CAUTION !

A FTER ADJUSTING THE CABLE , ALWAYS CHECK IF THE WHEEL TURNS SMOOTHLY .

5 min 50 mm

Checking the rear brake linings for wear

The brake linings must be replaced when the distance between the hub brake lever and the cable support, measured with the brake lever squeezed, is less than 50 mm (2 in) (see illustration).

!

CAUTION !

I

F THE BRAKE LININGS ARE REPLACED TOO LATE

,

I

.

E

.

WHEN THE LINING IS PARTLY OR

FULLY WORN AWAY

,

THE METAL SHOES WILL RUB AGAINST THE BRAKE DRUM

,

THUS

REDUCING THE BRAKING EFFECT AND DESTROYING THE BRAKE DRUM

.

6

Drum brake maintenance

Drum brake maintenance is limited to occasional blowing out of brake drum and brake shoes. Brake drum and brake linings can be slightly roughened with an abrasive cloth.

1

4

2

3

Removing and mounting the front wheel

– Jack up the motorcycle by the frame.

– Remove the right hexagon nut of the wheel spindle 1 together with the washer.

– Pull the wheel spindle halfway out and remove the spacer 2 .

– Now pull out the wheel spindle out until the wheel is free but not so far that the brake backing plate comes off.

– Turn both wheel and fork slider tube to the left and remove wheel.

– To mount the wheel reverse the procedure described above.

– Tighten the hexagon nut with 30 Nm (22 ft.lb).

Removing and mounting the rear wheel

– Jack up the motorcycle by the frame.

– Remove the right hexagon nut of the wheel spindle 3 together with the washer.

– Hold the rear wheel and remove the wheel spindle.

– Move the rear wheel downward, remove the chain and take the rear wheel out of the swing arm.

– To mount the wheel reverse the procedure described above.

– Always hook the brake backing plate into the swing arm support.

– Before tightening the hexagon nut of the wheel spindle, ensure that the supporting plates 4 are resting against the swing arm. Additionally, check that the rear wheel is aligned with the front wheel.

– Tighten the hexagon nut with 30 Nm (22 ft.lb).

15

4

Tires, air pressure

Tire type, tire condition, and air pressure level affect the way your motorcycle rides, and they must therefore be checked whenever you are getting ready to go anywhere on your motorcycle.

– Tire size can be found in the technical specifications.

– Tire condition has to be checked every time you want to ride your motorcycle. Before leaving, check tires for punctures and nails or other sharp objects that might have become embedded in them.

– Regularly check the "cold" tire pressure. Correct tire pressure (1.0 bar /

14 psi) guarantees optimum grip and maximum tire life.

WARNING

– D AMAGED TIRES MUST BE REPLACED IMMEDIATELY TO PROTECT YOUR YOUNGSTER .

– W ORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW THE MOTORCYCLE PERFORMS ,

ESPECIALLY ON WET SURFACES

– T IRE PRESSURE BELOW THE NORMAL LEVEL WILL LEAD TO PREMATURE TIRE WEAR .

Checking spoke tension

The correct spoke tension is very important for the stability of the wheels and thus for riding safety. A loose spoke causes the wheel to become unbalanced and before long other spokes will have come loose. Check spoke tension, especially on a new motorcycle, in regular intervals. If necessary, have the spokes retightened and the wheel centered by a KTM dealer.

WARNING

S POKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE . T HIS MAY LEAD TO AN

UNSTABLE HANDLING OF YOUR MOTORCYCLE .

1

Removing the seat

The quick-release mechanism 1 allows removal of the seat without tools.

Turn the quick-release device approximately 180° anticlockwise, lift the rear portion of the seat and pull the seat off backwards.

When mounting the seat ensure that the hook 2 engages at the tank.

16

2

3

4

3

Cleaning the air filter *

The air filter must be cleaned at intervals depending on the amount of dust accumulated. To clean the air filter, first remove the seat. Then remove the two screws 3 , the filter holder and the air filter 4 . The air filter consists of a foam rubber insert soaked with filter oil.

!

CAUTION !

– D

O NOT CLEAN FOAM FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE

THE FOAM

. KTM

RECOMMENDS THE PRODUCTS MADE BY

PUTOLINE

FOR AIR FIL

-

TER MAINTENANCE

.„A

CTION

C

LEANER

”

FOR CLEANING PURPOSES AND

„A

CTION

F

LUID

”

TO OIL THE FOAM FILTER

.

– N

EVER OPERATE YOUR MOTORCYCLE WITHOUT AIR FILTER

. O

THERWISE

,

DUST AND

DIRT MAY GET INTO THE ENGINE AND LEAD TO INCREASED WEAR

.

Thoroughly wash the foam filter in special cleaning fluid and allow it to dry well. Only press out the filter, do not wring it out under any circumstances.

Oil the dry foam filter with a high-grade filter oil. Also clean the air filter box. Check carburetor collar for damage and that it is filled correctly.

Insert the air filter in the opening and fasten it with the filter holder. Then mount the seat.

6

3-5 mm

5

Adjusting the throttle cable *

There must always be a 3-5 mm (0.1-0.2 in) play in the throttle cable. To check this, move back the protective cover 5 on the throttle grip. You must be able to lift the outer covering of the cable 3-5 mm from the adjusting screw 7 , until resistance is felt.

To adjust, loosen the counter nut 6 and turn the adjusting screw accordingly. Finally tighten counter nut and slide the protective cover back on.

7

Adjusting the idle speed (Dell’Orto SHA 1412) *

The idle speed can be adjusted with throttle stop screw 1 .

Turning in clockwise direction will increase the idle speed.

Turning in counterclockwise direction will reduce the idling speed.

1

2

Adjusting the idle speed (Mikuni VM18-144 / 16-519) *

The idle speed can be adjusted with throttle stop screw 2 .

Turning in clockwise direction will increase the idle speed.

Turning in counterclockwise direction will reduce the idling speed.

Adjusting the idle speed (Mikuni VM20-364) *

The idle speed can be adjusted with throttle stop screw 3 .

Turning in clockwise direction will increase the idle speed.

Turning in counterclockwise direction will reduce the idling speed.

17

3

4

5

Checking the gear oil level

To check the gear oil level, first remove the plug 4 . With the motorcycle parked in an upright position, a small quantity of oil should flow out of the indicator opening 5 . If oil must be added, tilt the motorcycle and pour gear oil SAE 30 (ex. Shell Advance VSX 4) into the opening.

!

CAUTION !

T OO LITTLE OIL OR A POOR OIL QUALITY LEAD TO PREMATURE TRANSMISSION WEAR .

T HEREFORE , ONLY USE BRANDED PRODUCTS ( EX . S HELL A DVANCE VSX 4).

18

Changing the gear oil *

The engine must be warmed up before changing the gear oil. Park the motorcycle on a horizontal surface, remove the oil drain plug 1 and drain the used oil into an appropriate container. Clean the sealing surface, mount the oil drain plug together with the gasket and tighten with 15 Nm (11 ft.lb).

1

3

2

Lay the motorcycle on its side and add 0.25 l gear oil SAE 30 (ex. Shell

Advance VSX 4). Mount the plug 3 and check the engine for leaks.

!

CAUTION !

T OO LITTLE OIL OR A POOR OIL QUALITY LEAD TO PREMATURE TRANSMISSION WEAR .

T HEREFORE , ONLY USE BRANDED PRODUCTS .

25 mm

Changing the seat height

The seat height of all 50 mini models can easily be increased by 25 mm (1 in).

The frame is provided with additional fastening points on which the tank and the tail can be mounted. Thus, you can easily adjust the seat height as your youngster grows.

Engine

Design

Displacement

Bore/Stroke

Compression ratio

Fuel

Oil/gasoline ratio

Lubrication

Crankshaft bearing

Connecting rod bearing

Piston pin bearing

Piston rings

Primary drive

Transmission oil

Spark plug

Electrode gap

Carburetor

Air filter

TECHNICAL DATA – ENGINE S5-E, S5-GS 2000

S5-E

(50 Mini Adventure) air cooled single cylinder 2-stroke engine

S5-GS

(50 SX Junior / 50 JR Adventure

50 SX Senior / 50 SR Adventure) air cooled single cylinder 2-stroke engine with reed valve inlet

49.8 ccm

39 / 41.7 mm

9 : 1

SUPER fuel, research octane no 95, mixed with 2-stroke oil

1 : 40 when using high grade 2-stroke oil (Shell Advance Racing X)

When in doupt, please contact your importer or use 1 : 33 mix ratio to be on the safe side

DellOrto SHA 1412 mixture lubrication

2 grooved ball bearing needle bearing needle bearing

1 L-ring, 1 rectangular ring helical gears, 15 : 52 t, cast

2 rectangular ring helical gears, 15 : 52 t, milled

0.25 l gear oil, SAE 30 (Shell Advance VSX4)

Bosch W 4 AC

0.6 mm

50 SX Junior: Mikuni VM 18-144

50 JR Adventure: Mikuni VM16-519

50 SX Senior / 50 SR Adventure: Mikuni VM 20-364 wet foam type air filter insert

19

BASIC CARBURETOR SETTING

Type Dell’Orto SHA 1412

Main jet

Needle jet

Idling jet

Jet needle

Needle position from top

Air reg. screw open

Throttle valve

––

––

––

60

––

––

––

Mikuni VM 16-519

70

D-8

25

3DJ3-3

3rd

2,0 turn

2,5

Mikuni VM 18-144

70

145

30

4F18-4

4th

1.5 turn

1

Mikuni VM 20-364

110

N-6

30

4J13-3

3rd

1.5 turn

2

TIGHTENING TORQUES - ENGINE

Hexagon nut primary gear

Hexagon nut flywheel

Nut for clutch hub

Nuts cylinder head

Nuts exhaust pipe

Oil drain plug

Other screws engine

M12x1,25

M8

M10

M6

M6

M8

M5

M6

40 Nm (30 ft.lb)

35 Nm (25 ft.lb)

Loctite 242 + 35 Nm (25 ft.lb)

12 Nm (8 ft.lb)

12 Nm (8 ft.lb)

15 Nm (10 ft.lb)

7 Nm (5 ft.lb)

10 Nm (7 ft.lb)

TECHNICAL SPECIFICATIONS - CHASSIS Mini 2000

20

Frame

Fork

Wheel travel front/rear

Rear suspension

Front brake

Rear brake

Tyres

Air pressure

Fuel tank capacity

Final drive ratio

Chain

Steering angle

Wheel base

Seat height, unloaded

Ground clearance

Dead weight without fuel

Rider’s body height

Rider’s body weight

Recommended age of rider

Engine

50 Mini Adventure 50 SX Junior / 50 JR Adventure 50 SX Senior / 50 SR Adventure

115/135 mm (4.5/5.3 in) single downtube, split-cradle telescopic fork Paiolo Ø = 31,8 mm (1,25 in)

140/160 mm (5.5/6.3 in) central shock absorber

165/170mm (6.5/6.7 in)

Paioli MC24 (l = 248 mm / 9,75 in) Paioli MC30 (l = 255 mm / 10 in) Paioli MC30 (l = 275 mm / 10,8 in) internal expanding, single/cam drum brake Ø 90 mm (3.5“) internal expanding, single/cam drum brake Ø 90 mm (3.5“) front / rear: Vee Rubber 2.50x10“ VRM-140 front / rear: 1.0 bar (14 psi) / 1.0 bar (14 psi)

2.9 liter (0,75 USgal)

10 : 45 t

1/2 x 3/16" (415) 94 rolls

11 : 45 t 11 : 45 t

1/2 x 3/16" (415) 102 rolls

895 mm (35.2 in)

63°

910 mm (35.8 in) 1030 mm (40.5“)

560 / 585 mm (22 / 23 in) (adjustable)

205 mm (8 in)

39 kg (86 lbs)

S5-E

585 / 610 mm (23 / 24 in) (adjustable) 650 / 675 mm (25.6 / 26.6 in) (adjustable)

230 mm (9.05 in) 255 mm (10 in)

39.5 kg (87.2 lbs) max. 130 cm (51 in)

40.5 kg (89.4 lbs) max 35 kg (78 lbs)

4 to 6 years

S5-GS

7 to 8 years

S5-GS

STANDARD-ADJUSTMENT – FORK

50 Mini Adventure

Spring

Spring preload

Capacity per fork leg

Fork oil

2,55 N/mm

10 mm (0.4 in)

––

––

50 SX Junior

50 JR Adventure

2,55 N/mm

20 mm (0.8 in) ca 150 ccm

SAE 7.5

50 SX Senior

50 SR Adventure

2,55 N/mm

15 mm (0.6 in) ca 160 ccm

SAE 7.5

TIGHTENING TORQUES

Hexagon nuts front axle

Hexagon nuts rear axle

Hexagon nut swing arm bolt

Clamping screw upper fork bridge

Clamping screw lower fork bridge

Other screws chassis

M12x1

M12x1

M10

M8

M8

M6

M8

M10

30 Nm (22 ft.lb)

30 Nm (22 ft.lb)

20 Nm (15 ft.lb)

15 Nm (11 ft.lb)

15 Nm (11 ft.lb)

10 Nm (7 ft.lb)

25 Nm (19 ft.lb)

45 Nm (33 ft.lb)