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KTM 50 SX 2017, Owner'S Manual

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KTM 50 SX 2017 Owner'S Manual Download Page 58

12

BRAKE SYSTEM

56

12.1

Checking play of handbrake lever

H00073-10

–

Push the handbrake lever forwards and check the play

.

Play of hand brake lever

3… 5 mm (0.12… 0.2 in)

» If the play does not meet specifications:

–

Adjust the play of the hand brake lever. (

p. 56)

12.2

Adjusting the play of the hand brake lever

H00098-10

–

Check the play of the handbrake lever. (

p. 56)

–

Adjust the play of the hand brake lever with the adjusting screw

.

Guideline

Play of hand brake lever

3… 5 mm (0.12… 0.2 in)

12.3

Adjusting the basic position of the hand brake lever

H00098-11

–

Remove screw

. Take off cover

.

H00099-10

–

Check the play of the handbrake lever. (

p. 56)

–

Adjust the basic position of the hand brake lever with adjusting screw

to the

rider's hand size.

Info

Turn the adjusting screw clockwise to increase the distance between the
hand brake lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the hand brake lever and the handlebar.
The range of adjustment is limited.

H00098-11

–

Position cover

. Mount and tighten screw

.

Summary of Contents for 50 SX 2017

Page 1: ...OWNER S MANUAL 2017 50 SX 50 SX Mini Art no 3213469en...

Page 2: ......

Page 3: ...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 acce...

Page 4: ...ompression damping of the shock absorber 50 SX 25 10 6 Adjusting the rebound damping of the shock absorber 26 10 7 Measuring rear wheel sag unloaded 27 10 8 Checking the static sag of the shock absorb...

Page 5: ...14 1 Cooling system 71 14 2 Checking the antifreeze and coolant level 71 14 3 Checking the coolant level 72 14 4 Draining the coolant 72 14 5 Refilling with coolant 73 15 TUNING THE ENGINE 74 15 1 Che...

Page 6: ...here your motorcycle will be optimally cared for by specially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page Indicate...

Page 7: ...onmental damage if the appropriate measures are not taken 2 4 Tampering warning Tampering with the noise control system is prohibited Federal law prohibits the following acts or the causing thereof 1...

Page 8: ...ings pins lock washers must be replaced by new parts In some instances a thread locker e g Loctite is required The manufacturer instructions for use must be followed After disassembly clean the parts...

Page 9: ...current KTM PowerParts for your vehicle can be found on the KTM website International KTM Website http www ktm com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is...

Page 10: ...4 VIEW OF VEHICLE 8 4 1 View of vehicle front left example H01462 10 1 Filler cap 2 Quick release of seat 3 Chain guide 4 Plug in stand p 15 5 Choke p 14 6 Fuel tap p 14...

Page 11: ...9 4 2 View of vehicle rear right example H01463 10 1 Kill switch p 12 2 Throttle grip p 12 3 Hand brake lever p 12 4 Chassis number p 10 5 Kick starter p 14 6 Foot brake lever p 15 7 Level viewer for...

Page 12: ...0 SX The type label is located on the front frame tube 402007 11 50 SX Mini The type label is located on the frame at the front right 5 3 Engine number 401949 10 The engine number is located on the le...

Page 13: ...number H01186 10 50 SX The shock absorber article number is stamped on the bottom of the shock absorber towards the rear 0 0 1 1 401948 11 50 SX Mini The shock absorber article number is stamped on t...

Page 14: ...ghly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling M...

Page 15: ...counterclockwise and pull it up 6 5 Closing filler cap V00252 11 Put the tank cap on and turn it clockwise Info Run the fuel tank breather hose without kinks 6 6 Opening oil tank cap 50 SX Mini V0025...

Page 16: ...function activated Choke knob is in upper position The O ring is visible Choke function deactivated Choke knob is in lower position The O ring is not visible 6 10 Choke 50 SX Mini H00086 10 The choke...

Page 17: ...of the right footrest The rear brake is engaged with the foot brake lever 6 13 Plug in stand 402581 10 The fixture for plug in stand is located on the frame on the left side of the vehicle The plug i...

Page 18: ...ng Warning Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling characteristic Different tire tread patterns can make the vehicle significantly more difficu...

Page 19: ...ur child ride 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 rid...

Page 20: ...for tightness Check the fuel supply 8 2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient vent...

Page 21: ...the wheels Explain to your child that he or she must adapt the braking to the traffic situation and the road conditions Warning Danger of accidents A spongy pressure point on the front or rear brake r...

Page 22: ...hazard Hot vehicle components pose a fire hazard and explosion risk Do not park the vehicle near to materials which are highly flammable or explosive Allow the vehicle to cool down before covering it...

Page 23: ...5 RON 95 PON 91 p 94 Fuel tank capacity approx 50 SX 2 3 l 2 4 qt Super unleaded 95 octane mixed with 2 stroke engine oil 1 60 p 94 Close the filler cap p 13 8 9 Filling up with oil 50 SX Mini Warning...

Page 24: ...n p 70 Check the chain rear sprocket engine sprocket and chain guide p 52 Check the chain tension p 51 Grease all moving parts e g hand lever chain and check for smooth operation Check the front brake...

Page 25: ...d bearing p 42 Check adjust the carburetor components Perform minor engine service Change the spark plug Check the cylinder and piston Check the inlet mem brane Perform major engine service including...

Page 26: ...the left fork leg as an end stop Info If the fork is frequently overloaded then the air pressure in the fork must be increased to avoid damage to the fork and frame The air pressure in the fork can be...

Page 27: ...15 clicks Sport 12 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 10 5 Adjusting the high speed compression damping of the shock absorber 50 SX Caution Risk o...

Page 28: ...the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase damping turn counterclockwi...

Page 29: ...n the side cover Make a note of the value as measurement Finishing work Remove the motorcycle from the lift stand p 34 10 8 Checking the static sag of the shock absorber 0 0 A A 0 0 B B 400989 10 Meas...

Page 30: ...hock absorber is disassembled incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized KTM workshop will be glad to help Preparat...

Page 31: ...e from the lift stand p 34 10 11 Adjusting the riding sag Preparatory work 50 SX Raise the motorcycle with a lift stand p 34 50 SX Mini Raise the motorcycle with a lift stand p 34 Remove the rear whee...

Page 32: ...eme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components Only make adjustments within the recommended range Make sure your c...

Page 33: ...Turn counterclockwise by the number of clicks corresponding to the fork type Guideline Rebound damping Comfort 15 clicks Standard 12 clicks Sport 10 clicks Info Turn clockwise to increase damping tur...

Page 34: ...e positioned correctly Position the handlebar clamps Fit and evenly tighten the screws Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Info Make sure the gap width is even 10 17 Adjusting the sea...

Page 35: ...10 TUNING THE CHASSIS 33 V00264 10 Mount nut and tighten fitting Guideline Screw top shock absorber M10 45 Nm 33 2 lbf ft Loctite 243 Finishing work Remove the motorcycle from the lift stand p 34...

Page 36: ...Park the vehicle on a firm and level surface 402581 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle insert plug in stand into the plug in stand bracket on th...

Page 37: ...the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray p 96 Press the du...

Page 38: ...screws and take off the clamp Remove screws and take off the brake caliper Allow the brake caliper and brake line to hang loosely to the side V00269 10 50 SX Loosen screws Take out the left fork leg L...

Page 39: ...1 lbf ft V00271 10 Position the brake caliper and mount and tighten screws Guideline Screw front brake caliper M8 20 Nm 14 8 lbf ft Loctite 243 Position the brake line and clamp Mount and tighten scre...

Page 40: ...r triple clamp with the steering stem Mount upper steering head bearing Check whether upper steering head seal is correctly positioned Push on protective ring V00282 10 Position the upper triple clamp...

Page 41: ...deline Screw top triple clamp M8 20 Nm 14 8 lbf ft H01183 10 50 SX Mini Position the fork legs Bleeder screws are positioned toward the front Info The second milled groove in the fork leg must be flus...

Page 42: ...irs the handling characteristic and damages components Correct incorrect steering head bearing play immediately Your authorized KTM workshop will be glad to help Info If the bike is ridden with play i...

Page 43: ...Tighten screws Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Position the fuel tank breather in the steering stem H01423 10 50 SX Mini Pull fuel tank breather out of the steering stem Loosen s...

Page 44: ...rning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin...

Page 45: ...you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with...

Page 46: ...H01427 10 Mount and tighten screw Guideline Screw start number plate M6 4 Nm 3 lbf ft 11 18 Dismounting the front fender H01428 10 Remove screws Remove the front fender 11 19 Installing the front fend...

Page 47: ...t blocking the rear wheel Secure the rear wheel in this position Remove screw push splash protector to the side and remove the shock absorber V00279 10 50 SX Mini Remove nut and V00280 10 Remove screw...

Page 48: ...ft Loctite 243 V00280 11 50 SX Mini Push splash protector to the side Position the shock absorber with screw depending on the desired seating height Raise the swingarm position the shock absorber wit...

Page 49: ...ental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regu lations Preparatory work Remove the seat p 46 H01432 10 Main work...

Page 50: ...Oil the dry air filter with a high quality filter oil Oil for foam air filter p 95 Clean the air filter box Check the intake flange for damage and looseness Finishing work Install the air filter p 47...

Page 51: ...ncer cap Remove end cap and outer tube Remove glass fiber yarn filling from the inner tube Clean the parts that need to be reinstalled and check for damage Mount the new glass fiber yarn filling on th...

Page 52: ...ycle from the lift stand p 34 11 32 Checking the chain for dirt 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 50 11 33 Cleaning the chain Warning...

Page 53: ...in tension regularly Set the chain tension in accordance with the specification Preparatory work Raise the motorcycle with a lift stand p 34 H01438 10 Main work 50 SX Press the chain upward at the end...

Page 54: ...2 0 31 in Turn adjusting nuts equally on the left and right The rear wheel must be aligned with the front wheel Make sure that the chain adjuster support plates are in contact with adjusting nuts Tig...

Page 55: ...the screw of the chain sliding guard Guideline Screw chain sliding piece M6 3 Nm 2 2 lbf ft V00285 01 Check the chain sliding piece for wear If the lower edge of the chain pins is in line with or bel...

Page 56: ...10 Loosen screw Position the chain guide Tighten the screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 38 Checking the frame S00876 01 Check the frame for cracks and deformation If the...

Page 57: ...must be routed to the carburetor behind the handlebars and above the fuel tank bracket If the throttle cable is not routed as specified Correct the throttle cable routing Finishing work Install the fu...

Page 58: ...rew Guideline Play of hand brake lever 3 5 mm 0 12 0 2 in 12 3 Adjusting the basic position of the hand brake lever H00098 11 Remove screw Take off cover H00099 10 Check the play of the handbrake leve...

Page 59: ...minated Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and...

Page 60: ...ive clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area...

Page 61: ...arning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into conta...

Page 62: ...voir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Press the brake piston back into the basic position and ensure that brake fluid does not flow out of the...

Page 63: ...sc and there is a pressure point Correct the brake fluid level Guideline Brake fluid level under top level of con tainer 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 93 Position the cover with the membrane...

Page 64: ...er spring Check whether the basic position of the foot brake lever is suitable for the rider When the basic position of the foot brake lever needs to be adjusted Adjust the basic position of the foot...

Page 65: ...be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid t...

Page 66: ...he minimum thickness is less than specified Change the rear brake linings p 64 Check the brake linings for damage and cracking If damage or wear is encountered Change the rear brake linings p 64 12 15...

Page 67: ...al hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regu lations Info Never us...

Page 68: ...ite 243 Mount screw Guideline Screw brake linings M5 8 Nm 5 9 lbf ft Mount lock washer Check the brake discs p 57 H01187 10 Operate the foot brake lever repeatedly until the brake linings are in conta...

Page 69: ...is removed H00934 10 Remove spacers 13 2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and...

Page 70: ...a lift stand p 34 V00281 10 Main work Remove nut with washer Info Cover the components to protect them against damage Pull out wheel spindle with washer Remove the chain from the rear sprocket Warning...

Page 71: ...bf ft Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand p 34 13...

Page 72: ...of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage The spokes break due to being overloaded if they are too tightly tensioned If the tension in...

Page 73: ...ses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coo...

Page 74: ...rface Remove the radiator cap Check the coolant level in the radiator Coolant level above the radiator fins 10 mm 0 39 in If the coolant level does not match the specified value Correct the coolant le...

Page 75: ...h water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing H00105 10 Main work Make sure that screw is tightened Position the motorcycl...

Page 76: ...t the play in the throttle cable p 74 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when...

Page 77: ...tting of the carburetor has a big influence on the starting behavior stable idling and the response to throttle opening This means that an engine with a correctly set idle speed is easier to start tha...

Page 78: ...r temperature or altitude changes adjust the idle speed again 15 7 Carburetor adjusting idle speed 50 SX Mini H00078 10 Screw in idle air adjusting screw all the way and turn it to the specified basic...

Page 79: ...icle make contact with a fixed object Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when...

Page 80: ...ectable click Turn adjusting screws clockwise by 9 clicks to the basic setting Guideline Basic setting of slip speed 8 700 9 300 rpm Info The springs may not be pretensioned by more than 17 clicks fro...

Page 81: ...eck the gear oil level p 81 Check the clutch setting p 77 15 11 Installing the clutch cover H01458 11 Main work Position clutch cover with the seal ring Mount and tighten screws Guideline Screw clutch...

Page 82: ...nk the oil tank must be filled up toMIN mark at a minimum If the oil level does not meet specifications Fill up with oil p 21 16 2 Bleeding the oil pump 50 SX Mini Condition The fuel tank has been rem...

Page 83: ...screw Guideline Screw gear oil level check M6 6 Nm 4 4 lbf ft S00882 10 50 SX Mini Remove gear oil monitoring screw Check the gear oil level A small amount of gear oil should flow out If no gear oil...

Page 84: ...magnet Clean the sealing surface on the engine Mount and tighten the oil drain plug with magnet and seal ring Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft H01460 10 Remove filler plu...

Page 85: ...3 p 93 Mount and tighten screw in the opening used to check the gear oil level Guideline Screw gear oil level check M6 6 Nm 4 4 lbf ft Mount and tighten filler plug Danger Danger of poisoning Exhaust...

Page 86: ...r and then clean with a brush Motorcycle cleaner p 95 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry vehicle always rinse with wat...

Page 87: ...new season 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 95 Fill up with fuel p 20 Clean the motorcycle p 84 Change the gear...

Page 88: ...50 SX Check set the carburetor components 50 SX Mini Check set the carburetor components Engine has no idle Idling jet blocked 50 SX Check set the carburetor components 50 SX Mini Check set the carbu...

Page 89: ...intake flange and carburetor for tightness The connector or ignition coil is loose or oxidized Clean the plug in connection and treat it with contact spray Engine overheats Too little coolant in cooli...

Page 90: ...4 lbf ft Screw stator clamp M5 6 Nm 4 4 lbf ft Loctite 222 Screw water pump wheel M5 5 Nm 3 7 lbf ft Loctite 243 Bleeder flange of engine case M6 4 Nm 3 lbf ft Loctite 243 Drain plug water pump cover...

Page 91: ...oil Gear oil 0 20 l 0 21 qt Gear oil ATF Dexron 3 p 93 20 4 2 Coolant Coolant 0 7 l 0 7 qt Coolant p 93 20 4 3 Fuel Fuel tank capacity approx 50 SX 2 3 l 2 4 qt Super unleaded 95 octane mixed with 2...

Page 92: ...50 SX Mini 558 mm 21 97 in Ground clearance unloaded 50 SX 252 mm 9 92 in Ground clearance unloaded 50 SX Mini 184 mm 7 24 in Weight without fuel approx 50 SX 41 5 kg 91 5 lb Weight without fuel appro...

Page 93: ...ems 3614 DCC Compression damping low speed Comfort 18 clicks Standard 15 clicks Sport 12 clicks Compression damping high speed Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Rebound damping Comfor...

Page 94: ...plate M6 4 Nm 3 lbf ft Screw throttle grip M6 4 5 Nm 3 32 lbf ft Nut foot brake lever M8 22 Nm 16 2 lbf ft Nut rim lock M8 10 Nm 7 4 lbf ft Remaining nuts chassis M8 25 Nm 18 4 lbf ft Remaining screws...

Page 95: ...water Recommended supplier Motorex COOLANT M3 0 Engine oil 2 stroke Standard classification JASO FD p 97 Guideline Only use high grade 2 stroke engine oil of a reputable brand Fully synthetic Recomme...

Page 96: ...RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel co...

Page 97: ...ended supplier SKF LGHB 2 Long life grease Recommended supplier Motorex Bike Grease 2000 Motorcycle cleaner Recommended supplier Motorex Moto Clean Off road chain spray Recommended supplier Motorex Ch...

Page 98: ...22 AUXILIARY SUBSTANCES 96 Universal oil spray Recommended supplier Motorex Joker 440 Synthetic...

Page 99: ...irst 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 Automotiv...

Page 100: ...24 LIST OF ABBREVIATIONS 98 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 101: ...g 84 Clutch adjusting 78 setting checking 77 Clutch cover clutch cover removing 77 installing the clutch cover 79 Compression damping high speed shock absorber adjusting 25 Compression damping low spe...

Page 102: ...e advice on first use 16 after storage 85 checks and maintenance measures when preparing for use 18 Protective clothing 6 R Rear sprocket checking 52 Rear wheel installing 68 removing 68 Rebound dampi...

Page 103: ...r 91 tires 90 Throttle cable routing checking 55 Throttle grip 12 Tire air pressure checking 70 Tire condition checking 69 Transport 20 Troubleshooting 86 87 Type label 10 U Use definition 5 V View of...

Page 104: ...3213469en 3213469en 04 2016 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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