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KTM 50 SX 2020, Owner'S Manual, Page: 124 / 141

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KTM 50 SX 2020 Owner'S Manual Download Page 124

20 TROUBLESHOOTING

122

Faults

Possible cause

Action

Engine overheats

Bent radiator hose

–

Change the radiator hose.

White smoke emission (steam
in exhaust gas)

Damaged cylinder head or
cylinder head gasket

–

Check the cylinder head or cylinder
head gasket.

Gear oil exits at the vent hose

Too much gear oil added

–

Check the gear oil level. (

p. 106)

Water in the gear oil

Damaged shaft seal ring or
water pump

–

Check the shaft seal ring and water
pump.

Summary of Contents for 50 SX 2020

Page 1: ...OWNER S MANUAL 2020 50 SX 50 SX Mini Art no 3213996en...

Page 2: ......

Page 3: ...ces 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 produc tion of a particular model wi...

Page 4: ...n preparing for first use 19 7 2 Running in the engine 21 8 RIDING INSTRUCTIONS 22 8 1 Checks and maintenance measures when preparing for use 22 8 2 Starting the vehicle 22 8 3 Starting off 23 8 4 Rid...

Page 5: ...ing 69 11 41 Checking the rubber grip 70 11 42 Additionally securing the rubber grip 70 12 BRAKE SYSTEM 71 12 1 Checking play of handbrake lever 71 12 2 Adjusting the play of the hand brake lever 71 1...

Page 6: ...1 Cleaning the motorcycle 116 19 STORAGE 118 19 1 Storage 118 19 2 Preparing for use after storage 119 20 TROUBLESHOOTING 120 21 TECHNICAL DATA 123 21 1 Engine 123 21 2 Engine tightening torques 123...

Page 7: ...There 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 Indicat...

Page 8: ...instruction and all further instructions included carefully The safety instructions are highlighted in the text and are referred to at the relevant passages Info Various information and warning label...

Page 9: ...e operation Danger Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others Do not operate the vehicle if you are not fit to ride due to alcohol drugs or medicati...

Page 10: ...ce work check the operating safety of the vehicle 2 9 Environment If you use your motorcycle responsibly you can ensure that problems and conflicts do not occur To protect the future of the motorcycle...

Page 11: ...SAFETY ADVICE 2 9 The Owner s Manual is also available for download from your authorized KTM dealer and on the KTM website International KTM Website http www ktm com...

Page 12: ...4 Service A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly carried out as described in the Owner s...

Page 13: ...VIEW OF VEHICLE 4 11 4 1 View of vehicle front left example F02182 10 1 Fuel tank filler cap 2 Quick release of seat 3 Chain guide 4 Plug in stand p 18 5 Choke 6 Fuel tap p 17...

Page 14: ...w of vehicle rear right example F02183 10 1 Kill switch p 15 2 Throttle grip p 15 3 Hand brake lever p 15 4 Vehicle identification number p 13 5 Kick starter lever p 18 6 Foot brake lever p 18 7 Level...

Page 15: ...the right side of the steering head 5 2 Type label 402154 10 50 SX The type label 1 is located on the front frame tube 401946 10 50 SX Mini Type label 1 is fixed to the front of the steering head 5 3...

Page 16: ...e of the axle clamp 5 5 Shock absorber article number H01186 10 50 SX The shock absorber article number 1 is stamped on the bot tom of the shock absorber toward the right hand side 401948 11 50 SX Min...

Page 17: ...circuit is closed and the engine can be started Kill switch pressed In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start 6 4 Opening the...

Page 18: ...lls on them Keep fuels correctly in a suitable canister and out of the reach of children Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter t...

Page 19: ...ing the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel This results in a richer fuel air mixture which is needed for a cold start Info If the engine i...

Page 20: ...located in front 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 1 is located on the frame on the left side of the...

Page 21: ...such as helmet boots gloves as well as trousers and a jacket with protectors on all rides Alway use protective clothing for your child that is in good condition and meets the legal require ments When...

Page 22: ...sure that the basic settings of the chassis are suitable for the weight of your child Allow your child to become accustomed to the handling of the motorcycle on suitable terrain preferably on a large...

Page 23: ...in the engine During the running in phase do not exceed the specified engine performance Guideline Maximum engine performance During the first 3 operating hours 70 During the first 5 operating hours 1...

Page 24: ...eck the tire condition p 91 Check tire pressure p 92 Check the spoke tension p 93 Info The spoke tension must be checked regularly as incor rect spoke tension will strongly impair riding safety Clean...

Page 25: ...tep on the kick starter lever pushing it all the way forward Info Do not open the throttle Final steps Remove the motorcycle from the lift stand p 41 8 3 Starting off Info The plug in stand must be re...

Page 26: ...if the engine is running Protect the vehicle against access by unauthorized persons Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch any parts...

Page 27: ...he vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immed...

Page 28: ...ngine oil 1 60 p 131 Close the fuel tank filler cap p 16 8 9 Filling up with oil 50 SX Mini Warning Engine damage The engine will not be lubricated unless there is 2 stroke oil in the oil tank For a f...

Page 29: ...t brake lever p 78 Check the frame p 69 Check the link fork p 69 Check the fork bearing for play Check the heim joint for play Check the tire condition p 91 Check tire pressure p 92 Check the wheel be...

Page 30: ...erating hours Once after 20 operating hours Every 20 operating hours Once after 10 operating hours every 12 months Change the front brake fluid Change the rear brake fluid Change the rear brake fluid...

Page 31: ...nsion is located in the left fork leg and damping in the right fork leg As fork springs are no longer required a significant weight advantage is achieved when compared to conventional forks The respon...

Page 32: ...the compression damping in the low speed range and vice versa 10 4 Adjusting the low speed compression damping of the shock absorber 50 SX Caution Risk of injury Parts of the shock absorber will move...

Page 33: ...fitting 2 Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline High speed compression damping Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Info Turn c...

Page 34: ...t stand p 41 V00257 10 Remove nut 1 V00258 10 Remove screw 2 Pull the shock absorber out of the support and push the rear wheel upwards V00259 10 Turn adjusting screw 3 clockwise up to the last percep...

Page 35: ...a marking on the side cover Note the value as dimension A Finishing work Remove the motorcycle from the lift stand p 41 10 8 Checking the static sag of the shock absorber 400989 10 Measure dimension...

Page 36: ...just the riding sag p 36 10 10 Adjusting the spring preload of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The...

Page 37: ...down the value Loosen retaining ring 1 Turn adjusting ring 2 until the spring is no longer under tension Hook wrench T304 Hook wrench T1533 Measure the total spring length while the spring is not unde...

Page 38: ...35 kg 55 77 lb 35 N mm 200 lb in Weight of rider 35 45 kg 77 99 lb 40 N mm 228 lb in Spring rate 50 SX Mini Weight of rider 15 25 kg 33 55 lb 65 N mm 371 lb in Weight of rider stan dard 25 35 kg 55 77...

Page 39: ...ng may seriously alter the handling characteris tic Extreme modifications to the suspension setting may cause a serious deterioration in the handling char acteristic and overload components Only make...

Page 40: ...isconnecting excess pressure will escape from the hose the fork leg itself does not lose any air The fork airpump indicator switches off automatically after 80 seconds Mount the protection cap Info On...

Page 41: ...epaired handlebar poses a safety risk If the handlebar is bent or straightened the material becomes fatigued The handlebar may break as a result Change the handlebar if the handlebar is damaged or ben...

Page 42: ...ing characteristic Preparatory work Raise the motorcycle with a lift stand p 41 E00746 10 Main work Remove nut 1 E00745 10 Hold the rear wheel with the link fork and remove screw 2 Position the shock...

Page 43: ...rcycle from the lift stand Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 402581 10 Remove the motorcycle from the lift stand Remove t...

Page 44: ...remove dust and coarse dirt particles from the inside fork tubes Over time dirt can accumu late behind the dust boots If this dirt is not removed the seals rings behind can start to leak Warning Dange...

Page 45: ...ork pro tector 11 6 Installing the fork protector V00267 10 Position fork protector on the right fork leg Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft V00266 11 Po...

Page 46: ...to hang loosely to the side Info Do not kink the brake line V00269 10 50 SX Loosen screws 3 Remove the left fork leg Loosen screws 4 Remove the right fork leg V00268 10 50 SX Mini Loosen screws 3 Remo...

Page 47: ...triple clamp V00268 11 Tighten screws 2 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft E00762 10 Position the brake ca...

Page 48: ...the handlebar and set aside Info Cover the components to protect them against damage Do not kink the cables and lines V00273 10 Remove protective ring 4 Remove the lower triple clamp with the steerin...

Page 49: ...e upper edge of the upper triple clamp V00274 10 Tighten screws 6 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft F02190 10 Tighten nut 4 Guideline Nut steering head M20x1 5 10 Nm 7 4 lbf ft...

Page 50: ...t Position the fuel tank breather 7 in the steering stem F02193 11 Tighten screw 8 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to...

Page 51: ...perated for a lengthy period with play in the steering head bearing the bearings and the bearing seats in the frame can become damaged over time Preparatory work Raise the motorcycle with a lift stand...

Page 52: ...ten screws 2 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Position the fuel tank breather 1 in the steering stem F02194 10 50 SX Mini Pull fuel tank breather 1 out of the steering stem Loosen...

Page 53: ...y fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immed...

Page 54: ...lled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health haz...

Page 55: ...ather in the steering stem Finishing work Mount the seat p 57 11 16 Removing the start number plate H01425 10 Remove screw 1 Unhook the start number plate from the brake line and remove it 11 17 Insta...

Page 56: ...rt number plate H01428 11 Position front fender Mount and tighten screws 2 Guideline Screw fender M6 6 Nm 4 4 lbf ft 11 20 Removing the shock absorber Preparatory work 50 SX Raise the motorcycle with...

Page 57: ...protector 5 to the side and remove the shock absorber 11 21 Installing the shock absorber Warning Danger of accidents Modifications to the suspension setting may seriously alter the handling character...

Page 58: ...ide Position the shock absorber with screw 2 depending on the desired seating height Raise the link fork position the shock absorber with screw 3 V00279 11 Mount nut 4 and tighten the fitting Guidelin...

Page 59: ...and dirt will enter the engine without an air filter Never start to use the vehicle without an air filter Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils gre...

Page 60: ...of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Do not clean the air filter with fuel or petroleum since these substances...

Page 61: ...e silent block with screw 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the collar bushings Mount and tighten screw 3 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 29 C...

Page 62: ...de the outer tube over the glass fiber yarn filling Insert the end cap into the outer tube Mount and tighten the screws with the toothed washers Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft...

Page 63: ...engine sprocket cover M6 10 Nm 7 4 lbf ft H01436 10 50 SX Mini Position the engine sprocket cover Mount screws 1 but do not tighten yet Mount and tighten screw 2 Guideline Screw engine sprocket cover...

Page 64: ...motorcycle with a lift stand p 41 400725 01 Main work Rinse off loose dirt with a soft jet of water Remove old grease residue with chain cleaner Chain cleaner p 132 After drying apply chain spray Off...

Page 65: ...erent chain positions Chain tension 5 8 mm 0 2 0 31 in If the chain tension does not meet the specification Adjust the chain tension p 63 Finishing work Remove the motorcycle from the lift stand p 41...

Page 66: ...ts 2 Make sure that chain adjusters 4 are fitted correctly on adjusting screws 3 Tighten nut 1 Guideline Nut rear wheel spindle M12x1 40 Nm 29 5 lbf ft 101947 10 50 SX Mini Loosen nut 1 Adjust the cha...

Page 67: ...cover 400227 01 Check the rear sprocket and the engine sprocket for wear If the rear sprocket or engine sprocket is worn Change the drivetrain kit Info The engine sprocket rear sprocket and chain shou...

Page 68: ...g piece M6 3 Nm 2 2 lbf ft F02200 10 Check the chain sliding piece for wear If the lower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece Check th...

Page 69: ...ing guard Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the screw of the chain sliding guard Guideline Screw chain sliding piece M6 3 Nm 2 2 lbf ft V0...

Page 70: ...s chassis M6 10 Nm 7 4 lbf ft Finishing work Install the engine sprocket cover p 61 Remove the motorcycle from the lift stand p 41 11 37 Adjusting the chain guide Info The size of the chain wheel vari...

Page 71: ...ing the link fork is not authorized by KTM F02203 01 50 SX Mini Check the link fork for damage cracking and deformation If the link fork shows signs of damage cracking or deformation Change the link f...

Page 72: ...the rubber grip 401197 01 Check the rubber grips on the handlebar for damage wear and looseness If a rubber grip is damaged worn or loose Change the rubber grip Rubber grip adhesive 00062030051 p 133...

Page 73: ...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 71 12 2 Adjusting the play of the hand brake lever H00098 10 Check the play of the han...

Page 74: ...rn out brake discs are replaced immediately Your authorized KTM workshop will be glad to help 400257 10 Check the front and rear brake disc thickness at multiple points for the dimension A Info Wear r...

Page 75: ...brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in...

Page 76: ...inse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If b...

Page 77: ...accidents Worn out brake linings reduce the braking effect Ensure that worn out brake linings are replaced immediately Your authorized KTM workshop will be glad to help H01441 10 Check the brake lini...

Page 78: ...Not all brake linings are tested and approved for KTM motorcycles The structure and friction coefficient of the brake linings and thus their brake power may vary greatly from that of original brake l...

Page 79: ...ring Mount and tighten screw 7 Guideline Screw brake linings M5 8 Nm 5 9 lbf ft Mount lock ring 6 Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep th...

Page 80: ...immedi ately with water 12 9 Checking the free travel of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brak...

Page 81: ...t brake lever needs to be adjusted Adjust the basic position of the foot brake lever p 79 12 11 Adjusting the basic position of the foot brake lever Warning Danger of accidents The brake system fails...

Page 82: ...f an air bubble is visible in viewer 1 Add rear brake fluid p 80 12 13 Adding rear brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the...

Page 83: ...als and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container Preparatory...

Page 84: ...he rear brake p 82 Check the brake linings for damage and cracking If damage or wear is encountered Change the brake lingings of the rear brake p 82 12 15 Changing the brake linings of the rear brake...

Page 85: ...ion is not guaranteed In this case the vehicle no longer corresponds to its condition at delivery and the warranty shall be void Only use brake linings approved and recommended by KTM Note Environment...

Page 86: ...Ensure that the brake linings are correctly posi tioned in the holding spring Position the brake caliper on the brake disc The brake linings are correctly positioned F02206 10 Mount and tighten screw...

Page 87: ...brake fluid does not flow out of the brake fluid reservoir extract some if necessary F02167 10 Position the new brake linings Info Always change the brake linings in pairs Ensure that the brake lining...

Page 88: ...point Add brake fluid up to level A Guideline Level A brake fluid level below reservoir rim 10 mm 0 39 in Brake fluid DOT 4 DOT 5 1 p 130 Position cover with washer and membrane Mount and tighten the...

Page 89: ...own in such a way that the brake disc is not damaged Hold the front wheel and remove the wheel spindle Take the front wheel out of the fork Info Do not actuate the hand brake lever when the front whee...

Page 90: ...heel spindle H01451 10 Mount and tighten screw 1 Guideline Screw front wheel spindle M10 40 Nm 29 5 lbf ft Loctite 243 Operate the hand brake lever several times until the brake lin ings are seated co...

Page 91: ...disc is not damaged Hold the rear wheel and remove the wheel spindle Take the rear wheel out of the link fork Info Do not operate the foot brake lever when the rear wheel is removed F02175 10 Remove s...

Page 92: ...1 Main work Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the rear wheel bearing Clean and grease the contact surfaces A of the spacers Long life grease p...

Page 93: ...yet Make sure that the chain adjuster support plates are in contact with the adjusting nuts Check the chain tension p 62 Tighten nut 4 Guideline Nut rear wheel spindle M12x1 40 Nm 29 5 lbf ft Operate...

Page 94: ...s of the DOT number The first two digits indicate the week of manufacture and the last two digits the year of manu facture KTM recommends that the tires be changed after 5 years at the latest regardle...

Page 95: ...ult Check spoke tension regularly and in particular on a new vehicle Your authorized KTM workshop will be glad to help 400694 01 Strike each spoke briefly using a screwdriver blade Info The frequency...

Page 96: ...es 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 cool...

Page 97: ...h plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clot...

Page 98: ...adiator cap Completely drain the coolant Mount and tighten screw 1 with a new seal ring Guideline Drain plug water pump cover M6 6 Nm 4 4 lbf ft 14 5 Refilling with coolant Warning Danger of poisoning...

Page 99: ...of the air to be able to escape from the cooling system the vehicle must be raised at the front If the cooling system is poorly de aerated its cooling power will be reduced and the engine may overhea...

Page 100: ...g throttle cable play Preparatory work Check the installation position of the throttle grip p 98 400192 11 Main work Check the throttle grip for smooth operation Move the handlebar to the straight ahe...

Page 101: ...ttle grip Guideline Throttle cable play 3 5 mm 0 12 0 2 in Tighten nut 3 Slide on sleeve 1 Finishing work Install the fuel tank p 52 Mount the seat p 57 Check the throttle cable play p 98 15 4 Carbure...

Page 102: ...the way and turn it to the specified basic setting Guideline Idle air adjusting screw Open 3 turns Run the engine until warm Guideline Warming up phase 5 min Danger Danger of poisoning Exhaust gases a...

Page 103: ...basic setting Guideline Idle air adjusting screw Open 1 turn Run the engine until warm Guideline Warming up phase 5 min Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result...

Page 104: ...ust the idle speed again 15 8 Checking the clutch setting 102041 10 Connect special tool 1 Tachometer 45129075000 401521 01 Let the front wheel of the vehicle make contact with a fixed object Danger D...

Page 105: ...Remove clutch cover 2 with the seal ring 15 10 Adjusting the clutch Preparatory work Remove the clutch cover p 103 H01459 10 Main work Turn the outer clutch hub 1 until adjusting screws 2 become acces...

Page 106: ...urn adjusting screws 2 counterclockwise Guideline 1 click decreases the slip speed by 250 350 rpm Finishing work Install the clutch cover p 104 Check the gear oil level p 106 Check the clutch setting...

Page 107: ...evel in the oil tank For a full fuel tank the oil tank must be filled up toMIN mark A at a minimum If the oil level does not meet specifications Fill up with oil p 26 16 2 Bleeding the oil pump 50 SX...

Page 108: ...pump Mount and tighten screws 2 Guideline Screw oil pump M5 6 Nm 4 4 lbf ft 16 3 Checking the gear oil level Condition The engine is cold Preparatory work Stand the motorcycle upright on a horizontal...

Page 109: ...h lukewarm water Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the appl...

Page 110: ...3 p 131 Info Too little gear oil or poor quality gear oil results in pre mature wear to the transmission Mount and tighten filler plug 2 with the O ring Danger Danger of poisoning Exhaust gases are to...

Page 111: ...exron 3 p 131 Mount and tighten gear oil level monitoring screw 1 Guideline Screw gear oil level monitoring M6 6 Nm 4 4 lbf ft Mount and tighten filler plug 2 with the O ring Danger Danger of poisonin...

Page 112: ...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 contact rinse the affected area w...

Page 113: ...efuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spi...

Page 114: ...2 Loosen hose clip 3 R00566 10 Push back hose clamp 4 and pull off the vent hose Pull the carburetor out of the intake flange Pull the carburetor forward out of the inlet sleeve R04490 10 Remove thro...

Page 115: ...retainer 2 Position the throttle slide spring R04499 11 Position the throttle slide and throttle slide cover Mount and tighten screw 3 Guideline Screw throttle slide cover M5 3 Nm 2 2 lbf ft T00392 11...

Page 116: ...X G01287 11 Main work Attach throttle cable wire 1 Position the spring retainer and throttle slide spring T03275 10 Position the throttle slide and throttle slide cover Tighten throttle slide cover 2...

Page 117: ...engine breather hose and position clamp 3 R04489 11 Mount the inlet sleeve Position and tighten hose clip 4 Position and tighten hose clip 5 R00564 11 Mount fuel hose 6 Finishing work Check the throt...

Page 118: ...ver a long period Avoid direct sunshine when cleaning the motorcycle 401061 01 Close off the exhaust system to keep water from entering Remove loose dirt first with a soft jet of water Spray heavily s...

Page 119: ...After the motorcycle has cooled off lubricate all moving parts and pivot points Clean the chain p 62 Treat bare metal except for brake discs and the exhaust sys tem with a corrosion inhibitor Preserv...

Page 120: ...riod less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 401058 01 When refueling for the last time before taking the motorcycle out of service...

Page 121: ...STORAGE 19 119 19 2 Preparing for use after storage 401059 01 Remove the motorcycle from the lift stand p 41 Perform checks and maintenance measures when preparing for use p 22 Take a test ride...

Page 122: ...ult in ignition system Check the ignition system Short circuit cable in wiring harness frayed kill switch defective Check the kill switch The connector or ignition coil is loose or oxidized Clean the...

Page 123: ...silencer p 59 Ignition system defective Check the ignition coil Check the spark plug connector Diaphragm or reed valve hous ing damaged Check the diaphragm and reed valve housing Noticeable wear Over...

Page 124: ...smoke emission steam in exhaust gas Damaged cylinder head or cylinder head gasket Check the cylinder head or cylinder head gasket Gear oil exits at the vent hose Too much gear oil added Check the gea...

Page 125: ...R 8 B Spark plug electrode gap 0 60 mm 0 0236 in Cooling Water cooled Starting aid Kick starter system 21 2 Engine tightening torques Screw bearing retainer M5 5 Nm 3 7 lbf ft Screw kick starter lever...

Page 126: ...mary gear wheel M10x1 25 40 Nm 29 5 lbf ft Loctite 243 Nut rotor M10x1 25 15 Nm 11 1 lbf ft Loctite 243 Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft 21 3 Carburetor with carburetor tuning 21 3...

Page 127: ...ini WP Suspension XACT 5035 Shock absorber 50 SX WP Suspension XACT 5735 Shock absorber 50 SX Mini WP Suspension XACT 5435 Suspension travel 50 SX front 205 mm 8 07 in rear 185 mm 7 28 in Suspension t...

Page 128: ...xxis MAXX CROSS SI 2 75 10 38J TT Maxxis MAXX CROSS SI The tires specified represent one of the possible series production tires Additional information is available in the Service section under http w...

Page 129: ...2 clicks High speed compression damping Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 3 mm 0 12 in Spring rate...

Page 130: ...joint on foot brake cylinder M6 10 Nm 7 4 lbf ft Remaining nuts chassis M6 10 Nm 7 4 lbf ft Remaining screws chassis M6 10 Nm 7 4 lbf ft Screw chain sliding piece M6 3 Nm 2 2 lbf ft Screw fender M6 6...

Page 131: ...iple clamp M8 20 Nm 14 8 lbf ft Nut link fork pivot M10 45 Nm 33 2 lbf ft Remaining nuts chassis M10 45 Nm 33 2 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw bottom shock absorber M10 45...

Page 132: ...irements stated see specifications on the container and that has the relevant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze prot...

Page 133: ...ntainer and that exhibit the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or...

Page 134: ...er High viscosity grease Recommended supplier SKF LGHB 2 Long life grease Recommended supplier MOTOREX Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX Moto Clean Multi purpose grease...

Page 135: ...upplier MOTOREX Moto Protect Rubber grip adhesive 00062030051 Recommended supplier KTM AG GRIP GLUE Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommended supplier...

Page 136: ...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 Automoti...

Page 137: ...LIST OF ABBREVIATIONS 25 135 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 138: ...g 101 installing 113 114 removing 110 111 Chain checking 65 cleaning 62 Chain guide adjusting 68 checking 65 Chain tension adjusting 63 checking 62 Choke 17 Cleaning 116 117 Clutch adjusting 103 setti...

Page 139: ...d compression damping shock absorber adjusting 30 M Main silencer glass fiber yarn filling changing 59 installing 59 removing 59 Manufacturer warranty 10 Misuse 6 Motorcycle cleaning 116 lift stand ra...

Page 140: ...teering head bearing play adjusting 50 checking 49 Storage 118 T Technical data capacities 125 carburetor 124 chassis 125 chassis tightening torques 128 engine 123 engine tightening torques 123 fork 1...

Page 141: ...3213996en 3213996en 03 2019 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KISKA KTM...

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