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KTM 50 SX MINI 2010, Owner'S Manual, Page: 62 / 85

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KTM 50 SX MINI 2010 Owner'S Manual Download Page 62

MAINTENANCE WORK ON CHASSIS AND ENGINE

60

1

1

2

2

3

3

301870-01

Clutch spring with yellow mark

–

Correct the washer

according to the measured value.

Guideline

A washer of 0.2 mm (0.008 in)
changes the clutch engagement
speed by about:

100 rpm

Info

The spacing washer

of 1.7 mm (0.067 in) and the spacing washer

of 0.5 mm (0.02 in) must always be fitted.
If you fit the washer

, the clutch engagement speed is increased.

If you remove the washer

, the clutch engagement speed is reduced.

–

Assemble the centrifugal clutch.

x

(

p. 62)

–

Fit the centrifugal force clutch.

x

(

p. 61)

–

Check the clutch engagement speed.

x

(

p. 59)

9.92

Removing centrifugal clutch

x

300654-10

–

Remove nut

.

–

Disconnect spring

.

–

Take off the footbrake pedal.

300655-10

–

Lay the motorcycle on its side.

–

Remove screws

.

–

Take off the clutch cover.

300656-10

–

Hold the clutch drum using the special tool

.

Holding spanner (54629012100)

–

Remove screw

.

–

Remove the clutch drum.

300657-10

–

Take off the centrifugal clutch

.

Summary of Contents for 50 SX MINI 2010

Page 1: ...OWNER S MANUAL 2010 50 SX 50 SX Mini Art no 3211477en ...

Page 2: ......

Page 3: ... specifica tions prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for deliv ery options deviations from illustrations and descriptions as well as for printing and other errors The models portrayed partly...

Page 4: ...ng the lower triple clamp x 28 Installing the lower triple clamp x 29 Greasing the steering head bearing x 30 Dismounting the front fender 30 Installing the front fender 31 Dismounting the start number plate 31 Installing the start number plate 31 Handlebar position 32 Adjusting handlebar position x 32 Checking the play in the throttle cable 32 Adjusting the play in the throttle cable x 33 Checkin...

Page 5: ...ch x 60 Fitting centrifugal force clutch x 61 Checking measuring clutch x 61 Dismantling centrifugal clutch x 62 Assembling centrifugal clutch x 62 TROUBLESHOOTING 64 CLEANING 66 Cleaning motorcycle 66 STORAGE 67 Storage 67 Putting into operation after storage 67 TECHNICAL DATA ENGINE 68 Capacity gear oil 68 Capacity coolant 68 TECHNICAL DATA ENGINE TIGHTENING TORQUES 69 TECHNICAL DATA CARBURETOR ...

Page 6: ...understanding In the interest of your own safety have these jobs done in an authorized KTM workshop There your motorcycle will be serviced optimally by specially trained experts using the specialist tools required Identifies a page reference more information is provided on the specified page Formats used The typographical and other formats used are explained in the following Proper name Identifies...

Page 7: ...ccording to specifications as listed in the owner s manual Spare parts accessories For your own safety only use spare parts and accessory products that have been approved and or recommended by KTM and have them installed by an authorized KTM workshop KTM accepts no liability for other products and any resulting damage or loss Certain spare parts and accessories are specified in parentheses in the ...

Page 8: ...hat will invariably lead to severe or even fatal injury if the appropriate measures are not taken Warning Indicates immediate danger that may lead to severe or even fatal injury if the appropriate measures are not taken Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken Warning Indicates immediate danger that will invariabl...

Page 9: ...HICLE 7 3 1 View of the vehicle from the left front example B00068 10 1 Hand brake lever 2 Filler cap 3 Fuel tap 4 Quick release for seat lock 5 Shock absorber compression adjustment 6 Chain guide 7 Plug in stand ...

Page 10: ...IEW OF VEHICLE 8 3 2 View of the vehicle from the right rear example B00069 10 1 Short circuit button 2 Chassis number 3 Throttle grip 4 Level viewer for brake fluid rear 5 Foot brake pedal 6 Kickstarter ...

Page 11: ...ht of the steering head 4 2 Engine number 700461 01 The engine number is stamped on the left side of the engine under the engine sprocket 4 3 Shock absorber part number 700469 01 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring towards the rear ...

Page 12: ...n In this position the ignition circuit is closed and the engine can be started Short circuit button pressed In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start 5 4 Fuel tap 700463 01 Fuel tap is on the left of the fuel tank Possible states Fuel tap is closed The knurled screw is turned all the way clockwise Fuel cannot flow out of th...

Page 13: ... richer fuel air mixture which is needed for a cold start Info If the engine is warm the choke function must be deactivated Possible states Choke function activated Choke knob is in upper position The O ring is visible Choke function deactivated Choke knob is in lower position No O ring is visible 5 10 Choke 50 SX Mini 700519 01 The choke lever is fitted on the right of the carburetor Activating t...

Page 14: ...01 Foot brake pedal is located in front of the right footrest The foot brake pedal is used to activate the rear brake 5 13 Plug in stand 700474 01 Note Danger of damage The parked vehicle can roll away or fall over Always place the vehicle on a firm and even surface To park the motorcycle insert the plug in stand in the support for the plug in stand on the left of the vehicle Info Remove the plug ...

Page 15: ...ccidents Critical riding behavior due to inappropriate riding Ensure that your child adjusts the riding speed to the road conditions and to his or her riding abilities Warning Danger of accidents Accident risk caused by presence of a passenger Your vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of accidents Brake system failure If the foot brake pedal is no...

Page 16: ...hicle Do not let your child try any off road rides that would exceed the ability and experience of your child Your child should hold the handlebar firmly with both hands and keep his or her feet on the footrests when riding Do not exceed the maximum allowable rider weight Guideline Maximum rider weight 35 kg 77 lb Maximum rider size 130 cm 51 2 in Check the spoke tension p 47 Info The spoke tensio...

Page 17: ...equipment 7 2 Starting Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in a closed space without an effective exhaust extraction system Note Engine failure High engine speeds in cold engines have a negative effect on the service life of t...

Page 18: ... point of front or rear brake Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently On sandy wet or slippery surfaces use the rear brake Braking should always be completed before you go into a bend 7 6 Stopping...

Page 19: ...lothing Do not inhale fuel vapors If fuel gets into your eyes rinse imme diately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doctor immediately Change clothing that has come into contact with fuel Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground ...

Page 20: ...ge Check the play of the handbrake lever p 37 Check the free travel of the foot brake lever p 41 Check the function of the brake system Check screws and guide bolts of brake system for tightness Chassis Check shock absorber and fork for leakage and functioning x Clean dust boots of fork legs p 24 Check swingarm bearing Check play of steering head bearing p 25 Check all screws to see if they are ti...

Page 21: ...spection and care work by the supervisory individual NB1A Check the gear oil level p 57 Check the front brake fluid level p 37 Check the rear brake fluid level p 42 Check the front brake linings p 39 Check the rear brake linings p 43 Check and adjust throttle cables Bleed fork legs Clean dust boots of fork legs p 24 Clean the chain p 33 Check the chain tension p 34 Check the chain wear Check rear ...

Page 22: ...ssembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help 700476 01 Turn adjusting screw clockwise to the last perceptible click Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping 50 SX Standard 10 clic...

Page 23: ...n and seat the rider wearing a full set of protective clothing on the motorcycle in the normal sitting position feet on the footrests The rider should bounce up and down several times so that the rear wheel suspension can level out Now measure the distance between the rear axle and the fixed point again Make a note of the value as measurement Info The riding sag is the difference between measureme...

Page 24: ... clean it thoroughly Choose and mount a suitable spring Guideline Spring rate 50 SX Weight of rider 25 kg 55 lb 30 N mm 171 lb in Weight of rider 25 35 kg 55 77 lb 35 N mm 200 lb in Weight of rider 40 kg 88 lb 40 N mm 228 lb in Spring rate 50 SX Mini Weight of rider 25 kg 55 lb 65 N mm 371 lb in Weight of rider 25 35 kg 55 77 lb 75 N mm 428 lb in Weight of rider 35 kg 77 lb 85 N mm 485 lb in Info ...

Page 25: ...ally adjusted to the size of the child In the lower position standard the fork is completely pushed through In the higher position the cone is flush with the upper triple clamp Fork overhang over the upper triple clamp 10 17 mm 0 39 0 67 in 700521 11 The seat height can be individually adjusted to the size of the child The shock absorber can be mounted at two different holes in the frame Differenc...

Page 26: ...the required seat height Guideline Low seat position standard High seat position Install shock absorber x p 23 9 14 Cleaning dust boots of fork legs Jack up the motorcycle p 20 700478 11 Push dust boots of both fork legs upwards Info The dust boots should remove dust and coarse dirt particles from the fork tubes Over time dirt can penetrate behind the dust boots If this dirt is not removed the oil...

Page 27: ...eable play Adjust play of the steering head bearing x p 25 Move the handlebar to and fro over the entire steering range The handlebar must move smoothly over the entire steering range There should be no perceptible detent positions If detent positions are noticeable Adjust play of the steering head bearing x p 25 Check the steering head bearing and replace if required Remove the motorcycle from th...

Page 28: ... Position the handlebar support Mount and tighten screws Guideline Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 300743 11 Position the handlebar with the handlebar clamps Mount and tighten screws Position the fuel tank breather Check play of steering head bearing p 25 Check the cable harness bowden cables and brake line for freedom of movement and routing Remove the motorcycle from th...

Page 29: ...just fork overhang Guideline Upper fork projection 10 17 mm 0 39 0 67 in 300733 11 Tighten screw Guideline Screw top triple clamp M8 25 Nm 18 4 lbf ft Tighten screws Guideline Screw bottom triple clamp M6 10 Nm 7 4 lbf ft 300732 11 Position the brake caliper fit and tighten the screws with washers Guideline Screw front brake caliper M8 20 Nm 14 8 lbf ft Loctite 243 300731 11 Position the brake lin...

Page 30: ...r clamp Remove the handlebar and lay it to one side Info Protect the motorcycle and its attachments from damage by covering them Do not bend the cables and lines 300737 10 Remove screws Take off the handlebar support 300738 11 Remove nut Take off the upper triple clamp 300739 10 Remove nut 300740 10 Remove protector ring Remove the lower triple clamp with the steering stem Remove the upper steerin...

Page 31: ...20x1 5 10 Nm 7 4 lbf ft 300738 10 Position the upper triple clamp Mount nut but do not tighten it yet Guideline Nut steering stem M20x1 5 10 Nm 7 4 lbf ft 300741 10 Position the fork leg Adjust fork overhang Guideline Upper fork projection 10 17 mm 0 39 0 67 in Tighten screw Guideline Screw top triple clamp M8 25 Nm 18 4 lbf ft Tighten screws Guideline Screw bottom triple clamp M6 10 Nm 7 4 lbf ft...

Page 32: ...ctite 243 300731 12 Position the brake line Put the clamp on and mount and tighten screws Install the front fender p 31 Install the start number plate p 31 Install the front wheel x p 45 Check that the wiring harness Bowden cables and brake line have freedom of movement and are routed correctly Check play of steering head bearing p 25 9 21 Greasing the steering head bearing x 400563 01 Remove the ...

Page 33: ... screws chassis M6 10 Nm 7 4 lbf ft 9 24 Dismounting the start number plate 700466 01 Remove screw and take off clamp Remove screw Remove the start number plate 9 25 Installing the start number plate 700467 01 Position the start number plate with the drill holes onto the holding lugs of the fender 700468 01 Mount and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the...

Page 34: ...its attachments from damage by covering them Do not bend the cables and lines Remove the two screws Remove the handlebar support Place the handlebar support in the required position Mount and tighten the two screws Guideline Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Position the handlebar Info Make sure cables and wiring are positioned correctly Position the handlebar clamp Mount a...

Page 35: ... dirty Clean the chain p 33 9 31 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Environmental h...

Page 36: ...nsion If the chain is over tensioned the components of the secondary power train chain engine sprocket rear sprocket bear ings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain may snap or the countershaft of the transmission can break On the other hand if the chain is loose it may jump off the engine sprocket or the rear sprocket causing...

Page 37: ...st be taut Because chain wear is not always even repeat this measurement at differ ent chain positions 700484 11 Loosen nut Adjust the chain tension by turning the adjusting screws left and right Guideline Chain tension 5 8 mm 0 2 0 31 in Turn adjusting screws equally on the left and right Check that the rear wheel is aligned with the front wheel Make sure that the chain adjuster supports are fitt...

Page 38: ...crews chassis M6 10 Nm 7 4 lbf ft 9 39 Checking brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc s Change the worn brake disc s without delay Your authorized KTM workshop will be glad to help A A 400257 10 Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement Info Wear reduces the thickness ...

Page 39: ...ar The range of adjustment is limited 9 43 Checking the front brake fluid level Warning Danger of accidents Brake system failure If the brake fluid level drops below the specified marking or the specified value this is an indication that the brake system is leaking or that the brake linings are completely worn down Check the brake system and do not continue riding Your authorized KTM workshop will...

Page 40: ... Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediately Warning Danger of accidents Reduced braking efficiency due to o...

Page 41: ... front brake linings x p 40 Check the brake linings for damage and cracking If damage or wear is encountered Change the front brake linings x p 40 9 46 Removing front brake linings x Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Your authorized KTM workshop will be glad to help Remove front wheel x p 45 700499 01 Remove the lock was...

Page 42: ...Changing the front brake linings x Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid C...

Page 43: ...Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free travel Guideline Free play at foot brake lever 3 5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the free travel of the foot brake pedal x Attach spring 9 50 Adjusting basic position of foot brake pedal x Warning Danger of accidents Brake system fa...

Page 44: ... system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediately Warning Danger of accidents R...

Page 45: ...ly Your authorized KTM workshop will be glad to help 700491 01 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings x p 44 Check the brake linings for damage and cracking If damage or wear is encountered Change the rear brake linings x p 44 9 54 Removing rear brake linings x Warning Danger of acci...

Page 46: ...rake linings are correctly positioned in the holding spring 700494 01 Mount screw Fit the lock washer Install the rear wheel x p 46 9 56 Changing the rear brake linings x Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid gets into your eyes rins...

Page 47: ...ghten the screws Info Clean up overflowed or spilt brake fluid immediately with water 9 57 Removing front wheel x Jack up the motorcycle p 20 700502 01 Remove nut with washer 700503 01 Hold the front wheel and pull out the wheel spindle with the washer Take the front wheel out of the fork Info Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down in such a way ...

Page 48: ...eel down in such a way that the brake disc is not dam aged 9 60 Installing the rear wheel x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Clean and grease wheel spindle Long life grease p 78 700496 01 Lift the rear wheel into the swingarm and place th...

Page 49: ...ted by the last four digits of the DOT marking The first two digits refer to the week of manufacture and last two digits refer to the year of manufac ture KTM recommends that the tires be changed regardless of the actual wear at the latest after 5 years If a tire is more than 5 years old Change the tires 9 62 Checking tire air pressure Info Low tire air pressure leads to abnormal wear and overheat...

Page 50: ... 64 Removing the seat 300611 10 Open quick release and raise the rear of the seat Pull back the seat and remove it 9 65 Mounting the seat 300612 10 Hook the seat onto screw and lower the seat at the rear while pushing it forward Projection hooks into the fuel tank 300611 11 Close quick release 9 66 Cooling system 700509 01 The water pump in the engine forces the coolant to flow The pressure result...

Page 51: ...C 13 49 F If the antifreeze of the coolant does not meet specifications Correct the antifreeze of the coolant 400243 10 Check the coolant level in the radiator Coolant level above the radiator fins 10 mm 0 39 in If the coolant level does not meet specifications Correct the coolant level Alternative 1 Coolant p 76 Alternative 2 Coolant mixed ready to use p 76 Mount the radiator cap 9 68 Checking th...

Page 52: ...ted skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolants out of the reach of children Info Carry out this work with a cold engine 300617 10 Stand the vehicle upright Place a suitable container under the engine Remove screw Remover the radiator cap Completely drain the coolant Mount and...

Page 53: ...lace the vehicle back on a level surface Add coolant to level Mount the radiator cap Make a short test ride Check the coolant level p 49 9 71 Removing main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down Do not touch hot components 700512 01 Remove screw Remove screw 700513 10 Pull the main silencer off of the manif...

Page 54: ...p and outer tube Pull the glass fiber yarn filling from the inner tube Clean the parts that are to be reinstalled 9 75 Installing the glass fiber yarn filling of the main silencer x 700514 10 Slide the glass fiber yarn filling over the inner tube Slide the outer tube over the glass fiber yarn filling Insert the locking cap into the outer tube Fit and tighten screws with tooth lock washer Guideline...

Page 55: ...fuel or petroleum since these substances attack the foam Remove the air filter x p 52 Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 78 Info Only press the air filter to dry it never wring it out Oil the dry air filter with a high quality filter oil Oil for foam air filter p 78 Clean the air filter box Check carburetor connection boot fo...

Page 56: ...eath When running the engine always make sure there is sufficient venti lation and do not start or run the engine in a closed space without an effective exhaust extraction system Adjust the idle speed with the adjusting screw Guideline Choke function deactivated Choke knob is in lower position No O ring is visi ble p 11 Idle speed 1 400 1 500 rpm Turn the idle adjusting screw slowly clockwise unti...

Page 57: ...speed begins to fall Note the position and turn the idle air adjusting screw slowly counterclockwise until the idle speed falls again Adjust to the point between these two positions with the highest idle speed Info If the speed rise is too high reduce the idle speed to a normal level and repeat the preceding steps If the procedure described here does not lead to satisfactory results the cause may ...

Page 58: ...0 10 Pull off the oil line 300652 10 Fill the oil line with a syringe 2 stroke engine oil p 76 300650 10 Connect the oil line 300651 10 Remove screws Take off the oil pump Pull off the oil line from the carburetor 300653 10 Turn the oil pump gear anticlockwise until oil flows out of the oil line without bubbles ...

Page 59: ...the motorcycle upright on a horizontal surface 700525 01 Condition Engine is cold Remove gear oil level check screw Stand the vehicle upright Check the gear oil level A small amount of gear oil should flow out If no gear oil flows out Add gear oil x p 58 Mount and tighten the gear oil level check screw Guideline Screw gear oil level check M6 10 Nm 7 4 lbf ft 9 86 Changing the gear oil x 400721 01 ...

Page 60: ...ith magnet Clean the sealing area on the engine Fit 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 9 88 Filling up with gear oil x Info Too little gear oil or poor quality oil results in premature wear of the transmission 700516 01 Remove screw cap and fill up with gear oil Gear oil 0 20 l 0 21 qt Gear oil ATF Dexron 3 p 76 M...

Page 61: ...ness and or death When running the engine always make sure there is sufficient venti lation and do not start or run the engine in a closed space without an effective exhaust extraction system Start the motorcycle Slowly increase engine speed until the clutch begins to engage Measure the engine speed Clutch engagement speed 7 200 7 500 rpm If the specified value is not reached Adjust the clutch eng...

Page 62: ...he clutch engagement speed is increased If you remove the washer the clutch engagement speed is reduced Assemble the centrifugal clutch x p 62 Fit the centrifugal force clutch x p 61 Check the clutch engagement speed x p 59 9 92 Removing centrifugal clutch x 300654 10 Remove nut Disconnect spring Take off the footbrake pedal 300655 10 Lay the motorcycle on its side Remove screws Take off the clutc...

Page 63: ... M6 10 Nm 7 4 lbf ft 300654 11 Position the foot brake pedal Mount and tighten nut Guideline Remaining nuts chassis M8 30 Nm 22 1 lbf ft Mount the spring Check the gear oil level p 57 Check the clutch engagement speed x p 59 9 94 Checking measuring clutch x Condition Centrifugal clutch removed 300610 10 Measure clutch Guideline Clutch shoe height 98 00 mm 3 8583 in if the specified value is not me...

Page 64: ...marked with the same color Remove clutch shoe Repeat these steps on the other clutch shoes 9 96 Assembling centrifugal clutch x Condition Centrifugal clutch removed 300514 11 Clutch spring with green mark Position the clutch shoe Fit screw with spacing washer and spring Info Washer is used for adjusting the clutch engagement speed and must be fitted consistently on all clutch shoes depending on th...

Page 65: ...MAINTENANCE WORK ON CHASSIS AND ENGINE 63 300513 11 Tighten screws with special tool Guideline Screw clutch spring M6 7 Nm 5 2 lbf ft Mortise key 45229021000 ...

Page 66: ...or and treat it with contact spray Water in carburetor or jets blocked 50 SX Mini Check set the carburetor components x 50 SX Check set the carburetor components x Engine has no idle Idling jet blocked 50 SX Mini Check set the carburetor components x 50 SX Check set the carburetor components x Adjusting screws on carburetor dis torted 50 SX Mini Carburetor adjust the idle speed x p 55 50 SX Carbur...

Page 67: ...he intake flange and carburetor for tightness Socket connector or ignition coil is loose or oxidized Clean the socket connector and treat it with contact spray Engine overheats Too little coolant in cooling system Check the cooling system for leakage Check the coolant level p 49 Too little air stream Switch off engine when standing Radiator fins very dirty Clean radiator fins Foam formation in coo...

Page 68: ...ycle cleaner p 78 Info Use warm water containing normal motorcycle cleaner and a soft sponge After rinsing the motorcycle with a gentle water spray allow it to dry thoroughly Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently After cleaning let your child ride the vehicle a short distance until the engine ...

Page 69: ...d less workshop overload In this way you can avoid long workshop waiting times at the start of the new season Clean the motorcycle p 66 Change the gear oil x p 57 Check the antifreeze and coolant level p 49 Drain the fuel from the tank into a suitable container Check the tire air pressure p 47 The storage place should be dry and not subject to large temperature fluctuations Info KTM recommends jac...

Page 70: ...ixture oil lubrication Engine lubrication 50 SX Mini Separate lubrication Primary transmission 61 33 straight cut spur gear Clutch 3 lining automatic clutch on the main shaft centrifugal force Gearbox Rigid 1 stage reduction gear Transmission ratio 19 42 Ignition SELETTRA 2p D36 Spark plug NGK LR 8 B Spark plug electrode gap 0 60 mm 0 0236 in Cooling Water cooled Starting aid Kickstarter 13 1 Capa...

Page 71: ...ne housing M6 10 Nm 7 4 lbf ft Screw engine sprocket cover M6 10 Nm 7 4 lbf ft Screw exhaust flange M6 10 Nm 7 4 lbf ft Screw gear oil level check M6 10 Nm 7 4 lbf ft Screw ignition coil M6 5 Nm 3 7 lbf ft Screw intake flange M6 5 Nm 3 7 lbf ft Loctite 243 Screw water pump cover M6 10 Nm 7 4 lbf ft Screw cyliner head M7 18 Nm 13 3 lbf ft Nuts cylinder base M8 20 Nm 14 8 lbf ft Screw clutch drum M8...

Page 72: ...ng screw Open 3 turns Main jet 85 Jet needle W9 Idling jet 58 Needle jet 260AU Throttle slide 60 Cold start jet 60 15 2 50 SX Mini Carburetor type Dell Orto PHVA 12XS Needle position 4th position from top Idle air adjusting screw Open 1 turn Main jet 60 Jet needle A10 Idling jet 35 Needle jet 211FA Throttle slide 40 Cold start jet 60 ...

Page 73: ...tio 50 SX Mini 10 42 Chain 1 2 x 3 16 Rear sprockets available 38 39 40 41 42 Steering head angle 50 SX 66 Steering head angle 50 SX Mini 67 4 Wheelbase 50 SX 1 032 mm 40 63 in Wheelbase 50 SX Mini 914 mm 35 98 in Seat height unloaded 50 SX 684 mm 26 93 in Seat height unloaded 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...

Page 74: ... 72 16 2 Capacity fuel Fuel tank capacity approx 50 SX 2 3 l 2 4 qt Super unleaded gasoline mixed with 2 stroke engine oil 1 60 p 77 Fuel tank capacity approx 50 SX Mini 2 0 l 2 1 qt Super unleaded ROZ 95 RON 95 PON 91 p 77 ...

Page 75: ...r length 100 2 5 mm 3 94 0 098 in Fork length 692 mm 27 24 in Fork oil 210 ml 7 1 fl oz Fork oil SAE 7 5 p 76 17 2 50 SX Mini Fork part number 45201000233 Fork Marzocchi Spring rate Weight of rider 25 35 kg 55 77 lb 2 N mm 11 lb in Air chamber length 100 2 5 mm 3 94 0 098 in Fork length 578 mm 22 76 in Fork oil 210 ml 7 1 fl oz Fork oil SAE 7 5 p 76 ...

Page 76: ...g 45 55 mm 1 77 2 17 in Fitted length 275 mm 10 83 in Shock absorber oil Shock absorber oil SAE 2 5 50180342S1 p 77 18 2 50 SX Mini Shock absorber part number 03 18 9E 04 Shock absorber WP Suspension 3614 BAEM Rebound damping Standard 12 clicks Spring preload Standard 5 mm 0 2 in Spring rate Weight of rider 25 kg 55 lb 65 N mm 371 lb in Weight of rider 25 35 kg 55 77 lb 75 N mm 428 lb in Weight of...

Page 77: ...0 Nm 7 4 lbf ft Remaining nuts chassis M8 30 Nm 22 1 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft Screw front brake caliper M8 20 Nm 14 8 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw top triple clamp M8 25 Nm 18 4 lbf ft Nut swingarm pivot M10 45 Nm 33 2 lbf ft Remaining nuts chassis M10 50 Nm 36 9 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw bottom sh...

Page 78: ...peratures Use of low quality antifreeze can lead to corrosion and foam ing KTM recommends Motorex products Mixture ratio Antifreeze protection 25 45 C 13 49 F 50 corrosion inhibitor antifreeze 50 distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Supplier Motorex Anti Freeze Fork oil SAE 7 5 According to SAE p 80 SAE 7 5 Guideline Use only oils that comply with the specified standards...

Page 79: ...ards see specifications on the container and that possess the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91 Super unleaded gasoline mixed with 2 stroke engine oil 1 60 According to DIN EN 228 JASO FC p 80 1 60 Mixture ratio 1 60 2 stroke engine oil p 76 Super unleaded ROZ 95 RON 95 PON 91 p 77 ...

Page 80: ... products Supplier Motorex Protect Shine 645 Contact spray Guideline KTM recommends Motorex products Supplier Motorex Accu Contact Long life grease Guideline KTM recommends Motorex products Supplier Motorex Fett 2000 Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Offroad chain spray Guideline KTM recommends Motorex products Supplier Motorex Chain Lube ...

Page 81: ...AUXILIARY SUBSTANCES 79 Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Universal ...

Page 82: ...rst rate synthetic esters and specially designed additives superb combustion is achieved even under extreme operating conditions SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis cosity The viscosity describes only one property of oil and says nothing about quality ...

Page 83: ... 36 Chain tension adjusting 35 checking 34 Chassis number 9 Choke 11 Cleaning 66 Coolant draining 50 refilling 50 Coolant level checking 49 Cooling system 48 D Dust boots cleaning 24 E Engine running in 14 Engine Work on individual parts assembling centrifugal clutch 62 checking measuring clutch 61 dismantling centrifugal clutch 62 Engine number 9 Environment 6 F Filler cap closing 11 opening 10 F...

Page 84: ...t mounting 48 removing 48 Seat height adjusting 24 Service schedule 18 19 Shock absorber installing 23 removing 22 riding sag checking 21 static sag checking 21 Shock absorber part number 9 Short circuit button 10 Spare parts accessories 5 Spoke tension checking 47 Spring preload shock absorber adjusting 21 Start number plate installing 31 removing 31 Starting 15 Steering head bearing greasing 30 ...

Page 85: ... 3211477en 3211477en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 04 2009 Photo Mitterbauer ...

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