KTM 50 SX Mini Repair Manual Download

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30/ASSEMBLING THE ENGINE

17.1

Installing the crankshaft

300501-10

–

Clamp the right section of the engine case into the engine work stand.

–

Slide crankshaft



all the way into the bearing seat of the right section of the

engine case.

17.2

Installing the transmission shafts

300500-10

–

Push both transmission shafts



into the bearing seats together.

17.3

Installing the left engine case

300499-11

–

Mount engine case gasket



and dowels



Info

The axial play cannot be adjusted.

300498-12

–

Mount the left section of the engine case.

–

Mount screws



but do not tighten yet.

Guideline

Screw, engine case

M6x40

10 Nm (7.4 lbf ft)

–

Mount screw



but do not tighten yet.

Guideline

Screw, engine case

M6x35

10 Nm (7.4 lbf ft)

–

Mount screw



but do not tighten yet.

Guideline

Screw, engine case

M6x55

10 Nm (7.4 lbf ft)

–

Mount screws



and tighten all screws in a crisscross pattern.

Guideline

Screw, engine case

M6x30

10 Nm (7.4 lbf ft)

–

Mount distance bushing



with the chamfer facing inward.

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877-999-5686

Summary of Contents for 50 SX Mini

Page 1: ...REPAIR MANUAL 2009 50 SX 50 SX Junior 50 SX Mini Article no 3206060en P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 2: ...P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 3: ... or delete technical 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 delivery options deviations from illustrations and descriptions as well as misprints and other errors The models ...

Page 4: ...ving the air filter 41 Installing the air filter 41 Cleaning air filter 41 07 FUEL TANK SEAT TRIM 42 Removing the seat 42 Mounting the seat 42 Removing the fuel tank 42 Installing the fuel tank 43 08 MASK FENDER 44 Dismounting the front fender 44 Installing the front fender 44 Dismounting the start number plate 44 Installing the start number plate 44 09 FRONT WHEEL 46 Removing front wheel 46 Insta...

Page 5: ...stalling the oil pump drive gear 50 SX Mini 89 Installing the reed valve housing ignition coil and intake flange 89 Installing the alternator cover 90 Installing the oil pumps 50 SX Mini 90 Installing the piston 91 Installing the cylinder 91 Checking the X distance 92 Setting the X distance 92 Installing the cylinder head 92 Installing the oil drain plug 93 Refilling with gear oil 93 Mounting the ...

Page 6: ...132 50 SX Junior 132 50 SX Mini 132 TECHNICAL DATA TIGHTENING TORQUES FOR CHASSIS 134 CLEANING CONSERVATION 135 Cleaning motorcycle 135 STORAGE 136 Storage 136 Putting into operation after storage 136 SERVICE SCHEDULE 137 Important maintenance work that must be done in an authorized KTM workshop 137 Important maintenance work that must be done in an authorized KTM workshop as additional order 137 ...

Page 7: ...cted reaction e g of a work step or a function Identifies a page reference more information is provided on the specified page Formats used The typographical and other formats used are explained below Specific name Denotes a proper name Name Denotes a protected name Brand Denotes a brand available on the open market P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 8: ...ructions regarding its use Parts that are to be reused after disassembly must be cleaned and checked for damage and wear Change damaged or worn parts After repair and maintenance ensure that the vehicle is roadworthy Notes warnings Pay close attention to the notes warnings Info Various information and warning labels are affixed to the vehicle Do not remove information warning labels If they are mi...

Page 9: ...not start or run the engine in an enclosed space without an effective exhaust extraction system Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always warm up the engine at low engine speeds Info If the motorcycle is unwilling to start the cause can be old fuel in the float chamber The flammable elements of the fuel evaporate after a ...

Page 10: ...of the shock absorber 700523 10 The fork overhang can be individually 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 abso...

Page 11: ...cs free of oil and grease and clean them with brake cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray p 145 Press the dust boots back into their normal position Remove excess oil Remove the motorcycle from the work stand p 7 4 2 Removing the fork legs Remove front wheel p 46 Dismount the start number plate p 44 300731 10 Remove screws and...

Page 12: ...s 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 line Put the clamp on and mount and tighten screws Install the start number plate p 44 Install the front wheel p 46 4 4 Servicing fork Condition The fork legs have bee...

Page 13: ...rk legs lies in the piston ring of the piston rod which is only mounted on the left fork leg Condition The fork legs have been removed 201177 10 Clamp the fork leg in the area of the lower triple clamp Info Use soft jaws Remove locking cap Remove preload bush 201178 10 Remove spring Unclamp the fork leg Drain the oil Remove dust boot 201179 10 Clamp the fork leg with the axle clamp Remove screw P ...

Page 14: ...er tube for damage If there is damage Change the outer tube Check the spring length Guideline Spring length with preload bush es 347 353 mm 13 66 13 9 in If the measured value is greater than the specified value Reduce the thickness of the preload spacer If the measured value is less than the specified value Increase the thickness of the preload spacer 200684 10 Measure the outside diameter at sev...

Page 15: ...t fork leg 201184 10 Position washer in the outer tube with the collar facing forward 201181 11 Mount washer Lubricate seal ring and press it in all the way Lubricant T511 p 144 Mount lock ring 201180 11 Slide piston rod into inner tube Position damping bush Slide the inner tube with the piston rod into the outer tube 201179 11 Mount and tighten screw with the seal ring Guideline Screw piston rod ...

Page 16: ...gth 100 2 5 mm 3 94 0 098 in Squeeze bottle T137S p 151 201188 10 Mount spring Mount preload bush 201189 10 Clamp the fork leg in the area of the lower triple clamp Info Use soft jaws Lubricate O ring of locking cap Lubricant T158 p 144 Mount and tighten the locking cap Guideline Locking cap M28x1 5 20 Nm 14 8 lbf ft 4 8 Adjusting the fork overhang Warning Danger of accidents Modifications to the ...

Page 17: ...w bottom triple clamp M6 10 Nm 7 4 lbf ft Repeat the adjustment on the other fork leg Info The setting of the vehicle level via the fork legs must be identical on both fork legs 4 9 Removing the lower triple clamp Remove the fork legs p 9 Dismount the front fender p 44 300736 10 Remove the fuel tank breather Remove screws Remove the handlebar clamp Remove the handlebar and lay it to one side Info ...

Page 18: ...the upper steering head bearing Info Check that the O rings of the steering head seal are correctly positioned 300739 11 Push on protective ring Mount and tighten nut Guideline Steering head nut M20x1 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 overh...

Page 19: ...osition the fuel tank breather 300732 12 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 12 Position the brake line Put the clamp on and mount and tighten screws Install the front fender p 44 Install the start number plate p 44 Install the front wheel p 46 Check that the wiring harness throttle cables an...

Page 20: ...18 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 the play of the steering head bearing p 18 Check the steering head bearing and replace if required Remove the motorcycle from the work stand p 7 4 13 Adjusting the play of the steeri...

Page 21: ... 10 Nm 7 4 lbf ft 300742 11 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 handlebar clamps Mount and tighten screws Position the fuel tank breather Check play of steering head bearing p 18 Check that the wiring harness throttle cables and brake line have freedom of move ment and are ...

Page 22: ... 0 0 0 B B 0 0 A A 400565 10 On the upper triple clamp there are 2 holes at a distance of to each other Distance between holes 15 mm 0 59 in The holes on the handlebar support are placed at a distance of from the center Distance between holes 3 5 mm 0 138 in The handlebar supports can be mounted in 4 different positions 5 4 Adjusting handlebar position Warning Danger of accidents Handlebar breakag...

Page 23: ... AND INSTRUMENTS 21 Position the handlebar clamp Mount and evenly tighten the four screws Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Info Make sure the gap width is even P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 24: ...Jack up the motorcycle p 7 0 0 A A 400220 10 Measure the distance as vertical as possible between the rear axle and a fixed point for example a mark on the side cover Make a note of the value as measurement Remove the motorcycle from the work stand p 7 6 3 Checking the static sag of the shock absorber 0 0 0 B B 0 0 A A 400221 10 Measure distance of rear wheel unloaded p 22 Ask someone to help you ...

Page 25: ...spring preload of the shock absorber Danger Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Remove shock absorber p 24 After removing the shock absorber clean it thoroughly 700506 01 Measure the full spring length while it is under tension and note down the value Loosen lock ring Turn...

Page 26: ...maller weight differences can be compensated by changing the spring preload Install shock absorber p 24 Check the static sag of the shock absorber p 22 Check the riding sag of the shock absorber p 23 Adjust the rebound damping of the shock absorber p 22 6 7 Removing the shock absorber Jack up the motorcycle p 7 700477 01 Remove screw and lower the rear wheel with the swing arm as far as possible w...

Page 27: ... seat position Install shock absorber p 24 6 10 Servicing shock absorber Condition The shock absorber has been removed 201193 01 Remove the spring p 25 Disassemble the damper p 26 Disassemble the piston rod p 27 Remove the heim joint p 28 Check the damper p 29 Install the heim joint p 30 Assemble the piston rod p 31 Assemble the damper p 32 Install the spring p 35 6 11 Removing the spring Conditio...

Page 28: ... Take off the spring with the retaining and adjusting rings 6 12 Disassembling the damper Remove the spring p 25 200897 10 Clamp the damper into the vise using soft jaws Note down the current state of the rebound damping Fully open the rebound damping Remove screw The nitrogen pressure dissipates Info The screw of the filling port must be in the highest position Let the oil drain 300432 10 Remove ...

Page 29: ...p the piston rod with the heim joint into a vise Remove nut 300436 10 Remove supporting plate and rebound shim stack together with piston Info Thread the rebound shim stack onto a screwdriver and set the shims down together 300437 10 Remove compression shim stack Info Thread the compression shim stack onto a screwdriver and set the shims down together 300439 10 Remove supporting plate Remove seal ...

Page 30: ...using soft jaws Remove collar bushing of the heim joint Pin T120 p 150 Turn around the shock absorber and remove collar bushing of the heim joint Pin T120 p 150 200578 10 Remove seal rings on both sides 200579 10 Remove lock rings on both sides 200580 10 Place special tool underneath and press out the heim joint using special tool Pressing tool T1207S p 151 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 ...

Page 31: ...damage or wear Change the damper cartridge 300554 10 Measure the diameter of the piston rod Piston rod Diameter 13 93 13 98 mm 0 5484 0 5504 in If the specified value is not reached Change the piston rod Measure the run out of the piston rod Piston rod Run out 0 08 mm 0 0031 in If the measured value is greater than the specified value Change the piston rod Check the piston rod for damage and wear ...

Page 32: ...ng tool T129 p 151 200579 11 Mount lock rings on both sides 200578 11 Mount and grease seal rings on both sides Lubricant T158 p 144 200901 10 Press in both collar bushings of the heim joint Info Because the collar bushings are different thin thick ensure that they are installed in the correct positions see the photos If the collar bushings are installed incorrectly the shock absorber will rub aga...

Page 33: ...lide seal ring retainer on the piston rod Lubricant T625 p 145 Remove the special tool 300412 10 Mount supporting plate with the round side first 300413 10 Mount compression shim stack with the smaller disks facing down 300415 10 Grind the piston on both sides on a surface plate with sandpaper grit 1200 Mount the piston Guideline View Piston from above View Piston from below Clean the piston 30041...

Page 34: ...m 2 2 lbf ft Fill the damper cartridge Guideline Fluid level below top edge 55 mm 2 17 in Shock absorber oil SAE 2 5 50180342S1 p 143 300442 10 Mount and oil piston ring in the groove of the piston Grease the O ring of the gasket support Lubricant T158 p 144 Carefully mount the piston rod 300443 10 Push in seal ring retainer Mount lock ring Info First insert the closed part of the lock ring and th...

Page 35: ... serious deterioration in the handling characteristics and overload some components Only make adjustments within the recommended range After making adjustments ride slowly at first to get the feel of the new ride behavior Turn adjusting screw to the position measured during disassembly 6 19 Assembling the damper 50 SX Assemble the piston rod p 31 300441 10 Mount and tighten the screw of the fillin...

Page 36: ...10 clicks Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seri ously alter the vehicle s ride behavior Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteristics and overload some components Only make adjustments within the recommended range After making adjustments ride slowly at first to ...

Page 37: ... the damper is filled to the required pressure Close the screw of the filling port using tap handle Close the spigot and take the damper out of the special tool Tighten the screw of the filling port Guideline Screw filling port M5 3 Nm 2 2 lbf ft 6 21 Installing the spring 50 SX Junior 50 SX Mini Assemble the damper p 32 200896 10 Clamp the damper into the vise using soft jaws Mount the retaining ...

Page 38: ...bly by turning the adjusting ring Lock the lock nut and adjusting ring 6 22 Installing the spring 50 SX Assemble the damper p 33 200896 10 Clamp the damper into the vise using soft jaws Mount the retaining ring and turn it all the way down The collar faces the adjusting ring Mount the adjusting ring and turn it all the way down The collar faces the spring Measure the overall spring length when not...

Page 39: ...g elements can cause a serious deterioration in the handling characteristics and overload some components Only make adjustments within the recommended range After making adjustments ride slowly at first to get the feel of the new ride behavior Tension the spring to the length measured during disassembly by turning the adjusting ring Lock the lock nut and adjusting ring P a r t S h a r k c o m 8 7 ...

Page 40: ...manifold 300615 10 Grease the O ring of the exhaust manifold Long life grease p 144 Position the exhaust manifold Mount springs Spring hooks 50305017000 p 148 Mount and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 300616 10 Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 7 3 Removing main silencer Warning Danger of burns The exhaust system ge...

Page 41: ...the collar sleeves Mount and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 7 5 Removing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down Do not touch hot components Remove the main silencer p 38 700514 01 Remove screws of locking cap Remove locking cap a...

Page 42: ...iber yarn filling over the inner tube Slide the outer tube over the glass fiber yarn filling Insert locking cap into the outer tube Fit and tighten screws with tooth lock washer Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Install the main silencer p 39 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 43: ...ug Lower the air filter cover and allow the front holding lug to snap in Info If the air filter is not correctly mounted dust and dirt can penetrate into the engine and can cause damage Mount the seat p 42 8 3 Cleaning air filter Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in appli...

Page 44: ...n up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immedi ately with water and contact a doctor Wash affected skin areas immediately wi...

Page 45: ...ueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immedi ately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed con tact a doctor immediately Change clothing that has come into contact with fuel Store f...

Page 46: ...ate 700479 11 Position the front fender Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 10 3 Dismounting the start number plate 700466 01 Remove screw and take off clamp Remove screw Remove the start number plate 10 4 Installing the start number plate 700467 01 Position the start number plate with the drill holes onto the holding lugs of the fender P a r t S h a r k...

Page 47: ... FENDER 45 700468 01 Mount and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line Put the clamp on mount and tighten screw P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 48: ...dents 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 144 700503 10 Lift the front wheel into the fork position it and insert wheel spindle with washer 700502 10 Position washer Mount and tighten nut Guideline Front wheel spindle n...

Page 49: ...k the tire age Info The tire s date of manufacture is usually part of the tire markings and is indicated 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...

Page 50: ... to incorrect spoke tension Ensure that the spoke tension is correct Info A loose spoke can cause wheel imbalance which leads to more loose spokes in a short time If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle 400694 01 Briefly strike each spoke with the blade of a screwdriver Info The frequency of the tone depends ...

Page 51: ...n necessary Clean and grease wheel spindle Long life grease p 144 700496 01 Lift the rear wheel into the swingarm and place the chain on the rear sprocket Insert the wheel spindle with the washer Position washer Mount nut but do not tighten it yet Check chain tension when installing the rear wheel p 51 Make sure that the chain adjuster supports are fitted correctly on the adjusting screws Tighten ...

Page 52: ...er caused by incorrect chain tension If the chain tension is too high 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 can rupture or the countershaft of the transmission can break On the other hand if the chain is loose it can fall off the engine s...

Page 53: ...ar sprocket engine sprocket for wear 400227 01 Check rear sprocket engine sprocket for wear If the rear sprocket engine sprocket are worn Replace rear sprocket engine sprocket Info When fitting the chain joint always make sure that the closed side of the joint faces forward riding direction The engine sprocket rear sprocket and chain should always be replaced together Check the chain guide for tig...

Page 54: ...justing 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 fitted correctly on the adjusting screws Tighten nut Guideline Nut rear wheel spindle M12x1 40 Nm 29 5 lbf ft 12 10 Adjusting chain tension installing rear wheel 700484 12 Adjust the chain tension by turning the adjusting screws left and right Guidel...

Page 55: ...he hand brake lever and the handlebar The range of adjustment is limited 13 4 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 ridin...

Page 56: ...ation 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 effect caused by old brake fluid Change the brake fluid of the front and rear brakes acc...

Page 57: ... from a sealed container 201174 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Draw the used brake fluid out of the brake fluid reservoir using a syringe and fill in new brake fluid Bleed syringe 50329050000 p 149 Brake fluid DOT 4 DOT 5 1 p 142 201173 10 Pull off dust cap and connect a conventional suction device worksh...

Page 58: ...an brake caliper and brake caliper support 13 9 Installing the front brake linings 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 Danger of accidents Reduced braking efficiency due to use of non approved brake linings Brake linings available fr...

Page 59: ...rs brake fluid etc should be disposed of as stipulated in applicable regulations Info Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Remove the front brake linings p 56 301...

Page 60: ...1 Detach the spring Loosen nut Turn push rod until clearance is created Guideline Free travel of foot brake lever 3 5 mm 0 12 0 2 in Hold push rod and tighten nut Attach the spring Check whether the basic position of the foot brake lever is suitable for the rider If the basic position of the foot brake lever needs to be adjusted Adjust the basic position of the foot brake lever p 58 13 13 Adjustin...

Page 61: ... in the brake system or worn out brake linings Check the brake system and do not continue riding 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...

Page 62: ... cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from ...

Page 63: ...n brake linings Change worn brake linings immediately 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 p 62 Check the brake linings for damage and cracking If damage or wear is encountered Change the rear brake linings p 62 13 18 Removing rear brake linings Warning Danger of accident...

Page 64: ...y positioned in the holding spring 700494 01 Mount screw Fit the lock washer Install the rear wheel p 49 13 20 Changing the rear brake linings 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 ...

Page 65: ... fluid reservoir Install the rear brake linings p 62 201170 10 Add brake fluid to level Guideline Dimension brake fluid level below top edge of container 10 mm 0 39 in Brake fluid DOT 4 DOT 5 1 p 142 Position the membrane and the cover with the washer Mount and tighten the screws Info Clean up overflowed or spilt brake fluid immediately with water P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 66: ...the hose clamps Detach the radiator hoses 300619 10 Remove the cable binder Disconnect plug in connector 300620 10 50 SX Mini Detach oil line of the oil pump Close the oil line using a suitable object 300662 10 Remove screws Take off the engine sprocket cover 300621 10 Remove connecting link of the chain Remove the chain P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 67: ... throttle cable 300623 10 Remove screws 300624 10 Remove nut Remove the swingarm pivot 300625 10 Lift out the engine from the side 14 2 Installing the engine 300625 10 Position the engine in the frame Mount the swingarm pivot 300623 11 Mount screws but do not tighten yet P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 68: ...Remove the plug Attach oil line to the connection of the oil pump Position the clamp 300619 11 Connect the plug in connectors Secure the cables with the cable binder 300621 11 Mount the chain Connect the chain with connecting link 300662 11 Position the engine sprocket cover Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount and tighten screw Guideline Remaining ...

Page 69: ...s Install the exhaust manifold p 38 50 SX Mini Bleed the oil pump p 119 Install the fuel tank p 43 Refill the coolant p 114 Make a short test ride Check the engine for leakage Check the gear oil level p 118 Check the coolant level p 115 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 70: ...01070 p 146 Mount the engine on special tool 15 2 Pulling off the spark plug connector 300460 10 Pull of spark plug connector 15 3 Draining the gear oil 300461 10 Remove oil drain plug with the magnet and seal ring Completely drain the gear oil 15 4 Removing the cylinder head 300462 10 Remove spark plug Alternately loosen screws and remove them Take off the cylinder head 300463 10 Remove the O rin...

Page 71: ...ngine case opening with a cloth Remove the piston pin Take off the piston Remove the upper conrod bearing 15 7 Removing the oil pump 50 SX Mini 300467 10 Remove screws Take off the oil pump 15 8 Removing the alternator cover 300468 10 50 SX Mini Remove screws Remove the alternator cover Remove the gasket Remove the dowels 300851 10 50 SX 50 SX Junior Remove screws Remove the alternator cover Remov...

Page 72: ... gasket 15 10 Removing the oil pump drive gear 50 SX Mini 300472 10 Remove lock ring Take off oil pump drive gear 15 11 Removing the stator 300473 10 Remove cable support sleeve out of the engine case Remove screw Take out the stator 15 12 Removing the rotor 300475 10 50 SX Mini Hold the rotor in place with special tool Holding spanner rotor 45229012000 p 147 Remove nut of the rotor P a r t S h a ...

Page 73: ... 50 SX 50 SX Junior Hold the rotor in place with special tool Holding spanner rotor 45229012000 p 147 Remove nut and the washer of the rotor 300854 10 Mount special tool on the rotor apply counterpressure and pull off the rotor by screwing in the screw Extractor 46129021000 p 148 15 13 Removing the engine sprocket 300479 10 Remove lock ring Take off the engine sprocket P a r t S h a r k c o m 8 7 ...

Page 74: ...cover 300482 10 Remove screws Take off the outer clutch cover Remove the clutch cover gasket 15 17 Removing the clutch cover 300483 10 Remove screws Take off the clutch cover Info Ensure that the kickstarter shaft remains in the engine case Remove the dowels and clutch cover gasket 15 18 Removing the clutch drum 300485 10 Hold the clutch drum with special tool Holding spanner 54629012100 p 149 Rem...

Page 75: ...the primary gear 300492 10 Hold the clutch in place with special tool Gear segment 45229081000 p 147 Loosen nut 15 22 Removing the centrifugal force clutch 300491 10 Take off centrifugal force clutch completely 15 23 Removing the kickstarter shaft 300493 10 Remove kickstarter shaft with the washer Info The washer usually sticks to the bearing Remove kickstarter spring P a r t S h a r k c o m 8 7 7...

Page 76: ...w connection of the engine holder 300987 10 Mount the special tool on the crankshaft Protecting sleeve 45229090000 p 148 Mount the special tool Extractor 45229048000 p 147 Info Use the hole labeled 452 Separate the engine case sections by screwing in screw Info Ensure that the engine case section is raised evenly Take off the left section of the engine case Remove the special tools Remove the spac...

Page 77: ...se gasket and dowels 15 27 Removing the transmission shafts 300500 10 Pull both transmission shafts out of the bearing seats together 15 28 Removing the crankshaft 300501 10 Remove crankshaft 300504 10 Remove O ring P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 78: ...ed when they are pressed in Press crankshaft seal ring from the outside to the inside with the open side fac ing inward Info The shaft seal ring must be flush on the outside 16 2 Work on the left section of the engine case 300506 10 Pull the dowels out of the engine case Remove crankshaft seal ring Remove shaft seal ring of the countershaft Remove lock ring Warm the engine case section in an oven ...

Page 79: ...k web with a suitable push out drift Info Hold the lower crank web Take off the connecting rod bearing and stop disks 300840 10 Press the crank pin out of the crank web 300845 10 Press the new crank pin all the way in Anchor plate 46229047002 p 148 300841 10 Mount stop disks bearing and connecting rod Info Oil the bearing thoroughly 300842 10 Position special tool on the press Pressing device cran...

Page 80: ...rrect the axial clearance to the specified value Check the crankshaft run out on the bearing pin p 78 16 4 Checking the crankshaft run out on the bearing pin 300846 10 Position the crankshaft on a roller block Turn the crankshaft slowly Check the crankshaft run out on both bearing pins Crankshaft run out on bearing pin 0 10 mm 0 0039 in If the crankshaft run out on the bearing pin is larger than t...

Page 81: ...ing in Press in the shaft seal ring until it is flush 300508 11 Mount water pump shaft Info Do not damage the shaft seal ring Mount the water pump impeller Mount and tighten screw Guideline Screw water pump wheel M5 5 Nm 3 7 lbf ft Loctite 243 300507 11 Mount drive gear 16 7 Changing the shaft seal ring of the kick starter 300510 10 Remove shaft seal ring of the kick starter Press the new shaft se...

Page 82: ...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 the clutch engagement speed Repeat these steps on the other clutch shoes 300513 11 Tighten screws with special tool Guideline Screw clutch spring M6 7 Nm 5 2 lbf ft Mortise key 45229021000 p 147 16 10 Checking measur...

Page 83: ...amage If the piston bearing surface is damaged Change the piston and if necessary the cylinder Check that the piston ring moves smoothly in the piston ring groove If the piston ring is stiff Clean the piston ring groove Tip Use an old piston ring to clean the piston ring groove Check the piston ring for damage If the piston ring is damaged Change the piston ring Check the piston ring anti rotation...

Page 84: ...n cylinder mounting clearance New condition 0 042 0 065 mm 0 00165 0 00256 in Wear limit 0 10 mm 0 0039 in 16 14 Checking the piston ring end gap 0 0 B B 400542 10 Remove the piston ring from the piston Place the piston ring in the cylinder and align it with the piston Guideline Under the upper edge of the cylinder 10 mm 0 39 in Measure the end gap using a feeler gauge Guideline Piston ring end ga...

Page 85: ...30 ENGINE WORK ON INDIVIDUAL PARTS 83 Change the intake flange P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 86: ...unt engine case gasket and dowels Info The axial play cannot be adjusted 300498 12 Mount the left section of the engine case Mount screws but do not tighten yet Guideline Screw engine case M6x40 10 Nm 7 4 lbf ft Mount screw but do not tighten yet Guideline Screw engine case M6x35 10 Nm 7 4 lbf ft Mount screw but do not tighten yet Guideline Screw engine case M6x55 10 Nm 7 4 lbf ft Mount screws and...

Page 87: ...arter spring and hook it in at area Mount washer Hook the kickstarter spring into kickstarter shaft The kickstarter spring is spring loaded by turning the kickstarter shaft clock wise Insert the kickstarter shaft into the engine case and let it engage 17 7 Installing the centrifugal force clutch 300491 10 Position the centrifugal force clutch 17 8 Tightening the nut of the primary gear 300730 10 H...

Page 88: ... Holding spanner 54629012100 p 149 Mount and tighten screw Guideline Screw clutch drum M8 30 Nm 22 1 lbf ft Loctite 243 17 12 Installing the clutch cover 300484 10 Mount dowels Mount clutch cover gasket 300483 12 Position the clutch cover Mount screws but do not tighten yet Guideline Screw clutch cover M6x25 10 Nm 7 4 lbf ft Mount screw but do not tighten yet Guideline Screw clutch cover M6x30 10 ...

Page 89: ... 7 4 lbf ft 17 14 Mounting the water pump cover 300481 10 Mount the gasket and dowels Position the water pump cover Mount and tighten screws Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft 17 15 Installing the kickstarter 300480 10 Position the kickstarter Mount and tighten screw Guideline Screw kickstarter M5 6 Nm 4 4 lbf ft Loctite 243 17 16 Installing the engine sprocket 300479 10 Slide on...

Page 90: ...Holding spanner rotor 45229012000 p 147 Mount and tighten nut Guideline Nut rotor M10x1 25 15 Nm 11 1 lbf ft 300855 10 50 SX 50 SX Junior Ensure that the spring washer is seated properly Mount rotor 300853 11 Hold the rotor in place with the special tool Holding spanner rotor 45229012000 p 147 Mount the washer and nut Tighten the nut Guideline Nut rotor M10x1 25 15 Nm 11 1 lbf ft P a r t S h a r k...

Page 91: ...screws Guideline Screw stator clamp M5 6 Nm 4 4 lbf ft 17 20 Installing the oil pump drive gear 50 SX Mini 300472 11 Position oil pump drive gear Mount lock ring 17 21 Installing the reed valve housing ignition coil and intake flange 300471 10 Position the gasket Position reed valve housing in the engine case opening 300469 10 Position the ignition coil and intake flange Mount and tighten screws G...

Page 92: ... Screw alternator cover M6 6 Nm 4 4 lbf ft 300852 10 50 SX 50 SX Junior Position alternator cover gasket 300851 11 Position the alternator cover Mount and tighten screws Guideline Screw alternator cover M6 6 Nm 4 4 lbf ft 17 23 Installing the oil pumps 50 SX Mini 300467 10 Position the oil pump Mount and tighten screws Guideline Screw oil pump M5 6 Nm 4 4 lbf ft P a r t S h a r k c o m 8 7 7 9 9 9...

Page 93: ...des Remove the cloth 17 25 Installing the cylinder 300465 10 Position the new cylinder base gasket Info If neither the piston cylinder crankshaft or engine case need to be changed the same gasket thickness can be used as before Oil the cylinder and piston Position the piston ring The anti rotation lock engages in piston ring end Slide the cylinder over the piston Carefully push the cylinder down a...

Page 94: ... gauge off of the cylinder X distance distance from adjusting gauge to piston 0 0 10 mm 0 0 0039 in If the specified value is not reached Set the X distance p 92 17 27 Setting the X distance Info The X distance is adjusted by inserting cylinder base gaskets of various thicknesses Check the X distance p 92 Remove the cylinder p 69 300503 10 Replace cylinder base gasket with a cylinder base gasket o...

Page 95: ...h magnet M12x1 5 20 Nm 14 8 lbf ft 17 30 Refilling with gear oil 300529 10 Remove screw cap and refill with gear oil Gear oil 0 20 l 0 21 qt Gear oil ATF Dexron 3 p 142 Mount and tighten the screw cap 17 31 Mounting the spark plug connector 300460 10 Mount spark plug connector 17 32 Removing the engine from the universal mounting rack 300729 11 Remove screw cap Remove the engine from the universal...

Page 96: ...and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed con tact a doctor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister according to regulations and keep it out of the reach of children Turn the knurled screw on the fuel tap all the way clockwise 300890 10 Pull off fuel hose Info Remaining fuel may run ...

Page 97: ...poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immedi ately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed con tact a doctor immediately Change clothing that has come into contact with fuel Store fuel in a suitable caniste...

Page 98: ...k spring retainer and the throttle slide spring Detach the throttle cable 18 3 Installing the carburetor 50 SX 300895 11 Attach throttle cable Position the spring retainer and throttle slide spring 300893 11 Position the throttle slide gasket and throttle slide cover Mount and tighten screws Guideline Screw throttle slide cover M5 3 Nm 2 2 lbf ft 300892 10 Mount the carburetor Position and tighten...

Page 99: ... Junior 50 SX Mini 300903 10 Attach throttle cable 300902 11 Position spring retainer Position the throttle slide spring 300901 11 Position the throttle slide and throttle slide cover Mount and tighten screw Guideline Screw throttle slide cover 50 SX Junior M5 3 Nm 2 2 lbf ft Screw throttle slide cover 50 SX Mini M5 3 Nm 2 2 lbf ft 300900 11 Mount the carburetor Position and tighten hose clamp P a...

Page 100: ...se clip 300896 11 Connect the fuel hose 50 SX Mini Bleed the oil pump p 119 Check the play in the throttle cable p 20 Carburetor adjust the idle speed p 109 18 5 Checking setting the carburetor components 50 SX 300916 01 Disassemble the carburetor p 99 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 101: ...ing the carburetor components 50 SX Junior 50 SX Mini 300926 01 Disassemble the carburetor p 101 Check the jet needle p 108 Check the throttle slide p 107 Check the float needle valve p 108 Check the choke slide p 107 Assemble the carburetor p 104 18 7 Disassembling the carburetor 50 SX Condition The carburetor has been removed 300904 10 Pull the hoses off of the carburetor P a r t S h a r k c o m...

Page 102: ...he float needle valve 300908 10 Remove cold start jet Remove idling jet Remove needle jet 300909 10 Note the setting of the idle mixture control screw Remove the idle mixture control screw with the O ring Info Make sure not to misplace the spring Remove the choke slide 300910 10 Pull the jet needle out of the throttle slide P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 103: ... hose off the carburetor 300917 10 Remove screws Remove the float chamber 300918 10 Remove fulcrum pin Remove float and the float needle valve 300919 10 Remove main jet Remove idling jet Remove cold start jet 300927 10 Press the needle jet out of the carburetor in the direction of the venturi tube P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 104: ...e slide M10 5 Nm 3 7 lbf ft 300909 11 Alternative 1 Mount idle mixture control screw with the spring and O ring Set the idle mixture control screw to the specified value Guideline Idle mixture adjusting screw Open 3 turns Alternative 2 Set the idle mixture control screw to the value determined when it was disas sembled 300908 11 Mount and tighten cold start jet Guideline Cold start jet M5 2 Nm 1 5...

Page 105: ...oat chamber 300907 11 Position the float needle valve and float Mount fulcrum pin Check set the float level p 108 300905 11 Mount the gasket Position the float chamber Mount and tighten screws Guideline Other screws carburetor M4 2 Nm 1 5 lbf ft 300904 10 Mount the hoses on the carburetor 300910 10 Position the jet needle in the throttle slide P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 106: ...as disassem bled 300920 11 Mount the choke slide Mount and tighten screws Guideline Other screws carburetor M4 2 Nm 1 5 lbf ft 300928 10 Position the needle jet in the carburetor 300919 11 Mount and tighten cold start jet Guideline Cold start jet M5 2 Nm 1 5 lbf ft Mount and tighten idling jet Guideline Idling jet M4 1 5 Nm 1 11 lbf ft Mount and tighten main jet Guideline Main jet M6x0 75 3 Nm 2 2...

Page 107: ...ni 300921 11 Alternative 1 Mount idle air adjusting screw with the spring Set the idle air adjusting screw to the specified value Guideline Idle air adjusting screw Open 1 turn Alternative 2 Set the idle air adjusting screw to the value determined when it was disassem bled 300920 11 Mount the choke slide Mount and tighten screws Guideline Other screws carburetor M4 2 Nm 1 5 lbf ft 300928 10 Positi...

Page 108: ...ghten main jet Guideline Main jet M6x0 75 3 Nm 2 2 lbf ft 300918 11 Position the float needle valve and float Mount fulcrum pin 300917 11 Position the float chamber Mount and tighten screws Guideline Other screws carburetor M4 2 Nm 1 5 lbf ft 300916 10 Mount the fuel hose on the carburetor 300923 10 Position the jet needle in the throttle slide P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 109: ...tor cleaner p 144 Check the piston of the choke slide for damage and wear If the piston of the choke slide is damaged or worn Change the choke slide Check the rubber sleeve and lock If the rubber sleeve is damaged or brittle or if the lock is not functioning Change the choke slide 18 14 Checking the throttle slide 50 SX Condition The throttle slide has been removed 300914 10 Check the throttle sli...

Page 110: ...uretor and float chamber have been removed 300915 10 Tilt the carburetor sideways preventing the fulcrum pin from falling out Tilt the carburetor until the float is resting against the float needle valve but the float needle valve is not being pressed together If the edge of the float is not parallel max 1 deviation upwards to the sealing area of the float housing in this position Adjust the float...

Page 111: ... adjust the idle speed again 18 20 Carburetor adjusting idle speed 50 SX Junior 50 SX Mini 700522 01 Screw in idle air adjusting screw all the way and turn it to the specified basic position Guideline Idle air adjusting screw 50 SX Junior Open 3 5 turns Idle air adjusting screw 50 SX Mini Open 1 turn Run the engine until warm Guideline Warm up time 5 min Danger Danger of poisoning Exhaust gases ar...

Page 112: ...lts the cause may be a wrongly dimensioned idling jet If you can turn the idle air adjusting screw to the end without any change of engine speed you need to install a smaller idling jet After changing the idling jet start from the beginning with the adjusting steps Following extreme air temperature or altitude changes adjust the idle speed again P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 113: ...cle on its side Remove screws Take off the clutch cover 300656 10 Hold the clutch drum with the special tool Holding spanner 54629012100 p 149 Remove screw Take off the clutch cover 300657 10 Take off the centrifugal clutch 19 2 Fitting centrifugal force clutch 300657 11 Position the centrifugal force clutch P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 114: ...pecial tool Tachometer 45129075000 p 146 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the motorcycle Slowly increase engine speed until the clutch...

Page 115: ...out 100 rpm Info The spacing washer of 1 7 mm 0 067 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 p 80 Fit the centrifugal force clutch p 111 Check the clutch engagement speed p 112 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 116: ... it Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft 20 2 Refilling coolant Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and con tact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immedi ately Change...

Page 117: ...If the coolant level does not meet specifications Correct the coolant level Alternative 1 Coolant p 142 Alternative 2 Coolant mixed ready to use p 142 Mount the radiator cap 20 4 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system compon...

Page 118: ...adiator 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 142 Alternative 2 Coolant mixed ready to use p 142 Mount the radiator cap P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 119: ... etc should be disposed of as stipulated in applicable regulations Info Drain the gear oil only when the engine is warm Stand the motorcycle on its side stand on a horizontal surface 700515 01 Place a suitable container under the engine Remove the oil drain plug with magnet Completely drain the gear oil Thoroughly clean the oil drain plug with magnet Clean the sealing area on the engine Mount and ...

Page 120: ...cycle upright on a horizontal surface 700525 01 Condition The engine is cold Remove gear oil level check screw Stand the motorcycle upright Check the gear oil level A small amount of gear oil should flow out If no gear oil flows out Add gear oil p 118 Mount and tighten the gear oil level check screw Guideline Screw gear oil level check M6 10 Nm 7 4 lbf ft 21 5 Adding gear oil Info Too little gear ...

Page 121: ...e If the vehicle is run without 2 stroke oil in the tank the result is engine failure The oil tank must always be filled up to the MIN mark Switch off the engine Open the oil tank cap 700518 01 Fill the oil tank at least up to the MIN mark Guideline MIN mark Sufficient for a single tank filling Oil tank contents ca 0 2 l 0 2 qt 2 stroke engine oil p 142 Close the oil tank cap 21 7 Bleeding the oil...

Page 122: ... line from the carburetor 300653 10 Turn the oil pump gear counterclockwise until oil flows out of oil line without bubbles 300651 10 Connect oil line Position the oil pump Mount and tighten screws Guideline Screw oil pump M5 6 Nm 4 4 lbf ft P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 123: ...eck the cable from the alternator to the ignition coil Check the ignition coil p 121 Check the spark plug connector p 121 Change the spark plug 300930 10 Mount the spark plug connector back on the ignition wire Turn out the spark plug and insert it into the spark plug connector Keep the spark plug connected to ground Forcefully step on the kickstarter pushing it all the way down Info Do not open t...

Page 124: ...f the displayed value does not equal the specification Change the ignition coil 22 4 Checking the kill switch Condition Fuel tank removed 300986 10 Disconnect ignition coil and kill switch Measure resistance on cable of kill switch to ground Resistance kill switch not activated If the displayed value does not equal the specification Check the wiring harness Change the kill switch Activate the kill...

Page 125: ...2 Socket connector or ignition coil is loose or oxidized Clean the socket connector and treat it with contact spray Water in carburetor or jets blocked 50 SX Junior 50 SX Mini Check set the carburetor components p 99 50 SX Check set the carburetor components p 98 Engine has no idle Idling jet blocked 50 SX Junior 50 SX Mini Check set the carburetor components p 99 50 SX Check set the carburetor co...

Page 126: ...etor Lack of fuel Turn the knurled screw on the fuel tap all the way counterclockwise Fill up with fuel Engine takes in bad air Check the 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 cool...

Page 127: ...cation 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 24 1 Capacity gear oil Ge...

Page 128: ... 00165 0 00256 in Wear limit 0 10 mm 0 0039 in Piston ring end gap Piston ring 0 60 mm 0 0236 in Cylinder bore diameter Size A 39 505 39 517 mm 1 55531 1 55578 in Size B 39 517 39 530 mm 1 55578 1 5563 in Connecting rod axial clearance of lower conrod bearing 0 40 0 75 mm 0 0157 0 0295 in Crankshaft run out on bearing pin 0 10 mm 0 0039 in X distance distance from adjusting gauge to piston 0 0 10 ...

Page 129: ...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 cylinder head M7 18 Nm 13 3 lbf ft Nuts cylinder base M8 20 Nm 14 8 lbf ft Screw clutch drum M8 30 Nm 22 1 lbf ft Loctite 243 Stud bolt cy...

Page 130: ...arburetor type Dell Orto PHVA 14DS Needle position 3rd position from top Idle air adjusting screw Open 3 5 turns Main jet 70 Jet needle A10 Idling jet 45 Needle jet 211FA Throttle slide 40 Cold start jet 60 27 3 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...

Page 131: ...bar 15 psi Rear 1 0 bar 15 psi Secondary drive ratio 50 SX 11 40 Secondary drive ratio 50 SX Junior 10 40 Secondary drive ratio 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 Junior 50 SX Mini 67 4 Wheelbase 50 SX 1 032 mm 40 63 in Wheelbase 50 SX Junior 910 mm 35 83 in Wheelbase 50 SX Mini 914 mm 35 98 in Seat heigh...

Page 132: ...ON MX Mid Soft 32 NHS 2 75 10 37J TT Pirelli SCORPION MX Mid Soft 32 NHS Additional information is available in the Service section under http www ktm com 28 2 Capacity fuel Fuel tank capacity approx 50 SX 50 SX Junior 2 3 l 2 4 qt Super unleaded gasoline mixed with 2 stroke engine oil 1 60 p 143 Fuel tank capacity approx 50 SX Mini 2 0 l 2 1 qt Super unleaded ROZ 95 RON 95 PON 91 p 143 P a r t S ...

Page 133: ...r 45201000133 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 607 mm 23 9 in Fork oil 210 ml 7 1 fl oz Fork oil SAE 7 5 p 142 29 3 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 7...

Page 134: ...ing 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 rider 35 kg 77 lb 85 N mm 485 lb in Spring length 130 mm 5 12 in Gas pressure 10 bar 145 psi Static sag 15 mm 0 59 in Riding sag 40 50 mm 1 57 1 97 in Fitted length 255 mm 10 04 in Shock absorber oil Shock absorber oil SA...

Page 135: ...TECHNICAL DATA SHOCK ABSORBER 133 Riding sag 40 50 mm 1 57 1 97 in Fitted length 245 mm 9 65 in Shock absorber oil Shock absorber oil SAE 2 5 50180342S1 p 143 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 136: ...maining 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 shock absorber M10 4...

Page 137: ...5 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 warms up and the...

Page 138: ... this way you can avoid long workshop waiting times at the start of the new season Clean the motorcycle p 135 Change the gear oil p 117 Check the antifreeze and coolant level p 115 Drain the fuel from the tank into a suitable container Check the tire air pressure p 47 Store the vehicle in a dry location that is not subject to large fluctuations in temperature Info KTM recommends jacking up the mot...

Page 139: ...he free travel of the foot brake lever p 58 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 Clean dust boots of fork legs p 9 Check swingarm bearing Check play of steering head bearing p 18 Check all screws to see if they are tight Wheels Check the spoke tension p 48 Check rim run ou...

Page 140: ... absorber p 25 Clean and lubricate swingarm bearing Grease the steering head bearing p 17 Change the glass fiber yarn filling of the main silencer Change the front brake fluid p 55 Change the rear brake fluid p 60 S20A Every 20 operating hours S40A Every 40 operating hours S80A Every 80 operating hours J1A Annually P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 141: ...139 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 142: ...WIRING DIAGRAM 140 35 1 Wiring diagram G k c a l b black k c a l b 0 0 1 1 0 0 2 2 0 0 3 3 300929 01 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 143: ...WIRING DIAGRAM 141 Components 1 Kill switch 2 Alternator 3 Ignition coil Cable colors black Black P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 144: ...y 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 153 SAE 7 5 Guideline Use only oils that comply with the specified standards see specifications on the...

Page 145: ...he 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 153 1 60 Mixture ratio 1 60 2 stroke engine oil p 142 Super unleaded ROZ 95 RON 95 PON 91 p 143 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 146: ...olishing materials for metal rubber and plastic Guideline KTM recommends Motorex 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 Lubricant T511 Guideline KTM recommends Lubcon products Supplier Lubcon Turmsilon GTI 300 P Lubricant T...

Page 147: ...pplier Motorex Moto Clean 900 Off road chain spray Guideline KTM recommends Motorex products Supplier Motorex Chain Lube 622 Oil for foam air filter Guideline KTM recommends Motorex products Supplier Motorex Twin Air Liquid Bio Power Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Universal P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 148: ...6000 Tachometer 400044 01 Art no 45129075000 Fitting for work stand 400576 01 Art no 45229001060 Holder of engine work stand 300673 01 Art no 45229001070 Bushing crankshaft pressing device 300991 01 Art no 45229008001 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 149: ...or 300669 01 Art no 45229012000 Mortise key 300671 01 Art no 45229021000 Press plate 301066 10 Art no 45229047050 Extractor 300937 10 Art no 45229048000 Gear segment 300670 01 Art no 45229081000 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 150: ...rt no 45229090000 Extractor 400045 01 Art no 46129021000 Anchor plate 300939 10 Art no 46229047002 Spring hooks 400363 01 Art no 50305017000 Pressing device crankshaft complete 300940 10 Art no 50329047000 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 151: ...0000 Holding spanner 300676 01 Art no 54629012100 Work stand 500071 01 Art no 54829055000 Peak voltage adapter 400083 01 Art no 58429042000 Torque wrench with various accessories in set 200910 10 Art no 58429094000 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 152: ...0 30 15 10 12 5 3 5 400110 01 Art no 59029041100 Engine work stand 200306 01 Art no 61229001000 Hook wrench 301085 01 Art no T106S Pin 201235 10 Art no T120 Pressing tool 200583 10 Art no T1206 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 153: ... tool 200585 01 Art no T1207S Pressing tool 200584 01 Art no T129 Squeeze bottle 201187 10 Art no T137S Hook wrench 301085 01 Art no T1533 Nitrogen filling tool 300574 10 Art no T170S1 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 154: ...SPECIAL TOOLS 152 Hook wrench 301085 01 Art no T304 Mounting sleeve 300578 10 Art no T313 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 155: ...ters 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 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 156: ...ngs front brake linings changing 57 front brake checking 56 front brake installing 56 front brake removing 56 rear brake changing 62 rear brake checking 61 rear brake installing 62 rear brake removing 61 C Carburetor assembling 102 104 105 disassembling 99 101 idle speed adjusting 108 109 installing 96 97 removing 94 95 Carburetor Work on individual parts choke slide checking 107 float level check...

Page 157: ...ng 38 F Filling up oil 119 Foot brake lever basic position adjusting 58 free travel adjusting 58 free travel checking 58 Fork legs assembling 13 checking 12 disassembling 11 installing 10 removing 9 servicing fork 10 Fork overhang adjusting 14 Front fender installing 44 removing 44 Front wheel installing 46 removing 46 Fuel tank installing 43 removing 42 Fuel oils etc 6 G Gear oil adding 118 chang...

Page 158: ...ing 35 36 spring removing 25 static sag checking 22 Spare parts accessories 6 Spark plug connector checking 121 Spoke tension checking 48 Spring preload shock absorber adjusting 23 Start number plate installing 44 removing 44 Starting 7 Steering head bearing greasing 17 Steering head bearing play adjusting 18 checking 18 Storage 136 T Technical data carburetor 128 chassis 129 130 chassis tightenin...

Page 159: ... 3206060en 3206060en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 07 2009 Photo Mitterbauer P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

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KTM 50 SX Mini, Repair Manual

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