KTM 50 SX PRO SENIOR LC, 50 SX PRO JUNIOR LC User Manual
OWNERS HANDBOOK
MANUALE D’USO
MANUEL D’UTILISATION
MANUAL DE INSTRUCCIONES
2002
BEDIENUNGSANLEITUNG
Art.Nr. 3.210.12 8/2001
50 SX PRO JUNIOR LC, 50 SX PRO SENIOR LC
ENGLISH
1
Please insert below the series numbers of the motorcycle
Chassis number
Engine number
Stamp of dealer
IMPORTANT
PLEASE READ THIS MANUAL THOROUGHLY BEFORE LETTING YOUR
YOUNGSTER RIDE THE MOTORCYCLE FOR THE FIRST TIME. THIS MANUAL
CONTAINS IMPORTANT INFORMATION AND RECOMMENDATIONS THAT
WILL HELP YOU AND YOUR YOUNGSTER TO OPERATE AND HANDLE THE
MOTORCYCLE PROPERLY.
IN THE INTEREST OF EVERYBODY INVOLVED, WE URGE YOU TO PAY PARTICULAR ATTENTION TO INSTRUCTIONS AND INFORMATION MARKED AS
FOLLOWS:
WARNING
IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY
AND YOUR LIFE.
!
CAUTION
!
IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO
PARTS OF THE MOTORCYCLE OR THAT THE MOTORCYCLE IS
NOT ROAD-SAFE ANYMORE.
KTM S
PORTMOTORCYCLE
AG
RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT, TECHNICAL SPECIFICATIONS, COLORS
,
MATERIALS, SERVICES OFFERED AND RENDERED, AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT
PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS
,
OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTI
-
TUTING THEM WITH OTHERS
. I
T SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS
ANNOUNCEMENT
. I
N THE EVENT OF SUCH MODIFICATIONS, PLEASE ASK YOUR LOCAL
KTM
DEALER FOR INFORMATION
.
W
E SHALL NOT BE HELD LIABLE FOR ANY PRINTING ERRORS
.
ENGLISH
2
Introduction
Now you own a modern motorcycle that you and your youngster will certainly enjoy, provided
that you service and maintain it properly. This manual contains important information on the
operation and maintenance of your new KTM motorcycle. It went to press describing your
model’s latest state of development. Nevertheless, the descriptions may deviate slightly from the
current design as our motorcycles are permanently improved.
Maybe you are one of those riders who have acquired good technical skills and can perform
many of the maintenance tasks themselves using the instructions contained in this manual. If this
is not the case, please keep in mind that the maintenance tasks marked with an asterisk (*) in
the chapter „Maintenance of chassis and engine“ should rather be performed by a KTM dealer
to protect you and your youngster.
Please strictly observe the prescribed running-in periods and inspection and maintenance intervals. Compliance with these instructions will significantly prolong the life of your motorcycle.
Maintenance work should only be performed by a KTM dealer.
When special needs arise, please contact a KTM dealer, who will seek the assistance of the KTM
importer if necessary.
PARENTS SHOULD KEEP IN MIND that the safety of their youngsters always depends on the
efforts made by the parents to ensure that the motorcycle is kept in good working order and
only used on safe terrains. Nevertheless, driving the motorcycle, like driving any other vehicle,
involves a potential risk. Therefore, please make sure that all fundamental precautions are taken.
Please also read the „INFORMATION ON SAFE DRIVING FOR PARENTS“ on page 4.
Riding an off-highway motorcycle is a wonderful form of outdoor recreation and we certainly
hope that you and your youngsters will enjoy it to the full. However, this enjoyable outdoor
activity can cause environmental problems or lead to conflicts with other people. Responsible use
of the motorcycle will prevent such problems and conflicts. You can contribute to securing the
future of motorcycling by making sure that you and your youngsters only use the motorcycle
within the limits established by the applicable laws, making environmental protection one of
your top priorities and never violating other people’s rights.
In this spirit, we hope that you and your youngsters will always safely enjoy your motorcycle!
KTM SPORTMOTORCYCLE AG
5230 MATTIGHOFEN, AUSTRIA
ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL.
©
by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved
KTM Austria’s certificate of achievement for its Quality System ISO 9001 is the beginning of an on-going
total re-engineering quality plan for a brighter tomorrow.
ENGLISH
3
Page
IMPORTANT INFORMATION ON SAFE DRIVING
FOR PARENTS....................................................................4
SERIAL NUMBER LOCATIONS...........................................5
Chassis number..............................................................5
Engine number, engine type ..........................................5
OPERATION INSTRUMENTS..............................................5
Throttle grip...................................................................5
Hand brake lever ...........................................................5
Short circuit button........................................................5
Filler cap ........................................................................6
Refueling, fuel ...............................................................6
Fuel tap .........................................................................6
Choke (DELL’ORTO PHVA 14 DS) ................................6
Choke (DELL’ORTO PHBG 19 BS).................................6
Kickstarter......................................................................7
Foot brake lever.............................................................7
Sidestand .......................................................................7
Rebound damping function of the shock absorber.........7
DRIVING INSTRUCTIONS ..................................................8
What you should check before each start......................8
Instructions for the first ride...........................................8
Running in .....................................................................8
Starting when engine is cold..........................................8
Starting when engine is warm........................................9
What to do when the engine is „flooded“ ....................9
Starting off ....................................................................9
Driving...........................................................................9
Braking ..........................................................................9
Stopping ........................................................................9
PERIODIC MAINTENANCE SCHEDULE............................10
MAINTENANCE WORK ON CHASSIS AND ENGINE........12
Checking and adjusting the steering head bearing.......12
Cleaning the dust scrabbers of the telescopic fork .......12
Telescopic fork maintenance........................................13
Changing the telescopic fork oil...................................13
How to change the handle bar position.......................14
Check chain tension.....................................................14
Correct chain tension...................................................14
Chain maintenance ......................................................14
INDEX
Page
Generel information about KTM disc brakes................15
Setting the basic position and play of the hand brake lever.15
Checking/refilling the front brake fluid level................15
Checking front brake pads...........................................16
Replacing the front brake pads ....................................16
Changing the basic position of the foot brake lever.....16
Adjusting the control cable on the rear wheel .............16
Checking the rear brake linings for wear .....................16
Drum brake maintenance ............................................17
Removing and mounting the front wheel ....................17
Removing and mounting the rear wheel......................17
Tires, air pressure.........................................................18
Checking spoke tension...............................................18
Cooling system ............................................................18
Checking coolant level.................................................19
Changing spring preloading of the shock absorber......19
Removing the seat.......................................................19
Cleaning the air filter ...................................................19
Exhaust system ............................................................20
Adjusting the throttle cable .........................................20
Adjusting the idle speed (Dell’Orto PHVA 14 DS)........20
Adjusting the idle speed (Dell’Orto PHBG 19 BS) ........20
Checking the gear oil level...........................................21
Changing the gear oil ..................................................21
Changing the seat hight ..............................................21
CLEANING .......................................................................22
STORAGE ........................................................................22
TECHNICAL DATA - ENGINE...........................................23
TECHNICAL DATA - CHASSIS .........................................24
ENGLISH
4
KTM mini motorcycles are off-road motorcycles designed for one person only. They are not allowed on public roads.
The vehicle is designed to be used by children from 6 to 10 years of age with a maximum weight of 35 kg
(78 lbs) and a maximum height of 130 cm (51 in) .
– Have your youngster wear proper protective gear whenever he or she rides the motorcycle: helmet, eye
protection, chest, back, arm and leg protectors, gloves and boots. To set a good example, be sure to wear
protective gear yourself whenever riding a motorcycle!
– Before your youngster takes his or her first ride, explain how each of the controls works and check if your
youngster has understood what you explained. We recommend to review the entire owner’s manual with
your youngster item by item, paying particular attention to the specially marked warnings and pointing out
the danger of injury.
– Instruct your youngster about riding and falling techniques, explain how the motorcycle will respond to
shifting of the rider’s weight, etc.
– Before using the motorcycle you should always check all components for proper operation (see mainenan-
ce schedule). Have your youngster perform these technical checks himself / herself as well.
– Whenever you go for a ride with your youngster, keep in mind that the speed should be adjusted to your
youngster and not the other way around.
–Your youngster must understand that all instructions he or she receives from you or any other supervising
adult must be followed.
–Your child must be physically ready to ride a motorcycle. This means that he or she must at least be able to
ride a bicycle. Being good at sports that require fast reactions is an additional advantage. Your youngster
should be strong enough to pick up the motorcycle after a fall.
– Never demand too much of your youngster. Give him or her time to get used to the motorcycle and to
improve his / her riding skills. Do not even consider letting your youngster participate in a race before
his / her physical condition, riding skills and motivation have sufficiently developed.
– Explain to your youngster that he / she should always adjust his / her riding speed to the local conditions
as well as to his / her own riding skills and that excessive speed can cause falls and severe injuries. Always
keep in mind that youngsters tend to underestimate dangers or fail to recognize them altogether. The riding
speed must be reduced, in particular, on unknown terrain.
– Never let your youngster ride the motorcycle without supervision. An adult should always be present.
– The motorcycle is designed for one rider only. Your youngster is not allowed to transport a passenger.
– When you go for a ride, somebody at home should always know where you are going and when you will
be back. This makes it easier to send you help, should problems occur.
IMPORTANT INFORMATION FOR PARENTS ABOUT SAFE DRIVING
ENGLISH
Chassis number
The chassis number is located on the type plate on the steering head. Write
this number into the field on page no 1.
Engine number
The engine number is stamped into the right half of the engine case next to
the kickstarter. Write this number into the relevant area on page 1.
Engine typ
50 MCH
Throttle grip
The throttle grip is located on the right side of the handlebar. It is used to
reduce the engine speed and, thus, the driving speed.
WARNING
T
HE MOTORCYCLE IS EQUIPPED WITH A CENTRIFUGAL CLUTCH
. THE MOTORCYCLE BEGINS
TO MOVE AS SOON AS THE THROTTLE IS OPENED
.
Hand brake lever
The hand brake lever is located on the right side of the handlebars and
actuates the front wheel brake. The basic position can be adjusted to fit
your child's hand.
!
CAUTION
!
IF THE RESISTANCE OF THE HAND BRAKE LEVER FEELS UNRESPONSIVE, SOMETHING IS
WRONG WITH THE BRAKE SYSTEM
. HAVE THE BRAKE SYSTEM CHECKED AT A KTM
WORKSHOP BEFORE YOU LET YOUR CHILD DRIVE THE MOTORCYCLE.
Short circuit button
The short circuit button 1 turns off the engine. When pressing this button,
the ignition circuit is short-circuited.
5
SERIAL NUMBER LOCATIONS
OPERATION INSTRUMENTS
1
ENGLISH
Filler cap
To open it: turn filler cap counter-clockwise.
To close it: put filler cap back on and tighten it by turning it clockwise.
Install tank breather hose
1 without kinks.
Refueling, fuel
Oil (high-grade two-stroke engine oil) must be mixed with the fuel
(ROZ 95) at a mixing ratio of 1:40.
Fuel and engine oil should only be mixed immediately before use.
KTM recommends SHELL ADVANCE RACING X.
WARNING
G
ASOLINE IS HIGHLY FLAMMABLE AND POISONOUS
. EXTREME CAUTION SHOULD BE USED
WHEN HANDLING GASOLINE
. NEVER REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR
BURNING CIGARETTES
. ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELING
. BE CAREFUL
NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT
.
W
IPE UP SPILLS PROMPTLY
. IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES, SEEK
A DOCTOR
’SADVICE IMMEDIATELY
.
!
CAUTION
!
–O
NLY USE PREMIUM-GRADE GASOLINE ROZ 95 MIXED WITH HIGH-GRADE TWO-
STROKE ENGINE OIL. OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE.
–O
NLY USE KNOWN BRANDS OF HIGH-GRADE 2-STROKE ENGINE OIL (SHELL ADVANCE
RACING X).
–N
OT ENOUGH OIL OR LOW
-GRADE OIL CAN CAUSE EROSION OF THE PISTON. WHEN
U
SING TOO MUCH OIL, THE ENGINE MAY START SMOKING AND FOUL THE SPARK PLUG
.
–FUEL EXPANDS WHEN ITS TEMPERATURE RISES. THEREFORE DO NOT FILL THE TANK TO
THE TOP
. (
SEE FIG.)
Fuel tap
The fuel tap 2 is located at the front of the motorcycle on the left side of
the tank.
Opening the fuel tap: Turn the knob all the way to the left.
Closing the fuel tap: Turn the knob all the way to the right.
!
CAUTION
!
T
HE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED. IF THE TAP
IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL GET INTO THE ENGINE
.
Choke (Dell’Orto carburetor PHVA 14 DS)
Choke lever 3 is mounted to the right side of the carburetor. If you move
the choke lever up to the stop, a hole is opened in the carburetor through
which the engine can draw in additional fuel. This results in a "rich" fuel-air
mixture required for a cold start.
Moving the choke lever back closes the hole in the carburetor again.
Choke (Dell’Orto carburetor PHBG 19 BS)
Choke control knob 4 is mounted to the left side of the carburetor. If you
pull the choke control knob up to the stop and turn it 90º, a hole is opened
in the carburetor through which the engine can draw additional fuel. This
results in a "rich" fuel-air mixture required for a cold start.
Turning back the choke control knob returns the knob to the starting position and closes the hole in the carburetor again.
6
40 mm
1
2
4
3
ENGLISH
Kickstarter
The kickstarter is mounted on the right side of the engine. Its upper part can
be swivelled.
WARNING
W
HEN STARTING THE ENGINE, PUT ON MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES
.
YOU MAY SLIP OFF THE KICKSTARTER, OR THE ENGINE MAY STRIKE BACK WHEN KICKING
NOT VEHEMENTLY ENOUGH
.
NOTE: an accessory kit for kick starter backwards operation is available.
Foot brake lever
The foot brake lever is located in front of the right footrest. The basic position can be adjusted to the seating position (see maintenance work).
Side stand
Use your foot to swing the side stand forwards to the stop. Make sure it
rests securely on solid ground.
WARNING
–THE SIDE STAND IS ONLY DESIGNED FOR THE WEIGHT OF THE MOTORCYCLE. IF YOU
GET ON THE MOTORCYCLE AND THUS PUT ADDITIONAL WEIGHT ON THE SIDE STAND
,
THE SIDE STAND OR THE FRAME CAN BE DAMAGED AND THE MOTORCYCLE MAY FALL
ON THE SIDE
.
–A
LWAYS CHECK BEFORE GOING FOR A RIDE THAT YOU HAVE FOLDED UP THE SIDE
STAND AS FAR AS POSSIBLE
. IF THE STAND TOUCHES THE GROUND WHILE YOU ARE
DRIVING
, YOU MAY LOSE CONTROL OF YOUR MOTORCYCLE.
Rebound damping function of the shock absorber
The damping effect of the rebound damping mechanism can be adjusted
by means of the setting wheel
1. Turn the setting wheel clockwise (in) to
increase and counterclockwise (out) to reduce the damping effect.
STANDARD SETTING: 5 CLICKS OPEN
WARNING
–NEVER TURN THE SETTING WHEEL MORE THAN TWO CLICKS BETWEEN TWO TEST RIDES.
–D
O NOT TRY TO DISASSEMBLE THE SHOCK ABSORBER OR TO PERFORM MAINTENAN-
CE WORK YOURSELF. DANGER OF INJURY!
7
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