Page 1
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
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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
.
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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.
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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
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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
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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
Page 7
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
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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
1
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8
DRIVING INSTRUCTIONS
– To ensure that your youngster gets the feel of the brakes,
have your youngster operate the brakes while you push the
motorcycle. Do not start the engine before your youngster
has learned to apply both brakes with appropriate pressure.
– Now your youngster must get the feel of the throttle. Start
the engine, hold the motorcycle and have your youngster
slowly open the throttle. Then, your youngster can take
his/her first ride. Initially, your youngster should ride back
and forth between two persons who help the young rider to
stop the motorcycle. However, you should also teach your
youngster how to stop the motorcycle himself/herself.
– To improve his/her riding skills, your youngster should prac-
tise to ride the motorcycle standing on the footpegs or to
ride at the slowest possible speed. Additionally, you can
arrange a series of obstacles and have your youngster drive
around them, etc.
– Tell your youngster to look 3-10 m ahead, depending on the
speed, to recognize and avoid obstacles. When riding
through curves, the rider should also look far ahead into the
curve.
WARNING
– KTM
MINI MODELS ARE DESIGNED FOR ONE PERSON ONLY.
P
ASSENGERS ARE NOT ALLOWED
.
–T
HESE MODELS DO NOT COMPLY WITH THE REGULATIONS AND SAFETY
STANDARDS ESTABLISHED BY THE LAW
. THEREFORE, THEY ARE NOT
PERMITTED ON PUBLIC ROADS
.
–A
LWAYS KEEP IN MIND THAT OTHER PEOPLE FEEL MOLESTED BY
EXCESSIVE NOISE
.
Running in
– Even very precisely machined sections of engine components
have rougher surfaces than components which have been
sliding across one another for quite some time. Therefore,
every engine needs to be broken in. Do not load the engine
to the power limit during the first half hour for this reason.
– Apply low but changing loads for running-in.
– NO FULL-LOAD OPERATION DURING THE FIRST HALF
HOUR!
Starting when the engine is cold
1 Open fuel tap
2 Operate the choke
3 Swing the side stand all the way up.
4 Applying the front brake.
5 Operate the kickstarter, depressing it all the way, without
opening the throttle.
WARNING
–T
O AVOID INJURY WHEN STARTING THE ENGINE, ALWAYS WEAR BOOTS!
–
A
LWAYS APPLY THE FRONT BRAKE WHEN STARTING THE ENGINE AND
RELEASE THE BRAKE SLOWLY WHEN THE ENGINE IS RUNNING
. A
N ACTIVA
-
TED CHOKE INCREASES THE IDLE SPEED OF THE ENGINE, THE CENTRIFUGAL
CLUTCH THUS BEGINNING TO ENGAGE
. T
HEREFORE, THE MOTORCYCLE
CAN BEGIN TO MOVE WHEN THE BRAKE LEVERS ARE RELEASED
.
–THE MOTORCYCLE HAS A CENTRIFUGAL CLUTCH. THE MOTORCYCLE
BEGINS TO MOVE AS SOON AS THE THROTTLE IS OPENED
.
–D
O NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA.
E
XHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONS-
CIOUSNESS AND DEATH. ALWAYS PROVIDE ADEQUATE VENTILATION
WHILE THE ENGINE IS RUNNING
.
What you should check before each start
When you start off, the motorcycle must be in a perfect technical condition. For safety reasons, you should make it a habit to
perform an overall check of your motorcycle before each start.
The following checks should be performed:
1 CHECK TRANSMISSION OIL LEVEL.
A lack of gear oil leads to premature wear and finally results
in destruction of the gear wheels.
2 FUEL
Check that there is sufficient fuel in the tank; when closing the
filler cap, check that the tank venting hose is free of kinks.
3 COOLING FLUID
Check the level of cooling fluid when the engine is cold.
4 CHAIN
A loose chain was fall off the chain wheels; an extremely
worn chain may tear, and insufficient lubrication may result
in unnecessary wear of chain and chain wheels.
5 TIRES
Check for damaged tyres. Tires showing cuts or dents must
be replaced. Also check the air pressure. Insufficient tread and
incorrect air pressure deteriorate the driving performance.
6 BRAKES
Check for proper functioning, check brake fluid level in the
tank. The tank is designed such that it does not need to be
refilled, even if the brake shoes are worn. If the brake fluid falls
below the minimum level, the brake system is either leaking or
the brake shoes are completely worn out. Have the brake
system checked at a KTM workshop to avoid brake failure.
Also have the condition of the brake hose and the brake-lining
thickness checked.
Check the play of the hand brake lever and foot brake lever.
7 THROTTLE CABLE
Check the throttle cable for proper adjustment and smooth
operation.
WARNING
–H
AVE 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. TOSETA
GOOD EXAMPLE
, BE SURE TO WEAR PROTECTIVE GEAR YOURSELF
WHENEVER RIDING A MOTORCYCLE
!
–O
NLY USE ACCESSORY PARTS RECOMMENDED BY KTM.
Instructions for the first ride
– Verify that your KTM dealer performed the PREPARATION
OF VEHICLE jobs (see Customer Service Manual).
– 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.
– Adjust the basic position of the hand brake lever to fit the
size of your child's hand. You child should of course wear
gloves. Adjust the foot brake lever to your child's seating
position.
– To prevent injury, teach your youngster the basic riding skills
on soft ground, e.g. on a meadow or in the garden. Be sure
that there is room enough to maneuver, and that no other
riders are close.
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9
Starting when the engine is warm
1 Open fuel tap
2 Swing the side stand all the way up.
3 Applying the front brake.
4 Operate the kickstarter, depressing it all the way, without
opening the throttle.
What to do when the engine is „flooded”
1 Close fuel tap
2 Applying the front brake.
3 Start engine with full throttle. If necessary, unscrew spark
plug and dry it.
4 Once the engine is running, open fuel tap again.
Starting off
Slowly release the brake lever while simultaneously opening the
throttle.
WARNING
A
LWAYS MAKE SURE THE SIDE STAND IS KICKED ALL THE WAY UP BEFORE
YOU LET YOUR CHILD DRIVE OFF
. IF THE STAND DRAGS ON THE FLOOR,
YOU MAY LOSE CONTROL OF YOUR MOTORCYCLE.
Driving
The engine speed, and thus the driving speed, are regulated by
the throttle grip.
The choke must always be deactivated as soon as the engine
has warmed up.
WARNING
–Y
OUR CHILD SHOULD NEVER DRIVE FASTER THAN ITS SKILLS AND THE
TERRAIN PERMIT
.
–N
EVER LET YOUR CHILD DRIVE ITS MOTORCYCLE UNCHAPERONED.
–WHEN THE ENGINE SPEED DROPS TO THE LEVEL AT WHICH THE CENTRI-
FUGAL CLUTCH DISENGAGES, BRAKING WITH THE ENGINE IS NO LON-
GER POSSIBLE AND THE MOTORCYCLE CAN ONLY BE SLOWED DOWN
USING THE BRAKES
.
–R
EPLACE THE HELMET VISOR OR GOGGLE GLASSES EARLY ENOUGH.
W
HEN LIGHT SHINES DIRECTLY ON A SCRATCHED VISOR OR GOGGLES
,
YOU WILL BE PRACTICALLY BLIND.
–A
FTER FALLING WITH THE MOTORCYCLE, CHECK ALL ITS FUNCTIONS
THOROUGHLY BEFORE USING IT AGAIN
.
–A
BENT HANDLEBAR MUST ALWAYS BE REPLACED. NEVER TRY TO
STRAIGHTEN THE HANDLEBAR BECAUSE THIS WILL CAUSE IT TO LOSE ITS
STABILITY
.
!
CAUTION
!
–DRIVING A COLD ENGINE AT HIGH SPEED WILL REDUCE THE LIFE OF THE
ENGINE
. WE RECOMMEND TO WARM THE ENGINE UP AT A MEDIUM
ENGINE SPEED FOR SEVERAL MINUTES BEFORE SWITCHING TO FULL
LOAD
.
–N
EVER TILT THE MOTORCYCLE OVER THE SIDE STAND TO WARM UP THE
ENGINE
. T
HE SIDE STAND COULD FOLD AWAY AND THE MOTORCYCLE
RUN OUT OF CONTROL
.
–I
N THE EVENT THAT, WHILE YOUR CHILD IS RIDING ON THE MOTORCY-
CLE, YOU NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, YOUR
CHILD SHOULD STOP IMMEDIATELY
, TURN THE ENGINE OFF, AND
CONTACT AN AUTHORIZED
KTM DEALER.
Braking
Close the throttle and squeeze both brake levers simultaneously. On sandy, wet or slippery terrain the rear wheel brake should
be preferred. The brakes should always be operated carefully as
locking wheels can cause skidding or falls.
WARNING
–B
RAKE DRUM AND LININGS HEAT UP DURING BRAKE OPERATION, THUS
REDUCING THE EFFECT OF THE BRAKES
.
–W
ET BRAKES HAVE REDUCED BRAKE PERFORMANCE
, THEREFORE BE
SHURE TO BRAKE THEM DRY AFTER CLEANING
.
Stopping
Reduce the speed. Immediately before the motorcycle comes to
a stop, put the left foot down. To turn off the engine, press the
short circuit button until the engine stops. Close the fuel tap.
WARNING
–N
EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS
THE ENGINE IS RUNNING
.
–MOTORCYCLES PRODUCE GREAT HEAT DURING OPERATION.
T
HEREFORE, KEEP IN MIND THAT THE ENGINE, THE EXHAUST SYSTEM
AND THE BRAKES CAN HEAT UP CONSIDERABLY
. MAKE SURE THAT THESE
PARTS ARE NOT TOUCHED AND ALWAYS TAKE CARE
, WHEN PARKING
THE MOTORCYCLE, THAT OTHER PERSONS WILL NOT BURN THEMSELVES
.
!
CAUTION
!
–CLOSE THE FUEL TAP WHEN LEAVING THE MOTORCYCLE. OTHERWISE
THE CARBURETOR MAY GET FLOODED AND FUEL WILL ENTER THE ENGINE
.
–T
HE SIDE STAND IS DESIGNED TO HOLD THE WEIGHT OF THE MOTORCY-
CLE ONLY. BY SITTING ON THE MOTORCYCLE, YOUR CHILD WILL PUT
ADDITIONAL WEIGHT ON THE SIDE STAND
, POSSIBLY CAUSING THE SIDE
STAND OR FRAME TO BE DAMAGED OR THE MOTORCYCLE TO FALL
DOWN
.
Page 11
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10
PERIODIC MAINTENANCE SCHEDULE 2002
Service
every
5 hours
Service
every
20 hours
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
A washed motorcycle can be checked more quickly which saves money!
Check engine for leaks ●
Change transmission oil ●
Check spark plug, change it if necessary, set electrode gap ●
Check carburetor for tight fit at intake flange ●
Check intake flange for cracks ●
Check idle setting when engine is warm ●
Check cooling system for leaks, check quantity of anti freeze ●
Check exhaust system for leaks and suspension ●
Check actuating cables for damage, smooth operation, and kink-less ●
arrangement, adjust and lubricate
Clean air filter and air filter box ●
Check brake fluid level, lining thickness, brake discs ●
Check the brake line and the brake control cable for damage ●
Check/adjust smooth operation, free travel of handbrake/footbrake levers ●
Check screws of brake system for tight fit ●
Check suspension strut and fork for leaks and proper function ●
Check swinging-fork pivot ●
Check/adjust steering-head bearing ●
Check all chassis screws for tight fit (fork plates, axle nuts, ●
swinging-fork pivot, suspension strut)
Check spoke tension and rim joint ●
Check tire condition and inflation pressure ●
Check chain, chain wheels, chain wheel guides for wear, tight fit, and tension ●
Lubricate chain ●
Check wheel bearings for play ●
IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER
Drain and clean the carburetor's float chamber ●
Perform complete fork maintenance ●
Clean and lubricate the swinging-arm bearing ●
Clean and lubricate the steering-head bearing and sealing elements ●
Change brake fluid ●
WHEELS CHASSIS BRAKES
ADD-ON-PARTS
ENGINE
50 SX PRO JUNIOR/SENIOR LC
water cooled
once a year
CARBURETOR
Page 12
ENGLISH
11
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC
Check transmission oil level ●
Check cooling liquid level ●
Check brake fluid level ●
Check brake pads for wear ●
Check brake performance ●●
Lubricate and adjust actuating cables and nipples ●
Remove and clean dust sleeves of telescopic fork in regular intervals ●
Clean and lubricate chain, check tension and readjust it if necessary ●●
Clean air filter and filter box ●
Check tire inflation pressure and wear ●
Check fuel line for leaks ●
Drain and clean float chamber ●
Verify smooth operation of all controls ●
Treat exposed metal components (except for the brake and exhaust systems) ●
with wax-based anti-corrosion agents
Check all screws, nuts, and hose clamps for their tight fit in regular intervals ●
for cross
country use
once a year
after every
cleaning
before each
start
Page 13
ENGLISH
12
Checking and adjusting the steering head bearing *
The steering head bearing should regularly be checked for play. For this purpose, jack up the motorcycle by the frame so that the front wheel is in the
air. Now try to move the fork forward and backward. There should be no
clearance. For readjustment, release the two clamp screws
1 of the top tri-
ple clamp and the counter nut
2. Turn the adjusting nut 3 until almost no
play is left. Do not tighten the adjusting nut! Tightening the adjusting nut
can damage the bearings! Keep in mind that tightening the counter nut
2
reduces the play of the bearing. Slightly tap the top triple clamp with a
rubber hammer to prevent jamming. Then tighten the 2 clamp screws with
15 Nm (11 ft.lb).
WARNING
I
F THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF CLEARANCE, THE
MOTORCYCLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF
CONTROL
.
!
CAUTION
!
–THE HANDLEBAR MUST MOVE EASILY. OTHERWISE THE BEARINGS WILL BE DAMAGED.
–IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS, THE
BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME WILL BE DESTROYED
.
At least once a year, the steering head bearings should be smeared with
waterproof grease (Shell Advance Grease).
Cleaning the dust scrabbers of the telescopic fork
The dust-protection bellows 4 are to remove dust and coarse dirt particles
from the fork tube. However, after some time, dirt may also get in behind
the dust-protection bellows. If this dirt is not removed, the oil sealing rings
located behind it may start to leak.
For this purpose, use a screwdriver to lever the dust scrabbers out of the
slider tubes, clean them thoroughly with compressed air, spray the fork
tubes and dust scrabbers with silicon oil and press the scrabbers back into
the slider tubes.
MAINTENANCE WORK ON CHASSIS AND ENGINE
WARNING
MAINTENANCE WORK AND ADJUSTMENTS MARKED WITH AN ASTERISK (*) MUST BE PERFORMED BY AN EXPERT. TO PROTECT YOUR YOUNGSTER, ALWAYS HAVE SUCH WORK PERFORMED
BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY
APPROPRIATELY QUALIFIED SKILLED STAFF.
!
CAUTION
!
–WHEN CLEANING THE MOTORCYCLE
, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE, OTHERWISE WATER WILL PENETRATE THE
BEARINGS
, CARBURETOR
, ELECTRIC CONNECTORS, DRUM BRAKES, ETC
.
–B
EFOR CLEANING WITH WATER
, PLUG THE EXHAUST PIPE TO PREVENT WATER INGRESS
–WHEN TRANSPORTING YOUR MOTORCYCLE
, SECURE IT WITH ELASTIC STRAPS OR OTHER MECHANICAL DEVICES IN AN UPRIGHT POSITION.
BE SURE THAT THE FUEL TAP IS CLOSED
. IF THE MOTORCYCLE TOPPLES OVER
, FUEL CAN FLOW OUT OF THE CARBURETOR OR FUEL TANK.
–D
O NOT USE TOOTHED WASHERS OR SPRING RINGS WITH THE ENGINE FASTENING SCREWS, AS THESE WORK INTO THE FRAME PARTS AND KEEP
WORKING LOOSE
. INSTEAD, USE SELF-LOCKING NUTS.
–L
ET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED.
–R
EMOVE OILS, FATTY MATTERS, FILTERS, FUELS, WASHING DETERGENTS ETC. ORDERLY.
–U
NDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIZE. 1 LITER USED OIL
CONTAMINATES
1.000.000
LITERS WATER.
1
2
3
2
3
1
4
Page 14
ENGLISH
13
Telescopic fork maintenance *
The telescopic fork must be serviced at least once a year.
To service the fork, proceed as follows:
Prop up the motorcycle under the frame to take the load off the front
wheel.
Disassemble the front wheel, remove screw
1 from the brake caliper and
unscrew holding clamp. Measure the projection of the fork legs at the upper
fork stabilizer and make a note of the measurement.
Loosen the clamping screws
2 on the fork stabilizers and pull the fork legs
down out of the fork stabilizers.
!
CAUTION
!
–D
O NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN
DISMOUNTED
.
–M
AKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL
,
OTHERWISE THE BRAKE DISC CAN BE DAMAGED
.
Clamp the fork leg into a vise (use protective jaws) and remove the
plugs
3. Take the preload spacer and the spring out of the fork tube.
Remove screws
4 at the underside of the slider tubes and pull the fork
tubes out of the slider tubes.
Remove the dust scrabbers
5.
Thoroughly clean all parts and check for wear.
Generously lubricate seals and springs and reassemble the telescopic fork.
Tighten the screws on the bottom of the sliding tubes to 30 Nm (22 ft.lb).
Fill in fork oil and assemble the fork (see below). Degrease the screws on the
brake caliper and apply Loctite 243. Mount the brake caliper and tighten to
25 Nm (19 ft.lb). Mount brake line and holding clamp.
Insert fork legs in the fork stabilizers (projection as previously noted) and
tighten clamping screws to 15 Nm (11 ft.lb).
Mount front wheel (see chapter: mounting the front wheel).
Changing the telescopic fork oil *
Remove front wheel and fork legs (see above).
Remove plugs, preload spacers and springs.
Drain the fork oil into an appropriate container.
Clean the dust scrabbers.
WARNING
–I
TISVERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS.
O
THERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.
–A
FTER WORKING ON THE BRAKE SYSTEM, ALWAYS OPERATE THE HAND BRAKE LEVER
TO APPLY THE BRAKE SHOES TO THE BRAKE DISK AND HAVE A POINT OF PRESSURE
.
Pour 170 cm
3
SAE 7.5 fork oil into each fork tube.
Slide the fork tube all the way into the slider tube.
Adjust the air-chamber length
A to 110 mm (4.5 in) by extracting or
adding fork oil.
Insert springs and pretensioning sleeves into the fork tube.
Check O-rings, grease and mount plugs.
Mount the fork legs, front wheel and brake caliper (see above).
4
3
A
2
1
5
2
Page 15
ENGLISH
14
How to change the handlebar position
The handlebar position can be readjusted by 22 mm (0.9 in). The upper triple clamp 1 includes 2 bores arranged at a distance of 15 mm (0,6 in) from
one another. The bores at the handlebar support
2 are offset from the cen-
ter by 3.5 mm (0,13 in). Accordingly, you can mount the handlebar in
4 different positions.
For this purpose, remove screws
3 of the handlebar clamps and screws 4
of the handlebar support. Position handlebar support, and tighten screws 4
to 40 Nm (30 ft.lb). Mount handlebar and handlebar clamps, and tighten
screws
3 to 20 Nm (15 ft.lb). The gap between handlebar support and
handlebar clamps is to be of equal size in the front and in the rear.
Check chain tension
Put the motorcycle on the sidestand.
Chain tension has to be checked close to the lower rear shock mounting
A.
When pushing the chain upwards, the distance to the swingarm has to be
10 mm (0.4 in).
If necessary, correct chain tension.
WARNING
–I
F CHAIN TENSION IS TOO GREAT, PARTS WITHIN THE SECONDARY TRANSMISSION
(CHAIN
, CHAIN WHEELS,
GEAR BOX AND REAR WHEEL BEARINGS
) WILL BE SUBJECTED
TO UNNECESSARY STRESS, RESULTING IN PREMATURE WEAR AND EVEN CHAIN BREAKAGE
.
–TOO MUCH SLACK IN THE CHAIN, ON THE OTHER HAND, CAN RESULT IN THE CHAIN
JUMPING OFF THE CHAIN WHEELS
. I
F THIS HAPPENS
, THE CHAIN COULD ALSO BLOCK
THE REAR WHEEL OR DAMAGE THE ENGINE
.
–I
N EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE.
Correct chain tension
Release the hexagon nut of the wheel spindle 5 and turn the left and the
right hexagon nut
6 equally far.
Before tightening the hexagon nut of the wheel spindle with 30 Nm
(22 ft.lb), ensure that the supporting plates
7 are resting against the swing
arm. Additionally, check that the rear wheel is aligned with the front wheel.
Chain maintenance
For long chain life, good maintenance is very important. Chains without
O-rings should be cleaned in fireproof solvent regularly and afterwards
treated with hot grease or chain spray (Shell Advance Bio Chain).
WARNING
KEEP THE REAR WHEEL FREE OF GREASE! GREASE ON THE REAR WHEEL WILL SIGNIFICANTLY
REDUCE THE GRIP OF THE REAR TIRE AND THE MOTORCYCLE COULD EASILY GET OUT OF CONTROL
.
!
CAUTION
!
WHEN MOUNTING THE CHAIN MASTERLINK CLIP, THE CLOSED SIDE OF THE MASTERLINK
CLIP MUST POINT IN RUNNING DIRECTION
.
Also check sprockets and chain guides for wear, and replace if necessary.
✓
1
2
3
4
A
10 mm
6
6
7
7
15 mm
3,5 mm
5
Page 16
ENGLISH
General information about KTM disc brakes
BRAKE FLUID RESERVOIRS:
The brake fluid reservoirs for the front brake is designed such that it does
not need to be refilled, even if the brake shoes are worn. If the brake fluid
level drops below the minimum level either the brake system has a leak or
the brake pads are completely worn.
In this case, consult an authorized KTM dealer immediately.
BRAKE FLUID:
KTM fills the brake system with ”Shell Advance Brake DOT 5.1”, one of the
best brake fluids currently available. We recommend that you continue to
use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color.
If you do not have any DOT 5.1 for refilling, you may use DOT 4 brake
fluid. DOT 4 shown on the lid means minimum standard. However, you
should replace it as soon as possible by DOT 5.1.
BRAKE DISC:
Due to wear, the thickness of the brake disc in the area of the contact
face
1 of the brake pads decreases. At their thinnest point A, the brake
discs must not be more than 0.40 mm (0,016 in) thinner than the pad's
nominal thickness. Measure the nominal thickness in a location
B outside
the contact face. Check wear in several locations.
WARNING
–A
BRAKE DISK WORN DOWN 0.40 MM (0,016 IN) OR MORE IS A SAFETY RISK. HAVE
THE BRAKE DISK REPLACED AS SOON AS IT REACHES THE SERVICE LIMIT
.
–H
AVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BA A KTM DEALER.
Setting the basic position and play of the hand brake lever *
You can adjust the basic position of the hand brake lever to fit your child's
hand by turning stop screw
2. Afterwards, be sure to adjust the play of the
hand brake lever to 2 mm (0,08 in)with the adjusting screw
3. To adjust,
remove covering cap
4. Replace the covering cap after making the
adjustment.
!
CAUTION
!
A
T THE HAND BRAKE LEVER
, FREE TRAVEL MUST AT LEAST BE 2 MM (0,08 IN). ONLY
THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED
(TO BE RECOGNIZED BY
THE GREATER RESISTANCE OF THE HAND BRAKE LEVER
). IF THIS FREE TRAVEL IS NOT PRO-
VIDED,
PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM, AND THE FRONT-WHEEL BRAKE
MAY FAIL DUE TO OVERHEATING
.
Checking/refilling the front brake fluid level *
Put the hand brake cylinder in a horizontal position, remove screws 5 and
cover
6 with diaphragm 7. If necessary, refill DOT 5.1 (e.g. Shell Advance
Brake 5.1) brake fluid up to 5 mm (0,2 in) under the upper edge of the tank.
Remount the diaphragm, cover and screws. Wash off any overflowing or
spilled brake fluid with water.
WARNING
– NEVER
USE DOT 5 BRAKE FLUID! ITISBASED ON SILICONE OIL AND OF A PURPLE
COLOR
. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT.
–S
TORE BRAKE FLUID OUT OF REACH OF CHILDREN.
–BRAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND EYES.
I
F YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER AND CONSULT
A DOCTOR
.
!
CAUTION
!
–DON’TLET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE
PAINT REMOVER
.
–U
SE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.
15
DOT
5.1
DOT
5
✓
✕
min. 2 mm
2
4
3
5 mm
6
5
7
A
B
1
Page 17
ENGLISH
16
Checking front brake pads
Inspect the brake pads from in front of the vehicle. The linings must be at
least 1 mm (0.04 in) thick.
WARNING
A
T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM
(0,04 IN), OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN SAFETY
DON
’
T PUT OFF HAVING YOUR BRAKE PADS CHANGED.
!
CAUTION
!
I
F THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRE-
LY WORN
, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE
DISC
, THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC.
Replacing the front brake pads*
Remove the front wheel (see front wheel chapter).
Press brake shoes apart with a suitable screwdriver to put the brake pistons
in their basic position.
Remove the lock washer
1 from the screw as well as fixing screw 2 and
take the brake shoes out of the brake caliper. Clean brake caliper thoroughly
with compressed air.
Mount the right brake shoe and fix with screw. Mount the left brake shoe
and tighten the screw to 6 Nm (4,5 ft.lb). Mount the lock washer. Align
brake shoes, mount front wheel (see chapter: Mounting the front wheel).
WARNING
–I
TISVERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS.
OTHERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.
–A
FTER ASSEMBLY, CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY.
–D
O NOT UNSCREW ANY OTHER SCREWS ON THE BRAKE CALIPER OR YOU WILL HAVE
TO BLEED THE BRAKE SYSTEM
.
Changing the basic position of the foot brake lever
The basic position of the foot brake lever can be changed by unscrewing
screw
3 and then turning retainer 4.
Afterwards, check the setting of the rear wheel brake.
Adjusting the control cable on the rear wheel
You should be able to press the foot brake lever 5 to 10 mm (0,2-0,4 in)
before the rear wheel begins to brake.
The brake control cable is adjusted with adjusting screw
5 on the brake
anchor cover. First loosen lock nut 6 and then tighten again.
!
CAUTION
!
A
FTER MAKING ADJUSTMENTS, ALWAYS MAKE SURE THE WHEEL TURNS FREELY.
Checking the rear brake linings for wear
The brake linings must be replaced when the distance between the hub
brake lever and the cable support, measured with the brake lever squeezed,
is less than 50 mm (2 in) (see illustration).
!
CAUTION
!
IF THE BRAKE LININGS ARE REPLACED TOO LATE, I.E. WHEN THE LINING IS PARTLY OR
FULLY WORN AWAY
, THE METAL SHOES WILL RUB AGAINST THE BRAKE DRUM, THUS
REDUCING THE BRAKING EFFECT AND DESTROYING THE BRAKE DRUM
.
min 50 mm
6
min.
1 mm
5
1
2
5-10 mm
4
4
3
Page 18
ENGLISH
17
Drum brake maintenance
Drum brake maintenance is limited to occasional blowing out of brake drum
and brake shoes. Brake drum and brake linings can be slightly roughened
with an abrasive tape.
Removing and mounting the front wheel
Jack the motorcycle up by the frame so that the front wheel is suspended
above the ground.
Undo the hexagon nut
1 and remove it together with the washer.
Hold the front wheel and pull out the wheel spindle
2.
Carefully take the front wheel out of the fork.
!
CAUTION
!
–
D
O NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN DISMOUNTED
.
–MAKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL,
OTHERWISE THE BRAKE DISC CAN BE DAMAGED.
Lift the front wheel into the fork and correctly position it.
Mount the wheel spindle
2.
Mount the washer and the hexagon nut
1 and tighten (30 Nm/22 ft.lb).
Put the motorcycle back on the ground and operate the front wheel brake
until the working point is reached.
WARNING
–I
F YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE
THE TIGHTENING TORQUE CORRECTED BY A
KTM DEALER AS SOON AS POSSIBLE
. A
LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE
.
–AFTER MOUNTING THE FRONT WHEEL, KEEP OPERATING THE HAND BRAKE UNTIL THE
PRESSURE POINT RETURNS
.
–I
TISVERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS,
EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED.
Removing and mounting the rear wheel
Prop up the motorcycle under the frame.
Remove hexagon nut 3 on the wheel spindle and disk.
Hold the rear wheel and remove the wheel spindle.
Move the rear wheel forwards, remove chain, lift the rear wheel out of the
swinging fork and remove the brake anchor.
To mount the wheel reverse the procedure described above.
Always hook the brake backing plate into the swing arm support.
Before tightening the hexagon nut of the wheel spindle, ensure that the
supporting plates
4 are resting against the swing arm. Additionally, check
that the rear wheel is aligned with the front wheel.
Tighten the hexagon nut with 30 Nm (22 ft.lb).
WARNING
I
F YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE
THE TIGHTENING TORQUE CORRECTED BY A
KTM DEALER AS SOON AS POSSIBLE. A
LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE.
3
1
2
4
4
Page 19
ENGLISH
18
Tires, air pressure
Tire type, tire condition, and air pressure level affect the way your motorcycle rides, and they must therefore be checked whenever you are getting
ready to go anywhere on your motorcycle.
– Tire size can be found in the technical specifications.
– Tire condition has to be checked every time you want to ride your
motorcycle. Before leaving, check tires for punctures and nails or other
sharp objects that might have become embedded in them.
– Regularly check the "cold" tire pressure. Correct tire pressure (1.0 bar /
14 psi) guarantees optimum grip and maximum tire life.
WARNING
–D
AMAGED TIRES MUST BE REPLACED IMMEDIATELY TO PROTECT YOUR YOUNGSTER.
–W
ORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW THE MOTORCYCLE PERFORMS,
ESPECIALLY ON WET SURFACES
–TIRE PRESSURE BELOW THE NORMAL LEVEL WILL LEAD TO PREMATURE TIRE WEAR
.
Checking spoke tension
The correct spoke tension is very important for the stability of the wheels
and thus for riding safety. A loose spoke causes the wheel to become
unbalanced and before long other spokes will have come loose. Check
spoke tension, especially on a new motorcycle, in regular intervals. If necessary, have the spokes retightened and the wheel centered by a KTM dealer.
WARNING
–
S
POKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE
. T
HIS MAY LEAD TO AN
UNSTABLE HANDLING OF YOUR MOTORCYCLE
.
–EXCESSIVELY TENSIONED SPOKES MAY RUPTURE DUE TO LOCAL OVERLOADING.
Cooling system
The water pump 1 in the engine keeps the cooling liquid in circulation.
The cooling liquid is cooled by the air stream. Therefore, the cooling effect
is reduced when the traveling speed is reduced. Dirty radiators additionally
reduce the cooling effect.
The cooling liquid can be drained by removing screw
2 on the water-pump
cover.
WARNING
D
O NOT REMOVE ANY COOLER HOSES OR THE DRAIN SCREW WHEN THE ENGINE IS HOT.
A mixture of 40% anti freeze liquid and 60% water is used as coolant. However, the anti-freeze protection must be at least -25° C (-13° F). This mixture offers anti-freeze protection but also good corrosion protection and
should therefore not be replaced by pure water.
!
CAUTION
!
F
OR THE COOLING SYSTEM, USE ONLY WITH HIGH-GRADE ANTIFREEZE (SHELL ADVANCE
COOLANT). USING LOWER-GRADE ANTIFREEZE AGENTS, CAN CAUSE CORROSION AND
COOLANT FOAMING
.
Pressure induced by heating of the coolant in the system is controlled by a
valve in the radiator cap 3; a water temperature rising up to 120° C (248° F)
is admissible, without fear of problems.
1
3
2
Page 20
ENGLISH
19
when engine is cold
10 mm
1
Checking coolant level
The coolant should be 10 mm (0.4 in) above the radiator fins when the
engine is cold (see illustr.). In the event of the coolant being drained, always
fill and bleed the system.
WARNING
IFPOSSIBLE, ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD. IF YOU
HAVE TO OPEN THE RADIATOR CAP WHEN THE ENGINE IS HOT
, USE A RAG TO COVER THE
CAP AND OPEN SLOWLY TO RELEASE PRESSURE
.
Changing spring preloading of the shock absorber
This is easily done.
NOTE: Before changing the spring preload note down the basic setting, e.g.
how many threads are visible above the adjusting ring.
Remove the right side cover.
Loosen the locking ring
1 with the hook spanner. Change
the spring prelo-
ad with the adjusting ring
2 and re-tighten the locking ring 1.
BASIC SETTING – SPRING PRELOAD
7 mm (0.3 in)
Removing the seat
The quick-release mechanism 3 allows removal of the seat without tools.
Turn the quick-release device approximately 180° anticlockwise, lift the rear
portion of the seat and pull the seat off backwards.
When mounting the seat ensure that the hook engages at the tank.
Cleaning the air filter *
The air filter must be cleaned at intervals depending on the amount of dust
accumulated. To clean the air filter, first remove the seat. Then press both
retaining clips
4, remove the filter holder and the air filter 5. The air filter
consists of a foam rubber insert soaked with filter oil.
!
CAUTION
!
–D
O NOT CLEAN FOAM FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE
THE FOAM
. KTM RECOMMENDS THE PRODUCTS MADE BY TWIN AIR FOR AIR FILTER
MAINTENANCE
.
–N
EVER OPERATE YOUR MOTORCYCLE WITHOUT AIR FILTER
. OTHERWISE, DUST AND
DIRT MAY GET INTO THE ENGINE AND LEAD TO INCREASED WEAR
.
–T
HE HOLDER MUST RETAIN THE AIR FILTER THROUGHOUT ITS ENTIRE CIRCUMFEREN-
CE
. IF THE FILTER HAS BEEN MOUNTED INCORRECTLY
, THE ENGINE WILL TAKE IN UNFIL-
TERED AIR, THEREBY CAUSING INCREASED ENGINE WEAR.
Thoroughly wash the foam filter in special cleaning fluid and allow it to dry
well. Only press out the filter, do not wring it out under any circumstances.
Oil the dry foam filter with a high-grade filter oil. Also clean the air filter
box. Check carburetor collar for damage and that it is filled correctly.
Insert the air filter in the opening and fasten it with the filter holder. Then
mount the seat.
2
4
4
5
3
Page 21
ENGLISH
20
Exhaust system
The silencer is filled with glass-fiber yarn for damping. When in use, the
glass-fiber yarn becomes loose or coked with oil carbon. This can lead to a
power loss and a reduction of the silencer damping. The glass-fiber yarn
packing can be replaced in a few easy steps.
To replace, remove the silencer from the vehicle and mark the position of
the outer tube
1 to the inner tube 2. Remove screws 3 and the end cap
4. Pull of the outer tube and remove the old glass-fiber yarn packing 5
from the inner tube. Thoroughly clean all parts.
To assemble, mount a new glass-fiber yarn packing onto the inner tube (see
illustration) and slide into the outer tube. Mount end cap and fix with
scews
3. Before tightening the screws, turn the outer tube until they match
the positions you marked. Mount the silencer and check the exhaust system
for tightness.
NOTE: Glass fiber yarn packages are offered by your licensed KTM dealer.
WARNING
T
HE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUNNING
. TO
AVOID BURNS
DO NOT START WORK ON THE EXHAUST SYSTEM UNTIL IT HAS PROPERLY
COOLED DOWN
.
Adjusting the throttle cable *
There must always be a 3 to 5 mm (0.1 to 0.2 in) play in the throttle cable.
To check this, move back the protective cover
6 on the throttle grip. You
must be able to lift the outer covering of the cable 3-5 mm from the adjusting screw
7, until resistance is felt.
To adjust, loosen the counter nut
8 and turn the adjusting screw accor-
dingly. Finally tighten counter nut and slide the protective cover back on.
Adjusting the idle speed (Dell’Orto PHVA 14 DS) *
The idle speed can be adjusted with screw 9.
The idle speed is increased by turning clockwise.
The idle speed is reduced by turning counter-clockwise.
Adjusting the idle speed (Dell’Orto PHBG 19 BS) *
The idle speed can be adjusted with screw bk.
The idle speed is increased by turning clockwise.
The idle speed is reduced by turning counter-clockwise.
3-5 mm
6
8
7
9
10
3
5
4
2
1
Page 22
ENGLISH
21
Checking the gear oil level
To check the gear oil level, first remove the plug 1. With the motorcycle
parked in an upright position, a small quantity of oil should flow out of the
indicator opening
2. If oil must be added, tilt the motorcycle and pour
automatic gear oil ( Shell Donax TA) into the bore.
!
CAUTION
!
LESS OIL OR A POOR OIL QUALITY LEAD TO PREMATURE TRANSMISSION WEAR.
T
HEREFORE, ONLY USE BRANDED PRODUCTS (SHELL Donax TA).
Changing gear oil *
The engine must be warmed up before changing the gear oil. Park the
motorcycle on a horizontal surface, remove the oil drain plug
3 and drain
the used oil into an appropriate container. Clean the sealing surface, mount
the oil drain plug together with the gasket and tighten with 15 Nm (11 ft.lb).
Remove stopper 4 and fill in 0.15 liters of automatic gear oil (Shell Donax
TA). Mount the stopper and check the engine for tightness.
!
CAUTION
!
L
ESS OIL OR A POOR OIL QUALITY LEAD TO PREMATURE TRANSMISSION WEAR.
T
HEREFORE, ONLY USE BRANDED PRODUCTS (SHELL Donax TA).
Changing the seat height
The saddle can easily be raised by 25 mm (1 in). This lets you adjust the height
as your child grows.
Figures A and B show the fork and shock absorber positions for a low seat
position. The fork tubes extend approx. 17 mm (0.7 in) (H) above the upper
fork stabilizer. The shock absorber is attached to the upper hole in the frame.
Tighten the clamp screws on the fork stabilizers to 15 Nm (10 ft.lb) , the screw
on the shock absorber to 45 Nm (33 ft.lb).
Figures A and B: low seat position
Figures C and D: high seat position
Figures C and D show the fork and shock absorber positions for a high seat
position.Fork tubes are plane with top of upper fork stabilizer. (Screw cap
(Aluminium) protrudes top of upper fork stabilizer)
The shock absorber is attached to the lower hole in the frame. Tighten the
clamp screws on the fork stabilizers to 15 Nm (10 ft.lb) , the screw on the
shock absorber to 45 Nm (33 ft.lb).
WARNING
T
HE FORK TUBES MAY NOT BE LOWERED ANY FURTHER THAN AS DESCRIBED ABOVE, OTHER
-
WISE THE CLAMPING ON THE UPPER FORK STABILIZER WILL NO LONGER BE ADEQUATE
.
A
B
C
D
H
1
2
3
4
Page 23
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22
Clean your motorcycle regularly in order to keep its painted finish looking shiny and new.
The best manner would be to use warm water that has been mixed with a commercially available washing detergent and a sponge.
The hard dirt can be removed before with the help of a soft water jet.
!
CAUTION
!
N
EVER CLEAN YOUR MOTORCYCLE WITH A HIGH-PRESSURED CLEANER OR A HIGH-PRESSURED WATER JET. OTHERWISE THE WATER MIGHT RUN INTO THE ELEC-
TRICAL COMPONENTS
, CONNECTORS,
SHEATHED CABLES, BEARINGS, CARBURETOR ETC. AND CAUSE MAILFUNCTIONS, I.E., LEAD TO THE PREMATURE DESTRUC-
TION OF THESE PARTS.
– You should use commercially available detergents to clean the motorcycle. Heavily soiled parts should also be cleaned with the help
of a paint brush.
– Befor cleaning with water, plug the exhaust pipe to prevent water ingress
– After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Then take a short drive
until the engine has reached its operating temperature, and also operate the brakes. The heat also causes the water at the inac-
cessible parts of the engine and the brakes to evaporate.
– Slide back the protective covers on the handlebar-mounted instruments so that any water that may have seeped into this part of
the motorcycle is allowed to evaporate.
– After the motorcycle has cooled down, oil and grease all the gliding bearing parts. Also treat the chain with a chain spray.
– To prevent failures in the electric system, you should treat the short circuit button with a contact spray.
CLEANING
STORAGE
If you want to put your motorcycle away for longer periods of time, please observe the following instructions:
– Clean motorcycle thoroughly (see chapter: CLEANING)
– Change engine oil (old engine oil contains aggresive contaminations).
– Check antifreeze and amount of cooling liquid.
– Let the engine warm up again, close fuel tap and wait until the engine dies off by itself. In this way, the carburetor jets are preven-
ted from becoming resin-clogged by the old fuel.
– Remove spark plug and fill in approx. 5 ccm of engine oil into the cylinder through the opening. Actuate kickstarter 10 times in order
to distribute the oil onto the cylinder walls and mount the spark plug.
– Let fuel flow out of tank into an appropriate basin.
– Correct tire pressure.
– Lubricate bearing points of the control levers, foot rests, etc. as well as the chain.
– The storage place should be dry and not be subject to overly great temperature fluctuations.
– Cover the motorcycle with an air permeable tarpaulin or blanket. Do not use non-air-permeable materials, as possible humidity
might not be able to escape and thereby cause corrosion.
WARNING
I
T WOULD BE VERY BAD TO LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD. THE ENGINE WOULD NOT GET WARMED UP ENOUGH
AND THE THUS DEVELOPED STEAM WOULD CONDENSE DURING THE COMBUSTION PROCESS AND CAUSE THE EXHAUST TO RUST
.
USE AFTER PERIOD OF STORAGE
– Fill up tank with fresh fuel.
– Check motorcycle as before each start (see driving instructions)
– Take a short, careful test ride first.
NOTE: Before you put your motorcycle away for the winter, you have to check all parts for their function and wear. Should any service jobs, repairs, or any refitting be necessary, you should have them carried out during the off-season (lower workload at mechanics'
shops). This way, you can avoid the long waiting times at your mechanic at the beginning of the next biking season.
Page 24
ENGLISH
23
TECHNICAL DATA – ENGINE 50 LC 2002
Engine 50 SX PRO JUNIOR LC 50 SX PRO SENIOR LC
Design single cylinder 2-stroke engine, with reed valve inlet
Displacement 49.0 ccm
Bore/Stroke 39.5 / 40 mm
Fuel SUPER fuel, research octane no 95, mixed with 2-stroke oil
Oil/gasoline ratio 1 : 40 when using high grade 2-stroke oil (Shell Advance Racing X)
When in doupt, please contact your importer or use 1 : 33 mix ratio to be on the safe side
Lubrication mixture lubrication
Crankshaft bearing 2 grooved ball bearing
Connecting rod bearing
needle bearing
Piston pin bearing needle bearing
Piston rings 1 rectangular ring
Primary drive straight cut spur gears, 16 : 57 Z
Transmission oil 0.15-0,2 liter automatic gear oil Dexron II (Shell Donax TA)
Spark plug NGK BR 10 EG
Electrode gap 0.6 mm
Carbureto DellOrto PHVA 14 DS Dell’Orto PHBG 19 BS
Air filter wet foam type air filter insert
Cooling liquid 0,5 litres, 40% anti freeze, 60% water, at least -25 °C (-13 °F)
Primary gear nut M14x1,25 40 Nm (30 ft.lb)
Hexagon nut ignition rotor M10x1,25 20 Nm (15 ft.lb)
Nut of clutch hub M10x1,25
Loctite 243 + 35 Nm
(26 ft.lb)
Cylinder head screws M7 15 Nm (11 ft.lb)
Cylinder base nuts M8 18 Nm (13 ft.lb)
Allan head screw-Stator M5x25
Loctite 243 + 8
Nm (6 ft.lb)
Oil plug M16 5 Nm (4 ft.lb)
Oil drain plug M10 15 Nm (11 ft.lb)
Other screws engine M5 7 Nm (5 ft.lb)
M6 10 Nm (7 ft.lb)
M8 30 Nm (22 ft.lb)
TIGHTENING TORQUES - ENGINE
Model 50 SX PRO JUNIOR LC 50 SX PRO SENIOR LC
Type Dell’Orto PHVA 14 DS Dell’Orto PHBG 19 BS
Main jet 80 85
Needle jet 211 FA 260 AU
Idling jet 45 48
Jet needle A10 W9
Needle position from top 3. 3.
Air/Mixture reg. screw open 3,5 3,0
Slide 40 60
Starting jet 60 60
BASIC CARBURETOR SETTING
Page 25
ENGLISH
24
Hexagon nuts front/rear axle M12x1 30 Nm (22 ft.lb)
Hexagon nut swing arm bolt M12 40 Nm (30 ft.lb)
Clamping screw upper/lower fork bridge M8 15 Nm (11 ft.lb)
Screws handlebar clamp M8 20 Nm (15 ft.lb)
Shock absorber top/bottom M10 45 Nm (33 ft.lb)
Allan screw – Handlebar support M10 Loctite + 40 Nm (30 ft.lb)
Front brake caliper M8 Loctite + 25 Nm (19ft.lb)
Front brake disk M6 Loctite + 10 Nm (7 ft.lb)
Other screws chassis M5 6 Nm (4,5ft.lb)
M6 10 Nm (7 ft.lb)
M8 25 Nm (19 ft.lb)
M10 45 Nm (33 ft.lb)
TIGHTENING TORQUES
TECHNICAL SPECIFICATIONS- CHASSIS
50 MINI LC 2002
Spring 2,0 N/mm
Preload 10 mm (0,4 in)
Fork oil SAE 7,5
Air chamber lenght 110 mm (4,3 in)
STANDARD-ADJUSTMENT – FORK
50 SX PRO JUNIOR LC 50 SX PRO SENIOR LC
Frame single downtube, split-cradle
Fork Marzocchi Ø = 32 mm (1,26 in)
Wheel travel front/rear 135/200 mm (5,3/8 in) 175/185 mm (6,9/7,4 in)
Rear suspension Central shock absorber WP
Front brake Disk brace Ø 160 mm (6,4 in)
Rear brake Drumbrake Ø 90 mm (3,5 in)
Tyres front/rear 2.50x10“ Pirelli MT 32 / 2.75x10“MT 32
Tire pressure front/rear: 1,0 bar
Fuel tank capacity 1,8 Liter
Final drive ratio 11 : 48
Chain 1/2x3/16“ 96 rolls 1/2x3/16“ 104 rolls
Steering angle 63° 64°
Wheel base 914 mm (36 in) 1030 mm (40 in)
Seat height, unloaded
590 mm/615 mm (23,2/24,2 in) 650/675 mm (25,6/26,6 in)
Ground clearance 220 mm (8,6 in) 255 mm (10 in)
Dead weight without fuel 40 kg
Rider’s body height max. 130 cm (5,1 in)
Rider’s body weight max. 35 kg (78 lbs)
Recommended age of rider
6-10 years
Engine 50 LC
WP 0318W910 WP 0318W911
Rebound adjuster 5 5
Spring 85 N/mm 45 N/mm
Spring preload 7 mm (0.28 in) 7 mm (0.28 in)
STANDARD ADJUSTMENT - SHOCK ABSORBER
Page 26
KTM SPORTMOTORCYCLE AG
5230 Mattighofen
Austria
Internet: www.ktm.at
321012
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