KTM Motorcycle 50 SX PRO JUNIOR LC User Manual

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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 PARTI-

CULAR ATTENTION TO INSTRUCTIONS AND INFORMATION MARKED AS

FOLLOWS:

WARNING

IGNORING THESE INSTRUCTIONS CAN BE DANGEROUS TO LIFE

AND LIMB.

CAUTION

IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE

MOTORCYCLE OR IMPAIR THE MOTORCYCLE’S TRAFFIC

SAFETY.

Please insert the serial numbers of the motorcycle below

Chassis number

Engine number

Stamp of dealer

KTM SPORTMOTORCYCLE 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

^{PRIOR NOTICE ANNOUNCEMENT AND WITHOUT GIVING REASONS}, OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUB-

STITUTING THEM WITH OTHERS. IT SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS

^ANNOUNCEMENT. IN THE EVENT OF SUCH MODIFICATIONS, PLEASE ASK YOUR LOCAL KTM DEALER FOR INFORMATION.

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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.The Owner's Manual is an integral

part of the motorcycle and must be handed over to the new owner when the motorcycle is sold.

We expressly point out that work marked with an asterisk (*) in the chapter "Maintenance work

on the chassis and engine" must be performed by a KTM workshop. If maintenance work should

become necessary during a competition, it must be performed by a trained mechanic.

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.

Be sure to have the maintenance work carried out by a KTM workshop to avoid losing your right

to claim under the warranty.

For the safety of your child, only use spare parts and accessories approved by KTM. KTM shall

not assume any liability for other products or consequential damage resulting from the use of

such products.

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

Attachments: 1 spare parts manual chassis & engine

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IMPORTANT WARRANTY AND

GUARANTEE INFORMATIONE

KTM mini-sports motorcycles are designed and constructed to resist the usual

wear and tear of normal use in competitions.

The motorcycles comply with the regulations and categories currently in effect

with the leading international motorcycle associations.

Observance of the service, maintenance and tuning instructions for the engine

and chassis specified in the Owner's Manual is a prerequisite for faultless

operation and the avoidance of premature wear. An improperly tuned chassis

can lead to damage and breakage of the chassis components (see chapter on

checking the basic chassis setting).

The service work specified in the "Lubrication and Maintenance Schedule"

must be performed by a KTM workshop and recorded in the service manual

otherwise claims under the warranty shall become void.

The fuels and lubricants specified in the Owner's Manual or automotive fluids

with equivalent specifications must be used in accordance with the

maintenance schedule.

No claims can be filed under the warranty for damage or consequential

damage caused by manipulations or conversions to the motorcycle.

The use of the motorcycle under extreme conditions, e.g. on extremely

muddy and wet terrain, can lead to higher than average wear on components

such as the drive train or the brakes. In this case it may become necessary to

service or replace wear parts before the service limit specified in the

maintenance schedule has been reached.

In accordance with the international quality management

ISO 9001 standard, KTM uses quality assurance processes

that lead to the highest possible product quality.

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IMPORTANT INFORMATION FOR PARENTS ABOUT SAFE DRIVING

KTM mini motorcycles are off-road motorcycles designed for one person only. They are not allowed on public roads.

The vehicle dimensions and components are designed for 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 starting the motorcycle for the first time check whether the basic fork and shock absorber settings are

suitable for your child's weight (see chapter on checking the basic chassis setting)

– Before using the motorcycle you should always check all components for proper operation (see mainenance

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.

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TABLE OF CONTENTS

Page

IMPORTANT WARRANTY AND GUARANTEE INFORMATIONE ..3

IMPORTANT INFORMATION ON SAFE DRIVING

How to change the handlebar position .............................17

Basic suspension setup for the weight of the driver ..........18

To determine the sag of the shock absorber .....................18

To determine the sag of the telescopic fork ......................18

Telescopic fork maintenance.............................................19

Changing the telescoping fork oil .....................................19

Cleaning the dust scrabbers of the telescopic fork ............20

Changing spring preloading of the shock absorber ...........20

Checking the chain tension...............................................20

Correct chain tension........................................................20

Chain maintenance ...........................................................20

Generel information about KTM disc brakes .....................21

Setting the basic position and play of the hand brake lever..21

Checking/refilling the front brake fluid level .....................21

Checking the front brake pads..........................................22

Replacing the front brake pads .........................................22

Changing the basic position of the foot brake lever..........22

Adjusting the control cable on the rear wheel...................22

Checking the rear brake linings for wear...........................22

Drum brake maintenance..................................................23

Removing and mounting the front wheel .........................23

Removing and mounting the rear wheel...........................23

Tires, air pressure..............................................................24

Checking spoke tension ....................................................24

Cooling system .................................................................24

Checking coolant level......................................................25

Cleaning the air filter ........................................................25

Exhaust system .................................................................25

Changing the seat hight....................................................26

Adjusting the throttle cable...............................................26

Adjusting the idle speed (Dell’Orto PHVA 14 DS).............26

Adjusting the idle speed (Dell’Orto PHBG 19 BS)..............26

Checking the gear oil level................................................27

Changing the gear oil .......................................................27

FOR PARENTS........................................................................4

SERIAL NUMBER LOCATIONS...............................................6

Chassis number..................................................................6

Engine number, engine type ..............................................6

OPERATION INSTRUMENTS..................................................6

Throttle grip.......................................................................6

Hand brake lever................................................................6

Short circuit button ............................................................6

Filler cap.............................................................................7

Fuel tap..............................................................................7

Choke (DELL’ORTO PHVA 14 DS).....................................7

Choke (DELL’ORTO PHBG 19 BS) .....................................7

Kickstarter ..........................................................................7

Foot brake lever .................................................................8

Side stand ..........................................................................8

Plugin - Stand ....................................................................8

Rebound damping function of the shock absorber.............8

GENERAL TIPS AND WARNINGS FOR STARTING THE

MOTORCYCLE.....................................................................10

Instructions for the first ride .............................................10

Running in .......................................................................10

DRIVING INSTRUCTIONS ....................................................11

What you should check before each start ........................11

Starting when engine is cold ............................................12

Starting when engine is warm..........................................12

What to do when the engine is “flooded“.......................12

Starting off.......................................................................12

Driving .............................................................................12

Braking.............................................................................13

Stopping...........................................................................13

Refueling, fuel..................................................................13

TROUBLE SHOOTING...........................................................28

CLEANING / STORAGE.........................................................30

TECHNICAL DATA - ENGINE ................................................31

TECHNICAL DATA - CHASSIS...............................................32

HEAD WORD INDEX ............................................................33

PERIODIC MAINTENANCE SCHEDULE ................................14

MAINTENANCE WORK ON CHASSIS AND ENGINE............16

Removing the seat ...........................................................16

Checking and adjusting the steering head bearing (Junior) ...16

Checking and adjusting the steering head bearing (Senior)...17

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SERIAL NUMBER LOCATIONS

Chassis number

The chassis number is located on the type plate on the steering head. Enter

this number in 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. Enter this number in the relevant field on page 1.

Engine typ

50 MCH

OPERATION INSTRUMENTS

Throttle grip

The throttle grip is located on the right side of the handlebars. It is used to

reduce the engine speed and, thus, the driving speed.

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.

Short circuit button

The short circuit button 1 turns off the engine. When pressing this button,

the ignition circuit is short-circuited.

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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.

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.

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.

Kickstarter

The kickstarter is mounted on the right side of the engine. Its upper part can

be swivelled.

NOTE: an accessory kit for kickstarter backwards operation is available.

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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.

Plugin - Stand (50 SX PRO SENIOR)

A socket is provided on the left side of the frame for the plug-in stand 1

included in the scope of supply.

Rebound damping function of the shock absorber

The damping effect of the rebound damping mechanism can be adjusted

by means of the setting wheel 2. 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.

– DO NOT TRY TO DISASSEMBLE THE SHOCK ABSORBER OR TO PERFORM MAINTENANCE

WORK YOURSELF. DANGER OF INJURY!

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GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE

WARNING

Instructions for the first ride

– 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!

– THE MOTORCYCLE HAS A CENTRIFUGAL CLUTCH. THE MOTORCYCLE

BEGINS TO MOVE AS SOON AS THE THROTTLE IS OPENED.

– 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.

–

ALWAYS APPLY THE FRONT BRAKE WHEN STARTING THE ENGINE AND

^{RELEASE THE BRAKE SLOWLY WHEN THE ENGINE IS RUNNING}. AN ACTIVA-

TED CHOKE INCREASES THE IDLE SPEED OF THE ENGINE, THE CENTRIFUGAL

^{CLUTCH THUS BEGINNING TO ENGAGE}. THEREFORE, THE MOTORCYCLE

^{CAN BEGIN TO MOVE WHEN THE BRAKE LEVERS ARE RELEASED}.

– WHEN THE ENGINE SPEED DROPS TO THE LEVEL AT WHICH THE

CENTRIFUGAL CLUTCH DISENGAGES, BRAKING WITH THE ENGINE IS NO

LONGER POSSIBLE AND THE MOTORCYCLE CAN ONLY BE SLOWED

DOWN USING THE BRAKES.

– YOUR CHILD SHOULD NEVER DRIVE FASTER THAN ITS SKILLS AND THE

TERRAIN PERMIT.

– NEVER LET YOUR CHILD DRIVE ITS MOTORCYCLE UNCHAPERONED.

– REPLACE THE HELMET VISOR OR GOGGLE GLASSES EARLY ENOUGH.

WHEN LIGHT SHINES DIRECTLY ON A SCRATCHED VISOR OR GOGGLES,

YOU WILL BE PRACTICALLY BLIND.

– ONLY USE ACCESSORY PARTS RECOMMENDED BY KTM.

– NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS

THE ENGINE IS RUNNING.

– 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.

– 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

practise to ride the motorcycle standing on the footpegs or

riding at the slowest possible speed. Additionally, you can

arrange a series of obstacles and have your youngster drive

around them, etc.

WARNING

– KTM MINI MODELS ARE DESIGNED FOR ONE PERSON ONLY.

PASSENGERS ARE NOT ALLOWED.

– THESE MODELS DO NOT COMPLY WITH THE REGULATIONS AND SAFETY

STANDARDS ESTABLISHED BY THE LAW. THEREFORE, THEY ARE NOT

PERMITTED ON PUBLIC ROADS.

– ALWAYS KEEP IN MIND THAT OTHER PEOPLE FEEL MOLESTED BY

EXCESSIVE NOISE.

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.

– Pay attention to running-in procedure.

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!

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DRIVING INSTRUCTIONS

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 the

chain and chain wheels.

5 TIRES

Check for damaged tires. 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.

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Starting when the engine is cold

1 Open fuel tap 1.

2 Operate the choke 2.

3 Kick the side up all the way or remove the plug-in stand.

4 Apply the front brake.

5 Operate the kickstarter, depressing it all the way, without opening the

throttle.

WARNING

–

WHEN STARTING THE ENGINE, PUT ON MOTORCYCLE BOOTS IN ORDER TO AVOID

^INJURIES. YOU MAY SLIP OFF THE KICKSTARTER, OR THE ENGINE MAY KICK BACK IF

YOU DO NOT KICK HARD ENOUGH.

– DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA. EXHAUST

FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH.

ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING.

CAUTION

DON’T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND HIGH REVS WHEN ENGINE IS

COLD. BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED

CYLINDER, IT CAN CAUSE ENGINE DAMAGE.

Starting when the engine is warm

1 Open fuel tap 1.

2 Kick the side up all the way or remove the plug-in stand.

3 Apply 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 1.

2 Applying the front brake.

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

ALWAYS MAKE SURE THE SIDE STAND IS KICKED ALL THE WAY UP OR THE PLUG-IN STAND

REMOVED BEFORE YOU LET YOUR CHILD DRIVE OFF. THE MOTORCYCLE COULD RUN OUT

OF CONTROL IF THE STAND TOUCHES THE GROUND.

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

– AFTER 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.

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CAUTION

Refueling, fuel

Oil (high-grade two-stroke engine oil) must be mixed with the

fuel (ROZ 95) at a mixing ratio of 1:40.

– 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.

– NEVER TILT THE MOTORCYCLE OVER THE SIDE STAND TO WARM UP THE

ENGINE. THE SIDE STAND COULD FOLD AWAY AND THE MOTORCYCLE

RUN OUT OF CONTROL.

– IN THE EVENT THAT, WHILE YOUR CHILD IS RIDING ON THE MOTOR-

CYCLE, YOU NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, YOUR

CHILD SHOULD STOP IMMEDIATELY, TURN THE ENGINE OFF, AND

CONTACT AN AUTHORIZED KTM DEALER.

Fuel and engine oil should only be mixed immediately before use.

KTM recommends SHELL ADVANCE RACING X.

WARNING

GASOLINE 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.

WIPE UP SPILLS PROMPTLY. IF GASOLINE IS SWALLOWED OR SPLASHED IN

THE EYES, SEEK A DOCTOR’S ADVICE IMMEDIATELY.

Braking

CAUTION

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.

– ONLY USE PREMIUM-GRADE GASOLINE ROZ 95 MIXED WITH HIGH-

GRADE TWO-STROKE ENGINE OIL. OTHER TYPES OF GASOLINE CAN

CAUSE ENGINE FAILURE.

– ONLY USE KNOWN BRANDS OF HIGH-GRADE 2-STROKE ENGINE OIL

(SHELL ADVANCE RACING X).

– NOT ENOUGH OIL OR LOW-GRADE OIL CAN CAUSE EROSION OF THE

PISTON. WHEN USING 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.)

WARNING

– BRAKE DRUM AND LININGS HEAT UP DURING BRAKE OPERATION, THUS

REDUCING THE EFFECT OF THE BRAKES.

– WET BRAKES HAVE REDUCED BRAKE PERFORMANCE, THEREFORE BE SURE

TO BRAKE THEM DRY AFTER CLEANING.

– 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.

Stopping

40 mm

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

MOTORCYCLES PRODUCE GREAT HEAT DURING OPERATION. THEREFORE,

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.

– THE SIDE STAND OR PLUG-IN STAND IS DESIGNED TO HOLD THE WEIGHT

OF THE MOTORCYCLE 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.

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50 SX PRO JUNIOR/SENIOR LC

water cooled

PERIODIC MAINTENANCE SCHEDULE 2003

Service

every

5 hours

Service

every

20 hours

A clean 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 a 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 antifreeze

Check exhaust system for leaks and suspension

Check actuating cables for damage, smooth operation, and kinkless

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/function adjust smooth operation, free travel of handbrake/footbrake levers

Check screws of brake system for a tight fit

Check suspension strut and fork for leaks and a proper function

Check swinging-fork pivot

●

Check/adjust steering-head bearing

Check all chassis screws for a 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 joint, chain wheels, chain wheel guides for wear, a tight fit, and tension

Lubricate chain

●

Check wheel bearings for play

IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER

once a year

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

●

MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER!

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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 at 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 at regular intervals

●

RECOMMENDED INSPECTION OF THE MINI LC ENGINE BY YOUR KTM WORKSHOP

(ADDITIONAL ORDER FOR THE KTM WORKSHOP)

hours

120

hours

135

hours

Check the reed-type intake valve for wear

Check the clutch shoes for wear

●

Check the length of the clutch springs

Check the clutch drum for wear

Check the water pump shaft and bearings for wear

Check the water pump wheel for wear

Check the cylinder and piston for wear

Check the eccentricity of the crankshaft journal

Check the radial clearance of the conrod bearings

Check the radial clearance of the piston pin main bearing

Check the crankshaft main bearing for wear

Replace the crankshaft bearings and conrod bearings

Check the entire transmission including bearings for wear

●

NOTE: IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED, THE RESPECTIVE COMPONENTS MUST BE REPLACED.

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MAINTENANCE WORK ON CHASSIS AND ENGINE

WARNING

MAINTENANCE WORK AND ADJUSTMENTS MARKED WITH AN ASTERISK (*) MUST BE PER-

FORMED BY AN EXPERT. TO PROTECT YOUR YOUNGSTER, ALWAYS HAVE SUCH WORK PER-

FORMED 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.

– BEFORE 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.

– DO 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.

– LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED.

– DISPOSE OF OILS, FATTY MATTERS, FILTERS, FUELS, WASHING DETERGENTS, ETC. PROPERLY.

– UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIDE. 1 LITER OF USED OIL

CONTAMINATES 1,000,000 LITERS OF WATER.

Removing the seat

The quick-release mechanism 1 allows removal of the seat without tools.

Turn the quick-release device approximately 180° counterclockwise, 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.

Checking and adjusting the steering head bearing (50 SX

JUNIOR) *

The steering head bearing should be checked regularly 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 2 of the top

triple clamp and the counternut 3. Turn the adjusting nut 4 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 counternut

3 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.

WARNING

IF 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).

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Checking and adjusting the steering head bearing (50 SX

SENIOR) *

The steering head bearing should be checked regularly for play. To check,

support the motorcycle frame and lift the front wheel off the ground. Now

try to move the fork back and forth – you should not feel any play. To

adjust, loosen both clamping screws 1 on the upper triple clamp and loosen

the steering head screw 2 by a few turns. Lift the triple clamp slightly and

turn the adjusting nut 3 until hardly any play is left. Never tighten the

adjusting nut since you might damage the bearing. Tighten the steering

head screw to a torque of 10 Nm and the 2 clamping screws to 15 Nm.

WARNING

IF 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).

How to change the handlebar position

The handlebar position can be readjusted by 22 mm (0.9 in). The upper

triple clamp 4 includes 2 bores arranged at a distance of 15 mm (0.6 in)

from one another. The bores at the handlebar support 5 are offset from the

center by 3.5 mm (0.13 in). Accordingly, you can mount the handlebar in

4 different positions.

For this purpose, remove screws 6 of the handlebar clamps and screws 7

of the handlebar support. Position handlebar support, and tighten screws 7

to 40 Nm. Mount handlebar and handlebar clamps, and tighten screws 6

to 20 Nm. The gap between the handlebar support and handlebar clamps

should be the same size in the front and in the rear.

CAUTION

THE SCREWS 7 MUST BE SECURED WITH LOCTITE 243.

3,5 mm

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Basic suspension setup for the weight of the driver

To achieve maximum handling performance and to prevent the telescopic

fork and shock absorber from being damaged, the basic setup of the

suspension components must be suitable for your child's weight. At delivery,

KTM's mini motorcycles are set to accommodate a driver weighing 25 - 30

kg (wearing full protective clothing). If your child's weight exceeds or falls

short of this range, you will need to adjust the spring preload for the

telescopic fork and shock absorber accordingly.

To adjust, check the sag of the shock absorber and telescopic fork. The

motorcycle should be filled up and your child should be wearing full

protective clothing.

To determine the sag of the shock absorber

– Jack up the motorcycle until the rear wheel no longer touches the ground.

– Measure the vertical distance between the rear wheel axle and a fixed

point (e.g. a mark on the side cover) and write it down as dimension A.

– Place the motorcycle on the ground again.

– Have your child sit on the motorcycle in a normal seating position (feet on

the footrests) wearing full protective clothing and bounce up and down a

few times to allow the rear wheel suspension to become level.

– Holding your child and the bike, have another person measure the

distance between the same two points with the load on the motorcycle to

establish dimension B.

– The sag is the difference between dimensions A and B.

EXAMPLE:

Motorcycle jacked up (dimension A) . . . . . . . . . . . . . . . . . . . . . . .400 mm

Motorcycle on ground with driver seated (dimension B) . . . . . . .– 355 mm

Sag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 mm

50 SX Pro Junior LC shock absorber sag. . . . . . . . . . . . . 45 mm ( 5 mm)

50 SX Pro Senior LC shock absorber sag . . . . . . . . . . . . 50 mm ( 5 mm)

If the sag is lower, the spring preload of the shock absorber must be reduced,

if the sag is higher, the spring preload must be increased. A harder spring is

also available for the 50 SX Pro Senior LC (see spare parts catalog).

To determine the sag of the telescopic fork

– Jack up the motorcycle until the rear wheel no longer touches the ground.

– Measure the distance between the upper edge of the slider tube and the

triple clamp and write it down as dimension C.

– Have your child sit on the motorcycle in a normal seating position (feet on

the footrests) wearing full protective clothing, and bounce up and down

a few times to allow the telescopic fork to become level.

– Holding your child and the bike, have another person measure the

distance between the same two points with the load on the motorcycle to

establish dimension D.

– The sag is the difference between dimensions C and D.

EXAMPLE:

Motorcycle jacked up (dimension C) . . . . . . . . . . . . . . . . . . . . . . .200 mm

Motorcycle on ground with driver seated (dimension D) . . . . . . .– 160 mm

Sag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 mm

50 SX Pro Junior LC telescopic fork sag . . . . . . . . . . . . . 30 mm ( 5 mm)

50 SX Pro Senior LC telescopic fork sag . . . . . . . . . . . . . 45 mm ( 5 mm)

If the sag is lower, the spring preload of the telescopic fork must be reduced,

if the sag is higher, the spring preload must be increased.

The preload on the fork spring is determined by the length of preload spacer

1. If an adjustment is necessary, demount the fork legs, remove the plugs

and shorten the pretensioning sleeves or replace with longer ones (see

maintenance of telescopic fork). Harder fork springs are also available for

both models (see spare parts catalog).

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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

– DO 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.

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.

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

20 Nm. Mount brake line and holding clamp.

Insert fork legs in the fork stabilizers (projection as previously noted) and

tighten clamping screws to 15 Nm.

Mount front wheel (see chapter: mounting the front wheel).

WARNING

THE SCREWS 1 MUST BE SECURED WITH LOCTITE 243.

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

– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS.

OTHERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.

– AFTER 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 cm³SAE 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).

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Cleaning the dust scrabbers of the telescopic fork

The dust-protection bellows 1 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 lift 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.

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 2 with the hook spanner. Change the spring preload

with the adjusting ring 3 and re-tighten the locking ring 2.

BASIC SETTING – SPRING PRELOAD

7 mm (0.3 in)

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

10 mm

– IF 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. IF THIS HAPPENS, THE CHAIN COULD ALSO BLOCK

THE REAR WHEEL OR DAMAGE THE ENGINE.

– IN EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE.

Correct chain tension

Release the hexagon nut of the wheel spindle 4 and turn the left and the

right hexagon nut 5 equally far.

Before tightening the hexagon nut of the wheel spindle to 30 Nm, ensure

that the supporting plates 6 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

K^{EEP 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.

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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.

DOT

5.1

DOT

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.

●

WARNING

HAVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY. IF YOU WASH YOUR

MOTORCYCLE OFTEN, THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE FREQUENTLY.

BRAKE FLUID TENDS TO ABSORB WATER. THEREFORE, VAPOR POCKETS MAY FORM IN

"OLD" BRAKE FLUIDS EVEN AT LOW TEMPERATURES, CAUSING THE BRAKE SYSTEM TO FAIL.

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.

– HAVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BA A KTM DEALER.

min. 2 mm

BRAKE CALIPERS:

Secure the screws on the brake caliper with Loctite 243 and tighten to a

torque of 20 Nm.

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

AT 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

PROVIDED, 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! IT IS BASED ON SILICONE OIL AND OF A PURPLE

COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT.

– STORE BRAKE FLUID OUT OF REACH OF CHILDREN.

5 mm

– BRAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND EYES.

IF YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER AND CONSULT

A DOCTOR.

CAUTION

– DON’T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE

PAINT REMOVER.

– USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.

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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.

min.

1 mm

WARNING

AT 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

IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY

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. Mount the lock washer. Align brake shoes,

mount front wheel (see chapter: Mounting the front wheel).

WARNING

– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS.

OTHERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.

– AFTER ASSEMBLY, CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY.

– DO NOT UNSCREW ANY OTHER SCREWS ON THE BRAKE CALIPER OR YOU WILL HAVE

TO BLEED THE BRAKE SYSTEM.

– AFTER WORKING ON THE BRAKE SYSTEM ALWAYS OPERATE THE HAND BRAKE LEVER

TO APPLY THE BRAKE PADS TO THE BRAKE DISK AND CREATE A POINT OF PRESSURE.

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 the 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

5-10 mm

AFTER 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).

min 50 mm

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.

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Drum brake maintenance

Drum brake maintenance is limited to occasional blowing out of the 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

–

DO 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.

Put the motorcycle back on the ground and operate the front wheel brake

until the working point is reached.

WARNING

– IF 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.

– IT IS VERY 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 to 30 Nm.

WARNING

IF 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.

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Tires, air pressure

Tire type, tire condition, and air pressure level affect the way your motor-

cycle 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

– DAMAGED TIRES MUST BE REPLACED IMMEDIATELY TO PROTECT YOUR YOUNGSTER.

– WORN 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, at regular intervals. If neces-

sary, have the spokes retightened and the wheel centered by a KTM dealer.

WARNING

–

SPOKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE. THIS MAY LEAD TO AN

^{UNSTABLE HANDLING OF YOUR MOTORCYCLE}.

– EXCESSIVELY TENSIONED SPOKES MAY RUPTURE DUE TO LOCAL OVERLOADING. THE

SPOKES MUST BE TENSIONED TO 2,5 - 3 NM.

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

DO NOT REMOVE ANY COOLER HOSES OR THE DRAIN SCREW WHEN THE ENGINE IS HOT.

A mixture of 40% antifreeze liquid and 60% water is used as coolant.

How-ever, the antifreeze protection must be at least -25° C (-13° F). This

mixture offers antifreeze protection but also good corrosion protection and

should therefore not be replaced by pure water.

CAUTION

FOR 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.

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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.

10 mm

WARNING

IF POSSIBLE, 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.

when engine is cold

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 1, remove the filter holder and the air filter 2. The air filter

consists of a foam rubber insert soaked with filter oil.

CAUTION

– DO NOT CLEAN THE FOAM FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL

DAMAGE THE FOAM. KTM RECOMMENDS THE PRODUCTS MADE BY TWIN AIR FOR

AIR FILTER MAINTENANCE.

– NEVER OPERATE YOUR MOTORCYCLE WITHOUT AN AIR FILTER. OTHERWISE, DUST

AND DIRT MAY GET INTO THE ENGINE AND LEAD TO INCREASED WEAR.

–

THE HOLDER MUST RETAIN THE AIR FILTER THROUGHOUT ITS ENTIRE CIRCUMFERENCE.

IF THE FILTER HAS BEEN MOUNTED INCORRECTLY, THE ENGINE WILL TAKE IN UNFILTERED

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.

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 3 to the inner tube 4. Remove screws 5 and the end cap

6. Pull of the outer tube and remove the old glass-fiber yarn packing 7

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

screws 5. 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

THE 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.

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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, the screw

on the shock absorber to 45 Nm.

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 from the top of the 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, the screw on the shock

absorber to 45 Nm.

WARNING

THE FORK TUBES MAY NOT BE LOWERED ANY FURTHER THAN AS DESCRIBED ABOVE,

OTHERWISE THE CLAMPING ON THE UPPER FORK STABILIZER WILL NO LONGER BE

ADEQUATE.

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 1 on the throttle grip. You

must be able to lift the outer covering of the cable 3-5 mm from the

adjusting screw 2, until resistance is felt.

To adjust, loosen the counter nut 3 and turn the adjusting screw

accordingly. Finally tighten counter nut and slide the protective cover back on.

3-5 mm

Adjusting the idle speed (Dell’Orto PHVA 14 DS) *

The idle speed can be adjusted with screw 4.

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 5.

The idle speed is increased by turning clockwise.

The idle speed is reduced by turning counter-clockwise.

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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

POOR OIL QUALITY LEAD TO PREMATURE TRANSMISSION WEAR.

THEREFORE, 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 to 15 Nm.

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

LESS OIL OR

POOR OIL QUALITY LEAD TO PREMATURE TRANSMISSION WEAR.

THEREFORE, ONLY USE BRANDED PRODUCTS (SHELL Donax TA).

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TROUBLE SHOOTING

If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error

occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error.

We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer.

TROUBLE

CAUSE

REMEDY

Engine fails to start

Operating error

Open fuel tap, replenish fuel, do not use choke

Fuel supply interrupted

Close fuel tap, loosen fuel hose at carburettor, lead into a

basin and open fuel tap,

– if fuel leaks out, clean carburettor

–

if no fuel leaks out, check tank ventilation, i.e. clean fuel tap

Electrode distance too large

Reduce electrode distance (0.60 mm)

Clean spark plug or renew

Plug fouled by oil, wet or bridged

Ignition wire or spark plug Dismount spark plug, connect ignition cable, hold to ground

connector damaged

(blank place on engine) and actuate kickstarter, a strong spark

must be produced at the spark plug

– If no spark is produced, loosen spark plug cap from ignition

cable, hold about 5 mm from ground and actuate kickstarter

– If a spark now occurs, replace spark plug cap

– If no spark is produced, control ignition system

Kill button wire or

short-circuit switch faulty

Disconnect black coloured cable from short circuit button at

ignition coil and check ignition spark. If the spark is O.K. repair

defective part of cable or ignition switch

Loose ignition cable connectors

Spark too weak

Inspect cable connectors

Examine ignition system

Water in the carburetor and jets Dismantle and clean carburetor

blocked

Engine without idle run- Idle adjusting screw out of adjust- Readjust idle running or replace idle adjusting screw

ning

ment

Ignition system damaged

Examine ignition system

Overhaul engine

Wear

Less power of engine

Air filter obstructed

Clean or renew airfilter

Fuel supply partly interrupted or Blow through fuel pipe and clean carburetor

blocked

Loss of compression due to loose Tighten spark plug

spark plug

Exhaust system damaged

Check exhaust system for damage

Check and adjust ignition

Engine has not enough preignition

Reed paddles tensionless or dama- Replace reed paddles or reed valve housing

ged, surface of reed valve housing

damaged

Wear

Overhaul engine

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TROUBLE

CAUSE

REMEDY

Engine stalling or running Carburetor overflows if level adjust Clean carburetor, if necessary replace float needle and adjust

with four stroke cycle

too high, float needle seating is level

dirty or enlarged

Loose carburetor jets

Tighten jets

Refer to technical data section

High rpm misfiring

Incorrect heat range spark plug or

low quality spark plug

Loose, corroded or non conductive Check and seal with silicon

ignition socket connector

Engine spluters into the Lack of fuel

carburetor

Clean fuel pipes, examine tank aeration and clean

Spark plug with incorrect heat value Fit correct spark plug

(Ignition by incandescence)

Engine takes air out of control

Check intake flange and carburettor if firmly setted

Engine overheating

Insufficient liquid in cooling system Top up coolant and bleed cooling system check cooling

system for leaks

Radiator fins clogged

Clean radiatar fins with water jet

Frothing in cooling system

Renew coolant using branded anti-freeze/anti-corrosive (Shell

Advance Coolant)

Pinched or kinked water hoses

Replace with correct routed hoses

Incorrect ignition timing because of Readjust to correct ignition timing specifications, secure scr-

loose stator screws

ews with Loctite 243

Incorrect compression ratio

Measure and adjust compression ratio

Emission of white smoke Cylinder head or O-ring of cylinder Check cylinder head, replace O-ring

(steam) head gasket leaks

Excessive oil escapes from Excessive oil quantity in transmissi- Correct transmission oil level

transmission breather tube on

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CLEANING

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

NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH-PRESSURED CLEANER OR A HIGH-PRESSURED WATER JET, OTHERWISE THE WATER MIGHT RUN INTO THE

ELECTRICAL COMPONENTS, CONNECTORS, SHEATHED CABLES, BEARINGS, CARBURETOR ETC. AND CAUSE MAILFUNCTIONS, I.E., LEAD TO THE PREMATURE

DESTRUCTION 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.

– Before 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 inaccessible

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.

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 aggressive 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 prevented

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, footrests, etc. as well as the chain.

– The storage place should be dry and not be subjected to overly great temperature fluctuations.

– Cover the motorcycle with an air permeable tarpaulin or blanket. Do not use airtight materials, as possible humidity might not be

able to escape and thereby cause corrosion.

CAUTION

IT 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 should 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 shop at the beginning of the next biking season.

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TECHNICAL DATA – ENGINE 50 LC 2003

Engine

50 SX PRO JUNIOR LC

50 SX PRO SENIOR LC

Design

single cylinder 2-stroke engine, with reed valve inlet

Displacement

Bore/Stroke

Fuel

49.0 ccm

39.5 / 40 mm

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 doubt, please contact your importer or use 1 : 33 mix ratio to be on the safe side

Lubrication

mixture lubrication

2 grooved ball bearing

Crankshaft bearing

Connecting rod bearing

Piston pin bearing

Piston rings

needle bearing

1 rectangular ring

Primary drive

Transmission oil

Spark plug

straight cut spur gears, 16 : 57 Z

0.15-0,2 liter automatic gear oil Dexron II (Shell Donax TA)

NGK BR 8 ECM

Electrode gap

Carburetor

0.6 mm

DellOrto PHVA 14 DS

Dell’Orto PHBG 19 BS

Air filter

wet foam type air filter insert

Cooling liquid

0.5 litres, 40% antifreeze, 60% water, at least -25 °C (-13 °F)

BASIC CARBURETOR SETTING

Model

Type

50 SX PRO JUNIOR LC

Dell’Orto PHVA 14 DS

50 SX PRO SENIOR LC

Dell’Orto PHBG 19 BS

Main jet

211 FA

260 AU

Needle jet

Idling jet

Jet needle

A10

Needle position from top

Air/Mixture reg. screw open

Slide

3.5

3.0

Starting jet

TIGHTENING TORQUES - ENGINE

Primary gear nut

M14x1,25

M10x1,25

40 Nm

20 Nm

Hexagon nut ignition rotor

Nut of clutch hub

Loctite 243 + 35 Nm

15 Nm

Cylinder head screws

Cylinder base nuts

18 Nm

Allan head screw-Stator

Oil plug

M5x25

M16

Loctite 243 + 8 Nm

5 Nm

Oil drain plug

M10

15 Nm

Other engine screws

7 Nm

10 Nm

30 Nm

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50 MINI LC 2003

TECHNICAL SPECIFICATIONS CHASSIS

50 SX PRO JUNIOR LC

50 SX PRO SENIOR LC

Frame

single downtube, split-cradle

Marzocchi Ø = 32 mm (1.26 in)

135/200 mm (5.3/8 in) 175/185 mm (6.9/7.4 in)

Fork

Wheel travel front/rear

Rear suspension

Front brake

Central shock absorber WP

Disk brake Ø 160 mm (6.4 in)

Drum brake Ø 90 mm (3.5 in)

Rear brake

Tires front/rear

Tire pressure

2.50x10” Pirelli MT32A / 2.75x10” MT320

2.50x12” Vee Rubber V270 / 2.75x10” V271

front/rear: 1.0 bar

1.8 Liters

Fuel tank capacity

Final drive ratio

Chain

11 : 48

1/2x3/16“ 96 rolls

63°

1/2x3/16“ 104 rolls

64°

Steering angle

Wheel base

914 mm (36 in)

1030 mm (40 in)

650/675 mm (25.6/26.6 in)

255 mm (10 in)

Seat height, unloaded

Ground clearance

Rider’s body height

Rider’s body weight

Recommended age of rider

Engine

590 mm/615 mm (23.2/24.2 in)

220 mm (8.6 in)

max. 130 cm (51 in)

max. 35 kg (78 lbs)

6-10 years

50 LC

TIGHTENING TORQUES

Hexagon nuts front/rear axle

Hexagon nut swing arm bolt

M12x1

M12

30 Nm

40 Nm

15 Nm

20 Nm

45 Nm

Clamping screw upper/lower fork bridge

Screws handlebar clamp

Shock absorber top/bottom

Allan screw – Handlebar support

Front brake caliper

M10

Loctite + 40 Nm

Loctite + 20 Nm

Loctite + 10 Nm

2,5 - 3 Nm

Front brake disk

Spoke nipple

Other chassis screws

6 Nm

10 Nm

25 Nm

45 Nm

M10

STANDARD-ADJUSTMENT – FORK

STANDARD ADJUSTMENT - SHOCK ABSORBER

Spring

2.0 N/mm

10 mm (0.4 in)

WP 0318X914

WP 0318X915

Preload

Rebound adjuster

Spring

Fork oil

SAE 7.5

85 N/mm

7 mm (0.28 in)

45 N/mm

7 mm (0.28 in)

Air chamber length

110 mm (4.3 in)

Spring preload

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HEAD WORD INDEX

Page

General tips and warnings for starting the motorcycle........10

Generel information about KTM disc brakes.......................21

Hand brake lever ..................................................................6

How to change the handlebar position...............................17

Important information on safe driving for parents ................4

Instructions for the first ride................................................10

Kickstarter.............................................................................7

Maintenance work on chassis and engine...........................16

Operation instruments..........................................................6

Periodic maintenance schedule ...........................................14

Plugin - Stand.......................................................................8

Rebound damping function of the shock absorber ...............8

Refueling, fuel ....................................................................13

Removing and mounting the front wheel...........................23

Removing and mounting the rear wheel.............................23

Removing the seat..............................................................16

Replacing the front brake pads...........................................22

Running in..........................................................................10

Serial number locations.........................................................6

Setting the basic position and play of the hand brake lever.....21

Short circuit button...............................................................6

Side stand.............................................................................8

Starting off .........................................................................12

Starting when engine is cold...............................................12

Starting when engine is warm ............................................12

Stopping.............................................................................13

Technical data - chassis ......................................................32

Technical data - engine ......................................................31

Telescopic fork maintenance...............................................19

Throttle grip .........................................................................6

Tires, air pressure................................................................24

To determine the sag of the shock absorber.......................18

To determine the sag of the telescopic fork........................18

Trouble shooting ................................................................28

What to do when the engine is “flooded“ .........................12

What you should check before each start...........................11

Adjusting the control cable on the rear wheel ....................22

Adjusting the idle speed (Dell’Orto PHBG 19 BS) ...............26

Adjusting the idle speed (Dell’Orto PHVA 14 DS) ..............26

Adjusting the throttle cable ................................................26

Basic suspension setup for the weight of the driver ............18

Braking ...............................................................................13

Chain maintenance.............................................................20

Changing spring preloading of the shock absorber.............20

Changing the basic position of the foot brake lever............22

Changing the gear oil.........................................................27

Changing the seat hight .....................................................26

Changing the telescoping fork oil .......................................19

Chassis number ....................................................................6

Checking and adjusting the steering head bearing (Junior) ....16

Checking and adjusting the steering head bearing (Senior)....17

Checking coolant level........................................................25

Checking spoke tension......................................................24

Checking the chain tension.................................................20

Checking the front brake pads............................................22

Checking the gear oil level..................................................27

Checking the rear brake linings for wear ............................22

Checking/refilling the front brake fluid level.......................21

Choke (DELL’ORTO PHBG 19 BS)........................................7

Choke (DELL’ORTO PHVA 14 DS).......................................7

Cleaning / Storage..............................................................30

Cleaning the air filter..........................................................25

Cleaning the dust scrabbers of the telescopic fork..............20

Cooling system...................................................................24

Correct chain tension..........................................................20

Driving................................................................................12

Driving instructions.............................................................11

Drum brake maintenance ...................................................23

Engine number, engine type.................................................6

Exhaust system...................................................................25

Filler cap...............................................................................7

Foot brake lever....................................................................8

Fuel tap ................................................................................7

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