KTM Motorcycle Accessories 50 AC LC User Manual

REPAIRMANUAL2002-2006

50 AC/LC

REPARATURANLEITUNG

MANUALE DI RIPARAZIONE

MANUEL DE REPARATION

MANUAL DE REPARACION

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KTM Group Partner

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1 SERVICE-INFORMATIONS

2 GENERAL INFORMATION

3 REMOVING AND REFITTING ENGINE

4 DISASSEMBLING ENGINE

5 SERVICING INDIVIDUAL COMPONENTS

6 ASSEMBLING ENGINE

7 TROUBLE SHOOTING

8 TECHNICAL SPECIFICATIONS

9 PERIODIC MAINTENANCE SCHEDULE

10 WIRING DIAGRAM

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IMPORTANT INFORMATION/UPDATING INSTRUCTIONS

To be able to continue using the existing loose-leaf repair instructions, simply print the following

pages and insert them in the existing repair instructions:

1, 3, 7, 9, 13, 15, 17, 20, 21, 33, 46, 61, 63, 74, 76 - 81, 82, 84, 86, 87

Remove page (s)

Replace by page (s)

Insert page (s)

2-5E to 2-6E

after page

2-1

2-2

2-1E

2-2E

2-4

4-2

5-7

4-2E

5-7E

8-1

8-1E

8-2

8-2E

8-12

8-14

8-12E

8-18E

8-14E to 8-17E

9-6E to 9-7E

8-13

9-5

9-1 to 9-2

9-4

9-1E to 9-2E

9-4E

KTM REPAIR MANUAL IN LOOSE-LEAF FORM

STORING THE REPAIR MANUAL IN THE BINDER

– Put the index into the binder.

– Put the front page of the repair manual (210x297 mm) into the transparent pocket provided for this purpose on the outside of

the binder.

– Put the spine label (170x45 mm) into the transparent pocket provided for this purpose on the spine of the binder.

– Put the summary list of contents (150x297 mm) into the transparent pocket provided for this purpose on the inside of the

binder or insert this page on the beginning of the manual.

– Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in

the right bottom corner of each page.

Example: page no. 3-5, 3 = chapter 3, 5 = page 5. All pages with a page number that begins with the digit 3, for example,

must be put under the index heading "Chapter 3".

– Index sheets that have not been marked with a certain chapter are for your personal convenience. The respective headings

can be entered in the list of contents.

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EXPLANATION - UPDATE

This repair manual contains the following supplements:

3.210.24-E Repair Manual 50 AC/LC

5/2001

5/2002

Basic version Model year 2002

3.210.64-E Updating of Rep.Manual 3.210.24-E

Model year 2003

(Engine number with first digit „3“)

3.206.010-E Updating of Rep.Manual 3.210.24-E

Model year 2004

5/2003

4/2004

7/2005

(Engine number with first digit „4“)

3.206.018-E Updating of Rep.Manual 3.210.24-E

Model year 2005

(Engine number with first digit „5“)

3.206.028-E Updating of Rep.Manual 3.210.24-E

Model year 2006

(Engine number with first digit „6“)

Modification / Updating:

Technical Details Model 2006, Changing brake fluid, Special Tools,

Technical Specifications, tightening torques, Periodic Maintenance Schedule

Edition: 7/2005

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INTRODUCTION

This repair manual offers extensiv repair-instructions and is an up-to-date version that describes

the latest models of the series. However, the right to modifications in the interest of technical

improvement is reserved without updating the current issue of this manual.

A description of general working modes common in work shops has not been included. Safety

rules common in the work shop have also not been listed. We take it for granted that the repairs

are made by qualified profesionally trained mechanics.

Read through the repair manual before beginning with the repair work.

WARNING

STRICT COMPLIANCE WITH THESE INSTRUCTIONS IS

ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB.

CAUTION

NON-COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD

TO DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER

MOTORCYCLES UNFIT FOR TRAFFIC !

„NOTE“ POINTS OUT USEFUL TIPS.

Use only ORIGINAL KTM SPARE PARTS when replacing parts.

The KTM high performance engine is only able to meet user expectations if the maintenance

work is performed regularly and professionally.

In accordance with the international quality management ISO 9001 standard, KTM uses quality

assurance processes that lead to the highest possible product quality.

also in extracts, with written allowance of KTM-SPORTMOTORCYCLE AG, Mattighofen only.

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REPLY FAX FOR REPAIR MANUALS

We have made every effort to make our repair manuals as accurate as possible but it is always possible

for a mistake or two to creep in.

To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us

as follows:

If you find any errors or inaccuracies in one of our repair manual - whether these are technical errors,

incorrect or unclear repair procedures, tool problems, missing technical data or torques, inaccurate or

incorrect translations or wording, etc. - please enter the error(s) in the table below and fax the completed

form to us at 0043/7742/6000/5349.

NOTE to table:

–

Enter the complete item no. for the repair manual in column 1 (e.g.: 3.210.028-E).

You will find the number on the cover page or in the left margin on each right page of the manual.

–

Enter the corresponding page number in the repair manual (e.g.: 5-7c) in column 2.

Enter the current text (inaccurate or incomplete) in column 3 by quoting or describing the

respective

passage of the text. If your text deviates from the text contained in the repair manual, please write your

text in German or English if possible.

–

Enter the correct text in column 4.

Your corrections will be reviewed and incorporated in the next issue of our repair manual.

Item no. of repair manual

Page

Current text

Correct text

Additional suggestions, requests or comments on our Repair Manuals (in German or English):

Name mechanic/shop foreman:

Company/work shop:

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2-1E

GENERAL INFORMATION

INDEX

OPERATING RANGES OF THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

CLEANING AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

BLEEDING OILPUMP FOR SEPARATE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . .2-4

CHANGING FRONT BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

CHANGING REAR BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

CHECKING BRAKE PADS AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

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2-2E

Carburetor adjustment

Basic information about original carburetor setting

The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient

temperature of approx. 20° C (68° F), mainly for off-road use and central European premium-grade fuel (ROZ 95).

Mixing ratio 2-stroke motor oil:super fuel up to model 2005 1:40, as of model 2006 1:60.

Basic information about change of the carburetor setting

Always start out from the original carburetor setting. Essential requirements are a clean air filter system, air-tight exhaust system

and an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and the jet needle is sufficient and that

changes of other parts of the carburetor will not greatly affect engine performance.

RULE OF THUMB:

high altitude or high temperatures

low altitude or low temperatures

ꢀ

choose leaner carburetor adjustment

choose richer carburetor adjustment

WARNING

– ONLY USE PREMIUM-GRADE GASOLINE ROZ 95 MIXED WITH HIGH-GRADE TWO-STROKE ENGINE OIL. OTHER TYPES OF GASOLINE CAN CAUSE

ENGINE FAILURE, AND USE OF SAME WILL VOID YOUR WARRANTY.

– ONLY USE HIGH-GRADE 2-STROKE ENGINE OIL OF KNOWN BRANDS (I. E. Motorex Cross Power 2T).

– LESS OIL OR LOW-GRADE OIL CAN CAUSE EXCESSIVE WEAR OF THE PISTON. USING TOO MUCH OIL, THE ENGINE CAN START SMOKING AND FOUL THE

SPARK PLUG.

– IN THE CASE OF A LEANER ADJUSTMENT OF THE CARBURETOR PROCEED CAUTIOUSLY. ALWAYS REDUCE THE JET SIZE IN STEPS OF ONE NUMBER TO

AVOID OVERHEATING AND PISTON SEIZURE.

NOTE: If despite a changed adjustment the engine does not run properly, look for mechanical faults and check the ignition

system.

Basic information on carburetor wear

As a result of engine vibrations, throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause

carburetor malfunction (e.g., rich mixture). Therefore, these parts should be replaced after 1000 hours of using.

Idling range – A

Operation with closed throttle valve. This range is influenced by the

position of the mixture adjusting screw 1 and the idle adjusting screw

2. Only make adjustments when the engine is hot.

To this end, slightly decrease the idling speed of the engine by means

of the idle adjusting screw. Turning it clockwise produces a higher

idling speed and turning the screw counterclockwise produces a lower

idling speed. Create a round and stable engine speed using the mixture

adjusting screw (basic position of the mixture adjusting screw = open

3.5/3 turns). Then adjust to the normal idling speed by means of the

idle adjusting screw.

Opening up – B

Engine behavior when the throttle opens. The idle jet and the shape of

the throttle valve influences this range. If, despite good idling-speed

and part-throttle setting, the engine sputters and smokes when the

throttle is fully opened and develops its full power not smoothly but

suddenly at high engine speeds, the mixture to the carburetor will be

too rich, the fuel level too high or the float needle is leaking.

main jet

jet needle

Part-throttle range – C

Operation with partly open throttle valve. This range is only influenced

by the jet needle (shape and position). The optimum part-throttle

setting is controlled by the idling setting in the lower range and by the

main jet in the upper range. If the engine runs on a four-stroke cycle or

with reduced power when it is accelerated with the throttle partly open,

the jet needle must be lowered by one notch. If then the engine pings,

especially when accelerating under full power at maximum engine revs,

the jet needle should be raised.

idling jet

throttle valve

idling jet

If these faults should occur at the lower end of the part throttle range

at a four-stroke running, make the idling range leaner; if the engine

pings, adjust the idling range richer.

Full throttle range – D

Betrieb bei offenem Gasschieber (Vollgas). Dieser Bereich wird durch

Operation with the throttle fully open (flat out). This range is

influenced by the main jet and the jet needle. If the porcelain of the

new spark plug is found to have a very bright or white coating or if the

engine rings, after a short distance of riding flat out, a larger main jet

is required. If the porcelain is dark brown or black with soot the main

jet must be replaced by a smaller one.

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2-3E

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.

– 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 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 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

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 kick-starter 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.

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.

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2-4E

Bleeding oilpump for separate lubrication up to model 2003

Clamp oil lines 1 and 2 as shown.

Add 2 stroke engine oil (for example Motorex Cross Power 2T) with a

syringe until the bubble-free oil starts to leak out of the line 2.

After bleeding the oil pump, mount both oil lines and fill the oil tank

with 2 stroke engine oil (for example Motorex Cross Power 2T).

CAUTION

HOSE 2 LEADING FROM THE OIL PUMP TO THE CARBURETOR MUST BE INSTALLED

WITHOUT KINKS.

Bleeding the oil pump for the separate lubrication from the 2004

model

Disconnect the oil line 3 from the oil tank and oil line 4 from the oil

pump. Add two-stroke engine oil for separate lubrication with a syringe

until the bubble-free oil leaks out of hole A on the oil pump. Connect

the oil line 2 to the oil tank. Use the syringe to bleed the oil line 4 to

the carburetor and connect to the oil pump.

Afterwards, fill the oil tank with two stroke engine oil (e.g.: Motorex

Cross Power 2T).

CAUTION

ALWAYS MAKE SURE YOU RUN THE OIL HOSES WITHOUT KINKS.

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2-5E

Changing front brake fluid (not Mini Adventure)

– Move the hand brake cylinder into horizontal position.

– Disassemble the cover 1 together with the rubber boot 2 from the

brake fluid reservoir.

– Press the brake caliper pistons all the way back.

– Use a syringe to extract the used brake fluid and add fresh DOT 5.1

brake fluid (Motorex Brake Fluid DOT 5.1).

– Use a commercial extractor (shop equipment) to extract the used

brake fluid out of the system through the bleeder screw 3 on the

brake caliper. Make sure the brake fluid reservoir is always filled

with enough fresh brake fluid.

– Tighten the bleeder screw 3 and attach the dust cap 4 again.

– Add DOT 5.1 brake fluid (Motorex Brake Fluid DOT 5.1) up to

5 mm under the top edge of the reservoir. Remount the rubber boot,

cover and screws.

5 mm

– Wash off any overflowing or spilled brake fluid with water.

– Actuate the hand brake lever until you feel the point of pressure.

CAUTION

– NEVER USE DOT 5 BRAKE FLUID. IT IS BASED ON SILICONE OIL AND DYED

PURPLE. GASKETS AND BRAKE HOSES WILL BE DAMAGED IF DOT 5 BRAKE

FLUID IS USED.

– BRAKE FLUID CAN CAUSE SKIN IRRITATIONS. AVOID COMING INTO CONTACT WITH

THE SKIN OR EYES. IF BRAKE FLUID SPLASHES INTO YOUR EYES, RINSE

THOROUGHLY WITH WATER AND CONSULT A DOCTOR.

– MAKE SURE NO BRAKE FLUID COMES INTO CONTACT WITH PAINTED PARTS SINCE

BRAKE FLUID WILL CORRODE THE PAINTWORK!

– ONLY USE CLEAN, NEW BRAKE FLUID FROM TIGHTLY SEALED CONTAINERS.

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2-6E

Changing rear brake fluid (50 SX, 50 Supermoto)

– Move the vehicle in a vertical position.

– Disassemble the cover 1 together with the rubber boot 2 from the

brake fluid reservoir.

– Press the brake caliper pistons all the way back.

– Use a syringe to extract the used brake fluid and add fresh DOT 5.1

brake fluid (Motorex Brake Fluid DOT 5.1).

– Completely remove the bleeder screw 3 .

– Extract the old brake fluid from the system using the bleeder syringe

503.29.050.000. Always make sure that the brake fluid reservoir is

filled with sufficient fresh brake fluid.

– Mount the bleeder screw 3 .

– Add DOT 5.1 brake fluid (Motorex Brake Fluid DOT 5.1) up to

15 mm under the top edge of the reservoir. Remount the rubber

boot, cover and screws.

15 mm

– Wash off any overflowing or spilled brake fluid with water.

– Actuate the foot brake lever until you feel the point of pressure.

CAUTION

– NEVER USE DOT 5 BRAKE FLUID. IT IS BASED ON SILICONE OIL AND DYED

PURPLE. GASKETS AND BRAKE HOSES WILL BE DAMAGED IF DOT 5 BRAKE

FLUID IS USED.

– BRAKE FLUID CAN CAUSE SKIN IRRITATIONS. AVOID COMING INTO CONTACT WITH

THE SKIN OR EYES. IF BRAKE FLUID SPLASHES INTO YOUR EYES, RINSE

THOROUGHLY WITH WATER AND CONSULT A DOCTOR.

– MAKE SURE NO BRAKE FLUID COMES INTO CONTACT WITH PAINTED PARTS SINCE

BRAKE FLUID WILL CORRODE THE PAINTWORK!

– ONLY USE CLEAN, NEW BRAKE FLUID FROM TIGHTLY SEALED CONTAINERS.

Checking brake pads and brake disks

– See Owner's Manual

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3-1E

REMOVING AND REFITTING ENGINE

INDEX

REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

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3-2E

Removing the engine

NOTE: the following steps are shown on a model with LC-engine, on a

model with AC-engine a few works are not necessary like draining

coolant liquid, removing and mounting the radiator and the radiator

shield, bleeding the cooling system.

Clean the entire vehicle thoroughly before removing the engine.

To avoid burns, allow the motorcycle to cool before starting to work.

– Jack up the motorcycle on a sturdy work stand.

– Turn quick release 1 on the seat 180°, lift back of seat slightly and

pull back.

– Remove the cover of the air filter by reaching through the recess in

the panel and pushing the locating tab 2 forwards with your finger.

– Remove air filter element.

– Loosen hose clamp 3 on the air filter box of the carburetor and

remove air filter box.

– Pull air filter box 4 up through the retaining bracket 5 by

deforming it.

– Close fuel cock and disconnect fuel hose 6 from the carburetor.

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3-3E

– Loosen retaining bolt on tank 1 and remove from tank together with

the rubber grommet.

– Lift tank from the frame.

– Open chain joint 2 and remove chain.

– Loosen hose clamp 3 of the intake flange on the carburetor, pull

carburetor back and swing to the side.

NOTE: if the carburetor is not being serviced, it does not need to be

removed - the carburetor openings should however be covered with a

clean cloth and the gasoline drained from the float chamber.

– Remove radiator shield on the right and left 4.

– Unbolt radiator cap, open drain plug 5 and allow cooling fluid to

drain into a receptacle. Then remount the drain plug with a new

sealing ring and tighten (5 Nm/4 ft.lb).

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3-4E

– Loosen hose clamp 1 and pull both hoses from their connections.

– Unbolt radiator retaining bolt 2 and laterally remove radiator with

water hoses from the frame.

– Carefully pull socket connector 3 apart.

– Detach both exhaust springs 4 with a suitable wrench, remove

springs.

– Unbolt the exhaust bracket on the right and pull exhaust off towards

the front.

– Loosen engine mounting bolts 5 and 6, lift engine from the frame.

Installing the engine

– Lift engine into the frame and fasten with bolt 5 (M8x65 with nut)

and 2 bolts 6 (M8x55).

– Tighten bolts to 30 Nm (22 ft.lb).

– Mount exhaust, insert springs 4 and tighten bolt for exhaust bracket

M6x15 on the right.

– Carefully connect socket connector 3.

– Position radiator in the frame and tighten the radiator retaining bolts

2 (M6x10 with washer 18/6,5/1,5) to 10 Nm (7 ft.lb). Connect

hoses and tighten hose clamps 1.

– Fill cooling liquid (total filling amount approx. 0,5 liter).

– Mount radiator shield on the right and left.

NOTE: bolts 7 (M6x10) are bolted onto the side of the frame, bolt 8

(M6x15) is bolted into the radiator bracket.

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3-5E

– Install carburetor on the intake flange and tighten hose clamp 1.

– Place chain on rear sprocket and pinion, mount chain joint 2 and

secure.

NOTE: make sure the locking member runs in the right direction (see

photo). The closed side of the safety device must point in the running

direction.

– Mount tank and bolt tight. Do not forget the rubber grommet 3 for

the bolt.

– Connect fuel hose 4 to the carburetor and secure.

– Slide air filter box into the frame bracket.

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3-6E

– Attach connection 1 of the air filter box to the carburetor and

tighten hose clamp.

– Insert air filter element in the air filter box and mount cover.

NOTE: the locating tabs in the cover must engage in the panel.

– Mount seat. Make sure the retaining bracket 2 is inserted properly.

Insert quick release 3 in the dolly and turn 180°.

After installing the engine, perform a short test run and correct the

cooling fluid level (LC-engine). Then take the motorcycle on a road test.

After the road test, check the engine, the fuel system and the exhaust

system for tightness.

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4-1E

DISASSEMBLING THE ENGINE

INDEX

SPECIAL TOOLS - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

FIXING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

DRAINING GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

DISMOUNTING INTAKE FLANGE AND IGNITION COIL . . . . . . . . . . . . . . . . . . . . . .4-3

DISMOUNTING IGNITION COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

DISMOUNTING IGNITION STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

DISMOUNTING CYLINDER, CYLINDERHEAD AND PISTON . . . . . . . . . . . . . . . . . . .4-4

DISMOUNTING IGNITION ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

SPLIT THE CASING HALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

DISMOUNTING CLUTCH AND PRIMARY DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

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4-2E

SPECIAL TOOLS ENGINE 50 AC/LC

FIG

PARTNUMBER

590.29.021.000

451.12.021.000

451.29.006.000

6 899 785

DESCRIPTION

Puller for flywheel

Rotor holding tool

Adjusting plate for Dimension „X“

Loctite 243 blue

Tachometer

451.29.075.000

503.29.050.000

Bleeding syringe

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4-3E

Clamp the engine using a vice

– Clean the engine thoroughly prior to disassembling.

– The engine can be clamped with a vice, using a protective pad to

clamp the lower rear bracket (see photo).

Drain the transmission oil

– Remove the transmission oil drain plug 1 including the sealing ring

and allow transmission oil to drain.

– Mount the transmission oil drain plug with new sealing ring and

tighten to 15 Nm (11 ft.lb).

Remove water hose, intake flange and ignition coil

– Loosen hose clamps and remove water hose 2 (only LC-engine).

– Pull plug 3 from the ignition coil, disconnect spark plug cap from

the spark plug.

– Loosen 4 bolts on the intake flange 4. Remove the ignition coil with

bracket, intake flange and reed valve housing.

– Remove spark plug.

Remove ignition cover and pump.

– Loosen bolt 5 and remove ignition cover.

NOTE:

– The water pump 6 is located on the ignition cover of the LC-engine.

– The ignition cover is centered with 2 dowels. They usually stay in the

engine case and should be removed with a suitable wrench.

NOTE: water pump shafts from the 2004 model have a hole containing

a spring 7.

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4-4E

Remove ignition stator.

– Pull cable guide 1 from the case.

– Remove allan bolts 2 of the ignition stator 3.

– Carefully pull stator 3 out of the case.

Remove cylinder head, cylinder and pistons.

– Loosen bolts on cylinder head crosswise and remove.

– Discard washers (LC-engine), remove cylinder head 4.

– Remove gasket 5 (AC-engine) or O-rings 6 (LC-engine) from

cylinder and discard.

– Loosen 4 bolts 7 on the cylinder base crosswise and remove;

carefully lift the cylinder off.

– Place pistons on a self-made mounting board.

– Remove ring lock 8 from the piston pin using a suitable tool.

– Push piston pins out of the piston by hand, remove pistons and pull

needle bearing from the conrod.

– Remove cylinder base gasket.

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4-5E

Pull off ignition rotor

– Hold ignition rotor 1 with special tool 2, open the nut and remove.

NOTE: a washer is located under the nut; the magnetic attraction of the

rotor causes it to adhere to the rotor.

CAUTION

MAKE SURE THE TWO PINS OF THE SPECIAL TOOL DO NOT CATCH THE THREADED

HOLES, OTHERWISE THE THREADING WILL BE DAMAGED AND THE ROTOR CAN NO

LONGER BE REMOVED.

– Remove circlip 3 from the chain sprocket and remove chain

sprocket.

– Bolt extractor to the rotor with 2 M4x35 bolts, hold extractor in place

and pull rotor 4 off by bolting in the extractor bolt.

– Remove woodruff key from the groove.

Split the casing halves

– Loosen all 7 allan bolts 5 holding the two casing halves together

and set aside.

– Bolt extractor to the casing with 2 M5x50 bolts 7.

– Hold extractor in place and separate the casing by bolting in the

extractor bolt, gently tapping the casing with a plastic hammer to

prevent the bearing on the drive shaft 6 from canting.

CAUTION

IF THE BEARING ON THE DRIVE SHAFT CANTS, STOP PULLING OFF THE CASING. USE

THE PLASTIC HAMMER TO CAREFULLY CORRECT THE DISTORTION, OTHERWISE THE

CASING WILL BE DAMAGED.

– Remove casing; remove seal and discard.

NOTE: the housing halves are centered with 2 dowels which should also

be removed.

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4-6E

Disassemble the clutch and primary drive

– Rechuck the engine to provide access to the clutch side.

– Remove kickstarter and bolts 1 on the clutch cover.

– Remove clutch cover, discarding the seal.

WARNING

DO NOT REMOVE THE CIRCLIP 2, OTHERWISE THE KICKSTARTER SPINDLE MAY FALL

FROM THE CASING AND THE KICKSTARTER SPRING CAUSE INJURIES.

– Block the centrifugal clutch 3 with a suitable mandrel 4.

NOTE: the drum and the gear wheel of the primary drive have holes.

Push the mandrel through both holes.

– Bend up the lock washer 5 on the output shaft nut.

– Loosen the nut on the clutch and the output shaft and pull the

mandrel out.

– Remove nut and washer from the crankshaft.

– Bolt the extractor to the hub of centrifugal clutch 6 using bolts

M5x50, hold the extractor in place and pull the centrifugal clutch

from the crankshaft by bolting in the extractor bolt.

– Remove the centrifugal clutch from the crankshaft together with the

bearing and spacing washers.

– Remove nut 7 and lock washer from the output shaft.

– Remove gear 8 on the primary drive from the shaft, remove woodruff

key 9 from the shaft groove.

– Press the crankshaft and output shaft out of the casing using a press

or suitable extractor.

CAUTION

THE TWO SHAFTS MAY NOT BE STRUCK OUT OF THE CASING WITH A HAMMER SINCE

THE CRANKSHAFT OR THE CASING MAY BE DAMAGED.

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5-1E

SERVICING INDIVIDUAL COMPONENTS

INDEX

RIGHT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

LEFT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

REED VALVE HOUSING, INTAKE FLANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

CHECKING CYLINDER FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

SPRINGS OF CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

CHECKING CLUTCH FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

Engine housing

Note: Read through the following section before commencing work. Then determine the assembly sequence so that the engine

housing halves only need to be heated up once before replacing the bearings.

Having first removed the dowels, in order to expel the bearings or remove them with light mallet blows, the housing halves must

be placed on a suitably large plane surface, supporting the whole of the sealing surface without damaging it. A wooden panel is

best used as a base.

Bearings or shaft seal rings should not be hammered into their seats. If no suitable press is available, use a suitable mandrel and

hammer them in with great care. Cold bearings will practically drop into their seats at an engine housing temperature of approx.

150° C.

After cooling, should the bearings fail to lock in the bore, they are bound to rotate after warming. In that event the housing must

be replaced.

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5-2E

Working on the right half of the engine case

Remove shaft sealing ring 1 and heat the engine case half on a heating

plate to approx. 150° C.

NOTE: if the engine case is heated to 150° C and struck on a wooden

surface, the bearings usually fall out of the bearing seats automatically.

If necessary, the bearings must be pushed out.

CAUTION

– ALWAYS REMOVE DOWELS FIRST TO PREVENT THE CASE FROM BEING DAMAGED.

– THE DEVICES (MANDRELS) TO PRESS THE NEW BEARINGS IN PLACE SHOULD BE

DESIGNED SUCH THAT THEY ONLY REST ON THE OUTER RING OF THE BEARING,

OTHERWISE THE BEARINGS WILL BE DAMAGED WHEN FITTED.

Grooved ball bearing for crankshaft 2

Use a suitable mandrel to press the grooved ball bearing into place.

Press the new grooved ball bearing all the way in.

NOTE: the grooved ball bearing of the crankshaft will protrude approx.

1 mm from the surface of the case.

Grooved ball bearing for output shaft 3

Use a suitable mandrel to press the grooved ball bearing into place.

Press the new grooved ball bearing all the way in.

NOTE: the grooved ball bearing of the output shaft should fit flush with

the surface of the case.

Shaft sealing ring for crankshaft 1

Press a new shaft sealing ring into place with the sealing lip to the

inner side.

NOTE: the seal shaft ring will fit approx. 1 mm lower than the surface

of the case.

After the engine case halves have cooled, check all bearings for firm

retention in the bearing seats.

Finally, check the greasing hole S for the grooved ball bearing of the

crankshaft and the connection for the gearbox ventilation for clearance.

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5-3E

Working on the left half of the engine case

Remove shaft sealing rings 1/2 and heat engine case halves on a

heating plate to approx. 150° C.

NOTE:

– If the engine case is heated to 150° C and struck on a wooden

surface, the bearings usually fall out of the bearing seats

automatically. If necessary, the bearings must be pushed out.

– The devices (mandrels) to press the new bearings in place should be

designed such that they only rest on the outer ring of the bearing,

otherwise the bearings will be damaged when fitted.

Grooved ball bearing for crankshaft 3

Use a suitable mandrel to press the grooved ball bearing into place.

Press the new grooved ball bearing all the way in.

NOTE: the grooved ball bearing of the crankshaft will protrude approx.

1 mm from the surface of the case.

Grooved ball bearing for output shaft 4

Use a suitable mandrel to press the grooved ball bearing into place.

Press the new grooved ball bearing all the way in.

NOTE: the grooved ball bearing of the output shaft should fit flush with

the surface of the case.

Shaft sealing ring for crankshaft 1

Press a new shaft sealing ring into place with the sealing lip to the

inner side.

After the engine case halves have cooled, check bearings for firm

retention.

Measure the crankshaft

If continuing to use the crankshaft, check crankshaft journal for lateral

runout.

The lateral runout of the crankshaft journal should be no more than

0.05 mm

NOTE: Conrod bearing and crankshaft can only be checked in

dismantled condition, this should be done in a special workshop.

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5-4E

Working on the clutch cover

NOTE: dismantling the clutch cover is neccessary if parts are damaged

or the O-ring is leaking.

– Turn kickstarter shaft 1 counter-clockwise and remove ratchet gear

2. Check gearing for wear.

NOTE: If the kickstarter shaft is to be removed, the outer circlip must

be removed, carefully pulling the kickstarter shaft out of the cover.

WARNING

THE KICKSTARTER SPRING IS PRETENSIONED. IT MUST BE STRESS-RELIEVED WHEN

THE KICKSTARTER SHAFT IS PULLED OUT.

– Clean kickstarter shaft and renew O-ring 3 (up to the 2003 model).

NOTE:

– make shure that the O-ring is mounted in the second groove 4.

– starting with the 2004 model, a shaft seal ring 5 is installed in the

engine instead of an O-ring and the kickstarter shaft no longer has a

second groove. Pry out the old shaft seal ring and press the new

shaft seal ring in until flush with a suitable tool.

During assembly only push the kickstarter shaft into the clutch cover far

enough to be able to reinsert the spring (6 and 7). The spring is

pretensioned by turning the kickstarter shaft in a counter-clockwise

direction, then completely push the kickstarter shaft into the clutch

cover. Hold the kickstarter shaft turned, mount the ratchet gear and

release the kickstarter shaft again.

NOTE: the end of the kickstarter shaft gearing has a deformation 8 to

prevent the kickstarter shaft from hitting against the clutch cover,

causing it to wedge with the gearing of the ratchet gear. Make sure to

keep a gap between the kickstarter shaft and stop 9.

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5-5E

Overhaul the water pump (LC-engine)

– Remove cover 1, discard the O-rings.

– Remove circlip 2 with a suitable wrench.

– Remove the water pump wheel 3 from the pump shaft 4.

– Press out shaft 4, press out both bearings (6 and 7).

– Remove seal shaft ring 5.

NOTE: a spring 8 is installed starting with the 2004 model. Remove

before disassembling.

– Press in a new seal shaft ring 5, make shure that the open side of

the seal shaft ring is located on the side of the water pump wheel.

– Slide both new bearings (6 and 7) onto the pump shaft 4.

– Lightly grease pump shaft and press the pump shaft with the

bearings in all the way into the ignition cover 9, check for smooth

operation.

– Mount the water pump wheel and the circlip.

– Mount cover 1 with a new O-ring.

– Mount the spring 8 (applies to models from 2004), fix in the hole

with a small amount of grease, if necessary.

Reed valve housing, intake flange

NOTE: the reed paddles gradually lose their tension, leading to power

loss. Defective or worn reed paddles must be replaced.

If the sealing surfaces of the reed valve housing are also damaged,

replace the entire reed valve housing.

CAUTION

SECURE ALL BOLTS OF THE DIAPHRAGM HOUSING WITH LOCTITE 243 AFTER

ASSEMBLY.

Intake flange

Check for cracks and other damage.

Reed valve housing

Measure the distance M between the stop plates with a sliding gauge.

If the measured value deviates from the desired value, the stop plates

must be bent accordingly.

Distance M = 17 mm

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5-6E

Check pistons

If continuing to use a used piston, check as follows:

1. Check piston bearing surface for pressure marks, piston seizure (light

friction can be removed with a fine emery stone).

2. The piston ring may not jam in the piston ring groove. To clean the

piston ring groove, use an old piston ring or sanding paper (400

grain size).

3. Piston ring anti-rotation device must fit tightly in the piston and may

not be worn.

4. Check piston ring for wear and gaps in the cylinder.

Measuring the piston ring end gap

– Insert the piston ring in the cylinder and align with the piston

(approx. 10 mm / 0.39 in under the upper edge of the cylinder).

– Measure end gap B with a feeler gauge.

End gap: max. 0.20 mm / 0.0078 in

NOTE: If the end gap is larger than specified above, pistons and

cylinder must be checked for wear. If the piston wear and cylinder wear

are within the tolerance zone, the piston ring must be replaced.

Measure the piston and cylinder, determine the piston

– To determine cylinder wear, measure the cylinder 10 mm and 50

mm from the top using a micrometer (shown in the drawing).

– Measure the cylinder diameter in the X and the Y axis to establish

any ovality.

10mm

50mm

– The piston is measured at the piston skirt, transverse to the piston

pin 32 mm below the top, as shown in the illustration.

– The smallest cylinder diameter minus the largest piston diameter

determines the piston fitting clearance.

Piston fitting clearance

AC-engine:

LC-engine:

0.055 - 0.065 mm

(0.00216 - 0.00256 in)

0.045 - 0.055 mm

(0.00177 - 0.00216 in)

MARK

PISTON

CYLINDER AC

CYLINDER LC

39.455 - 39.460 mm 39.515 - 39.520 mm 39.505 - 39.510 mm

1.5533 - 1.5535 in 1.5557 - 1.5559 in 1.5553 - 1.5555 in

39.461 - 39.465 mm 39.521 - 39.525 mm 39.511 - 39.515 mm

1.5535 - 1.5537 in 1.5559 - 1.5561 in 1.5555 - 1.5557 in

39.466 - 39.470 mm 39.526 - 39.530 mm 39.516 - 39.520 mm

1.5537 - 1.5539 in 1.5561 - 1.5563 in 1.5557 - 1.5559 in

39.471 - 39.475 mm 39.531 - 39.535 mm 39.521 - 39.525 mm

1.5539 - 1.5541 in 1.55663 - 1.5565 in 1.5559 - 1.5561 in

NOTE:

When replacing piston and cylinder always make sure to use a piston

and cylinder of the same type. The type identification mark (A to D) can

be found on the cylinder base or the piston head, respectively.

The table to the right indicates the tolerance thresholds for the listed

components.

Always keep in mind that a minimum piston fitting clearance of

0.055 mm (0.00216 in) (AC-engine) or 0.045 mm (0.00117 in)

(LC-engine) is required.

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5-7E

Overhauling the centrifugal clutch

– Loosen HH bolts 1 on the clutch shoes 2 and remove together with

the set of springs 3 from the clutch hub 4.

NOTE: coilsprings 7 are used instead of the spring washers for the

AC-engine. Length of clutch springs: min. 19.6 mm (0.748 in).

– Remove HH bolts with sleeves and set of springs from the clutch

shoes.

NOTE:

– the set of springs consists of 14 spring washers 5, make sure the

spring washers are placed exactly in the same order A shown below

(only LC-engine).

– Washers 6 to pretension the spring sets are located between the

spring sets and the clutch shoes. The preload on the spring set has

an influence on the clutch engagement speed. 0.5 mm more preload

increases the clutch speed by approx. 500 rpm.

– the clutch speed is the speed at which the clutch begins to engage

and the motorcycle begins to move.

– check the clutch speed with the tachometer 451.29.075.000 and

adjust if necessary:

AC-engine: 4000 - 4500 rpm

LC-engine: 8500 - 9000 rpm

Balancing the clutch wear

– Check clutch shoes for wear; if the lining only shows minor signs of

wear, the linings can be reinstalled.

NOTE:

– the centrifugal clutch has an outer diameter of approx. 82.5 mm

(3.248 in) when new.

– to compensate for minor wear in the lining, one of the preload

washers 6 from any set of springs can be inserted between the

clutch hub and clutch shoes - see Fig. B. If only one washer is

installed, this washer can be used.

– the inner diameter of the clutch drum must not exceed 84.4 mm

(3.3228 in) (new condition 84.0 mm [3.3071 in]).

– Make sure the spring sets are kept free of contamination during

maintenance and repair work to the clutch, otherwise they may

malfunction.

Assembly is in the reverse order as disassembly. HH bolts 1 must be

secured with Loctite 243 and tightened to 12 Nm (9 ft.lb).

Clutch new

used

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6-1E

ASSEMBLING THE ENGINE

INDEX

MOUNTING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

MOUNTING THE PRIMARY DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

MOUNTING LEFT ENGINE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

MOUNTING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

MOUNTING THE CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

IGNITION COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

MOUNTING PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

MOUNTING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

ADJUSTING DIMENSION „X“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

MOUNTING WATERHOSE, INTAKE FLANGE AND IGNITION COIL . . . . . . . . . . . . . . . .6-6

FILLING IN GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

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6-2E

Mounting the crankshaft and output shaft

– Heat the engine case on a heating plate.

– Lubricate both bearings, lightly grease the seal shaft ring.

– Push the output shaft and crankshaft into the bearing.

NOTE: the conrod must be in a vertical position.

CAUTION

DO NOT INSERT THE SHAFTS INTO THE BEARINGS WITH A HAMMER SINCE THE

BEARINGS AND CRANKSHAFT MAY BE DAMAGED.

Mounting primary drive

– Insert woodruff key 1 in the output shaft groove.

– Place the gear of the primary drive on the output shaft, collar 2

first.

– Slide on the nut lock washer.

NOTE: the tab of the lock washer 3 must engage in the bore of the

primary drive wheel.

– Bolt nut M14x1,25 into place.

Mounting the left half of the case

– Mount 2 dowels 7x9x10, apply new seal.

NOTE: the seal is not cut until after the second half of the case is

mounted.

– Heat the left half of the case on a heating plate and mount.

– Bolt 7 allan bolts into place.

NOTE: 4, 8 and bk are M6x40; 5, 6, 7 and 9 are M6x35 bolts.

– Tighten 4 to 7 crosswise to 10 Nm (7 ft.lb).

– Tighten 8 to bk to 10 Nm (7 ft.lb).

– Gently tap the case with a plastic hammer a few times near the

bearings to relieve the pretensioning.

– Check both shafts for smooth operation by turning.

– Cut protruding seal bl with a sharp knife for a flush fit.

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6-3E

– Wrap insulating tape around the output shaft in the area of the sharp

edge 1 to prevent the seal shaft ring from being damaged.

NOTE: wrap insulating tape just above edge to allow the tape to be

easily pulled off after the seal shaft ring is mounted.

– Grease the seal lip and press in the seal shaft ring.

– Pull off the tape.

Mounting the ignition

– Place woodruff key in the crankshaft groove.

– Mount ignition rotor 2 with a washer, holding back with special tool,

secure nut with Loctite 243 and tighten to 20 Nm (15 ft.lb).

CAUTION

THE PINS ON THE SPECIAL TOOL MAY NOT ENGAGE IN THE ROTOR'S THREADED

HOLES, OTHERWISE THE THREAD WILL BE DAMAGED.

– Slide the chain sprocket 3 on the output shaft with the collar

towards housing and mount the circlip.

– Mount ignition stator 4 in the case.

NOTE: for easier installation, gently press the stator together with your

fingers. Check for a correct fit prior to bolting tight, stator may not

cant.

– Secure allan bolts M5x25 5 on the stators with Loctite 243 and

tighten to 8 Nm (6 ft.lb).

– Position cable guide 6.

Mount the clutch

– Slide spacing washer(s) (25x15) onto the crankshaft, mount needle

bearings and the centrifugal clutch unit.

– Block the centrifugal clutch, drum and gear of the primary drive with

a suitable mandrel 7.

– Secure the nut M10x1.25 on the crankshaft with Loctite 243 and

tighten to 35 Nm (25 ft.lb).

– Tighten the output shaft nut to 40 Nm (30 ft.lb).

– Bend over the lock washer on the output shaft nut.

NOTE: for a correct function of the centifugal clutch axial clearance S

between 0,2 and 0,7 mm (0,039 and 0,0055 in) must remain between

the bottom of the drum and the clutch unit.

– Checking the axial clearance with a sliding gauge 8 by pressing the

drum against the spacer and measure the distance from the upper

edge of the drum to the drive wheel.Then pull the drum against the

clutch unit, hold in position and measure again - the difference

between these measurements is the axial clearance.

– Press drum against the spacing washers by hand and measure the

distance between the drum and the gear of the primary drive using a

feeler gauge 9 - it should be at least 0.5 mm.

NOTE: if the clearances are outside of the tolerance zone, use spacing

washers to balance. Spacing washers are available in different thicknesses.

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6-4E

Mounting the clutch cover

– Put new seals in place and mount the clutch cover .

– Bolt clutch cover into place with 6 bolts M6x25 1, tighten the bolts

to 10 Nm (7 ft.lb).

Mount the ignition cover and water pump.

– Put the dowels 7x9x10 in place.

– Align the driving slot on the water pump drive 2 with the driver

blade 3 on the crankshaft (LC-engine).

NOTE: make sure the spring is mounted in the water pump shaft

(models from 2004).

– Put cover on and engage by turning the pump drive cover back and

forth.

CAUTION

DO NOT TRY TO MOUNT THE IGNITION COVER BY FORCE, OTHERWISE COMPONENTS

WILL BE DAMAGED.

ꢀ2003

2004ꢀ

– Bolt 3 HH bolts M6x25 4 into ignition cover and tighten to 10 Nm

(7 ft.lb).

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6-5E

Mount the pistons

– Fix conrod with a mounting board.

– Grease the conrod bearings and attach to conrod eye.

– Mount pistons, the arrow on the bottom of the piston should point

towards the outlet port.

– Slide piston pin into the conrod eye by hand and mount piston pin

lock with the open side facing down.

– Turn the piston ring until the anti-rotation device engages in the

piston ring end gap 1.

– Mount cylinder base gasket, press piston rings together with your

fingers and slide the greased cylinder over the pistons.

NOTE: if neither the pistons, cylinder, crankshaft or engine case are

being replaced, the same seal thickness can be used as before.

– Tighten collar nut 2 on the cylinder base bolting crosswise to a

torque of 18 Nm (13 ft.lb).

– Mount a new seal 3 (AC-engine) or insert new O-rings 4 in the

recesses (LC-engine).

Adjust measurement „X“

NOTE:

– Measurement „X“ is the distance from the upper piston edge to the

upper cylinder edge, piston set in TDC position and cylinder base

bolts tightened.

– Measurement „X“ must be set with special care, adjusting various

thicknesses of cylinder base gaskets.

CAUTION

IF THE „X“ MEASUREMENT IS TOO LARGE-THIS MEANS THAT A GAP IS VISIBLE

BETWEEN PISTON AND ADJUSTING PLATE-THE COMPRESSION WILL SINK AND THE

ENGINE WILL LOSE POWER. IF THE „X“ MEASUREMENT IS TOO SMALL-THIS MEANS

THAT A GAP IS VISIBLE BETWEEN CYLINDER AND ADJUSTING PLATE-THE ENGINE WILL

PING AND OVERHEAT.

– Place the adjusting plate on the cylinder and set pistons to TDC (see

diagram). If the „X“ measurement is correctly adjusted, the feeler

gauge will lie flush on the pistons and on the cylinder.

– Adjust the „X“ measurement by adding or removing cylinder base

gaskets.

NOTE: the „X“ measurement is increased by adding cylinder base

gaskets and decreased by removing cylinder base gaskets.

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6-6E

Mount the cylinder head

– Mount the cylinder head 1, making sure the water connection is on

the intake side (LC-engine).

– Use new washers for the cylinder head bolts (LC-engine), tighten

cylinder head bolts crosswise in 2 stages to 15 Nm (11 ft.lb).

Mount water hose, intake flange and ignition coil

– Apply water hose and tighten hose clamp (only LC-engine).

– Mount the reed valve housing and intake flange with new seal.

NOTE:

– the longer bolts (M6x40) 2 are bolted into the upper holes, the

bracket and the ground connection of the ignition coil are also fixed

with these bolts.

– the shorter bolts (M6x20) 3 are bolted into the lower holes.

– the intake flange should point to the chain sprocket.

– Bolt in the spark plug, spark plug cap and ignition connection,

mount kickstarter and transmission vent hose.

Fill in transmission oil

– Make sure the transmission drain plug is tightened to 15 Nm

(11 ft.lb).

– Remove oil filler bolt 4 and add 150-200 ccm gear oil Dexron II

(Motorex ATF Super), remount oil filler bolt and tighten to 5 Nm

(4 ft.lb).

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7-1E

TROUBLE SHOOTING

INDEX

TROUBLE SHOOTING 50 AC/LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

IGNITION MEASUREMENT 50 AC/LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

MEASUREMENT WITH PEAK VOLTAGE ADAPTER . . . . . . . . . . . . . . . . . . . . . . . .7-4

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7-2E

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) (0.0236 in)

Clean spark plug or renew

Plug fouled by oil, wet or bridged

Ignition wire or spark plug

connector damaged

Dismount spark plug, connect ignition cable, hold to

ground (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 Disconnect black coloured cable from short circuit button

switch faulty

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 running

Idle adjusting bolt out of Readjust idle running or replace idle adjusting bolt

adjustment

Ignition system damaged

Wear

Examine ignition system

Overhaul engine

Less power of engine

Air filter obstructed

Clean or renew airfilter

Fuel supply partly interrupted or

blocked

Blow through fuel pipe and clean carburetor

Loss of compression due to loose

spark plug

Tighten spark plug

Exhaust system damaged

Check exhaust system for damage

Engine

preignition

has

not

enough Check and adjust ignition

Reed paddles tensionless or Replace reed paddles or reed valve housing

damaged, surface of reed valve

housing damaged

Wear

Overhaul engine

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7-3E

TROUBLE

CAUSE

REMEDY

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

with four stroke cycle

adjust too high, float needle adjust level

seating is dirty or enlarged

Loose carburetor jets

Tighten jets

High rpm misfiring

Incorrect heat range spark plug Refer to technical data section

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 Top up coolant and bleed cooling system check cooling

system for leaks

system

(only LC-engine)

Radiator fins clogged

(only LC-engine)

Clean radiatar fins with water jet

Frothing in cooling system

(only LC-engine)

Renew coolant using branded anti-freeze/anti-corrosive

(Motorex Anti-Freeze)

Pinched or kinked water hoses

(only LC-engine)

Replace with correct routed hoses

Incorrect ignition timing because Readjust to correct ignition timing specifications, secure

bolts with Loctite 243

of loose stator bolts

Incorrect compression ratio

Measure and adjust compression ratio

Check cylinder head, replace O-ring

Emission of white smoke Cylinder head or O-ring of

cylinder head gasket leaks

(steam)

(only LC-engine)

Excessive oil escapes from Excessive oil quantity in

transmission breather tube transmission

Correct transmission oil level

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7-4E

Resistor values of the ignition system - Stator

– Unplug the ignition stator and measure the resistance of the stator

using a digital measuring tool.

– The resistance must be 500 Ω 40 Ω at 20º C.

NOTE: it is not neccessary to take the stator out of the engine housing.

Ignition coil

– Undo the spark plug cap

– Measure the resistor of the secundary side of the Ignition coil

between high tension lead and mass of the coil.

– The resistance must be 2250 Ω 250 Ω at 20º C.

Measuring static ignition values with peak voltage adapter

Measuring conditions:

– cold engine

– seat and tank removed

– all connector and socket connectors and the ground connection in a

non-corroding condition

– kick the kick starter forcefully at least 5 times for each measurement

Check the pulse generator/charging coil for an output signal - one-pin

connector 1:

– Apply the red measuring lead R of the peak voltage adapter to the

connector and the black measuring lead S to the ground, disconnect

connector 1 from the ignition coil 2

Multimeter display for 50 SX AC: 220 Volt 10 Volt

Multimeter display for 50 SX LC: 270 Volt 10 Volt

– Same measurement with connector connected to the ignition coil

Multimeter display for 50 SX AC: 250 Volt 10 Volt

Multimeter display for 50 SX LC: 270 Volt 10 Volt

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8-1E

TECHNICAL SPECIFICATIONS

INDEX

MODEL 2002

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3

BASIC CARBURETOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3

CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4

STANDARD-ADJUSTMENT – FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4

STANDARD ADJUSTMENT – SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . .8-4

MODEL 2003

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5

BASIC CARBURETOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5

CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6

STANDARD-ADJUSTMENT – FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6

STANDARD ADJUSTMENT – SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . .8-6

MODEL 2004

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7

BASIC CARBURETOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8

CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9

STANDARD-ADJUSTMENT – FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9

STANDARD ADJUSTMENT – SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . .8-9

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8-2E

INDEX

MODEL 2005 AC

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10

BASIC CARBURETOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10

CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11

STANDARD-ADJUSTMENT – FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11

STANDARD ADJUSTMENT – SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . .8-11

MODEL 2005 LC

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12

BASIC CARBURETOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12

CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13

STANDARD-ADJUSTMENT – FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13

STANDARD ADJUSTMENT – SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . .8-13

MODEL 2006 AC

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14

BASIC CARBURETOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14

CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-15

STANDARD-ADJUSTMENT – FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-15

STANDARD ADJUSTMENT – SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . .8-15

MODEL 2006 LC

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-16

BASIC CARBURETOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-16

CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-17

STANDARD-ADJUSTMENT – FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-17

STANDARD ADJUSTMENT – SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . .8-17

TOLERANCES AND FITTING CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-18

TIGHTENING TORQUES - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-18

TIGHTENING TORQUES - CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-18

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8-3E

TECHNICAL DATA - ENGINE 50 AC/LC 2002

Engine

50 AC (aircooled)

50 LC (liquid cooled)

Design

single cylinder 2-stroke engine, with reed valve inlet

Displacement

Bore/Stroke

Fuel

49,0 cm³

39,5 / 40 mm

SUPER fuel, research octane no 95, mixed with 2-stroke oil

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

Oil/gasoline ratio

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 t

0.15-0.2 liter gear oil Dexron II (Shell Donax TA)

NGK BR 8 EH

NGK BR 10 EG

Electrode gap

Carburetor

0,6 mm

Dell'Orto PHVA 14 DS

Dell'Orto PHVA 14 DS / PHBG 19 BS

Air filter

wet foam type air filter insert

0.5 liter (0.132 USgal); water : coolant = 2 : 1

Coolant

–

BASIC CARBURETOR SETTING

Model

50 MINI ADVENTURE 50 JUNIOR/SENIOR

ADVENTURE

Dell'Orto PHVA 14 DS Dell'Orto PHVA 14 DS

50 SX PRO JUNIOR LC

50 SX PRO SENIOR LC

Type

Dell'Orto PHVA 14 DS

Dell'Orto PHBG 19 BS

Main jet

60 (70/80)

211 FA

80 (70)

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

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8-4E

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8-5E

TECHNICAL DATA - ENGINE 50 AC/LC 2003

Engine

50 AC (aircooled)

50 LC (liquid cooled)

Design

single cylinder 2-stroke engine, with reed valve inlet

Displacement

Bore/Stroke

Fuel

49,0 cm³

39,5 / 40 mm

SUPER fuel, research octane no 95, mixed with 2-stroke oil (separate lubrication only ROZ 95)

1 : 40 when using high grade 2-stroke oil (Shell Advance Racing X)

(separate lubrication Shell Advance Ultra 2)

Oil/gasoline ratio

Lubrication

mixture lubrication / separate 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 t

0.15-0.2 liter gear oil Dexron II (Shell Donax TA)

NGK BR 8 ECM

Electrode gap

Carburetor

0,6 mm (0.0236 in)

Dell'Orto PHVA 14 DS / 12 XS

Dell'Orto PHVA 14 DS / PHBG 19 BS

Air filter

wet foam type air filter insert

Coolant

–

0.5 liter (0.132 USgal) ; water : coolant = 2 : 1

BASIC CARBURETOR SETTING

Model

50 MINI ADVENTURE 50 JUNIOR/SENIOR

(Separate lubrication) ADVENTURE

Dell'Orto PHVA 12 XS Dell'Orto PHVA 14 DS

50 SX PRO JUNIOR LC

50 SX PRO SENIOR LC

Type

Dell'Orto PHVA 14 DS

Dell'Orto PHBG 19 BS

Main jet

211 FA

80 (70)

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

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8-6E

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8-7E

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8-8E

BASIC CARBURETOR SETTING

50 MINI ADVENTURE 50 SENIOR ADVENTURE

(SEPARATE LUBRICATION) (MIXTURE LUBRICATION)

Model

Type

Dell'Orto PHVA 12 XS

Dell'Orto PHVA 14 DS

Main jet

211 FA

80 (70)

211 FA

Needle jet

Idling jet

Jet needle

A10

Needle position from top

Air/Mixture reg. screw open

Slide

3,5

Starting jet

BASIC CARBURETOR SETTING

Model

50 SX PRO JUNIOR LC

50 SX PRO SENIOR LC

Type

Dell'Orto PHVA 14 DS

Dell'Orto PHBG 19 BS

Main jet

211 FA

Needle jet

Idling jet

Jet needle

A10

Needle position from top

Air/Mixture reg. screw open

Slide

3,5

3,0

Starting jet

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8-9E

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8-10E

TECHNICAL DATA – ENGINE 2005 AC

ENGINE

50 AC SENIOR ADVENTURE

50 AC MINI ADVENTURE

Design

single cylinder 2-stroke engine, with reed valve inlet

Displacement

Bore/Stroke

Fuel

49.0 ccm

39.5 / 40 mm

Lead-free SUPER FUEL (ROZ 95), mixed with 2-stroke oil

Lead-free SUPER FUEL (ROZ 95)

Lubrication

Oil/gasoline ratio

2-stroke oil

mixture lubrication

1 : 40

separate lubrication

–

high-grade two-stroke oils for mixture lubrication

(Motorex Cross Power 2T)

high-grade two-stroke oils for separate lubrication

(Motorex Cross Power 2T)

Crankshaft bearing

Connecting rod bearing

Piston pin bearing

Piston rings

2 grooved ball bearing

needle bearing

1 rectangular ring

Primary drive

Transmission oil

Spark plug

straight cut spur gears, 16 : 57 t

0.15-0.2 liter gear oil Dexron II (Motorex ATF Super)

NGK BR 8 ECM

Electrode gap

Carburetor

0.6 mm

Dell’Orto PHVA 14 DS

wet foam type air filter insert

Dell’Orto PHVA 12 XS

Airfilter

BASIC CARBURETOR SETTING

MODEL

50 SENIOR ADVENTURE

50 MINI ADVENTURE

Type

Dell’Orto PHVA 14 DS

Dell’Orto PHVA 12 XS

Main jet

80 (70)

211 FA

65 (70)

211 FA

Needle jet

Idling jet

Jet needle

A10

Needle position from top

Air/Mixture reg. screw open

Slide

3.5

Starting jet

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8-11E

TECHNICAL SPECIFICATIONS – CHASSIS 2005 AC

CHASSIS

50 SENIOR ADVENTURE

single downtube, split-cradle

Marzocchi Ø = 32 mm (1,26 in)

175/190 mm (6.9/7.5 in)

Central shock absorber Paioli

Disk brake Ø 160 mm (6.4 in)

Drumbrake Ø 90 mm (3,5 in)

2.50x12“ Pirelli MT32A / 2.75x10“ MT320

front/rear: 1.0 bar / 1.0 bar

2 liter (0.5 gallons)

50 MINI ADVENTURE

Frame

Fork

Wheel travel front/rear

Rear suspension

Front brake

115/185 mm (4,5/7,3 in)

Drum brake Ø 90 mm (3,5 in)

Rear brake

Tires front/rear

Tire pressure

2.50x10“ Pirelli MT32A / 2.75x10“ MT320

front/rear: 1.0 bar / 1.0 bar

Fuel tank capacity

Final drive ratio

Chain

11 : 48

1/2x3/16“ 104 rolls

1/2x3/16“ 96 rolls

66°

Steering angle

Wheel base

66°

1030 mm (40 in)

910 mm (35.8 in)

Seat height, unloaded

Ground clearance

Rider’s body height

Rider’s body weight

Recommended age of rider

Engine

650 or 675 mm (25.6 or 26.6 in) adjustable 530 or 550 mm (21 or 21.7 in) adjustable

255 mm (10 in)

max. 130 cm (51 in)

max. 35 kg (78 lbs)

4 - 6 years

182mm (7.2 in)

50 AC

STANDARD-ADJUSTMENT – FORK

50 SENIOR / MINI ADVENTURE

Spring

2,0 N/mm

Preload

10 mm (0.4 in)

SAE 7.5

Fork oil

Air chamber length

110 mm (4.3 in)

STANDARD ADJUSTMENT – SHOCK ABSORBER

50 SENIOR ADVENTURE

50 MINI ADVENTURE

Spring preload

12 mm (0.5 in)

8 mm (0.3. in)

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8-12E

TECHNICAL DATA – ENGINE 2005 LC

TYP

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

1 : 40 when using high grade 2-stroke oil (Motorex 2T Cross Power)

Oil/gasoline ratio

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

Lubrication

mixture lubrication

Crankshaft bearing

Connecting rod bearing

Piston pin bearing

Piston rings

2 grooved ball bearing

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 (Motorex Topspeed 4T 15W50)

NGK BR 8 ECM

0.6 mm

Electrode gap

Carburetor

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

50 SX PRO JUNIOR LC

50 SX PRO SENIOR LC

Type

Dell’Orto PHVA 14 DS

Dell’Orto PHBG 19 BS

Main jet

Needle jet

211 FA

260 AU

Idling jet

Jet needle

A10

Needle position from top

Air/Mixture reg. screw open

Slide

3.5

3.0

Starting jet

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8-13E

TECHNICAL SPECIFICATIONS - CHASSIS 2005 LC

50 SX PRO JUNIOR LC

50 SX PRO SENIOR LC

Frame

single downtube, split-cradle

Marzocchi Ø = 32 mm (1.26 in)

140/205 mm (5.5/8 in)

Fork

Wheel travel front/rear

Rear suspension

Front brake

185/185 mm (7.3/7.3 in)

Central shock absorber WP

Disk brake Ø 160 mm (6.4 in)

Drum brake Ø 90 mm (3.5 in)

Rear brake

Disk brake Ø 140 mm (5.5 in)

Tires front/rear

Tire pressure

2.50x10” Pirelli MT32A / 2.75x10” MT320 2.50x12” Pirelli MT32A / 2.75x10” MT320

front/rear: 1.0 bar

1.8 Liters

Fuel tank capacity

Final drive ratio

Chain

11 : 48

10 : 44

1/2x3/16“ 96 rolls

66°

1/2x3/16“ 102 rolls

66°

Steering angle

Wheel base

910 mm (35.8 in)

585 mm/610 mm (23/24 in)

220 mm (8.6 in)

max. 130 cm (51 in)

max. 35 kg (78 lbs)

4-7 years

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

6-10 years

50 LC

STANDARD-ADJUSTMENT – FORK

Spring

2.0 N/mm

Preload

10 mm (0.4 in)

SAE 7.5

Fork oil

Air chamber length

110 mm (4.3 in)

STANDARD ADJUSTMENT – SHOCK ABSORBER

JUNIOR LC

SENIOR LC

WP 03189A02

WP 03189A01

Rebound adjuster

Spring

85 N/mm

10 mm (0.39 in)

45 N/mm

7 mm (0.28 in)

Spring preload

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8-14E

TECHNICAL DATA – ENGINE 2006 AC

ENGINE

50 SENIOR ADVENTURE

50 MINI ADVENTURE

Design

single cylinder 2-stroke engine, with reed valve inlet

Displacement

Bore/Stroke

Fuel

49.0 ccm

39.5 / 40 mm

Lead-free SUPER FUEL (ROZ 95), mixed with 2-stroke oil

Lead-free SUPER FUEL (ROZ 95)

Lubrication

Oil/gasoline ratio

2-stroke oil

mixture lubrication

1 : 60

separate lubrication

–

high-grade two-stroke oils for mixture lubrication

(Motorex Cross Power 2T)

high-grade two-stroke oils for separate lubrication

(Motorex Cross Power 2T)

Crankshaft bearing

Connecting rod bearing

Piston pin bearing

Piston rings

2 grooved ball bearing

needle bearing

1 rectangular ring

Primary drive

Transmission oil

Spark plug

straight cut spur gears, 16 : 57 t

0.15-0.2 liter gear oil Dexron II (Motorex ATF Super)

NGK BR 8 ECM

Electrode gap

Carburetor

0.6 mm

Dell’Orto PHVA 14 DS

wet foam type air filter insert

Dell’Orto PHVA 12 XS

Airfilter

BASIC CARBURETOR SETTING

MODEL

50 SENIOR ADVENTURE

50 MINI ADVENTURE

Type

Dell’Orto PHVA 14 DS

Dell’Orto PHVA 12 XS

Main jet

80 (70)

211 FA

65 (70)

211 FA

Needle jet

Idling jet

Jet needle

A10

Needle position from top

Air/Mixture reg. screw open

Slide

3.5

Starting jet

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8-15E

TECHNICAL SPECIFICATIONS – CHASSIS 2006 AC

CHASSIS

50 SENIOR ADVENTURE

single downtube, split-cradle

Marzocchi Ø = 32 mm (1,26 in)

175/190 mm (6.9/7.5 in)

Central shock absorber Paioli

Disk brake Ø 160 mm (6.4 in)

Drumbrake Ø 90 mm (3,5 in)

2.50x12“ Pirelli MT32A / 2.75x10“ MT320

front/rear: 1.0 bar / 1.0 bar

2 liter (0.5 gallons)

50 MINI ADVENTURE

Frame

Fork

Wheel travel front/rear

Rear suspension

Front brake

115/185 mm (4,5/7,3 in)

Drum brake Ø 90 mm (3,5 in)

Rear brake

Tires front/rear

Tire pressure

2.50x10“ Pirelli MT32A / 2.75x10“ MT320

front/rear: 1.0 bar / 1.0 bar

Fuel tank capacity

Final drive ratio

Chain

11 : 48

1/2x3/16“ 104 rolls

1/2x3/16“ 96 rolls

66°

Steering angle

Wheel base

66°

1030 mm (40 in)

910 mm (35.8 in)

Seat height, unloaded

Ground clearance

Rider’s body height

Rider’s body weight

Recommended age of rider

Engine

650 or 675 mm (25.6 or 26.6 in) adjustable 530 or 550 mm (21 or 21.7 in) adjustable

255 mm (10 in)

max. 130 cm (51 in)

max. 35 kg (78 lbs)

4 - 6 years

182mm (7.2 in)

50 AC

STANDARD-ADJUSTMENT – FORK

50 SENIOR / MINI ADVENTURE

2,0 N/mm

Spring

Preload

10 mm (0.4 in)

SAE 7.5

Fork oil

Air chamber length

110 mm (4.3 in)

STANDARD ADJUSTMENT – SHOCK ABSORBER

50 SENIOR ADVENTURE

50 MINI ADVENTURE

Spring preload

12 mm (0.5 in)

8 mm (0.3. in)

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8-16E

TECHNICAL DATA – ENGINE 2006 LC

TYP

50 SX JUNIOR

50 SX, 50 SUPERMOTO

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

1 : 60 when using high grade 2-stroke oil (Motorex 2T Cross Power)

When in doubt, please contact your importer

Oil/gasoline ratio

Lubrication

mixture lubrication

Crankshaft bearing

Connecting rod bearing

Piston pin bearing

Piston rings

2 grooved ball bearing

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 (Motorex Topspeed 4T 15W50)

NGK BR 8 ECM

0.6 mm

Electrode gap

Carburetor

DellOrto PHVA 14 DS

Dell’Orto PHBG 19 BS

Air filter

wet foam type air filter insert

Cooling liquid

0.5 litres, 50% antifreeze, 50% water, at least -25 °C (-13 °F)

BASIC CARBURETOR SETTING

Model

50 SX JUNIOR

50 SX, 50 SUPERMOTO

Type

Dell’Orto PHVA 14 DS

Dell’Orto PHBG 19 BS

Main jet

Needle jet

211 FA

260 AU

Idling jet

Jet needle

A10

Needle position from top

Air/Mixture reg. screw open

Slide

3.5

3.0

Starting jet

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8-17E

TECHNICAL SPECIFICATIONS - CHASSIS 2006 LC

50 SX JUNIOR

50 SUPERMOTO

50 SX

Frame

single downtube, split-cradle

Marzocchi Ø = 32 mm (1.26 in)

140/205 mm (5.5/8 in)

Central shock absorber WP

Disk brake Ø 160 mm (6.4 in)

Fork

Wheel travel front/rear

Rear suspension

Front brake

185/185 mm (7.3/7.3 in)

Rear brake

Drum brake Ø 90 mm (3.5 in) Disk brake Ø 140 mm (5.5 in)

Tires front

2.50x10” Pirelli MT32A

2.75x10” MT320

front/rear: 1.0 bar

1,8 Liter

2.50x12” Pirelli MT32A

90/90-10 Pirelli SL26

Tires rear

Tire pressure

Fuel tank capacity

Final drive ratio

Chain

11 : 48

10 : 44

1/2 x 3/16" 96 rolls

66°

1/2 x 3/16" 102 rolls

Steering angle

Wheel base

910 mm (35.8 in)

585 mm/610 mm (23/24 in)

220 mm (8.6 in)

max. 130 cm (51 in)

max. 35 kg (78 lbs)

4 - 7 years

1030 mm (40 in)

Seat height unloaded

Ground clearance unloaded

Rider’s body height

Rider’s body weight

Recommended age of rider

Engine

650/675 mm (25.6/26.6 in)

255 mm (10 in)

6 - 10 years

50 LC

STANDARD-ADJUSTMENT – FORK

Spring

2,0 N/mm

Preload

10 mm (0.4 in)

SAE 7,5

Fork oil

Air chamber length

110 mm (4.3 in)

STANDARD ADJUSTMENT – SHOCK ABSORBER

50 SX JUNIOR

50 SX, 50 SUPERMOTO

WP 03189B01

WP 03189B02

Rebound adjuster

Spring

85 N/mm

10 mm (0.39 in)

45 N/mm

7 mm (0.28 in)

Spring preload

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8-18E

TOLERANCES AND FITTING CLEARANCES

Crankshaft

run out of crank stud

max. 0.050 mm

38 mm 0.05 mm

Crankshaft webs outer dimension

Conrod bearing

Piston

radial play

max. 0.030 mm

fitting clearance

end gap

0.055-0.065 mm (AC) / 0.045-0.055 mm (LC)

max. 0.20 mm

Piston ring

Clutch shoes

Clutch drum

outer diameter

diameter

new 82.5 mm

max. 84.4 mm (new 84.00 - 84.01 mm)

min. 19.6 mm

Clutch springs (AC) length

TIGHTENING TORQUES - ENGINE

Hexagon nut primary gear

Hexagon nut ignition rotor

Hexagon nut of clutch hub

HH bolts clutch shoes

Cylinder head bolts

M14x1.25

M10x1.25

40 Nm

20 Nm

M10x1.25

Loctite 243 + 35 Nm

Loctite 243 + 12 Nm

15 Nm

Cylinder base nuts

18 Nm

Allen head bolt-Stator

Oil plug

Loctite 243 + 8 Nm

5 Nm

M16

M10

Oil drain plug

15 Nm

7 Nm

Other bolts engine

10 Nm

30 Nm

TIGHTENING TORQUES - CHASSIS

Hexagon nuts front/rear axle

M12x1

M10

M12

40 Nm

45 Nm

Hexagon nut swing arm bolt

HH bolts of top triple clamp

HH bolts of bottom triple clamp

40 Nm

20 Nm

10 Nm

15 Nm

HH bolts handlebar clamp

Shock absorber top/bottom

Allen head bolt - Handlebar support

Front brake caliper

20 Nm

M10

45 Nm

Loctite + 40 Nm

Loctite + 20 Nm

Loctite + 10 Nm

4 Nm

Front brake disk

Fixing screw brake pads

Mini Adventure

Spoke nipple

2,0 - 2,5 Nm

2,5 - 3,0 Nm

6 Nm

SX / Senior Adventure / Supermoto

10 Nm

Other bolts chassis

25 Nm

M10

45 Nm

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9-1E

LUBRICATION AND MAINTENANCE SCHEDULE

INDEX

LUBRICATION AND MAINTENANCE SCHEDULE 50 AC/LC

MODEL 2002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2

MODEL 2003-2005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4

MODEL 2006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6

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9-2E

50 MINIS

air/liquid cooled

PERIODIC MAINTENANCE 2002

Service

every

5 hours

ꢁ

Service

every

A washed motorcycle can be checked more quickly which saves money!

20 hours

Check engine for leaks

ꢁ

Change transmission oil

ꢁ

Check spark plug, change it if necessary, set electrode gap

Check the clutch engagement speed

ꢁ

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, antifreeze protection

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 fluid level, lining thickness, brake discs

Check brake lines for damage

ꢁ

Check/adjust smooth operation, free travel of hand/footbrake levers

Check bolts 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 bolts 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

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 OF CARE AND CHECKS DONE BY THE RIDER!

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9-3E

VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC

ꢁ

Check transmission oil level

Check coolant 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 bolts, nuts, and hose clamps for their tight fit in regular intervals

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9-4E

50 MINIS

air/liquid cooled

PERIODIC MAINTENANCE 2003-2005

Service

every

5 hours

ꢁ

Service

every

A washed motorcycle can be checked more quickly which saves money!

20 hours

Check engine for leaks

ꢁ

Change transmission oil

ꢁ

Check spark plug, change it if necessary, set electrode gap

Check the clutch engagement speed

ꢁ

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, antifreeze protection

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 fluid level, lining thickness, brake discs

Check brake lines for damage

ꢁ

Check/adjust smooth operation, free travel of hand/footbrake levers

Check bolts 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 bolts 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

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 OF CARE AND CHECKS DONE BY THE RIDER!

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9-5E

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 bolts, nuts, and hose clamps for their tight fit at regular intervals

RECOMMENDED INSPECTION OF THE MINI AC/LC ENGINE BY YOUR KTM WORKSHOP

(ADDITIONAL ORDER FOR THE KTM WORKSHOP)

hours

ꢁ

hours

ꢁ

hours

ꢁ

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 (AC)

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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9-6E

50 MINIS

air/liquid cooled

PERIODIC MAINTENANCE 2006

before

every

race

Service

every

5 hours

ꢁ

Service

A washed motorcycle can be checked more quickly which saves money!

every

20 hours

ꢁ

Check engine for leaks

ꢁ

Change transmission oil

Check spark plug, change it if necessary, set electrode gap

Check the clutch engagement speed

ꢁ

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, antifreeze protection

Check exhaust system for leaks and correct fit

Check actuating cables for damage, smooth operation, and kink-less

arrangement, adjust and lubricate

ꢁ

Clean air filter and air filter box

Check fluid level, lining thickness, brake discs

Check brake lines and brake control cables for damage

Check/adjust function, smooth operation and free travel of

hand/footbrake levers

ꢁ

Check bolts 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 bolts 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

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 OF CARE AND CHECKS DONE BY THE RIDER!

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9-7E

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

ꢁ

Check oil lines for cracks or kinks (for separate lubrication only)

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 bolts, nuts, and hose clamps for their tight fit at regular intervals

RECOMMENDED INSPECTION OF THE MINI AC/LC ENGINE BY YOUR KTM WORKSHOP

(ADDITIONAL ORDER FOR THE KTM WORKSHOP)

after every

20 hours

ꢁ

after every

40 hours

ꢁ

Check the reed-type intake valve for wear

Check the clutch shoes for wear

ꢁ

Check the length of the clutch springs (AC)

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 oil pump (only separate lubrication)

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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10-1E

WIRING DIAGRAM

INDEX

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2

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10-2E

k c a b l

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