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KTM 50 AC/LC manuale d’uso - BKManuals
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KTM 50 AC/LC manuale d’uso

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Un buon manuale d’uso

Le regole impongono al rivenditore l'obbligo di fornire all'acquirente, insieme alle merci, il manuale d’uso KTM 50 AC/LC. La mancanza del manuale d’uso o le informazioni errate fornite al consumatore sono la base di una denuncia in caso di inosservanza del dispositivo con il contratto. Secondo la legge, l’inclusione del manuale d’uso in una forma diversa da quella cartacea è permessa, che viene spesso utilizzato recentemente, includendo una forma grafica o elettronica KTM 50 AC/LC o video didattici per gli utenti. La condizione è il suo carattere leggibile e comprensibile.

Che cosa è il manuale d’uso?

La parola deriva dal latino "instructio", cioè organizzare. Così, il manuale d’uso KTM 50 AC/LC descrive le fasi del procedimento. Lo scopo del manuale d’uso è istruire, facilitare lo avviamento, l'uso di attrezzature o l’esecuzione di determinate azioni. Il manuale è una raccolta di informazioni sull'oggetto/servizio, un suggerimento.

Purtroppo, pochi utenti prendono il tempo di leggere il manuale d’uso, e un buono manuale non solo permette di conoscere una serie di funzionalità aggiuntive del dispositivo acquistato, ma anche evitare la maggioranza dei guasti.

Quindi cosa dovrebbe contenere il manuale perfetto?

Innanzitutto, il manuale d’uso KTM 50 AC/LC dovrebbe contenere:
- informazioni sui dati tecnici del dispositivo KTM 50 AC/LC
- nome del fabbricante e anno di fabbricazione KTM 50 AC/LC
- istruzioni per l'uso, la regolazione e la manutenzione delle attrezzature KTM 50 AC/LC
- segnaletica di sicurezza e certificati che confermano la conformità con le norme pertinenti

Perché non leggiamo i manuali d’uso?

Generalmente questo è dovuto alla mancanza di tempo e certezza per quanto riguarda la funzionalità specifica delle attrezzature acquistate. Purtroppo, la connessione e l’avvio KTM 50 AC/LC non sono sufficienti. Questo manuale contiene una serie di linee guida per funzionalità specifiche, la sicurezza, metodi di manutenzione (anche i mezzi che dovrebbero essere usati), eventuali difetti KTM 50 AC/LC e modi per risolvere i problemi più comuni durante l'uso. Infine, il manuale contiene le coordinate del servizio KTM in assenza dell'efficacia delle soluzioni proposte. Attualmente, i manuali d’uso sotto forma di animazioni interessanti e video didattici che sono migliori che la brochure suscitano un interesse considerevole. Questo tipo di manuale permette all'utente di visualizzare tutto il video didattico senza saltare le specifiche e complicate descrizioni tecniche KTM 50 AC/LC, come nel caso della versione cartacea.

Perché leggere il manuale d’uso?

Prima di tutto, contiene la risposta sulla struttura, le possibilità del dispositivo KTM 50 AC/LC, l'uso di vari accessori ed una serie di informazioni per sfruttare totalmente tutte le caratteristiche e servizi.

Dopo l'acquisto di successo di attrezzature/dispositivo, prendere un momento per familiarizzare con tutte le parti del manuale d'uso KTM 50 AC/LC. Attualmente, sono preparati con cura e tradotti per essere comprensibili non solo per gli utenti, ma per svolgere la loro funzione di base di informazioni e di aiuto.

Sommario del manuale d’uso

  • Pagina 1

    50 AC/LC REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE REPARATION MANUAL DE REPARACION REPAIR MANUAL 2002-2006 Art.NR.: 3.206.028-E[...]

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  • Pagina 3

    REPAIR MANUAL 2002-2006 50 AC/LC KTM Group Partner[...]

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  • Pagina 5

    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 11 12 13 14 15 16[...]

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  • Pagina 7

    Art.-Nr . 3.206.028 -E Repair manual KTM MINI 50 air/liquid cooled KTM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REP AIR 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 (17[...]

  • Pagina 8

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  • Pagina 9

    Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E E XPLANATION - U PDATE Edition: 7/2005 This repair manual contains the following supplements: 3.210.24-E Repair Manual 50 AC/LC 5/2001 Basic version Model year 2002 3.210.64-E Updating of Rep.Manual 3.210.24-E 5/2002 Model year 2003 (Engine number with first digit „3“) 3.206.010[...]

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  • Pagina 11

    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[...]

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    Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E REPLY FAX FOR REPAIR MANUALS W e 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. T o keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us as follows:[...]

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    2-1E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028-E GENERAL INFORMATION OPERATING RANGES OF THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 CLEANING AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 BLEEDING OILPUMP FOR SEPARATE LUBRICATION . . . . . . . . .[...]

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  • Pagina 17

    B C D A 1 2 2-2E main jet jet needle jet needle idling jet idling jet throttle valve Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E 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 ambien[...]

  • Pagina 18

    2-3E Clean your motorcycle regularly in order to keep its painted finish looking shiny and new . The best manner would be to use warm water that has been mixed with a commercially available washing detergent and a sponge. The hard dirt can be removed before with the help of a soft water jet. ! CAUTION ! N EVER CLEAN YOUR MOTORCYCLE WITH A HIGH - PR[...]

  • Pagina 19

    1 2 2 3 A 4 4 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[...]

  • Pagina 20

    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 Bra[...]

  • Pagina 21

    Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E 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[...]

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    3-1E REMOVING AND REFITTING ENGINE Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028-E REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 INDEX 3[...]

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    1 2 3 4 5 6 3-2E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028-E 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[...]

  • Pagina 26

    1 2 3 4 5 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 [...]

  • Pagina 27

    1 1 2 3 4 4 5 6 7 8 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 [...]

  • Pagina 28

    1 2 3 4 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 f[...]

  • Pagina 29

    1 2 3 3-6E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E – 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 i[...]

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    4-1E DISASSEMBLING THE ENGINE Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028-E SPECIAL TOOLS - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 FIXING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3 DRAINING GEAR OIL . . . . . . . . .[...]

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    15 50 8 130 75 2 1 4 3 5 6 4-2E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E SPECIAL TOOLS ENGINE 50 AC/LC FIG PARTNUMBER DESCRIPTION 1 590.29.021.000 Puller for flywheel 2 451.12.021.000 Rotor holding tool 3 451.29.006.000 Adjusting plate for Dimension „X“ 4 6 899 785 Loctite 243 blue 5 451.29.075.000 T achometer 6 503.29[...]

  • Pagina 34

    1 2 3 4 5 5 5 6 7 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 d[...]

  • Pagina 35

    1 2 2 3 4 4 5 6 7 8 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 . – Remo[...]

  • Pagina 36

    1 2 3 4 5 5 5 5 6 7 7 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 ! M AKE SURE THE TWO PINS OF THE SPECIAL TOOL DO NOT CA TCH THE THREADED HOLES , OTHERWISE THE THREADIN[...]

  • Pagina 37

    1 1 1 1 2 3 4 5 6 7 8 9 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   D O NOT REMOVE THE CIRCLIP 2 , OTHERWISE THE KICKST AR TER SPINDLE MAY F ALL FROM THE CASIN[...]

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    5-1E SERVICING INDIVIDUAL COMPONENTS Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028-E RIGHT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 LEFT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3 CRANKSHAFT . . . . . . . . . .[...]

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  • Pagina 41

    1 2 3 S 5-2E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E 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[...]

  • Pagina 42

    1 2 4 3 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 o[...]

  • Pagina 43

    1 2 6 7 8 9 3 4 5 5-4E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E Working on the clutch cover NOTE: dismantling the clutch cover is neccessary if parts are damaged or the O-ring is leaking. – T urn kickstarter shaft 1 counter -clockwise and remove ratchet gear 2 . Check gearing for wear . NOTE: If the kickstarter shaft is [...]

  • Pagina 44

    M 4 6 8 7 5 3 2 1 9 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[...]

  • Pagina 45

    x y 10mm x y 50mm 5-6E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E MARK PISTON CYLINDER AC CYLINDER LC A 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 B 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.[...]

  • Pagina 46

    B A 1 2 3 4 5 6 7 6 6 5-7E Clutch new used 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 washer[...]

  • Pagina 47

    6-1E ASSEMBLING THE ENGINE Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028-E MOUNTING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 MOUNTING THE PRIMARY DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 MOUNTING LEFT ENGINE HOUSING . . . . . . . . . . . . . .[...]

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    1 2 3 4 5 6 7 8 9 bk bl bl bl bl 6-2E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E 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 verti[...]

  • Pagina 50

    1 2 3 4 5 5 6 7 S 8 9 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 o[...]

  • Pagina 51

    2 3  2003 1 1 1 1 4 4 4 2 3 2004  6-4E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E 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 7x[...]

  • Pagina 52

    1 3 4 2 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. – T urn the piston r[...]

  • Pagina 53

    1 1 2 3 4 6-6E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E 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 [...]

  • Pagina 54

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  • Pagina 55

    7-1E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028-E TROUBLE SHOOTING TROUBLE SHOOTING 50 AC/LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 IGNITION MEASUREMENT 50 AC/LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 MEASUREMENT WITH PEAK VOLTAGE ADAPTER . . . . . . . . . . . [...]

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    7-2E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E 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 leak[...]

  • Pagina 58

    7-3E TROUBLE CAUSE REMEDY Engine stalling or running with four stroke cycle Carburetor overflows if level adjust too high, float needle seating is dirty or enlarged Clean carburetor , if necessary replace float needle and adjust level Loose carburetor jets T ighten jets High rpm misfiring Incorrect heat range spark plug or low quality spark plug Re[...]

  • Pagina 59

    1 2 R S 7-4E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E 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 engin[...]

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  • Pagina 61

    8-1E MODEL 2002 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3 BASIC CARBURETOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4[...]

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  • Pagina 63

    8-2E MODEL 2005 AC ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10 BASIC CARBURETOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11[...]

  • Pagina 64

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  • Pagina 65

    8-3E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E 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 49,0 cm³ Bore/Stroke 39,5 / 40 mm Fuel SUPER fuel, research octane no 95, mixed with 2-stroke oil Oil/gasoline ratio [...]

  • Pagina 66

    8-4E TECHNICAL SPECIFICATIONS - CHASSIS 50 MINI 2002 50 SX PRO SENIOR LC single downtube, split-cradle Marzocchi Ø = 32 mm 175/185 mm (6.9/7.3 in) Central shock absorber WP PDS Disc brake Ø 160 mm (6.3 in) Drumbrake Ø 90 mm (3.5 in) front/rear 2.50x10" Pirelli MT 32 / 2.75x10" MT 320 front/rear: 1.0 bar / 1.0 bar 1,8 Liter 11 : 48 1/2x[...]

  • Pagina 67

    8-5E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E 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 49,0 cm³ Bore/Stroke 39,5 / 40 mm Fuel SUPER fuel, research octane no 95, mixed with 2-stroke oil (separate lubricati[...]

  • Pagina 68

    8-6E TECHNICAL SPECIFICATIONS - CHASSIS 50 MINI 2003 50 SX PRO SENIOR LC single downtube, split-cradle Marzocchi Ø = 32 mm 175/185 mm (6.9/7.3 in) Central shock absorber WP PDS Disc brake Ø 160 mm (6.3 in) Drumbrake Ø 90 mm (3.5 in) 2.50x12" V eeRubber V270/ 2.75x10"V271 front/rear: 1.0 bar / 1.0 bar 1,8 Liter 11 : 48 1/2x3/16" 10[...]

  • Pagina 69

    8-7E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E TECHNICAL DATA - ENGINE 50 AC/LC 2004 50 SX PRO SENIOR LC single cylinder 2-stroke engine, with reed valve inlet 49,0 cm³ 39,5 / 40 mm Lead-free SUPER FUEL (ROZ 95), mixed with 2-stroke oil 1 : 40 when using high grade 2-stroke oil (Motorex 2T Cross Power) When in doubt, pleas[...]

  • Pagina 70

    8-8E BASIC CARBURETOR SETTING Model 50 MINI ADVENTURE (SEP ARA TE LUBRICA TION) 50 SENIOR ADVENTURE (MIXTURE LUBRICA TION) T ype Dell'Orto PHV A 12 XS Dell'Orto PHV A 14 DS Main jet 60 80 (70) Needle jet 211 F A 211 F A Idling jet 38 45 Jet needle A10 A10 Needle position from top 4. 3. Air/Mixture reg. screw open 4 3,5 Slide 40 40 Startin[...]

  • Pagina 71

    8-9E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E TECHNICAL SPECIFICATIONS - CHASSIS 50 MINI 2004 50 SX PRO SENIOR LC single downtube, split-cradle Marzocchi Ø = 32 mm 185/185 mm Central shock absorber WP PDS Disk brake Ø 160 mm Disk brake Ø 140 mm 2.50x12" Pirelli MT 32A 2.75x10" Pirelli MT320 1,0 bar / 1,0 bar 1[...]

  • Pagina 72

    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 49.0 ccm Bore/Stroke 39.5 / 40 mm Fuel Lead-free SUPER FUEL (ROZ 95), mixed with 2-stroke oil Lead-free SUPER FUEL (ROZ 95) Lubrication mixture lubrication separate lubrication Oil/gas[...]

  • Pagina 73

    8-11E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E TECHNICAL SPECIFICATIONS – CHASSIS 2005 AC CHASSIS 50 SENIOR ADVENTURE 50 MINI ADVENTURE Frame single downtube, split-cradle Fork Marzocchi Ø = 32 mm (1,26 in) Wheel travel front/rear 175/190 mm (6.9/7.5 in) 115/185 mm (4,5/7,3 in) Rear suspension Central shock absorber Pai[...]

  • Pagina 74

    8-12E TYP 50 SX PRO JUNIOR LC 50 SX PRO SENIOR LC Design single cylinder 2-stroke engine, with reed valve inlet Displacement 49.0 ccm Bore/Stroke 39.5 / 40 mm Fuel SUPER fuel, research octane no 95, mixed with 2-stroke oil Oil/gasoline ratio 1 : 40 when using high grade 2-stroke oil (Motorex 2T Cross Power) When in doubt, please contact your import[...]

  • Pagina 75

    8-13E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E 50 SX PRO JUNIOR LC 50 SX PRO SENIOR LC Frame single downtube, split-cradle Fork Marzocchi Ø = 32 mm (1.26 in) Wheel travel front/rear 140/205 mm (5.5/8 in) 185/185 mm (7.3/7.3 in) Rear suspension Central shock absorber WP Front brake Disk brake Ø 160 mm (6.4 in) Rear brake [...]

  • Pagina 76

    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 49.0 ccm Bore/Stroke 39.5 / 40 mm Fuel Lead-free SUPER FUEL (ROZ 95), mixed with 2-stroke oil Lead-free SUPER FUEL (ROZ 95) Lubrication mixture lubrication separate lubrication Oil/gasoline [...]

  • Pagina 77

    8-15E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E TECHNICAL SPECIFICATIONS – CHASSIS 2006 AC CHASSIS 50 SENIOR ADVENTURE 50 MINI ADVENTURE Frame single downtube, split-cradle Fork Marzocchi Ø = 32 mm (1,26 in) Wheel travel front/rear 175/190 mm (6.9/7.5 in) 115/185 mm (4,5/7,3 in) Rear suspension Central shock absorber Pai[...]

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    8-16E TYP 50 SX JUNIOR 50 SX, 50 SUPERMOTO Design single cylinder 2-stroke engine, with reed valve inlet Displacement 49.0 ccm Bore/Stroke 39.5 / 40 mm Fuel SUPER fuel, research octane no 95, mixed with 2-stroke oil Oil/gasoline ratio 1 : 60 when using high grade 2-stroke oil (Motorex 2T Cross Power) When in doubt, please contact your importer Lubr[...]

  • Pagina 79

    8-17E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E 50 SX JUNIOR 50 SX 50 SUPERMOTO Frame single downtube, split-cradle Fork Marzocchi Ø = 32 mm (1.26 in) Wheel travel front/rear 140/205 mm (5.5/8 in) 185/185 mm (7.3/7.3 in) Rear suspension Central shock absorber WP Front brake Disk brake Ø 160 mm (6.4 in) Rear brake Drum bra[...]

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    8-18E TOLERANCES AND FITTING CLEARANCES Crankshaft run out of crank stud max. 0.050 mm Crankshaft webs outer dimension 38 mm ±0.05 mm Conrod bearing radial play max. 0.030 mm Piston fitting clearance 0.055-0.065 mm (AC) / 0.045-0.055 mm (LC) Piston ring end gap max. 0.20 mm Clutch shoes outer diameter new 82.5 mm Clutch drum diameter max. 84.4 mm [...]

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    9-1E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028-E LUBRICATION AND MAINTENANCE SCHEDULE 50 AC/LC MODEL 2002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2 MODEL 2003-2005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4 MODEL 2006 . .[...]

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    9-2E M AINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER ! PERIODIC MAINTENANCE 2002 50 MINIS air/liquid cooled A washed motorcycle can be checked more quickly which saves money! Service Service every every 5 hours 20 hours ENGINE Check engine for leaks  Change transmission oil  Check sp[...]

  • Pagina 83

    9-3E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each start after every cleaning for cross country use once a year Check transmission oil level  Check coolant level  Check brake fluid level  Check brake pads for wear  Check brake [...]

  • Pagina 84

    9-4E PERIODIC MAINTENANCE 2003-2005 50 MINIS air/liquid cooled A washed motorcycle can be checked more quickly which saves money! Service Service every every 5 hours 20 hours ENGINE Check engine for leaks  Change transmission oil  Check spark plug, change it if necessary , set electrode gap  Check the clutch engagement speed  CARBURETOR[...]

  • Pagina 85

    9-5E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E NOTE: I F THE INSPECTION EST ABLISHES THA T PERMISSIBLE TOLERANCES ARE EXCEEDED , THE RESPECTIVE COMPONENTS MUST BE REPLACED . VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each start after every cleaning for cross country use once a year [...]

  • Pagina 86

    9-6E M AINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER ! PERIODIC MAINTENANCE 2006 50 MINIS air/liquid cooled A washed motorcycle can be checked more quickly which saves money! Service Service before every every every 5 hours 20 hours race ENGINE Check engine for leaks   Change transmi[...]

  • Pagina 87

    9-7E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E NOTE: I F THE INSPECTION EST ABLISHES THA T PERMISSIBLE TOLERANCES ARE EXCEEDED , THE RESPECTIVE COMPONENTS MUST BE REPLACED . VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each start after every cleaning for cross country use once a year [...]

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    [...]

  • Pagina 89

    10-1E 10 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2 WIRING DIAGRAM INDEX Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E[...]

  • Pagina 90

    l i o c n o i t i n g i C L 0 5 r o i n e S X S - . d A i n i M black 4 0 0 2 . 2 0 . 0 2 G k c a l b n o t t u b p o t s k c a l b r o t a r e n e g 10-2E Cable colours: black = black[...]