KTM 50 SX JUNIOR manual

KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.com KTM Group Partner 4/2007 FOTO: MITTERBAUER 50 SX JUNIOR 50 SX OWNER’S MANUAL 2008 3211222en *3211222en* 3211222en[...]

ENGLISH 1 INTRODUCTION » Please insert the serial numbers of the motorcycle below Chassis number Engine number Stamp of dealer All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, construc[...]

ENGLISH 2 IMPORTANT INFORMATION » INTENDED PURPOSE KTM mini-sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading interna- tional motorcycle associations. OWNER’S MANUAL Please read this manua[...]

ENGLISH 3 IMPORTANT INFORMATION » W ARRANTY The service work specified in the "Lubrication and Maintenance Schedule" must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void. No claims can be filed under the warranty for damage or consequential damage caused by manipulat[...]

ENGLISH 4 IMPORTANT INFORMATION FOR PARENTS ABOUT SAFE DRIVING » KTM mini motorcycles are off-road motorcycles designed for one person only. They are not allowed on public roads. The vehicle dimensions and components are designed for children from 4 to 10 years of age with a maximum weight of. 35 kg (78 lbs) and a maximum height of 130 cm (51 in).[...]

ENGLISH 5 TABLE OF CONTENTS » Page IMPOR T ANT INFORMA TION FOR P ARENTS ABOUT SAFE DRIVING . . . . . . . . . . . . . . . . . . . . . . . . .4 SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . .6 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

ENGLISH 6 SERIAL NUMBER LOCATIONS » Chassis number The chassis number is located on the type plate on the steering head. Enter this number in the field on page no 1. Engine number The engine number is stamped into the right half of the engine case next to the kickstarter . Enter this number in the relevant field on page 1.[...]

ENGLISH 7 OPERATION INSTRUMENTS » Throttle grip The throttle grip is located on the right side of the handlebars. It is used to reduce the engine speed and, thus, the driving speed. Hand brake lever The hand brake lever is located on the right side of the handlebars and actuates the front wheel brake. The basic position can be adjusted to fit your[...]

ENGLISH 8 OPERATION INSTRUMENTS » Choke Dell’Orto carburetor PHVA 14 DS (50SX Junior) Choke lever [1] is mounted to the right side of the carburetor . If you move the choke lever up to the stop, a hole is opened in the carburetor through which the engine can draw in additional fuel. This results in a "rich" fuel-air mixture required fo[...]

ENGLISH 9 OPERATION INSTRUMENTS » Plugin - Stand (50 SX) A socket is provided on the left side of the frame for the plug-in stand [1] included in the scope of supply . Rebound damping function of the shock absorber By using the adjusting screw [2] , the degree of damping of the rebound can be adjusted. T urn the knob clockwise to increase damping,[...]

ENGLISH 10 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » Running in – Even very precisely machined sections of engine components have rougher surfaces than components which have been slid- ing across one another for quite some time. Therefore, every engine needs to be broken in. Do not load the engine to the power limit during the firs[...]

ENGLISH 11 DRIVING INSTRUCTIONS » What you should check before each start When you start off, the motorcycle must be in a perfect technical condition. For safety reasons, you should make it a habit to perform an overall check of your motorcycle before each start. The following checks should be performed: 1 CHECK TRANSMISSION OIL LEVEL A lack of ge[...]

ENGLISH 12 DRIVING INSTRUCTIONS » Starting when the engine is cold 1 Open fuel tap [1] . 2 Operate the choke [2] . 3 Kick the side up all the way or remove the plug-in stand. 4 Apply the front brake. 5 Operate the kickstarter , depressing it all the way , without opening the throt- tle. – When starting the engine, put on motorcycle boots in orde[...]

ENGLISH 13 DRIVING INSTRUCTIONS » Driving The engine speed, and thus the driving speed, are regulated by the throttle grip. The choke must always be deactivated as soon as the engine has warmed up. – After falling with the motorcycle, check all its functions thor- oughly before using it again. – A bent handlebar must always be replaced. Never [...]

ENGLISH 14 PERIODIC MAINTENANCE SCHEDULE » 50 SX JUNIOR 50 SX A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! Service every 5 hours Service every 20 hours before every race ENGINE Check engine for leaks z z Change transmission oil z z Check spark plug, change it if necessary , set electrode gap z Check the clutch engagement speed[...]

ENGLISH 15 PERIODIC MAINTENANCE SCHEDULE » NOTE: If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced. The kilometer reading for inspection intervals should not exceed 5 hours. Maintenance work performed by your authorized KTM workshop is not a substitute for care and maintenance by the[...]

ENGLISH 16 MAINTENANCE WORK ON CHASSIS AND ENGINE » Removing the seat The quick-release mechanism [1] allows removal of the seat without tools. T urn the quick-release device approximately 180° counterclockwise, lift the rear portion of the seat and pull the seat off backwards. When mounting the seat ensure that the hook engages at the tank. Chec[...]

ENGLISH 17 MAINTENANCE WORK ON CHASSIS AND ENGINE » Checking and adjusting the steering head bearing (50 SX) * The steering head bearing should be checked regularly for play . T o check, support the motorcycle frame and lift the front wheel off the ground. Now try to move the fork back and forth – you should not feel any play . T o adjust, loose[...]

ENGLISH 18 MAINTENANCE WORK ON CHASSIS AND ENGINE » Basic suspension setup for the weight of the driver T o achieve maximum handling performance and to prevent the telescopic fork and shock absorber from being damaged, the basic setup of the suspension components must be suitable for your child's weight. At delivery , KTM's mini motorcyc[...]

ENGLISH 19 MAINTENANCE WORK ON CHASSIS AND ENGINE » Telescopic fork maintenance * The telescopic fork must be serviced at least once a year . T o service the fork, proceed as follows: Prop up the motorcycle under the frame to take the load off the front wheel. Disassemble the front wheel, remove screw [1] from the brake caliper and unscrew holding[...]

ENGLISH 20 MAINTENANCE WORK ON CHASSIS AND ENGINE » Cleaning the dust scrabbers of the telescopic fork The dust-protection bellows [1] are to remove dust and coarse dirt particles from the fork tube. However , after some time, dirt may also get in behind the dust-protection bellows. If this dirt is not removed, the oil sealing rings located behind[...]

ENGLISH 21 MAINTENANCE WORK ON CHASSIS AND ENGINE » General information about KTM disc brakes BRAKE FLUID RESERVOIRS: The brake fluid reservoirs for the front brake is designed such that it does not need to be refilled, even if the brake shoes are worn. If the brake fluid level drops below the minimum level either the brake system has a leak or th[...]

ENGLISH 22 MAINTENANCE WORK ON CHASSIS AND ENGINE » Checking the brake fluid level / refilling * The brake fluid reservoir is combined with the hand brake cylinder on the handlebar . T o check the brake fluid level, press the brake pistons back into the basic position. Move the hand brake cylinder in a horizontal position, remove the screws [1] an[...]

ENGLISH 23 MAINTENANCE WORK ON CHASSIS AND ENGINE » Changing the basic position of the foot brake lever (50 SX Junior) The basic position of the foot brake lever can be changed by unscrewing screw [1] and then turning the retainer [2] . Afterwards, check the setting of the rear wheel brake. Adjusting the control cable on the rear wheel (50 SX Juni[...]

Slide new brake shoes into the brake caliper a fasten with the screw [5] . T ighten the screw to 10 Nm and mount the locking screw [4] . Mount the rear wheel and actuate the foot brake lever until you can feel the pressure point. – It is very important to keep the brake disk free from oil and fatty matters. Otherwise, the braking effect would be [...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » Removing and mounting the front wheel Jack the motorcycle up by the frame so that the front wheel is suspended above the ground. Undo the hexagon nut [1] and remove it together with the washer . Hold the front wheel and pull out the wheel spindle [2] . Carefully take the front wheel out of the fork. – Do [...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 26 Tires, air pressure T ire type, tire condition, and air pressure level affect the way your motorcycle rides, and they must therefore be checked whenever you are getting ready to go anywhere on your motorcycle. – T ire size can be found in the technical specifications. – T ire condition has to[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 27 Checking coolant level The coolant should be 10 mm (0.4 in) above the radiator fins when the engine is cold (see illustr .). In the event of the coolant being drained, always fill and bleed the system. If possible, always check level of cooling liquid when engine is cold. If you have to open the [...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 28 Changing the seat height The saddle can easily be raised by 25 mm (1 in). This lets you adjust the height as your child grows. Figures A and B show the fork and shock absorber positions for a low seat position. The fork tubes extend approx. 17 mm (0.7 in) (H) above the upper fork stabilizer . The[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 29 Checking the gear oil level T o check the gear oil level, first remove the plug [1] . With the motorcycle parked in an upright position, a small quantity of oil should flow out of the indicator opening [2] . If oil must be added, tilt the motorcycle and pour automatic gear oil (Motorex A TF Super[...]

ENGLISH 30 Adjusting the centrifugal clutch * A correctly adjusted centrifugal clutch will provide maximum engine perform- ance and ease of driving and prevent the engine from overheating. Clutch wear can affect the clutch engagement speed. The clutch will slip for a longer period of time at higher clutch engagement speeds, generating more friction[...]

ENGLISH 31 CORRECTING CLUTCH WEAR: Check the clutch shoes for wear . If the surface is only slightly worn you can remount them again. NOTE: The centrifugal clutch has an outer diameter of approx. 82.5 mm when new . T o correct slight wear to the surface, you can insert one of the pretensioning disks [11] from each clutch spring between the clutch h[...]

TROUBLE SHOOTING » ENGLISH 32 If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error . W e would like to point out that many operations cannot be performed by oneself. In[...]

TROUBLE SHOOTING » ENGLISH 33 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 Loose carburetor jets Clean carburetor , if necessary replace float needle and adjust level T ighten jets High rpm misfiring Incorrect heat range spark plug or[...]

CLEANING » ENGLISH 34 STORAGE » If you want to put your motorcycle away for longer periods of time, please observe the following instructions: – Clean motorcycle thoroughly (see chapter: CLEANING) – Change engine oil (old engine oil contains aggressive contaminations). – Check antifreeze and amount of cooling liquid. – the engine warm up [...]

TECHNICAL DATA – ENGINE » ENGLISH 35 ENGINE 50 SX JUNIOR 50 SX Design single cylinder 2-stroke engine, with reed valve inlet Displacement 49.0 cc 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 cont[...]

ENGLISH 36 TECHNICAL SPECIFICATIONS - CHASSIS » CHASSIS 50 SX JUNIOR 50 SX Frame single downtube, split-cradle Fork Marzocchi Ø = 32 mm 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 brake Ø 90 mm (3.5 in) Disk brake Ø 140 [...]

ENGLISH 37 HEAD WORD INDEX » Page Adjusting the centrifugal clutch . . . . . . . . . . . . . . . . . .30 Adjusting the control cable on the rear wheel (50 SX Junior) .23 Adjusting the idle speed (Dell’Orto PHBG 19 BS) . . .28 Adjusting the idle speed (Dell’Orto PHV A 14 DS) . . .28 Adjusting the throttle cable . . . . . . . . . . . . . . . . .[...]

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KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.com KTM Group Partner 4/2007 FOTO: MITTERBAUER 50 SX JUNIOR 50 SX OWNER’S MANUAL 2008 3211222en *3211222en* 3211222en[...]