Closing filler cap..........13 11.23 Cleaning the air filter and air filter box ..36 Opening oil tank cap (50 SX Mini) ....13 11.24 Removing main silencer........36 Closing oil tank cap (50 SX Mini) ..... 13 11.25 Installing the main silencer......37 Fuel tap ............
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of the safety of your child, have these jobs performed in an authorized KTM workshop. There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.
SAFETY ADVICE Use definition - intended use KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply with currently valid regulations and categories of the top international motorsport organizations.
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.
Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle.
VIEW OF VEHICLE View of the vehicle from the left front (example) 101928-10 Filler cap Quick release of seat Fuel tap ( p. 13) Choke ( p. 14) Plug-in stand ( p. 14) Chain guide...
VIEW OF VEHICLE View of the vehicle from the right rear (example) 101929-10 Kill switch ( p. 12) Throttle grip ( p. 12) Hand brake lever ( p. 12) Chassis number ( p. 10) Shock absorber rebound adjustment Level viewer for brake fluid, rear Foot brake lever ( p.
101930-10 Type label (50 SX) The type label is located on the front frame tube. S00010-10 (50 SX Mini) The type label is located on the frame at the front right. S00009-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.
SERIAL NUMBERS Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring towards the rear. 700469-01...
CONTROLS Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The hand brake lever is used to activate the front brake. 601578-10 Throttle grip Throttle grip is fitted on the right side of the handlebar. 601577-10 Kill switch Kill switch...
Put the tank cap on and turn it clockwise. Info Run the fuel tank breather hose without kinks. 601580-11 Opening oil tank cap (50 SX Mini) – Turn the oil tank cap counterclockwise and pull it up. 601582-10 Closing oil tank cap (50 SX Mini) –...
Choke function deactivated – Choke knob is in lower position. No O-ring is visible. • 601583-10 6.10 Choke (50 SX Mini) The choke lever is fitted on the right of the carburetor. Activating the choke function frees an opening through which the engine can draw extra fuel.
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover.
PREPARING FOR USE Info To give your child a feel for the brake system, you should push your child at first. Do not start the engine until your child is able to apply the necessary front brake pressure. Initially, let your child drive to another person who can help your child stop and turn. –...
Before each use, check the condition of the vehicle and its operating safety. The vehicle must be in perfect technical condition when it is being operated. – Check the gear oil level. ( p. 69) (50 SX Mini) – Check the oil level. ( p. 68) –...
Open the throttle carefully. Riding Info If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized KTM workshop. – If the choke function was activated, deactivate it after the engine has warmed up.
RIDING INSTRUCTIONS – Always place the vehicle on a firm and even surface. Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run.
400214-10 – Close the filler cap. ( p. 13) Filling up with oil (50 SX Mini) Warning Engine failure If the vehicle is run without 2-stroke oil in the tank, the result is engine failure. – The oil tank must always be filled up to the MIN mark.
SERVICE SCHEDULE Service schedule Annually Every 80 operating hours Every 40 operating hours Every 20 operating hours Once after 10 operating hours ○ ● ● ● Check the front brake linings. ( p. 48) ○ ● ● ● Check the rear brake linings. ( p.
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○ ● ● ● Final inspection: check the vehicle for operating safety and take a test ride. ○ ● ● ● Create a service entry in the KTM DEALER.NET and in the service record. ○ One-time interval ● Periodic interval...
Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.
Adjusting the spring preload of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Preparatory work –...
TUNING THE CHASSIS – Remove the four screws . Remove the handlebar clamps. Remove the handlebar 0 0 1 and lay it to one side. Info 0 0 2 Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines.
SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (59229055000) The tires should no longer be in contact with the ground.
SERVICE WORK ON THE CHASSIS 11.4 Removing the fork protector – Remove screws . Take off clamp – Remove screws on the left fork leg. Take off the fork protector. 101934-10 – Remove screws on the right fork leg. Take off the fork protector. 101935-10 11.5 Installing the fork protector...
SERVICE WORK ON THE CHASSIS – Loosen screws . Remove the left fork leg. – Loosen screws . Remove the right fork leg. 601594-10 11.7 Installing the fork legs Main work – Position the fork legs. Info The upper milled groove in the fork leg must be flush with the top edge of the upper triple clamp.
SERVICE WORK ON THE CHASSIS – Remove protective ring – Remove the lower triple clamp with the steering stem. – Remove the upper steering head bearing. 601605-10 11.9 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p.
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam- aged over time.
SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: –...
SERVICE WORK ON THE CHASSIS 11.13 Dismounting the start number plate – Remove screw and take off clamp. – Remove screw . Remove the start number plate. C00050-10 11.14 Installing the start number plate – Position the start number plate with the drill holes onto the holding lugs of the fender.
SERVICE WORK ON THE CHASSIS – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 601982-11 11.17 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p.
SERVICE WORK ON THE CHASSIS 11.20 Mounting the seat – Hook the seat onto screw and lower the seat at the rear while pushing it forward. Projection hooks into the fuel tank. 101941-10 – Close quick release 101940-11 11.21 Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine.
SERVICE WORK ON THE CHASSIS 11.23 Cleaning the air filter and air filter box Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Do not clean the air filter with fuel or petroleum since these substances attack the foam.
Mount and tighten the screws with the toothed washers. 700514-01 Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) Finishing work – Install the main silencer. ( p. 37) 11.27 Removing the chain guard (50 SX) – Remove cable binder – Take off the chain guard. 101945-10...
SERVICE WORK ON THE CHASSIS 11.28 Installing the chain guard (50 SX) – Position the chain guard. Mount cable binder Info The cable binder must be run between chain sliding guard swingarm 201947-10 – Mount the cable binder at the rear.
» If the chain is very dirty: – Clean the chain. ( p. 39) 400678-01 Finishing work (50 SX) – Install the chain guard. ( p. 38) 11.32 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip.
» If the chain tension does not meet specifications: – Adjust the chain tension. ( p. 40) Finishing work (50 SX) – Install the chain guard. ( p. 38) – Remove the motorcycle from the lift stand. ( p. 27) 11.34...
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SERVICE WORK ON THE CHASSIS Main work – Check the engine sprocket cover for wear. » If the engine sprocket cover is worn through in the marked area – Change the engine sprocket cover. 100896-10 – Check the rear sprocket and engine sprocket for wear. »...
Remaining screws, chassis 10 Nm (7.4 lbf ft) 101948-01 Finishing work – Install the engine sprocket cover. p. 38) (50 SX) – Install the chain guard. ( p. 38) – Remove the motorcycle from the lift stand. ( p. 27) 11.36...
If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by KTM. 601599-01 11.38 Checking the swingarm –...
SERVICE WORK ON THE CHASSIS 11.40 Checking the rubber grip – Check the rubber grips on the handlebar for damage, wear, and looseness. » If a rubber grip is damaged, worn, or loose: – Change and secure the rubber grip. Rubber grip adhesive (00062030051) ( p.
BRAKE SYSTEM 12.1 Checking play of handbrake lever – Push the handbrake lever forwards and check the play Play of hand brake lever 3… 5 mm (0.12… 0.2 in) » If the play does not meet specifications: – Adjust the play of the hand brake lever. ( p.
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to use of non-approved brake linings.
BRAKE SYSTEM Main work – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir.
BRAKE SYSTEM – Disconnect spring – Move the foot brake lever back and forth between the end stop and the foot brake cylinder piston bracket and check free travel Guideline Free travel of foot brake lever 3… 5 mm (0.12… 0.2 in) »...
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to use of non-approved brake linings.
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Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container. Preparatory work – Raise the motorcycle with a lift stand. ( p. 27) (50 SX) – Remove the chain guard. ( p. 37) – Remove the rear wheel.
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Position the membrane and the cover with the washer. Mount and tighten the screws. 201170-10 Info Clean up overflowed or spilled brake fluid immediately with water. Finishing work (50 SX) – Install the chain guard. ( p. 38) – Remove the motorcycle from the lift stand. (...
WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 27) Main work – Remove screw – Loosen screws 601596-10 – Withdraw the wheel spindle while holding the front wheel. Take the front wheel out of the fork.
Checking the tire condition Info Only mount tires that have been approved and/or recommended by KTM. Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.
Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.
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WHEELS, TIRES » If the spoke tension differs: – Correct the spoke tension. – Check the spoke torque. Guideline Spoke nipple M3.5 3 Nm (2.2 lbf ft) Torque wrench with various accessories in set (58429094000)
COOLING SYSTEM 14.1 Cooling system The water pump in the engine forces the coolant to flow. The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.
COOLING SYSTEM 14.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.
COOLING SYSTEM 14.5 Refilling coolant Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water imme- diately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swal- lowed, contact a physician immediately.
TUNING THE ENGINE 15.1 Checking the installation position of the throttle grip – Position the throttle grip so that surface is vertical. Info If the throttle grip is tipped forward, the throttle cable will slip out of the guide on the carburetor. The throttle slide can no longer be closed. 601970-10 15.2 Checking the play of the throttle cable...
The idle mixture is adjusted with the idle mixture adjustment screw 700520-01 15.5 Carburetor - idle (50 SX Mini) The idle setting of the carburetor has a big influence on the starting behavior, stable idling and the response to throttle opening. That means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly.
Following extreme air temperature or altitude changes, adjust the idle speed again. 15.7 Carburetor - adjusting idle speed (50 SX Mini) – Screw in idle air adjusting screw all the way and turn it to the specified basic position.
TUNING THE ENGINE 15.8 Checking the clutch setting – Connect special tool Tachometer (45129075000) 101952-10 – Let the front wheel of the vehicle make contact with a fixed object. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
TUNING THE ENGINE – Remove screws – Remove clutch cover with the seal ring. S00001-10 15.10 Adjusting the clutch Preparatory work – Remove the clutch cover. p. 65) Main work – Turn the outer clutch hub until adjusting screws become accessible. S00002-10 Condition If there is no reference point:...
TUNING THE ENGINE 15.11 Installing the clutch cover Main work – Position clutch cover with the seal ring. – Mount and tighten screws Guideline Screw, clutch cover 10 Nm (7.4 lbf ft) S00004-10 Finishing work – Check the gear oil level. ( p.
SERVICE WORK ON THE ENGINE 16.1 Checking oil level (50 SX Mini) Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Check the oil level in the oil tank. For a full fuel tank, the oil tank must be filled up to MIN mark at a minimum.
SERVICE WORK ON THE ENGINE – Turn the oil pump gear counterclockwise until oil flows out of oil line without bubbles. 300653-10 – Connect oil line – Position the oil pump. – Mount and tighten screws Guideline Screw, oil pump 6 Nm (4.4 lbf ft) 300651-10 16.3...
SERVICE WORK ON THE ENGINE Main work – Place a suitable container under the engine. – Remove the oil drain plug with magnet – Completely drain the gear oil. – Thoroughly clean the oil drain plug with magnet. – Clean the sealing area on the engine. –...
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SERVICE WORK ON THE ENGINE – Start the engine and check that it is oil-tight.
CLEANING, CARE 17.1 Cleaning motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts.
57) – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with a lift stand. ( p. 27) – Cover the vehicle with a tarp or similar cover that is permeable to air.
– Fuel feed interrupted Check the fuel tank breather. – Clean the fuel tap. (50 SX Mini) – Check/set the carburetor components. (50 SX) – Check/set the carburetor components. –...
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TROUBLESHOOTING Faults Possible cause Action – Engine has too little power Exhaust system leaky, deformed or Check exhaust system for damage. too little glass fiber yarn filling in – Change the glass fiber yarn filling of the main main silencer silencer.
SUBSTANCES 2-stroke engine oil According to – JASO FC ( p. 85) Guideline – Only use high quality 2-stroke engine oil of a well-known brand. KTM recommends Motorex ® products. Fully synthetic Supplier Motorex ® – Cross Power 2T Brake fluid DOT 4 / DOT 5.1 According to –...
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SUBSTANCES Shock absorber oil (SAE 2.5) (50180342S1) According to – SAE ( p. 85) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) According to –...
AUXILIARY SUBSTANCES Air filter cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Dirt Bio Remover Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline –...
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AUXILIARY SUBSTANCES Oil for foam air filter Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Liquid Bio Power Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline – KTM recommends Motorex ®...
STANDARDS JASO FC JASO FC is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions. The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis- cosity.