..........45 Important maintenance work that must be done in an Installing the front wheel ........... 45 authorized KTM workshop (as additional order)....18 Removing rear wheel ..........46 Performance of urgent inspection and care work by the Installing the rear wheel ..........
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.
Warranty The work prescribed in the service schedule must be carried out in an authorized KTM workshop only and confirmed in the customer's service record, since otherwise no warranty claims will be honored. No warranty claims can be honored for damage resulting from manipulations and/or alterations to the vehicle.
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IMPORTANT INFORMATION Environment Motorcycling is a wonderful sport and we naturally hope that you and your child will be able to enjoy it to the fullest. However, it is a potential problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such problems and conflicts do not have to occur.
VIEW OF VEHICLE View of the vehicle from the left front (example) B00068-10 Hand brake lever Filler cap Fuel tap Quick release for seat lock Shock absorber compression adjustment Chain guide Plug-in stand...
VIEW OF VEHICLE View of the vehicle from the right rear (example) B00069-10 Short circuit button Chassis number Throttle grip Level viewer for brake fluid, rear Foot brake pedal Kickstarter...
LOCATION OF SERIAL NUMBERS Chassis number The chassis number is stamped on right of the steering head. 700460-01 Engine number The engine number is stamped on the left side of the engine under the engine sprocket. 700461-01 Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above ...
CONTROLS Throttle grip Throttle grip is fitted on the right side of the handlebar. 700470-01 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. 700471-01 Short circuit button Short circuit button...
CONTROLS Closing filler cap – Put the tank cap on and turn it clockwise. Info Run the fuel tank breather hose without kinks. 700465-11 Opening oil tank cap (50 SX Mini) – Turn the oil tank cap counterclockwise and pull it up. ...
CONTROLS Kickstarter 5.11 The kickstarter is fitted on the right of the engine. The kickstarter can be swiveled. Info Before riding, swing the kickstarter inwards towards the engine. 700472-01 Foot brake pedal 5.12 Foot brake pedal is located in front of the right footrest. ...
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.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION Info To give your child a feel for the brake, you should push your child at first. Do not start the engine until your child can is able to apply the necessary brake pressure. At the start, let your child ride to another person who can help him or her stop and turn.
RIDING INSTRUCTIONS Checks before putting into operation Info Make sure that the motorcycle is in a perfect technical condition before use. Info In the interests of riding safety, make it your own and your child's habit to perform a general check before going for a ride. Insist that your child perform the general checks himself or herself.
Open the throttle carefully. Shifting, 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 Note Material damage Damage and destruction of components due to excessive load. – The plug-in stand is designed for the weight of the motorcycle only. You or your child should not sit on the motorcycle when it is standing on the plug-in stand. The plug-in stand and/or the frame could be damaged and the motorcycle could fall over. –...
Clean and grease adjusting screws of chain adjuster. • • S20A: every 20 service hours S40A: every 40 service hours Important maintenance work that must be done in an authorized KTM workshop (as additional order) S20A S40A S80A Check/set the carburetor components. (50 SX Mini) •...
SERVICE SCHEDULE S20A S40A S80A Check main bearing of the crankshaft. • • • Check radial clearance of conrod bearing. • • • • • Change crankshafts and conrod bearings. Service the fork. • • • Service the shock absorber. Clean and lubricate swingarm bearing.
Adjusting the rebound damping of the shock absorber Danger 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 to the last perceptible click.
Adjusting the spring preload of the shock absorber Danger 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.) – Remove shock absorber.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Measure the full spring length while it is under tension and note down the value. – Loosen lock ring – Turn adjusting ring until the spring is no longer under tension. Hook wrench (T106S) –...
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing shock absorber 9.10 – Push the splash protector to the side and position the shock absorber according to the desired seat height. Mount and tighten screw Guideline Screw, top shock absorber 45 Nm (33.2 lbf ft) –...
MAINTENANCE WORK ON CHASSIS AND ENGINE – Tighten screw Guideline Screw, top triple clamp 25 Nm (18.4 lbf ft) – Fully tighten screws Guideline Screw, bottom triple clamp 10 Nm (7.4 lbf ft) – Repeat the adjustment on the other fork leg. Info The setting of the vehicle level via the fork legs must be identical on both fork legs.
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 for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Tighten nut Guideline Steering head nut M20x1.5 10 Nm (7.4 lbf ft) 300739-10 – Position the upper triple clamp. – Mount nut , but do not tighten it yet. Guideline Nut, steering stem M20x1.5 10 Nm (7.4 lbf ft) –...
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screws with washers and brake caliper. – Hang the brake caliper and the brake line loosely to the side. 300732-10 – Loosen screw . Remove the left fork leg. – Loosen screw .
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the lower triple clamp 9.19 – Remove the fork legs. p. 26) – Dismount the front fender. ( p. 30) – Remove the fuel tank breather – Remove screws – Remove the handlebar clamp. –...
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the lower triple clamp 9.20 – Clean the bearing and sealing elements, check for damage, and grease. Long-life grease ( p. 78) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the handlebar with handlebar clamps. – Mount and tighten screws Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) – Position the fuel tank breather 300743-10 – Position the brake caliper, fit and tighten the screws with washers.
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the front fender 9.23 – Position the fender with holding lugs into the drill holes on the start number plate. 700480-01 – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 700479-11...
MAINTENANCE WORK ON CHASSIS AND ENGINE Handlebar position 9.26 On the upper triple clamp, there are 2 holes at a distance of to each other. Distance between holes 15 mm (0.59 in) The holes on the handlebar support are placed at a distance of from the center.
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the play in the throttle cable 9.29 – Move the handlebar to the straight-ahead position. – Push back bellows – Loosen nut . Turn adjusting screw in as far as possible. ...
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the chain tension 9.32 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is over tensioned, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel) are under additional load.
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting chain tension 9.35 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is over tensioned, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain may snap or the countershaft of the transmission can break.
Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement ...
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brakes 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 brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
Removing front brake linings 9.46 Warning Danger of accident Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) – Remove front wheel. p. 45) – Remove the lock washer ...
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with diaphragm – Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir.
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.
Removing rear brake linings 9.54 Warning Danger of accident Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) – Remove the rear wheel. p. 46) – Remove the lock washer ...
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove the rear brake linings. p. 43) – Remove screws – Take off cover with washer and membrane – Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Lift the front wheel into the fork, position it, and insert wheel spindle with washer 700503-10 – Position washer – Mount and tighten nut Guideline Front wheel spindle nut M12x1 40 Nm (29.5 lbf ft)
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.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Briefly strike each spoke with the blade of a screwdriver. Info The frequency of the tone depends on the spoke length and diameter. If you hear different tone frequencies from spokes of the same length and thickness, this is an indication that the spoke tension differs.
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the antifreeze and coolant level 9.67 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the coolant level in the radiator. Coolant level above the radiator fins 10 mm (0.39 in) » If the coolant level does not meet specifications: –...
MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the vehicle as shown and secure it against rolling away. A height differ- ence of must be reached. Guideline Height difference 100 cm (39.4 in) Info To ensure that all of the air can escape from the cooling system, the front of 0 0 A 0 0 B the vehicle must be jacked up.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the collar sleeves. – Mount and tighten screw Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 700512-10 Glass fiber yarn filling of main silencer 9.73 The main silencer is filled with glass fiber yarn. Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out".
MAINTENANCE WORK ON CHASSIS AND ENGINE – Press the rear holding lugs together slightly and swing the air filer cover upward. Pull out the front holding lug and take off the air filter cover. – Take off the air filter. 700504-01 Installing the air filter 9.77...
MAINTENANCE WORK ON CHASSIS AND ENGINE Carburetor - idle (50 SX Mini) 9.80 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE Carburetor - adjusting idle speed (50 SX Mini) 9.82 – Screw in idle air adjusting screw all the way and turn it to the specified basic position. Guideline Idle air adjusting screw Open 1 turn –...
MAINTENANCE WORK ON CHASSIS AND ENGINE Bleeding oil pump (50 SX Mini) 9.84 Condition Fuel tank removed. – Pull off the oil line 300650-10 – Fill the oil line with a syringe. 2-stroke engine oil ( p. 76) 300652-10 –...
MAINTENANCE WORK ON CHASSIS AND ENGINE – Connect the oil line – Position the oil pump. – Mount and tighten screws Guideline Screw, oil pump 6 Nm (4.4 lbf ft) 300651-10 Checking gear oil level 9.85 Info The gear oil level must be checked when the engine is cold. –...
MAINTENANCE WORK ON CHASSIS AND ENGINE Draining the gear oil 9.87 Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screw cap . Stand the vehicle upright. – Add gear oil until it flows out of the bore of the gear oil level screw. Gear oil (ATF Dexron 3) ( p. 76) –...
MAINTENANCE WORK ON CHASSIS AND ENGINE Clutch spring with yellow mark – Correct the washer according to the measured value. Guideline A washer of 0.2 mm (0.008 in) 100 rpm changes the clutch engagement speed by about: Info The spacing washer of 1.7 mm (0.067 in) and the spacing washer ...
MAINTENANCE WORK ON CHASSIS AND ENGINE Fitting centrifugal force clutch 9.93 – Position the centrifugal force clutch 300657-11 – Position the clutch drum. – Hold the clutch drum with the special tool – Mount and tighten screw Guideline Screw, clutch drum 30 Nm...
MAINTENANCE WORK ON CHASSIS AND ENGINE Dismantling centrifugal clutch 9.95 Condition Centrifugal clutch removed. – Loosen screws with special tool. Mortise key (45229021000) 300513-10 Clutch spring with green mark – Remove screw with spacing washer and spring ...
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MAINTENANCE WORK ON CHASSIS AND ENGINE – Tighten screws with special tool. Guideline Screw, clutch spring 7 Nm (5.2 lbf ft) Mortise key (45229021000) 300513-11...
TROUBLESHOOTING Faults Possible cause Action – Engine turns but does not start Operating error Go through the steps of starting the engine. p. 15) – Motorcycle was out of use for a long Empty the carburetor float chamber. time and there is old fuel in the float chamber –...
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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.
CLEANING Cleaning motorcycle 11.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
Check the tire air pressure. ( p. 47) – The storage place should be dry and not subject to large temperature fluctuations. Info KTM recommends jacking up the motorcycle. – Jack up the motorcycle. ( p. 20) – Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.
TECHNICAL DATA - CARBURETOR 50 SX 15.1 Carburetor type Dell`Orto PHBG 19BS Needle position 3rd position from top Idle mixture adjusting screw Open 3 turns Main jet Jet needle Idling jet Needle jet 260AU Throttle slide Cold start jet 50 SX Mini 15.2 Carburetor type Dell`Orto PHVA 12XS...
TECHNICAL DATA - CHASSIS Capacity - fuel 16.2 Fuel tank capacity, approx. 2.3 l (2.4 qt.) Super unleaded gasoline, mixed with 2-stroke engine oil (1:60) (50 SX) p. 77) Fuel tank capacity, approx. 2.0 l (2.1 qt.) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p.
TECHNICAL DATA - FORK 50 SX 17.1 Fork part number 45101000644 Fork Marzocchi Spring rate Weight of rider: 25… 35 kg (55… 77 lb.) 2 N/mm (11 lb/in) Air chamber length 100±2.5 mm (3.94±0.098 in) Fork length 692 mm (27.24 in) Fork oil 210 ml (7.1 fl.
TECHNICAL DATA - SHOCK ABSORBER 50 SX 18.1 Shock absorber part number 03.18.9E.02 Shock absorber WP Suspension 3614 BAEM Rebound damping Standard 10 clicks Spring preload Standard 3 mm (0.12 in) Spring rate Weight of rider: < 25 kg (< 55 lb.) 30 N/mm (171 lb/in) Weight of rider: 25…...
2-stroke engine oil According to – JASO FC ( p. 80) 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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OPERATING SUBSTANCES Shock absorber oil (SAE 2.5) (50180342S1) According to – SAE ( p. 80) (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 –...
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.
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