KTM -Sportmotorcycle AG Motorcycle Accessories 50 AC/LC User's Manual
Contents
1. 9 7 CHECKING CLUTCH FOR WEAR 9 1 Art Nr 3 206 028 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 Repair manual KTM MINI 50 air liquid cooled 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 1507 After cooling should the bearings to lock in the bore they are bound to rotate after warming In that event the housing must be replaced Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 9 2E Working on the right half of the engine case Remove shaft sealing ring and heat the engine case half on a heating plate to approx 150 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 autom2. 8 13 STANDARD ADJUSTMENT SHOCK ABSORBER 8 13 MODEL 2006 AC ENGINE 8 14 BASIC CARBURETOR SETTING 8 14 RSS 8 15 STANDARD ADJUSTMENT FORK 8 15 STANDARD ADJUSTMENT SHOCK ABSORBER 8 15 MODEL 2006 LC ENGINE uode SERE ARS TEE 8 16 BASIC CARBURETOR SETTING 8 16 C RN 8 17 STANDARD ADJUSTMENT FORK 8 17 STANDARD ADJUSTMENT SHOCK ABSORBER 8 17 TOLERANCES AND FITTING CLEARANCES 8 18 TIGHTENING TORQUES 8 18 TIGHTENING TORQUES CHASSIS 8 18 8 2E Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 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 Bore Stroke 39 5 40 mm Fuel SUPER fuel research octane no 95 mixed with 2 stroke oil 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 Transmission oil 0 15 0 2 liter gear oi
3. ZE 1 2202 9 peJo 1i ds sqnjumop 8 5 9 1 YOINAS Odd XS 09 XS OG YOINIS 09 JANINIAAV OS ININ OS COOC ININ OS SISSVHJ SNOLLVII4193dS TVIINHI3L Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 8 5E TECHNICAL DATA ENGINE 50 AC LC 2003 40 when using high grade 2 stroke oil Shell Advance Racing X separate lubrication Shell Advance Ultra 2 0 5 liter 0 132 USgal water coolant 2 2 1 Oil gasoline ratio BASIC CARBURETOR SETTING Model 50 MINI ADVENTURE SO JUNIOR SENIOR 50SXPRO JUNIOR LC 50 SX PRO SENIOR LC Separate lubrication ADVENTURE Type Dell Orto PHVA 12 XS Dell Orto PHVA 14 DS Dell Orto PHVA 14 DS Dell Orto PHBG 19 BS Wem o e me o 9 mum o lw 9 8 ul p OTT ww Qr ut 1uBue peojaid Suuds G Z 3VS G Z AVS po WW N WW N 98 Bund zT ul TE Q WW g peojed Suuds QT u 0 5 5 AGYJVANVIS JV AJOHS 5 GYVGNVLS A404 INJINLSN AV GYVANVLS 54 82 84 GE 1u8IoM poq s 1epi ii YET Ju Stay Apoq su piu u 9 92 9 92 Z vz z z 9 92 9 92 2 92 2 72 Z vz
4. 4 5 SPLIT THE CASING HALVES 4 5 DISMOUNTING CLUTCH AND PRIMARY DRIVE 4 6 Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 4 2E SPECIAL TOOLS ENGINE 50 AC LC PARTNUMBER DESCRIPTION Puller for flywheel Rotor holding too Adjusting plate for Dimension 6 503 29 050 000 Bleeding singe x 4 Clamp 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 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 Ib Remove water hose intake flange and ignition coil Loosen hose clamps and remove water hose only LC engine Pull plug from the ignition coil disconnect spark plug cap from the spark plug Loosen 4 bolts on the intake flange O Remove the ignition coil with bracket intake flange and reed valve housing Remove spark plug Remove ignition cover and pump Loosen bolt and remove ignition cover NOTE The water pump Q is located on the ignition cover of the LC engine The ignition cover is centered with 2 dowels They usually stay in the engine cas
5. 8 3 BASIC CARBURETOR SETTING 8 3 CHASSIS iili RS RARE ai a ie de ert mi ii k ERE 8 4 STANDARD ADJUSTMENT FORK 6 4 STANDARD ADJUSTMENT SHOCK ABSORBER 8 4 MODEL 2003 3101 AAPP E E A A kus as 8 5 BASIC CARBURETOR SETTING 8 5 CHASSIS OA ARA 8 6 STANDARD ADJUSTMENT FORK 6 6 STANDARD ADJUSTMENT SHOCK ABSORBER 8 6 MODEL 2004 ENGINE ossaa anr 8 7 BASIC CARBURETOR SETTING 8 8 CHASSIS ne Fee Avi RUN EPR TS Ee RES eae 8 9 STANDARD ADJUSTMENT FORK 6 9 STANDARD ADJUSTMENT SHOCK ABSORBER 8 9 Art Nr 3 206 028 E Repair manual KTM MINI 50 air liquid cooled INDEX MODEL 2005 AC ENGINE aros FREER EERE eRe Gennes ee 8 10 BASIC CARBURETOR SETTING itr RR 8 10 A er ee ee ee ee 8 11 STANDARD ADJUSTMENT FORK 6 11 STANDARD ADJUSTMENT SHOCK ABSORBER 8 11 MODEL 2005 LC ENGINE a ati ke an AO 8 12 BASIC CARBURETOR SETTING 8 12 erc 8 13 STANDARD ADJUSTMENT FORK
6. 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 9 must be secured with Loctite 243 and tightened to 12 Nm Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled ASSEMBLING THE ENGINE INDEX MOUNTING THE CRANKSHAFT MOUNTING THE PRIMARY DRIVE MOUNTING LEFT ENGINE HOUSING IGNITION SYSTEM AAA AAA MOUNTING THE CLUTCH kr EKA A EAR en MOUNTING THE CLUTCH COVER IGNITION COVER zu uns vann a Aa e ki MOUNTING PISTON MOUNTING GVEINDER qp A RR uma ADJUSTING 5 0 4 MOUNTING WATERHOSE INTAKE FLANGE AND IGNITION COIL FILLING IN GEAR OIL wont ai qe dide were enon ees 6 1E Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 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
7. Loose carburetor jets Incorrect heat range spark plug or low quality spark plug Loose corroded or non conductive ignition socket connector Lack of fuel Spark plug with incorrect heat value Ignition by incandescence Engine takes air out of control Insufficient system only LC engine liquid in cooling Radiator fins clogged only LC engine Frothing in cooling system only LC engine Pinched or kinked water hoses only LC engine Incorrect ignition timing because of loose stator bolts Incorrect compression ratio Cylinder head or O ring of cylinder head gasket leaks Clean carburetor if necessary replace float needle and adjust level Tighten jets Refer to technical data section Check and seal with silicon Clean fuel pipes examine tank aeration and clean Fit correct spark plug Check intake flange and carburettor if firmly setted Top up coolant and bleed cooling system check cooling system for leaks Clean radiatar fins with water jet Renew coolant using branded anti freeze anti corrosive Motorex Anti Freeze Replace with correct routed hoses Readjust to correct ignition timing specifications secure bolts with Loctite 243 Measure and adjust compression ratio Check cylinder head replace O ring Excessive oil quantity in Correct transmission oil level transmission Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 1 4 Resistor values of the igniti
8. Air chamber length 110 mm 4 3 in STANDARD ADJUSTMENT SHOCK ABSORBER 90 SX JUNIOR 90 SX 50 SUPERMOTO WP 03189B01 WP 03189B02 Rebound adjuster 9 9 Spring Spring preload 10 mm 0 39 in 85 N mm 45 N mm 7 mm 0 28 in 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 new 84 00 84 01 mm Clutch springs length min 19 6 mm TIGHTENING TORQUES ENGINE Hexagon nut primary gear M14x1 25 Hexagon nut ignition rotor M10x1 25 Hexagon nut of clutch hub M10x1 25 HH bolts clutch shoes m Cylinder head bolts Allen head bolt Stator Loctite 243 8 Nm 5N N Oil drain plug M10 M Other bolts engine M M6 M7 1 Cylinder base nuts M8 M5 1 B 6 1 8 M TIGHTENING TORQUES CHASSIS Hexagon nuts front rear axle N am O O O O O jO O Z Z Z Z Z Z Hexagon nut swing arm bolt HH bolts of top triple clamp HH bolts of bottom triple clamp Spoke nipple al Other bolts chassis M8 N 9 1E LUBRICATION AND MAINTENANCE SCHEDULE 9 INDEX LUBRICATION AND MAINTENANCE SCHEDULE 50 AC LC MOD
9. Check exhaust system for leaks and suspension Check actuating cables for damage smooth operation and kink less aan Clean air filter air filter box Check fluid level lining thickness prakediscs o 4 4 4 4 4 4 4 4 4 Pen 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 L Check swinging fork pivot I Check adjust steering head bearing L Check all chassis bolts for tight fit fork plates axle nuts props Check spoke tension and rim joint Check tire condition and inflation pressure Check chain chain wheels chain wheel guides for wear tight ft and tension O Lubricate chain Check wheel bearings for play IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER once MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER WHEELS CHASSIS BRAKES ADD ON PARTS CARBURETOR ENGINE Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 9 5E VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC Check transmission oil level gt before each start after every cleaning for cross countr Treat exposed metal components except for the brake and e
10. 150 C NOTE f the engine case is heated to 150 C and struck on a wooden surface the bearings usually fall out of the bearing seats automatically f 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 O 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 O 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 O 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 Art Nr 3 206 028
11. Seat height unloaded 650 or 675 mm 25 6 or 26 6 in adjustable 530 or 550 mm 21 or 21 7 in adjustable Ground clearance 255 mm 10 in Rider s body height max 130 cm 51 in STANDARD ADJUSTMENT FORK 50 SENIOR MINI ADVENTURE Spring 2 0 N mm 10 mm 0 4 in Fork oil SAE 7 5 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 8 16E TECHNICAL DATA ENGINE 2006 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 60 when using high grade 2 stroke oil Motorex 2T Cross Power Oil gasoline ratio When in doubt please contact your importer Lubrication mixture lubrication Crankshaft bearing 2 grooved ball bearing Connecting rod bearing needle bearing Piston pin bearing needle bearing Piston rings 1 rectangular ring Primary drive straight cut spur gears 16 57 Z Transmission oil 0 15 0 2 liter automatic gear oil Dexron Motorex Topspeed 4T 15W50 Spark plug NGK BR 8 ECM Electrode gap 0 6 mm 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 13 F BASIC CARBURETOR SETTING Model 90 SX JUNIOR
12. and press in the seal shaft ring Pull off the tape Mounting the ignition Place woodruff key in the crankshaft groove Mount ignition rotor with a washer holding back with special tool secure nut with Loctite 243 and tighten to 20 Nm 15 ft Ib 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 on the output shaft with the collar towards housing and mount the circlip Mount ignition stator 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 on stators with Loctite 243 and tighten to 8 Nm 6 0 Position cable guide Q 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 Secure the nut M10x1 25 on the crankshaft with Loctite 243 and tighten to 35 Nm 25 ft Ib Tighten the output shaft nut to 40 Nm SO ft Ib Bend over the lock washer on the output shaft nut NOTE for a correct function of the clutch axial clearance 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 axia
13. 90 SX 50 SUPERMOTO Type Dell Orto PHVA 14 DS Dell Orto PHBG 19 BS Needle jet 211 FA 260 AU Jet needle A10 W9 Needle position from top 9 J 40 60 Slide 60 Starting jet 60 Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 8 17E TECHNICAL SPECIFICATIONS CHASSIS 2006 LC x OS 5 Frame single downtube split cradle Fork Wheel travel front rear Marzocchi 32 mm 1 26 in 140 205 mm 5 5 8 in 185 185 mm 7 3 7 3 in Rear suspension Central shock absorber WP Front brake Rear brake Disk brake 0 160 mm 6 4 in Drum brake 90 mm 3 5 in Disk brake 140 mm 5 5 in Tires front Tires rear 2 50x10 Pirelli MT32A 2 5x10 MT320 2 50x12 Pirelli MT32A 90 90 10 Pirelli 5126 90 90 10 Pirelli 5126 Tire pressure front rear 1 0 bar Fuel tank capacity 1 8 Liter Final drive ratio Chain Steering angle 11 48 10 44 1 2 x 3 16 96 rolls 1 2 x 3 16 102 rolls 66 Wheel base Seat height unloaded 910 mm 35 8 in 585 mm 610 mm 23 24 in 1030 mm 40 in 650 675 mm 25 6 26 6 in Ground clearance unloaded 220 mm 8 6 in 255 mm 10 in Rider s body height Rider s body weight max 130 cm 51 in max 35 kg 78 lbs Recommended age of rider 4 7 years 6 10 years Engine 50 LE STANDARD ADJUSTMENT FORK Spring Preload 2 0 N mm 10 mm 0 4 in Fork oil SAE 7 5
14. Cross Power When in doubt please contact your importer or use 1 33 mix ratio to be on the safe side mixture lubrication Crankshaft bearing 2 grooved ball bearing Connecting rod bearing needle bearing Piston pin bearing needle bearing Piston rings Primary drive 1 rectangular ring straight cut spur gears 16 57 2 Transmission oil 0 15 0 2 liter automatic gear oil Dexron Motorex Topspeed 4T 15W50 Spark plug Electrode gap NGK BR 8 ECM 0 6 mm Carburetor Air filter DellOrto PHVA 14 DS Dell Orto PHBG 19 BS 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 90 SX PRO JUNIOR LC Type Main Jet Needle jet 50 SX PRO SENIOR LC Dell Orto PHVA 14 DS Dell Orto PHBG 19 BS BO 55 Idling jet Jet needle 211 FA 260 AU Needle position from top Air Mixture reg screw open A10 W9 3 3 9 3 0 40 60 Slide 60 starting jet 60 Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 8 13E TECHNICAL SPECIFICATIONS CHASSIS 2005 LC single downtube split cradle Marzocchi 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 160 mm 6 4 in Rear brake Drum brake 90 mm 3 5 in Disk brake 140 mm 5 5 in Ti
15. If then the engine pings especially when accelerating under full power at maximum engine revs the Jet needle should be raised 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 idling jet E throttle valve idling jet 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 2 n 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 LEAD TO THE PREMATURE DESTRUCTION OF THESE PARTS You
16. out check tank ventilation i e clean fuel tap Reduce electrode distance 0 60 mm 0 0236 in Clean spark plug or renew 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 f no spark is produced loosen spark plug cap from ignition cable hold about 5 mm from ground and actuate kickstarter fa spark now occurs replace spark plug cap f no spark is produced control ignition system Disconnect black coloured cable from short circuit button at ignition coil and check ignition spark If the spark is O K repair defective part of cable or ignition switch Inspect cable connectors Examine ignition system Dismantle and clean carburetor Readjust idle running or replace idle adjusting bolt Examine ignition system Overhaul engine Clean or renew airfilter Blow through fuel pipe and clean carburetor Tighten spark plug Check exhaust system for damage Check and adjust ignition Replace reed paddles or reed valve housing Overhaul engine 7 3E TROUBLE CAUSE REMEDY Engine stalling or running with four stroke cycle High rpm misfiring Engine spluters into the carburetor Engine overheating Emission of white smoke steam only LC engine Excessive oil escapes from transmission breather tube Carburetor overflows if level adjust too high float needle seating is dirty or enlarged
17. with reed valve inlet Displacement Bore Stroke 49 0 com 39 5 40 mm Fuel Lead free SUPER FUEL ROZ 95 mixed with 2 stroke oil Lead free SUPER FUEL ROZ 95 Lubrication Oil gasoline ratio mixture lubrication separate lubrication 1 40 2 stroke oil 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 2 grooved ball bearing Connecting rod bearing Piston pin bearing needle bearing needle bearing Piston rings rectangular ring Primary drive straight cut spur gears 16 571 Transmission oil 0 15 0 2 liter gear oil Dexron Motorex ATF Super Spark plug Electrode gap NGK BR 8 ECM 0 6 mm Carburetor Dell Orto PHVA 14 DS Dell Orto PHVA 12 XS Airfilter wet foam type air filter insert BASIC CARBURETOR SETTING MODEL 50 SENIOR ADVENTURE 50 MINI ADVENTURE Dell Orto PHVA 12 XS Type Dell Orto PHVA 14 DS Main jet 80 70 211 FA Needle jet 211 FA Idling jet Jet needle Needle position from top Air Mixture reg screw open 35 slide starting jet Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 8 11E TECHNICAL SPECIFICATIONS CHASSIS 2005 AC CHASSIS SO SENIOR ADVENTURE BOMINI ADVENTURE Frame single downtube split cradle Fork Marzocchi 32 mm 1 26 in Wheel tr
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20. 2 XS Dell Orto PHVA 14 DS 50 SX PRO JUNIOR LC 50 SX PRO SENIOR LC Dell Orto PHVA 14 DS Dell Orto PHBG 19 BS ___ 08 e Ul Q WW Ul Oo WW OT sulids Ul OTT Ul WW OTT 1usue GIGABLEOdM HLGASLEO dM yroyww 21 8 peojaid Buds wuyn 02 WW N 02 JI 18805940 20 5 AGYJVANVIS JV AJOHS LNAWILSNIAV AJVANVLS A404 INJINLSN AV GYVANVLS 5 8 9 0689 e1qezsnfpe 9 alqelsn pe ww 9 9 099 ejqe1snipe 919 069 papeojun 1y3ray 1695 51102 POT 5101 96 9T EXZ T sllol POT 5102 96 OT EXZ T uuo OZELIN OTXG Z SOIL YZE LIN eld z POS VZELIN 01 062 YZE LIN 21 09 2 VZELN 01 062 0 3u0j sel Oy T exe 06 Y axel 091 06 Y 0 AQWA S d Jequosge yoous 190105486 x2ous esUaJ uoisuedsns Jeay 9 peJo 1i ds 8 5 21 YOINIS XS OS 91 JOINNI XS 06 JUNINIAGY YOINIS OS FPININIAAVINIWOS 00 ININ OS SISSWHJ 53 011191319395 J 860 90 AN OG WAY lenueu 8 10E TECHNICAL DATA ENGINE 2005 AC Design single cylinder 2 stroke engine
21. Art NR 3 206 028 E MANUAL 90 AC LC REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE REPARATION MANUAL DE REPARACION 7 2002 2006 278 50 AC LC 575 47 9 02 5 777 7 of Switzerland AL EI KTM Group Partner SERVICE INFORMATIONS GENERAL INFORMATION REMOVING AND REFITTING ENGINE DISASSEMBLING ENGINE SERVICING INDIVIDUAL COMPONENTS ASSEMBLING ENGINE TROUBLE SHOOTING TECHNICAL SPECIFICATIONS PERIODIC MAINTENANCE SCHEDULE WIRING DIAGRAM Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 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 27 7 a ze Jj TO a 2 _ a ere j ee er see I tee _ os KTM REPAIR MANUAL IN LOOSE LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER Putthe index into the binder Putthe front page of the repair manual 210x297 mm into the transparent pocket provided for this purpose on the outside of the binder Putthe spine label 170x45 mm into the transparent pocket provided for this purpose on the
22. EL WO 9 2 MODEL 2003 2009 9 4 MODEL 2000 ai sos GS me 9 6 Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 9 2 PERIODIC MAINTENANCE 2002 S air liquid cooled Service Service A washed motorcycle can be checked more quickly which saves money every every 5 hours 20 hours Check engine for leak tp Change transmission ofl 0 0 Check spark plug change it if necessary set electrode gap Do Check the clutch engagement speed A Check carburetor for tight fit at intake lan 6 Check intake flange for cracks er Check idle setting when engineiswam Check cooling system for leaks antifreeze protection _ Check exhaust system for leaks and suspension Check actuating cables for damage smooth operation and kink less hry ir Clean air filter and air filter box Check fluid level lining thickness brake discs Pen Check brake linesfordamage I jJ 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 L Check swinging fork pivot I Check adjust steering head bearing L Check all chassis bolts for tight fit fork plates axle nuts props Check spoke tension and rim joint Check tire condit
23. HEAT Place the adjusting plate on the cylinder and set pistons to TDC see diagram If the measurement is correctly adjusted the feeler gauge will lie flush on the pistons and on the cylinder Adjust the 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 Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 6 6E Mount the cylinder head Mount the cylinder head 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 Ib 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 8 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 O 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 1b Remove oil filler
24. Repair manual KTM MINI 50 air liquid cooled 2 4 Working on clutch cover NOTE dismantling the clutch cover is neccessary if parts are damaged or the O ring is leaking Turn kickstarter shaft 6 counter clockwise and remove ratchet gear 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 T MUST STRESS RELIEVED WHEN THE KICKSTARTER SHAFT IS PULLED OUT Clean kickstarter shaft and renew O ring up to the 2003 model NOTE make shure that the O ring is mounted in the second groove 6 starting with the 2004 model a shaft seal ring O 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 and 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 to prevent the kickstarter shaft from hitting
25. 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 gt choose leaner carburetor adjustment low altitude or low temperatures gt 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 1 E Motorex Cross Power 2T 1 LOW GRADE OIL CAN CAUSE EXCESSIVE WEAR OF THE 5 USING TOO MUCH OIL THE ENGINE CAN START SMOKING AND FOUL THE 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 and the idle adjus
26. 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 9E Overhaul the water pump LC engine Remove cover discard the O rings Remove circlip with a suitable wrench Remove the water pump wheel from the pump shaft O Press out shaft press out both bearings and Remove seal shaft ring 6 NOTE a spring 6 is installed starting with the 2004 model Remove before disassembling Press a new seal shaft ring 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 and onto the pump shaft O Lightly grease pump shaft and press the pump shaft with the bearings in all the way into the ignition cover 8 check for smooth operation Mount the water pump wheel and the circlip Mount cover 1 with a new O ring Mount the spring 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 crack
27. 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 nsert woodruff key in the output shaft groove Place the gear of the primary drive on the output shaft collar first Slide on the nut lock washer NOTE the tab of the lock washer 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 15 mounted Heat the left half of the case on a heating plate and mount Bolt 7 allan bolts into place NOTE and are M6x40 6 and O are M6x35 bolts Tighten to crosswise to 10 Nm 7 ft Ib Tighten to to 10 Nm 7 ft Ib 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 with a sharp knife for a flush fit 6 3E Wrap insulating tape around the output shaft in the area of the sharp edge 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 15 mounted Grease the seal
28. atically 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 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 6 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 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 for the grooved ball bearing of the crankshaft and the connection for the gearbox ventilation for clearance 9 3E Working on the left half of the engine case Remove shaft sealing rings 9 6 and heat engine case halves on a heating plate to approx
29. ations tightening torques Periodic Maintenance Schedule 9 2001 9 2002 9 2003 4 2004 1 2005 Edition 7 2005 INTRODUCTION This repair manual offers extensiv repair instructions and 15 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 15 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 150 9001 REG NO 12 100 6061 In accordance with the international quality management 150 9001 standard KTM uses quality assurance processes that lead to the highest possible product quality 2004 by KTM SPORTMOTORCYCLE AG Mattighofen AUSTRIA All ri
30. avel front rear 175 190 mm 6 9 7 5 in 115 185 mm 4 5 7 3 in Rear suspension Central shock absorber Paioli Front brake Disk brake 160 mm 6 4 in Drum brake 90 mm 3 5 in Rear brake Drumbrake 0 90 mm 3 5 in Tires front rear 2 50x12 Pirelli MT32A 2 75x10 MT320 2 50 10 Pirelli MT32A 2 75x10 MT320 Tire pressure front rear 1 0 bar 1 0 bar front rear 1 0 bar 1 0 bar Fuel tank capacity 2 liter 0 5 gallons Final drive ratio 11 48 Chain 1 2x3 16 104 rolls 1 2x3 16 96 rolls Steering angle 66 66 Wheel 1030 mm 40 in 910 mm 35 8 in Seat height unloaded 650 or 675 mm 25 6 or 26 6 in adjustable 530 or 550 mm 21 or 21 7 in adjustable Ground clearance 255 mm 10 in Rider s body height max 130 cm 51 in STANDARD ADJUSTMENT FORK 50 SENIOR MINI ADVENTURE Spring 2 0 N mm Preload 10 mm 0 4 in Fork oil SAE 7 5 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 8 12 TECHNICAL DATA ENGINE 2005 LC TYP Design 90 SX PRO JUNIOR LC 90 SX PRO SENIOR LC single cylinder 2 stroke engine with reed valve inlet Displacement Bore Stroke 49 0 ccm 39 5 40 mm Fuel SUPER fuel research octane no 95 mixed with 2 stroke oil Oil gasoline ratio Lubrication 1 40 when using high grade 2 stroke oil Motorex 2T
31. bolt and add 150 200 ccm gear oil Dexron 11 Motorex ATF Super remount oil filler bolt and tighten to 5 Nm 4 ft 1b 7 1E TROUBLE SHOOTING 7 INDEX TROUBLE SHOOTING 50 1 2 IGNITION MEASUREMENT 50 1 4 MEASUREMENT WITH PEAK VOLTAGE ADAPTER 1 4 Art Nr 3 206 028 E Repair manual KTM MINI 50 air liquid cooled Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled Engine fails to start Engine without idle running Less power of engine Operating error Fuel supply interrupted Electrode distance too large Plug fouled by oil wet or bridged Ignition wire or spark plug connector damaged Kill button wire or short circuit switch faulty Loose ignition cable connectors Spark too weak Water in the carburetor and jets blocked Idle adjusting bolt out of adjustment Ignition system damaged Wear Air filter obstructed Fuel supply partly interrupted or blocked Loss of compression due to loose spark plug Exhaust system damaged Engine has not preignition enough Reed paddles tensionless or damaged surface of reed valve housing damaged Wear 1 2E TROUBLE CAUSE REMEDY Open fuel tap replenish fuel do not use choke 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
32. dle bearing needle bearing Piston rings rectangular ring Primary drive straight cut spur gears 16 571 Transmission oil 0 15 0 2 liter gear oil Dexron Motorex ATF Super Spark plug Electrode gap NGK BR 8 ECM 0 6 mm Carburetor Dell Orto PHVA 14 DS Dell Orto PHVA 12 XS Airfilter wet foam type air filter insert BASIC CARBURETOR SETTING MODEL 50 SENIOR ADVENTURE 50 MINI ADVENTURE Dell Orto PHVA 12 XS Type Dell Orto PHVA 14 DS Main jet 80 70 211 FA Needle jet 211 FA Idling jet Jet needle Needle position from top Air Mixture reg screw open 35 slide starting jet Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 8 15E TECHNICAL SPECIFICATIONS CHASSIS 2006 AC cassis SO SENIOR ADVENTURE SO MINIADVENTURE Frame single downtube split cradle Fork Marzocchi 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 Paioli Front brake Disk brake 160 mm 6 4 in Drum brake 90 mm 3 5 in Rear brake Drumbrake 0 90 mm 3 5 in Tires front rear 2 50x12 Pirelli MT32A 2 75x10 MT320 2 50 10 Pirelli MT32A 2 75x10 MT320 Tire pressure front rear 1 0 bar 1 0 bar front rear 1 0 bar 1 0 bar Fuel tank capacity 2 liter 0 5 gallons Final drive ratio 11 48 Chain 1 2x3 16 104 rolls 1 2x3 16 96 rolls Steering angle 66 66
33. e and should be removed with a suitable wrench NOTE water pump shafts from the 2004 model have a hole containing a spring Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 4 4 Remove ignition stator Pull cable guide from the case Remove allan bolts of the ignition stator Carefully pull stator 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 6 Remove gasket AC engine or O rings LC engine from cylinder and discard Loosen 4 bolts 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 4 Pull off ignition rotor Hold ignition rotor with special tool 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 from the chain sprocket and remove chain sprocket Bolt extractor to
34. example Motorex Cross Power 2T CAUTION Hose LEADING FROM THE 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 from the oil tank and oil line O from the oil pump Add two stroke engine oil for separate lubrication with a syringe until the bubble free oil leaks out of hole on the oil pump Connect the oil line to the oil tank Use the syringe to bleed the oil line 6 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 5mm Ch anging front brake fluid not Mini Adventure Move the hand brake cylinder into horizontal position Disassemble the cover together with the rubber boot 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 on the brake caliper Make sure the brake fluid reservoir is always filled with enough fresh brake fluid Tighten the bleeder screw and attach the dust cap O 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
35. ghts reserved Reprint also in extracts with written allowance of KTM SPORTMOTORCYCLE AG Mattighofen only Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 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 quoting or describing the respective passage of the text f 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
36. he rubber grommet for the bolt Connect fuel hose to the carburetor and secure Slide air filter box into the frame bracket Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 3 6E Attach connection of the air filter box to 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 is inserted properly Insert quick release 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 Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled DISASSEMBLING THE ENGINE INDEX SPECIAL TOOLS ENGINE ics AREA XC 4 2 FIXING THE ENGINE ae 4 3 DRAINING 01 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
37. he top edge of the reservoir Remount the rubber boot cover and screws 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 IS BASED ON SILICONE OIL AND 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 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 3 1E REMOVING AND REFITTING ENGINE 3 INDEX REMOVING THE ENGINE 3 2 INSTALLING THE ENGINE 3 4 Art Nr 3 206 028 E Repair manual KTM MINI 50 air liquid cooled Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 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 eng
38. ine To avoid burns allow the motorcycle to cool before starting to work Jack up the motorcycle on a sturdy work stand Turn quick release 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 on the air filter box of the carburetor and remove air filter box Pull air filter box up through the retaining bracket by deforming it Close fuel cock and disconnect fuel hose Q from the carburetor Loosen retaining on tank and remove from tank together with the rubber grommet Lift tank from the frame Open chain joint and remove chain Loosen hose clamp 8 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 6 Unbolt radiator cap open drain plug 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 Ib Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 3 4 Loosen hose clamp and pull both hoses from
39. inging 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 WHEELS CHASSIS BRAKES ADD ON PARTS CARBURETOR ENGINE IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES 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 9 MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled SE VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each start after every cleaning for cross country 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 b
40. ion and inflation pressure Check chain chain wheels chain wheel guides for wear tight ft and tension O Lubricate chain Check wheel bearings for play IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER once MAINTENANCE WORK DONE BY AUTHORISED WORKSHOPS IS NOT SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER WHEELS CHASSIS BRAKES ADD ON PARTS CARBURETOR ENGINE Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 9 3E VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC gt before each start after every cleaning for cross countr Check transmission oil level 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 9 4 PERIODIC MAINTENANCE 2003 2005 air liquid cooled Service Service A washed motorcycle can be checked more quickly which saves money every every 5 hours 20 hours Check engine for leak Change transmission of 0 0 Check spark plug change it if necessary set electrode gap Do Check the clutch engagement speed A Check carburetor for tight fit at intake flange oo S i S Check intake flange for cracks ea Check idle setting when engine is warm Check cooling system for leaks antifreeze protection
41. l Dexron Shell Donax TA Dell Orto PHVA 14 DS PHBG 19 BS 0 5 liter 0 132 USgal water coolant 2 2 1 Oil gasoline ratio BASIC CARBURETOR SETTING Model 50 MINI ADVENTURE SO JUNIOR SENIOR 50SXPRO JUNIOR LC 50 SX PRO SENIOR LC ADVENTURE Dell Orto PHVA 14 DS Dell Orto PHVA 14 DS Dell Orto PHVA 14 DS Dell Orto PHBG 19 BS Be _____ __ 9 ewm 9 9 8 4 p OTT OTT ugouu peojaid Suuuds G Z AVS G Z AVS MIOHS LNANISNIAV GuvaNvis A404 IN3A1SRnfav quvaNviS 1ySiam poq 5 82 87 GE 115191 poq sept u 9 92 9 g2 lq lsn pe 6 9 0389 ar T 9 9Z 9 GZ lqel1sn pe ww G 9 0G9 Qzv2uust9 wzezuuoog pepeojun Iys ay 1695 51101 YOT YT EXZ T 51101 96 ST EXZ T sllol YOT 9U EXZ T sllol 96 91 EXZ T 7 Jeq O T 184 911101 emsseiei OZE LIN OTXGZ Z ZE LIN OTXOS z 2891 1001 oOyT NJA OTX0S Z ul g g 06 0 exeiquinaq ALQ eos Ul 2 9 091 Y eyeiq 251 g g 06 exeiq wnq og quo S d dM 19310538 yoous 6 1199 DEIN 19410548 x2ous e1ua uoisuedsns 1 6 DET xeu ul 69 SgT G T Ul B Z E G QOZ GET 69 O61 S I ul Z G E G WU vec GET ul 7 G y 1894 4404 9
42. l clearance with a sliding gauge O 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 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 Art Nr 3 206 028 E Repair manual KTM MINI 50 air liquid cooled 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 tighten the bolts to 10 Nm 7 ft Ib Mount the ignition cover and water pump Put the dowels 7x9x10 in place Align the driving slot on the water pump drive with the driver blade 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 Bolt 3 HH bolts M6x25 into ignition cover and tighten to 10 Nm 7 ft 1b 6 5E Mount the pistons Fix co
43. linder diameter in the X and the Y axis to establish any ovality 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 0 055 0 065 mm 0 00216 0 00256 in C engine 0 045 0 055 mm 0 00177 0 00216 in 39 505 39 510 mm L5533 15535in 1 5557 1 5559 1 5553 1 5555 B 39461 39465 mm 39 521 39 525 mm 39 511 39 515 mm L5535 15537in 1 5559 1 5561in 1 5555 1 5657 in 15537 15539in L5561 1 5563in 1 5557 1 5509 in D 39471 39475 mm 39 531 39 535 mm 39 521 39 525 mm 15539 1 5541in 1 55663 1 5565 1 5559 1 5561in 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 9 7E So 200 Clutch new S 2 Sor MOE Overhauling the centrifugal clutch Loosen HH bolts on the clutch shoes and remove together with the set of springs from
44. nrod 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 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 on the cylinder base bolting crosswise to a torque of 18 Nm 13 ft Ib Mount a new seal AC engine or insert new O rings in the recesses LC engine Adjust measurement NOTE Measurement is the distance from the upper piston edge to the upper cylinder edge piston set in TDC position and cylinder base bolts tightened Measurement must be set with special care adjusting various thicknesses of cylinder base gaskets CAUTION THE 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 THE MEASUREMENT IS TOO SMALL THIS MEANS THAT A GAP IS VISIBLE BETWEEN CYLINDER AND ADJUSTING PLATE THE ENGINE WILL PING AND OVER
45. on system Stator Unplug the ignition stator and measure the resistance of the stator using a digital measuring tool The resistance must be 500 2 40 O at 20 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 lgnition coil between high tension lead and mass of the coil The resistance must be 2250 250 Q at 20 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 Apply the red measuring lead of the peak voltage adapter to the connector and the black measuring lead to the ground disconnect connector from the ignition coil 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 Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled TECHNICAL SPECIFICATIONS INDEX MODEL 2002 ENGINE aes dora
46. our repair manual Item no of repair manual Current text Correct text Additional suggestions requests or comments on our Repair Manuals in German or English Name mechanic shop foreman Company work shop Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 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 5 5 2 6 2 1E Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 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 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
47. ox 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 after every 2222 2 eee Check the reed ye intake vale for mear Check the clutch shoes for wear es Check the length of the clutch Springs Check the clutch drum for we Check the water pump shaft and bearings for ear Check the water pump wheel for wear Check the cylinder and piston for wear A EM ___ _ _ NE NE 0 AN Check the oil pump only separate lubrication Check the eccentricity of the crankshaft journal NOTE F THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED THE RESPECTIVE COMPONENTS MUST BE REPLACED 10 1E WIRING DIAGRAM 10 INDEX WIRING DIAGRAM 10 2 Art Nr 3 206 028 E Repair manual KTM MINI 50 air liquid cooled 10 2 vOOC Oc 105 XS PV 511010
48. prox 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 Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 2 4 Bleeding oilpump for separate lubrication up to model 2003 Clamp oil lines and 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 8 After bleeding the oil pump mount both oil lines and fill the oil tank with 2 stroke engine oil for
49. res front rear 2 50x10 Pirelli MT32A 2 75x10 MT320 2 50x12 Pirelli MT32A 2 75x10 MT320 Tire pressure front rear 1 0 bar Fuel tank capacity 1 8 Liters Final drive ratio 11 48 Chain 1 2x3 16 96 rolls 1 2x3 16 102 rolls Steering angle 662 66 Seat height unloaded 585 mm 610 mm 23 24 in 650 675 mm 25 6 26 6 in Ground clearance 220 mm 8 6 in 255 mm 10 in Rider s body height max 130 cm 51 in Rider s body weight max 35 kg 78 lbs Engine SD EC STANDARD ADJUSTMENT FORK Spring 2 0 N mm Preload 10 mm 0 4 in Fork oil SAE 7 5 Air chamber length 110 mm 4 3 in STANDARD ADJUSTMENT SHOCK ABSORBER JUNIOR LC SENIOR LC WP 03189A01 WP 03189A02 Rebound adjuster 5 5 Spring 85 N mm 45 N mm Spring preload 10 mm 0 39 in mm 0 28 in 8 14 TECHNICAL DATA ENGINE 2006 AC Design single cylinder 2 stroke engine with reed valve inlet Displacement Bore Stroke 49 0 com 39 5 40 mm Fuel Lead free SUPER FUEL ROZ 95 mixed with 2 stroke oil Lead free SUPER FUEL ROZ 95 Lubrication Oil gasoline ratio mixture lubrication separate lubrication 1 60 2 stroke oil 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 2 grooved ball bearing Connecting rod bearing Piston pin bearing nee
50. s and other damage Reed valve housing Measure the distance 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 17 mm Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 3 6 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 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 nsert 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 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 cy
51. 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 ap
52. 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 for your personal convenience The respective headings can be entered in the list of contents Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled KIM EXPLANATION UPDATE This repair manual contains the following supplements 3 210 24 E Repair Manual 50 AC LC Basic version Model year 2002 3 210 64 E Updating of Rep Manual 3 210 24 Model year 2003 Engine number with first digit 3 3 206 010 E Updating of Rep Manual 3 210 24 E Model year 2004 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 Specific
53. the clutch hub O NOTE coilsprings 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 make sure the spring washers are placed exactly in the same order shown below only LC engine Washers Q 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 C 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 Q from any set of springs can be inserted between the clutch hub and clutch shoes see Fig 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
54. 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 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 and lock washer from the output shaft Remove gear Q on the primary drive from the shaft remove woodruff key O 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 9 1E SERVICING INDIVIDUAL COMPONENTS 5 INDEX RIGHT HOUSING HALF 9 2 LEFT HERE HERO RR ROS RR E 9 3 CRANKSHAFT tid nennen RES 9 3 ULUTGH COVER cuiu d te aie ar re onr 9 4 WATER PUMP 54 55 m ma A ss 9 9 REED VALVE HOUSING INTAKE FLANGE 9 9 PISTON asesor rara 9 6 PISTON RING END GAP 9 6 CHECKING CYLINDER FOR WEAR 9 6 CLUIGH C 9 1 SPRINGS OF
55. the rotor with 2 M4x35 bolts hold extractor in place and pull rotor O off by bolting in the extractor bolt Remove woodruff key from the groove Split the casing halves Loosen all 7 allan bolts holding the two casing halves together and set aside Bolt extractor to the casing with 2 M5x50 bolts 6 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 from canting CAUTION 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 Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 4 6E Disassemble the clutch and primary drive Rechuck the engine to provide access to the clutch side Remove kickstarter and bolts on the clutch cover Remove clutch cover discarding the seal WARNING DO NOT REMOVE THE CIRCLIP e OTHERWISE THE KICKSTARTER SPINDLE MAY FALL FROM THE CASING AND THE KICKSTARTER SPRING CAUSE INJURIES Block the centrifugal clutch with a suitable mandrel 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
56. the rubber boot cover and screws 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 IS BASED ON SILICONE 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 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 Art Nr 3 206 028 Repair manual KTM MINI 50 air liquid cooled 2 6E Changing rear brake fluid 50 SX 50 Supermoto Move the vehicle in a vertical position Disassemble the cover together with the rubber boot 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 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 Add DOT 5 1 brake fluid Motorex Brake Fluid DOT 5 1 up to 15 mm under t
57. their connections Unbolt radiator retaining bolt and laterally remove radiator with water hoses from the frame Carefully pull socket connector apart Detach both exhaust springs O with a suitable wrench remove springs Unbolt the exhaust bracket on the right and pull exhaust off towards the front Loosen engine mounting bolts and 0 lift engine from the frame Installing the engine Lift engine into the frame and fasten with bolt M8x65 with nut and 2 bolts O M8x55 Tighten bolts to 30 Nm 22 ft Ib Mount exhaust insert springs and tighten bolt for exhaust bracket M6x15 on the right Carefully connect socket connector Position radiator in the frame and tighten the radiator retaining bolts 6 10 with washer 18 6 5 1 5 to 10 Nm 7 ft lb Connect hoses and tighten hose clamps Fill cooling liquid total filling amount approx 0 5 liter Mount radiator shield on the right and left NOTE bolts M6x10 are bolted onto the side of the frame bolt 6 M6x15 is bolted into the radiator bracket 7 Install carburetor on the intake flange and tighten hose clamp 0 Place chain on rear sprocket and pinion mount chain joint 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 t
58. ting screw 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 main jet and part throttle setting the engine sputters and smokes when the jet needle 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 gt jet needle Part throttle range C Operation with partly open throttle valve This range is only influenced gt pe S XS ESA GI 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 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
59. uojsid p u uolsid p u 3ulJeaq Buijpouuoj 3ulJeaq 8 2 3ulJeaq yeysyueig 12 55049 12 55019 1 e1eJedes 10 5110 94041S 0M ape13 y31y 5110 2115 spe43 USIU opis ajes ay uo eq 0 XIU ee I 95 Jo non 1961109 aseajd ui 49MOg 55019 2 940 45 2 usiu SUISN uaym T 5 amp 36 ZON 1404 YIANS 96 ZOM 83415 19 1 euigue 15 1 ajauis 21 YOINIS XS 06 91 30INRf XS OS oamxiu DY YOINAS uoneohqnl ayesedas JV ININ Ba 006 JIVIVOS ANIINA VIVO TVIINHIiL 3 860 906 OG WAY Jenueu 8 BASIC CARBURETOR SETTING Model Type Main Jet Needle jet Idling jet Jet needle Needle position from top Air Mixture reg screw open Slide starting jet BASIC CARBURETOR SETTING Model Type Main Jet Needle jet Idling jet Jet needle Needle position from top Air Mixture reg screw open Starting jet 50 MINI ADVENTURE 50 SENIOR ADVENTURE SEPARATE LUBRICATION MIXTURE LUBRICATION Dell Orto PHVA 1
60. xhaust 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 30 A5 60 90 120 135 Ten EON NN EON ELI e NON M EN EM NL NOTE THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED THE RESPECTIVE COMPONENTS MUST BE REPLACED 9 PERIODIC MAINTENANCE 2006 Service Service before A washed motorcycle can be checked more quickly which saves money every every every 5 hours 20 hours race Check engine for leaks Change transmission oil Check spark plug change it if necessary set electrode 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 sw
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