Konica Minolta Z3 Digital Camera User Manual
Contents
1. 5 mm General information about KTM disc brakes BRAKE FLUID RESERVOIRS The brake fluid reservoirs for the front brake is designed such that it does not need to be refilled even if the brake shoes are worn If the brake fluid level drops below the minimum level either the brake system has a leak or the brake pads are completely worn In this case consult an authorized KTM dealer immediately BRAKE FLUID KTM fills the brake system with Shell Advance Brake DOT 5 1 one of the best brake fluids currently available We recommend that you continue to use it DOT 5 1 brake fluid is based on glycol ether and of an amber color If you do not have any DOT 5 1 for refilling you may use DOT 4 brake fluid DOT 4 shown on the lid means minimum standard However you should replace it as soon as possible by DOT 5 1 A WARNING A HAVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY IF YOU WASH YOUR MOTORCYCLE OFTEN THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE FREQUENTLY BRAKE FLUID TENDS TO ABSORB WATER THEREFORE VAPOR POCKETS MAY FORM IN OLD BRAKE FLUIDS EVEN AT LOW TEMPERATURES CAUSING THE BRAKE SYSTEM TO FAIL BRAKE DISC Due to wear the thickness of the brake disc in the area of the contact face 0 of the brake pads decreases At their thinnest point the brake discs must not be more than 0 40 mm 0 016 in thinner than the pad s nominal thickness Measure the nominal thickness in a location outside the2. 24 Instructions for the first ride 10 syste ia ea pad oe DO dn 24 10 Checking coolant 25 Cleaning the air Titer 25 DRIVING INSTRUCTIONS enr ctt i Dinan 11 25 What you should check before each start 11 Changing the seat night beraten 26 Starting when engine is cold 12 Adjusting the throttle cable 26 Starting when engine is 12 Adjusting the idle speed Dell Orto PHVA 14 DS 26 What to do when the engine is flooded 12 Adjusting the idle speed Dell Orto PHBG 19 85 26 STAIN S OT niuri 12 Checking the gear ON Te Vel 27 II Io femen dv 12 Change tie sear o bid 27 Puoi reer re Ec DN 13 SLO DOING axesesas 13 TROUBLE SHOOTING m Or SAP REM ERO s 28 PROTEC MINS o aerae det n dde a addon Bd Dupin td rid 13 CLEANING Z STORAGE s tu pu exa 30 PERIODIC MAINTENANCE SCHEDULE
3. Basic suspension setup for the weight of the driver To achieve maximum handling performance and to prevent the telescopic fork and shock absorber from being damaged the basic setup of the suspension components must be suitable for your child s weight At delivery KTM s mini motorcycles are set to accommodate a driver weighing 25 30 kg wearing full protective clothing If your child s weight exceeds or falls short of this range you will need to adjust the spring preload for the telescopic fork and shock absorber accordingly To adjust check the sag of the shock absorber and telescopic fork The motorcycle should be filed up and your child should be wearing full protective clothing To determine the sag of the shock absorber Jack up the motorcycle until the rear wheel no longer touches the ground Measure the vertical distance between the rear wheel axle and a fixed point e g a mark on the side cover and write it down as dimension A Place the motorcycle on the ground again Have your child sit on the motorcycle in a normal seating position feet on the footrests wearing full protective clothing and bounce up and down a few times to allow the rear wheel suspension to become level Holding your child and the bike have another person measure the distance between the same two points with the load on the motorcycle to establish dimension B The sag is the difference between dimensions A and B
4. 14 TECHNICAL DATA ENGINE 31 MAINTENANCE WORK ON CHASSIS AND ENGINE 16 REMOV INS pret 16 TECHNICAL CHASSIS 32 Checking and adjusting the steering head bearing Junior 16 Checking and adjusting the steering head bearing Senior 17 HEADSVVORDUINDIEX ta Ru cibi ios ui 33 SERIAL NUMBER LOCATIONS Chassis number The chassis number is located on the type plate on the steering head Enter this number in the field on page no 1 Engine number The engine number is stamped into the right half of the engine case next to the kickstarter Enter this number in the relevant field on page 1 Engine typ 50 MCH OPERATION INSTRUMENTS Throttle grip The throttle grip is located on the right side of the handlebars It is used to reduce the engine speed and thus the driving speed Hand brake lever The hand brake lever is located on the right side of the handlebars and actuates the front wheel brake The basic position can be adjusted to fit your child s hand Short circuit button The short circuit button turns off the engine When pressing this button the ignition circuit is short circuited Filler cap To open it turn filler cap counter clockwise To close it put filler cap back on and tighten it by turning it clockwise Install tank breather hose without kinks Fuel tap The fuel tap is located at t
5. 9V OIC AN MV SINOIDDNYLSNI 3d IYNNYW X d 4113434010WI1d 0dS NOILLVSITLLO CO TANNVW OSN d FJIVANVW IWANVW S adaNMO ONALITINVSONANAIGA 27 401 35 Od XS OS 27 YOINNS Odd XS OS IMPORTANT PLEASE READ THIS MANUAL THOROUGHLY BEFORE LETTING YOUR YOUNGSTER RIDE THE MOTORCYCLE FOR THE FIRST TIME THIS MANUAL CONTAINS IMPORTANT INFORMATION AND RECOMMENDATIONS THAT WILL HELP YOU AND YOUR YOUNGSTER TO OPERATE AND HANDLE THE MOTORCYCLE PROPERLY IN THE INTEREST OF EVERYBODY INVOLVED WE URGE YOU TO PAY PARTI CULAR ATTENTION TO INSTRUCTIONS AND INFORMATION MARKED AS FOLLOWS A WARNING A IGNORING THESE INSTRUCTIONS CAN BE DANGEROUS TO LIFE AND LIMB CAUTION IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE MOTORCYCLE OR IMPAIR THE MOTORCYCLE S TRAFFIC SAFETY Please insert the serial numbers of the motorcycle below Stamp of dealer KTM SPORTMOTORCYCLE AG RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT TECHNICAL SPECIFICATIONS COLORS MATERIALS SERVICES OFFERED AND RENDERED AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT PRIOR NOTICE ANNOUNCEMENT AND WITHOUT GIVING REASONS OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUB STITUTING THEM WITH OTHERS SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS ANNOUNCEMENT IN THE EVENT OF SUCH MODIFICATIONS PLEASE ASK YOUR LOCAL KTM DEALER FOR INFORMATION Introduction Now you own a mo
6. 16 Replacing the front brake 22 RUNDINS siden or 10 Seal number te 6 Setting the basic position and play of the hand brake lever 21 SHOE CIRCUIT DUTTON 3 0 Oc Ope Ud atn 6 SIMS Sa ierat dao mad ue prt pauta dam tet 8 Starmie IT votado sae RS ERR PER ERA RUNS RAD SERRE EARS 12 Starting when engine is 12 Starting when engine is warm 12 DIME e m 13 Tecpnical data CHASSIS a 32 Technical data 31 Telescopic fork 19 REO c 6 Tires iq pues 24 To determine the sag of the shock 18 To determine the sag of the telescopic fork 18 TROUDISSNOOUINE Tc 28 What to do when the engine is flooded 12 What you should check before each start 11 3901910 5110 31242HO010W JINVAGY 0229 27177 95072917517 DV ATDADYOLOWLYOdS WLI 9vOLct
7. 2 Kick the side up all the way or remove the plug in stand 3 Apply the front brake 4 Operate the kickstarter depressing it all the way without opening the throttle What to do when the engine is flooded 1 Close fuel tap 2 Applying the front brake 3 Start engine with full throttle If necessary unscrew spark plug and dry it 4 Once the engine is running open fuel tap again Starting off Slowly release the brake lever while simultaneously opening the throttle AN WARNING AN ALWAYS MAKE SURE THE SIDE STAND IS KICKED ALL THE WAY UP OR THE PLUG IN STAND REMOVED BEFORE YOU LET YOUR CHILD DRIVE OFF THE MOTORCYCLE COULD RUN OUT OF CONTROL IF THE STAND TOUCHES THE GROUND Driving The engine speed and thus the driving speed are regulated by the throttle grip The choke must always be deactivated as soon as the engine has warmed up AN VVARNING AN AFTER FALLING WITH THE MOTORCYCLE CHECK ALL ITS FUNCTIONS THOROUGHLY BEFORE USING IT AGAIN BENT HANDLEBAR MUST ALWAYS BE REPLACED NEVER TRY TO STRAIGHTEN THE HANDLEBAR BECAUSE THIS WILL CAUSE IT TO LOSE ITS STABILITY CAUTION DRIVING A COLD ENGINE HIGH SPEED WILL REDUCE THE LIFE OF THE ENGINE WE RECOMMEND TO WARM THE ENGINE UP AT A MEDIUM ENGINE SPEED FOR SEVERAL MINUTES BEFORE SWITCHING TO FULL LOAD NEVER TILT THE MOTORCYCLE OVER THE SIDE STAND TO WARM UP THE ENGINE THE SIDE STAND COULD FOLD AWAY AND THE MOTORCYCLE RUN OUT OF CONT
8. 30 mm x 5 mm 50 SX Pro Senior LC telescopic fork sag 45 mm x 5 mm If the sag is lower the spring preload of the telescopic fork must be reduced if the sag is higher the spring preload must be increased The preload on the fork spring is determined by the length of preload spacer f an adjustment is necessary demount the fork legs remove the plugs and shorten the pretensioning sleeves or replace with longer ones see maintenance of telescopic fork Harder fork springs are also available for both models see spare parts catalog Telescopic fork maintenance The telescopic fork must be serviced at least once a year To service the fork proceed as follows Prop up the motorcycle under the frame to take the load off the front wheel Disassemble the front wheel remove screw from the brake caliper and unscrew holding clamp Measure the projection of the fork legs at the upper fork stabilizer and make a note of the measurement Loosen the clamping screws on the fork stabilizers and pull the fork legs down out of the fork stabilizers CAUTION NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN DISMOUNTED MAKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL OTHERWISE THE BRAKE DISC CAN BE DAMAGED Clamp the fork leg into a vise use protective jaws and remove the plugs Take the preload spacer and the spring out of the fork tube Remove screws at the u
9. EXAMPLE Motorcycle jacked up dimension 400 mm Motorcycle on ground with driver seated dimension B 355 mm oo ___ 45 mm 50 SX Pro Junior LC shock absorber sag 45 mm x 5 mm 50 SX Pro Senior LC shock absorber sag 50 mm x 5 mm If the sag is lower the spring preload of the shock absorber must be reduced if the sag is higher the spring preload must be increased A harder spring is also available for the 50 SX Pro Senior LC see spare parts catalog To determine the sag of the telescopic fork Jack up the motorcycle until the rear wheel no longer touches the ground Measure the distance between the upper edge of the slider tube and the triple clamp and write it down as dimension C Have your child sit on the motorcycle in a normal seating position feet on the footrests wearing full protective clothing and bounce up and down a few times to allow the telescopic fork to become level Holding your child and the bike have another person measure the distance between the same two points with the load on the motorcycle to establish dimension D The sag is the difference between dimensions C and D EXAMPLE Motorcycle jacked up dimension 200 mm Motorcycle on ground with driver seated dimension D 160 mm _ 40 50 SX Pro Junior LC telescopic fork sag
10. OTHERWISE THE CARBURETOR MAY GET FLOODED AND FUEL WILL ENTER THE ENGINE THE SIDE STAND OR PLUG IN STAND IS DESIGNED TO HOLD THE WEIGHT OF THE MOTORCYCLE ONLY SITTING ON THE MOTORCYCLE YOUR CHILD WILL PUT ADDITIONAL WEIGHT ON THE SIDE STAND POSSIBLY CAUSING THE SIDE STAND OR FRAME TO BE DAMAGED OR THE MOTORCYCLE TO FALL DOWN Refueling fuel Oil high grade two stroke engine oil must be mixed with the fuel ROZ 95 at a mixing ratio of 1 40 Fuel and engine oil should only be mixed immediately before use KTM recommends SHELL ADVANCE RACING X A WARNING A GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS EXTREME CAUTION SHOULD BE USED WHEN HANDLING GASOLINE NEVER REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARETTES ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELING BE CAREFUL NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT WIPE UP SPILLS PROMPTLY IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES SEEK A DOCTOR S ADVICE IMMEDIATELY CAUTION ONLY USE PREMIUM GRADE GASOLINE ROZ 95 MIXED WITH HIGH GRADE TWO STROKE ENGINE OIL OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE ONLY USE KNOWN BRANDS OF HIGH GRADE 2 STROKE ENGINE OIL SHELL ADVANCE RACING X NOT ENOUGH OIL OR LOW GRADE OIL CAN CAUSE EROSION OF THE PISTON WHEN USING TOO MUCH OIL THE ENGINE MAY START SMOKING AND FOUL THE SPARK PLUG FUEL EXPANDS WHEN ITS TEMPERATURE RISES THEREFORE DO NOT FILL THE T
11. Examine ignition system Dismantle and clean carburetor Readjust idle running or replace idle adjusting screw 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 TROUBLE CAUSE REMEDY Engine stalling or running Carburetor overflows if level adjust Clean carburetor if necessary replace float needle and adjust with four stroke cycle too high float needle seating is level dirty or enlarged Loose carburetor jets Tighten jets High rpm misfiring Incorrect heat range spark plug or Refer to technical data section low quality spark plug Loose corroded or non conductive Check and seal with silicon ignition socket connector Engine spluters into the Lack of fuel Clean fuel pipes examine tank aeration and clean carburetor Spark plug with incorrect heat value Fit correct spark plug Ignition by incandescence Engine takes air out of control Check intake flange and carburettor if firmly setted Engine overheating Insufficient liquid in cooling system Top up coolant and bleed cooling system check cooling system for leaks Radiator fins clogged Clean radiatar fins with water jet Frothing in cooling system Renew coolant using branded anti freeze anti corrosive Shell Advance Coolant Pinched or kinked water hoses Re
12. PREVENT WATER INGRESS WHEN TRANSPORTING YOUR MOTORCYCLE SECURE IT WITH ELASTIC STRAPS OR OTHER MECHANICAL DEVICES IN AN UPRIGHT POSITION BE SURE THAT THE FUEL IS CLOSED THE MOTORCYCLE TOPPLES OVER FUEL CAN FLOW OUT OF THE CARBURETOR OR FUEL TANK DO NOT USE TOOTHED WASHERS OR SPRING RINGS WITH THE ENGINE FASTENING SCREWS AS THESE WORK INTO THE FRAME PARTS AND KEEP WORKING LOOSE INSTEAD USE SELF LOCKING NUTS LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED DISPOSE OF OILS FATTY MATTERS FILTERS FUELS WASHING DETERGENTS ETC PROPERLY UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIDE 1 LITER OF USED OIL CONTAMINATES 1 000 000 LITERS OF WATER Removing the seat The quick release mechanism allows removal of the seat without tools Turn the quick release device approximately 180 counterclockwise lift the rear portion of the seat and pull the seat off backwards When mounting the seat ensure that the hook engages at the tank Checking and adjusting the steering head bearing 50 SX JUNIOR The steering head bearing should be checked regularly for play For this purpose jack up the motorcycle by the frame so that the front wheel is in the air Now try to move the fork forward and backward There should be no clearance For readjustment release the two clamp screws of the top triple clamp and the counternut T
13. contact face Check wear in several locations A WARNING A A BRAKE DISK WORN DOWN 0 40 0 016 IN OR MORE IS A SAFETY RISK HAVE THE BRAKE DISK REPLACED AS SOON AS IT REACHES THE SERVICE LIMIT HAVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BA A KTM DEALER BRAKE CALIPERS Secure the screws on the brake caliper with Loctite 243 and tighten to a torque of 20 Nm Setting the basic position and play of the hand brake lever You can adjust the basic position of the hand brake lever to fit your child s hand by turning stop screw Afterwards be sure to adjust the play of the hand brake lever to 2 mm 0 08 in with the adjusting screw To adjust remove covering cap Replace the covering cap after making the adjustment CAUTION AT THE HAND BRAKE LEVER FREE TRAVEL MUST AT LEAST BE 2 MM 0 08 IN ONLY THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED TO BE RECOGNIZED BY THE GREATER RESISTANCE OF THE HAND BRAKE LEVER THIS FREE TRAVEL IS NOT PROVIDED PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM AND THE FRONT WHEEL BRAKE MAY FAIL DUE TO OVERHEATING Checking refilling the front brake fluid level Put the hand brake cylinder in a horizontal position remove screws and cover Q with diaphragm If necessary refill DOT 5 1 e g Shell Advance Brake 5 1 brake fluid up to 5 mm 0 2 in under the upper edge of the tank Remount the diaphragm cover and screws Wash off any overflowing or spilled brake f
14. indicator opening If oil must be added tilt the motorcycle and pour automatic gear oil Shell Donax TA into the bore CAUTION LESS OIL POOR OIL QUALITY LEAD TO PREMATURE TRANSMISSION WEAR THEREFORE ONLY USE BRANDED PRODUCTS SHELL Donax TA Changing gear oil The engine must be warmed up before changing the gear oil Park the motorcycle on a horizontal surface remove the oil drain plug and drain the used oil into an appropriate container Clean the sealing surface mount the oil drain plug together with the gasket and tighten to 15 Nm Remove stopper and fill in 0 15 liters of automatic gear oil Shell Donax TA Mount the stopper and check the engine for tightness CAUTION LESS OIL POOR OIL QUALITY LEAD TO PREMATURE TRANSMISSION WEAR THEREFORE ONLY USE BRANDED PRODUCTS SHELL Donax TA 4 m 2 T NJ mJ TROUBLE SHOOTING If you let the specified maintenance work on your motorcycle be carried out disturbances can hardly be expected Should an error occur nevertheless we advise you to use the trouble shooting chart in order to find the cause of error We would like to point out that many operations cannot be performed by oneself In case of uncertainty please contact a KTM dealer TROUBLE CAUSE REMEDY Engine fails to start Engine without idle run ning Less power of engine Operating error Fuel supply interrupted Electrode distance too large Plug foule
15. is reduced Dirty radiators additionally reduce the cooling effect The cooling liquid can be drained by removing screw on the water pump cover A WARNING A DO NOT REMOVE ANY COOLER HOSES OR THE DRAIN SCREW WHEN THE ENGINE IS HOT A mixture of 40 antifreeze liquid and 60 water is used as coolant How ever the antifreeze protection must be at least 25 C 13 F This mixture offers antifreeze protection but also good corrosion protection and should therefore not be replaced by pure water _ CAUTION FOR THE COOLING SYSTEM USE ONLY WITH HIGH GRADE ANTIFREEZE SHELL ADVANCE COOLANT USING LOWER GRADE ANTIFREEZE AGENTS CAN CAUSE CORROSION AND COOLANT Pressure induced by heating of the coolant in the system is controlled by a valve in the radiator cap a water temperature rising up to 120 C 248 is admissible without fear of problems Checking coolant level The coolant should be 10 mm 0 4 in above the radiator fins when the engine is cold see illustr In the event of the coolant being drained always an fill and bleed the system t 10mm A WARNING A IF POSSIBLE ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD IF YOU when engine is cold HAVE TO OPEN THE RADIATOR CAP WHEN THE ENGINE IS HOT USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE Cleaning the air filter The air filter must be cleaned at intervals depending on the amount of dust accu
16. it does not need to be refilled even if the brake shoes are worn If the brake fluid falls below the minimum level the brake system is either leaking or the brake shoes are completely worn out Have the brake system checked at a KTM workshop to avoid brake failure Also have the condition of the brake hose and the brake lining thickness checked Check the play of the hand brake lever and foot brake lever 7 THROTTLE CABLE Check the throttle cable for proper adjustment and smooth operation ZN 97 Starting when the engine is cold Open fuel tap Operate the choke Kick the side up all the way or remove the plug in stand Apply the front brake Operate the kickstarter depressing it all the way without opening the throttle OW A WARNING A WHEN STARTING THE ENGINE PUT ON MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES YOU MAY SLIP OFF THE KICKSTARTER OR THE ENGINE MAY KICK BACK IF YOU DO NOT KICK HARD ENOUGH DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING CAUTION DON T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND HIGH REVS WHEN ENGINE IS COLD BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLINDER IT CAN CAUSE ENGINE DAMAGE Starting when the engine is warm 1 Open fuel tap
17. skills on soft ground e g on a meadow or in the garden Be sure that there is room enough to maneuver and that no other riders are close To ensure that your youngster gets the feel of the brakes have your youngster operate the brakes while you push the motorcycle Do not start the engine before your youngster has learned to apply both brakes with appropriate pressure Now your youngster must get the feel of the throttle Start the engine hold the motorcycle and have your youngster slowly open the throttle Then your youngster can take his her first ride Initially your youngster should ride back and forth between two persons who help the young rider to stop the motorcycle However you should also teach your youngster how to stop the motorcycle himself herself To improve his her riding skills your youngster should practise to ride the motorcycle standing on the footpegs or riding at the slowest possible speed Additionally you can arrange a series of obstacles and have your youngster drive around them etc Tell your youngster to look 3 10 m ahead depending on the speed to recognize and avoid obstacles When riding through curves the rider should also look far ahead into the curve Pay attention to running in procedure Running in Even very precisely machined sections of engine components have rougher surfaces than components which have been sliding across one another for quite some time Therefore every engine needs to be
18. technical specifications Tire condition has to be checked every time you want to ride your motorcycle Before leaving check tires for punctures and nails or other sharp objects that might have become embedded in them Regularly check the cold tire pressure Correct tire pressure 1 0 bar 14 psi guarantees optimum grip and maximum tire life A WARNING A DAMAGED TIRES MUST BE REPLACED IMMEDIATELY TO PROTECT YOUR YOUNGSTER WORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW THE MOTORCYCLE PERFORMS ESPECIALLY ON WET SURFACES TIRE PRESSURE BELOW THE NORMAL LEVEL WILL LEAD TO PREMATURE TIRE WEAR Checking spoke tension The correct spoke tension is very important for the stability of the wheels and thus for riding safety A loose spoke causes the wheel to become unbalanced and before long other spokes will have come loose Check spoke tension especially on a new motorcycle at regular intervals If neces sary have the spokes retightened and the wheel centered by a KTM dealer A WARNING A SPOKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE THIS MAY LEAD TO AN UNSTABLE HANDLING OF YOUR MOTORCYCLE EXCESSIVELY TENSIONED SPOKES MAY RUPTURE DUE TO LOCAL OVERLOADING THE SPOKES MUST BE TENSIONED TO 2 5 3 NM Cooling system The water pump in the engine keeps the cooling liquid in circulation The cooling liquid is cooled by the air stream Therefore the cooling effect is reduced when the traveling speed
19. 85 mm 6 9 7 4 in Rear suspension Central shock absorber WP Front brake Disk brake 160 mm 6 4 Tires front rear 2 50x10 Pirelli MT32A 2 75x10 MT320 2 50x12 Vee Rubber V270 2 75x10 V271 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 16 104 rolls Steering angle 63 64 Wheel base 914 mm 36 in 1030 mm 40 in Seat height unloaded 590 mm 615 mm 23 2 24 2 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 78 165 Recommended age of rider 6 10 years Engine 50 LC TIGHTENING TORQUES Hexagon nuts front rear axle Hexagon nut swing arm bolt M12 40 Nm Screws handlebar clamp M8 20 Nm Allan screw Handlebar support M10 Loctite 40 Nm Spoke nipple 2 5 3 5 M6 Other chassis screws 6 Nm 10 Nm 25 Nm 45 Nm STANDARD ADJUSTMENT FORK STANDARD ADJUSTMENT SHOCK ABSORBER Preload 10 mm 0 4 in Rebound adjuster Fork oil SAE 7 5 Spring 85 N mm 45 N mm Air chamber length 110 mm 4 3 in Spring preload 7 mm 0 28 in 7 mm 0 28 in HEAD WORD INDEX Page Adjusting the control cable on the rear wheel 22 Adjusting the idle speed Dell Orto PHBG 19 BS 26 Adjusting the idle speed Dell Orto PHVA 14 DS 26 Adjusting the throttle
20. ANK TO THE TOP SEE FIG PERIODIC MAINTENANCE SCHEDULE 2003 Cooled SPORTMOTORCYCLES water cooled Service Service A clean motorcycle can be checked more quickly which saves money every every 5 hours 20 hours Check engine for leaks Change transmission oil Check spark plug change it if necessary set electrode gap Check carburetor for a tight fit at intake flange Check intake flange for cracks Check idle setting when engine is warm Check cooling system for leaks check quantity of antifreeze Check exhaust system for leaks and suspension Check actuating cables for damage smooth operation and kinkless arrangement adjust and lubricate Clean air filter and air filter box Check brake fluid level lining thickness brake discs Check the brake line and the brake control cable for damage Check function adjust smooth operation free travel of handbrake footbrake levers BRAKES ADD ON PARTS CARBURETOR Check screws of brake system for a tight fit Check suspension strut and fork for leaks and a proper function Check swinging fork pivot Check adjust steering head bearing CHASSIS Check all chassis screws for a 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 joint chain wheels chain wheel guides for wear a tight fit and tension Lu
21. Correct TENSION dabo 20 DEVIIS 12 Drivin S MISC HCIIODS 11 Drum brake maintenance 23 Engine number engine 6 EXMQUS Syste bibere 25 ICA UNE 7 FOO EID lak ClEV EF stich 8 e re etre oer TA Conn 7 Page General tips and warnings for starting the motorcycle 10 Generel information about KTM disc brakes 21 Drake TEVE leis tre dei tede ete 6 How to change the handlebar position 17 Important information on safe driving for parents 4 Instructions for the first 10 sects NUS 7 Maintenance work on chassis and engine 16 COberatton TES deo verte e 6 Periodic maintenance schedule 14 s Stand pate bia teg Oda dieu dd e rin bres bet 8 Rebound damping function of the shock absorber 8 Refueling TUE decades rir rab Gent ona d obo neben 13 Removing and mounting the front 23 Removing and mounting the rear wheel 23 REMOVING Sea soda
22. ENGINE IS RUNNING A WARNING A KTM MINI MODELS ARE DESIGNED FOR ONE PERSON ONLY PASSENGERS ARE NOT ALLOWED THESE MODELS DO NOT COMPLY WITH THE REGULATIONS AND SAFETY STANDARDS ESTABLISHED BY THE LAW THEREFORE THEY ARE NOT PERMITTED ON PUBLIC ROADS ALWAYS KEEP IN MIND THAT OTHER PEOPLE FEEL MOLESTED BY EXCESSIVE NOISE DRIVING INSTRUCTIONS What you should check before each start When you start off the motorcycle must be in a perfect technical condition For safety reasons you should make it a habit to perform an overall check of your motorcycle before each start The following checks should be performed 1 CHECK TRANSMISSION OIL LEVEL A lack of gear oil leads to premature wear and finally results in destruction of the gear wheels 2 FUEL Check that there is sufficient fuel in the tank when closing the filler cap check that the tank venting hose is free of kinks 3 COOLING FLUID Check the level of cooling fluid when the engine is cold 4 CHAIN A loose chain was fall off the chain wheels an extremely worn chain may tear and insufficient lubrication may result in unnecessary wear of the chain and chain wheels 5 TIRES Check for damaged tires Tires showing cuts or dents must be replaced Also check the air pressure Insufficient tread and incorrect air pressure deteriorate the driving performance 6 BRAKES Check for proper functioning check brake fluid level in the tank The tank is designed such that
23. M uses quality assurance processes that lead to the highest possible product quality REG NO 12 100 6061 IMPORTANT INFORMATION FOR PARENTS ABOUT SAFE DRIVING KTM mini motorcycles are off road motorcycles designed for one person only They are not allowed on public roads The vehicle dimensions and components are designed for children from 6 to 10 years of age with a maximum weight of 35 kg 78 lbs and a maximum height of 130 cm 51 in Have your youngster wear proper protective gear whenever he or she rides the motorcycle helmet eye protection chest back arm and leg protectors gloves and boots To set a good example be sure to wear protective gear yourself whenever riding a motorcycle Before your youngster takes his or her first ride explain how each of the controls works and check if your youngster has understood what you explained We recommend to review the entire owner s manual with your youngster item by item paying particular attention to the specially marked warnings and pointing out the danger of injury Instruct your youngster about riding and falling techniques explain how the motorcycle will respond to shifting of the rider s weight etc Before starting the motorcycle for the first time check whether the basic fork and shock absorber settings are suitable for your child s weight see chapter on checking the basic chassis setting Before using the motorcycle you should always check all compone
24. MINI LC ENGINE BY YOUR KTM WORKSHOP ADDITIONAL ORDER FOR THE KTM WORKSHOP 30 hours 45 hours 60 hours 90 hours 120 135 hours hours Check the length of the clutch springs Check the clutch drum for wear Check the water pump shaft and bearings for wear Check the water pump wheel for wear Check the reed type intake valve for wear Check the clutch shoes for wear Check the cylinder and piston for wear Check the eccentricity of the crankshaft journal Check the radial clearance of the conrod bearings Check the radial clearance of the piston pin main bearing Check the crankshaft main bearing for wear Replace the crankshaft bearings and conrod bearings Check the entire transmission including bearings for wear NOTE IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED THE RESPECTIVE COMPONENTS MUST BE REPLACED MAINTENANCE WORK ON CHASSIS AND ENGINE A WARNING A MAINTENANCE WORK AND ADJUSTMENTS MARKED WITH AN ASTERISK MUST BE PER FORMED BY AN EXPERT TO PROTECT YOUR YOUNGSTER ALWAYS HAVE SUCH WORK PER FORMED BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED SKILLED STAFF CAUTION WHEN CLEANING THE MOTORCYCLE DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE OTHERWISE WATER WILL PENETRATE THE BEARINGS CARBURETOR ELECTRIC CONNECTORS DRUM BRAKES ETC BEFORE CLEANING WITH WATER PLUG THE EXHAUST PIPE TO
25. OO GREAT PARTS WITHIN THE SECONDARY TRANSMISSION CHAIN CHAIN WHEELS GEAR BOX AND REAR WHEEL BEARINGS WILL BE SUBJECTED TO UNNECESSARY STRESS RESULTING IN PREMATURE WEAR AND EVEN CHAIN BREAKAGE TOO MUCH SLACK IN THE CHAIN ON THE OTHER HAND CAN RESULT IN THE CHAIN JUMPING OFF THE CHAIN WHEELS IF THIS HAPPENS THE CHAIN COULD ALSO BLOCK THE REAR WHEEL OR DAMAGE THE ENGINE IN EITHER CASE THE OPERATOR IS LIKELY LOSE CONTROL OF THE MOTORCYCLE Correct chain tension Release the hexagon nut of the wheel spindle and turn the left and the right hexagon nut equally far Before tightening the hexagon nut of the wheel spindle to 30 Nm ensure that the supporting plates are resting against the swing arm Additionally check that the rear wheel is aligned with the front wheel Chain maintenance For long chain life good maintenance is very important Chains without O rings should be cleaned in fireproof solvent regularly and afterwards treated with hot grease or chain spray Shell Advance Bio Chain AN VVARNING AN KEEP THE REAR WHEEL FREE OF GREASE GREASE ON THE REAR WHEEL WILL SIGNIFICANTLY REDUCE THE GRIP OF THE REAR TIRE AND THE MOTORCYCLE COULD EASILY GET OUT OF CONTROL CAUTION WHEN MOUNTING THE CHAIN MASTERLINK CLIP THE CLOSED SIDE OF THE MASTERLINK CLIP MUST POINT IN RUNNING DIRECTION Also check sprockets and chain guides for wear and replace if necessary E o Amm
26. ROL IN THE EVENT THAT WHILE YOUR CHILD IS RIDING ON THE MOTOR CYCLE YOU NOTICE ANY UNUSUAL OPERATION RELATED NOISE YOUR CHILD SHOULD STOP IMMEDIATELY TURN THE ENGINE OFF AND CONTACT AN AUTHORIZED KTM DEALER Braking Close the throttle and squeeze both brake levers simultaneously On sandy wet or slippery terrain the rear wheel brake should be preferred The brakes should always be operated carefully as locking wheels can cause skidding or falls A WARNING A BRAKE DRUM AND LININGS HEAT UP DURING BRAKE OPERATION THUS REDUCING THE EFFECT OF THE BRAKES WET BRAKES HAVE REDUCED BRAKE PERFORMANCE THEREFORE BE SURE TO BRAKE THEM DRY AFTER CLEANING F THE RESISTANCE OF THE HAND BRAKE LEVER FEELS UNRESPONSIVE SOMETHING IS WRONG WITH THE BRAKE SYSTEM HAVE THE BRAKE SYSTEM CHECKED AT A KTM WORKSHOP BEFORE YOU LET YOUR CHILD DRIVE THE MOTORCYCLE Stopping Reduce the speed Immediately before the motorcycle comes to a stop put the left foot down To turn off the engine press the short circuit button until the engine stops Close the fuel tap A WARNING A MOTORCYCLES PRODUCE GREAT HEAT DURING OPERATION THEREFORE KEEP IN MIND THAT THE ENGINE THE EXHAUST SYSTEM AND THE BRAKES CAN HEAT UP CONSIDERABLY MAKE SURE THAT THESE PARTS ARE NOT TOUCHED AND ALWAYS TAKE CARE WHEN PARKING THE MOTORCYCLE THAT OTHER PERSONS WILL NOT BURN THEMSELVES CAUTION CLOSE THE FUEL WHEN LEAVING THE MOTORCYCLE
27. SIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE AFTER MOUNTING THE FRONT WHEEL KEEP OPERATING THE HAND BRAKE UNTIL THE PRESSURE POINT RETURNS T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED Removing and mounting the rear wheel Prop up the motorcycle under the frame Remove hexagon nut on the wheel spindle and disk Hold the rear wheel and remove the wheel spindle Move the rear wheel forwards remove chain lift the rear wheel out of the swinging fork and remove the brake anchor To mount the wheel reverse the procedure described above Always hook the brake backing plate into the swing arm support Before tightening the hexagon nut of the wheel spindle ensure that the supporting plates are resting against the swing arm Additionally check that the rear wheel is aligned with the front wheel Tighten the hexagon nut to 30 Nm A WARNING A IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE Tires air pressure Tire type tire condition and air pressure level affect the way your motor cycle rides and they must therefore be checked whenever you are getting ready to go anywhere on your motorcycle Tire size can be found in the
28. 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 aggressive 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 approx 5 ccm of engine oil into the cylinder through the opening Actuate kickstarter 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 footrests etc a
29. bricate chain WHEELS Check wheel bearings for play IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER once a year Drain and clean the carburetor s float chamber Perform complete fork maintenance Clean lubricate the swinging arm bearing Clean and lubricate the steering head bearing and sealing elements Change brake fluid MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS A SUBSTITUTE FOR AND CHECKS DONE BY THE RIDER VITAL CHECKS AND CARE PROCEDURES TO CONDUCTED BY THE OWNER OR THE Check transmission oil level before each after every cleaning for cross country use 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 box Check tire inflation pressure and wear Check fuel line for leaks Drain and clean float chamber 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 screws nuts and hose clamps for their tight fit at regular intervals ULL RECOMMENDED INSPECTION OF THE
30. broken in Do not load the engine to the power limit during the first half hour for this reason Apply low but changing loads for running in NO FULL LOAD OPERATION DURING THE FIRST HALF HOUR A WARNING A HAVE YOUR YOUNGSTER WEAR PROPER PROTECTIVE GEAR WHENEVER HE OR SHE RIDES THE MOTORCYCLE HELMET EYE PROTECTION CHEST BACK ARM AND LEG PROTECTORS GLOVES AND BOOTS TO SET A GOOD EXAMPLE BE SURE TO WEAR PROTECTIVE GEAR YOURSELF WHENEVER RIDING A MOTORCYCLE THE MOTORCYCLE HAS A CENTRIFUGAL CLUTCH THE MOTORCYCLE BEGINS TO MOVE AS SOON AS THE THROTTLE IS OPENED ALWAYS APPLY THE FRONT BRAKE WHEN STARTING THE ENGINE AND RELEASE THE BRAKE SLOWLY WHEN THE ENGINE IS RUNNING AN ACTIVA TED CHOKE INCREASES THE IDLE SPEED OF THE ENGINE THE CENTRIFUGAL CLUTCH THUS BEGINNING TO ENGAGE THEREFORE THE MOTORCYCLE CAN BEGIN TO MOVE WHEN THE BRAKE LEVERS ARE RELEASED WHEN THE ENGINE SPEED DROPS TO THE LEVEL AT WHICH THE CENTRIFUGAL CLUTCH DISENGAGES BRAKING WITH THE ENGINE IS NO LONGER POSSIBLE AND THE MOTORCYCLE CAN ONLY BE SLOWED DOWN USING THE BRAKES YOUR CHILD SHOULD NEVER DRIVE FASTER THAN ITS SKILLS AND THE TERRAIN PERMIT NEVER LET YOUR CHILD DRIVE ITS MOTORCYCLE UNCHAPERONED REPLACE THE HELMET VISOR OR GOGGLE GLASSES EARLY ENOUGH WHEN LIGHT SHINES DIRECTLY ON A SCRATCHED VISOR OR GOGGLES YOU WILL BE PRACTICALLY BLIND ONLY USE ACCESSORY PARTS RECOMMENDED BY KTM NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE
31. cable 26 Basic suspension setup for the weight of the driver 18 SCIT TS 13 Chaintmatnteridtite Eam d rr 20 Changing spring preloading of the shock absorber 20 Changing the basic position of the foot brake 22 Cha Sine the Sedit Oll ome eb Da 27 Changing the seat nie DE er lene 26 Changing the telescoping fork 19 CHASSIS EET 6 Checking and adjusting the steering head bearing Junior 16 Checking and adjusting the steering head bearing Senior 17 Checkine coolant IeVel sisi aic co b vu HO Ad 25 Checking spoke tension 24 Checking the chain 5 20 Checking the front brake 22 Checking te Seadr oll level Dus titor isis 27 Checking the rear brake linings for wear 22 Checking refilling the front brake fluid level 21 Choke DELL ORTO PHBG 19 5 7 Choke DELL ORTO PHVA 14 7 Cleaning 5 0 erudi 30 Cleaning the 25 Cleaning the dust scrabbers of the telescopic fork 20 COONS SV SUSI 24
32. d by oil wet or bridged Ignition wire or connector damaged spark plug Kill button wire or short circuit switch faulty Loose ignition cable connectors Spark too weak Water in the carburetor and jets blocked Idle adjusting screw out of adjust ment 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 enough preignition Reed paddles tensionless or dama ged surface of reed valve housing damaged Wear 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 out check tank ventilation i e clean fuel tap Reduce electrode distance 0 60 mm 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 f a 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
33. dern motorcycle that you and your youngster will certainly enjoy provided that you service and maintain it properly This manual contains important information on the operation and maintenance of your new KTM motorcycle It went to press describing your model s latest state of development Nevertheless the descriptions may deviate slightly from the current design as our motorcycles are permanently improved The Owner s Manual is an integral part of the motorcycle and must be handed over to the new owner when the motorcycle is sold We expressly point out that work marked with an asterisk in the chapter Maintenance work on the chassis and engine must be performed by a KTM workshop If maintenance work should become necessary during a competition it must be performed by a trained mechanic Please strictly observe the prescribed running in periods and inspection and maintenance intervals Compliance with these instructions will significantly prolong the life of your motorcycle Be sure to have the maintenance work carried out by a KTM workshop to avoid losing your right to claim under the warranty For the safety of your child only use spare parts and accessories approved by KTM KTM shall not assume any liability for other products or consequential damage resulting from the use of such products When special needs arise please contact a KTM dealer who will seek the assistance of the KTM importer if necessary PARENTS SHOULD KEEP IN MIND
34. e steering head screw to a torque of 10 Nm and the 2 clamping screws to 15 Nm A WARNING A THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF CLEARANCE THE MOTORCYCLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL CAUTION THE HANDLEBAR MUST MOVE EASILY OTHERWISE THE BEARINGS WILL BE DAMAGED F YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS THE BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME WILL BE DESTROYED At least once a year the steering head bearings should be smeared with waterproof grease Shell Advance Grease How to change the handlebar position The handlebar position can be readjusted by 22 mm 0 9 in The upper triple clamp O includes 2 bores arranged at a distance of 15 mm 0 6 in from one another The bores at the handlebar support are offset from the center by 3 5 mm 0 13 in Accordingly you can mount the handlebar in 4 different positions For this purpose remove screws Q of the handlebar clamps and screws of the handlebar support Position handlebar support and tighten screws to 40 Nm Mount handlebar and handlebar clamps and tighten screws to 20 Nm The gap between the handlebar support and handlebar clamps should be the same size in the front and in the rear CAUTION THE SCREWS MUST BE SECURED WITH LOCTITE 243 E 2 T E EN
35. e stop Make sure it rests securely on solid ground Plugin Stand 50 SX PRO SENIOR A socket is provided on the left side of the frame for the plug in stand included in the scope of supply Rebound damping function of the shock absorber The damping effect of the rebound damping mechanism can be adjusted by means of the setting wheel Turn the setting wheel clockwise in to increase and counterclockwise out to reduce the damping effect STANDARD SETTING 5 CLICKS OPEN A WARNING A NEVER TURN THE SETTING WHEEL MORE THAN TWO CLICKS BETWEEN TWO TEST RIDES DO NOT TRY TO DISASSEMBLE THE SHOCK ABSORBER OR TO PERFORM MAINTENANCE WORK YOURSELF DANGER OF INJURY GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for the first ride Verify that your KTM dealer performed the PREPARATION OF VEHICLE jobs see Customer Service Manual Before your youngster takes his or her first ride explain how each of the controls works and check if your youngster has understood what you explained We recommend to review the entire owner s manual with your youngster item by item paying particular attention to the specially marked warnings and pointing out the danger of injury Adjust the basic position of the hand brake lever to fit the size of your child s hand You child should of course wear gloves Adjust the foot brake lever to your child s seating position To prevent injury teach your youngster the basic riding
36. er and the cable support measured with the brake lever squeezed is less than 50 mm 2 in see illustration CAUTION THE BRAKE LININGS ARE REPLACED TOO LATE I E WHEN THE LINING IS PARTLY OR FULLY WORN AWAY THE METAL SHOES WILL RUB AGAINST THE BRAKE DRUM THUS REDUCING THE BRAKING EFFECT AND DESTROYING THE BRAKE DRUM Drum brake maintenance Drum brake maintenance is limited to occasional blowing out of the brake drum and brake shoes Brake drum and brake linings can be slightly roughened with an abrasive tape Removing and mounting the front wheel Jack the motorcycle up by the frame so that the front wheel is suspended above the ground Undo the hexagon nut and remove it together with the washer Hold the front wheel and pull out the wheel spindle Carefully take the front wheel out of the fork CAUTION DO NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN DISMOUNTED MAKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL OTHERWISE THE BRAKE DISC CAN BE DAMAGED Lift the front wheel into the fork and correctly position it Mount the wheel spindle Mount the washer and the hexagon nut and tighten 30 Nm Put the motorcycle back on the ground and operate the front wheel brake until the working point is reached A WARNING A F YOU DON T HAPPEN TO HAVE A TORQUE WRENCH HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POS
37. fusi eta dr 20 SHOR 6 Generel information about KTM disc brakes 21 REE tere 7 Setting the basic position and play of the hand brake 21 Fuel 7 Checking refilling the front brake fluid level 21 Choke DELL ORTO PHVA 14 5 7 Checking the front brake 22 Choke DELL ORTO PHBG 19 BS 7 Replacing the front brake pads 22 a cet tu 7 Changing the basic position of the foot brake lever 22 FOOL Drake TEVE E ipse nnd T Eo RUE anemones 8 Adjusting the control cable on the rear wheel 22 OD ECL 8 Checking the rear brake linings 22 PIU SUR SCAG ipic 8 Drum brake maintenarice uiuere e edo 23 Rebound damping function of the shock absorber 8 Removing and mounting the front wheel 23 Removing and mounting the rear wheel 23 GENERAL TIPS AND WARNINGS FOR STARTING THE WIRES mui 24 MOTORG 10 CHECKING spoke
38. he front of the motorcycle on the left side of the tank Opening the fuel tap Turn the knob all the way to the left Closing the fuel tap Turn the knob all the way to the right Choke Dell Orto carburetor PHVA 14 DS Choke lever is mounted to the right side of the carburetor If you move the choke lever up to the stop a hole is opened in the carburetor through which the engine can draw in additional fuel This results in a rich fuel air mixture required for a cold start Moving the choke lever back closes the hole in the carburetor again Choke Dell Orto carburetor PHBG 19 BS Choke control knob is mounted to the left side of the carburetor If you pull the choke control knob up to the stop and turn it 90 a hole is opened in the carburetor through which the engine can draw additional fuel This results in a rich fuel air mixture required for a cold start Turning back the choke control knob returns the knob to the starting position and closes the hole in the carburetor again Kickstarter The kickstarter is mounted on the right side of the engine Its upper part can be swivelled NOTE an accessory kit for kickstarter backwards operation is available axi e 7 Foot brake lever The foot brake lever is located in front of the right footrest The basic position can be adjusted to the seating position see maintenance work Side stand Use your foot to swing the side stand forwards to th
39. ings and pretensioning sleeves into the fork tube Check O rings grease and mount plugs Mount the fork legs front wheel and brake caliper see above COCIGBC ICO X Cleaning the dust scrabbers of the telescopic fork The dust protection bellows are to remove dust and coarse dirt particles from the fork tube However after some time dirt may also get in behind the dust protection bellows If this dirt is not removed the oil sealing rings located behind it may start to leak For this purpose use a screwdriver to lift the dust scrabbers out of the slider tubes clean them thoroughly with compressed air spray the fork tubes and dust scrabbers with silicon oil and press the scrabbers back into the slider tubes Changing spring preloading of the shock absorber This is easily done NOTE Before changing the spring preload note down the basic setting e g how many threads are visible above the adjusting ring Remove the right side cover Loosen the locking ring with the hook spanner Change the spring preload with the adjusting ring and re tighten the locking ring BASIC SETTING SPRING PRELOAD 7 mm 0 3 in Check chain tension Put the motorcycle on the sidestand Chain tension has to be checked close to the lower rear shock mounting When pushing the chain upwards the distance to the swingarm has to be 10 mm 0 4 in If necessary correct chain tension A WARNING A IF CHAIN TENSION IS T
40. ke caliper thoroughly with compressed air 22 Mount the right brake shoe and fix with screw Mount the left brake shoe and tighten the screw to 6 Nm Mount the lock washer Align brake shoes mount front wheel see chapter Mounting the front wheel A WARNING A IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED AFTER ASSEMBLY CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY DO NOT UNSCREW ANY OTHER SCREWS ON THE BRAKE CALIPER OR YOU WILL HAVE TO BLEED THE BRAKE SYSTEM AFTER WORKING ON THE BRAKE SYSTEM ALWAYS OPERATE THE HAND BRAKE LEVER TO APPLY THE BRAKE PADS TO THE BRAKE DISK AND CREATE A POINT OF PRESSURE Changing the basic position of the foot brake lever The basic position of the foot brake lever can be changed by unscrewing screw and then turning the retainer Afterwards check the setting of the rear wheel brake Adjusting the control cable on the rear wheel You should be able to press the foot brake lever 5 to 10 mm 0 2 0 4 in before the rear wheel begins to brake The brake control cable is adjusted with adjusting screw on the brake anchor cover First loosen lock nut and then tighten again CAUTION AFTER MAKING ADJUSTMENTS ALWAYS SURE THE WHEEL TURNS FREELY Checking the rear brake linings for wear The brake linings must be replaced when the distance between the hub brake lev
41. luid with water A WARNING A NEVER use DOT 5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT STORE BRAKE FLUID OUT OF REACH OF CHILDREN BRAKE FLUID CAN CAUSE SKIN IRRITATION AVOID CONTACT WITH SKIN AND EYES IF YOU GET BRAKE FLUID IN YOUR EYES RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR CAUTION DON T LET BRAKE FLUID GET IN CONTACT WITH PAINT IT IS AN EFFECTIVE PAINT REMOVER USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER Checking front brake pads Inspect the brake pads from in front of the vehicle The linings must be at least 1 mm 0 04 in thick A WARNING A AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM 0 04 IN OTHERWISE THEY COULD LEAD TO BRAKE FAILURE FOR YOUR OWN SAFETY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED CAUTION THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY WORN THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC Replacing the front brake pads Remove the front wheel see front wheel chapter Press brake shoes apart with a suitable screwdriver to put the brake pistons in their basic position Remove the lock washer from the screw as well as fixing screw and take the brake shoes out of the brake caliper Clean bra
42. mulated To clean the air filter first remove the seat Then press both retaining clips remove the filter holder and the air filter The air filter consists of a foam rubber insert soaked with filter oil CAUTION DO NOT CLEAN THE FOAM FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE THE FOAM RECOMMENDS THE PRODUCTS MADE BY TWIN AIR FOR AIR FILTER MAINTENANCE NEVER OPERATE YOUR MOTORCYCLE WITHOUT AN AIR FILTER OTHERWISE DUST AND DIRT MAY GET INTO THE ENGINE AND LEAD TO INCREASED WEAR THE HOLDER MUST RETAIN THE AIR FILTER THROUGHOUT ITS ENTIRE CIRCUMFERENCE THE FILTER HAS BEEN MOUNTED INCORRECTLY THE ENGINE WILL TAKE IN UNFILTERED AIR THEREBY CAUSING INCREASED ENGINE WEAR ENGLISH NJ Ul Thoroughly wash the foam filter in special cleaning fluid and allow it to dry well Only press out the filter do not wring it out under any circumstances Oil the dry foam filter with a high grade filter oil Also clean the air filter box Check carburetor collar for damage and that it is filled correctly Insert the air filter in the opening and fasten it with the filter holder Then mount the seat Exhaust system The silencer is filled with glass fiber yarn for damping When in use the glass fiber yarn becomes loose or coked with oil carbon This can lead to a power loss and a reduction of the silencer damping The glass fiber yarn packing can be replaced in a few easy steps To replace remove
43. nderside of the slider tubes and pull the fork tubes out of the slider tubes Remove the dust scrabbers ENGLISH Thoroughly clean all parts and check wear Generously lubricate seals and springs and reassemble the telescopic fork Tighten the screws on the bottom of the sliding tubes to 30 Nm Fill in fork oil and assemble the fork see below Degrease the screws on the brake caliper and apply Loctite 243 Mount the brake caliper and tighten to 20 Nm Mount brake line and holding clamp Insert fork legs in the fork stabilizers projection as previously noted and tighten clamping screws to 15 Nm Mount front wheel see chapter mounting the front wheel A WARNING A THE SCREWS MUST BE SECURED WITH LOCTITE 243 Changing the telescopic fork oil Remove front wheel and fork legs see above Remove plugs preload spacers and springs Drain the fork oil into an appropriate container Clean the dust scrabbers A WARNING A IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED AFTER WORKING ON THE BRAKE SYSTEM ALWAYS OPERATE THE HAND BRAKE LEVER TO APPLY THE BRAKE SHOES TO THE BRAKE DISK AND HAVE A POINT OF PRESSURE Pour 170 cm SAE 7 5 fork oil into each fork tube Slide the fork tube all the way into the slider tube Adjust the air chamber length A to 110 mm 4 5 in by extracting or adding fork oil Insert spr
44. nts for proper operation see mainenance schedule Have your youngster perform these technical checks himself herself as well Whenever you go for a ride with your youngster keep in mind that the speed should be adjusted to your youngster and not the other way around Your youngster must understand that all instructions he or she receives from you or any other supervising adult must be followed Your child must be physically ready to ride a motorcycle This means that he or she must at least be able to ride a bicycle Being good at sports that require fast reactions is an additional advantage Your youngster should be strong enough to pick up the motorcycle after a fall Never demand too much of your youngster Give him or her time to get used to the motorcycle and to improve his her riding skills Do not even consider letting your youngster participate in a race before his her physical condition riding skills and motivation have sufficiently developed Explain to your youngster that he she should always adjust his her riding speed to the local conditions as well as to his her own riding skills and that excessive speed can cause falls and severe injuries Always keep in mind that youngsters tend to underestimate dangers or fail to recognize them altogether The riding speed must be reduced in particular on unknown terrain Never let your youngster ride the motorcycle without supervision An adult should always be
45. place with correct routed hoses Incorrect ignition timing because of Readjust to correct ignition timing specifications secure scr loose stator screws ews with Loctite 243 Incorrect compression ratio Measure and adjust compression ratio Emission of white smoke Cylinder head or O ring of cylinder Check cylinder head replace O ring steam head gasket leaks Excessive oil escapes from Excessive oil quantity in transmissi Correct transmission oil level transmission breather tube 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 HIGH PRESSURED WATER 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 should use commercially available detergents to clean the motorcycle Heavily soiled parts should also be cleaned with the help of a paint brush Before 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
46. present The motorcycle is designed for one rider only Your youngster is not allowed to transport a passenger When you go for a ride somebody at home should always know where you are going and when you will be back This makes it easier to send you help should problems occur 5 Page Page IMPORTANT WARRANTY AND GUARANTEE INFORMATIONE 3 How to change the handlebar position 17 IMPORTANT INFORMATION ON SAFE DRIVING Basic suspension setup for the weight of the driver 18 FOR PARENTS 56 sic m 4 To determine the sag of the shock absorber 18 To determine the sag of the telescopic fork 18 SERIAL NUMBER LOCATIONS 6 Telescopic fork maintenance 19 Chassis HUP DT 6 Changing the telescoping fork oil 19 Engine number engine type eee 6 Cleaning the dust scrabbers of the telescopic fork 20 Changing spring preloading of the shock absorber 20 OPERATION 6 Checking the chain tension 20 6 Correct chalp 20 Hand Drake C t ob d et 6 Cham maintenance cibo
47. rk stabilizer Screw cap Aluminium protrudes from the top of the upper fork stabilizer The shock absorber is attached to the lower hole in the frame Tighten the clamp screws on the fork stabilizers to 15 Nm the screw on the shock absorber to 45 Nm A WARNING A THE FORK TUBES MAY NOT BE LOWERED ANY FURTHER THAN AS DESCRIBED ABOVE OTHERWISE THE CLAMPING ON THE UPPER FORK STABILIZER WILL NO LONGER BE ADEQUATE Adjusting the throttle cable There must always be a 3 to 5 mm 0 1 to 0 2 in play in the throttle cable To check this move back the protective cover on the throttle grip You must be able to lift the outer covering of the cable 3 5 mm from the adjusting screw until resistance is felt To adjust loosen the counter nut 6 and turn the adjusting screw accordingly Finally tighten counter nut and slide the protective cover back on Adjusting the idle speed Dell Orto PHVA 14 DS The idle speed can be adjusted with screw The idle speed is increased by turning clockwise The idle speed is reduced by turning counter clockwise Adjusting the idle speed Dell Orto PHBG 19 BS The idle speed can be adjusted with screw The idle speed is increased by turning clockwise The idle speed is reduced by turning counter clockwise Checking the gear oil level To check the gear oil level first remove the plug With the motorcycle parked in an upright position a small quantity of oil should flow out of the
48. s well as the chain The storage place should be dry and not be subjected to overly great temperature fluctuations Cover the motorcycle with an air permeable tarpaulin or blanket Do not use airtight materials possible humidity might not be able to escape and thereby cause corrosion CAUTION 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 NOTE Before you put your motorcycle away for the winter you should check all parts for their function and wear Should any service jobs repairs or any refitting be necessary you should have them carried out during the off season lower workload at mechanics shops This way you can avoid the long waiting times at your shop at the beginning of the next biking season TECHNICAL DATA ENGINE 50LC 2003 ee ________ 0 SOSXNOSMORIC _ Design single cylinder 2 stroke engine with reed valve inlet Displacement 49 0 ccm Bore Stroke 39 5 40 mm Fuel SUPER fuel research octane no 95 mixed with 2 stroke oil Oil gasoline ratio 1 40 when using high grade 2 stroke oil Shell Advance Racing X When in do
49. that the safety of their youngsters always depends on the efforts made by the parents to ensure that the motorcycle is kept in good working order and only used on safe terrains Nevertheless driving the motorcycle like driving any other vehicle involves a potential risk Therefore please make sure that all fundamental precautions are taken Please also read the INFORMATION ON SAFE DRIVING FOR PARENTS on page 4 Riding an off highway motorcycle is a wonderful form of outdoor recreation and we certainly hope that you and your youngsters will enjoy it to the full However this enjoyable outdoor activity can cause environmental problems or lead to conflicts with other people Responsible use of the motorcycle will prevent such problems and conflicts You can contribute to securing the future of motorcycling by making sure that you and your youngsters only use the motorcycle within the limits established by the applicable laws making environmental protection one of your top priorities and never violating other people s rights In this spirit we hope that you and your youngsters will always safely enjoy your motorcycle KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN AUSTRIA Attachments 1 spare parts manual chassis amp engine ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL KTM SPORTMOTORCYCLE AG AUSTRIA rights reserved IMPORTANT WARRANTY AND GUARANTEE INFORMATIONE KTM mini sports motorcycles are designed and constr
50. the silencer from the vehicle and mark the position of the outer tube to the inner tube 0 Remove screws and the end cap Pull of the outer tube and remove the old glass fiber yarn packing from the inner tube Thoroughly clean all parts To assemble mount a new glass fiber yarn packing onto the inner tube see illustration and slide into the outer tube Mount end cap and fix with screws G Before tightening the screws turn the outer tube until they match the positions you marked Mount the silencer and check the exhaust system for tightness NOTE Glass fiber yarn packages are offered by your licensed KTM dealer A WARNING A THE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUNNING TO AVOID BURNS DO NOT START WORK ON THE EXHAUST SYSTEM UNTIL IT HAS PROPERLY COOLED DOWN Changing the seat height The saddle can easily be raised by 25 mm 1 in This lets you adjust the height as your child grows Figures A and B show the fork and shock absorber positions for a low seat position The fork tubes extend approx 17 mm 0 7 in H above the upper fork stabilizer The shock absorber is attached to the upper hole in the frame Tighten the clamp screws on the fork stabilizers to 15 Nm the screw on the shock absorber to 45 Nm Figures A and B low seat position Figures C and D high seat position Figures C and D show the fork and shock absorber positions for a high seat position Fork tubes are plane with top of upper fo
51. ubt please contact your importer or use 1 33 mix ratio to be on the safe side 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 II Shell Donax TA Spark plug NGK BR 8 ECM Electrode gap Carburetor DellOrto PHVA 14 DS Dell Orto PHBG 19 BS Air filter wet foam type air filter insert Cooling liquid 0 5 litres 4096 antifreeze 6096 water at least 25 13 F BASIC CARBURETOR SETTING Model 50 SX PRO JUNIOR LC 50 SX PRO SENIOR LC Type Dell Orto PHVA 14 DS Dell Orto PHBG 19 BS Main jet 80 85 Needle jet Jet needle A10 W9 Needle position from top 2 3 Air Mixture reg screw open 3 5 3 0 Slide 40 60 TIGHTENING TORQUES ENGINE Primary gear nut M14x1 25 Hexagon nut ignition rotor M10x1 25 Nut of clutch hub M10x1 25 Loctite 243 35 Nm Cylinder head screws M7 15 Nm Cylinder base nuts M8 18 Nm Allan head screw Stator M5x25 Loctite 243 8 Nm Oil plug M16 Oil drain plug M10 Other engine screws M5 M6 M8 TECHNICAL SPECIFICATIONS CHASSIS 50 MINI LC 2003 50 SX PRO JUNIOR LC 50 SX PRO SENIOR LC Frame single downtube split cradle Fork Marzocchi 32 mm 1 26 in Wheel travel front rear 135 200 mm 5 3 8 in 175 1
52. ucted to resist the usual wear and tear of normal use in competitions The motorcycles comply with the regulations and categories currently in effect with the leading international motorcycle associations Observance of the service maintenance and tuning instructions for the engine and chassis specified in the Owner s Manual is a prerequisite for faultless operation and the avoidance of premature wear An improperly tuned chassis can lead to damage and breakage of the chassis components see chapter on checking the basic chassis setting The service work specified in the Lubrication and Maintenance Schedule must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void The fuels and lubricants specified in the Owner s Manual or automotive fluids with equivalent specifications must be used in accordance with the maintenance schedule No claims can be filed under the warranty for damage or consequential damage caused by manipulations or conversions to the motorcycle The use of the motorcycle under extreme conditions e g on extremely muddy and wet terrain can lead to higher than average wear on components such as the drive train or the brakes In this case it may become necessary to service or replace wear parts before the service limit specified in the maintenance schedule has been reached In accordance with the international quality management ISO 9001 standard KT
53. urn the adjusting nut O until almost no play is left Do not tighten the adjusting nut Tightening the adjusting nut can damage the bearings Keep in mind that tightening the counternut reduces the play of the bearing Slightly tap the top triple clamp with a rubber hammer to prevent jamming Then tighten the 2 clamp screws with 15 Nm A WARNING A IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF CLEARANCE THE MOTORCYCLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL CAUTION THE HANDLEBAR MUST MOVE EASILY OTHERWISE THE BEARINGS WILL BE DAMAGED F YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS THE BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME WILL BE DESTROYED At least once a year the steering head bearings should be smeared with waterproof grease Shell Advance Grease Checking and adjusting the steering head bearing 50 SX SENIOR The steering head bearing should be checked regularly for play To check support the motorcycle frame and lift the front wheel off the ground Now try to move the fork back and forth you should not feel any play To adjust loosen both clamping screws on the upper triple clamp and loosen the steering head screw by a few turns Lift the triple clamp slightly and turn the adjusting nut until hardly any play is left Never tighten the adjusting nut since you might damage the bearing Tighten th
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