KTM 50 SX Mini - Repair Manual

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REPAIR MANUAL 2009

50 SX

50 SX Junior

50 SX Mini

Article no. 3206060en

PartShark.com

877-999-5686

Table of Contents

Table of Contents4
Means of Representation7
Important Notes8
Motorcycle9
- Jacking up the Motorcycle9
- Removing the Motorcycle from the Work Stand9
- Starting9
- Vehicle Level10
01/Fork, Triple Clamp11
- Cleaning Dust Boots of Fork Legs11
- Removing the Fork Legs11
- Installing the Fork Legs12
- Servicing Fork12
- Disassembling the Fork Legs13
- Checking the Fork Legs14
- Assembling the Fork Legs15
- Adjusting the Fork Overhang16
- Removing the Lower Triple Clamp17
- Installing the Lower Triple Clamp18
- Greasing the Steering Head Bearing19
- Checking Play of Steering Head Bearing20
- Adjusting the Play of the Steering Head Bearing20
02/Handlebar, Controls and Instruments22
- Checking the Play in the Throttle Cable22
- Adjusting the Play in the Throttle Cable22
- Handlebar Position22
- Adjusting Handlebar Position22
04/Shock Absorber, Swingarm24
- Adjusting the Rebound Damping of the Shock Absorber24
- Measuring Rear Wheel Sag Unloaded24
- Checking the Static Sag of the Shock Absorber24
- Checking the Riding Sag of the Shock Absorber25
- Adjusting the Spring Preload of the Shock Absorber25
- Adjusting the Riding Sag26
- Removing the Shock Absorber26
- Installing Shock Absorber26
- Adjusting Seat Height27
- Servicing Shock Absorber27
- Removing the Spring27
- Disassembling the Damper28
- Disassembling the Piston Rod29
- Removing the Heim Joint30
- Checking the Damper31
- Installing the Heim Joint32
- Assembling the Piston Rod33
- Assembling the Damper (50 SX Junior, 50 SX Mini)34
- Assembling the Damper (50 SX)35
- Filling the Damper with Nitrogen36
- Installing the Spring (50 SX Junior, 50 SX Mini)37
- Installing the Spring (50 SX)38
05/Exhaust40
- Removing the Exhaust Manifold40
- Installing the Exhaust Manifold40
- Removing Main Silencer40
- Installing the Main Silencer41
- Removing the Glass Fiber Yarn Filling of the Main Silencer41
- Installing the Glass Fiber Yarn Filling of the Main Silencer42
06/Air Filter43
- Removing the Air Filter43
- Installing the Air Filter43
- Cleaning Air Filter43
07/Fuel Tank, Seat, Trim44
- Removing the Seat44
- Mounting the Seat44
- Removing the Fuel Tank44
- Installing the Fuel Tank45
08/Mask, Fender46
- Dismounting the Front Fender46
- Installing the Front Fender46
- Dismounting the Start Number Plate46
- Installing the Start Number Plate46
09/Front Wheel48
- Removing Front Wheel48
- Installing the Front Wheel48
- Checking the Tire Condition49
- Checking Tire Air Pressure49
- Checking Brake Discs49
- Checking Spoke Tension50
10/Rear Wheel51
- Removing Rear Wheel51
- Installing the Rear Wheel51
- Checking Chain Dirt51
- Cleaning the Chain52
- Checking the Chain Tension52
- Checking the Chain Tension - Installing Rear Wheel53
- Checking Rear Sprocket / Engine Sprocket for Wear53
- Adjusting Chain Tension53
- Adjusting Chain Tension - after Checking54
- Adjusting Chain Tension - Installing Rear Wheel54
- Adjusting the Chain Guide54
13/Brake System55
- Checking the Play of the Hand Brake Lever55
- Adjusting the Play of the Hand Brake Lever55
- Adjusting the Basic Position of the Hand Brake Lever55
- Checking the Front Brake Fluid Level55
- Adding Front Brake Fluid56
- Changing the Front Brake Fluid57
- Checking the Front Brake Linings58
- Removing Front Brake Linings58
- Installing the Front Brake Linings58
- Changing the Front Brake Linings59
- Checking the Free Travel of the Foot Brake Lever60
- Adjusting the Free Travel of the Foot Brake Lever60
- Adjusting the Basic Position of the Foot Brake Lever60
- Checking Rear Brake Fluid Level61
- Adding Rear Brake Fluid61
- Changing the Rear Brake Fluid62
- Checking the Rear Brake Linings63
- Removing Rear Brake Linings63
- Installing the Rear Brake Linings64
- Changing the Rear Brake Linings64
30/Engine66
- Removing the Engine66
- Installing the Engine67
30/Disassembling the Engine70
- Clamping the Engine into the Engine Work Stand70
- Pulling off the Spark Plug Connector70
- Draining the Gear Oil70
- Removing the Cylinder Head70
- Removing the Cylinder71
- Removing the Piston71
- Removing the Oil Pump (50 SX Mini)71
- Removing the Alternator Cover71
- Removing the Ignition Coil, Intake Flange, and Reed Valve Housing72
- Removing the Oil Pump Drive Gear (50 SX Mini)72
- Removing the Stator72
- Removing the Rotor72
- Removing the Engine Sprocket73
- Removing the Kickstarter74
- Removing the Water Pump Cover74
- Removing the Outer Clutch Cover74
- Removing the Clutch Cover74
- Removing the Clutch Drum74
- Removing the Kickstarter Gear75
- Removing the Kickstarter Idler Shaft75
- Loosening the Nut of the Primary Gear75
- Removing the Centrifugal Force Clutch75
- Removing the Kickstarter Shaft75
- Removing the Clutch Bearing76
- Removing the Primary Gear76
- Removing the Left Engine Case76
- Removing the Transmission Shafts77
- Removing the Crankshaft77
30/Engine - Work on Individual Parts78
- Work on the Right Section of the Engine Case78
- Work on the Left Section of the Engine Case78
- Changing the Conrod Bearing79
- Checking the Crankshaft Run-Out on the Bearing Pin80
- Removing the Water Pump80
- Installing the Water Pump81
- Changing the Shaft Seal Ring of the Kick Starter81
- Dismantling Centrifugal Clutch82
- Assembling Centrifugal Clutch82
- Checking/Measuring Clutch82
- Checking/Measuring the Cylinder83
- Checking/Measuring the Piston83
- Determining Piston/Cylinder Mounting Clearance84
- Checking the Piston Ring End Gap84
- Checking Reed Valve Housing, Diaphragm and Intake Flange84
30/Assembling the Engine86
- Installing the Crankshaft86
- Installing the Transmission Shafts86
- Installing the Left Engine Case86
- Installing the Primary Gear87
- Installing the Clutch Bearing87
- Installing the Kickstarter Shaft87
- Installing the Centrifugal Force Clutch87
- Tightening the Nut of the Primary Gear87
- Installing the Kickstarter Idler Shaft88
- Installing the Kickstarter Gear88
- Installing the Clutch Drum88
- Installing the Clutch Cover88
- Installing the Outer Clutch Cover89
- Mounting the Water Pump Cover89
- Installing the Kickstarter89
- Installing the Engine Sprocket89
- Installing the Rotor90
- Installing the Stator91
- Adjusting the Stator/Rotor Distance91
- Installing the Oil Pump Drive Gear (50 SX Mini)91
- Installing the Reed Valve Housing, Ignition Coil, and Intake Flange91
- Installing the Alternator Cover92
- Installing the Oil Pumps (50 SX Mini)92
- Installing the Piston93
- Installing the Cylinder93
- Checking the X-Distance94
- Setting the X-Distance94
- Installing the Cylinder Head94
- Installing the Oil Drain Plug95
- Refilling with Gear Oil95
- Mounting the Spark Plug Connector95
- Removing the Engine from the Universal Mounting Rack95
31/Carburetor96
- Removing the Carburetor (50 SX)96
- Removing the Carburetor (50 SX Junior, 50 SX Mini)97
- Installing the Carburetor (50 SX)98
- Installing the Carburetor (50 SX Junior, 50 SX Mini)99
- Checking/Setting the Carburetor Components (50 SX)100
- Checking/Setting the Carburetor Components (50 SX Junior, 50 SX Mini)101
- Disassembling the Carburetor (50 SX)101
- Disassembling the Carburetor (50 SX Junior, 50 SX Mini)103
- Assembling the Carburetor (50 SX)104
- Assembling the Carburetor (50 SX Junior)106
- Assembling the Carburetor (50 SX Mini)107
- Checking the Choke Slide (50 SX)109
- Checking the Choke Slide (50 SX Junior, 50 SX Mini)109
- Checking the Throttle Slide (50 SX)109
- Checking the Throttle Slide (50 SX Junior, 50 SX Mini)109
- Checking the Jet Needle110
- Checking the Float Needle Valve110
- Checking/Setting the Float Level (50 SX)110
- Carburetor - Adjusting Idle Speed (50 SX)110
- Carburetor - Adjusting Idle Speed (50 SX Junior, 50 SX Mini)111
32/Clutch113
- Removing the Centrifugal Force Clutch113
- Fitting Centrifugal Force Clutch113
- Checking Clutch Engagement Speed114
- Adjust the Clutch Engagement Speed114
35/Water Pump, Cooling System116
- Draining the Coolant116
- Refilling Coolant116
- Checking the Coolant Level117
- Checking the Antifreeze and Coolant Level117
38/Lubrication System119
- Changing the Gear Oil119
- Draining the Gear Oil119
- Filling up with Gear Oil119
- Checking the Gear Oil Level120
- Adding Gear Oil120
- Filling up with Oil (50 SX Mini)121
- Bleeding the Oil Pump (50 SX Mini)121
39/Ignition System123
- Checking the Ignition System123
- Checking the Spark Plug Connector123
- Checking the Ignition Coil123
- Checking the Kill Switch124
- Checking the Alternator124
Troubleshooting125
Technical Data - Engine127
- Capacity - Gear Oil127
- Capacity - Coolant127
Technical Data - Tolerance, Wear Limits of Engine128
Technical Data - Engine Tightening Torques129
Technical Data - Carburetor130
- 50 SX Junior130
- 50 SX Mini130
Technical Data - Chassis131
- Tires132
- Capacity - Fuel132
Technical Data - Fork133
- 50 SX Junior133
- 50 SX Mini133
Technical Data - Shock Absorber134
- 50 SX Junior134
- 50 SX Mini134
Technical Data - Tightening Torques for Chassis136
Cleaning/Conservation137
- Cleaning Motorcycle137
Storage138
- Putting into Operation after Storage138
Service Schedule139
- Important Maintenance Work that Must be Done in an Authorized KTM Workshop139
- Important Maintenance Work that Must be Done in an Authorized KTM Workshop (as Additional Order)139
Wiring Diagram142
Substances144
Auxiliary Substances146
Special Tools148
Standards155
Index156

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