KTM 50 SX 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

Other manuals for KTM 50 SX

Owner's Manual91 pages

Setup Instructions19 pages

Questions and Answers:

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KTM 50 SX Specifications

General

Displacement	49 cm³
Cooling System	Liquid cooled
Transmission	Single-speed automatic
Starter	Kickstarter
Front Brake	Disc brake
Rear Brake	Disc brake
Weight (without fuel)	41.5 kg
Seat Height	684 mm
Engine Type	Single cylinder, 2-stroke
Front Suspension	WP XACT 35 USD fork, Ø 35 mm
Rear Suspension	WP monoshock
Fuel Tank Capacity	2.3 liters

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