OWNER'SMANUAL2015 50SX 50SXMini - Judd Racing · 2 SAFETYADVICE 6 Warning Dangerofburns Somevehiclecomponentsbecomeveryhotwhenthevehicleisoperated. – Donottouchhotcomponentssuchasexhaustsystem,radiator,engine

OWNER'S MANUAL 2015

50 SX50 SX Mini

Art. no. 3213170en

DEAR KTM CUSTOMER 1

DEAR KTM CUSTOMER

Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that willgive you and your child enormous pleasure if you service and maintain it accordingly.

We wish you a lot of enjoyment in riding this vehicle.

Enter the serial numbers of your vehicle below.

Chassis number ( p. 10) Dealer's stamp

Engine number ( p. 10)

The Owner's Manual contained the latest information for this model at the time of going to print. Slight deviations resulting from con-tinuing development and design can, however, not be completely excluded.

All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adaptthese to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for deliveryoptions, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-cial equipment that does not belong to the regular scope of supply.

© 2014 KTM-Sportmotorcycle AG, Mattighofen AustriaAll rights reservedReproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyrightowner.

ISO 9001(12 100 6061)According to the international quality management standard ISO 9001, KTM uses quality assurance processes that leadto the maximum possible quality of the products.Issued by: TÜV Management Service

KTM-Sportmotorcycle AG5230 Mattighofen, Austria

TABLE OF CONTENTS 2

TABLE OF CONTENTS

1 MEANS OF REPRESENTATION ..................................... 41.1 Symbols used ................................................... 41.2 Formats used.................................................... 4

2 SAFETY ADVICE........................................................... 52.1 Use definition - intended use ............................. 52.2 Safety advice.................................................... 52.3 Degrees of risk and symbols ............................... 52.4 Tampering warning............................................ 52.5 Safe operation .................................................. 52.6 Protective clothing ............................................ 62.7 Work rules........................................................ 62.8 Environment..................................................... 62.9 Owner's Manual ................................................ 6

3 IMPORTANT INFORMATION ......................................... 73.1 Guarantee, warranty .......................................... 73.2 Operating and auxiliary substances ..................... 73.3 Spare parts, accessories .................................... 73.4 Service ............................................................ 73.5 Figures ............................................................ 73.6 Customer service............................................... 7

4 VIEW OF VEHICLE ....................................................... 84.1 View of the vehicle from the left front

(example)......................................................... 84.2 View of the vehicle from the right rear

(example)......................................................... 95 SERIAL NUMBERS .................................................... 10

5.1 Chassis number .............................................. 105.2 Type label ...................................................... 105.3 Engine number ............................................... 105.4 Fork part number ............................................ 105.5 Shock absorber part number ............................ 11

6 CONTROLS................................................................ 126.1 Hand brake lever............................................. 126.2 Throttle grip ................................................... 126.3 Kill switch...................................................... 126.4 Opening filler cap ........................................... 126.5 Closing filler cap............................................. 136.6 Opening oil tank cap (50 SX Mini) .................... 136.7 Closing oil tank cap (50 SX Mini) ..................... 136.8 Fuel tap ......................................................... 136.9 Choke (50 SX) ................................................ 146.10 Choke (50 SX Mini)......................................... 146.11 Kickstarter ..................................................... 146.12 Foot brake lever .............................................. 146.13 Plug-in stand.................................................. 14

7 PREPARING FOR USE................................................ 157.1 Advice on first use .......................................... 157.2 Running in the engine ..................................... 16

8 RIDING INSTRUCTIONS............................................. 178.1 Checks and maintenance measures when

preparing for use............................................. 178.2 Starting.......................................................... 178.3 Starting up..................................................... 188.4 Riding............................................................ 188.5 Braking .......................................................... 188.6 Stopping, parking............................................ 188.7 Transport ....................................................... 198.8 Refueling ....................................................... 198.9 Filling up with oil (50 SX Mini) ........................ 20

9 SERVICE SCHEDULE ................................................. 219.1 Service schedule............................................. 21

10 TUNING THE CHASSIS .............................................. 2310.1 Adjusting the rebound damping of the shock

absorber......................................................... 2310.2 Measuring rear wheel sag unloaded................... 2310.3 Checking the static sag of the shock absorber .... 2310.4 Checking the riding sag of the shock absorber.... 2410.5 Adjusting the spring preload of the shock

absorberx.................................................... 2410.6 Adjusting the riding sagx .............................. 2510.7 Handlebar position.......................................... 2510.8 Adjusting handlebar positionx ....................... 2510.9 Adjusting seat heightx.................................. 26

11 MAINTENANCE WORK ON CHASSIS ........................... 2711.1 Raising the motorcycle with a lift stand............. 2711.2 Removing the motorcycle from the lift stand...... 2711.3 Cleaning the dust boots of the fork legs............. 2711.4 Removing the fork protectorx ........................ 2811.5 Installing the fork protectorx ......................... 2811.6 Removing the fork legsx ............................... 2811.7 Installing the fork legsx ................................ 2911.8 Removing the lower triple clampx.................. 2911.9 Installing the lower triple clampx .................. 3011.10 Checking play of steering head bearing ............. 3111.11 Adjusting the play of the steering head

bearingx ..................................................... 3211.12 Greasing the steering head bearingx .............. 3211.13 Dismounting the start number plate.................. 3311.14 Installing the start number plate....................... 3311.15 Dismounting the front fender ........................... 3311.16 Installing the front fender ................................ 3311.17 Removing the shock absorberx ...................... 3411.18 Installing shock absorberx ............................ 3411.19 Removing the seat .......................................... 3411.20 Mounting the seat ........................................... 3511.21 Removing the air filterx ................................ 3511.22 Installing the air filterx................................. 3511.23 Cleaning the air filter and air filter boxx ......... 3611.24 Removing main silencer................................... 3611.25 Installing the main silencer.............................. 3711.26 Changing the glass fiber yarn filling of the

main silencerx............................................. 3711.27 Removing the chain guard (50 SX) ................... 3711.28 Installing the chain guard (50 SX) .................... 3811.29 Removing the engine sprocket coverx ............ 3811.30 Installing the engine sprocket coverx ............. 3811.31 Checking the chain for dirt............................... 3911.32 Cleaning the chain .......................................... 3911.33 Checking the chain tension .............................. 4011.34 Adjusting chain tension ................................... 4011.35 Checking the chain, rear sprocket, engine

sprocket and chain guide................................. 4111.36 Adjusting the chain guidex ........................... 4211.37 Checking the framex .................................... 4311.38 Checking the swingarmx ............................... 4311.39 Checking the throttle cable routing ................... 4311.40 Checking the rubber grip ................................. 4411.41 Additionally securing the rubber grip................. 44

12 BRAKE SYSTEM ........................................................ 4512.1 Checking play of handbrake lever ..................... 4512.2 Adjusting the play of the hand brake lever ......... 4512.3 Adjusting the basic position of the hand brake

lever .............................................................. 45

TABLE OF CONTENTS 3

12.4 Checking brake discs....................................... 4612.5 Checking front brake fluid level ........................ 4612.6 Adding front brake fluidx .............................. 4712.7 Checking the front brake linings ....................... 4812.8 Changing the front brake liningsx .................. 4812.9 Checking the free travel of the foot brake

lever .............................................................. 4912.10 Adjusting the free travel of the foot brake

leverx ......................................................... 5012.11 Adjusting the basic position of the foot brake

leverx ......................................................... 5012.12 Checking rear brake fluid level ......................... 5112.13 Adding rear brake fluidx ............................... 5112.14 Checking the rear brake linings ........................ 5212.15 Changing the rear brake liningsx ................... 52

13 WHEELS, TIRES ........................................................ 5513.1 Removing the front wheelx ........................... 5513.2 Installing the front wheelx ............................ 5513.3 Removing rear wheelx .................................. 5613.4 Installing the rear wheelx.............................. 5613.5 Checking the tire condition .............................. 5713.6 Checking tire air pressure ................................ 5713.7 Checking spoke tension ................................... 57

14 COOLING SYSTEM..................................................... 5914.1 Cooling system ............................................... 5914.2 Checking the antifreeze and coolant level .......... 5914.3 Checking the coolant level ............................... 6014.4 Draining the coolantx ................................... 6014.5 Refilling coolantx......................................... 61

15 TUNING THE ENGINE................................................ 6215.1 Checking the installation position of the

throttle grip .................................................... 6215.2 Checking the play of the throttle cable .............. 6215.3 Adjusting the play in the throttle cablex ......... 6215.4 Carburetor - idle (50 SX).................................. 6315.5 Carburetor - idle (50 SX Mini) .......................... 6315.6 Carburetor - adjusting idle speedx (50 SX) ..... 6315.7 Carburetor - adjusting idle speedx

(50 SX Mini) .................................................. 6415.8 Checking the clutch settingx......................... 6515.9 Removing the clutch coverx .......................... 6515.10 Adjusting the clutchx ................................... 6615.11 Installing the clutch coverx........................... 67

16 MAINTENANCE WORK ON THE ENGINE ..................... 6816.1 Checking oil level (50 SX Mini) ........................ 6816.2 Bleeding the oil pumpx (50 SX Mini)............. 6816.3 Checking the gear oil level ............................... 6916.4 Changing the gear oilx.................................. 6916.5 Adding gear oilx........................................... 70

17 CLEANING, CARE ...................................................... 7217.1 Cleaning motorcycle ........................................ 72

18 STORAGE.................................................................. 7318.1 Storage .......................................................... 7318.2 Preparing for use after storage.......................... 73

19 TROUBLESHOOTING ................................................. 7420 TECHNICAL DATA...................................................... 76

20.1 Engine ........................................................... 7620.2 Engine tightening torques ................................ 7620.3 Carburetor with carburetor tuning ..................... 7720.3.1 50 SX........................................................ 7720.3.2 50 SX Mini ................................................ 77

20.4 Capacities ...................................................... 7720.4.1 Gear oil...................................................... 7720.4.2 Coolant ...................................................... 7720.4.3 Fuel .......................................................... 7720.5 Chassis .......................................................... 7720.6 Tires .............................................................. 7820.7 Fork............................................................... 7820.7.1 50 SX Mini ................................................ 7820.7.2 50 SX........................................................ 7920.8 Shock absorber ............................................... 7920.8.1 50 SX........................................................ 7920.8.2 50 SX Mini ................................................ 7920.9 Chassis tightening torques ............................... 80

21 SUBSTANCES ........................................................... 8122 AUXILIARY SUBSTANCES .......................................... 8323 STANDARDS ............................................................. 85INDEX .............................................................................. 86

1 MEANS OF REPRESENTATION 4

1.1 Symbols usedThe symbols used are explained in the following.

Indicates an expected reaction (e.g., to a work step or a function).

Indicates an unexpected reaction (e.g., to a work step or a function).

All work marked with this symbol requires specialist knowledge and technical understanding. In the interest ofthe safety of your child, have these jobs performed in an authorized KTM workshop. There, your motorcycle willbe serviced optimally by specially trained experts using the specialist tools required.

Identifies a page reference (more information is provided on the specified page).

1.2 Formats usedThe typographical and other formats used are explained in the following.

Proper name Identifies a proper name.

Name® Identifies a protected name.

Brand™ Identifies a brand in merchandise traffic.

2 SAFETY ADVICE 5

2.1 Use definition - intended useKTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com-ply with currently valid regulations and categories of the top international motorsport organizations.

InfoThe motorcycle may only be used in closed off areas remote from public road traffic.

2.2 Safety adviceA number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safetyinstructions are highlighted in the text and are referred to at the relevant passages.

InfoThe vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. Ifthey are missing, you or others may not recognize dangers and may therefore be injured.

2.3 Degrees of risk and symbols

DangerIdentifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measuresare not taken.

WarningIdentifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

CautionIdentifies a danger that may lead to minor injuries if the appropriate measures are not taken.

NoteIdentifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

WarningIdentifies a danger that will lead to environmental damage if the appropriate measures are not taken.

2.4 Tampering warningTampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:

1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any deviceor element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimatepurchaser or while it is in use, or

2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases.

2 Removal or puncturing of parts of the intake system.

3 Lack of proper maintenance.

4 Replacing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manu-facturer.

2.5 Safe operation

DangerDanger of accidents Danger arising from the rider's judgement being impaired.

– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentallyimpaired.

DangerDanger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.

– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosedspace without an effective exhaust extraction system.

2 SAFETY ADVICE 6

WarningDanger of burns Some vehicle components become very hot when the vehicle is operated.

– Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow thesecomponents to cool down before starting work on them.

Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use and in a safe and environmen-tally compatible manner.The vehicle should only be used by trained persons.Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.Adhere to the information and warning labels on the vehicle.

2.6 Protective clothing

WarningRisk of injury Missing or poor protective clothing presents an increased safety risk.

– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Alwayswear protective clothing that is in good condition and meets the legal requirements.

In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.

2.7 Work rulesSpecial tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren-theses. E.g.: bearing puller (15112017000)During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must bereplaced by new parts.In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed.After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.After you complete the repair or service work, check the operating safety of the vehicle.

2.8 EnvironmentIf you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcy-cle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of therespective country.Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations thatpertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.

2.9 Owner's ManualIt is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual containsuseful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to cus-tomize the vehicle ideally for your own use and how you can protect yourself from injury.Keep the Owner's Manual in an accessible place to enable you to refer to it as needed.If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.The Owner's Manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold.

3 IMPORTANT INFORMATION 7

3.1 Guarantee, warrantyThe work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer'sService & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid-ered for damage resulting from manipulations and/or alterations to the vehicle.Additional information on the guarantee or warranty and the procedures involved can be found in the Service & Warranty Booklet.

3.2 Operating and auxiliary substances

WarningEnvironmental hazard Improper handling of fuel is a danger to the environment.

– Do not allow fuel to get into the ground water, the ground, or the sewage system.

Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.

3.3 Spare parts, accessoriesFor your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have theminstalled by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized KTM dealer will be gladto advise you.

The current KTM PowerParts for your vehicle can be found on the KTM website.International KTM Website: http://www.ktm.com

3.4 ServiceA prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the engine andchassis is properly carried out as described in the Owner's Manual. Incorrect adjustment and tuning of the engine and chassis canlead to damage and breakage of components.Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can lead to considerably more rapid wearof components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect orreplace parts before the next scheduled service.It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure amuch longer service life for your motorcycle.

3.5 FiguresThe figures contained in the manual may depict special equipment.In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to dis-assemble the component to perform the activity in question. Please follow the instructions in the text.

3.6 Customer serviceYour authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.

A list of authorized KTM dealers can be found on the KTM website.International KTM Website: http://www.ktm.com

4 VIEW OF VEHICLE 8

4.1 View of the vehicle from the left front (example)

102029-10

1 Filler cap

2 Quick release of seat

3 Fuel tap ( p. 13)

4 Choke ( p. 14)

5 Plug-in stand ( p. 14)

6 Chain guide

4 VIEW OF VEHICLE 9

4.2 View of the vehicle from the right rear (example)

102030-10

1 Kill switch ( p. 12)

2 Throttle grip ( p. 12)

3 Hand brake lever ( p. 12)

4 Chassis number ( p. 10)

5 Shock absorber rebound adjustment

6 Level viewer for brake fluid, rear

7 Foot brake lever ( p. 14)

8 Kickstarter ( p. 14)

5 SERIAL NUMBERS 10

5.1 Chassis number

101930-10

The chassis number is stamped on right of the steering head.

5.2 Type label

S00010-10

(50 SX)The type label is located on the front frame tube.

S00009-10

(50 SX Mini)The type label is located on the frame at the front right.

5.3 Engine number

700461-01

The engine number is stamped on the left side of the engine under the enginesprocket.

5.4 Fork part number

S00008-10

The fork part number is stamped on the outside of the axle clamp.

5 SERIAL NUMBERS 11

5.5 Shock absorber part number

700469-01

The shock absorber part number is stamped on the top of the shock absorber abovethe adjusting ring towards the rear.

6 CONTROLS 12

6.1 Hand brake lever

601578-10

Hand brake lever is fitted on the right side of the handlebar.The hand brake lever is used to activate the front brake.

6.2 Throttle grip

601577-10

Throttle grip is fitted on the right side of the handlebar.

6.3 Kill switch

601579-10

Kill switch is fitted on the left side of the handlebar.

Possible states• Kill switch in basic position – In this position, the ignition circuit is closed, and

the engine can be started.• Kill switch pressed – In this position, the ignition circuit is interrupted, a run-

ning engine stops, and a non-running engine will not start.

6.4 Opening filler cap

DangerFire hazard Fuel is highly flammable.

– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that nofuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

– The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.

WarningDanger of poisoning Fuel is poisonous and a health hazard.

– Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs withthe eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin withsoap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.Store fuel properly in a suitable canister and keep away from children.



6 CONTROLS 13

601580-10

– Turn the tank cap counterclockwise and pull it up.

6.5 Closing filler cap

601580-11

– Put the tank cap on and turn it clockwise.

InfoRun the fuel tank breather hose without kinks.

6.6 Opening oil tank cap (50 SX Mini)

601582-10

– Turn the oil tank cap counterclockwise and pull it up.

6.7 Closing oil tank cap (50 SX Mini)

601582-11

– Put the oil tank cap on and turn it clockwise.

InfoRun the oil tank breather hose without kinks.

6.8 Fuel tap

601581-10

Fuel tap is on the left of the fuel tank.

Possible states• Fuel tap is closed – The knurled screw is turned all the way clockwise. Fuel cannot

flow out of the fuel tank.• Fuel tap is open – The knurled screw is turned all the way counterclockwise. Fuel

can flow out of the fuel tank.

6 CONTROLS 14

6.9 Choke (50 SX)

601583-10

The choke knob is fitted on the left of the carburetor.Activating the choke function frees an opening through which the engine can drawextra fuel. This results in a richer fuel-air mixture, which is needed for a cold start.

InfoIf the engine is warm, the choke function must be deactivated.

Possible states• Choke function activated – Choke knob is in upper position. The O-ring is visible.• Choke function deactivated – Choke knob is in lower position. No O-ring is visible.

6.10 Choke (50 SX Mini)

700519-01

The choke lever is fitted on the right of the carburetor.Activating the choke function frees an opening through which the engine can drawextra fuel. This results in a richer fuel-air mixture, which is needed for a cold start.

InfoIf the engine is warm, the choke function must be deactivated.

Possible states• Choke function activated – The choke lever is pushed up all the way.• Choke function deactivated – The choke lever is pushed down all the way.

6.11 Kickstarter

601584-10

The kickstarter is fitted on the right of the engine.The kickstarter can be swiveled.

InfoBefore riding, swing the kickstarter inwards towards the engine.

6.12 Foot brake lever

601587-10

Foot brake lever is located in front of the right footrest.The foot brake lever is used to activate the rear brake.

6.13 Plug-in stand

101931-10

The fixture for the plug-in stand is located on the frame on the left side of the vehi-cle.The plug-in stand is used to park the motorcycle.

InfoRemove the plug-in stand before riding.

7 PREPARING FOR USE 15

7.1 Advice on first use

WarningDanger of accidents Physical and mental readiness of a child.

– Your child must be able to ride a bicycle and must be able to erect the vehicle independently after a fall. In addition, yourchild must understand the regulations and instructions from you or from other guardians. Do not ask too much of yourchild; participation in competitive activities should not be considered until your child's stamina, riding techniques andmotivation are at the necessary levels. Children often underestimate or fail to recognize dangerous situations; make it clearto your child that it should not, under any circumstances, operate the vehicle without supervision and that your child mayonly drive at speeds that are commensurate with the child's riding abilities and the road conditions.

– Only let your child ride on the vehicle if it is physically and mentally ready to operate the vehicle.

WarningRisk of injury Missing or poor protective clothing presents an increased safety risk.

– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. You andyour child should always used protective clothing that is in good condition and meets the legal requirements. When youride a motorcycle, set an example for your child and wear suitable protective clothing.

WarningDanger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.

– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.

WarningDanger of accidents Critical riding behavior due to inappropriate riding.

– Ensure that your child adapts the riding speed to the road conditions and to his or her riding abilities.

WarningDanger of accidents Accident risk caused by presence of a passenger.

– Your vehicle is not designed to carry passengers. Do not ride with a passenger.

WarningDanger of accidents Brake system failure.

– If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating.Ensure that your child raises his or her foot from the foot brake lever when the child does not want to brake.

WarningDanger of accidents Destruction of chassis components.

– Do not exceed the maximum allowable rider weight.

WarningRisk of misappropriation Usage by unauthorized persons.

– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.

InfoWhen using your motorcycle, remember that others may feel disturbed by excessive noise.

– Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.

You receive a delivery certificate and the service record at vehicle handover.

– Carefully read the entire owner's manual together with your child before going for the first ride.

InfoPay special attention to the safety warnings and injury risks.Explain to your child the techniques of riding and falling, e.g. how shifting weight can influence handling characteristics.

– Familiarize your child with the controls.

– Adjust the basic position of the hand brake lever. ( p. 45)

– Adjust the basic position of the foot brake lever.x ( p. 50)

– Before using the vehicle for the first time, ensure that the basic settings of the chassis are suitable for the weight of your child.

– Accustom your child to the handling of the motorcycle on suitable terrain, preferably on a large open meadow.

7 PREPARING FOR USE 16

InfoTo give your child a feel for the brake system, you should push your child at first. Do not start the engine until your child isable to apply the necessary front brake pressure.Initially, let your child drive to another person who can help your child stop and turn.

– Erect obstacles for your child to navigate around to accustom your child to handling the vehicle.

– Your child should also try to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.

– Do not let your child ride on terrain that exceed your child's capabilities and experience.

– Your child should hold the handlebar firmly with both hands and keep his or her feet on the footrests when riding.

– Do not exceed the maximum allowable rider weight.

Guideline

Maximum rider weight < 35 kg (< 77 lb.)

Maximum rider size < 130 cm (< 51.2 in)

– Check the spoke tension. ( p. 57)

InfoThe spoke tension must be checked after riding the motorcycle for half an hour.

– Run the engine in. ( p. 16)

7.2 Running in the engine– During the running-in phase, do not exceed the specified engine performance.

Guideline

Maximum engine performance

During the first 3 operating hours < 70 %

During the first 5 operating hours < 100 %

– Avoid fully opening the throttle!

8 RIDING INSTRUCTIONS 17

8.1 Checks and maintenance measures when preparing for use

InfoBefore each use, check the condition of the vehicle and its operating safety.The vehicle must be in perfect technical condition when it is being operated.

– Check the gear oil level. ( p. 69)

(50 SX Mini)– Check the oil level. ( p. 68)

– Check the front brake fluid level. ( p. 46)

– Check the rear brake fluid level. ( p. 51)

– Check the front brake linings. ( p. 48)

– Check the rear brake linings. ( p. 52)

– Check that the brake system is functioning properly.

– Check the coolant level. ( p. 60)

– Check the chain dirt accumulation. ( p. 39)

– Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 41)

– Check the chain tension. ( p. 40)

– Check the tire condition. ( p. 57)

– Check the tire air pressure. ( p. 57)

– Check the spoke tension. ( p. 57)

– Clean the dust boots of the fork legs. ( p. 27)

– Check the air filter.

– Check the settings of all controls and ensure that they can be operated smoothly.

– Check all screws, nuts and hose clamps regularly for tightness.

– Check the fuel supply.

8.2 Starting

DangerDanger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.

– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosedspace without an effective exhaust extraction system.

NoteEngine failure High engine speeds in cold engines have a negative effect on the service life of the engine.

– Always warm up the engine at low engine speeds.

InfoIf the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuelevaporate after a long time of standing.If the float chamber is filled with fresh fuel, the engine starts immediately.

Engine has been out of use for more than 1 week– Empty the carburetor float chamber.x

– Turn the knurled screw on the fuel tap all the way counterclockwise.

Fuel can flow from the fuel tank to the carburetor.

The engine is cold– Raise the motorcycle with a lift stand. ( p. 27)

InfoThe rear wheel must not be in contact with the ground.

(50 SX)– Pull the choke knob fully out and turn it by max. ¼ turn.


(50 SX Mini)– Push the choke lever up all the way.

– Forcefully step on the kick starter, pushing it all the way forward.

InfoDo not open the throttle.

8.3 Starting up

InfoThe plug-in stand must be removed before beginning to ride.

– Open the throttle carefully.

8.4 Riding

InfoIf you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized KTM workshop.

– If the choke function was activated, deactivate it after the engine has warmed up.

– When you reach maximum speed after fully opening the throttle, turn back the throttle to about ¾ of its range. The speed hardlydrops, but the fuel consumption falls considerably.

– Your child should always open the throttle only as much as the engine can handle – abruptly opening the throttle increases fuelconsumption.

– Your child should switch off the engine if he or she expects to be standing for a long time.

Guideline

≥ 2 min

8.5 Braking

WarningDanger of accidents If you brake too hard, the wheels can lock.

– Adapt your braking to the traffic situation and the road conditions.

WarningDanger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake.

– Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

WarningDanger of accidents Reduced braking efficiency due to a wet or dirty brake system.

– Clean or dry a dirty or wet brake system by riding and braking gently.

– On sandy, wet or slippery surfaces, use the rear brake.

– Braking should always be completed before you go into a bend.

8.6 Stopping, parking

WarningRisk of misappropriation Usage by unauthorized persons.

– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.

WarningDanger of burns Some vehicle components become very hot when the vehicle is operated.

– Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow thesecomponents to cool down before starting work on them.

NoteDanger of damage The parked vehicle may roll away or fall over.


– Always place the vehicle on a firm and even surface.

NoteFire hazard Some vehicle components become very hot when the vehicle is operated.

– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm frombeing run. Always let the vehicle cool first.

NoteMaterial damage Damage and destruction of components due to excessive load.

– The plug-in stand is designed for the weight of the motorcycle only. You or your child should not sit on the motorcycle when it isstanding on the plug-in stand. The plug-in stand and/or the frame could be damaged and the motorcycle could fall over.

– Brake the motorcycle.

– Press and hold the kill switch while the engine is idling until the engine stops.

– Turn the knurled screw on the fuel tap all the way clockwise.

– Park the motorcycle on firm ground.

8.7 Transport



NoteFire hazard Some vehicle components become very hot when the vehicle is operated.

– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm frombeing run. Always let the vehicle cool first.

401475-01

– Switch off the engine.

– Use tension belts or other suitable devices to secure the motorcycle against acci-dents or falling over.

8.8 Refueling

DangerFire hazard Fuel is highly flammable.

– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that nofuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

– The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.


– Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs withthe eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin withsoap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.




– Open the filler cap. ( p. 12)


000

AA

400214-10

– Fill the fuel tank with fuel up to measurement.

Guideline

Measurement of 35 mm (1.38 in)

Fuel tankcapacity, approx.(50 SX Mini)

2.0 l (2.1 qt.) Super unleaded (ROZ 95/RON 95/PON91) ( p. 82)

Fuel tankcapacity, approx.(50 SX)

2.3 l (2.4 qt.) Super unleaded gasoline (95 octane),mixed with 2-stroke engine oil (1:60)( p. 82)

– Close the filler cap. ( p. 13)

8.9 Filling up with oil (50 SX Mini)

WarningEngine failure If the vehicle is run without 2-stroke oil in the tank, the result is engine failure.

– The oil tank must always be filled up to the MIN mark.


– Open the oil tank cap. ( p. 13)

102031-10

– Fill the oil tank at least up to the MIN mark.

Guideline

MIN mark Sufficient for a single tank filling

Oil tank contentsca.

0.2 l (0.2 qt.) 2-stroke engine oil ( p. 81)

– Close the oil tank cap. ( p. 13)

9 SERVICE SCHEDULE 21

9.1 Service schedule

Annually

Every 80 operating hours



Once after 10 operating hours

Check the front brake linings. ( p. 48) ○ ● ● ●

Check the rear brake linings. ( p. 52) ○ ● ● ●

Check the brake discs. ( p. 46) ○ ● ● ●

Check brake lines for damage and leakage. ○ ● ● ●

Change the sealing sleeves of the foot brake cylinder.x ● ● ●

Change the rear brake fluid.x ●

Check the rear brake fluid level. ( p. 51) ○ ● ● ●

Check the free travel of the foot brake lever. ( p. 49) ○ ● ● ●

Check the frame and swingarm.x ● ● ●

Check swingarm bearing.x ● ● ●

Check the heim joints on the upper and lower shock absorbers.x ● ● ●

Service the fork.x ● ●

Service the shock absorber.x ●

Check the tire condition. ( p. 57) ○ ● ● ●

Check the tire air pressure. ( p. 57) ○ ● ● ●

Check wheel bearing for play.x ● ● ●

Check the wheel hubs.x ● ● ●

Check rim run-out.x ○ ● ● ●

Check the spoke tension. ( p. 57) ○ ● ● ●

Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 41) ○ ● ● ●

Check the chain tension. ( p. 40) ○ ● ● ●

Lubricate all moving parts (e. g. hand levers, chain, ...) and check for smooth operation.x ○ ● ● ●

Change the front brake fluid.x ●

Check the front brake fluid level. ( p. 46) ○ ● ● ●

Check the play of the handbrake lever. ( p. 45) ○ ● ● ●

Grease the steering head bearing.x ( p. 32) ●

Check play of steering head bearing. ( p. 31) ○ ● ● ●

Check the clutch.x ● ●

Change the piston.x ● ●

Change the connecting rod, conrod bearing and crank pin.x ● ●

Change the crankshaft bearing.x ● ●

Check the transmission.x ● ●

Change all engine bearings.x ●

Change the gear oil.x ( p. 69) ○ ● ●

Check the gear oil level. ( p. 69) ● ● ●

Change the spark plug.x ● ● ●

Change the spark plug connector.x ● ●

Check the cylinder and piston.x ● ● ●

Check the intake membrane.x ● ● ●

Check all hoses (e. g. fuel, cooling, bleeding, drainage) and sleeves for tearing, tightness and correctrouting.x

○ ● ● ●

Check the antifreeze and coolant level. ( p. 59) ○ ● ● ●

Check the cables for damage and routing without sharp bends.x ○ ● ● ●

Check the cables for damage, routing without sharp bends and correct adjustment. ○ ● ● ●

Clean the air filter and air filter box.x ( p. 36) ○ ● ● ●

9 SERVICE SCHEDULE 22

Annually




Once after 10 operating hours

Change the glass fiber yarn filling of the main silencer.x ( p. 37) ● ● ●

Check the screws and nuts for tightness.x ○ ● ● ●

Check/set the carburetor components.x ●

Check idle.x ○ ● ● ●

Check the clutch setting.x ( p. 65) ● ● ●

Final inspection: check the vehicle for operating safety and take a test ride. ○ ● ● ●

Create a service entry in the KTM DEALER.NET and in the service record.x ○ ● ● ●

○ One-time interval

● Periodic interval

10 TUNING THE CHASSIS 23

10.1 Adjusting the rebound damping of the shock absorber

CautionDanger of accidents Disassembly of pressurized parts can lead to injury.

– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshopwill be glad to help.)

601591-10

– Turn adjusting screw clockwise up to the last perceptible click.

– Turn counterclockwise by the number of clicks corresponding to the shock absorbertype.

Guideline

Rebound damping (50 SX)

Standard 10 clicks

Rebound damping (50 SX Mini)

Standard 12 clicks

InfoTurn clockwise to increase damping; turn counterclockwise to reduce damp-ing.

10.2 Measuring rear wheel sag unloadedPreparatory work– Raise the motorcycle with a lift stand. ( p. 27)

00AA

400988-10

Main work– Measure the distance – as vertical as possible – between the rear axle and a fixed

point, for example, a mark on the side cover.

– Make a note of the value as measurement.

Finishing work– Remove the motorcycle from the lift stand. ( p. 27)

10.3 Checking the static sag of the shock absorber

00AA

00BB

400989-10

– Measure distance of rear wheel unloaded. ( p. 23)

– Hold the motorcycle in a vertical position with the assistance of another person.

– Measure the distance between the rear axle and the fixed point again.


InfoThe static sag is the difference between measurements and.

– Check the static sag.

Static sag (50 SX) 20 mm (0.79 in)

Static sag (50 SX Mini) 15 mm (0.59 in)

» If the static sag is less or more than the specified value:

– Adjust the spring preload of the shock absorber.x ( p. 24)


10.4 Checking the riding sag of the shock absorber

00AA

00CC

400990-10

– Measure distance of rear wheel unloaded. ( p. 23)

– With another person holding the motorcycle, the rider sits down on the saddle infull protective clothing in a normal sitting position (feet on footrests) and bouncesup and down a few times.

The rear wheel suspension levels out.

– Another person now measures the distance between the rear axle and a fixed point.


InfoThe riding sag is the difference between measurements and.

– Check the riding sag.

Riding sag (50 SX) 45… 55 mm (1.77… 2.17 in)

Riding sag (50 SX Mini) 40… 50 mm (1.57… 1.97 in)

» If the riding sag differs from the specified measurement:

– Adjust the riding sag.x ( p. 25)

10.5 Adjusting the spring preload of the shock absorberx

CautionDanger of accidents Disassembly of pressurized parts can lead to injury.

– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshopwill be glad to help.)

Preparatory work– Raise the motorcycle with a lift stand. ( p. 27)

– Remove shock absorber.x ( p. 34)

– After removing the shock absorber, clean it thoroughly.

700506-01

Main work– Measure the full spring length while it is under tension and note down the value.

– Loosen retaining ring.

– Turn adjusting ring until the spring is no longer under tension.

Hook wrench (T106S)

– Measure the overall spring length when not under tension.

– Tighten the spring by turning adjusting ring to the specified measurement.

Guideline

Spring preload (50 SX)

Standard 3 mm (0.12 in)

Spring preload (50 SX Mini)


InfoThe spring preload is the difference between the relaxed spring length andthe tensioned spring length.Depending on the static sag and/or the riding sag, it may be necessary toincrease or decrease the spring preload.

– Tighten retaining ring.

Finishing work– Install shock absorber.x ( p. 34)

– Remove the motorcycle from the lift stand. ( p. 27)


10.6 Adjusting the riding sagxPreparatory work– Raise the motorcycle with a lift stand. ( p. 27)

– Remove shock absorber.x ( p. 34)

– After removing the shock absorber, clean it thoroughly.

B00292-10

Main work– Choose and mount a suitable spring.

Guideline

Spring rate (50 SX)

Weight of rider: 15… 25 kg (33…55 lb.)

30 N/mm (171 lb/in)

Weight of rider (standard): 25…35 kg (55… 77 lb.)

35 N/mm (200 lb/in)


40 N/mm (228 lb/in)

Spring rate (50 SX Mini)


65 N/mm (371 lb/in)

Weight of rider (standard): 25…35 kg (55… 77 lb.)

75 N/mm (428 lb/in)


85 N/mm (485 lb/in)

InfoThe spring rate is shown on the outside of the spring.Smaller weight differences can be compensated by changing the springpreload.

Finishing work– Install shock absorber.x ( p. 34)


– Check the static sag of the shock absorber. ( p. 23)

– Check the riding sag of the shock absorber. ( p. 24)

– Adjust the rebound damping of the shock absorber. ( p. 23)

10.7 Handlebar position

000BB00AA

400565-10

On the upper triple clamp, there are 2 holes at a distance of to each other.

Distance between holes 15 mm (0.59 in)

The holes on the handlebar support are placed at a distance of from the center.

Distance between holes 3.5 mm (0.138 in)

The handlebar supports can be mounted in 4 different positions.

10.8 Adjusting handlebar positionx

WarningDanger of accidents Handlebar breakage.

– If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle-bar.


0011

0022

400564-10

– Remove the screws. Take off the handlebar clamps. Remove the handlebar andlay it to one side.

InfoProtect the motorcycle and its attachments from damage by covering them.Do not bend the cables and lines.

– Remove the screws. Remove the handlebar support.

– Place the handlebar support in the required position. Fit and tighten thescrews.

Guideline

Screw, handlebar support M10 40 Nm(29.5 lbf ft)

Loctite® 243™

– Position the handlebar.

InfoMake sure cables and wiring are positioned correctly.

– Position the handlebar clamps. Fit and evenly tighten the screws.

Guideline

Screw, handlebar clamp M8 20 Nm(14.8 lbf ft)

InfoMake sure the gap width is even.

10.9 Adjusting seat heightx

WarningDanger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior.

– Following modifications, ride slowly at first to get the feel of the new ride behavior.


102032-10

Main work– Hold the rear wheel with the swingarm and remove screw.

– Position the shock absorber according to the required seat height.

Guideline

Low seat position (standard) High seat position

– Mount and tighten screw.

Guideline

Screw, top shock absorber M10 45 Nm(33.2 lbf ft)


11 MAINTENANCE WORK ON CHASSIS 27

11.1 Raising the motorcycle with a lift stand



101933-01

– Raise the motorcycle at the frame underneath the engine.

Lift stand (59229055000)

The tires should no longer be in contact with the ground.

– Secure the motorcycle against falling over.

11.2 Removing the motorcycle from the lift stand



101931-10

– Remove the motorcycle from the lift stand.

– Remove the lift stand.

– To park the motorcycle, insert plug-in stand into the plug-in stand bracket onthe left side of the vehicle.

InfoRemove the plug-in stand before riding.

11.3 Cleaning the dust boots of the fork legsPreparatory work– Raise the motorcycle with a lift stand. ( p. 27)

601592-10

Main work– Push dust boots of both fork legs downwards.

InfoThe dust boots remove dust and coarse dirt particles from the inside forktubes. Over time, dirt can penetrate behind the dust boots. If this dirt is notremoved, the shaft seal rings behind can start to leak.

WarningDanger of accidents Reduced braking efficiency due to oil or grease on thebrake discs.

– Always keep the brake discs free of oil and grease, and clean them withbrake cleaner when necessary.

– Clean and oil the dust boots and inner fork tube of both fork legs.

Universal oil spray ( p. 84)

– Press the dust boots back into their normal position.

– Remove excess oil.



11.4 Removing the fork protectorx

101934-10

– Remove screws. Take off clamp.

– Remove screws on the left fork leg. Take off the fork protector.

101935-10

– Remove screws on the right fork leg. Take off the fork protector.

11.5 Installing the fork protectorx

101935-11

– Position the fork protection on the right fork leg. Mount and tighten screws.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

101936-10

– Position the fork protection on the left fork leg. Mount and tighten screws.

Guideline


– Position the brake line. Mount clamp.

– Mount the screws.

11.6 Removing the fork legsxPreparatory work– Raise the motorcycle with a lift stand. ( p. 27)

– Remove the front wheel.x ( p. 55)

601593-10

Main work– Remove screws and take off the clamp.

– Remove screws and take off the brake caliper.

– Hang the brake caliper and the brake line loosely to the side.


601594-10

– Loosen screws. Remove the left fork leg.

– Loosen screws. Remove the right fork leg.

11.7 Installing the fork legsx

601595-10

Main work– Position the fork legs.

InfoThe upper milled groove in the fork leg must be flush with the top edge ofthe upper triple clamp.Position bleeder screws to the front.

601594-11

– Tighten screws.

Guideline

Screw, top triple clamp M8 20 Nm(14.8 lbf ft)

– Tighten screws.

Guideline

Screw, bottom triple clamp M8 15 Nm(11.1 lbf ft)

601593-11

– Position brake caliper, mount, and tighten screws.

Guideline

Screw, front brake caliper M8 20 Nm(14.8 lbf ft)

Loctite® 243™

– Position the brake line. Put the clamp on, and mount and tighten screws.

Finishing work– Install the front wheel.x ( p. 55)

11.8 Removing the lower triple clampxPreparatory work– Raise the motorcycle with a lift stand. ( p. 27)


– Remove the fork legs.x ( p. 28)

– Dismount the start number plate. ( p. 33)

– Dismount the front fender. ( p. 33)

601604-10

Main work– Remove fuel tank breather.

– Loosen screw. Remove nut, take off the top triple clamp with the handle-bar, and place it on one side.

InfoProtect the motorcycle and its attachments from damage by covering them.Do not bend the cables and lines.


601605-10

– Remove protective ring.

– Remove the lower triple clamp with the steering stem.

– Remove the upper steering head bearing.

11.9 Installing the lower triple clampx

601602-10

Main work– Clean the bearing and sealing elements, check for damage, and grease.

High viscosity grease ( p. 83)

– Insert the lower triple clamp with the steering stem. Mount the upper steering headbearing.

– Check whether the top steering head seal is correctly positioned.

– Slide on protective ring.

601603-10

– Position the upper triple clamp with the steering.

– Mount nut, but do not tighten it yet.

601595-11

– Position the fork legs.

InfoThe upper milled groove in the fork leg must be flush with the top edge ofthe upper triple clamp.Position bleeder screws to the front.

601594-12

– Tighten screws.

Guideline

Screw, bottom triple clamp M8 15 Nm(11.1 lbf ft)


601606-10

– Tighten nut.

Guideline

Nut, steering head M20x1.5 No play≤ 9 Nm(≤ 6.6 lbf ft)

Only applies whenusing:Holding wrenchfor steeringhead bearing(45229050000)

– Position the fuel tank breather.

601606-11

– Tighten screw.

Guideline


601594-13

– Tighten screws.

Guideline


601593-12

– Position brake caliper, and mount and tighten screws .

Guideline

Screw, front brake caliper M8 20 Nm(14.8 lbf ft)

Loctite® 243™

– Position the brake line and clamp. Mount and tighten screws .

Finishing work– Install the front fender. ( p. 33)

– Install the start number plate. ( p. 33)

– Check that the wiring harness, cables, and brake and clutch lines can move freelyand are routed correctly.

– Install the front wheel.x ( p. 55)

– Check play of steering head bearing. ( p. 31)


11.10 Checking play of steering head bearing

WarningDanger of accidents Unstable vehicle handling from incorrect steering head bearing play.

– Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.)

InfoIf the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam-aged over time.



400738-11

Main work– Move the handlebar to the straight-ahead position. Move the fork legs to and fro in

the direction of travel.

No play should be noticeable in the steering head bearing.

» If there is noticeable play present:

– Adjust the play of the steering head bearing.x ( p. 32)

– Move the handlebar to and fro over the entire steering range.

The handlebar must be able to move easily over the entire steering range. Noresting locations should be noticeable.

» If click positions are noticeable:

– Adjust the play of the steering head bearing.x ( p. 32)

– Check the steering head bearing and replace if required.


11.11 Adjusting the play of the steering head bearingxPreparatory work– Raise the motorcycle with a lift stand. ( p. 27)

101937-10

Main work– Remove fuel tank breather.

– Loosen screws.

– Loosen screw.

– Loosen and retighten nut.

Guideline

Nut, steering head M20x1.5 No play≤ 9 Nm(≤ 6.6 lbf ft)

Only applies whenusing:Holding wrenchfor steeringhead bearing(45229050000)

– Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.

– Tighten screw.

Guideline


– Tighten screws.

Guideline


– Position the fuel tank breather.

Finishing work– Check play of steering head bearing. ( p. 31)


11.12 Greasing the steering head bearingx

400563-01

– Remove the lower triple clamp.x ( p. 29)

– Install the lower triple clamp.x ( p. 30)


11.13 Dismounting the start number plate

C00050-10

– Remove screw and take off clamp.

– Remove screw. Remove the start number plate.

11.14 Installing the start number plate

C00058-10

– Position the start number plate with the drill holes onto the holding lugs of thefender.

C00052-10


Guideline


– Position the brake line. Put the clamp on, mount and tighten screw.

11.15 Dismounting the front fender

601982-10

– Remove screws. Remove the front fender.

11.16 Installing the front fender

101938-10

– Position the fender with holding lugs into the drill holes on the start numberplate.


601982-11

– Position the front fender. Mount and tighten screws.

Guideline


11.17 Removing the shock absorberxPreparatory work– Raise the motorcycle with a lift stand. ( p. 27)

102033-10

Main work– Remove screw and lower the rear wheel with the swingarm as far as possible

without blocking the rear wheel. Fix the rear wheel in this position.

– Remove screw, push splash protector to the side, and remove the shockabsorber.

11.18 Installing shock absorberx

WarningDanger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior.

– Following modifications, ride slowly at first to get the feel of the new ride behavior.

102033-11

Main work– Push the splash protector to the side and position the shock absorber according

to the desired seat height. Mount and tighten screw.

Guideline

Screw, top shock absorber M10 45 Nm(33.2 lbf ft)


Guideline

Screw, bottom shock absorber M10 45 Nm(33.2 lbf ft)


11.19 Removing the seat

102034-10

– Open quick release and raise the rear of the seat.

– Pull back the seat and remove it.


11.20 Mounting the seat

102035-10

– Hook the seat onto screw and lower the seat at the rear while pushing it for-ward.

Projection hooks into the fuel tank.

102034-11

– Close quick release.

11.21 Removing the air filterx

NoteEngine failure Unfiltered intake air has a negative effect on the service life of the engine.

– Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to increased wear.

WarningEnvironmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Preparatory work– Remove the seat. ( p. 34)

102036-10

Main work– Press the rear holding lugs together slightly and swing the air filter box cover

upward. Pull out the front holding lug and take off the air filter box cover.

– Take off the air filter.

11.22 Installing the air filterx

102037-10

Main work– Position the clean air filter.

– Position the rear holding lug. Lower the air filter box cover and allow the front hold-ing lug to snap in.

InfoIf the air filter is not correctly mounted, dust and dirt can enter the engineand cause damage.

Finishing work– Mount the seat. ( p. 35)


11.23 Cleaning the air filter and air filter boxx



InfoDo not clean the air filter with fuel or petroleum since these substances attack the foam.

Preparatory work– Remove the seat. ( p. 34)

– Remove the air filter.x ( p. 35)

Main work– Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.

Air filter cleaner ( p. 83)

InfoOnly press the air filter to dry it, never wring it out.

– Oil the dry air filter with a high quality filter oil.

Oil for foam air filter ( p. 83)

– Clean the air filter box.

– Check the intake flange for damage and looseness.

Finishing work– Install the air filter.x ( p. 35)

– Mount the seat. ( p. 35)

11.24 Removing main silencer

WarningDanger of burns The exhaust system gets very hot when the vehicle is driven.

– Allow the exhaust system to cool down. Do not touch hot components.

102038-10

– Remove screw.

– Remove screw.

102043-10

– Pull the main silencer off of the manifold at the rubber sleeve.


11.25 Installing the main silencer

700513-01

– Position the main silencer.

– Mount the main silencer with the rubber sleeve.

– Mount the silentblock with the screw.

Guideline


102039-10

– Position the collar sleeves.


Guideline


11.26 Changing the glass fiber yarn filling of the main silencerx

WarningDanger of burns The exhaust system gets very hot when the vehicle is driven.

– Allow the exhaust system to cool down. Do not touch hot components.

InfoOver time, the fibers of the fiber glass yarn volatilize outwards; the silencer "burns" out.Not only is the noise level higher, the performance characteristic changes.

Preparatory work– Remove the main silencer. ( p. 36)

700514-01

Main work– Remove screws of end cap. Remove end cap and outer tube.

– Pull the glass fiber yarn filling from the inner tube.

– Clean the parts that are to be reinstalled.

– Mount the new glass fiber yarn filling on the inner tube.

– Slide the outer tube over the glass fiber yarn filling.

– Insert the end cap into the outer tube.

– Mount and tighten the screws with the toothed washers.

Guideline


Finishing work– Install the main silencer. ( p. 37)

11.27 Removing the chain guard (50 SX)

101945-10

– Remove cable binder.

– Take off the chain guard.


11.28 Installing the chain guard (50 SX)

201947-10

– Position the chain guard. Mount cable binder.

InfoThe cable binder must be run between chain sliding guard andswingarm.

101945-11

– Mount the cable binder at the rear.

– Align the chain guard so that screws of the chain guide are visible.

– Tighten the cable binder and cut off the ends.

11.29 Removing the engine sprocket coverxPreparatory work– Raise the motorcycle with a lift stand. ( p. 27)

100895-10

Main work– Remove screws.

– Remove screw.

– Take off the engine sprocket cover.

11.30 Installing the engine sprocket coverx

100895-10

Main work– Position the engine sprocket cover. Mount screws but do not tighten yet.


Guideline

Screw, engine sprocket cover M8 12 Nm (8.9 lbf ft)

– Tighten screws.

Guideline

Screw, engine sprocket cover M6 10 Nm (7.4 lbf ft)



11.31 Checking the chain for dirtPreparatory work(50 SX)

– Remove the chain guard. ( p. 37)

400678-01

Main work– Check the chain for coarse dirt accumulation.

» If the chain is very dirty:

– Clean the chain. ( p. 39)

Finishing work(50 SX)

– Install the chain guard. ( p. 38)

11.32 Cleaning the chain

WarningDanger of accidents Oil or grease on the tires reduces their grip.

– Remove oil and grease with a suitable cleaning material.

WarningDanger of accidents Reduced braking efficiency due to oil or grease on the brake discs.

– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.



InfoThe service life of the chain depends largely on its maintenance.

Preparatory work(50 SX)


400725-01

Main work– Clean the chain regularly and then treat with chain spray.

Chain cleaner ( p. 83)

Off-road chain spray ( p. 83)




11.33 Checking the chain tension

WarningDanger of accidents Danger caused by incorrect chain tension.

– If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear-ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can causethe chain or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may falloff the engine sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension iscorrect and adjust it if necessary.


(50 SX)– Remove the chain guard. ( p. 37)

101946-10

Main work– Push the chain at the end of the chain sliding component upward to measure the

chain tension.

InfoThe upper chain section must be taut.Because chain wear is not always even, repeat this measurement at differ-ent chain positions.

Chain tension 5… 8 mm (0.2… 0.31 in)

» If the chain tension does not meet specifications:

– Adjust the chain tension. ( p. 40)




11.34 Adjusting chain tension

WarningDanger of accidents Danger caused by incorrect chain tension.

– If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear-ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can causethe chain or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may falloff the engine sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension iscorrect and adjust it if necessary.




101947-10

Main work– Loosen nut.

– Adjust the chain tension by turning adjusting nuts left and right.

Guideline

Chain tension 5… 8 mm (0.2… 0.31 in)

Turn adjusting nuts equally on the left and right. The rear wheel must bealigned with the front wheel.

– Make sure that the chain adjuster support plates are in contact with adjustingnuts.

– Tighten nut.

Guideline

Nut, rear wheel spindle M12x1 40 Nm(29.5 lbf ft)


11.35 Checking the chain, rear sprocket, engine sprocket and chain guidePreparatory work– Raise the motorcycle with a lift stand. ( p. 27)


– Remove the engine sprocket cover.x ( p. 38)

100896-10

Main work– Check the engine sprocket cover for wear.

» If the engine sprocket cover is worn through in the marked area:

– Change the engine sprocket cover.x

400227-01

– Check the rear sprocket and engine sprocket for wear.

» If the rear sprocket and engine sprocket are worn:

– Change.the drive set.x

InfoThe engine sprocket, rear sprocket, and chain should always bechanged together.When fitting the chain joint, always make sure that the closed sideof the joint faces forward (riding direction).

– Check the chain for wear.

» If the chain is worn:

– Change.the drive set.x

InfoWhen you replace the chain, you should also change the rearsprocket and engine sprocket.New chains wear out faster on old, worn sprockets.

401035-01

– Check the chain sliding guard for wear.

» If the ridge is worn down to the level of the main corpus:

– Change the chain sliding guard.x– Check the chain sliding guard for tightness.

» If the chain sliding guard is loose:

– Tighten the chain sliding guard.

Guideline

Screw, chain sliding piece M6 3 Nm(2.2 lbf ft)


401036-01

– Check the chain sliding piece for wear.

» If the lower edge of the chain pins is in line with or below the chain slidingpiece:

– Change the chain sliding piece.x– Check the chain sliding piece for tightness.

» If the chain sliding piece is loose:

– Tighten the chain sliding piece.

Guideline

Screw, chain sliding piece M8 15 Nm(11.1 lbf ft)

401034-01

– Check the chain guide for wear.

» If the chain guide is worn down to the top or bottom edge:

– Change the chain guide.x

101948-01

– Check the chain guide for tightness.

» If the chain guide is loose:

– Tighten the chain guide.

Guideline

Remaining screws, chassis M6 10 Nm(7.4 lbf ft)

Finishing work– Install the engine sprocket cover.x ( p. 38)

(50 SX)– Install the chain guard. ( p. 38)


11.36 Adjusting the chain guidex

InfoThe size of the chain wheel varies with the number of teeth. The chain guide can be adjusted on small sprockets.

Preparatory work(50 SX)



101949-10

Main work– Loosen screw.

– Position the chain guide.

– Tighten screw.

Guideline




11.37 Checking the framex

601599-01

– Check the frame for cracking and deformation.

» If the frame exhibits cracking or deformation due to a mechanical impact:

– Change the frame.x

InfoA frame that has been damaged due to a mechanical impact mustalways be changed. Repair of the frame is not authorized by KTM.

11.38 Checking the swingarmx

601598-01

– Check the swingarm for damage, cracking, and deformation.

» If the swingarm exhibits damage, cracking, or deformation:

– Change the swingarm.x

InfoAlways replace a damaged swingarm. Repair of the swingarm is notauthorized by KTM.

11.39 Checking the throttle cable routingPreparatory work– Remove the seat. ( p. 34)


– Remove the fuel tank.x

C00060-10

Main work– Check the throttle cable routing.

The throttle cable must be routed to the carburetor behind the handlebars abovethe fuel tank bearing.

» If the throttle cable is not routed as specified:

– Correct the throttle cable routing.

Finishing work– Install the fuel tank.x– Mount the seat. ( p. 35)


11.40 Checking the rubber grip

401197-01

– Check the rubber grips on the handlebar for damage, wear, and looseness.

» If a rubber grip is damaged, worn, or loose:

– Change and secure the rubber grip.

Rubber grip adhesive (00062030051) ( p. 83)

11.41 Additionally securing the rubber gripPreparatory work– Check the rubber grip. ( p. 44)

401198-01

Main work– Secure the rubber grip at two locations with the retaining wire.

Securing wire (54812016000)

Wire twister forceps (U6907854)

The twisted wire ends face away from the palms and are bent in toward therubber grip.

12 BRAKE SYSTEM 45

12.1 Checking play of handbrake lever

601980-10

– Push the handbrake lever forwards and check the play.

Play of hand brake lever 3… 5 mm (0.12… 0.2 in)

» If the play does not meet specifications:

– Adjust the play of the hand brake lever. ( p. 45)

12.2 Adjusting the play of the hand brake lever

601981-10

– Check the play of the handbrake lever. ( p. 45)

– Adjust the play of the hand brake lever with the adjusting screw.

Guideline

Play of hand brake lever 3… 5 mm (0.12… 0.2 in)

12.3 Adjusting the basic position of the hand brake lever

601981-11

– Remove screw. Take off cover.

601983-10

– Check the play of the handbrake lever. ( p. 45)

– Adjust the basic position of the hand brake lever with adjusting screw to therider's hand size.

InfoTurn the adjusting screw clockwise to increase the distance between thehand brake lever and the handlebar.Turn the adjusting screw counterclockwise to decrease the distance betweenthe hand brake lever and the handlebar.The range of adjustment is limited.

601981-11

– Position cover. Mount and tighten screw.

12 BRAKE SYSTEM 46

12.4 Checking brake discs

WarningDanger of accidents Reduced braking efficiency due to worn brake disc(s).

– Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.)

AA

400257-10

– Check the thickness of the front and rear brake discs at several places on the discto see if it conforms to measurement.

InfoWear reduces the thickness of the brake disc around the area used by thebrake linings.

Brake discs - wear limits

Front 2.5 mm (0.098 in)

Rear 2.5 mm (0.098 in)

» If the brake disc thickness is less than the specified value:

– Change the brake disc.

– Check the front and rear brake discs for damage, cracking and deformation.

» If the brake disk exhibits damage, cracking or deformation:

– Change the brake disc.

12.5 Checking front brake fluid level


– If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake systemis leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding. (Yourauthorized KTM workshop will be glad to help.)

WarningSkin irritation Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.

– Wear suitable protective clothing and goggles.

– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.

WarningDanger of accidents Reduced braking efficiency due to old brake fluid.

– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop willbe glad to help.)



InfoNever use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5brake fluid.Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!Use only clean brake fluid from a sealed container.

12 BRAKE SYSTEM 47

601984-10

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

– Remove screws.

– Remove cover with membrane.

– Check the brake fluid level.

Brake fluid level under top level of con-tainer

5 mm (0.2 in)

» If the brake fluid level does not meet specifications:

– Add front brake fluid.x ( p. 47)

– Position the cover with the membrane. Mount and tighten the screws.

InfoClean up overflowed or spilt brake fluid immediately with water.

12.6 Adding front brake fluidx


– If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake systemis leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding. (Yourauthorized KTM workshop will be glad to help.)










Preparatory work– Check the front brake linings. ( p. 48)

601984-10

Main work– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

– Remove screws.


– Correct the brake fluid level.

Guideline


5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 ( p. 81)



12 BRAKE SYSTEM 48

12.7 Checking the front brake linings

WarningDanger of accidents Reduced braking efficiency caused by worn brake linings.

– Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)

601607-10

– Check the brake linings for minimum thickness.

Minimum thickness ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

– Change the front brake linings.x ( p. 48)

– Check the brake linings for damage and cracking.

» If damage or wear is encountered:

– Change the front brake linings.x ( p. 48)

12.8 Changing the front brake liningsx

WarningDanger of accident Brake system failure.

– Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.)







WarningDanger of accidents Reduced braking efficiency due to use of non-approved brake linings.

– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTMbrake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi-nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.






12 BRAKE SYSTEM 49

601984-10

Main work– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

– Remove screws.


– Press the brake piston back to its basic position and make sure that no brake fluidoverflows from the brake fluid reservoir.

C00053-12

– Remove the lock washer.

– Remove screw.

C00054-01

– Remove the brake linings.

– Clean brake caliper.

– Insert new brake linings.

InfoAlways change the brake linings in pairs.Ensure that the brake linings are correctly positioned in the holding spring.

C00055-12

– Mount screw.

Guideline

Screw, brake linings M5 8 Nm (5.9 lbf ft)

– Mount lock washer.

– Check the brake discs. ( p. 46)

– Install the front wheel.x ( p. 55)

– Correct the brake fluid level.

Guideline


5 mm (0.2 in)



InfoClean up overflowed or spilled brake fluid immediately with water.

12.9 Checking the free travel of the foot brake lever


– If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due tooverheating. Adjust the free travel on foot brake lever according to specifications.

12 BRAKE SYSTEM 50

700488-01

– Disconnect spring.

– Move the foot brake lever back and forth between the end stop and the foot brakecylinder piston bracket and check free travel.

Guideline

Free travel of foot brake lever 3… 5 mm (0.12… 0.2 in)

» If the free travel does not meet specifications:

– Adjust the free travel of the foot brake lever.x ( p. 50)

– Attach spring.

12.10 Adjusting the free travel of the foot brake leverx



C00141-10

– Detach the spring.

– Loosen nut.

– Turn push rod until clearance is created.

Guideline


– Hold push rod and tighten nut.

– Attach the spring.

– Check whether the basic position of the foot brake lever is suitable for the rider.

» When the basic position of the foot brake lever needs to be adjusted:

– Adjust the basic position of the foot brake lever.x ( p. 50)

12.11 Adjusting the basic position of the foot brake leverx



700489-01

– Detach the spring.

– Loosen nut.

– Turn back push rod until free travel is at a maximum.

– For an individual adjustment of the basic position of the foot brake lever, loosenthe screw and turn the eccentric brake lever stop accordingly.

– Tighten screw.

Guideline


– Turn push rod until clearance is created.

Guideline


– Hold push rod and tighten nut.

– Attach spring.

– Check whether the basic position of the foot brake lever is suitable for the rider.

12 BRAKE SYSTEM 51

12.12 Checking rear brake fluid level

WarningDanger of accidents Failure of the brake system.

– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)



700490-01

– Stand the vehicle upright.

– Check the brake fluid level in the viewer.

» When an air bubble is visible in the viewer:

– Add rear brake fluid.x ( p. 51)

12.13 Adding rear brake fluidx

WarningDanger of accidents Failure of the brake system.

– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)











– Check the rear brake linings. ( p. 52)

12 BRAKE SYSTEM 52

201175-12

Main work– Remove screws.

– Take off cover with washer and membrane.

201170-10

– Add brake fluid to level.

Guideline

Dimension (brake fluid level belowtop edge of container)

10 mm (0.39 in)


– Position the membrane and the cover with the washer. Mount and tighten thescrews.



12.14 Checking the rear brake linings

WarningDanger of accidents Reduced braking efficiency caused by worn brake linings.

– Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)

700491-01

– Check the brake linings for minimum thickness.

Minimum thickness ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

– Change the rear brake linings.x ( p. 52)

– Check the brake linings for damage and cracking.

» If damage or wear is encountered:

– Change the rear brake linings.x ( p. 52)

12.15 Changing the rear brake liningsx

WarningDanger of accident Brake system failure.

– Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.)







12 BRAKE SYSTEM 53

WarningDanger of accidents Reduced braking efficiency due to use of non-approved brake linings.

– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTMbrake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi-nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.






– Remove the rear wheel.x ( p. 56)

700492-01

Main work– Remove the lock washer.

– Remove screw.

700493-01

– Remove the brake linings.

– Clean brake caliper and brake caliper support.

201175-12

– Remove screws.

– Take off cover with washer and membrane.

– Press the brake piston back to its basic position and make sure that no brake fluidoverflows from the brake fluid reservoir.

700493-10

– Insert new brake linings.

InfoAlways change the brake linings in pairs.Ensure that the brake linings are correctly positioned in the holding spring.

12 BRAKE SYSTEM 54

700494-12

– Mount screw.

Guideline

Screw, brake linings M5 8 Nm (5.9 lbf ft)

– Mount lock washer.

– Check the brake discs. ( p. 46)

– Install the rear wheel.x ( p. 56)

201170-10

– Add brake fluid to level.

Guideline

Dimension (brake fluid level belowtop edge of container)

10 mm (0.39 in)


– Position the membrane and the cover with the washer. Mount and tighten thescrews.

InfoClean up overflowed or spilled brake fluid immediately with water.




13 WHEELS, TIRES 55

13.1 Removing the front wheelxPreparatory work– Raise the motorcycle with a lift stand. ( p. 27)

601596-10

Main work– Remove screw.

– Loosen screws.

601597-10

– Withdraw the wheel spindle while holding the front wheel. Take the front wheel outof the fork.

InfoDo not pull the hand brake lever when the front wheel is removed.Always lay the wheel down in such a way that the brake disc is not dam-aged.

13.2 Installing the front wheelx



601597-11

– Check the wheel bearing for damage and wear.

» If the wheel bearing is broken or worn:

– Change the wheel bearing.x– Clean and grease wheel spindle.

Long-life grease ( p. 83)

– Lift the front wheel into the fork, position it, and insert wheel spindle.

The brake linings are correctly positioned.

601596-10


Guideline

Front wheel spindle screw M10 40 Nm(29.5 lbf ft)

– Operate the hand brake lever several times until the brake linings are in contactwith the brake disc.


– Pull the front wheel brake and push down hard on the fork several times to alignthe fork legs.

– Tighten screws.

Guideline

Screw, fork stub M6 10 Nm (7.4 lbf ft)

13 WHEELS, TIRES 56

13.3 Removing rear wheelxPreparatory work– Raise the motorcycle with a lift stand. ( p. 27)


101950-11

Main work– Remove nut.

– Remove the washer.

InfoProtect the motorcycle and its attachments against damage by coveringthem.

– Pull out the wheel spindle with the washer.

– Remove the chain from the rear sprocket.

– Take the rear wheel out of the swing arm.

InfoDo not operate the foot brake when the rear wheel is removed.Always lay the wheel down in such a way that the brake disc is not dam-aged.

13.4 Installing the rear wheelx



101950-10

Main work– Check the wheel bearing for damage and wear.

» If the wheel bearing is broken or worn:

– Change the wheel bearing.x– Clean and grease wheel spindle.

Long-life grease ( p. 83)

– Lift the rear wheel into the swingarm and place the chain on the rear sprocket.

The brake linings are correctly positioned.

– Insert the wheel spindle with the washer.

– Position washer. Mount nut, but do not tighten it yet.

– Make sure that the chain adjuster support plates are in contact with the adjustingnuts.


– Tighten nut.

Guideline

Nut, rear wheel spindle M12x1 40 Nm(29.5 lbf ft)

– Operate the foot brake lever repeatedly until the brake linings lie on the brake discand there is a pressure point.




13 WHEELS, TIRES 57

13.5 Checking the tire condition

InfoOnly mount tires that have been approved and/or recommended by KTM.Other tires could have a negative effect on riding behavior.The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.The front and rear wheels must be mounted with tires with similar profiles.Worn tires have a negative effect on riding behavior, especially on wet surfaces.

400602-10

– Check the front and rear tires for cuts, run-in objects and other damage.

» If the tires exhibit cuts, run-in objects or other damage:

– Change the tires.

– Check the depth of the tread.

InfoNote local national regulations concerning the minimum tread depth.

Minimum tread depth ≥ 2 mm (≥ 0.08 in)

» If the tread depth is less than the minimum permissible depth:


– Check the tire age.

InfoThe tire's date of manufacture is usually part of the tire markings and isindicated by the last four digits of the DOT marking. The first two digits referto the week of manufacture and last two digits refer to the year of manufac-ture.KTM recommends that the tires be changed after 5 years at the latest,regardless of the actual state of wear.

» If a tire is more than 5 years old:


13.6 Checking tire air pressure

InfoLow tire air pressure leads to abnormal wear and overheating of the tire.Correct tire air pressure ensures optimal riding comfort and maximum tire service life.

400695-01

– Remove the protection cap.

– Check the tire air pressure when the tires are cold.

Tire air pressure off road

Front 1.0 bar (15 psi)

Rear 1.0 bar (15 psi)

» If the tire pressure does not meet specifications:

– Correct the tire pressure.

– Mount the protection cap.

13.7 Checking spoke tension

WarningDanger of accidents Instable handling due to incorrect spoke tension.

– Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.)

InfoA loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.If the spokes are too tight, they can break due to local overload.Check the spoke tension regularly, especially on a new motorcycle.

13 WHEELS, TIRES 58

400694-01

– Briefly strike each spoke with the blade of a screwdriver.

InfoThe frequency of the tone depends on the spoke length and diameter.If you hear different tone frequencies from spokes of the same length andthickness, this is an indication that the spoke tension differs.

You should hear a high note.

» If the spoke tension differs:

– Correct the spoke tension.x– Check the spoke torque.

Guideline

Spoke nipple M3.5 3 Nm (2.2 lbf ft)

Torque wrench with various accessories in set (58429094000)

14 COOLING SYSTEM 59

14.1 Cooling system

C00062-10

The water pump in the engine forces the coolant to flow.The pressure resulting from the warming of the cooling system is regulated by a valvein the radiator cap. This ensures that operating the vehicle at the specified coolanttemperature will not result in a risk of malfunctions.

120 °C (248 °F)

Cooling is effected by the air stream.The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cool-ing effect.

14.2 Checking the antifreeze and coolant level

WarningDanger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.

– Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow theengine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

WarningDanger of poisoning Coolant is poisonous and a health hazard.

– Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water imme-diately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swal-lowed, contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach ofchildren.

InfoCarry out this work with a cold engine.

102040-10

– Stand the motorcycle upright on a horizontal surface.

– Remove radiator cap.

– Check the antifreeze of the coolant.

−25… −45 °C (−13… −49 °F)

» If the antifreeze of the coolant does not meet specifications:

– Correct the antifreeze of the coolant.

400243-10

– Check the coolant level in the radiator.

Coolant level above the radiatorfins

10 mm (0.39 in)

» If the level of the coolant does not meet specifications:

– Correct the coolant level.

Alternative 1

Coolant ( p. 81)

Alternative 2

Coolant (mixed ready to use) ( p. 81)

– Mount the radiator cap.


14.3 Checking the coolant level






400243-10

– Stand the motorcycle upright on a horizontal surface.

– Remove the radiator cap.

– Check the coolant level in the radiator.

Coolant level above the radiatorfins

10 mm (0.39 in)

» If the coolant level does not meet specifications:

– Correct the coolant level.

Alternative 1

Coolant ( p. 81)

Alternative 2



14.4 Draining the coolantx






G01288-10


– Place a suitable container under the engine.

– Remove screw. Remove the radiator cap.

– Completely drain the coolant.

– Mount screw with a new seal ring and tighten it.

Guideline

Drain plug, water pump cover M6 6 Nm (4.4 lbf ft)


14.5 Refilling coolantx



700511-01

Main work– Make sure that the screw is tightened.


– Add coolant to level.

Guideline

Level above the radiator fins 10 mm (0.39 in)

Coolant 0.5 l (0.5 qt.) Coolant ( p. 81)


00AA00BB

400677-11

– Position the vehicle as shown and secure it against rolling away. A height differ-ence of must be reached.

Guideline

Height difference 100 cm (39.4 in)

InfoTo ensure that all of the air can escape from the cooling system, the front ofthe vehicle must be jacked up. A poorly bled cooling system is less effectiveat cooling and may result in overheating of the engine.

– Place the vehicle back on a level surface.

– Add coolant to level.


– Make a short test ride.

Finishing work– Check the coolant level. ( p. 60)

15 TUNING THE ENGINE 62

15.1 Checking the installation position of the throttle grip

601970-10

– Position the throttle grip so that surface is vertical.

InfoIf the throttle grip is tipped forward, the throttle cable will slip out of theguide on the carburetor. The throttle slide can no longer be closed.

15.2 Checking the play of the throttle cable

400192-10

– Check the throttle grip for smooth operation.

– Move the handlebar to the straight-ahead position. Move the throttle grip back-wards and forwards to ascertain play in the throttle cable.

Play in gas throttle cable 3… 5 mm (0.12… 0.2 in)

» If the throttle cable play does not meet specifications:

– Adjust the play in the throttle cable.x ( p. 62)

DangerDanger of poisoning Exhaust gases are toxic and inhaling them may resultin unconsciousness and/or death.

– When running the engine, always make sure there is sufficient ventila-tion, and do not start or run the engine in an enclosed space without aneffective exhaust extraction system.

– Start the engine and let it idle. Move the handlebar to and fro over the entire steer-ing range.

The idle speed should not change.

» If the idle speed changes:

– Adjust the play in the throttle cable.x ( p. 62)

15.3 Adjusting the play in the throttle cablexPreparatory work– Remove the seat. ( p. 34)


– Remove the fuel tank.x– Check the throttle cable routing. ( p. 43)

S00012-10

Main work– Move the handlebar to the straight-ahead position.

– Push back sleeve.

– Ensure that the throttle cable sleeve is pushed all the way into adjusting screw.

– Loosen nut.

400192-11

– Turn adjusting screw so that there is throttle cable play at the throttle grip.

Guideline

Play in gas throttle cable 3… 5 mm (0.12… 0.2 in)

– Tighten nut.

– Slide on sleeve.


Finishing work– Install the fuel tank.x– Mount the seat. ( p. 35)

– Check the play of the throttle cable. ( p. 62)

15.4 Carburetor - idle (50 SX)

700520-01

The idle setting of the carburetor has a big influence on the starting behavior, stableidling and the response to throttle opening. That means that an engine with a correctlyset idle speed is easier to start than if the idle is set wrongly.

InfoThe carburetor and its components are subject to increased wear caused byengine vibration. Wear can result in malfunctioning.

The idle speed is adjusted with idle speed adjusting screw.The idle mixture is adjusted with the idle mixture adjustment screw.

15.5 Carburetor - idle (50 SX Mini)

700522-01

The idle setting of the carburetor has a big influence on the starting behavior, stableidling and the response to throttle opening. That means that an engine with a correctlyset idle speed is easier to start than if the idle is set wrongly.

InfoThe carburetor and its components are subject to increased wear caused byengine vibration. Wear can result in malfunctioning.

The idle speed is adjusted with idle speed adjusting screw.The idle mixture is adjusted with the idle mixture adjustment screw.

15.6 Carburetor - adjusting idle speedx (50 SX)

700520-01

– Screw in the idle adjusting screw until it stops and then to the prescribed basicsetting.

Guideline

Idle mixture adjusting screw

Open 3 turns

– Run the engine until warm.

Guideline

Warming-up phase ≥ 5 min



– Adjust the idle speed using the idle speed adjusting screw.

Guideline

Choke function deactivated – Choke knob is in lower position. No O-ring is visi-ble. ( p. 14)

Idle speed 1,400… 1,500 rpm

– Turn the idle adjusting screw slowly clockwise until the idle speed begins tofall.

– Note the position and turn the idle adjusting screw slowly counterclockwise untilthe idle speed falls.

– Adjust to the point between these two positions with the highest idle speed.


InfoIf the speed rise is too high, reduce the idle speed to a normal level andrepeat the preceding steps.If the procedure described here does not lead to satisfactory results, thecause may be a wrongly dimensioned idling jet.If you can turn the idle adjusting screw to the end without any change ofengine speed, you have to install a smaller idling jet.After changing the idling jet, start from the beginning with the adjustingsteps.Following extreme air temperature or altitude changes, adjust the idle speedagain.

15.7 Carburetor - adjusting idle speedx (50 SX Mini)

700522-01

– Screw in idle air adjusting screw all the way and turn it to the specified basicposition.

Guideline

Idle air adjusting screw

Open 1 turn

– Run the engine until warm.

Guideline

Warming-up phase ≥ 5 min



– Adjust the idle speed using the idle speed adjusting screw.

Guideline

Choke function deactivated – The choke lever is pushed down all the way.( p. 14)

Idle speed 1,400… 1,500 rpm

– Turn idle air adjusting screw slowly in a clockwise direction until the idle speedbegins to fall.

– Note the position and turn the idle air adjusting screw slowly counterclockwise untilthe idle speed falls again.

– Adjust to the point between these two positions with the highest idle speed.

InfoIf the engine speed rises considerably, reduce the idle speed to a normallevel and repeat the above steps.If the procedure described here does not lead to satisfactory results, thecause may be a wrongly dimensioned idling jet.If you can turn the idle air adjusting screw to the end without any change ofengine speed, you need to install a smaller idling jet.After changing the idling jet, start from the beginning with the adjustingsteps.Following extreme air temperature or altitude changes, adjust the idle speedagain.


15.8 Checking the clutch settingx

102041-10

– Connect special tool.

Tachometer (45129075000)

401521-01

– Let the front wheel of the vehicle make contact with a fixed object.



– Start the motorcycle.

– Only ride full throttle to the point where the maximum engine speed is reached.

Guideline

≤ 3 s

– Read the speed.

Slip speed 8,700… 9,300 rpm

» If the specified value is not reached:

– Adjust the clutch.x ( p. 66)

15.9 Removing the clutch coverx



InfoFuel can emerge via the carburetor.Capture emerging fuel using a suitable container.


102042-01

– Lay the vehicle down on its left side as shown.


S00001-10

– Remove screws.

– Remove clutch cover with the seal ring.

15.10 Adjusting the clutchxPreparatory work– Remove the clutch cover.x ( p. 65)

S00002-10

Main work– Turn the outer clutch hub until adjusting screws become accessible.

S00003-10

ConditionIf there is no reference point:

– Turn adjusting screws counterclockwise to the last detectable click.

– Turn adjusting screws clockwise by 9 clicks to the basic setting.

Guideline

Basic setting of slip speed 8,700… 9,300 rpm

InfoThe springs may not be pretensioned by more than 17 clicks from thestop using the adjusting screws.

ConditionIf the slip speed is too low:

– Turn adjusting screws clockwise.

Guideline

1 click increases the slip speed by 250… 350 rpm

InfoThe springs may not be pretensioned by more than 17 clicks from thestop using the adjusting screws.

ConditionIf the slip speed is too high:

– Turn adjusting screws counterclockwise.

Guideline

1 click decreases the slip speed by 250… 350 rpm

Finishing work– Install the clutch cover.x ( p. 67)

– Check the gear oil level. ( p. 69)

– Check the clutch setting.x ( p. 65)


15.11 Installing the clutch coverx

S00004-10

Main work– Position clutch cover with the seal ring.

– Mount and tighten screws.

Guideline

Screw, clutch cover M6 10 Nm (7.4 lbf ft)

Finishing work– Check the gear oil level. ( p. 69)

16 MAINTENANCE WORK ON THE ENGINE 68

16.1 Checking oil level (50 SX Mini)Preparatory work– Stand the motorcycle upright on a horizontal surface.

102031-10

Main work– Check the oil level in the oil tank.

For a full fuel tank, the oil tank must be filled up to MIN mark at a minimum.

» If the oil level does not meet specifications:

– Fill up with oil. ( p. 20)

16.2 Bleeding the oil pumpx (50 SX Mini)ConditionThe fuel tank has been removed.

300650-10

– Pull off oil line.

300652-10

– Fill the oil line with a syringe.

2-stroke engine oil ( p. 81)

300650-10

– Connect oil line.

300651-10

– Remove screws.

– Take off the oil pump.

– Pull off oil line from the carburetor.


300653-10

– Turn the oil pump gear counterclockwise until oil flows out of oil line with-out bubbles.

300651-10

– Connect oil line.

– Position the oil pump.

– Mount and tighten screws.

Guideline

Screw, oil pump M5 6 Nm (4.4 lbf ft)

16.3 Checking the gear oil levelConditionThe motor is cold.

Preparatory work– Stand the motorcycle upright on a horizontal surface.

G01291-10

Main work– Remove gear oil level check screw.

– Check the gear oil level.

A small amount of gear oil should flow out.

» If no gear oil flows out:

– Add gear oil.x ( p. 70)

– Mount and tighten the gear oil level check screw.

Guideline

Screw, gear oil level check M6 6 Nm (4.4 lbf ft)

16.4 Changing the gear oilx

WarningDanger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.

– Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.



InfoDrain the gear oil only when the engine is warm.

Preparatory work– Stand the motorcycle on its side stand on a horizontal surface.


G01290-10

Main work– Place a suitable container under the engine.

– Remove the oil drain plug with magnet.

– Completely drain the gear oil.

– Thoroughly clean the oil drain plug with magnet.

– Clean the sealing area on the engine.

– Mount and tighten the oil drain plug with magnet and seal ring.

Guideline

Oil drain plug with magnet M12x1.5 20 Nm(14.8 lbf ft)

G01289-10

– Remove screw cap and top up gear oil.

Gear oil 0.20 l (0.21 qt.) Gear oil (ATF Dexron 3) ( p. 81)

InfoToo little gear oil or poor-quality oil results in premature wear of the trans-mission.

– Mount and tighten screw cap.



– Start the engine and check that it is oil-tight.

Finishing work– Check the gear oil level. ( p. 69)

16.5 Adding gear oilx

InfoToo little gear oil or poor-quality oil results in premature wear of the transmission.

G01291-10

– Remove gear oil level check screw.

G01289-10

– Remove screw cap. Stand the vehicle upright.

– Add gear oil until it flows out of the bore of the gear oil level screw.

Gear oil (ATF Dexron 3) ( p. 81)

– Mount and tighten the gear oil level check screw.

Guideline

Screw, gear oil level check M6 6 Nm (4.4 lbf ft)

– Mount and tighten screw cap.




– Start the engine and check that it is oil-tight.

17 CLEANING, CARE 72

17.1 Cleaning motorcycle

NoteMaterial damage Damage and destruction of components by high-pressure cleaning equipment.

– When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors,cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component.Excessive pressure can cause malfunctions or destroy these parts.



InfoIf you clean the motorcycle regularly, its value and appearance will be maintained over a long period.Avoid direct sunshine on the motorcycle during cleaning.

401061-01

– Seal the exhaust system to prevent penetration by water.

– First remove coarse dirt particles with a gentle water spray.

– Spray very dirty areas with a normal motorcycle cleaner and then clean with abrush.

Motorcycle cleaner ( p. 83)

InfoUse warm water containing normal motorcycle cleaner and a soft sponge.Never apply motorcycle cleaner to the dry vehicle; always rinse with waterfirst.

– After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly.

– Remove the plug from the exhaust system.

– Empty the carburetor float chamber.x

WarningDanger of accidents Reduced braking efficiency due to a wet or dirty brakesystem.

– Clean or dry a dirty or wet brake system by riding and braking gently.

– After cleaning, let your child ride the vehicle a short distance until the enginewarms up and the brakes are dried by applying the brakes carefully.

InfoThe heat produced causes water at inaccessible locations in the engine andthe brake system to evaporate.

– Push back the protection covers on the handlebar controls to allow water to evapo-rate.

– After the motorcycle has cooled off, lubricate all moving parts and bearings.

– Clean the chain. ( p. 39)

– Treat bare metal parts (except for brake discs and exhaust system) withanti-corrosion materials.

Preserving materials for paints, metal and rubber ( p. 83)

– Treat all plastic parts and powder-coated parts with a mild cleaning and care prod-uct.

Special cleaner for glossy and matte paint finishes, metal and plastic surfaces( p. 83)

18 STORAGE 73

18.1 Storage


– Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs withthe eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin withsoap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.Store fuel properly in a suitable canister and keep away from children.

InfoIf you want to garage the motorcycle for a longer period, take the following actions.Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, youshould do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at thestart of the new season.

401058-01

– When refueling the last time before taking the motorcycle out of service, add fueladditive.

Fuel additive ( p. 83)

– Fill up with fuel. ( p. 19)

– Clean the motorcycle. ( p. 72)

– Change the gear oil.x ( p. 69)

– Check the antifreeze and coolant level. ( p. 59)

– Empty the carburetor float chamber.x– Check the tire air pressure. ( p. 57)

– Store the vehicle in a dry location that is not subject to large fluctuations in tem-perature.

InfoKTM recommends raising the motorcycle.

– Raise the motorcycle with a lift stand. ( p. 27)

– Cover the vehicle with a tarp or similar cover that is permeable to air.

InfoDo not use non-porous materials since they prevent humidity from escaping,thus causing corrosion.Avoid running the engine for a short time only. Since the engine cannotwarm up properly, the water vapor produced during combustion condensesand causes valves and exhaust system to rust.

18.2 Preparing for use after storage

401059-01


– Perform checks and maintenance measures when preparing the motorcycle for use.( p. 17)

– Take a test ride.

19 TROUBLESHOOTING 74

Faults Possible cause Action

Engine turns but does not start Operating error – Go through the steps of starting the engine.( p. 17)

Motorcycle was out of use for a longtime and there is old fuel in the floatchamber

– Empty the carburetor float chamber.x

Fuel feed interrupted – Check the fuel tank breather.

– Clean the fuel tap.

(50 SX Mini)– Check/set the carburetor components.x

(50 SX)– Check/set the carburetor components.x

Spark plug oily or wet – Clean and dry the spark plug, or change it ifnecessary.

Electrode distance (plug gap) of sparkplug too wide

– Adjust the plug gap.

GuidelineSpark plug electrode gap0.60 mm (0.0236 in)

Fault in ignition system – Check the ignition system.xShort circuit cable in wiring harnessfrayed, kill switch defective

– Check the kill switch.x

The connector or ignition coil is looseor oxidized

– Clean the plug-in connection and treat it withcontact spray.

Water in carburetor or jets blocked (50 SX Mini)– Check/set the carburetor components.x


Engine has no idle Idling jet blocked (50 SX Mini)– Check/set the carburetor components.x


Adjusting screws on carburetor dis-torted

(50 SX Mini)– Carburetor - adjust the idle speed.x

( p. 64)

(50 SX)– Carburetor - adjust the idle speed.x

( p. 63)

Spark plug defective – Change spark plug.

Ignition system defective – Check the ignition coil.x– Check the spark plug connector.x

Engine does not speed up Carburetor running over because floatneedle dirty or worn



Loose carburetor jets (50 SX Mini)– Check/set the carburetor components.x


Fault in ignition system – Check the ignition system.xEngine has too little power Fuel feed interrupted – Check the fuel tank breather.

– Clean the fuel tap.



Air filter very dirty – Clean the air filter and air filter box.x( p. 36)

19 TROUBLESHOOTING 75

Faults Possible cause Action

Engine has too little power Exhaust system leaky, deformed ortoo little glass fiber yarn filling inmain silencer

– Check exhaust system for damage.

– Change the glass fiber yarn filling of the mainsilencer.x ( p. 37)

Ignition system defective – Check the ignition coil.x– Check the spark plug connector.x

Diaphragm or reed valve housingdamaged

– Check the diaphragm and reed valve housing.

Noticeable wear – Overhaul the engine.

Clutch engagement speed too low ortoo high

– Check the clutch setting.x ( p. 65)

Engine stalls or is popping into thecarburetor

Lack of fuel – Turn the knurled screw on the fuel tap all theway counterclockwise.

– Fill up with fuel. ( p. 19)

Engine takes in bad air – Check the intake flange and carburetor fortightness.

The connector or ignition coil is looseor oxidized

– Clean the plug-in connection and treat it withcontact spray.

Engine overheats Too little coolant in cooling system – Check the cooling system for leakage.

– Check the coolant level. ( p. 60)

Too little air stream – Switch off engine when standing.

Radiator fins very dirty – Clean radiator fins.

Foam formation in cooling system – Drain the coolant.x ( p. 60)

– Refill the coolant.x ( p. 61)

Damaged cylinder head or cylinderhead gasket

– Check the cylinder head or cylinder head gas-ket.

Bent radiator hose – Change the radiator hose.xWhite smoke emission (steam inexhaust gas)

Damaged cylinder head or cylinderhead gasket

– Check the cylinder head or cylinder head gas-ket.

Gear oil exits at the vent hose Too much gear oil added – Check the gear oil level. ( p. 69)

Water in the gear oil Damaged shaft seal ring or waterpump

– Check the shaft seal ring and water pump.

20 TECHNICAL DATA 76

20.1 Engine

Design 1-cylinder 2-stroke engine, water-cooled, with reed intake

Displacement 49.0 cm³ (2.99 cu in)

Stroke 40 mm (1.57 in)

Bore 39.5 mm (1.555 in)

Crankshaft bearing 2 grooved ball bearings

Conrod bearing Needle bearing

Piston pin bearing Needle bearing

Pistons Aluminum cast

Piston rings 1 rectangular ring

Engine lubrication (50 SX) Mixture oil lubrication

Engine lubrication (50 SX Mini) Separate lubrication

Primary transmission 33:61 straight cut spur gear

Clutch Multi-disc automatic clutch on the main shaft/centrifugal force

Gearbox Rigid 1-stage reduction gear

Transmission ratio 14:31

Ignition SELETTRA 2p D36

Spark plug NGK LR 8 B

Spark plug electrode gap 0.60 mm (0.0236 in)

Cooling Water-cooled

Starting aid Kickstarter

20.2 Engine tightening torques

Screw, bearing retainer M5 5 Nm (3.7 lbf ft) –

Screw, kickstarter M5 6 Nm (4.4 lbf ft) Loctite® 243™

Screw, oil pump (50 SX Mini) M5 6 Nm (4.4 lbf ft) –

Screw, stator clamp M5 6 Nm (4.4 lbf ft) Loctite® 222™

Screw, water pump wheel M5 5 Nm (3.7 lbf ft) Loctite® 243™

Bleeder flange of engine case M6 4 Nm (3 lbf ft) Loctite® 243™

Drain plug, water pump cover M6 6 Nm (4.4 lbf ft) –

Screw, alternator cover M6 6 Nm (4.4 lbf ft) –

Screw, clutch cover M6 10 Nm (7.4 lbf ft) –

Screw, engine case M6 10 Nm (7.4 lbf ft) –

Screw, engine sprocket cover M6 10 Nm (7.4 lbf ft) –

Screw, exhaust flange M6 10 Nm (7.4 lbf ft) Loctite® 243™

Screw, fitting pin M6 10 Nm (7.4 lbf ft) Loctite® 648™

Screw, gear oil level check M6 6 Nm (4.4 lbf ft) –

Screw, ignition coil M6 4 Nm (3 lbf ft) Loctite® 243™

Screw, intake flange M6 5 Nm (3.7 lbf ft) Loctite® 243™

Screw, pressure plate M6 10 Nm (7.4 lbf ft) Loctite® 243™

Screw, water pump cover M6 10 Nm (7.4 lbf ft) –

Screw, cylinder head M7 18 Nm (13.3 lbf ft) –

Nuts, cylinder base M8 20 Nm (14.8 lbf ft) –

Screw, outer clutch hub M8 35 Nm (25.8 lbf ft) Loctite® 243™

Stud bolt, cylinder base M8 10 Nm (7.4 lbf ft) –

Spark plug M10x1 10… 12 Nm (7.4…8.9 lbf ft)

–

Nut, primary gear M10x1.25 40 Nm (29.5 lbf ft) Loctite® 243™

Nut, rotor M10x1.25 15 Nm (11.1 lbf ft) Loctite® 243™

Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –


20.3 Carburetor with carburetor tuning

20.3.1 50 SX

Carburetor type Dell`Orto PHBG 19BS

Needle position 2nd position from top

Idle mixture adjusting screw

Open 3 turns

Main jet 95

Jet needle W7

Idling jet 50

Needle jet 262AU

Throttle slide 40

Cold start jet 60

20.3.2 50 SX Mini

Carburetor type Dell`Orto PHVA 12XS

Needle position 3rd position from top

Idle air adjusting screw

Open 1 turn

Main jet 65

Jet needle A8

Idling jet 30

Needle jet 211FA

Throttle slide 40

Cold start jet 60

20.4 Capacities

20.4.1 Gear oil

Gear oil 0.20 l (0.21 qt.) Gear oil (ATF Dexron 3) ( p. 81)

20.4.2 Coolant

Coolant 0.5 l (0.5 qt.) Coolant ( p. 81)


20.4.3 Fuel

Fuel tank capacity, approx.(50 SX)

2.3 l (2.4 qt.) Super unleaded gasoline (95 octane), mixed with 2-strokeengine oil (1:60) ( p. 82)

Fuel tank capacity, approx.(50 SX Mini)

2.0 l (2.1 qt.) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 82)

20.5 Chassis

Frame Central tube frame of chrome molybdenum steel tubing, powder-coated

Fork WP Suspension USD 35

Shock absorber WP Suspension 3614 BAEM

Suspension travel (50 SX)

Front 205 mm (8.07 in)

Rear 185 mm (7.28 in)

Suspension travel (50 SX Mini)


Rear 171 mm (6.73 in)


Fork offset 22 mm (0.87 in)

Brake system

Front Disc brake with four-pot brake caliper

Rear Disc brake with two-pot brake caliper

Brake disc diameters


Rear 160 mm (6.3 in)

Brake discs - wear limits

Front 2.5 mm (0.098 in)

Rear 2.5 mm (0.098 in)

Tire air pressure off road

Front 1.0 bar (15 psi)

Rear 1.0 bar (15 psi)

Secondary drive ratio (50 SX) 11:40

Secondary drive ratio (50 SX Mini) 10:42

Chain 1/2 x 3/16”

Rear sprockets available 38, 39, 40, 41, 42

Steering head angle (50 SX) 66°

Steering head angle (50 SX Mini) 67.4°

Wheelbase (50 SX) 1,032±10 mm (40.63±0.39 in)

Wheelbase (50 SX Mini) 914±10 mm (35.98±0.39 in)

Seat height unloaded (50 SX) 684 mm (26.93 in)

Seat height unloaded (50 SX Mini) 558 mm (21.97 in)

Ground clearance unloaded (50 SX) 252 mm (9.92 in)

Ground clearance unloaded (50 SX Mini) 184 mm (7.24 in)

Weight without fuel, approx. (50 SX) 39.8 kg (87.7 lb.)

Weight without fuel, approx. (50 SX Mini) 39 kg (86 lb.)

20.6 Tires

Validity Front tires Rear tires

(50 SX) 2.50 - 12 42J TTMAXXIS MAXX CROSS SI

2.75 - 10 38J TTMAXXIS MAXX CROSS SI

(50 SX Mini) 2.50 - 10 38J TTMAXXIS MAXX CROSS SI

2.75 - 10 38J TTMAXXIS MAXX CROSS SI

Additional information is available in the Service section under:http://www.ktm.com

20.7 Fork

20.7.1 50 SX Mini

Fork part number 07.18.1L.01


Fork length 580 mm (22.83 in)

Spring rate

Weight of rider: 15… 25 kg (33… 55 lb.) 1.8 N/mm (10.3 lb/in)

Weight of rider (standard): 25… 35 kg (55… 77 lb.) 2.0 N/mm (11.4 lb/in)


Spring length with preload spacer(s) 337.5 mm (13.287 in)

Fork oil per fork leg 240±10 ml(8.11±0.34 fl. oz.)

Fork oil (SAE 4) (48601166S1) ( p. 81)


20.7.2 50 SX

Fork part number 07.18.1L.03


Fork length 685 mm (26.97 in)

Spring rate


Weight of rider (standard): 25… 35 kg (55… 77 lb.) 2.0 N/mm (11.4 lb/in)


Spring length with preload spacer(s) 337.5 mm (13.287 in)

Fork oil per fork leg 240±10 ml(8.11±0.34 fl. oz.)

Fork oil (SAE 4) (48601166S1) ( p. 81)

20.8 Shock absorber

20.8.1 50 SX

Shock absorber part number 03.18.9L.02


Rebound damping

Standard 10 clicks

Spring preload


Spring rate

Weight of rider: 15… 25 kg (33… 55 lb.) 30 N/mm (171 lb/in)

Weight of rider (standard): 25… 35 kg (55… 77 lb.) 35 N/mm (200 lb/in)


Spring length 130 mm (5.12 in)

Gas pressure 10 bar (145 psi)

Static sag 20 mm (0.79 in)

Riding sag 45… 55 mm (1.77… 2.17 in)

Fitted length 275 mm (10.83 in)

Shock absorber oil Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 82)

20.8.2 50 SX Mini

Shock absorber part number 03.18.9E.04


Rebound damping

Standard 12 clicks

Spring preload


Spring rate


Weight of rider (standard): 25… 35 kg (55… 77 lb.) 75 N/mm (428 lb/in)


Spring length 120 mm (4.72 in)

Gas pressure 10 bar (145 psi)

Static sag 15 mm (0.59 in)

Riding sag 40… 50 mm (1.57… 1.97 in)

Fitted length 245 mm (9.65 in)

Shock absorber oil Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 82)


20.9 Chassis tightening torques

Spoke nipple M3.5 3 Nm (2.2 lbf ft) –

Screw, brake linings M5 8 Nm (5.9 lbf ft) –

Rear brake caliper screw M6 10 Nm (7.4 lbf ft) Loctite® 243™

Remaining nuts, chassis M6 10 Nm (7.4 lbf ft) –

Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –

Screw, ball joint of push rod on footbrake cylinder

M6 10 Nm (7.4 lbf ft) –

Screw, chain sliding piece M6 3 Nm (2.2 lbf ft) –

Screw, fork stub M6 10 Nm (7.4 lbf ft) –

Screw, front brake disc M6 14 Nm (10.3 lbf ft) Loctite® 243™

Screw, rear brake disc M6 14 Nm (10.3 lbf ft) Loctite® 243™

Screw, throttle grip M6 4.5 Nm (3.32 lbf ft) –

Engine carrying screw M8 25 Nm (18.4 lbf ft) –

Nut, foot brake lever M8 22 Nm (16.2 lbf ft) –

Nut, rim lock M8 10 Nm (7.4 lbf ft) –



Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) –

Screw, chain sliding piece M8 15 Nm (11.1 lbf ft) –

Screw, front brake caliper M8 20 Nm (14.8 lbf ft) Loctite® 243™

Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –

Screw, rear sprocket M8 25 Nm (18.4 lbf ft) Loctite® 243™

Screw, top triple clamp M8 20 Nm (14.8 lbf ft) –

Front wheel spindle screw M10 40 Nm (29.5 lbf ft) –

Nut, swingarm pivot M10 45 Nm (33.2 lbf ft) –



Screw, bottom shock absorber M10 45 Nm (33.2 lbf ft) –

Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite® 243™

Screw, top shock absorber M10 45 Nm (33.2 lbf ft) –

Nut, rear wheel spindle M12x1 40 Nm (29.5 lbf ft) –

Nut, steering head M20x1.5 No play≤ 10 Nm (≤ 7.4 lbf ft)

–

21 SUBSTANCES 81

2-stroke engine oilStandard/classification– JASO FC ( p. 85)

Guideline– Only use high grade 2-stroke engine oil of a reputable brand.

Fully synthetic

Recommended supplierMotorex®

– Cross Power 2T

Brake fluid DOT 4 / DOT 5.1Standard/classification– DOT

Guideline– Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre-

sponding properties.

Recommended supplierCastrol– RESPONSE BRAKE FLUID SUPER DOT 4

Motorex®

– Brake Fluid DOT 5.1

CoolantGuideline– Use only suitable coolant (even in countries with high temperatures). Using inferior antifreeze can result in corrosion and foaming.

– Use only coolant based on ethylene glycol.

Mixture ratio

Antifreeze protection: −25… −45 °C (−13…−49 °F)

50 % corrosion inhibitor/antifreeze50 % distilled water

Coolant (mixed ready to use)

Antifreeze −40 °C (−40 °F)


– COOLANT M5.0

Fork oil (SAE 4) (48601166S1)Standard/classification– SAE ( p. 85) (SAE 4)

Guideline– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding

properties.

Gear oil (ATF Dexron 3)Standard/classification– Dexron III (ATF Dexron 3)

Guideline– Use only ATF gear oils that comply with the specified standards (see specifications on the container) and that possess the neces-

sary properties.


– ATF Dexron 3

21 SUBSTANCES 82

Shock absorber fluid (SAE 2.5) (50180751S1)Standard/classification– SAE ( p. 85) (SAE 2.5)

Guideline– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding

properties.

Super unleaded (ROZ 95/RON 95/PON 91)Standard/classification– DIN EN 228 (ROZ 95/RON 95/PON 91)

Guideline– Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.

– Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.

InfoDo not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).

Super unleaded gasoline (95 octane), mixed with 2-stroke engine oil (1:60)Standard/classification– DIN EN 228

– JASO FC ( p. 85) (1:60)

Mixture ratio

1:60 2-stroke engine oil ( p. 81)Super unleaded (ROZ 95/RON 95/PON 91) ( p. 82)


– Cross Power 2T

22 AUXILIARY SUBSTANCES 83

Air filter cleanerRecommended supplierMotorex®

– Twin Air Dirt Bio Remover

Chain cleanerRecommended supplierMotorex®

– Chain Clean

Fuel additiveRecommended supplierMotorex®

– Fuel Stabilizer

High viscosity greaseRecommended supplierSKF®

– LGHB 2

Long-life greaseRecommended supplierMotorex®

– Bike Grease 2000

Motorcycle cleanerRecommended supplierMotorex®

– Moto Clean

Off-road chain sprayRecommended supplierMotorex®

– Chainlube Offroad

Oil for foam air filterRecommended supplierMotorex®

– Twin Air Liquid Bio Power

Preserving materials for paints, metal and rubberRecommended supplierMotorex®

– Moto Protect

Rubber grip adhesive (00062030051)Recommended supplierKTM-Sportmotorcycle AG– GRIP GLUE

Special cleaner for glossy and matte paint finishes, metal and plastic surfacesRecommended supplierMotorex®

– Quick Cleaner

22 AUXILIARY SUBSTANCES 84

Universal oil sprayRecommended supplierMotorex®

– Joker 440 Synthetic

23 STANDARDS 85

JASO FCJASO FC is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to firstrate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions.

SAEThe SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis-cosity. The viscosity describes only one property of oil and says nothing about quality.

INDEX 86

INDEX

A

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Air filtercleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Air filter boxcleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Antifreezechecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Auxiliary substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

B

Brake discschecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Brake fluidfront brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 47rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Brake fluid levelfront brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 46rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 51

Brake liningsfront brake, changing . . . . . . . . . . . . . . . . . . . . . . . . 48front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 48rear brake, changing . . . . . . . . . . . . . . . . . . . . . . . . . 52rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 52

C

Capacitycoolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61, 77fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20, 77gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 77

Carburetoridle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63idle speed, adjusting . . . . . . . . . . . . . . . . . . . . . . . 63-64

Chainchecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Chain guardinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Chain guideadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Chain tensionadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Clutchadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66setting, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Clutch coverclutch cover, removing . . . . . . . . . . . . . . . . . . . . . . . 65installing clutch cover . . . . . . . . . . . . . . . . . . . . . . . . 67

Coolantdraining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Coolant levelchecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59-60

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

D

Dust bootscleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

E

Enginerunning in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Engine sprocketchecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Engine sprocket coverinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

F

Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Filler capclosing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Filling upfuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Foot brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 50free travel, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 50free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 49

Fork legsinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Fork part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Fork protectorinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Framechecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Front fenderinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Front wheelinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

G

Gear oiladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Gear oil levelchecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

INDEX 87

H

Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 45checking play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45play, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Handlebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

I

Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

K

Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Kill switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

L

Lower triple clampinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

M

Main silencerglass fiber yarn filling, changing . . . . . . . . . . . . . . . . . 37installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Motorcyclecleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72raising with lift stand . . . . . . . . . . . . . . . . . . . . . . . . 27removing from the lift stand . . . . . . . . . . . . . . . . . . . . 27

O

Oil levelchecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Oil pumpbleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Oil tank capclosing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Operating substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Owner's Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

P

Play in throttle cableadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Plug-in stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Preparing for useadvice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . 15after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73checks and maintenance measures when preparing for use 17

Protective clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

R

Rear sprocketchecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Rear wheelinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Rebound dampingshock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 23

Riding sagadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Rubber gripchecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

S

Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Seatmounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Seat heightadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-22

Shock absorberinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34riding sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 24spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . . 24static sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 23

Shock absorber part number . . . . . . . . . . . . . . . . . . . . . . . 11Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Spoke tensionchecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Start number plateinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Steering head bearinggreasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Steering head bearing playadjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Swingarmchecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

T

Technical datacapacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77chassis tightening torques . . . . . . . . . . . . . . . . . . . . . 80engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76engine tightening torques . . . . . . . . . . . . . . . . . . . . . 76fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Throttle cable routingchecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Throttle grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Tire air pressurechecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Tire conditionchecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

INDEX 88

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-75Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

U

Use definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

V

View of vehicleleft front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8right rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

W

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Work rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

*3213170en*3213170en

03/2014

KTM-Sportmotorcycle AG5230 Mattighofen/Austriahttp://www.ktm.com

Photo: Mitterbauer/KTM

Documents

OWNER'SMANUAL2015 50SX 50SXMini - Judd Racing · 2 SAFETYADVICE 6 Warning Dangerofburns Somevehiclecomponentsbecomeveryhotwhenthevehicleisoperated. – Donottouchhotcomponentssuchasexhaustsystem,radiator,engine