Instruction/ maintenance manual of the product 50 SX JUNIOR KTM
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KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.com KTM Group Partner 4/2007 FOTO: MITTERBAUER 50 SX JUNIOR 50 SX OWNER’S MANUAL 2008 3211222en *3211222en* 3211222en.
ENGLISH 1 INTRODUCTION » Please insert the serial numbers of the motorcycle below Chassis number Engine number Stamp of dealer All information contained is without obligation.
ENGLISH 2 IMPORTANT INFORMATION » INTENDED PURPOSE KTM mini-sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading interna- tional motorcycle associations.
ENGLISH 3 IMPORTANT INFORMATION » W ARRANTY The service work specified in the "Lubrication and Maintenance Schedule" must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void.
ENGLISH 4 IMPORTANT INFORMATION FOR PARENTS ABOUT SAFE DRIVING » KTM mini motorcycles are off-road motorcycles designed for one person only. They are not allowed on public roads. The vehicle dimensions and components are designed for children from 4 to 10 years of age with a maximum weight of.
ENGLISH 5 TABLE OF CONTENTS » Page IMPOR T ANT INFORMA TION FOR P ARENTS ABOUT SAFE DRIVING . . . . . . . . . . . . . . . . . . . . . . . . .4 SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . .6 Chassis number . . . . . . . . . . . . . .
ENGLISH 6 SERIAL NUMBER LOCATIONS » Chassis number The chassis number is located on the type plate on the steering head. Enter this number in the field on page no 1. Engine number The engine number is stamped into the right half of the engine case next to the kickstarter .
ENGLISH 7 OPERATION INSTRUMENTS » Throttle grip The throttle grip is located on the right side of the handlebars. It is used to reduce the engine speed and, thus, the driving speed. Hand brake lever The hand brake lever is located on the right side of the handlebars and actuates the front wheel brake.
ENGLISH 8 OPERATION INSTRUMENTS » Choke Dell’Orto carburetor PHVA 14 DS (50SX Junior) Choke lever [1] is mounted to the right side of the carburetor . If you move the choke lever up to the stop, a hole is opened in the carburetor through which the engine can draw in additional fuel.
ENGLISH 9 OPERATION INSTRUMENTS » Plugin - Stand (50 SX) A socket is provided on the left side of the frame for the plug-in stand [1] included in the scope of supply . Rebound damping function of the shock absorber By using the adjusting screw [2] , the degree of damping of the rebound can be adjusted.
ENGLISH 10 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » Running in – Even very precisely machined sections of engine components have rougher surfaces than components which have been slid- ing across one another for quite some time. Therefore, every engine needs to be broken in.
ENGLISH 11 DRIVING INSTRUCTIONS » What you should check before each start When you start off, the motorcycle must be in a perfect technical condition. For safety reasons, you should make it a habit to perform an overall check of your motorcycle before each start.
ENGLISH 12 DRIVING INSTRUCTIONS » Starting when the engine is cold 1 Open fuel tap [1] . 2 Operate the choke [2] . 3 Kick the side up all the way or remove the plug-in stand. 4 Apply the front brake. 5 Operate the kickstarter , depressing it all the way , without opening the throt- tle.
ENGLISH 13 DRIVING INSTRUCTIONS » Driving The engine speed, and thus the driving speed, are regulated by the throttle grip. The choke must always be deactivated as soon as the engine has warmed up. – After falling with the motorcycle, check all its functions thor- oughly before using it again.
ENGLISH 14 PERIODIC MAINTENANCE SCHEDULE » 50 SX JUNIOR 50 SX A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! Service every 5 hours Service every 20 hours before every race ENGINE C.
ENGLISH 15 PERIODIC MAINTENANCE SCHEDULE » NOTE: If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced.
ENGLISH 16 MAINTENANCE WORK ON CHASSIS AND ENGINE » Removing the seat The quick-release mechanism [1] allows removal of the seat without tools. T urn the quick-release device approximately 180° counterclockwise, lift the rear portion of the seat and pull the seat off backwards.
ENGLISH 17 MAINTENANCE WORK ON CHASSIS AND ENGINE » Checking and adjusting the steering head bearing (50 SX) * The steering head bearing should be checked regularly for play . T o check, support the motorcycle frame and lift the front wheel off the ground.
ENGLISH 18 MAINTENANCE WORK ON CHASSIS AND ENGINE » Basic suspension setup for the weight of the driver T o achieve maximum handling performance and to prevent the telescopic fork and shock absorber from being damaged, the basic setup of the suspension components must be suitable for your child's weight.
ENGLISH 19 MAINTENANCE WORK ON CHASSIS AND ENGINE » Telescopic fork maintenance * The telescopic fork must be serviced at least once a year . T o service the fork, proceed as follows: Prop up the motorcycle under the frame to take the load off the front wheel.
ENGLISH 20 MAINTENANCE WORK ON CHASSIS AND ENGINE » Cleaning the dust scrabbers of the telescopic fork The dust-protection bellows [1] are to remove dust and coarse dirt particles from the fork tube. However , after some time, dirt may also get in behind the dust-protection bellows.
ENGLISH 21 MAINTENANCE WORK ON CHASSIS AND ENGINE » General information about KTM disc brakes BRAKE FLUID RESERVOIRS: The brake fluid reservoirs for the front brake is designed such that it does not need to be refilled, even if the brake shoes are worn.
ENGLISH 22 MAINTENANCE WORK ON CHASSIS AND ENGINE » Checking the brake fluid level / refilling * The brake fluid reservoir is combined with the hand brake cylinder on the handlebar . T o check the brake fluid level, press the brake pistons back into the basic position.
ENGLISH 23 MAINTENANCE WORK ON CHASSIS AND ENGINE » Changing the basic position of the foot brake lever (50 SX Junior) The basic position of the foot brake lever can be changed by unscrewing screw [1] and then turning the retainer [2] . Afterwards, check the setting of the rear wheel brake.
Slide new brake shoes into the brake caliper a fasten with the screw [5] . T ighten the screw to 10 Nm and mount the locking screw [4] . Mount the rear wheel and actuate the foot brake lever until you can feel the pressure point. – It is very important to keep the brake disk free from oil and fatty matters.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Removing and mounting the front wheel Jack the motorcycle up by the frame so that the front wheel is suspended above the ground. Undo the hexagon nut [1] and remove it together with the washer . Hold the front wheel and pull out the wheel spindle [2] .
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 26 Tires, air pressure T ire type, tire condition, and air pressure level affect the way your motorcycle rides, and they must therefore be checked whenever you are getting ready to go anywhere on your motorcycle.
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 27 Checking coolant level The coolant should be 10 mm (0.4 in) above the radiator fins when the engine is cold (see illustr .). In the event of the coolant being drained, always fill and bleed the system.
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 28 Changing the seat height The saddle can easily be raised by 25 mm (1 in). This lets you adjust the height as your child grows. Figures A and B show the fork and shock absorber positions for a low seat position.
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 29 Checking the gear oil level T o check the gear oil level, first remove the plug [1] . With the motorcycle parked in an upright position, a small quantity of oil should flow out of the indicator opening [2] .
ENGLISH 30 Adjusting the centrifugal clutch * A correctly adjusted centrifugal clutch will provide maximum engine perform- ance and ease of driving and prevent the engine from overheating.
ENGLISH 31 CORRECTING CLUTCH WEAR: Check the clutch shoes for wear . If the surface is only slightly worn you can remount them again. NOTE: The centrifugal clutch has an outer diameter of approx.
TROUBLE SHOOTING » ENGLISH 32 If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error .
TROUBLE SHOOTING » ENGLISH 33 TROUBLE CAUSE REMEDY Engine stalling or running with four stroke cycle Carburetor overflows if level adjust too high, float needle seating is dirty or enlarged Loose car.
CLEANING » ENGLISH 34 STORAGE » If you want to put your motorcycle away for longer periods of time, please observe the following instructions: – Clean motorcycle thoroughly (see chapter: CLEANING) – Change engine oil (old engine oil contains aggressive contaminations).
TECHNICAL DATA – ENGINE » ENGLISH 35 ENGINE 50 SX JUNIOR 50 SX Design single cylinder 2-stroke engine, with reed valve inlet Displacement 49.0 cc Bore/Stroke 39.
ENGLISH 36 TECHNICAL SPECIFICATIONS - CHASSIS » CHASSIS 50 SX JUNIOR 50 SX Frame single downtube, split-cradle Fork Marzocchi Ø = 32 mm Wheel travel front/rear 140/205 mm (5.5/8 in) 185/185 mm (7.3/7.3 in) Rear suspension Central shock absorber WP Front brake Disk brake Ø 160 mm (6.
ENGLISH 37 HEAD WORD INDEX » Page Adjusting the centrifugal clutch . . . . . . . . . . . . . . . . . .30 Adjusting the control cable on the rear wheel (50 SX Junior) .23 Adjusting the idle speed (Dell’Orto PHBG 19 BS) . . .28 Adjusting the idle speed (Dell’Orto PHV A 14 DS) .
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KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.com KTM Group Partner 4/2007 FOTO: MITTERBAUER 50 SX JUNIOR 50 SX OWNER’S MANUAL 2008 3211222en *3211222en* 3211222en.
An important point after buying a device KTM 50 SX JUNIOR (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought KTM 50 SX JUNIOR yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data KTM 50 SX JUNIOR - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, KTM 50 SX JUNIOR you will learn all the available features of the product, as well as information on its operation. The information that you get KTM 50 SX JUNIOR will certainly help you make a decision on the purchase.
If you already are a holder of KTM 50 SX JUNIOR, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime KTM 50 SX JUNIOR.
However, one of the most important roles played by the user manual is to help in solving problems with KTM 50 SX JUNIOR. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device KTM 50 SX JUNIOR along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
