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50 AC/LC

REPARATURANLEITUNG

MANUALE DI RIPARAZIONE

MANUEL DE REPARATION

MANUAL DE REPARACION

REPAIRMANUAL2002-2006

Art.NR.: 3.206.028-E

Summary of content (90 pages)

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REPAIRMANUAL2002-2006 50 AC/LC REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE REPARATION Art.NR.: 3.206.
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REPAIRMANUAL2002-2006 50 AC/LC KTM Group Partner
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1 SERVICE-INFORMATIONS 2 GENERAL INFORMATION 3 REMOVING AND REFITTING ENGINE 4 DISASSEMBLING ENGINE 5 SERVICING INDIVIDUAL COMPONENTS 6 ASSEMBLING ENGINE 7 TROUBLE SHOOTING 8 TECHNICAL SPECIFICATIONS 9 PERIODIC MAINTENANCE SCHEDULE 10 WIRING DIAGRAM 11 12 13 14 15 16
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IMPORTANT INFORMATION/UPDATING INSTRUCTIONS To be able to continue using the existing loose-leaf repair instructions, simply print the following pages and insert them in the existing repair instructions: Art.-Nr. 3.206.
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EXPLANATION - UPDATE This repair manual contains the following supplements: 3.210.24-E Repair Manual 50 AC/LC 5/2001 Basic version Model year 2002 3.210.64-E Updating of Rep.Manual 3.210.24-E 5/2002 Art.-Nr. 3.206.028 -E Model year 2003 (Engine number with first digit „3“) 3.206.010-E Updating of Rep.Manual 3.210.24-E 5/2003 Model year 2004 (Engine number with first digit „4“) 3.206.018-E Updating of Rep.Manual 3.210.
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INTRODUCTION This repair manual offers extensiv repair-instructions and is an up-to-date version that describes the latest models of the series. However, the right to modifications in the interest of technical improvement is reserved without updating the current issue of this manual. A description of general working modes common in work shops has not been included. Safety rules common in the work shop have also not been listed.
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REPLY FAX FOR REPAIR MANUALS We have made every effort to make our repair manuals as accurate as possible but it is always possible for a mistake or two to creep in.
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2-1E GENERAL INFORMATION INDEX Repair manual KTM MINI 50 air/liquid cooled Art.-Nr. 3.206.028-E OPERATING RANGES OF THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 CLEANING AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 BLEEDING OILPUMP FOR SEPARATE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . .2-4 CHANGING FRONT BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2-2E Carburetor adjustment Basic information about original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20° C (68° F), mainly for off-road use and central European premium-grade fuel (ROZ 95). Mixing ratio 2-stroke motor oil:super fuel up to model 2005 1:40, as of model 2006 1:60.
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2-3E CLEANING Clean your motorcycle regularly in order to keep its painted finish looking shiny and new. The best manner would be to use warm water that has been mixed with a commercially available washing detergent and a sponge. The hard dirt can be removed before with the help of a soft water jet. ! CAUTION ! NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH-PRESSURED CLEANER OR A HIGH-PRESSURED WATER JET.
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2-4E Bleeding oilpump for separate lubrication up to model 2003 Clamp oil lines 1 and 2 as shown. Add 2 stroke engine oil (for example Motorex Cross Power 2T) with a syringe until the bubble-free oil starts to leak out of the line 2. After bleeding the oil pump, mount both oil lines and fill the oil tank with 2 stroke engine oil (for example Motorex Cross Power 2T). 2 1 ! CAUTION ! HOSE 2 LEADING FROM THE OIL PUMP TO THE CARBURETOR MUST BE INSTALLED WITHOUT KINKS. 2 Art.-Nr. 3.206.
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2-5E Changing front brake fluid (not Mini Adventure) – Move the hand brake cylinder into horizontal position. 1 – Disassemble the cover 1 together with the rubber boot 2 from the brake fluid reservoir. – Press the brake caliper pistons all the way back. – Use a syringe to extract the used brake fluid and add fresh DOT 5.1 brake fluid (Motorex Brake Fluid DOT 5.1).
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2-6E Changing rear brake fluid (50 SX, 50 Supermoto) – Move the vehicle in a vertical position. 1 2 – Disassemble the cover 1 together with the rubber boot 2 from the brake fluid reservoir. – Press the brake caliper pistons all the way back. – Use a syringe to extract the used brake fluid and add fresh DOT 5.1 brake fluid (Motorex Brake Fluid DOT 5.1). – Completely remove the bleeder screw 3 . – Extract the old brake fluid from the system using the bleeder syringe 503.29.050.000.
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3-1E REMOVING AND REFITTING ENGINE INDEX Repair manual KTM MINI 50 air/liquid cooled Art.-Nr. 3.206.028-E REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3-2E Removing the engine NOTE: the following steps are shown on a model with LC-engine, on a model with AC-engine a few works are not necessary like draining coolant liquid, removing and mounting the radiator and the radiator shield, bleeding the cooling system. 1 Clean the entire vehicle thoroughly before removing the engine. To avoid burns, allow the motorcycle to cool before starting to work. – Jack up the motorcycle on a sturdy work stand.
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3-3E 1 – Loosen retaining bolt on tank 1 and remove from tank together with the rubber grommet. – Lift tank from the frame. – Open chain joint 2 and remove chain. 2 – Loosen hose clamp 3 of the intake flange on the carburetor, pull carburetor back and swing to the side. NOTE: if the carburetor is not being serviced, it does not need to be removed - the carburetor openings should however be covered with a clean cloth and the gasoline drained from the float chamber.
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3-4E – Loosen hose clamp 1 and pull both hoses from their connections. – Unbolt radiator retaining bolt 2 and laterally remove radiator with water hoses from the frame. 2 1 1 – Carefully pull socket connector 3 apart. Art.-Nr. 3.206.028 -E 3 – Detach both exhaust springs 4 with a suitable wrench, remove springs. – Unbolt the exhaust bracket on the right and pull exhaust off towards the front. 4 4 – Loosen engine mounting bolts 5 and 6, lift engine from the frame.
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3-5E – Install carburetor on the intake flange and tighten hose clamp 1. 1 – Place chain on rear sprocket and pinion, mount chain joint 2 and secure. 2 NOTE: make sure the locking member runs in the right direction (see photo). The closed side of the safety device must point in the running direction. – Mount tank and bolt tight. Do not forget the rubber grommet 3 for the bolt. 3 – Connect fuel hose 4 to the carburetor and secure. 4 – Slide air filter box into the frame bracket.
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3-6E – Attach connection 1 of the air filter box to the carburetor and tighten hose clamp. 1 – Insert air filter element in the air filter box and mount cover. NOTE: the locating tabs in the cover must engage in the panel. Repair manual KTM MINI 50 air/liquid cooled Art.-Nr. 3.206.028 -E – Mount seat. Make sure the retaining bracket 2 is inserted properly. Insert quick release 3 in the dolly and turn 180°.
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4-1E DISASSEMBLING THE ENGINE INDEX Repair manual KTM MINI 50 air/liquid cooled Art.-Nr. 3.206.028-E SPECIAL TOOLS - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 FIXING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3 DRAINING GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3 DISMOUNTING INTAKE FLANGE AND IGNITION COIL . . . . . . . . . . . . . . . . .
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4-2E SPECIAL TOOLS ENGINE 50 AC/LC 1 2 4 5 8 6 75 15 0 13 50 Repair manual KTM MINI 50 air/liquid cooled Art.-Nr. 3.206.028 -E 3 FIG PARTNUMBER DESCRIPTION 1 590.29.021.000 Puller for flywheel 2 451.12.021.000 Rotor holding tool 3 451.29.006.000 Adjusting plate for Dimension „X“ 4 6 899 785 5 451.29.075.000 Tachometer 6 503.29.050.
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4-3E Clamp the engine using a vice – Clean the engine thoroughly prior to disassembling. – The engine can be clamped with a vice, using a protective pad to clamp the lower rear bracket (see photo). Drain the transmission oil – Remove the transmission oil drain plug 1 including the sealing ring and allow transmission oil to drain. – Mount the transmission oil drain plug with new sealing ring and tighten to 15 Nm (11 ft.lb). .
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4-4E Remove ignition stator. 1 2 3 – Pull cable guide 1 from the case. – Remove allan bolts 2 of the ignition stator 3. – Carefully pull stator 3 out of the case. 2 Remove cylinder head, cylinder and pistons. – Loosen bolts on cylinder head crosswise and remove. – Discard washers (LC-engine), remove cylinder head 4. 4 4 – Remove gasket 5 (AC-engine) or O-rings 6 (LC-engine) from cylinder and discard. – Loosen 4 bolts 7 on the cylinder base crosswise and remove; carefully lift the cylinder off. Art.
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4-5E Pull off ignition rotor 3 1 – Hold ignition rotor 1 with special tool 2, open the nut and remove. NOTE: a washer is located under the nut; the magnetic attraction of the rotor causes it to adhere to the rotor. ! CAUTION ! MAKE SURE THE TWO PINS OF THE SPECIAL TOOL DO NOT CATCH THE THREADED HOLES, OTHERWISE THE THREADING WILL BE DAMAGED AND THE ROTOR CAN NO LONGER BE REMOVED. – Remove circlip 3 from the chain sprocket and remove chain sprocket.
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4-6E Disassemble the clutch and primary drive 1 – Rechuck the engine to provide access to the clutch side. – Remove kickstarter and bolts 1 on the clutch cover. – Remove clutch cover, discarding the seal. 2 1 1  WARNING  NOT REMOVE THE CIRCLIP 2, OTHERWISE THE KICKSTARTER SPINDLE MAY FALL FROM THE CASING AND THE KICKSTARTER SPRING CAUSE INJURIES. DO 1 – Block the centrifugal clutch 3 with a suitable mandrel 4. 5 NOTE: the drum and the gear wheel of the primary drive have holes.
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5-1E SERVICING INDIVIDUAL COMPONENTS 5 Repair manual KTM MINI 50 air/liquid cooled Art.-Nr. 3.206.028-E INDEX RIGHT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 LEFT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3 CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . .
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5-2E Working on the right half of the engine case Remove shaft sealing ring 1 and heat the engine case half on a heating plate to approx. 150° C. NOTE: if the engine case is heated to 150° C and struck on a wooden surface, the bearings usually fall out of the bearing seats automatically. If necessary, the bearings must be pushed out. ! CAUTION ! – ALWAYS REMOVE DOWELS FIRST TO PREVENT THE CASE FROM BEING DAMAGED.
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5-3E Working on the left half of the engine case 2 Remove shaft sealing rings 1/2 and heat engine case halves on a heating plate to approx. 150° C. NOTE: – If the engine case is heated to 150° C and struck on a wooden surface, the bearings usually fall out of the bearing seats automatically. If necessary, the bearings must be pushed out.
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5-4E 6 Working on the clutch cover 8 7 NOTE: dismantling the clutch cover is neccessary if parts are damaged or the O-ring is leaking. – Turn kickstarter shaft 1 counter-clockwise and remove ratchet gear 2. Check gearing for wear. 2 1 9 NOTE: If the kickstarter shaft is to be removed, the outer circlip must be removed, carefully pulling the kickstarter shaft out of the cover.  WARNING  KICKSTARTER SPRING IS PRETENSIONED. IT MUST BE STRESS-RELIEVED WHEN THE KICKSTARTER SHAFT IS PULLED OUT.
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5-5E Overhaul the water pump (LC-engine) – Remove cover 1, discard the O-rings. 1 – – – – 8 4 6 Remove circlip 2 with a suitable wrench. Remove the water pump wheel 3 from the pump shaft 4. Press out shaft 4, press out both bearings (6 and 7). Remove seal shaft ring 5. NOTE: a spring 8 is installed starting with the 2004 model. Remove before disassembling. 7 5 3 2 – Press in a new seal shaft ring 5, make shure that the open side of the seal shaft ring is located on the side of the water pump wheel.
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5-6E Check pistons If continuing to use a used piston, check as follows: 1. Check piston bearing surface for pressure marks, piston seizure (light friction can be removed with a fine emery stone). 2. The piston ring may not jam in the piston ring groove. To clean the piston ring groove, use an old piston ring or sanding paper (400 grain size). 3. Piston ring anti-rotation device must fit tightly in the piston and may not be worn. 4. Check piston ring for wear and gaps in the cylinder.
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5-7E Overhauling the centrifugal clutch 3 56 – Loosen HH bolts 1 on the clutch shoes 2 and remove together with the set of springs 3 from the clutch hub 4. 2 4 NOTE: coilsprings 7 are used instead of the spring washers for the AC-engine. Length of clutch springs: min. 19.6 mm (0.748 in). – Remove HH bolts with sleeves and set of springs from the clutch shoes.
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6-1E ASSEMBLING THE ENGINE Repair manual KTM MINI 50 air/liquid cooled Art.-Nr. 3.206.028-E INDEX MOUNTING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 MOUNTING THE PRIMARY DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 MOUNTING LEFT ENGINE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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6-2E Mounting the crankshaft and output shaft – Heat the engine case on a heating plate. – Lubricate both bearings, lightly grease the seal shaft ring. – Push the output shaft and crankshaft into the bearing. NOTE: the conrod must be in a vertical position. ! CAUTION ! DO NOT INSERT THE SHAFTS INTO THE BEARINGS WITH A HAMMER SINCE THE BEARINGS AND CRANKSHAFT MAY BE DAMAGED. Mounting primary drive – Insert woodruff key 1 in the output shaft groove.
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6-3E – Wrap insulating tape around the output shaft in the area of the sharp edge 1 to prevent the seal shaft ring from being damaged. NOTE: wrap insulating tape just above edge to allow the tape to be easily pulled off after the seal shaft ring is mounted. 1 – Grease the seal lip and press in the seal shaft ring. – Pull off the tape. Mounting the ignition 3 2 – Place woodruff key in the crankshaft groove.
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6-4E Mounting the clutch cover 1 – Put new seals in place and mount the clutch cover . – Bolt clutch cover into place with 6 bolts M6x25 1, tighten the bolts to 10 Nm (7 ft.lb). 1 1 1 Mount the ignition cover and water pump. – Put the dowels 7x9x10 in place. – Align the driving slot on the water pump drive 2 with the driver blade 3 on the crankshaft (LC-engine). 3 2 NOTE: make sure the spring is mounted in the water pump shaft (models from 2004).
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6-5E Mount the pistons – Fix conrod with a mounting board. – Grease the conrod bearings and attach to conrod eye. – Mount pistons, the arrow on the bottom of the piston should point towards the outlet port. – Slide piston pin into the conrod eye by hand and mount piston pin lock with the open side facing down. – Turn the piston ring until the anti-rotation device engages in the piston ring end gap 1.
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6-6E Mount the cylinder head – Mount the cylinder head 1, making sure the water connection is on the intake side (LC-engine). – Use new washers for the cylinder head bolts (LC-engine), tighten cylinder head bolts crosswise in 2 stages to 15 Nm (11 ft.lb). 1 1 Mount water hose, intake flange and ignition coil – Apply water hose and tighten hose clamp (only LC-engine). – Mount the reed valve housing and intake flange with new seal.
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7-1E TROUBLE SHOOTING INDEX Repair manual KTM MINI 50 air/liquid cooled Art.-Nr. 3.206.028-E TROUBLE SHOOTING 50 AC/LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 IGNITION MEASUREMENT 50 AC/LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 MEASUREMENT WITH PEAK VOLTAGE ADAPTER . . . . . . . . . . . . . . . . . . . . . . . .
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7-2E TROUBLE Art.-Nr. 3.206.028 -E Engine fails to start Engine without idle running Repair manual KTM MINI 50 air/liquid cooled Less power of engine CAUSE REMEDY Operating error Open fuel tap, replenish fuel, do not use choke Fuel supply interrupted Close fuel tap, loosen fuel hose at carburettor, lead into a basin and open fuel tap, – if fuel leaks out, clean carburettor – if no fuel leaks out, check tank ventilation, i.e.
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7-3E 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 Clean carburetor, if necessary replace float needle and adjust level Loose carburetor jets Tighten jets Incorrect heat range spark plug or low quality spark plug Refer to technical data section Loose, corroded or non conductive ignition socket connector Check and seal with silicon Lack of fuel Clean fuel pipes, examine tank aeration
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7-4E Resistor values of the ignition system - Stator – Unplug the ignition stator and measure the resistance of the stator using a digital measuring tool. – The resistance must be 500 Ω ± 40 Ω at 20º C. NOTE: it is not neccessary to take the stator out of the engine housing. Ignition coil – Undo the spark plug cap – Measure the resistor of the secundary side of the Ignition coil between high tension lead and mass of the coil. – The resistance must be 2250 Ω ± 250 Ω at 20º C. Art.-Nr. 3.206.
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8-1E TECHNICAL SPECIFICATIONS INDEX Repair manual KTM MINI 50 air/liquid cooled Art.-Nr. 3.206.028-E MODEL 2002 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3 BASIC CARBURETOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4 STANDARD-ADJUSTMENT – FORK . . . . . . . . . . . . . . . . .
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8-2E INDEX MODEL 2005 AC ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10 BASIC CARBURETOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11 STANDARD-ADJUSTMENT – FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11 STANDARD ADJUSTMENT – SHOCK ABSORBER . . . . . . . . .
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8-3E TECHNICAL DATA - ENGINE 50 AC/LC 2002 Engine 50 AC (aircooled) Design 50 LC (liquid cooled) single cylinder 2-stroke engine, with reed valve inlet Displacement 49,0 cm³ Bore/Stroke 39,5 / 40 mm Fuel Oil/gasoline ratio SUPER fuel, research octane no 95, mixed with 2-stroke oil 1 : 40 when using high grade 2-stroke oil (Shell Advance Racing X) When in doubt, please contact your importer or use 1 : 33 mix ratio to be on the safe side Lubrication mixture lubrication Crankshaft bearing 2 groo
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front/rear 2.50x10" VRM-140 Drum brake Ø 90 mm (3.5 in) 175/190 mm (6.9/7.5 in) 220 mm (8.6 in) 190 mm (7.5 in) Ground clearance Engine SAE 7,5 Fork oil SAE 7,5 10 mm (0.4 in) 2,0 N/mm 110 mm (4.3 in) 110 mm (4.3 in) 10 mm (0.4 in) Preload Luftkammerlänge 2,0 N/mm Spring 50 AC 50 AC Spring preload Spring Rebound adjuster 175/185 mm (6.9/7.3 in) 50 SX PRO SENIOR LC 220 mm (8.6 in) 615 mm (24.2 in) 914 mm (36 in) 63° 1/2x3/16" 96 rolls 7 mm/0.
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8-5E TECHNICAL DATA - ENGINE 50 AC/LC 2003 Engine 50 AC (aircooled) Design 50 LC (liquid cooled) single cylinder 2-stroke engine, with reed valve inlet Displacement 49,0 cm³ Bore/Stroke Fuel 39,5 / 40 mm SUPER fuel, research octane no 95, mixed with 2-stroke oil (separate lubrication only ROZ 95) Oil/gasoline ratio 1 : 40 when using high grade 2-stroke oil (Shell Advance Racing X) (separate lubrication Shell Advance Ultra 2) Lubrication mixture lubrication / separate lubrication Crankshaft bea
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2.50x10" VRM-140 Drum brake Ø 90 mm (3.5 in) 175/190 mm (6.9/7.5 in) 615/640 mm (adjustable) (24.2/25.2 in) 590/615 mm (adjustable) (23.2/24.2 in) Air chamber lenght Fork oil Preload Spring 50 AC 2,0 N/mm 50 LC (4.3 in)110 mm SAE 7,5 110 mm (4.3 in) SAE 7,5 10 mm (0.4 in) 10 mm (0.4 in) 2,0 N/mm STANDARD-ADJUSTMENT - FORK Engine Recommended age of rider Spring preload 8 mm/0.31 in 50 JUNIOR Adventure 12 mm/0.
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– straight cut spur gears, 16 : 57 Z Primary drive Cooling liquid Air filter Carburetor Electrode gap Spark plug Dell'Orto PHBG 19 BS 0.5 litres, 40% antifreeze, 60% water, at least -25 °C wet foam type air filter insert Dell'Orto PHVA 14 DS 0,6 mm NGK BR 8 ECM 0.15-0.
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8-8E BASIC CARBURETOR SETTING 50 MINI ADVENTURE (SEPARATE LUBRICATION) 50 SENIOR ADVENTURE (MIXTURE LUBRICATION) Dell'Orto PHVA 12 XS Dell'Orto PHVA 14 DS 60 80 (70) Needle jet 211 FA 211 FA Idling jet 38 45 Jet needle A10 A10 Needle position from top 4. 3. Air/Mixture reg.
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Air chamber lenght Fork oil Preload 4 - 6 years 8 mm/0.31 in 2,0 N/mm SAE 7,5 110 mm (4.3 in) SAE 7,5 110 mm (4.3 in) Spring preload 50 MINI 12 mm/0.47 in 50 SENIOR STANDARD ADJUSTMENT - SHOCK ABSORBER AC 50 AC 50 LC 10 mm (0.4 in) 10 mm (0.4 in) 2,0 N/mm 50 AC Engine Recommended age of rider 910 mm 1/2x3/16" 96 rolls 50 LC 6 - 10 years 255 mm 650/675 mm (adjustable) 1030 mm 1/2x3/16" 104 rolls 11 : 44 2.
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8-10E TECHNICAL DATA – ENGINE 2005 AC ENGINE 50 AC SENIOR ADVENTURE Design single cylinder 2-stroke engine, with reed valve inlet 50 AC MINI ADVENTURE Displacement 49.0 ccm Bore/Stroke 39.
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8-11E Art.-Nr. 3.206.028 -E TECHNICAL SPECIFICATIONS – CHASSIS 2005 AC CHASSIS 50 SENIOR ADVENTURE Frame single downtube, split-cradle 50 MINI ADVENTURE Fork Marzocchi Ø = 32 mm (1,26 in) Wheel travel front/rear 175/190 mm (6.9/7.5 in) Rear suspension Central shock absorber Paioli Front brake Disk brake Ø 160 mm (6.4 in) Rear brake Drumbrake Ø 90 mm (3,5 in) Tires front/rear 2.50x12“ Pirelli MT32A / 2.75x10“ MT320 2.50x10“ Pirelli MT32A / 2.75x10“ MT320 Tire pressure front/rear: 1.
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8-12E TECHNICAL DATA – ENGINE 2005 LC TYP 50 SX PRO JUNIOR LC Design single cylinder 2-stroke engine, with reed valve inlet 50 SX PRO SENIOR LC Displacement 49.0 ccm Bore/Stroke 39.
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8-13E TECHNICAL SPECIFICATIONS - CHASSIS 2005 LC Art.-Nr. 3.206.028 -E 50 SX PRO JUNIOR LC 50 SX PRO SENIOR LC Frame single downtube, split-cradle Fork Marzocchi Ø = 32 mm (1.26 in) Wheel travel front/rear 140/205 mm (5.5/8 in) Rear suspension Central shock absorber WP Front brake Disk brake Ø 160 mm (6.4 in) Rear brake Drum brake Ø 90 mm (3.5 in) Tires front/rear 2.50x10” Pirelli MT32A / 2.75x10” MT320 2.50x12” Pirelli MT32A / 2.75x10” MT320 Tire pressure front/rear: 1.
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8-14E TECHNICAL DATA – ENGINE 2006 AC ENGINE 50 SENIOR ADVENTURE Design single cylinder 2-stroke engine, with reed valve inlet 50 MINI ADVENTURE Displacement 49.0 ccm Bore/Stroke 39.
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8-15E Art.-Nr. 3.206.028 -E TECHNICAL SPECIFICATIONS – CHASSIS 2006 AC CHASSIS 50 SENIOR ADVENTURE Frame single downtube, split-cradle 50 MINI ADVENTURE Fork Marzocchi Ø = 32 mm (1,26 in) Wheel travel front/rear 175/190 mm (6.9/7.5 in) Rear suspension Central shock absorber Paioli Front brake Disk brake Ø 160 mm (6.4 in) Rear brake Drumbrake Ø 90 mm (3,5 in) Tires front/rear 2.50x12“ Pirelli MT32A / 2.75x10“ MT320 2.50x10“ Pirelli MT32A / 2.75x10“ MT320 Tire pressure front/rear: 1.
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8-16E TECHNICAL DATA – ENGINE 2006 LC TYP 50 SX JUNIOR Design single cylinder 2-stroke engine, with reed valve inlet 50 SX, 50 SUPERMOTO Displacement 49.0 ccm Bore/Stroke 39.
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8-17E TECHNICAL SPECIFICATIONS - CHASSIS 2006 LC Art.-Nr. 3.206.028 -E 50 SX JUNIOR 50 SUPERMOTO 50 SX Frame single downtube, split-cradle Fork Marzocchi Ø = 32 mm (1.26 in) Wheel travel front/rear 140/205 mm (5.5/8 in) Rear suspension Central shock absorber WP Front brake Disk brake Ø 160 mm (6.4 in) Rear brake Drum brake Ø 90 mm (3.5 in) Disk brake Ø 140 mm (5.5 in) Tires front 2.50x10” Pirelli MT32A 2.50x12” Pirelli MT32A Tires rear 2.75x10” MT320 Tire pressure front/rear: 1.
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8-18E TOLERANCES AND FITTING CLEARANCES Crankshaft run out of crank stud Crankshaft webs outer dimension max. 0.050 mm 38 mm ±0.05 mm Conrod bearing radial play max. 0.030 mm Piston fitting clearance Piston ring end gap max. 0.20 mm Clutch shoes outer diameter new 82.5 mm Clutch drum diameter Clutch springs (AC) length 0.055-0.065 mm (AC) / 0.045-0.055 mm (LC) max. 84.4 mm (new 84.00 - 84.01 mm) min. 19.6 mm TIGHTENING TORQUES - ENGINE Hexagon nut primary gear M14x1.
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9-1E LUBRICATION AND MAINTENANCE SCHEDULE 9 INDEX Repair manual KTM MINI 50 air/liquid cooled Art.-Nr. 3.206.028-E LUBRICATION AND MAINTENANCE SCHEDULE 50 AC/LC MODEL 2002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2 MODEL 2003-2005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4 MODEL 2006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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9-2E 50 MINIS air/liquid cooled PERIODIC MAINTENANCE 2002 WHEELS CHASSIS BRAKES ADD-ON-PARTS CARBURETOR ENGINE A washed motorcycle can be checked more quickly which saves money! Check engine for leaks Change transmission oil Check spark plug, change it if necessary, set electrode gap Check the clutch engagement speed Check carburetor for tight fit at intake flange Check intake flange for cracks Check idle setting when engine is warm Check cooling system for leaks, antifreeze protection Check exhaust
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9-3E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr. 3.206.
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9-4E 50 MINIS air/liquid cooled PERIODIC MAINTENANCE 2003-2005 WHEELS CHASSIS BRAKES ADD-ON-PARTS CARBURETOR ENGINE A washed motorcycle can be checked more quickly which saves money! Check engine for leaks Change transmission oil Check spark plug, change it if necessary, set electrode gap Check the clutch engagement speed Check carburetor for tight fit at intake flange Check intake flange for cracks Check idle setting when engine is warm Check cooling system for leaks, antifreeze protection Check ex
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9-5E Art.-Nr. 3.206.
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9-6E 50 MINIS air/liquid cooled PERIODIC MAINTENANCE 2006 WHEELS CHASSIS BRAKES ADD-ON-PARTS CARBURETOR ENGINE A washed motorcycle can be checked more quickly which saves money! Check engine for leaks Change transmission oil Check spark plug, change it if necessary, set electrode gap Check the clutch engagement speed Check carburetor for tight fit at intake flange Check intake flange for cracks Check idle setting when engine is warm Check cooling system for leaks, antifreeze protection Check exhaust
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9-7E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr. 3.206.
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10-1E WIRING DIAGRAM INDEX Repair manual KTM MINI 50 air/liquid cooled Art.-Nr. 3.206.028 -E WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Mini Ad.-SX Senior 50 LC black stop button black G generator 20.02.