Page 2 - ENGLISH; Please insert the serial numbers of the motorcycle below; IMPORTANT
ENGLISH 1 Please insert the serial numbers of the motorcycle below Chassis number Engine number Stamp of dealer IMPORTANT PLEASE READ THIS MANUAL THOROUGHLY BEFORE LETTING YOURYOUNGSTER RIDE THE MOTORCYCLE FOR THE FIRST TIME. THIS MANUALCONTAINS IMPORTANT INFORMATION AND RECOMMENDATIONS THATWILL HEL...
Page 3 - Introduction; KTM SPORTMOTORCYCLE AG
ENGLISH 2 Introduction Now you own a modern motorcycle that you and your youngster will certainly enjoy, providedthat you service and maintain it properly. This manual contains important information on theoperation and maintenance of your new KTM motorcycle. It went to press describing yourmodel’s l...
Page 4 - IMPORTANT WARRANTY AND
ENGLISH 3 IMPORTANT WARRANTY AND GUARANTEE INFORMATIONE KTM mini-sports motorcycles are designed and constructed to resist the usualwear and tear of normal use in competitions.The motorcycles comply with the regulations and categories currently in effectwith the leading international motorcycle asso...
Page 5 - IMPORTANT INFORMATION FOR PARENTS ABOUT SAFE DRIVING; youngster and not the other way around.
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 6 to 10 years of age with a maximumweight of. 35 kg (7...
Page 6 - TABLE OF CONTENTS
ENGLISH 5 Page IMPORTANT WARRANTY AND GUARANTEE INFORMATIONE ..3 IMPORTANT INFORMATION ON SAFE DRIVING FOR PARENTS ........................................................................4 SERIAL NUMBER LOCATIONS ...............................................6 Chassis number ..........................
Page 7 - SERIAL NUMBER LOCATIONS
ENGLISH 6 Chassis number The chassis number is located on the type plate on the steering head. Enterthis number in the field on page no 1. Engine number The engine number is stamped into the right half of the engine case next tothe kickstarter. Enter this number in the relevant field on page 1. Engi...
Page 8 - Filler cap; Kickstarter
ENGLISH 7 Filler cap To open it: turn filler cap counter-clockwise. To close it: put filler cap back on and tighten it by turning it clockwise. Install tank breather hose 1 without kinks. Fuel tap The fuel tap 2 is located at the front of the motorcycle on the left side of the tank. Opening the fuel...
Page 9 - Foot brake lever; Rebound damping function of the shock absorber
ENGLISH 8 Foot brake lever The foot brake lever is located in front of the right footrest. The basicposition can be adjusted to the seating position (see maintenance work). Side stand Use your foot to swing the side stand forwards to the stop. Make sure itrests securely on solid ground. Plugin - Sta...
Page 11 - GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE; Instructions for the first ride
ENGLISH 10 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE WARNING – H AVE YOUR YOUNGSTER WEAR PROPER PROTECTIVE GEAR WHENEVER HE OR SHE RIDES THE MOTORCYCLE : HELMET , EYE PROTECTION , CHEST , BACK , ARM AND LEG PROTECTORS , GLOVES AND BOOTS . T O SET A GOOD EXAMPLE , BE SURE TO WEAR PROTECTI...
Page 12 - DRIVING INSTRUCTIONS; What you should check before each start
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 checkof your motorcycle before each start. The following checks should be performed...
Page 13 - Starting when the engine is cold; Starting when the engine is warm; What to do when the engine is “flooded”; Starting off; Driving
ENGLISH 12 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 throttle. WARNING – W HEN STARTING THE ENGINE , PUT ON ...
Page 14 - Braking; Stopping
ENGLISH 13 ! CAUTION ! – D RIVING A COLD ENGINE AT HIGH SPEED WILL REDUCE THE LIFE OF THE ENGINE . W E RECOMMEND TO WARM THE ENGINE UP AT A MEDIUM ENGINE SPEED FOR SEVERAL MINUTES BEFORE SWITCHING TO FULLLOAD . – N EVER TILT THE MOTORCYCLE OVER THE SIDE STAND TO WARM UP THE ENGINE . T HE SIDE STAND ...
Page 15 - PERIODIC MAINTENANCE SCHEDULE 2003; A clean motorcycle can be checked more quickly which saves money!; CARBURETOR
ENGLISH 14 PERIODIC MAINTENANCE SCHEDULE 2003 Service every 5 hours Service every 20 hours M AINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE FOR CARE AND CHECKS DONE BY THE RIDER ! A clean motorcycle can be checked more quickly which saves money! Check engine for leaks ● Change ...
Page 16 - LC
ENGLISH 15 V ITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC Check transmission oil level ● Check cooling liquid level ● Check brake fluid level ● Check brake pads for wear ● Check brake performance ● ● Lubricate and adjust actuating cables and nipples ● Remove and clean...
Page 17 - Removing the seat; MAINTENANCE WORK ON CHASSIS AND ENGINE
ENGLISH 16 Removing the seat The quick-release mechanism 1 allows removal of the seat without tools. Turn the quick-release device approximately 180° counterclockwise, lift therear portion of the seat and pull the seat off backwards.When mounting the seat ensure that the hook engages at the tank. Ch...
Page 18 - How to change the handlebar position
ENGLISH 17 1 2 3 Checking and adjusting the steering head bearing (50 SXSENIOR) * The steering head bearing should be checked regularly for play. To check,support the motorcycle frame and lift the front wheel off the ground. Nowtry to move the fork back and forth – you should not feel any play. Toad...
Page 19 - Basic suspension setup for the weight of the driver; To determine the sag of the telescopic fork
ENGLISH 18 A B C D 1 Basic suspension setup for the weight of the driver To achieve maximum handling performance and to prevent the telescopicfork and shock absorber from being damaged, the basic setup of thesuspension components must be suitable for your child's weight. At delivery,KTM's mini motor...
Page 20 - Telescopic fork maintenance *; Changing the telescopic fork oil *
ENGLISH 19 Telescopic fork maintenance * The telescopic fork must be serviced at least once a year. To service the fork, proceed as follows:Prop up the motorcycle under the frame to take the load off the frontwheel.Disassemble the front wheel, remove screw 1 from the brake caliper and unscrew holdin...
Page 21 - Cleaning the dust scrabbers of the telescopic fork; Correct chain tension
ENGLISH 20 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 behindthe dust-protection bellows. If this dirt is not removed, the oil sealing ringslocated beh...
Page 22 - General information about KTM disc brakes; Setting the basic position and play of the hand brake lever *; Checking/refilling the front brake fluid level *; DOT
ENGLISH 21 General information about KTM disc brakes BRAKE FLUID RESERVOIRS:The brake fluid reservoirs for the front brake is designed such that it doesnot need to be refilled, even if the brake shoes are worn. If the brake fluidlevel drops below the minimum level either the brake system has a leak ...
Page 23 - Checking front brake pads; Replacing the front brake pads *; Changing the basic position of the foot brake lever; Checking the rear brake linings for wear
ENGLISH 22 Checking front brake pads Inspect the brake pads from in front of the vehicle. The linings must be atleast 1 mm (0.04 in) thick. WARNING A T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM (0.04 IN ), OTHERWISE THEY COULD LEAD TO BRAKE FAILURE . F OR YOUR OWN SAFET...
Page 24 - Drum brake maintenance; Removing and mounting the rear wheel
ENGLISH 23 Drum brake maintenance Drum brake maintenance is limited to occasional blowing out of the brakedrum and brake shoes. Brake drum and brake linings can be slightly roughened with an abrasive tape. Removing and mounting the front wheel Jack the motorcycle up by the frame so that the front wh...
Page 25 - Checking spoke tension; Cooling system
ENGLISH 24 Tires, air pressure Tire type, tire condition, and air pressure level affect the way your motor-cycle rides, and they must therefore be checked whenever you are gettingready to go anywhere on your motorcycle.– Tire size can be found in the technical specifications.– Tire condition has to ...
Page 26 - when engine is cold; Checking coolant level; Cleaning the air filter *
ENGLISH 25 when engine is cold 10 mm Checking coolant level The coolant should be 10 mm (0.4 in) above the radiator fins when theengine is cold (see illustr.). In the event of the coolant being drained, alwaysfill and bleed the system. WARNING I F POSSIBLE , ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN...
Page 27 - Changing the seat height; Adjusting the throttle cable *
ENGLISH 26 Changing the seat height The saddle can easily be raised by 25 mm (1 in). This lets you adjust theheight as your child grows. Figures A and B show the fork and shock absorber positions for a low seatposition. The fork tubes extend approx. 17 mm (0.7 in) (H) above the upperfork stabilizer....
Page 28 - Checking the gear oil level
ENGLISH 27 Checking the gear oil level To 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 theindicator opening 2 . If oil must be added, tilt the motorcycle and pour automatic gear oil ( Shell Donax TA)...
Page 29 - TROUBLE SHOOTING; CAUSE
ENGLISH 28 If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an erroroccur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error.We would like to point out that many operations cannot b...
Page 30 - TROUBLE
ENGLISH 29 TROUBLE Engine stalling or runningwith four stroke cycle High rpm misfiring Engine spluters into thecarburetor Engine overheating Emission of white smoke(steam) Excessive oil escapes fromtransmission breather tube CAUSE Carburetor overflows if level adjusttoo high, float needle seating is...
Page 31 - CLEANING; USE AFTER PERIOD OF STORAGE
ENGLISH 30 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. ! CA...
Page 32 - TIGHTENING TORQUES - ENGINE
ENGLISH 31 TECHNICAL DATA – ENGINE 50 LC 2003 Engine 50 SX PRO JUNIOR LC 50 SX PRO SENIOR LC Design single cylinder 2-stroke engine, with reed valve inlet Displacement 49.0 ccm Bore/Stroke 39.5 / 40 mm Fuel SUPER fuel, research octane no 95, mixed with 2-stroke oil Oil/gasoline ratio 1 : 40 when usi...
Page 33 - TIGHTENING TORQUES; TECHNICAL SPECIFICATIONS - CHASSIS; STANDARD-ADJUSTMENT – FORK; STANDARD ADJUSTMENT - SHOCK ABSORBER
ENGLISH 32 Hexagon nuts front/rear axle M12x1 30 Nm Hexagon nut swing arm bolt M12 40 Nm Clamping screw upper/lower fork bridge M8 15 Nm Screws handlebar clamp M8 20 Nm Shock absorber top/bottom M10 45 Nm Allan screw – Handlebar support M10 Loctite + 40 Nm Front brake caliper M8 Loctite + 20 Nm Fron...
Page 34 - HEAD WORD INDEX
ENGLISH 33 HEAD WORD INDEX Page Adjusting the control cable on the rear wheel ....................22 Adjusting the idle speed (Dell’Orto PHBG 19 BS) ...............26 Adjusting the idle speed (Dell’Orto PHVA 14 DS) ..............26 Adjusting the throttle cable ..........................................
