Benutzeranleitung / Produktwartung 50 AC/LC des Produzenten KTM
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50 AC/LC REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE REPARATION MANUAL DE REPARACION REPAIR MANUAL 2002-2006 Art.NR.: 3.206.028-E.
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REPAIR MANUAL 2002-2006 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 .
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Art.-Nr . 3.206.028 -E Repair manual KTM MINI 50 air/liquid cooled KTM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REP AIR MANUAL IN THE BINDER – Put the index into the binder . – Put the front page of the repair manual (210x297 mm) into the transparent pocket provided for this purpose on the outside of the binder .
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Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E E XPLANATION - U PDATE Edition: 7/2005 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.
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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.
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Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E REPLY FAX FOR REPAIR MANUALS W e 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 Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028-E GENERAL INFORMATION OPERATING RANGES OF THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 CLEANING AND STORAGE . . . . . . . . . . . . . . . . . . . . . . .
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B C D A 1 2 2-2E main jet jet needle jet needle idling jet idling jet throttle valve Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E Carburetor adjustment Basic information about original carburetor setting The original carburetor setting was adapted for an altitude of approx.
2-3E 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.
1 2 2 3 A 4 4 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 .
Changing front brake fluid (not Mini Adventure) – Move the hand brake cylinder into horizontal position. – Disassemble the cover 1 together with the rubber boot 2 from the brake fluid reservoir . – Press the brake caliper pistons all the way back.
Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E Changing rear brake fluid (50 SX, 50 Supermoto) – Move the vehicle in a vertical position. – Disassemble the cover 1 together with the rubber boot 2 from the brake fluid reservoir .
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3-1E REMOVING AND REFITTING ENGINE 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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1 2 3 4 5 6 3-2E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028-E 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 2 3 4 5 3-3E – 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. – Loosen hose clamp 3 of the intake flange on the carburetor , pull carburetor back and swing to the side.
1 1 2 3 4 4 5 6 7 8 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. – Carefully pull socket connector 3 apart. – Detach both exhaust springs 4 with a suitable wrench, remove springs.
1 2 3 4 3-5E – Install carburetor on the intake flange and tighten hose clamp 1 . – Place chain on rear sprocket and pinion, mount chain joint 2 and secure. 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.
1 2 3 3-6E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E – Attach connection 1 of the air filter box to the carburetor and tighten hose clamp. – Insert air filter element in the air filter box and mount cover . NOTE: the locating tabs in the cover must engage in the panel.
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4-1E DISASSEMBLING THE ENGINE Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028-E SPECIAL TOOLS - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 FIXING THE ENGINE . . . . . . . . . . . . . . .
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15 50 8 130 75 2 1 4 3 5 6 4-2E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E SPECIAL TOOLS ENGINE 50 AC/LC 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 Loctite 243 blue 5 451.
1 2 3 4 5 5 5 6 7 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).
1 2 2 3 4 4 5 6 7 8 4-4E Remove ignition stator. – Pull cable guide 1 from the case. – Remove allan bolts 2 of the ignition stator 3 . – Carefully pull stator 3 out of the case. Remove cylinder head, cylinder and pistons. – Loosen bolts on cylinder head crosswise and remove.
1 2 3 4 5 5 5 5 6 7 7 4-5E Pull off ignition rotor – 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 .
1 1 1 1 2 3 4 5 6 7 8 9 4-6E Disassemble the clutch and primary drive – Rechuck the engine to provide access to the clutch side. – Remove kickstarter and bolts 1 on the clutch cover .
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5-1E SERVICING INDIVIDUAL COMPONENTS Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028-E RIGHT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 LEFT HOUSING HALF . . . . . . . . . . . .
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1 2 3 S 5-2E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E 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.
1 2 4 3 5-3E Working on the left half of the engine case 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 .
1 2 6 7 8 9 3 4 5 5-4E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E Working on the clutch cover NOTE: dismantling the clutch cover is neccessary if parts are damaged or the O-ring is leaking. – T urn kickstarter shaft 1 counter -clockwise and remove ratchet gear 2 .
M 4 6 8 7 5 3 2 1 9 5-5E Overhaul the water pump (LC-engine) – Remove cover 1 , discard the O-rings. – 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 ).
x y 10mm x y 50mm 5-6E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E MARK PISTON CYLINDER AC CYLINDER LC A 39.455 - 39.460 mm 39.515 - 39.520 mm 39.505 - 39.510 mm 1.5533 - 1.5535 in 1.5557 - 1.5559 in 1.5553 - 1.5555 in B 39.461 - 39.
B A 1 2 3 4 5 6 7 6 6 5-7E Clutch new used Balancing the clutch wear – Check clutch shoes for wear; if the lining only shows minor signs of wear , the linings can be reinstalled. NOTE: – the centrifugal clutch has an outer diameter of approx. 82.5 mm (3.
6-1E ASSEMBLING THE ENGINE Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028-E MOUNTING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 MOUNTING THE PRIMARY DRIVE . . . . . . . . . . . . . . . .
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1 2 3 4 5 6 7 8 9 bk bl bl bl bl 6-2E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E Mounting the crankshaft and output shaft – Heat the engine case on a heating plate. – Lubricate both bearings, lightly grease the seal shaft ring.
1 2 3 4 5 5 6 7 S 8 9 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.
2 3 2003 1 1 1 1 4 4 4 2 3 2004 6-4E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E Mounting the clutch cover – 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.
1 3 4 2 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.
1 1 2 3 4 6-6E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E 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.
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7-1E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028-E TROUBLE SHOOTING TROUBLE SHOOTING 50 AC/LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 IGNITION MEASUREMENT 50 AC/LC . . . . . . . . . . . . . . . .
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7-2E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E TROUBLE CAUSE REMEDY Engine fails to start Operating error Open fuel tap, replenish fuel, do not use choke Fuel supply interrupt.
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 rep.
1 2 R S 7-4E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E 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.
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8-1E MODEL 2002 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3 BASIC CARBURETOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3 CHASSIS . . . .
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8-2E MODEL 2005 AC ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10 BASIC CARBURETOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10 CHASSIS . . . .
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8-3E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E TECHNICAL DATA - ENGINE 50 AC/LC 2002 Engine 50 AC (aircooled) 50 LC (liquid cooled) Design single cylinder 2-stroke engine, wit.
8-4E TECHNICAL SPECIFICATIONS - CHASSIS 50 MINI 2002 50 SX PRO SENIOR LC single downtube, split-cradle Marzocchi Ø = 32 mm 175/185 mm (6.9/7.3 in) Central shock absorber WP PDS Disc brake Ø 160 mm (6.3 in) Drumbrake Ø 90 mm (3.5 in) front/rear 2.50x10" Pirelli MT 32 / 2.
8-5E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E TECHNICAL DATA - ENGINE 50 AC/LC 2003 Engine 50 AC (aircooled) 50 LC (liquid cooled) Design single cylinder 2-stroke engine, wit.
8-6E TECHNICAL SPECIFICATIONS - CHASSIS 50 MINI 2003 50 SX PRO SENIOR LC single downtube, split-cradle Marzocchi Ø = 32 mm 175/185 mm (6.9/7.3 in) Central shock absorber WP PDS Disc brake Ø 160 mm (6.3 in) Drumbrake Ø 90 mm (3.5 in) 2.50x12" V eeRubber V270/ 2.
8-7E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E TECHNICAL DATA - ENGINE 50 AC/LC 2004 50 SX PRO SENIOR LC single cylinder 2-stroke engine, with reed valve inlet 49,0 cm³ 39,5 .
8-8E BASIC CARBURETOR SETTING Model 50 MINI ADVENTURE (SEP ARA TE LUBRICA TION) 50 SENIOR ADVENTURE (MIXTURE LUBRICA TION) T ype Dell'Orto PHV A 12 XS Dell'Orto PHV A 14 DS Main jet 60 80 (70) Needle jet 211 F A 211 F A Idling jet 38 45 Jet needle A10 A10 Needle position from top 4.
8-9E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E TECHNICAL SPECIFICATIONS - CHASSIS 50 MINI 2004 50 SX PRO SENIOR LC single downtube, split-cradle Marzocchi Ø = 32 mm 185/185 mm Central shock absorber WP PDS Disk brake Ø 160 mm Disk brake Ø 140 mm 2.
8-10E TECHNICAL DATA – ENGINE 2005 AC ENGINE 50 AC SENIOR ADVENTURE 50 AC MINI ADVENTURE Design single cylinder 2-stroke engine, with reed valve inlet Displacement 49.
8-11E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E TECHNICAL SPECIFICATIONS – CHASSIS 2005 AC CHASSIS 50 SENIOR ADVENTURE 50 MINI ADVENTURE Frame single downtube, split-cradle Fork Marzocchi Ø = 32 mm (1,26 in) Wheel travel front/rear 175/190 mm (6.
8-12E TYP 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, m.
8-13E Repair manual KTM MINI 50 air/liquid cooled 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) 185/185 mm (7.3/7.3 in) Rear suspension Central shock absorber WP Front brake Disk brake Ø 160 mm (6.
8-14E TECHNICAL DATA – ENGINE 2006 AC ENGINE 50 SENIOR ADVENTURE 50 MINI ADVENTURE Design single cylinder 2-stroke engine, with reed valve inlet Displacement 49.
8-15E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E TECHNICAL SPECIFICATIONS – CHASSIS 2006 AC CHASSIS 50 SENIOR ADVENTURE 50 MINI ADVENTURE Frame single downtube, split-cradle Fork Marzocchi Ø = 32 mm (1,26 in) Wheel travel front/rear 175/190 mm (6.
8-16E TYP 50 SX JUNIOR 50 SX, 50 SUPERMOTO 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 wi.
8-17E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E 50 SX JUNIOR 50 SX 50 SUPERMOTO Frame single downtube, split-cradle Fork Marzocchi Ø = 32 mm (1.26 in) 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.
8-18E TOLERANCES AND FITTING CLEARANCES Crankshaft run out of crank stud max. 0.050 mm Crankshaft webs outer dimension 38 mm ±0.05 mm Conrod bearing radial play max. 0.030 mm Piston fitting clearance 0.055-0.065 mm (AC) / 0.045-0.055 mm (LC) Piston ring end gap max.
9-1E 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 . . . .
9-2E M AINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER ! PERIODIC MAINTENANCE 2002 50 MINIS air/liquid cooled A washed motorcycle can be check.
9-3E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each start after every cleaning for cross c.
9-4E PERIODIC MAINTENANCE 2003-2005 50 MINIS air/liquid cooled A washed motorcycle can be checked more quickly which saves money! Service Service every every 5 hours 20 hours ENGINE Check engine for l.
9-5E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E NOTE: I F THE INSPECTION EST ABLISHES THA T PERMISSIBLE TOLERANCES ARE EXCEEDED , THE RESPECTIVE COMPONENTS MUST BE REPLACED .
9-6E M AINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER ! PERIODIC MAINTENANCE 2006 50 MINIS air/liquid cooled A washed motorcycle can be check.
9-7E Repair manual KTM MINI 50 air/liquid cooled Art.-Nr . 3.206.028 -E NOTE: I F THE INSPECTION EST ABLISHES THA T PERMISSIBLE TOLERANCES ARE EXCEEDED , THE RESPECTIVE COMPONENTS MUST BE REPLACED .
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10-1E 10 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2 WIRING DIAGRAM INDEX Repair manual KTM MINI 50 air/liquid cooled Art.
l i o c n o i t i n g i C L 0 5 r o i n e S X S - . d A i n i M black 4 0 0 2 . 2 0 . 0 2 G k c a l b n o t t u b p o t s k c a l b r o t a r e n e g 10-2E Cable colours: black = black.
Ein wichtiger Punkt beim Kauf des Geräts KTM 50 AC/LC (oder sogar vor seinem Kauf) ist das durchlesen seiner Bedienungsanleitung. Dies sollten wir wegen ein paar einfacher Gründe machen:
Wenn Sie KTM 50 AC/LC noch nicht gekauft haben, ist jetzt ein guter Moment, um sich mit den grundliegenden Daten des Produkts bekannt zu machen. Schauen Sie zuerst die ersten Seiten der Anleitung durch, die Sie oben finden. Dort finden Sie die wichtigsten technischen Daten für KTM 50 AC/LC - auf diese Weise prüfen Sie, ob das Gerät Ihren Wünschen entspricht. Wenn Sie tiefer in die Benutzeranleitung von KTM 50 AC/LC reinschauen, lernen Sie alle zugänglichen Produktfunktionen kennen, sowie erhalten Informationen über die Nutzung. Die Informationen, die Sie über KTM 50 AC/LC erhalten, werden Ihnen bestimmt bei der Kaufentscheidung helfen.
Wenn Sie aber schon KTM 50 AC/LC besitzen, und noch keine Gelegenheit dazu hatten, die Bedienungsanleitung zu lesen, sollten Sie es aufgrund der oben beschriebenen Gründe machen. Sie erfahren dann, ob Sie die zugänglichen Funktionen richtig genutzt haben, aber auch, ob Sie keine Fehler begangen haben, die den Nutzungszeitraum von KTM 50 AC/LC verkürzen könnten.
Jedoch ist die eine der wichtigsten Rollen, die eine Bedienungsanleitung für den Nutzer spielt, die Hilfe bei der Lösung von Problemen mit KTM 50 AC/LC. Sie finden dort fast immer Troubleshooting, also die am häufigsten auftauchenden Störungen und Mängel bei KTM 50 AC/LC gemeinsam mit Hinweisen bezüglich der Arten ihrer Lösung. Sogar wenn es Ihnen nicht gelingen sollte das Problem alleine zu bewältigen, die Anleitung zeigt Ihnen die weitere Vorgehensweise – den Kontakt zur Kundenberatung oder dem naheliegenden Service.
