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50 SX 2010
KTM 50 SX 2010 User Manual
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30/DISAS
SEMBLING
THE
ENGINE
75
300499-10
–
Remove
engine
case
gasket
and
dowels
.
15.27
Removing
the
tra
nsmission
shafts
300500-10
–
Pull
both
transmission
shafts
out
of
the
bearing
seats
together.
15.28
Removing
the
cr
ankshaft
300501-10
–
Remove
crankshaft
.
300504-10
–
Remove
O-ring
.
76
78
Table of Contents
Table of Contents
4
Means of Representation
7
Important Notes
8
Motorcycle
9
Jacking up the Motorcycle
9
Removing the Motorcycle from the Work Stand
9
Starting
9
Vehicle Level
10
01/Fork, Triple Clamp
11
Cleaning Dust Boots of Fork Legs
11
Removing the Fork Legs
11
Installing the Fork Legs
12
Servicing Fork
12
Disassembling the Fork Legs
13
Checking the Fork Legs
14
Assembling the Fork Legs
15
Adjusting the Fork Overhang
16
Removing the Lower Triple Clamp
17
Installing the Lower Triple Clamp
18
Greasing the Steering Head Bearing
19
Checking Play of Steering Head Bearing
20
Adjusting the Play of the Steering Head Bearing
20
02/Handlebar, Controls and Instruments
22
Checking the Play in the Throttle Cable
22
Adjusting the Play in the Throttle Cable
22
Handlebar Position
22
Adjusting Handlebar Position
22
04/Shock Absorber, Swingarm
24
Adjusting the Rebound Damping of the Shock Absorber
24
Measuring Rear Wheel Sag Unloaded
24
Checking the Static Sag of the Shock Absorber
24
Checking the Riding Sag of the Shock Absorber
25
Adjusting the Spring Preload of the Shock Absorber
25
Adjusting the Riding Sag
26
Removing the Shock Absorber
26
Installing Shock Absorber
26
Adjusting Seat Height
27
Servicing Shock Absorber
27
Removing the Spring
27
Disassembling the Damper
28
Disassembling the Piston Rod
29
Removing the Heim Joint
30
Checking the Damper
31
Installing the Heim Joint
32
Assembling the Piston Rod
33
Assembling the Damper (50 SX)
34
Assembling the Damper (50 SX Mini)
35
Filling the Damper with Nitrogen
36
Installing the Spring (50 SX)
37
Installing the Spring (50 SX Mini)
38
05/Exhaust
40
Removing the Exhaust Manifold
40
Installing the Exhaust Manifold
40
Removing Main Silencer
40
Installing the Main Silencer
41
Removing the Glass Fiber Yarn Filling of the Main Silencer
41
Installing the Glass Fiber Yarn Filling of the Main Silencer
42
06/Air Filter
43
Removing the Air Filter
43
Installing the Air Filter
43
Cleaning Air Filter
43
07/Fuel Tank, Seat, Trim
44
Removing the Seat
44
Mounting the Seat
44
Removing the Fuel Tank
44
Installing the Fuel Tank
45
08/Mask, Fender
46
Dismounting the Front Fender
46
Installing the Front Fender
46
Dismounting the Start Number Plate
46
Installing the Start Number Plate
46
09/Front Wheel
48
Removing Front Wheel
48
Installing the Front Wheel
48
Checking the Tire Condition
49
Checking Tire Air Pressure
49
Checking Brake Discs
49
Checking Spoke Tension
50
10/Rear Wheel
51
Removing Rear Wheel
51
Installing the Rear Wheel
51
Checking Chain Dirt
51
Cleaning the Chain
52
Checking the Chain Tension
52
Checking the Chain Tension - Installing Rear Wheel
53
Checking Rear Sprocket / Engine Sprocket for Wear
53
Adjusting Chain Tension
53
Adjusting Chain Tension - after Checking
54
Adjusting Chain Tension - Installing Rear Wheel
54
Adjusting the Chain Guide
54
13/Brake System
55
Checking the Play of the Hand Brake Lever
55
Adjusting the Play of the Hand Brake Lever
55
Adjusting the Basic Position of the Hand Brake Lever
55
Checking the Front Brake Fluid Level
55
Adding Front Brake Fluid
56
Changing the Front Brake Fluid
57
Checking the Front Brake Linings
58
Removing Front Brake Linings
58
Installing the Front Brake Linings
58
Changing the Front Brake Linings
59
Checking the Free Travel of the Foot Brake Lever
60
Adjusting the Free Travel of the Foot Brake Lever
60
Adjusting the Basic Position of the Foot Brake Lever
60
Checking Rear Brake Fluid Level
61
Adding Rear Brake Fluid
61
Changing the Rear Brake Fluid
62
Checking the Rear Brake Linings
63
Removing Rear Brake Linings
63
Installing the Rear Brake Linings
64
Changing the Rear Brake Linings
64
30/Engine
66
Removing the Engine
66
Installing the Engine
67
30/Disassembling the Engine
70
Clamping the Engine into the Engine Work Stand
70
Pulling off the Spark Plug Connector
70
Draining the Gear Oil
70
Removing the Cylinder Head
70
Removing the Cylinder
71
Removing the Piston
71
Removing the Oil Pump (50 SX Mini)
71
Removing the Alternator Cover
71
Removing the Ignition Coil, Intake Flange, and Reed Valve Housing
72
Removing the Oil Pump Drive Gear (50 SX Mini)
72
Removing the Stator
72
Removing the Rotor
72
Removing the Engine Sprocket
73
Removing the Kickstarter
74
Removing the Water Pump Cover
74
Removing the Outer Clutch Cover
74
Removing the Clutch Cover
74
Removing the Clutch Drum
74
Removing the Kickstarter Gear
75
Removing the Kickstarter Idler Shaft
75
Loosening the Nut of the Primary Gear
75
Removing the Centrifugal Force Clutch
75
Removing the Kickstarter Shaft
75
Removing the Clutch Bearing
76
Removing the Primary Gear
76
Removing the Left Engine Case
76
Removing the Transmission Shafts
77
Removing the Crankshaft
77
30/Engine - Work on Individual Parts
78
Work on the Right Section of the Engine Case
78
Work on the Left Section of the Engine Case
78
Changing the Conrod Bearing
79
Checking the Crankshaft Run-Out on the Bearing Pin
80
Removing the Water Pump
80
Installing the Water Pump
81
Changing the Shaft Seal Ring of the Kick Starter
81
Dismantling Centrifugal Clutch
82
Assembling Centrifugal Clutch
82
Checking/Measuring Clutch
83
Checking/Measuring the Cylinder
83
Checking/Measuring the Piston
84
Determining Piston/Cylinder Mounting Clearance
84
Checking the Piston Ring End Gap
85
Checking Reed Valve Housing, Diaphragm and Intake Flange
85
30/Assembling the Engine
86
Installing the Crankshaft
86
Installing the Transmission Shafts
86
Installing the Left Engine Case
86
Installing the Primary Gear
87
Installing the Clutch Bearing
87
Installing the Kickstarter Shaft
87
Installing the Centrifugal Force Clutch
87
Tightening the Nut of the Primary Gear
87
Installing the Kickstarter Idler Shaft
88
Installing the Kickstarter Gear
88
Installing the Clutch Drum
88
Installing the Clutch Cover
88
Installing the Outer Clutch Cover
89
Mounting the Water Pump Cover
89
Installing the Kickstarter
89
Installing the Engine Sprocket
89
Installing the Rotor
90
Installing the Stator
91
Adjusting the Stator/Rotor Distance
91
Installing the Oil Pump Drive Gear (50 SX Mini)
91
Installing the Reed Valve Housing, Ignition Coil, and Intake Flange
91
Installing the Alternator Cover
92
Installing the Oil Pumps (50 SX Mini)
92
Installing the Piston
92
Installing the Cylinder
93
Checking the X-Distance
93
Setting the X-Distance
94
Installing the Cylinder Head
94
Installing the Oil Drain Plug
94
Refilling with Gear Oil
95
Mounting the Spark Plug Connector
95
Removing the Engine from the Universal Mounting Rack
95
31/Carburetor
96
Removing the Carburetor (50 SX)
96
Removing the Carburetor (50 SX Mini)
97
Installing the Carburetor (50 SX)
98
Installing the Carburetor (50 SX Mini)
99
Checking/Setting the Carburetor Components (50 SX)
100
Checking/Setting the Carburetor Components (50 SX Mini)
101
Disassembling the Carburetor (50 SX)
101
Disassembling the Carburetor (50 SX Mini)
103
Assembling the Carburetor (50 SX)
104
Assembling the Carburetor (50 SX Mini)
106
Checking the Choke Slide (50 SX)
107
Checking the Choke Slide (50 SX Mini)
107
Checking the Throttle Slide (50 SX)
108
Checking the Throttle Slide (50 SX Mini)
108
Checking the Jet Needle
108
Checking the Float Needle Valve
108
Checking/Setting the Float Level (50 SX)
109
Carburetor - Adjusting Idle Speed (50 SX)
109
Carburetor - Adjusting Idle Speed (50 SX Mini)
110
32/Clutch
111
Removing the Centrifugal Force Clutch
111
Fitting Centrifugal Force Clutch
111
Checking Clutch Engagement Speed
112
Adjust the Clutch Engagement Speed
112
35/Water Pump, Cooling System
114
Draining the Coolant
114
Refilling Coolant
114
Checking the Coolant Level
115
Checking the Antifreeze and Coolant Level
115
38/Lubrication System
117
Changing the Gear Oil
117
Draining the Gear Oil
117
Filling up with Gear Oil
117
Checking the Gear Oil Level
118
Adding Gear Oil
118
Filling up with Oil (50 SX Mini)
119
Bleeding Oil Pump (50 SX Mini)
119
39/Ignition System
121
Checking the Ignition System
121
Checking the Spark Plug Connector
121
Checking the Ignition Coil
121
Checking the Kill Switch
122
Checking the Alternator
122
Troubleshooting
123
Technical Data - Engine
125
Capacity - Gear Oil
125
Capacity - Coolant
125
Technical Data - Tolerance, Wear Limits of Engine
126
Technical Data - Engine Tightening Torques
127
Technical Data - Carburetor
128
50 SX Mini
128
Technical Data - Chassis
129
Tires
129
Capacity - Fuel
130
Technical Data - Fork
131
50 SX Mini
131
Technical Data - Shock Absorber
132
50 SX Mini
132
Technical Data - Tightening Torques for Chassis
133
Cleaning/Conservation
134
Cleaning Motorcycle
134
Storage
135
Putting into Operation after Storage
135
Service Schedule
136
Important Maintenance Work that Must be Done in an Authorized KTM Workshop
136
Important Maintenance Work that Must be Done in an Authorized KTM Workshop (as Additional Order)
136
Wiring Diagram
138
Substances
140
Auxiliary Substances
142
Special Tools
144
Standards
151
Index
152
4
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KTM 50 SX 2010 Specifications
General
Brand
KTM
Model
50 SX 2010
Category
Motorcycle
Language
English
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