50 SX MINI 2011 SPARE PARTS MANUAL: ENGINE ENGLISH ART.NO.: 3CM080858KEN

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1 SPARE PARTS MANUAL: ENGINE ART.NO.: 3CM080858KEN ENGLISH

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3 INDEX SPECIAL TOOLS CLUTCH COVER CYLINDER, CYLINDER HEAD CRANKSHAFT, PISTON 3x 4x 5x 6x ENGINE CASE REED VALVE CASE CARBURETOR CLUTCH 7x 8x 9x 10x TRANSMISSION KICK STARTER WATER PUMP COOLING SYSTEM 11x 12x 13x 14x 1

4 INDEX LUBRICATING SYSTEM IGNITION SYSTEM 15x 16x x x x x x x All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models. by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTM- SPORTMOTORCYCLE AG, Mattighofen only. x 2

5 SPECIAL TOOLS REVMETER EXTRACTOR PRIM. GEAR 65 SX ADJUSTING PLATE 50SX MINI WRENCH FOR ROTOR HOLD. SPANNER ROTOR 2K-1/2/3/ GEAR SEGMENT CPL SPECIAL SOCKET CLUTCH RETAIN. ARM F. ENG.WORK STAND PICKUP ENGINE STAND CPL ASSY SUPPORT (WITHOUT HOLDER) / C * NEW PART X AS REQUIRED 3

6 CLUTCH COVER CLUTCH COVER INNER CPL PLUG CPL. M24X O-RING 19,00X3,00 NBR CLUTCH COVER GASKET INSIDE DOWEL 9,8 X 7 X CLUTCH COVER GASKET CLUTCH COVER OUTSIDE HH COLLAR SCREW M6X8 TX CU-SEAL RING DIN7603-6X10X HH COLLAR SCREW M6X60 TX HH COLLAR SCREW M6X20 TX HH COLLAR SCREW M6X25 TX HH COLLAR SCREW M6X30 TX HH COLLAR SCREW M6X35 TX HH COLLAR SCREW M6X50 TX CYLINDER STUD DIN6325 8X30 M / C * NEW PART X AS REQUIRED 4

7 CYLINDER, CYLINDER HEAD CYL. HEAD BOLT M 7X30 WS= CU-SEAL RING DIN7603-7,3X12X CYLINDER HEAD CYLINDER PIN DIN6325-4X CYLINDER + PISTON CYLINDER BASE GASKET 0,2 MM x CYLINDER BASE GASKET 0,4 MM x CYLINDER BASE GASKET 0,5 MM x CYLINDER BASE GASKET 0,6MM x EXHAUST FLANGE GASKET EXHAUST FLANGE BRACKET FOR SPRINGHOLDER HH COLLAR SCREW M6X30 TX COLLAR NUT M8 WS= O-RING 78,00X2,00 VIT. BLACK O-RING 52,00X2,0 VITON / C * NEW PART X AS REQUIRED 5

8 CRANKSHAFT, PISTON HH COLLAR NUT M10X1,25 WS= LOCKING RING VSK PRIMARY DRIVE 33T WOODRUFF KEY DIN6888-3X3, SHAFT SEAL RING 25X35X7 BTSL SPACER WASHER - CRANKSHAFT O-RING 12,00X2,00 NBR BALL BEARING 6203 JR2 C CRANKSHAFT GS CPL SHAFT SEAL RING 15X24X7 A-DUO PISTON ROD REP-SET NEEDLE BEAR.PISTONPIN 12X15X I PISTON CPL. I II PISTON CPL. II PISTON BOLT CIRCLIP PISTONRING / C * NEW PART X AS REQUIRED 6

9 ENGINE CASE ENGINE CASES CPL. 50SX ENGINE CASE GASKET OILDRAIN PLUG W.MAG. M 12X1, CU-SEAL RING DIN X18X1, DOWEL 12X9X14, DOWEL 17 X 14 X 9, DOWEL 10X8,2X STUD M8X VACUUM CONECTION M6/3MM ' BEARING BRACKET INT. TORX FLAT HEAD M 5X CHAIN GUARD HH COLLAR SCREW M6X35 TX CYLINDER STUD DIN6325 8X20 M HH COLLAR SCREW M6X55 TX HH COLLAR SCREW M6X30 TX HH COLLAR SCREW M6X40 TX PVC-HOSE 4X6MM x YDNAC-CLAMP (6,8MM) GASKET SET 50 SX / C * NEW PART X AS REQUIRED 7

10 REED VALVE CASE GASKET MEMBRAN CASE MEMBRANE CASE CPL. V-VORCE MEMBRANE INTAKE FLANGE HH COLLAR SCREW M6X20 TX IGNIT. COIL RETAIN. PLATE CPL RUBBER SLEEVE D=8MM OPEN COLLAR BUSHING 6,3X8X13X9, HH COLLAR SCREW M6X30 TX CLAMP SGT / C * NEW PART X AS REQUIRED 8

11 CARBURETOR CARBURETOR DELLO. PHVA 12XS 05 1 CHECK THE JETTING CYL.HEAD SCREW DIN0084-M 5X16A CARBURETOR COVER DELLOR SPRING SPRING CAP THROTTLE VALVE CLAMP SPRING JET NEEDLE A IDLE ADJUST SCREW SPRING STARTING LEVER CPL. DELL SPRING ADJUST SCREW ATOMIZER 211FA MAIN JET 65 DELLORTO x MAIN JET 70 DELLORTO x MAIN JET 75 DELLORTO x MAIN JET 80 x JET 60 DELLORTO M6X0,75 x STARTING JET IDLING JET 35 x IDLING JET 38 x IDLING JET 45 x FLOAT CPL FLOAT BOWL DELLORTO CYL.SCREW DIN0084-M 4X20 A FUEL HOSE VITON 6X1,5 PER/M x GASKET SET DELLORTO PHVA / C * NEW PART X AS REQUIRED 9

12 CLUTCH CLUTCH CPL CLUTCH BLOCK KIT CPL DISTANCE SHIM 9,5X19X0,2 x SPACER SHIM KIT x DISTANCE SHIM 9,5X19X0,5 x CLUTCH SPRING KIT "A" x SOFT SPRINGS CLUTCH SPRING KIT "B" x HARD SPRINGS HH COLLAR SCREW KIT NEEDLE BEARING 18X24X12A INNER RING WITH COLLAR OUT. CLUTCH HUB LOOSE WASHER 8,5X31X HH SCREW DIN0933-M 8X / C * NEW PART X AS REQUIRED 10

13 TRANSMISSION CIRCLIP DIN X SPROCKET 10 T. x SPROCKET 11 T. x DISANCESPACER F. SPROCKET O-RING 15,00X1, SHAFT SEAL RING 22X32X7 BSL BALL BEARING 15X35X COUNTER SHAFT 1 ONLY USE WITH MAIN SHAFT 1 ONLY USE WITH NEEDLE BEAR.HK X20X / C * NEW PART X AS REQUIRED 11

14 KICK STARTER INT. TORX FLAT HEAD M 5X SPECIAL WASHER FOR M KICKSTARTER CPL SHAFT SEAL RING BALANC. SHAFT WASHER 16,3X25,8X KICK START SHAFT CPL WASHER 8,2X16X KICKSTARTER SPRING CYLINDER STUD DIN6325 8X20 M KICKSTARTER SHAFT SPRING RATCHET GEAR RATCHET GEAR CYLINDER STUD DIN6325 8X30 M / C * NEW PART X AS REQUIRED 12

15 WATER PUMP WATERPUMP COVER WATER PUMP COVER GASKET DOWEL 9,8 X 7 X CU-SEAL RING DIN7603-6X10X HH COLLAR SCREW M6X8 TX HH COLLAR SCREW M6X25 TX HH COLLAR SCREW M6X40 TX WATER PUMP WHEEL HH COLLAR SCREW M 5X12 WS= SHAFT SEAL RING 8X24X7 A DUO BALL BEARING 6000/C WATER PUMP SHAFT DRIVE WHEEL GROOVED BALL BEAR RS C / C * NEW PART X AS REQUIRED 13

16 COOLING SYSTEM RADIATOR L/S 50 SX RADIATOR R/S 50 SX RUBBER SLEEVE D=12MM RADIATOR CAP 1,8 BAR RAD. PROTECT. L/S 50 SXS RAD. PROTECT. R/S 50 SX SPACER BUSHING HH COLLAR SCREW M6X20 TX RADIATOR HOSE AHEAD 50 SX JUN RADIATOR HOSE BELOW 50 SX JUN PREFORMED HOSE 50 SX JUN. L/S PREFORMED RAD.HOSE 50 SX JUN PVC-HOSE 7X10 PER METER HOSE CLAMP NORMA 12/ / C * NEW PART X AS REQUIRED 14

17 LUBRICATING SYSTEM OIL TANK CPL. 50 SX MINI RUBBER GROMMET 6X9X13MM ANGLE CONNECTION EXPANS. TANK RUBBER SLEEVE D=8MM OPEN EJOT PT SCREW K60X20 WS= HH COLLAR SCREW M6X10 TX HOSE 5X9MM OIL TANK SCREW SX MINI OIL PUMP O-RING 19,10X1,60 NBR AH SCREW DIN0912-M 5X PREFORM. HOSE CARB.-PUMP 2X5MM YDNAC CLAMP (9MM) CLAMP 5 FOR OIL PUMP SPACER FOR OIL PUMP GEAR NEEDLE PIN DIN5402 NRB3X7,8 G OIL PUMP DRIVE WHEEL CIRCLIP DIN X1, HH COLLAR NUT M10X1,25 WS= / C * NEW PART X AS REQUIRED 15

18 IGNITION SYSTEM IGNITION COIL 50CCM LC HH COLLAR SCREW M6X12 TX HH COLLAR SCREW M6X30 TX COLLAR BUSHING 6,3X8X13X9, IGNIT. COIL RETAIN. PLATE CPL RUBBER SLEEVE D=8MM OPEN SPARK PLUG CONNECTOR SPARK PLUG LR8B O-RING 12,00X3,0 VITON FLYWEEL ROTOR WOODRUFF KEY DIN6888-2,5X HH COLLAR NUT M10X1,25 WS= FLYWHEEL STATOR 50CCM LC AH SCREW DIN6912 M5X DOWEL 9,8 X 7 X IGNITION COVER HH COLLAR SCREW M6X35 TX GASKET - IGNITION COVER / C * NEW PART X AS REQUIRED 16

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20 KTM Group Partner KTM-Sportmotorcycle AG A-5230 Mattighofen *3CM080858KEN* 3CM080858KEN Art.Nr.: 3CM080858KEN 2/2010