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REPAIRMANUAL2002-2006
50 AC/LC
REPARATURANLEITUNG
MANUALE DI RIPARAZIONE
MANUEL DE REPARATION
MANUAL DE REPARACION
Art.NR.: 3.206.028-E
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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: 1, 3, 7, 9, 13, 15, 17, 20, 21, 33, 46, 61, 63, 74, 76 - 81, 82, 84, 86, 87 Remove page (s) Replace by page (s) Insert page (s) after page 2-1 2-1E 2-2 2-2E 2-5E to 2-6E 2-4 4-2 4-2E 5-7 5-7E 8-1 8-1E 8-2 8-2E 8-12 8-12E 8-14 8-18E 8-14E to 8-17E 8-13 9-1 to 9-2 9-1E to 9-2E 9-4 9-4E 9-6E to 9-7
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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 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 3.210.24-E 4/2004 Model year 2005 (Engine number with first digit „5“) 3.206.028-E Updating of Rep.Manual 3
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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. We take it for granted that the repairs are made by qualified profe
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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. To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us as follows: If you find any errors or inaccuracies in one of our repair manual - whether these are technical errors, incorrect or unclear repair procedures, tool problems, missing technical data or torques, inaccurate or incorrec
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2-1E GENERAL INFORMATION 2 INDEX OPERATING RANGES OF THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 CLEANING AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 BLEEDING OILPUMP FOR SEPARATE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . .2-4 CHANGING FRONT BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 CHANGING REAR 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. Basic information about change of the carburetor setting Always start out from the original c
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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. OTHERWISE THE WATER MIGHT RUN INTO THE ELECTRICAL COMPONENTS, CONNECTORS, SHEATHED CABLES, BEARING
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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 ! HOSE2 LEADING FROM THE OIL PUMP TO THE CARBURETOR MUST BE INSTALLED WITHOUT KINKS. 2 Bleeding the oil pump for the
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2-5E 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 1 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). 2 – Use a commercial extractor (shop equipment) to extract the used brake fluid out of the system through the bleeder screw 3 on the
