After purchasing this manual you will receive a PDF file providing you with an email to contact. You will then receive a reply with a link to visit to download the PDF manual for your 2002 KTM 50 SENIOR ADVENTURE MOTORCYCLE This manual will show you every nut and bolt on your Machine! With hundreds of pages, it will show you how to distinguish any problem (from an oil change to a transmission swap) and how to fix it on your own. There are many illustrations to aid you during your job and easy to read text throughout the manual. You will be able to use the search function to browse the manual and print out your needed pages. This Factory Service Repair Manual will guide you through fundamentals of maintaining and repairing, step-by-step, to teach you what the factory trained technicians already know by heart.
Complete professional technical service and repair manual written for your 2017 KTM 50 SX Junior Mini. This is the same type of service manual your local dealer will use when doing a repair. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also. Adventure, Purity, Performance, Extreme - KTM is READY TO RACE.
By applying the knowledge in this service repair manual, any owner will be able to make the right decisions about what they need to do to maintain and repair their machine. Not only do we guarantee a great quality service manual, but we will also follow up with excellent customer service! Customer Satisfaction Guaranteed!!!
BRAKES This motorcycle has a hydraulic brake system of front and rear. Brakes are items of personal safety and should be properly adjusted. Remember to check periodically the brake system and these checks should be conducted by qualified Jincheng dealer. Do not use the remained brake fluid from on a unsealed container, never reuse the brake fluid remained in the last repairing, because the used brake fluid may absorb the water from the air. Use DOT 4 brake fluid from a sealed container.
Do not spill out the brake fluid, when the brake fluid is glued to the paint, plastic and rubber material, a chemical reaction shall take place, causing the damage. (1)lower level mark Front brake Rear brake BRAKE FLUID (1) (2) (3) (1) (1)Brake fluid cap (2)Max. Fluid level mark (3)Min. Fluid level mark Brake fluid may cause irritation. Avoid contact with skin or eyes. In case of contact, flush thoroughly with water and call a doctor if your eyes were exposed NOTICE WARINING. 9 BRAKE LINING The main points for checking the front brake lining are to see whether the lining wear is out of the range.
Replace the brake lining wear is out of the range. Replace the brake lining if the lining wear is beyond the brake wear limit mark. FRONT BRAKE FLUID LEVEL Check that the fluid level is above the lower level mark(1) with the motorcycle in an upright position.
Brake fluid must be added to the reservoir when ever the fluid level begins to reach the lower level mark(1). Fill the reservoir up to upper level mark. REAR BRAKE FLUID LEVEL There are two marks in rear brake fluid cap,keep the fluid lever between the Max. Fluid level mark (2) and the Min. Fluid level mark (3) always. Check if it is short of brake fluid, check the hose and other components for corrosion or cracks. Limit mark Brake Pad Front brake Rear brake If the brake system or brake linings have to be repaired, we suggest that these repair should be performed by your authorized SKYTEAM dealer.
SKYTEAM dealer knows your motorcycle best and is dedicated to your complete satisfaction Incoming search terms:. High-pressure fluid flow The engine rotates the pump swash plate, which has a gear mechanism. The rotating swash plate pushes the pump pistons to increase the pressure on the hydraulic fluid and feed it to the high-pressure annular chamber. The high- pressure fluid is then fed to the oil motor piston chamber where it pushes the pistons forward, which then push the motor swash plate. Power Fluid flow from pump to motor Fluid flow from motor to pump Low-pressure fluid flow The lower-pressure hydraulic fluid returns to the pump through the low-pressure annular chamber.
In this way, the fluid circulates between the pump and the motor. Movement of distributor valves and pistons The distributor valves play an important role in fluid circulation. The valves are placed both in the oil pump and motor. When the pump pistons move to the compression side, the valves connect the piston chamber and the high- pressure chamber. When the pump pistons move to the expansion side, the valves allow a connection between the piston chamber and the low-pressure chamber.
The valve in the oil motor moves opposite to its counterpart in the pump, ensuring the circulation of fluid within the system. For vehicles equipped witha transmission requiring the use of the overflow type automatic transmission fluid (ATF) inspection process, the A TF must be withinaspecific temperature range for accurate fluid level inspection. Inspecting the A TF outside of the specified temperature range may result in incorrectA TF fluid levels and could lead to shift quality, M.I.L. “ON”, and/or transmission damage issues. Please seethe information in this bulletin for updated A TF level inspection temperature ranges. HINT For additional information including animations and video illustrations, please seethe Technical Training course E076: “Toyota ATF Level Inspection”. NOTE Please see TSB No.
TC 010-07, “World Standard Automatic Transmission Fluid”, for important tips when working with A TFWS. ©2008 ToyotaMotor Sales, USA Page 1of3 T-SB-0129-08 July9,2008 Page 2of3 Automatic Transmission/Transaxle Fluid Level Inspection Temperature Ranges Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – - — Parts Information PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY 00289-ATFWS Same ATFWS As needed Required Tools&Equipment Incoming search terms:. With so many automatic transmission fluids, it’s hard to choose the one best-suited for each vehicle. Beginning in 2007, there will be several changes to the way we look at transmission fluids. Products meeting current DEXRON®-III /MERCON® specifications will no longer be officially licensed by GM and Ford.
However, products meeting these specifications will still be available – packaged as Valvoline® DEX/MERC and Valvoline’s MaxLife® DEX/MERC transmission fluids. The DEX/MERC fluids are recommended for GM, Ford and many import vehicles, 2005 and older. MERCON®V will also be compatible for Ford vehicles, 1996 and newer. GM has introduced DEXRON®-VI -a new, full-synthetic transmission fluid for GM vehicles and select imports, 2006 and newer. It is also backwards compatible for older GM vehicles.
Valvoline now offers DEXRON®- VI fluid, officially licensed and approved by General Motors Incoming search terms:. Refer to the Owner’s Manual and follow the instructions given to remove the maxi-fuse.
3 1 2 is02998 1. Transmission top cover screw (4) 2. Oil spout assembly screw 3. Upper bearing housing screw (2) Figure 1. Interface Cover Installation 2. See Figure 1. Remove and retain the four socket head cap screws (1) that fasten the front and right side of the transmission cover.
See Figure 3. Obtain the chrome top interface cover (3) from the kit.
NOTE The top interface cover can be carefully brought into position on top of the transmission housing from either the right or left side without removing or loosening any vehicle components. Position the top interface cover over the transmission top cover. Loosely fasten the chrome cover to the top of the transmission housing with the screws removed in Step 2. Obtain the chrome filler neck cover (4), 1/4-20 socket head screw (5), flat washer (6) and spacer (7) from the kit. Remove the oil level dipstick from the oil spout on the side of the transmission housing, wipe off and set it aside for later installation. NOTE Insert a clean shop rag into the oil spout opening while the dipstick is not installed. With the dipstick removed, small parts or other foreign material could fall into the transmission, leading to equipment damage or malfunction.
See Figure 1. Remove and discard the socket head cap screw (2) that fastens the oil spout assembly to the transmission housing. DO NOT remove the oil spout from the vehicle. Place the flat washer over the threads of the new screw, and insert the screw into the unthreaded hole in the chrome filler neck cover. Place the spacer onto the screw threads. Apply a few drops of Loctite® 243 (Blue) to the screw threads, and position the chrome cover onto the oil spout on the transmission housing.
Lubricate the filler neck gasket with soapy water to aid in installation. Tighten the screw to 84-132 in-lbs (9.5-15 Nm).
See Figure 3. Obtain the chrome lower side interface cover (1), one #10-24 socket head screw (8) and one chrome flat washer (9) from the kit. NOTE For models with mid controls, the right-side rider footrest (foot peg) support bracket must be loosened to allow installation of the lower side interface cover.
After the cover has been installed, tighten the footrest bracket attaching screws to 25- 35 ft-lbs (34-47 Nm). Position the cover around the chrome filler neck cover installed in Step 6. Loosely fasten the cover to the threaded hole in the filler neck cover with the screw and washer. Obtain the chrome upper side interface cover (2), three #10-24 socket head screws (8) and three chrome flat washers (9) from the kit Incoming search terms:.
INSTALLATION Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns.
Refer to the Owner’s Manual and follow the instructions given to remove the maxi-fuse. 3 1 2 is02998 1. Transmission top cover screw (4) 2. Oil spout assembly screw 3. Upper bearing housing screw (2) Figure 1. Interface Cover Installation 2.
See Figure 1. Remove and retain the four socket head cap screws (1) that fasten the front and right side of the transmission cover. See Figure 3. Obtain the chrome top interface cover (3) from the kit. NOTE The top interface cover can be carefully brought into position on top of the transmission housing from either the right or left side without removing or loosening any vehicle components.
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Position the top interface cover over the transmission top cover. Loosely fasten the chrome cover to the top of the transmission housing with the screws removed in Step 2. Obtain the chrome filler neck cover (4), 1/4-20 socket head screw (5), flat washer (6) and spacer (7) from the kit. Remove the oil level dipstick from the oil spout on the side of the transmission housing, wipe off and set it aside for later installation. NOTE Insert a clean shop rag into the oil spout opening while the dipstick is not installed.
With the dipstick removed, small parts or other foreign material could fall into the transmission, leading to equipment damage or malfunction. See Figure 1. Remove and discard the socket head cap screw (2) that fastens the oil spout assembly to the transmission housing. DO NOT remove the oil spout from the vehicle. Place the flat washer over the threads of the new screw, and insert the screw into the unthreaded hole in the chrome filler neck cover. Place the spacer onto the screw threads.
Apply a few drops of Loctite® 243 (Blue) to the screw threads, and position the chrome cover onto the oil spout on the transmission housing. Lubricate the filler neck gasket with soapy water to aid in installation.
Tighten the screw to 84-132 in-lbs (9.5-15 Nm). See Figure 3.
Obtain the chrome lower side interface cover (1), one #10-24 socket head screw (8) and one chrome flat washer (9) from the kit Incoming search terms:. INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. Disconnect battery cable, negative (-) cable only. NOTE The starter does not need to be removed to install this kit. Remove exhaust system only if needed to access transmission top cover hardware. Refer to Service Manual for instructions. NOTES Replace existing zinc hardware with chrome-plated hardware one at a time so the transmission top and side covers do not need to be replaced.
Remove and discard existing six 1/4-20 x 1 in. Hex socket- head screws and washers from top transmission cover. Install six chrome hex socket head screws (1) and washers (2) on top transmission cover (3). Tighten to 84-108 in-lbs (9.5-12.2 Nm).
Remove and discard existing two 1/4-20 x 1 in. Hex socket head screws and washers from side transmission cover. Install two chrome hex socket head screws (1) and washers (2) on side transmission cover (5).
Tighten to 84- 108 in-lbs (9.5-12.2 Nm). Remove and discard existing four 1/4-20 x 1-1/2 in. Hex socket head screws and washers from side transmission cover. Install four chrome hex socket head screws (4) and washers (2) on transmission side cover (5). Tighten to 84- 108 in-lbs (9.5-12.2 Nm). Install exhaust system if previously removed. Refer to Service Manual for instructions.
Connect negative (-) battery cable. INSTALLATION Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. Refer to the Owner’s Manual and follow the instructions given to remove the maxi-fuse. 1 4 3 2 is03621 1.
Transmission top cover screw (3) 2. Upper and lower rear bearing housing screw (2) 3. Upper front bearing housing screw 4. Lower front bearing housing screw Figure 1.
Interface Cover Installation 2. See Figure 1.
Remove the two rear bearing housing screws (2) from the side of the transmission case. Remove the oil level dipstick from the oil spout on the side of the transmission housing, wipe off and set it aside for later installation. NOTE Insert a clean shop rag into the oil spout opening while the dipstick is not installed. With the dipstick removed, small parts or other foreign material could fall into the transmission, leading to equipment damage or malfunction. See Figure 2.
Obtain the rear interface mounting bracket (1) from the kit. Apply a few drops of Loctite 243 (Blue) to the threads of the two bearing housing screws removed in Step 2. Install the rear interface mounting bracket to the bearing housing with the screws, and tighten to 13-18 ft-lbs (17.6-24.4 Nm). See Figure 1. Remove the upper front bearing housing screw (3) from the side of the transmission case. Loosen the lower front bearing housing screw (4).
See Figure 2. Obtain the front interface mounting bracket (2) from the kit.
Apply a few drops of Loctite 243 (Blue) to the threads of the upper front bearing housing screw removed in Step 6. Hook the slot in the front interface mounting bracket under the loosened lower screw head. Install the bracket to the bearing housing with the upper screw, and tighten both screws to 13-18 ft-lbs (17.6-24.4 Nm). See Figure 1. Remove and retain the three socket head cap screws (1) that fasten the right side and left front corner of the transmission cover. Remove and retain the screw fastening the rear brake line P-clamp to the rear fork bracket. See Figure 2.
Obtain the right rear interface cover (3), two chrome 1/4-20 screws (6) and two flat washers (7) from the kit. From the rear of the motorcycle, bring the right rear interface cover into position behind the rear exhaust pipe, over the bearing housing. The hole in the top surface of the cover should be positioned over the right rear transmission top cover hole. Loosely fasten the interface cover to the rear interface mounting bracket with the two chrome screws and flat washers.
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Obtain the chrome top interface cover (4) from the kit. Position the top interface cover over the transmission top cover, overlapping the tab at the top front of the chrome right rear interface cover.