50 sx mini chassis

50 SX MINI 2009 SPARE PARTS MANUAL: CHASSIS

ENGLISH

ART.NO.: 3CF6001I5EN

50 SX MINI 2009

INDEX

FRONT FORK, TRIPLE CLAMP

FRONT FORK D IS AS S EMB LED

3x S H OCK AB S ORB ER D IS AS S EMB LED

4x S H OCK AB S ORB ER D IS AS S EMB LED

7x AIR FILTER

FRAME

5x S W ING ARM

8x TANK, S EAT, COV ER

1 1 x 1

H AND LEB AR, CONTROLS

EX H AU S T S Y S TEM

9x MAS K, FEND ERS

1 2 x

6x

1 0 x D ECAL

1 3x

1 4x

50 SX MINI 2009

INDEX FRONT WHEEL

REAR WHEEL

15x BRAKE CALIPER FRONT

HAND BRAKE CYLINDER

16x BRAKE CALIPER REAR

19x

REAR BRAKE CONTROL

17x

18x

21x

x

ACCESSORIES KIT

20x

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 lik e 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 ex tra equipment, which is not applied to standard models. Š by KTM-SP O R TMO TO R C Y C L E AG, Mattighofen AU STR I A; All rights reserved; R eprint, also in ex tracts, with written allowance of KTMSP O R TMO TO R C Y C L E AG, Mattighofen only.

x 2

50 SX MINI 2009

FRONT FORK , TRIP L E C L A M P FIG 1 5 6 7 2 5 3 6 3 7 3 8 3 9 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 5 0

PART NUMBER 4 5 2 0 1 0 0 0 2 3 3 7 5 0 1 4 9 8 A 0 9 1 2 0 8 0 3 0 3 0 9 1 2 0 6 0 2 5 3 7 7 0 5 1 2 6 4 0 0 2 5 0 8 0 3 0 6 0 9 1 2 1 0 0 2 5 0 5 0 3 0 1 0 3 8 0 0 0 4 5 1 0 1 0 3 9 0 0 0 0 9 8 5 0 5 0 0 0 3 4 5 0 0 1 0 7 0 0 0 0 0 0 2 5 0 5 0 2 0 6 5 9 0 3 0 0 2 9 0 0 0 4 6 0 0 1 0 4 3 0 0 0 4 9 0 0 1 0 8 6 0 0 0 0 7 7 0 0 2 1 3 0 0 4 9 0 0 1 0 8 1 0 0 0 4 6 0 0 1 0 8 6 0 0 0 0 7 7 0 3 6 0 0 3 0

094520110 / C094520111

3

DESCRIPTION F RON T F ORK CPL. 5 0 SX MIN I 2 0 0 9 TOP F ORK PLATE 5 0 LC SEN . 0 3 AH SCREW D IN 0 9 1 2 -M 8 X 3 0 AH SCREW D IN 0 9 1 2 -M 6 X 2 5 B OTTOM TRIP. CLAMP CPL. H H COLLAR SCREW M8 X 3 0 TX 4 0 AH SCREW D IN 6 9 1 2 -M1 0 X 2 5 ,1 0 .9 ,L H AN D LEB AR CLAMP D = 2 2 MM 2 0 0 1 H AN D LEB AR SUPPORT D = 2 2 MM 2 0 0 1 SELF LOCKIN G N UT D IN 0 9 8 5 -M 5 B RAKE CAB LE CLAMP RSGU 9 /1 2 H H COLLAR SCREW M5 X 2 0 TX 3 0 H H N UT M2 0 X 1 ,5 W S= 2 7 RIGH T STEERIN G H EAD N UT M2 0 X 1 ,5 COV ERIN G CAP O-RIN G 4 0 ,9 4 X 2 ,6 2 N B R7 0 TAPERED ROLLER B EARIN G 3 2 0 0 4 X PROTECTION RIN G 2 0 ,1 X 3 9 X 5 O-RIN G 3 6 ,0 0 X 3 ,0 0 N B R

* N E W

QTY 1 1 2 4 1 4 2 2 1 1 1 1 1 1 1 1 2 1 1

P A R T

X

A S R E Q U IR E D

50 SX MINI 2009

FRONT FORK DIS AS S EMB LED FIG 8 9 11 12 12 13 14 15 16 17

PART NUMBER 7504212AC 7528010 7518031 75141169 75141214 7533297 7523264 7528230 7522166AA 7524157

19 20 21 22 23 26 27 28 29 31 40 40 98

75141015 75031570A 75031570A/R 7522225 0912080403 7708247/R 7708248/R 7512068 75031571A 75031571A/R 7547325 7547331 7550013

094520131 / C094520131

4

DESCRIPTION PLUG CAP O-RING PRE LOAD BUSH L=55MM 2002 SPRING 2N/MM SPRING 2,5N/MM DUST SEAL STOP RING OIL SEAL 32/42/6,5-9,5 WASHER D42X32,5X1,5 PISTON RING D32 ONLY FOR REBOUND DAMPING REBOUND SPRING SLIDER L/S 50 LC 2002 SLIDER CPL. L/S 50LC 2002 WASHER 14X8X1,5 AH SCREW DIN912 M8X40 FORK TUBE R/S MINI/J UN. 02 FORK TUBE L/S MINI/J UN. 02 FOOT BUFFER SLIDER R/S 50 LC 2002 SLIDER CPL. R/S 50LC 2002 STICKER LEFT SIDE MARZ OCCHI STICKER RIGHT SIDE MARZ OCCHI FORKOIL EBH16 SAE 7.5

* NEW PART

QTY 2 2 2 2 x 2 2 2 2 1 2 1 1 2 1 1 1 2 1 1 1 1 1

X AS REQUIRED

50 SX MINI 2009

HANDLEBAR, CONTROLS FIG 1 2 4 5 8 9 10

PART NUMBER 45202001000 45002010050 45002010000 45002021000 45202091100 50311089200 45011089044

15 15

44011076100 44011076200

094520210 / C094520211

5

DESCRIPTION HANDLEBAR MINI ADJUSTING SCREW TWIST GRIP CPL. 50 SXR GRIPP SET THROTTLE CABLE 50SX JUN/MINI SHORT CIRCUIT BUTTON 02 S.CIRCUIT BUTTON W. RIP CORD ACCESSORY CABLE TIE 100/2,5MM BLACK CABLE TIE 200/3,6MM BLACK

* NEW PART

QTY 1 1 1 1 1 1 x x x

X AS REQUIRED

50 SX MINI 2009

FRAME FIG 1 2 3 4 5 6 7 8 9 10 11 12 13 14

PART NUMBER 4520300120030 54310086200 0025080656 51103053000 51103053051 36003014000 0025080306 4700304003390 59003040050 59003041050 54803044000 0125100003 54603041000 0094032253

094520312 / C094520312

6

DESCRIPTION FRAME " MC09" 50SX MINI 2009 SELF LOCKING NUT M8 10.9 HH COLLAR SCREW M8X65 TX40 CHAIN SLIDING PIECE BELOW ' 97 BUSHING 8,2X10X20 LOCK WASHER 8MM HH COLLAR SCREW M8X30 TX40 FOOTPEG L.+ R. CPL. 85 SX 03 FOOT PED L/S EXC SILVER 2000 FOOT PED R/S EXC SILVER 2000 BOLT FOR FOOT PED 03 WASHER DIN0125-A10,5 FOOTREST SPRING L/S & R/S PIN DIN0094-3,2X25 STEEL

* NEW PART

QTY 1 2 2 1 1 2 1 1 1 1 2 2 2 2

X AS REQUIRED

50 SX MINI 2009

SHOCK ABSORBER DISASSEMBLED FIG 1 2 3 4 5 6 7 7 7 8 9 10 11 12 13 14 15 16 17 18 90

PART NUMBER 36120784S R306 36120785 36120782 36120015 36120418 93010184S 93010185S 93010186S 36120461 36120052 36120604 36120040 36120071 36120786 36120787S 40540015 36120780 36120427 36120777S1 50180342S1

084510430 / C084510432

7

DESCRIPTION MONOSHOCK TOP PART L140 CPL.07 REPAIR KIT BEARINGS 50SX JUN07 SCREW M5 C.K. RVS SEAL D5,21XD8,38X1,22 COUNTERNUT ADJUSTING NUT SPRING 65N/MM 65-120 120MM ORA SPRING 75N/MM 75-120 120MM ORA SPRING 85N/MM 85-120 120MM ORA SPRING RETAINER D=39 * PISTON ROD NUT M10X1 SHIM D10XD22X2,5 PISTON RING 8X1X108,3 * PISTON 6+6XD5.5/3.5 REBOUND DISC H=10 D=28,5 ADAPTOR 36MM H26,6 CPL. 07 CIRCLIP 38X1,5 RESERVOIR CAP D=36 H=9,5 BUMP RUBBER WP65 L=20 MONOSH. BOTTOM PART L86 CPL.07 SHOCK ABSORBER FLUID 5 LT '03

* NEW PART

QTY 1 2 1 1 1 1 x x x 1 1 1 1 1 1 1 1 1 1 1 1

X AS REQUIRED

50 SX MINI 2009

SHOCK ABSORBER DISASSEMBLED FIG 1 2 3 4

PART NUMBER 03189E04 0125100003 0982100003 0931100453

094520410 / C094520412

8

DESCRIPTION MONOSHOCK 50 SX MINI 2009 WASHER DIN0125-A10,5 SELF LOCK.NUT DIN0982-M10 HIGH HH SCREW DIN0931-M10X45

* NEW PART

QTY 1 4 2 2

X AS REQUIRED

50 SX MINI 2009

SWING ARM FIG 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 20 21 22

PART NUMBER 45204030133 46004030070 54603097000 0770160021 46004030071 55003139900 45103014144 45213053000 0934120103 54611076100 0009050103 45004070000 45104170000 0985050003 0025050306 0025050126 45010083000 45010083060 0985080003 45204066000 0991060203

094520491 / C094520491

9

DESCRIPTION SWING ARM 50 SX JUNIOR 09 MA9S SPACER BUSHING 20X26X30X9,7 NEEDLE BUSH HK 2016 O-RING 16,00X2,00 VITON BUSHING BOX 12X20X36,5 BLIND RIVET THREAD M6 STE. 4MM SWING ARM BOLT CPL. 2004 LOCK WASHER 50 SX HEXAGON NUT DIN0934-M12X1 RETAIN.CLAMP FOR BRAKE HOSE'96 SPECIAL SCREW M 5,0X10 CHAIN GUIDE REAR BRACKET FOR CHAIN GUARD 02 SELF LOCKING NUT DIN0985-M 5 HH COLLAR SCREW M5X30 TX30 HH COLLAR SCREW M5X12 TX30 CHAIN ADJUSTER SUPPORTING BRACKET SELF LOCKING NUT DIN0985-M 8 CHAIN SLIDING GUARD FLAT H.SCREW DIN7991-M6X20 8.8

* NEW PART

QTY 1 4 2 4 2 1 1 1 1 2 2 1 1 3 2 1 2 2 2 1 1

X AS REQUIRED

50 SX MINI 2009

EXHAUST SY STEM FIG 1 2 3 4 5 6 7 8 9 10 11

PART NUMBER 45205007000 0770320030 0025060166 54603048100 45105057000 45205079100 54605069000 54605068000 0025060306 50305012000 45105079056

094520510 / C094520511

10

DESCRIPTION EXHAUST MANIFOLD JUN/MINI 2009 O-RING 32,00X3,00 VITON HH COLLAR SCREW M6X16 TX30 RANGE CHANGE METAL NUT M6 EXHAUST RUBBER MINI 2002 SILENCER 50 SX 2009 BUSHING 7,5X12X28X7,8 '96 EXHAUST BRACKET RUBBER BLACK HH COLLAR SCREW M6X30 TX30 SWINGELEMENT FOR EXHAUST PIPE ROCKWOOL PREFOMED 50 2002

* NEW PART

QTY 1 2 4 3 1 1 2 1 1 2 1

X AS REQUIRED

50 SX MINI 2009

AIR FILTER FIG 1 2 3 4 5 6 7

PART NUMBER 0017060203 54808020000 4520600100030 45206002000 45206015000 45206026100 76235028000

094520611 / C094520611

11

DESCRIPTION EJOT PT SCREW K60X20 WS=6 SPACER BUSHING 03 AIRFILTERBOX 50 SX 09 FILTER BOX COVER 50 SX 09 AIR FILTER 50 SX 09 CARBURETOR CONNECT. 50 SX HOSE CLAMP GEMI 20-32 MM

* NEW PART

QTY 2 2 1 1 1 1 1

X AS REQUIRED

50 SX MINI 2009

TANK, SEAT, COV ER FIG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PART NUMBER 4520701313330 49007008044 58507003000 55007006200 0017060203 58307016001 45031005000 78007000270 45107011000 50307014000 45207040000 45007040051 50307014000 0025060126 4520805400030A 0017060204

094520711 / C094520711

12

DESCRIPTION FUEL TANK CPL. 50SX MINI 2009 FILLER CAP CPL. SMALL FUEL COCK CPL. SMALL RALLYE'96 O-RING 11X1,8 NBR 70 EJOT PT SCREW K60X20 WS=6 FUEL HOSE VITON 6X1,5 PER/M YDNAC-CLAMP FUEL HOSE ( 8MM) PVC-HOSE 5,6X10X270MM TANK SCREW MINI 50 2001 TANK ROLLER 12X26X12 '98 SEAT 50 SX 09 Q UICK RELEASE CPL. 50 SXR '97 TANK ROLLER 12X26X12 '98 HH COLLAR SCREW M6X12 TX30 SPOILER SET BLACK 50 SX 2009 EJOT PT SCREW K60X20 ALU WS=6

* NEW PART

QTY 1 1 1 1 2 1 2 1 1 1 1 1 2 2 1 6

X AS REQUIRED

50 SX MINI 2009

MASK, FENDERS FIG 1 2 3 4 6 7 8 9 10 11 12 13 14 15

PART NUMBER 4520800700004 45208022000 0017060204 0024060106 54808020000 4520801000004 0024060156 4520801300004 45007040050 0981350163 54808020000 0025060206 45206010100 72210079000

094520810 / C094520810

13

DESCRIPTION NUMBER PLATE 50 SX 09 BRAKE HOSE GUIDE 50 SX 09 EJOT PT SCREW K60X20 ALU WS=6 HH COLLAR SCREW M6X10 TX30 SPACER BUSHING 03 FENDER 50 SX 09 HH COLLAR SCREW M6X15 TX30 REAR PART QUICK RELEASE LATCHPLATE SHEET MET.SCR.DIN7981- 3,5X16 SPACER BUSHING 03 HH COLLAR SCREW M6X20 TX30 SPLASH PROTECT. 50SX JUN./MINI BUCKET

* NEW PART

QTY 1 1 1 1 2 1 4 1 1 2 2 4 1 2

X AS REQUIRED

50 SX MINI 2009

DECAL FIG 1

PART NUMBER 45208091200

094520832 / C094520832

14

DESCRIPTION DECAL SET CPL. 50 SX MINI 09

QTY 1

* NEW PART

X AS REQUIRED

50 SX MINI 2009

FRONT WHEEL FIG 1 2 4 7 8 9 15 16 17 22

PART NUMBER 45209001144 45109010044 0625062028 45109071102 45109072000 4520907010030 45209060000 59009062013 46010085044 45009073000

094520910 / C094520910

15

DESCRIPTION FRONT WHEEL 50 SX JUNIOR 2009 FRONT WHEEL HUB CPL. 2002 BALL BEARING 6202-2RSH/C3 SPOKE 3X100X6MM-110째 SPOKE NIPPLE 3MM FRONT RIM 10"X1,6 BLACK 09 BRAKE DISC FRONT JUN/SEN 09 SPECIAL SCREW M6X13 WS=8 10.9 AXLE CPL. 207MM M12X1 RIM BAND 10" 22MM

* NEW PART

QTY 1 1 2 28 28 1 1 4 1 1

X AS REQUIRED

50 SX MINI 2009

REAR WHEEL FIG 1 2 4 5 6 7 8 9 10 10 10 10 10 11 12 13 14 15 16 17 18 19 20 21 22

PART NUMBER 45210001044 45110010144 0625062027 45110014000 45110013000 45210071111 45109072000 4521007000030 45210051038 45210051039 45210051040 45210051041 45210051042 0015070203 45110052000 45110265104 45110266000 45210060000 59009062016 45110081000 0125120003 0934120103 45110090000 50310090050 45009073000

094521010 / C094521010

16

DESCRIPTION REAR WHEEL 50 SX 2009 REAR WHEEL HUB CPL. 2004 BALL BEARING 6202 2RS1 C3 DISTANCE SLEEVE L/S DISTANCE SLEEVE R/S SPOKE 3X111 C.166째 SPOKE NIPPLE 3MM REAR RIM 10"X1,6 BLACK 2009 SPROCKET 38-T 50 SX 2009 SPROCKET 39-T 50 SX 2009 SPROCKET 40-T 50 SX 2009 SPROCKET 41-T 50 SX 2009 SPROCKET 42-T 50 SX 2009 HH COLLAR SCREW M 7X20 WS=11 SHIM RACING CHAIN 1/2X3/16" 50 SX CONNECTING LINK 1/2X3/16" 90RS BRAKE DISC REAR D=140MM 09 SPECIAL SCREW M6X16 WS=8 10.9 AXLE REAR CPL. SEN."LC" FLAT WASHER DIN0125-A13 HEXAGON NUT DIN0934-M12X1 RIM LOCK CPL. 2004 NUT FOR WHEEL HOLDER '96 RIM BAND 10" 22MM

* NEW PART

QTY 1 1 2 1 1 28 28 1 x x x x x 5 5 1 1 1 5 1 2 2 1 1 1

X AS REQUIRED

50 SX MINI 2009

HAND BRAKE CYLINDER FIG 1 2 3 4 5 6 7 8 9 10 11 12 13 14

PART NUMBER 45113101044 45113002000 45113012000 00062030000 45113004000 0966030083 45113003000 45113009000 45113006000 45113013000 45113021000 45113007000 0912050103 45113008000

094521310 / C094521311

17

DESCRIPTION HAND BRAKE CYLIND.CPL.50 LC 02 HANDBRAKE LEVER CPL. R/S 02 BRAKE HOSE FR. SX JUN. LC 2002 BRAKE FLUID DOT5.1 0,25L PROT.CAP HAND BRAKE CYL. 50 LC OVAL HEAD SCREW DIN0966-M 3X8 HAND BRAKE CYLINDER COVER 04 GASKET HAND BRAKE CYLINDER 04 SPECIAL-AH SCREW M 5X18 NUT M5 DIN 6334 SPRING FOR HAND BRAKE LEVER 04 ADJUSTING SCREW M 3X16 04 AH SCREW DIN0912-M 5X10 REP.KIT PISTON FRONT 50 04

* NEW PART

QTY 1 1 1 1 1 2 1 1 1 1 1 1 1 1

X AS REQUIRED

50 SX MINI 2009

REAR BRAKE CONTROL FIG 22 23 43 46 47 48 50 52 53 55 56 60 61 62 63 65 66 70 71 80

PART NUMBER 0025060166 56509064100 0934060003 54310086200 0991060203 58303063000 45213050000 54603062000 45213053000 54813055000 47013056100 46113060000 47013061000 47013062000 47013063000 46113325000 0912040103 45213170100 0770060019 00062030000

094521330 / C094521331

18

DESCRIPTION HH COLLAR SCREW M6X16 TX30 SELF LOCKING NUT M6 10.9 HEXAGON NUT DIN0934-M 6 SELF LOCKING NUT M8 10.9 FLAT H.SCREW DIN7991-M6X20 8.8 BRAKE LEVER STOP '93 FOOT BRAKE LEVER RETURN SPRING FOR BRAKE LEVER LOCK WASHER 50 SX SWIVEL HEAD KA6 03 PRESSURE ROD 85 SX 06 REAR BRAKE CYL. 50+65 04 REP. SET PISTON REAR D=11 2003 CYLINDER COVER REAR 85 SX 03 GASKET CYLINDER COVER REAR 03 HOLLOW SCREW M6 AH.SCREW DIN0912-M 4X10 BRAKE TUBE REAR O-RING 6,00X1,00 FORMULA BRAKE FLUID DOT5.1 0,25L

* NEW PART

QTY 2 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1

X AS REQUIRED

50 SX MINI 2009

BRAKE CALIPER FRONT FIG 2 3 4 6 7 8 9 14 16 17 18 19 20 21 50

PART NUMBER 45113025000 45113125000 0799025000 0770060019 45113019000 45113015000 45113030000 45113019050 0025080406 0025080256 0125080003 45113018000 0912050203 45113020000 45119050000

094521360 / C094521360

19

DESCRIPTION HOLLOW SCREW M6X34 50 LC 2002 AH SCREW+CIRCLIP LC 50 02 TAB WASHER DIN6799 RS2,5 O-RING 6,00X1,00 FORMULA REP.KIT SEAL RING 50LC 2002 BRAKE CALIPER CPL.FR. 50 LC 02 BRAKE PAD SET 50 LC 2002 REPAIR KIT BRAKEPISTON HH COLLAR SCREW M8X40 TX40 HH COLLAR SCREW M8X25 TX40 WASHER DIN0125-A 8,4 RETAINING SPRING 50 LC AH SCREW DIN0912-M 5X20 BREATHER SCREW 50 2002 BLEEDER INJECTION-SET 50-65

* NEW PART

QTY 1 1 1 2 1 1 1 1 1 1 2 1 1 1 x

X AS REQUIRED

50 SX MINI 2009

BRAKE CALIPER REAR FIG 18 25 26 30 31 50 71 72 79 80 81 82 83 90

PART NUMBER 45113018000 46113225000 0912050163 0025060166 0025060406 45119050000 0770060019 0770080019 45113019100 45113080000 0770022020 45113225000 0799025000 45113030000

094521390 / C094521390

20

DESCRIPTION RETAINING SPRING 50 LC HOLLOW SCREW CPL. AH SCREW DIN0912-M 5X16 HH COLLAR SCREW M6X16 TX30 HH COLLAR SCREW M6X40 TX30 BLEEDER INJECTION-SET 50-65 O-RING 6,00X1,00 FORMULA O-RING 8,00X1,00 FORMULA REPAIR KIT BRAKEPISTON BRAKE CALIPER REAR CPL.50LC 04 O-RING 22X2X2 EPDM AH SCREW + CIRCLIP 50/65 04 TAB WASHER DIN6799 RS2,5 BRAKE PAD SET 50 LC 2002

* NEW PART

QTY 1 1 1 1 1 x 2 1 1 1 2 1 1 1

X AS REQUIRED

50 SX MINI 2009

ACCESSORIES KIT FIG 0 0 1 1 1 1 29 30 34 35 36

PART NUMBER 312305 312313 3211344EN 322000 3CF6001I5EN 3CM080858IEN 45229099000 45103023300 60029070200 50329080100 45229073000

094522001 / C094522003

21

DESCRIPTION DOCUMENTS BAG 2006 KTM BALLPOINT ORANGE OWNERS MANUAL MINI 2009 SAFETY BROCHURES SPORTMINICYC. SPM CHASSIS 50 SX MINI 2009 SPM ENGINE 50 SX MINI 2009 TOOL KIT 50 SX 09 PLUG-IN STAND 50 SEN LC 03 T-WRENCH WS=6/8/10 TX=45 B&F WRENCH SW=17/21/27/32 B&F SPARK PLUG WRENCH

* NEW PART

QTY 1 1 1 1 1 1 1 1 1 1 1

X AS REQUIRED

NOTICE

50 SX MINI 2009

NOTICE

50 SX MINI 2009

NOTICE

50 SX MINI 2009

8/2008 Art.Nr.: 3CF6001I5EN

*3CF6001I5EN* 3CF6001I5EN KTM Group Partner

KTM-Sportmotorcycle AG A-5230 Mattighofen w

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