2004 Ktm 50 Pro Senior Manual

1. Ktm 50 Senior Adventure
2. 2004 Ktm 50 Pro Senior Manual

The engine power needs to get to the ground by way of the clutch assembly. The clutch is an another important area with great gains in KTM50 performance with clutch replacement and fine tuning. A old worn out clutch will slip and not allow the engines full power to get to the rear wheel. If your KTM50 has a unknown amount of hours or you bought the bike 2nd hand its probadly a good idea to replace the complete clutch assembly & basket with a new one to make sure everything is in proper specs. You can always keep the old clutch as a spare if you think it still has some life in it. Above is a 1997 - 2000 KTM 50 Pro senior model.

These year models all use a Morini Franco S5-GS engine. The “GS” is the code for the 4-pedal reed block cylinder. This easy to see it from a distance because the cylinder is BLACK in color and uses a intake manifold with four bolts. The piston has a ovel hole in the intake side.

The ring are the same top and bottom. Check the head gasket some models had a rubber “o”ring and other bikes had a copper ring/paper head gasket. The other only difference for the different years is the clutch assembly. The early year bikes had a 2-shoe clutch design and the last couple of models had a disc style clutch. Its best to remove the clutch cover and see what model clutch style you have. 1997 KTM50 Pro Junior To the left is a 1997 KTM 50 Pro Junior model.

This year KTM50 Pro Jr. Model uses a Morini Franco S5-T engine. The “T” is the code for the 2-pedal reed block cylinder. The 1997 Junior model was the only year & model that used the “T” cylinder. This easy to see it from a distance because the cylinder is silver in color and uses a intake manifold with only two bolts. The piston has a round hole in the intake side. The ring are not the same top and bottom.

The top ring is a “L” shape the bottom ring is just flat. Above is a 1995-1997 KTM 50SX or KTM50 SXR model. This year KTM 50 model uses a Morini Franco S5-E or S5N engine. The “E” code is for non-reed block STEEL cylinder.

The “N” is code for non-reed ALUMINUM cylinder. This easy to see it from a distance because if the cylinder is “SILVER” in color is the aluminum cylinder. If its BLACK in color it's the STEEL cylinder. Both cylinders have a intake manifold with only two bolts.

The pistons are different for these two models. The STEEL cylinder piston rings are not the same top and bottom.

The top ring is a “L” shape the bottom ring is just flat. The aluminum cylinder piston uses two flat rings. Have any questions about parts? Or need help choosing the right ones?

Our sales reps are some of the most knowledgeable. E-mail us, or call (239)566-9666 9:00AM to 7:00PM eastern time Mon-Sun. KTM50.com is NOT affiliated with KTM Sportcycles or KTM USA.

Charlie's KTM50 Clutch Maintenance Video How to setup clutch and how to do regular Maintenance The proper clutch is so important on all 50cc motocross race bikes that have the standard three shoe clutch. Cobra King 50cc, Cobra CM50cc, Polini X1, X3 LEM R2, R3 or KTM50 Pro Jr, KTM 50 Pro Sr.All use the same type of clutch design. YES these bikes are very different, but the clutch design and theory are all the same. Our specs, measurements and setups are used for the KTM 50 L/C engine. However owners of other brands of bike may find some of these tips helpful.

Looking to put “maximum power to the ground” then, clutch adjusting procedures on your KTM 50s is maintenance and setup. In proper working order with clutch shoe engagement adjusted to optimum RPM is your key to the best performance possible.

Is your bike purchased used? Is your bike over six months old? Bikes with a clutch that's worn out or not adjusted correctly will make the bike feel slow, sluggish, bogg or give it a slipping feel. If your bike is not brand new then think about replacing the spring washers, clutch shoes and possibly the clutch basket with new parts. This will give you the best performance possible because the clutch tolerances are very important to maintain.

Also improperly maintained clutch or worn clutch could confuse people in thinking that the need different size sprockets, carb jets or it may have bad ignition system but most of the time its due to a clutch not engaging correctly maybe too-early or too-low in the working RPM range. The three shoe clutch design seems to remain a mystery to people who are afraid to maintain, clean, adjust or inspect them.

With knowing a few basics these clutches will not be so confusing or frustrating. The following is some basic advice received by a very experienced racer dad that we would like to share with you. If you have any tips or ideas please email us so we can post them here for everyone to see.

There are several things to consider when setting initial stack set for these KTM 3-shoe clutches. First and foremost: Skill and ability of the rider. Second: Type of terrain, “motocross” hare scambles” “flat track” or recreational trail riding. Third: How the bike is presently geared.

You have to treat gearing and clutch set up independently. Example: If you were to make a rear sprocket change to increase top end speed, (Less teeth on rear sprocket) then you loose some bottom end power.

Ktm 50 Senior Adventure

Now with the clutch set up you can change your power curve to compensate. My advise, buy a good dial/electronic caliper. This is the most important tool in your toolbox.

2004 Ktm 50 Pro Senior Manual

Next; for your initial stack setup go conservative. I recommend the following as a base line setup for a beginner rider on flat terrain. Legend for clutch washers: (HH) = head of clutch block bolt. ( = Bevel spring washer –notice direction. / = Flat washer in various thinknesses so all three of your stacks are within 0.003” of each other. Beginner setup is as follows. HH (( )) (( )) (( )) ( ) / - add flat washer if needed to bring stack in tolerance.

= 0.585” – 0.590” Alllow your child to ride the bike. Is he/she blipping throttle? If so allow child to ride bike longer to see if child can adapt.

If your child is comfortable and riding more aggressive, this is my preferred stack HH (( )) (( )) (( )) ((( / = 0.610 This setup is more aggressive. The flat washer can be taken away or made thinner or made thicker if needed for fine adjustment. Again flat washer in stack up to adjust overall engagement speed. Some basic pack thicknesses.

Motocross: anywhere from 0.590” – 0.670” Hare Scrambles: anywhere from 0.590” – 0.640” Recreational: anywhere from 0.580” – 0.610” Remember change oil after every hard practice seesion and after every race. At motocross races change between each moto. Use only Maxima MTL 75 wt Ultra light trans oil. Clean & inspect spring washers. The most important advice I can give is; Don't be afraid to experiment. Keep a notebook and record your findings.

Some stacks work better then others at different tracks, conditions, weather, sand, hard pack, mud, hills long starts etc Good luck! – Tex by Ken Crews, from Crews racing Got some ideas about KTM50 clutch info or set up you want to share with us? Please send us a email Clutch Basket Measurement The measurement of the inside diameter of clutch drum/basket should be approx., 84mm new. Difference between drum/basket and shoe assembly should be no less than 1.5mm, no more than 2.0mm. Freightliner part manual. Clutch Measurement Remove and measure the diameter of three assembled clutch shoes (approx., 82mm new).

Spring Washers - $29.99 When you reassemble spring washers, use Loctite 'Thread Locker 243' and torque to 96 lbs/inch - 11 Nm Martin & Slater uses Belleville spring washers that are USA made and have design standards based on DIN 2092 specifications and are manufactured to DIN 2093 specifications. This quality supplier is a USA OEM supplier of spring washers since the late 1960s.

USA made carbon STEEL Belleville spring washers Qty: Stainless Spring Washers - $39.99 Stainless steel spring washers are considered a performance part, because they are not AMA stock class legal. Many people use these stainless washers because they are much stronger then the normal carbon spring washers. They also resist fading less then standard carbon spring washers when the clutch heats up. Keep in mind that a these stainless spring washers will use a different stack compared to the standard steel spring washers. USA made STAINLESS STEEL Belleville spring washers. Qty: Loctite Thread Locker 243 Clutch & Flywheel Puller - $29.99 Use a clutch puller tool and piston stop tool for clutch removal.

Reinstall drum/basket and clutch shoes onto crankshaft and tighten clutch assembly nut to 22 lbs/ft - 30 Nm. WARNING: Do not use a AIR impact wrench or exceed maximum torque specs or center hub will fracture or you could damage the crankshaft. Qty: Piston Stop Tool - $19.99 Qty: © Martin & Slater, 2016.