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5-1E
SERVICING INDIVIDUAL COMPONENTS
Repair manual KTM MINI 50 air/liquid cooled Art.-Nr. 3.206.028-E
RIGHT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
LEFT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
REED VALVE HOUSING, INTAKE FLANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
CHECKING CYLINDER FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
SPRINGS OF CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
CHECKING CLUTCH FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
INDEX
5
Engine housing
Note: Read through the following section before commencing work. Then determine the assembly sequence so that the engine
housing halves only need to be heated up once before replacing the bearings.
Having first removed the dowels, in order to expel the bearings or remove them with light mallet blows, the housing halves must
be placed on a suitably large plane surface, supporting the whole of the sealing surface without damaging it. A wooden panel is
best used as a base.
Bearings or shaft seal rings should not be hammered into their seats. If no suitable press is available, use a suitable mandrel and
hammer them in with great care. Cold bearings will practically drop into their seats at an engine housing temperature of approx.
150° C.
After cooling, should the bearings fail to lock in the bore, they are bound to rotate after warming. In that event the housing must
be replaced.