2002–2008 KTM 50 AC/LC Service & Repair Manual (P/N 3.206.047-E)

This 350-page PDF combines KTM and WP publications for the 2002-2008 KTM 50 AC/LC family. The repair sections are written for qualified, professionally trained mechanics; the included owner's manuals distinguish routine owner care from work marked for a specialized KTM dealer.

• Exact model-year coverage: The 2002-2003 tables cover the 50 Mini Adventure, Junior Adventure, Senior Adventure, SX Pro Junior LC, and SX Pro Senior LC. Later coverage is grouped as 2004-2005 Mini/Senior Adventure and SX Pro Junior/Senior LC; 2006 Mini/Senior Adventure, SX Junior, SX, and Supermoto; 2007 Mini/Senior Adventure, SX Junior, and SX; and 2008 Mini SX, Mini Adventure, SX Junior, and SX.
• Engine repair coverage runs from removal and refitting through complete teardown, crankcase splitting, crankshaft and output-shaft service, piston/cylinder inspection, LC water-pump overhaul, and reassembly with Dimension X setup.
• Centrifugal-clutch and primary-drive sections cover disassembly, shoe and drum inspection, AC/LC spring arrangements, axial-clearance setup, reassembly, and symptom-based troubleshooting.
• Fuel and ignition material includes carburetor operating ranges and year/model jetting tables, separate-lubrication oil-pump bleeding for the two production layouts, stator resistance checks, peak-voltage testing, and fault-isolation charts.
• The four 2007-2008 owner's manuals add steering-head, fork, suspension-sag, chain, wheel, brake, cooling, air-filter, control, gear-oil, and clutch-adjustment procedures specific to their covered configurations.
• Two WP rear-shock manuals provide exploded views, model-specific parts and settings, shock removal, full disassembly and assembly, DU-bush and heim-joint work, oil filling, nitrogen charging, spring installation, and rebound/preload adjustment.

How the 350 Pages Are Divided

The first 104 pages are the KTM 50 AC/LC Repair Manual, Art. Nr. 3.206.047-E, Edition 6/2008. Its loose-leaf update record starts with the 2002 base issue and incorporates annual revisions through 2008; model years 2003-2008 are identified by engine-number first digits 3 through 8.

Four owner's-manual segments follow: 2007 50 Senior Adventure/50 Mini Adventure, 38 pages, Art. Nr. 3.211.140 GB; 2007 50 SX Junior/50 SX, 42 pages, Art. Nr. 3.211.141 EN; 2008 50 Mini Adventure/50 Mini SX, 40 pages, cover code 3211221en; and 2008 50 SX Junior/50 SX, 42 pages, cover code 3211222en. Their service content is in English; the two 2007 segments each include one trailing alternate-language cover leaf. The set closes with the 45-page WP 3612 BAEM shock workshop manual and the 39-page WP 3614 BAEM 50 SX/50 SX Junior repair manual, Art. No. 3.211.201-E.

AC/LC Reference Data, Tools, and Repair Scope

Year-specific tables separate AC and LC engine builds, mixture- and separate-lubrication systems, Dell'Orto carburetor applications, chassis and brake configurations, fork/shock setups, and maintenance schedules. The repair data covers component-specific tightening torques, wear limits, fitting clearances, fluid and lubricant requirements, carburetor settings, ignition test values, and suspension settings.

Named visual and diagnostic material includes the 50 AC/LC stop-button/generator/ignition-coil wiring diagram, the ignition-stator resistance and peak-voltage test chart, the 3612 BAEM exploded view, the 3614 BAEM exploded view, and the 2007 50 SX Junior 03.18.9C.01 and 50 SX 03.18.9C.02 parts-and-settings views.

Factory-tool references include flywheel puller 590.29.021.000, rotor holder 451.12.021.000, Dimension X plate 451.29.006.000, and bleeding syringe 503.29.050.000. The WP section identifies its own spring, seal, bushing, and nitrogen-service equipment, including T101S, T313, T1207S, and T170S1.

The engine assembly section warns that the output-shaft seal can be damaged by the shaft's sharp edge and that hammering the shafts into place can damage the bearings and crankshaft. On the 3614 BAEM shock, incorrect 50 SX Junior distance-bushing position or shock orientation can make the spring rub the swingarm. Shock teardown and nitrogen charging involve stored pressure and require the specified WP equipment and trained handling.

The 104-page core repair manual is primarily engine-focused. Chassis coverage consists of maintenance and adjustment work in the owner's manuals plus the two dedicated rear-shock publications, rather than a complete frame-and-chassis overhaul manual.