KTM 450 SX 2004 User Manual

ENGLISH
4
TABLE OF CONTENTS
IMPORTANT LIMITED WARRANTY AND LIMITED
GUARANTEE INFORMATION . . . . . . . . . . . . . . . . . . . . . . .3
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . .5
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Engine number, engine type . . . . . . . . . . . . . . . . . . . . . . .5
OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . .5
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Hand decompression lever . . . . . . . . . . . . . . . . . . . . . . . .5
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Short circuit button (SX/MXC) . . . . . . . . . . . . . . . . . . . . .6
Combination switch (EXC) . . . . . . . . . . . . . . . . . . . . . . . .6
Headlamp switch (EXC USA) . . . . . . . . . . . . . . . . . . . . . .6
Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Starter button (EXC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Digital speedometer, indicator lamps . . . . . . . . . . . . . . . .7
Electronic speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Tripmaster switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Activating/deactivating the display modes . . . . . . . . . . .10
Kilometers or miles . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Emergency OFF switch (EXC Australia) . . . . . . . . . . . . . .12
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Hot start device (450/525 SX) . . . . . . . . . . . . . . . . . . . .13
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Compression damping of fork . . . . . . . . . . . . . . . . . . . .14
Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . .14
Damping action during compression of shock absorber (SX) . . .14
Compression damping of shock absorber (MXC, EXC) . .15
Rebound damping of shock absorber (SX, MXC, EXC) . .15
Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
GENERAL TIPS AND WARNINGS FOR STARTING THE
MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Instructions for initial operation . . . . . . . . . . . . . . . . . . .16
Running in the Racing models . . . . . . . . . . . . . . . . . . . .16
DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .17
Check the following before each start . . . . . . . . . . . . . .17
Starting when the engine is cold . . . . . . . . . . . . . . . . . .18
Starting when the engine is warm . . . . . . . . . . . . . . . . .18
What to do when the engine is “flooded” . . . . . . . . . . .18
Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . . . .19
PERIODIC MAINTENANCE SCHEDULE 2004 . . . . . . . . . . .20
MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . .24
Checking and adjusting the steering head bearing . . . . .24
Breather plug front fork . . . . . . . . . . . . . . . . . . . . . . . . .25
Cleaning the dust sleeves of the telescopic fork . . . . . . .25
Adjusting the spring preload on the fork (SX) . . . . . . . . .25
Basic suspension setup for the weight of the driver . . . . .26
How to change the handlebar position . . . . . . . . . . . . . .28
Changing the spring preloading of the shock absorber . .28
Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Check chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
General information about KTM disc brakes . . . . . . . . . .31
Adjusting the free travel at the hand brake lever . . . . . .32
Checking the brake fluid level - front brake . . . . . . . . . .32
Refilling the front brake fluid reservoir . . . . . . . . . . . . . .32
Checking the front brake pads . . . . . . . . . . . . . . . . . . . .32
Replacing the front brake pads . . . . . . . . . . . . . . . . . . . .33
Changing the basic position of the foot brake pedal . . . .33
Checking the rear brake fluid level . . . . . . . . . . . . . . . . .33
Refilling the rear brake fluid reservoir . . . . . . . . . . . . . . .33
Checking the rear brake pads . . . . . . . . . . . . . . . . . . . . .34
Replacing the rear brake pads . . . . . . . . . . . . . . . . . . . . .34
Dismounting and mounting the front wheel . . . . . . . . . .34
Dismounting and mounting the rear wheel . . . . . . . . . . .35
Checking spoke tension . . . . . . . . . . . . . . . . . . . . . . . . .35
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Check/set distance of the magnetic sensor . . . . . . . . . . .36
Replacing the battery of the digital speedometer . . . . . .36
Battery (MXC/EXC) . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Fuse (MXC/EXC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Replacing headlight lamp/parking light lamp . . . . . . . . .38
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Checking the coolant level . . . . . . . . . . . . . . . . . . . . . . .39
Bleeding the cooling system . . . . . . . . . . . . . . . . . . . . . .39
Replacing the glassfiber yarn packing of the silencer . . . .40
Cleaning the spark arrester (MXC/EXC USA) . . . . . . . . .40
Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Checking the adjustment of the hand decompression
release cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Adjusting the throttle cables . . . . . . . . . . . . . . . . . . . . . .41
Changing the original position of the clutch lever . . . . . .42
Checking the oil level of the hydraulic clutch . . . . . . . . .42
Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . . . . .42
Carburetor – Adjust idling (Keihin-FCRMX 37/39/41) . . . . .43
Adjusting the mixture control screw . . . . . . . . . . . . . . . .43
Checking the float level (float height) . . . . . . . . . . . . . . .43
Draining the float chamber of the carburetor . . . . . . . . .44
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Checking the engine oil level . . . . . . . . . . . . . . . . . . . . .44
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Changing the engine oil . . . . . . . . . . . . . . . . . . . . . . . . .45
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
CONSERVATION FOR WINTER OPERATION . . . . . . . . . .49
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
USE AFTER A PERIOD OF STORAGE . . . . . . . . . . . . . .49
TECHNICAL DATA – ENGINE . . . . . . . . . . . . . . . . . . . . . . .50
TECHNICAL DATA – CHASSIS . . . . . . . . . . . . . . . . . . . . . .53
HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . .Appendix
Page Page

KTM 450 SX 2004 Specifications

General

Engine type	Single-cylinder, 4-stroke
Displacement	449 cc
Compression ratio	12.5:1
Cooling system	Liquid cooled
Ignition	Kokusan digital
Transmission	5-speed
Front suspension	WP USD 48 mm
Front brakes	Single 260mm disc
Rear brakes	Single 220mm disc
Fuel capacity	7.5 liters
Starter	Kickstarter
Seat height	925 mm
Bore x Stroke	95.0 mm x 63.4 mm
Fuel system	Carburetor
Rear suspension	WP shock absorber