KTM 450 SX-F 2023 User Manual

TUNING THE CHASSIS 10
41
F03630-10
Main work
– Position the sag gage in the rear axle and measure the
distance to marking SAG on the rear fender.
Sag gauge (00029090200)
–
Note the value as dimension
A
.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 53)
10.8 Checking the static sag of the shock absorber
402416-10
–
Measure dimension
A
of rear wheel unloaded. ( p. 40)
– Hold the motorcycle upright with aid of an assistant.
– Measure the distance again between the rear axle and mark-
ing SAG on the rear fender using the sag gage.
–
Note the value as dimension
B
.
Info
The static sag is the difference between
measurements
A
and
B
.
– Check the static sag.
Static sag (SX‑F EU) 35 mm (1.38 in)
Static sag (SX‑F US) 35 mm (1.38 in)
Static sag (XC‑F US) 35 mm (1.38 in)
Static sag (Factory Edition) 35 mm (1.38 in)
» If the static sag is less or more than the specified value:
– Adjust the spring preload of the shock absorber.
( p. 42)

KTM 450 SX-F 2023 Specifications

General

Engine Type	Single-cylinder, 4-stroke
Displacement	449.9 cc
Bore x Stroke	95 mm x 63.4 mm
Starter	Electric starter
Compression Ratio	13.1:1
Transmission	5-speed
Final Drive	Chain
Cooling	Liquid-cooled
Frame	Central Double-Cradle Type 25CrMo4 Steel
Front Suspension	WP XACT-USD, Ø 48 mm
Rear Suspension	WP XACT Monoshock with linkage
Ground Clearance	370 mm
Fuel System	Keihin EFI, 44 mm
Front Brake	260 mm disc
Rear Brake	220 mm disc
Fuel Tank Capacity	7.2 L

Summary

Owner Welcome and Vehicle Information

Vehicle Identification and Dealer Stamp

Fields for vehicle identification number and dealer's stamp.

Manual Information and Disclaimer

Notes on manual content, specifications, and liability.

1 Means of Representation

1.1 Symbols Used

Explains the meaning of symbols used in the manual.

1.2 Formats Used

Explains typographical formats used in the document.

2 Safety Advice

2.1 Intended Use and Limitations

Specifies the intended use and limitations of the vehicle.

2.2 Misuse and Dangers

Defines misuse and its potential dangers.

2.3 General Safety Instructions

General instructions for safe operation and adherence to warnings.

2.4 Risk Degrees and Symbols

Explains danger levels and associated symbols.

2 Safety Advice (Continued)

2.5 Tampering Warning

Prohibits tampering with noise control systems and lists presumed acts.

2.6 Safe Operation Guidelines

Critical safety warnings for rider fitness, exhaust gases, and hot components.

2.7 Protective Clothing Requirements

Emphasizes wearing appropriate protective clothing for safety.

2 Safety Advice (Continued)

2.8 Work Rules and Conditions

Rules for vehicle work, conditions, and special tools.

2.9 Environmental Considerations

Advises on responsible use and environmental consciousness.

2.10 Owner's Manual Importance

Stresses reading the manual and provides access information.

3 Important Notes

3.1 Warranty Information

Explains warranty terms and voiding conditions.

3.2 Fuel and Auxiliary Substance Use

Highlights fuel hazards and specifies correct usage.

3.3 Spare Parts and Accessories

Recommends approved parts and accessories for safety.

3.4 Service Importance

Emphasizes proper service for operation and longevity.

4 View of Vehicle

4.1 Front Left View (Example)

Illustrates the front left view with numbered components.

4 View of Vehicle (Continued)

4.2 Rear Right View (Example)

Illustrates the rear right view with numbered components.

5 Serial Numbers

5.1 Vehicle Identification Number Location

Shows the location of the VIN on the steering head.

5.2 Steering Head Label Location

Indicates the location of the steering head label.

5.3 Engine Number Location

Shows the location of the engine number on the engine.

5.4 Fork Article Number Location

Shows the location of the fork article number on the axle clamp.

5 Serial Numbers (Continued)

5.5 Shock Absorber Article Number Location

Shows the location of the shock absorber article number.

6 Controls

6.1 Clutch Lever Description

Describes the clutch lever and its operation.

6.2 Hand Brake Lever Description

Describes the hand brake lever and its function.

6.3 Throttle Grip Description

Describes the throttle grip and its function.

6.4 Stop Button Function

Explains the location and function of the stop button.

6 Controls (Continued)

6.5 Start Button Function

Describes the location and function of the start button.

6.6 Combination Switch Operation

Details controls for engine characteristics and traction control.

6.7 Indicator Lights Overview (SX-F)

Explains the meaning of various indicator lamps.

6 Controls (Continued)

6.8 Indicator Lights Overview (XC-F US)

Explains indicator lamps specific to XC-F US models.

6.9 Combination Instrument Details

Describes the functions of the combination instrument.

6.10 Opening Fuel Tank Filler Cap

Instructions and safety for opening the fuel tank cap.

6 Controls (Continued)

6.11 Closing Fuel Tank Filler Cap

Provides instructions for closing the fuel tank filler cap.

6 Controls (Continued)

6.12 Cold Start Button Operation

Explains the function and operation of the cold start button.

6.13 Idle Speed Adjustment

Describes how to adjust the idle speed.

6.14 Shift Lever Location

Shows the location of the shift lever and gear positions.

6 Controls (Continued)

6.15 Foot Brake Lever Description

Describes the location and function of the foot brake lever.

6.16 Plug-in Stand Use

Explains the use of the plug-in stand for parking and transport.

6.17 Side Stand Use (XC-F US)

Describes the use of the side stand for XC-F US models.

6 Controls (Continued)

6.18 Factory Start Activation

Explains the function and activation of the Factory Start system.

7 Preparing for Use

7.1 First Use Preparation Advice

Essential advice and safety warnings before the first ride.

7 Preparing for Use (Continued)

7.2 Engine Break-in Procedure

Details the procedure and limits for running in the engine.

7.3 Low Temperature Battery Performance

Explains how temperature affects battery performance and starting.

7 Preparing for Use (Continued)

7.4 Difficult Operating Conditions Prep

Advises on preparing for challenging conditions.

7.5 Dry Sand Riding Preparation

Specific preparation steps for riding on dry sand.

7 Preparing for Use (Continued)

7.6 Wet Sand Riding Preparation

Specific preparation steps for riding on wet sand.

7.7 Wet/Muddy Circuit Riding Prep

Specific preparation steps for wet and muddy circuits.

7 Preparing for Use (Continued)

7.8 High Temp/Slow Riding Prep

Recommendations for hot conditions or slow riding.

7.9 Low Temp/Snow Riding Prep

Recommendations for cold conditions or snow.

8 Riding Instructions

8.1 Pre-Ride Checks and Maintenance

Lists essential checks before every trip for safe operation.

8 Riding Instructions (Continued)

8.2 Starting the Vehicle Safely

Provides instructions and safety warnings for starting the engine.

8 Riding Instructions (Continued)

8.3 Launch Control Activation

Explains how to activate and use launch control.

8 Riding Instructions (Continued)

8.4 Traction Control Activation

Details how to activate and use traction control.

8.5 Factory Start Activation (Factory Edition)

Instructions for activating Factory Start and warnings.

8 Riding Instructions (Continued)

8.6 Starting Off Procedure

Basic procedure for starting from a standstill.

8.7 Quickshifter Functionality

Explains the function and limitations of the quickshifter.

8.8 Quickshifter Activation

Describes how to activate the quickshifter system.

8 Riding Instructions (Continued)

8.9 Shifting and Riding Techniques

Provides guidance on shifting gears and riding.

8 Riding Instructions (Continued)

8.10 Brake Application Guidance

Safety warnings and techniques for effective braking.

8.11 Stopping and Parking Safely

Instructions and precautions for stopping and parking.

8 Riding Instructions (Continued)

8.12 Motorcycle Transport Guidelines

Guidelines for safely transporting the motorcycle.

8 Riding Instructions (Continued)

8.13 Refueling Procedure and Safety

Instructions and safety warnings for refueling.

9 Service Schedule

9.1 Additional Service Information

Notes on service intervals, local conditions, and updates.

9.2 Detailed Service Schedule

Details periodic maintenance tasks and intervals.

10 Tuning the Chassis

10.1 Basic Chassis Setting by Rider Weight

Adjusting chassis settings based on rider weight.

10.2 Air Suspension XACT System

Describes the air suspension system and its adjustment.

10 Tuning the Chassis (Continued)

10.3 Shock Absorber Compression Damping

Explains high-speed and low-speed compression damping.

10.4 Adjusting Low-Speed Compression Damping

Details how to adjust low-speed compression damping.

10 Tuning the Chassis (Continued)

10.5 Adjusting High-Speed Compression Damping

Details how to adjust high-speed compression damping.

10 Tuning the Chassis (Continued)

10.6 Adjusting Rebound Damping (Shock Absorber)

Details how to adjust rebound damping.

10.7 Measuring Rear Wheel Dimension

Procedure for measuring rear wheel dimension before sag adjustment.

10 Tuning the Chassis (Continued)

10.8 Checking Static Sag (Shock Absorber)

Explains how to check static sag.

10 Tuning the Chassis (Continued)

10.9 Checking Riding Sag (Shock Absorber)

Explains how to check riding sag.

10.10 Adjusting Spring Preload (Shock Absorber)

Details how to adjust spring preload.

10 Tuning the Chassis (Continued)

10.11 Adjusting Riding Sag

Details how to adjust riding sag.

10 Tuning the Chassis (Continued)

10.12 Checking Basic Fork Setting

Explains how to check the basic fork setting.

10.13 Adjusting Fork Air Pressure

Details how to adjust fork air pressure and warnings.

10 Tuning the Chassis (Continued)

10.14 Adjusting Fork Compression Damping

Details how to adjust fork compression damping.

10 Tuning the Chassis (Continued)

10.15 Adjusting Fork Rebound Damping

Details how to adjust fork rebound damping.

10 Tuning the Chassis (Continued)

10.16 Handlebar Position Adjustment

Explains how to adjust handlebar position for rider comfort.

10 Tuning the Chassis (Continued)

10.17 Adjusting Handlebar Position

Provides instructions for adjusting handlebar position.

11 Service Work on the Chassis

11.1 Raising Motorcycle with Lift Stand

Instructions for safely lifting the motorcycle using a stand.

11 Service Work on the Chassis (Continued)

11.2 Removing Motorcycle from Lift Stand

Instructions for safely removing the motorcycle from a lift stand.

11.3 Bleeding Fork Legs

Procedure for bleeding the fork legs.

11.4 Cleaning Fork Dust Boots

Instructions for cleaning fork dust boots.

11 Service Work on the Chassis (Continued)

11.5 Fork Protector Removal

Steps for removing fork protectors.

11.6 Fork Protector Installation

Steps for installing fork protectors.

11 Service Work on the Chassis (Continued)

11.7 Engine Guard Removal (Factory Edition)

Steps for removing engine guard (Factory Edition).

11.8 Engine Guard Installation (Factory Edition)

Steps for installing engine guard (Factory Edition).

11.9 Removing Fork Legs

Steps for removing front fork legs.

11 Service Work on the Chassis (Continued)

11.10 Installing Fork Legs

Steps for installing front fork legs.

11 Service Work on the Chassis (Continued)

11.11 Lower Triple Clamp Removal

Steps for removing the lower triple clamp.

11 Service Work on the Chassis (Continued)

11.12 Lower Triple Clamp Installation

Steps for installing the lower triple clamp.

11 Service Work on the Chassis (Continued)

11.13 Checking Steering Head Bearing Play

Procedure for checking steering head bearing play.

11 Service Work on the Chassis (Continued)

11.14 Adjusting Steering Head Bearing Play

Steps for adjusting steering head bearing play.

11 Service Work on the Chassis (Continued)

11.15 Lubricating Steering Head Bearing

Instructions for lubricating the steering head bearing.

11.16 Start Number Plate Removal

Steps for removing the start number plate.

11.17 Start Number Plate Installation

Steps for installing the start number plate.

11.18 Front Fender Removal Prep

Preparation for removing the front fender.

11 Service Work on the Chassis (Continued)

11.19 Front Fender Installation

Steps for installing the front fender.

11 Service Work on the Chassis (Continued)

11.20 Shock Absorber Removal

Steps for removing the rear shock absorber.

11 Service Work on the Chassis (Continued)

11.21 Shock Absorber Installation

Steps for installing the rear shock absorber.

11 Service Work on the Chassis (Continued)

11.22 Seat Removal

Steps for removing the motorcycle seat.

11.23 Seat Installation

Steps for mounting the motorcycle seat.

11 Service Work on the Chassis (Continued)

11.24 Air Filter Box Cover Removal

Steps for removing the air filter box cover.

11 Service Work on the Chassis (Continued)

11.25 Air Filter Box Cover Installation

Steps for installing the air filter box cover.

11 Service Work on the Chassis (Continued)

11.26 Air Filter Removal

Steps for removing the air filter and its warnings.

11.27 Cleaning Air Filter and Box

Instructions for cleaning the air filter and air filter box.

11 Service Work on the Chassis (Continued)

11.28 Air Filter Installation

Steps for installing a clean air filter.

11 Service Work on the Chassis (Continued)

11.29 Preparing Air Filter Box Cover

Steps to prepare the air filter box cover for securing.

11.30 Main Silencer Removal

Steps for removing the main silencer with safety warnings.

11 Service Work on the Chassis (Continued)

11.31 Main Silencer Installation

Steps for installing the main silencer.

11.32 Changing Main Silencer Filling

Instructions for changing the silencer's internal filling.

11 Service Work on the Chassis (Continued)

11.33 Fuel Tank Removal

Steps for removing the fuel tank with safety warnings.

11 Service Work on the Chassis (Continued)

11.34 Fuel Tank Installation

Steps for installing the fuel tank with safety warnings.

11 Service Work on the Chassis (Continued)

11.35 Checking Chain Dirt Accumulation

Procedure for checking the chain for dirt.

11.36 Cleaning the Chain

Detailed instructions for cleaning the motorcycle chain.

11 Service Work on the Chassis (Continued)

11.37 Checking Chain Tension

Procedure for checking and setting chain tension.

11 Service Work on the Chassis (Continued)

11.38 Adjusting Chain Tension

Steps for adjusting chain tension.

11 Service Work on the Chassis (Continued)

11.39 Checking Chain, Sprockets, and Guide

Inspecting wear on chain, sprockets, and guide.

11 Service Work on the Chassis (Continued)

11.40 Frame Inspection

Instructions for checking the motorcycle frame for damage.

11.41 Link Fork Inspection

Instructions for checking the link fork for damage.

11.42 Throttle Cable Routing Check

Instructions for checking throttle cable routing and play.

11 Service Work on the Chassis (Continued)

11.43 Rubber Grips Inspection

Instructions for checking rubber grips for wear and damage.

11 Service Work on the Chassis (Continued)

11.44 Quickshifter Programming

Steps for reprogramming the quickshifter system.

11.45 Adjusting Clutch Lever Position

Instructions for adjusting the clutch lever position.

11.46 Hydraulic Clutch Fluid Level Check

Procedure for checking and correcting hydraulic clutch fluid level.

11 Service Work on the Chassis (Continued)

11.47 Changing Hydraulic Clutch Fluid

Steps for changing hydraulic clutch fluid with safety warnings.

12 Brake System

12.1 Checking Hand Brake Lever Free Travel

Procedure for checking hand brake lever free travel.

12.2 Adjusting Hand Brake Lever Position

Instructions for adjusting hand brake lever position.

12.3 Checking Brake Discs

Instructions for checking the condition of brake discs.

12 Brake System (Continued)

12.4 Checking Front Brake Fluid Level

Procedure for checking front brake fluid level and warnings.

12 Brake System (Continued)

12.5 Adding Front Brake Fluid

Instructions for adding front brake fluid with safety warnings.

12 Brake System (Continued)

12.6 Checking Front Brake Linings Security

Procedure for checking front brake lining thickness, damage, and security.

12 Brake System (Continued)

12.7 Changing Front Brake Linings

Steps for changing front brake linings with safety warnings.

12 Brake System (Continued)

12.8 Checking Foot Brake Lever Free Travel

Procedure for checking foot brake lever free travel.

12.9 Adjusting Foot Brake Lever Position

Instructions for adjusting foot brake lever position.

12 Brake System (Continued)

12.10 Checking Rear Brake Fluid Level

Procedure for checking rear brake fluid level and warnings.

12 Brake System (Continued)

12.11 Adding Rear Brake Fluid

Instructions for adding rear brake fluid with safety warnings.

12 Brake System (Continued)

12.12 Checking Rear Brake Linings Security

Procedure for checking rear brake lining thickness, damage, and security.

12 Brake System (Continued)

12.13 Changing Rear Brake Linings

Steps for changing rear brake linings with safety warnings.

13 Wheels, Tires

13.1 Front Wheel Removal

Steps for removing the front wheel with safety warnings.

13 Wheels, Tires (Continued)

13.2 Front Wheel Installation

Steps for installing the front wheel with safety warnings.

13 Wheels, Tires (Continued)

13.3 Rear Wheel Removal

Steps for removing the rear wheel with safety warnings.

13 Wheels, Tires (Continued)

13.4 Rear Wheel Installation

Steps for installing the rear wheel with safety warnings.

13 Wheels, Tires (Continued)

13.5 Checking Tire Condition

Instructions for checking tire condition, age, and profile.

13 Wheels, Tires (Continued)

13.6 Checking Tire Pressure

Procedure for checking and correcting tire pressure.

13.7 Checking Spoke Tension

Instructions for checking spoke tension and warnings.

14 Electrical System

14.1 12-V Battery Removal

Steps for removing the 12-V battery with safety warnings.

14 Electrical System (Continued)

14.2 12-V Battery Installation

Steps for installing the 12-V battery.

14 Electrical System (Continued)

14.3 Charging the 12-V Battery

Instructions for charging the 12-V battery with safety warnings.

14 Electrical System (Continued)

14.4 Changing the Main Fuse

Steps for changing the main fuse with safety warnings.

14 Electrical System (Continued)

14.5 Changing Fuel Pump Fuse

Steps for changing the fuel pump fuse with safety warnings.

14 Electrical System (Continued)

14.6 Diagnostics Connector Location

Location of the diagnostics connector and its function.

15 Cooling System

15.1 Cooling System Overview

Explains the basic function of the cooling system.

15.2 Checking Coolant Level and Antifreeze

Procedure for checking coolant level and antifreeze with warnings.

15 Cooling System (Continued)

15.3 Checking Coolant Level in Radiator

Procedure for checking radiator coolant level with warnings.

15.4 Draining Coolant

Instructions for draining the coolant with scalding warnings.

15 Cooling System (Continued)

15.5 Refilling Coolant

Steps for refilling the cooling system with coolant.

15 Cooling System (Continued)

15.6 Changing Coolant

Steps for changing the coolant with safety warnings.

16 Tuning the Engine

16.1 Checking Throttle Cable Play

Procedure for checking throttle cable play and related issues.

16 Tuning the Engine (Continued)

16.2 Adjusting Throttle Cable Play

Instructions for adjusting throttle cable play.

16.3 Adjusting Throttle Response Map

Details how to change throttle response by swapping guide plates.

16 Tuning the Engine (Continued)

16.4 Changing Engine Mapping

Explains how to select different engine mapping modes.

16.5 Adjusting Idle Speed

Instructions for adjusting engine idle speed with warnings.

16 Tuning the Engine (Continued)

16.6 Programming Throttle Valve Position

Procedure for programming the throttle valve position.

16 Tuning the Engine (Continued)

16.7 Checking Basic Shift Lever Position

Procedure for checking shift lever's basic position.

16.8 Adjusting Basic Shift Lever Position

Instructions for adjusting shift lever's basic position.

17 Service Work on the Engine

17.1 Changing Fuel Screen

Steps for changing fuel screen with safety warnings.

17 Service Work on the Engine (Continued)

17.2 Checking Engine Oil Level

Procedure for checking engine oil level.

17.3 Engine Oil and Filter Change

Steps for changing engine oil, filter, and cleaning screens.

17 Service Work on the Engine (Continued)

17.4 Adding Engine Oil

Instructions for adding engine oil and warnings about oil quality.

18 Cleaning, Care

18.1 Motorcycle Cleaning Instructions

Instructions for cleaning the motorcycle, including pressure washer warnings.

19 Storage

19.1 Motorcycle Storage Procedure

Steps for preparing the motorcycle for long-term storage.

19 Storage (Continued)

19.2 Preparing for Use After Storage

Steps for preparing the motorcycle after a period of storage.

20 Troubleshooting

Faults, Causes, and Actions

Lists common faults, their causes, and recommended actions.

21 Blink Code

Malfunction Indicator Lamp Blink Codes

Lists blink codes, error levels, and descriptions for malfunctions.

22 Technical Data

22.1 Engine Specifications

Provides technical specifications for the engine.

22 Technical Data (Continued)

22.2 Engine Tightening Torques

Lists tightening torques for engine components.

22 Technical Data (Continued)

22.3 Capacities (Oil, Coolant, Fuel)

Lists capacities for engine oil, coolant, and fuel.

22.4 Chassis Specifications

Provides technical specifications for chassis, frame, suspension.

22 Technical Data (Continued)

22.5 Electrical System Specifications

Lists specifications for battery, fuses, and lighting.

22.6 Tire Specifications

Specifies tire sizes and types for different models.

22 Technical Data (Continued)

22.7 Fork Specifications

Provides detailed specifications for the front fork.

22 Technical Data (Continued)

22.8 Shock Absorber Specifications

Provides detailed specifications for the shock absorber.

22 Technical Data (Continued)

22.9 Chassis Tightening Torques

Lists tightening torques for chassis components.

23 Substances

Brake Fluid Specifications

Specifications and recommended suppliers for brake fluid.

Coolant Specifications

Specifications and recommendations for coolant.

Engine Oil Specifications

Specifications and recommended suppliers for engine oil.

23 Substances (Continued)

Fork Oil Specifications

Specifications and recommendations for fork oil.

Shock Absorber Fluid Specifications

Specifications and recommendations for shock absorber fluid.

Super Unleaded Fuel (ROZ 95)

Fuel specifications and ethanol content guidelines.

24 Auxiliary Substances

Recommended Maintenance Fluids and Cleaners

Lists recommended suppliers for air filter cleaner, chain cleaner, fuel additive, etc.

24 Auxiliary Substances (Continued)

Silicone Spray Recommendations

Recommended supplier for silicone spray.

Special Cleaner Recommendations

Recommended supplier for special cleaner.

Special Grease Recommendations

Recommended supplier for special grease.

Universal Oil Spray Recommendations

Recommended supplier for universal oil spray.

25 Standards

JASO T903 MA2 Standard Explained

Explains the JASO T903 MA2 standard for motorcycle oils.

SAE Viscosity Classification Explained

Explains the SAE viscosity classification system for oils.

26 Index of Special Terms

Launch Control Definition

Definition of Launch Control.

OBD Definition

Definition of On-board diagnosis.

Quickshifter Definition

Definition of Quickshifter.

Traction Control (TC) Definition

Definition of Traction Control.

27 List of Abbreviations

28 List of Symbols

28.1 Yellow and Orange Symbols

Explains symbols for errors or driving aids.

28.2 Green and Blue Symbols

Explains symbols for information.

28.3 White Symbols

Explains symbols conveying information.