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301ENGINE

ASSEMBLY

- Position oil pump housing

- Mount and tighten screws

Guideline

Screw, oil pump casing

(7.4lbfft)

Loctile-

243'"

- Crank the oil pump gear wheel and ensure that

can

move

easily.

- Position the drive wheel of balancer shaft

- Position primary gear

- Mount nut but

not tighten yet.

Guideline

Nut, pri mary gear

M27xl 80

(59 Ibf

ft)

- Mount collar bushing and needle bearing .

- Mount the outer clutch hub.

•

Info

Loctilee

243'"

163

I Turn the outer clutch hub and oil pump gear wheels back and forth slightly

to help them engage.

Mou

nt washer .

Table of Contents2
Means of Representation6
Important Notes7
Serial Numbers8
- Chassis Number8
- Type Label8
- Engine Number8
- Fork Part Number8
- Shock Absorber Part Number8
Motorcycle9
- Raising the Motorcycle with the Lift Stand9
- Removing the Motorcycle from the Lift Stand9
- Starting9
- Starting the Motorcycle for Checking10
Ollfork, TRIPLE CLAMP11
- Adjusting the Compression Damping of the Fork11
- Adjusting the Rebound Damping of the Fork11
- Bleeding Fork Legs12
- Cleaning the Dust Boots of the Fork Legs12
- Loosening the Fork Protector12
- Positioning the Fork Protection13
- Removing the Fork Legs13
- Installing the Fork Legs13
- Removing the Fork Protector14
- Installing the Fork Protector14
- Conducting Major Fork Service14
- Conducting Minor Fork Service15
- Disassembling the Fork Legs15
- Disassembling the Cartridge18
- Disassembling the Piston Rod20
- Disassembling the Screw Cap with the Membrane Holder21
- Preliminary Work21
- Disassembling the Screw Sleeve22
- Checking the Fork Legs (450 SX-F EU)23
- Checking the Fork Legs (450 SX-F USA)24
- Checking the Fork Legs - During a Minor Fork Service26
- Checking the Fork Legs - During a Minor Fork Service27
- Changing the Pilot Bushing28
- Assembling the Screw Sleeve29
- Assembling the Screw Cap with the Membrane Holder29
- Assembling the Piston Rod30
- Assembling the Cartridge31
- Assembling the Fork Legs (450 SX-F EU)33
- Assembling the Fork Legs (450 SX-F USA)36
- Bleeding and Filling the Cartridge39
- Filling the Cartridge with Nitrogen41
- Greasing the Steering Head Bearing41
- Removing the Lower Triple Clamp42
- Installing the Lower Triple Clamp42
- Checking Steering Head Bearing Play44
- Adjusting Play of Steering Head Bearing44
02/Handlebar, Instruments45
- Hot Start Lever45
- Handlebar Position45
- Adjusting the Handlebar Position45
- Adjusting the Basic Position of the Clutch Lever46
- Checking the Throttle Cable Routing46
- Checking the Play in the Throttle Cable46
- Adjusting the Play in the Throttle Cable47
Checking the Frame48
03/Frame48
Adjusting the High-Speed Compression Damping of the Shock Absorber49
- Adjusting the Low-Speed Compression Damping of the Shock Absorber49
- Adjusting the Rebound Damping of the Shock Absorber50
- Measuring Rear Wheel Sag Unloaded50
- Checking the Static Sag of the Shock Absorber51
- Checking the Riding Sag of the Shock Absorber51
- Adjusting the Spring Preload of the Shock Absorber51
- Adjusting the Riding Sag52
- Removi Ng the Shock Absorber53
- Installing the Shock Absorber53
- Checking the Shock Absorber Linkage54
- Servicing the Shock Absorber56
- Remove the Spring56
- Disassemble the Damper56
- Disassemble the Piston Rod56
- Disassemble the Seal Ring Retainer56
- Removing the Spring57
- Disassembling the Damper57
- Disassembling the Piston Rod58
- Disassembling the Seal Ring Retainer59
- Changing the Pilot Bushing60
- Checking the Damper61
- Removing the Heim Joint61
- Installing the Heim Joint62
- Assembling the Seal Ring Retainer63
- Assembling the Piston Rod64
- Assemble the Seal Ring Retainer64
- Assembling the Damper65
- Bleeding and Filling the Damper67
- Filling the Damper with Nitrogen69
- Installing the Spring (450 SX-F EU)70
- Installing the Spring (450 SX-F USA)71
- Checking the Swingarm72
041Shock Absorber, Swingarm49
05/Exhaust73
- Removing Main Silencer73
- Installing the Main Silencer73
- Changing the Glass Fiber Yarn Filling of the Main Silencer73
06/Air Filter75
- Removing the Air Filter Box Lid75
- Installing the Air Filter Box Lid75
- Removing the Air Filter75
- Installing the Air Filter75
- Cleaning the Air Filter and Air Filter Box76
- Removing the Carburetor Connection Boot76
- Installing the Carburetor Connection Boot77
- Opening Filler Cap78
- Closing Filler Cap78
- Removing the Seat78
07/Fuel Tank, Seat, Trim79
- Mounting the Seat79
- Removing the Fuel Tank79
- Installing the Fuel Tank80
- Fuel Tap81
08/Mask, Fender82
- Removi Ng the Front Fender82
- Install I Ng the Front Fender82
- Removing the Start Number Plate82
- Installing the Start Number Plate82
09/Front Wheel83
- Removi Ng Front Wheel83
- Checking the Brake Discs84
- Removing the Front Brake Disc84
- Install I Ng the Front Wheel85
- Installing the Front Brake Disc85
- Checking the Tire Condition85
- Checking Tire Air Pressure85
- Checking Spoke Tension86
Lo/Rear WHEEL87
- Removing the Rear Wheel87
- Installing the Rear Wheel87
- Removing the Rear Brake Disc88
- Installing the Rear Brake Disc88
- Checking the Chain Tension89
- Adjusting the Chain Tension89
- Adjusting the Chain Guide90
- Chain Guide91
- Checking for Chain Dirt Accumulation92
- Clean I Ng the Chai N92
11Iwiring Harness, Batiery93
- Removing the Main Fuse93
- Installing the Main Fuse93
- Removi Ng the Battery93
- Installing the Battery94
- Charging the Battery94
- Checking the Charging Voltage95
- Checking the Quiescent Currenl95
- Checking the Starter Relay96
13/Brake System97
- Checking the Front Brake Linings97
- Changing the Front Brake Linings97
- Checking Free Travel on Hand Brake Lever99
- Adjusting the Basic Position of the Hand Brake Lever99
- Checking the Brake Fluid Level of the Front Brake99
- Adding Front Brake Fluid100
- Changing the Front Brake Fluid100
- Checking Rear Brake Linings101
- Changing the Rear Brake Linings102
- Checking the Free Travel of the Foot Brake Lever103
- Adjusting the Basic Position of the Foot Brake Lever103
- Checking Rear Brake Fluid Level104
- Adding Brake Fluid to the Rear Brake Circuit104
- Changing the Rear Brake Fluid105
30/Engine106
- Removing the Engine106
- Installing the Engine111
30/Disassembling the ENGINE117
- Preparations117
- Removing the Shift Lever117
- Draining the Engine Oil117
- Removi Ng the Oi I Fi Iter117
- Removing the Spark Plug118
- Removing the Valve Cover118
- Removing the Starter Motor118
- Removing the Alternator Cover118
- Removing the Torque Limiter and Starter Idler Gear119
- Positioning the Engine at Ignition Top Dead Center (TDC)119
- Removing the Camshaft120
- Removing the Timing Chain Tensioner120
- Removing the Double Wheel121
- Removing the Cylinder Head121
- Removing the Water Pump Cover122
- Removing the Clutch Cover122
- Removing the Piston123
- Removing the Timing Chain Rails123
- Removing the Timing Chain123
- Removing the Ignition Pulse Generator124
- Removing the Rotor124
- Removing the Drive Wheel of the Balancer Gear125
- Removing the Force Pump125
- Removing the Spacer126
- Removing the Outer Clutch Hub126
- Removing the Primary Gear127
- Removing the Suction Pump127
- Removing the Shift Shaft128
- Removing the Shift Drum Locating Unit128
- Removing the Locking Lever129
- Removing the Left Section of the Engine Case129
- Removing the Shift Rails129
- Removing the Shift Drum130
- Removing the Shift Forks130
- Removing the Transmission Shafts130
- Removing the Crankshaft130
30/Engine - Work on the Individual Parts131
- Worki Ng on the Right Seclion of the Engi Ne Case131
- Working on the Left Seclion of the Engine Case132
- Removing the Water Pump133
- Changing the Shaft Seal Ring of the Water Pump134
- Installing the Water Pump135
- Removing the Crankshaft Seal Ring in the Clutch Cover136
- Installing the Crankshaft Seal Ring in the Clutch Cover136
- Removing the Stator136
- Installing the Stator136
- Removing the Oil Pressure Regulator Valve137
- Checking Spring Length of Oil Pressure Regulator Valve137
- Installing the Oil Pressure Regulator Valve137
- Checking the Lubrication System138
- Removing the Crankshaft Bearing Inner Race138
- Installing the Crankshaft Bearing Inner Race139
- Changing Connecting Rod, Conrod Bearing and Crank Pin139
Checking Crankshaft Run-Out at Bearing Pin140
- Measuring the Crankshaft End Play141
Cylinder - Nikasil" Coating141
Checking/Measuring Cylinder141
Checking/Measuring the Piston142
- Measuring Piston/Cylinder Mounting Clearance143
- Checking the Piston Ring End Gap143
- Changing the Camshaft Bearing143
Checking the Autodecompressor144
- Checking Camshafls144
- Checking the Radial Clearance of the Camshaft Bearings144
- Checking the Camshaft Bearing Bridges145
- Removing the Valves145
- Checking the Valves146
- Checking the Valve Springs146
- Checking Valve Spring Seal147
Checking the Cam Levers147
Checking Cylinder Head147
- Installing the Valves148
- Removing the Freewheel149
Checking the Freewheel149
Installing the Free Wheel149
Checking the Starter Drive150
Checking the Timing Assembly151
Preparing the Timing Chain Tensioner for Installation151
- Checking Clutch152
- Checking Shift Mechanism153
- Preassembling the Shift Shaft154
- Disassembling the Main Shaft155
- Disassembling the Countershaft155
- Checking Transmission156
- Assembling the Main Shaft157
- Assembling the Countershaft158
30/ENGINE Assembly159
- Installing the Crankshaft159
- Installing the Transmission Shafts159
- Installing the Shift Forks159
- Installing the Shift Drum160
- Installing the Shift Rails160
- Installing the Left Engine Case160
- Installing the Locking Lever161
- Installing the Shift Drum Locating Uni161
- Installing the Shift Shaft161
- Installing the Suction Pumps161
- Installing the Spacer162
- Installing the Force Pump162
- Installing the Primary Gear163
- Installing the Outer Clutch Hub163
- Installing the Drive Wheel of the Balancer Gear164
- Installing the Timing Chain165
- Installing the Free Wheel Gear165
- Installing the Rotor165
- Installing the Ignition Pulse Generator166
- Adjusting the Ignition Pulse Generator Gap166
- Installing the Timing Chain Rails166
- Installing the Piston167
- Installing the Clutch Cover168
- Installing the Water Pump Cover169
- Installing the Cylinder Head169
- Installing the Double Wheel170
- Installing the Timing Chain Tensioner170
- Checking the Valve Timing171
- Adjusting the Valve Timing171
- Checking the Valve Clearance172
- Adjusting the Valve Clearance173
- Installing the Torque Limiter and Starter Idler Gear173
- Installing the Alternator Cover173
- Installing the Starter Motor174
- Installing the Valve Cover174
- Installing the Spark Plug174
- Installing the Oil Screen174
- Installing the Oil Filter175
- Installing the Shift Lever175
- Removing the Engine from the Universal Mounting Rack175
311Carburetor176
- Choke176
- Removing the Carburetor176
- Installing the Carburetor177
- Disassembling the Carburetor178
- Checking/Adjusting the Carburetor Components180
- Checking/Adjusting the Accelerator Pump181
- Checking the Choke Slide181
- Checking the Jet Needle181
- Checking the Throttle Slide182
- Checking the Needle Jet182
- Checking the Float Needle Valve183
- Checking/Adjusting the Float Level183
- Checking/Adjusting the Throttle Slide Opening183
- Checking the Throttle Position Sensor183
- Adjusting the Position of the Throttle Position Sensor184
- Assembling the Carburetor185
Carburetor - Adjusting Idle187
- Emptying the Carburetor Float Chamber188
321Clutch190
- Checking the Fluid Level of Hydraulic Clutch190
- Changing the Hydraulic Clutch Fluid190
35Iwater Pump, Cooling System191
- Cooling System191
- Checking the Anti-Freeze and Coolant Level191
- Checking the Coolant Level191
- Draining the Coolant192
- Refilling Coolant192
38/Lubrication System194
- Oil Circuit194
- Checking Engine Oil Level194
- Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen195
- Adding Engine Oil197
- Checking the Engine Oil Pressure197
39/Ignition System199
- Checking the Ignition System199
- Ignition Coil - Checking the Primary Winding200
- Ignition Coil - Checking the Secondary Winding200
- Checking the Spark Plug Connector201
- Checking the Ignition Pulse Generator201
- Alternator - Checking the Stator Winding202
- Removi Ng the Stator202
- Install I Ng the Stator202
40/Electrostarter203
- Checking the Starter Motor203
Technical Data - Engine204
- Capacity - Engine Oil204
- Capacity - Coolan204
Technical Data - Engine Tolerances, Wear Limits205
Technical Data - Engine Tightening Torques206
Technical Data - Carburetor208
Technical Data - Carburetor Tightening Torques209
Technical Data - Chassis210
- Tires210
- Capacity - Fuel211
Technical Data - Fork212
- 450 Sx-F Eu212
- 450 Sx-F Usa212
Technical Data - Shock Absorber213
- 450 Sx-F Eu213
- 450 Sx-F Usa213
Technical Data - Chassis Tightening Torques215
Cleaning216
- Cleaning Motorcycle216
Storage217
- Preparing for Use after Storage217
Service Schedule218
- Service Work (as Additional Order)219
- 220220
Wiring Diagram221
- 222222
Substances224
Auxiliary Substances226
Special Tools228
Standards241
Index242

Brand	KTM
Model	450 SX-F EU
Category	Motorcycle
Language	English

KTM 450 SX-F EU Repair Manual

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