KTM 450 SX-F EU Repair Manual

TABLE OF CONTENTS 2
MEANS OF REPRESENTATION ............................................ 6
041SHOCK ABSORBER, SWINGARM ................................... 49
IMPORTANT NOTES ............................................................ 7
Adjusting the
high-speed compression damping of the
SERIAL NUMBERS .............................................................. 8
shock absorber .............................................................. 49
Chassis number ............................................................... 8
Adjusting the
low-speed compression damping of the
Type label ....................................................................... 8
Engine number ................................................................ 8
Fork part number ............................................................. 8
Shock absorber part number ............................................. 8
MOTORCyCLE ..................................................................... 9
shock absorber .............................................................. 49
Adjusting the
rebound damping of the shock absorber ....... 50
Measuring rear wheel sag unloaded ................................. 50
Checking the static sag of the shock absorber .................. 51
Checking the riding sag of the shock absorber .................. 51
Raising the motorcycle with the lift stand .......................... 9
Removing the motorcycle from the lift stand ...................... 9
Starting .......................................................................... 9
Starting the
motorcycle for checking ............................... 10
OllFORK,
TRIPLE CLAMP .................................................. 11
Adjusting the compression damping of the fork ................ 11
Adjusting the rebound damping of the fork ....................... 11
Bleeding fork legs .......................................................... 12
Cleaning the dust boots of the fork legs ........................... 12
Loosening the fork protector ........................................... 12
Positioning the fork protection ........................................ 13
Removing the fork legs ................................................... 13
Installing the fork legs ................................................... 13
Removing the fork protector ............................................ 14
Installing
the fork protector ............................................ 14
Conducting
major fork service ......................................... 14
Conducting minor fork service ......................................... 15
Disassembling the fork legs ............................................ 15
Disassembling the cartridge ............................................ 18
Disassembling the piston rod .......................................... 20
Disassembling the screw cap with the membrane holder ... 21
Disassembling the screw sleeve ...................................... 22
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 service
(450 SX-F EU) .............................................................. 26
Adjusting the spring
preload of the shock absorber ........... 51
Adjusting the riding sag ................................................. 52
Removi ng the shock absorber .............. ...... .............. ....... 53
Installing
the shock absorber .......................................... 53
Checking the shock absorber linkage ............................... 54
Servicing
the shock absorber .......................................... 56
Removing the spring ...................................................... 56
Disassembling the damper ............................................. 57
Disassembling the piston rod .......................................... 58
Disassembling the seal ring retainer ................................ 59
Changing the pilot bushing ............................................. 60
Checking the damper ..................................................... 61
Removing the heim joint ................................................ 61
Installing the heim joint ................................................. 62
Assembling the seal ring retainer .................................... 63
Assembling the piston rod .............................................. 64
Assembling the damper .................................................. 65
Bleeding and filling the damper ...................................... 67
Filling
the damper with nitrogen ..................................... 69
Installing
the spring (450 SX-F EU) ................................ 70
Installing
the spring (450 SX-F USA) .............................. 71
Checking the swingarm .................................................. 72
05/EXHAUST .................................................................... 73
Removing main silencer ................................................. 73
Installing the main silencer ............................................ 73
Changing the glass fiber yarn filling of the main silencer ... 73
Checking the fork legs - during a minor fork service
06/AIR FILTER .................................................................. 75
(450
SX-F USA) ............................................................ 27
Removing the air filter box lid ......................................... 75
Changing the pilot bushing ............................................. 28
Installing
the air filter box lid .......................................... 75
Assembling the screw sleeve ........................................... 29
Removing the air filter ................................................... 75
Assembling the screw cap with the membrane holder ........ 29
Installing
the air filter .................................................... 75
Assembling the piston rod .............................................. 30
Cleaning the air filter and air filter box ............................ 76
Assembling the cartridge ................................................ 31
Removing the carburetor connection boot ........................ 76
Assembling the fork legs (450 SX-F EU) .......................... 33
Installing
the carburetor connection boot ......................... 77
Assembling the fork legs (450 SX-F USA) ........................ 36
07/FUEL TANK, SEAT, TRIM .............................................. 78
Bleeding and filling the cartridge .................................... 39
Opening filler cap .......................................................... 78
Filling the cartridge with
nitrogen .................................... 41
Closing filler cap ........................................................... 78
Greasing the steering head bearing .................................. 41
Removing the seat ......................................................... 78
Removing the lower triple clamp ..................................... 42
Mounting the
seat ......................................................... 79
Installing
the lower triple clamp ...................................... 42
Removing the fuel tank .................................................. 79
Checking steering head bearing play ................................ 44
Installing the fuel tank ................................................... 80
Adjusting
play of steering head bearing ............................ 44
Fuel tap ........................................................................ 81
02/HANDLEBAR, INSTRUMENTS ....................................... 45
08/MASK, FENDER ........................................................... 82
Hot start lever ............................................................... 45
Removi ng the front fender ............ ...... .............. ...... ........ 82
Handlebar position ........................................................ 45
Install i ng the front fender...... ...... ........ ...... ...... ........ ....... 82
Adjusting
the handlebar position ..................................... 45
Removing the start number plate .................................... 82
Adjusting
the basic position of the clutch lever ................. 46
Installing the start number plate ..................................... 82
Checking the throttle cable routing .................................. 46
09/FRONT WHEEL ............................................................ 83
Checking the play in the throttle cable ............................. 46
Removi ng front wheel.... .............. ...... .............. ...... ........ 83
Adjusting
the play in the throttle cable ............................ 47
Install i
ng the front wheeL...... ...... ........ ...... ...... ........ ....... 83
03/FRAM E...... .................... .................... .................... ...... 48
Checking the brake discs ................................................ 84
Checking the frame ....................................................... 48
Removing the front brake disc ........................................ 84
Installing
the front brake disc ......................................... 85

KTM 450 SX-F EU Specifications

General

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