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450 SX-F EU
KTM 450 SX-F EU Repair Manual
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




04LSHOCK
ABSORBER,
SWINGARM
58
-
Remove
lock
ring
•
Info
I
Do
not
scratch
the
inner
surface.
-
Remove
the
piston
rod.
-
Remove
adjusting
ring
with
the
intermediate
washer.
-
Drain
the
oil.
-
Remove
compression
adjuster
.
Remove
the
spring
and
piston.
Disassamblin
tIIa
p'iston
rod
Preliminary
work
-
Remove
the
spring.
(
r
p.
56)
-
Disassemble
the
damper.
(
r
p.
57)
Main
work
-
Clamp
the
piston
rod
with
the
fork
in
a
vise.
-
Remove
nut
-
Remove
washer
57
59
Table of Contents
Table of Contents
2
Means of Representation
6
Important Notes
7
Serial Numbers
8
Chassis Number
8
Type Label
8
Engine Number
8
Fork Part Number
8
Shock Absorber Part Number
8
Motorcycle
9
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
Preliminary Work
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
26
Checking the Fork Legs - During a Minor Fork Service
27
Changing the Pilot Bushing
28
Assembling the Screw Sleeve
29
Assembling the Screw Cap with the Membrane Holder
29
Assembling the Piston Rod
30
Assembling the Cartridge
31
Assembling the Fork Legs (450 SX-F EU)
33
Assembling the Fork Legs (450 SX-F USA)
36
Bleeding and Filling the Cartridge
39
Filling the Cartridge with Nitrogen
41
Greasing the Steering Head Bearing
41
Removing the Lower Triple Clamp
42
Installing the Lower Triple Clamp
42
Checking Steering Head Bearing Play
44
Adjusting Play of Steering Head Bearing
44
02/Handlebar, Instruments
45
Hot Start Lever
45
Handlebar Position
45
Adjusting the Handlebar Position
45
Adjusting the Basic Position of the Clutch Lever
46
Checking the Throttle Cable Routing
46
Checking the Play in the Throttle Cable
46
Adjusting the Play in the Throttle Cable
47
Checking the Frame
48
03/Frame
48
Adjusting the High-Speed Compression Damping of the Shock Absorber
49
Adjusting the Low-Speed Compression Damping of the 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
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
Remove the Spring
56
Disassemble the Damper
56
Disassemble the Piston Rod
56
Disassemble the Seal Ring Retainer
56
Removing the Spring
57
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
Assemble the Seal Ring Retainer
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
041Shock Absorber, Swingarm
49
05/Exhaust
73
Removing Main Silencer
73
Installing the Main Silencer
73
Changing the Glass Fiber Yarn Filling of the Main Silencer
73
06/Air Filter
75
Removing the Air Filter Box Lid
75
Installing the Air Filter Box Lid
75
Removing the Air Filter
75
Installing the Air Filter
75
Cleaning the Air Filter and Air Filter Box
76
Removing the Carburetor Connection Boot
76
Installing the Carburetor Connection Boot
77
Opening Filler Cap
78
Closing Filler Cap
78
Removing the Seat
78
07/Fuel Tank, Seat, Trim
79
Mounting the Seat
79
Removing the Fuel Tank
79
Installing the Fuel Tank
80
Fuel Tap
81
08/Mask, Fender
82
Removi Ng the Front Fender
82
Install I Ng the Front Fender
82
Removing the Start Number Plate
82
Installing the Start Number Plate
82
09/Front Wheel
83
Removi Ng Front Wheel
83
Checking the Brake Discs
84
Removing the Front Brake Disc
84
Install I Ng the Front Wheel
85
Installing the Front Brake Disc
85
Checking the Tire Condition
85
Checking Tire Air Pressure
85
Checking Spoke Tension
86
Lo/Rear WHEEL
87
Removing the Rear Wheel
87
Installing the Rear Wheel
87
Removing the Rear Brake Disc
88
Installing the Rear Brake Disc
88
Checking the Chain Tension
89
Adjusting the Chain Tension
89
Adjusting the Chain Guide
90
Chain Guide
91
Checking for Chain Dirt Accumulation
92
Clean I Ng the Chai N
92
11Iwiring Harness, Batiery
93
Removing the Main Fuse
93
Installing the Main Fuse
93
Removi Ng the Battery
93
Installing the Battery
94
Charging the Battery
94
Checking the Charging Voltage
95
Checking the Quiescent Currenl
95
Checking the Starter Relay
96
13/Brake System
97
Checking the Front Brake Linings
97
Changing the Front Brake Linings
97
Checking Free Travel on Hand Brake Lever
99
Adjusting the Basic Position of the Hand Brake Lever
99
Checking the Brake Fluid Level of the Front Brake
99
Adding Front Brake Fluid
100
Changing the Front Brake Fluid
100
Checking Rear Brake Linings
101
Changing the Rear Brake Linings
102
Checking the Free Travel of the Foot Brake Lever
103
Adjusting the Basic Position of the Foot Brake Lever
103
Checking Rear Brake Fluid Level
104
Adding Brake Fluid to the Rear Brake Circuit
104
Changing the Rear Brake Fluid
105
30/Engine
106
Removing the Engine
106
Installing the Engine
111
30/Disassembling the ENGINE
117
Preparations
117
Removing the Shift Lever
117
Draining the Engine Oil
117
Removi Ng the Oi I Fi Iter
117
Removing the Spark Plug
118
Removing the Valve Cover
118
Removing the Starter Motor
118
Removing the Alternator Cover
118
Removing the Torque Limiter and Starter Idler Gear
119
Positioning the Engine at Ignition Top Dead Center (TDC)
119
Removing the Camshaft
120
Removing the Timing Chain Tensioner
120
Removing the Double Wheel
121
Removing the Cylinder Head
121
Removing the Water Pump Cover
122
Removing the Clutch Cover
122
Removing the Piston
123
Removing the Timing Chain Rails
123
Removing the Timing Chain
123
Removing the Ignition Pulse Generator
124
Removing the Rotor
124
Removing the Drive Wheel of the Balancer Gear
125
Removing the Force Pump
125
Removing the Spacer
126
Removing the Outer Clutch Hub
126
Removing the Primary Gear
127
Removing the Suction Pump
127
Removing the Shift Shaft
128
Removing the Shift Drum Locating Unit
128
Removing the Locking Lever
129
Removing the Left Section of the Engine Case
129
Removing the Shift Rails
129
Removing the Shift Drum
130
Removing the Shift Forks
130
Removing the Transmission Shafts
130
Removing the Crankshaft
130
30/Engine - Work on the Individual Parts
131
Worki Ng on the Right Seclion of the Engi Ne Case
131
Working on the Left Seclion of the Engine Case
132
Removing the Water Pump
133
Changing the Shaft Seal Ring of the Water Pump
134
Installing the Water Pump
135
Removing the Crankshaft Seal Ring in the Clutch Cover
136
Installing the Crankshaft Seal Ring in the Clutch Cover
136
Removing the Stator
136
Installing the Stator
136
Removing the Oil Pressure Regulator Valve
137
Checking Spring Length of Oil Pressure Regulator Valve
137
Installing the Oil Pressure Regulator Valve
137
Checking the Lubrication System
138
Removing the Crankshaft Bearing Inner Race
138
Installing the Crankshaft Bearing Inner Race
139
Changing Connecting Rod, Conrod Bearing and Crank Pin
139
Checking Crankshaft Run-Out at Bearing Pin
140
Measuring the Crankshaft End Play
141
Cylinder - Nikasil" Coating
141
Checking/Measuring Cylinder
141
Checking/Measuring the Piston
142
Measuring Piston/Cylinder Mounting Clearance
143
Checking the Piston Ring End Gap
143
Changing the Camshaft Bearing
143
Checking the Autodecompressor
144
Checking Camshafls
144
Checking the Radial Clearance of the Camshaft Bearings
144
Checking the Camshaft Bearing Bridges
145
Removing the Valves
145
Checking the Valves
146
Checking the Valve Springs
146
Checking Valve Spring Seal
147
Checking the Cam Levers
147
Checking Cylinder Head
147
Installing the Valves
148
Removing the Freewheel
149
Checking the Freewheel
149
Installing the Free Wheel
149
Checking the Starter Drive
150
Checking the Timing Assembly
151
Preparing the Timing Chain Tensioner for Installation
151
Checking Clutch
152
Checking Shift Mechanism
153
Preassembling the Shift Shaft
154
Disassembling the Main Shaft
155
Disassembling the Countershaft
155
Checking Transmission
156
Assembling the Main Shaft
157
Assembling the Countershaft
158
30/ENGINE Assembly
159
Installing the Crankshaft
159
Installing the Transmission Shafts
159
Installing the Shift Forks
159
Installing the Shift Drum
160
Installing the Shift Rails
160
Installing the Left Engine Case
160
Installing the Locking Lever
161
Installing the Shift Drum Locating Uni
161
Installing the Shift Shaft
161
Installing the Suction Pumps
161
Installing the Spacer
162
Installing the Force Pump
162
Installing the Primary Gear
163
Installing the Outer Clutch Hub
163
Installing the Drive Wheel of the Balancer Gear
164
Installing the Timing Chain
165
Installing the Free Wheel Gear
165
Installing the Rotor
165
Installing the Ignition Pulse Generator
166
Adjusting the Ignition Pulse Generator Gap
166
Installing the Timing Chain Rails
166
Installing the Piston
167
Installing the Clutch Cover
168
Installing the Water Pump Cover
169
Installing the Cylinder Head
169
Installing the Double Wheel
170
Installing the Timing Chain Tensioner
170
Checking the Valve Timing
171
Adjusting the Valve Timing
171
Checking the Valve Clearance
172
Adjusting the Valve Clearance
173
Installing the Torque Limiter and Starter Idler Gear
173
Installing the Alternator Cover
173
Installing the Starter Motor
174
Installing the Valve Cover
174
Installing the Spark Plug
174
Installing the Oil Screen
174
Installing the Oil Filter
175
Installing the Shift Lever
175
Removing the Engine from the Universal Mounting Rack
175
311Carburetor
176
Choke
176
Removing the Carburetor
176
Installing the Carburetor
177
Disassembling the Carburetor
178
Checking/Adjusting the Carburetor Components
180
Checking/Adjusting the Accelerator Pump
181
Checking the Choke Slide
181
Checking the Jet Needle
181
Checking the Throttle Slide
182
Checking the Needle Jet
182
Checking the Float Needle Valve
183
Checking/Adjusting the Float Level
183
Checking/Adjusting the Throttle Slide Opening
183
Checking the Throttle Position Sensor
183
Adjusting the Position of the Throttle Position Sensor
184
Assembling the Carburetor
185
Carburetor - Adjusting Idle
187
Emptying the Carburetor Float Chamber
188
321Clutch
190
Checking the Fluid Level of Hydraulic Clutch
190
Changing the Hydraulic Clutch Fluid
190
35Iwater Pump, Cooling System
191
Cooling System
191
Checking the Anti-Freeze and Coolant Level
191
Checking the Coolant Level
191
Draining the Coolant
192
Refilling Coolant
192
38/Lubrication System
194
Oil Circuit
194
Checking Engine Oil Level
194
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen
195
Adding Engine Oil
197
Checking the Engine Oil Pressure
197
39/Ignition System
199
Checking the Ignition System
199
Ignition Coil - Checking the Primary Winding
200
Ignition Coil - Checking the Secondary Winding
200
Checking the Spark Plug Connector
201
Checking the Ignition Pulse Generator
201
Alternator - Checking the Stator Winding
202
Removi Ng the Stator
202
Install I Ng the Stator
202
40/Electrostarter
203
Checking the Starter Motor
203
Technical Data - Engine
204
Capacity - Engine Oil
204
Capacity - Coolan
204
Technical Data - Engine Tolerances, Wear Limits
205
Technical Data - Engine Tightening Torques
206
Technical Data - Carburetor
208
Technical Data - Carburetor Tightening Torques
209
Technical Data - Chassis
210
Tires
210
Capacity - Fuel
211
Technical Data - Fork
212
450 Sx-F Eu
212
450 Sx-F Usa
212
Technical Data - Shock Absorber
213
450 Sx-F Eu
213
450 Sx-F Usa
213
Technical Data - Chassis Tightening Torques
215
Cleaning
216
Cleaning Motorcycle
216
Storage
217
Preparing for Use after Storage
217
Service Schedule
218
Service Work (as Additional Order)
219
220
220
Wiring Diagram
221
222
222
Substances
224
Auxiliary Substances
226
Special Tools
228
Standards
241
Index
242
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Owner's Manual
107 pages
4
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KTM 450 SX-F EU Specifications
General
Brand
KTM
Model
450 SX-F EU
Category
Motorcycle
Language
English
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