KTM 450 SX-F EU Repair Manual page 3

TABLE OF CONTENTS
3
Checking the tire condition ............................................. 85 Removing the timing chain ........................................... 123
Checking tire air pressure ............................................... 85 Removing the ignition pulse generator ........................... 124
Checking spoke tension .................................................. 86 Removing the rotor ...................................................... 124
lO/REAR WHEEL .............................................................. 87
Removing the drive wheel of the balancer gear ............... 125
Removing the rear wheel ................................................ 87 Removing the force pump ............................................ 125
Installing the rear wheel ................................................. 87 Removing the spacer ................................................... 126
Removing the rear brake disc .......................................... 88 Removing the outer clutch hub ..................................... 126
Installing the rear brake disc .......................................... 88 Removing the primary gear ........................................... 127
Checking the chain tension ............................................ 89 Removing the suction pump ......................................... 127
Adjusting the chain tension ............................................ 89 Removing the shift shaft .............................................. 128
Adjusting the chain guide ............................................... 90 Removing the shift drum locating unit ........................... 128
Checking the chain, rear sprocket, engine sprocket and Removing the locking lever ........................................... 129
chain guide ................................................................... 90
Removing the left section of the engine case .................. 129
Checking for chain dirt accumulation .............................. 92
Removing the shift rails ............................................... 129
Clean i ng the chai n ..... ....... ....... ...... ....... ....... ...... ....... ..... 92
Removing the shift drum .............................................. 130
11IWIRING HARNESS, BATIERY ....................................... 93
Removing the shift forks .............................................. 130
Removing the main fuse ................................................. 93
Removing the transmission shafts ................................. 130
Installing the main fuse ................................................. 93
Removing the crankshaft .............................................. 130
Removi ng the battery .............. ...... .............. ...... ............. 93
30/ENGINE - WORK ON THE INDIVIDUAL PARTS ............. 131
Installing the battery ...................................................... 94
Worki ng on the right seclion of the engi ne case.. ............ 131
Charging the battery ...................................................... 94
Working on the left seclion of the engine case ................ 132
Checking the charging voltage ........................................ 95
Removing the water pump ............................................ 133
Checking the quiescent currenl.. ..................................... 95
Changing the shaft seal ring of the water pump .............. 134
Checking the starter relay ............................................... 96
Installing the water pump ............................................. 135
13/BRAKE SYSTEM ........................................................... 97
Removing the crankshaft seal ring in the clutch cover ..... 136
Checking the front brake linings ...................................... 97
Installing the crankshaft seal ring in the clutch cover ...... 136
Changing the front brake linings ..................................... 97
Removing the stator ..................................................... 136
Checking free travel on hand brake lever .......................... 99
Installing the stator ..................................................... 136
Adjusting the basic position of the hand brake lever .......... 99
Removing the oil pressure regulator valve ....................... 137
Checking the brake fluid level of the front brake ............... 99
Checking spring length of oil pressure regulator valve ...... 137
Adding front brake fluid ............................................... 100
Installing the oil pressure regulator valve ....................... 137
Changing the front brake fluid ...................................... 100
Checking the lubrication system .................................... 138
Checking rear brake linings .......................................... 101
Removing the crankshaft bearing inner race ................... 138
Changing the rear brake linings ..................................... 102
Installing the crankshaft bearing inner race .................... 139
Checking the free travel of the foot brake lever ............... 103
Changing connecting rod, conrod bearing and crank
Adjusting the basic position of the foot brake lever ......... 103
pin ............................................................................. 139
Checking rear brake fluid level ...................................... 104 Checking crankshaft run-out at bearing pin .................... 140
Adding brake fluid to the rear brake circuit .................... 104 Measuring the crankshaft end play ................................ 141
Changing the rear brake fluid ........................................ 105 Cylinder - Nikasil" coating ............................................ 141
30/ENGINE ..................................................................... 106 Checking/measuring cylinder ........................................ 141
Removing the engine ................................................... 106 Checking/measuring the piston ..................................... 142
Installing the engine .................................................... 111 Measuring piston/cylinder mounting clearance ................ 143
30/DiSASSEMBLING THE ENGINE ................................... 117
Checking the piston ring end gap .................................. 143
Preparations....... .................... .................... ................. 117
Changing the camshaft bearing ..................................... 143
Removing the shift lever ............................................... 117 Checking the autodecompressor .................................... 144
Draining the engine oil .................................................
117
Checking camshafls ..................................................... 144
Removi ng the oi I fi Iter...... .............. ...... .............. .......... 117
Checking the radial clearance of the camshaft
Removing the spark plug .............................................. 118
bearings ..................................................................... 144
Removing the valve cover ............................................. 118
Checking the camshaft bearing bridges .......................... 145
Removing the starter motor .......................................... 118
Removing the valves .................................................... 145
Removing the alternator cover ....................................... 118
Checking the valves ..................................................... 146
Removing the torque limiter and starter idler gear ........... 119
Checking the valve springs ........................................... 146
Positioning the engine at ignition top dead center
Checking valve spring seal.. .......................................... 147
(TDC) ......................................................................... 119 Checking the cam levers .............................................. 147
Removing the camshaft ................................................ 120 Checking cylinder head ................................................ 147
Removing the timing chain tensioner ............................. 120 Installing the valves ..................................................... 148
Removing the double wheel .......................................... 121 Removing the freewheel ............................................... 149
Removing the cylinder head .......................................... 121 Checking the freewheel ................................................ 149
Removing the water pump cover ................................... 122 Installing the free wheel ............................................... 149
Removing the clutch cover ........................................... 122 Checking the starter drive ............................................. 150
Removing the piston .................................................... 123 Checking the timing assembly ...................................... 151
Removing the timing chain rails .................................... 123 Preparing the timing chain tensioner for installation ....... 151