KTM 450 SX-F EU Repair Manual page 4

TABLE OF CONTENTS
4
Checking clutch .......................................................... 152 Checking/adjusting the float level .................................. 183
Checking shift mechanism ........................................... 153 Checking/adjusting the throttle slide opening ................. 183
Preassembling the shift shaft ........................................ 154 Checking the throttle position sensor ............................. 183
Disassembling the main shaft ....................................... 155 Adjusting the position of the throttle position sensor ....... 184
Disassembling the countershaft .................................... 155 Assembling the carburetor ............................................ 185
Checking transmission ................................................. 156 Carburetor - adjusting idle ............................................ 187
Assembling the main shaft ........................................... 157 Emptying the carburetor float chamber .......................... 188
Assembling the countershaft ......................................... 158
321CLUTCH .................................................................... 190
30/ENGINE ASSEMBLy ................................................... 159 Checking the fluid level
of
hydraulic clutch .................... 190
Installing the crankshaft ............................................... 159 Changing the hydrauliC clutch fluid ............................... 190
Installing the transmission shafts .................................. 159
35IWATER PUMP, COOLING SYSTEM .............................. 191
Installing the shift forks ............................................... 159 Cooling system ............................................................ 191
Installing the shift drum ............................................... 160 Checking the anti-freeze and coolant level ..................... 191
Installing the shift rails ................................................ 160 Checking the coolant level ............................................ 191
Installing the left engine case ....................................... 160 Draining the coolant .................................................... 192
Installing the locking lever ............................................ 161 Refilling coolant .......................................................... 192
Installing the shift drum locating uni!.. .......................... 161
38/LUBRICATION SYSTEM .............................................. 194
Installing the shift shaft ............................................... 161 Oil circuit ................................................................... 194
Installing the suction pumps ........................................ 161 Checking engine oil level .............................................. 194
Installing the spacer .................................................... 162 Changing the engine oil and oil filter, cleaning the oil
Installing the force pump ............................................. 162
screen ........................................................................ 195
Installing the primary gear ............................................ 163
Adding engine oil ........................................................ 197
Installing the outer clutch hub ...................................... 163
Checking the engine oil pressure ................................... 197
Installing the drive wheel of the balancer gear ................ 164
39/IGNITION SYSTEM ..................................................... 199
Installing the timing chain ............................................ 165
Checking the ignition system ........................................ 199
Installing the free wheel gear ........................................ 165
Ignition coil - checking the primary winding ................... 200
Installing the rotor ....................................................... 165
Ignition coil - checking the secondary winding ................ 200
Installing the ignition pulse generator ............................ 166
Checking the spark plug connector ................................ 201
Adjusting the ignition pulse generator gap ...................... 166
Checking the ignition pulse generator ............................ 201
Installing the timing chain rails ..................................... 166
Alternator - checking the stator winding ......................... 202
Installing the piston ..................................................... 167
Removi ng the stator. .................... ....... ............. ....... ..... 202
Installing the clutch cover ............................................ 168
Install i ng the stator .............. ...... ........ ...... ...... ........ ..... 202
Installing the water pump cover .................................... 169
40/ELECTROSTARTER ..................................................... 203
Installing the cylinder head .......................................... 169
Checking the starter motor ........................................... 203
Installing the double wheel ........................................... 170
TECHNICAL DATA - ENGINE ............................................ 204
Installing the timing chain tensioner ............................. 170
Capacity - engine oil .................................................... 204
Checking the valve timing ............................................ 171
Capacity - coolan!.... ...... .............. ...... .............. ...... ...... 204
Adjusting the valve timing ............................................ 171
TECHNICAL DATA - ENGINE TOLERANCES, WEAR
Checking the valve clearance ........................................ 172
LIMITS ........................................................................... 205
Adjusting the valve clearance ........................................ 173
TECHNICAL DATA - ENGINE TIGHTENING TORQUES ........ 206
Installing the torque limiter and starter idler gear ........... 173
TECHNICAL DATA - CARBURETOR ................................... 208
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
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
311CARBURETOR ........................................................... 176
450 SX-F EU .............................................................. 213
Choke ......................................................................... 176
450 SX-F USA ............................................................ 213
Removing the carburetor .............................................. 176
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 215
Installing the carburetor ............................................... 177
CLEANING ...................................................................... 216
Disassembling the carburetor ........................................ 178
Cleaning motorcycle .................................................... 216
Checking/adjusting the carburetor components ............... 180
STORAGE ....................................................................... 217
Checking/adjusting the accelerator pump ....................... 181
Storage ....................................................................... 217
Checking the choke slide .............................................. 181
Preparing for use after storage ...................................... 217
Checking the jet needle ................................................ 181
SERVICE SCHEDULE ....................................................... 218
Checking the throttle slide ............................................ 182
Service schedule ......................................................... 218
Checking the needle jet ................................................ 182
Service work (as additional order) .................................. 219
Checking the float needle valve ..................................... 183