KTM 450 SX-F Repair Manual
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KTM 450 SX-F Repair Manual

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REPAIRMANUAL2007
450 / 505 SX-F
450 SXS-F
REPARATURANLEITUNG
MANUALE DI RIPARAZIONE
MANUEL DE RÉPARATION
MANUAL DE REPARACIÓN

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Евгений
July 17, 2025

Какое давление в радиаторе системы охлаждения мотоцикла КТМ 450 SXF 2011

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Summary of Contents for KTM 450 SX-F

  • Page 1 REPAIRMANUAL2007 450 / 505 SX-F 450 SXS-F REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE RÉPARATION MANUAL DE REPARACIÓN...
  • Page 3 KTM Group Partner...

  • Page 5: General Information

    1 SERVICE-INFORMATIONS 2 GENERAL INFORMATION 3 DISMOUNTING AND MOUNTING THE ENGINE 4 DISASSEMBLING THE ENGINE 5 SERVICING INDIVIDUAL COMPONENTS 6 ASSEMBLING THE ENGINE 7 ELECTRICAL 8 FUEL SYSTEM 9 TROUBLE SHOOTING 10 TECHNICAL SPECIFICATIONS 11 PERIODIC MAINTENANCE SCHEDULE 12 WIRING DIAGRAMS...
  • Page 7 X P L A N A T I O N P D A T I N G 3.206.029-E Repair Manual 450/505 SX-F 10/2006 Basic version Model year 2007 Edition: 10/2006...
  • Page 9 “NOTE” POINTS OUT USEFUL TIPS. Use only ORIGINAL KTM SPARE PARTS. The KTM high performance engine is only able to meet user expectations if the maintenance work is performed regularly and professionally. In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality.
  • Page 11 REPLY FAX FOR REPAIR MANUALS We have made every effort to make our repair manuals as accurate as possible but it is always possible for a mistake or two to creep in. To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us as follows: If you find any errors or inaccuracies in one of our repair manuals –...

  • Page 13: Table Of Contents

    GENERAL INFORMATION INDEX CHANGING THE COOLING LIQUID ........2-2 CHECKING THE COOLING LIQUID LEVEL .

  • Page 15: Changing The Cooling Liquid

    Only use fully synthetic engine oils that meet the JASO MA quality requirements (see information on the can). 5W/40 10W/50 KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for temperatures over 5°C, 41°F) or 5W/40 (for temperatures under 5°C, 41°F). Changing the engine oil CAUTION N ENGINE AT OPERATING TEMPERATURE AND THE ENGINE OIL IT CONTAINS ARE –...

  • Page 16: Changing The Oil Filter

    Changing the oil filter – Place a pan under the engine to drain the oil. Remove the 2 screws and take off the oil filter cover and O-ring. – Pull the oil filter insert out of the housing with circlip pliers 510.12.011.000.

  • Page 17: Engine Oil Circuit

    Engine oil circuit Engine oil circuit oil screen Pressure oil pump Bypass valve Oil filter insert Throttle to meter the oil for the timing chain tensioner Oil spraying nozzle for piston Jet to meter the oil to the lower conrod bearing Throttle to meter the oil to the clutch pushrod Oil duct for the cam lever support Oil spraying nozzle for the camshaft...

  • Page 18: Checking The Oil Level Of The Hydraulic Clutch

    Checking the oil level of the hydraulic clutch CAUTION SAE 10 NLY FILL BIODEGRADABLE HYDRAULIC OIL OTOREX YDRAULIC LUID INTO THE MASTER CYLINDER O NOT ADD BRAKE FLUID NOTE: remove the cover to check the oil level in the master cylinder of the clutch.

  • Page 19: Changing The Front Brake Fluid

    Changing the front brake fluid – Move the hand brake cylinder into a horizontal position. – Remove the screws and the cover together with the rubber boot – Use a syringe to extract the used brake fluid and add fresh DOT 5.1 brake fluid (Motorex Brake Fluid DOT 5.1).

  • Page 20: Changing The Rear Brake Fluid

    Changing the rear brake fluid – Move the vehicle into a vertical position. – Disassemble the screw cap together with the rubber boot from the brake fluid reservoir. – Use a syringe to extract the used brake fluid and fill with fresh DOT 5.1 brake fluid (Motorex Brake Fluid DOT 5.1).

  • Page 21: Special Tools - Engine

    SPECIAL TOOLS - ENGINE 36 36...
  • Page 22 SPECIAL TOOLS - ENGINE ITEM PART NO. DESCRIPTION 560.12.001.000 Universal engine work stand 773.29.002.000 Retaining arm, complete 600.29.012.000 Plastigauge measuring strips 510.12.011.000 Circlip pliers, inverted 590.29.033.000 Double jaw puller 600.29.015.000 Piston ring compressor 6899785 Loctite 243 blue 151.12.017.000 Bearing puller 151.12.018.000 Insert 12-16mm 151.12.018.100...
  • Page 23 DISMOUNTING AND MOUNTING THE ENGINE INDEX DISMOUNTING THE ENGINE ........3-2 MOUNTING THE ENGINE .

  • Page 25: Dismounting The Engine

    Dismounting the engine – Thoroughly clean the motorcycle and jack it up on a suitable assembly stand. Make sure it cannot tip over. – Remove the seat and tank with the spoiler. – Disconnect the battery. – Open the chain and remove. –...
  • Page 26 – Loosen the hose clamp and remove the coolant hose – Disconnect the spark plug connector – Remove the vent hose – Unscrew the chain guard from the clutch slave cylinder and from the frame and remove. – Cut off the cable tie, unscrew the clutch slave cylinder and tilt aside.
  • Page 27 – Push the carburetor back and remove the rubber sleeve from the cylinder head. – Dismount the carburetor towards the right and let it hang down. CAUTION O NOT PLACE THE CARBURETOR IN THE AIR FILTER BOX SINCE THE AIR FILTER WILL ABSORB ANY LEAKING FUEL –...

  • Page 28: Mounting The Engine

    Mounting the engine – Lift the engine into the frame from the left, position and screw in the lower and the front engine fixing screws (M10x123) but do not tighten them yet. – Mount the upper engine brace (all screws are M8x42), do not tighten yet.
  • Page 29 – Screw the hot start actuator in the carburetor. – Connect the socket connectors on the throttle position sensor pulse generator and generator. Fasten the wiring harnesses with cable ties. – Mount the clutch slave cylinder , screw in both of the front screws (M6x25) and tighten to 10 Nm.
  • Page 30 – Position the header pipe from the front of the motorcycle. – Attach the exhaust springs to the cylinder head with a suitable tool. – Mount the fixing screw (M6x25) for the header pipe with a washer and rubber sleeve and tighten to 10 Nm. –...
  • Page 31 DISASSEMBLING THE ENGINE INDEX PREPARATION ..........4-2 DRAINING THE ENGINE OIL .

  • Page 33: Preparation

    Preparation – Thoroughly clean the outside of the engine and clamp in the universal work stand 560.12.001.000 with the engine holders 773.29.002.000. – Remove the shift lever. Draining the engine oil – Remove the oil drain plug together with the seal ring. –...

  • Page 34: Removing The Sprocket

    Removing the sprocket – Use holding wrench 510.12.012.000 to hold the sprocket while you remove the screw with the spring washer. – Remove the sprocket, distance bushing and O-ring. Removing the ignition cover – Remove the 7 screws on the ignition cover and take off the ignition cover –...

  • Page 35: Moving The Engine To Ignition Tdc

    Moving the engine to ignition TDC – Remove the 3 screws on the valve covers together with the rubber seal. – Remove the valve cover together with both gaskets. – Remove the spark plug. – Move the crankshaft to ignition TDC. Both cams point towards the outside in this position.

  • Page 36: Removing The Clutch Cover

    Removing the clutch cover – Remove the plug including the O-ring. – Insert the mounting pin 773.29.012.100. NOTE: you do not need to remove the water pump cover to remove the clutch cover. – Remove the screws and completely take off the clutch cover. –...

  • Page 37: Removing The Timing Chain Tensioner

    – Bend up the lock washer on the drive nut. – Hold the driver with the clutch holder 773.29.003.000 while you remove the drive nut together with the lock washer. – Remove the driver together with the stop disk mounted underneath. NOTE: the stop disk usually sticks to the driver.

  • Page 38: Removing The Cylinder Head

    Removing the cylinder head – Remove the screws and take off the retaining bracket. – Grasp the double gear and use a screw to pull the axle for the double gear out of the cylinder head. – Remove the timing chain from the double gear. –...

  • Page 39: Removing The Cylinder / Piston

    Removing the cylinder / piston – Remove the cylinder. – Remove the axles including the O-ring. – Take out the tensioning rail and guide rail. – Remove the lock ring – Gently push the piston bolt out of the piston and remove the piston. –...

  • Page 40: Removing The Timing Chain

    Removing the timing chain – Remove the screws and take off the retaining bracket. – Grasp the timing chain while you pull the axle for the balancer gear out of the engine case with a screw. – Simultaneously remove the timing chain, balancer gear, stop disk and both needle bearings.

  • Page 41: Removing The Primary Gear

    4-10 Removing the primary gear – Remove the nut with special socket wrench 773.29.021.000. – Remove the primary gear. – Remove the engine locking screw 773.29.010.000. Removing the oil pumps – Remove the screws – Remove the oil pump cover together with the gasket and oil pressure pump.

  • Page 42: Removing The Shift Mechanism

    4-11 – Remove the needle roller – Remove the screws on the oil pump cover and take off the oil pump cover. – Remove the suction oil pump together with the oil pump shaft and needle roller. Removing the shift mechanism –...

  • Page 43: Separating The Engine Case Halves

    4-12 Separating the engine case halves – Remove all screws from the housing. – Remove both nuts on the engine holder in the universal engine work stand. CAUTION O NOT PRY THE CASE HALVES APART WITH A SCREWDRIVER OR SIMILAR TOOL SINCE THIS WILL DAMAGE THE SEALING AREAS –...
  • Page 45 SERVICING INDIVIDUAL COMPONENTS INDEX LEFT ENGINE CASE HALF .........5-2 RIGHT ENGINE CASE HALF .

  • Page 47: Left Engine Case Half

    Left engine case half – Pry out the shaft seal ring on the crankshaft , the shift shaft and the countershaft without damaging the case. – Remove the bearing bolt – Remove the throttle in the oil duct. – Remove the oil jet –...

  • Page 48: Right Engine Case Half

    Right engine case half – Pry out the shaft seal ring on the crankshaft without damaging the case. – Remove the screws from the bearing bolt and take off the bearing bolt together with the lock washer. – Remove the screw and washer from the locking lever and take off the locking lever together with the sleeve and locking lever spring.

  • Page 49: Water Pump

    Water pump – Remove the screws – Remove the water pump cover and the seal ring. – Remove the cap nut and take off the water pump wheel. Assemble in the reverse order, paying attention to the following items: – Inspect the parts for damage or wear. –...

  • Page 50: Clutch Cover

    – Degrease the thread on the screws for the retaining bracket, apply Loctite 243 and tighten to 6 Nm. – Align the mark on the balancer gear with the mounting pin Clutch cover – Remove the screws on the bearing retainer and the retaining bracket –...

  • Page 51: Lubrication System

    Lubrication system – Check the O-rings and gaskets for damage and replace if necessary. – Replace the oil filter every time you change the engine oil. – Clean the oil screen and replace if damaged. – Check the inner and outer rotor on the oil pump for damage and deposits.

  • Page 52: Crankshaft

    Crankshaft CAUTION EVER CLAMP THE CRANKSHAFT IN A VISE TOGETHER WITH THE CRANKPIN TO TRY TO EXTRACT THE INNER BEARING RING HIS WILL ONLY COMPRESS THE CRANKSHAFT WEBS AND MAKE THE CRANKSHAFT UNUSABLE – Clamp the crankshaft in a vise using protective jaws. –...

  • Page 53: Axial Clearance Of The Crankshaft

    – If you will continue to use the crankshaft, check the crankshaft journal for runout. Place the crankshaft on a roller stand or similar stand and measure the crankshaft journal runout with a gauge. Crankshaft journal runout: max. 0.15 mm –...

  • Page 54: Piston / Cylinder

    – Measure the diameter of the cylinder in the X and the Y-axis to detect any ovality. Cylinder diameter 450 SX-F / 450 SXS-F 505 SX-F size I: 97.000 - 97.012 mm size I: 100.000 - 100.012 mm size II: 97.012 - 97.025 mm...
  • Page 55 5-10 – Insert the piston ring in the cylinder and align with the piston (approx. 10 mm under the upper edge of the cylinder). – Measure the end gap with a feeler gauge. Compression ring: max. 0.80 mm Oil scraper ring: max. 1.00 mm If the end gap is larger than indicated above, check the cylinder for wear.

  • Page 56: Camshafts

    5-11 Camshafts – Wrap some masking tape around the outer cam on the camshaft to protect it from being damaged in the vise. – Clamp the camshaft in a vise with aluminum protective jaws. Position the outer cam so that the camshaft will not rotate. –...

  • Page 57: Radial Clearance Of The Camshaft Bearings

    5-12 Radial clearance of the camshaft bearings – Insert the camshafts in the cylinder head without actuating the valves. – Position the plastigauge measuring strip 600.29.012.000 on the camshaft at the bearing positions Note: follow the instructions provided by the plastigauge measuring strip manufacturer.

  • Page 58: Cylinder Head

    5-13 Cylinder head – Fold up the cam lever. – Remove the shims (valve adjustment shims) from the spring retainer and mark the installed position. Note: if you mark the installed position you will only need to check the valve clearance when they are remounted. –...
  • Page 59 5-14 – Pretension the valve springs and remove both valve keys – Remove the valve spring retainer and valve springs – Remove the valve. – Remove the valve stem gasket and spring washer Note: proceed in the same way for the remaining valves. Check: –...
  • Page 60 5-15 Assemble in the reverse order, paying attention to the following items: – Replace any damaged or worn parts. – If the valves were removed, replace the valve stem gaskets. These must be oiled before they are mounted. – Oil the valve stems and insert the valves in the guides as marked when they were removed.

  • Page 61: Timing Chain Tensioner

    5-16 Timing chain tensioner CAUTION F YOU DO NOT FOLLOW THESE INSTRUCTIONS THE TIMING CHAIN WILL NOT BE TENSIONED CORRECTLY AND WILL SKIP RESULTING IN ENGINE DAMAGE NOTE: – The timing chain tensioner operates with spring force and with oil pressure.

  • Page 62: Timing Train

    5-17 Timing train – Check O-rings for damage and replace if necessary. – Inspect the parts for damage or wear. – Replace any damaged or worn parts. – Also check the timing chain for smooth operation of the chain links. NOTE: The smooth operation of the chain links can easily be checked by simply letting the timing chain hang down - the chain links should align in a row.

  • Page 63: Clutch

    5-18 LOCTITE 243 Clutch – Check the pressure piece for damage and smooth operation. – Check the axial bearing for damage and wear. – Lay the pushrod on a level surface and check for runout. – Check the length of the clutch springs .

  • Page 64: Shift Mechanism

    5-19 LOCTITE 243 LOCTITE 243 LOCTITE 243 Shift mechanism – Check the shift forks at the blade for damage and wear. New shift forks are 3.90 to 3.95 mm thick; the wear limit is 3.70 mm. – Check the shift grooves in the shift drum for damage and wear.
  • Page 65 5-20 – Clamp the short end of the shift shaft in a vise (use protective jaws). – Mount the shift rail with guide bolt facing down and attach the guide bolt to the shift quadrant. – Mount the pressure spring –...

  • Page 66: General Information On Servicing The Transmission

    5-21 General information on servicing the transmission Clamp the main shaft or countershaft in the vise (use protective jaws). If continuing to use the shift ring and fixed gears, mark the installed position. Remove the gears and check the following parts for damage and wear: –...

  • Page 67: Countershaft

    5-22 Countershaft – Clamp the countershaft in a vise with the toothed end facing down (use protective jaws). – Carefully oil all parts before mounting. – Mount the split needle bearing – Mount the 2 gear idler gear with the shift dogs facing up. –...

  • Page 68: Starter Drive

    5-23 Starter drive Freewheel hub Take the freewheel out of the freewheel hub. Check the freewheel hub for damage and wear. Check the contact area pressure marks. Thoroughly clean the freewheel hub. Freewheel Thoroughly clean the freewheel. Check the freewheel segments for damage and wear. Oil the freewheel. Starter gear Check the starter gear for damage and wear.

  • Page 69: Freewheel Hub

    5-24 Freewheel hub – Lightly compress the spreader ring with circlip pliers and remove together with the freewheel Assemble in the reverse order, paying attention to the following items: – Inspect the parts for damage or wear. – Replace any damaged or worn parts. –...
  • Page 71 ASSEMBLING THE ENGINE INDEX ASSEMBLING THE ENGINE CASE HALVES ......6-2 MOUNTING THE SHIFT MECHANISM ....... . .6-3 MOUNTING THE OIL PUMP .
  • Page 73 Assembling the engine case halves – Fasten the right engine case half to the universal engine work stand. – Oil all bearing positions. – Mount the crankshaft. NOTE: the cone for the rotor must point towards the left engine case half.
  • Page 74 – Mount the left engine case half, tapping lightly with a plastic hammer if necessary. – Fasten the engine to the universal engine work stand. – Insert the oiled case screws and tighten. M7x70 Tightening torques M6: 10Nm M7: 14Nm M6x70 –...
  • Page 75 Mounting the oil pump – Mount the suction oil pump with the oil pump shaft and oiled needle roller. NOTE: – The rounded side of the suction oil pump should face the engine case. – The groove in the oil pump shaft should face the right side of the engine.
  • Page 76 – Mount the oiled oil pressure pump. NOTE: the rounded side of the oil pressure pump should face the oil pump cover. – Degrease the thread on the screws and apply Loctite 243. Screw on the oil pump cover including the gasket and tighten to 10 Nm. Mounting the primary gear –...
  • Page 77 Mounting the timing chain – Place the timing chain on the balancer gear. – Insert both oiled needle bearings in the balancer gear and mount the stop disk with the collar facing the balancer gear. – Simultaneously insert all parts in the timing chain compartment. –...

  • Page 78: Mounting The Cylinder Head

    – Lightly grease the outside surface of the cylinder. – Attach a cable tie to the timing chain and pull it through the timing chain compartment. – Mount the pre-assembled cylinder/piston unit and align the conrod with the piston. – Gently slide in the oiled piston bolt. –...

  • Page 79: Mounting The Timing Chain Tensioner

    – Insert both oiled needle bearings in the double gear. – Remove the cable tie and place the timing chain on the double gear. – Align the mark on the double gear with the mark on the cylinder head. Mount the axle double gear with the O-ring.
  • Page 80 Mounting the camshafts NOTE: see Chapter 5 for camshaft reassembly / radial clearance of the camshaft bearing. – Place the pre-assembled camshafts in the oiled bearing positions and align with the flat sides facing up. NOTE: if the camshaft gears were not pressed off the camshafts, check the adjusting bearing bridge 773.29.050.000.
  • Page 81 6-10 Checking the valve clearance – Remove the engine locking screw. – Switch on the engine several times. – Move the engine to the ignition TDC position (see Chapter 4) and insert the engine locking screw. – Check the valve clearance with feeler gauge 590.29.041.000: Intake valves: 0.10 - 0.15 mm Exhaust valves: 0.15 - 0.20 mm –...
  • Page 82 6-11 Mounting the clutch – Mount the collar sleeve , oiled needle bearing and outer clutch NOTE: make sure the toothing engages in the oil pump idler gear. – Mount the stop disk and driver – Degrease the thread on the main shaft and apply Loctite 243. –...
  • Page 83 6-12 Mounting the clutch cover – Insert the O-ring and the quad ring – Insert the rollers – Oil all bearing positions. – Pour approx. 30 ml of engine oil into the oil duct to the conrod bearing. – Degrease the sealing area and apply a thin coat of Three-Bond silicone sealant.
  • Page 84 6-13 – Remove the engine locking screw – Insert the screw with the copper washer and tighten to 20 Nm. Mounting the pulse generator – Degrease the thread on the screws and apply Loctite 243. – Screw on the pre-assembled pulse generator and holder by hand. Do not tighten the screws yet.
  • Page 85 6-14 Mounting the sprocket – Mount the O-ring, oiled distance bushing with the recess for the O- ring on the inside. – Mount the sprocket with the collar on the inside. – Degrease the thread on the screw , apply Loctite 243 and mount the spring washer.
  • Page 86 6-15 Filling the engine with engine oil – Insert the oiled plug together with the oil screen and tighten to 30 Nm. – Insert the oil drain plug together with a new seal ring and tighten to 20 Nm. – Pour engine oil into the oil filter housing (approx. 1/3 full) and into the oil filter insert.
  • Page 87 ELECTRICAL INDEX IGNITION SYSTEM TROUBLESHOOTING ......7-2 CDI UNIT ........... .7-2 CHECKING THE IGNITION COIL .
  • Page 89 Ignition system troubleshooting Before beginning the testing procedures on the ignition system, make sure: – the short circuit button is not actuated – the battery is fully charged – the main fuse is working Check whether there is an ignition spark upon starting, proceeding as follows: –...
  • Page 90 Checking the pickup and stator Use an ohmmeter to take the following measurements (plug connectors disconnected): Pickup coil red - green setpoint value: 100 Ω ± 20 Ω Pickup coil red - ground setpoint value: ∞ Ω Stator coil yellow - yellow setpoint value: 1.8 Ω ± 0.3 Ω Stator coil yellow - ground setpoint value: ∞...
  • Page 91 UICK CHARGES WITH HIGH VOLTAGE WILL IMPAIR THE SERVICE LIFE OF YOUR BATTERY – Connect KTM battery charger no. 584.29.074.000. The battery charger can also be used to test the offload voltage, the battery's startability and the generator capacity. This battery charger cannot be overcharged.
  • Page 92 Checking the charging voltage NOTE: : the following figures only apply to fully charged batteries (charging condition at least 90 %). – Connect a voltmeter to both battery terminals. – Start the engine. – Rev the engine up to 5000 rpm and read the voltage. Setpoint value: 14.0 –...
  • Page 93 yellow-black blue-white brown yellow-black green blue blue yellow yellow black black red-white red-white white black-white black-white grey brown black yellow black yellow red-white red-white black-white...
  • Page 94 Static ignition values Measuring conditions: – Cold engine – Seat and tank removed – All plugs and the ground connections are in a non-corroding condition, plugs tightly connected – Battery fully charged – Gap between the rotor and the pickup: 0.7 mm –...
  • Page 95 Static generator values Measuring conditions: – Cold engine – Seat and tank removed – All plugs and the ground connections are in a non-corroding condition, plugs tightly connected – Battery fully charged – Actuate the starter at least 5 seconds for each measurement –...
  • Page 97 FUEL SYSTEM INDEX DISMOUNTING AND MOUNTING THE CARBURETOR ..... .8-3 DISASSEMBLING THE CARBURETOR ....... . .8-5 CHECKING THE CHOKE SLIDE .
  • Page 99 CARBURETOR - KEIHIN FCR-MX 4125 G...
  • Page 100 Dismounting and mounting the carburetor NOTE: clean motorcycle thoroughly. – Remove the seat and tank with spoilers. – Take off the filter box cover and completely remove the air filter. – Loosen the carburetor clamp and remove the carburetor connection boot –...
  • Page 101 – Pull the carburetor out of the rubber sleeve. – Unscrew the hot start actuator from the carburetor. – Remove the carburetor. Remount the carburetor in the reverse order, paying attention to the following points: – Check all parts for damage and wear. –...
  • Page 102 Disassembling the carburetor NOTE: Before you start to disassemble the carburetor, make sure your workplace is clean and offers enough room to spread out the individual carburetor parts. – Dismount the carburetor and remove any coarse dirt. – Remove the 2 screws and disconnect all vent hoses from the carburetor.
  • Page 103 – Remove the 3 screws from the accelerator pump cover and remove the accelerator pump cover. – Take the 2 seal rings , spring and diaphragm out of the accelerator pump housing. – Remove the remaining screws on the float chamber and take off the float chamber housing –...
  • Page 104 – Remove the screw and pull the hose connection out of the carburetor. NOTE: only remove the throttle sensor if it is defective. If you loosen the screw , you will need to readjust the throttle sensor. – Remove the screw and take off the throttle sensor –...
  • Page 105 Checking the choke slide The choke slide should operate smoothly. The choke slide piston should not have any deep score marks or deposits. Check the condition of the rubber boot and the choke lock. Checking the accelerator pump Check the membrane for cracks or brittleness. Check the gaskets for damage.
  • Page 106 Checking the float needle valve Check the needle valve at the sealing area for indentations. Make sure no dirt has accumulated between the valve seat and float needle. Checking the throttle slide The rollers on the throttle slide must turn easily and should not have any flat areas.
  • Page 107 8-10 Assembling the carburetor Assemble the carburetor in the reverse order, paying attention to the following points: – Lock the screw on the throttle sensor with Loctite 243 but do not tighten yet. – Lock the screws for the hose connection and the attachment of the throttle slide arm with Loctite 243.
  • Page 108 8-11 Checking/adjusting the float height – Tilt the carburetor until the float rests against the float needle valve without compressing it. – The edge of the float should be parallel to the sealing area of the float chamber in this position (see photo). –...
  • Page 109 8-12 Adjusting the position of the throttle sensor example NOTE: the following measurement must be made at a component temperature of approx. 20°C. The carburetor must be dismounted to take this measurement. The throttle slide must be in the starting position (1mm open).
  • Page 110 8-13 Checking the throttle sensor NOTE: the following measurement must be made at a component temperature of approx. 20°C. The carburetor must be dismounted to take this measurement. The throttle slide must be in the starting position (1mm open). – Connect a multimeter (measuring range kΩ) to the blue (+) and black (-) cables on the throttle sensor and measure the total resistance of the throttle sensor (R ges ).
  • Page 111 8-14 Adjusting the idle speed The carburetor idle speed strongly influences the starting performance, a stable idle and engine responsiveness when accelerating. An engine with a correct idle speed will be easier to start than one with an incorrect idle adjustment. The idle speed is adjusted with the adjusting screw and the idle mixture with the mixture control screw...
  • Page 113 TROUBLE SHOOTING INDEX TROUBLE SHOOTING ..........9-2...
  • Page 115 TROUBLE CAUSE REMEDY Engine doesn’t crank (E-starter). Blown fuse Dismount the filter box cover and replace the fuse in the starter relay. Discharged battery Recharge the battery and investigate the causes for discharging. Low outside temperature Use the 12 V / 4 Ah battery included in the scope of supply.
  • Page 116 TROUBLE CAUSE REMEDY Engine does not rev up Carburetor fuel level too high because Dismount carburetor and check if worn out float needle valve is dirty or worn out Loose carburetor jets Tighten jets Electronic ignition timing faulty Check ignition system Engine will not reach full power Fuel supply partially interrupted or Clean and check fuel system as well as carburetor carburetor dirty...
  • Page 117 10-1 TECHNICAL SPECIFICATIONS INDEX ENGINE ........... . 10-2 CHASSIS .
  • Page 119 10-2 TECHNICAL SPECIFICATIONS - ENGINE 2007 450 SX-F / 450 SXS-F 505 SX-F Design Liquid-cooled, 1-cylinder, 4-stroke Otto engine Displacement 449.3 ccm 477.5 ccm Bore / Stroke 97 / 60.8 mm 100 / 60.8 mm Compression ratio 12.5 : 1...
  • Page 120 10-3 TECHNICAL SPECIFICATIONS – CHASSIS 2007 450 / 505 SX-F 450 SXS-F Frame Central tube chrome-molybdenum-steel frame Fork 4860 MXMA CC Fork offset (caster) adjustable 18mm/20mm adjustable 17.5mm/20.5mm Front/rear suspension travel 300/335 mm Rear suspension WP Progressive Damping System shock absorber, aluminum swing arm Front brake Disk brake with perforated Ø...
  • Page 121 Conrod bearings Radial clearance max. 0.03 mm Axial clearance max. 0.80 mm Cylinder 450 SX-F / 450 SXS-F Bore diameter, size I 97.000 - 97.012 mm Bore diameter, size II 97.012 - 97.025 mm 505 SX-F Bore diameter, size I 100.000 - 100.012 mm...
  • Page 122 10-5 TIGHTENING TORQUES - ENGINE Oil jet for piston Loctite 243 + 4 Nm Oil restrictor jet for crankshaft Loctite 243 Crankcase air jet Loctite 243 Oil jet for cam lever / camshaft Loctite 243 + 6 Nm Throttle oil supply clutch Loctite 243 + 6 Nm Screw on locking lever Loctite 243 + 6 Nm...
  • Page 123 10-6 TIGHTENING TORQUES - CHASSIS Spoke nipple M4.5 / M5 5 Nm Screw on brake disk Loctite 243 + 14 Nm Screw on push rod ball joint 10 Nm Screw on brake caliper, front Loctite 243 + 25 Nm Screw on upper triple clamp 17 Nm Screw on lower triple clamp 12 Nm...
  • Page 125 11-1 PERIODIC MAINTENANCE SCHEDULE INDEX 450/505 SX-F / 450 SXS-F ........11-2...
  • Page 127 IF MOTORCYCLE IS USED FOR COMPETITION 10 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE. Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel. Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider.
  • Page 128 Treat blank metal parts (with the exception of brake and exhaust system) with wax-based anti corrosion agent Check tightness of screws, nuts and hose clamps regularly IMPORTANT INSPECTIONS OR MAINTENANCE WORK THAT MUST BE PERFORMED BY THE SPECIALIZED KTM WORKSHOP (SEPARATE ORDER FOR SPECIALIZED KTM WORKSHOP) every...
  • Page 129 12-1 WIRING DIAGRAMS INDEX WIRING DIAGRAM ..........12-2 TERMS/TRANSLATIONS, CABLE COLORS .
  • Page 131 12-2 yellow-black blue-white brown yellow-black green blue blue yellow yellow black black red-white red-white white black-white black-white grey brown black yellow black yellow red-white red-white black-white...
  • Page 132 12-3...

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