KTM 450 SX-F USA Manuals

Manuals and User Guides for KTM 450 SX-F USA. We have 3 KTM 450 SX-F USA manuals available for free PDF download: Repair Manual, Owner's Manual

KTM 450 SX-F USA Repair Manual

KTM 450 SX-F USA Repair Manual (245 pages)

Brand: KTM | Category: Motorcycle | Size: 82.86 MB

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
Ollfork, TRIPLE CLAMP
11
02/Handlebar, Instruments
45
Checking the Frame
48
03/Frame
48
Adjusting the High-Speed Compression Damping of the Shock Absorber
49
041Shock Absorber, Swingarm
49
05/Exhaust
73
06/Air Filter
75
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
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
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
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
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
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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KTM 450 SX-F USA Owner's Manual

KTM 450 SX-F USA Owner's Manual (107 pages)

2013 Year

Brand: KTM | Category: Motorcycle | Size: 3.72 MB

Table of Contents

Table of Contents

4
- 1 Means of Representation
  
  6
  - Symbols Used
    6
  - Formats Used
    6
- 2 Safety Advice
  
  7
  - Use Definition - Intended Use
    7
  - Degrees of Risk and Symbols
    7
  - Tampering Warning
    7
  - Safe Operation
    7
  - Protective Clothing
    8
  - Work Rules
    8
  - Environment
    8
  - Owner's Manual
    8
- 3 Important Notes
  
  9
  - Guarantee, Warranty
    9
  - Operating and Auxiliary Substances
    9
  - Spare Parts, Accessories
    9
  - Service
    9
  - Figures
    9
  - Customer Service
    9
- 4 View of Vehicle
  
  10
  - View of Vehicle, Front Left (Example)
    10
  - View of Vehicle, Rear Right (Example)
    11
- 5 Serial Numbers
  
  12
  - Chassis Number
    12
  - Type Label
    12
  - Engine Number
    12
  - Fork Part Number
    12
  - Shock Absorber Part Number
    12
- 6 Controls
  
  13
  - Clutch Lever
    13
  - Hand Brake Lever
    13
  - Throttle Grip
    13
  - Kill Switch
    13
  - Electric Starter Button
    13
  - Map-Select Switch for the Basic Setting (SX-F Factory Edition)
    14
  - Map-Select Switch for Vehicle Operation (SX-F Factory Edition)
    14
  - Overview of Indicator Lamps
    14
  - Opening the Filler Cap
    14
  - Closing the Filler Cap
    15
  - Factory Start (SX-F Factory Edition)
    16
  - Cold Start Button
    16
  - Idle Speed Adjusting Screw
    17
  - Shift Lever
    17
  - Foot Brake Lever
    18
  - Side Stand (XC-F)
    18
  - Plug-In Stand (All SX-F Models)
    18
  - Service Hour Counter (SX-F Factory Edition)
    18
- 7 Preparing for Use
  
  19
- 8 Riding Instructions
  
  23
  - Checks and Maintenance Work When Preparing for Use
    23
  - Starting
    23
  - Starting off
    24
  - Shifting, Riding
    24
  - Applying the Brakes
    24
  - Stopping, Parking
    24
  - Transport
    25
  - Refueling
    25
  - Service Schedule
    27
  - Service Work (as Additional Order)
    28
- 10 Tuning the Chassis
  
  29
- 11 Service Work on the Chassis
  
  37
11 Service Work on the Chassis

40
- Installing the Fork Protector
  40
- Removing the Fork Protector
  40
- Removing the Lower Triple Clamp
  40
- Installing the Lower Triple Clamp
  41
- Position the Brake Caliper. Mount and Tighten Screws
  42
  - Screw, Front Brake Caliper M8
    42
- Adjusting the Play of the Steering Head Bearing
  43
- Checking the Steering Head Bearing Play
  43
- Main Work
  43
  - Guideline
    43
- Nm Loctite
  43
- Preparatory Work
  43
  - Raise the Motorcycle with the Lift Stand
    43
- Greasing the Steering Head Bearing
  44
- Installing the Start Number Plate
  44
- Nm (7.4 Lbf Ft)
  44
- Removing the Front Fender
  44
  - Remaining Screws, Chassis M6
    44
- Removing the Start Number Plate
  44
- Installing the Front Fender
  45
- Removing the Shock Absorber
  45
- Installing the Shock Absorber
  46
- Mounting the Seat
  46
  - Guideline Remaining Screws, Chassis
    46
- Removing the Seat
  46
- Installing the Air Filter Box Lid
  47
- Removing the Air Filter
  47
- Removing the Air Filter Box Lid
  47
- Cleaning the Air Filter and Air Filter Box
  48
- Installing the Air Filter
  48
- Removing the Main Silencer
  49
- Sealing the Air Filter Box
  49
- Securing the Air Filter Box Lid
  49
- Changing the Glass Fiber Yarn Filling of the Main Silencer
  50
  - Remaining Screws, Chassis M6
    50
- Installing the Main Silencer
  50
- Nm (7.4 Lbf Ft)
  50
- Finishing Work
  51
- Removing the Fuel Tank
  51
- Installing the Fuel Tank
  52
- Checking for Chain Dirt Accumulation
  53
- Cleaning the Chain
  53
- Adjusting the Chain Tension
  54
- Checking the Chain Tension
  54
- Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide
  55
- Adjusting the Chain Guide
  57
- Checking the Frame
  57
- Checking the Swingarm
  57
- Checking the Throttle Cable Routing
  57
- Additionally Securing the Rubber Grip
  58
- Adjusting the Basic Position of the Clutch Lever
  58
- Checking the Rubber Grip
  58
- Checking/Correcting the Fluid Level of the Hydraulic Clutch
  58
- Changing the Hydraulic Clutch Fluid
  59
- 12 Brake System
  
  60
- 13 Wheels, Tires
  
  68
  - Removing the Front Wheel
    68
  - Installing the Front Wheel
    68
  - Removing the Rear Wheel
    69
  - Installing the Rear Wheel
    70
  - Checking the Tire Condition
    70
  - Checking the Tire Air Pressure
    71
  - Checking the Spoke Tension
    71
- 14 Electrical System
  
  73
- 17 Service Work on the Engine
  
  81
- 18 Cleaning, Care
  
  85
  - Cleaning the Motorcycle
    85
- 19 Storage
  
  86
  - Preparing for Use after Storage
    87
- 20 Troubleshooting
  
  88
- 21 Blink Code
  
  90
- 22 Technical Data
  
  91
  - Engine
    91
  - Engine Tightening Torques
    91
  - Capacities
    93
  - Engine Oil
    93
  - Coolant
    93
  - Fuel
    93
  - Chassis
    93
  - Electrical System
    94
  - Tires
    94
  - Fork
    94
  - Sx-F Eu
    94
  - Sx-F Usa
    94
  - XC-F
    95
  - Shock Absorber
    95
  - Sx-F Eu
    95
  - Sx-F Usa
    96
  - XC-F
    96
  - Chassis Tightening Torques
    97
- 23 Substances
  
  99
- 24 Auxiliary Substances
  
  101
- 25 Standards
  
  103
  - Index
    104

KTM 450 SX-F USA Owner's Manual

KTM 450 SX-F USA Owner's Manual (98 pages)

2009 year

Brand: KTM | Category: Motorcycle | Size: 2.72 MB

Table of Contents

Table of Contents
4
Means of Representation
6
Important Notes
7
View of Vehicle
9
- View of the Vehicle from the Left Front (Example)
  9
- View of the Vehicle from the Right Rear (Example)
  10
Location of Serial Numbers
11
- Chassis Number
  11
- Type Label
  11
- Engine Number
  11
- Fork Part Number
  11
- Shock Absorber Part Number
  11
Controls
12
- Clutch Lever
  12
- Hot Start Lever
  12
- Hand Brake Lever
  12
- Short Circuit Button
  12
- Electric Starter Button
  12
- Fuel Tap (SX-F)
  13
- Fuel Tap (XC-F)
  13
- Opening Filler Cap
  13
- Closing Filler Cap
  14
- Choke
  14
- Shift Lever
  14
- Foot Brake Pedal
  15
- Plug-In Stand (SX-F)
  15
- Side Stand (XC-F)
  15
General Tips and Hints on Putting into Operation
16
- Advice on First Use
  16
- Running in the Engine
  17
Riding Instructions
18
- Checks before Putting into Operation
  18
- Starting
  18
- Starting up
  19
- Shifting, Riding
  19
- Braking
  19
- Stopping, Parking
  20
- Refueling
  20
Service Schedule
21
Maintenance Work on Chassis and Engine
24
Installing the Shock Absorber
29
Checking Basic Setting of Fork
29
Adjusting the Compression Damping of the Fork
29
Adjusting the Rebound Damping of Fork
30
Bleeding Fork Legs
31
Cleaning Dust Boots of Fork Legs
31
Loosening the Fork Protection
31
Positioning the Fork Protection
31
Checking Play of Steering Head Bearing
32
Adjusting Play of Steering Head Bearing
32
Fork Offset
33
Adjusting the Fork Offset
33
Removing the Fork Legs
33
Installing the Fork Legs
34
Removing the Fork Protector
34
Installing the Fork Protector
34
Removing the Lower Triple Clamp
35
Installing the Lower Triple Clamp
35
Greasing the Steering Head Bearing
36
Dismounting the Front Fender
36
Installing the Front Fender
36
Dismount the Start Number Plate
36
Installing the Start Number Plate
37
Handlebar Position
37
Adjusting Handlebar Position
37
Checking Gas Bowden Cable Route
38
Checking Play in the Gas Bowden Cable
38
Adjusting the Gas Bowden Cable Play
38
Checking for Chain Dirt Accumulation
39
Cleaning the Chain
39
Checking the Chain Tension
39
Checking the Chain Tension When Fitting Rear Wheel
40
Checking the Rear Sprocket / Engine Sprocket for Wear
40
Checking Chain Wear
40
Adjusting the Chain Tension
41
Adjusting Chain Tension - after Checking
42
Adjusting Chain Tension - Fitting Rear Wheel
42
Adjusting the Chain Guide X (SX-F)

43
Adjusting the Chain Guide X (XC-F)

43
- Checking the Brake Discs
  43
- Checking Free Play of Hand Brake Lever
  44
- Adjusting Basic Position of Handbrake Lever
  44
- Checking the Front Brake Fluid Level
  44
- Adding Front Brake Fluid
  45
- Checking the Front Brake Linings
  46
- Removing Front Brake Linings
  46
- Installing the Front Brake Linings
  46
- Changing the Front Brake Linings
  47
- Checking Free Travel of Foot Brake Lever
  48
- Adjusting Basic Position of Footbrake Lever
  48
- Checking the Rear Brake Fluid Level
  48
- Adding Brake Fluid for the Rear Brake
  49
- Checking the Rear Brake Linings
  49
- Removing Rear Brake Linings
  50
- Installing the Rear Brake Linings
  50
- Changing the Rear Brake Linings
  51
- Removing the Front Wheel
  51
- Installing the Front Wheel
  52
- Removing Rear Wheel
  53
- Installing the Rear Wheel
  53
- Tire Condition Checking
  54
- Troubleshooting
  71
- Cleaning
  73
  - Cleaning Motorcycle
    73
- Storage
  74
  - Putting into Operation after Storage
    74
- Technical Data - Engine
  75
  - Capacity - Engine Oil
    75
  - Capacity - Coolant
    76
- Technical Data - Engine Tightening Torques
  77
- Technical Data - Carburetor
  79
  - Every 450 Models
    79
  - 505 XC-F Usa
    79
- Technical Data - Chassis
  80
  - Capacity - Fuel
    81
- Technical Data - Fork
  82
  - 450 Sx-F Eu
    82
  - 450 Sx-F Usa
    82
  - XC-F
    83
- Technical Data - Shock Absorber
  84
  - 450 Sx-F Eu
    84
  - 450 Sx-F Usa
    84
  - XC-F
    85
- Technical Data - Chassis Tightening Torques
  86
- Wiring Diagram
  88
- Substances
  90
- Auxiliary Substances
  92
- Standards
  94
- Index
  95

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