KTM 450 SX-F WorkShop Service Repair Manual 2011
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This Workshop Service repair manual offers detailed servicing instructions and will give you complete step by step information on repair, servicing, preventative maintenance & troubleshooting procedures for your Ktm.
This comprehensive service manual features photos and illustrations along with step-by-step instructions that will guide you through the entire repair process. This manual contains all you need to know to keep your Motorcycle working correctly.
Models covered :
450 SX-F EU
450 SX-F USA
Table Of Contents:
MEANS OF REPRESENTATION ............................................ 6 041SHOCK ABSORBER, SWINGARM ................................... 49
IMPORTANT NOTES ............................................................ 7 Adjusting the high-speed compression damping of the
SERIAL NUMBERS .............................................................. 8 shock absorber .............................................................. 49
Chassis number ............................................................... 8 Adjusting the low-speed compression damping of the
Type label ....................................................................... 8
Engine number ................................................................ 8
Fork part number ............................................................. 8
Shock absorber part number ............................................. 8
MOTORCyCLE ..................................................................... 9
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
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
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
(450 SX-F EU) .............................................................. 26
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
Removing the spring ...................................................... 56
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
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
05/EXHAUST .................................................................... 73
Removing main silencer ................................................. 73
Installing the main silencer ............................................ 73
Changing the glass fiber yarn filling of the main silencer ... 73
Checking the fork legs - during a minor fork service 06/AIR FILTER .................................................................. 75
(450 SX-F USA) ............................................................ 27 Removing the air filter box lid ......................................... 75
Changing the pilot bushing ............................................. 28 Installing the air filter box lid .......................................... 75
Assembling the screw sleeve ........................................... 29 Removing the air filter ................................................... 75
Assembling the screw cap with the membrane holder ........ 29 Installing the air filter .................................................... 75
Assembling the piston rod .............................................. 30 Cleaning the air filter and air filter box ............................ 76
Assembling the cartridge ................................................ 31 Removing the carburetor connection boot ........................ 76
Assembling the fork legs (450 SX-F EU) .......................... 33 Installing the carburetor connection boot ......................... 77
Assembling the fork legs (450 SX-F USA) ........................ 36 07/FUEL TANK, SEAT, TRIM .............................................. 78
Bleeding and filling the cartridge .................................... 39 Opening filler cap .......................................................... 78
Filling the cartridge with nitrogen .................................... 41 Closing filler cap ........................................................... 78
Greasing the steering head bearing .................................. 41 Removing the seat ......................................................... 78
Removing the lower triple clamp ..................................... 42 Mounting the seat ......................................................... 79
Installing the lower triple clamp ...................................... 42 Removing the fuel tank .................................................. 79
Checking steering head bearing play ................................ 44 Installing the fuel tank ................................................... 80
Adjusting play of steering head bearing ............................ 44 Fuel tap ........................................................................ 81
02/HANDLEBAR, INSTRUMENTS ....................................... 45 08/MASK, FENDER ........................................................... 82
Hot start lever ............................................................... 45 Removi ng the front fender ............ ...... .............. ...... ........ 82
Handlebar position ........................................................ 45 Install i ng the front fender...... ...... ........ ...... ...... ........ ....... 82
Adjusting the handlebar position ..................................... 45 Removing the start number plate .................................... 82
Adjusting the basic position of the clutch lever ................. 46 Installing the start number plate ..................................... 82
Checking the throttle cable routing .................................. 46 09/FRONT WHEEL ............................................................ 83
Checking the play in the throttle cable ............................. 46 Removi ng front wheel.... .............. ...... .............. ...... ........ 83
Adjusting the play in the throttle cable ............................ 47 Install i ng the front wheeL...... ...... ........ ...... ...... ........ ....... 83
03/FRAM E...... .................... .................... .................... ...... 48 Checking the brake discs ................................................ 84
Checking the frame ....................................................... 48 Removing the front brake disc ........................................ 84
Installing the front brake disc ......................................... 85
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
And Much More ...
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