KTM 450 SX-F WorkShop Service Repair Manual 2010
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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 NAGL EDITION EU
450 SX-F USA
Table Of Contents:
MEANS OF REPRESENTATION …………………………………….. 6 03/FRAM E…. ……. ……………….. ……………….. ………………… 52
IMPORTANT NOTES …………………………………………………… 7 Checking the frame ………………………………………………. 52
SERIAL NUMBERS …………………………………………………….. 8 04/SHOCK ABSORBER, SWINGARM …………………………….. 53
Chassis number ……………………………………………………… 8 Adjusting high-speed compression damping of the shock
Type label …………………………………………………………….. 8 absorber………. ……. ……………….. ……………….. ………….. 53
Engine number ………………………………………………………. 8
Fork part number ……………………………………………………. 8
Shock absorber part number ……………………………………… 8
MOTORCyCLE …………………………………………………………… 9
Adjusting the low-speed compression damping of the
shock absorber …………………………………………………….. 53
Adjusting the rebound damping of the shock absorber ……. 54
Measuring rear wheel sag unloaded …………………………… 54
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 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 (SX-F EU,
SX-F NAGL EDITION) ……………………………………………. 15
Checking static sag of shock absorber ………………………… 55
Checking riding sag of shock absorber ……………………….. 55
Adjusting the spring preload of the shock absorber ……….. 55
Adjusting the riding sag …………………………………………. 56
Removing the shock absorber ………………………………….. 57
Installing the shock absorber …………………………………… 57
Servicing the shock absorber …………………………………… 57
Removing the spring ……………………………………………… 58
Disassembling the damper ……………………………………… 58
Disassembling the piston rod …………………………………… 60
Disassembling the seal ring retainer ………………………….. 61
Replacing the pilot bushing …………………………………….. 62
Checking the damper …………………………………………….. 62
Disassembling the rebound adjuster ………………………….. 63
Removing the heim joint ………………………………………… 64
Installing the heim joint …………………………………………. 64
Assembling the rebound adjuster ……………………………… 65
Assembling the seal ring retainer ……………………………… 66
Assembling the piston rod ………………………………………. 66
Disassembling the fork legs (SX-F USA) ……………………… 18
Disassembling the cartridge …………………………………….. 20
Disassembling the piston rod …………………………………… 22
Disassembling the screw cap with the membrane holder … 24
Disassembling the screw sleeve ……………………………….. 25
Checking the fork legs (SX-F EU, SX-F NAGL EDITION) …. 25
Checking the fork legs (SX-F USA) ……………………………. 27
Checking the fork legs – during a minor fork service
(SX-F EU, SX-F NAGL EDITION) ………………………………. 28
Assembling the damper (SX-F EU,
SX-F NAGL EDITION) ……………………………………………. 68
Assembling the damper (SX-F USA) ………………………….. 70
Bleeding and filling the damper ……………………………….. 72
Filling the damper with nitrogen ………………………………. 74
Installing the spring (SX-F EU, SX-F NAGL EDITION) …….. 75
Installing the spring (SX-F USA) ………………………………. 76
Checking the swingarm ………………………………………….. 77
05/EXHAUST ………………………………………………………….. 78
Checking the fork legs – during a minor fork service Removing main silencer …………………………………………. 78
(SX-F USA) …………………………………………………………. 29 Installing the main silencer …………………………………….. 78
Changing the pilot bushing ……………………………………… 31 Changing the glass fiber yarn filling of the main silencer … 78
Assembling the screw sleeve ……………………………………. 31 06/AIR FILTER ………………………………………………………… 80
Assembling the screw cap with the membrane holder …….. 32 Removing the air filter box lid ………………………………….. 80
Assembling the piston rod ………………………………………. 33 Installing the air filter box lid …………………………………… 80
Assembling the cartridge ………………………………………… 34 Removing the air filter …………………………………………… 80
Assembling the fork legs (SX-F EU, Installing the air filter ……………………………………………. 80
SX-F NAGL EDITION) ……………………………………………. 35 Cleaning the air filter and air filter box ………………………. 81
Assembling the fork legs (SX-F USA) …………………………. 39 Removing the carburetor connection boot …………………… 81
Bleeding and filling the cartridge ……………………………… 42 Installing the carburetor connection boot ……………………. 82
Filling the cartridge with nitrogen ……………………………… 43 07/FUEL TANK, SEAT, TRIM ………………………………………. 83
Greasing the steering head bearing ……………………………. 44 Opening filler cap …………………………………………………. 83
Removing the lower triple clamp ………………………………. 44 Closing filler cap ………………………………………………….. 83
Installing the lower triple clamp ……………………………….. 45 Removi ng the seat… ……………….. ……. …………. ……. ……. 83
Checking steering head bearing play ………………………….. 46 Mounting the seat ………………………………………………… 84
Adjusting play of steering head bearing ………………………. 47 Removing the fuel tank ………………………………………….. 84
02/HANDLEBAR, INSTRUMENTS ………………………………… 48 Installing the fuel tank …………………………………………… 85
Hot start lever ……………………………………………………… 48 Fuel tap ……………………………………………………………… 86
Handlebar position ……………………………………………….. 48 08lMASK, FENDER ………………………………………………….. 87
Adjusting the handlebar position ………………………………. 48 Removing the front fender ………………………………………. 87
Adjusting the basic position of the clutch lever …………….. 50 Installing the front fender ……………………………………….. 87
Checking the throttle cable routing ……………………………. 50 Removing the start number plate ……………………………… 87
Checking the play in the throttle cable ……………………….. 50 Installing the start number plate ………………………………. 87
Adjusting the play in the throttle cable ………………………. 51
Checking valve spring sea!… ………………………………….. 152 Removing the carburetor ………………………………………. 181
Checking the cam levers ………………………………………. 152 Installing the carburetor ……………………………………….. 182
Checking cylinder head ………………………………………… 152 Disassembling the carburetor …………………………………. 183
Installing the valves …………………………………………….. 153 Checking/adjusting the carburetor components …………… 185
Removi ng the Ireewheel …. ……. …… ……. ……. …… ………. 154 Checking/adjusting the accelerator pump ………………….. 186
Checking the Ireewheel ………………………………………… 154 Checking the choke slide ………………………………………. 186
Installing the Iree wheel ……………………………………….. 154 Checking the jet needle ………………………………………… 186
Checking the starter drive ……………………………………… 155 Checking the throttle slide …………………………………….. 187
Checking the timing assembly ……………………………….. 156 Checking the needle jet ………………………………………… 187
Preparing the timing chain tensioner lor installation ……. 156 Checking the Iloat needle valve ………………………………. 188
Checking clutch …………………………………………………. 157 Checking/adjusting the Iloat level ……………………………. 188
Checking shift mechanism ……………………………………. 158 Checking/adjusting the throttle slide opening …………….. 188
Preassembling the shift shaft …………………………………. 159 Checking the throttle position sensor ……………………….. 188
Disassembling the main shaft ………………………………… 160 Adjusting the position 01 the throttle position sensor ……. 189
Disassembling the countershaft ……………………………… 160 Assembling the carburetor …………………………………….. 190
Checking transmission …………………………………………. 161 Carburetor – adjusting idle …………………………………….. 192
Assembling the main shaft ……………………………………. 162 Emptying the carburetor Iloat chamber …………………….. 193
Assembling the countershaft ………………………………….. 163 321CLUTCH ………………………………………………………….. 195
30/ENGINE ASSEMBLy …………………………………………… 164 Checking the Iluid level of hydraulic clutch ……………….. 195
Installing the crankshaft ……………………………………….. 164 Changing the hydraulic clutch Iluid …………………………. 195
Installing the transmission shafts ……………………………. 164 35IWATER PUMP, COOLING SYSTEM ………………………… 196
Installing the shift forks ……………………………………….. 164 Cooling system …………………………………………………… 196
Installing the shift drum ……………………………………….. 165 Checking the anti-Ireeze and coolant level ………………… 196
Installing the shift rails ………………………………………… 165 Checking the coolant level …………………………………….. 196
Installing the left engine case ………………………………… 165 Draining the coolant ……………………………………………. 197
Installing the locking lever …………………………………….. 166 Refilling coolant …………………………………………………. 197
Installing the shift drum locating unit ………………………. 166 38/LUBRICATION SYSTEM ………………………………………. 199
Installing the shift shaft ……………………………………….. 166 Oil circuit …………………………………………………………. 199
Installing the suction pumps …………………………………. 166 Checking engine oil level ………………………………………. 199
Installing the spacer ……………………………………………. 167 Changing the engine oil and oil lilter, cleaning the oil
Installing the lorce pump ……………………………………… 167 screen ……………………………………………………………… 200
Installing the primary gear …………………………………….. 168 Adding engine oil ……………………………………………….. 202
Installing the outer clutch hub ……………………………….. 168 Checking the engine oil pressure …………………………….. 202
Installing the drive wheel 01 the balancer gear ……………. 169 39/IGNITION SYSTEM …………………………………………….. 204
Installing the timing chain …………………………………….. 170 Checking the ignition system …………………………………. 204
Installing the Iree wheel gear …………………………………. 170 Ignition coil – checking the primary winding ………………. 205
Installing the rotor ………………………………………………. 170 Ignition coil – checking the secondary winding ……………. 205
Installing the ignition pulse generator ………………………. 171 Checking the spark plug connector ………………………….. 206
Adjusting the ignition pulse generator gap …………………. 171 Checking the ignition pulse generator ………………………. 206
Installing the timing chain rails ………………………………. 171 Alternator – checking the stator winding ……………………. 207
Installing the piston …………………………………………….. 172 Removi ng the stator. ……………….. ……. …………. ……. ….. 207
Installing the clutch cover …………………………………….. 173 Install i ng the stator ………….. …… …….. …… …… …….. ….. 207
Installing the water pump cover ……………………………… 174 40/ELECTROSTARTER …………………………………………….. 208
Installing the cylinder head …………………………………… 174 Checking the starter motor ……………………………………. 208
Installing the double wheel ……………………………………. 175 TECHNICAL DATA – ENGINE …………………………………….. 209
Installing the timing chain tensioner ……………………….. 175 Capacity – engine oil ……………………………………………. 209
Checking the valve timing …………………………………….. 176 Capacity – coolant…. …… ………….. …… ………….. …… …… 209
Adjusting the valve timing …………………………………….. 176 TECHNICAL DATA – ENGINE TOLERANCES, WEAR
Checking the valve clearance …………………………………. 177 LIMITS ………………………………………………………………… 210
Adjusting the valve clearance …………………………………. 178 TECHNICAL DATA – ENGINE TIGHTENING TORQUES …….. 211
Installing the torque limiter and starter idler gear ……….. 178 TECHNICAL DATA – CARBURETOR …………………………….. 213
Installing the alternator cover ………………………………… 178
Installing the starter motor ……………………………………. 179
Installing the valve cover ………………………………………. 179
Installing the spark plug ……………………………………….. 179
Installing the oil screen ………………………………………… 179
Installing the oil lilter ………………………………………….. 180
Installing the shift lever ……………………………………….. 180
Removing the engine from the universal mounting
rack ………………………………………………………………… 180
TECHNICAL DATA – CARBURETOR TIGHTENING
TORQUES …………………………………………………………….. 214
TECHNICAL DATA – CHASSIS …………………………………… 215
Tires ……………………………………………………………….. 215
Capacity – fuel.. ……. ……………….. ……………….. ………… 215
TECHNICAL DATA – FORK ………………………………………… 216
SX-F EU, SX-F NAGL EDITION ………………………………. 216
SX-F USA …………………………………………………………. 216
TECHNICAL DATA – SHOCK ABSORBER ……………………… 217
311CARBURETOR ………………………………………………….. 181 SX-F EU, SX-F NAGL EDITION ………………………………. 217
Choke ………………………………………………………………. 181 SX-F USA …………………………………………………………. 217
And Much More …
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