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TABLE OF CONTENTS
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IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . .2
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . .5
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Engine number, engine type . . . . . . . . . . . . . . . . . . . .5
OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . .5
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Hot start lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Short circuit button . . . . . . . . . . . . . . . . . . . . . . . . . .6
Starter button (450 SX-F) . . . . . . . . . . . . . . . . . . . . .6
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Kickstarter (250 SX-F) . . . . . . . . . . . . . . . . . . . . . . . .7
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Plug in stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Compression damping of fork . . . . . . . . . . . . . . . . . . .8
Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . .8
Compression damping of shock absorber . . . . . . . . . . .8
Rebound damping of shock absorber . . . . . . . . . . . . . .9
GENERAL TIPS AND WARNINGS FOR STARTING THE
MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Instructions for initial operation . . . . . . . . . . . . . . . .10
Running in the Racing models . . . . . . . . . . . . . . . . .10
DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .11
Check the following before each start . . . . . . . . . . . .11
Starting when the engine is cold . . . . . . . . . . . . . . . .12
Starting when the engine is warm . . . . . . . . . . . . . . .12
What to do when the engine is "flooded" . . . . . . . . . .12
Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . .13
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . .14
MAINTENANCE WORK ON CHASSIS AND ENGINE . . . .16
Changing the spring preloading of the shock absorber .16
Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Basic suspension setup for the weight of the driver . . .17
Checking the shock absorber and spring . . . . . . . . . .17
Determining the static sag of the shock absorber . . . .17
Determining the riding sag of the shock absorber . . . .17
Checking the basic setup of the telescopic fork . . . . .18
Changing the spring preload on the telescopic fork . . .18
Replacing fork springs . . . . . . . . . . . . . . . . . . . . . . .18
Breather plug front fork . . . . . . . . . . . . . . . . . . . . . .18
Cleaning the dust sleeves of the telescopic fork . . . . .18
Changing the fork offset (caster) . . . . . . . . . . . . . . . .19
Checking and adjusting the steering head bearing . . .20
Checking the throttle cable installation . . . . . . . . . . .20
How to change the handlebar position . . . . . . . . . . . .21
Check chain tension . . . . . . . . . . . . . . . . . . . . . . . .21
Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . .22
Adapting the chain guide to the number of rear
sprocket teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . .23
Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
General information about KTM disc brakes . . . . . . . .24
Adjusting the free travel at the hand brake lever . . . . .25
Checking the brake fluid level - front brake . . . . . . . .25
Refilling the front brake fluid reservoir . . . . . . . . . . .25
Checking the front brake pads . . . . . . . . . . . . . . . . .25
Replacing the front brake pads . . . . . . . . . . . . . . . . .26
Checking the rear brake fluid level . . . . . . . . . . . . . .26
Refilling the rear brake fluid reservoir . . . . . . . . . . . .26
Changing the basic position of the foot brake pedal . .27
Checking the rear brake pads . . . . . . . . . . . . . . . . . .27
Replacing the rear brake pads . . . . . . . . . . . . . . . . .27
Dismounting and mounting the front wheel . . . . . . . .28
Dismounting and mounting the rear wheel . . . . . . . . .29
Checking spoke tension . . . . . . . . . . . . . . . . . . . . . .29
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . .30
Battery (450 SX-F) . . . . . . . . . . . . . . . . . . . . . . . . .30
Charging the battery (450 SX-F) . . . . . . . . . . . . . . . .31
Fuse (450 SX-F) . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Checking the coolant level . . . . . . . . . . . . . . . . . . . .32
Bleeding the cooling system . . . . . . . . . . . . . . . . . . .32
Replacing the glassfiber yarn packing of the silencer .33
Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . .34
Adjusting the throttle cables . . . . . . . . . . . . . . . . . . .34
Changing the original position of the clutch lever . . . .35
Checking the oil level of the hydraulic clutch . . . . . .35
Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . .35
Carburetor - Adjust idling . . . . . . . . . . . . . . . . . . . . .36
Basic information on carburetor wear . . . . . . . . . . . .36
Checking the float level (float height) . . . . . . . . . . . .36
Draining the float chamber of the carburetor . . . . . . .37
Checking the engine oil level . . . . . . . . . . . . . . . . . .37
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Changing the engine oil . . . . . . . . . . . . . . . . . . . . . .38
Changing the oil filter . . . . . . . . . . . . . . . . . . . . . . .39
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . .40
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
TECHNICAL DATA - ENGINE . . . . . . . . . . . . . . . . . . . .43
TECHNICAL DATA - CHASSIS . . . . . . . . . . . . . . . . . . . .44
HEAD WORK INDEX . . . . . . . . . . . . . . . . . . . . . . . . . .47
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . .appendix
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