KTM 450 SX 2004 Owner'S Manual Download

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OWNER`S MANUAL

MANUALE D`USO

MANUEL D`UTILISATION

MANUAL DE INSTRUCCIONES

ART.NR: 3.210.77

250 EXC RACING
450 SX, MXC, EXC RACING
525 SX, MXC, EXC RACING

BEDIENUNGSANLEITUNG

2004

Summary of Contents for 450 SX 2004

Page 1: ...OWNER S MANUAL MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES ART NR 3 210 77 250 EXC RACING 450 SX MXC EXC RACING 525 SX MXC EXC RACING BEDIENUNGSANLEITUNG2004...

Page 2: ...moval or rendering inoperative by any person other than for purposes of mainten ance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise...

Page 3: ...formed If maintenance work should become necessary during a competition it should be performed by a trained mechanic KTM strongly recommends that all service work to your KTM should be performed by a...

Page 4: ...age or consequential damage caused by manipulations or conversions to the motorcycle The use of the motorcycle under extreme conditions e g on extremely muddy and wet terrain can lead to higher than a...

Page 5: ...ging the spring preloading of the shock absorber 28 Pivot bearing 28 Check chain tension 29 Correct chain tension 29 Chain maintenance 30 Chain wear 30 General information about KTM disc brakes 31 Adj...

Page 6: ...ch lever see maintenance work on chassis and engine Hand decompression lever The hand decompression lever 2 is needed only if the carburetor overflows after a fall To pump the engine free pull the han...

Page 7: ...to switch off the engine Leave the switch pressed until the engine stops Headlamp switch EXC USA In this model the headlamp is switched on with the pull switch 4 Flasher switch The flasher switch is...

Page 8: ...front wheel turns the display will automatically change to the SPEED ODO mode SPEED H hours display mode When you stop driving and no impulses are sent from the wheel sensor the display mode will auto...

Page 9: ...UTTON 3 SECONDS to reset the MAX figure to 0 SPEED LAP display mode LAP displays the stopped lap time in hours minutes and seconds BUTTON Starts and stops the stop watch The lap time is not reset to 0...

Page 10: ...the first impulse received from the wheel sensor when the front wheel starts to turn and stops 3 seconds after the last impulse is received when the front wheel has stopped The TRP1 AVS1 and STP1 fig...

Page 11: ...he SPEED STP2 mode and press the button BUTTON starts and stops the stop watch BUTTON no function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to reset STP...

Page 12: ...resets TRP1 STP1 and AVS1 to 0 resets TRP2 to 0 next display mode sets STP2 to 0 Kilometers or miles The unit kilometers or miles can also be changed The ODO figure will be retained and converted acc...

Page 13: ...l tap is closed No fuel can flow to the carburetor ON During operation the twist grip must be turned to ON This means that the fuel can flow to the carburetor With the twist grip in this position the...

Page 14: ...own in the illustration Neutral or the idle speed is located between first and second gear Kickstarter The kickstarter is mounted on the right side of the engine Its upper part can be swivelled Foot b...

Page 15: ...bsorber SX The shock absorber on the SX models can synchronize the compression damping in the low and high speed range separately Dual Compression Control Low and high speed refers to the movement of...

Page 16: ...ng of shock absorber SX MXC EXC By using the adjusting screw 3 the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counter clockwise to reduce damp...

Page 17: ...t ride Familiarize yourself with the operating elements Set the clutch lever the handbrake lever and the footbrake pedal to the positions that are most convenient for you Get used to handling the moto...

Page 18: ...Tires showing cuts or dents must be replaced The tread depth must comply with the legal regulations Also check the air pressure Insufficient tread and incorrect air pressure deteriorate the driving pe...

Page 19: ...o when the engine is flooded In the event of a fall more fuel than necessary may get into the engine In order to pump the engine free pull the hand decompression lever fully rev up the engine actuate...

Page 20: ...ED OR DIRTY ROADS CAN ALSO DELAY THE BRAKING EFFECT THE BRAKES MUST BE PULLED UNTIL THEY ARE CLEAN DIRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND BRAKE DISCS WHEN YOU BRAKE THE BRAKE DISCS B...

Page 21: ...etting Check function of electric systems low high beam brake light indicator lamps speedometer illumination horn emergency OFF switch or button Check brake fluid level lining thickness brake discs Ch...

Page 22: ...and adjust if necessary Clean air filter and filter box Check tires for pressure and wear Check cooling fluid level Check fuel lines for leaks Drain and clean float chamber Check all control elements...

Page 23: ...centricity of the valve disk Check the valve guides for wear Check the radial clearance of the rocker arm rollers Check the elongation of the timing chain Check the chain tensioner tooting for damage...

Page 24: ...tricity of the valve disk Check the valve guides for wear Check the radial clearance of the rocker arm rollers Check the elongation of the timing chain Check the chain tensioner tooting for damage vis...

Page 25: ...GINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED DISPOSE OILS FATTY MATTERS FILTERS FUELS WASHING DETERGENTS ETC PROPERLY UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE...

Page 26: ...rotection bellows If this dirt is not removed the oil sealing rings located behind it may start to leak Use a screwdriver to lift the dust protection bellows out of the outer tubes and slide them down...

Page 27: ...gain to establish dimension B The static sag is the difference between dimensions A and B EXAMPLE Motorcycle jacked up dimension A 600 mm Motorcycle on ground unloaded dimension B 565 mm Static sag 35...

Page 28: ...parts catalog The fork springs may not be pretensioned by more than 20 mm The preload adjuster used in the SX models can easily be retrofitted for the telescopic forks of the MXC EXC models NOTE WP p...

Page 29: ...purpose you should dismount the shock absorber and clean it thoroughly NOTE Before changing the spring preload note down the basic setting e g how many threads are visible above the adjusting ring One...

Page 30: ...HE MOTORCYCLE Correct chain tension Loosen collar nut 1 loosen lock nuts 2 and turn right and left adjusting screws 3 equally far Tighten lock nuts To ensure the correct alignment of the rear wheel th...

Page 31: ...K CLIP THE CLOSED SIDE OF THE MASTERLINK CLIP MUST POINT IN RUNNING DIRECTION Also check sprockets and chain guides for wear and replace if necessary Chain wear To check the chain wear observe the fol...

Page 32: ...ess in a location B outside the contact face Check wear in several locations WARNING BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0 4 MM 0 016 IN CONSTI TUTE A SAFETY RISK HAVE THE BRAKE DISCS REPLACE...

Page 33: ...oir Loosen screws 2 and remove lid 3 and membrane 4 Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm 0 2 in below the rim with clean brake fluid DOT 5 1 e...

Page 34: ...ve the piston in the brake cylinder to be recognised from the resistance on the foot brake pedal CAUTION IF THIS FREE PLAY IS NOT PRESENT THEN PRESSURE CAN BUILD UP IN THE BRAKE SYSTEM WHEN DRIVING CA...

Page 35: ...BRAKING SYSTEM ALWAYS ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER RESPECTIVELY TO ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED Dismounting and...

Page 36: ...the reverse order Before tightening the collar nut to 80 Nm push the rear wheel forwards so that the chain tensioners lie on the tension screws WARNING IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT H...

Page 37: ...TIRES WHICH HAVE NOT BEEN APPROVED BY KTM OTHER TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE BEHAVES FRONT AND REAR WHEELS MAY ONLY BE FITTED WITH TIRES HAVING THE SAME TREAD LAYOUT USE...

Page 38: ...ENGINE IS RUNNING THIS WILL DESTROY THE RECTIFIER REGULATOR THE BATTERY MUST BE INSTALLED WITH THE TERMINALS FACING THE FRONT AS SHOWN IN THE ILLUSTRATION OTHERWISE ELECTROLYTE CAN ESCAPE BATTERY STO...

Page 39: ...TREATMENT COULD DAMAGE THE WHOLE ELECTRICAL INSTALLATION Replacing headlight lamp parking light lamp Loosen both rubber bands and tilt headlight mask to the front Pull the parking light lamp with hold...

Page 40: ...Y AND CONSULT DOCTOR A mixture of 40 antifreeze liquid and 60 water is used as coolant However the antifreeze protection must be at least 25 C 13 F This mixture offers antifreeze protection but also g...

Page 41: ...ntaining the packing into the silencer such that the slot engages the web A Use a blunt ended object to stuff the glassfiber yarn packing all the way into the silencer and mount the front cap C To cha...

Page 42: ...the hand decompression release cable Start the engine and at idling speed slowly pull the hand decompression lever until you can feel the thumping of the rocker arm on the lever The backlash until sa...

Page 43: ...ble from your KTM dealer 50ml CAUTION KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS NEVER REFILL WITH MINERAL HYDRAULIC...

Page 44: ...s been screwed in up to the stop without causing any change in rotational speed a smaller idling jet has to be installed b the engine dies when the mixture control screw is still open by 2 turns a lar...

Page 45: ...il from the oil sump of the transmission This engine oil flows through an oil line 5 into the cylinder head for camshaft lubrication 6 the oil quantity is controlled by the jet screw 7 An oil duct bra...

Page 46: ...n the hex socket plug 3 at the engine bottom Insert a pin type key into the plug and tap on the key a few times with a hammer in order to relieve the stress acting on the plug Dis mount the oil screen...

Page 47: ...ide and fill the oil filter housings about halfway with engine oil Fill oil filter with oil place the long oil filter in the front and the short filter in the back of the filter box Grease the O rings...

Page 48: ...the new fuels evaporate during longer periods of standing still When the motorcycle has been out of operation for more than a week it is therefore recommended to drain the old fuel from the float cham...

Page 49: ...elay The battery isn t charged by the generator because REMEDY Dismount carburetor and check if worn out Tighten jets Have ignition system checked Clean and check fuel system as well as carburetor Rep...

Page 50: ...the next biking season STORAGE Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces The best manner would be to use warm water that has been mixed with a normal bran...

Page 51: ...n with two rotor pumps Engine oil full synthetic oil Motorex Power Synt 4T 10W 50 Quantity of engine oil 1 25 liters Primary ratio straight geared spur wheels 33 76 Z Clutch multi disc clutch in oil b...

Page 52: ...mm 858 2 15 mm 858 2 15 mm 858 2 15 mm Hot start device 2 2 mm 250 EXC RACING Six Days 250 EXC RACING 11 kW 450 EXC RACING 12 kW 450 SX RACING BASIC CARBURATOR SETTING Type Keihin FCR MX 39 Keihin FCR...

Page 53: ...0 Nm Hexagon collar screw locking lever M5 Loctite 243 6 Nm Hexagon collar screw shift roller M5 Loctite 243 6 Nm Hexagon collar screw securing guide chain guide chain tensioner M6 Loctite 243 8 Nm He...

Page 54: ...Nm M10 50 Nm TIGHTENING TORQUES CHASSIS TECHNICAL DATA CHASSIS 250 450 525 SX MXC EXC RACING 2004 450 525 SX RACING 250 450 525 EXC RACING 450 525 MXC EXC USA Frame Central tube chrome moly steel fra...

Page 55: ...mpression of shock absorber SX 14 Digital speedometer indicator lamps 7 Dismounting and mounting the front wheel 34 Dismounting and mounting the rear wheel 35 Draining the float chamber of the carbure...

Page 56: ...front flasher handle bar switch left front flasher rear brake switch regulator rectifier U rear light brakelight start button generator G 3 ye bl ye bl cooling fan black 10 br ye re br ye re ye re re...

Page 57: ...oil headlight handle bar switch regulator rectifier U rear light brakelight start bottom generator G 3 ye bl light switch cooling fan black 10 wh br ye re ye re br C_AB 9 ye br br bl wh ye bl br bu wh...

Page 58: ...blue green black generator ignition coil throttle position sensor pick up stop button yellow black black brown red blue white I D C red white wiring diagramm SX 450 525 2004 19 05 2003 ANHANG APPENDIC...

Page 59: ...sdigitaltacho Tachimetro digitale multifunzione Pick up Impulsgeber Pick up Position light Standlicht Luce di posizione Rear brake switch hinterer Bremslichtschalter Interruttore luce post di stop Rea...

Page 60: ...dinateur de bord Veloc metro digital multifuncional Pick up Capteur d allumage Generador de impulsos Position light feu de position luz de posicion Rear brake switch Contacteur de frein arri re Interr...

Page 61: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at KTM Group Partner 6 2003 FOTO MITTERBAUER...

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KTM 450 SX 2004, Owner'S Manual

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