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KTM 450 SX-F EU, Repair Manual

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KTM 450 SX-F EU Repair Manual Download Page 234

Summary of Contents for 450 SX-F EU

Page 1: ...450 SX F EU 450 SX F USA Art no 3206118en...

Page 2: ...im 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...

Page 3: ...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 l...

Page 4: ...the ignition pulse generator 166 Checking the spark plug connector 201 Adjusting the ignition pulse generator gap 166 Checking the ignition pulse generator 201 Installing the timing chain rails 166 A...

Page 5: ...TABLE OF CONTENTS 5 WIRING DIAGRAM 220 Page 1 of 2 220 Page 2 of 2 222 SUBSTANCES 224 AUXILIARY SUBSTANCES 226 SPECIAL TOOLS 228 STANDARDS 241 INDEX 242...

Page 6: ...page reference more information is provided on the specified page I Indicates information with more details or tips Indicates the result of a testing step v Denotes a voltage measurement A Denotes a c...

Page 7: ...ts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear Change damaged or worn parts Ensure that the vehicle is safe to operate after completing rep...

Page 8: ...to the front of the steering head The engine number is stamped on the left side of the engine under the engine sprocket The fork part number is stamped on the inner side of the fork stub The shock abs...

Page 9: ...and do not start or run the engine in an enclosed space without an effective exhaust extraction system Nole Engine failure High engine speeds in cold engines have a negative effect on the service life...

Page 10: ...ed space without an effective exhaust extraction system Info I Press the starter for a maximum of 5 seconds Wait for a least 5 seconds before trying again Turn handle of the fuel tap to the ON positio...

Page 11: ...rt 10 clicks Info I Turn clockwise to increase damping turn counterclockwise to reduce damp ing Ad ustinllhl I 8bound dampinl of hI forti Info I The hydraulic rebound damping determines the fork suspe...

Page 12: ...k tubes Over time there is an ingress of dirt inside the boots If this dirt is not removed it may cause the oil seals to leak Warning 12 Danger 01 accidents Reduced braking efficiency due to oil or gr...

Page 13: ...with the lift stand or p 9 Remove front wheel or p 83 Main work Remove screws and take off clamp Remove screws and take off brake caliper Hang the brake caliper and the brake line loosely to the side...

Page 14: ...Remove the fork legs p 13 Main work Loctile 243 Remove screws on the left fork leg Remove the fork protector upwards Remove the screws on the right fork leg Remove the fork protector upwards Main wor...

Page 15: ...Assemble the screw sleeve p 29 Assemble the screw cap with the membrane holder p 29 Assemble the piston rod p 30 Assemble the cartridge p 31 Assemble the fork legs p 33 I The steps are identical for...

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Page 17: ...e fork leg Remove the preload spacers and spring Remove dust boot Remove fork protector ri ng Info I The fork protector ring does not necessarily need to be disassembled for the further repair Remove...

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Page 21: ...ap rebound Remove the O rings 200862 10 Disassamblin tIIa screw cap with tIIa mambrana holdar Info I The steps are identical for both fork legs Preliminary work Disassemble the fork legs p 15 Disassem...

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Page 23: ...ure the outside diameter of the inner tube at several locations Outside diameter of the inner tube 47 975 48 005 mm 1 88878 1 88996 in If the measured value is less than the specified value Change the...

Page 24: ...of the check valve 1O 5 8 mm O 0 228 in If the measured value is less than the specified value Change the spring Check the piston rod for damage If there is damage Replace the piston rod Measure the o...

Page 25: ...value is greater than the specified value Change the outer tube Check the outer tube for damage If there is damage Change the outer tube Check the surface of the sliding bushing 25 If the bronze color...

Page 26: ...685 10 Condition The fork legs have been disassembled Check the inner tube and axle clamp for damage If there is damage Change the inner tube Measure the outside diameter of the inner tube at several...

Page 27: ...alue Increase the thickness of the preload spacers Cbeckin the fork 1m durin a minor fork service 450 SX F USA 20072IHO 200685 10 Condition The fork legs have been disassembled Check the inner tube an...

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Page 29: ...nted when the piston rod is assembled 20086 11 Assembllnl tile screw caP with the membrane holder Inlo I The steps are identical for both fork legs Preliminary work Check the fork legs p 23 Main work...

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Page 31: ...l SAE 5 or p 224 Mount rebou nd piston Guideline View View Mount rebound shim stack Info Rebound piston from above Rebound piston from below I Align triangular shims precisely with the opening of the...

Page 32: ...side forward Place the special tool onto the piston rod IMounting sleeve Tl4029 p 239 Grease seal ring and slide onto the piston rod with the open side forward Remove the special tool ILubricant T511...

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Page 34: ...239 Press the outer tube all the way in Position the support ring Hold the seal ring with the shorter shoulder of the special tool IAssembly tool Tl402S p 239 Press the outer tube all the way in Mount...

Page 35: ...line Rebound adjuster on the piston rod M12x1 Press the cartridge against the spring and remove special tool Tighten the rebound adjuster Guideline Rebound adjuster on the axle clamp M20xl Clamp in th...

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Page 37: ...outer tube Warm up the outer tube in area of the lower sliding bushing Guideline 150 C 122 OF Hold the lower sliding bushing with the longer shoulder of the special tool 1 Assembly tool T1402S or p 2...

Page 38: ...s it must be held to keep it from turning X If the rebound adjuster is not turned all the way to the stoP the rebound damping cannot be correctly adjusted Hold onto nut and tighten the rebound adjuste...

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Page 40: ...acuum Activate OnIDlI switch The suction process begins Pressure gauge drops to the required value 1 0 bar Vacuum gauge drops to the required value 110 mbar When the vacuum gauge reaches the required...

Page 41: ...gulator of the nitrogen bottle Nitrogen charging tool Tl4019 p 238 Filling gas nitrogen Adiust the pressure regulator of the nitrogen bottle Guideline 1 Gas pressure 11 2 bar 17 psi Pierce the membran...

Page 42: ...the motorcycle and its attachments against damage by covering them Do not bend the cables and lines Remove O ring Remove protective ring Take out the lower triple clamp with the steering stem Remove t...

Page 43: ...g head Mount and tighten screw Guideline Screw top steering stem Fully tighten screws Guideline Screw top triple clamp M8 1M20x1 5 M8 17 Nm 12 5 Ibf It Position the brake caliper Mount and tighten scr...

Page 44: ...able in the steering head bearing If there is noticeable play present Adjust play of the steering head bearing p 44 Move the handlebar to and fro over the entire steering range The handlebar must be a...

Page 45: ...four different positions In this way the handlebar can be mounted in the position that is most comfortable for the rider Danier of accidents Handlebar breakage If the handlebar is bent or straightene...

Page 46: ...d above the tank bearing If the throttle cable is not routed as specified Correct the throttle cable routing Subsequent work Install the fuel tank r p 80l Mount the seat r p 79 Check the throttle grip...

Page 47: ...as far as possible Loosen nut Turn adjusting screw so that there is play in the throttle cable at the throttle grip Guideline 1 Play in throttle cable 13 5 mm 0 12 0 2 in Tighten nut Press and hold th...

Page 48: ...for cracking and deformation If the frame exhibits cracking or deformation due to a mechanical impact Change the frame Info I A frame that has been damaged due to a mechanical impact must always be c...

Page 49: ...0 SX F USA Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Info 49 I Turn clockwise to increase damping turn counterclockwise to reduce damp ing Ad ustinllhe low s eed cam illl of the shack absartJ...

Page 50: ...Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping 450 SX F EU Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping 4...

Page 51: ...in a normal sitting position feet on footrests and bounces up and down a few times I The rear wheel suspension levels out Another person now measures the distance between the rear axle and a fixed poi...

Page 52: ...the main silencer p 73 M5 5 Nm 3 7 Ibf ft M5 5 Nm 3 7 Ibf ft Remove the motorcycle from the lift stand p 9 Preliminary work Raise the motorcycle with the lift stand p 9 Remove the main silencer p 73...

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Page 54: ...er to angle lever Mount and tighten screw Guideline Screw bottom shock absorber Subsequent work MlO Install the main silencer p 73 I M14x1 5 60 Nm 44 3 Ibf It Remove the motorcycle from the lift stand...

Page 55: ...If there is damage or wear Change the shalt seal rings Check dimension 154 91 55 00 mm 2 1618 2 1654 in If dimension is less than the specified value Add the corresponding spacing washers Position the...

Page 56: ...ogen Adhere to the description provided 6J a O OJ OJ OJ o RllmDYinl thll rinl I 0 C e OJ e O e 201457 01 Condition The shock absorber has been removed Remove the spring p 56 Disassemble the damper p 5...

Page 57: ...ve the spring p 56 Main work Note down the current state of rebound damping and compression damping Completely open the adjusters of the rebound and compression damping Remove rubber cap of the reserv...

Page 58: ...od Remove adjusting ring with the intermediate washer Drain the oil Remove compression adjuster Remove the spring and piston Disassamblin tIIa p iston rod Preliminary work Remove the spring r p 56 Dis...

Page 59: ...n Remove compression shim stack Info I Place the compression shim stack onto a screwdriver and set it down as a unit Remove rebound washer Remove seal ring retainer Remove locking cap and rubber buffe...

Page 60: ...tool IPress drift Tl504 p 240 Position the pilot bushing in the seal ring retainer using the special tool IPress drift Tl504 p 240 Support seal ring retainer with sleeve of the special tool Press the...

Page 61: ...iameter of the piston rod Piston rod Diameter I2 17 95 mm 2 0 7067 in If the measured value is less than the specified value Change the piston rod Measure the run lut of the piston rod IPiston rod Run...

Page 62: ...ock ring Place special tool underneath and press out heim joint with special tool IPressing tool Tl2078 p 236 Position the new heim joint and the special tool IPressing tool Tl206 p 236 Press the heim...

Page 63: ...or p 236 J Lubricate the sealing lip of the dust boot ILubricant T625 or p 227 20140 HO Mount washer 49 Position washer on seal ring I e 20140 HO Grease seal ring and mount with the washer facing dow...

Page 64: ...r p 236 Grease the dust boot and push seal ring retainer onto the piston rod ILubricant T625 r p 227 Remove the special tool Mount rebound washer with the cut out facing downward Mount the compression...

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Page 66: ...ck Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Compression damping low speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Turn adjusti...

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Page 68: ...turn the Damper control lever to Vacuum Guideline 13 bar The pressure gauge drops to the specified value lObar 68 When the pressure gauge reaches the specified value turn the Oil reservoir con trol l...

Page 69: ...sitioned at exactly this point when the rod is fully extended otherwise damage will occur during compression of the shock absorber Remove the special tool Remove adapter from connection of the vacuum...

Page 70: ...tin 165 lb Weight of rider 75 85 kg 165 57 Ntmm 325 Ibtin 187 lb Weight of rider 85 95 kg 187 60 Ntmm 343 Ibtin 209 lb Mount intermediate washer and spring retainer Mount ring Alternative 1 Tension th...

Page 71: ...ng retainer Mount ring Alternative 1 Tension the spring to the prescribed amount by turning the adjusting ring Guideline 1Spring preload 112 mm 0 47 in 1Hook wrench Tl06S r p 235 Alternative 2 Warning...

Page 72: ...w shock absorber adjusting ring 1 M5 Check the swingarm for damage cracking and deformation 15 Nm 3 7 Ibf ft If the swingarm shows signs of damage cracking or deformation Change the swingarm Info I A...

Page 73: ...g screws chassis Reconnect spring Chanlinl the IIlss fiber 1m fillinl of the main silencer Warning Danger 01 burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system...

Page 74: ...r yarn filling from the inner tube tt Clean the parts that are to be reinstalled Mount the new glass fiber yarn filling on the inner tube Slide the outer tube over the glass fiber yarn filling Insert...

Page 75: ...engine and result in increased wear Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated i...

Page 76: ...ces attack the foam Preliminary work Remove the air filter box lid p 75 Remove the air filter p 75 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly IAir...

Page 77: ...ER 77 Main work Position the carburetor connection boot and hang it into the filter wall Position the hose clip and tighten it Subsequent work Install the air filter or p 75 Install the air filter box...

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Page 79: ...arning Danier of poisonini Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immedi ately with wat...

Page 80: ...hale fuel vapors If fuel gets into your eyes rinse imme diately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doctor immediate...

Page 81: ...f the fuel tank Using tap handle on the fuel tap you can open or close the supply of fuel to the carburetor Possible states Fuel supply closed OFF No fuel can flow from the tank to the carburetor Fuel...

Page 82: ...Nm 7 4 Ibf It I Info I Make sure the holding lugs engage in the start number plate Removina tile start number plate Remove screw and take off the clamp Remove screw Take off the start number plate Pos...

Page 83: ...e front wheel out of the fork Info I Do not operate the hand brake lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged Remove spacers Dang...

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Page 85: ...n in objects and other damage If you find cuts foreign bodies or other damage on a tire Change the tire Check the depth of the tread Info I Note local national regulations concerning the minimum tread...

Page 86: ...ort time If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle Tap each spoke with a screwdriver Info I The sound frequency...

Page 87: ...wheel withdraw the wheel spindle Take the rear wheel out of the swingarm Info I Do not operate the foot brake when the rear wheel is removed Always lay the wheel down in such a way that the brake dis...

Page 88: ...ed by 180 Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Subsequent work Remove the motorcycle from the lift stand eo...

Page 89: ...cidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bear ings in transmission and rear whe...

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Page 91: ...with or below the chain sliding piece Change the chain sliding piece Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the chain sliding piece Guideline S...

Page 92: ...g efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warnin Environmental hazard Hazardous substance...

Page 93: ...se is located in the starter relay Replace a faulty fuse by an equivalent fuse only Replace the protective cover Mount the starter relay on the holder Install the air filter box lid p 75 Warning Risk...

Page 94: ...ents that are harmful to the environment Do not discard batteries with the household trash Dispose of a defective battery in an environmentally compatible manner Give the battery to your KTM dealer or...

Page 95: ...letely charged Preliminary work Remove the seat r p 78 Main work Start the motorcycle for checking r p 10 Measure the voltage between the specified points Measuring point Plus Measuring point Ground I...

Page 96: ...Main work Disconnect the negative cable from the battery Pull the starter relay off of the holder Pull off connector Disconnect cables and on the starter relay Connect the starter relay to a 12 V pow...

Page 97: ...to the service schedule Warning Danger 01 accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake clea...

Page 98: ...ns pull out the pin and remove the brake linings Clean the brake caliper and brake caliper support Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated...

Page 99: ...increase the distance between the hand brake lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar The range of adj...

Page 100: ...id It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clea...

Page 101: ...aw out the old brake fluid During suction always ensure that the brake fluid reservoir is filled with a suffi cient amount of new brake fluid Tighten the bleeder screw Remove the suction device and mo...

Page 102: ...se DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid is corros...

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Page 104: ...uid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Warning Skin irritation Brake fluid can caus...

Page 105: ...s silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake...

Page 106: ...73 Main work Disconnect negative cable of the battery Loosen hose clip Remove screw Loosen screw Repeat these steps on the opposite side Remove the cable binder of the frame protector on the right Sw...

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Page 111: ...n work Position the engine in the frame Mount screws but do not tighten yet Guideline Engine attachment bolt M10 60 Nm 44 3 Ibf tt Position engine braces Mount the fitting but do not tighten yet Guide...

Page 112: ...et with the collar facing the engine Mount screw but do not tighten yet Guideline Screw engine sprocket MlO Mount the chain Connect the chain links with connecting link Tighten screw Guideline Screw e...

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Page 117: ...nt the engine on the special tool Info I Use a helper or motorized hoist Remove screw Take off the shift lever Remove oil drain plug with the magnet Loosen screw plug by striking it lightly with a ham...

Page 118: ...00 p 228 RemDYinl lIIe artl plUI Remove the spark plug using special tool ISpark plug wrench 77329072000 p 234 RamDYinl ilia valva covar Remove screws Remove the valve cover with the valve cover seal...

Page 119: ...tor cover gasket RemDYinl tile ta llue limiter and starter idler r Remove torque limiter Remove starter idler gear Posilioninllha anlina at il ition lOp dud cantar TDe Remove screw Turn the crankshaft...

Page 120: ...be of assistant when the camshafts are assembled Mount special tool IEngine blocking screw 77329010000 p 232 RemDYina tile camshaft Remove screws Take off the camshaft bearing bridge Info I Ensure tha...

Page 121: ...ble wheel Remove screws Take off the retaining bracket Screw a fitting screw into spindle Hold the double wheel and remove spindle Take the timing chain off the double wheel Remove the double wheel wi...

Page 122: ...der head Remove centering pins and cylinder head gasket Remove screws Take off the water pump cover Remove the gasket Remove screw Info I If work is to be performed on the water pump unscrew the nut o...

Page 123: ...ut Remove the piston pin retainer Remove the piston pin Take off the cylinder and piston Push the piston upward out of the cylinder Info I If no further work is to be performed on the cylinder and pis...

Page 124: ...ake off the retaining bracket Pull the cable support sleeve from the engine case Remove screws Take off the ignition pulse generator with the holder Remove screw Insert special tool into the crankshaf...

Page 125: ...needle bearing Remove nut with Ihe special 1001 ISpecial socket 36 mm h drive 77329021000 r p 233 Take off drive wheel of the balancer gear Remove screws Take off oil pump housing Info I Ensure that t...

Page 126: ...e clutch pack Remove the special tool IEngine blocking screw 77329010000 p 232 Bend open lock washer Hold the inner clutch hub with special tool and remove nut with the lock washer IClutch holder 7732...

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Page 128: ...ove pin Remove suction pump with the needle roller and oil pump shaft Push sliding plate away from the shift drum locating unit Remove shift shaft with the washer Remove screw Push away locking lever...

Page 129: ...nto the crankshaft IProtection cover 75029090000 p 231 Mount special tool with the appropriate screws IExtractor 75029048000 p 231 Info I Use the drill hole marked with 773 Take off the section of the...

Page 130: ...Remove sh ift drum Remove sh ift forks Info I Do not misplace shift rollers Secure the engine in an upright position Remove lock ring Pull out both transmission shafts together from the bearing seats...

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Page 132: ...o I Any bearings still remaining in the section of the engine case must be removed with a suitable tool Insert the new cold bearings in the bearing seats of the heated section of the engine case if ne...

Page 133: ...M5 for piston cooling M4 Position all bearing retainers Mount and tighten screws Guideline Locking screw for bearing M5 Mount and tighlen oil suction pipe Guideline Oil suction pipe M14x1 6 Nm 4 4 Ibf...

Page 134: ...nKinK the shaft seal rinK of the water lIump 30124 10 301245 10 301245 11 30124 10 Remove shaft seal ring Remove shaft seal ring Press in shaft seal ring all the way with the open side facing inward D...

Page 135: ...IMounting sleeve 58529005000 or p 229 Press balancer gear into the clutch cover Position the retaining bracket Mount and tighten screws Guideline Locking screw for bearing M5 Align marking with speci...

Page 136: ...ned Lubricate the sealing lips ILong life grease or p 226 Blowout the oil channel with compressed air and check that it is clear RemDYinlllle stator Condition The alternator cover has been removed Rem...

Page 137: ...e regulator valve or p 137 Main work Measure the spring length of the oil pressure regulator valve Oil pressure regulator valve Minimum length of pressure spring 38 5 mm 1 516 in If the measured value...

Page 138: ...hange the oil pump housing oil pressure regulator valve and if necessary the engine case Check the oil pump cover for damage and wear If there is damage or wear Change the oil pump cover RemDYinl tile...

Page 139: ...nl and crank pin Main work Position the crankshaft in the press with the special tool 1Extrude plate base 77629009001 p 234 Position the special tool between the crank webs 1Extrude plate top 77629009...

Page 140: ...t out of the special tool and check that the connecting rod can move freely Measure the end play between the connecting rod and the crank webs with the spe cial tool IFeeler gauge 59029041100 p 230 Co...

Page 141: ...sating disks equally on both sides Info I If the end play is too small compensating disks must be removed If the end play is too large compensating disks must be added Install the crankshaft bearing i...

Page 142: ...on ring exhibits excessive resistance Clean the piston ring groove Tip I An old piston ring can be used to clean the piston ring groove Check the piston rings for damage If the piston ring is damaged...

Page 143: ...he piston ring in the cylinder and align with the piston Guideline 1Below the upper edge of the cylinder 110 mm 0 39 in Measure the end gap with feeler gauge Guideline Piston ring end gap Compression...

Page 144: ...d with engine oil 144 If the surface of the cams is damaged check the oil supply to the camshaft and cam lever Measure the cams of the camshaft Camshaft cam height Exhaust Camshaft cam height Intake 3...

Page 145: ...ts Check the camshaft bearing bridges for damage If there is damage or wear Change the cylinder head with the camshaft bearing bridge Fold up the cam levers Take shims out of the valve spring retainer...

Page 146: ...Valve run lut At the valve plate 0 05 mm 0 002 in If the measured value does not meet specifications Change the valve Check sealing seat on the valve Valve sealing seat width Intake 1 50 mm 0 0591 in...

Page 147: ...Limit plug gauge 59029026006 p 230 If the special tool is easy to insert into the valve guide Change the valve guide and valve Check the sealing area of the spark plug thread and the valve seals from...

Page 148: ...lever 77329060000 or p 234 Mount valve keys Info I When mounting the valve keys ensure that they are seated properly it is recommended to adhere the valve keys to the valves with a small amount of gre...

Page 149: ...k the locking action of starter gear If the freewheel gear does not turn clockwise or if it does not lock counterclock wise Remove the freewheel p 149 Turn the freewheel 180 Install the free wheel p 1...

Page 150: ...r If there is damage or wear Change the freewheel gear or bearing Check free wheel for damage and wear when it is disassembled If there is damage or wear Change the free wheel Checking the gear mesh o...

Page 151: ...chain guide rail Check camshaft gears for damage and wear If there is damage or wear Change the camshaft gears Check timing chain for damage and wear If there is damage or wear Replace the timing cha...

Page 152: ...can no longer be squeezed together This function is necessary in order to ensure sufficient timing chain tension even at low oil pressures 8 301246 01 Check the pressure piece for damage and wear If...

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Page 154: ...n surface on the sliding plate for wear If there is severe grooving Change the sliding plate Check guide bolts for firm seating and wear If the guide bolts are loose or worn Change the sliding plate P...

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Page 159: ...fts into the bearing seats Info I Do not misplace the washers Mount lock ring Shift fork has a smaller inside diameter mount this in the shift groove of the main shaft Mount shift fork in the lower sh...

Page 160: ...gine case ILoctite 5910 Mount the left section of the engine case If necessary strike it lightly with a rUD ber mallet and turn the transmission shafls Info I Do not use the screws to pull the two sec...

Page 161: ...drum locating M6 10 Nm 7 4lbfft Slide shift shaft with the washer into the bearing seat Lactile 243111 Push sliding plate away from the shift drum locating unit Insert the shift shaft all the way Let...

Page 162: ...ensure that it can move easily Mount the needle roller Insert suction pump Grease the shaft seal ring before mounting Position the O ring Mount spacer with the bevel facing inward Mount oil pump housi...

Page 163: ...e that it can move easily Position the drive wheel of balancer shaft Position primary gear Mount nut but do not tighten yet Guideline Nut primary gear M27xl 80 Nm 59 Ibf ft Mount collar bushing and ne...

Page 164: ...4 80 Nm 59 Ibf It LOclil 243111 Beginning with an intermediate clutch disc alternately insert all other clutch fac ing discs and intermediate clutch discs into the outer clutch hub Insert pressure pie...

Page 165: ...balancer gear with stop disk and needle bearings into the timing chain shaft Align markings and to each other Mount spindle with the a ring Position the retaining bracket Mount and tighten screws Gui...

Page 166: ...the gap between the ignition pulse generator and the conductive element of the rotor using special tool Guideline IIgnition pulse generator rotor gap I0 70 mm 0 0276 in IFeeler gauge 59029041100 r p...

Page 167: ...ly and lie flush with the cylinder Carefully tap the piston into the cylinder using the handle of the hammer The piston rings should not catch or they will be damaged Mount a rings Mount locating pins...

Page 168: ...chain taut Carefully push the cylinder downward letting the locating pins engage Insert quad ring Mount O ring Position the dowel pins Ensure that the crankshaft has been locked in the TDC position De...

Page 169: ...Mount screw and tighten all screws in a crisscross pattern Guideline IScrew water pump cover Mount centering pins Position cylinder head gasket Put the cylinder head in place 14 Nm 10 3 Ibf It 110 Nm...

Page 170: ...amshaft bearing retaining bracket M5 6Nm 4 4 Ibf ftl Loctit 243111 Position timing chain tensioner and insert it with new O ring Mount and tighten screw plug with the seal ring Guideline Plug timing c...

Page 171: ...act Take off the special tool Remove the camshafts Force the camshaft gears off the camshafts Adjust the valve timing p 171 Position the camshaft bearing bridges Info I Ensure that the needle rollers...

Page 172: ...Mount and tighten the screws Guideline Screw camshaft bearing bridge Remove special tool M7x1 14 Nm 10 3 Ibf It Lubricated with engine oil IEngine blocking screw 77329010000 p 232 Crank over the engi...

Page 173: ...e play Insert the fitting shims Position the camshaft bearing bridges Info I Ensure that the needle rollers and the O ring are correctly seated Mount screws and tighten from the inside to the outside...

Page 174: ...en screws Guideline IScrew starter motor 110 Nm 7 4 Ibf It I 110 Nm 7 4 Ibf It I Position the valve cover with the gasket Mount and tighten screws Guideline IScrew valve cover Mount and tighten the sp...

Page 175: ...ngine oil and place it in the oil filter container Oil the O ring of the oil filter cover Mount oil filter cover Mount and tighten screws Guideline IScrew oil filter cover 16 Nm 4 4 Ibf It Position th...

Page 176: ...ke function deactivated The choke lever is pushed in to the stop Preliminary work Remove the seat r p 78 Remove the fuel tank p 79 Remove the air filter box lid p 75 Remove the air filter p 75 Remove...

Page 177: ...arburetor vent hoses Attach the connector of throttle position sensor Mount cable binder Position and tighten hose clip Connect the cables Check the throttle cable routing p 46 Move the handlebar to t...

Page 178: ...0 Mount the seat p 79 Check the play in the throttle cable p 46 Disassamblinl tIIa carburetor Condition The carburetor has been removed Remove screws and detach all vent hoses from the carburetor Remo...

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Page 181: ...od overhang does not meet specifications Correct the piston rod overhang by turning adjusting screw Condition The choke slide has been removed Check the choke slide for smooth operation If the choke s...

Page 182: ...10 wear If the coating is damaged or worn Change the throttle slide Check the membrane of the throttle slide plate for damage brittleness and cor rect seating If the membrane is damaged or brittle Cha...

Page 183: ...e float needle valve is not pushed together If the edge of the float is not parallel to the sealing area of the float housing in this position Adjust the float level by bending float lever Cb8ckinll d...

Page 184: ...the thrDllle osition sensor Info I The value in the figure is an example only 1 y_ n t l1li 700064 10 Condition The carburetor has been removed Component temperature 20 C 68 F Preliminary work Check...

Page 185: ...clutch hub engages in the recess of the throttle position sensor Position the hose connection Mount and tighten screw Guideline Screw hose connection M4 2 Nm 1 5 Ibf ft Info Loctile 243 I The hose con...

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Page 188: ...The choke lever is pushed into the stop p 176 Idle speed I1 550 1 650 rpm Info I Following extreme air temperature or altitude changes adjust the idle speed again Never refuel the vehicle near open f...

Page 189: ...de the hose coming down behind the engine into a suitable container Info I Water in the float chamber results in malfunctioning Undo screw turn it counterclockwise a few turns and drain the fuel from...

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Page 191: ...ants Keep coolant out of the reach of children 400243 10 Chackinllha coolint lavel Warning Condition Engine is cold Stand the motorcycle upright on a horizontal surface Remove radiator cap Check the a...

Page 192: ...ted skin areas immediately with soap and water II coolant is swallowed contact a doctor immedi ately Change clothes that have come into contact with coolants Keep coolant out 01 the reach 01 children...

Page 193: ...35IWATER PUMP COOLING SYSTEM Refit the radiator cap Subsequent work Take a test ride Check the coolant level p 191 193...

Page 194: ...ing lubrication 8 Oil jet for oil supply clutch 9 Oil channel cam lever bearing 10 Oil jet for cam lever lubrication 11 Oil channel camshaft bearing Oil Circuit suction pump 12 Suction pump for evacua...

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Page 196: ...oil IiIter cover Mount and tighten the screws Guideline IScrew oil filter cover 16 Nm 4 4 Ibl It Stand the motorcycle upright Remove the oil liller plug on the clutch cover and fill up with engine oi...

Page 197: ...sure adapter I MlOxl 110 Nm 7 4 Ibf ft I IOil pressure adapter 77329006000 p 232 Connect pressure tester to the special tool without the t plate IPressure testing tool 61029094000 p 231 Danger t J Dan...

Page 198: ...38JLUBRICATION SYSTEM 198 Remove the special tools Mount and tighten the screw for unlocking the timing chain tensioner Guideline Screw unlocking of timing chain ten M1Ox1 10 Nm 7 4 Ibf It sioner...

Page 199: ...utton Info I Do not open the throttle Check the ignition spark If no ignition spark is visible Check the kill switch Check the ground connection of the CDI controller and ignition coil Check the cable...

Page 200: ...When using the peak voltage adapter set the measurement range of the multimeter to DCV Start the motorcycle for checking p 10 Ignition coil cylinder 1 check the primary winding voltage Measure the vol...

Page 201: ...20 n If the specification is not reached Replace the ignition pulse generator 400585 10 AT 400585 10 Measure the resistance between the specified points Ignition pulse generator connector AT pin 1 Mea...

Page 202: ...pecified points Q Alternator connector CR pin 1 Yellow Measuring point Ground IResistance loon If the displayed value does not equal the setpoint value Replace the stator Ramovinl ilia stator 301237 1...

Page 203: ...or has been removed Connect the negative cable of a 12 volt power supply to the housing of the starter motor Connect the positive cable of the power supply briefly to connector of the starter motor If...

Page 204: ...Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with 3 rotor pumps Primary transmission 29 74 Clutch Multidisc clutch...

Page 205: ...0 mm 3 81775 3 8181 in Cylinder drill hole diameter Size I 97 000 97 012 mm 3 81889 3 81936 in Size II 97 013 97 025 mm 3 8194 3 81987 in Piston cylinder mounting clearance Size I 0 030 0 052 mm 0 001...

Page 206: ...M6 6 Nm 4 4 Ibf It Loctite 243 Screw alternator cover M6 10 Nm 7 4 Ibf It Screw clutch cover M6 10 Nm 7 4 Ibf It Screw clutch slave cylinder M6 10 Nm 7 4 Ibf It Screw clutch spring M6 10 Nm 7 4 Ibf It...

Page 207: ...clutch cover M12x1 5 20 Nm 14 B Ibf tt LoClile 243 Axle timing chain guide rail M14xl 15 Nm 11 1 Ibf tt Axle timing chain tensioning rail M14xl 15 Nm 11 1 Ibf tt Nut compensating sprocket M14xl 20 Nm...

Page 208: ...tion number 4125M Needle position 4th position from top Idle mixture adjusting screw Open 1 5 turns Pump membrane stop 2 15 mm 0 0846 in Hot start button Diameter of bore in carburetor body 2 5 mm 0 0...

Page 209: ...ottle slide arm M4 2 Nm 1 5 Ibf It Lactite 243 Idle air jet M4 5xO 75 2 Nm 1 5 Ibf It Screw throttle position sensor M5 3 5 Nm 2 58 Ibf It Cold start jet M5xO 75 2 Nm 1 5 Ibf It Main jet M5xO 75 2 Nm...

Page 210: ...15 psi Rear 1 0 bar 15 pSi Final drive 14 52 Chain 5 8 x 114 Rear sprockets available 38 40 42 45 48 49 50 51 52 Steering head angle 63 5 Wheelbase 1 495 10 mm 58 86 0 39 in Seat height unloaded 985...

Page 211: ...TECHNICAL DATA CHASSIS CIp C tY tull Total fuel tank capacity approx 7 5 I 1 98 US gal 211 Super unleaded ROl 95 RON 95 PON 91 p 225...

Page 212: ...y per cartridge 195 ml 6 59 fl oz Fork oil SAE 5 r p 224 Oil capacity lork leg without 390 ml 13 19 II oz Fork oil SAE 5 r p 224 cartridge 450 SX F USA I Fork part number 14 18 7K 57 Fork WP Suspensio...

Page 213: ...re 10 bar 145 psi Static sag 30 mm 1 18 in Riding sag 90 mm 3 54 in Fitted length 490 mm 19 29 in IShock absorber all IShock absorber all SAE 2 5 50180342S1 r p 225 450 SX F USA I Shock absorber part...

Page 214: ...TECHNICAL DATA SHOCK ABSORBER 214 IFitted length I486 mm 19 13 in IShock absorber oiI IShock absorber oil SAE 2 5 50180342S1 p 225...

Page 215: ...ew front brake caliper MB 25 Nm 1B 4 Ibf It Loctite 243 Screw handlebar clamp MB 20 Nm 14 B Ibf It Screw side stand fixing MB 40 Nm 29 5 Ibf It Loctite 2701 Screw subframe MB 35 Nm 25 B Ibf It Loctite...

Page 216: ...r p 227 Inlo I Clean the vehicle with warm water containing normal motorcycle cleaner and a soft sponge After rinsing the motorcycle with a gentle water spray allow it to dry thoroughly Empty the carb...

Page 217: ...401059 01 Clean the motorcycle r p 216 Change the engine oil and oil filter clean the oil screen r p 195 Check the anti freeze and coolant level r p 191 Drain the fuel from the tanks into a suitable c...

Page 218: ...h p 190 Check the brake fluid level of the front brake p 99 Check the free travel on the hand brake lever p 99 Check the steering head bearing play p 44 Check the valve clearance Check the clutch Chec...

Page 219: ...ck the camshaft and cam lever Change the connecting rod conrod bearing and crank pin Change the crankshaft bearing Check the transmission and shift mechanism Change the outer clutch hub Check the oil...

Page 220: ......

Page 221: ...WIRING DIAGRAM 221 Components A15 CDI controlier GI0 Battery G20 Alternator KI0 Starter relay with main fuse MlO Starter motor T20 Voltage regulator 521 Electric starter button...

Page 222: ......

Page 223: ...ircuit A B37 Crankshaft position sensor R51 Ignition coil cylinder 1 S20 KiII switch X280 Connector ignition timing map X281 Connector ignition timing map Cable colors bl Black br Brown bu Blue gn Gre...

Page 224: ...arex COOLANT G48 Enline oil SAE 10WI5O According Ia JASO T903 MA r p 241 SAE r p 241 SAE lOW 50 Guideline I 40 C 40 OF Use only engine oils that comply with the specified standards see specifications...

Page 225: ...possess the corresponding properties SUlllr unleaded ROZ 95 RON 95 P0N 91 Accordinl to DIN EN 228 RDZ 95 RDN 95 PDN 91 Guideline Dnly use unleaded super fuel that matches or is equivalent to the spec...

Page 226: ...n Cle n Clnnlnllnd pl llllrvlni matlrilis far mllll rubblr and plastic Guideline KTM recommends Matorex products Supplier MOlDrex Pratect Shine HIIII1 viscOlilJ 8 Guideline KTM recommends sKI products...

Page 227: ...M recommends Moto products Supplier Molar Moto Clean 900 OIl road chain Guideline KTM recommends Motorex products Supplilr Molar Chainlube Offroad 011 lor 101m Ilr IlIlIr Guideline KTM recommends Moto...

Page 228: ...OLS 228 Sprlnl hDDks Art no 50305017000 400363 01 Art no 50329050000 400058 01 Circlip pliers reverse Art no 51012011000 400059 01 Lift stand Art no 54829055000 500071 01 Extractor Art no 58012009000...

Page 229: ...no 58429037037 400082 01 Peak voltan adalll r Art no 58429042000 400083 01 To ue wrench with various accessories in set Art no 58429094000 2009 0 rMountinl Sl8ev8 I Art no 58529005000 400095 01 Valve...

Page 230: ......

Page 231: ...tool I Art no 61029094000 400149 01 Enlln mbIJ ItInd Art no 61229001000 200306 01 dmcI far cranksh complltl Art no 75029047000 400185 01 Extractor Art no 75029048000 o 0 o 0 o 0 400162 01 PlDleCtIon c...

Page 232: ...PECIAL TOOLS 232 Art no 77329002000 Clutch holder Art no 77329003000 3014811 10 Dilliressure ada r Art no 77329006000 400176 01 Art no 77329010000 400177 01 AssemblyJ n J Art no 77329012100 p 400178 0...

Page 233: ...021000 301703 01 Insert for piston pin retainer Art no 77329030100 400160 01 Ad USlmant tool for mixture control scraw Art no 77329034000 Ad USlment bush bridll Art no 77329050000 301381 10 Ralaasa da...

Page 234: ...lliner J Art no 77329060000 ____ 4 O Ol 29 1 ______________ Sp rk plUI wranch Art no 77329072000 400170 01 Prusl l tool crankshaft J R Art no 77629008000 I 400185 01 Art no 77629009001 400187 01 Extr...

Page 235: ...SPECIAL TOOLS 235 Gur quadrant Art no 80029004000 50016W1 Pin wrench J Art no Tl03 a 200734 10 Hook wrench Art no Tl06S 301085 01 DaJ micramlltar J Art no Tl07S i 300577 10 Pin Art no Tl20 20123s 10...

Page 236: ...L TOOLS 236 Mauiitlnl sllIYI Art no Tl204 200788 10 Calibratian_p in J Art no Tl205 20079 10 Pressinl taal Art no Tl206 200583 10 Prassinl taal Art no Tl207S 200585 01 Mauntinl sleeve Art no Tl215 300...

Page 237: ...ECIAL TOOLS 237 Disassembly tool Art no Tl216 200816 10 Vacuum um Art no Tl240S Pratectinl sleeve Art no Tl401 200635 10 Claml inl stand Art no Tl40l6S 200688 10 L Rinl wrench J Art no Tl4017 200819 1...

Page 238: ...SPECIAL TOOLS 238 Art no Tl40l9 200832 10 5u J ort tool Art no Tl4020 200825 10 Calibratinl unit Art no Tl4021 200854 10 Mountinl tool Art no Tl4022 200853 10 Tbreaded bushinl Art no Tl4023 200852 10...

Page 239: ...SPECIAL TOOLS 239 Mauiitlnl sllIYI Art no Tl4029 200855 10 Assemb y taal Art no Tl402S 200634 10 Fillinlldl r Art no Tl4030 20088 10 Tweezers Art no Tl4033 200844 10 Art no Tl403S 200637 10...

Page 240: ...SPECIAL TOOLS 240 Press drift Art no T1504 200789 10 toDI Art no T150S 200791 10 Nitro n filiinl toDI Art no T170S1 300574 10...

Page 241: ...e intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated wit...

Page 242: ...talling 165 torque limiter and starter idler gear installing 173 transmission shafts installing 159 valve clearance adjusting 173 valve clearance checking 172 valve cover installing 174 valve timing a...

Page 243: ...positioning at ignition top dead center 119 removi ng 106 Engine Work an individual parts autodecompressor checking 144 cam levers checking 147 camshaft bearing bridges checking 145 camshaft changing...

Page 244: ...eel installing removing Fuel tank installing 48 82 82 83 83 80 removing 79 Fuel tap 81 Fuel ails etc 7 Fuse H main fuse installing main fuse removing Hand bllke I er 93 93 basic position adjusting 99...

Page 245: ...installing 70 71 spring removing 56 static sag checking 51 Shock Ibsorber linkage checki ng 54 Spire parts 7 Splrk plug connector checki ng 201 Spoke len ion checki ng 86 SlIrt number pllte installing...

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