KTM 450 SX-F, 505 SX-F, 505 XC-F, 450 XC-F User Manual
OWNER'S MANUAL 2008
450 SX-F
505 SX-F
450 XC-F
505 XC-F
ART. NO. 3211227en
Dear KTM customer 1
DearKTM customer
Congratulations on your decision to buy a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give
you enormous pleasure if you service and maintain it accordingly.
We wish you great pleasure riding the vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( 7) Dealer's stamp
Engine number ( 7)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing
development and design of our motorcycles can however not be completely excluded. The owner's manual is an important component
of the motorcycle and should be handed over to the new owner if the vehicle is sold.
All specifications are not binding. KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifications,
prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop prudction of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special
equipment that does not belong to the regular scope of delivery.
© 2007 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes
that lead to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
CONTENTS 2
CONTENTS
MEANS OF REPRESENTATION ............................................ 4
IMPORTANT NOTES............................................................ 5
LOCATION OF SERIAL NUMBERS ........................................ 7
Chassis number............................................................... 7
Type label....................................................................... 7
Engine number................................................................ 7
Fork part number............................................................. 7
Shock absorber part number............................................. 7
OPERATING ELEMENTS...................................................... 8
Clutch lever .................................................................... 8
Hot start lever ................................................................. 8
Hand brake lever ............................................................. 8
Short circuit button ......................................................... 8
Electric starter button ...................................................... 8
Fuel tap (450 SX-F, 505 SX-F)........................................ 9
Fuel tap (450 XC-F, 505 XC-F)......................................... 9
Opening filler cap............................................................ 9
Closing filler cap ........................................................... 10
Choke........................................................................... 10
Shift lever..................................................................... 10
Foot brake pedal ........................................................... 11
Plug-in stand (450 SX-F, 505 SX-F)................................ 11
Side stand (450 XC-F, 505 XC-F) ................................... 11
TIPS AND HINTS ON PUTTING INTO OPERATION............... 12
Advice on first use......................................................... 12
Running in the engine.................................................... 13
RIDING INSTRUCTIONS .................................................... 14
Checks before putting into operation ............................... 14
Starting ........................................................................ 14
Starting up ................................................................... 15
Shifting, riding.............................................................. 15
Braking ........................................................................ 15
Stopping, parking .......................................................... 16
Refueling...................................................................... 16
GREASING AND SERVICE TABLE....................................... 17
Important maintenance work to be carried out by an
authorized KTM workshop. ............................................. 17
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order)................ 18
Important checks and maintenance work to be carried out
by the rider. .................................................................. 18
MAINTENANCE WORK ON CHASSIS AND ENGINE.............. 20
Jacking up the motorcycle.............................................. 20
Removing the motorcycle from the work stand.................. 20
Checking the basic chassis setting with the rider's
weight .......................................................................... 20
Compression damping of shock absorber.......................... 20
Adjusting high-speed compression damping of the shock
absorber ....................................................................... 20
Adjusting the low-speed compression damping of the
shock absorber.............................................................. 21
Adjusting rebound damping of the shock absorber ............ 21
Measuring rear wheel sag unloaded ................................. 22
Checking static sag of the shock absorber ........................ 22
Check the riding sag of the shock absorber. ..................... 23
Adjusting spring preload of the shock absorber
Adjusting riding sag
Removing the shock absorber
Installing shock absorber
Checking basic setting of fork......................................... 25
Adjusting compression damping of fork ........................... 25
Adjusting rebound damping of fork.................................. 25
x.................................................. 24
x..................................... 24
x........................................... 24
x............ 23
Bleeding fork legs.......................................................... 26
Cleaning dust boots of fork legs ...................................... 26
Loosening the fork protection.......................................... 26
Positioning the fork protection ........................................ 27
Checking play of steering head bearing............................ 27
Adjusting play of steering head bearing
Fork offset .................................................................... 28
Setting the fork offset
Removing the fork legs
Installing the fork legs
Removing the fork protector
Installing the fork protector
Removing the lower triple clamp
Installing the lower triple clamp
Greasing the steering head bearing
Dismounting the front fender.......................................... 31
Installing the front fender............................................... 31
Dismount the start number plate..................................... 31
Fitting the start number plate ......................................... 32
Handlebar position ........................................................ 32
Adjusting handlebar position
Checking gas Bowden cable route ................................... 32
Checking play in gas Bowden cable ................................. 33
Adjusting play in gas Bowden cable
Checking chain dirt ....................................................... 33
Cleaning the chain......................................................... 33
Checking the chain tension ............................................ 34
Checking the chain tension - fitting rear wheel ................. 34
Checking rear sprocket / engine sprocket for wear............. 35
Checking chain wear...................................................... 35
Adjusting chain tension.................................................. 35
Adjusting chain tension - after checking .......................... 36
Adjusting chain tension - fitting rear wheel ...................... 37
Adjusting chain guide
Adjusting chain guide
Brake fluid reservoir....................................................... 38
Brake calipers ............................................................... 38
Checking brake discs ..................................................... 38
Checking free play of hand brake lever............................. 39
Adjusting basic position of handbrake lever...................... 39
Checking front brake fluid level....................................... 39
Topping up the front brake fluid
Checking the front brake linings...................................... 40
Removing front brake linings
Mounting front brake linings
Changing the fron brake linings
Checking free play of foot brake lever .............................. 42
Adjusting basic position of footbrake lever
Checking rear brake fluid level........................................ 43
Topping up brake fluid of front brake
Checking rear brake linings ............................................ 44
Removing rear brake linings
Mounting rear brake linings
Changing rear brake linings
Removing front wheel
Fitting front wheel
Removing rear wheel
Fitting rear wheel
Tire condition checking.................................................. 49
Checking tire air pressure............................................... 49
Checking spoke tension.................................................. 50
x ............................................... 28
x.............................................. 28
x............................................... 29
x....................................... 29
x ....................................... 29
x...................................... 32
x (450 SX-F, 505 SX-F)............... 37
x (450 XC-F, 505 XC-F)............... 38
x ..................................... 41
x...................................... 41
x.................................. 42
x....................................... 45
x ....................................... 45
x ....................................... 46
x................................................ 46
x .................................................... 47
x................................................. 48
x...................................................... 48
x....................... 27
x ................................ 30
x................................. 30
x............................. 31
x............................ 33
x................................. 40
x................... 43
x.......................... 44
CONTENTS 3
Removing the battery
Installing the battery
Recharging the battery
Removing a fuse............................................................ 52
Replacing the fuse......................................................... 52
Ignition curve................................................................ 52
Ignition curve plug connection........................................ 52
Changing ignition curve.................................................. 53
Removing the seat......................................................... 53
Mounting the seat ......................................................... 53
Dismounting the fuel tank
Installing the fuel tank
Cooling system.............................................................. 55
Checking antifreeze and coolant level.............................. 55
Checking the coolant level.............................................. 56
Draining coolant
Refilling coolant
Removing main silencer ................................................. 57
Fitting the main silencer ................................................ 57
Glass fiber yarn filling of main silencer ............................ 57
Removing glass fiber yarn filling from the main
silencer
Fitting glass fiber yarn filling in main silencer
Changing glass fiber yarn filling of main silencer
Dismounting the air filter box lid..................................... 59
Installing the air filter box lid.......................................... 59
Removing the air filter
Installing the air filter
Cleaning air filter
Adjusting basic position of clutch lever............................ 60
Checking fluid level of hydraulic clutch ........................... 60
Changing fluid level of hydraulic clutch
Carburetor - idle ............................................................ 61
Carburetor - adjusting idle
Emptying the carburetor float chamber
Checking engine oil level................................................ 63
Changing engine oil and oil filter, cleaning oil screen
Draining the engine oil
Cleaning the oil screen
Removing the oil filter
Mounting oil filter
Filling up with engine oil
Topping up engine oil .................................................... 66
TROUBLESHOOTING......................................................... 67
CLEANING........................................................................ 69
Cleaning motorcycle ...................................................... 69
Storage............................................................................. 70
Storage......................................................................... 70
TECHNICAL DATA - ENGINE.............................................. 71
Capacity- engine oil ....................................................... 72
Capacity- cooling liquid.................................................. 72
TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 73
TECHNICAL DATA - CARBURETOR..................................... 75
TECHNICAL DATA - CHASSIS ............................................ 76
Capacity - fuel............................................................... 76
TECHNICAL DATA - FORK.................................................. 77
CAPACITY - FORK OIL ................................................... 77
TECHNICAL DATA - SHOCK ABSORBER ............................. 78
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ........ 79
WIRING DIAGRAM ............................................................ 80
WIRING DIAGRAM ........................................................ 80
x ................................................................... 58
x................................................ 50
x................................................. 50
x.............................................. 51
x ......................................... 53
x.............................................. 54
x....................................................... 56
x....................................................... 57
x ............. 58
x ......... 59
x............................................... 59
x ............................................... 60
x...................................................... 60
x ...................... 61
x......................................... 62
x ....................... 63
x... 64
x.............................................. 64
x.............................................. 64
x............................................... 65
x..................................................... 65
x........................................... 66
SUBSTANCES................................................................... 82
AUXILIARY SUBSTANCES.................................................. 84
INDEX .............................................................................. 86
MEANS OF REPRESENTATION 4
1MEANSOFREPRESENTATION
Symbols used
The symbols used are explained in the following.
Indicates an expected reaction (e.g. of a work step or a function)
Indicates an unexpected reaction (e.g. of a work step or a function)
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of
your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced
optimally by specially trained experts using the specialist tools required.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained in the following.
Original name Identifies an original name
®
Name
Brand™ Identifies a brand in merchandise traffic
Identifies a protected name
IMPORTANT NOTES 5
2IMPORTANTNOTES
Use definition
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply
with currently valid regulations and categories of the top international motorsport organizations.
Maintenance
A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described
in the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage
of components.
Using the motorcycle in extreme conditions such as very muddy or wet terrain can lead to above-average wear of components such as
the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in
the greasing and service table is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will
ensure a much longer service life for your motorcycle.
Warranty
The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed
in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for
damage resulting from manipulations and alterations to the motorcycle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
Spare parts, accessories
For your own safety, use only spare parts and accessories approved by KTM. KTM accepts no liability for other products and any
resulting damage or loss.
Transport
Note
Danger of damage Danger of damage by the motorcycle running away or falling over.
– Always place the motorcycle on a firm and even surface.
Note
Fire hazard Some components (engine, radiator and exhaust system) get very hot when the engine is running.
– Do not place the motorcycle where there are flammable or explosive substances.
(450 XC-F, 505 XC-F)
– Turn the handle
(450 SX-F, 505 SX-F)
– Turn the handle
– Use straps or other suitable devices to secure the motorcycle against accidents or falling over.
1 of the fuel tap to the ON position. (Figure 400201-10 9)
1 of the fuel tap to the OFF position. (Figure 400200-10 9)
Environment
Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential
problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure
that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle
legally, display environmental consciousness, and respect the rights of others.
Warning notes
In your own interest, read the specified warning notes.
Info
Various warning labels are attached to your motorcycle. Do not remove any warning labels. If they are missing, you or others may
not recognize dangers and may therefore be injured.
IMPORTANT NOTES 6
Grades of risks
Danger
Danger that leads immediately and certainly to severe and permanent injury or death.
Warning
Danger that will probably lead to severe and permanent injury or death.
Note
Danger of serious damage to machine or material.
Warning
Risk of environmental damage.
OWNER'S MANUAL
– Read this owner's manual carefully and completely before making your first trip. It contains a lot of information and tips to help
you operate and handle your motorcycle. Only then will you find out how to customize the motorcycle ideally for your own use and
how you can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.
LOCATION OF SERIAL NUMBERS 7
3LOCATIONOFSERIAL NUMBERS
Chassis number
3.1
The chassis number 1 is stamped on the right side of the steering head tube.
400193-10
3.2Type label
The type label 1 is fixed to the front of the steering head.
3.3Engine number
3.4Fork part number
400284-10
The engine number 1 is stamped on the left side of the engine under the engine
sprocket.
400194-10
The fork part number 1 is stamped on the inner side of the fork stub.
3.5Shock absorber part number
500082-10
The shock absorber part number 1 is stamped on the top of the shock absorber above
the adjusting ring on the engine side.
500083-10
OPERATING ELEMENTS 8
4OPERATINGELEMENTS
Clutch lever
4.1
The clutch lever 1 is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
400195-10
4.2Hot start lever
The hot start lever 1 is fitted on the left of the handlebar.
If you pull the hot start lever to the handlebar during the start procedure, a hole is
opened in the carburetor to allow the engine to draw in extra air. This gives a leaner
fuel-air mixture, which is needed for a hot start.
Possible states
– Hot start lever in basic position
– Hot start lever pulled
4.3Hand brake lever
4.4Short circuit button
400195-12
The hand brake lever 1 is located on the right side of the handlebar and operates the
front wheel brake.
400196-10
The short circuit button 1 is fitted on the left side of the handlebar.
When you press the short circuit button , the ignition circuit is short-circuited, which
stops the engine.
Possible states
– Short circuit button in basic position
– Short circuit button pressed
4.5Electric starter button
400197-10
The electric starter button 1 is fitted on the right side of the handlebar.
Pressing the electric start button operates the electric starter.
Possible states
– Starter button in basic position
– Electric starter button pressed
400198-10
OPERATING ELEMENTS 9
4.6Fuel tap (450 SX-F, 505 SX-F)
With the tap handle 1 on the fuel tap, you can open or close the supply of fuel to the
carburetor.
Possible states
– Fuel supply closed (OFF)
– Fuel supply open (ON)
400200-10
4.7Fuel tap (450 XC-F, 505 XC-F)
4.8Opening filler cap
With the tap handle 1 on the fuel tap, you can open or close the supply of fuel to the
carburetor.
Possible states
– Fuel supply closed (OFF)
– Fuel supply open (ON)
– Reserve fuel supply open (RES)
400201-10
– Press release button 1, turn filler cap counterclockwise and lift it free.
400199-10
OPERATING ELEMENTS 10
4.9Closing filler cap
– Replace the filler cap and turn clockwise until the release button 1 locks in place.
Info
Run the fuel tank breather hose 2 without kinks.
400199-11
4.10Choke
The choke 1 is fitted on the left side side of the carburetor.
Activating the choke function frees an opening through which the engine can draw extra
fuel. This gives a richer fuel-air mixture, which is needed for a cold start.
Info
If the engine is warm, the choke function must be deactivated.
Possible states
– Choke function activated
400202-10
– Choke function deactivated
4.11Shift lever
(450 SX-F, 505 SX-F)
(450 XC-F, 505 XC-F)
The shift lever 1 is mounted on the left side of the engine.
400204-12
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
400204-10
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
400204-11
OPERATING ELEMENTS 11
4.12Foot brake pedal
The foot brake pedal 1 is located in front of the right footrest and operates the rear
wheel brake.
400205-10
4.13Plug-in stand (450 SX-F, 505 SX-F)
Note
Danger of damage Danger of damage by the motorcycle running away or falling over.
– Always place the motorcycle on a firm and even surface.
400203-10
4.14Side stand (450 XC-F, 505 XC-F)
400218-10
To park the motorcycle, insert the plug-in stand
1 in the left side of the wheel spindle.
Info
Remove the plug-in stand before the journey.
Note
Danger of damage Danger of damage by the motorcycle running away or falling over.
– Always place the motorcycle on a firm and even surface.
To park the motorcycle, press the side stand
the motorcycle on it.
When you are riding, the side stand 1 must be folded up and secured with the rubber
band
2.
1 with your foot to the ground and lean
400219-10
TIPS AND HINTS ON PUTTING INTO OPERATION 12
5TIPSANDHINTS ONPUTTING INTOOPERATION
Advice on first use
5.1
Danger
Danger of accidents Danger from inadequate traffic experience.
– Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs.
Warning
Risk of injury Risk of injury by missing/inadequate protective clothing.
– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the motorcycle.
Warning
Danger of crashing Impairment of riding behavior due to different tire tread patterns on front and rear wheels.
– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the motorcycle.
Warning
Danger of accidents Critical riding behavior due to inappropriate riding.
– Adapt your riding speed to the road conditoins and your riding ability.
Warning
Danger of accidents Accident risk caused by presence of a passenger.
– Your motorcycle is not designed to carry passengers. Do not ride with a passenger.
Warning
Danger of accidents Brake system failure.
– If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take
your foot off the foot brake pedal if you do not want to brake.
Warning
Danger of accidents Unstable riding behavior.
– Do not exceed the maximum permitted weight and axle loads.
Warning
Risk of misappropriation Usage by unauthorized persons.
– Never leave the motorcycle while the engine is running. Secure the motorcycle against use by unauthorized persons.
Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.
– Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.
You receive a delivery certificate and the service record at vehicle handover.
– Before your first trip, read the entire operating instructions carefully.
– Get to know the operating elements.
– adjust the basic position of clutch lever. ( 60)
– adjust the basic position of handbrake lever. ( 39)
– Adjust the basic position of the footbrake lever. ( 43)
– Get used to handling the motorcycle on a suitable piece of land before making a longer trip.
Info
Your motorcycle is not licensed for use on public roads.
Offroad, you should be accompanied by another person on another machine so that you can help each other.
– Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.
– Do not make any offroad trips that over-stress your ability and experience.
– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
– Do not make any changes to the motorcycle, and use only KTM approved parts.
TIPS AND HINTS ON PUTTING INTO OPERATION 13
– If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight
distribution between the front and rear wheels.
Info
Motorcycles react sensitively to any changes of weight distribution.
– Do not exceed the overall maximum permitted weight and the axle loads.
Rules
Maximum permissible overall weight 335 kg (738.54 lb.)
Maximum permissible front axle load 145 kg (319.67 lb.)
Maximum permissible rear axle load 190 kg (418.87 lb.)
– Run the engine in.
5.2Running in the engine
– During the running-in phase, do not exceed the specified engine speed and engine performance.
Rules
Maximum engine speed
During the first 3 service hours 7000 rpm
Maximum engine performance during the running-in period
During the first 3 service hours ≤ 50 %
During the next 12 service hours ≤ 75 %
– Avoid fully opening the throttle!
RIDING INSTRUCTIONS 14
6RIDINGINSTRUCTIONS
Checks before putting into operation
6.1
Info
Make sure that the motorcycle is in a perfect technical condition before use.
Info
In the interests of riding safety, make a habit of making a general check before you ride.
– Check the engine oil level. ( 63)
– Check the chain tension. ( 34)
– Check the chain dirt accumulation. ( 33)
– Check the tire condition. ( 49)
– Checking the tire air pressure. ( 49)
– Check the front brake brake fluid level. ( 39)
– Check the rear brake fluid level. ( 43)
– Check the front brake linings. ( 40)
– Check the rear brake linings. ( 44)
– Check braking.
– Check the coolant level. ( 56)
– Check that all operating elements are correctly adjusted and free to move.
6.2Starting
Danger
Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed
space.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
– Always warm up the engine at low engine speeds.
Info
If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel
evaporate after a long time of standing.
If the float chamber is filled with fresh fuel, the engine starts immediately.
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds until trying again.
Conditions
Motorcycle standing still: ≥ 1 week
– Empty the carburetor float chamber. ( 63)
(450 XC-F, 505 XC-F)
– Turn the handle
Fuel can flow from the tank to the carburetor.
(450 SX-F, 505 SX-F)
– Turn the handle
Fuel can flow from the tank to the carburetor.
– Remove the motorcycle from the stand.
– Shift gear to neutral.
Conditions
Engine cold
– Pull choke out as far as possible.
Conditions
Engine warm
– Pull hot start lever.
– Press the electric starter button.
1 of the fuel tap to the ON position. (Figure 400201-10 9)
1 of the fuel tap to the ON position. (Figure 400200-10 9)
Info
Don't open the throttle.
RIDING INSTRUCTIONS 15
6.3Starting up
– Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.
6.4Shifting, riding
Warning
Danger of accidents If you change down at high engine speed, the rear wheel can block.
– Do not change into a low gear at high engine speed. The engine races and the rear wheel can block.
Info
If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.
First gear is used for starting off or for steep inclines.
– When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while
simultaneously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.
– If the choke function was activated, deactivate it after the engine has warmed up.
– When you reach maximum speed after fully opening the throttle, turn back the throttle to about 3/4 of its range; the speed hardly
drops, but the fuel consumption falls considerably.
– Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel consumption.
– To shift down, brake if necessary and close the throttle at the same time.
– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again.
– Switch off the engine if you expect to be standing for a long time.
Rules
≥ 2 min
– Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and the cooling system.
– Ride with a lower engine speed instead of with a high engine speed and a slipping clutch.
6.5Braking
Warning
Danger of accidents If you brake too hard, the wheels can lock.
– Adapt your braking to the traffic situation and the road conditions.
Warning
Danger of accidents Reduced braking caused by spongy pressure point of front or rear brake.
– Have the brake system checked in an authorized KTM workshop, and do not ride any further.
Warning
Danger of accidents Reduced braking due to wet or dirty brakes.
– Clean or dry dirty or wet brakes by riding and braking gently.
– On sandy, wet or slippery surfaces, use the rear brake.
– Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
– On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine.
In this way, you have to brake far less and the brakes do not overheat.
0
RIDING INSTRUCTIONS 16
6.6Stopping, parking
Warning
Danger of burns Some motorcycle components get very hot when the machine is driven.
– Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these components
to cool down before starting work on them.
Note
Danger of damage Danger of damage by the motorcycle running away or falling over.
– Always place the motorcycle on a firm and even surface.
Note
Fire hazard Some components (engine, radiator and exhaust system) get very hot when the engine is running.
– Do not place the motorcycle where there are flammable or explosive substances.
– Apply the brakes and shift into neutral.
– To switch off the engine from idle speed, press the short circuit button until the engine stops.
– Close the fuel tap, and park the motorcycle on firm ground.
6.7Refueling
Danger
Fire hazard Fuel can easily catch fire.
– Never fill up the motorcycle near open flames or burning cigerettes, and always switch off the engine first. Be careful that
no fuel is spilt, especially on hot motorcycle components. Clean up spilt fuel immediately.
– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.
Warning
Danger of poisoning 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
immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
– Open the filler cap. ( 9)
00
– Fill the fuel tank with fuel up to measurement
Rules
Measurement of
A: 35 mm (1.38 in)
A.
AA
Super unleaded ( 82)
Super unleaded ( 82)
400214-10
Tank capacity 8.2 l (2.17 US
gal) (450 SX-F,
505 SX-F)
9.2 l (2.43 US
gal) (450 XC-F,
505 XC-F)
– Close the filler cap. ( 10)
GREASING AND SERVICE TABLE 17
7GREASINGANDSERVICE TABLE
Important maintenance work to be carried out by an authorized KTM workshop.
7.1
After 3 service
hours / 20 liters
of fuel
Every 10
service hours /
70 liters of fuel
/ after each
race
Engine Change the engine oil and oil filter, and clean the oil screen.
••
(64)
Replace spark plug. •
Check and adjust valve clearance. • •
Check engine mounting screws for tightness. • •
Clean spark plug connectors and check for tightness. • •
Check shift lever screw for tightness. • •
Carburetor Check carburetor connection boots for cracks and leakage. •
Check vent hoses for damage and routing without sharp bends. • •
Check idle. • •
Attachments
Check the cooling system for leakage. • •
Check the antifreeze and coolant level. ( 55) • •
Check the exhaust system for leakage and looseness. •
Check Bowden cables for damage, smooth operation and routing
••
without sharp bends.
Check the fluid level of the hydraulic clutch. ( 60) • •
Clean the air filter. ( 60) • •
Check cables for damage and routing without sharp bends. •
Brakes Check the front brake linings. ( 40) • •
Check the rear brake linings. ( 44) • •
Check the brake discs. ( 38) • •
Check the front brake brake fluid level. ( 39) • •
Check the rear brake fluid level. ( 43) • •
Check brake lines for damage and leakage. • •
Check the free play of the hand brake lever. ( 39) • •
Check the free play of the foot brake lever. ( 42) • •
Check brake system function. • •
Check screws and guide bolts of brake system for tightness. • •
Chassis Check shock absorber and fork for leakage and functioning. • •
Clean dust boots of fork legs. ( 26) •
Bleed fork legs. ( 26) •
Check swingarm bearing. •
Check play of steering head bearing. ( 27) • •
Check all screws to see if they are tight. • •
Wheels Check the spoke tension. ( 50) • •
Check rim run-out. • •
Check the tire condition. ( 49) • •
Checking the tire air pressure. ( 49) • •
Check the chain wear. ( 35) • •
Check the chain tension. ( 34) • •
Clean the chain. ( 33) • •
Check wheel bearing for play. • •
Clean and grease adjusting screws of chain adjuster. • •
Every 30
service hours /
210 liters of
fuel
GREASING AND SERVICE TABLE 18
7.2Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)
Every 10
service hours
/ 70 liters of
fuel / after
each race
Every 20
service
hours / 140
liters of
fuel
Every 40
service
hours / 270
liters of
fuel
annually every 2
years
Carry out a complete fork service. •
Carry out a complete shock absorber service. •
Grease the steering head bearing. ( 31) •
Clean and adjust carburetor. •
Treat electric contacts with contact spray. •
Change hydraulic clutch fluid. •
Change brake fluid. •
Check wear of clutch discs. •
Check long clutch springs. •
Check clutch slave cylinder for dents. •
Check outer clutch hub for dents. •
Check cylinder wear and change pistons. •
Check camshaft wear. (visual check) •
Check wear of valve spring seat. •
Check wear of valve guides. •
Change valves. •
Change valve springs. •
Check the timing-chain tensioner function. •
Check crankshaft and crankshaft journal for run-out. •
Change conrod bearing. •
Check piston pin bearing. •
Change the crankshaft main bearing. •
Check wear of all transmission components including shafts
•
and bearings.
Check long bypass valve spring. •
Change glass fiber yarn filling of main silencer. ( 59) •
Replace foot brake cylinder seals. •
Check carburetor components. •
7.3Important checks and maintenance work to be carried out by the rider.
Conditions:
For use on offroad
terrain
according to
requirements
Check the engine oil level. ( 63) •
Check the front brake brake fluid level. ( 39) •
Check the rear brake fluid level. ( 43) •
Check the front brake linings. ( 40) •
Check the rear brake linings. ( 44) •
Check and adjust Bowden cables. •
Bleed fork legs. ( 26) •
Clean dust boots of fork legs. ( 26) •
Clean the chain. ( 33) •
Check the chain tension. ( 34) •
Check the chain wear. ( 35) •
GREASING AND SERVICE TABLE 19
Conditions:
For use on offroad
terrain
according to
requirements
Check rear sprocket / engine sprocket for wear. ( 35) •
Clean the air filter. ( 60) •
Checking the tire air pressure. ( 49) •
Check the tire condition. ( 49) •
Check the coolant level. ( 56) •
Empty the carburetor float chamber. ( 63) •
Check that all operating elements for smooth operation. •
Check braking. •
Check all screws, nuts and hose clamps regularly for tightness. •
MAINTENANCE WORK ON CHASSIS AND ENGINE 20
8MAINTENANCEWORK ONCHASSIS ANDENGINE
Jacking up the motorcycle
8.1
Note
Danger of damage Danger of damage by the motorcycle running away or falling over.
– Always place the motorcycle on a firm and even surface.
– Jack up the motorcycle underneath the engine. The wheels must no longer touch
the ground.
Work stand (54829055000)
500074-01
8.2Removing the motorcycle from the work stand
– Secure the motorcycle against falling over.
Note
Danger of damage Danger of damage by the motorcycle running away or falling over.
– Always place the motorcycle on a firm and even surface.
– Remove the motorcycle from the work stand.
– Remove the work stand.
8.3Checking the basic chassis setting with the rider's weight
Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swing arm and frame, the basic settings of
the suspension components must match your body weight.
As delivered, KTM offroad motorcycles are adjusted for a standard rider weight (with full protective clothing).
Standard rider weight 75…85 kg (165.34…187.39 lb.)
If your weight is above or below the standard range, you have to adjust the basic setting of the suspension components accordingly.
Small weight differences can be compensated by adjusting the spring preload, but in the case of large weight differences, the springs
must be replaced.
8.4Compression damping of shock absorber
The shock absorber can regulate compression damping in low- and high-speed range separately (Dual Compression Control).
The term low and high speed refers to the movement of the shock absorber during compression and not the riding speed of the
motorcycle.
The low- and high-speed technology works non-specifically.
8.5Adjusting high-speed compression damping of the shock absorber
Danger
Danger of accidents The shock absorber is under high pressure.
– The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any
maintenance on it yourself.
Info
The high-speed setting can be seen during the fast compression of the shock absorber.
– Turn the adjusting screw 1 clockwise with a ring wrench until it stops.
Info
Do not loosen nut 2!
400208-10
MAINTENANCE WORK ON CHASSIS AND ENGINE 21
– Turn back counterclockwise the number of turns corresponding to the shock absorber
type.
Rules
Compression damping, high-speed (450 SX-F, 505 SX-F)
Comfort 1 turn
Standard 1 turn
Sport 3/4 turn
Compression damping, high-speed (450 XC-F, 505 XC-F)
Standard 1 turn
Info
Turn clockwise to increase damping, turn counterclockwise to reduce
suspension damping.
8.6Adjusting the low-speed compression damping of the shock absorber
Danger
Danger of accidents The shock absorber is under high pressure.
– The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any
maintenance on it yourself.
Info
The low-speed setting can be seen during the slow to normal compression of the shock absorber.
– Turn the adjusting screw 1 clockwise with a screwdriver until it stops.
Info
Do not loosen nut 2!
– Turn back counterclockwise the number of clicks corresponding to the shock
absorber type.
Rules
Compression damping, low-speed (450 SX-F, 505 SX-F)
400209-10
Comfort 16 clicks
Standard 14 clicks
Sport 12 clicks
Compression damping, low-speed (450 XC-F, 505 XC-F)
Standard 15 clicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce
suspension damping.
8.7Adjusting rebound damping of the shock absorber
Danger
Danger of accidents The shock absorber is under high pressure.
– The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any
maintenance on it yourself.
MAINTENANCE WORK ON CHASSIS AND ENGINE 22
– Turn the adjusting screw 1 clockwise until it stops.
Info
Do not loosen nut 2!
– Turn back counterclockwise the number of clicks corresponding to the shock
absorber type.
Rules
Rebound damping (450 SX-F, 505 SX-F)
400210-10
8.8Measuring rear wheel sag unloaded
– Jack up the motorcycle. ( 20)
– Measure the distance – as vertical as possible – between the rear axle and a fixed point, for example, a mark on the side cover.
– Make a note of the value as measurement
– Remove the motorcycle from the work stand. ( 20)
A.
Comfort 25 clicks
Standard 23 clicks
Sport 22 clicks
Rebound damping (450 XC-F, 505 XC-F)
Standard 23 clicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce
suspension damping.
8.9Checking static sag of the shock absorber
– Measure distance A of rear wheel unloaded. ( 22)
– Ask someone to help you by holding the motorcycle upright.
– Measure the distance between the rear axle and the fixed point again.
00AA
– Make a note of the value as measurement
– Check the static sag.
000BB
400221-10
B.
Info
The static sag is the difference between measurements A and B.
Static sag 33 mm (1.3 in)
> If the static sag is less or more than the specified value:
– Adjust the spring preload of the shock absorber. ( 23)
MAINTENANCE WORK ON CHASSIS AND ENGINE 23
8.10Check the riding sag of the shock absorber.
– Measure distance A of rear wheel unloaded. ( 22)
– With another person holding the motorcycle, sit on the saddle with full protective
clothing in a normal sitting position (feet on footrests) and bounce up and down a
few times until the rear suspension levels out.
00AA
– The other person now has to measure the distance between the rear axle and a fixed
point.
– Make a note of the value as measurement
C.
Info
The riding sag is the difference between measurements A and C.
– Check the riding sag.
Riding sag (450 SX-F, 505 SX-F) 107 mm (4.21 in)
Riding sag (450 XC-F, 505 XC-F) 110 mm (4.33 in)
CC
400222-10
8.11Adjusting spring preload of the shock absorber x
> If the riding sag differs from the specified measurement:
– Adjust the riding sag. ( 24)
Danger
Danger of accidents The shock absorber is under high pressure.
– The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any
maintenance on it yourself.
Info
Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
– Remove shock absorber. ( 24)
– After removing the shock absorber, clean it thoroughly.
– Loosen screw 1.
22
11
AA
– Turn adjusting ring
Combination wrench (50329080000)
Hook wrench (T106S)
– Measure the overall spring length when not under tension.
– Tighten the spring by turning adjusting ring
Rules
Spring preload 7 mm (0.28 in)
2 until the spring is no longer under tension.
1 to measurement A.
400216-10
– Tighten screw
Rules
Screw, shock absorber
adjusting ring
– Installing shock absorber ( 24)
2.
M6 5 Nm (3.69 lbf ft)
MAINTENANCE WORK ON CHASSIS AND ENGINE 24
8.12Adjusting riding sag x
– Remove shock absorber. ( 24)
– After removing the shock absorber, clean it thoroughly.
– Choose and fit a suitable spring.
Rules
Spring rate
Weight of rider: 65…75 kg (143.3…165.34 lb.) 66 N/mm (376.87 lb/in)
Weight of rider: 75…85 kg (165.34…187.39 lb.) 69 N/mm (394 lb/in)
Weight of rider: 85…95 kg (187.39…209.44 lb.) 72 N/mm (411.13 lb/in)
Info
The spring rate is shown on the outside of the spring.
– Installing shock absorber ( 24)
– Check the static sag of the shock absorber. ( 22)
– Adjust the rebound damping of the shock absorber. ( 21)
8.13Removing the shock absorber x
– Jack up the motorcycle. ( 20)
– Remove screw 1 and lower the rear wheel with the swing arm as far as possible
without blocking the rear wheel. Fix the rear wheel in this position.
– Remove screw
absorber.
2, push splash protector 3 to the side, and remove the shock
8.14Installing shock absorber x
400249-10
400249-11
– Check parts for damage and wear. Replace damaged or worn parts.
– Push splash protector
tighten screw
2.
1 to the side and position the shock absorber. Mount and
Rules
Screw, top shock
M12 80 Nm
absorber
– Mount and tighten screw
(59.01 lbf ft)
3.
Loctite
®
243™ (84)
Rules
Screw, bottom
shock absorber
M12 80 Nm
(59.01 lbf ft)
Loctite
®
243™ (84)
Info
The heim joint for the shock absorber at the swing arm is Teflon coated. It
must not be greased with grease or with other lubricants. Lubricants dissolve
the Teflon coating, thereby drastically reducing the service life.
– Remove the motorcycle from the work stand. ( 20)
MAINTENANCE WORK ON CHASSIS AND ENGINE 25
8.15Checking basic setting of fork
Info
For various reasons, no exact riding sag can be determined for the forks.
As with the shock absorber, smaller weight differences can be compensated by the
spring preload.
However, if your fork is often overloaded (hard end stop on compression), you must fit
harder springs to avoid damage to the fork and frame.
400189-01
8.16Adjusting compression damping of fork
Info
The hydraulic compression damping determines the fork suspension behavior.
– Adjusting screws 1 clockwise until they stop.
Info
The adjusting screws 1 are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
– Turn back counterclockwise the number of clicks corresponding to the fork type.
Rules
Compression damping (450 SX-F, 505 SX-F)
400206-10
Comfort 16 clicks
Standard 14 clicks
Sport 12 clicks
Compression damping (450 XC-F, 505 XC-F)
Standard 20 clicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce
suspension damping.
8.17Adjusting rebound damping of fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
– Remove protection covers 1.
– Turn the adjusting screws
2 clockwise until they stop.
400207-10
Info
The adjusting screws 2 are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
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