KTM 450 SX-F 2012 Owner's manual

4.7 (3)

OWNER'S MANUAL 2012

450 SX F EU

450 SX F USA

Art. no. 3211717en

DEAR KTM CUSTOMER

Congratulations on your decision to purchase 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 a lot of enjoyment in riding this vehicle.

Enter the serial numbers of your vehicle below.

Chassis number ( p. 9)

Dealer's stamp

Engine number ( p. 9)

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.

All specifications are non-binding. KTM Sportmotorcycle AG specifically 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 production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery.

Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)

According to 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

TABLE OF CONTENTS

MEANS OF REPRESENTATION ............................................	4
IMPORTANT INFORMATION ................................................	5
VIEW OF VEHICLE...............................................................	7
View of the vehicle from the left front (example).................	7
View of the vehicle from the right rear (example) ................	8
SERIAL NUMBERS..............................................................	9
Chassis number...............................................................	9
Type label.......................................................................	9
Engine number................................................................	9
Fork part number.............................................................	9
Shock absorber part number.............................................	9
CONTROLS .......................................................................	10
Clutch lever ..................................................................	10
Hot start lever ...............................................................	10
Hand brake lever ...........................................................	10
Throttle grip..................................................................	10
Short circuit button .......................................................	10
Electric starter button ....................................................	11
Opening filler cap..........................................................	11
Closing filler cap ...........................................................	11
Factory Start (450 SX F USA).........................................	12
Fuel tap........................................................................	12
Choke...........................................................................	12
Shift lever.....................................................................	13
Foot brake lever.............................................................	13
Plug-in stand ................................................................	13
PREPARING FOR USE.......................................................	14
Advice on first use.........................................................	14
Running-in the engine ...................................................	15
Preparing vehicle for arduous riding conditions.................	15
Preparing for rides on dry sand .......................................	15
Preparing for rides on wet sand.......................................	16
Preparing for rides on wet and muddy surfaces.................	16
Preparing for rides at high temperatures and low speeds ...	17
Preparing for rides at low temperatures or in snow ............	17
RIDING INSTRUCTIONS ....................................................	18
Checks and maintenance before putting into operation......	18
Starting ........................................................................	18
Starting up ...................................................................	19
Shifting, riding..............................................................	19
Braking ........................................................................	19
Stopping, parking ..........................................................	20
Refueling......................................................................	20
SERVICE SCHEDULE.........................................................	21
Service schedule ...........................................................	21
Service work (as additional order)....................................	22
TUNING THE CHASSIS......................................................	23
Checking the basic suspension setting against the rider's
weight ..........................................................................	23
Compression damping of shock absorber..........................	23
Adjusting the low-speed compression damping of the
shock absorber ..............................................................	23
Adjusting the high-speed compression damping of the
shock absorber ..............................................................	24
Adjusting the rebound damping of the shock absorber.......	24
Measuring rear wheel sag unloaded .................................	25
Checking the static sag of the shock absorber ..................	25
Checking the riding sag of the shock absorber ..................	26
Adjusting the spring preload of the shock absorber x......	26
Adjusting the riding sag x.............................................	27
Checking basic setting of fork .........................................	27
Adjusting the compression damping of the fork ................	27

Adjusting the rebound damping of the fork.......................	28
Handlebar position ........................................................	28
Adjusting handlebar position x......................................	29
Activating the Factory Start (450 SX F USA) ....................	29
SERVICE WORK ON THE CHASSIS.....................................	30
Raising the motorcycle with the lift stand ........................	30
Removing the motorcycle from the lift stand ....................	30
Bleeding fork legs..........................................................	30
Cleaning the dust boots of the fork legs ...........................	30
Loosening the fork protector ...........................................	31
Positioning the fork protection ........................................	31
Removing the fork legs x..............................................	31
Installing the fork legs x...............................................	32
Removing the fork protector x.......................................	32
Installing the fork protector x.......................................	32
Removing the lower triple clamp x................................	33
Installing the lower triple clamp x.................................	33
Checking the steering head bearing play ..........................	35
Adjusting play of steering head bearing x.......................	35
Greasing the steering head bearing x.............................	35
Dismount the start number plate.....................................	36
Installing the start number plate .....................................	36
Removing the front fender ..............................................	36
Installing the front fender...............................................	36
Removing the shock absorber x.....................................	36
Installing the shock absorber x.....................................	37
Removing the seat .........................................................	38
Mounting the seat .........................................................	38
Removing the air filter box lid.........................................	38
Installing the air filter box lid..........................................	38
Removing the air filter x...............................................	38
Installing the air filter x...............................................	39
Cleaning the air filter and air filter box x........................	39
Removing main silencer .................................................	40
Installing the main silencer ............................................	40
Changing the glass fiber yarn filling of the main
silencer x...................................................................	40
Removing the fuel tank x.............................................	41
Installing the fuel tank x..............................................	41
Checking for chain dirt accumulation ..............................	42
Cleaning the chain.........................................................	42
Checking the chain tension ............................................	43
Adjusting the chain tension ............................................	43
Checking the chain, rear sprocket, engine sprocket and
chain guide...................................................................	44
Adjusting the chain guide x..........................................	46
Checking the frame x...................................................	46
Checking the swingarm x.............................................	46
Checking the throttle cable routing..................................	46
Checking the rubber grip ................................................	47
Additionally securing the rubber grip ...............................	47
Adjusting the basic position of the clutch lever.................	47
Checking the fluid level of hydraulic clutch......................	47
Changing the hydraulic clutch fluid x............................	48
BRAKES ...........................................................................	49
Checking free travel on hand brake lever..........................	49
Adjusting the basic position of the hand brake lever..........	49
Checking the brake discs................................................	49
Checking the brake fluid level of the front brake...............	50
Adding front brake fluid x............................................	50
Checking the front brake linings......................................	51

TABLE OF CONTENTS

Changing the front brake linings x.................................	51
Checking the free travel of the foot brake lever .................	53
Adjusting the basic position of the foot brake lever x......	53
Checking rear brake fluid level........................................	54
Adding brake fluid to the rear brake circuit x.................	54
Checking rear brake linings ............................................	55
Changing the rear brake linings x..................................	55
WHEELS, TIRES ...............................................................	57
Removing front wheel x................................................	57
Installing the front wheel x...........................................	57
Removing the rear wheel x...........................................	58
Installing the rear wheel x............................................	58
Checking the tire condition.............................................	59
Checking tire air pressure...............................................	60
Checking spoke tension..................................................	60
ELECTRICAL SYSTEM .......................................................	61
Removing the battery x................................................	61
Installing the battery x.................................................	61
Recharging the battery x..............................................	61
Removing the main fuse.................................................	62
Installing the main fuse .................................................	63
COOLING SYSTEM ............................................................	64
Cooling system ..............................................................	64
Checking the anti-freeze and coolant level .......................	64
Checking the coolant level..............................................	64
Draining the coolant x..................................................	65
Refilling coolant x.......................................................	65
TUNING THE ENGINE .......................................................	67
Checking the play in the throttle cable.............................	67
Adjusting the play in the throttle cable x.......................	67
Carburetor - idle ............................................................	67
Carburetor - adjusting idle x.........................................	68
Emptying the carburetor float chamber x.......................	68
Ignition curve plug connection ........................................	69
Changing the ignition curve ............................................	69
Checking the basic position of the shift lever....................	69
Adjusting the basic position of the shift lever x..............	70
SERVICE WORK ON THE ENGINE ......................................	71
Checking engine oil level................................................	71
Changing the engine oil and oil filter, cleaning the oil
screen x.....................................................................	71
Adding engine oil ..........................................................	73
CLEANING, CARE .............................................................	74
Cleaning motorcycle ......................................................	74
STORAGE .........................................................................	75
Storage.........................................................................	75
Preparing for use after storage ........................................	75
TROUBLESHOOTING.........................................................	76
TECHNICAL DATA - ENGINE..............................................	78
Capacity - engine oil ......................................................	78
Capacity - coolant..........................................................	78
TECHNICAL DATA - ENGINE TIGHTENING TORQUES..........	79
TECHNICAL DATA - CARBURETOR.....................................	81
TECHNICAL DATA - CHASSIS ............................................	82
Tires ............................................................................	82
Capacity - fuel...............................................................	83
TECHNICAL DATA - FORK..................................................	84
450 SX F EU ................................................................	84
450 SX F USA ..............................................................	84
TECHNICAL DATA - SHOCK ABSORBER .............................	85
450 SX F EU ................................................................	85

450 SX F USA ..............................................................	85
TECHNICAL DATA - TIGHTENING TORQUES FOR
CHASSIS ..........................................................................	87
SUBSTANCES...................................................................	88
AUXILIARY SUBSTANCES..................................................	90
STANDARDS.....................................................................	92
INDEX ..............................................................................	93

MEANS OF REPRESENTATION

Symbols used

The symbols used are explained in the following.

Indicates an expected reaction (e.g., to a work step or a function).

Indicates an unexpected reaction (e.g., to 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 below.

Proprietary name	Denotes a proprietary name.
Name®	Denotes a protected name.
Brand™	Denotes a brand available on the open market.

IMPORTANT INFORMATION

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.

Info

The motorcycle must be used only in closed off areas remote from public road traffic.

Service

A prerequisite for perfect operation and prevention of premature wear is that the service, care and tuning work on the engine and chassis is properly carried out as described in the owner's manual. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of components.

Using the vehicle in difficult conditions such as on sand or very muddy or wet terrain can lead to above-average wear of components such as the drive train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached.

Pay careful attention to the prescribed running-in period and service intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle.

Warranty

The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claim can be honored for damage resulting from manipulation and/or other changes to the vehicle.

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, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss. Some spare parts and accessories are specified in brackets in the respective descriptions. Your KTM dealer will be happy to advise you.

You will find the current KTM PowerParts for your vehicle on the KTM website.

International KTM Website: http://www.ktm.com

Work rules

Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in parentheses. Ex: valve spring compressor (59029019000)

During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts.

If thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its usage.

Parts 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 repair and maintenance work.

Transport

Note

Danger of damage The parked vehicle may roll away or fall over.

–Always place the vehicle on a firm and even surface.

Note

Fire hazard Some vehicle components become very hot when the vehicle is operated.

–Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first.

–Switch off the engine.

–Turn handle of the fuel tap to the OFF position. (Figure 800189-10 p. 12)

–Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

IMPORTANT INFORMATION

Environment

Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. 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.

Notes/warnings

Pay close attention to the notes/warnings.

Info

Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing, you or others may not recognize potential hazards and may therefore be injured.

Grades of risks

Danger

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.

Warning

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Caution

Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

Note

Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Warning

Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.

Owner's manual

–It is important that you read this owner's manual carefully and completely before making your first trip. It contains information and tips to help you operate and handle your motorcycle. Only then will you learn how to best adjust the motorcycle for your own use and how to protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.

–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.

VIEW OF VEHICLE

View3.1 of the vehicle from the left front (example)

800180-10

1Hand brake lever ( p. 10)

2Clutch lever ( p. 10)

3Filler cap

4Air filter box lid

5Fuel tap ( p. 12)

6Choke ( p. 12)

7Chain guide

8Shift lever ( p. 13)

VIEW OF VEHICLE

View3.2 of the vehicle from the right rear (example)

800183-10

1Short circuit button ( p. 10)

2Electric starter button ( p. 11)

3Fork compression adjustment

4Fork rebound adjustment

5Level viewer, engine oil

6Foot brake lever ( p. 13)

7Level viewer for brake fluid, rear

8Shock absorber rebound adjustment

9Shock absorber compression adjustment

SERIAL NUMBERS

Chassis4.1 number

The chassis number is stamped on the steering head on the right.

B00262-10

Type4.2 label

The type label is fixed to the front of the steering head.

B00262-20

Engine4.3 number

The engine number is stamped on the left side of the engine under the engine sprocket.

B00425-10

Fork4.4 part number

The fork part number is stamped on the inner side of the fork stub.

B00265-01

Shock4.5 absorber part number

The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side.

B00392-10

CONTROLS

Clutch5.1 lever

The clutch lever is fitted on the left side of the handlebar.

The clutch is hydraulically operated and self-adjusting.

B00406-10

Hot5.2 start lever

B00406-11

The hot start lever is fitted on the left side of the handlebar.

If you pull the hot start lever to the handlebar during the start procedure, a bore is opened in the carburetor through which the engine can draw in extra air. This gives a leaner fuel-air mixture, which is needed for a hot start.

Possible states

•Hot start function activated – Hot start lever is pulled out to the stop.

•Hot start function deactivated – Hot start lever is pushed back to the stop.

Hand5.3 brake lever

Hand brake lever is located on the right side of the handlebar.

The hand brake lever is used to activate the front brake.

400196-10

Throttle5.4 grip

The throttle grip is fitted on the right side of the handlebar.

B00368-10

Short5.5 circuit button

Short circuit button is fitted on the left side of the handlebar.

Possible states

•Short circuit button in basic position – In this position, the ignition circuit is closed, and the engine can be started.

•Short circuit button pressed – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.

400197-10

CONTROLS

Electric5.6 starter button

Electric starter button is fitted on the right side of the handlebar.

Possible states

•Electric starter button in basic position

•Electric starter button pressed – In this position, the electric starter is actuated.

400198-10

Opening5.7 filler cap

Danger

Fire hazard Fuel is highly flammable.

–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

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. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.

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.

–Press release button , turn filler cap counterclockwise and lift it upwards and remove.

B00277-10

Closing5.8 filler cap

–Replace the filler cap and turn clockwise until the release button locks in place.

Info

Route the fuel tank breather hose without kinking.

B00278-10

CONTROLS

Factory5.9 Start (450 SX F USA)

The Factory Start is mounted on the right fork protector.

Possible states

•Factory Start is deactivated – The fork is in the normal operating mode.

•Factory Start is activated – The fork is compressed and the front of the motorcycle is lowered.

By activating the Factory Start, the front of the motorcycle is lowered; this causes the front wheel to rise up off the ground later during acceleration.

When the fork compresses for the first time, the Factory Start lock button is released automatically. From this point on, the fork operates as if the Factory Start were deactivated or not installed.

800182-10

Fuel5.10 tap

800189-10

The fuel tap is on the left side of 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 supply open ON – Fuel can flow from the tank to the carburetor. The fuel tank empties completely.

Choke5.11

	Choke is fitted on the left side of the carburetor.
	Choke is fitted on the left 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
		Info
		If the engine is warm, the choke function must be deactivated.

	Possible states
	• Choke function activated – The choke lever is pulled out to the stop.
	• Choke function deactivated – The choke lever is pushed in to the stop.
B00405-10
B00405-10

CONTROLS

Shift5.12 lever

Shift lever is mounted on the left side of the engine.

B00426-11

The gear positions can be seen in the photograph.

The neutral or idle position is between the first and second gears.

B00426-10

Foot5.13 brake lever

Foot brake lever is located in front of the right footrest.

The foot brake lever is used to activate the rear brake.

800005-10

Plug5.14 -in stand

The holder for the plug-in stand is the left side of the wheel spindle.

The plug-in stand is used to park the motorcycle.

Info

Remove the plug-in stand before starting on a trip.

B00283-10

PREPARING FOR USE

Advice6.1 on first use

Danger

Danger of accidents Danger arising from the rider's judgement being impaired.

–Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired.

Warning

Risk of injury Missing or poor protective clothing present an increased safety risk.

–Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing, which must be undamaged and meet legal requirements.

Warning

Danger of crashing Poor vehicle handling 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 vehicle.

Warning

Danger of accidents Critical riding behavior due to inappropriate riding.

–Adapt your riding speed to the road conditions and your riding ability.

Warning

Danger of accidents Accident risk caused by presence of a passenger.

–Your vehicle is not designed to carry passengers. Do not ride with a passenger.

Warning

Danger of accidents Failure of brake system.

–If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take your foot off the foot brake lever when you are not braking.

Warning

Danger of accidents Unstable riding behavior.

–Do not exceed the maximum permissible weight and axle loads.

Warning

Risk of misappropriation Usage by unauthorized persons.

–Never leave the vehicle while the engine is running. Secure the vehicle 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 controls.

–Adjust the basic position of the clutch lever. ( p. 47)

–Adjust the basic position of the hand brake lever. ( p. 49)

–Adjust the basic position of the foot brake lever. x( p. 53)

–Get used to handling the motorcycle on a suitable piece of land before making a longer trip.

Info

Your motorcycle is not authorized for riding 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 transport luggage.

–Do not exceed the overall maximum permitted weight and the axle loads.

PREPARING FOR USE		15
	Guideline

	Maximum permissible overall weight	335 kg (739 lb.)

	Maximum permissible front axle load	145 kg (320 lb.)

	Maximum permissible rear axle load	190 kg (419 lb.)

– Run in the engine. ( p. 15)

Running6.2 -in the engine

–During the running-in phase, do not exceed the specified engine speed and engine performance. Guideline

Maximum engine speed

During the first operating hour	7,000 rpm

Maximum engine performance

During the first 3 service hours	≤ 75 %

– Avoid fully opening the throttle!

Preparing6.3 vehicle for arduous riding conditions

Info

Using a motorcycle in difficult conditions can lead to excessive wear of components such as the drive train or brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached.

–Seal the air filter box. x

Tip

Seal the air filter box at the edges against dirt.

–Clean the air filter and air filter box. x( p. 39)

Info

Check the air filter approx. every 30 minutes.

–Additionally secure the rubber grip. ( p. 47)

–Check the electrical connector for humidity and corrosion and to ensure it is firmly seated. » If humidity, corrosion, or damage is found:

–Clean and dry the connector, or change it if necessary.

Arduous riding conditions are:

–Rides on dry sand. ( p. 15)

–Rides on wet sand. ( p. 16)

–Rides on wet and muddy surfaces. ( p. 16)

–Rides at high temperatures and low speeds. ( p. 17)

–Rides at low temperatures or in snow. ( p. 17)

Preparing6.4 for rides on dry sand

–Fit a dust protection device on the air filter.

Dust protection device for air filter (77206920000)

Info

See the KTM PowerParts fitting instructions.

B00435-01

PREPARING FOR USE

B00436-01

600868-01

–Fit a sand protection device on the air filter.

Sand protection device for air filter (77206922000)

Info

See the KTM PowerParts fitting instructions.

–Adjust the carburetor jetting and settings.

Info

Your authorized KTM workshop has the recommended carburetor tuning settings.

–Clean the chain.

Chain cleaner ( p. 90)

–Fit the steel sprocket.

Tip

Do not grease the chain.

–Clean radiator fins.

–Straighten bent radiator fins carefully.

Preparing6.5 for rides on wet sand

B00437-01

600868-01

–Fit a waterproofing device on the air filter. Waterproofing device for air filter (77206921000)

Info

See the KTM PowerParts fitting instructions.

–Adjust the carburetor jetting and settings.

Info

Your authorized KTM workshop has the recommended carburetor tuning settings.

–Clean the chain.

Chain cleaner ( p. 90)

–Fit the steel sprocket.

Tip

Do not grease the chain.

–Clean radiator fins.

–Straighten bent radiator fins carefully.

Preparing6.6 for rides on wet and muddy surfaces

–Fit a waterproofing device on the air filter. Waterproofing device for air filter (77206921000)

Info

See the KTM PowerParts fitting instructions.

–Adjust the carburetor jetting and settings.

						Info
						Info
	B00437-01					Your authorized KTM workshop has the recommended carburetor tuning


						settings.

PREPARING FOR USE

–Fit the steel sprocket.

–Clean the motorcycle. ( p. 74)

–Straighten bent radiator fins carefully.

600868-01

Preparing6.7 for rides at high temperatures and low speeds

–Adjust the secondary drive to the road conditions.

Info

The engine oil quickly gets hot if the clutch has to be operated very often due to an excessively high secondary drive.

–Clean the chain.

		Chain cleaner ( p. 90)
	–
		Clean radiator fins.
600868-01		Clean radiator fins.
600868-01	– Straighten bent radiator fins carefully.
	– Straighten bent radiator fins carefully.
	–	Check the coolant level. ( p. 64)

Preparing6.8 for rides at low temperatures or in snow

–Fit a waterproofing device on the air filter. Waterproofing device for air filter (77206921000)

Info

See the KTM PowerParts fitting instructions.

–Adjust the carburetor jetting and settings.

						Info
						Info
	B00437-01					Your authorized KTM workshop has the recommended carburetor tuning


						settings.

RIDING INSTRUCTIONS

Checks7.1 and maintenance before putting into operation

Info

Before every trip, check the condition of the vehicle and ensure that it is safe to operate.

The vehicle must be in perfect technical condition when used.

–Check the engine oil level. ( p. 71)

–Check the brake fluid level of the front brake. ( p. 50)

–Check the rear brake fluid level. ( p. 54)

–Check the front brake linings. ( p. 51)

–Check the rear brake linings. ( p. 55)

–Check that the brake system is functioning properly.

–Check the coolant level. ( p. 64)

–Check for chain dirt accumulation. ( p. 42)

–Check the chain, rear sprocket, engine sprocket and chain guide. ( p. 44)

–Check the chain tension. ( p. 43)

–Check the tire condition. ( p. 59)

–Check the tire air pressure. ( p. 60)

–Check the spoke tension. ( p. 60)

–Clean the dust boots of the fork legs. ( p. 30)

–Bleed fork legs. ( p. 30)

–Check the air filter.

–Check the settings of all controls and ensure that they can be operated smoothly.

–Check all screws, nuts and hose clamps regularly for tightness.

–Check the fuel reserves.

Starting7.2

Danger

Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.

–When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

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 may 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 at least 5 seconds before trying again.

	Engine has been out of use for more than 1 week
	Engine has been out of use for more than 1 week
		– Empty the carburetor float chamber. x( p. 68)
	–	Turn handle of the fuel tap to the ON position. (Figure 800189-10 p. 12)
		Fuel can flow from the fuel tank to the carburetor.
	– Remove the motorcycle from the stand.
	– Shift transmission to neutral.
	The engine is cold
		– Pull choke lever out as far as possible.
400733-01	The engine is hot
	–	– Pull the hot start lever out to the stop.
	–	Press the electric starter button .

Info

Do not open the throttle.

RIDING INSTRUCTIONS

The engine is hot and running

–Push back the hot start lever to the stop with the engine running.

Starting7.3 up

–Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.

Shifting,7.4 riding

Warning

Danger of accidents If you change down at high engine speed, the rear wheel can lock up.

–Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up.

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 ¾ of its range. This barely reduces vehicle speed but lowers fuel consumption considerably.

–Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel consumption.

–To shift down, brake 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 stationary for a long time. Guideline

≥2 min

–Avoid frequent and prolonged slipping of the clutch. This causes heat build-up in the engine oil, the engine and the cooling system.

–Ride at lower engine speeds instead of high revs and a slipping clutch.

Braking7.5

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 efficiency caused by spongy pressure point of front or rear brake.

–Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

Warning

Danger of accidents Reduced braking efficiency 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.

RIDING INSTRUCTIONS

Stopping,7.6 parking

Warning

Risk of misappropriation Usage by unauthorized persons.

–Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.

Warning

Danger of burns Some vehicle components become very hot when the vehicle is operated.

–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 The parked vehicle may roll away or fall over.

–Always place the vehicle on a firm and even surface.

Note

Fire hazard Some vehicle components become very hot when the vehicle is operated.

–Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first.

–Brake the motorcycle.

–Shift transmission to neutral.

–Press the Press and hold the short circuit button while the engine is idling until the engine stops.

–Turn handle of the fuel tap to the OFF position. (Figure 800189-10 p. 12)

–Park the motorcycle on firm ground.

Refueling7.7

Danger

Fire hazard Fuel is highly flammable.

–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

–Avoid contact of the fuel with 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.

–Switch off engine.

–Open the filler cap. ( p. 11)

	– Fill the fuel tank with fuel up to measurement .
	Guideline
	Measurement of		35 mm (1.38 in)
A	Total fuel tank	7.5 l	Super unleaded (ROZ 95/RON 95/PON
	capacity, approx.	(1.98 US gal)	91) (	p. 89)
	– Close the filler cap. (	p. 11)
400382-10

SERVICE SCHEDULE

Service8.1

schedule

S1N

S10A

S20A

S30A

Check and charge the battery. x

•

Change the engine oil and oil filter, clean the oil screen. x(

p. 71)

•

Check the front brake linings. (

p. 51)

•

Check the rear brake linings. ( p. 55)

•

Check the brake discs. ( p. 49)

•

Check the brake lines for damage and leakage.

•

Check the rear brake fluid level. (

p. 54)

•

Check the free travel of the foot brake lever. (

p. 53)

•

Check the frame and swingarm. x

•

Check the swingarm bearing. x

•

Check the shock absorber linkage. x

•

Conduct a minor fork service. x

•

Conduct a major fork service. x

•

Check the tire condition. (

p. 59)

•

Check the tire air pressure. (

p. 60)

•

Check the wheel bearing for play. x

•

Check the wheel hubs. x

•

Check the rim run-out. x

•

Check the spoke tension. (

p. 60)

•

Check the chain, rear sprocket, engine sprocket and chain guide. ( p. 44)

•

Check the chain tension. (

p. 43)

•

Lubricate all moving parts (e.g., hand lever, chain, ...) and check for smooth operation. x

•

Check the fluid level of the hydraulic clutch. (

p. 47)

•

Check the brake fluid level of the front brake. (

p. 50)

•

Check the free travel on the hand brake lever. (

p. 49)

•

Check the steering head bearing play. (

p. 35)

•

Check the valve clearance. x

•

Check the clutch. x

•

Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks and

•

correct routing. x

Check the anti-freeze and coolant level. (

p. 64)

•

Check the cables for damage and routing without sharp bends. x

•

Check that the cables are undamaged, routed without sharp bends and set correctly.

•

Clean the air filter and air filter box. x(

p. 39)

•

Change the glass fiber yarn filling of the main silencer. x(

p. 40)

•

Check the screws and nuts for tightness. x

•

Check idle. x

•

Final check: Check the vehicle for safe operation and take a test ride.

•

Make the service entry in KTM DEALER.NET and in the service record. x

•

S1N: Once after 1 service hour - corresponds to about 7 liters of fuel (1.8 US gal)

S10A: Every 10 service hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race

S20A: Every 20 service hours - corresponds to about 140 liters of fuel (37 US gal)

S30A: Every 30 service hours - corresponds to about 210 liters of fuel (55.5 US gal)

SERVICE SCHEDULE

Service8.2	work (as additional order)

			S20N	S20A	S40A	S80A	J1A

Change the front brake fluid. x							•
Change the rear brake fluid. x							•

Change the hydraulic clutch fluid. x(		p. 48)					•
Grease the steering head bearing. x(		p. 35)					•
Check/set the carburetor components.					•	•	•

Service the shock absorber. x			•		•	•
Change the spark plug and spark plug connector. x					•	•

Change the piston. x					•	•
Change the piston. (in difficult operating conditions) x				•	•	•
Check/measure the cylinder. x					•	•

Check the cylinder head. x					•	•
Change the valves, valve springs and valve spring seats. x					•	•
Check the camshaft and cam lever. x					•	•

Change the connecting rod, conrod bearing and crank pin. x					•	•
Change the crankshaft bearing. x					•	•
Check the transmission and shift mechanism. x					•	•

Check the oil pressure regulator valve. x					•	•
Check the oil pumps and lubrication system. x					•	•
Check the timing assembly. x					•	•

Change all engine bearings. x						•

S20N: Once after 20 service hours - corresponds to about 140 liters of fuel (37 US gal)

S20A: Every 20 service hours - corresponds to about 140 liters of fuel (37 US gal)

S40A: Every 40 service hours - corresponds to about 280 liters of fuel (74 US gal)

S80A: Every 80 service hours - corresponds to about 560 liters of fuel (148 US gal)

J1A: Annually

TUNING THE CHASSIS

Checking9.1 the basic suspension setting against the rider's weight

Info

When adjusting the basic suspension setting, first adjust the shock absorber and then the fork.

401030-01

–For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swingarm and frame, the basic settings of the suspension components must match the rider's weight.

–As delivered, KTM offroad motorcycles are adjusted for a standard rider weight (with full protective clothing).

Guideline

Standard rider weight	75… 85 kg (165… 187 lb.)

–If the rider's weight is above or below the standard range, the basic setting of the suspension components must be adjusted 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.

Compression9.2 damping of shock absorber

The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.

High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.

The high-speed setting, for example, has an effect on the landing after a jump: the rear wheel suspension compresses more quickly. The low-speed setting, for example, has an effect when riding over long ground swells: the rear wheel suspension compresses more slowly.

These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, changes in the high-speed range affect the compression damping in the low-speed range and vice versa.

Adjusting9.3 the low-speed compression damping of the shock absorber

Caution

Danger of accidents Disassembly of pressurized parts can lead to injury.

–The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)

Info

The low-speed setting can be seen during the slow to normal compression of the shock absorber.

–Turn adjusting screw clockwise with a screwdriver up to the last perceptible click.

Info

Do not loosen nut !

–Turn back counterclockwise by the number of clicks corresponding to the shock absorber type.

B00290-10

TUNING THE CHASSIS

Guideline

Compression damping, low-speed (450 SX F EU)

Comfort	17 clicks

Standard	15 clicks

Sport	13 clicks

Compression damping, low-speed (450 SX F USA)

Comfort	17 clicks

Standard	15 clicks

Sport	13 clicks

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damping.

Adjusting9.4 the high-speed compression damping of the shock absorber

Caution

Danger of accidents Disassembly of pressurized parts can lead to injury.

–The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)

Info

The high-speed setting can be seen during the fast compression of the shock absorber.

	– Turn adjusting screw all the way clockwise with a socket wrench.


				Info
				Info
				Do not loosen nut !

	– Turn back counterclockwise by the number of turns corresponding to the shock
		absorber type.
		Guideline

		Compression damping, high-speed (450 SX F EU)

B00289-10			Comfort		2.5 turns
			Comfort		2.5 turns

			Standard		2 turns

			Sport		1.5 turns

		Compression damping, high-speed (450			SX F USA)

			Comfort		2.5 turns

			Standard		2 turns

			Sport		1.5 turns

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damping.

Adjusting9.5 the rebound damping of the shock absorber

Caution

Danger of accidents Disassembly of pressurized parts can lead to injury.

–The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)

TUNING THE CHASSIS

B00291-10

Measuring9.6 rear wheel sag unloaded

–Turn adjusting screw clockwise up to the last perceptible click.

–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 (450 SX F USA)

Comfort	17 clicks

Standard	15 clicks

Sport	13 clicks

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damping.

–Raise the motorcycle with the lift stand. ( p. 30)

400988-10

–Measure the distance – as vertically as possible – between the rear axle and a fixed point, such as a mark on the side cover.

–Make note of the value as measurement .

–Remove the motorcycle from the lift stand. ( p. 30)

Checking9.7 the static sag of the shock absorber

400989-10

–Measure distance of rear wheel unloaded. ( p. 25)

–Hold the motorcycle upright with the aid of an assistant.

–Measure the distance between the rear axle and the fixed point again.

–Note down the value as dimension .

Info

The static sag is the difference between measurements and .

– Check the static sag.

Static sag (450	SX F EU)	30 mm (1.18 in)


Static sag (450	SX F USA)	34 mm (1.34 in)

»If the static sag is less or more than the specified value:

– Adjust the spring preload of the shock absorber. x( p. 26)

TUNING THE CHASSIS		26

Checking9.8	the riding sag of the shock absorber

400990-10

–Measure distance of rear wheel unloaded. ( p. 25)

–With another person holding the motorcycle, the rider, wearing full protective clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.

The rear wheel suspension levels out.

–Another person now measures the distance between the rear axle and a fixed point.

–Note down the value as dimension .

Info

The riding sag is the difference between measurements and .

– Check the riding sag.

	Riding sag (450	SX F EU)	90 mm (3.54 in)


	Riding sag (450	SX F USA)	100 mm (3.94 in)

»If the riding sag differs from the specified measurement:

– Adjust the riding sag. x( p. 27)

Adjusting9.9 the spring preload of the shock absorber x

Caution

Danger of accidents Disassembly of pressurized parts can lead to injury.

–The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)

Info

Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.

–Remove the shock absorber. x( p. 36)

–After removing the shock absorber, clean it thoroughly.

–Loosen screw .

–Turn adjusting ring until the spring is no longer under tension.

Hook wrench (T106S)

–Measure the overall spring length while the spring is not under tension.

–Tighten the spring by turning adjusting ring to measurement . Guideline

Spring preload (450	SX F EU)	15 mm (0.59 in)

Spring preload (450	SX F USA)	12 mm (0.47 in)

Info

Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload.

	–	Tighten screw .
		Guideline

		Screw, shock absorber adjusting ring	M5	5 Nm (3.7 lbf ft)
		(450 SX F EU)

		Screw, shock absorber adjusting ring	M5	5 Nm (3.7 lbf ft)
401025-10		Screw, shock absorber adjusting ring	M5	5 Nm (3.7 lbf ft)
401025-10		(450 SX F USA)
	–	(450 SX F USA)

		Install the shock absorber. x( p. 37)

TUNING THE CHASSIS

Adjusting9.10 the riding sag x

B00292-10

–Remove the shock absorber. x( p. 36)

–After removing the shock absorber, clean it thoroughly.

–Choose and mount a suitable spring. Guideline

Spring rate (450 SX F EU)

Weight of rider: 65… 75 kg (143…	54 N/mm (308 lb/in)
165 lb.)

Weight of rider: 75… 85 kg (165…	57 N/mm (325 lb/in)
187 lb.)

Weight of rider: 85… 95 kg (187…	60 N/mm (343 lb/in)
209 lb.)

Spring rate (450 SX F USA)

Weight of rider: 65… 75 kg (143…	54 N/mm (308 lb/in)
165 lb.)

Weight of rider: 75… 85 kg (165…	57 N/mm (325 lb/in)
187 lb.)

Weight of rider: 85… 95 kg (187…	60 N/mm (343 lb/in)
209 lb.)

Info

The spring rate is shown on the outside of the spring.

–Install the shock absorber. x( p. 37)

–Check the static sag of the shock absorber. ( p. 25)

–Check the riding sag of the shock absorber. ( p. 26)

–Adjust the rebound damping of the shock absorber. ( p. 24)

Checking9.11 basic setting of fork

Info

For various reasons, no exact riding sag can be determined for the forks.

–As with the shock absorber, smaller differences in the rider's weight can be compensated by the spring preload.

–However, if the fork is often overloaded (hard end stop on compression), harder springs must be fit to avoid damage to the fork and frame.

401000-01

Adjusting9.12 the compression damping of the fork

Info

The hydraulic compression damping determines the fork suspension behavior.

–Turn adjusting screws clockwise all the way.

Info

Adjusting screws are located at the top end of the fork legs.

Make the same adjustment on both fork legs.

–Turn back counterclockwise by the number of clicks corresponding to the fork type.

101275-10

TUNING THE CHASSIS		28
	Guideline

	Compression damping (450 SX F EU)

	Comfort	14 clicks

	Standard	12 clicks

	Sport	10 clicks

	Compression damping (450 SX F USA)

	Comfort	14 clicks

	Standard	12 clicks

	Sport	10 clicks

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damping.

Adjusting9.13 the rebound damping of the fork

Info

The hydraulic rebound damping determines the fork suspension behavior.

	– Remove protection caps .
	– Remove protection caps .
	– Turn adjusting screws clockwise all the way.

				Info
				Info
				Adjusting screws are located at the bottom end of the fork legs.
				Make the same adjustment on both fork legs.

	– Turn back counterclockwise by the number of clicks corresponding to the fork type.
		Guideline

B00295-10		Rebound damping (450 SX F EU)

			Comfort		14 clicks

			Standard		12 clicks

			Sport		10 clicks

		Rebound damping (450 SX F USA)

			Comfort		14 clicks

			Standard		12 clicks

			Sport		10 clicks

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damping.

–Mount protection covers .

Handlebar9.14 position

0A 0B

On the upper triple clamp, there are 2 holes at a distance of to each other.

Hole distance A	15 mm (0.59 in)

The holes on the handlebar support are placed at a distance of from the center.

Hole distance B	3.5 mm (0.138 in)

The handlebar can be mounted in four different positions. In this way, the handlebar can be mounted in the position that is most comfortable for the rider.

800116-10

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