Ktm 450 Sxf 2015

Ktm 450 Sxf 2015

• Contents
• Table of Contents
• Troubleshooting
• Bookmarks

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  Summary of Contents for KTM 450 SX-F

• Page 1 OWNER'S MANUAL 2014 450 SX‑F EU 450 SX‑F USA 450 SX‑F FACTORY EDITION USA 450 XC-F USA Art. no. 3213090en...
• Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.

• Page 4: Table Of Contents

  TABLE OF CONTENTS Preparing for rides at low temperatures or in TABLE OF CONTENTS MEANS OF REPRESENTATION ........4 snow.............. 20 Symbols used ........... 4 RIDING INSTRUCTIONS..........21 Formats used............ 4 Checks and maintenance work when preparing SAFETY ADVICE............5 for use ............
• Page 5 TABLE OF CONTENTS 13.6 Checking the tire air pressure......72 11.17 Greasing the steering head bearing ....43 13.7 Checking the spoke tension......72 11.18 Removing the start number plate ...... 44 11.19 Installing the start number plate....... 44 14 ELECTRICAL SYSTEM ..........74 11.20 Removing the front fender .......

• Page 6: Means Of Representation

  All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required.

• Page 7: Safety Advice

  SAFETY ADVICE Use definition - intended use KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply with currently valid regulations and categories of the top international motorsport organizations.

• Page 8: Protective Clothing

  Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.

• Page 9: Important Notes

  Guarantee, 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 & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle.

• Page 10: View Of Vehicle

  VIEW OF VEHICLE View of vehicle, front left (example) C00485-10 Kill switch ( p. 11) Clutch lever ( p. 11) Filler cap Air filter box lid Cold start button ( p. 14) Shift lever ( p. 15) Chain guide...

• Page 11: View Of Vehicle, Rear Right (Example)

  VIEW OF VEHICLE View of vehicle, rear right (example) C00486-10 Electric starter button ( p. 11) Hand brake lever ( p. 11) Level viewer for brake fluid, rear Shock absorber part number ( p. 10) Foot brake lever ( p. 16) Fork part number ( p.

• Page 12: Serial Numbers

  SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. 401945-10 Type label The type label is fixed to the front of the steering head. 401946-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.

• Page 13: Controls

  CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. C00214-10 Hand 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. C00215-10 Throttle grip The throttle grip...

• Page 14: Map-Select Switch For The Basic Setting (Sx-F Factory Edition)

  CONTROLS Map‑Select switch for the basic setting (SX‑F Factory Edition) The Map‑Select switch for the basic setting is fitted under the seat. Possible states SOFT – The mapping with reduced peak performance for better ride- ability is activated. ADVANCED – The mapping for performance with a very direct response is activated.

• Page 15: Closing The Filler Cap

  CONTROLS (All SX‑F models) – Turn filler cap counterclockwise and lift it off. C00395-10 (XC‑F) – Press release button , turn the filler cap counterclockwise, and lift it free. C00396-10 6.10 Closing the filler cap (All SX‑F models) – Mount filler cap and turn it clockwise until the fuel tank is tightly closed.

• Page 16: Factory Start (Sx-F Factory Edition)

  CONTROLS 6.11 Factory Start (SX‑F Factory Edition) 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 motor- cycle is lowered.

• Page 17: Idle Speed Adjusting Screw

  CONTROLS 6.13 Idle speed adjusting screw The idle setting of the throttle valve body has a big influence on the vehicle's starting behavior, on stable idling, and on vehicle response when the throttle is opened. This means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly.

• Page 18: Foot Brake Lever

  CONTROLS 6.15 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 601840-10 6.16 Side stand (XC‑F) The side stand is on the left side of the vehicle. C00491-10 The side stand is used to park the motorcycle.

• Page 19: Preparing For Use

  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.

• Page 20: Running In The Engine

  PREPARING FOR USE (All SX‑F models) – Do not transport luggage. (XC‑F) – 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.

• Page 21: Preparing For Rides On Dry Sand

  – Fit a dust cover on the air filter. Dust protection device for air filter (77206920000) Info See the KTM PowerParts fitting instructions. B00435-01 – Fit a sand cover on the air filter. Sand protection device for air filter (77206922000) Info See the KTM PowerParts fitting instructions.

• Page 22: Preparing For Rides On Wet And Muddy Surfaces

  Preparing 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. B00437-01 – Fit the steel sprocket. – Clean the motorcycle. ( p.

• Page 23: Riding Instructions

  RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p. 82) –...

• Page 24: Starting Off

  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.

• Page 25: Transport

  – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards.
• Page 26 RIDING INSTRUCTIONS – Switch off the engine. – Open the filler cap. ( p. 12) – Fill the fuel tank with fuel up to measurement Guideline 35 mm (1.38 in) Measurement of Total fuel tank 7.5 l Super unleaded (ROZ 95/RON 95/PON capacity, approx.

• Page 27: Service Schedule

  Final check: Check the vehicle for safe operation and take a test ride. ○ ● ● ● ● Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● ● ● ● Make the service entry in KTM DEALER.NET and in the service record.

• Page 28: Service Work (As Additional Order)

  SERVICE SCHEDULE ○ One-time interval ● Periodic interval Service work (as additional order) Annually Every 100 operating hours - corresponds to about 700 liters of fuel (185 US gal) Every 50 operating hours - corresponds to about 350 liters of fuel (92.5 US gal) Every 40 operating hours - corresponds to about 280 liters of fuel (74 US gal) Once after 20 operating hours ●...

• Page 29: Tuning The Chassis

  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.

• Page 30: Adjusting 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.

• Page 31: Adjusting The Rebound Damping Of The Shock Absorber

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

• Page 32: Measuring Rear Wheel Sag Unloaded

  TUNING THE CHASSIS 10.6 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with the lift stand. ( p. 36) Main work – Measure the vertical distance between the rear axle and a fixed point such as a marking on the side cover.

• Page 33: Adjusting The Spring Preload 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 Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.

• Page 34: Checking The Basic Setting Of The Fork

  TUNING THE CHASSIS Main work – Choose and mount a suitable spring. Guideline Spring rate (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…...

• Page 35: Adjusting The Compression Damping Of The Fork

  TUNING THE CHASSIS 10.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. (SX‑F EU, SX‑F USA) – 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.

• Page 36: Adjusting The Rebound Damping Of The Fork

  TUNING THE CHASSIS 10.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. (SX‑F EU, SX‑F USA) – Remove protection caps – Turn adjusting screws clockwise all the way. Info Adjusting screws are located at the bottom end of the fork legs.

• Page 37: Handlebar Position

  TUNING THE CHASSIS 10.14 Handlebar position On the upper triple clamp, there are two 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.

• Page 38: Service Work On The Chassis

  SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. The wheels must no longer touch the ground.

• Page 39: Cleaning The Dust Boots Of The Fork Legs

  SERVICE WORK ON THE CHASSIS 11.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 36) (SX‑F EU, SX‑F USA, XC‑F) – Loosen the fork protection. ( p. 37) (SX‑F Factory Edition) –...

• Page 40: Removing The Fork Legs

  SERVICE WORK ON THE CHASSIS 11.7 Removing the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 36) – Remove the front wheel. p. 69) Main work – Remove screws and take off the clamp. –...

• Page 41: Removing The Fork Protector

  SERVICE WORK ON THE CHASSIS – Position the brake caliper. Mount and tighten screws Guideline Screw, front brake caliper 25 Nm Loctite ® 243™ (18.4 lbf ft) – Position the brake line and clamp. Mount and tighten screws B00300-11 Finishing work –...

• Page 42: Installing The Fork Protector

  SERVICE WORK ON THE CHASSIS – Remove screws on the right fork leg. Take off the fork protector. 101956-10 11.12 Installing the fork protector (SX‑F Factory Edition) – Position the fork protector on the right fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft)

• Page 43: Installing The Lower Triple Clamp

  SERVICE WORK ON THE CHASSIS 11.14 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. 0 0 3 High viscosity grease ( p. 102) – Insert the lower triple clamp with the steering stem. Mount the upper steering head 0 0 2 bearing.

• Page 44: Checking The Steering Head Bearing Play

  Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam-...

• Page 45: Adjusting The Play Of The Steering Head Bearing

  SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with the lift stand. ( p. 36) Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing.

• Page 46: Removing The Start Number Plate

  SERVICE WORK ON THE CHASSIS 11.18 Removing the start number plate – Remove screw and take off the clamp. – Remove screw . Take off the start number plate. C00419-10 11.19 Installing the start number plate – Position the start number plate. Mount and tighten screw Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft)

• Page 47: Installing The Front Fender

  SERVICE WORK ON THE CHASSIS 11.21 Installing the front fender Main work – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) C00420-10 Finishing work – Install the start number plate. ( p.

• Page 48: Installing The Shock Absorber

  SERVICE WORK ON THE CHASSIS – Remove the cable binder of the frame protector. – Remove screw – Remove the frame protector. Info Pay attention to the holding lugs. L01277-10 – Remove screw – Carefully remove the shock absorber upward out of the vehicle. L01279-10 11.23 Installing the shock absorber...

• Page 49: Removing The Seat

  SERVICE WORK ON THE CHASSIS Finishing work – Install the manifold. – Remove the motorcycle from the lift stand. ( p. 36) 11.24 Removing the seat – Remove screw – Lift up the seat at the rear, pull it back and then remove it from above. C00427-10 11.25 Mounting the seat...

• Page 50: Removing The Air Filter

  SERVICE WORK ON THE CHASSIS Condition The air filter box lid is secured. – Mount and tighten screws Guideline Screw, air filter box lid EJOT PT ® 3 Nm (2.2 lbf ft) K60x20-Z EJOT PT screw (0017060204) C00492-10 11.28 Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine.

• Page 51: Cleaning The Air Filter And Air Filter Box

  SERVICE WORK ON THE CHASSIS 11.30 Cleaning the air filter and air filter box Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Do not clean the air filter with fuel or petroleum since these substances attack the foam.

• Page 52: Removing The Main Silencer

  SERVICE WORK ON THE CHASSIS 11.33 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. – Disconnect spring Spring hooks (50305017000) –...

• Page 53: Removing The Fuel Tank

  SERVICE WORK ON THE CHASSIS Main work (SX‑F EU, SX‑F USA, XC‑F) – Remove all screws from the main silencer. – Remove silencer cap and O-ring – Remove outer tube and O-ring – Pull the glass fiber yarn filling from the inner tube –...
• Page 54 SERVICE WORK ON THE CHASSIS Main work – Unplug connector of the fuel pump. C00166-10 – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve.

• Page 55: Installing The Fuel Tank

  SERVICE WORK ON THE CHASSIS 11.37 Installing the fuel tank 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. –...

• Page 56: Checking For Chain Dirt Accumulation

  SERVICE WORK ON THE CHASSIS 11.38 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 54) 400678-01 11.39 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. –...

• Page 57: Adjusting The Chain Tension

  SERVICE WORK ON THE CHASSIS Main work – Push the chain at the end of the chain sliding component upwards to measure the chain tension Info The lower chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions.

• Page 58: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

  SERVICE WORK ON THE CHASSIS 11.42 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with the lift stand. ( p. 36) Main work – Shift gear to neutral. – Check the rear sprocket and engine sprocket for wear. »...

• Page 59: Checking The Frame

  If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by KTM. 401519-01...

• Page 60: Checking The Swingarm

  If the swingarm shows signs of damage, cracking, or deformation: – Change the swingarm. Info A damaged swingarm must always be changed. Repair of the swingarm is not authorized by KTM. 401520-01 11.45 Checking the throttle cable routing Preparatory work –...

• Page 61: Additionally Securing The Rubber Grip

  SERVICE WORK ON THE CHASSIS 11.47 Additionally securing the rubber grip Preparatory work – Check the rubber grip. ( p. 58) Main work – Secure the rubber grip at two points using the securing wire. Securing wire (54812016000) Wire twister forceps (U6907854) The twisted wire ends face away from the hands and are bent toward the rub- ber grip.
• Page 62 SERVICE WORK ON THE CHASSIS – Fill bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p. 100) – On the clutch slave cylinder, remove bleeder screw and mount bleeding syringe C00163-10 –...

• Page 63: Brake System

  Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disk...

• Page 64: Checking The Brake Fluid Level Of The Front Brake

  KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Preparatory work –...

• Page 65: Checking The Front Brake Linings

  Changing the front brake linings Warning Danger of accident Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid can cause skin irritation on contact. –...
• Page 66 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

• Page 67: Checking The Free Travel Of Foot Brake Lever

  BRAKE SYSTEM – Add brake fluid to level Guideline 5 mm (0.2 in) Dimension (brake fluid level below top edge of container) Brake fluid DOT 4 / DOT 5.1 ( p. 100) – Position cover with membrane – Mount and tighten screws Info Clean up overflowed or spilt brake fluid immediately with water.

• Page 68: Checking The Rear Brake Fluid Level

  KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Preparatory work –...

• Page 69: Checking The Rear Brake Linings

  Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
• Page 70 BRAKE SYSTEM Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.

• Page 71: Wheels, Tires

  WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 36) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

• Page 72: Removing The Rear Wheel

  WHEELS, TIRES (SX‑F Factory Edition) – Align the brake disc guard so that gaps are the same size. 101961-10 – Mount and tighten screw Guideline (SX‑F EU, SX‑F USA, XC‑F) Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) (SX‑F Factory Edition) Screw, front wheel spindle M20x1.5...

• Page 73: Installing The Rear Wheel

  WHEELS, TIRES – Remove spacers S00173-10 13.4 Installing the rear wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Main work –...

• Page 74: Checking The Tire Condition

  Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes.
• Page 75 WHEELS, TIRES – Briefly strike each spoke with the tip of a screwdriver. Info The tone frequency depends on the length of the spoke and the spoke diam- eter. If you hear different tone frequencies from different spokes of equal length and diameter, this is an indication of different spoke tensions.

• Page 76: Electrical System

  ELECTRICAL SYSTEM 14.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...

• Page 77: Charging The Battery

  – Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

• Page 78: Changing The Main Fuse

  ELECTRICAL SYSTEM 14.4 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box lid. Preparatory work –...

• Page 79: Cooling System

  COOLING SYSTEM 15.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

• Page 80: Draining The Coolant

  COOLING SYSTEM Condition The engine is cold. – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the coolant level in the radiator. 10 mm (0.39 in) Coolant level above radiator fins. » If the coolant level does not meet specifications: –...

• Page 81: Refilling Coolant

  COOLING SYSTEM 15.5 Refilling coolant Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water imme- diately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swal- lowed, contact a physician immediately.

• Page 82: Tuning The Engine

  TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3…...

• Page 83: Adjusting The Idle Speed

  TUNING THE ENGINE 16.3 Adjusting the idle speed – Run the engine until warm. – Set the desired idle speed by turning the idle speed adjusting screw Guideline Idle speed 2,250… 2,350 rpm Tachometer (45129075000) Info Turn counterclockwise to decrease the idle speed. Turn clockwise to increase the idle speed.

• Page 84: Service Work On The Engine

  SERVICE WORK ON THE ENGINE 17.1 Changing the fuel screen 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. –...

• Page 85: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens

  SERVICE WORK ON THE ENGINE 17.3 Changing the engine oil and oil filter, cleaning the oil screens Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.
• Page 86 SERVICE WORK ON THE ENGINE – Place the long oil screen with the O-rings onto a pin wrench. – Push the pin wrench through the opening into the drill hole of the opposite engine case wall and push the engine oil screen as far as possible into the engine case. C00236-10 –...

• Page 87: Adding Engine Oil

  SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

• Page 88: Cleaning, Care

  CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts.

• Page 89: Storage

  – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 36) – Cover the vehicle with a tarp or a cover that is permeable to air.

• Page 90: Troubleshooting

  – Check the electrical system. – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool.
• Page 91 TROUBLESHOOTING Faults Possible cause Action – Battery is discharged Unwanted power consumer Check the quiescent current.

• Page 92: Blink Code

  BLINK CODE Blink code FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Crankshaft position sensor - circuit fault Blink code FI warning lamp (MIL) 06 FI warning lamp (MIL) flashes 6x short Error level condition Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high Blink code FI warning lamp (MIL)

• Page 93: Technical Data

  TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 449.3 cm³ (27.418 cu in) Stroke 63.4 mm (2.496 in) Bore 95 mm (3.74 in) Compression ratio 12.6:1 Idle speed 2,250… 2,350 rpm Control OHC, 4 valves controlled via rocker arm Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust...
• Page 94 TECHNICAL DATA – Screw, oil filter cover 6 Nm (4.4 lbf ft) Screw, suction pump cover 6 Nm (4.4 lbf ft) Loctite ® 243™ Nut, water-pump wheel 8 Nm (5.9 lbf ft) Loctite ® 243™ – Screw, alternator cover 10 Nm (7.4 lbf ft) Screw, bearing bolt for starter idler 10 Nm (7.4 lbf ft) Loctite...

• Page 95: Capacities

  TECHNICAL DATA 22.3 Capacities 22.3.1 Engine oil Engine oil 1.50 l (1.59 qt.) Engine oil (SAE 10W/50) ( p. 100) 22.3.2 Coolant Coolant 1.20 l (1.27 qt.) Coolant ( p. 100) Coolant (mixed ready to use) ( p. 100) 22.3.3 Fuel Total fuel tank capacity, 7.5 l (1.98 US gal)

• Page 96: Electrical System

  (XC‑F) 80/100 - 21 M/C 51M TT 110/100 - 18 64M TT Dunlop GEOMAX MX 51 FA Dunlop GEOMAX MX 51 Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork 22.7.1 SX‑F EU Fork part number 14.18.7N.09...

• Page 97: Sx-F Usa

  TECHNICAL DATA 22.7.2 SX‑F USA Fork part number 14.18.7N.59 Fork WP Suspension Up Side Down 4860 MXMA CC Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Spring length with preload spacer(s) 490 mm (19.29 in) Spring rate...

• Page 98: Shock Absorber

  TECHNICAL DATA Sport 11 clicks Spring length with preload spacer(s) 470 mm (18.5 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 4.4 N/mm (25.1 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 4.6 N/mm (26.3 lb/in) Weight of rider: 85…...

• Page 99: Sx-F Factory Edition

  TECHNICAL DATA Standard 15 clicks Sport 13 clicks Spring preload 12 mm (0.47 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 54 N/mm (308 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 57 N/mm (325 lb/in) Weight of rider: 85…...

• Page 100: Chassis Tightening Torques

  TECHNICAL DATA Sport 1.5 turns Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 12 mm (0.47 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 54 N/mm (308 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 57 N/mm (325 lb/in) Weight of rider: 85…...
• Page 101 TECHNICAL DATA – Remaining screws, chassis 45 Nm (33.2 lbf ft) Screw, bottom shock absorber 60 Nm (44.3 lbf ft) Loctite ® 2701™ Screw, handlebar support 40 Nm (29.5 lbf ft) Loctite ® 243™ Screw, top shock absorber 60 Nm (44.3 lbf ft) Loctite ®...

• Page 102: Substances

  SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®...
• Page 103 SUBSTANCES Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification – DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e.

• Page 104: Auxiliary Substances

  Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Rubber grip adhesive (00062030051) Recommended supplier KTM-Sportmotorcycle AG – GRIP GLUE Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ® –...
• Page 105 AUXILIARY SUBSTANCES Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic...

• Page 106: Standards

  STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation.

• Page 107: Index

  INDEX Clutch lever ........11 INDEX basic position, adjusting ..... . 59 Accessories .
• Page 108 INDEX rebound damping, adjusting ....34 Oil screens removing ....... . . 38 cleaning .
• Page 109 INDEX Start number plate installing ....... . . 44 removing ....... . . 44 Starting .
• Page 110 *3213090en* 3213090en 11/2013 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

Ktm 450 Sxf 2015

Source: https://www.manualslib.com/manual/1150142/Ktm-450-Sx-F.html

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