2014r Repair manual.pdf
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REPAIR MANUAL
2014
450 SX‑F EU
450 SX‑F USA
450 XC-F USA
Art. no. 3206171en
INTRODUCTION
It is important that you read this repair manual carefully and completely before starting work.
INTRODUCTION
1
This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified
experts.
The repair manual was written to correspond to the most current state of this model series. We reserve the right to make changes in
the interest of technical advancement without, at the same time, updating this repair manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that repair work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, 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 spe-
cial equipment that does not belong to the regular scope of supply.
© 2013 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
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
TABLE OF CONTENTS
2
Disassembling the piston rod .......................
Disassembling the hydrostop unit .................
Disassembling the seal ring retainer..............
Checking the fork legs .................................
Assembling the seal ring retainer..................
Assembling the hydrostop unit .....................
Assembling the piston rod ...........................
Assembling the cartridge .............................
Assembling the fork legs..............................
Greasing the steering head bearing ...............
Removing the lower triple clamp ..................
Installing the lower triple clamp ...................
Checking the steering head bearing play .......
Adjusting the play of the steering head
bearing ......................................................
6.13 Greasing the steering head bearing ...................
6.14 Removing the lower triple clamp.......................
6.15 Installing the lower triple clamp .......................
6.16 Checking the steering head bearing play............
6.17 Adjusting the play of the steering head
bearing ..........................................................
HANDLEBAR, CONTROLS...........................................
7.1
Handlebar position..........................................
7.2
Adjusting the handlebar position ......................
7.3
Adjusting the basic position of the clutch
lever ..............................................................
7.4
Checking the throttle cable routing ...................
7.5
Checking the play in the throttle cable ..............
7.6
Adjusting the play in the throttle cable..............
SHOCK ABSORBER, SWINGARM ................................
8.1
Adjusting the high-speed compression
damping of the shock absorber.........................
8.2
Adjusting the low-speed compression damping
of the shock absorber ......................................
8.3
Adjusting the rebound damping of the shock
absorber.........................................................
8.4
Measuring rear wheel sag unloaded...................
8.5
Checking the static sag of the shock absorber ....
8.6
Checking the riding sag of the shock absorber....
8.7
Adjusting the spring preload of the shock
absorber.........................................................
8.8
Adjusting the riding sag ...................................
8.9
Removing the shock absorber ...........................
8.10 Installing the shock absorber............................
8.11 Checking the shock absorber linkage.................
8.12 Servicing the shock absorber............................
8.13 Removing the spring........................................
8.14 Disassembling the damper ...............................
8.15 Disassembling the piston rod ...........................
8.16 Disassembling the seal ring retainer..................
8.17 Changing the pilot bushing ..............................
8.18 Checking the damper ......................................
8.19 Removing the heim joint..................................
8.20 Installing the heim joint...................................
8.21 Assembling the seal ring retainer ......................
8.22 Assembling the piston rod................................
8.23 Assembling the damper ...................................
8.24 Bleeding and filling the damper .......................
8.25 Filling the damper with nitrogen .......................
8.26 Installing the spring (SX‑F EU) .........................
8.27 Installing the spring (SX‑F USA, XC‑F) ..............
6.12.5
6.12.6
6.12.7
6.12.8
6.12.9
6.12.10
6.12.11
6.12.12
6.12.13
6.12.14
6.12.15
6.12.16
6.12.17
6.12.18
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MEANS OF REPRESENTATION ..................................... 6
1.1
Symbols used ................................................... 6
1.2
Formats used.................................................... 6
SAFETY ADVICE........................................................... 7
2.1
Repair Manual .................................................. 7
2.2
Safety advice.................................................... 7
2.3
Degrees of risk and symbols ............................... 7
2.4
Work rules........................................................ 7
IMPORTANT NOTES..................................................... 8
3.1
Guarantee, warranty .......................................... 8
3.2
Operating and auxiliary substances ..................... 8
3.3
Spare parts, accessories .................................... 8
3.4
Figures ............................................................ 8
SERIAL NUMBERS ...................................................... 9
4.1
Chassis number ................................................ 9
4.2
Type label ........................................................ 9
4.3
Engine number ................................................. 9
4.4
Fork part number .............................................. 9
4.5
Shock absorber part number .............................. 9
MOTORCYCLE ........................................................... 10
5.1
Raising the motorcycle with the lift stand.......... 10
5.2
Removing the motorcycle from the lift stand...... 10
5.3
Starting.......................................................... 11
5.4
Starting the motorcycle for a check................... 11
FORK, TRIPLE CLAMP ............................................... 12
6.1
Adjusting the compression damping of the
fork ............................................................... 12
6.2
Adjusting the rebound damping of the fork ........ 12
6.3
Bleeding the fork legs...................................... 13
6.4
Cleaning the dust boots of the fork legs............. 14
6.5
Loosening the fork protection ........................... 14
6.6
Positioning the fork protection.......................... 14
6.7
Removing the fork legs .................................... 15
6.8
Installing the fork legs ..................................... 15
6.9
Removing the fork protector ............................. 16
6.10 Installing the fork protector.............................. 16
6.11 All SX‑F models .............................................. 16
6.11.1
Conducting major fork service ...................... 16
6.11.2
Conducting minor fork service ...................... 17
6.11.3
Disassembling the fork legs ......................... 17
6.11.4
Disassembling the cartridge ......................... 20
6.11.5
Disassembling the piston rod ....................... 22
6.11.6
Disassembling the screw cap with the
membrane holder........................................ 23
6.11.7
Disassembling the screw sleeve.................... 24
6.11.8
Checking the fork legs ................................. 25
6.11.9
Checking the fork legs - during a minor fork
service ....................................................... 26
6.11.10 Changing the pilot bushing .......................... 27
6.11.11 Assembling the screw sleeve ........................ 28
6.11.12 Assembling the screw cap with the
membrane holder........................................ 28
6.11.13 Assembling the piston rod ........................... 29
6.11.14 Assembling the cartridge ............................. 31
6.11.15 Assembling the fork legs.............................. 32
6.11.16 Bleeding and filling the cartridge.................. 36
6.11.17 Filling the cartridge with nitrogen ................. 37
6.12 XC‑F .............................................................. 38
6.12.1
Performing a fork service ............................. 38
6.12.2
Disassembling the fork legs ......................... 38
6.12.3
Removing the spring ................................... 40
6.12.4
Disassembling the cartridge ......................... 41
7
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TABLE OF CONTENTS
9
EXHAUST .................................................................. 87
9.1
Removing the manifold.................................... 87
9.2
Installing the manifold .................................... 87
9.3
Removing the main silencer ............................. 88
9.4
Installing the main silencer.............................. 88
9.5
Changing the glass fiber yarn filling of the
main silencer.................................................. 88
AIR FILTER ............................................................... 90
10.1 Removing the air filter box lid .......................... 90
10.2 Installing the air filter box lid ........................... 90
10.3 Removing the air filter ..................................... 90
10.4 Installing the air filter...................................... 91
10.5 Cleaning the air filter and air filter box .............. 91
10.6 Sealing the air filter box .................................. 92
10.7 Securing the air filter box lid............................ 92
FUEL TANK, SEAT, TRIM ........................................... 93
11.1 Opening the filler cap...................................... 93
11.2 Closing the filler cap ....................................... 93
11.3 Removing the seat .......................................... 94
11.4 Mounting the seat ........................................... 94
11.5 Removing the fuel tank.................................... 94
11.6 Installing the fuel tank .................................... 95
11.7 Checking the fuel pressure............................... 96
11.8 Changing the fuel pump .................................. 97
11.9 Changing the fuel filter.................................... 99
11.10 Changing the fuel screen ............................... 101
MASK, FENDER....................................................... 103
12.1 Removing the front fender ............................. 103
12.2 Installing the front fender .............................. 103
12.3 Removing the start number plate .................... 103
12.4 Installing the start number plate..................... 104
WHEELS ................................................................. 105
13.1 Checking the tire air pressure......................... 105
13.2 Checking the tire condition ............................ 105
13.3 Checking the brake discs ............................... 105
13.4 Checking the spoke tension............................ 106
13.5 Front wheel .................................................. 106
13.5.1
Removing the front wheel .......................... 106
13.5.2
Installing the front wheel ........................... 107
13.5.3
Removing the brake disc of the front
brake ....................................................... 108
13.5.4
Installing the brake disc of the front
brake ....................................................... 108
13.6 Rear wheel ................................................... 108
13.6.1
Removing the rear wheel ........................... 108
13.6.2
Installing the rear wheel ............................ 109
13.6.3
Removing the brake disc of the rear
brake ....................................................... 110
13.6.4
Installing the brake disc of the rear brake.... 110
13.6.5
Checking the chain tension........................ 110
13.6.6
Adjusting the chain tension ....................... 111
13.6.7
Adjusting the chain guide .......................... 112
13.6.8
Checking the chain, rear sprocket, engine
sprocket, and chain guide.......................... 112
13.6.9
Checking for chain dirt accumulation.......... 114
13.6.10 Cleaning the chain .................................... 114
WIRING HARNESS, BATTERY................................... 115
14.1 Changing the main fuse ................................. 115
14.2 Removing the battery .................................... 116
14.3 Installing the battery ..................................... 116
14.4 Charging the battery ...................................... 116
14.5 Checking the charging voltage ........................ 117
14.6 Checking the quiescent current ......................
14.7 Checking the capacitor ..................................
14.8 Checking the starter relay ..............................
15 BRAKE SYSTEM ......................................................
15.1 Checking the front brake linings .....................
15.2 Changing the front brake linings .....................
15.3 Checking the free travel of the hand brake
lever ............................................................
15.4 Adjusting the basic position of the hand
brake lever ...................................................
15.5 Checking the brake fluid level of the front
brake ...........................................................
15.6 Adding front brake fluid.................................
15.7 Changing the front brake fluid ........................
15.8 Checking the rear brake linings ......................
15.9 Changing the rear brake linings ......................
15.10 Checking the free travel of foot brake lever ......
15.11 Adjusting the basic position of the foot brake
lever ............................................................
15.12 Checking the rear brake fluid level..................
15.13 Adding rear brake fluid ..................................
15.14 Changing the rear brake fluid .........................
16 ENGINE ..................................................................
16.1 Removing the engine.....................................
16.2 Installing the engine......................................
16.3 Engine disassembly.......................................
16.3.1
Preparations .............................................
16.3.2
Draining the engine oil ..............................
16.3.3
Removing the clutch push rod....................
16.3.4
Removing the oil filter ...............................
16.3.5
Removing the starter motor........................
16.3.6
Removing the spark plug ...........................
16.3.7
Removing the valve cover...........................
16.3.8
Removing the alternator cover ....................
16.3.9
Positioning the engine at ignition top dead
center......................................................
16.3.10 Removing the timing chain tensioner ..........
16.3.11 Removing the camshaft .............................
16.3.12 Removing the cylinder head .......................
16.3.13 Removing the piston .................................
16.3.14 Removing the rotor....................................
16.3.15 Removing the timing chain ........................
16.3.16 Removing the ignition pulse generator ........
16.3.17 Removing the suction pump.......................
16.3.18 Removing the water pump cover.................
16.3.19 Removing the clutch cover.........................
16.3.20 Removing the clutch discs .........................
16.3.21 Removing the outer clutch hub ..................
16.3.22 Removing the torque limiter.......................
16.3.23 Removing the starter idler gear...................
16.3.24 Removing the shift shaft............................
16.3.25 Removing the shift drum locating unit ........
16.3.26 Removing the locking lever ........................
16.3.27 Removing the force pump..........................
16.3.28 Removing the primary gear ........................
16.3.29 Removing the freewheel gear .....................
16.3.30 Removing the left engine case section ........
16.3.31 Removing the shift rails.............................
16.3.32 Removing the shift drum ...........................
16.3.33 Removing the shift forks............................
16.3.34 Removing the transmission shafts...............
16.3.35 Removing the crankshaft ...........................
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