2012r Repair manual.pdf

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REPAIR MANUAL
2012
450 SX‑F EU
450 SX‑F USA
Art. no. 3206119en
INTRODUCTION
It is important that you read this owner's manual carefully and completely before the start of work.
INTRODUCTION
1
Only use
ORIGINAL KTM SPARE PARTS.
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 delivery.
© 2011 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
Adjusting the rebound damping of the shock absorber.......
Measuring rear wheel sag unloaded .................................
Checking the static sag of the shock absorber ..................
Checking the riding sag of the shock absorber ..................
Adjusting the spring preload of the shock absorber ...........
Adjusting the riding sag .................................................
Removing the shock absorber .........................................
Installing the shock absorber ..........................................
Checking the shock absorber linkage ...............................
Servicing the shock absorber ..........................................
Removing the spring ......................................................
Disassembling the damper .............................................
Disassembling the piston rod ..........................................
Disassembling the seal ring retainer ................................
Changing the pilot bushing.............................................
Checking the damper .....................................................
Removing the heim joint ................................................
Installing the heim joint .................................................
Assembling the seal ring retainer ....................................
Assembling the piston rod ..............................................
Assembling the damper..................................................
Bleeding and filling the damper ......................................
Filling the damper with nitrogen .....................................
Installing the spring (450 SX‑F EU) ................................
Installing the spring (450 SX‑F USA) ..............................
Checking the swingarm ..................................................
05/EXHAUST ....................................................................
Removing main silencer .................................................
Installing the main silencer ............................................
Changing the glass fiber yarn filling of the main silencer ...
06/AIR FILTER..................................................................
Removing the air filter box lid.........................................
Installing the air filter box lid..........................................
Removing the air filter ...................................................
Installing the air filter ....................................................
Cleaning the air filter and air filter box ............................
Removing the carburetor connection boot ........................
Installing the carburetor connection boot .........................
07/FUEL TANK, SEAT, TRIM..............................................
Opening filler cap ..........................................................
Closing filler cap ...........................................................
Removing the seat .........................................................
Mounting the seat .........................................................
Removing the fuel tank ..................................................
Installing the fuel tank ...................................................
Fuel tap........................................................................
08/MASK, FENDER ...........................................................
Removing the front fender ..............................................
Installing the front fender...............................................
Removing the start number plate ....................................
Installing the start number plate .....................................
09/FRONT WHEEL ............................................................
Removing front wheel ....................................................
Installing the front wheel................................................
Checking the brake discs................................................
Removing the front brake disc ........................................
Installing the front brake disc .........................................
Checking the tire condition.............................................
Checking tire air pressure ...............................................
Checking spoke tension..................................................
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MEANS OF REPRESENTATION ............................................ 6
IMPORTANT NOTES ............................................................ 7
SERIAL NUMBERS.............................................................. 8
Chassis number............................................................... 8
Type label....................................................................... 8
Engine number................................................................ 8
Fork part number............................................................. 8
Shock absorber part number............................................. 8
MOTORCYCLE..................................................................... 9
Raising the motorcycle with the lift stand .......................... 9
Removing the motorcycle from the lift stand ...................... 9
Starting .......................................................................... 9
Starting the motorcycle for checking ............................... 10
01/FORK, TRIPLE CLAMP.................................................. 11
Adjusting the compression damping of the fork ................ 11
Adjusting the rebound damping of the fork....................... 11
Bleeding fork legs.......................................................... 12
Cleaning the dust boots of the fork legs ........................... 12
Loosening the fork protector ........................................... 12
Positioning the fork protection ........................................ 13
Removing the fork legs................................................... 13
Installing the fork legs ................................................... 13
Removing the fork protector............................................ 14
Installing the fork protector ............................................ 14
Conducting major fork service......................................... 14
Conducting minor fork service......................................... 15
Disassembling the fork legs ............................................ 15
Disassembling the cartridge............................................ 18
Disassembling the piston rod .......................................... 20
Disassembling the screw cap with the membrane holder ... 21
Disassembling the screw sleeve ...................................... 22
Checking the fork legs.................................................... 23
Checking the fork legs - during a minor fork service .......... 24
Changing the pilot bushing............................................. 25
Assembling the screw sleeve........................................... 26
Assembling the screw cap with the membrane holder........ 27
Assembling the piston rod .............................................. 28
Assembling the cartridge ................................................ 29
Assembling the fork legs (450 SX‑F EU) .......................... 30
Assembling the fork legs (450 SX‑F USA) ........................ 34
Bleeding and filling the cartridge .................................... 37
Filling the cartridge with nitrogen.................................... 38
Greasing the steering head bearing.................................. 39
Removing the lower triple clamp ..................................... 39
Installing the lower triple clamp...................................... 40
Checking steering head bearing play................................ 41
Adjusting play of steering head bearing............................ 42
02/HANDLEBAR, INSTRUMENTS....................................... 43
Hot start lever ............................................................... 43
Handlebar position ........................................................ 43
Adjusting the handlebar position..................................... 43
Adjusting the basic position of the clutch lever................. 44
Checking the throttle cable routing.................................. 44
Checking the play in the throttle cable............................. 44
Adjusting the play in the throttle cable ............................ 45
03/FRAME........................................................................ 46
Checking the frame ....................................................... 46
04/SHOCK ABSORBER, SWINGARM................................... 47
Adjusting the high-speed compression damping of the
shock absorber .............................................................. 47
Adjusting the low-speed compression damping of the
shock absorber .............................................................. 47
TABLE OF CONTENTS
10/REAR WHEEL .............................................................. 85
Removing the rear wheel ................................................ 85
Installing the rear wheel ................................................. 85
Removing the rear brake disc.......................................... 86
Installing the rear brake disc .......................................... 86
Checking the chain tension ............................................ 87
Adjusting the chain tension ............................................ 87
Adjusting the chain guide............................................... 88
Checking the chain, rear sprocket, engine sprocket and
chain guide................................................................... 88
Checking for chain dirt accumulation .............................. 90
Cleaning the chain......................................................... 90
11/WIRING HARNESS, BATTERY ....................................... 91
Removing the main fuse................................................. 91
Installing the main fuse ................................................. 91
Removing the battery ..................................................... 91
Installing the battery...................................................... 92
Charging the battery ...................................................... 92
Checking the charging voltage ........................................ 93
Checking the quiescent current....................................... 93
Checking the starter relay ............................................... 94
13/BRAKE SYSTEM........................................................... 95
Checking the front brake linings...................................... 95
Changing the front brake linings ..................................... 95
Checking free travel on hand brake lever.......................... 97
Adjusting the basic position of the hand brake lever.......... 97
Checking the brake fluid level of the front brake ............... 97
Adding front brake fluid ................................................. 98
Changing the front brake fluid ........................................ 98
Checking rear brake linings ............................................ 99
Changing the rear brake linings..................................... 100
Checking the free travel of the foot brake lever ............... 101
Adjusting the basic position of the foot brake lever ......... 101
Checking rear brake fluid level...................................... 102
Adding brake fluid to the rear brake circuit .................... 102
Changing the rear brake fluid........................................ 103
30/ENGINE..................................................................... 104
Removing the engine ................................................... 104
Installing the engine .................................................... 109
30/DISASSEMBLING THE ENGINE................................... 115
Preparations................................................................ 115
Removing the shift lever............................................... 115
Draining the engine oil ................................................. 115
Removing the oil filter.................................................. 115
Removing the spark plug .............................................. 116
Removing the valve cover ............................................. 116
Removing the starter motor .......................................... 116
Removing the alternator cover....................................... 116
Removing the torque limiter and starter idler gear........... 117
Positioning the engine at ignition top dead center
(TDC) ......................................................................... 117
Removing the camshaft................................................ 118
Removing the timing chain tensioner............................. 118
Removing the double wheel .......................................... 119
Removing the cylinder head.......................................... 119
Removing the water pump cover ................................... 120
Removing the clutch cover ........................................... 120
Removing the piston .................................................... 121
Removing the timing chain rails.................................... 121
Removing the timing chain........................................... 121
Removing the ignition pulse generator ........................... 122
Removing the rotor ...................................................... 122
Removing the drive wheel of the balancer gear ...............
Removing the force pump ............................................
Removing the spacer ...................................................
Removing the clutch discs............................................
Removing the outer clutch hub .....................................
Removing the primary gear ...........................................
Removing the suction pump .........................................
Removing the shift shaft ..............................................
Removing the shift drum locating unit ...........................
Removing the locking lever...........................................
Removing the left section of the engine case..................
Removing the shift rails ...............................................
Removing the shift drum ..............................................
Removing the shift forks ..............................................
Removing the transmission shafts .................................
Removing the crankshaft ..............................................
30/ENGINE - WORK ON THE INDIVIDUAL PARTS .............
Working on the right section of the engine case ..............
Working on the left section of the engine case................
Removing the water pump ............................................
Changing the shaft seal ring of the water pump ..............
Installing the water pump.............................................
Removing the crankshaft seal ring in the clutch cover .....
Installing the crankshaft seal ring in the clutch cover......
Removing the stator.....................................................
Installing the stator .....................................................
Removing the oil pressure regulator valve.......................
Checking spring length of oil pressure regulator valve......
Installing the oil pressure regulator valve .......................
Checking the lubrication system....................................
Removing the crankshaft bearing inner race ...................
Installing the crankshaft bearing inner race....................
Changing connecting rod, conrod bearing and crank
pin.............................................................................
Checking crankshaft run-out at bearing pin ....................
Measuring the crankshaft end play ................................
Cylinder - Nikasil
®
coating ............................................
Checking/measuring cylinder ........................................
Checking/measuring the piston .....................................
Measuring piston/cylinder mounting clearance................
Checking the piston ring end gap ..................................
Changing the camshaft bearing.....................................
Checking the autodecompressor....................................
Checking camshafts.....................................................
Checking the radial clearance of the camshaft
bearings .....................................................................
Checking the camshaft bearing bridges..........................
Removing the valves ....................................................
Checking the valves .....................................................
Checking the valve springs ...........................................
Checking valve spring seat............................................
Checking the cam levers ..............................................
Checking cylinder head ................................................
Installing the valves .....................................................
Removing the freewheel ...............................................
Checking the freewheel ................................................
Installing the free wheel ...............................................
Checking the starter drive.............................................
Checking the timing assembly ......................................
Preparing the timing chain tensioner for installation .......
Checking the clutch.....................................................
Checking shift mechanism ...........................................
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