2009r Repair manual.pdf

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REPAIR MANUAL
2009
450 SX‑F EU
450 SX‑F USA
450 XC‑F USA
505 XC‑F USA
Art. no. 3206071en
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
Checking the play in the throttle cable.............................
Adjusting the play in the throttle cable ............................
03/FRAME........................................................................
Checking the frame .......................................................
04/SHOCK ABSORBER, SWINGARM...................................
Adjusting high-speed compression damping of the shock
absorber .......................................................................
Adjusting the low-speed compression damping of the
shock absorber ..............................................................
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 ..........................................
Servicing the shock absorber ..........................................
Removing the spring ......................................................
Disassembling the damper .............................................
Disassembling the piston rod ..........................................
Disassembling the seal ring retainer ................................
Replacing the pilot bushing ............................................
Checking the damper .....................................................
Disassembling the rebound adjuster ................................
Removing the heim joint ................................................
Installing the heim joint .................................................
Assembling the rebound adjuster ....................................
Assembling the seal ring retainer ....................................
Assembling the piston rod ..............................................
Assembling the damper (450 SX‑F EU) ...........................
Assembling the damper (450 SX‑F USA) .........................
Assembling the damper (XC‑F)........................................
Bleeding and filling the damper ......................................
Filling the damper with nitrogen .....................................
Installing the spring (450 SX‑F EU) ................................
Installing the spring (450 SX‑F USA) ..............................
Installing the spring (XC‑F).............................................
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 (SX‑F)..............................................................
Fuel tap (XC‑F)..............................................................
08/MASK, FENDER ...........................................................
Removing the front fender ..............................................
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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 (450 SX‑F EU)...................... 15
Disassembling the fork legs (450 SX‑F USA).................... 18
Disassembling the fork legs (XC‑F) .................................. 20
Disassembling the cartridge............................................ 23
Disassembling the piston rod .......................................... 25
Disassembling the screw cap with the membrane holder ... 26
Disassembling the screw sleeve ...................................... 27
Checking the fork legs (SX‑F).......................................... 28
Checking the fork legs (XC‑F).......................................... 29
Checking the fork legs - during a minor fork service
(SX‑F) .......................................................................... 31
Checking the fork legs - during a minor fork service
(XC‑F) .......................................................................... 32
Changing the pilot bushing............................................. 33
Assembling the screw sleeve........................................... 34
Assembling the screw cap with the membrane holder........ 34
Assembling the piston rod .............................................. 35
Assembling the cartridge ................................................ 36
Assembling the fork legs (450 SX‑F EU) .......................... 38
Assembling the fork legs (450 SX‑F USA) ........................ 41
Assembling the fork legs (XC‑F) ...................................... 44
Bleeding and filling the cartridge .................................... 48
Filling the cartridge with nitrogen.................................... 49
Greasing the steering head bearing.................................. 50
Removing the lower triple clamp ..................................... 50
Installing the lower triple clamp...................................... 51
Fork offset .................................................................... 52
Adjusting the fork offset ................................................. 52
Checking steering head bearing play................................ 53
Adjusting play of steering head bearing............................ 53
02/HANDLEBAR, INSTRUMENTS....................................... 55
Hot start lever ............................................................... 55
Handlebar position ........................................................ 55
Adjusting handlebar position .......................................... 55
Adjusting the basic position of the clutch lever................. 56
Checking the throttle cable routing.................................. 56
TABLE OF CONTENTS
Installing the front fender............................................... 97
Removing the start number plate .................................... 97
Installing the start number plate ..................................... 97
09/FRONT WHEEL ............................................................ 98
Removing front wheel .................................................... 98
Installing the front wheel................................................ 98
Checking the brake discs................................................ 99
Removing the front brake disc ........................................ 99
Installing the front brake disc ....................................... 100
Checking the tire condition........................................... 100
Checking tire air pressure ............................................. 100
Checking spoke tension................................................ 101
10/REAR WHEEL ............................................................ 102
Removing the rear wheel .............................................. 102
Installing the rear wheel ............................................... 102
Removing the rear brake disc........................................ 103
Installing the rear brake disc ........................................ 103
Checking the chain tension .......................................... 104
Adjusting the chain tension .......................................... 104
Adjusting the chain guide (SX‑F)................................... 105
Adjusting the chain guide (XC‑F)................................... 105
Checking the chain, rear sprocket, engine sprocket and
chain guide................................................................. 105
Checking for chain dirt accumulation ............................ 107
Cleaning the chain....................................................... 108
11/WIRING HARNESS, BATTERY ..................................... 109
Removing the main fuse............................................... 109
Installing the main fuse ............................................... 109
Removing the battery ................................................... 109
Installing the battery.................................................... 110
Charging the battery .................................................... 110
Checking the charging voltage ...................................... 111
Checking the quiescent current..................................... 111
Checking the starter relay ............................................. 112
13/BRAKE SYSTEM......................................................... 113
Checking the front brake linings.................................... 113
Removing front brake linings ........................................ 113
Installing the front brake linings ................................... 113
Changing the front brake linings ................................... 114
Checking free travel on hand brake lever........................ 115
Adjusting the basic position of the hand brake lever........ 115
Checking the brake fluid level of the front brake ............. 115
Adding front brake fluid ............................................... 116
Changing the front brake fluid ...................................... 116
Checking rear brake linings .......................................... 117
Removing rear brake linings.......................................... 118
Mounting rear brake linings .......................................... 118
Changing the rear brake linings..................................... 119
Checking the free travel of the foot brake lever ............... 119
Adjusting the basic position of the foot brake lever ......... 120
Checking rear brake fluid level...................................... 120
Adding brake fluid to the rear brake circuit .................... 121
Changing the rear brake fluid........................................ 121
30/ENGINE..................................................................... 123
Removing the engine ................................................... 123
Installing the engine .................................................... 128
30/DISASSEMBLING THE ENGINE................................... 133
Preparations................................................................ 133
Removing the shift lever............................................... 133
Draining the engine oil ................................................. 133
Removing the oil filter.................................................. 133
Removing the spark plug .............................................. 134
Removing the valve cover .............................................
Removing the starter motor ..........................................
Removing the alternator cover.......................................
Removing the torque limiter and starter idler gear...........
Positioning the engine at ignition top dead center
(TDC) .........................................................................
Removing the camshaft................................................
Removing the timing chain tensioner.............................
Removing the double wheel ..........................................
Removing the cylinder head..........................................
Removing the water pump cover ...................................
Removing the clutch cover ...........................................
Removing the piston ....................................................
Removing the timing chain rails....................................
Removing the timing chain...........................................
Removing the ignition pulse generator ...........................
Removing the rotor ......................................................
Removing the drive wheel of the balancer gear ...............
Removing the force pump ............................................
Removing the spacer ...................................................
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 .....................................................................
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