2010 KTM 450 SX-F Repair Manual Paper

Description

This 244 page, 2010 KTM 450 SX-F Repair Manual is an authorized reproduction of the original, out of print manual. It covers 2010 KTM 450 SX-F motorcycles.

The following topics are covered:

MEANS OF REPRESENTATION

IMPORTANT NOTES

LOCATION OF SERIAL NUMBERS

Chassis number

Type label

Engine number

Fork part number

Shock absorber part number

MOTORCYCLE

Jacking up the motorcycle

Removing the motorcycle from the work stand

Starting

Starting the motorcycle for checking

FORK, TRIPLE CLAMP

Adjusting the compression damping of the fork

Adjusting the rebound damping of fork

Bleeding fork legs

Cleaning the dust boots of the fork legs

Loosening the fork protector

Positioning the fork protection

Removing the fork legs

Installing the fork legs

Removing the fork protector

Installing the fork protector

Conducting major fork service

Conducting minor fork service

Disassembling the fork legs

Disassembling the cartridge

Disassembling the piston rod

Disassembling the screw cap with the membrane holder

Disassembling the screw sleeve

Checking the fork legs (450 SX-F EU)

Checking the fork legs (450 SX-F USA)

Checking the fork legs – during a minor fork service

(450 SX-F EU)

Checking the fork legs – during a minor fork service

(450 SX-F USA)

Changing the pilot bushing

Assembling the screw sleeve

Reassembling the screw cap with the membrane holder

Assembling the piston rod

Assembling the cartridge

Assembling the fork legs (450 SX-F EU)

Assembling the fork legs (450 SX-F USA)

Bleeding and filling the cartridge

Filling the cartridge with nitrogen

Greasing the steering head bearing

Removing the lower triple clamp

Installing the lower triple clamp

Checking steering head bearing play

Adjusting play of steering head bearing

HANDLEBAR, INSTRUMENTS

Hot start lever

Handlebar position

Adjusting handlebar position

Adjusting basic position of clutch lever

Checking throttle cable route

Checking the play in the throttle cable

Adjusting the play in the throttle cable

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 static sag of shock absorber

Checking riding sag of shock absorber

Adjusting the spring preload of the shock absorber

Adjusting the riding sag

Removing the shock absorber

Installing the shock absorber

Performing a shock absorber service

Removing the spring

Disassembling the shock absorber

Disassembling the piston rod

Disassembling the seal ring retainer

Replacing the pilot bushing

Checking the shock absorber

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)

Bleeding and filling the damper

Filling the damper with nitrogen

Installing the spring (450 SX-F EU)

Installing the spring (450 SX-F USA)

EXHAUST

Removing main silencer

Installing the main silencer

Removing the glass fiber yarn filling of the main

silencer

Installing the glass fiber yarn filling of the main silencer

AIR FILTER

Removing the air filter box lid

Installing the air filter box lid

Removing the air filter

Installing the air filter

Cleaning air filter

Removing the carburetor connection boot

Installing the carburetor connection boot

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

MASK, FENDER

Removing the front fender

Installing the front fender

Dismount the start number plate

Installing the start number plate

FR0NT WHEEL

Removing front wheel

Installing the front wheel

Checking brake discs

Removing the front brake disc

Installing the front brake disc

Tire condition checking

Checking tire air pressure

Checking spoke tension

REAR WHEEL

Removing the rear wheel

Installing the rear wheel

Removing the rear brake disc

Installing the rear brake disc

Checking chain tension when fitting rear wheel

Adjusting chain tension – fitting rear wheel

Checking the chain tension

Adjusting chain tension – after checking

Adjusting chain tension

Adjusting the chain guide

Checking the rear sprocket/engine sprocket for wear

Checking chain wear

Checking for chain dirt accumulation

Cleaning the chain

WIRING HARNESS, BATTERY

Removing a fuse

Installing the fuse

Removing the battery

Installing the battery

Recharging the battery

Checking the stall current

Checking the charging voltage

Checking the charging current

Checking the starter relay

BRAKE SYSTEM

Checking the front brake linings

Removing front brake linings

Installing the front brake linings

Changing the front brake linings

Checking free travel on hand brake lever

Adjusting the basic position of the hand brake lever

Checking the brake fluid level of the front brake

Topping up the front brake fluid

Changing the front brake fluid

Checking rear brake linings

Removing rear brake linings

Mounting rear brake linings

Changing the rear brake linings

Checking the free travel of the foot brake lever

Adjusting the basic position of the foot brake lever

Checking rear brake fluid level

Adding brake fluid to the rear brake circuit

Changing the rear brake fluid

ENGINE

Removing the engine

Installing the engine

DISASSEMBLING THE ENGINE

Preparations

Removing the shift lever

Draining the engine oil

Removing the oil filter

Removing the spark plug

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

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 crankpin

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 electric starter mode

Checking the timing assembly

Preparing the timing chain tensioner for installation

Checking clutch

Checking shift mechanism

Preassembling the shift shaft

Disassembling the main shaft

Disassembling the countershaft

Checking transmission

Assembling the main shaft

Assembling the countershaft

ENGINE ASSEMBLY

Installing the crankshaft and balancer shaft

Installing the transmission shafts

Installing the shift forks

Installing the shift drum

Installing the shift rails

Installing the left engine case

Installing the locking lever

Installing the shift drum locating unit

Installing the shift shaft

Installing the suction pumps

Installing the spacer

Installing the force pump

Installing the primary gear

Installing the outer clutch hub

Installing the drive wheel of the balancer gear

Installing the timing chain

Installing the free wheel gear

Installing the rotor

Installing the ignition pulse generator

Adjusting the ignition pulse generator gap

Installing the timing chain rails

Installing the piston

Installing the clutch cover

Installing the water pump cover

Installing the cylinder head

Installing the double wheel

Installing the timing chain tensioner

Checking the valve timing

Adjusting the valve timing

Checking the valve clearance

Adjusting the valve clearance

Installing the torque limiter and starter idler gear

Installing the alternator cover

Installing the starter motor

Installing the valve cover

Installing the spark plug

Installing the oil screen

Installing the oil filter

Installing the shift lever

Removing the engine from the universal mounting rack

CARBURETOR

Choke

Removing the carburetor

Installing the carburetor

Disassembling the carburetor

Checking/adjusting the carburetor components

Checking/adjusting the accelerator pump

Checking the choke slide

Checking the jet needle

Checking the throttle slide

Checking the needle jet

Checking the float needle valve

Checking/adjusting the float level

Checking/adjusting the throttle slide opening

Checking the throttle position sensor

Adjusting the position of the throttle position sensor

Assembling the carburetor

Carburetor – adjusting idle

Emptying the carburetor float chamber

CLUTCH

Checking the fluid level of hydraulic clutch

Changing the hydraulic clutch fluid

WATER PUMP, COOLING SYSTEM

Cooling system

Checking the anti-freeze and coolant level

Checking the coolant level

Draining the coolant

Refilling coolant

LUBRICATION SYSTEM

Oil circuit

Checking engine oil level

Changing engine oil and oil filter, cleaning oil screen

Draining the engine oil

Cleaning the oil screen

Removing the oil filter

Installing the oil filter

Filling up with engine oil

Topping up engine oil

IGNITION SYSTEM

Checking the ignition system

Checking the ignition coil

Checking the spark plug connector

Check CDI controller

Checking the ignition pulse generator

Checking the generator

Removing the stator

Installing the stator

ELECTROSTARTER

Checking the starter motor

TROUBLESHOOTING

TECHNICAL DATA – ENGINE

Capacity – engine oil

Capacity – coolant

TECHNICAL DATA – ENGINE TOLERANCES, WEAR LIMITS

TECHNICAL DATA – ENGINE TIGHTENING TORQUES

TECHNICAL DATA – CARBURETOR

TECHNICAL DATA – CARBURETOR TIGHTENING

TORQUES

TECHNICAL DATA – CHASSIS

Tires

Capacity – fuel

TECHNICAL DATA – FORK

450 SX-F EU

450 SX-F USA