KTM 450 SX-F Operating instructions

450 / 505 SX-F
450 SXS-F
REPARATURANLEITUNG
MANUALE DI RIPARAZIONE
MANUEL DE RÉPARATION
MANUAL DE REPARACIÓN
ART.NR.: 3.206.029-E
REPAIRMANUAL2007

REPAIRMANUAL2007 450 / 505 SX-F 450 SXS-F
KTM Group Partner

1 SERVICE-INFORMATIONS
2 GENERAL INFORMATION
3 DISMOUNTING AND MOUNTING THE ENGINE
4 DISASSEMBLING THE ENGINE
5 SERVICING INDIVIDUAL COMPONENTS
6 ASSEMBLING THE ENGINE
7 ELECTRICAL
8 FUEL SYSTEM
9 TROUBLE SHOOTING
10 TECHNICAL SPECIFICATIONS
11 PERIODIC MAINTENANCE SCHEDULE
12 WIRING DIAGRAMS
13
14
15
16

EXPLANATION - UPDATING
Edition: 10/2006
3.206.029-E Repair Manual 450/505 SX-F 10/2006
Basic version Model year 2007

INTRODUCTION
This repair manual offers extensive repair-instructions and is an up-to-date version that describes
the latest models of the series. However, the right to modifications in the interest of technical
improvement is reserved without updating the current issue of this manual.
A description of general working procedures common in workshops has not been included. Safety
rules common in the work shop have also not been listed. We take it for granted that the repairs
are made by qualified professionally trained mechanics.
Read through the repair manual before beginning with any repair work.

WARNING

STRICT COMPLIANCE WITH THESE INSTRUCTIONS IS
ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB.
!
CAUTION
!
NON-COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD
TO THE DAMAGE OF MOTORCYCLE COMPONENTS OR
RENDER MOTORCYCLES UNFIT FOR RIDING!
“NOTE” POINTS OUT USEFUL TIPS.
Use only ORIGINAL KTM SPARE PARTS.
The KTM high performance engine is only able to meet user expectations if the maintenance
work is performed regularly and professionally.
In accordance with the international quality management ISO 9001 standard, KTM uses quality
assurance processes that lead to the highest possible product quality.
KTM Sportmotorcycle AG
5230 Mattighofen, Austria
All design and assembly modification rights reserved.
C by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved

REPLY FAX FOR REPAIR MANUALS
We have made every effort to make our repair manuals as accurate as possible but it is always possible
for a mistake or two to creep in.
To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us
as follows:
If you find any errors or inaccuracies in one of our repair manuals – whether these are technical errors,
incorrect or unclear repair procedures, tool problems, missing technical data or torques, inaccurate or
incorrect translations or wording, etc. – please enter the error(s) in the table below and fax the completed
form to us at 0043/7742/6000/5349.
NOTE:
–Enter the complete item no. for the repair manual in column 1 (e.g.: 3.206.029-E).
You will find the number on the cover page or in the left margin on each right page of the manual.
–Enter the corresponding page number in the repair manual (e.g.: 5-7C) in column 2.
–Enter the current text (inaccurate or incomplete) in column 3 by quoting or describing the respective
passage of the text. If your text deviates from the text contained in the repair manual, please write
your text in German or English if possible.
–Enter the correct text in column 4.
Your corrections will be reviewed and incorporated in the next issue of our repair manual.
Item no. of repair manual Page Current text Correct text
Additional suggestions, requests or comments on our Repair Manuals (in German or English):
Name mechanic/shop foreman Company/work shop

GENERAL INFORMATION
Repair manual KTM 450/505 SX-F Art.-Nr. 3.206.029-E
2-1
2
CHANGING THE COOLING LIQUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
CHECKING THE COOLING LIQUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
CHANGING THE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
ENGINE OIL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
CHECKING THE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
CHECKING THE OIL LEVEL OF THE HYDRAULIC CLUTCH . . . . . . . . . . . . . . . . . . .2-5
BLEEDING OF THE HYDRAULIC CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
ADJUSTING THE THROTTLE CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
CHANGING THE FRONT BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
CHANGING THE REAR BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
SPECIAL TOOLS - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
INDEX

Changing the cooling liquid
– Remove the radiator cap 1when the engine is cold.
– Remove the drain plug 2on the water pump cover and allow the
cooling liquid to drain into a suitable pan.
– Remount the drain plug 2and tighten to 10 Nm.
– Fill the cooling system with cooling liquid in a ratio of 50%
antifreeze and 50% distilled water (freeze protection down to at
least -25°C) to 10 mm over the radiator fins
.
– Mount the radiator cap 1.
– Go for a short ride and check the cooling liquid level again.
Checking the cooling liquid level
– When the engine is cold, the cooling liquid should be approx. 10
mm over the radiator fins (see illustration).
Engine oil
Automobile engine oil used to be used for four-stroke motorcycles before
there were separate motorcycle specifications. Different technical
developments made it necessary to have a separate specification for four-
stroke motorcycles - the JASO T903 MA standard. Whereas car engines
require long changing intervals, motorcycle engines require a higher power
output at higher speeds. Most motorcycle engines also use the same oil
to lubricate the transmission and the clutch. The JASO MA standard responds
to these special requirements.
Only use fully synthetic engine oils that meet the JASO MA quality
requirements (see information on the can).
KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for
temperatures over 5°C, 41°F) or 5W/40 (for temperatures under 5°C, 41°F).
Changing the engine oil

CAUTION

AN ENGINE AT OPERATING TEMPERATURE AND THE ENGINE OIL IT CONTAINS ARE
VERY HOT – DO NOT BURN OR SCALD YOURSELF.
NOTE: When changing the engine oil, it is necessary to clean the oil screen
and to replace the oil filter. Engine oil has be changed with the engine at
an operating temperature..
– Place the motorcycle on a level surface.
– Remove the oil drain plug 3and allow the engine oil to drain into a
pan.
– Relieve the plug 4by tapping gently a few times with a hammer.
– Remove the plug with the oil screen.
– Allow the engine oil to drain completely and clean the sealing areas.
– Thoroughly clean all parts.
– Check the O-rings for damage and replace if necessary.
– Mount the oil drain plug with a new seal ring and tighten to 20 Nm.
– Mount the plug with the oil screen and tighten to 30 Nm.
Repair manual KTM 450/505 SX-F Art.-Nr. 3.206.029-E
2-2
2
1
when the engine is cold
10 mm
5°C
41°F
10W/50
5W/40
JASO T903 MA
TEMPERATURE
3
4

2-3
Changing the oil filter
– Place a pan under the engine to drain the oil. Remove the 2 screws
1and take off the oil filter cover and O-ring.
– Pull the oil filter insert 2out of the housing with circlip pliers
510.12.011.000.
– Clean the oil filter cover, the sealing area on the O-ring and the
engine case. Check the O-ring in the oil filter cover for damage and
replace if necessary.
– Lay the motorcycle down on its side and fill the oil filter housing
approx. 1/3 full with engine oil; insert the oil filter in the housing.
– Grease the O-ring in the oil filter cover and mount the cover 3.
Mount the screws and tighten to 10 Nm.
– Stand the motorcycle up again.
– Remove the oil filler screw 4in the clutch cover and add approx.
1.3 liters of fully synthetic engine oil (Motorex Power Synt 4T
10W/50 for temperatures over 5°C or 5W/40 for temperatures under
5°C).
– Start the engine and check all screw connections and the oil filter
cover for leaks.
– Finally, check the engine oil level and correct if necessary.
Checking the engine oil level
– You can check the engine oil level with the engine cold or warm.
Stand the motorcycle upright on a level surface (not on the side
stand).
– The oil should be visible at the lower edge Aof the inspection
window if the engine is cold.
– If the engine is warm, the engine oil should reach the upper edge B
of the inspection window.
– Correct the engine oil level if necessary.
– Check the engine for leaks.
A
B
4
1
2
3

2-4
Repair manual KTM 450/505 SX-F Art.-Nr. 3.206.029-E
Engine oil circuit
Engine oil circuit
1oil screen
2Pressure oil pump
3Bypass valve
4Oil filter insert
5Throttle to meter the oil for the timing chain tensioner
6Oil spraying nozzle for piston
7Jet to meter the oil to the lower conrod bearing
8Throttle to meter the oil to the clutch pushrod
9Oil duct for the cam lever support
bk Oil spraying nozzle for the camshaft
bl Oil duct for the camshaft support
bm Suction pump for the crankcase
bn Oil duct for transmission lubrication
1
34
6
8
bk
bm
bn
2
6
7
9
9
bk
bl
bl
bm
5
Checking the oil pressure
– Remove the plug for the oil duct from the cylinder head.
– Screw on oil pressure adapter 773.29.006.000 and tighten.
– Connect EFI pressure gauge 610.29.094.000 without the T-piece to
the oil pressure adapter; tighten the banjo bolt.
! CAUTION !
–C
HECK THE ENGINE OIL LEVEL AND CORRECT IF NECESSARY.
–M
AKE SURE THE OIL FILTER IS IN A GOOD CONDITION.
– Allow the engine to warm up and measure the oil pressure with the
engine at operating temperature (engine oil temperature approx.
100ºC):
min. 1.0 bar at 1600 rpm
– Remove the special tools, screw the plug on with a new O-ring and
tighten to 10 Nm.

2-5
Checking the oil level of the hydraulic clutch
! CAUTION !
ONLY FILL SAE 10 BIODEGRADABLE HYDRAULIC OIL (E.G. MOTOREX HYDRAULIC
FLUID 75) INTO THE MASTER CYLINDER. DO NOT ADD BRAKE FLUID.
NOTE: remove the cover to check the oil level in the master cylinder of
the clutch.
– Move the master cylinder into a horizontal position.
– Remove the screws 1and the cover 2together with the rubber
boot 3.
– The oil level should be 4 mm under the upper edge with the master
cylinder in a horizontal position. If necessary, add SAE 10
biodegradable hydraulic oil (e.g. Motorex Hydraulic Fluid 75).
– Remount the rubber boot, cover and screws.
Bleeding of the hydraulic clutch
! CAUTION !
ONLY FILL SAE 10 BIODEGRADABLE HYDRAULIC OIL (E.G. MOTOREX HYDRAULIC
FLUID 75) INTO THE MASTER CYLINDER. DO NOT ADD BRAKE FLUID.
– Move the master cylinder into a horizontal position.
– Remove the screws 1and the cover 2together with the rubber
boot 3.
– Remove the bleeder screw on the slave cylinder of the clutch and
mount the bleeding syringe 4filled with SAE 10 biodegradable
hydraulic oil (e.g. Motorex Hydraulic Fluid 75).
– Press the SAE 10 biodegradable hydraulic oil into the system until
oil starts to run out of the hole Ain the master cylinder without
bubbles. Make sure the oil does not overflow.
– After bleeding the clutch, remove the bleeding syringe and mount
the bleeder screw.
– Add SAE 10 biodegradable hydraulic oil (e.g. Motorex Hydraulic
Fluid 75) up to 4 mm under the upper edge.
– Remount the rubber boot, cover and screws.
Adjusting the throttle cables
– Push back the dust boots.
– Set 3-5 mm free travel at the throttle grip with the adjusting screw
5. The idling speed should not change with the engine running if
the handlebar is turned all the way to the left or right.
– Slip on the dust boots.
– Check the throttle grip for smooth operation.
4
A
5
1
2
3

2-6
Repair manual KTM 450/505 SX-F Art.-Nr. 3.206.029-E
5 mm
2
5
4
1
3
Changing the front brake fluid
– Move the hand brake cylinder into a horizontal position.
– Remove the screws 1and the cover 2together with the rubber
boot 3.
– Use a syringe to extract the used brake fluid and add fresh DOT 5.1
brake fluid (Motorex Brake Fluid DOT 5.1).
– Use a commercial extractor (shop equipment) to extract the used
brake fluid out of the system through the bleeder screw 4on the
brake caliper. Make sure the brake fluid reservoir is always filled
with enough fresh brake fluid.
– Tighten the bleeder screw 4and attach the dust cap 5again.
– Add DOT 5.1 brake fluid (Motorex Brake Fluid DOT 5.1) up to 5 mm
under the top edge of the reservoir. Remount the rubber boot, cover
and screws.
– Wash off any overflowing or spilled brake fluid with water.
– Actuate the hand brake lever until you feel the point of pressure.
! CAUTION !
–N
EVER USE DOT 5 BRAKE FLUID. IT IS BASED ON SILICONE OIL AND DYED
PURPLE. GASKETS AND BRAKE HOSES WILL BE DAMAGED IF DOT 5 BRAKE
FLUID IS USED.
–B
RAKE FLUID CAN CAUSE SKIN IRRITATIONS. AVOID CONTACT WITH THE SKIN OR
EYES. IF BRAKE FLUID SPLASHES INTO YOUR EYES, RINSE THOROUGHLY WITH
WATER AND CONSULT A DOCTOR.
–M
AKE SURE NO BRAKE FLUID COMES INTO CONTACT WITH PAINTED PARTS AS
BRAKE FLUID WILL CORRODE THE PAINTWORK!
–O
NLY USE CLEAN, NEW BRAKE FLUID FROM TIGHTLY SEALED CONTAINERS.

2-7
1
A
4
3
2
Changing the rear brake fluid
– Move the vehicle into a vertical position.
– Disassemble the screw cap 1together with the rubber boot 2from
the brake fluid reservoir.
– Use a syringe to extract the used brake fluid and fill with fresh DOT
5.1 brake fluid (Motorex Brake Fluid DOT 5.1).
– Use a commercial extractor (shop equipment) to extract the used
brake fluid out of the system through the bleeder screw 3on the
brake caliper. Make sure the brake fluid reservoir is always filled
with enough fresh brake fluid.
– Tighten the bleeder screw 3and attach the dust cap 4again.
– Fill with DOT5.1 brake fluid (Motorex Brake Fluid DOT 5.1) up to
the mark Aon the inside of the reservoir.
– Check the O-ring of the screw cap for damage, exchange it if
necessary and remount the screw cap again.
– Wash off any overflowing or spilled brake fluid with water.
– Press the foot brake pedal until you feel the point of pressure.
! CAUTION !
–N
EVER USE DOT 5 BRAKE FLUID. IT IS BASED ON SILICONE OIL AND DYED
PURPLE. GASKETS AND BRAKE HOSES WILL BE DAMAGED IF DOT 5 BRAKE
FLUID IS USED.
–B
RAKE FLUID CAN CAUSE SKIN IRRITATIONS. AVOID CONTACT WITH THE SKIN OR
EYES. IF BRAKE FLUID SPLASHES INTO YOUR EYES, RINSE THOROUGHLY WITH
WATER AND CONSULT A DOCTOR.
–M
AKE SURE NO BRAKE FLUID COMES INTO CONTACT WITH PAINTED PARTS AS
BRAKE FLUID WILL CORRODE THE PAINTWORK!
–O
NLY USE CLEAN, NEW BRAKE FLUID FROM TIGHTLY SEALED CONTAINERS.