KTM 450 SX-F EU 2012 Manual

SETUP INSTRUCTIONS 2012
450 SX‑F EU
450 SX‑F USA
Art. no. 3211818en

INTRODUCTION 1
INTRODUCTION
The work described in these setup instructions must be performed before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
Print out the current PDI form found on the KTM DEALER.NET.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter-
est of technical advancement without at the same time updating this 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 the 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

MEANS OF REPRESENTATION 2
Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.

SETUP 3
2.1Unpacking and setting up the vehicle
601701-01
Packaging 2
–Remove the box and the plastic packaging.
Info
To avoid damaging the motorcycle during the setup, leave the protective
film on the vehicle until you have finished.
–Remove the separate enclosure and unpack it. Check that the scope of delivery
is complete on the basis of the enclosed packing list.
–Have a lift stand available.
Lift stand (54829055000)
–Carefully loosen and remove the footrest mount.
Info
An assistant prevents the motorcycle from falling over.
101010-01
–Together with an assistant, take the vehicle off the palette.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
101012-01
Package 12
–Remove the box and the plastic packaging.
Info
An assistant prevents the motorcycle from falling over.
To avoid damaging the motorcycle during the setup, leave the protective
film on the vehicle until you have finished.
–Remove the separate enclosure and unpack it. Check that the scope of delivery
is complete on the basis of the enclosed packing list.
101013-01
–Have a lift stand available.
Lift stand (54829055000)
–Together with an assistant, take the vehicle off the palette.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
101014-10
–Remove the cardboard from around the shock absorber.
–Position the angle lever and linkage lever.
–Mount and tighten screw cap 1.
Guideline
Nut, linkage lever to angle lever M14x1.5 80 Nm (59 lbf ft)
–Mount and tighten screw 2.
Guideline
Screw, bottom shock
absorber
M10 60 Nm
(44.3 lbf ft)
Loctite®2701

SETUP 4
B00542-10
–Route the clutch line with the clutch master cylinder toward the front between
the upper and lower triple clamps.
–Position the fork legs and tighten the screws of the triple clamp.
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
Screw, bottom triple clamp M8 12 Nm
(8.9 lbf ft)
Info
The topmost milled groove in the fork leg must be flush with the top
edge of the upper triple clamp.
Position bleeder screws 3toward the front.
0
0
55
0
0
44
0
0
55
44
B00375-12
–Remove screws 4. Take off the handlebar clamps.
–Remove screws 5. Remove the handlebar supports.
–Place the handlebar supports in the required position. Mount and tighten
screws 8.
Guideline
Screw, handlebar support M10 40 Nm
(29.5 lbf ft)
Loctite®243™
Info
Position the left and right handlebar supports evenly.
B00543-10
–Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
–Position the handlebar clamps. Mount and tighten the screws.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
Info
The markings on the handlebar should be at the center of the handlebar
clamps.
Keep the gap widths equal when tightening.
B00544-01
–Position the controls on the right half of the handlebar.
Info
The routing of the cables can be seen in the figure.
B00545-01
–Position the controls on the left half of the handlebar.
Info
The figure shows how to route the clutch line and wiring harness.
–Install the front fender. ( p. 6)
–Install the front wheel. ( p. 6)
–Correctly mount the fuel tank breather.

SETUP 5
C00138-01
–Mount the handlebar cushion.
–Install the start number plate. ( p. 6)
800042-10
–Mount the footrests with the springs and bolts. Secure the bolts using the washers
and pins.
Pliers for footrest spring (58429083000)
800035-10
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep the battery away from sparks or open flames. Charge only in well-
ventilated areas.
–In the event of skin contact, rinse with large amounts of water. If battery
acid gets in the eyes, rinse with water for at least 15 minutes and con-
tact a physician.
–Fill the battery.
Info
Read the notes in the battery package.
–Charge the battery. ( p. 7)
–Install the battery. ( p. 7)
–Unpack and mount the KTM PowerParts included in the delivery (optional).
Info
Read the accompanying KTM PowerParts installation instructions.
–Apply the label included in the delivery (optional).
–Refuel. ( p. 9)
–Position all controls in their exact positions on the handlebar. Tighten all screws.
–Print out the current PDI form found on KTM DEALER.NET and perform the delivery
inspection.

WORK 6
3.1Installing the front wheel
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
–Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
B00304-11
–Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
–Change the wheel bearing.
–Clean and grease shaft seal rings 1and bearing surface Aof the spacers.
Long-life grease ( p. 12)
–Insert the spacers.
B00302-11
–Lift the front wheel into the fork, position it, and insert the wheel spindle.
–Mount and tighten screw 2.
Guideline
Screw, front wheel spindle M24x1.5 45 Nm
(33.2 lbf ft)
–Activate the hand brake lever multiple times until the brake linings are in contact
with the brake disc.
–Remove the motorcycle from the lift stand.
–Pull the front wheel brake and push down hard on the fork several times to align
the fork legs.
–Fully tighten screw 3.
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
3.2Installing the front fender
B00307-10
–Ensure that the spacers are mounted in the fender.
–Position the front fender. Mount and tighten screws 1.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Info
Make sure the holding lugs engage in the start number plate.
3.3Installing the start number plate
101278-11
–Position the start number plate. Mount and tighten screw 1.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Info
Ensure that the retaining lugs engage in the fender.
–Position the brake line. Put the clamp on, and mount and tighten screw 2.

WORK 7
3.4Removing the seat
101279-10
–Remove screw 1.
–Lift up the seat at the rear, pull it back and then remove it from above.
3.5Mounting the seat
B00410-01
–Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear
and simultaneously push it forward.
–Make sure that the seat is correctly locked in.
–Mount and tighten the screw of the seat fixing.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
3.6Installing the battery
B00361-11
Main work
–Place the battery in the battery holder.
External temperature ≥10 °C (≥50 °F)
Battery (YTX4L-BS)
External temperature ≤10 °C (≤50 °F)
Battery (YTX5L-BS)
–Reconnect the rubber band 1.
–Attach the plus cable and replace the plus pole cover 2.
–Attach the minus cable 3.
Subsequent work
–Mount the seat. ( p. 7)
3.7Charging the battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep the battery away from sparks or open flames. Charge only in well-ventilated areas.
–In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.
Warning
Environmental hazard The battery contains elements that are harmful to the environment.
–Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner.
Give the battery to your KTM dealer or to a recycling center that accepts used batteries.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

WORK 8
Info
Even when there is no load on the battery, it still loses power steadily.
The charge state and the type of charge are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the battery's service life.
If the charging current, charging voltage, and charging time are exceeded, electrolyte escapes through the safety valves. This
reduces the battery capacity.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the
battery.
The battery is maintenance-free, which means that the acid level does not need to be checked.
Preliminary work
–Switch off all power consumers and switch off the engine.
–Remove the seat. ( p. 7)
–Disconnect the negative cable of the battery to avoid damage to the onboard elec-
tronics.
400240-10
Main work
–Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test the open-circuit voltage and starting
voltage of the battery, and to test the alternator. With this device, you cannot over-
charge the battery.
Info
Never remove lid 1.
Charge the battery with a maximum of 10% of the capacity specified on
battery housing 2.
–Switch off the battery charger after charging. Disconnect the battery.
Guideline
The charge current, charge voltage, and charge time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use
3 months
Subsequent work
–Mount the seat. ( p. 7)
3.8Opening filler cap
Danger
Fire hazard Fuel is highly flammable.
–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.

WORK 9
B00277-10
–Press release button 1, turn filler cap counterclockwise and lift it upwards and
remove.
3.9Closing filler cap
B00278-10
–Replace the filler cap and turn clockwise until the release button 1locks in place.
Info
Route the fuel tank breather hose 2without kinking.
3.10Refueling
Danger
Fire hazard Fuel is highly flammable.
–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.
–Switch off engine.
–Open the filler cap. ( p. 8)
AA
400382-10
–Fill the fuel tank with fuel up to measurement A.
Guideline
Measurement of A35 mm (1.38 in)
Total fuel tank
capacity, approx.
7.5 l
(1.98 US gal)
Super unleaded (ROZ 95/RON 95/PON
91) ( p. 11)
–Close the filler cap. ( p. 9)

TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS 10
Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) –
Spoke nipple, rear wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) –
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft) –
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –
Screw, ball joint of push rod on foot
brake cylinder
M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, front brake disc M6 14 Nm (10.3 lbf ft) Loctite®243™
Screw, rear brake disc M6 14 Nm (10.3 lbf ft) Loctite®243™
Nut, foot brake lever stop M8 20 Nm (14.8 lbf ft) –
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite®2701
Nut, rim lock M8 10 Nm (7.4 lbf ft) –
Remaining nuts, chassis M8 25 Nm (18.4 lbf ft) –
Remaining screws, chassis M8 25 Nm (18.4 lbf ft) –
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft) –
Screw, engine brace M8 33 Nm (24.3 lbf ft) –
Screw, fork stub M8 15 Nm (11.1 lbf ft) –
Screw, front brake caliper M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –
Screw, subframe M8 35 Nm (25.8 lbf ft) Loctite®2701
Screw, top steering stem M8 17 Nm (12.5 lbf ft) Loctite®243™
Screw, top triple clamp M8 17 Nm (12.5 lbf ft) –
Engine attachment bolt M10 60 Nm (44.3 lbf ft) –
Remaining nuts, chassis M10 45 Nm (33.2 lbf ft) –
Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –
Screw, bottom shock absorber M10 60 Nm (44.3 lbf ft) Loctite®2701
Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite®243™
Screw, top shock absorber M10 60 Nm (44.3 lbf ft) Loctite®2701
Nut, seat fixing M12x1 20 Nm (14.8 lbf ft) –
Nut, frame to linkage lever M14x1.5 80 Nm (59 lbf ft) –
Nut, linkage lever on swingarm M14x1.5 80 Nm (59 lbf ft) –
Nut, linkage lever to angle lever M14x1.5 80 Nm (59 lbf ft) –
Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) –
Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft) –
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) –
Screw-in nozzles, cooling system M20x1.5 12 Nm (8.9 lbf ft) Loctite®243™
Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) –

SUBSTANCES 11
Super unleaded (ROZ 95/RON 95/PON 91)
According to
–DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
–Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
–Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).

AUXILIARY SUBSTANCES 12
Long-life grease
Guideline
–KTM recommends Motorex®products.
Supplier
Motorex®
–Bike Grease 2000

*3211818en*
3211818en
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
11/2011
Photo: Mitterbauer