KTM 450 SX-F EU Operating instructions

450 SX-F EU
450 SX-F USA
Art. no. 3206118en

TABLE OF CONTENTS 2
MEANS OF REPRESENTATION ............................................ 6
041SHOCK ABSORBER, SWINGARM ................................... 49
IMPORTANT NOTES ............................................................ 7 Adjusting the
high-speed compression damping of the
SERIAL NUMBERS .............................................................. 8
shock absorber .............................................................. 49
Chassis number ............................................................... 8 Adjusting the
low-speed compression damping of the
Type label ....................................................................... 8
Engine number ................................................................ 8
Fork part number ............................................................. 8
Shock absorber part number ............................................. 8
MOTORCyCLE ..................................................................... 9
shock absorber .............................................................. 49
Adjusting the
rebound damping of the shock absorber ....... 50
Measuring rear wheel sag unloaded ................................. 50
Checking the static sag of the shock absorber .................. 51
Checking the riding sag of the shock absorber .................. 51
Raising the motorcycle with the lift stand .......................... 9
Removing the motorcycle from the lift stand ...................... 9
Starting .......................................................................... 9
Starting the
motorcycle for checking ............................... 10
OllFORK,
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 (450 SX-F EU) ............................. 23
Checking the fork legs (450 SX-F USA) ........................... 24
Checking the fork legs -during a minor fork service
(450 SX-F EU) .............................................................. 26
Adjusting the spring
preload of the shock absorber ........... 51
Adjusting the riding sag ................................................. 52
Removi ng the shock absorber ......................................... 53
Installing
the shock absorber .......................................... 53
Checking the shock absorber linkage ............................... 54
Servicing
the shock absorber .......................................... 56
Removing the spring...................................................... 56
Disassembling the damper ............................................. 57
Disassembling the piston rod .......................................... 58
Disassembling the seal ring retainer ................................ 59
Changing the pilot bushing ............................................. 60
Checking the damper ..................................................... 61
Removing the heim joint ................................................ 61
Installing the heim joint................................................. 62
Assembling the seal ring retainer .................................... 63
Assembling the piston rod .............................................. 64
Assembling the damper .................................................. 65
Bleeding and filling the damper ...................................... 67
Filling
the damper with nitrogen ..................................... 69
Installing
the spring (450 SX-F EU) ................................ 70
Installing
the spring (450 SX-F USA) .............................. 71
Checking the swingarm .................................................. 72
05/EXHAUST .................................................................... 73
Removing main silencer ................................................. 73
Installing the main silencer ............................................ 73
Changing the glass fiber yarn filling of the main silencer ... 73
Checking the fork legs -during a minor fork service
06/AIR FILTER .................................................................. 75
(450
SX-F USA) ............................................................ 27
Removing the air filter box lid......................................... 75
Changing the pilot bushing ............................................. 28 Installing
the air filter box lid.......................................... 75
Assembling the screw sleeve ........................................... 29
Removing the air filter ................................................... 75
Assembling the screw cap with the membrane holder ........ 29 Installing
the air filter .................................................... 75
Assembling the piston rod .............................................. 30
Cleaning the air filter and air filter box ............................ 76
Assembling the cartridge................................................ 31
Removing the carburetor connection boot ........................ 76
Assembling the fork legs (450 SX-F EU) .......................... 33 Installing
the carburetor connection boot ......................... 77
Assembling the fork legs (450 SX-F USA) ........................ 36
07/FUEL TANK, SEAT, TRIM .............................................. 78
Bleeding and filling the cartridge .................................... 39
Opening filler cap .......................................................... 78
Filling the cartridge with
nitrogen .................................... 41
Closing filler cap ........................................................... 78
Greasing the steering head bearing .................................. 41
Removing the seat ......................................................... 78
Removing the lower triple clamp ..................................... 42 Mounting the
seat ......................................................... 79
Installing
the lower triple clamp ...................................... 42
Removing the fuel tank .................................................. 79
Checking steering head bearing play ................................ 44
Installing the fuel tank................................................... 80
Adjusting
play of steering head bearing ............................ 44
Fuel tap ........................................................................ 81
02/HANDLEBAR, INSTRUMENTS ....................................... 45
08/MASK, FENDER ........................................................... 82
Hot start lever ............................................................... 45
Removi ng the front fender .............................................. 82
Handlebar position ........................................................ 45
Installi ng the front fender............................................... 82
Adjusting
the handlebar position..................................... 45
Removing the start number plate .................................... 82
Adjusting
the basic position of the clutch lever ................. 46
Installing the start number plate ..................................... 82
Checking the throttle cable routing.................................. 46
09/FRONT WHEEL ............................................................ 83
Checking the play in the throttle cable ............................. 46
Removi ng front wheel.................................................... 83
Adjusting
the play in the throttle cable ............................ 47 Installi
ng the front wheeL............................................... 83
03/FRAM E........................................................................ 48
Checking the brake discs ................................................ 84
Checking the frame ....................................................... 48
Removing the front brake disc ........................................ 84
Installing
the front brake disc ......................................... 85

TABLE OF CONTENTS 3
Checking the tire condition............................................. 85 Removing the timing chain........................................... 123
Checking tire air pressure ............................................... 85 Removing the ignition pulse generator ........................... 124
Checking spoke tension.................................................. 86 Removing the rotor ...................................................... 124
lO/REAR
WHEEL .............................................................. 87
Removing the drive wheel of the balancer gear ............... 125
Removing the rear wheel ................................................ 87 Removing the force pump ............................................ 125
Installing the
rear wheel ................................................. 87 Removing the spacer ................................................... 126
Removing the rear brake disc.......................................... 88 Removing the outer clutch hub ..................................... 126
Installing the
rear brake disc .......................................... 88 Removing the primary gear ........................................... 127
Checking the chain tension ............................................ 89 Removing the suction pump ......................................... 127
Adjusting the chain tension ............................................
89 Removing the shift shaft .............................................. 128
Adjusting the chain guide............................................... 90
Removing the shift drum locating unit........................... 128
Checking the chain, rear sprocket, engine sprocket and Removing the locking lever ........................................... 129
chain guide................................................................... 90
Removing the left section of the engine case .................. 129
Checking for chain dirt accumulation .............................. 92
Removing the shift rails ............................................... 129
Clean i ng the chain......................................................... 92
Removing the shift drum .............................................. 130
11IWIRING
HARNESS, BATIERY ....................................... 93
Removing the shift forks .............................................. 130
Removing the main fuse ................................................. 93
Removing the transmission shafts ................................. 130
Installing the
main fuse ................................................. 93
Removing the crankshaft.............................................. 130
Removi ng the battery..................................................... 93 30/ENGINE -
WORK ON THE INDIVIDUAL PARTS ............. 131
Installing the battery...................................................... 94
Worki ng on the right seclion of the engi ne case.............. 131
Charging the battery ...................................................... 94
Working on the left seclion of the engine case ................ 132
Checking the charging voltage ........................................ 95
Removing the water pump............................................ 133
Checking the quiescent currenl....................................... 95
Changing the shaft seal ring of the water pump .............. 134
Checking the starter relay ............................................... 96 Installing the
water pump............................................. 135
13/BRAKE
SYSTEM ........................................................... 97
Removing the crankshaft seal ring in the clutch cover ..... 136
Checking the front brake linings...................................... 97 Installing the crankshaft
seal ring in the clutch cover ...... 136
Changing the front brake linings ..................................... 97
Removing the stator..................................................... 136
Checking free travel on hand brake lever .......................... 99 Installing the stator ..................................................... 136
Adjusting the basic position of the
hand brake lever .......... 99
Removing the oil pressure regulator valve ....................... 137
Checking the brake fluid level of the front brake ............... 99 Checking spring length of oil
pressure regulator valve ...... 137
Adding front
brake fluid ............................................... 100
Installing the oil pressure regulator valve ....................... 137
Changing the front brake fluid ...................................... 100 Checking the lubrication
system .................................... 138
Checking rear brake linings .......................................... 101
Removing the crankshaft bearing inner race ................... 138
Changing the rear brake linings..................................... 102 Installing the crankshaft bearing inner
race .................... 139
Checking the free travel of the foot brake lever ............... 103
Changing connecting rod, conrod bearing and crank
Adjusting the basic position of the foot
brake lever ......... 103 pin............................................................................. 139
Checking rear brake fluid level ...................................... 104 Checking crankshaft run-out at bearing pin .................... 140
Adding
brake fluid to the rear brake circuit .................... 104 Measuring the crankshaft end play................................ 141
Changing the rear brake fluid........................................ 105 Cylinder -Nikasil" coating ............................................ 141
30/ENGINE..................................................................... 106 Checking/measuring cylinder ........................................ 141
Removing the engine ................................................... 106 Checking/measuring the piston ..................................... 142
Installing the engine .................................................... 111
Measuring piston/cylinder mounting clearance................ 143
30/DiSASSEMBLING
THE ENGINE ................................... 117 Checking the piston ring
end gap .................................. 143
Preparations................................................................ 117
Changing the camshaft bearing..................................... 143
Removing the shift lever ............................................... 117 Checking the autodecompressor .................................... 144
Draining the engine oil ................................................. 117 Checking camshafls..................................................... 144
Removi ng the oi I fiIter.................................................. 117 Checking the radial clearance of the camshaft
Removing the spark plug.............................................. 118 bearings ..................................................................... 144
Removing the valve cover ............................................. 118 Checking the camshaft bearing bridges.......................... 145
Removing the starter motor .......................................... 118
Removing the valves .................................................... 145
Removing the alternator cover ....................................... 118 Checking the
valves ..................................................... 146
Removing the torque limiter and starter idler gear ........... 119 Checking the
valve springs ........................................... 146
Positioning the engine at ignition top
dead center Checking
valve spring seal............................................ 147
(TDC) ......................................................................... 119 Checking the cam levers .............................................. 147
Removing the camshaft................................................ 120 Checking cylinder head ................................................ 147
Removing the timing chain tensioner............................. 120 Installing the valves ..................................................... 148
Removing the double wheel .......................................... 121 Removing the freewheel ............................................... 149
Removing the cylinder head .......................................... 121 Checking the freewheel ................................................ 149
Removing the water pump cover ................................... 122 Installing the free wheel ............................................... 149
Removing the clutch cover ........................................... 122 Checking the starter drive............................................. 150
Removing the piston .................................................... 123 Checking the timing assembly ...................................... 151
Removing the timing chain rails.................................... 123 Preparing the timing chain tensioner for installation ....... 151

TABLE OF CONTENTS 4
Checking clutch .......................................................... 152 Checking/adjusting the float level.................................. 183
Checking shift mechanism ........................................... 153 Checking/adjusting the throttle slide opening ................. 183
Preassembling the shift shaft........................................ 154 Checking the throttle position sensor............................. 183
Disassembling the main shaft....................................... 155 Adjusting the position of the throttle position sensor....... 184
Disassembling the countershaft .................................... 155 Assembling the carburetor............................................ 185
Checking transmission ................................................. 156 Carburetor -adjusting idle............................................ 187
Assembling the main shaft ........................................... 157 Emptying the carburetor float chamber.......................... 188
Assembling the countershaft......................................... 158
321CLUTCH .................................................................... 190
30/ENGINE ASSEMBLy................................................... 159 Checking the fluid level of hydraulic clutch.................... 190
Installing the crankshaft............................................... 159 Changing the hydrauliC clutch fluid............................... 190
Installing the transmission shafts.................................. 159
35IWATER PUMP, COOLING SYSTEM .............................. 191
Installing the shift forks ...............................................
159 Cooling system ............................................................ 191
Installing the shift drum...............................................
160 Checking the anti-freeze and coolant level ..................... 191
Installing the shift rails ................................................
160 Checking the coolant level............................................ 191
Installing the left engine case.......................................
160 Draining the coolant .................................................... 192
Installing the locking lever............................................ 161 Refilling coolant.......................................................... 192
Installing the shift drum locating uni!............................ 161
38/LUBRICATION SYSTEM .............................................. 194
Installing the shift shaft............................................... 161 Oil circuit ................................................................... 194
Installing the suction pumps ........................................ 161 Checking engine oil level .............................................. 194
Installing the spacer .................................................... 162 Changing the engine oil and oil filter, cleaning the oil
Installing the force pump .............................................
162
screen ........................................................................ 195
Installing the primary gear............................................ 163
Adding engine oil ........................................................ 197
Installing the outer clutch hub...................................... 163
Checking the engine oil pressure................................... 197
Installing the drive wheel of the balancer gear................ 164
39/IGNITION SYSTEM ..................................................... 199
Installing the timing chain............................................ 165
Checking the ignition system ........................................ 199
Installing the free wheel gear........................................ 165
Ignition coil -checking the primary winding................... 200
Installing the rotor....................................................... 165
Ignition coil -checking the secondary winding................ 200
Installing the ignition pulse generator............................ 166
Checking the spark plug connector................................ 201
Adjusting the ignition pulse generator gap...................... 166
Checking the ignition pulse generator............................ 201
Installing the
timing chain rails..................................... 166
Alternator -checking the stator winding......................... 202
Installing the piston..................................................... 167
Removi ng the stator..................................................... 202
Installing the clutch cover ............................................ 168
Installi ng the stator ..................................................... 202
Installing the water pump cover .................................... 169
40/ELECTROSTARTER..................................................... 203
Installing the cylinder head .......................................... 169
Checking the starter motor ........................................... 203
Installing the double wheel........................................... 170
TECHNICAL DATA -ENGINE............................................ 204
Installing the timing chain tensioner ............................. 170
Capacity -engine oil .................................................... 204
Checking the valve timing ............................................ 171
Capacity -coolan!........................................................ 204
Adjusting the valve timing............................................ 171
TECHNICAL DATA -ENGINE TOLERANCES, WEAR
Checking the valve clearance........................................ 172
LIMITS........................................................................... 205
Adjusting the valve clearance........................................ 173
TECHNICAL DATA -ENGINE TIGHTENING TORQUES ........ 206
Installing the torque limiter and starter idler gear ........... 173
TECHNICAL DATA - CARBURETOR ................................... 208
Installing the alternator cover ....................................... 173
Installing the starter motor ........................................... 174
Installing the valve cover.............................................. 174
Installing the spark plug............................................... 174
Installing the oil screen................................................ 174
Installing the oil filter .................................................. 175
Installing the shift lever ............................................... 175
Removing the engine from the universal mounting
rack ...........................................................................
175
TECHNICAL DATA - CARBURETOR TIGHTENING
TORQUES ....................................................................... 209
TECHNICAL DATA -CHASSIS .......................................... 210
Tires .......................................................................... 210
Capacity -fuel............................................................. 211
TECHNICAL
DATA - FORK ................................................ 212
450 SX-F EU .............................................................. 212
450 SX-F USA ............................................................ 212
TECHNICAL DATA - SHOCK ABSORBER ........................... 213
311CARBURETOR ........................................................... 176
450 SX-F EU .............................................................. 213
Choke......................................................................... 176
450 SX-F USA ............................................................ 213
Removing the carburetor .............................................. 176
TECHNICAL DATA -CHASSIS TIGHTENING TORQUES ...... 215
Installing the carburetor............................................... 177
CLEANING...................................................................... 216
Disassembling the carburetor........................................ 178
Cleaning motorcycle .................................................... 216
Checking/adjusting the carburetor components............... 180
STORAGE ....................................................................... 217
Checking/adjusting the accelerator pump....................... 181
Storage....................................................................... 217
Checking the choke slide.............................................. 181
Preparing for use after storage ...................................... 217
Checking the jet needle................................................ 181
SERVICE SCHEDULE....................................................... 218
Checking the throttle slide............................................ 182
Service schedule ......................................................... 218
Checking the needle jet ................................................ 182
Service work (as additional order).................................. 219
Checking the float needle valve..................................... 183

TABLE OF CONTENTS 5
WIRING DIAGRAM .......................................................... 220
Page 1 of 2................................................................. 220
Page 2 of 2................................................................. 222
SUBSTANCES ................................................................. 224
AUXILIARY SUBSTANCES ................................................ 226
SPECIAL TOOLS .............................................................. 228
STANDARDS ................................................................... 241
INDEX ............................................................................ 242

MEANS OF REPRESENTATION 6
~ balsus.d
The meaning of specific symbols is described below.
Indicates
an expected reaction (e.g. of a work step or a function).
x 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).
•
I Indicates information with more details or tips.
» Indicates the result of a testing step.
v Denotes a voltage measurement.
A Denotes a current measurement.
Denotes a resistance measurement.
Fannaa used
The typographical formals used in this document are explained below.
Proprietary name Identifies a proprietary name.
Identifies a protected name.
Identifies a trademark.

IMPORTANT NOTES 7
WalTl!!IJ
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
service record and in the KTM deller.net; otherwise, all warranty claims will be void. No warranty claim can be honored for damage
resulting from manipulation and/or other changes to the vehicle.
FUll, 0111, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
Sp'!!re p.!!rtI accessories
Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any
resulting damage or loss.
You will find the current KIM PDwerPiris for your vehicle on the KTM website.
International KTM Website, httpdlwww.ktm.com
Work rules
Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in
parentheses. Ex, valve spring compressor (59029019000)
During assembly, non·reusable parts (e.g. self·locking screws and nuts, seals and seal rings, O'rings, pins, lock washers) must be
replaced by new parts.
If thread lock (e.g. Loctite
e)
is used for screw connections, be sure to comply with the manufacturer's specific instructions on its
usage.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Ensure that the vehicle is safe to operate after completing repair and maintenance work.
NDtIIIwami!IP
Pay close attention to the noteslwarnings.
• Info
I Various information and warning labels are affixed to the vehicle. Do not remove informationlWarning labels. If they are miss-
ing, you or others may not recognize potential hazards and may therefore be injured.
Grades 01 risks
n Danger
W Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
* Warning
'f1" Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
RI Ir manual
-It is imperative that you read this owner's manual carefully and completely before the start of work. It contains useful information
and many tips on how to repair and maintain your vehicle.
- This manual assumes that the necessary special KTM tools and workplace and workshop equipment are available.

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SERIAL NUMBERS B
The chassis number is stamped on the steering head on the right.
The type label is fixed to the front of the steering head.
The engine number is stamped
on the left side of the engine under the engine
sprocket.
The fork part number is stamped
on the inner side of the fork stub.
The shock absorber part number is stamped
on the top of the shock absorber above
the adjusting ring on the engine side.


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MOTORCYCLE
Note
Danger 01 damage The parked vehicle may roll away or fall over.
-Always place the vehicle on a firm and even surface.
-
Raise the motorcycle at the frame underneath the engine.
I Lift stand (54829055000) ( .. p. 228)
,/ The wheels should no longer touch the ground.
-Secure the motorcycle against falling
over.
ilia motorcycla from ilia lift stand
Nole
Danger 01 damage The parked vehicle may roll away or fall over.
-Always place the vehicle on a firm and even surface.
-
Remove the motorcycle from the lift stand.
-
Remove the lift stand.
-
To park the motorcycle. insert plug-in stand into the left side of the wheel spin-
dle.
• Info
I Remove the plug-in stand before starting on a trip.
Startinl(
~ Danger
W Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness andlor death.
9
-
When running the engine. always make sure there is sufficient ventilation. and do not start or run the engine in an enclosed
space without
an effective exhaust extraction system.
Nole
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
-Always warm up the engine at low engine speeds.
• Info
I If the motorcycle is unwilling to start. the cause may be old fuel in the float chamber. The flammable elements of the fuel
evaporate after a long time of standing.
If the float chamber is filled with fresh fuel. the engine starts immediately.
Press the starter for a maximum of 5 seconds. Wait for at least 5 seconds before trying again.
400733-01
Engine has been out of use for more Ihan 1 week
-Empty the carburetor float chamber. ( .. p. 188)
-Turn handle of the fuel tap to the ON position. (Figure 800189-10 " p. 81)
,/ Fuel can flow from the fuel tank to the carburetor.
-
Remove the motorcycle from the stand.
-
Shift transmission to neutral.
The engine is cold
-Pull choke lever out as far as possible.
The enline is hot
-Pull the hot start lever out to the stop.
-
Press the electric starter button (J).
• Info
I Do not open the throttle.


MOTORCYCLE
1Q
The enline is hat and runninl
- Push back the hot start lever to the stop with the engine running.
Startinl thl mato !:!=J!! 11 far chlckinl
n Danger
W Danger a' poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness andlor death.
- When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
• Info
I Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again.
- Turn handle of the fuel tap to the ON position. (Figure 800189-10 '" p. 81)
./ Fuel can flow from the fuel tank to the carburetor.
-Shift transmission to neutral.
The engine is cold
- Pull choke lever out as far as possible.
The enline is hot
- Pull the hot start lever out to the stop.
- Press the electric starter button (J).
• Inlo
I Do not open the throttle.
The enline i. hot and running
- Push back the hot start lever to the stop with the engine running.

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Ol/FORK, TRIPLE CLAMP 11
Adjustinllhe comp'ression damp'inl of !he forti
• Inlo
I The hydraulic compression damping determines the fork suspension behavior.
-Turn adjusting screws clockwise all the
way.
• Info
I Adjusting screws are located at the top end of the fork legs.
Make the same adjustment
on both fork legs.
-Turn back counterclockwise by the number of clicks corresponding
to the fork type.
Guideline
Compression damping
(450 SX-F EU)
Comfort 14 clicks
Standard
12 clicks
Sport
10 clicks
Compression damping
(450 SX-F USA)
Comfort 14 clicks
Standard
12 clicks
Sport
10 clicks
• Info
I Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
Ad'ustinllhl I'8bound dampinl of !hI forti
• Info
I The hydraulic rebound damping determines the fork suspension behavior.
-
Remove protection caps .
-Turn adjusting screws clockwise all the
way.
• Info
I Adjusting screws are located at the bottom end of the fork legs.
Make the same adjustment
on both fork legs.
-Turn back counterclockwise by the number of clicks corresponding
to the fork type.
Guideline
Rebound damping
(450 SX-F EU)
Comfort
14 clicks
Standard
12 clicks
Sport
10 clicks
Rebound damping
(450 SX-F USA)
Comfort
14 clicks
Standard
12 clicks
Sport
10 clicks
• Info
I Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
-Mount protection covers

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Ol/FORK, TRIPLE CLAMP
Bleedina: fork 1m
Claanina: ilia dust boots of ilia fork la~
Preliminary work
- Raise the motorcycle with the lift stand. (r p. 9)
Main work
- Remove bleeder screws briefly.
,/ Any excess pressure escapes from the interior of the fork.
-
Mou nt and tighten bleeder screws.
Follow-up work
- Remove the motorcycle from the lift stand. (r p. 9)
Preliminary work
- Raise the motorcycle with the lift stand. (r p. 9)
- Loosen the fork protector. (r p. 12)
Main work
- Push dust boots of both fork legs downwards.
• Info
I The dust boots should remove dust and coarse dirt particles from the fork
tubes.
Over time, there is an ingress of dirt inside the boots. If this dirt is
not removed,
it may cause the oil seals to leak.
Warning
12
Danger 01 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.
-Clean and oil the dust boots and inner fork tube of both fork legs.
IUniversal oil spray (r p. 227)
- Press the dust boots back into their normal position.
- Remove excess oi I.
Follow-up work
-Position the fork protection. (r p. 13)
-
Remove the motorcycle from the lift stand. (r p. 9)
-
Remove screws and remove the clamp.
-
Remove screws on the left fork leg. Push the fork protector downwards.
-
Remove the screws on the right fork leg. Push the fork protector downwards.

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
Ol/FORK, TRIPLE CLAMP
Installinllhl fork I~
-Position the fork protection on the left fork leg. Mount and tighten screws
Guideline
13
I Remaining screws, chassis
110 Nm (7.4 Ibf ft) I
-Position brake line. Put the clamp on, mount and tighten screws
-Position the fork protection
on the right fork leg. Mount and tighten screws.
Guideline
I Remaining screws, chassis
110 Nm (7.4 Ibf ft) I
Preliminary work
- Raise the motorcycle with the lift stand. (or p. 9)
- Remove front wheel. (or p. 83)
Main work
- Remove screws and take off clamp.
-
Remove screws and take off brake caliper.
-Hang the brake caliper and the brake line loosely to the side.
-
Loosen screw . Remove the fork leg on the left.
-
Loosen screw . Remove the fork leg on the right.
Main work
-Position the fork legs.
• Info
I The upper milled groove in the fork leg must be flush with the top edge of
the upper triple clamp.
Position bleeder screws toward the fron!.
-Tighten screws
Guideline
Screw, top triple clamp
-Tighten screws
Guideline
IScrew, bottom triple clamp
M8 17 Nm
(12.5 Ibf ft)
112 Nm (8.9 Ibf ft) I

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Ol/FORK, TRIPLE CLAMP
R.movinl tIIa fork rotector
800306-10
Installinl the fork protector
800306-10
Conductinl major fortls.lviea
• Info
-Position the brake caliper. Mount and tighten screws
Guideline
Screw, front brake caliper M8
25 Nm
(18.4 Ibf ft)
-Position the brake line
and clamp. Mount and tighten screws
Subsequent work
-Install the front wheel. ( -- p. 83)
Preliminary work
- Raise the motorcycle with the lift stand. ( -- p. 9)
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Remove front wheel. ( -- p. 83)
- Remove the fork legs. ( -- p. 13)
Main work
Loctile- 243'"
- Remove screws on the left fork leg. Remove the fork protector upwards.
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Remove the screws on the right fork leg. Remove the fork protector upwards.
Main work
-Position the fork protection on the left fork leg. Mount and tighten screws
Guideline
14
J
I Remaining screws, chassis
110 Nm (7.4 Ibf It) I
-Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
I Remaining screws, chassis
110 Nm (7.4 Ibf It) I
Subsequent work
-Install the fork legs. ( -- p. 13)
-Install the front wheel. (
-- p. 83)
I The steps are identical for both fork legs.
Condition
The fork legs are disassembled.

Ol/FORK, TRIPLE CLAMP
o
..
..
9
e 200974-01
Conductinl minor forti slrvicI
• Info
-Disassemble the fork legs. ( .. p. 15)
-Disassemble the cartridge. ( .. p. 18)
-Disassemble the piston rod. ( .. p. 20)
-Disassemble the screw cap with the membrane holder. ( .. p. 21)
- Disassemble the screw sleeve. ( ... p. 22)
-Check the fork legs. ( .. p. 23)
-Change the pilot bushing. ( .. p. 28)
-Assemble the screw sleeve. ( .. p. 29)
-Assemble the screw cap with the membrane holder. ( .. p. 29)
-Assemble the piston rod. ( .. p. 30)
-Assemble the cartridge. ( .. p. 31)
-Assemble the fork legs. ( .. p. 33)
I The steps are identical for both fork legs.
o
§
<0
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o
e
8
Disasslmblinl tltl forti I
• Info
Condition
The fork legs are disassembled.
-Disassemble the fork legs. ( .. p. 15)
-Check the fork legs -during a minor fork service. ( .. p. 26)
-Assemble the fork legs. ( .. p. 33)
200978-01
I The steps are identical for both fork legs.
Condition
The fork legs are disassembled.
15

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Ol/FORK, TRIPLE CLAMP 17
20135~10
4D8
I I
201357-10
- Press the cartridge against the spring and mount special tool on the piston rod.
1 Support tool (Tl4020) ( .. p. 238)
-Hold nut and remove the rebound adjuster.
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Press the cartridge against the spring and remove special tool
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Remove the cartridge from the fork leg.
-Take out the fork
leg.
- Remove the preload spacers and spring.
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Remove dust boot
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Remove fork protector ri ng
• Info
I The fork protector ring does not necessarily need to be disassembled for the
further repair.
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Remove lock ring
• Info
I The lock ring has a coarsely finished end against which the screwdriver can
be placed.
-Heat up the outer tube in
area of the lower sliding bushing.
Guideline
150 'C (122 'F)
-Jerk the outer tube out of the inner tube.
• Info
I The lower sliding bushing must be pulled out of its bearing seat when
doing this.

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