KTM 450 SXS-F Operating instructions

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