KTM 450 SXS-F User manual

OWNER'S MANUAL 2008
450bSXS-F
ART. NO. 3211253en

DEAR KTM CUSTOMER 1
'($5 .70 &86720(5
Congratulations on your decision to buy a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give
you enormous pleasure if you service and maintain it accordingly.
We wish you great pleasure riding the vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( P. 9) Dealer's stamp
Engine number ( P. 9)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing
development and design of our motorcycles can however not be completely excluded.
All specifications are not binding. KTM Sportmotorcycle AG in particular 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 printing and other errors. The models portrayed partly contain special
equipment that does not belong to the regular scope of delivery.
© 2007 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
Within the meaning of 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

CONTENTS 2
&217(176
MEANS OF REPRESENTATION ............................................ 4
IMPORTANT NOTES............................................................ 5
VIEW OF VEHICLE............................................................... 7
View of vehicle, front left side........................................... 7
View of vehicle, rear right side .......................................... 8
LOCATION OF SERIAL NUMBERS ........................................ 9
Chassis number............................................................... 9
Type label....................................................................... 9
Engine number................................................................ 9
Fork part number............................................................. 9
Shock absorber part number............................................. 9
OPERATING ELEMENTS.................................................... 10
Clutch lever .................................................................. 10
Hot start lever ............................................................... 10
Hand brake lever ........................................................... 10
Short circuit button ....................................................... 10
Electric starter button .................................................... 10
Fuel tap........................................................................ 11
Opening filler cap.......................................................... 11
Closing filler cap ........................................................... 11
Choke........................................................................... 11
Shift lever..................................................................... 12
Foot brake pedal ........................................................... 12
Plug-in stand ................................................................ 12
TIPS ON PUTTING INTO OPERATION ................................. 13
Advice on first use......................................................... 13
Running in the engine.................................................... 14
RIDING INSTRUCTIONS .................................................... 15
Checks before putting into operation ............................... 15
Starting ........................................................................ 15
Starting up ................................................................... 16
Shifting, riding.............................................................. 16
Braking ........................................................................ 16
Stopping, parking .......................................................... 17
Refueling...................................................................... 17
GREASING AND SERVICE TABLE ....................................... 18
Important maintenance work to be carried out by an
authorized KTM workshop. ............................................. 18
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order)................ 19
Important checks and maintenance work to be carried
out by the rider. ............................................................ 19
MAINTENANCE ON CHASSIS AND ENGINE ........................ 21
Jacking up the motorcycle.............................................. 21
Removing the motorcycle from the work stand.................. 21
Checking the basic chassis setting with the rider's
weight .......................................................................... 21
Compression damping of shock absorber.......................... 21
Adjusting high-speed compression damping of the shock
absorber ....................................................................... 21
Adjusting the low-speed compression damping of the
shock absorber.............................................................. 22
Adjusting rebound damping of the shock absorber ............ 22
Measuring rear wheel sag unloaded ................................. 23
Checking static sag of the shock absorber ........................ 23
Checking riding sag of shock absorber ............................. 24
Adjusting spring preload of the shock absorberbx............ 24
Adjusting riding sagbx.................................................. 25
Removing the shock absorberbx..................................... 25
Installing shock absorberbx........................................... 25
Checking basic setting of fork ......................................... 26
Adjusting compression damping of fork ........................... 26
Adjusting rebound damping of fork.................................. 26
Bleeding fork legs.......................................................... 27
Cleaning dust boots of fork legs ...................................... 27
Loosening the fork protection.......................................... 27
Positioning the fork protection ........................................ 27
Checking play of steering head bearing ............................ 28
Adjusting play of steering head bearingbx....................... 28
Fork offset .................................................................... 29
Setting the fork offsetbx............................................... 29
Removing the fork legsbx.............................................. 30
Installing the fork legsbx............................................... 31
Removing the fork protectorbx....................................... 31
Installing the fork protectorbx........................................ 32
Removing the lower triple clampbx................................ 32
Installing the lower triple clampbx................................. 32
Greasing the steering head bearingbx............................. 33
Dismounting the front fender .......................................... 33
Installing the front fender............................................... 33
Dismount the start number plate..................................... 34
Fitting the start number plate ......................................... 34
Handlebar position ........................................................ 34
Adjusting handlebar positionbx...................................... 34
Checking gas Bowden cable route ................................... 35
Checking play in the gas Bowden cable ........................... 35
Adjusting the gas Bowden cable playbx.......................... 35
Checking chain dirt ....................................................... 36
Cleaning the chain......................................................... 36
Checking the chain tension ............................................ 36
Checking the chain tension when fitting rear wheel........... 37
Checking the rear sprocket / engine sprocket for wear ....... 37
Checking chain wear...................................................... 37
Adjusting the chain tension ............................................ 38
Adjusting chain tension - after checking .......................... 39
Adjusting chain tension - fitting rear wheel ...................... 39
Adjusting chain guidebx............................................... 40
Brake fluid reservoir....................................................... 40
Brake calipers ............................................................... 40
Checking brake discs ..................................................... 40
Checking free play of hand brake lever............................. 41
Adjusting basic position of handbrake lever...................... 41
Checking the front brake fluid level................................. 41
Topping up the front brake fluidbx................................. 42
Checking the front brake linings...................................... 42
Removing front brake liningsbx...................................... 43
Mounting front brake liningsbx...................................... 43
Changing the front brake liningsbx................................. 44
Checking free play of foot brake lever .............................. 44
Adjusting basic position of footbrake leverbx................... 45
Checking the rear brake fluid level .................................. 45
Adding rear brake fluidbx.............................................. 46
Checking rear brake linings ............................................ 46
Removing rear brake liningsbx....................................... 47
Installing the rear brake liningsbx.................................. 47
Changing the rear brake liningsbx.................................. 48
Removing front wheelbx................................................ 48
Fitting front wheelbx.................................................... 49
Removing rear wheelbx................................................. 50
Fitting rear wheelbx...................................................... 50
Tire condition checking.................................................. 51
Checking tire air pressure............................................... 51
Checking spoke tension.................................................. 52

CONTENTS 3
Removing the batterybx................................................ 52
Installing the batterybx................................................. 52
Recharging the batterybx.............................................. 53
Removing a fuse............................................................ 54
Replacing the fuse......................................................... 54
Ignition curve plug connection........................................ 55
Changing the ignition curve ............................................ 55
Removing the seat ......................................................... 55
Mounting the seat ......................................................... 55
Dismounting the fuel tankbx......................................... 55
Installing the fuel tankbx.............................................. 56
Cooling system.............................................................. 57
Checking antifreeze and coolant level .............................. 57
Checking the coolant level.............................................. 58
Draining coolantbx....................................................... 58
Refilling coolantbx....................................................... 59
Removing main silencer ................................................. 59
Fitting the main silencer ................................................ 59
Glass fiber yarn filling of main silencer............................ 60
Removing glass fiber yarn filling from main silencerbx..... 60
Fitting glass fiber yarn filling in main silencerbx.............. 60
Changing glass fiber yarn filling of main silencerbx.......... 60
Dismounting the air filter box lid..................................... 60
Installing the air filter box lid.......................................... 61
Removing the air filterbx............................................... 61
Installing the air filterbx............................................... 61
Cleaning air filterbx...................................................... 61
Adjusting basic position of clutch lever............................ 62
Checking fluid level of hydraulic clutch ........................... 62
Changing fluid level of hydraulic clutchbx...................... 62
Carburetor - idle ............................................................ 63
Carburetor - adjusting idlebx......................................... 63
Emptying the carburetor float chamberbx....................... 64
Checking engine oil level................................................ 65
Changing engine oil and oil filter, cleaning oil screenbx... 65
Draining engine oilbx.................................................... 65
Cleaning the oil screenbx.............................................. 66
Removing the oil filterbx............................................... 66
Mounting oil filterbx..................................................... 67
Filling up with engine oilbx........................................... 67
Topping up engine oil .................................................... 67
TROUBLESHOOTING......................................................... 68
CLEANING........................................................................ 70
Cleaning motorcycle ...................................................... 70
STORAGE ......................................................................... 71
Storage......................................................................... 71
Putting into operation after storage ................................. 71
TECHNICAL DATA - ENGINE.............................................. 72
Capacity - engine oil ...................................................... 72
Capacity - cooling liquid................................................. 72
TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 73
TECHNICAL DATA - CARBURETOR..................................... 75
TECHNICAL DATA - CHASSIS ............................................ 76
Capacity - fuel............................................................... 76
TECHNICAL DATA - FORK.................................................. 77
Capacity - fork oil .......................................................... 77
TECHNICAL DATA - SHOCK ABSORBER ............................. 78
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ........ 79
WIRING DIAGRAM ............................................................ 80
Wiring diagram.............................................................. 80
SUBSTANCES................................................................... 82
AUXILIARY SUBSTANCES.................................................. 84
STANDARDS..................................................................... 86
INDEX .............................................................................. 87

MEANS OF REPRESENTATION 4
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Symbols used
The symbols used are explained in the following.
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).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of
your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced
optimally by specially trained experts using the specialist tools required.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained in the following.
Specific name Identifies a specific name.
Name®Identifies a protected name.
Brand™ Identifies a brand in merchandise traffic.

IMPORTANT NOTES 5
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Use definition
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com-
ply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle must be used only on secluded property remote from public road traffic.
Maintenance
A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described
in the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and break-
age of components.
Using the motorcycle in extreme conditions such as very muddy or wet terrain can lead to above-average wear of components such as
the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in
the greasing and service table is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will
ensure a much longer service life for your motorcycle.
Warranty
The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed
in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for
damage resulting from manipulations and alterations to the motorcycle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
Spare parts, accessories
For your own safety, use only spare parts and accessories approved by KTM. KTM accepts no liability for other products and any
resulting damage or loss.
Transport
Note
Danger of damageಘDanger of damage by the vehicle running away or falling over.
ದAlways place the vehicle on a firm and even surface.
Note
Fire hazardಘSome components (engine, radiator and exhaust system) get very hot when the engine is running.
ದDo not place the vehicle where there are flammable or explosive substances.
ದSwitch off the engine.
ದTurn the handlebof the fuel tap to thebOFF position. (Figureb500178-10bP. 11)
ದUse straps or other suitable devices to secure the motorcycle against accidents or falling over.
Environment
Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a poten-
tial problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can
ensure that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your
motorcycle legally, display environmental consciousness, and respect the rights of others.
Warning notes
In your own interest, read the specified warning notes.
Info
Various warning labels are attached to your vehicle. Do not remove any warning labels. If they are missing, you or others may
not recognize dangers and may therefore be injured.

IMPORTANT NOTES 6
Grades of risks
Danger
Danger that leads immediately and certainly to severe and permanent injury or death.
Warning
Danger that will probably lead to severe and permanent injury or death.
Note
Danger of serious damage to machine or material.
Warning
Risk of environmental damage.
OWNER'S MANUAL
ದRead this owner's manual carefully and completely before making your first trip. It contains a lot of information and tips to help
you operate and handle your motorcycle. Only then will you find out how to customize the motorcycle ideally for your own use and
how you can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.
ದThe owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is
sold.

VIEW OF VEHICLE 7
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
View of vehicle, front left side
200393-10
1 Hand brake lever
2 Start number plate
3 Front fender
4 Front wheel
5 Fork part number
6 Oil filter cover
7 Plug-in stand
8 Shift lever
9 Choke button
10 Air filter
11 Filler cap
12 Clutch lever

VIEW OF VEHICLE 8
View of vehicle, rear right side
200394-10
1 Main silencer
2 Shock absorber
3 Brake caliper of rear brake
4 Rear wheel
5 Foot brake pedal
6 Manifold
7 Chassis number/type label
8 Throttle grip