Description
This 244 page, 2010 KTM 450 SX-F Repair Manual is an authorized reproduction of the original, out of print manual. It covers 2010 KTM 450 SX-F motorcycles.
The following topics are covered:
MEANS OF REPRESENTATION
IMPORTANT NOTES
LOCATION OF SERIAL NUMBERS
Chassis number
Type label
Engine number
Fork part number
Shock absorber part number
MOTORCYCLE
Jacking up the motorcycle
Removing the motorcycle from the work stand
Starting
Starting the motorcycle for checking
FORK, TRIPLE CLAMP
Adjusting the compression damping of the fork
Adjusting the rebound damping of fork
Bleeding fork legs
Cleaning the dust boots of the fork legs
Loosening the fork protector
Positioning the fork protection
Removing the fork legs
Installing the fork legs
Removing the fork protector
Installing the fork protector
Conducting major fork service
Conducting minor fork service
Disassembling the fork legs
Disassembling the cartridge
Disassembling the piston rod
Disassembling the screw cap with the membrane holder
Disassembling the screw sleeve
Checking the fork legs (450 SX-F EU)
Checking the fork legs (450 SX-F USA)
Checking the fork legs – during a minor fork service
(450 SX-F EU)
Checking the fork legs – during a minor fork service
(450 SX-F USA)
Changing the pilot bushing
Assembling the screw sleeve
Reassembling the screw cap with the membrane holder
Assembling the piston rod
Assembling the cartridge
Assembling the fork legs (450 SX-F EU)
Assembling the fork legs (450 SX-F USA)
Bleeding and filling the cartridge
Filling the cartridge with nitrogen
Greasing the steering head bearing
Removing the lower triple clamp
Installing the lower triple clamp
Checking steering head bearing play
Adjusting play of steering head bearing
HANDLEBAR, INSTRUMENTS
Hot start lever
Handlebar position
Adjusting handlebar position
Adjusting basic position of clutch lever
Checking throttle cable route
Checking the play in the throttle cable
Adjusting the play in the throttle cable
SHOCK ABSORBER, SWINGARM
Adjusting high-speed compression damping of the shock absorber
Adjusting the low-speed compression damping of the
shock absorber
Adjusting the rebound damping of the shock absorber
Measuring rear wheel sag unloaded
Checking static sag of shock absorber
Checking riding sag of shock absorber
Adjusting the spring preload of the shock absorber
Adjusting the riding sag
Removing the shock absorber
Installing the shock absorber
Performing a shock absorber service
Removing the spring
Disassembling the shock absorber
Disassembling the piston rod
Disassembling the seal ring retainer
Replacing the pilot bushing
Checking the shock absorber
Disassembling the rebound adjuster
Removing the heim joint
Installing the heim joint
Assembling the rebound adjuster
Assembling the seal ring retainer
Assembling the piston rod
Assembling the damper (450 SX-F EU)
Assembling the damper (450 SX-F USA)
Bleeding and filling the damper
Filling the damper with nitrogen
Installing the spring (450 SX-F EU)
Installing the spring (450 SX-F USA)
EXHAUST
Removing main silencer
Installing the main silencer
Removing the glass fiber yarn filling of the main
silencer
Installing the glass fiber yarn filling of the main silencer
AIR FILTER
Removing the air filter box lid
Installing the air filter box lid
Removing the air filter
Installing the air filter
Cleaning air filter
Removing the carburetor connection boot
Installing the carburetor connection boot
FUEL TANK, SEAT, TRIM
Opening filler cap
Closing filler cap
Removing the seat
Mounting the seat
Removing the fuel tank
Installing the fuel tank
Fuel tap
MASK, FENDER
Removing the front fender
Installing the front fender
Dismount the start number plate
Installing the start number plate
FR0NT WHEEL
Removing front wheel
Installing the front wheel
Checking brake discs
Removing the front brake disc
Installing the front brake disc
Tire condition checking
Checking tire air pressure
Checking spoke tension
REAR WHEEL
Removing the rear wheel
Installing the rear wheel
Removing the rear brake disc
Installing the rear brake disc
Checking chain tension when fitting rear wheel
Adjusting chain tension – fitting rear wheel
Checking the chain tension
Adjusting chain tension – after checking
Adjusting chain tension
Adjusting the chain guide
Checking the rear sprocket/engine sprocket for wear
Checking chain wear
Checking for chain dirt accumulation
Cleaning the chain
WIRING HARNESS, BATTERY
Removing a fuse
Installing the fuse
Removing the battery
Installing the battery
Recharging the battery
Checking the stall current
Checking the charging voltage
Checking the charging current
Checking the starter relay
BRAKE SYSTEM
Checking the front brake linings
Removing front brake linings
Installing the front brake linings
Changing the front brake linings
Checking free travel on hand brake lever
Adjusting the basic position of the hand brake lever
Checking the brake fluid level of the front brake
Topping up the front brake fluid
Changing the front brake fluid
Checking rear brake linings
Removing rear brake linings
Mounting rear brake linings
Changing the rear brake linings
Checking the free travel of the foot brake lever
Adjusting the basic position of the foot brake lever
Checking rear brake fluid level
Adding brake fluid to the rear brake circuit
Changing the rear brake fluid
ENGINE
Removing the engine
Installing the engine
DISASSEMBLING THE ENGINE
Preparations
Removing the shift lever
Draining the engine oil
Removing the oil filter
Removing the spark plug
Removing the valve cover
Removing the starter motor
Removing the alternator cover
Removing the torque limiter and starter idler gear
Positioning the engine at ignition top dead center (TDC)
Removing the camshaft
Removing the timing chain tensioner
Removing the double wheel
Removing the cylinder head
Removing the water pump cover
Removing the clutch cover
Removing the piston
Removing the timing chain rails
Removing the timing chain
Removing the ignition pulse generator
Removing the rotor
Removing the drive wheel of the balancer gear
Removing the force pump
Removing the spacer
Removing the outer clutch hub
Removing the primary gear
Removing the suction pump
Removing the shift shaft
Removing the shift drum locating unit
Removing the locking lever
Removing the left section of the engine case
Removing the shift rails
Removing the shift drum
Removing the shift forks
Removing the transmission shafts
Removing the crankshaft
ENGINE – WORK ON THE INDIVIDUAL PARTS
Working on the right section of the engine case
Working on the left section of the engine case
Removing the water pump
Changing the shaft seal ring of the water pump
Installing the water pump
Removing the crankshaft seal ring in the clutch cover
Installing the crankshaft seal ring in the clutch cover
Removing the stator
Installing the stator
Removing the oil pressure regulator valve
Checking spring length of oil pressure regulator valve
Installing the oil pressure regulator valve
Checking the lubrication system
Removing the crankshaft bearing inner race
Installing the crankshaft bearing inner race
Changing connecting rod, conrod bearing and crankpin
Checking crankshaft run-out at bearing pin
Measuring the crankshaft end play
Cylinder – Nikasil® coating
Checking/measuring cylinder
Checking/measuring the piston
Measuring piston/cylinder mounting clearance
Checking the piston ring end gap
Changing the camshaft bearing
Checking the autodecompressor
Checking camshafts
Checking the radial clearance of the camshaft bearings
Checking the camshaft bearing bridges
Removing the valves
Checking the valves
Checking the valve springs
Checking valve spring seat
Checking the cam levers
Checking cylinder head
Installing the valves
Removing the freewheel
Checking the freewheel
Installing the free wheel
Checking the electric starter mode
Checking the timing assembly
Preparing the timing chain tensioner for installation
Checking clutch
Checking shift mechanism
Preassembling the shift shaft
Disassembling the main shaft
Disassembling the countershaft
Checking transmission
Assembling the main shaft
Assembling the countershaft
ENGINE ASSEMBLY
Installing the crankshaft and balancer shaft
Installing the transmission shafts
Installing the shift forks
Installing the shift drum
Installing the shift rails
Installing the left engine case
Installing the locking lever
Installing the shift drum locating unit
Installing the shift shaft
Installing the suction pumps
Installing the spacer
Installing the force pump
Installing the primary gear
Installing the outer clutch hub
Installing the drive wheel of the balancer gear
Installing the timing chain
Installing the free wheel gear
Installing the rotor
Installing the ignition pulse generator
Adjusting the ignition pulse generator gap
Installing the timing chain rails
Installing the piston
Installing the clutch cover
Installing the water pump cover
Installing the cylinder head
Installing the double wheel
Installing the timing chain tensioner
Checking the valve timing
Adjusting the valve timing
Checking the valve clearance
Adjusting the valve clearance
Installing the torque limiter and starter idler gear
Installing the alternator cover
Installing the starter motor
Installing the valve cover
Installing the spark plug
Installing the oil screen
Installing the oil filter
Installing the shift lever
Removing the engine from the universal mounting rack
CARBURETOR
Choke
Removing the carburetor
Installing the carburetor
Disassembling the carburetor
Checking/adjusting the carburetor components
Checking/adjusting the accelerator pump
Checking the choke slide
Checking the jet needle
Checking the throttle slide
Checking the needle jet
Checking the float needle valve
Checking/adjusting the float level
Checking/adjusting the throttle slide opening
Checking the throttle position sensor
Adjusting the position of the throttle position sensor
Assembling the carburetor
Carburetor – adjusting idle
Emptying the carburetor float chamber
CLUTCH
Checking the fluid level of hydraulic clutch
Changing the hydraulic clutch fluid
WATER PUMP, COOLING SYSTEM
Cooling system
Checking the anti-freeze and coolant level
Checking the coolant level
Draining the coolant
Refilling coolant
LUBRICATION SYSTEM
Oil circuit
Checking engine oil level
Changing engine oil and oil filter, cleaning oil screen
Draining the engine oil
Cleaning the oil screen
Removing the oil filter
Installing the oil filter
Filling up with engine oil
Topping up engine oil
IGNITION SYSTEM
Checking the ignition system
Checking the ignition coil
Checking the spark plug connector
Check CDI controller
Checking the ignition pulse generator
Checking the generator
Removing the stator
Installing the stator
ELECTROSTARTER
Checking the starter motor
TROUBLESHOOTING
TECHNICAL DATA – ENGINE
Capacity – engine oil
Capacity – coolant
TECHNICAL DATA – ENGINE TOLERANCES, WEAR LIMITS
TECHNICAL DATA – ENGINE TIGHTENING TORQUES
TECHNICAL DATA – CARBURETOR
TECHNICAL DATA – CARBURETOR TIGHTENING
TORQUES
TECHNICAL DATA – CHASSIS
Tires
Capacity – fuel
TECHNICAL DATA – FORK
450 SX-F EU
450 SX-F USA
