KTM 450 SX-F (2007) manual

KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at KTM Group Partner 6/2006 FOTO: MITTERBAUER 250 SX-F 450 SX-F OWNER’S MANUAL 2007 ART. NR. 3.211.146 EN ENGLISH[...]

ENGLISH 1 INTRODUCTION » Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Stamp of dealer All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service wo[...]

ENGLISH 2 IMPORTANT » INTENDED PURPOSE KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading international motorcycle associations. OWNER’S MANUAL Please read this manual carefully and com[...]

ENGLISH 3 IMPORTANT » The service work specified in the "Lubrication and Maintenance Schedule" must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void. The fuels and lubricants specified in the Owner's Manual or automotive fluids with equivalent specifications must[...]

ENGLISH 4 TABLE OF CONTENTS » IMPOR T ANT INFORMA TION . . . . . . . . . . . . . . . . . . . . . .2 SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . .5 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Engine number , engine type . . . . . . . . . . . . . . . . . . . .5 OPERA TION INSTRUMENTS . . . . . . . . . .[...]

ENGLISH 5 SERIAL NUMBER LOCATIONS » Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number, engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket. Enter this number on page 1. OPERATION IN[...]

Fuel tap OFF In this position the fuel tap is closed. No fuel can flow to the carburetor . ON During operation the twist grip must be turned to ON. This means that the fuel can flow to the carburetor . OPERATION INSTRUMENTS » Starter button (450 SX-F) Pushing the black starter button [3] will actuate the E-starter . ENGLISH 6 Hand brake lever The [...]

ENGLISH 7 OPERATION INSTRUMENTS » Choke If you pull the choke button [1] out as far as possible, a bore in the carburetor will be opened through which the engine may take in additional fuel. The result is a “fat“ fuel-air mixture of the type needed for cold starts. T o deactivate the choke, push the choke button back into its basic position. S[...]

ENGLISH 8 OPERATION INSTRUMENTS » Compression damping of fork Hydraulic compression damping determines the reaction when the fork is compressed. The degree of compression can be adjusted with adjusting screws at the top of the fork legs. T urn the adjusting screws [1] clockwise to increase damping, turn it counterclockwise to reduce damping during[...]

ENGLISH 9 OPERATION INSTRUMENTS » Rebound damping of shock absorber By using the adjusting screw [1] , the degree of damping of the rebound can be adjusted. T urn the knob clockwise to increase damping, turn it counter- clockwise to reduce damping during rebounding. ST ANDARD ADJUSTMENT : – turn the adjusting screw clockwise to the stop. – the[...]

ENGLISH 10 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » – Dress properly for the ride. Smart KTM drivers always wear a helmet, boots, gloves and the right Enduro/Motocross clothing. Protective clothing should be conspicuous to make sure other road users see you in time. – Do not drive after drinking alcohol. – Always switch on the[...]

ENGLISH 11 DRIVING INSTRUCTIONS » Check the following before each start When you start off, the motorcycle must be in perfect technical condition. For safety reasons, you should make a habit of performing an overall check of your motorcycle before each start. The following checks should be performed: 1 CHECK THE OIL LEVEL Insufficient oil results [...]

ENGLISH 12 Starting when the engine is cold 1 Open the fuel tap [1] . 2 Swing up the side stand or center stand. 3 Put the gear in neutral. 4 Operate the choke [2] . 5 Leave throttle closed and kick the kickstarter briskly ALL THE WA Y or actuate the E-starter . – If you want to start the engine, make sure that you always put on sturdy motorcycle[...]

ENGLISH 13 DRIVING INSTRUCTIONS » Starting off Pull the clutch lever . Put the engine into first gear , slowly release the clutch lever and open the throttle at the same time. Shifting/Riding Y ou are now in first gear , refered to as the drive or uphill gear . Depending on the conditions (hill size etc.), you can shift to a higher gear . Close th[...]

ENGLISH 14 PERIODIC MAINTENANCE » 250/450 SX-F 2007 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! 1st service after 3 hours or 20 l fuel every 10 hours or 70 l fuel ENGINE Change engine oil, oil filter z z Clean oil screen and drain plug magnet z z Replace spark plug (after 30 hours) Check and adjust valve clearance z z Check e[...]

ENGLISH 15 PERIODIC MAINTENANCE » 250/450 SX-F 2007 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Before each start After every cleaning For cross- country use at least once a year Check oil level z Check brake fluid level z Check brake pads for wear z Lubricate and adjust cables and nipples z Bleed fork legs regularly z Remove a[...]

Changing the spring preloading of the shock absorber The spring preload can be changed by turning the adjusting ring [1] . For this purpose, you should dismount the shock absorber and clean it thoroughly . NOTE: – Before changing the spring preload note down the basic setting, e.g. how many threads are visible above the adjusting ring. – One ro[...]

ENGLISH 17 MAINTENANCE WORK ON CHASSIS AND ENGINE » Basic suspension setup for the weight of the driver T o achieve maximum handling performance and to prevent the fork, shock absorber , swing arm and frame from being damaged, the basic setup of the suspension components must be suitable for your weight. At delivery , KTM's offroad motorcycle[...]

ENGLISH 18 Checking the basic setup of the telescopic fork The precise riding sag of the telescopic fork cannot be determined for various reasons. Similar to the shock absorber , smaller deviations in your weight can be compensated by adjusting the spring preload. However , if your telescopic fork bumps frequently (hard end stop during compression)[...]

ENGLISH 19 MAINTENANCE WORK ON CHASSIS AND ENGINE » Changing the fork offset (caster) * The fork offset [A] in the 250/450 SX-F models (center fork legs - center steering head angle) can be set to either 18 or 20 mm. This allows you to optimize the handling to match the race course. Remove the blind screw [1] to see which offset is set. If the mar[...]

ENGLISH 20 MAINTENANCE WORK ON CHASSIS AND ENGINE » Checking and adjusting the steering head bearing * Check steering head bearing for play periodically . T o check, put the motorcycle on a stand so that the front wheel is off the ground. Now try to move the fork forward and backward. T o adjust, loosen the 5 clamp screws [1] and [3] on the upper [...]

ENGLISH 21 MAINTENANCE WORK ON CHASSIS AND ENGINE » How to change the handlebar position The handlebar position can be readjusted by 22 mm. Thus, you can put the handlebar in the position that is the most convenient for you. The upper triple clamp [1] includes 2 bores arranged at a distance of 15 mm (0.6 in) from one another . The bores at the han[...]

ENGLISH 22 MAINTENANCE WORK ON CHASSIS AND ENGINE » Correct chain tension Loosen collar nut [1] , loosen lock nuts [2] , and turn right and left adjusting screws [3] equally far . T ighten lock nuts. T o ensure the correct alignment of the rear wheel, the marks at the left and right chain adjusters must be positioned identically in relation to the[...]

ENGLISH 23 MAINTENANCE WORK ON CHASSIS AND ENGINE » Chain maintenance For a long chain life, good maintenance is very important. Chains without X-rings should be cleaned in fireproof solvent regularly and afterwards treated with hot grease or chain spray (e.g. Motorex Chainlube 622). No lubrication is allowed to reach the rear tire or the brake di[...]

General information about KTM disc brakes BRAKE CALIPERS: The brake calipers of this series use a “floating“ mount. This means that the brake calipers are not solidly attached to the caliper support, which enables them to “float“ for maximum braking contact. Secure the screws of the caliper support with Loctite 243 and tighten to 25 Nm. BRA[...]

ENGLISH 25 MAINTENANCE WORK ON CHASSIS AND ENGINE » Adjusting the free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw [1] . In this way , the position of the point of pressure (i.e. the resis-tance you feel on the hand brake lever when the brake pads are pressed against the brake disc[...]

Replacing the front brake pads * Press the brake caliper toward the brake disk, to put the brake piston in its basic position. Remove clips [1] and pull out bolt [2] . Remove brake pads from the brake caliper . Clean the brake caliper and the brake caliper support with compressed air . Check the sleeves of the guide bolts for damage, and grease gui[...]

ENGLISH 27 MAINTENANCE WORK ON CHASSIS AND ENGINE » Changing the basic position of the foot brake pedal * The basic position of the foot brake pedal can be altered by turning the stop screw [1] . The free play at the foot brake pedal must then be adjusted by means of the piston rod [2] . Measured on the outside, the foot brake pedal must have 3-5 [...]

– If you don’t happen to have a torque wrench at hand, make sure you have the tightening torque corrected by a KTM dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle. – After mounting the front wheel, keep operating the hand brake until the pressure point returns. – It is very important to k[...]

ENGLISH 29 MAINTENANCE WORK ON CHASSIS AND ENGINE » Dismounting and mounting the rear wheel Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Remove the collar nut [1] , remove the chain tensioner [2] and pull out the wheel spindle [3] until you can push the rear wheel forwards. T ake the chain off the rear s[...]

ENGLISH 30 MAINTENANCE WORK ON CHASSIS AND ENGINE » Tires, air pressure T ire type, tire condition, and air pressure level affect the way your motor -cycle rides and must therefore be checked whenever you are getting ready to go anywhere on your motorcycle. – T ire size can be found in the technical specifications. – T ire condition has to be [...]

ENGLISH 31 MAINTENANCE WORK ON CHASSIS AND ENGINE » Charging the battery (450 SX-F) The battery discharges every day , even if it is not used. Always disconnect the battery when charging. Charge the battery as described in the instructions [1] on the battery housing. Do not exceed the amperage and charging time. Quick charging at a high amperage h[...]

ENGLISH 32 MAINTENANCE WORK ON CHASSIS AND ENGINE » Cooling system Coolant is circulated by a water pump [1] located in the engine. Air blowing in through the radiators cools the coolant. The slower the speed of the motorcycle, the less the coolant is cooled down. Dirty radiators also reduce the cooling efficiency . Pressure induced by heating of [...]

ENGLISH 33 MAINTENANCE WORK ON CHASSIS AND ENGINE » Replacing the glassfiber yarn packing of the silencer * Aluminum silencers are filled with glassfiber yarn to muffle noise. Have the filling checked regularly by an authorized KTM workshop (see Lubrication and Service Chart). The insulating material fibers escape through the holes in the perforat[...]

Cleaning the air filter * The air filter must be cleaned prior to each race or whenever dust has accumulated. T o clean, lift the filter box cover [1] . Detach the filter retaining clip [2] at the bottom, swing aside and take the air filter [3] and filter support [4] out of the filter box. – Do not clean foam filter with fuel or petroleum since t[...]

ENGLISH 35 MAINTENANCE WORK ON CHASSIS AND ENGINE » Changing the original position of the clutch lever The adjusting screw [1] can be used for individual adjustment of the original position of the clutch lever , thus allowing adjustment to an optimal position for every hand size. T urning the adjusting screw counterclockwise reduces the distance b[...]

CARBURETOR – Adjust idling (Keihin FCR-MX 39/41) * Idling adjustment of the carburetor strongly affects the engine’ s starting behavior . That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly . The idle speed is controlled by means of the adjusting wheel [[...]

ENGLISH 37 MAINTENANCE WORK ON CHASSIS AND ENGINE » Draining the float chamber of the carburetor Following every wet-cleaning procedure, the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it. W ater in the float chamber leads to engine malfunction. Make sure you do this while the engine[...]

Engine oil Automobile engine oil used to be used for four -stroke motorcycles before there were separate motorcycle specifications. Different technical developments made it necessary to have a separate specification for four -stroke motorcycles - the JASO T903 MA standard. Whereas car engines require long changing intervals, motorcycle engines requ[...]

ENGLISH 39 MAINTENANCE WORK ON CHASSIS AND ENGINE » Changing the oil filters Place a receptacle underneath the engine to collect the drained oil. Remove the 2 screws [1] and dismount the oil filter cover . Using circlip pliers, pull the oil-filter insert [2] out of the housing. Clean the oil filter cover , the sealing surface of the O-ring and the[...]

ENGLISH 40 TROUBLESHOOTING » TROUBLE CAUSE REMEDY Engine doesn’t crank (E-starter). Blown fuse Discharged battery . Low outside temperature Dismount the left paneling and the filter box cover and replace the fuse in the starter relay . Recharge the battery and investigate the causes for discharging; contact a KTM dealer . Use the 12 V / 4 A-h ba[...]

ENGLISH 41 TROUBLESHOOTING » TROUBLE CAUSE REMEDY Engine does not rev up Carburetor fuel level too high because float needle valve is dirty or worn out Loose carburetor jets Electronic ignition timing faulty Dismount carburetor and check if worn out T ighten jets Have ignition system checked Engine will not reach full power Fuel supply partially i[...]

ENGLISH 42 CLEANING » Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge. The hard dirt can be removed before washing with the help of a soft water jet. If using a power washer , do not point [...]

ENGLISH 43 TECHNICAL DATA – ENGINE » ENGINE 250 SX-F 450 SX-F Design Liquid-cooled single cylinder 4-stroke engine Displacement 249.51 ccm 449.3 ccm Bore/Stroke 76 / 55 mm 97 / 60.8 mm Ratio 12.8 : 1 12.5 : 1 Fuel unleaded fuel with at least RON 95 V alve timing 4 valves controlled by finger levers and 2 camshafts, driven by a pair of spur gears[...]

ENGLISH 44 TECHNICAL DATA – ENGINE » TIGHTENING TORQUES – ENGINE 250/450 SX-F Hexagon collar screw , engine case, clutch cover , ignition cover , water pump cover M6 10 Nm Hexagon collar screw , engine case, clutch case M7x1 14 Nm Oil drain plug M12x1.5 20 Nm Allen head plug, oil screen short (250 SX-F) M16x1.5 10 Nm oiled Hexagon plug, oil sc[...]

ENGLISH 45 TECHNICAL DATA – CHASSIS » STANDARD ADJUSTMENT – FORK 250 SX-F 450 SX-F WP 4860 CC MA 14.18.7C.03 WP 4860 CC MA 14.18.7C.05 Compression adjuster 15 15 Rebound adjuster 20 21 Spring 4.4 N/mm 4.6 N/mm Oil capacity without CC 385 ml 375 ml Oil capacity CC 195 ml 195 ml Gas pressure 1.2 bar 1.2 bar Fork oil SAE 5 SAE 5 STANDARD ADJUSTME[...]

ENGLISH 46 TECHNICAL DATA – CHASSIS » TIGHTENING TORQUES – CHASSIS 250/450 SX-F Collar screw , front wheel spindle M24x1,5 40 Nm Brake caliper , front M8 Loctite 243 + 25 Nm Brake disks M6 Loctite 243 + 14 Nm Clamping screws, top triple clamp M8 17 Nm Clamping screws, bottom triple clamp M8 12 Nm Clamping screws, fork stubs M8 15 Nm Clamping s[...]

ENGLISH 47 HEAD WORD INDEX » Page Page Adjusting the free travel at the hand brake lever . . . . .25 Adjusting the throttle cables . . . . . . . . . . . . . . . . . . .34 Basic information on carburetor wear . . . . . . . . . . . .36 Basic suspension setup for the weight of the driver . . .17 Battery (450 SX-F) . . . . . . . . . . . . . . . . . . [...]

ANHANG – APPENDICE APPENDIX – APÉNDICE 1 SCHALTPLAN » WIRING DIAGRAM 7 0 0 2 F - X S 0 5 2 6 0 0 2 . 4 0 . 8 0 p u k c i p G 3 r o t a r e n e g n o t t u b p o t s C D I l i o c n o i t i n g i 0 0 0 . 2 3 0 . 9 3 . 4 9 5 - s s e n r a h I D C red -whi te red-black d e r n e e r g e t i h w - e u l b n w o r b k c a l b - w o l l e y k c a l[...]

ANHANG – APPENDICE APPENDIX – APÉNDICE 2 SCHALTPLAN » WIRING DIAGRAM 7 0 0 2 0 5 4 F - X S 7 0 0 2 . 4 0 . 0 1 n o t t u b p o t s C D I l i o c n o i t i n g i n o t t u b t r a t s S P T p u k c i p M A 0 1 y r e t t a b y a l e r t r a t s r o t o m r e t r a t s U r e i f i t c e r - r o t a l u g e r G 3 r o t a r e n e g 0 0 0 . 2 3 0 .[...]

ANHANG – APPENDICE APPENDIX – APÉNDICE 3 SCHALTPLAN » WIRING DIAGRAM ENGLISH DEUTSCH IT ALIANO FRANCAIS ESP ANOL Battery Batterie Batteria Batterie Batería Generator Generator Generatore Alternateur Generador Ignition coil Zündspule Bobina d‘accensione Bobine d’allumage Bobina de encendido Pick up Impulsgeber Pick up Capteur d’allumag[...]

KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at KTM Group Partner 6/2006 FOTO: MITTERBAUER 250 SX-F 450 SX-F BEDIENUNGSANLEITUNG 2007 ART. NR. 3.211.146 DE DEUTSCH[...]