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450 SX 2009
KTM 450 SX 2009 User Manual
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MAINTENA
NCE
ON
CHASSIS
AND
ENGINE
137
300251-10
–
Mount
and
tighten
screws
on
the
radi
ator.
Guideline
Remaining
screws,
chas
sis
M6
10
Nm
(7.4
lbf
ft)
–
Mount
and
tighten
screws
on
the
fuel
tan
k.
Guideline
Screw
on
fuel
tank
M6
6
Nm
(4.4
lbf
ft)
–
Mount
the
seat.
(
p.
134)
9.66
Removing
the
front
cover
300252-10
–
Remove
screw
.
–
Slide
the
front
cover
up
and
remove
it.
138
140
Table of Contents
Table of Contents
5
Means of Representation
9
Important Notes
10
Overview of Labels
14
View of Vehicle
24
View of the Vehicle from the Left Front (Example)
24
View of the Vehicle from the Right Rear (Example)
26
Location of Serial Numbers
28
Chassis Number
28
Type Label
28
Key Number
29
Engine Number
29
Shock Absorber Part Number, Front
30
Shock Absorber Part Number, Rear
30
Control Elements
31
Clutch Lever
31
Hot Start Lever
31
Handbrake Lever, Parking Brake
32
Throttle Lever
33
Light Switch
33
Light Switch
34
ENG. STOP Switch
34
ENG. STOP Switch
35
Electric Starter Button
35
Electric Starter Button
36
Ignition Switch
36
Indicator Lamp Overview
37
Emergency off Switch with Rip Cord
37
Opening Filler Cap
38
Closing Filler Cap
38
Fuel Tap
39
Choke
40
Shift Lever
40
Foot Brake Pedal
41
Tips on Putting into Operation
42
Advice on First Use
42
Running in the Engine
45
Riding Instructions
46
Checks before Putting into Operation
46
Starting
47
Starting up
49
Shifting
49
Braking
50
Riding
51
Riding in Bends
51
Riding Downhill
53
Riding Uphill
54
Riding Perpendicular to the Slope
55
Turning on Slopes
55
Riding through Water
57
Switching off the Engine
57
Stopping, Parking
58
Refueling
59
Service Schedule
61
Important Maintenance Work to be Carried out by an Authorized KTM Workshop
61
Important Maintenance Work to be Carried out by an Authorized KTM Workshop. (as Additional Job)
63
Important Checks and Maintenance Work to be Carried out by the Rider
65
Maintenance on Chassis and Engine
66
Jacking up the Vehicle
66
Removing the Vehicle from the Work Stand
66
Basic Information on Changing the Chassis Settings
66
Compression Damping of the Shock Absorber
67
Front Shock Absorber - Adjusting the High-Speed Compression Damping
67
Front Shock Absorber - Adjusting the Low-Speed Compression Damping
68
Front Shock Absorber - Adjusting the Rebound Damping
70
Front Shock Absorber - Adjusting the Cross over
71
Front Shock Absorber - Adjusting the Spring Preload
73
Rear Shock Absorber - Adjusting the High Speed Compression Damping
75
Rear Shock Absorber - Adjusting the Low-Speed Compression Damping
76
Rear Shock Absorber - Adjusting the Rebound Damping
77
Rear Shock Absorber - Adjusting the Spring Preload
78
Removing the Rear Shock Absorber
80
Installing the Rear Shock Absorber
82
Checking the Toe
82
Adjusting the Toe
85
Checking/Adjusting the Camber
87
Fork Offset
89
Adjusting the Fork Offset
90
Toe Width of Rear Axle
90
Adjusting the Toe Width of the Rear Axle
91
Handlebar Position
93
Adjusting the Handlebar Position
94
Checking Play in Gas Bowden Cable
96
Adjusting Play in Gas Bowden Cable
97
Checking Chain Dirt
98
Cleaning the Chain
98
Checking the Chain Tension
99
Checking Rear Sprocket / Engine Sprocket for Wear
100
Checking Chain Wear
100
Adjusting Chain Tension
102
Greasing the Rear Wheel Eccentric Element
104
Checking the Brake Discs
104
Checking the Free Play of the Hand Brake Lever
105
Adjusting Basic Position of Handbrake Lever
106
Checking Front Brake Fluid Level
107
Adding Front Brake Fluid
107
Checking the Front Brake Linings
109
Removing Front Brake Linings
110
Installing the Front Brake Linings
111
Changing the Front Brake Linings
112
Checking Free Play of Foot Brake Lever
114
Adjusting Basic Position of Footbrake Lever
115
Checking Rear Brake Fluid Level
116
Adding Rear Brake Fluid
117
Checking Rear Brake Linings
119
Removing Rear Brake Linings
120
Installing the Rear Brake Linings
121
Changing the Rear Brake Linings
123
Removing Wheel/Wheels
124
Installing the Wheel/Wheels
125
Checking Tire Air Pressure
127
Checking the Tire Condition
127
Removing the Battery
128
Installing the Battery
129
Recharging the Battery
129
Changing Main Fuse
131
Changing the Fuses of Individual Power-Consuming Components
132
Ignition Curve Plug Connection
135
Changing the Ignition Curve
135
Removing the Seat
136
Mounting the Seat
136
Removing the Radiator Spoiler
137
Installing the Radiator Spoiler
138
Removing the Front Cover
139
Installing the Front Cover
140
Removing the Front Trim
140
Installing the Front Trim
142
Removing the Rear Fender
142
Installing the Rear Fender
144
Removing the Engine Guard
146
Installing the Engine Guard
146
Removing the Air Filter
147
Installing the Air Filter
148
Cleaning Air Filter
148
Adjusting Basic Position of Clutch Lever
149
Checking the Fluid Level of the Hydraulic Clutch
150
Cooling System
150
Radiator Fan
151
Checking the Antifreeze and Coolant Level
151
Checking the Coolant Level
152
Draining Coolant
153
Filling Coolant/Bleeding the Cooling System
155
Carburetor - Idle
157
Carburetor - Adjusting the Idle Speed
157
Emptying the Carburetor Float Chamber
159
Checking Engine Oil Level
160
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen
161
Draining the Engine Oil
162
Cleaning the Oil Screen
163
Removing the Oil Filter
163
Installing the Oil Filter
165
Filling up with Engine Oil
165
Topping up Engine Oil
166
Troubleshooting
168
Cleaning
173
Cleaning the Vehicle
173
Storage
175
Putting the Vehicle into Operation after Storage
176
Technical Data - Engine
177
Capacity - Engine Oil
178
Capacity - Coolant
178
Technical Data - Engine Tightening Torques
179
Technical Data - Carburetor
182
Technical Data - Chassis
183
Lighting Equipment
185
Tires
185
Capacity - Fuel
185
Technical Data - Front Shock Absorber
186
Technical Data - Rear Shock Absorber
188
Technical Data - Chassis Tightening Torques
190
Substances
192
Auxiliary Substances
196
Standards
199
Index
200
5
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KTM 450 SX 2009 Specifications
General
Brand
KTM
Model
450 SX 2009
Category
Offroad Vehicle
Language
English
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