CONTENTS 2
CONTENTS
MEANS OF REPRESENTATION ............................................ 4
IMPORTANT NOTES............................................................ 5
LOCATION OF SERIAL NUMBERS ........................................ 7
Chassis number............................................................... 7
Type label....................................................................... 7
Engine number................................................................ 7
Fork part number............................................................. 7
Shock absorber part number............................................. 7
OPERATING ELEMENTS...................................................... 8
Clutch lever .................................................................... 8
Hot start lever ................................................................. 8
Hand brake lever ............................................................. 8
Short circuit button ......................................................... 8
Electric starter button ...................................................... 8
Fuel tap (450 SX-F, 505 SX-F)........................................ 9
Fuel tap (450 XC-F, 505 XC-F)......................................... 9
Opening filler cap............................................................ 9
Closing filler cap ........................................................... 10
Choke........................................................................... 10
Shift lever..................................................................... 10
Foot brake pedal ........................................................... 11
Plug-in stand (450 SX-F, 505 SX-F)................................ 11
Side stand (450 XC-F, 505 XC-F) ................................... 11
TIPS AND HINTS ON PUTTING INTO OPERATION............... 12
Advice on first use......................................................... 12
Running in the engine.................................................... 13
RIDING INSTRUCTIONS .................................................... 14
Checks before putting into operation ............................... 14
Starting ........................................................................ 14
Starting up ................................................................... 15
Shifting, riding.............................................................. 15
Braking ........................................................................ 15
Stopping, parking .......................................................... 16
Refueling...................................................................... 16
GREASING AND SERVICE TABLE ....................................... 17
Important maintenance work to be carried out by an
authorized KTM workshop. ............................................. 17
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order)................ 18
Important checks and maintenance work to be carried out
by the rider. .................................................................. 18
MAINTENANCE WORK ON CHASSIS AND ENGINE.............. 20
Jacking up the motorcycle.............................................. 20
Removing the motorcycle from the work stand.................. 20
Checking the basic chassis setting with the rider's
weight .......................................................................... 20
Compression damping of shock absorber.......................... 20
Adjusting high-speed compression damping of the shock
absorber ....................................................................... 20
Adjusting the low-speed compression damping of the
shock absorber.............................................................. 21
Adjusting rebound damping of the shock absorber ............ 21
Measuring rear wheel sag unloaded ................................. 22
Checking static sag of the shock absorber ........................ 22
Check the riding sag of the shock absorber. ..................... 23
Adjusting spring preload of the shock absorber
x............ 23
Adjusting riding sag
x.................................................. 24
Removing the shock absorber
x..................................... 24
Installing shock absorber
x........................................... 24
Checking basic setting of fork ......................................... 25
Adjusting compression damping of fork ........................... 25
Adjusting rebound damping of fork.................................. 25
Bleeding fork legs.......................................................... 26
Cleaning dust boots of fork legs ...................................... 26
Loosening the fork protection.......................................... 26
Positioning the fork protection ........................................ 27
Checking play of steering head bearing............................ 27
Adjusting play of steering head bearing
x....................... 27
Fork offset .................................................................... 28
Setting the fork offset
x ............................................... 28
Removing the fork legs
x.............................................. 28
Installing the fork legs
x............................................... 29
Removing the fork protector
x....................................... 29
Installing the fork protector
x ....................................... 29
Removing the lower triple clamp
x ................................ 30
Installing the lower triple clamp
x................................. 30
Greasing the steering head bearing
x............................. 31
Dismounting the front fender .......................................... 31
Installing the front fender............................................... 31
Dismount the start number plate..................................... 31
Fitting the start number plate ......................................... 32
Handlebar position ........................................................ 32
Adjusting handlebar position
x...................................... 32
Checking gas Bowden cable route ................................... 32
Checking play in gas Bowden cable ................................. 33
Adjusting play in gas Bowden cable
x............................ 33
Checking chain dirt ....................................................... 33
Cleaning the chain......................................................... 33
Checking the chain tension ............................................ 34
Checking the chain tension - fitting rear wheel ................. 34
Checking rear sprocket / engine sprocket for wear ............. 35
Checking chain wear...................................................... 35
Adjusting chain tension.................................................. 35
Adjusting chain tension - after checking .......................... 36
Adjusting chain tension - fitting rear wheel ...................... 37
Adjusting chain guide
x (450 SX-F, 505 SX-F)............... 37
Adjusting chain guide
x (450 XC-F, 505 XC-F)............... 38
Brake fluid reservoir....................................................... 38
Brake calipers ............................................................... 38
Checking brake discs ..................................................... 38
Checking free play of hand brake lever............................. 39
Adjusting basic position of handbrake lever...................... 39
Checking front brake fluid level....................................... 39
Topping up the front brake fluid
x................................. 40
Checking the front brake linings...................................... 40
Removing front brake linings
x ..................................... 41
Mounting front brake linings
x...................................... 41
Changing the fron brake linings
x.................................. 42
Checking free play of foot brake lever .............................. 42
Adjusting basic position of footbrake lever
x................... 43
Checking rear brake fluid level........................................ 43
Topping up brake fluid of front brake
x.......................... 44
Checking rear brake linings ............................................ 44
Removing rear brake linings
x....................................... 45
Mounting rear brake linings
x ....................................... 45
Changing rear brake linings
x ....................................... 46
Removing front wheel
x................................................ 46
Fitting front wheel
x .................................................... 47
Removing rear wheel
x................................................. 48
Fitting rear wheel
x...................................................... 48
Tire condition checking.................................................. 49
Checking tire air pressure............................................... 49
Checking spoke tension.................................................. 50
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