2014 KTM 450 SX-F XC-F SX-F FACTORY Service Repair Manual

Online PDF 2014 KTM 450 SX-F XC-F SX-F FACTORY Service Repair Manual

Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle. This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available. A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages. Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any resulting damage or loss.

1  MEANS OF REPRESENTATION. ... 6
1.1  KTM Symbols used.  6
1.2  KTM Formats used. . 6

2 SAFETY ADVICE.  7
2.1  KTM Repair Manual. ..  7
2.2  KTM Safety advice. . 7
2.3  KTM Degrees of risk and symbols. .. 7
2.4  KTM Work rules. ....  7

3  IMPORTANT NOTES. .. 8
3.1  Guarantee, warranty.  8
3.2  Operating and auxiliary substances. ....... 8
3.3  Spare parts, accessories. .. 8
3.4  Figures.   8

4  KTM SERIAL NUMBERS. ... 9
4.1  KTM Chassis number. . 9
4.2  KTM Type label. ...... 9
4.3  KTM Engine number. .  9
4.4  KTM Fork part number. ..... 9
4.5  KTM Shock absorber part number. . 9

5  KTM MOTORCYCLE. ........  10
5.1  Raising the motorcycle with the lift stand.  10
5.2  Removing the motorcycle from the lift stand. ..... 10
5.3  Starting. ........ 10
5.4  Starting the motorcycle for a check. ....  11

6  KTM FORK, TRIPLE CLAMP.  12
6.1  KTM Adjusting the compression damping of the fork. 12
6.2  KTM Adjusting the rebound damping of the fork. ......  13
6.3  KTM Bleeding the fork legs. .... 14
6.4  KTM Cleaning the dust boots of the fork legs. ...  14
6.5  KTM Loosening the fork protection (SX-F EU/US, XC-F).  ......  14
6.6  KTM Positioning the fork protection (SX-F EU/US, XC-F).  ......  15
6.7  KTM Removing the fork legs. .. 15
6.8  KTM Installing the fork legs. ... 15
6.9  KTM Removing the fork protector (SX-F EU/US, XC-F).  ......  16
6.10  KTM Installing the fork protector (SX-F EU/US, XC-F).  ......  16
6.11 KTM Removing the fork protector (SX-F Factory Edition).  ....... 17
6.12 KTM Installing the fork protector (SX-F Factory Edition).  ....... 17
6.13  KTM Activating the Factory Start (SX-F Factory Edition).  ....... 17

6.14  KTM SX-F EU, SX-F USA. ........ 18
6.14.1  KTM Conducting major fork service.  18
6.14.2  KTM Conducting minor fork service.  18
6.14.3 KTM Disassembling the fork legs. .... 19
6.14.4 KTM Disassembling the cartridge. .... 21
6.14.5 KTM Disassembling the piston rod. .  23
6.14.6  KTM Disassembling the screw cap with the membrane holder. ....  24
6.14.7  KTM Disassembling the screw sleeve. ...... 25
6.14.8  KTM Checking the fork legs. ....  26
6.14.9  KTM Checking the fork legs - during a minor fork service. ...  27
6.14.10  KTM Changing the pilot bushing. ..... 29
6.14.11  KTM Assembling the screw sleeve. ..  29
6.14.12  KTM Assembling the screw cap with the membrane holder. .....  30
6.14.13  KTM Assembling the piston rod. ...... 31
6.14.14  KTM Assembling the cartridge.   32
6.14.15  KTM Assembling the fork legs. .  33
6.14.16  KTM Bleeding and filling the cartridge.   37
6.14.17  KTM Filling the cartridge with nitrogen. .. 38

6.15  KTM XC-F.   39
6.15.1 KTM Performing a fork service.   39
6.15.2 KTM Disassembling the fork legs.  39
6.15.3 KTM Removing the spring. .  41
6.15.4 KTM Disassembling the cartridge.  42
6.15.5 KTM Disassembling the piston rod.   43
6.15.6 KTM Disassembling the hydrostop unit. ..  44
6.15.7 KTM Disassembling the seal ring retainer. .. 45
6.15.8 KTM Checking the fork legs.   45
6.15.9 KTM Assembling the seal ring retainer.   46
6.15.10 KTM Assembling the hydrostop unit. . 47
6.15.11 KTM Assembling the piston rod. .. 47
6.15.12 KTM Assembling the cartridge.   49
6.15.13 KTM Assembling the fork legs. .  50
6.16  KTM SX-F Factory Edition. .  53
6.16.1 KTM Performing a fork service.   53
6.16.2 KTM Disassembling the fork legs.  54
6.16.3 KTM Removing the spring. .  56
6.16.4 KTM Disassembling the cartridge.  57
6.16.5 KTM Disassembling the piston rod.   58
6.16.6 KTM Disassembling the hydrostop unit. ..  59
6.16.7 KTM Disassembling the seal ring retainer. .. 59
6.16.8 KTM Checking the fork legs.   60
6.16.9 KTM ssembling the seal ring retainer.   61
6.16.10 KTM Assembling the hydrostop unit. . 61
6.16.11 KTM Assembling the piston rod. .. 62
6.16.12 KTM Assembling the cartridge.   63
6.16.13 KTM Assembling the fork legs. .  64
6.17  KTM Greasing the steering head bearing. .  68
6.18  KTM Removing the lower triple clamp.   68
6.19  KTM Installing the lower triple clamp.   69
6.20  KTM Checking the steering head bearing play. ..  71
6.21  KTM Adjusting the play of the steering head bearing. . 71

7  KTM HANDLEBAR, CONTROLS.  73
7.1  Handlebar position. .. 73
7.2  Adjusting the handlebar position. .. 73
7.3  Adjusting the basic position of the clutch lever.  73
7.4 Checking the throttle cable routing. .  74
7.5 Checking the play in the throttle cable. .. 74
7.6 Adjusting the play in the throttle cable. .  75
8  KTM SHOCK ABSORBER, SWINGARM. .. 76
8.1 KTM Adjusting the high-speed compression damping of the shock absorber.  76
8.2 KTM Adjusting the low-speed compression damping of the shock absorber.  76
8.3 KTM Adjusting the rebound damping of the shock absorber. .. 77
8.4  KTM Measuring rear wheel sag unloaded. .  78
8.5 KTM Checking the static sag of the shock absorber. 79
8.6 KTM Checking the riding sag of the shock absorber. 79
8.7 KTM Adjusting the spring preload of the shock absorber.   79
8.8 KTM Adjusting the riding sag. .  80
8.9  KTM Removing the shock absorber. .. 81
8.10  KTM Installing the shock absorber.   82
8.11  KTM Checking the shock absorber linkage. .. 83

Online PDF 2014 KTM 450 SX-F XC-F SX-F FACTORY Service Repair Manual