OWNER'S MANUAL 2010 450 SXF EU 450 SXF USA Art. no. 3211482en DEAR KTM CUSTOMER DEAR KTM CUSTOMER 1 Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. We wish you great pleasure riding the vehicle! Enter the serial numbers of your vehicle below. Chassis number ( p. 9) Dealer's stamp Engine number ( p. 9) The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing development and design of our motorcycles can however not be completely excluded. All details contained in it are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as for printing and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery. © 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products. Issued by: TÜV Management Service KTM-Sportmotorcycle AG 5230 Mattighofen, Austria TABLE OF CONTENTS TABLE OF CONTENTS 2 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 Checking basic setting of fork ......................................... 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 ........................................ Checking steering head bearing play................................ Adjusting play of steering head bearing Removing the fork legs Installing the fork legs Removing the fork protector Installing the fork protector ....................................... Removing the lower triple clamp Installing the lower triple clamp Greasing the steering head bearing Removing the front fender .............................................. Installing the front fender............................................... Dismount the start number plate..................................... Installing the start number plate ..................................... Handlebar position ........................................................ Adjusting handlebar position Checking throttle cable route .......................................... Checking the play in the throttle cable............................. Adjusting the play in the throttle cable ....................... Checking for chain dirt accumulation .............................. Cleaning the chain......................................................... Checking the chain tension ............................................ Checking chain tension when fitting rear wheel ................ Checking the rear sprocket/engine sprocket for wear ......... Checking chain wear ...................................................... Adjusting chain tension.................................................. Adjusting chain tension - after checking .......................... Adjusting chain tension - fitting rear wheel ...................... Adjusting the chain guide Checking brake discs ..................................................... Checking free travel on hand brake lever.......................... Adjusting basic position of handbrake lever...................... Checking the brake fluid level of the front brake ............... Topping up the front brake fluid Checking the front brake linings...................................... Removing front brake linings ..................................... Installing the front brake linings Changing the front brake linings Checking free play of foot brake lever .............................. Adjusting basic position of foot brake lever Checking rear brake fluid level........................................ Adding brake fluid to the rear brake circuit ................. Checking rear brake linings ............................................ Removing rear brake linings Mounting rear brake linings Changing the rear brake linings Removing front wheel Fitting front wheel .................................................... Removing the rear wheel ........................................... Fitting rear wheel 27 MEANS OF REPRESENTATION ............................................ 4 IMPORTANT INFORMATION ................................................ 5 VIEW OF VEHICLE............................................................... 7 View of the vehicle from the left front (example) ................. 7 View of the vehicle from the right rear (example) ................ 8 LOCATION OF SERIAL NUMBERS ........................................ 9 Chassis number............................................................... 9 Type label....................................................................... 9 Engine number................................................................ 9 Fork part number............................................................. 9 Shock absorber part number............................................. 9 CONTROLS ....................................................................... 10 Clutch lever .................................................................. 10 Hot start lever ............................................................... 10 Hand brake lever ........................................................... 10 Short circuit button ....................................................... 10 Electric starter button .................................................... 10 Fuel tap........................................................................ 11 Opening filler cap .......................................................... 11 Closing filler cap ........................................................... 11 Choke........................................................................... 11 Shift lever..................................................................... 12 Foot brake pedal ........................................................... 12 Plug-in stand ................................................................ 12 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION...................................................................... 13 Advice on first use ......................................................... 13 Running-in the engine ................................................... 14 Preparing vehicle for arduous riding conditions................. 14 Preparing for riding on dry sand ...................................... 14 Preparing for riding on wet sand...................................... 15 Preparing for riding on wet and muddy surfaces................ 16 Preparing for rides at high temperature and slow speed ..... 17 Preparing for rides at low temperatures or in snow ............ 17 RIDING INSTRUCTIONS .................................................... 18 Checks before putting into operation ............................... 18 Starting ........................................................................ 18 Starting up ................................................................... 19 Shifting, riding .............................................................. 19 Braking ........................................................................ 19 Stopping, parking .......................................................... 19 Refueling...................................................................... 20 SERVICE SCHEDULE......................................................... 21 Important maintenance work to be carried out by an authorized KTM workshop. ............................................. 21 Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)................ 22 Important checks and maintenance work to be carried out by the rider. ............................................................ 22 MAINTENANCE WORK ON CHASSIS AND ENGINE .............. 24 Jacking up the motorcycle .............................................. 24 Removing the motorcycle from the work stand.................. 24 Checking the basic suspension setting with the rider's weight .......................................................................... 24 Compression damping of shock absorber.......................... 24 Adjusting high-speed compression damping of the shock absorber ....................................................................... 24 Adjusting the low-speed compression damping of the shock absorber .............................................................. 25 Adjusting the rebound damping of the shock absorber....... 26 Measuring rear wheel sag unloaded ................................. 26 Checking static sag of shock absorber.............................. 27 x 27 x............................................. 28 x..................................... 28 x..................................... 29 29 29 30 30 30 31 31 31 32 32 32 33 33 33 34 35 35 35 35 35 36 36 36 37 37 37 38 38 39 39 39 40 41 41 42 42 42 43 43 43 44 45 45 46 46 47 47 48 48 49 49 50 50 51 52 52 x....................... x.............................................. x............................................... x....................................... x x................................ x................................. x............................. x...................................... x x.......................................... x................................. x x................................. x................................. x.................. x x....................................... x....................................... x.................................. x................................................ x x x...................................................... TABLE OF CONTENTS Checking the tire condition............................................. Checking tire air pressure ............................................... Checking spoke tension.................................................. Removing the battery Installing the battery Recharging the battery Removing a fuse............................................................ Installing the fuse ......................................................... Ignition curve plug connection ........................................ Changing the ignition curve ............................................ Removing the seat ......................................................... Mounting the seat ......................................................... Removing the fuel tank ............................................. Installing the fuel tank Cooling system .............................................................. Checking the anti-freeze and coolant level ....................... Checking the coolant level.............................................. Draining the coolant Refilling coolant Removing main silencer ................................................. Installing the main silencer ............................................ Glass fiber yarn filling of main silencer ............................ Removing glass fiber yarn filling from the main silencer ................................................................... Installing the glass fiber yarn filling of the main silencer ................................................................... Changing glass fiber yarn filling of main silencer ......... Removing the air filter box lid......................................... Installing the air filter box lid.......................................... Removing the air filter Installing the air filter ............................................... Cleaning air filter Adjusting basic position of clutch lever............................ Checking fluid level of hydraulic clutch ........................... Changing the hydraulic clutch fluid Carburetor - idle ............................................................ Carburetor - adjust ...