Ra 450-505 SXF 2007-E
Ra 450-505 SXF 2007-E
Ra 450-505 SXF 2007-E
ART.NR.: 3.206.029-E
MANUAL DE REPARACIN
REPAIRMANUAL2007
450 / 505 SX-F
450 SXS-F
KTM Group Partner
1 SERVICE-INFORMATIONS
2 GENERAL INFORMATION
3 DISMOUNTING AND MOUNTING THE ENGINE
4 DISASSEMBLING THE ENGINE
5 SERVICING INDIVIDUAL COMPONENTS
6 ASSEMBLING THE ENGINE
7 ELECTRICAL
8 FUEL SYSTEM
9 TROUBLE SHOOTING
10 TECHNICAL SPECIFICATIONS
11 PERIODIC MAINTENANCE SCHEDULE
12 WIRING DIAGRAMS
13
14
15
16
EXPLANATION - UPDATING
3.206.029-E Repair Manual 450/505 SX-F
10/2006
Edition: 10/2006
INTRODUCTION
This repair manual offers extensive repair-instructions and is an up-to-date version that describes
the latest models of the series. However, the right to modifications in the interest of technical
improvement is reserved without updating the current issue of this manual.
A description of general working procedures common in workshops has not been included. Safety
rules common in the work shop have also not been listed. We take it for granted that the repairs
are made by qualified professionally trained mechanics.
Read through the repair manual before beginning with any repair work.
WARNING
CAUTION
IS
In accordance with the international quality management ISO 9001 standard, KTM uses quality
assurance processes that lead to the highest possible product quality.
KTM Sportmotorcycle AG
5230 Mattighofen, Austria
All design and assembly modification rights reserved.
C by KTM SPORTMOTORCYCLE AG, AUSTRIA
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2-1
GENERAL INFORMATION
Art.-Nr. 3.206.029-E
INDEX
2-2
Changing the cooling liquid
Remove the radiator cap 1 when the engine is cold.
Remove the drain plug 2 on the water pump cover and allow the
cooling liquid to drain into a suitable pan.
Remount the drain plug 2 and tighten to 10 Nm.
Fill the cooling system with cooling liquid in a ratio of 50%
antifreeze and 50% distilled water (freeze protection down to at
least -25C) to 10 mm over the radiator fins.
Mount the radiator cap 1.
1
2
Go for a short ride and check the cooling liquid level again.
10 mm
when the engine is cold
Art.-Nr. 3.206.029-E
Engine oil
JASO T903 MA
TEMPERATURE
5C
41F
5W/40
10W/50
CAUTION
AN
NOTE: When changing the engine oil, it is necessary to clean the oil screen
and to replace the oil filter. Engine oil has be changed with the engine at
an operating temperature..
Place the motorcycle on a level surface.
Remove the oil drain plug 3 and allow the engine oil to drain into a
pan.
Allow the engine oil to drain completely and clean the sealing areas.
Thoroughly clean all parts.
Check the O-rings for damage and replace if necessary.
Mount the oil drain plug with a new seal ring and tighten to 20 Nm.
Mount the plug with the oil screen and tighten to 30 Nm.
2-3
Changing the oil filter
Place a pan under the engine to drain the oil. Remove the 2 screws
1 and take off the oil filter cover and O-ring.
Pull the oil filter insert 2 out of the housing with circlip pliers
510.12.011.000.
Clean the oil filter cover, the sealing area on the O-ring and the
engine case. Check the O-ring in the oil filter cover for damage and
replace if necessary.
Lay the motorcycle down on its side and fill the oil filter housing
approx. 1/3 full with engine oil; insert the oil filter in the housing.
Grease the O-ring in the oil filter cover and mount the cover 3.
Mount the screws and tighten to 10 Nm.
You can check the engine oil level with the engine cold or warm.
Stand the motorcycle upright on a level surface (not on the side
stand).
B
A
2-4
Engine oil circuit
bk bk
bl
99
bl
6
6
5
7
8
bn
bm
Art.-Nr. 3.206.029-E
bm
1
Engine oil circuit
1 oil screen
2 Pressure oil pump
3 Bypass valve
4 Oil filter insert
5 Throttle to meter the oil for the timing chain tensioner
6 Oil spraying nozzle for piston
7 Jet to meter the oil to the lower conrod bearing
8 Throttle to meter the oil to the clutch pushrod
9 Oil duct for the cam lever support
bk Oil spraying nozzle for the camshaft
bl Oil duct for the camshaft support
bm Suction pump for the crankcase
bn Oil duct for transmission lubrication
Allow the engine to warm up and measure the oil pressure with the
engine at operating temperature (engine oil temperature approx.
100C):
min. 1.0 bar at 1600 rpm
Remove the special tools, screw the plug on with a new O-ring and
tighten to 10 Nm.
2-5
2
3
!
SAE 10
CAUTION
HYDRAULIC
NOTE: remove the cover to check the oil level in the master cylinder of
the clutch.
Move the master cylinder into a horizontal position.
Remove the screws 1 and the cover 2 together with the rubber
boot 3.
The oil level should be 4 mm under the upper edge with the master
cylinder in a horizontal position. If necessary, add SAE 10
biodegradable hydraulic oil (e.g. Motorex Hydraulic Fluid 75).
Remount the rubber boot, cover and screws.
CAUTION
HYDRAULIC
Press the SAE 10 biodegradable hydraulic oil into the system until
oil starts to run out of the hole A in the master cylinder without
bubbles. Make sure the oil does not overflow.
After bleeding the clutch, remove the bleeding syringe and mount
the bleeder screw.
Add SAE 10 biodegradable hydraulic oil (e.g. Motorex Hydraulic
Fluid 75) up to 4 mm under the upper edge.
Remount the rubber boot, cover and screws.
A
Adjusting the throttle cables
Push back the dust boots.
Set 3-5 mm free travel at the throttle grip with the adjusting screw
5. The idling speed should not change with the engine running if
the handlebar is turned all the way to the left or right.
Slip on the dust boots.
Check the throttle grip for smooth operation.
2-6
Changing the front brake fluid
2
3
5
Art.-Nr. 3.206.029-E
5 mm
Add DOT 5.1 brake fluid (Motorex Brake Fluid DOT 5.1) up to 5 mm
under the top edge of the reservoir. Remount the rubber boot, cover
and screws.
Wash off any overflowing or spilled brake fluid with water.
Actuate the hand brake lever until you feel the point of pressure.
NEVER
!
DOT 5
CAUTION
FLUID. IT IS BASED
USE
BRAKE
ON SILICONE OIL AND DYED
PURPLE. GASKETS AND BRAKE HOSES WILL BE DAMAGED IF DOT 5 BRAKE
FLUID IS USED.
BRAKE FLUID CAN CAUSE SKIN IRRITATIONS. AVOID CONTACT WITH THE SKIN OR
EYES. IF BRAKE FLUID SPLASHES INTO YOUR EYES, RINSE THOROUGHLY WITH
WATER AND CONSULT A DOCTOR.
MAKE SURE NO BRAKE FLUID COMES INTO CONTACT WITH PAINTED PARTS AS
BRAKE FLUID WILL CORRODE THE PAINTWORK!
ONLY USE CLEAN, NEW BRAKE FLUID FROM TIGHTLY SEALED CONTAINERS.
2-7
Changing the rear brake fluid
Move the vehicle into a vertical position.
Disassemble the screw cap 1 together with the rubber boot 2 from
the brake fluid reservoir.
Use a syringe to extract the used brake fluid and fill with fresh DOT
5.1 brake fluid (Motorex Brake Fluid DOT 5.1).
3
A
Fill with DOT5.1 brake fluid (Motorex Brake Fluid DOT 5.1) up to
the mark A on the inside of the reservoir.
Check the O-ring of the screw cap for damage, exchange it if
necessary and remount the screw cap again.
Wash off any overflowing or spilled brake fluid with water.
Press the foot brake pedal until you feel the point of pressure.
NEVER
!
DOT 5
CAUTION
FLUID. IT IS BASED
USE
BRAKE
ON SILICONE OIL AND DYED
PURPLE. GASKETS AND BRAKE HOSES WILL BE DAMAGED IF DOT 5 BRAKE
FLUID IS USED.
BRAKE FLUID CAN CAUSE SKIN IRRITATIONS. AVOID CONTACT WITH THE SKIN OR
EYES. IF BRAKE FLUID SPLASHES INTO YOUR EYES, RINSE THOROUGHLY WITH
WATER AND CONSULT A DOCTOR.
MAKE SURE NO BRAKE FLUID COMES INTO CONTACT WITH PAINTED PARTS AS
BRAKE FLUID WILL CORRODE THE PAINTWORK!
ONLY USE CLEAN, NEW BRAKE FLUID FROM TIGHTLY SEALED CONTAINERS.
2-8
2
cq
Art.-Nr. 3.206.029-E
cl
bl
bk
em
2
bt
4
0
BAR
en
do
bq
5
ck
dp
ek
36
el bm
br
bp
dl
ds
dn
bn
3
dm
bo
dt
dr
cs
cr
bs
2-9
PART NO.
DESCRIPTION
560.12.001.000
773.29.002.000
600.29.012.000
510.12.011.000
590.29.033.000
600.29.015.000
6899785
151.12.017.000
Bearing puller
10
151.12.018.000
Insert 12-16mm
10
151.12.018.100
Insert 18-23mm
10
151.12.018.200
Insert 5-7mm
10
773.29.020.000
Insert 8-12mm
11
590.29.026.006
12
585.29.005.000
Mounting sleeve
13
590.29.041.000
14
773.29.060.000
15
590.29.019.000
16
584.29.037.037
17
590.31.017.200
18
580.12.009.000
Magneto extractor
19
309098
20
510.12.012.000
21
773.29.072.000
26
503.29.050.000
Bleeding syringe
27
584.29.059.000
28
773.29.003.000
Clutch holder
31
750.29.090.000
32
773.29.012.100
33
600.29.010.000
34
773.29.034.000
35
773.29.081.000
37
773.29.050.000
38
773.29.051.000
39
773.29.010.000
40
773.29.021.000
41
773.29.030.000
41
776.29.030.000
42
773.29.006.000
43
610.29.094.000
3-1
Art.-Nr. 3.206.029-E
3-2
Remove the foot brake lever and detach the return spring on the foot
brake lever.
Remove the upper shock absorber screw 2.
Loosen the nut on the swing arm pivot 3, knock out the swing arm
pivot with a suitable driver and completely remove the swing arm,
shock absorber and rear wheel from the motorcycle.
Detach the exhaust spring 4 between the header pipe and silencer
with a suitable tool.
Remove both fixing screws 5 on the silencer and remove the
silencer.
5
4
Detach the exhaust springs 6 on the cylinder head with a suitable
tool.
Art.-Nr. 3.206.029-E
Remove the fixing screw 7 on the header pipe together with the
washer and rubber sleeve.
Pull the header pipe forward and remove from the motorcycle.
Open the drain plug on the water pump 8 and allow the cooling
liquid to drain into a suitable container.
9
8
3-3
Loosen the hose clamp and remove the coolant hose 1.
Disconnect the spark plug connector 2.
3
1
Unscrew the chain guard 4 from the clutch slave cylinder and from
the frame and remove.
Cut off the cable tie, unscrew the clutch slave cylinder 5 and tilt
aside.
NOTE: do not actuate the clutch lever as long as the clutch slave
cylinder is dismounted.
6
Unscrew the hot start actuator 8 from the carburetor.
8
Loosen the carburetor clamps 9.
3-4
Push the carburetor back and remove the rubber sleeve from the
cylinder head.
Dismount the carburetor towards the right and let it hang down.
!
CAUTION
DO
NOT PLACE THE CARBURETOR IN THE AIR FILTER BOX SINCE THE AIR FILTER
WILL ABSORB ANY LEAKING FUEL.
Unscrew the nut and remove the electric connection 1 from the
starter engine.
Art.-Nr. 3.206.029-E
Press the fixing tabs 2 towards the inside and remove the left
radiator shield.
Loosen the hose connection on the left radiator and both radiator
fixing screws 3 and remove the left radiator.
NOTE: the left radiator does not have to be dismounted if someone
helps you lift out the engine to prevent the radiator and lower radiator
connection from being damaged.
3
4
Remove the front 5 and lower 6 engine fixing screws and lift the
engine out of the frame towards the left.
Repair manual KTM 450/505 SX-F
!
MAKE
5
6
CAUTION
3-5
Mounting the engine
Lift the engine into the frame from the left, position and screw in
the lower 1 and the front 2 engine fixing screws (M10x123) but
do not tighten them yet.
Mount the upper engine brace 3 (all screws are M8x42), do not
tighten yet.
2
1
Mount the left radiator and tighten the radiator screws 4 to 10 Nm.
Mount the radiator shield 5 and the hose and tighten the hose
clamps.
4
5
4
8
7
8
3-6
Screw the hot start actuator 1 in the carburetor.
1
Connect the socket connectors on the throttle position sensor 2,
pulse generator 3 and generator. Fasten the wiring harnesses with
cable ties.
2
Mount the clutch slave cylinder 4, screw in both of the front screws
(M6x25) and tighten to 10 Nm.
Art.-Nr. 3.206.029-E
8
6
Mount the coolant hoses 9 and tighten the hose clamps.
Mount the drain plug bk with a new sealing washer and tighten.
9
bk
3-7
Position the header pipe from the front of the motorcycle.
Mount the silencer on the vehicle and tighten the screws (M6x30)
3 to 10 Nm
Attach the exhaust spring 4 between the header pipe and the
silencer with a suitable tool.
3
4
5
Position the swing arm and shock absorber on the motorcycle, insert
the swing arm pivot and tighten to 100 Nm.
Lock the upper shock absorber screw 5 with Loctite 243 and
tighten to 70 Nm.
Tighten the screws on the engine fastening and engine brace:
M10 to 60 Nm, M8 to 33 Nm.
Mount the foot brake lever and attach the return spring to the foot
brake lever, apply Loctite 243 to the screw (M10x40) and tighten to
45 Nm.
Mount the foot brake cylinder 6, apply Loctite 243 to the screws
(M6x12) and tighten to 10 Nm.
Position the chain and mount (make sure the closed side of the
guide points in the running direction).
Connect the battery.
Mount the tank with the spoiler and seat.
Add cooling liquid.
Take the motorcycle off the assembly stand.
Check the engine oil level.
4-1
Art.-Nr. 3.206.029-E
INDEX
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
DRAINING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
REMOVING THE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
REMOVING THE STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
REMOVING THE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
REMOVING THE IGNITION COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
REMOVING THE STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
REMOVING THE PULSE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
MOVING THE ENGINE TO IGNITION TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
REMOVING THE CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
REMOVING THE TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
REMOVING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
REMOVING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
REMOVING THE CYLINDER / PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
REMOVING THE TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
REMOVING THE ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
REMOVING THE FREEWHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
REMOVING THE PRIMARY GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
REMOVING THE OIL PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
REMOVING THE SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
SEPARATING THE ENGINE CASE HALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
4-2
Preparation
Thoroughly clean the outside of the engine and clamp in the
universal work stand 560.12.001.000 with the engine holders
773.29.002.000.
Remove the shift lever.
Remove the oil drain plug 1 together with the seal ring.
Tap lightly with a hammer to relieve the plug 2.
Remove the plug together with the oil screen.
Completely drain the engine oil.
Art.-Nr. 3.206.029-E
Pull the oil filter insert 4 out of the housing with the circlip pliers
510.12.011.000.
Remove both screws 5 and take out the starter together with the Oring.
4-3
Removing the sprocket
Use holding wrench 510.12.012.000 to hold the sprocket 1 while
you remove the screw 2 with the spring washer.
Remove the sprocket, distance bushing and O-ring.
1
2
4
Removing the starter drive
Remove the torque limiter 5.
Remove the starter idler gear 6.
5
6
Removing the pulse generator
7
9
4-4
Moving the engine to ignition TDC
Remove the 3 screws on the valve covers together with the rubber
seal.
Remove the valve cover 1 together with both gaskets.
Remove the spark plug.
Move the crankshaft to ignition TDC. Both cams point towards the
outside in this position.
The bores A in the camshafts are flush with the valve cover above
the sealing area B.
Art.-Nr. 3.206.029-E
Check whether the C and D marks were made. If the marks were
made, they should be in alignment with each other in the ignition
TDC position (they only show once every 6 crankshaft revolutions).
NOTE: the marks make it easier to mount the camshafts.
4-5
Removing the clutch cover
Remove the plug 1 including the O-ring.
Insert the mounting pin 2 773.29.012.100.
NOTE: you do not need to remove the water pump cover to remove the
clutch cover.
2
Remove the screws 3 and completely take off the clutch cover.
3
3
3 3
5
4
4
Removing the clutch
Take out the pressure piece 8 and pull out the pushrod.
Take the clutch disk package 9 out of the outer clutch hub.
8
9
4-6
Bend up the lock washer on the drive nut.
Hold the driver 1 with the clutch holder 773.29.003.000 while you
remove the drive nut together with the lock washer.
Remove the driver together with the stop disk mounted underneath.
Remove the outer clutch hub 2, needle bearing 3 and collar sleeve
4.
4 2
Removing the timing chain tensioner
Art.-Nr. 3.206.029-E
5 6
7
Removing the camshafts
Remove the screws on the camshaft bearing bridges 8.
Remove the camshaft bearing bridges.
Do not lose the needle rollers and O-ring.
4-7
Removing the cylinder head
Remove the screws 1 and take off the retaining bracket.
Grasp the double gear 2 and use a screw to pull the axle for the
double gear 3 out of the cylinder head.
Remove the timing chain from the double gear.
Remove the double gear with both needle bearings and allow the
timing chain to drop into the timing chain compartment.
Remove the screw from the double gear axle.
4-8
Removing the cylinder / piston
Remove the cylinder.
Art.-Nr. 3.206.029-E
3
4
4-9
Removing the timing chain
Remove the screws 1 and take off the retaining bracket.
1
2
Grasp the timing chain 2 while you pull the axle for the balancer
gear 3 out of the engine case with a screw.
Simultaneously remove the timing chain, balancer gear, stop disk
and both needle bearings.
Remove the screw from the balancer gear axle.
4-10
Removing the primary gear
Art.-Nr. 3.206.029-E
4
3
6
7
Remove the lock washer 6, shim, oil pump idler gear and needle
bearing.
Remove the lock washer 7, shim and oil pump gear.
4-11
Remove the needle roller 1.
Remove the screws on the oil pump cover and take off the oil pump
cover.
Remove the suction oil pump together with the oil pump shaft and
needle roller.
Push back the shift rail 2 and remove the shift shaft 3 together
with the stop disk.
3
Remove the screw 4.
Press back the locking lever 5 and remove the shift lock; release
the locking lever again.
4
5
NOTE: the locking lever 5 does not need to be removed when the
engine is dismounted.
Remove the lock ring 6.
4-12
Separating the engine case halves
Remove all screws from the housing.
Remove both nuts on the engine holder in the universal engine work
stand.
Art.-Nr. 3.206.029-E
23
1
52
CAUTION
DO NOT PRY THE CASE HALVES APART WITH A SCREWDRIVER OR SIMILAR TOOL
SINCE THIS WILL DAMAGE THE SEALING AREAS.
Remove the left case half, tapping with a plastic hammer if
necessary.
Do not lose the stop disk 1.
Remove the dowels and fasten the engine case half to the universal
engine work stand with shims and nuts 2.
Do not lose the dowel in the oil duct 3.
Remove the rollers 4.
Remove the shift rail 5 together with the springs.
7
6
5-1
Art.-Nr. 3.206.029-E
INDEX
5-2
bl
5
4
Pry out the shaft seal ring on the crankshaft 1, the shift shaft 2
and the countershaft 3 without damaging the case.
bk
NOTE: only remove the studs, case bushing bk and roller bl if you are
replacing the engine case.
Clean all oil ducts and check whether they are clogged.
Art.-Nr. 3.206.029-E
7
9
Inspect the engine case half and add-on parts for damage and wear.
Check the oil pump housing for score marks or seizing marks.
Heat the engine case half in an oven to approx. 150C and tap on a
level wooden surface, causing the bearings to fall out of the bearing
seats. Any bearings that remain in the case must be pressed out
with a suitable press/drift tool or with bearing puller
151.12.017.000 and a suitable bit.
Push new bearings in the bearing seats of the hot engine case,
pressing all the way in until flush with a suitable press/drift tool if
necessary.
Mount the bearing bolt 4.
NOTE:
To avoid damage, make sure the case lies flat when pressing in the
bearings.
Always press in bearings on the outer ring or the bearings will be
damaged in the process.
Check the bearings for a tight fit when the case has cooled.
Press in a new shaft seal ring for the crankshaft 1 with the open
side on the outside until flush.
Press in a new shaft seal ring for the shift shaft 2 with the open
side on the inside until flush.
Press in a new shaft seal ring for the countershaft 3 with the open
side on the inside until flush.
Degrease the thread on the throttle 5 in the oil duct, apply Loctite
243 and tighten to 6 Nm.
Degrease the thread on the jet 6, apply Loctite 243 and tighten to
4 Nm.
Degrease the thread on the screw 7 and apply Loctite 243. Mount
the retaining brackets and tighten the screws on the bearing retainer
to 6 Nm.
Mount the dowel 8.
Degrease the thread on the oil intake snorkel 9, apply Loctite 243
and tighten to 15 Nm.
Make sure the oil ducts are not clogged.
Check the studs, case bushing bk and roller bl for a tight fit.
5-3
Right engine case half
Pry out the shaft seal ring on the crankshaft 1 without damaging
the case.
Remove the screws from the bearing bolt and take off the bearing
bolt 2 together with the lock washer.
Remove the screw and washer from the locking lever and take off
the locking lever 3 together with the sleeve and locking lever
spring.
Remove the jet for the crankcase ventilation 4.
Remove the oil metering jet for the lower conrod bearing 5.
Remove the jet 6.
Clean all oil ducts and check whether they are clogged.
Inspect the engine case half and add-on parts for damage and wear.
Check the oil pump housing for score marks or seizing marks.
Heat the engine case half in an oven to approx. 150C and tap on a
level wooden surface, causing the bearings to fall out of the bearing
seats. Any bearings that remain in the case must be pressed out
with a suitable press/drift tool or with bearing puller
151.12.017.000 and a suitable bit.
Push new bearings in the bearing seats of the hot engine case,
pressing all the way in until flush with a suitable press/drift tool if
necessary.
NOTE:
The bore in bearing 9 and the bore 8 in the engine case must be
aligned. Press in the sealing on the bearing bk towards the outside.
When pressing it in, make sure the case lies flat to avoid damage.
Always press in the bearings on the outer ring or the bearings will be
damaged in the process.
Check the bearings for a tight fit when the case has cooled.
Press in a new shaft seal ring for the crankshaft 1 with the open
side on the outside until flush.
8
bk
9
Degrease the thread on the screws for the bearing bolt and apply
Loctite 243. Mount the bearing bolt 2 and lock washer and tighten
the screws to 6 Nm.
Degrease the thread on the screw for the locking lever and apply
Loctite 243. Screw on the locking lever 3, washer, sleeve and
spring and tighten to 6 Nm.
Degrease the thread on the jet for the crankcase ventilation 4,
apply Loctite 243 and tighten.
Degrease the thread on the oil metering jet for the lower conrod
bearing 5, apply Loctite 243 and tighten.
Degrease the thread on the jet 6, apply Loctite 243 and tighten to
4 Nm.
Degrease the thread on the bearing retainer and apply Loctite 243.
Mount the retaining brackets 7 and tighten the screws on the
bearing retainer to 6 Nm.
Make sure the oil ducts are not clogged.
Check the studs and case bushing 8 for a tight fit.
5-4
Water pump
Remove the screws 1.
Remove the water pump cover and the seal ring.
Remove the cap nut 2 and take off the water pump wheel.
Assemble in the reverse order, paying attention to the following items:
3
2
Art.-Nr. 3.206.029-E
Balancer gear
Remove the mounting pin 3 773.29.012.100.
Remove the screws 4.
Press out the balancer gear.
5
6
7
Assemble in the reverse order, paying attention to the following items:
5-5
Degrease the thread on the screws for the retaining bracket, apply
Loctite 243 and tighten to 6 Nm.
Align the mark A on the balancer gear with the mounting pin 1.
1
A
Clutch cover
5
2
Remove the screws on the bearing retainer and the retaining bracket
2.
Pry out the shaft seal rings 3.
Remove the lock ring 4.
Pry out the shaft seal rings 5.
4
Pry out the water pump shaft seal rings 6 and 7.
6
7
Assemble in the reverse order, paying attention to the following items:
5-6
9
8
6
5
7
1
4
2
bk
1
1
bl
5
Art.-Nr. 3.206.029-E
1
Lubrication system
Check the O-rings 1 and gaskets 2 for damage and replace if necessary.
Replace the oil filter 3 every time you change the engine oil.
Clean the oil screen 4 and replace if damaged.
Check the inner and outer rotor on the oil pump 5 for damage and deposits. If they will be used again, do not replace the
inner and outer rotors with each other.
Check the oil pump covers 6 for seizing marks on the inside and replace if necessary.
Lay the oil pump shaft 7 on a level surface and check for runout.
Check the oil pump gear 8 and oil pump idler gear 9 for damage and wear.
Check the oil pump housing bk and bypass valve bl for damage and wear.
bo
bp
bn
bm
5-7
Crankshaft
!
CAUTION
NEVER
CAUTION
IF
If you are replacing the conrod bearing, make sure the crankpin is
correctly positioned. The bores in the crankshaft web and crankpin
must be perfectly aligned. Mark A must be lined up with mark B.
Make sure the oil duct C and the ventilation duct D are not
clogged.
5-8
If you will continue to use the crankshaft, check the crankshaft
journal for runout. Place the crankshaft on a roller stand or similar
stand and measure the crankshaft journal runout with a gauge.
Crankshaft journal runout: max. 0.15 mm
Check the radial and axial clearance at the conrod bearing.
Radial clearance: max. 0.03 mm
Axial clearance: max. 0.80 mm
Art.-Nr. 3.206.029-E
5-9
Piston / Cylinder
NIKASIL COATING ON CYLINDER:
Nikasil is the brand name for a cylinder coating process developed by
the Mahle piston company. The name is derived from the two materials
used in the process - one layer of nickel in which the exceptionally
hard silicon carbite is embedded. The major advantages of the Nikasil
coating include its outstanding heat dissipation and the improved
power output, the insignificant wear and low weight of the cylinder. It
is inexpensive to repair (replace) a worn coating if the cylinder barrel is
not damaged.
x
y
1
2
NOTE: The cylinder size 1 is marked on the cylinder collar, the piston
size 2 on the piston head.
The piston is measured at the piston skirt across the piston pin, as
illustrated.
Piston diameter
450 SX-F / 450 SXS-F
size I: 96.960 - 96.970 mm
size II: 96.971 - 96.980 mm
505 SX-F
size I: 99.960 - 99.970 mm
size II: 99.971 - 99.980 mm
5-10
Insert the piston ring in the cylinder and align with the piston
(approx. 10 mm under the upper edge of the cylinder).
Measure the end gap with a feeler gauge.
Compression ring: max. 0.80 mm
Oil scraper ring: max. 1.00 mm
If the end gap is larger than indicated above, check the cylinder for
wear. If the cylinder wear is within the tolerance limits, replace the
piston ring.
CAUTION
IF
Make sure the piston ring joints do not align with each other.
Place piston ring compressor 600.29.015.000 on the oiled piston
and compress the piston rings.
Push the piston approx. 15 mm out of the piston ring compressor
and into the cylinder. The piston ring compressor must fit flush
against the cylinder.
Carefully tap into the cylinder with a hammer handle, making sure
the piston rings do not get caught.
Art.-Nr. 3.206.029-E
Carefully push the piston with the piston skirt out of the cylinder
until you can insert the piston pin.
Insert the oiled piston pin on the coolant connection side.
NOTE: only push the piston pin in far enough to still be able to insert
the conrod.
5-11
Camshafts
Wrap some masking tape around the outer cam on the camshaft to
protect it from being damaged in the vise.
Clamp the camshaft in a vise with aluminum protective jaws.
Position the outer cam so that the camshaft will not rotate.
Remove the screw 1.
2
4
3
Automatic decompression
Check:
Push the camshaft bearing lager towards the camshaft gear and
hold.
Pull the lever 5 away from the camshaft and release.
The lever 5 should automatically move back to the initial position.
Replace the exhaust camshaft if damaged or worn.
5-12
Radial clearance of the camshaft bearings
Art.-Nr. 3.206.029-E
Note: camshaft bearing bridges are only available together with the
cylinder head.
5-13
Cylinder head
Fold up the cam lever.
Remove the shims (valve adjustment shims) from the spring retainer
and mark the installed position.
Note: if you mark the installed position you will only need to check the
valve clearance when they are remounted.
Remove the plugs on the cam lever shaft together with the O-ring.
Hold the cam lever 1 while you pull the cam lever shaft out of the
cylinder head with a screw 2.
Remove the cam lever.
Note: if you will continue to use the cam lever, make a mental note of
the installed position.
2
Remove the screws 3.
Remove the oil jets together with the O-ring.
3
3
7
6
Remove
Remove
Remove
Remove
gasket.
5
Clamp the valve lifter 590.29.019.000 and bit 773.29.060.000 in
the vise.
Clamp the cylinder head together with the valve to be removed.
Note: if you will continue to use the valves, make a mental note of the
installed position.
5-14
Pretension the valve springs and remove both valve keys 1.
2
3
Art.-Nr. 3.206.029-E
5
Check:
Clean all oil ducts and make sure they are not clogged.
Make sure the drain bore in the spark plug shaft is not clogged.
Check the sealing area on the spark plug thread and the valve seats
for damage or cracks.
Check the valve guides with limit plug gauge 590.29.026.006.
Replace if you can easily slide the limit plug gauge into the valve
guide.
Make sure the valve seats are not impacted. Check the sealing seat
width.
Inlet/Outlet: max. 1.50 mm
Use a straight edge and feeler gauge to look for warpage of the
sealing area along the cylinder.
Max. warpage: 0.1mm
Measure the thickness of the valve spring shim.
Min. thickness: 1.4 mm
Check the valve disk for wear and runout. The valve seat may not be
impacted. The sealing area should be in the center of the valve seat.
Check the valve springs for fractures and wear.
Minimum length of outer spring: 40.0 mm
Minimum length of inner spring: 39.0 mm
Check the cam lever and cam lever shafts for damage and wear.
The cam lever should turn easily on the cam lever shaft. Clean the
oil ducts and make sure they are not clogged.
Check all O-rings for damage and replace if necessary.
5-15
Assemble in the reverse order, paying attention to the following items:
Degrease the thread on the screws for the exhaust flange, apply
Loctite 243 and tighten to 10 Nm.
Degrease the thread on the throttle for the oil supply to the timing
chain tensioner, apply Loctite 243 and tighten to 6 Nm. Make sure
the throttle is not clogged.
Degrease the thread on the screw for the oil jet, apply Loctite 243
and tighten to 4 Nm. Make sure the oil jet is not clogged.
Oil the cam lever and mount in the position you marked when it was
removed.
Mount the shims with the labeled side facing the valve. Mount in
the same position they were in before they were removed.
5-16
Timing chain tensioner
!
CAUTION
YOU DO NOT FOLLOW THESE INSTRUCTIONS, THE TIMING CHAIN WILL NOT BE
TENSIONED CORRECTLY AND WILL SKIP, RESULTING IN ENGINE DAMAGE.
IF
NOTE:
The timing chain tensioner 1 operates with spring force and with oil
pressure. A stop system is used to ensure the right timing chain
tension in the engine starting phase, even if the oil pressure is
insufficient. The stop system prevents the piston 2 on the timing
chain tensioner from being retracted.
In a dismounted state, the piston on the timing chain tensioner
extends completely.
Art.-Nr. 3.206.029-E
Fully depress the spring tensioner. This will require some effort
since the oil must be squeezed out. If the timing chain tensioner is
released it will extend completely again; it may not be mounted in
this state, since the locking mechanism will not function.
Press down on the timing chain tensioner to ensure smooth
operation.
If you press the timing chain tensioner again and it extends no more
than half way (preventing it from extending completely), the stop
system will lock and the timing chain tensioner can no longer be
pressed together - this position is necessary to ensure that the
timing chain is adequately tensioned, even if the oil pressure is low.
5-17
Timing train
NOTE: The smooth operation of the chain links can easily be checked by simply letting the timing chain hang down - the chain
links should align in a row. Replace the timing chain if the chain links do not align in a row - they are no longer free-moving.
5-18
4
5
7
LOCTITE 243
1
3
bk
Art.-Nr. 3.206.029-E
Clutch
Check the pressure piece 1 for damage and smooth operation.
Check the axial bearing 2 for damage and wear.
Lay the pushrod 3 on a level surface and check for runout.
Check the length of the clutch springs 4. Minimum length 39.0 mm (40.0 mm new), replace all 6 springs if necessary.
Check the pressure cap sealing area 5 for damage and wear.
Check the thickness of the lining disks (9 pieces) 6. Minimum thickness 2.6 mm (2.7 mm new). The lining disks must be
flat.
Check the clutch disks (8 pieces) 7 for mechanical damage and warpage. Replace the clutch disks if you detect any
roughness or chipped material.
Check the driver 8 for damage and wear.
Check the thrust face 9 of the outer clutch hubs and the lining disks for damage and wear. If the recesses are bigger than
0.5 mm, replace the lining disks and the outer clutch hub.
Check the needle bearing bk for damage and smooth operation.
Replace any damaged or worn parts.
5-19
1
4
D
C
E
5
A
1
8
LOCTITE 243
3
LOCTITE 243
LOCTITE 243
B
3
Shift mechanism
Check the shift forks 1 at the blade A for damage and wear. New shift forks are 3.90 to 3.95 mm thick; the wear limit is
3.70 mm.
Check the shift grooves B in the shift drum 2 for damage and wear.
Check whether the shift drum is correctly seated in the grooved ball bearing 3.
Check the grooved ball bearing 3 for smooth operation.
Check the shift rollers 4 for damage and wear.
Lay the shift rail 5 on a level surface and check for runout. Check the shift rail for damage and wear. Check the smooth
operation of the shift forks on the shift rail.
Check the shift rail 6 for wear at the points of contact C. Check the return area D on the shift rail for wear (replace if
strongly indented).
Check the guide bolt E for a tight fit and wear.
Check the roller on the locking lever 7 for smooth operation.
Check the springs 8 in the shift rail for a tight fit. If this is not the case, slightly bend up the springs on the conical end and
attach this end to the shift rail.
Replace any damaged or worn parts.
5-20
5
1
Clamp the short end of the shift shaft in a vise (use protective jaws).
Mount the shift rail 1 with guide bolt facing down and attach the
guide bolt to the shift quadrant.
Mount the pressure spring 2.
Mount the spring guide 3.
Slide the twisted end of the return spring 4 over the spring guide
and lift the twisted end over the dolly bolt 5.
Mount the stop disk 6.
3 4
6
2
Check the clearance A between the shift rail 1 and the shift
quadrant. The clearance must be between 0.40 and 0.80 mm.
Art.-Nr. 3.206.029-E
5-21
3
4
5
2
6
7
Main shaft
Clamp the main shaft in a vise with the toothed end facing down (use protective jaws).
Carefully oil all parts before mounting.
Mount the distance sleeve 2.
Mount the 4th gear fixed gear 3 to match the installed position mark.
Mount the distance ring 4 (25x29x2.4mm).
Mount the 3rd gear fixed gear 5 to match the installed position mark.
Mount the distance sleeve 2.
Mount the 2nd gear fixed gear 6 to match the installed position mark.
Mount the stop disk 7 (31x17x1mm).
5-22
bk 9
1
8
4
7
1
5
4
Art.-Nr. 3.206.029-E
Countershaft
Clamp the countershaft in a vise with the toothed end facing down (use protective jaws).
Carefully oil all parts before mounting.
Mount the split needle bearing 1.
Mount the 2nd gear idler gear 2 with the shift dogs facing up.
Mount the stop disk 3 (33x25x1.5mm).
Mount the lock ring 4.
Mount the shift ring 5 to match the installed position mark.
Mount the lock ring 4.
Mount the stop disk 3 (33x25x1.5mm).
Mount the split needle bearing 1.
Mount the 3rd gear idler gear 6 with the shift dogs facing down.
Mount the split needle bearing 1.
Mount the 4th gear idler gear 7 with the shift dogs facing up.
Mount the stop disk 3 (33x25x1.5mm).
Mount the lock ring 4.
Mount the shift ring 8 to match the installed position mark.
Mount the lock ring 4.
Mount the stop disk 3 (33x25x1.5mm).
Mount the split needle bearing 1.
Mount the 1st gear idler gear 9 with the shift dogs facing down.
Mount the stop disk bk (32x17x2.7mm).
Finally, check all of the gear wheels for smooth operation.
5-23
5
1
2
3
A
Starter drive
Freewheel hub 1
Take the freewheel out of the freewheel hub. Check the freewheel hub for damage and wear. Check the contact area A for
pressure marks. Thoroughly clean the freewheel hub.
Freewheel 2
Thoroughly clean the freewheel. Check the freewheel segments for damage and wear. Oil the freewheel.
Starter gear 3
Check the starter gear for damage and wear. Mount the starter gear including needle bearing on the crankshaft and check for
clearance. Replace the needle bearing if necessary. Check the contact area facing the freewheel for pressure marks.
Starter idler gear 4
Check the toothing and bearing position of the starter idler gear for damage and wear. Check the bearing bolt for damage and
wear.
Torque limiter 5
Check the toothing and bearing positions of the torque limiter for damage and wear.
Starter 6
Replace the O-ring 7 on the flange.
5-24
Freewheel hub
Lightly compress the spreader ring 1 with circlip pliers and remove
together with the freewheel 2.
Art.-Nr. 3.206.029-E
4
Repair manual KTM 450/505 SX-F
6
Pull out the bearing 7 with bearing puller 151.12.017.000 and a
suitable bit.
Assemble in the reverse order, paying attention to the following items:
Inspect the parts for damage or wear.
Replace any damaged or worn parts.
Degrease the thread on the screws, apply Loctite 243 and tighten to
6 Nm.
Press in a new bearing with a suitable press/drift tool until flush.
6-1
Art.-Nr. 3.206.029-E
INDEX
6-2
Assembling the engine case halves
Fasten the right engine case half to the universal engine work stand.
Oil all bearing positions.
Mount the crankshaft.
NOTE: the cone 1 for the rotor must point towards the left engine case
half.
Hold the conrod in place with an O-ring.
1
Simultaneously position the pre-assembled transmission shafts in
the engine case half.
Art.-Nr. 3.206.029-E
Insert the oiled shift forks with rollers 2 in the shift rings.
NOTE: if continuing to use the shift forks, match the installed position
marks.
3
2
5
46
Make sure the dowel 8 in the left engine case half is in place.
Oil all bearing positions.
Degrease the sealing area and apply a thin coat of Three-Bond
silicone sealant.
6-3
Mount the left engine case half, tapping lightly with a plastic
hammer if necessary.
Fasten the engine to the universal engine work stand.
M7x70
M6x70
Tightening torques
M6: 10Nm
M7: 14Nm
Check the shafts for smooth operation.
Check the axial clearance of the crankshaft.
M6x55
2
5
4
Mount the pre-assembled shift shaft 4 together with the stop disk.
Push back the shift rail 5 and slide the shift shaft all the way in.
Allow the shift rail to engage in the shift lock.
Make sure the return spring is correctly seated.
6-4
Mounting the oil pump
Mount the suction oil pump with the oil pump shaft and oiled
needle roller.
Degrease the thread on the oil pump cover screws and apply Loctite
243. Screw on the oil pump cover with mark A facing up and
tighten to 6 Nm.
Mount the oil pump gear and shim. Mount the lock washer 2.
Mount the oiled needle bearing, oil pump idler gear and shim.
Mount the lock washer 3.
3
Art.-Nr. 3.206.029-E
NOTE:
The rounded side A of the suction oil pump should face the engine
case.
The groove B in the oil pump shaft should face the right side of the
engine.
Insert the needle roller for the suction oil pump drive in the oil
pump shaft.
Mount the oiled suction oil pump.
NOTE: the rounded side of the suction oil pump should face the engine
case.
5
6
6-5
Mount the oiled oil pressure pump.
NOTE: the rounded side of the oil pressure pump should face the oil
pump cover.
Degrease the thread on the screws 1 and apply Loctite 243. Screw
on the oil pump cover including the gasket and tighten to 10 Nm.
1
Mounting the primary gear
Move the crankshaft into the TDC position and insert the engine
locking screw.
Mount the primary gear and tighten the nut 2 to 60 Nm.
NOTE: the starter gear should turn in a clockwise direction and lock in
a counterclockwise direction.
6-6
Mounting the timing chain
Place the timing chain on the balancer gear.
Insert both oiled needle bearings in the balancer gear and mount
the stop disk 1 with the collar facing the balancer gear.
Simultaneously insert all parts in the timing chain compartment.
2
A
B
Art.-Nr. 3.206.029-E
3
Mounting the piston / cylinder
4
Repair manual KTM 450/505 SX-F
6-7
Pull the timing chain through the timing chain compartment with
the cable tie and mount the pre-assembled cylinder head without
damaging the tensioning rail and guide rail.
Screw on the cylinder head with oiled washers and nuts 3:
1st step in a crosswise direction: 10 Nm
2nd step in a crosswise direction: 30 Nm
3rd step in a crosswise direction: 50 rotational angle
6-8
Insert both oiled needle bearings in the double gear.
Remove the cable tie and place the timing chain on the double gear.
Align the mark A on the double gear with the mark B on the
cylinder head. Mount the axle double gear 1 with the O-ring.
A
1
B
Align the axle double gear for the retaining bracket.
Degrease the thread on the screws 2 and apply Loctite 243. Screw
on the retaining bracket and tighten to 6 Nm.
Art.-Nr. 3.206.029-E
6-9
Mounting the camshafts
NOTE: see Chapter 5 for camshaft reassembly / radial clearance of the
camshaft bearing.
A A
NOTE: if the camshaft gears were not pressed off the camshafts, check
the adjusting bearing bridge 773.29.050.000. Its entire surface must
rest against the cylinder head and the flat sides against the camshaft.
If not, press off the camshaft gears and readjust.
6-10
Checking the valve clearance
Remove the engine locking screw.
Switch on the engine several times.
Move the engine to the ignition TDC position (see Chapter 4) and
insert the engine locking screw.
Art.-Nr. 3.206.029-E
6-11
Mounting the clutch
Mount the collar sleeve 1, oiled needle bearing 2 and outer clutch
hub 3.
NOTE: make sure the toothing engages in the oil pump idler gear.
1 3
4
7
6
LOCTITE 243
5
Insert the oiled pushrod 7 with the shorter stepping facing the
clutch .
Insert the pressure piece 8.
6-12
Mounting the clutch cover
2
3
Art.-Nr. 3.206.029-E
M6x55
5
M6x30
M7x45
7
Mounting the rotor
Make sure the woodruff key is in place.
Degrease the cone and mount the rotor.
Insert the oiled rotor screw and tighten to 80 Nm.
6-13
Remove the engine locking screw 1.
Insert the screw 2 with the copper washer and tighten to 20 Nm.
4
0,7 mm
7
6
Mounting the ignition cover
Make sure the needle rollers 8 are in place.
Degrease the sealing area mount a new ignition cover gasket.
8
Degrease the sealing area on the ignition cover.
Mount the pre-assembled ignition cover.
Insert the ignition cover screws and tighten to 10 Nm.
6-14
Mounting the sprocket
Mount the O-ring, oiled distance bushing with the recess for the Oring on the inside.
Mount the sprocket with the collar on the inside.
Degrease the thread on the screw 1, apply Loctite 243 and mount
the spring washer. Screw on the rear sprocket and tighten to 60 Nm.
NOTE: Use holding wrench 510.12.012.000 to hold the sprocket.
1
Mounting the starter
Art.-Nr. 3.206.029-E
6-15
Filling the engine with engine oil
Insert the oiled plug 1 together with the oil screen and tighten to
30 Nm.
Insert the oil drain plug 2 together with a new seal ring and tighten
to 20 Nm.
1
Pour engine oil into the oil filter housing (approx. 1/3 full) and into
the oil filter insert.
Mount the oil filter insert.
Mount the oil filter cover together with the greased O-ring, screw on
and tighten to 10 Nm.
Remove the oil filling screw 3 and add approx. 1.3 liters of fullysynthetic engine oil (Motorex Power Synt 4T 10W/50 for
temperatures over 5C or 5W/40 for temperatures under 5C).
Take the engine off the universal engine work stand.
7-1
ELECTRICAL
Art.-Nr. 3.206.029-E
INDEX
7-2
Ignition system troubleshooting
Before beginning the testing procedures on the ignition system, make sure:
the short circuit button is not actuated
the battery is fully charged
the main fuse is working
Check whether there is an ignition spark upon starting, proceeding as follows:
Pull off the spark plug connector.
Disconnect the spark plug connector from the ignition wire.
Hold the loose end of the ignition wire approx. 5 mm from the ground.
A strong spark should be visible when the starter is actuated.
If a spark is visible, mount the spark plug connector again.
Unscrew the spark plug and insert in the spark plug connector.
Hold the spark plug against the ground. A strong spark should be visible when the starter is actuated. If not, the spark plug
connector or spark plug is defective.
Art.-Nr. 3.206.029-E
NOTE: the CDI unit cannot be tested with simple devices. It can only be tested on an ignition test bench.
CDI unit
Check the cables and socket connections to the CDI unit.
The CDI unit can only be tested on an ignition test bench.
!
CAUTION
NEVER
HIGHLY
0.3
6,3 k
7-3
Checking the pickup and stator
Use an ohmmeter to take the following measurements (plug connectors
disconnected):
1.8
100
blue
blue yellow
yellow
black
black
Main fuse
The main fuse (10 amperes) is located under the filter box cover in
the starter engine relay.
The main fuse 1 is visible after you remove the filter box cover and
protection cover.
CAUTION
NEVER
2
Checking the starter
Disconnect the negative terminal from the battery and remove the
starter.
Connect the negative terminal from a 12V battery to the starter case
and briefly connect the positive terminal from the battery to
connector 3 on the starter (use thick cables).
The starter should start to turn when the electric circuit is closed.
If not, replace the starter.
7-4
Checking the start relay
Setpoint value: 0 OK
Setpoint value: defective
NOTE: you should hear a click when you switch the starter relay.
Art.-Nr. 3.206.029-E
CAUTION
DO
TO
7-5
Checking the charging voltage
NOTE: : the following figures only apply to fully charged batteries
(charging condition at least 90 %).
Connect a voltmeter to both battery terminals.
Start the engine.
Rev the engine up to 5000 rpm and read the voltage.
14.5 V
Engine characteristic
Two ignition curves (performance and soft) are stored in the CDI
unit. The performance ignition curve is activated in the condition at
delivery.
Remove the seat and tank to change the ignition curve:
A Performance
(higher engine performance)
B Soft
(better driveability)
brown
blue
blue
yellow
yellow
black
black
Art.-Nr. 3.206.029-E
yellow-black
10
A
battery
10.04.2007
regulator-rectifier
start relay
generator
red-white
starter motor
black-white
red-white
yellow
start buttom
black
black-white
brown-white
white
black
yellow
T PS
black-white
red-white
white
green
red
brown
grey
black-white
pick up
blue-white
blue-white
stop button
bl ac k
brown
red-white
1
3
red
yellow-black
ignition coil
green
C
D
7-6
7-7
Static ignition values
Measuring conditions:
Cold engine
Seat and tank removed
All plugs and the ground connections are in a non-corroding condition, plugs tightly connected
Battery fully charged
Gap between the rotor and the pickup: 0.7 mm
Actuate the starter at least 5 seconds for each measurement
Peak voltage adapter 584.29.042.000 connected to the multimeter
Check the pickup for an output signal - bipolar plug 1 with green and
red cable colors (also see circuit diagram on page 7-6):
Check the primary voltage for ignition coil control (also see circuit
diagram on page 7-6) for voltage (blue/white cable):
Apply the red measuring tip on the peak voltage adapter to the
ground 2 and the black measuring tip to the blue/white cable 3,
CDI unit and ignition coil connected.
Setpoint value : 200 volts +/- 10 volt
7-8
Static generator values
Measuring conditions:
Cold engine
Seat and tank removed
All plugs and the ground connections are in a non-corroding condition, plugs tightly connected
Battery fully charged
Actuate the starter at least 5 seconds for each measurement
Peak voltage adapter 584.29.042.000 connected to the multimeter
Check the generator outlet (also see circuit diagram on page 7-6) for
voltage between the following cable colors:
Between connector 4 yellow cable and connector 5 yellow cable,
plug disconnected
Setpoint value: 11 volts +/- 1 volt
Art.-Nr. 3.206.029-E
8-1
FUEL SYSTEM
Art.-Nr. 3.206.029-E
INDEX
Art.-Nr. 3.206.029-E
8-2
8-3
Dismounting and mounting the carburetor
NOTE: clean motorcycle thoroughly.
Remove the seat and tank with spoilers.
Take off the filter box cover 1 and completely remove the air filter.
5
4
6
7
Remove the cable tie 8 and disconnect the throttle sensor plug
connector 9.
Pull out the vent hose.
8-4
Pull the carburetor out of the rubber sleeve.
Unscrew the hot start actuator 1 from the carburetor.
Remove the carburetor.
Art.-Nr. 3.206.029-E
Set 3-5 mm free travel at the throttle grip with the adjusting screw
2. The idling speed should not change with the engine running if
the handlebar is turned all the way to the left or right.
Check the throttle grip for smooth operation.
Check the condition of the air filter and clean or replace if
necessary.
8-5
Disassembling the carburetor
NOTE: Before you start to disassemble the carburetor, make sure your
workplace is clean and offers enough room to spread out the individual
carburetor parts.
Dismount the carburetor and remove any coarse dirt.
Remove the 2 screws 1 and disconnect all vent hoses from the
carburetor.
Remove the 2 screws 2 and take the throttle slide cover and gasket
off the carburetor.
Remove the screw 3 with spring and washer and pull the jet needle
out of the throttle slide.
Remove the screw 4.
4
Lift the throttle slide arm 5, remove the throttle slide including the
roller 6 and the throttle slide plate from the carburetor.
8-6
Remove the 3 screws from the accelerator pump cover and remove
the accelerator pump cover.
Take the 2 seal rings 1, spring 2 and diaphragm 3 out of the
accelerator pump housing.
1
1
2
3
Remove the remaining screws on the float chamber and take off the
float chamber housing 4.
Pull out the float hinge pin 5 and remove the float together with the
float needle valve.
Remove the main jet 6.
Art.-Nr. 3.206.029-E
6
5
bl
bk
9
7
8
Remove the idling jet 7, starting jet 8, needle jet 9 and damper
body bk.
Turn the mixture control screw bl all the way in (count and write
down the number of turns).
Unscrew the mixture control screw and remove together with the
spring, washer and O-ring.
NOTE: The spring, washer and O-ring usually stay in the bore. These
parts can be removed with compressed air. The mixture control screw
bl should not be open more than 2 turns. If more than two turns are
required (richer mixture), use a larger idling jet.
bm
bm
bm
8-7
Remove the screw 1 and pull the hose connection out of the
carburetor.
2
Unscrew the idle-air jet 5.
Thoroughly clean all jets and the other parts and blow dry with
compressed air.
Clean the carburetor housing and blow compressed air through all
the carburetor ducts.
8-8
Checking the choke slide
2
2
A
B
A
C
Insert the market jet needle in the needle jet to be tested. Carefully
push the two parts together. If the mark A on the jet needle can still
be seen on the upper edge C of the needle jet, the needle jet can still
be used.
If the mark on the jet needle is no longer visible, replace the needle
jet.
8-9
Checking the float needle valve
Check the needle valve at the sealing area for indentations. Make sure
no dirt has accumulated between the valve seat and float needle.
2
1
Check the membrane 3 on the throttle slide plate for cracks or
brittleness and make sure it is correctly seated.
8-10
Assembling the carburetor
Assemble the carburetor in the reverse order, paying attention to the
following points:
Lock the screw on the throttle sensor with Loctite 243 but do not
tighten yet.
Lock the screws for the hose connection and the attachment of the
throttle slide arm with Loctite 243.
NOTE: it should be possible to turn the hose connection freely when
mounted.
Unscrew the mixture control screw the number of turns written down
during disassembly. See "Technical Specifications" for the basic
carburetor setting.
NOTE: the mixture control screw should not be open more than 2
turns. Use a bigger idling jet if more than two turns are necessary
(richer mixture).
Art.-Nr. 3.206.029-E
8-11
Checking/adjusting the float height
Tilt the carburetor until the float rests against the float needle valve
without compressing it.
The edge of the float should be parallel to the sealing area of the
float chamber in this position (see photo).
If the float height does not correspond to the setpoint value, check
the float needle valve and replace if necessary.
If the float needle valve is good you can adjust the float height by
bending the float tab 1.
1mm
Use the adjusting screw 2 to set the opening of the throttle slide to
1 mm. This test is easily performed with a 1 mm drill bit shaft or
wire.
0.9 mm
The basic setting for the accelerator pump piston rod projection is
0.9 mm.
8-12
example
example
2
1
Art.-Nr. 3.206.029-E
blue
blue yellow
yellow
black
black
8-13
Checking the throttle sensor
NOTE: the following measurement must be made at a component
temperature of approx. 20C. The carburetor must be dismounted to
take this measurement. The throttle slide must be in the starting
position (1mm open).
Connect a multimeter (measuring range k) to the blue (+) and
black (-) cables on the throttle sensor and measure the total
resistance of the throttle sensor (Rges).
Throttle sensor total resistance (Rges): 4 - 6 k
blue
blue yellow
yellow
black
black
Removing and mounting the throttle sensor
Disconnect the plug connector from the throttle sensor and remove
the screw 1.
Remove the throttle sensor from the carburetor.
1
2
When you mount the throttle sensor make sure the flat part of the
driver 2 engages in the recess in the throttle sensor.
Degrease the screw thread and apply Loctite 243.
Mount the screw but do not tighten yet. Adjust the position of the
throttle sensor.
8-14
Adjusting the idle speed
The carburetor idle speed strongly influences the starting performance,
a stable idle and engine responsiveness when accelerating. An engine
with a correct idle speed will be easier to start than one with an
incorrect idle adjustment.
The idle speed is adjusted with the adjusting screw 1 and the idle
mixture with the mixture control screw 2. The adjusting screw sets the
basic position of the throttle slide. Turning in a clockwise direction will
decrease the amount of fuel (lean mixture), turning in a
counterclockwise direction will increase the amount of fuel (rich
mixture).
TO SET THE CORRECT IDLE SPEED, PROCEED AS FOLLOWS:
1. Turn the mixture control screw 2 all the way in and adjust to the
specified basic setting (see Technical Specifications - Engine).
NOTE: use special tool 773.29.034.000 to adjust the mixture control
screw on the vehicle.
Art.-Nr. 3.206.029-E
9-1
TROUBLE SHOOTING
INDEX
Art.-Nr. 3.206.029-E
9-2
TROUBLE
CAUSE
Engine doesnt crank (E-starter). Blown fuse
REMEDY
Dismount the filter box cover and replace the fuse in the
starter relay.
Discharged battery
Flooded engine
Art.-Nr. 3.206.029-E
Spark plug connector or spark plug Dismount spark plug, connect ignition cable, hold to
ground (blank place on engine) and actuate starter, a strong
faulty
spark must be produced at the spark plug
If no spark is created replace the spark plug.
If the new spark plug doesn't produce a spark either,
disconnect the spark plug connector from the ignition
cable, hold it a distance of approx. 5 mm from ground
and start.
If a spark now occurs, replace spark plug cap
If no spark is produced, control ignition system
Short circuit cable scored in wiring Dismount the fuel tank, disconnect the black/yellow
cable from the cable of the short-circuit button,
harness, short circuit button faulty
respectively, and check the ignition spark.
If a spark is generated, look for the problem in the shortcircuit circuit.
The plug connection of the CDI-unit, Remove the seat and the fuel tank. Clean the plug
the pulse generator or the ignition coil connection and treat it with contact spray
has oxydized
9-3
TROUBLE
Engine does not rev up
CAUSE
REMEDY
Carburetor fuel level too high because Dismount carburetor and check if worn out
float needle valve is dirty or worn out
Loose carburetor jets
Tighten jets
Engine will not reach full power Fuel supply partially interrupted or Clean and check fuel system as well as carburetor
carburetor dirty
Air filter very dirty
Exhaust system is not tight, deformed, or Check if exhaust is damaged, replace glasfiber yarn in
the silencer does not contain enough exhaust silencer
glassfiber yarn
Valve gap too small
Drive on briskly
The battery isnt charged by the generator Remove seat and fuel tank and check voltage regulator
connections; voltage regulator and generator should be
checked.
10-1
TECHNICAL SPECIFICATIONS
INDEX
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
MOUNTING CLEARANCES, WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-4
Art.-Nr. 3.206.029-E
TIGHTENING TORQUES
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-5
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-6
10
10-2
505 SX-F
Displacement
449.3 ccm
477.5 ccm
Bore / Stroke
97 / 60.8 mm
100 / 60.8 mm
Compression ratio
12.5 : 1
Fuel
Unleaded premium fuel with at least RON 95 (USA = Premium PON 91)
Valve timing
40.4 mm
31.7 mm
0.10 - 0.15 mm
0.15 - 0.20 mm
Crankshaft bearing
Conrod bearing
Needle bearing
Bronze bushing
Piston
Piston rings
Engine lubrication
Engine oil
Art.-Nr. 3.206.029-E
1.3 liters
Primary drive
29:74
4-speed
1 gear
17:32
2nd gear
19:30
3 gear
21:28
st
rd
4 gear
23:26
th
Ignition system
Breakerless DC-CDI ignition system with digital ignition timing, type KOKUSAN
Generator
42 W at 6000 rpm
Spark plug
NGK CR 9 EKB
Cooling system
Cooling liquid
Starting aid
Electric starter
450 SXS-F
505 SX-F
Type of carburetor
Main jet
185
190
185
Jet needle
OBDTP
OBDTR
OBDTP
Idling jet
40
40
42
100
100
100
Needle position
4 from top
4 from top
Starting jet
85
85
85
1.5
1.5
1.5
Slide
15
15
15
Throttling
2.5 mm
2.5 mm
2.5 mm
th
th
10-3
Fork
Fork offset (caster)
450 SXS-F
4860 MXMA CC
adjustable 18mm/20mm
adjustable 17.5mm/20.5mm
300/335 mm
Rear suspension
Front brake
Disk brake with perforated 260 mm brake disk, brake caliper floated
Rear brake
Brake disks, Wear limit
Disk brake with perforated 220 mm brake disk, brake caliper floated
2.5 mm front; 3.5 mm rear
Tires, front
80/100 - 21
1.0 bar
Tires, rear
110/90 - 19
1.0 bar
approx. 8 liters
14:52
Chain
Battery
5/8 x 1/4"
maintenance-free battery 12V 3 Ah and 4 Ah
63.5
Wheel base
1475 10 mm
925 mm
380 mm
approx. 104 kg
Compression adjuster
Rebound adjuster
450 SXS-F
WP 4860 MXMA CC
WP 4860 MXMA CC
14.18.7C.05
14.18.7C.16
15
15
21
22
4.6 N/mm
4.6 N/mm
375 ml
380 ml
Oil quantity CC
195 ml
195 ml
Gas pressure
1.2 bar
1.8 bar
Fork oil
SAE 5
SAE 5
Spring
Compression adjuster
Rebound adjuster
Spring
Spring preload
450 SXS-F
12.18.7C.05
12.18.7C.12
15 LS (low speed)
12 LS (low speed)
1 HS (high speed)
20 HS (high speed)
25
20
66-250
72-250
7 mm
7 mm
Static sag
33 mm
33 mm
Riding sag
110 mm
107 mm
10-4
MOUNTING CLEARANCES, WEAR LIMITS
Crankshaft
Axial clearance
Lateral runout
Crankshaft web - outer size
Conrod bearings
Cylinder
Piston
max. 0.03 mm
Axial clearance
max. 0.80 mm
97.000 - 97.012 mm
97.012 - 97.025 mm
100.000 - 100.012 mm
100.012 - 100.025 mm
Diameter, size I
96.960 - 96.970 mm
Diameter, size II
96.971 - 96.980 mm
Diameter, size I
99.960 - 99.970 mm
Diameter, size II
99.971 - 99.980 mm
0.030 - 0.052 mm
0.032 - 0.054 mm
0.070 mm
Compression ring
Oil scraper ring
max. 1.00 mm
Valves
max. 1.50 mm
max. 1.50 mm
Spring washer
min. 1.40 mm
Valve springs
Art.-Nr. 3.206.029-E
max: 0.15 mm
64 mm 0.05 mm
Radial clearance
Wear limit
Bypass valve
Clutch
max. 0.80 mm
Radial clearance
Wear limit
Shift fork
0.25 - 0.35 mm
10-5
TIGHTENING TORQUES - ENGINE
Oil jet for piston
M4
Loctite 243 + 4 Nm
M4
Loctite 243
M4
Loctite 243
M4
Loctite 243 + 6 Nm
M5
Loctite 243 + 6 Nm
M5
Loctite 243 + 6 Nm
M5
Loctite 243 + 6 Nm
M5
Loctite 243 + 6 Nm
M5
Loctite 243 + 6 Nm
M5
Loctite 243 + 6 Nm
M5
Loctite 243 + 6 Nm
Screw on stator
M5
Loctite 243 + 6 Nm
M5
Loctite 243 + 6 Nm
M5
Loctite 243 + 6 Nm
M6
oiled 10 Nm
M6
10 Nm
M6
Loctite 243 + 10 Nm
M6
10 Nm
M6
10 Nm
M6
10 Nm
M6
Loctite 243 + 10 Nm
M6
Loctite 243 + 6 Nm
M6
8 Nm
M6
oiled 10 Nm
M6
Loctite 243 + 6 Nm
M6
10 Nm
M6
Loctite 243 + 10 Nm
M6
10 Nm
M6
Loctite 243 + 10 Nm
M6
Loctite 243 + 10 Nm
M7x1
oiled 14 Nm
M7x1
14 Nm
M7
gelt 14 Nm
M8
20 Nm
M10x1
oiled 50 Nm
M10x1
10 Nm
M10x1
10 Nm
M10x1
10 Nm
Screw on rotor
M10x1
oiled 80 Nm
M10x1.25
20 Nm
M10x1.25
oiled 10/30 Nm + 50
Spark plug
M10
10 - 12 Nm
M10
Loctite 243 + 60 Nm
M12x1.5
20 Nm
M12x1.5
16 Nm
M14x1
Loctite 243 + 20 Nm
M14x1
Loctite 243 + 15 Nm
M14x1
15 Nm
M14x1.5
18 Nm
M18x1.5
Loctite 243 + 80 Nm
M24x1.5
25 Nm
M27x1
60 Nm
M32x1.5
oiled 30 Nm
10-6
Art.-Nr. 3.206.029-E
M4.5 / M5
5 Nm
M6
Loctite 243 + 14 Nm
M6
10 Nm
M8
Loctite 243 + 25 Nm
M8
17 Nm
M8
12 Nm
M8
Loctite 243 + 17 Nm
M8
15 Nm
M8
20 Nm
M8
Loctite 2701 + 35 Nm
M8
Loctite 2701 + 35 Nm
M8
33 Nm
M8
10 Nm
M10
Loctite 243 + 40 Nm
M10
60 Nm
M12x1
20 Nm
M12
Loctite 243 + 70 Nm
M16x1.5
100 Nm
M20x1.5
10 Nm
M20x1.5
Loctite 243 + 60 Nm
M20x1.5
80 Nm
M20x1.5
Loctite 243 + 12 Nm
M24x1.5
40 Nm
M6
10 Nm
M8
25 Nm
M10
45 Nm
M6
15 Nm
M8
30 Nm
M10
50 Nm
11-1
Art.-Nr. 3.206.029-E
11
11-2
every
10 hours
or
70 l fuel
z
BRAKES
CHASSIS
WHEELS
Art.-Nr. 3.206.029-E
ADD-ON PARTS
CARBURETOR
ENGINE
z
z
Check/function smooth operation and adjust free travel of handbrake/foot brake lever
Check the screws and guide bolts on the brake system for a tight fit
Check tightness of chassis screws (triple clamps, fork leg axle passage,
swingarm, shock aborber)
Check chain, chain joint, rear sprockets and chain guides for wear, fit and tension
Lubricate chain, clean and grease the adjusting screws on the chain tensioner
at least
once a year
z
every
2 years
IF MOTORCYCLE IS USED FOR COMPETITION 10 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE.
Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel.
Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider.
11-3
After
every
cleaning
For crosscountry
use
at least
once
a year
z
z
z
z
z
z
z
z
z
z
z
z
z
z
Treat blank metal parts (with the exception of brake and exhaust system)
with wax-based anti corrosion agent
z
z
IMPORTANT INSPECTIONS OR MAINTENANCE WORK THAT MUST BE PERFORMED BY THE SPECIALIZED KTM WORKSHOP
(SEPARATE ORDER FOR SPECIALIZED KTM WORKSHOP)
every
10
hours
70
liter
every
20
hours
140
liter
z
z
z
z
z
z
every
40
hours
270
liter
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
every
60
hours
400
liter
z
z
z
z
z
z
NOTE:
If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced.
every
80
hours
540
liter
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
12-1
WIRING DIAGRAMS
INDEX
Art.-Nr. 3.206.029-E
12
blue
blue
yellow
yellow
black
black
yellow-black
10
A
battery
10.04.2007
regulator-rectifier
start relay
red-white
generator
black-white
starter motor
black-white
brown-white
white
red-white
yellow
start button
black
brown
T PS
black-white
red-white
white
green
red
brown
grey
black-white
pick up
blue-white
red-white
stop button
bl ac k
brown
blue-white
red
yellow-black
ignition coil
green
C
D
black
yellow
12-2
12-3
COULEUR DE CABLE
bl: noir
ye: jaune
bu: bleu
gn: vert
re: rouge
wh: blanc
br: brun
or: orange
pi: rose
gr: gris
pu: violet
FRANCAIS
Batterie
Alternateur
Bobine dallumage
Capteur dallumage
Rgulateur/redresseur
Bouton de dmarrage
Relais de dmarreur
Dmarreur
Bouton de mise la masse
Capteur douverture de carburateur
CDI
Prise de courbe d'allumage
COLOR DE CABLE
bl: negro
ye: amarillo
bu: azul
gn: verde
re: rojo
wh: blanco
br: marron
or: naranja
pi: rosado
gr: gris
pu: violeta
ITALIANO
Batteria
Generatore
Bobina daccensione
Pick up
Regolatore-raddrizzatore
Pulsante davviamento
Rel davviamento
Motorino davviamento
Bottone di massa
Potenziometro carburatore (sensore TPS)
CDI
Connettore curve d'accensione
CAVO COLORATO
bl: nero
ye: giallo
bu: blu
gn: verde
re: rosso
wh: bianco
br: marrone
or: arancione
pi: rosa
gr: grigio
pu: violetto
DEUTSCH
Batterie
Generator
Zndspule
Impulsgeber
Regelgleichrichter
Starttaster
Startrelais
Startermotor
Kurzschlusstaster
Drosselklappensensor
CDI
Zndkurvenstecker
KABELFARBEN
bl: schwarz
ye: gelb
bu: blau
gn: grn
re: rot
wh: wei
br: braun
or: orange
pi: rosa
gr: grau
pu: violett
ENGLISH
Battery
Generator
Ignition coil
Pick up
Regulator-rectifier
Start button
Start relay
Starter motor
Stop button
Throttle position sensor (TPS)
CDI
Ignition curve selector
CABLE COLOURS
bl: black
ye: yellow
bu: blue
gn: green
re: red
wh: white
br: brown
or: orange
pi: pink
gr: grey
pu: purple
ESPANOL
Batera
Generador
Bobina de encendido
Generador de impulsos
Regulador rectificador
Botn de arranque
Rel del arranque
Motor de arranque elctrico
Botn de cortocircuito
Potencimetro del carburador
CDI
Terminal de la curva de encendido