KTM 450 XC 2008 - Technical Data - Carburetor; 450;525 XC Atv

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TECHNICAL DATA - CARBURETOR 188

31TECHNICAL DATA - C ARBURETOR

31.1450/525XCATV

Carburetor type KEIHIN FCR-MX 39

Carburetor identification number 3925H

Needle position (450 XC ATV) 2nd position from top

Needle position (525 XC ATV) 3rd position from top

Idle mixture adjusting screw

Open 1.0turn

Pump membrane stop 2.15mm (0.0846in)

Main jet 170

Jet needle OBEKR

Idling jet (450 XC ATV) 40

Idling jet (525 XC ATV) 42

Main air jet 200

Idle air jet 100

Cold start jet 85

Throttle slide 15

Main Page

Table of Contents4
Means of Representation7
Important Notes8
- Overview of Warning Labels10
View of Vehicle12
- Vehicle View, Front Left12
- View of Vehicle, Rear Right13
Location of Serial Numbers14
- Chassis Number14
- Type Label14
- Key Number14
- Engine Number14
- Setting Number, Front Shock Absorber14
- Setting Number, Rear Shock Absorber15
Vehicle16
- Jacking up the Vehicle16
- Removing the Vehicle from the Work Stand16
02/Handlebar, Controls17
- Adjusting Handlebar Position17
- Adjusting Basic Position of Clutch Lever17
- Checking Play in Gas Bowden Cable18
- Adjusting Play in Gas Bowden Cable18
- Checking the Play in the Bowden Cable Using the Reverse Gear Release Lever18
- Adjusting the Play in the Bowden Cable Using the Reverse Gear Release Lever18
- Detaching the Reverse Gear Bowden Cable19
- Attaching the Reverse Gear Bowden Cable19
03/Frame20
- Removing the Engine Guard20
- Installing the Engine Guard20
04/Shock Absorber, Swingarm21
- Front Shock Absorber - Adjusting the Compression Damping21
- Front Shock Absorber - Adjusting the Rebound Damping21
- Front Shock Absorber - Adjusting the Cross over22
- Front Shock Absorber - Spring Preload22
- Removing the Front Shock Absorber23
- Installing the Front Shock Absorber24
- Front Shock Absorber - Removing the Spring24
- Front Shock Absorber - Installing the Spring25
- Front Shock Absorber - Disassembling the Shock Absorber26
- Front Shock Absorber - Assembling the Shock Absorber27
- Bleeding and Filling Shock Absorber30
- Front Shock Absorber - Disassembling the Piston Rod33
- Front Shock Absorber - Assembling the Piston Rod34
- Front Shock Absorber - Removing the Heim Joint35
- Front Shock Absorber - Installing the Heim Joint36
- Rear Shock Absorber - Adjusting the Compression Damping36
- Rear Shock Absorber - Adjusting the Rebound Damping37
- Rear Shock Absorber - Spring Preload37
- Removing the Rear Shock Absorber38
- Installing the Rear Shock Absorber39
- Rear Shock Absorber - Removing the Spring39
- Rear Shock Absorber - Installing the Spring39
- Rear Shock Absorber - Disassembling the Shock Absorber40
- Rear Shock Absorber - Assembling the Shock Absorber42
- Rear Shock Absorber - Disassembling the Piston Rod44
- Rear Shock Absorber - Assembling the Piston Rod46
- Rear Shock Absorber - Removing the Heim Joint48
- Rear Shock Absorber - Installing the Heim Joint49
05/Exhaust50
- Removing the Main Silencer50
- Installing the Main Silencer50
- Removing the Manifold50
- Installing the Manifold51
06/Air Filter52
- Removing the Air Filter52
- Installing the Air Filter52
- Cleaning Air Filter52
- Removing the Air Filter Box Lid with the Carburetor Connection Boot53
- Installing the Air Filter Box Lid and the Carburetor Connection Boot53
07/Fuel Tank, Seat, Trim54
- Removing the Seat54
- Mounting the Seat54
- Removing the Radiator Spoiler54
- Installing the Radiator Spoiler55
- Removing the Fuel Tank55
- Installing the Fuel Tank56
- Fuel Tap57
08/Mask, Fender58
- Removing the Front Cover58
- Installing the Front Cover58
- Removing the Front Trim58
- Installing the Front Trim59
- Removing the Rear Fender59
- Installing the Rear Fender60
09/Front Wheel61
- Checking Tire Air Pressure61
- Tire Condition Checking61
- Removing Wheel/Wheels61
- Mounting Wheel/Wheels62
- Checking Brake Discs62
10/Rear Wheel63
- Checking Chain Dirt63
- Cleaning the Chain63
- Checking Chain Wear63
- Checking Rear Sprocket / Engine Sprocket for Wear63
- Checking the Chain Tension64
- Adjusting Chain Tension64
- Adjusting the Toe Width of Rear Axle65
- Removing the Rear Axle66
- Installing the Rear Axle67
- Changing the Rear Axle Bearing69
11/Wiring Harness, Battery71
- Ignition Curve Plug Connection71
- Changing Ignition Curve71
- Removing the Battery71
- Installing the Battery71
- Recharging the Battery72
- Changing the Main Fuse73
- Changing the Fuses of Individual Power-Consuming Components73
- Checking the Battery Voltage74
- Checking the Charging Voltage74
- Checking the Closed-Circuit Current74
- Checking the Starter Relay75
13/Brake System76
- Handbrake Lever, Parking Brake76
- Checking Free Play of Hand Brake Lever76
- Adjusting Basic Position of Handbrake Lever76
- Checking the Brake Fluid Level of the Front Brake77
- Adding Brake Fluid for the Front Brake77
- Checking the Front Brake Linings78
- Removing the Front Brake Linings78
- Mounting Front Brake Linings78
- Changing the Front Brake Linings79
- Checking Free Play of Foot Brake Lever79
- Adjusting Basic Position of Footbrake Lever80
- Checking the Brake Fluid Level of the Rear Brake80
- Adding Brake Fluid for the Rear Brake81
- Checking the Rear Brake Linings81
- Removing the Rear Brake Linings82
- Mounting Rear Brake Linings82
- Changing the Rear Brake Linings83
30/Engine84
- Removing the Engine84
- Installing the Engine86
30/Disassembling the Engine89
- Preparations89
- Draining the Engine Oil89
- Removing the Oil Filter89
- Removing the Starter Motor89
- Removing the Shift Lever90
- Removing the Clutch Cover90
- Removing the Clutch Discs90
- Removing the Outer Clutch Hub91
- Removing the Starter Idler Gear/Torque Limiter92
- Removing the Shift Shaft92
- Removing the Shift Drum Locating92
- Removing the Locking Lever92
- Removing the Oil Pump Gear92
- Removing the Primary Gear with the Free-Wheel-Gear93
- Removing the Spark Plug93
- Removing the Generator Cover93
- Installing the Crankshaft Locking Bolt93
- Removing the Ignition Pulse Generator94
- Removing the Rotor94
- Removing the Oil Pumps95
- Removing the Oil Line95
- Removing the Timing Chain Tensioner96
- Removing the Water Pump Cover96
- Removing the Cylinder Head Top Section96
- Removing the Camshaft96
- Removing the Cylinder Head97
- Removing the Cylinder97
- Removing the Piston98
- Removing the Timing Chain98
- Removing the Timing Chain Sprocket98
- Removing the Locking Shaft Lever98
- Removing the Gear Sensor99
- Taking off the Left Section of the Engine Case99
- Remove the Shift Rails and Forks100
- Removing the Shift Drum100
- Removing the Transmission Shaft101
- Removing the Balancer Shaft101
- Removing the Crankshaft101
30/Engine - Work on Individual Parts102
- Work on the Right Section of the Engine Case102
- Removing the Oil Pressure Regulator Valve103
- Checking the Spring Length of the Oil Pressure Regulator Valve103
- Installing the Oil Pressure Regulator Valve103
- Work on the Left Section of the Engine Case104
- Changing the Crankshaft Seal Ring in the Clutch Cover104
- Disassembling the Autodecompressor105
- Assembling the Autodecompressor106
- Changing the Camshaft Bearing107
- Checking the Rocker Arms and Rocker Arm Shafts108
- Removing the Valves109
- Checking the Valves110
- Checking the Valve Springs110
- Checking the Lower Valve Spring Retainer110
- Checking the Cylinder Head111
- Installing the Valves111
- Checking the Timing Assembly112
- Preparing the Timing Chain Tensioner for Installation112
- Changing the Conrod Bearing112
- Checking the Crankshaft Run-Out on the Bearing Pin113
- Measuring the Axial Clearance of the Crankshaft114
- Correcting the Axial Clearance of the Crankshaft114
- Cylinder - Nikasil Coating115
- Checking/Measuring the Cylinder115
- Checking/Measuring the Piston116
- Checking the Piston Ring End Gap116
- Checking the Piston/Cylinder Mounting Clearance117
- Checking the Oil Pumps for Wear117
- Checking the Shift Mechanism118
- Disassembling the Shift Shaft119
- Preassembling the Shift Shaft120
- Checking the Clutch120
- Disassembling the Main Shaft121
- Checking the Main Shaft122
- Assembling the Main Shaft123
- Disassembling the Countershaft124
- Checking the Countershaft125
- Assembling the Countershaft126
- Checking/Premounting the Reverse Gear Shaft127
- Checking Electric Starter Operation128
- Removing the Free-Wheel129
- Checking the Free-Wheel129
- Installing the Free-Wheel129
30/Assembling the Engine130
- Installing the Crankshaft130
- Installing the Balancer Shaft130
- Installing the Transmission Shaft130
- Installing the Shift Forks131
- Installing the Shift Drum131
- Installing the Shift Rails131
- Installing the Left Engine Case131
- Installing the Timing Chain Sprocket133
- Installing the Timing Chain Rails133
- Installing the Piston133
- Installing the Cylinder134
- Installing the Cylinder Head134
- Installing the Camshaft135
- Installing the Cylinder Head Top Section136
- Installing the Timing Chain Tensioner137
- Installing the Rotor137
- Checking the Valve Clearance137
- Adjusting the Valve Clearance138
- Installing the Valve Cover138
- Installing the Water Pump Cover138
- Installing the Oil Line138
- Installing the Spark Plug138
- Installing the Primary Gear with the Free-Wheel-Gear139
- Installing the Oil Pumps139
- Installing the Ignition Pulse Generator140
- Installing the Generator Cover140
- Installing the Gear Sensor141
- Installing the Locking Shaft Lever141
- Installing the Locking Lever141
- Installing the Shift Drum Locating142
- Installing the Shift Shaft142
- Installing the Starter Idler Gear/Torque Limiter142
- Removing the Crankshaft Locking Bolt142
- Installing the Outer Clutch Hub and Clutch Discs143
- Installing the Clutch Cover144
- Installing the Starter Motor145
- Installing the Oil Drain Plug145
- Installing the Oil Screen145
- Mounting the Oil Filter145
- Filling up with Engine Oil146
- Installing the Shift Lever146
- Installing the Clutch Push Rod146
- Removing the Engine from the Universal Mounting Rack146
31/Carburetor147
- Choke147
- Hot Start Button147
- Removing the Carburetor147
- Disassembling the Carburetor148
- Checking/Adjusting the Carburetor Components151
- Checking/Adjusting the Accelerator Pump151
- Checking the Hot Start Slide152
- Checking the Choke Slide152
- Checking the Jet Needle152
- Checking the Throttle Slide153
- Checking the Needle Jet153
- Checking the Float Needle Valve153
- Checking the Throttle Valve Sensor TPS154
- Adjusting the Position of Throttle Valve Sensor TPS154
- Checking/Adjusting the Throttle Slide Opening155
- Checking/Adjusting the Float Level155
- Assembling the Carburetor155
- Installing the Carburetor158
- Carburetor - Adjusting Idle159
- Checking the Throttle Valve Sensor Position160
- Emptying the Carburetor Float Chamber161
32/Clutch162
- Checking Fluid Level of Hydraulic Clutch162
33/Transmission163
- Removing the Engine Sprocket163
- Installing the Engine Sprocket163
35/Water Pump, Cooling System164
- Checking Antifreeze and Coolant Level164
- Checking the Coolant Level164
- Draining Coolant165
- Filling Coolant / Bleeding Cooling System166
38/Lubrication System168
- Changing Engine Oil and Oil Filter, Cleaning Oil Screens168
- Draining Engine Oil, Cleaning Oil Screens168
- Removing the Oil Filter169
- Mounting Oil Filter170
- Filling up with Engine Oil170
- Checking Engine Oil Level171
- Topping up Engine Oil171
39/Ignition System172
- Checking the Generator172
- Checking the Ignition Pulse Generator172
- Checking the Ignition Coil172
- Checking the Spark Plug Connector173
61/Atv Front Section174
- Toe, Checking174
- Adjusting the Toe175
- Checking/Adjusting Camber176
- Adjusting the Fork Offset177
- Removing the Wheel Carrier177
- Installing the Wheel Carrier179
- Removing the A-Arms180
- Installing the A-Arms180
- A-Arm Top - Changing the Bearing181
- A-Arm Bottom - Changing the Bearing182
Technical Data - Engine185
- Capacity - Engine Oil185
- Capacity - Coolant186
Technical Data - Tolerance, Wear Limits of Engine187
Technical Data - Engine Tightening Torques188
Technical Data - Carburetor190
- 450/525 XC Atv190
Technical Data - Carburetor Tightening Torques191
Technical Data - Chassis192
- Lighting Equipment193
- Tires193
- Capacity - Fuel193
Technical Data - Front Shock Absorber194
Technical Data - Rear Shock Absorber195
Technical Data - Chassis Tightening Torques196
Cleaning197
- Cleaning the Vehicle197
Storage198
- Putting the Vehicle into Operation after Storage198
Greasing and Service Table199
- Important Maintenance Work to be Carried out by an Authorized KTM Workshop199
- Important Maintenance Work to be Carried out by an Authorized KTM Workshop. (as Additional Order)200
- Important Checks and Maintenance Work to be Carried out by the Rider200
Wiring Diagram202
- 450/525 XC Atv202
Substances205
Auxiliary Substances207
Special Tools209
Standards218
Index219

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KTM 450 XC 2008 - Technical Data - Carburetor; 450;525 XC Atv

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