KTM 450 XC 2008 - Page 2

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Table of Contents

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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