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KTM
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450 XC 2008
KTM 450 XC 2008 User Manual
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03/FRAM
E
18
7
03/FRAME
7.1
Removing
the
en
gine
guard
600133-10
–
Remove
screws


and


.
Remove
the
engine
guard.
7.2
Installing
the
eng
ine
guard
600133-10
–
Check
parts
for
damage
and
wear.
Replace
damaged
or
worn
parts.
–
Position
the
engine
guard
on
the
frame
bearer.
Mount
and
tighten
screws


and


.
Specification
Remaining
screws,
chassis
M6
10

Nm
(7.4

lbf

ft)
Remaining
screws,
chassis
M8
25

Nm
(18.4

lbf

ft)
19
21
Table of Contents
Table of Contents
4
Means of Representation
7
Important Notes
8
Overview of Warning Labels
10
View of Vehicle
12
Vehicle View, Front Left
12
View of Vehicle, Rear Right
13
Location of Serial Numbers
14
Chassis Number
14
Type Label
14
Key Number
14
Engine Number
14
Setting Number, Front Shock Absorber
14
Setting Number, Rear Shock Absorber
15
Vehicle
16
Jacking up the Vehicle
16
Removing the Vehicle from the Work Stand
16
02/Handlebar, Controls
17
Adjusting Handlebar Position
17
Adjusting Basic Position of Clutch Lever
17
Checking Play in Gas Bowden Cable
18
Adjusting Play in Gas Bowden Cable
18
Checking the Play in the Bowden Cable Using the Reverse Gear Release Lever
18
Adjusting the Play in the Bowden Cable Using the Reverse Gear Release Lever
18
Detaching the Reverse Gear Bowden Cable
19
Attaching the Reverse Gear Bowden Cable
19
03/Frame
20
Removing the Engine Guard
20
Installing the Engine Guard
20
04/Shock Absorber, Swingarm
21
Front Shock Absorber - Adjusting the Compression Damping
21
Front Shock Absorber - Adjusting the Rebound Damping
21
Front Shock Absorber - Adjusting the Cross over
22
Front Shock Absorber - Spring Preload
22
Removing the Front Shock Absorber
23
Installing the Front Shock Absorber
24
Front Shock Absorber - Removing the Spring
24
Front Shock Absorber - Installing the Spring
25
Front Shock Absorber - Disassembling the Shock Absorber
26
Front Shock Absorber - Assembling the Shock Absorber
27
Bleeding and Filling Shock Absorber
30
Front Shock Absorber - Disassembling the Piston Rod
33
Front Shock Absorber - Assembling the Piston Rod
34
Front Shock Absorber - Removing the Heim Joint
35
Front Shock Absorber - Installing the Heim Joint
36
Rear Shock Absorber - Adjusting the Compression Damping
36
Rear Shock Absorber - Adjusting the Rebound Damping
37
Rear Shock Absorber - Spring Preload
37
Removing the Rear Shock Absorber
38
Installing the Rear Shock Absorber
39
Rear Shock Absorber - Removing the Spring
39
Rear Shock Absorber - Installing the Spring
39
Rear Shock Absorber - Disassembling the Shock Absorber
40
Rear Shock Absorber - Assembling the Shock Absorber
42
Rear Shock Absorber - Disassembling the Piston Rod
44
Rear Shock Absorber - Assembling the Piston Rod
46
Rear Shock Absorber - Removing the Heim Joint
48
Rear Shock Absorber - Installing the Heim Joint
49
05/Exhaust
50
Removing the Main Silencer
50
Installing the Main Silencer
50
Removing the Manifold
50
Installing the Manifold
51
06/Air Filter
52
Removing the Air Filter
52
Installing the Air Filter
52
Cleaning Air Filter
52
Removing the Air Filter Box Lid with the Carburetor Connection Boot
53
Installing the Air Filter Box Lid and the Carburetor Connection Boot
53
07/Fuel Tank, Seat, Trim
54
Removing the Seat
54
Mounting the Seat
54
Removing the Radiator Spoiler
54
Installing the Radiator Spoiler
55
Removing the Fuel Tank
55
Installing the Fuel Tank
56
Fuel Tap
57
08/Mask, Fender
58
Removing the Front Cover
58
Installing the Front Cover
58
Removing the Front Trim
58
Installing the Front Trim
59
Removing the Rear Fender
59
Installing the Rear Fender
60
09/Front Wheel
61
Checking Tire Air Pressure
61
Tire Condition Checking
61
Removing Wheel/Wheels
61
Mounting Wheel/Wheels
62
Checking Brake Discs
62
10/Rear Wheel
63
Checking Chain Dirt
63
Cleaning the Chain
63
Checking Chain Wear
63
Checking Rear Sprocket / Engine Sprocket for Wear
63
Checking the Chain Tension
64
Adjusting Chain Tension
64
Adjusting the Toe Width of Rear Axle
65
Removing the Rear Axle
66
Installing the Rear Axle
67
Changing the Rear Axle Bearing
69
11/Wiring Harness, Battery
71
Ignition Curve Plug Connection
71
Changing Ignition Curve
71
Removing the Battery
71
Installing the Battery
71
Recharging the Battery
72
Changing the Main Fuse
73
Changing the Fuses of Individual Power-Consuming Components
73
Checking the Battery Voltage
74
Checking the Charging Voltage
74
Checking the Closed-Circuit Current
74
Checking the Starter Relay
75
13/Brake System
76
Handbrake Lever, Parking Brake
76
Checking Free Play of Hand Brake Lever
76
Adjusting Basic Position of Handbrake Lever
76
Checking the Brake Fluid Level of the Front Brake
77
Adding Brake Fluid for the Front Brake
77
Checking the Front Brake Linings
78
Removing the Front Brake Linings
78
Mounting Front Brake Linings
78
Changing the Front Brake Linings
79
Checking Free Play of Foot Brake Lever
79
Adjusting Basic Position of Footbrake Lever
80
Checking the Brake Fluid Level of the Rear Brake
80
Adding Brake Fluid for the Rear Brake
81
Checking the Rear Brake Linings
81
Removing the Rear Brake Linings
82
Mounting Rear Brake Linings
82
Changing the Rear Brake Linings
83
30/Engine
84
Removing the Engine
84
Installing the Engine
86
30/Disassembling the Engine
89
Preparations
89
Draining the Engine Oil
89
Removing the Oil Filter
89
Removing the Starter Motor
89
Removing the Shift Lever
90
Removing the Clutch Cover
90
Removing the Clutch Discs
90
Removing the Outer Clutch Hub
91
Removing the Starter Idler Gear/Torque Limiter
92
Removing the Shift Shaft
92
Removing the Shift Drum Locating
92
Removing the Locking Lever
92
Removing the Oil Pump Gear
92
Removing the Primary Gear with the Free-Wheel-Gear
93
Removing the Spark Plug
93
Removing the Generator Cover
93
Installing the Crankshaft Locking Bolt
93
Removing the Ignition Pulse Generator
94
Removing the Rotor
94
Removing the Oil Pumps
95
Removing the Oil Line
95
Removing the Timing Chain Tensioner
96
Removing the Water Pump Cover
96
Removing the Cylinder Head Top Section
96
Removing the Camshaft
96
Removing the Cylinder Head
97
Removing the Cylinder
97
Removing the Piston
98
Removing the Timing Chain
98
Removing the Timing Chain Sprocket
98
Removing the Locking Shaft Lever
98
Removing the Gear Sensor
99
Taking off the Left Section of the Engine Case
99
Remove the Shift Rails and Forks
100
Removing the Shift Drum
100
Removing the Transmission Shaft
101
Removing the Balancer Shaft
101
Removing the Crankshaft
101
30/Engine - Work on Individual Parts
102
Work on the Right Section of the Engine Case
102
Removing the Oil Pressure Regulator Valve
103
Checking the Spring Length of the Oil Pressure Regulator Valve
103
Installing the Oil Pressure Regulator Valve
103
Work on the Left Section of the Engine Case
104
Changing the Crankshaft Seal Ring in the Clutch Cover
104
Disassembling the Autodecompressor
105
Assembling the Autodecompressor
106
Changing the Camshaft Bearing
107
Checking the Rocker Arms and Rocker Arm Shafts
108
Removing the Valves
109
Checking the Valves
110
Checking the Valve Springs
110
Checking the Lower Valve Spring Retainer
110
Checking the Cylinder Head
111
Installing the Valves
111
Checking the Timing Assembly
112
Preparing the Timing Chain Tensioner for Installation
112
Changing the Conrod Bearing
112
Checking the Crankshaft Run-Out on the Bearing Pin
113
Measuring the Axial Clearance of the Crankshaft
114
Correcting the Axial Clearance of the Crankshaft
114
Cylinder - Nikasil Coating
115
Checking/Measuring the Cylinder
115
Checking/Measuring the Piston
116
Checking the Piston Ring End Gap
116
Checking the Piston/Cylinder Mounting Clearance
117
Checking the Oil Pumps for Wear
117
Checking the Shift Mechanism
118
Disassembling the Shift Shaft
119
Preassembling the Shift Shaft
120
Checking the Clutch
120
Disassembling the Main Shaft
121
Checking the Main Shaft
122
Assembling the Main Shaft
123
Disassembling the Countershaft
124
Checking the Countershaft
125
Assembling the Countershaft
126
Checking/Premounting the Reverse Gear Shaft
127
Checking Electric Starter Operation
128
Removing the Free-Wheel
129
Checking the Free-Wheel
129
Installing the Free-Wheel
129
30/Assembling the Engine
130
Installing the Crankshaft
130
Installing the Balancer Shaft
130
Installing the Transmission Shaft
130
Installing the Shift Forks
131
Installing the Shift Drum
131
Installing the Shift Rails
131
Installing the Left Engine Case
131
Installing the Timing Chain Sprocket
133
Installing the Timing Chain Rails
133
Installing the Piston
133
Installing the Cylinder
134
Installing the Cylinder Head
134
Installing the Camshaft
135
Installing the Cylinder Head Top Section
136
Installing the Timing Chain Tensioner
137
Installing the Rotor
137
Checking the Valve Clearance
137
Adjusting the Valve Clearance
138
Installing the Valve Cover
138
Installing the Water Pump Cover
138
Installing the Oil Line
138
Installing the Spark Plug
138
Installing the Primary Gear with the Free-Wheel-Gear
139
Installing the Oil Pumps
139
Installing the Ignition Pulse Generator
140
Installing the Generator Cover
140
Installing the Gear Sensor
141
Installing the Locking Shaft Lever
141
Installing the Locking Lever
141
Installing the Shift Drum Locating
142
Installing the Shift Shaft
142
Installing the Starter Idler Gear/Torque Limiter
142
Removing the Crankshaft Locking Bolt
142
Installing the Outer Clutch Hub and Clutch Discs
143
Installing the Clutch Cover
144
Installing the Starter Motor
145
Installing the Oil Drain Plug
145
Installing the Oil Screen
145
Mounting the Oil Filter
145
Filling up with Engine Oil
146
Installing the Shift Lever
146
Installing the Clutch Push Rod
146
Removing the Engine from the Universal Mounting Rack
146
31/Carburetor
147
Choke
147
Hot Start Button
147
Removing the Carburetor
147
Disassembling the Carburetor
148
Checking/Adjusting the Carburetor Components
151
Checking/Adjusting the Accelerator Pump
151
Checking the Hot Start Slide
152
Checking the Choke Slide
152
Checking the Jet Needle
152
Checking the Throttle Slide
153
Checking the Needle Jet
153
Checking the Float Needle Valve
153
Checking the Throttle Valve Sensor TPS
154
Adjusting the Position of Throttle Valve Sensor TPS
154
Checking/Adjusting the Throttle Slide Opening
155
Checking/Adjusting the Float Level
155
Assembling the Carburetor
155
Installing the Carburetor
158
Carburetor - Adjusting Idle
159
Checking the Throttle Valve Sensor Position
160
Emptying the Carburetor Float Chamber
161
32/Clutch
162
Checking Fluid Level of Hydraulic Clutch
162
33/Transmission
163
Removing the Engine Sprocket
163
Installing the Engine Sprocket
163
35/Water Pump, Cooling System
164
Checking Antifreeze and Coolant Level
164
Checking the Coolant Level
164
Draining Coolant
165
Filling Coolant / Bleeding Cooling System
166
38/Lubrication System
168
Changing Engine Oil and Oil Filter, Cleaning Oil Screens
168
Draining Engine Oil, Cleaning Oil Screens
168
Removing the Oil Filter
169
Mounting Oil Filter
170
Filling up with Engine Oil
170
Checking Engine Oil Level
171
Topping up Engine Oil
171
39/Ignition System
172
Checking the Generator
172
Checking the Ignition Pulse Generator
172
Checking the Ignition Coil
172
Checking the Spark Plug Connector
173
61/Atv Front Section
174
Toe, Checking
174
Adjusting the Toe
175
Checking/Adjusting Camber
176
Adjusting the Fork Offset
177
Removing the Wheel Carrier
177
Installing the Wheel Carrier
179
Removing the A-Arms
180
Installing the A-Arms
180
A-Arm Top - Changing the Bearing
181
A-Arm Bottom - Changing the Bearing
182
Technical Data - Engine
185
Capacity - Engine Oil
185
Capacity - Coolant
186
Technical Data - Tolerance, Wear Limits of Engine
187
Technical Data - Engine Tightening Torques
188
Technical Data - Carburetor
190
450/525 XC Atv
190
Technical Data - Carburetor Tightening Torques
191
Technical Data - Chassis
192
Lighting Equipment
193
Tires
193
Capacity - Fuel
193
Technical Data - Front Shock Absorber
194
Technical Data - Rear Shock Absorber
195
Technical Data - Chassis Tightening Torques
196
Cleaning
197
Cleaning the Vehicle
197
Storage
198
Putting the Vehicle into Operation after Storage
198
Greasing and Service Table
199
Important Maintenance Work to be Carried out by an Authorized KTM Workshop
199
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 Rider
200
Wiring Diagram
202
450/525 XC Atv
202
Substances
205
Auxiliary Substances
207
Special Tools
209
Standards
218
Index
219
4
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KTM 450 XC 2008 Specifications
General
Brand
KTM
Model
450 XC 2008
Category
Offroad Vehicle
Language
English
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