KTM 450 XC User Manual

208 pages

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OWNER'S MANUAL 2009

450 XC ATV

525 XC ATV

ART. NO. 3211377en

Questions and Answers:

N
nthomasJul 28, 2025
What to do if my KTM Offroad Vehicle engine turns but does not start?
- R
  Ricky BrownJul 28, 2025
  If your KTM Offroad Vehicle's engine turns over but doesn't start, there are several potential causes and solutions: * **Operating Error**: Make sure to follow the correct engine starting procedure. * **Old Fuel**: If the vehicle has been sitting for a while, the fuel in the float chamber may be old. In this case, empty the carburetor float chamber. * **Fuel Feed Interrupted**: Check the tank breather, clean the fuel tap and clean the carburetor. * **Engine Flooded**: Clean and dry the spark plug, replacing it if necessary. * **Spark Plug Issues**: If the spark plug is oily or wet, clean and dry it, replacing it if needed. Also, check the electrode distance (plug gap) and adjust it to the recommended 0.6 mm (0.024 in) if it's too wide.

KTM 450 XC Specifications

General

Brand	KTM
Model	450 XC
Category	Offroad Vehicle
Language	English

Summary

Important Notes

Maintenance

Emphasizes the importance of proper maintenance for optimal operation and longevity.

Rider Training

Stresses the importance of professional rider training for new ATV users.

Operating Elements

Clutch Lever

Describes the clutch lever's function and possible states.

Handbrake Lever, Parking Brake

Details the handbrake lever and its parking brake function.

Throttle Lever

Explains the throttle lever's use for controlling engine speed.

ENG. STOP Switch

Details ENG. STOP switch positions for vehicle operation.

Electric Starter Button

Illustrates the electric starter button and its states.

Ignition Switch

Explains the ignition switch positions for starting the engine.

Emergency OFF Switch with Rip Cord

Explains the emergency engine shut-off mechanism with a rip cord.

Fuel Tap

Explains the function and operation of the fuel tap.

Shift Lever

Illustrates gear positions and operation of the shift lever.

Foot Brake Pedal

Explains the location and function of the foot brake pedal.

Tips on Putting into Operation

Advice on First Use

Provides essential advice and warnings for initial vehicle operation.

Running in the Engine

Details guidelines for the engine's running-in phase to ensure longevity.

Riding Instructions

Checks Before Putting into Operation

Lists crucial checks to perform before riding the vehicle.

Starting

Provides instructions on how to start the engine safely.

Starting Up

Guides on preparing to ride after the engine starts.

Shifting

Explains how to shift gears for smooth and safe riding.

Shifting to Reverse Gear

Details the procedure for engaging reverse gear.

Disengaging Reverse Gear

Explains how to safely disengage reverse gear.

Braking

Provides essential techniques and warnings for effective braking.

Riding in Bends

Explains techniques for safely navigating bends, including body positioning.

Riding Downhill

Gives instructions and warnings for riding safely on downhill slopes.

Riding Uphill

Provides guidance and warnings for riding safely on uphill slopes.

Switching off the Engine

Details the three methods for safely switching off the engine.

Stopping, Parking

Explains how to properly stop and park the vehicle.

Refueling

Provides crucial safety instructions and procedures for refueling.

Service Schedule

Important Maintenance Work to be Carried out by an Authorized KTM Workshop

Lists maintenance tasks recommended for authorized KTM workshops.

Important Checks and Maintenance Work to be Carried out by the Rider

Outlines essential maintenance checks the rider should perform.

Maintenance on Chassis and Engine

Front Shock Absorber - Adjusting the Compression Damping

Guides on adjusting the compression damping of the front shock absorber.

Front Shock Absorber - Adjusting the Rebound Damping

Details how to adjust the rebound damping of the front shock absorber.

Front Shock Absorber - Adjusting the Spring Preload

Guides on adjusting the spring preload for the front shock absorber.

Rear Shock Absorber - Adjusting the Compression Damping

Details how to adjust the compression damping on the rear shock absorber.

Rear Shock Absorber - Adjusting the Rebound Damping

Explains how to adjust the rebound damping on the rear shock absorber.

Rear Shock Absorber - Adjusting the Spring Preload

Guides on adjusting the spring preload for the rear shock absorber.

Adjusting the Toe

Guides on adjusting the front wheel toe alignment for proper handling.

Adjusting the Fork Offset

Guides on adjusting the fork offset for desired handling characteristics.

Adjusting the Toe Width of Rear Axle

Provides instructions for adjusting the rear axle toe width.

Adjusting Handlebar Position

Guides on adjusting the handlebar position for rider comfort.

Checking the Chain Tension

Explains how to check the drive chain tension.

Adjusting Chain Tension

Provides steps for adjusting the drive chain tension.

Checking Brake Discs

Checking the Free Play of the Hand Brake Lever

Adjusting Basic Position of Handbrake Lever

Checking Front Brake Fluid Level

Explains how to check the front brake fluid level.

Topping up the Front Brake Fluid

Provides instructions for topping up the front brake fluid.

Checking Front Brake Linings

Changing the Front Brake Linings

Checking Free Play of Foot Brake Lever

Adjusting Basic Position of Footbrake Lever

Checking Rear Brake Fluid Level

Explains how to check the rear brake fluid level.

Checking Rear Brake Linings

Tire Condition Checking

Checking Tire Air Pressure

Recharging the Battery

Changing Main Fuse

Changing Ignition Curve

Removing the Air Filter

Installing the Air Filter

Cleaning Air Filter

Adjusting Basic Position of Clutch Lever

Checking Fluid Level of Hydraulic Clutch

Cooling System

Checking Antifreeze and Coolant Level

Guides on checking the coolant's antifreeze level and overall condition.

Checking the Coolant Level

Explains how to check the coolant level in the system.

Draining Coolant

Filling Coolant / Bleeding Cooling System

Guides on refilling and bleeding the cooling system.

Carburetor - Idle

Carburetor - Adjusting Idle

Details the procedure for adjusting the carburetor's idle speed.

Checking Engine Oil Level

Explains how to check the engine oil level accurately.

Changing Engine Oil and Oil Filter, Cleaning Oil Screens

Details the process of changing engine oil, filter, and cleaning screens.

Draining Engine Oil, Cleaning Oil Screens

Provides steps for draining engine oil and cleaning oil screens.

Removing the Oil Filter

Mounting the Oil Filter

Filling up with Engine Oil

Explains how to fill the engine with the correct amount of oil.

Topping up Engine Oil

Guides on adding engine oil to reach the correct level.

Troubleshooting

Engine Turns but Does Not Start

Addresses potential causes and solutions for starting issues.

The Engine Cannot Be Cranked (Electric Starter)

Engine Does Not Speed Up

Engine Has No Idle

Engine Stalls or Is Popping into the Carburetor

Engine Overheats

Discusses causes and solutions for engine overheating.

Engine Has Too Little Power

Battery Discharged

Storage

Putting the Vehicle into Operation After Storage

Technical Data - Engine

Capacity - Engine Oil

Capacity - Coolant

Technical Data - Engine Tightening Torques

Technical Data - Carburetor

Technical Data - Chassis

Capacity - Fuel

Technical Data - Front Shock Absorber

Technical Data - Rear Shock Absorber

Technical Data - Chassis Tightening Torques

Substances

Brake Fluid DOT 4 / DOT 5.1

Coolant

Engine Oil (SAE 10W/50)

Specifies approved engine oil for specific temperature ranges.

Engine Oil (SAE 5W/40)

Specifies approved engine oil for colder temperatures.

Super Unleaded (ROZ 95 / RON 95 / PON 91)

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