Table Of Contents - KTM 450 XC 2008 Repair Manual

CONTENTS
CONTENTS
MEANS OF REPRESENTATION ............................................ 5
IMPORTANT NOTES ............................................................ 6
Overview of warning labels................................................ 8
VIEW OF VEHICLE............................................................. 10
Vehicle view, front left ................................................... 10
View of vehicle, rear right ............................................... 11
LOCATION OF SERIAL NUMBERS ...................................... 12
Chassis number............................................................. 12
Type label..................................................................... 12
Key number .................................................................. 12
Engine number.............................................................. 12
Setting number, front shock absorber .............................. 12
Setting number, rear shock absorber ............................... 13
VEHICLE .......................................................................... 14
Jacking up the vehicle ................................................... 14
Removing the vehicle from the work stand ....................... 14
02/HANDLEBAR, CONTROLS ............................................. 15
Adjusting handlebar position .......................................... 15
Adjusting basic position of clutch lever............................ 15
Checking play in gas Bowden cable ................................. 16
Adjusting play in gas Bowden cable................................. 16
Checking the play in the Bowden cable using the reverse
gear release lever........................................................... 16
Adjusting the play in the Bowden cable using the reverse
gear release lever........................................................... 16
Detaching the reverse gear Bowden cable ........................ 17
Attaching the reverse gear Bowden cable ......................... 17
03/FRAME........................................................................ 18
Removing the engine guard ............................................ 18
Installing the engine guard ............................................. 18
04/SHOCK ABSORBER, SWINGARM................................... 19
Front shock absorber - adjusting the compression
damping ....................................................................... 19
Front shock absorber - adjusting the rebound damping...... 19
Front shock absorber - adjusting the cross over................. 20
Front shock absorber - spring preload .............................. 20
Removing the front shock absorber.................................. 21
Installing the front shock absorber .................................. 22
Front shock absorber - removing the spring ...................... 22
Front shock absorber - installing the spring ...................... 23
Front shock absorber - disassembling the shock
absorber ....................................................................... 24
Front shock absorber - assembling the shock absorber ...... 25
Bleeding and filling shock absorber ................................. 28
Front shock absorber - disassembling the piston rod ......... 31
Front shock absorber - assembling the piston rod.............. 32
Front shock absorber - removing the heim joint ................ 33
Front shock absorber - installing the heim joint ................ 34
Rear shock absorber - adjusting the compression
damping ....................................................................... 34
Rear shock absorber - adjusting the rebound damping....... 35
Rear shock absorber - spring preload ............................... 35
Removing the rear shock absorber ................................... 36
Installing the rear shock absorber.................................... 37
Rear shock absorber - removing the spring ....................... 37
Rear shock absorber - installing the spring ....................... 37
Rear shock absorber - disassembling the shock absorber ... 38
Rear shock absorber - assembling the shock absorber ....... 40
Rear shock absorber - disassembling the piston rod .......... 42
Rear shock absorber - assembling the piston rod .............. 44
Rear shock absorber - removing the heim joint ................. 46
Rear shock absorber - installing the heim joint ................. 47
05/EXHAUST .................................................................... 48
Removing the main silencer............................................ 48
Installing the main silencer ............................................ 48
Removing the manifold .................................................. 48
Installing the manifold ................................................... 49
06/AIR FILTER.................................................................. 50
Removing the air filter ................................................... 50
Installing the air filter .................................................... 50
Cleaning air filter........................................................... 50
Removing the air filter box lid with the carburetor
connection boot ............................................................ 51
Installing the air filter box lid and the carburetor
connection boot ............................................................ 51
07/FUEL TANK, SEAT, TRIM.............................................. 52
Removing the seat ......................................................... 52
Mounting the seat ......................................................... 52
Removing the radiator spoiler ......................................... 52
Installing the radiator spoiler .......................................... 53
Removing the fuel tank .................................................. 53
Installing the fuel tank ................................................... 54
Fuel tap........................................................................ 55
08/MASK, FENDER ........................................................... 56
Removing the front cover................................................ 56
Installing the front cover ................................................ 56
Removing the front trim ................................................. 56
Installing the front trim .................................................. 57
Removing the rear fender ............................................... 57
Installing the rear fender ................................................ 58
09/FRONT WHEEL ............................................................ 59
Checking tire air pressure ............................................... 59
Tire condition checking.................................................. 59
Removing wheel/wheels.................................................. 59
Mounting wheel/wheels .................................................. 60
Checking brake discs ..................................................... 60
10/REAR WHEEL .............................................................. 61
Checking chain dirt ....................................................... 61
Cleaning the chain......................................................... 61
Checking chain wear ...................................................... 61
Checking rear sprocket / engine sprocket for wear ............. 61
Checking the chain tension ............................................ 62
Adjusting chain tension.................................................. 62
Adjusting the toe width of rear axle ................................. 63
Removing the rear axle................................................... 64
Installing the rear axle ................................................... 65
Changing the rear axle bearing........................................ 67
11/WIRING HARNESS, BATTERY ....................................... 69
Ignition curve plug connection ........................................ 69
Changing ignition curve.................................................. 69
Removing the battery ..................................................... 69
Installing the battery...................................................... 69
Recharging the battery ................................................... 70
Changing the main fuse ................................................. 71
Changing the fuses of individual power-consuming
components .................................................................. 71
Checking the battery voltage........................................... 72
Checking the charging voltage ........................................ 72
Checking the closed-circuit current ................................. 72
Checking the starter relay ............................................... 73
13/BRAKE SYSTEM........................................................... 74
Handbrake lever, parking brake....................................... 74
Checking free play of hand brake lever............................. 74
Adjusting basic position of handbrake lever...................... 74
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