KTM 450 XC 2008 Repair Manual page 6

CONTENTS
Installing the spark plug............................................... 136
Installing the primary gear with the free-wheel-gear ........ 137
Installing the oil pumps ............................................... 137
Installing the ignition pulse generator............................ 138
Installing the generator cover........................................ 138
Installing the gear sensor ............................................. 139
Installing the locking shaft lever ................................... 139
Installing the locking lever............................................ 139
Installing the shift drum locating .................................. 140
Installing the shift shaft ............................................... 140
Installing the starter idler gear/torque limiter.................. 140
Removing the crankshaft locking bolt ............................ 140
Installing the outer clutch hub and clutch discs ............. 141
Installing the clutch cover ............................................ 142
Installing the starter motor ........................................... 143
Installing the oil drain plug........................................... 143
Installing the oil screen................................................ 143
Mounting the oil filter .................................................. 143
Filling up with engine oil.............................................. 144
Installing the shift lever ............................................... 144
Installing the clutch push rod ....................................... 144
Removing the engine from the universal mounting
rack ........................................................................... 144
31/CARBURETOR ........................................................... 145
Choke......................................................................... 145
Hot start button........................................................... 145
Removing the carburetor .............................................. 145
Disassembling the carburetor........................................ 146
Checking/adjusting the carburetor components............... 149
Checking/adjusting the accelerator pump....................... 149
Checking the hot start slide .......................................... 150
Checking the choke slide.............................................. 150
Checking the jet needle................................................ 150
Checking the throttle slide............................................ 151
Checking the needle jet................................................ 151
Checking the float needle valve..................................... 151
Checking the throttle valve sensor TPS .......................... 152
Adjusting the position of throttle valve sensor TPS .......... 152
Checking/adjusting the throttle slide opening ................. 153
Checking/adjusting the float level.................................. 153
Assembling the carburetor ............................................ 153
Installing the carburetor ............................................... 156
Carburetor - adjusting idle ............................................ 157
Checking the throttle valve sensor position..................... 158
Emptying the carburetor float chamber .......................... 159
32/CLUTCH .................................................................... 160
Checking fluid level of hydraulic clutch ......................... 160
33/TRANSMISSION......................................................... 161
Removing the engine sprocket ...................................... 161
Installing the engine sprocket ....................................... 161
35/WATER PUMP, COOLING SYSTEM .............................. 162
Checking antifreeze and coolant level ............................ 162
Checking the coolant level............................................ 162
Draining coolant .......................................................... 163
Filling coolant / bleeding cooling system ........................ 164
38/LUBRICATION SYSTEM .............................................. 166
Changing engine oil and oil filter, cleaning oil screens .... 166
Draining engine oil, cleaning oil screens ........................ 166
Removing the oil filter.................................................. 167
Mounting oil filter........................................................ 168
Filling up with engine oil.............................................. 168
Checking engine oil level.............................................. 169
Topping up engine oil .................................................. 169
39/IGNITION SYSTEM ..................................................... 170
Checking the generator ................................................ 170
Checking the ignition pulse generator ............................ 170
Checking the ignition coil............................................. 170
Checking the spark plug connector................................ 171
61/ATV FRONT SECTION ................................................. 172
Toe, checking ............................................................. 172
Adjusting the toe ......................................................... 173
Checking/adjusting camber........................................... 174
Adjusting the fork offset ............................................... 175
Removing the wheel carrier .......................................... 175
Installing the wheel carrier ........................................... 177
Removing the A-arms................................................... 178
Installing the A-arms ................................................... 178
A-Arm top - changing the bearing.................................. 179
A-Arm bottom - changing the bearing ............................ 180
TECHNICAL DATA - ENGINE ............................................ 183
Capacity - engine oil .................................................... 183
Capacity - coolant........................................................ 184
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF
ENGINE ......................................................................... 185
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ 186
TECHNICAL DATA - CARBURETOR................................... 188
450/525 XC ATV ......................................................... 188
TECHNICAL DATA - CARBURETOR TIGHTENING
TORQUES....................................................................... 189
TECHNICAL DATA - CHASSIS .......................................... 190
Lighting equipment ..................................................... 191
Tires .......................................................................... 191
Capacity - fuel............................................................. 191
TECHNICAL DATA - FRONT SHOCK ABSORBER................ 192
TECHNICAL DATA - REAR SHOCK ABSORBER.................. 193
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 194
CLEANING...................................................................... 195
Cleaning the vehicle .................................................... 195
STORAGE ....................................................................... 196
Storage....................................................................... 196
Putting the vehicle into operation after storage ............... 196
GREASING AND SERVICE TABLE ..................................... 197
Important maintenance work to be carried out by an
authorized KTM workshop. ........................................... 197
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order).............. 198
Important checks and maintenance work to be carried
out by the rider. .......................................................... 198
WIRING DIAGRAM .......................................................... 200
450/525 XC ATV ......................................................... 200
SUBSTANCES................................................................. 203
AUXILIARY SUBSTANCES................................................ 205
SPECIAL TOOLS.............................................................. 207
STANDARDS................................................................... 216
INDEX ............................................................................ 217
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