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KTM Manuals
Offroad Vehicle
2008 450 XC ATV
Repair manual
KTM 450 XC 2008 Repair Manual
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Also See for 450 XC 2008
:
Owner's manual
(103 pages)
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Contents
Table of Contents
Bookmarks
Table of Contents
Table of Contents
Means of Representation
Important Notes
Overview of Warning Labels
View of Vehicle
Vehicle View, Front Left
View of Vehicle, Rear Right
Location of Serial Numbers
Chassis Number
Type Label
Key Number
Engine Number
Setting Number, Front Shock Absorber
Setting Number, Rear Shock Absorber
Vehicle
Jacking up the Vehicle
Removing the Vehicle from the Work Stand
02/Handlebar, Controls
Adjusting Handlebar Position
Adjusting Basic Position of Clutch Lever
Checking Play in Gas Bowden Cable
Adjusting Play in Gas Bowden Cable
Checking the Play in the Bowden Cable Using the Reverse Gear Release Lever
Adjusting the Play in the Bowden Cable Using the Reverse Gear Release Lever
Detaching the Reverse Gear Bowden Cable
Attaching the Reverse Gear Bowden Cable
03/Frame
Removing the Engine Guard
Installing the Engine Guard
04/Shock Absorber, Swingarm
Front Shock Absorber - Adjusting the Compression Damping
Front Shock Absorber - Adjusting the Rebound Damping
Front Shock Absorber - Adjusting the Cross over
Front Shock Absorber - Spring Preload
Removing the Front Shock Absorber
Installing the Front Shock Absorber
Front Shock Absorber - Removing the Spring
Front Shock Absorber - Installing the Spring
Front Shock Absorber - Disassembling the Shock Absorber
Front Shock Absorber - Assembling the Shock Absorber
Bleeding and Filling Shock Absorber
Front Shock Absorber - Disassembling the Piston Rod
Front Shock Absorber - Assembling the Piston Rod
Front Shock Absorber - Removing the Heim Joint
Front Shock Absorber - Installing the Heim Joint
Rear Shock Absorber - Adjusting the Compression Damping
Rear Shock Absorber - Adjusting the Rebound Damping
Rear Shock Absorber - Spring Preload
Removing the Rear Shock Absorber
Installing the Rear Shock Absorber
Rear Shock Absorber - Removing the Spring
Rear Shock Absorber - Installing the Spring
Rear Shock Absorber - Disassembling the Shock Absorber
Rear Shock Absorber - Assembling the Shock Absorber
Rear Shock Absorber - Disassembling the Piston Rod
Rear Shock Absorber - Assembling the Piston Rod
Rear Shock Absorber - Removing the Heim Joint
Rear Shock Absorber - Installing the Heim Joint
05/Exhaust
Removing the Main Silencer
Installing the Main Silencer
Removing the Manifold
Installing the Manifold
06/Air Filter
Removing the Air Filter
Installing the Air Filter
Cleaning Air Filter
Removing the Air Filter Box Lid with the Carburetor Connection Boot
Installing the Air Filter Box Lid and the Carburetor Connection Boot
07/Fuel Tank, Seat, Trim
Removing the Seat
Mounting the Seat
Removing the Radiator Spoiler
Installing the Radiator Spoiler
Removing the Fuel Tank
Installing the Fuel Tank
Fuel Tap
08/Mask, Fender
Removing the Front Cover
Installing the Front Cover
Removing the Front Trim
Installing the Front Trim
Removing the Rear Fender
Installing the Rear Fender
09/Front Wheel
Checking Tire Air Pressure
Tire Condition Checking
Removing Wheel/Wheels
Mounting Wheel/Wheels
Checking Brake Discs
10/Rear Wheel
Checking Chain Dirt
Cleaning the Chain
Checking Chain Wear
Checking Rear Sprocket / Engine Sprocket for Wear
Checking the Chain Tension
Adjusting Chain Tension
Adjusting the Toe Width of Rear Axle
Removing the Rear Axle
Installing the Rear Axle
Changing the Rear Axle Bearing
11/Wiring Harness, Battery
Ignition Curve Plug Connection
Changing Ignition Curve
Removing the Battery
Installing the Battery
Recharging the Battery
Changing the Main Fuse
Changing the Fuses of Individual Power-Consuming Components
Checking the Battery Voltage
Checking the Charging Voltage
Checking the Closed-Circuit Current
Checking the Starter Relay
13/Brake System
Handbrake Lever, Parking Brake
Checking Free Play of Hand Brake Lever
Adjusting Basic Position of Handbrake Lever
Checking the Brake Fluid Level of the Front Brake
Adding Brake Fluid for the Front Brake
Checking the Front Brake Linings
Removing the Front Brake Linings
Mounting Front Brake Linings
Changing the Front Brake Linings
Checking Free Play of Foot Brake Lever
Adjusting Basic Position of Footbrake Lever
Checking the Brake Fluid Level of the Rear Brake
Adding Brake Fluid for the Rear Brake
Checking the Rear Brake Linings
Removing the Rear Brake Linings
Mounting Rear Brake Linings
Changing the Rear Brake Linings
30/Engine
Removing the Engine
Installing the Engine
30/Disassembling the Engine
Preparations
Draining the Engine Oil
Removing the Oil Filter
Removing the Starter Motor
Removing the Shift Lever
Removing the Clutch Cover
Removing the Clutch Discs
Removing the Outer Clutch Hub
Removing the Starter Idler Gear/Torque Limiter
Removing the Shift Shaft
Removing the Shift Drum Locating
Removing the Locking Lever
Removing the Oil Pump Gear
Removing the Primary Gear with the Free-Wheel-Gear
Removing the Spark Plug
Removing the Generator Cover
Installing the Crankshaft Locking Bolt
Removing the Ignition Pulse Generator
Removing the Rotor
Removing the Oil Pumps
Removing the Oil Line
Removing the Timing Chain Tensioner
Removing the Water Pump Cover
Removing the Cylinder Head Top Section
Removing the Camshaft
Removing the Cylinder Head
Removing the Cylinder
Removing the Piston
Removing the Timing Chain
Removing the Timing Chain Sprocket
Removing the Locking Shaft Lever
Removing the Gear Sensor
Taking off the Left Section of the Engine Case
Remove the Shift Rails and Forks
Removing the Shift Drum
Removing the Transmission Shaft
Removing the Balancer Shaft
Removing the Crankshaft
30/Engine - Work on Individual Parts
Work on the Right Section of the Engine Case
Removing the Oil Pressure Regulator Valve
Checking the Spring Length of the Oil Pressure Regulator Valve
Installing the Oil Pressure Regulator Valve
Work on the Left Section of the Engine Case
Changing the Crankshaft Seal Ring in the Clutch Cover
Disassembling the Autodecompressor
Assembling the Autodecompressor
Changing the Camshaft Bearing
Checking the Rocker Arms and Rocker Arm Shafts
Removing the Valves
Checking the Valves
Checking the Valve Springs
Checking the Lower Valve Spring Retainer
Checking the Cylinder Head
Installing the Valves
Checking the Timing Assembly
Preparing the Timing Chain Tensioner for Installation
Changing the Conrod Bearing
Checking the Crankshaft Run-Out on the Bearing Pin
Measuring the Axial Clearance of the Crankshaft
Correcting the Axial Clearance of the Crankshaft
Cylinder - Nikasil Coating
Checking/Measuring the Cylinder
Checking/Measuring the Piston
Checking the Piston Ring End Gap
Checking the Piston/Cylinder Mounting Clearance
Checking the Oil Pumps for Wear
Checking the Shift Mechanism
Disassembling the Shift Shaft
Preassembling the Shift Shaft
Checking the Clutch
Disassembling the Main Shaft
Checking the Main Shaft
Assembling the Main Shaft
Disassembling the Countershaft
Checking the Countershaft
Assembling the Countershaft
Checking/Premounting the Reverse Gear Shaft
Checking Electric Starter Operation
Removing the Free-Wheel
Checking the Free-Wheel
Installing the Free-Wheel
30/Assembling the Engine
Installing the Crankshaft
Installing the Balancer Shaft
Installing the Transmission Shaft
Installing the Shift Forks
Installing the Shift Drum
Installing the Shift Rails
Installing the Left Engine Case
Installing the Timing Chain Sprocket
Installing the Timing Chain Rails
Installing the Piston
Installing the Cylinder
Installing the Cylinder Head
Installing the Camshaft
Installing the Cylinder Head Top Section
Installing the Timing Chain Tensioner
Installing the Rotor
Checking the Valve Clearance
Adjusting the Valve Clearance
Installing the Valve Cover
Installing the Water Pump Cover
Installing the Oil Line
Installing the Spark Plug
Installing the Primary Gear with the Free-Wheel-Gear
Installing the Oil Pumps
Installing the Ignition Pulse Generator
Installing the Generator Cover
Installing the Gear Sensor
Installing the Locking Shaft Lever
Installing the Locking Lever
Installing the Shift Drum Locating
Installing the Shift Shaft
Installing the Starter Idler Gear/Torque Limiter
Removing the Crankshaft Locking Bolt
Installing the Outer Clutch Hub and Clutch Discs
Installing the Clutch Cover
Installing the Starter Motor
Installing the Oil Drain Plug
Installing the Oil Screen
Mounting the Oil Filter
Filling up with Engine Oil
Installing the Shift Lever
Installing the Clutch Push Rod
Removing the Engine from the Universal Mounting Rack
31/Carburetor
Choke
Hot Start Button
Removing the Carburetor
Disassembling the Carburetor
Checking/Adjusting the Carburetor Components
Checking/Adjusting the Accelerator Pump
Checking the Hot Start Slide
Checking the Choke Slide
Checking the Jet Needle
Checking the Throttle Slide
Checking the Needle Jet
Checking the Float Needle Valve
Checking the Throttle Valve Sensor TPS
Adjusting the Position of Throttle Valve Sensor TPS
Checking/Adjusting the Throttle Slide Opening
Checking/Adjusting the Float Level
Assembling the Carburetor
Installing the Carburetor
Carburetor - Adjusting Idle
Checking the Throttle Valve Sensor Position
Emptying the Carburetor Float Chamber
32/Clutch
Checking Fluid Level of Hydraulic Clutch
33/Transmission
Removing the Engine Sprocket
Installing the Engine Sprocket
35/Water Pump, Cooling System
Checking Antifreeze and Coolant Level
Checking the Coolant Level
Draining Coolant
Filling Coolant / Bleeding Cooling System
38/Lubrication System
Changing Engine Oil and Oil Filter, Cleaning Oil Screens
Draining Engine Oil, Cleaning Oil Screens
Removing the Oil Filter
Mounting Oil Filter
Filling up with Engine Oil
Checking Engine Oil Level
Topping up Engine Oil
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REPAIR MANUAL
2008
450 XC ATV
525 XC ATV
ART. NO. 3206058en
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