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KTM 450 SMR Owner's Manual

Ktm motorcycle owner's manual.
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OWNER'S MANUAL
2008
450 SMR
ART. NO. 3211243en
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   Summary of Contents for KTM 450 SMR

  • Page 1 OWNER'S MANUAL 2008 450 SMR ART. NO. 3211243en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors.

  • Page 4: Table Of Contents

    Important maintenance work to be carried out by an authorized KTM workshop..18 Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)... 19 Important checks and maintenance work to be carried out by the rider..19 MAINTENANCE WORK ON CHASSIS AND ENGINE...
  • Page 5 Filling up with engine oil ... 64 Topping up engine oil ... 65 TROUBLESHOOTING... 66 CLEANING... 68 Cleaning motorcycle ... 68 STORAGE ... 69 Storage... 69 Putting into operation after storage ... 69 TECHNICAL DATA - ENGINE ... 70 Capacity - engine oil ... 70 Capacity - coolant...

  • Page 6: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.

  • Page 7: Important Notes

    You should use the fuels, oils and greases according to specifications as listed in the owner's manual. Spare parts, accessories For your own safety, use only spare parts and accessories approved by KTM. KTM accepts no liability for other products and any re- sulting damage or loss.
  • Page 8 Read this owner's manual carefully and completely before making your first trip. It contains a lot of information and tips to help you operate and handle your motorcycle. Only then will you find out how to customize the motorcycle ideally for your own use and how you can protect yourself from injury.

  • Page 9: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left side Hand brake lever Start number plate Front fender Front wheel Fork part number Oil filter cover Plug-in stand Shift lever Choke button Air filter Filler cap Clutch lever 500182-10...

  • Page 10: View Of Vehicle, Rear Right Side

    VIEW OF VEHICLE View of vehicle, rear right side Main silencer Shock absorber Brake caliper of rear wheel brake Rear wheel Foot brake pedal Manifold Chassis number/type label Throttle grip 500183-10...

  • Page 11: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS Chassis number 400193-10 Type label 400284-10 Engine number 400194-10 Fork part number 500175-10 Shock absorber part number 500083-10 The chassis number is stamped on the steering head on the right. The type label is fixed to the front of the steering head. The engine number is stamped on the left side of the engine under the engine sprocket.

  • Page 12: Operating Elements

    OPERATING ELEMENTS Clutch lever 400195-10 Hot start lever 400195-12 Hand brake lever 500176-10 Short circuit button 400197-10 Electric starter button 500177-10 The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. The hot start lever is fitted on the left side of the handlebar.

  • Page 13: Fuel Tap

    OPERATING ELEMENTS Fuel tap 500178-10 Opening filler cap 400199-10 Closing filler cap 400199-11 Choke 500179-10 With the tap handle on the fuel tap, you can open or close the supply of fuel to the carburetor. Possible states • Fuel supply closed OFF No fuel can flow from the tank to the carburetor.

  • Page 14: Shift Lever

    Note Danger of damage Danger of damage by the vehicle running away or falling over. Always place the vehicle on a firm and even surface. To stand the motorcycle, plug the plug-in stand dle. Info Before riding, remove the plug-in stand.

  • Page 15: General Tips And Hints On Putting Into Operation

    When using your motorcycle, remember that others may feel disturbed by excessive noise. Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover.

  • Page 16: Running In The Engine

    GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION Running in the engine During the running-in phase, do not exceed the specified engine speed and engine performance. Specification Maximum engine speed During the first 3 service hours Maximum engine performance during the running-in period During the first 3 service hours During the next 12 service hours Avoid fully opening the throttle!

  • Page 17: Riding Instructions

    Always warm up the engine at low engine speeds. Info If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel evaporate after a long time of standing.

  • Page 18: Starting Up

    Do not change into a low gear at high engine speed. The engine races and the rear wheel can block. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines.

  • Page 19: Refueling

    Press the short circuit button when the engine is idling until the engine stops. Turn the handle of the fuel tap to the OFF position. (Figure 500178-10 Stand the motorcycle on a hard surface. Refueling Danger Fire hazard Fuel can easily catch fire.

  • Page 20: Greasing And Service Table

    GREASING AND SERVICE TABLE Important maintenance work to be carried out by an authorized KTM workshop. Engine Change the engine oil and oil filter, and clean the oil screen. ( Replace spark plug. Check and adjust valve clearance. Check engine mounting screws for tightness.

  • Page 21: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop. (as Additional Order)

    GREASING AND SERVICE TABLE Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) Carry out a complete fork service. Carry out a complete shock absorber service. Grease the steering head bearing. ( Clean and adjust carburetor.
  • Page 22 GREASING AND SERVICE TABLE Check the coolant level. ( P. 55) Empty the carburetor float chamber. ( Check that all operating elements for smooth operation. Check braking. Check all screws, nuts and hose clamps regularly for tightness. NB1A: Depending on conditions of use according to requirements. P.

  • Page 23: Maintenance Work On Chassis And Engine

    When adjusting the basic chassis setting, first adjust the shock absorber and then the fork. For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swing arm and frame, the basic settings of the suspension components must match your body weight.

  • Page 24: Adjusting The Low-speed Compression Damping Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the low-speed compression damping of the shock absorber Danger Danger of accidents The shock absorber is under high pressure. The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main- tenance on it yourself.

  • Page 25: Measuring Rear Wheel Sag Unloaded

    Measure distance of rear wheel unloaded. ( With another person holding the motorcycle, sit on the saddle with full protective clothing in a normal sitting position (feet on footrests) and bounce up and down a few times until the rear suspension levels out.

  • Page 26: Adjusting Spring Preload Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting spring preload of the shock absorber Danger Danger of accidents The shock absorber is under high pressure. The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main- tenance on it yourself.

  • Page 27: Removing The Shock Absorber

    Lubricants dis- solve the Teflon coating, thereby drastically reducing the service life. Remove the motorcycle from the work stand. ( As with the shock absorber, smaller weight differences can be compensated by the spring preload.

  • Page 28: Adjusting Rebound Damping Of Fork

    Remove bleeder screws briefly. Any excess pressure escapes from the interior of the fork. Mount and tighten bleeder screws. Remove the motorcycle from the work stand. ( Jack up the motorcycle. ( P. 21) Remove the fork protector. ( P. 27)

  • Page 29: Removing The Fork Protector

    Warning Danger of accidents Unsafe riding behavior due to incorrect steering head bearing play. The steering head bearing play should be adjusted immediately in an authorized KTM workshop. Info If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time.

  • Page 30: Adjusting Play Of Steering Head Bearing

    » If click positions are noticeable: Adjust play of the steering head bearing ( Check the steering head bearing and replace if required. Remove the motorcycle from the work stand. ( Jack up the motorcycle. ( P. 21) Loosen screw .

  • Page 31: Setting The Fork Offset

    MAINTENANCE WORK ON CHASSIS AND ENGINE Setting the fork offset 500104-10 Removing the fork legs 500200-12 500094-12 Installing the fork legs 400248-10 500094-11 Remove the lower triple clamp. ( P. 30) Remove screw . Remove the steering stem. Clean the parts and check for damage. Rotate the steering stem 180°...

  • Page 32: Removing The Lower Triple Clamp

    , take off top triple clamp with the handlebar and place it on one side. Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines. Remove o-ring . Remove protector ring Remove the lower triple clamp with the steering stem.

  • Page 33: Greasing The Steering Head Bearing

    MAINTENANCE WORK ON CHASSIS AND ENGINE 500099-11 500103-10 Greasing the steering head bearing Remove the lower triple clamp. ( Install the lower triple clamp. ( P. 30) Dismounting the front fender 500190-10 Installing the front fender 500190-10 Position the upper triple clamp with the steering. Mount and tighten screw Specification Screw, top steering head...

  • Page 34: Dismount The Start Number Plate

    . Remove the handlebar clamp. Remove the handlebar and lay it to one side. Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines. Remove the two screws . Remove the handlebar support.

  • Page 35: Checking Gas Bowden Cable Route

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking gas Bowden cable route 500201-10 Checking play in the gas Bowden cable 400192-10 Adjusting the gas Bowden cable play 400269-10 The two gas Bowden cables must run parallel behind the handlebar down to the frame.

  • Page 36: Checking Chain Dirt

    Chain wear is not always even, so you should repeat this measurement at different chain positions. Chain tension » If the chain tension does not meet specifications: Adjusting chain tension - after checking. ( Remove the motorcycle from the work stand. ( 8… 10 mm (0.31… 0.39 in) P. 37) P. 21)

  • Page 37: Checking The Chain Tension When Fitting Rear Wheel

    When you replace the chain, you should also replace the rear and engine sprockets. New chains wear out faster on old, worn sprockets. Remove the motorcycle from the work stand. ( 8… 10 mm (0.31… 0.39 in) P. 37) 10… 15 kg (22.05… 33.07 lb.) 272 mm (10.71 in)

  • Page 38: Adjusting The Chain Tension

    The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length. Chain adjusters can be turned by 180°. Remove the motorcycle from the work stand. ( 8… 10 mm (0.31… 0.39 in) so that the markings on the left and M20x1,5 80 Nm (59.01 lbf ft)

  • Page 39: Adjusting Chain Tension - After Checking

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting chain tension - after checking 500193-13 Adjusting chain tension - fitting rear wheel 500193-11 Loosen nut Loosen nuts Adjust the chain tension by turning the adjusting screws Specification Chain tension Turn the adjusting screws left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks The rear wheel is then correctly aligned.

  • Page 40: Adjusting Chain Guide

    If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further. The brake fluid reservoirs of the front and rear brakes are dimensioned so that they do not need topping up with brake fluid even if the brake linings are worn.

  • Page 41: Checking Free Play Of Hand Brake Lever

    Warning Danger of accidents Reduced braking due to old brake fluid. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. 500195-10 Push the hand brake lever forwards and check free play.

  • Page 42: Topping Up The Front Brake Fluid

    If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 43: Removing Front Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

  • Page 44: Changing The Front Brake Linings

    If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 45: Checking Free Play Of Foot Brake Lever

    Warning Danger of accidents Reduced braking due to old brake fluid. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Disconnect spring Move the foot brake lever backwards and forwards between the end stop and the...

  • Page 46: Adding Rear Brake Fluid

    If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 47: Removing Rear Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

  • Page 48: Changing The Rear Brake Linings

    If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 49: Fitting Front Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE 500210-10 500211-10 Fitting front wheel Warning Danger of accidents Reduced braking due to oil or grease on the brake discs. Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. 500211-11 500212-10 500208-10...

  • Page 50: Removing Rear Wheel

    Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot. Remove the motorcycle from the work stand. ( Pull the front wheel brake and push down hard on the fork several times to align the fork legs.

  • Page 51: Tire Condition Checking

    Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle. The front and rear wheels must be fitted with tires with similar profiles.

  • Page 52: Checking Spoke Tension

    Warning Danger of accidents Unstable riding behavior due to loose spokes. If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop. Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.

  • Page 53: Recharging The Battery

    Switch off the charger after charging. Disconnect the battery. Specification The charge current, charge voltage and charge time must not be exceeded. Charge the battery regularly when the motorcycle is not in use. Mount the seat. ( P. 53) on the battery casing.

  • Page 54: Removing A Fuse

    Replace a burned-out fuse Refit the fuse. Fuse (58011109110) Info If the new fuse burns out, contact an authorized KTM workshop. Replace the protection cover. Install the air filter box lid. ( P. 58) The plug connection is located in front of the fuel tank on the left of the frame.

  • Page 55: Removing The Seat

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the seat 500080-10 Mounting the seat 500068-01 Dismounting the fuel tank 500219-10 500066-10 Remove screw . Lift up the seat at the rear, pull it back and then remove from above. Check parts for damage and wear. Replace damaged or worn parts. Hook the front of the seat into the flange adapter of the fuel tank, lower the rear of the seat and simultaneously push it forwards.

  • Page 56: Installing The Fuel Tank

    MAINTENANCE WORK ON CHASSIS AND ENGINE 500220-10 Installing the fuel tank Danger Fire hazard Fuel can easily catch fire. Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components.

  • Page 57: Cooling System

    Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure. Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 58: Draining Coolant

    Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure. Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 59: Removing Main Silencer

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. Allow the exhaust system to cool down. Do not touch hot components. 500221-10 Fitting the main silencer 500221-11 Glass fiber yarn filling of main silencer The main silencer is filled with glass fiber yarn.

  • Page 60: Fitting Glass Fiber Yarn Filling Of Main Silencer

    MAINTENANCE WORK ON CHASSIS AND ENGINE Fitting glass fiber yarn filling of main silencer 500226-11 Changing glass fiber yarn filling of main silencer Remove glass fiber yarn filling of main silencer. ( Fit the glass fiber yarn filling of the main silencer. ( Dismounting the air filter box lid 500222-10 Installing the air filter box lid...

  • Page 61: Installing The Air Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the air filter 500223-10 Cleaning air filter Warning Environmental hazard Problem materials cause environmental damage. Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info Do not use fuel or kerosene for cleaning the air filter. 500225-01 Adjusting basic position of clutch lever 400195-11...

  • Page 62: Checking Fluid Level Of Hydraulic Clutch

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking fluid level of hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid. 400245-10 Changing fluid level of hydraulic clutch Warning Environmental hazard Problem materials cause environmental damage. Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc.

  • Page 63: Carburetor - Idle

    MAINTENANCE WORK ON CHASSIS AND ENGINE Carburetor - idle 400266-10 Carburetor - adjusting idle 400266-10 The idle setting of the carburetor has a big influence on the starting behavior, stable idling and the response to throttle opening. That means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly.

  • Page 64: Emptying The Carburetor Float Chamber

    Undo the screw (turn it counterclockwise) a few turns and drain the fuel from the float chamber. Tighten screw Stand the motorcycle upright on a horizontal surface. Condition The engine is at operating temperature. Check the engine oil level. The engine oil reaches the top of the viewer »...

  • Page 65: Changing Engine Oil And Oil Filter, Cleaning Oil Screen

    Environmental hazard Problem materials cause environmental damage. Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. 400261-11 Stand the motorcycle on its side stand on a horizontal surface. Place a suitable container under the engine. Remove the oil drain plug with the seal ring.

  • Page 66: Removing The Oil Filter

    Thoroughly clean parts and sealing area. Check parts for damage and wear. Replace damaged or worn parts. Lay the motorcycle on its side and fill the oil filter housing to about gine oil. Fill the oil filter with engine oil and place it in the oil filter container.

  • Page 67: Topping Up Engine Oil

    MAINTENANCE WORK ON CHASSIS AND ENGINE Topping up engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. 400265-10 Check the engine oil level. ( P. 62) Remove the screw cap on the clutch cover and fill up with engine oil. Engine oil (SAE 10W/50) ( P.

  • Page 68: Troubleshooting

    Do not touch parts of the ig- nition system. Have work on the ignition system carried out in an authorized KTM workshop. Remove spark plug, connect ignition cable, hold spark plug to ground (bare metal area on engine), and try to start the engine.
  • Page 69 TROUBLESHOOTING Faults Engine has no idle. Engine does not speed up. Engine has too little power. Engine stalls or is popping into the carbu- retor Engine overheats. High oil consumption Battery discharged Possible cause Ignition system defective Carburetor running over because float needle dirty or worn Loose carburetor jets Electronic ignition adjustment defective...

  • Page 70: Cleaning

    Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info If you clean the motorcycle regularly, its value and appearance are maintained over a long period. Avoid direct sunshine on the motorcycle during cleaning.

  • Page 71: Storage

    KTM recommends jacking up the motorcycle. Jack up the motorcycle. ( P. 21) Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Info Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust.

  • Page 72: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design Displacement Stroke Bore Compression ratio Idle speed Control Valve diameter, intake Valve diameter, exhaust Valve clearance, cold, intake Valve clearance, cold, exhaust Crankshaft bearing Conrod bearing Piston pin bearing Pistons Piston rings Engine lubrication Primary transmission Transmission ratio 1st gear 2nd gear...

  • Page 73: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES Engine housing vent jet Oil jet, piston cooling Oil jet, cam lever lubrication Oil jet, clutch oil supply Screw, locking lever Screw, camshaft bearing retaining bracket Screw, timing train axle retaining bracket Screw, ignition pulse generator Screw, ignition pulse generator adapter Screw, stator cable holder Screw, bearing bolt of oil pump idler...
  • Page 74 TECHNICAL DATA - ENGINE TIGHTENING TORQUES Stud, cylinder head Screw, engine sprocket Spark plug Screw-in studs for clutch cover Oil drain plug with magnet Axle guide rail for timing chain Axle tension rail for timing chain Nut, compensating sprocket Oil suction pipe Oil pressure regulator valve plug Nut, inner clutch hub Plug, timing chain tensioner...

  • Page 75: Technical Data - Carburetor

    TECHNICAL DATA - CARBURETOR Carburetor type Carburetor identfication number Needle position Idle mixture adjusting screw Open Pump membrane stop Hot start button Diameter of bore in carburetor body Main jet Jet needle Idling jet Main air jet Idle air jet Cold start jet Throttle slide KEIHIN FCR-MX 41...

  • Page 76: Technical Data - Chassis

    4Ah battery Front tire 125/80 R 420 TL Dunlop KR106 For further information, see: http://www.ktm.com Central tube frame made of chrome molybdenum steel tubing WP 4860 MXMA CC 280 mm (11.02 in) 310 mm (12.2 in) 14 mm (0.55 in) 16 mm (0.63 in)

  • Page 77: Capacity - Fuel

    TECHNICAL DATA - CHASSIS Capacity - fuel Tank capacity 8.2 l (2.17 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( P. 82)

  • Page 78: Technical Data - Fork

    TECHNICAL DATA - FORK Fork part number Fork Compression damping Standard Rebound damping Standard Spring length with preload spacer(s) Spring rate Weight of rider: 65… 75 kg (143.3… 165.34 lb.) Weight of rider: 75… 85 kg (165.34… 187.39 lb.) Weight of rider: 85… 95 kg (187.39… 209.44 lb.) Gas pressure Fork length Capacity - fork oil...

  • Page 79: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number Shock absorber Compression damping, low-speed Standard Compression damping, high-speed Standard Rebound damping Standard Spring preload Spring rate Weight of rider: 65… 75 kg (143.3… 165.34 lb.) Weight of rider: 75… 85 kg (165.34… 187.39 lb.) Weight of rider: 85…...

  • Page 80: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES Spoke nipple, front wheel Spoke nipple, rear wheel Remaining nuts, chassis Remaining screws, chassis Screw, rear brake disc Screw, front brake disc Screw, shock absorber adjusting ring Screw, ball joint of push rod on foot- brake cylinder Nut, rear sprocket screw Nut, rim lock...

  • Page 82: Wiring Diagram

    WIRING DIAGRAM Wiring diagram blue-white brown yellow-black green blue yellow black red-white white grey-black grey yellow yellow yellow-black blue yellow black red-white black-white brown black black red-white red-white black-white 400277-10...
  • Page 83 WIRING DIAGRAM Components Battery Generator Ignition coil Pulse generator Voltage regulator/rectifier Starter button Starter relay Starter motor Short circuit button Throttle valve sensor TPS Ignition curve plug connection CDI controller Cable colors black black black-white black-white brown brown brown-white brown-white blue blue blue-white...

  • Page 84: Substances

    DIN EN 228 (ROZ 95 / RON 95 / PON 91) Brake fluid DOT 5.1 according to Specification Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Motorex Supplier Motorex ® Motorex Brake Fluid DOT 5.1...
  • Page 85 SUBSTANCES Supplier Motorex ® Motorex Racing Fork Oil...

  • Page 86: Auxiliary Substances

    AUXILIARY SUBSTANCES Universal oil spray Specification ® KTM recommends Motorex products. Supplier Motorex ® Motorex Joker 440 Universal Long-life grease Specification ® KTM recommends Motorex products. Supplier Motorex ® Motorex Long Therm 2000 Chain cleaner Specification ® KTM recommends Motorex products.
  • Page 87 AUXILIARY SUBSTANCES High-luster polish for paint Specification ® KTM recommends Motorex products. Supplier Motorex ® Motorex Moto Polish Contact spray Specification ® KTM recommends Motorex products. Supplier Motorex ® Motorex Accu Contact...
  • Page 88 Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the fore- ground for motorcycle engines. With most motorcycles, the gearbox and the clutch are lubricated with the oil as the engine. The JASO MA Standard meets these special requirements.
  • Page 89 INDEX Accessories ........5 Air filter cleaning .
  • Page 90 Removing glass fiber yarn filling ....57 Maintenance ........5 Motorcycle cleaning .
  • Page 91 *3211243en* 3211243en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

This manual is also suitable for:

450 smr 2008

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