KTM 2007 SMR 450 User manual

ERGÄNZUNG ART. NR. 3.211.152
ZUR BEDIENUNGSANLEITUNG ART. NR. 3.211.145
SUPPLEMENT ART. NO. 3.211.152
TO OWNER’S MANUAL ART. NR. 3.211.145
450/560SMR2007
KTM Sportmotorcycle AG
A–5230 Mattighofen
www.ktm.at
KTM Group Partner

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OPERATION INSTRUMENTS »
Hand brake lever
The basic position of the hand brake lever can be modified by turning the
adjusting screw [1]. This lets you adapt the position of the pressure point (the
resistance you feel on the hand brake lever when the brake pads are pressed
against the brake disk) to fit any hand.
Adjustment of the hand brake lever position is only possible within certain
limits. only turn the adjusting screw manually and never apply excessive
force.
Replacing the front brake pads *
Remove the lock clip. Press the bar on the lock spring [2] while you slide the
bolt [3] from the bracket.
Remove the brake pads [4] from the brake caliper and thoroughly clean the
brake caliper with compressed air. Mount the brake pads. Mount the lock spring
[2] and bolt [3] and hold in place with the lock clip.
It is very important to keep the brake disk free from oil and fatty matters.
Otherwise, the braking effect would be strongly reduced.
After working on the braking system, always actuate the hand brake lever or
foot brake lever, respectively to ensure that the brake pads will lie against the
brake disk and the pressure point is established.
MAINTENANCE WORK ON CHASSIS AND ENGINE »
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4

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TECHNICAL DATA - CHASSIS 450/560 SMR 2007»
STANDARD ADJUSTMENT – FORK
450 / 560 SMR
WP 4860 MXMA PA
14.18.7C.18
Compression adjuster 20
Rebound adjuster 10
Preload Adjuster (turns) 5
Spring 432.485.00.046
Air chamber length 100 mm
Fork oil 4860 0401 Motorex
STANDARD ADJUSTMENT – SHOCK ABSORBER
450 / 560 SMR
WP 5018 PDS DDC
12.18.7C.15
Compression adjuster 13 LS (low speed)
2 HS (high speed)
Rebound adjuster 19
Spring 88/250
Spring preload 9 mm
CHASSIS 450 SMR 560 SMR
Frame Central tube chrome-moly-steel frame
Fork WP Up Side Down 4860 MXMA PA
Wheel travel front/rear 275/310 mm
Rear suspension WP Progressive Damping System shock absorber aluminium swing arm
Front brake Disk brake with carbon-steel brake disc Ø 310 mm brake caliper radial
Rear brake Disk brake with carbon-steel brake disc Ø 220 mm brake caliper floated
Brake disc Wear limit max. 2,5 mm front and 3,5 mm rear
Brake disc front SBS-RSI-97-HH
Brake disc rear TOYO B 143 FF
Front tires Dunlop 120/75-17" KR 106
Air pressure front 1.5 bar
Front rim 3.50x17“
Rear tire Dunlop 170/55-17" KR 108
Air pressure rear 1.6 bar
Rear rim 5,00x17“
Fuel tank capacity 7 liters
Final drive ratio 14:45Z
Chain 5/8 x 1/4"
Available final sprockets 38Z, 40Z, 42Z, 45Z, 48Z, 49Z, 50Z, 51Z, 52Z
Steering head angle 63,5°
Wheel base 1471 ± 10 mm
Seat height, unloaded 855 mm
Ground clearance, unloaded 310 mm
Weight 107.5 Kg 108.5 Kg

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TECHNICAL DATA - CHASSIS 450/560 SMR 2007»
TIGHTENING TORQUES – CHASSIS
Collar screw, front wheel spindle M24x1.5 40 Nm
Brake caliper, MAGURA radial front M10x1.25 Loctite 243 + 40 Nm
Brake disks M6 Loctite 243 + 14 Nm
Clamping screws, upper fork bridge M8 17 Nm
Clamping screws, lower fork bridge M8 12 Nm
Clamping screws, fork stubs M8 15 Nm
Hexagon nut, swing arm bolt M16x1.5 100 Nm
Hexagon collar screw, handlebar clamp M8 20 Nm
Allan head srew, handlebar support M10 Loctite 243 + 40 Nm
Shock absorber, top M12 Loctite 243 + 70 Nm
Shock absorber, bottom M12 Loctite 243 + 70 Nm
Collar nut, swing arm bolt M20x1.5 80 Nm
Sprocket Screws M8 35 Nm
Ball joint for push rod M6 10 Nm
Engine mounting bolt M10 60 Nm
Engine brace M8 33 Nm
Spoke nipple M4.5 / M5 5 Nm
Screw adjusting ring spring preload shock abs. M6 8 Nm
Other screws on chassis M6
M8
M10
10 Nm
25 Nm
45 Nm
Other collar nuts on chassis M6
M8
M10
15 Nm
30 Nm
50 Nm

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TYPE 450 SMR 560 SMR
Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft
Displacement 449.4 cm3565.5 cm3
Bore/Stroke 95 / 63.4 mm 100 / 72 mm
Ratio 12 : 1 11 : 1
Fuel unleaded fuel with at least RON 95 (USA = Premium RON 91)
Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
Camshaft 590/5521
Valve diameter Intake 35 mm (Titan)
Valve diameter Exhaust 30 mm (Titan)
Valve clearence cold Intake 0.1 – 0.15 mm
Valve clearence cold Exhaust 0.1 – 0.15 mm
Crank shaft bearing 2 cylinder roller bearing
Connecting rod bearing needle bearing
Top end bearing bronze bushing
Piston alluminium alloy forged
Piston rings 1 compression ring, 1 oil scraper ring
Engine lubrication pressure circulation lubrication with two rotor pumps
Engine oil full synthetic oil (Motorex Power Synt 4T 10W/50)
Quantity of engine oil 1.25 liters
Primary ratio straight geared spur wheels 33:76 Z
Clutch multi disc clutch in oil bath
Transmission claw shifted 6-speed
Gear ratio
1st Gear 16:32
2nd Gear 18:30
3rd Gear 20:28
4th Gear 22:26
5th Gear 24:24
6th Gear 21:18
Ignition system contactless DC-CDI ignition with digital advanced system by KOKUSAN 4K-3A
Generator 12V 40W
Spark plug NGK DCPR 8 E
Spark plug gap 0,6 mm
Cooling system liquid cooled, permanent rotation of cooling liquid through mechanically driven water pump
Cooling liquid 1 liter, 50% antifreeze, 50% distilled water, at least -25° (-13° F)
Starting equipment kickstarter
BASIC CARBURATOR SETTING
450 SMR 560 SMR
Type Keihin FCR-MX 4122B Keihin FCR-MX 4125E
Main jet 185 190
Jet needle OBDTP OBDTP
Idling jet 40 42
Main air jet 200 200
Idling air jet 100 100
Needle position 4th from top 5th from top
Starting jet 85 85
Mixture control screw open 1,5 1,5
Slide 15 15
Performance restrictor – –
Stop pump membrane 858 / 2.15 mm 858 / 2.15 mm
Hot start device 2.2 mm 2.5 mm
TECHNICAL DATA - ENGINE 450/560 SMR 2007»