KTM 450 XC User manual

OWNER'S MANUAL 2009
450 XC ATV
525 XC ATV
ART. NO. 3211377en

DEAR KTM CUSTOMER 1
DEAR KTM CUSTOMER
Congratulations on your decision to buy a KTM ATV. You are now the owner of a state-of-the-art sports ATV that will give you enormous
pleasure if you service and maintain it accordingly.
We wish you great pleasure riding the vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( p. 26) Dealer's stamp
Engine number ( p. 27)
Key number ( p. 27)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing devel-
opment and design can however not be completely excluded.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications,
prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to
local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, devi-
ations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special equipment that
does not belong to the regular scope of delivery.

DEAR KTM CUSTOMER 2
© 2008 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes that
lead to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

CONTENTS 3
CONTENTS
MEANS OF REPRESENTATION ............................................... 7
IMPORTANT NOTES............................................................... 8
Overview of labels............................................................. 12
VIEW OF VEHICLE................................................................ 22
View of the vehicle from the left front (symbol display)......... 22
View of the vehicle from the right rear (symbol display) ........ 24
LOCATION OF SERIAL NUMBERS ......................................... 26
Chassis number................................................................ 26
Type label........................................................................ 26
Key number ..................................................................... 27
Engine number................................................................. 27
Setting number, front shock absorber ................................. 28
Setting number, rear shock absorber .................................. 28
OPERATING ELEMENTS....................................................... 29
Clutch lever ..................................................................... 29
Reverse gear release lever ................................................. 29
Handbrake lever, parking brake.......................................... 30
Throttle lever.................................................................... 31
Light switch ..................................................................... 31
Light switch ..................................................................... 32
ENG. STOP switch............................................................ 32
ENG. STOP switch............................................................ 33
Electric starter button ....................................................... 33
Electric starter button ....................................................... 34
Ignition switch ................................................................. 34
Indicator lamp overview .................................................... 35
Emergency OFF switch with rip cord................................... 35
Opening filler cap............................................................. 36
Closing filler cap .............................................................. 36
Fuel tap........................................................................... 37
Choke.............................................................................. 38
Hot start button................................................................ 38
Shift lever........................................................................ 39
Foot brake pedal .............................................................. 40
TIPS ON PUTTING INTO OPERATION .................................... 41
Advice on first use............................................................ 41
Running in the engine....................................................... 44
RIDING INSTRUCTIONS ....................................................... 45
Checks before putting into operation .................................. 45
Starting ........................................................................... 46
Starting up ...................................................................... 48
Shifting ........................................................................... 48
Shifting to reverse gear ..................................................... 49
Disengaging reverse gear ................................................... 49
Braking ........................................................................... 50
Riding ............................................................................. 51
Riding in bends................................................................ 52
Riding downhill ................................................................ 53
Riding uphill.................................................................... 54
Riding perpendicular to the slope....................................... 55
Turning on slopes ............................................................. 55
Riding through water ........................................................ 57
Switching off the engine ................................................... 57
Stopping, parking ............................................................. 58
Refueling......................................................................... 60
SERVICE SCHEDULE............................................................ 61
Important maintenance work to be carried out by an
authorized KTM workshop. ................................................ 61

CONTENTS 4
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order)................... 63
Important checks and maintenance work to be carried out
by the rider...................................................................... 65
MAINTENANCE ON CHASSIS AND ENGINE ........................... 66
Jacking up the vehicle ...................................................... 66
Removing the vehicle from the work stand .......................... 66
Basic information on changing the chassis settings.............. 66
Front shock absorber - adjusting the compression
damping .......................................................................... 67
Front shock absorber - adjusting the rebound damping......... 68
Front shock absorber - adjusting the cross over.................... 70
Front shock absorber - adjusting the spring preload ............. 71
Rear shock absorber - adjusting the compression damping ... 73
Rear shock absorber - adjusting the rebound damping.......... 75
Rear shock absorber - adjusting the spring preload x......... 76
Removing the rear shock absorber x................................. 78
Installing the rear shock absorber x.................................. 80
Checking the toe x......................................................... 80
Adjusting the toe x......................................................... 83
Checking/adjusting camber x........................................... 85
Fork offset ....................................................................... 87
Adjusting the fork offset x............................................... 88
Toe width of rear axle........................................................ 88
Adjusting the toe width of rear axle x............................... 89
Handlebar position ........................................................... 91
Adjusting handlebar position x........................................ 92
Checking play in gas Bowden cable .................................... 94
Adjusting play in gas Bowden cable.................................... 95
Checking the play in the Bowden cable using the reverse
gear release lever.............................................................. 96
Adjusting the play in the Bowden cable using the reverse
gear release lever.............................................................. 96
Checking chain dirt .......................................................... 97
Cleaning the chain............................................................ 97
Checking the chain tension ............................................... 98
Checking rear sprocket / engine sprocket for wear ................ 99
Checking chain wear......................................................... 99
Adjusting chain tension................................................... 101
Greasing the rear wheel eccentric element ........................ 103
Checking brake discs ...................................................... 103
Checking the free play of the hand brake lever .................. 104
Adjusting basic position of handbrake lever....................... 105
Checking front brake fluid level........................................ 106
Topping up the front brake fluid x.................................. 106
Checking the front brake linings....................................... 108
Removing front brake linings x...................................... 109
Mounting front brake linings x....................................... 110
Changing the front brake linings x................................. 111
Checking free play of foot brake lever ............................... 113
Adjusting basic position of footbrake lever x................... 114
Checking rear brake fluid level......................................... 115
Topping up brake fluid of front brake x........................... 116
Checking rear brake linings ............................................. 118
Removing rear brake linings x........................................ 119
Mounting the rear brake linings x................................... 120
Changing rear brake linings x........................................ 122
Removing wheel/wheels................................................... 123

CONTENTS 5
Mounting wheel/wheels ................................................... 124
Tire condition checking................................................... 125
Checking tire air pressure................................................ 126
Removing the battery...................................................... 126
Installing the battery....................................................... 127
Recharging the battery x............................................... 128
Changing main fuse........................................................ 130
Changing the fuses of individual power-consuming
components ................................................................... 131
Ignition curve plug connection......................................... 133
Changing ignition curve................................................... 133
Removing the seat.......................................................... 134
Mounting the seat .......................................................... 134
Removing the radiator spoiler .......................................... 135
Installing the radiator spoiler ........................................... 136
Removing the front cover................................................. 137
Installing the front cover ................................................. 138
Removing the front trim .................................................. 138
Installing the front trim................................................... 140
Removing the rear fender ................................................ 140
Installing the rear fender................................................. 142
Removing the engine guard ............................................. 144
Installing the engine guard .............................................. 144
Removing the air filter x............................................... 145
Installing the air filter x................................................ 147
Cleaning air filter x....................................................... 147
Adjusting basic position of clutch lever............................. 148
Checking fluid level of hydraulic clutch ............................ 149
Cooling system ............................................................... 150
Radiator fan................................................................... 150
Checking antifreeze and coolant level............................... 151
Checking the coolant level............................................... 152
Draining coolant x........................................................ 153
Filling coolant / bleeding cooling system x...................... 156
Carburetor - idle ............................................................. 158
Carburetor - adjusting idle x.......................................... 159
Emptying the carburetor float chamber x........................ 161
Checking engine oil level................................................. 162
Changing engine oil and oil filter, cleaning oil
screens x..................................................................... 163
Draining engine oil, cleaning oil screens x...................... 163
Removing the oil filter x................................................ 166
Mounting the oil filter x................................................ 168
Filling up with engine oil x............................................ 168
Topping up engine oil ..................................................... 169
TROUBLESHOOTING.......................................................... 171
CLEANING......................................................................... 177
Cleaning the vehicle ....................................................... 177
STORAGE .......................................................................... 179
Storage.......................................................................... 179
Putting the vehicle into operation after storage.................. 180
TECHNICAL DATA - ENGINE............................................... 181
Capacity - engine oil ....................................................... 182
Capacity - coolant........................................................... 182
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 183
TECHNICAL DATA - CARBURETOR...................................... 186
TECHNICAL DATA - CHASSIS ............................................. 187
Lighting equipment ........................................................ 189

CONTENTS 6
Tires ............................................................................. 189
Capacity - fuel................................................................ 189
TECHNICAL DATA - FRONT SHOCK ABSORBER................... 190
TECHNICAL DATA - REAR SHOCK ABSORBER..................... 191
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 192
SUBSTANCES.................................................................... 194
AUXILIARY SUBSTANCES................................................... 197
STANDARDS...................................................................... 200
INDEX ............................................................................... 201

MEANS OF REPRESENTATION 7
1MEANS OF REPRESENTAT ION
Symbols used
The symbols used are explained in the following.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
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 vehicle will be serviced optimally by
specially trained experts using the specialist tools required.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained in the following.
Specific name Identifies a specific name.
Name®Identifies a protected name.
Brand™ Identifies a brand in merchandise traffic.

IMPORTANT NOTES 8
2IMPORTANT NOTES
Use definition
KTM ATVs are designed and built to withstand the normal stresses and strains of competitive use. The vehicles comply with currently valid
regulations and categories of the top international motorsport organizations.
Warning
Danger of accidents Incorrect assessment of riding situations.
–The vehicle may only be ridden by persons over the age of 16.
Info
The ATV must be used only on secluded property remote from public road traffic.
The ATV is designed for off-road sport endurance competition (Enduro) and not for the predominant motocross use.
Maintenance
A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in
the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of
components.
Using the vehicle in extreme conditions such as very muddy or wet terrain can lead to above-average wear of components such as the
transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the
service schedule is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will
ensure a much longer service life for your vehicle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.

IMPORTANT NOTES 9
Spare parts, accessories
For your own safety, only use spare parts and accessories that have been approved and/or recommended by KTM and have them installed
by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
Work rules
When assembling the equipment, non-reusable parts (e.g. self-locking screws and nuts, seals, seal rings, O-rings, pins, lock washers) must
be replaced with new parts.
If a thread locker (e.g. Loctite®) is used for screw connections, follow the instructions for use from the manufacturer.
Parts that are to be reused after being disassembled should be cleaned and checked for damage and wear. Replace damaged or worn
parts.
After finishing the repair and maintenance work, ensure that the vehicle is roadworthy.
Transport
Note
Danger of damage Danger of damage from accidental rolling of vehicle.
–Park the vehicle on a surface that is as horizontal as possible and activate the parking brake.
Note
Fire hazard Some components (engine, radiator and exhaust system) get very hot when the engine is running.
–Do not place the vehicle where there are flammable or explosive substances.
–Switch off the engine.
–Turn the handle of the fuel tap to OFF. (Figure 100013-10 p. 37)
–Use straps or other suitable devices to secure the vehicle against accidents or falling over.
–Pull handbrake lever, push the locking pawl downwards, and release the handbrake lever. (Figure 100006-10 p. 30)

IMPORTANT NOTES 10
Environment
Offroad riding is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential problem
for the environment and can lead to conflicts with other persons. But if you use your vehicle responsibly, you can ensure that such prob-
lems and conflicts do not have to occur. To protect the future of offroad sport, make sure that you use your ATV legally, display environ-
mental consciousness, and respect the rights of others.
Rider training
If you have never ridden an ATV before, it is important that you participate in a driver training course before you ride the vehicle for the
first time.
A professional trainer will show you how to handle your ATV safely in various riding situations and on different terrain.
Your KTM dealer will be glad to advise you.

IMPORTANT NOTES 11

IMPORTANT NOTES 12
2.1Overview of labels
700376-01

IMPORTANT NOTES 13
1 Hangtag
2 Information on use
3 Emission control 450 XC ATV
3 Emission control 525 XC ATV
4 Warning label
5 Information on not riding as a passenger
6 Information on putting into operation
7 Information on chain tension

IMPORTANT NOTES 14
700367-01
Hangtag

IMPORTANT NOTES 15
700372-01
Information on use
700373-01
Emission control 450 XC ATV

IMPORTANT NOTES 16
700374-01
Emission control 525 XC ATV

IMPORTANT NOTES 17
700368-01
Warning label

IMPORTANT NOTES 18
700370-01
Information on not riding as a passenger
700371-01
Information on putting into operation