KTM 450 XC-F (2008) Manual
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OWNER'S MANUAL 2008
450 SX-F
505 SX-F
450 XC-F
505 XC-F
ART. NO. 3211227en
Dear KTM customer 1
Congratulations on your decision to buy a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle 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 ( 7) Dealer's stamp
Engine number ( 7)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing
development and design of our motorcycles can however not be completely excluded. The owner's manual is an important component
of the motorcycle and should be handed over to the new owner if the vehicle is sold.
All specifications are not binding. KTM Sportmotorcycle AG in particular 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 prudction of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations 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.
© 2007 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 2
MEANS OF REPRESENTATION ............................................ 4
IMPORTANT NOTES............................................................ 5
LOCATION OF SERIAL NUMBERS ........................................ 7
Chassis number............................................................... 7
Type label............ ........................................... ................ 7
Engine number................................................................ 7
Fork part number............ ....... 7............ ..............................
Shock absorber part number............................................. 7
OPERATING ELEMENTS...................................................... 8
Clutch lever .................................................................... 8
Hot start lever ................................................................. 8
Hand brake lever ............................................................. 8
Short circuit button ......................................................... 8
Electric starter button ...................................................... 8
Fuel tap (450 SX-F, 505 SX-F)........................................ 9
Fuel tap (450 XC-F, 505 XC-F) ......................................... 9
Opening filler cap ........... ................................. ................ 9
Closing filler cap ............ ....... 10..................... ...................
Choke........................................................................... 10
Shift lever..................................................................... 10
Foot brake pedal ............ ....... 11..................... ...................
Plug-in stand (450 SX-F, 505 SX-F)................................ 11
Side stand (450 XC-F, 505 XC-F) ................................... 11
TIPS AND HINTS ON PUTTING INTO OPERATION............... 12
Advice on first use............................... ................... ....... 12
Running in the engine.................................................... 13
RIDING INSTRUCTIONS .................................................... 14
Checks before putting into operation ............................... 14
Starting .............................................. ................... ....... 14
Starting up ............. ............................................... ....... 15
Shifting, riding .............................................................. 15
Braking .............................................. ................... ....... 15
Stopping, parking ........... ............................... ................ 16
Refueling...................................................................... 16
GREASING AND SERVICE TABLE ........ ....... 17........................
Important maintenance work to be carried out by an
authorized KTM workshop. ............................................. 17
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order)................ 18
Important checks and maintenance work to be carried out
by the rider. .................................................................. 18
MAINTENANCE WORK ON CHASSIS AND ENGINE.............. 20
Jacking up the motorcycle........... ....... 20......... ...................
Removing the motorcycle from the work stand .................. 20
Checking the basic chassis setting with the rider's
weight ................................................ ................... ....... 20
Compression damping of shock absorber.......................... 20
Adjusting high-speed compression damping of the shock
absorber ............................................. ................... ....... 20
Adjusting the low-speed compression damping of the
shock absorber.............................................................. 21
Adjusting rebound damping of the shock absorber ............ 21
Measuring rear wheel sag unloaded ................................. 22
Checking static sag of the shock absorber ........................ 22
Check the riding sag of the shock absorber. ..................... 23
Adjusting spring preload of the shock absorber x............ 23
Adjusting riding sag x.................................................. 24
Removing the shock absorber x..................................... 24
Installing shock absorber x........................................... 24
Checking basic setting of fork ......................................... 25
Adjusting compression damping of fork ........ ....... 25............
Adjusting rebound damping of fork.................................. 25
Bleeding fork legs........................ ................... ............... 26
Cleaning dust boots of fork legs .............. ................... ..... 26
Loosening the fork protection.................. ................... ..... 26
Positioning the fork protection ........................................ 27
Checking play of steering head bearing............................ 27
Adjusting play of steering head bearing x....................... 27
Fork offset .................................. ................... ............... 28
Setting the fork offset x............................................... 28
Removing the fork legs x.............................................. 28
Installing the fork legs x............................................... 29
Removing the fork protector x....................................... 29
Installing the fork protector x....................................... 29
Removing the lower triple clamp x................................ 30
Installing the lower triple clamp x................................. 30
Greasing the steering head bearing x............................. 31
Dismounting the front fender.................. ................... ..... 31
Installing the front fender............................................... 31
Dismount the start number plate..................................... 31
Fitting the start number plate ......................................... 32
Handlebar position ...................... ................... ............... 32
Adjusting handlebar position x...................................... 32
Checking gas Bowden cable route ................................... 32
Checking play in gas Bowden cable ................................. 33
Adjusting play in gas Bowden cable x............................ 33
Checking chain dirt ..................... ................... ............... 33
Cleaning the chain........... .......... ...................... ......... ..... 33
Checking the chain tension .................... ................... ..... 34
Checking the chain tension - fitting rear wheel ................. 34
Checking rear sprocket / engine sprocket for wear ............. 35
Checking chain wear........ .......... ...................... ......... ..... 35
Adjusting chain tension.................................................. 35
Adjusting chain tension - after checking .......................... 36
Adjusting chain tension - fitting rear wheel ...................... 37
Adjusting chain guide x(450 SX-F, 505 SX-F)............... 37
Adjusting chain guide x(450 XC-F, 505 XC-F)............... 38
Brake fluid reservoir..................... ................... ............... 38
Brake calipers ............................................................... 38
Checking brake discs ..................................................... 38
Checking free play of hand brake lever............................. 39
Adjusting basic position of handbrake lever...................... 39
Checking front brake fluid level....................................... 39
Topping up the front brake fluid x................................. 40
Checking the front brake linings...................................... 40
Removing front brake linings x..................................... 41
Mounting front brake linings x...................................... 41
Changing the fron brake linings x.................................. 42
Checking free play of foot brake lever .............................. 42
Adjusting basic position of footbrake lever x................... 43
Checking rear brake fluid level................ ................... ..... 43
Topping up brake fluid of front brake x.......................... 44
Checking rear brake linings .................... ................... ..... 44
Removing rear brake linings x....................................... 45
Mounting rear brake linings x....................................... 45
Changing rear brake linings x....................................... 46
Removing front wheel x................................................ 46
Fitting front wheel x.................................................... 47
Removing rear wheel x................................................. 48
Fitting rear wheel x...................................................... 48
Tire condition checking.................................................. 49
Checking tire air pressure............................................... 49
Checking spoke tension.................................................. 50
CONTENTS 3
Removing the battery x................................................ 50
Installing the battery x................................................. 50
Recharging the battery x.............................................. 51
Removing a fuse............................................................ 52
Replacing the fuse............................... ................... ....... 52
Ignition curve................................................................ 52
Ignition curve plug connection........................................ 52
Changing ignition curve.................................................. 53
Removing the seat ......................................................... 53
Mounting the seat ............................... ................... ....... 53
Dismounting the fuel tank x......................................... 53
Installing the fuel tank x.............................................. 54
Cooling system .............................................................. 55
Checking antifreeze and coolant level ........... ....... 55............
Checking the coolant level........... ....... 56......... ...................
Draining coolant x....................................................... 56
Refilling coolant x....................................................... 57
Removing main silencer ................................................. 57
Fitting the main silencer .......... ...................... ................ 57
Glass fiber yarn filling of main silencer ............................ 57
Removing glass fiber yarn filling from the main
silencer x................................................................... 58
Fitting glass fiber yarn filling in main silencer x............. 58
Changing glass fiber yarn filling of main silencer x......... 59
Dismounting the air filter box lid ..................................... 59
Installing the air filter box lid................ ................... ....... 59
Removing the air filter x............................................... 59
Installing the air filter x............................................... 60
Cleaning air filter x...................................................... 60
Adjusting basic position of clutch lever............................ 60
Checking fluid level of hydraulic clutch ........ ....... 60............
Changing fluid level of hydraulic clutch x...................... 61
Carburetor - idle ............................................................ 61
Carburetor - adjusting idle x......................................... 62
Emptying the carburetor float chamber x....................... 63
Checking engine oil level.......... ...................... ................ 63
Changing engine oil and oil filter, cleaning oil screen x... 64
Draining the engine oil x.............................................. 64
Cleaning the oil screen x.............................................. 64
Removing the oil filter x............................................... 65
Mounting oil filter x..................................................... 65
Filling up with engine oil x........................................... 66
Topping up engine oil ............ ....... 66.................................
TROUBLESHOOTING......................................................... 67
CLEANING........................................................................ 69
Cleaning motorcycle ...................................................... 69
Storage....................... ............................................... ....... 70
Storage............................................... ................... ....... 70
TECHNICAL DATA - ENGINE........... ................... ................ 71
Capacity- engine oil ....................................................... 72
Capacity- cooling liquid.................................................. 72
TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 73
TECHNICAL DATA - CARBURETOR..................................... 75
TECHNICAL DATA - CHASSIS .................. ................... ....... 76
Capacity - fuel............................................................... 76
TECHNICAL DATA - FORK....... ....... 77....................................
CAPACITY - FORK OIL ................................................... 77
TECHNICAL DATA - SHOCK ABSORBER ............................. 78
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ........ 79
WIRING DIAGRAM ............................................................ 80
WIRING DIAGRAM ........................................................ 80
SUBSTANCES........................ ................................... ........ 82
AUXILIARY SUBSTANCES.................................................. 84
INDEX ................................... ................................... ........ 86
MEANS OF REPRESENTATION 4
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 motorcycle 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.
Original name Identifies an original name
Name®Identifies a protected name
Brand™ Identifies a brand in merchandise traffic
IMPORTANT NOTES 5
Use definition
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply
with currently valid regulations and categories of the top international motorsport organizations.
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 motorcycle 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 greasing and service table 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 motorcycle.
Warranty
The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed
in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for
damage resulting from manipulations and alterations to the motorcycle.
Fuel, oils, etc.
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
resulting damage or loss.
Transport
Note
Danger of damage Danger of damage by the motorcycle running away or falling over.
Always place the motorcycle on a firm and even surface.
Note
Fire hazard Some components (engine, radiator and exhaust system) get very hot when the engine is running.
Do not place the motorcycle where there are flammable or explosive substances.
(450 XC-F, 505 XC-F)
Turn the handle of the fuel tap to the ON position. (Figure 400201-10 9)
(450 SX-F, 505 SX-F)
Turn the handle of the fuel tap to the OFF position. (Figure 400200-10 9)
Use straps or other suitable devices to secure the motorcycle against accidents or falling over.
Environment
Offroad motorcycling 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 motorcycle responsibly, you can ensure
that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle
legally, display environmental consciousness, and respect the rights of others.
Warning notes
In your own interest, read the specified warning notes.
Info
Various warning labels are attached to your motorcycle. Do not remove any warning labels. If they are missing, you or others may
not recognize dangers and may therefore be injured.
Produkt Specifikationer
| Mærke: | KTM |
| Kategori: | Motor |
| Model: | 450 XC-F (2008) |
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