OWNER'S MANUAL 2008 450 SMR ART. NO. 3211243en DEAR KTM CUSTOMER 1 Congratulations on your decision to purchase 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 ( P. 9) Dealer's stamp Engine number ( P. 9) 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. 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 MEANS OF REPRESENTATION ............................................ 4 IMPORTANT NOTES ............................................................ 5 VIEW OF VEHICLE............................................................... 7 View of vehicle, front left side........................................... 7 View of vehicle, rear right side .......................................... 8 LOCATION OF SERIAL NUMBERS ........................................ 9 Chassis number............................................................... 9 Type label....................................................................... 9 Engine number................................................................ 9 Fork part number............................................................. 9 Shock absorber part number............................................. 9 OPERATING ELEMENTS.................................................... 10 Clutch lever .................................................................. 10 Hot start lever ............................................................... 10 Hand brake lever ........................................................... 10 Short circuit button ....................................................... 10 Electric starter button .................................................... 10 Fuel tap........................................................................ 11 Opening filler cap .......................................................... 11 Closing filler cap ........................................................... 11 Choke........................................................................... 11 Shift lever..................................................................... 12 Foot brake pedal ........................................................... 12 Plug-in stand ................................................................ 12 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION...................................................................... 13 Advice on first use......................................................... 13 Running in the engine.................................................... 14 RIDING INSTRUCTIONS .................................................... 15 Checks before putting into operation ............................... 15 Starting ........................................................................ 15 Starting up ................................................................... 16 Shifting, riding.............................................................. 16 Braking ........................................................................ 16 Stopping, parking .......................................................... 16 Refueling...................................................................... 17 GREASING AND SERVICE TABLE ....................................... 18 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.............. 21 Jacking up the motorcycle .............................................. 21 Removing the motorcycle from the work stand.................. 21 Checking the basic chassis setting with the rider's weight .......................................................................... 21 Compression damping of shock absorber.......................... 21 Adjusting high-speed compression damping of the shock absorber ....................................................................... 21 Adjusting the low-speed compression damping of the shock absorber .............................................................. 22 Adjusting rebound damping of the shock absorber ............ 22 Measuring rear wheel sag unloaded ................................. 23 Checking static sag of the shock absorber ........................ 23 Check the riding sag of the shock absorber. ..................... 23 24 Adjusting spring preload of the shock absorber 24 Adjusting riding sag Removing the shock absorber 25 25 Installing shock absorber Checking basic setting of fork ......................................... 25 Adjusting compression damping of fork ........................... Adjusting rebound damping of fork.................................. Bleeding fork legs.......................................................... Cleaning dust boots of fork legs ...................................... Removing the fork protector............................................ Installing the fork protector ............................................ Checking play of steering head bearing ............................ Adjusting play of steering head bearing Fork offset .................................................................... Setting the fork offset ............................................... Removing the fork legs Installing the fork legs ................................ Removing the lower triple clamp Installing the lower triple clamp Greasing the steering head bearing Dismounting the front fender .......................................... Installing the front fender............................................... Dismount the start number plate..................................... Fitting the start number plate ......................................... Handlebar position ........................................................ Adjusting handlebar position Checking gas Bowden cable route ................................... Checking play in the gas Bowden cable ........................... Adjusting the gas Bowden cable play Checking chain dirt ....................................................... Cleaning the chain......................................................... Checking the chain tension ............................................ Checking the chain tension when fitting rear wheel........... Checking the rear sprocket / engine sprocket for wear ....... Checking chain wear ...................................................... Adjusting the chain tension ............................................ Adjusting chain tension - after checking .......................... Adjusting chain tension - fitting rear wheel ...................... ............................................... Adjusting chain guide Brake fluid reservoir....................................................... Brake calipers ............................................................... Checking brake discs ..................................................... Checking free play of hand brake lever............................. Adjusting basic position of handbrake lever...................... Checking front brake fluid level....................................... Topping up the front brake fluid Checking the front brake linings...................................... Removing 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 rear brake fluid level .................................. Adding rear brake fluid Checking rear brake linings ............................................ Removing rear brake linings Installing the rear brake linings Changing the rear brake linings Removing front wheel .................................................... Fitting front wheel Removing rear wheel Fitting rear wheel Tire condition checking.................................................. Checking tire air pressure............................................... Checking spoke tension.................................................. Removing the battery 2 25 26 26 26 27 27 27 28 28 29 29 29 30 30 31 31 31 32 32 32 32 33 33 33 34 34 34 35 35 35 36 37 37 38 38 38 38 39 39 39 40 40 41 41 42 43 43 43 44 44 45 45 46 46 47 48 48 49 49 50 50 x x.............................................. x............................................... x x................................. x............................. x...................................... x.......................... x....................... x x............ x.................................................. x..................................... x........................................... x................................. x...................................... x...................................... x................................. x................... x.............................................. x....................................... x.................................. x.................................. x................................................ x x................................................. x...................................................... x................................................ CONTENTS Installing the battery Recharging the battery Removing a fuse............................................................ Replacing the fuse......................................................... Ignition curve plug connection ........................................ Changing the ignition curve ............................................ Removing the seat ......................................................... Mounting the seat ......................................................... ......................................... Dismounting the fuel tank Installing the fuel tank Cooling system .............................................................. Checking antifreeze and coolant level .............................. Checking the coolant level.............................................. Draining coolant Refilling coolant Removing main silencer ................................................. Fitting the main silencer ................................................ Glass fiber yarn filling of main silencer ............................ Removing glass fiber yarn filling of main silencer Fitting glass fiber yarn filling of main silencer Changing glass fiber yarn filling of main silencer Dismounting the air filter box lid..................................... Installing the air filter box lid.......................................... Removing the air filter ............................................... Installing the air filter Cleaning air filter Adjusting basic position of clutch lever............................ Checking fluid level of hydraulic clutch ........................... ...................... Changing fluid level of hydraulic clutch Carburetor - idle ............................................................ Carburetor - adjusting idle Emptying the carburetor float chamber Checking engine oil level................................................ Changing engine oil and oil filter, cleaning oil screen Draining engine oil Cleaning the oil screen Removing the oil filter Mounting oil filter Filling up with engine oil Topping up engine oil .................................................... TRO ...