OWNER'S MANUAL 2008 450 XC ATV 525 XC ATV ART. NO. 3211251en DEAR KTM CUSTOMER 1 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 ( Engine number ( Key number ( P. 12) P. 12) Dealer's stamp P. 12) 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 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 production 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 Overview of warning labels................................................ 8 VIEW OF VEHICLE............................................................. 10 Vehicle view, front left ................................................... 10 View of vehicle, rear right ............................................... 11 LOCATION OF SERIAL NUMBERS ...................................... 12 Chassis number............................................................. 12 Type label..................................................................... 12 Key number .................................................................. 12 Engine number.............................................................. 12 Setting number, front shock absorber .............................. 12 Setting number, rear shock absorber ............................... 13 OPERATING ELEMENTS.................................................... 14 Clutch lever .................................................................. 14 Reverse gear release lever .............................................. 14 Hand brake lever, parking brake...................................... 14 Throttle lever................................................................. 14 Light switch .................................................................. 15 ENG. STOP Switch ........................................................ 15 Electric starter button .................................................... 15 Ignition switch .............................................................. 15 Indicator lamp overview ................................................. 15 Emergency OFF switch with rip cord................................ 16 Opening filler cap .......................................................... 16 Closing filler cap ........................................................... 16 Fuel tap........................................................................ 16 Choke........................................................................... 17 Hot start button............................................................. 17 Shift lever..................................................................... 17 Foot brake pedal ........................................................... 17 TIPS ON PUTTING INTO OPERATION ................................. 18 Advice on first use ......................................................... 18 Running in the engine.................................................... 19 RIDING INSTRUCTIONS .................................................... 20 Checks before putting into operation ............................... 20 Starting ........................................................................ 20 Starting up ................................................................... 21 Shifting ........................................................................ 21 shifting to reverse gear ................................................... 22 Disengaging reverse gear ................................................ 22 Braking ........................................................................ 22 Riding .......................................................................... 23 Riding in bends............................................................. 23 Riding downhill ............................................................. 24 Riding uphill................................................................. 24 Riding perpendicular to the slope.................................... 25 Turning on slopes .......................................................... 25 Riding through water ..................................................... 25 Switching off the engine ................................................ 26 Stopping, parking .......................................................... 26 Refueling...................................................................... 27 GREASING AND SERVICE TABLE ....................................... 28 Important maintenance work to be carried out by an authorized KTM workshop. ............................................. 28 Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)................ 29 Important checks and maintenance work to be carried out by the rider. ............................................................ 29 MAINTENANCE ON CHASSIS AND ENGINE ........................ 31 Jacking up the vehicle ................................................... 31 Removing the vehicle from the work stand ....................... 31 Basic information on changing the chassis settings........... Adjusting front shock absorber compression damping ....... Adjusting front shock absorber rebound damping.............. Adjusting front shock absorber cross over......................... Adjusting front shock absorber spring preload .................. Adjusting rear shock absorber compression damping......... Adjusting rear shock absorber rebound damping ............... Adjusting rear shock absorber spring preload Removing the rear shock absorber Installing the rear shock absorber Toe, checking Adjusting the toe Checking/adjusting camber Fork offset .................................................................... Adjusting the fork offset Toe width of rear axle..................................................... Adjusting the toe width of rear axle Handlebar position ........................................................ Adjusting handlebar position Checking play in gas Bowden cable ................................. Adjusting play in gas Bowden cable................................. Checking the play in the Bowden cable using the reverse gear release lever........................................................... Adjusting the play in the Bowden cable using the reverse gear release lever........................................................... Checking chain dirt ....................................................... Cleaning the chain......................................................... Checking the chain tension ............................................ Checking rear sprocket / engine sprocket for wear ............. Checking chain wear ...................................................... Adjusting chain tension.................................................. Greasing the rear wheel eccentric element ....................... 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 rear brake fluid level........................................ Topping up brake fluid of front brake Checking rear brake linings ............................................ Removing rear brake linings ....................................... Mounting rear brake linings Changing rear brake linings Removing wheel/wheels.................................................. Mounting wheel/wheels .................................................. Tire condition checking.................................................. Checking tire air pressure............................................... Removing the battery ..................................................... Installing the battery...................................................... Recharging the battery changing main fuse ....................................................... Changing the fuses of individual power-consuming components .................................................................. Ignition curve plug connection ........................................ Changing ignition curve.................................................. 2 31 31 32 33 33 34 35 36 37 37 37 38 40 41 41 41 41 42 43 43 44 44 44 45 45 45 45 46 46 47 47 48 48 48 49 49 50 50 51 52 52 52 53 54 54 55 55 56 56 57 57 57 58 58 59 59 60 61 x............... x.............................. x............................... x........................................................... x...................................................... x........................................ x............................................ x............................. x...................................... x................................. x...................................... x...................................... x................................. x................... x.......................... x....................................... x x........................................ x.............................................. CONTENTS Removing the seat ......................................................... Mounting the seat ......................................................... Removing the radiator spoiler ......................................... Installing the radiator spoiler .......................................... Removing the front cover................................................ Installing the front cover ................................................ Removing the front trim ................................................. Installing the front trim .................................................. Removing the rear fender ............................................... Installing the rear fender ................................................ Removing the engine guard ............................................ Installing the engine guard ............................................. Removing the air filter ............................................... Installing the air filter Cleaning air filter Adjusting basic position of clutch lever............................ Checking fluid level of hydraulic clutch ........................... Cooling system .............................................................. Radiator fan.................................................................. Checking antifreeze and coolant level .............................. Checking the coolant level.............................................. Draining coolant Filling coolant / bleeding cooling system Carburetor - idle ............................................................ Carburetor - adjusting idle Emptying the carburetor float chamber Checking engine oil level................................................ Changing engine oil and oil filter, cleaning oil screens ..................... Draining engine oil, cleaning oil screens Removing the oil filter Mounting oil filter Filling up with engine oil Topping up engine oil .................................................... TROUBLESHOOTING......................................................... CLEANING... ...