KTM 450 SMR User manual

OWNER'S MANUAL 2008

450SMR

ART. NO. 3211243en

DEAR KTM CUSTOMER 1

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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 specifica-

tions, 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.

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

&217(176

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

Adjusting spring preload of the shock absorberx............ 24

Adjusting riding sagx.................................................. 24

Removing the shock absorberx..................................... 25

Installing shock absorberx........................................... 25

Checking basic setting of fork ......................................... 25

Adjusting compression damping of fork ........................... 25

Adjusting rebound damping of fork.................................. 26

Bleeding fork legs.......................................................... 26

Cleaning dust boots of fork legs ...................................... 26

Removing the fork protector............................................ 27

Installing the fork protector ............................................ 27

Checking play of steering head bearing ............................ 27

Adjusting play of steering head bearingx....................... 28

Fork offset .................................................................... 28

Setting the fork offsetx............................................... 29

Removing the fork legsx.............................................. 29

Installing the fork legs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..................................... 32

Fitting the start number plate ......................................... 32

Handlebar position ........................................................ 32

Adjusting handlebar positionx...................................... 32

Checking gas Bowden cable route ................................... 33

Checking play in the gas Bowden cable ........................... 33

Adjusting the gas Bowden cable playx.......................... 33

Checking chain dirt ....................................................... 34

Cleaning the chain......................................................... 34

Checking the chain tension ............................................ 34

Checking the chain tension when fitting rear wheel........... 35

Checking the rear sprocket / engine sprocket for wear ....... 35

Checking chain wear...................................................... 35

Adjusting the chain tension ............................................ 36

Adjusting chain tension - after checking .......................... 37

Adjusting chain tension - fitting rear wheel ...................... 37

Adjusting chain guidex............................................... 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 front brake liningsx................................. 42

Checking free play of foot brake lever .............................. 43

Adjusting basic position of footbrake leverx................... 43

Checking the rear brake fluid level .................................. 43

Adding rear brake fluidx.............................................. 44

Checking rear brake linings ............................................ 44

Removing rear brake liningsx....................................... 45

Installing the rear brake liningsx.................................. 45

Changing the 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

Removing the batteryx................................................ 50

CONTENTS 3

Installing the batteryx................................................. 50

Recharging the batteryx.............................................. 51

Removing a fuse............................................................ 52

Replacing the fuse......................................................... 52

Ignition curve plug connection........................................ 52

Changing the ignition curve ............................................ 52

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.............................................. 55

Draining coolantx....................................................... 56

Refilling coolantx....................................................... 56

Removing main silencer ................................................. 57

Fitting the main silencer ................................................ 57

Glass fiber yarn filling of main silencer............................ 57

Removing glass fiber yarn filling of main silencerx......... 57

Fitting glass fiber yarn filling of main silencerx.............. 58

Changing glass fiber yarn filling of main silencerx.......... 58

Dismounting the air filter box lid..................................... 58

Installing the air filter box lid.......................................... 58

Removing the air filterx............................................... 58

Installing the air filterx............................................... 59

Cleaning air filterx...................................................... 59

Adjusting basic position of clutch lever............................ 59

Checking fluid level of hydraulic clutch ........................... 60

Changing fluid level of hydraulic clutchx...................... 60

Carburetor - idle ............................................................ 61

Carburetor - adjusting idlex......................................... 61

Emptying the carburetor float chamberx....................... 62

Checking engine oil level................................................ 62

Changing engine oil and oil filter, cleaning oil screenx... 63

Draining engine oilx.................................................... 63

Cleaning the oil screenx.............................................. 63

Removing the oil filterx............................................... 64

Mounting oil filterx..................................................... 64

Filling up with engine oilx........................................... 64

Topping up engine oil .................................................... 65

TROUBLESHOOTING......................................................... 66

CLEANING........................................................................ 68

Cleaning motorcycle ...................................................... 68

STORAGE ......................................................................... 69

Storage......................................................................... 69

Putting into operation after storage ................................. 69

TECHNICAL DATA - ENGINE.............................................. 70

Capacity - engine oil ...................................................... 70

Capacity - coolant.......................................................... 70

TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 71

TECHNICAL DATA - CARBURETOR..................................... 73

TECHNICAL DATA - CHASSIS ............................................ 74

Capacity - fuel............................................................... 75

TECHNICAL DATA - FORK.................................................. 76

Capacity - fork oil .......................................................... 76

TECHNICAL DATA - SHOCK ABSORBER ............................. 77

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ........ 78

WIRING DIAGRAM ............................................................ 80

Wiring diagram.............................................................. 80

SUBSTANCES................................................................... 82

AUXILIARY SUBSTANCES.................................................. 84

STANDARDS..................................................................... 86

INDEX .............................................................................. 87

MEANS OF REPRESENTATION 4

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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.

Specific name Identifies a specific name.

Name®Identifies a protected name.

Brand™ Identifies a brand in merchandise traffic.

IMPORTANT NOTES 5

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Use definition

KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com-

ply with currently valid regulations and categories of the top international motorsport organizations.

Info

The motorcycle must be used only on secluded property remote from public road traffic.

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 break-

age 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 re-

sulting damage or loss.

Transport

Note

Danger of damageಗDanger of damage by the vehicle running away or falling over.

ಥAlways place the vehicle on a firm and even surface.

Note

Fire hazardಗSome components (engine, radiator and exhaust system) get very hot when the engine is running.

ಥDo not place the vehicle where there are flammable or explosive substances.

ಥswitch off engine.

ಥTurn the handleof the fuel tap to theOFF position.

ಥUse 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 poten-

tial problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can en-

sure that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your mo-

torcycle 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 vehicle. Do not remove any warning labels. If they are missing, you or others may

not recognize dangers and may therefore be injured.

IMPORTANT NOTES 6

Grades of risks

Danger

Danger that leads immediately and certainly to severe and permanent injury or death.

Warning

Danger that will probably lead to severe and permanent injury or death.

Note

Danger of serious damage to machine or material.

Warning

Risk of environmental damage.

OWNER'S MANUAL

ಥRead this owner's manual carefully and completely before making your first trip. It contains a lot of information and tips to help

you operate and handle your motorcycle. Only then will you find out how to customize the motorcycle ideally for your own use and

how you can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.

ಥThe owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is

sold.

VIEW OF VEHICLE 7

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

View of vehicle, front left side

500182-10

1 Hand brake lever

2 Start number plate

3 Front fender

4 Front wheel

5 Fork part number

6 Oil filter cover

7 Plug-in stand

8 Shift lever

9 Choke button

10 Air filter

11 Filler cap

12 Clutch lever

VIEW OF VEHICLE 8

View of vehicle, rear right side

500183-10

1 Main silencer

2 Shock absorber

3 Brake caliper of rear wheel brake

4 Rear wheel

5 Foot brake pedal

6 Manifold

7 Chassis number/type label

8 Throttle grip

LOCATION OF SERIAL NUMBERS 9

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

Chassis number

400193-10

The chassis numberis stamped on the steering head on the right.

Type label

400284-10

The type labelis fixed to the front of the steering head.

Engine number

400194-10

The engine numberis stamped on the left side of the engine under the engine

sprocket.

Fork part number

500175-10

The fork part numberis stamped on the inner side of the fork stub.

Shock absorber part number

500083-10

The shock absorber part numberis stamped on the top of the shock absorber above

the adjusting ring on the engine side.

OPERATING ELEMENTS 10

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

Clutch lever

400195-10

The clutch leveris fitted on the left side of the handlebar.

The clutch is hydraulically operated and self-adjusting.

Hot start lever

400195-12

The hot start leveris fitted on the left side of the handlebar.

If you pull the hot start lever to the handlebar during the start procedure, a bore is

opened in the carburetor through which the engine can draw in extra air. This gives a

leaner fuel-air mixture, which is needed for a hot start.

Possible states

• Hot start function activated ಥHot start lever is pulled out to the stop.

• Hot start function deactivated ಥHot start lever is pushed back to the stop.

Hand brake lever

500176-10

The hand brake leveris located on the right side of the handlebar and operates the

front wheel brake.

Short circuit button

400197-10

The short circuit buttonis fitted on the left side of the handlebar.

Possible states

• Short circuit buttonin basic position ಥIn this position, the ignition circuit is

closed, and the engine can be started.

• Short circuit buttonpressed ಥIn this position, the ignition circuit is interrupted,

a running engine stops, and a non-running engine will not start.

Electric starter button

500177-10

The electric starter buttonis fitted on the right side of the handlebar.

Possible states

• Electric starter buttonin basic position

• Electric starter buttonpressed ಥIn this position, the electric starter is actuated.

OPERATING ELEMENTS 11

Fuel tap

500178-10

With the tap handleon the fuel tap, you can open or close the supply of fuel to the

carburetor.

Possible states

• Fuel supply closed OFF ಥNo fuel can flow from the tank to the carburetor.

• Fuel supply open ON ಥFuel can flow from the tank to the carburetor. The fuel tank

empties completely.

Opening filler cap

400199-10

ಥPress release button, turn filler cap counterclockwise and lift it free.

Closing filler cap

400199-11

ಥReplace the filler cap and turn clockwise until the release buttonlocks in place.

Info

Run the fuel tank breather hosewithout kinks.

Choke

500179-10

The chokeis fitted on the left side of the carburetor.

Activating the choke function frees an opening through which the engine can draw ex-

tra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.

Info

If the engine is warm, the choke function must be deactivated.

Possible states

• Choke function activated ಥThe choke lever is pulled out to the stop.

• Choke function activated ಥThe choke lever is pushed in to the stop.

OPERATING ELEMENTS 12

Shift lever

400204-12

The shift leveris mounted on the left side of the engine.

400204-11

The gear positions can be seen in the photograph.

The neutral or idle position is between the first and second gears.

Foot brake pedal

400205-10

The foot brake pedalis located in front of the right footrest and operates the rear

wheel brake.

Plug-in stand

500180-10

Note

Danger of damageಗDanger of damage by the vehicle running away or falling over.

ಥAlways place the vehicle on a firm and even surface.

To stand the motorcycle, plug the plug-in standinto the left side of the wheel spin-

dle.

Info

Before riding, remove the plug-in stand.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 13

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

Advice on first use

Danger

Danger of accidentsಗDanger from inadequate traffic experience.

ಥDo not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs.

Warning

Risk of injuryಗRisk of injury by missing/inadequate protective clothing.

ಥWear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle.

Warning

Danger of accidentsಗCritical riding behavior due to inappropriate riding.

ಥAdapt your riding speed to the road conditoins and your riding ability.

Warning

Danger of accidentsಗAccident risk caused by presence of a passenger.

ಥYour vehicle is not designed to carry passengers. Do not ride with a passenger.

Warning

Danger of accidentsಗBrake system failure.

ಥIf the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take

your foot off the foot brake pedal if you do not want to brake.

Warning

Danger of accidentsಗUnstable riding behavior.

ಥDo not exceed the maximum permitted weight and axle loads.

Warning

Risk of misappropriationಗUsage by unauthorized persons.

ಥNever leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.

Info

When using your motorcycle, remember that others may feel disturbed by excessive noise.

ಥMake sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.

You receive a delivery certificate and the service record at vehicle handover.

ಥBefore your first trip, read the entire operating instructions carefully.

ಥGet to know the operating elements.

ಥadjust the basic position of clutch lever. ( P. 59)

ಥadjust the basic position of handbrake lever. ( P. 39)

ಥAdjust the basic position of the footbrake lever. ( P. 43)

ಥGet used to handling the motorcycle on a suitable piece of land before making a longer trip.

Info

Your motorcycle is not licensed for use on public roads.

ಥTry also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.

ಥDo not make any trips that over-stress your ability and experience.

ಥHold the handlebar firmly with both hands and keep your feet on the footrests when riding.

ಥDo not make any changes to the motorcycle, and use only KTM approved parts.

ಥDo not carry any baggage.

Info

Motorcycles react sensitively to any changes of weight distribution.

ಥDo not exceed the overall maximum permitted weight and the axle loads.

Specification

Maximum permissible overall weight 335kg (738.54lb.)

Maximum permissible front axle load 145kg (319.67lb.)

Maximum permissible rear axle load 190kg (418.87lb.)

ಥRun the engine in.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 14

Running in the engine

ಥDuring the running-in phase, do not exceed the specified engine speed and engine performance.

Specification

Maximum engine speed

During the first 3 service hours 7000rpm

Maximum engine performance during the running-in period

During the first 3 service hours 싨50%

During the next 12 service hours 싨75%

ಥAvoid fully opening the throttle!

RIDING INSTRUCTIONS 15

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

Checks before putting into operation

Info

Make sure that the motorcycle is in a perfect technical condition before use.

Info

In the interests of riding safety, make a habit of making a general check before you ride.

ಥCheck the engine oil level. ( P. 62)

ಥCheck the chain tension. ( P. 34)

ಥCheck the chain dirt accumulation. ( P. 34)

ಥCheck the tire condition. ( P. 49)

ಥChecking the tire air pressure. ( P. 49)

ಥCheck the front brake brake fluid level. ( P. 39)

ಥCheck the rear brake fluid level. ( P. 43)

ಥCheck the front brake linings. ( P. 40)

ಥCheck the rear brake linings. ( P. 44)

ಥCheck brake system function.

ಥCheck the coolant level. ( P. 55)

ಥCheck that all operating elements are correctly adjusted and free to move.

Starting

Danger

Danger of poisoningಗExhaust gases are poisonous and can result in unconsciousness and/or death.

ಥWhen running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed

space.

Note

Engine failureಗHigh engine speeds in cold engines have a negative effect on the service life of the engine.

ಥAlways warm up the engine at low engine speeds.

Info

If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel

evaporate after a long time of standing.

If the float chamber is filled with fresh fuel, the engine starts immediately.

Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds until trying again.

Conditions

Motorcycle standing still: 싩1week

ಥEmpty the carburetor float chamber. ( P. 62)

ಥTurn the handleof the fuel tap to theON position. (Figure500178-10P. 11)

Fuel can flow from the tank to the carburetor.

ಥRemove the motorcycle from the stand.

ಥShift gear to neutral.

Conditions

Engine cold

ಥPull choke lever out as far as possible.

Conditions

Engine warm

ಥPull the hot start lever out to the stop.

ಥPress the electric starter button.

Info

Don't open the throttle.

Conditions

Engine hot and running

ಥPush back the hot start lever to the stop with the engine running.

RIDING INSTRUCTIONS 16

Starting up

ಥPull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.

Shifting, riding

Warning

Danger of accidentsಗIf you change down at high engine speed, the rear wheel can lock up.

ಥDo not change into a low gear at high engine speed. The engine races and the rear wheel can block.

Info

If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.

First gear is used for starting off or for steep inclines.

ಥWhen conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simulta-

neously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.

ಥIf the choke function was activated, deactivate it after the engine has warmed up.

ಥWhen you reach maximum speed after fully opening the throttle, turn back the throttle to about 3/4 of its range; the speed hardly

drops, but the fuel consumption falls considerably.

ಥAlways open the throttle only as much as the engine can handle ಥabrupt throttle opening increases fuel consumption.

ಥTo shift down, brake if necessary and close the throttle at the same time.

ಥPull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again.

ಥSwitch off the engine if you expect to be standing for a long time.

Specification

싩2min

ಥAvoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and the cooling system.

ಥRide with a lower engine speed instead of with a high engine speed and a slipping clutch.

Braking

Warning

Danger of accidentsಗIf you brake too hard, the wheels can lock.

ಥAdapt your braking to the traffic situation and the road conditions.

Warning

Danger of accidentsಗReduced braking caused by spongy pressure point of front or rear brake.

ಥHave the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Danger of accidentsಗReduced braking due to wet or dirty brakes.

ಥClean or dry dirty or wet brakes by riding and braking gently.

ಥOn sandy, wet or slippery surfaces, use the rear brake.

ಥBraking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.

ಥOn long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine.

In this way, you have to brake far less and the brakes do not overheat.

Stopping, parking

Warning

Danger of burnsಗSome vehicle components get very hot when the machine is driven.

ಥDo not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these compo-

nents to cool down before starting work on them.

Note

Danger of damageಗDanger of damage by the vehicle running away or falling over.

ಥAlways place the vehicle on a firm and even surface.

RIDING INSTRUCTIONS 17

Note

Fire hazardಗSome components (engine, radiator and exhaust system) get very hot when the engine is running.

ಥDo not place the vehicle where there are flammable or explosive substances.

ಥBrake the motorcycle.

ಥShift gear to neutral.

ಥPress the short circuit buttonwhen the engine is idling until the engine stops.

ಥTurn the handleof the fuel tap to theOFF position. (Figure500178-10P. 11)

ಥStand the motorcycle on a hard surface.

Refueling

Danger

Fire hazardಗFuel can easily catch fire.

ಥNever fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no

fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

ಥFuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.

Warning

Danger of poisoningಗFuel is poisonous and a health hazard.

ಥAvoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-

diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,

contact a doctor immediately. Change clothing that has come into contact with fuel.

Warning

Environmental hazardಗImproper handling of fuel is a danger to the environment.

ಥDo not allow fuel to get into the ground water, the ground, or the sewage system.

400382-10

ಥOpen the filler cap. ( P. 11)

ಥFill the fuel tank with fuel up to measurement.

Specification

Measurement of35mm (1.38in)

Tank capacity 8.2l

(2.17USgal)

Super unleaded (ROZ 95 / RON 95 /

PON 91) ( P. 82)

ಥClose the filler cap. ( P. 11)

GREASING AND SERVICE TABLE 18

*5($6,1* $1' 6(59,&( 7$%/(



Important maintenance work to be carried out by an authorized KTM workshop.

S3N S10A S30A

Engine Change the engine oil and oil filter, and clean the oil screen. ( P. 63) • •

Replace spark plug. •

Check and adjust valve clearance. • •

Check engine mounting screws for tightness. • •

Clean spark plug connectors and check for tightness. • •

Check screw of shift lever for tightness. • •

Carburetor Check carburetor connection boots for cracks and leakage. •

Check vent hoses for damage and routing without sharp bends. • •

Check idle. ••

Attachments Check the cooling system for leakage. • •

Check the antifreeze and coolant level. ( P. 55) • •

Check the exhaust system for leakage and looseness. •

Check Bowden cables for damage, smooth operation and routing without sharp

bends. ••

Check the fluid level of the hydraulic clutch. ( P. 60) • •

Clean the air filter. ( P. 59) • •

Check cables for damage and routing without sharp bends. •

Brakes Check the front brake linings. ( P. 40) • •

Check the rear brake linings. ( P. 44) • •

Check the brake discs. ( P. 38) • •

Check the front brake brake fluid level. ( P. 39) • •

Check the rear brake fluid level. ( P. 43) • •

Check brake lines for damage and leakage. • •

Check the free play of the hand brake lever. ( P. 39) • •

Check the free play of the foot brake lever. ( P. 43) • •

Check brake system function. • •

Check screws and guide bolts of brake system for tightness. • •

Chassis Check shock absorber and fork for leakage and functioning. • •

Clean dust boots of fork legs. ( P. 26) •

Bleed fork legs. ( P. 26) •

Check swingarm bearing. •

Check play of steering head bearing. ( P. 27) • •

Check all screws to see if they are tight. • •

Wheels Check the spoke tension. ( P. 50) • •

Check rim run-out. • •

Check the tire condition. ( P. 49) • •

Checking the tire air pressure. ( P. 49) • •

Check the chain wear. ( P. 35) • •

Check the chain tension. ( P. 34) • •

Clean the chain. ( P. 34) • •

Check wheel bearing for play. • •

Clean and grease adjusting screws of chain adjuster. • •

S3N: After 3 service hours - corresponds to about 21 liters of fuel

S10A: Every 10 service hours - corresponds to about 70 liters of fuel / after every race

S30A: Every 30 service hours - corresponds to about 210 liters of fuel

KTM 450 SMR User manual

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