KTM 450 SMR 2021 Page 80 Owner'S Manual Download

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12 BRAKE SYSTEM

V01453-11

–

Fill brake fluid up to the

MAX

marking.

Brake fluid DOT 4 / DOT 5.1 (

p. 126)

–

Position cover

with membrane

. Mount and tighten

screws

Info

Clean up overflowed or spilled brake fluid immediately
with water.

12.7

Checking the free travel of foot brake lever

Warning

Danger of accidents

The brake system fails in the event of overheating.

If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear
brake.

–

Set the free travel on the foot brake lever in accordance with the specification.

402026-10

–

Disconnect spring

–

Move the foot brake lever back and forth between the end stop
and the contact to the foot brake cylinder piston and check
free travel

Guideline

Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in)

» If the free travel does not meet specifications:

–

Adjust the basic position of the foot brake lever.
(

p. 78)

–

Reconnect spring

12.8

Adjusting the basic position of the foot brake lever

Warning

Danger of accidents

The brake system fails in the event of overheating.

If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear
brake.

–

Set the free travel on the foot brake lever in accordance with the specification.

Summary of Contents for 450 SMR 2021

Page 1: ...OWNER S MANUAL 2021 450 SMR Art no 3214231en...

Page 2: ......

Page 3: ...rs forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop produc tion of a particular model without pr...

Page 4: ...USE 20 7 1 Advice on preparing for first use 20 7 2 Running in the engine 21 7 3 Starting power of lithium ion batteries at low temperatures 21 8 RIDING INSTRUCTIONS 22 8 1 Checks and maintenance mea...

Page 5: ...and chain guide 66 11 37 Checking the frame 68 11 38 Checking the link fork 68 11 39 Checking the throttle cable routing 68 11 40 Checking the rubber grips 69 11 41 Adjusting the basic position of th...

Page 6: ...G CARE 110 18 1 Cleaning the motorcycle 110 19 STORAGE 112 19 1 Storage 112 19 2 Preparing for use after storage 113 20 TROUBLESHOOTING 114 21 BLINK CODE 116 22 TECHNICAL DATA 118 22 1 Engine 118 22 2...

Page 7: ...y trained experts using the special tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of...

Page 8: ...instruction and all further instructions included carefully The safety instructions are highlighted in the text and are referred to at the relevant passages Info Various information and warning label...

Page 9: ...e operation Danger Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others Do not operate the vehicle if you are not fit to ride due to alcohol drugs or medicati...

Page 10: ...If you use your motorcycle responsibly you can ensure that problems and conflicts do not occur To protect the future of the motorcycle sport make sure that you use your motorcycle legally be environm...

Page 11: ...m 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly carried out as described in the Owner...

Page 12: ...HICLE 10 4 1 View of vehicle front left example E01949 10 1 Hand brake lever p 14 2 Clutch lever p 14 3 Fuel tank filler cap 4 Air filter box cover 5 Engine number p 12 6 Shift lever p 18 7 Cold start...

Page 13: ...adjustment 2 Combination switch p 15 3 Stop button p 14 4 Start button p 15 5 Throttle grip p 14 6 Fork compression adjuster 7 Shock absorber compression adjustment 8 Foot brake lever p 18 9 Level vi...

Page 14: ...on the right side of the steering head 5 2 Type label 401946 10 The type label 1 is fixed to the front of the steering head 5 3 Engine number H00940 10 The engine number 1 is stamped on the left side...

Page 15: ...SERIAL NUMBERS 5 13 5 5 Shock absorber article number 401948 10 The shock absorber article number 1 is stamped on the top of the shock absorber above the adjusting ring towards the engine side...

Page 16: ...d using the hand brake lever 6 3 Throttle grip H01728 10 The throttle grip 1 is fitted on the right side of the handlebar 6 4 Stop button E01952 10 The stop button 1 is fitted on the left side of the...

Page 17: ...ted when LED 1 and TC light up 2 ADVANCED ADVANCED mapping is activated when LED 2 lights up 2 TC ADVANCED with TC ADVANCED mapping with trac tion control is activated when LED 2 and TC light up The e...

Page 18: ...sult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fu...

Page 19: ...t button has returned to its basic position Possible states The cold start button is activated The cold start button is pushed in all the way The cold start button is deactivated The cold start button...

Page 20: ...between the first and second gears 6 13 Foot brake lever 401956 10 Foot brake lever 1 is located in front of the right footrest The foot brake lever is used to activate the rear brake 6 14 Plug in st...

Page 21: ...itted in front of the handlebar It shows the total number of service hours of the engine The service hour counter begins counting when the engine is started and stops when the engine is switched off I...

Page 22: ...c Adapt your riding speed to the road conditions and your riding ability Warning Danger of accidents The vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of acci...

Page 23: ...phase do not exceed the specified engine speed and engine performance Guideline Maximum engine speed During the first operating hour 7 000 rpm Maximum engine performance During the first 3 operating h...

Page 24: ...e tire condition p 88 Check tire pressure p 89 Check the spoke tension p 89 Info The spoke tension must be checked regularly as incor rect spoke tension will strongly impair riding safety Clean the du...

Page 25: ...lve fully opened full throttle is reduced After the start it is gradually increased up to the maximum engine speed The clutch must be operated exactly as it would be without launch control activated C...

Page 26: ...at high engine speed Info If unusual noises occur while riding stop immediately switch off the engine and contact an authorized KTM workshop First gear is used for starting off and for steep inclines...

Page 27: ...braking before you go into a bend Shift down to a lower gear appropriate to your speed Use the braking effect of the engine on long downhill stretches Shift back one or two gears but do not over rev t...

Page 28: ...e Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk Do not park the vehicle near to materials which are highly flammable or explosive Allow the vehicle to cool down before...

Page 29: ...fuel filter to quickly become clogged In some countries and regions the available fuel quality and cleanliness may not be sufficient This will result in problems with the fuel system Refuel only with...

Page 30: ...k the brake linings of the rear brake p 81 Check the brake discs p 73 Check the brake lines for damage and leakage Check the rear brake fluid level p 79 Check the free travel of the foot brake lever p...

Page 31: ...l screen p 105 Check the fuel pressure Check idle speed Final check Check the vehicle for operating safety and take a test ride Read out the error memory after the test ride using the KTM diagnostics...

Page 32: ...valves valve springs valve spring seats and valve spring retainers Change the con necting rod conrod bearing and crank pin Check the transmission and the shift mechanism Check the oil pressure control...

Page 33: ...the left fork leg and damp ing in the right fork leg As fork springs are no longer required a significant weight advantage is achieved when compared to conventional forks The response on slightly une...

Page 34: ...s modifications in the high speed range affect the compression damping in the low speed range and vice versa 10 4 Adjusting the low speed compression damping of the shock absorber Caution Risk of inju...

Page 35: ...by the number of turns corresponding to the shock absorber type Guideline Highspeed compression damping Comfort 2 turns Standard 1 5 turns Sport 1 turn Info Turn clockwise to increase damping turn co...

Page 36: ...the rear wheel dimension unloaded Preparatory work Raise the motorcycle with a lift stand p 42 402415 10 Main work Position the sag gage in the rear axle and measure the distance to marking SAG on th...

Page 37: ...oad of the shock absorber p 36 10 9 Checking the riding sag of the shock absorber 402417 10 Measure dimension A of rear wheel unloaded p 34 With another person holding the motorcycle the rider wear in...

Page 38: ...it thoroughly 402405 10 Main work Loosen screw 1 Turn adjusting ring 2 until the spring is no longer under ten sion Hook wrench 90129051000 Info If the spring cannot be fully released the spring must...

Page 39: ...Check the free travel of the foot brake lever p 78 Check the static sag of the shock absorber p 35 Check the riding sag of the shock absorber p 35 Adjust the rebound damping of the shock absorber p 33...

Page 40: ...right fork leg Preparatory work Raise the motorcycle with a lift stand p 42 V01857 10 Main work Remove protection cap 1 Push together fork airpump 2 fully Fork airpump 79412966100 Info The fork airpum...

Page 41: ...ise all the way Info Adjusting screw 1 is located at the upper end of the right fork leg Turn counterclockwise by the number of clicks corresponding to the fork type Guideline Compression damping Comf...

Page 42: ...itions This allows the handlebar to be mounted in the most comfortable posi tion for the rider 10 17 Adjusting the handlebar position Preparatory work Remove the handlebar cushion B00375 10 Main work...

Page 43: ...s 1 but do not tighten yet First bolt the handlebar clamps with screws 1 onto the longer higher side of the handlebar supports so that both parts touch Guideline Screw handlebar clamp M8 20 Nm 14 8 lb...

Page 44: ...if the vehicle rolls away or falls over The components for parking the vehicle are designed only for the weight of the vehicle Park the vehicle on a firm and level surface Ensure that nobody sits on...

Page 45: ...ng Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when nec essary Clean and...

Page 46: ...2 Position the fork protector on the right fork leg Mount and tighten screws 3 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 7 Removing the fork legs Preparatory work Raise the motorcycle...

Page 47: ...is located in the left fork leg The pressure and rebound damping is located in the right fork leg V01431 11 Tighten screws 2 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws 3 Gui...

Page 48: ...nk the cables and lines V01433 10 Remove O ring 4 Remove protective ring 5 Remove the lower triple clamp with the steering stem Remove the upper steering head bearing 11 10 Installing the lower triple...

Page 49: ...es are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the upper edge of the upper triple clamp The air suspension is located in the lef...

Page 50: ...the front wheel p 85 Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check steering head bearing play p 48 Remove the motorcycle from...

Page 51: ...he steering head bearing and adjust if neces sary Finishing work Remove the motorcycle from the lift stand p 42 11 12 Adjusting steering head bearing play Preparatory work Raise the motorcycle with a...

Page 52: ...triple clamp 11 14 Removing the start number plate E01955 10 Remove screw 1 Swivel the start number plate to one side Unhook the start number plate from the brake line and remove it 11 15 Installing...

Page 53: ...move screws 1 and 2 Take off the front fender 11 17 Installing front fender F01526 10 Main work Position front fender Mount and tighten screws 1 and 2 Guideline Remaining screws chassis M6 10 Nm 7 4 l...

Page 54: ...h the right frame protector to the front and take off at the bottom E01957 10 Remove screw 3 Remove fitting 4 Info Raise the swingarm slightly to be able to remove the screws more easily E01958 10 Pre...

Page 55: ...n work Carefully position the shock absorber into the vehicle from the bottom Mount and tighten screw 1 Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 V01441 10 Position the lin...

Page 56: ...ntion to flat area B Mount and tighten screw 7 Guideline Screw bottom shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Info Raise the swingarm slightly to be able to mount the screw more easily F0152...

Page 57: ...l the seat back and lift it off 11 21 Mounting the seat H02218 11 Mount the front of the seat on the collar bushing of the fuel tank and the rear in the bracket Push the seat forward Make sure the sea...

Page 58: ...with openings for greater airflow and a more direct response is included 11 24 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine...

Page 59: ...ining tab 2 Retaining pin 3 is secured by retaining tab 2 Info If the air filter is not mounted correctly dust and dirt may enter the engine and result in damage Finishing work Install the air filter...

Page 60: ...lter p 128 Clean the air filter box Clean the intake flange and check it for damage and tightness Finishing work Install the air filter p 57 Install the air filter box cover p 56 11 27 Removing the ma...

Page 61: ...is M6 10 Nm 7 4 lbf ft 11 29 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to...

Page 62: ...azard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not fuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine f...

Page 63: ...tances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve V01450 10 Disconnect the quick release coupling Info Remaining fuel may flow out of the fuel hose Mount wash...

Page 64: ...ct with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and co...

Page 65: ...Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 63 11 33 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip Remove...

Page 66: ...s may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tensi...

Page 67: ...cle with a lift stand p 42 Check the chain tension p 64 F00395 10 Main work Loosen nut 1 Loosen nuts 2 Adjust the chain tension by turning adjusting screws 3 left and right Guideline Chain tension 55...

Page 68: ...gether 400987 10 Pull on the top section of the chain with the specified weight A Guideline Weight chain wear measure ment 10 15 kg 22 33 lb Measure distance B of 18 chain rollers in the lower chain s...

Page 69: ...m 4 4 lbf ft Loctite 243 V01422 10 Check the chain sliding piece for wear If the lower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece Check that...

Page 70: ...me for damage cracking and deformation If the frame shows signs of damage cracking or deforma tion Change the frame Guideline Repairs on the frame are not permitted 11 38 Checking the link fork 401520...

Page 71: ...nishing work Install the fuel tank p 62 11 40 Checking the rubber grips 401197 01 Check the rubber grips on the handlebar for damage wear and looseness Info The rubber grips are vulcanized onto a slee...

Page 72: ...immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if b...

Page 73: ...zardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake...

Page 74: ...cylinder reser voir to prevent overflowing Tighten the bleeder screw and remove the bleeding syringe with the hose Mount the protection cap Correct the fluid level of the hydraulic clutch Guideline Fl...

Page 75: ...ts while riding 12 2 Checking the brake discs Warning Danger of accidents Worn out brake discs reduce the braking effect Make sure that worn out brake discs are replaced immediately Your authorized KT...

Page 76: ...reservoir 1 If the brake fluid level is below the MIN marking Add front brake fluid p 74 12 4 Adding front brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brak...

Page 77: ...eparatory work Check the front brake linings p 75 V01453 10 Main work Move the brake reservoir mounted on the handlebar to a hori zontal position Remove screws 1 Take off cover 2 with membrane 3 Fill...

Page 78: ...the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your auth...

Page 79: ...points in the direction of rotation of the brake disc F00419 10 Position the new brake linings 6 in the guides and press toward the pistons The spring plate is seated correctly in the brake caliper I...

Page 80: ...in accordance with the specification 402026 10 Disconnect spring 1 Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel...

Page 81: ...t 2 Guideline Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Attach spring 1 12 9 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake...

Page 82: ...if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid co...

Page 83: ...1 Check the brake linings for damage and cracking If damage or wear is encountered Change the rear brake linings p 81 12 12 Changing the rear brake linings Warning Danger of accidents Incorrect servic...

Page 84: ...and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container K01107 10 Position the vehicle upright Remove screw cap 1 with membrane 2 and the O ring F00405 11 Manua...

Page 85: ...ted on the piston side brake lining Operate the foot brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point K01106 10 Add brake fluid to level...

Page 86: ...c and hang to the side loosely Info Do not operate the hand brake lever if the brake caliper has been removed E01977 10 Loosen screw 3 by several rotations Loosen screws 4 Press on screw 3 to push the...

Page 87: ...sert the narrow spacer on the opposite side E01978 10 Clean and grease the wheel spindle Long life grease p 128 Position the front wheel and insert the wheel spindle Mount and tighten screw 2 Guidelin...

Page 88: ...t press the brake caliper against the spokes when pushing back the brake piston Remove nut 1 Take off chain adjuster 2 Pull out wheel spindle 3 far enough to allow the rear wheel to be pushed forward...

Page 89: ...cleaner when necessary H03001 10 Main work Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the rear wheel bearing Clean and grease shaft seal rings 1 and co...

Page 90: ...brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand p 42 13 5 Checking the tire condition Info Only mount tires approved and or recommended by KTM Other t...

Page 91: ...ection cap Check the tire pressure on cold or warm tires Tire pressure cold front 10 30 C 50 86 F 1 9 bar 28 psi rear 10 30 C 50 86 F 1 7 bar 25 psi Tire pressure warm front 75 85 C 167 185 F 2 1 bar...

Page 92: ...f spokes of the same length and diameter vibrate with a different tone this is an indication that the spoke tensions differ You should hear a high note If the spoke tension differs Correct the spoke t...

Page 93: ...mum clearance 1 m 3 ft Do not charge deeply discharged 12 V batteries if the charge is already below the minimum voltage Minimum voltage before the start of the charge 9 V Dispose of 12 V batteries wi...

Page 94: ...Nm 1 84 lbf ft Position the voltage regulator Finishing work Mount the seat p 55 14 3 Charging the 12 V battery Warning Risk of injury 12 V batteries contain harmful substances Keep 12 V batteries ou...

Page 95: ...tage 9 V Do not charge the 12 V battery Replace the 12 V battery and dispose of the old 12 V battery properly If the specifications have been met Battery voltage 9 V Connect a battery charger to the 1...

Page 96: ...ay hous ing under the seat Preparatory work Remove the seat p 55 F00136 10 Main work Pull starter relay 1 from the holder F00135 10 Take off protection caps 2 Remove faulty main fuse 3 Info A faulty f...

Page 97: ...ponents of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the...

Page 98: ...er in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Condition...

Page 99: ...nd tighten screw 1 with a new seal ring Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft 15 5 Refilling coolant Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of...

Page 100: ...h the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes thorough...

Page 101: ...its original posi tion Adjust the play in the throttle cable p 99 Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness and death Always make sure there...

Page 102: ...here is play in the throttle cable at the throttle grip Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Tighten nut 2 Slide on sleeve 1 Check the throttle grip for smooth operation Finishing work...

Page 103: ...e more slowly The black guide plate opens the throttle valve more quickly The gray guide plate is mounted upon delivery V00384 01 Clean the outside of the handlebar and the inside of the grip tube Mou...

Page 104: ...o be changed during the ride H02889 01 Activating STANDARD mapping Press button MAP until LED 1 lights up Guideline Engine speed 4 000 rpm STANDARD balanced response H02886 01 Activating ADVANCED mapp...

Page 105: ...ckwise raises the idle speed 16 6 Teaching the throttle valve position Info If the control unit detects that the throttle valve position for idle speed needs to be retaught then the mal function indic...

Page 106: ...of boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the basic position of the shift lever p 104 16 8 Adjusting the basic position of the shift lever 401950 12 Remove scr...

Page 107: ...of fuel spills on them Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system Clean quick release...

Page 108: ...of the level viewer A and the upper edge of the level viewer B If the engine oil does not reach the middle of level viewer A Add engine oil p 109 17 3 Changing the engine oil and oil filter cleaning...

Page 109: ...g oil screen 4 and the O rings Allow the engine oil to drain completely Thoroughly clean the parts and the sealing surfaces K01069 11 Mount and tighten screw plug 2 with the short oil screen and the O...

Page 110: ...ly Thoroughly clean the parts and the sealing surfaces E01974 11 Lay the motorcycle on its side and fill the oil filter housing to about full with engine oil Place the new oil filter into the housing...

Page 111: ...01955 10 Main work Remove filler plug 1 with the O ring Add the same engine oil used when the last oil change was carried out Engine oil SAE 10W 50 p 126 Info For optimal performance of the engine oil...

Page 112: ...ularly Avoid direct sunshine when cleaning the motorcycle 401061 01 Close off exhaust system to keep water from entering Remove loose dirt first with a soft jet of water Spray the heavily soiled parts...

Page 113: ...exhaust sys tem with a corrosion inhibitor Preserving materials for paints metal and rubber p 128 Treat all plastic parts and powder coated parts with a mild cleaning and care product Special cleaner...

Page 114: ...repairs or replacements are necessary you should do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 401058 0...

Page 115: ...only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and the exhaust system to rust 19 2 Preparing for use after storage 401059 01 Inst...

Page 116: ...isual check Check the electrical system Malfunction in the electronic fuel injection Read out the fault memory using the KTM diagnostics tool Engine does not speed up Malfunction in the electronic fue...

Page 117: ...he KTM diagnostics tool High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary Engine oil level too high Check the engine oil level p 106 Engine oil too...

Page 118: ...for malfunction indicator lamp 12 Malfunction indicator lamp flashes 1x long 2x short Error level condition Coolant temperature sensor circuit fault Coolant temperature sensor input signal too low Bli...

Page 119: ...rcuit fault Blink code for malfunction indicator lamp 41 Malfunction indicator lamp flashes 4x long 1x short Error level condition Fuel pump controller short circuit to ground open circuit Fuel pump c...

Page 120: ...g Piston pin bearing No bearing bush DLC coated piston pin Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with 2 troc...

Page 121: ...Loctite 243 Screw suction pump cover M5 6 Nm 4 4 lbf ft Loctite 243 Nut water pump impeller M6 6 Nm 4 4 lbf ft Loctite 243 Screw alternator cover M6 10 Nm 7 4 lbf ft Screw clutch cover M6 10 Nm 7 4 l...

Page 122: ...cylinder head M10x1 25 1st stage 10 Nm 7 4 lbf ft 2nd stage 30 Nm 22 1 lbf ft 3rd stage 50 Nm 36 9 lbf ft Collar and thread oiled Nut rotor M12x1 60 Nm 44 3 lbf ft Thread oiled with engine oil cone d...

Page 123: ...66 in Brake discs wear limit front 4 5 mm 0 177 in rear 3 5 mm 0 138 in Tire pressure cold front 10 30 C 50 86 F 1 9 bar 28 psi rear 10 30 C 50 86 F 1 7 bar 25 psi Tire pressure warm front 75 85 C 167...

Page 124: ...ice section under http www ktm com 22 7 Fork Fork article number 0262C108U406000 Fork WP XACT 5448 Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Rebound damping Comfort 17 cl...

Page 125: ...rider 75 85 kg 165 187 lb 260 mm 10 24 in Weight of rider 85 95 kg 187 209 lb 260 mm 10 24 in Gas pressure 10 bar 145 psi Static sag 20 mm 0 79 in Riding sag 80 mm 3 15 in Fitted length 468 mm 18 43...

Page 126: ...ft Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Nut rear sprocket screw M8 35 Nm 25 8 lbf ft Loctite 2701 Nut rim lock M8 12 Nm 8 9 lbf ft Remaining nuts chassis M8 25 Nm 18 4 lbf ft Remaining scre...

Page 127: ...f ft Nut angle lever to link fork M14x1 5 60 Nm 44 3 lbf ft Nut frame on linkage lever M14x1 5 60 Nm 44 3 lbf ft Nut linkage lever on angle lever M14x1 5 60 Nm 44 3 lbf ft Nut fork pivot M16x1 5 100 N...

Page 128: ...Only use coolant that complies with the requirements stated see specifications on the container and that has the relevant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must...

Page 129: ...n SAE p 130 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties Super unleaded ROZ 95 Standard cl...

Page 130: ...High viscosity grease Recommended supplier SKF LGHB 2 Long life grease Recommended supplier MOTOREX Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX Moto Clean Off road chain spray Re...

Page 131: ...ray Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Special grease 00062010053 Recommended supplier Kl ber Lubrication KL BERF...

Page 132: ...ce intervals are demanded for automobile engines the focus for motorcycle engines is on high performance at high engine speeds In most motorcycle engines the transmission and clutch are lubricated wit...

Page 133: ...131 Launch control Vehicles electronics functions for achieving the best possible acceleration from a standing position OBD On board diagnosis Vehicle system which monitors the specified parame ters o...

Page 134: ...27 LIST OF ABBREVIATIONS 132 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 135: ...intervention Active driving aids are also represented by yellow or orange symbols Malfunction indicator lamp lights up flashes orange The OBD has detected an error in the vehicle electronics Come safe...

Page 136: ...ine oil 108 120 Chain checking 66 cleaning 63 Chain guide checking 66 Chain tension adjusting 65 checking 64 Characteristic map of the throttle response adjusting 100 Clutch fluid level checking corre...

Page 137: ...clamp installing 46 removing 45 Low speed compression damping shock absorber adjusting 32 M Main fuse changing 94 Main silencer glass fiber yarn filling changing 59 installing 59 removing 58 Manufact...

Page 138: ...n 15 Start number plate installing 50 removing 50 Starting 22 Starting power of lithium ion batteries at low tempera tures 21 Steering head bearing lubricating 50 Steering head bearing play adjusting...

Page 139: ...3214231en 3214231en 09 2020 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KISKA KTM...

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KTM 450 SMR 2021, Owner'S Manual

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