KTM 450 SX ATV 2009 Setup Instructions Download Page 3

INTRODUCTION

1

INTRODUCTION

The work described in these setup instructions must be performed before the vehicle is delivered to the customer.

Read the setup instructions in their entirety before beginning work.

Print out the current

PDI

form found on the

KTM DEALER.NET

.

These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter-
est of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that the work will be performed by a fully trained mechanic.

All specifications are non-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 production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not belong to the regular scope of delivery.

© 2008 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)
According to 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

Summary of Contents for 450 SX ATV 2009

Page 1: ...SETUP INSTRUCTIONS 2009 450 SX ATV 505 SX ATV ART NO 3211428en ...

Page 2: ......

Page 3: ...serves 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 production of a particular model without prior notice KTM accepts no liability for delivery options deviations from illustrations and descriptions as well as misprints an...

Page 4: ...ndicates an unexpected reaction e g of a work step or a function 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 proprietary name Name Identifies a protected name Brand Identifies a brand in merchandise traffic ...

Page 5: ... battery acid and battery gases Keep the battery away from sparks or open fire Charge only in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and con tact a physician Fill the battery Info Observe the instructions in the separate enclosure of the battery Recharge the battery p 6 Install t...

Page 6: ...Guideline Screw steering bridge M8 20 Nm 14 8 lbf ft Mount and tighten screw Guideline Screw steering column top M20x1 5 25 Nm 18 4 lbf ft Mount and tighten screws Guideline Screw steering bridge M8 20 Nm 14 8 lbf ft Mount handlebar support in the desired position using the screws Mount new self locking nuts and tighten Guideline Nut handlebar support M10 45 Nm 33 2 lbf ft Position the handlebar a...

Page 7: ...ok engages Make sure that the seat is correctly locked in 3 4 Removing the rear fender Remove the seat p 4 300254 10 Remove screws 300255 10 Raise the rear of the air filter box lid At the same time use your other hand to press on the carburetor connection boot to kink it at that location This prevents the carburetor connection boot from disconnecting from the carburetor Raise fender at the rear a...

Page 8: ...f battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Warning Environmental hazard Components and battery acid are a danger to the environment Do not dispose of batteries in normal household waste Take defective or used batteries to a battery recycling operator Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease...

Page 9: ...onnect the battery Guideline The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the vehicle is not in use 3 months Install the rear fender p 6 3 7 Installing the battery 300279 11 Place the battery in the battery holder 4Ah battery YTX5L BS Reconnect rubber band Attach the positive plus cable and replace the plus pole cover Connect the negative...

Page 10: ...es 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 hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the...

Page 11: ...ts chassis M10 50 Nm 36 9 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw A arm bottom M10x70 45 Nm 33 2 lbf ft Screw A arm top M10x52 45 Nm 33 2 lbf ft Screw footrest M10 45 Nm 33 2 lbf ft Screw front shock absorber M10 45 Nm 33 2 lbf ft Screw steering column at bottom of steering lever M10 25 Nm 18 4 lbf ft Nut ball head A arm top M10x1 25 35 Nm 25 8 lbf ft Nut rear sprocket screw M1...

Page 12: ...SUBSTANCES 10 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91 ...

Page 13: ... 3211428en 3211428en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 7 2008 Photo Mitterbauer ...

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