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OWNER'S MANUAL 2013
450 SMR
Art. no. 3211866en
DEAR KTM CUSTOMER
1
DEAR KTM CUSTOMER
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 a lot of enjoyment in riding this vehicle!
Enter the serial numbers of your vehicle below.
Chassis number (
p. 10)
Dealer's stamp
Engine number (
p. 10)
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 non-binding. KTM Sportmotorcycle AG specifically 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 printing and other errors. The models portrayed partly contain special
equipment that does not belong to the regular scope of delivery.
© 2012 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, 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
TABLE OF CONTENTS
2
TABLE OF CONTENTS
1
MEANS OF REPRESENTATION ..................................... 4
1.1
Symbols used ................................................... 4
1.2
Formats used.................................................... 4
2
SAFETY ADVICE........................................................... 5
2.1
Use definition - intended use ............................. 5
2.2
Safety advice.................................................... 5
2.3
Degrees of risk and symbols............................... 5
2.4
Tampering warning............................................ 5
2.5
Safe operation .................................................. 5
2.6
Protective clothing ............................................ 6
2.7
Work rules........................................................ 6
2.8
Environment..................................................... 6
2.9
Owner's Manual ................................................ 6
3
IMPORTANT NOTES..................................................... 7
3.1
Guarantee, warranty .......................................... 7
3.2
Operating and auxiliary substances ..................... 7
3.3
Spare parts, accessories .................................... 7
3.4
Service ............................................................ 7
3.5
Figures ............................................................ 7
3.6
Customer service............................................... 7
4
VIEW OF VEHICLE ....................................................... 8
4.1
View of vehicle, front left (example) .................... 8
4.2
View of vehicle, rear right (example) ................... 9
5
SERIAL NUMBERS .................................................... 10
5.1
Chassis number .............................................. 10
5.2
Type label ...................................................... 10
5.3
Engine number ............................................... 10
5.4
Fork part number ............................................ 10
5.5
Shock absorber part number ............................ 10
6
CONTROLS................................................................ 11
6.1
Clutch lever.................................................... 11
6.2
Hand brake lever............................................. 11
6.3
Throttle grip ................................................... 11
6.4
Kill switch...................................................... 11
6.5
Electric starter button...................................... 11
6.6
Overview of indicator lamps ............................. 12
6.7
Opening the filler cap...................................... 12
6.8
Closing the filler cap ....................................... 12
6.9
Cold start button............................................. 13
6.10
Idle speed adjusting screw............................... 13
6.11
Shift lever ...................................................... 13
6.12
Foot brake lever .............................................. 14
6.13
Plug-in stand.................................................. 14
7
PREPARING FOR USE................................................ 15
7.1
Advice on first use .......................................... 15
7.2
Running in the engine ..................................... 16
8
RIDING INSTRUCTIONS............................................. 17
8.1
Checks and maintenance work when preparing
for use ........................................................... 17
8.2
Starting.......................................................... 17
8.3
Starting off..................................................... 18
8.4
Shifting, riding ............................................... 18
8.5
Applying the brakes......................................... 18
8.6
Stopping, parking............................................ 18
8.7
Transport ....................................................... 19
8.8
Refueling ....................................................... 19
9
SERVICE SCHEDULE ................................................. 21
9.1
Service schedule............................................. 21
9.2
Service work (as additional order) ..................... 22
10
TUNING THE CHASSIS .............................................. 23
10.1
Checking the basic chassis setting with the
rider's weight.................................................. 23
10.2
Compression damping of the shock absorber...... 23
10.3
Adjusting the low-speed compression damping
of the shock absorber ...................................... 23
10.4
Adjusting the high-speed compression
damping of the shock absorber......................... 24
10.5
Adjusting the rebound damping of the shock
absorber......................................................... 24
10.6
Measuring rear wheel sag unloaded................... 25
10.7
Checking static sag of shock absorber ............... 25
10.8
Checking riding sag of shock absorber............... 25
10.9
Adjusting the spring preload of the shock
absorberx.................................................... 26
10.10 Adjusting the riding sagx .............................. 26
10.11 Checking the basic setting of the fork ............... 27
10.12 Adjusting the compression damping of the
fork ............................................................... 27
10.13 Adjusting the rebound damping of the fork ........ 28
10.14 Handlebar position.......................................... 28
10.15 Adjusting the handlebar positionx ................. 28
11
SERVICE WORK ON THE CHASSIS.............................. 30
11.1
Raising the motorcycle with the lift stand.......... 30
11.2
Removing the motorcycle from the lift stand...... 30
11.3
Bleeding the fork legs...................................... 30
11.4
Cleaning the dust boots of the fork legs............. 31
11.5
Removing the fork legsx ............................... 31
11.6
Installing the fork legsx ................................ 32
11.7
Removing the fork protector ............................. 32
11.8
Installing the fork protector.............................. 32
11.9
Removing the lower triple clampx.................. 33
11.10 Installing the lower triple clampx .................. 33
11.11 Checking the steering head bearing play............ 35
11.12 Adjusting the play of the steering head
bearingx ..................................................... 35
11.13 Greasing the steering head bearingx .............. 36
11.14 Removing the start number plate...................... 36
11.15 Installing the start number plate....................... 36
11.16 Removing the front fender ............................... 36
11.17 Installing the front fender ................................ 37
11.18 Removing the shock absorberx ...................... 37
11.19 Installing the shock absorberx....................... 38
11.20 Removing the seat .......................................... 38
11.21 Mounting the seat........................................... 38
11.22 Removing the air filter box lid .......................... 39
11.23 Installing the air filter box lid ........................... 39
11.24 Removing the air filterx ................................ 39
11.25 Installing the air filterx................................. 40
11.26 Cleaning the air filter and air filter boxx ......... 40
11.27 Securing the air filter box lidx....................... 41
11.28 Removing the main silencer ............................. 41
11.29 Installing the main silencer.............................. 41
11.30 Changing the glass fiber yarn filling of the
main silencerx............................................. 42
11.31 Removing the fuel tankx............................... 42
11.32 Installing the fuel tankx................................ 43
11.33 Checking for chain dirt accumulation................ 44
11.34 Cleaning the chain .......................................... 45
11.35 Checking the chain tension.............................. 45
11.36 Adjusting the chain tension.............................. 46
11.37 Checking the chain, rear sprocket, engine
sprocket and chain guide................................. 46
11.38 Adjusting the chain guidex ........................... 48
11.39 Checking the framex .................................... 49
TABLE OF CONTENTS
3
11.40 Checking the swingarmx............................... 49
11.41 Checking the throttle cable routing ................... 49
11.42 Checking the rubber grip ................................. 49
11.43 Additionally securing the rubber grip................. 50
11.44 Adjusting the basic position of the clutch
lever .............................................................. 50
11.45 Checking/correcting the fluid level of the
hydraulic clutch.............................................. 50
11.46 Changing the hydraulic clutch fluidx.............. 50
12
BRAKE SYSTEM ........................................................ 52
12.1
Checking the free travel of the hand brake
lever .............................................................. 52
12.2
Adjusting the basic position of the hand brake
lever .............................................................. 52
12.3
Checking the brake discs ................................. 52
12.4
Checking the brake fluid level of the front
brake ............................................................. 53
12.5
Adding front brake fluidx.............................. 53
12.6
Checking the front brake linings ....................... 54
12.7
Changing the front brake liningsx .................. 54
12.8
Checking the free travel of foot brake lever ........ 56
12.9
Adjusting the basic position of the foot brake
leverx ......................................................... 56
12.10 Checking the rear brake fluid level.................... 57
12.11 Adding rear brake fluidx ............................... 57
12.12 Checking the rear brake linings ........................ 58
12.13 Changing the rear brake liningsx ................... 58
13
WHEELS, TIRES ........................................................ 60
13.1
Removing the front wheelx ........................... 60
13.2
Installing the front wheelx ............................ 60
13.3
Removing the rear wheelx............................. 61
13.4
Installing the rear wheelx.............................. 62
13.5
Checking the tire condition .............................. 63
13.6
Checking the tire air pressure........................... 63
13.7
Checking the spoke tension.............................. 63
14
ELECTRICAL SYSTEM ................................................ 65
14.1
Removing the batteryx.................................. 65
14.2
Installing the batteryx .................................. 65
14.3
Charging the batteryx ................................... 65
14.4
Changing the main fuse................................... 66
15
COOLING SYSTEM ..................................................... 68
15.1
Cooling system ............................................... 68
15.2
Checking the antifreeze and coolant level.......... 68
15.3
Checking the coolant level ............................... 68
15.4
Draining the coolantx ................................... 69
15.5
Refilling coolantx......................................... 70
16
TUNING THE ENGINE................................................ 71
16.1
Checking the play in the throttle cable .............. 71
16.2
Adjusting the play in the throttle cablex......... 71
16.3
Adjusting the idle speedx ............................. 72
16.4
Checking the basic position of the shift lever ..... 72
16.5
Adjusting the basic position of the shift
leverx ......................................................... 72
16.6
Antihopping clutch.......................................... 73
16.7
Adjusting the antihopping clutch...................... 73
17
SERVICE WORK ON THE ENGINE ............................... 75
17.1
Changing the fuel screenx ............................ 75
17.2
Checking the engine oil level............................ 75
17.3
Changing the engine oil and oil filter, cleaning
the oil screensx ........................................... 76
17.4
Adding engine oil............................................ 78
18
CLEANING, CARE ...................................................... 79
18.1
Cleaning the motorcycle .................................. 79
19
STORAGE.................................................................. 80
19.1
Storage .......................................................... 80
19.2
Preparing for use after storage.......................... 80
20
TROUBLESHOOTING ................................................. 81
21
BLINK CODE ............................................................. 83
22
TECHNICAL DATA...................................................... 84
22.1
Engine ........................................................... 84
22.2
Engine tightening torques ................................ 84
22.3
Capacities ...................................................... 85
22.3.1
Engine oil .................................................. 85
22.3.2
Coolant...................................................... 85
22.3.3
Fuel .......................................................... 86
22.4
Chassis .......................................................... 86
22.5
Electrical system............................................. 86
22.6
Tires.............................................................. 87
22.7
Fork............................................................... 87
22.8
Shock absorber............................................... 87
22.9
Chassis tightening torques ............................... 88
23
SUBSTANCES ........................................................... 90
24
AUXILIARY SUBSTANCES .......................................... 92
25
STANDARDS ............................................................. 94
INDEX .............................................................................. 95
1
MEANS OF REPRESENTATION
4
1.1
Symbols used
The meaning of specific symbols is described below.
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 performed by an authorized KTM workshop. There, your motorcycle will be opti-
mally cared for by specially trained experts using the specialist tools required.
Indicates a page reference (more information is provided on the specified page).
1.2
Formats used
The typographical formats used in this document are explained below.
Specific name
Identifies a proprietary name.
Name®
Identifies a protected name.
Brand™
Identifies a brand available on the open market.
2
SAFETY ADVICE
5
2.1
Use definition - intended use
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 may only be used in closed off areas remote from public road traffic.
2.2
Safety advice
A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety
instructions are highlighted in the text and are referred to at the relevant passages.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If
they are missing, you or others may not recognize dangers and may therefore be injured.
2.3
Degrees of risk and symbols
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
2.4
Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
1
The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device
or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate
purchaser or while it is in use, or
2
the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
1
Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases.
2
Removal or puncturing of any part of the intake system.
3
Lack of proper maintenance.
4
Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the
manufacturer.
2.5
Safe operation
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
–
Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally
impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
–
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
2
SAFETY ADVICE
6
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
–
Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these
components to cool down before starting work on them.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmen-
tally compatible manner.
The vehicle should only be used by trained persons.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
2.6
Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
–
Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always
wear protective clothing that is in good condition and meets the legal requirements.
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.
2.7
Work rules
Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren-
theses. E.g.: bearing puller (15112017000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.
2.8
Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcy-
cle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the
respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that
pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.
2.9
Owner's Manual
It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains
useful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to cus-
tomize the vehicle ideally for your own use and how you can protect yourself from injury.
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed.
If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.
The Owner's Manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold.
3
IMPORTANT NOTES
7
3.1
Guarantee, warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage
resulting from manipulations and/or alterations to the vehicle.
Additional information on the guarantee or warranty and the procedures involved can be found in the service record.
3.2
Operating and auxiliary substances
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–
Do not allow fuel to get into the ground water, the ground, or the sewage system.
Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.
3.3
Spare parts, accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them
installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise
you.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
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's Manual. Incorrect adjustment and tuning of the engine and chassis can
lead to damage and breakage of components.
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can lead to considerably more rapid wear
of components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or
replace parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a
much longer service life for your motorcycle.
3.5
Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to dis-
assemble the component to perform the activity in question. Please follow the instructions in the text.
3.6
Customer service
Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.
A list of authorized KTM dealers can be found on the KTM website.
International KTM Website: http://www.ktm.com
4
VIEW OF VEHICLE
8
4.1
View of vehicle, front left (example)
L00097-10
1
Hand brake lever (
p. 11)
2
Clutch lever (
p. 11)
3
Filler cap
4
Plug-in stand (
p. 14)
5
Air filter box lid
6
Engine number (
p. 10)
7
Shift lever (
p. 13)
8
Cold start button (
p. 13)
4
VIEW OF VEHICLE
9
4.2
View of vehicle, rear right (example)
L00098-10
1
Kill switch (
p. 11)
2
Electric starter button (
p. 11)
3
Fork compression adjustment
4
Fork rebound adjustment
5
Foot brake lever (
p. 14)
6
Level viewer, engine oil
7
Shock absorber compression adjustment
8
Level viewer for brake fluid, rear
9
Shock absorber rebound adjustment
5
SERIAL NUMBERS
10
5.1
Chassis number
L00099-10
The chassis number 1 is stamped on the right side of the steering head.
5.2
Type label
L00099-11
The type label 1 is fixed to the front of the steering head.
5.3
Engine number
C00175-10
The engine number 1 is stamped on the left side of the engine under the engine
sprocket.
5.4
Fork part number
L00100-10
The fork part number 1 is stamped on the inner side of the axle clamp.
5.5
Shock absorber part number
601833-10
The shock absorber part number 1 is stamped on the top of the shock absorber above
the adjusting ring on the engine side.
6
CONTROLS
11
6.1
Clutch lever
L00162-10
The clutch lever 1 is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
6.2
Hand brake lever
L00163-10
Hand brake lever 1 is located on the right side of the handlebar.
The hand brake lever is used to activate the front brake.
6.3
Throttle grip
L00103-10
The throttle grip 1 is fitted on the right side of the handlebar.
6.4
Kill switch
L00104-10
Kill switch 1 is fitted on the left side of the handlebar.
Possible states
•
Kill switch
in basic position – In this position, the ignition circuit is closed and
the engine can be started.
•
Kill switch
pressed – In this position, the ignition circuit is interrupted, a run-
ning engine stops, and a non-running engine will not start.
6.5
Electric starter button
L00103-11
Electric starter button 1 is fitted on the right side of the handlebar.
Possible states
•
Electric starter button
in basic position
•
Electric starter button
pressed – In this position, the electric starter is actuated.
6
CONTROLS
12
6.6
Overview of indicator lamps
L00105-10
Possible states
FI warning lamp (MIL) lights up/flashes orange – The OBD (on-board
diagnosis) has detected an emission- or safety-critical error.
6.7
Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
–
Never refuel 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.
–
Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–
Do not allow fuel to get into the ground water, the ground, or the sewage system.
L00106-10
–
Turn filler cap 1 counterclockwise and lift it off.
6.8
Closing the filler cap
L00106-11
–
Mount the filler cap and turn it clockwise until the fuel tank is firmly closed.
Info
Run the fuel tank breather hose 1 without kinks.
6
CONTROLS
13
6.9
Cold start button
C00244-10
The cold start button 1 is fitted on the left on the throttle valve body.
The injection system extends the injection time if the engine is cold and the outside
temperature is low. The engine can only burn the increased fuel quantity if it receives
more air. It obtains more air by pulling the cold start button.
Possible states
•
The cold start button is activated – The cold start button is pulled out all the way.
•
The cold start button is deactivated – The cold start button is pushed in all the
way.
6.10
Idle speed adjusting screw
C00245-10
The idle setting of the throttle valve body has a big influence on the starting behavior,
stable idling and the response to throttle opening. This means that an engine with a
correctly set idle speed is easier to start than if the idle is set wrongly.
The idle speed is adjusted with idle speed adjusting screw 1.
Turning the adjusting screw clockwise increases the idle speed.
Turning the adjusting screw counterclockwise lowers the idle speed.
6.11
Shift lever
601839-12
Shift lever 1 is mounted on the left side of the engine.
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