2012r Repair manual.pdf

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REPAIR MANUAL

2012

450 SMR

Art. no. 3206124en

INTRODUCTION

It is important that you read this owner's manual carefully and completely before the start of work.

INTRODUCTION

Only use

ORIGINAL KTM SPARE PARTS.

This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified

experts.

The repair manual was written to correspond to the most current state of this model series. We reserve the right to make changes in

the interest of technical advancement without, at the same time, updating this repair 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 repair work will be performed by a fully trained mechanic.

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 misprints and other errors. The models portrayed partly contain spe-

cial equipment that does not belong to the regular scope of delivery.

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

Measuring rear wheel sag unloaded .................................

Checking static sag of shock absorber..............................

Checking riding sag of shock absorber .............................

Adjusting the spring preload of the shock absorber ...........

Adjusting the riding sag .................................................

Removing the shock absorber .........................................

Installing the shock absorber ..........................................

Checking the shock absorber linkage ...............................

Servicing the shock absorber ..........................................

Removing the spring ......................................................

Disassembling the damper .............................................

Disassembling the piston rod ..........................................

Disassembling the seal ring retainer ................................

Changing the pilot bushing.............................................

Checking the damper .....................................................

Removing the heim joint ................................................

Installing the heim joint .................................................

Assembling the seal ring retainer ....................................

Assembling the piston rod ..............................................

Assembling the damper..................................................

Bleeding and filling the damper ......................................

Filling the damper with nitrogen .....................................

Installing the spring.......................................................

05/EXHAUST ....................................................................

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

Installing the main silencer ............................................

Changing the glass fiber yarn filling of the main silencer ...

06/AIR FILTER..................................................................

Removing the air filter box lid.........................................

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

Removing the air filter ...................................................

Installing the air filter ....................................................

Cleaning the air filter and air filter box ............................

Removing the carburetor connection boot ........................

Installing the carburetor connection boot .........................

07/FUEL TANK, SEAT, TRIM..............................................

Opening filler cap ..........................................................

Closing filler cap ...........................................................

Removing the seat .........................................................

Mounting the seat .........................................................

Removing the fuel tank ..................................................

Installing the fuel tank ...................................................

Fuel tap........................................................................

08/MASK, FENDER ...........................................................

Removing the front fender ..............................................

Installing the front fender...............................................

Removing the start number plate ....................................

Installing the start number plate .....................................

09/FRONT WHEEL ............................................................

Removing the front wheel ...............................................

Installing the front wheel................................................

Checking the brake discs................................................

Removing the front brake disc ........................................

Installing the front brake disc .........................................

Checking the tire condition.............................................

Checking the tire air pressure .........................................

Checking spoke tension..................................................

10/REAR WHEEL ..............................................................

Removing the rear wheel ................................................

Installing the rear wheel .................................................

Removing the rear brake disc..........................................

MEANS OF REPRESENTATION ............................................ 6

IMPORTANT NOTES ............................................................ 7

SERIAL NUMBERS.............................................................. 8

Chassis number............................................................... 8

Type label....................................................................... 8

Engine number................................................................ 8

Fork part number............................................................. 8

Shock absorber part number............................................. 8

MOTORCYCLE..................................................................... 9

Raising the motorcycle with the lift stand .......................... 9

Removing the motorcycle from the lift stand ...................... 9

Starting .......................................................................... 9

Starting the motorcycle for checking ............................... 10

01/FORK, TRIPLE CLAMP.................................................. 11

Adjusting the compression damping of the fork ................ 11

Adjusting the rebound damping of the fork....................... 11

Bleeding fork legs.......................................................... 11

Cleaning the dust boots of the fork legs ........................... 12

Removing the fork legs................................................... 12

Installing the fork legs ................................................... 13

Removing the fork protector............................................ 13

Installing the fork protector ............................................ 13

Conducting major fork service......................................... 14

Conducting minor fork service......................................... 14

Disassembling the fork legs ............................................ 15

Disassembling the cartridge............................................ 17

Disassembling the piston rod .......................................... 19

Disassembling the screw cap with the membrane holder ... 20

Disassembling the screw sleeve ...................................... 21

Checking the fork legs.................................................... 22

Checking the fork legs - during a minor fork service .......... 24

Changing the pilot bushing............................................. 25

Assembling the screw sleeve........................................... 26

Assembling the screw cap with the membrane holder........ 26

Assembling the piston rod .............................................. 27

Assembling the cartridge ................................................ 28

Assembling the fork legs ................................................ 30

Bleeding and filling the cartridge .................................... 33

Filling the cartridge with nitrogen.................................... 34

Greasing the steering head bearing.................................. 35

Removing the lower triple clamp ..................................... 35

Installing the lower triple clamp...................................... 36

Fork offset .................................................................... 37

Adjusting the fork offset ................................................. 37

Checking steering head bearing play................................ 38

Adjusting play of steering head bearing............................ 38

02/HANDLEBAR, INSTRUMENTS....................................... 40

Hot start lever ............................................................... 40

Handlebar position ........................................................ 40

Adjusting handlebar position .......................................... 40

Adjusting basic position of clutch lever............................ 41

Checking the throttle cable routing.................................. 41

Checking the play in the throttle cable............................. 41

Adjusting the play in the throttle cable ............................ 42

03/FRAME........................................................................ 43

Checking the frame ....................................................... 43

04/SHOCK ABSORBER, SWINGARM................................... 44

Adjusting the high-speed compression damping of the

shock absorber .............................................................. 44

Adjusting the low-speed compression damping of the

shock absorber .............................................................. 44

Adjusting the rebound damping of the shock absorber....... 45

TABLE OF CONTENTS

Installing the rear brake disc .......................................... 81

Checking the chain tension ............................................ 82

Adjusting the chain tension ............................................ 82

Adjusting the chain guide............................................... 83

Checking the chain, rear sprocket, engine sprocket and

chain guide................................................................... 83

Checking for chain dirt accumulation .............................. 85

Cleaning the chain......................................................... 85

11/WIRING HARNESS, BATTERY ....................................... 86

Removing the main fuse................................................. 86

Installing the main fuse ................................................. 86

Removing the battery ..................................................... 86

Installing the battery...................................................... 87

Charging the battery ...................................................... 87

Checking the charging voltage ........................................ 88

Checking the quiescent current....................................... 89

Checking the starter relay ............................................... 89

13/BRAKE SYSTEM........................................................... 90

Checking the front brake linings...................................... 90

Removing front brake linings .......................................... 90

Installing the front brake linings ..................................... 91

Changing the front brake linings ..................................... 91

Checking free travel on hand brake lever.......................... 93

Adjusting the basic position of the hand brake lever.......... 94

Checking the front brake fluid level ................................. 94

Adding front brake fluid ................................................. 94

Changing the front brake fluid ........................................ 95

Checking rear brake linings ............................................ 96

Removing rear brake linings............................................ 96

Mounting rear brake linings ............................................ 96

Changing the rear brake linings....................................... 97

Checking the free travel of the foot brake lever ................. 97

Adjusting the basic position of the foot brake lever ........... 98

Checking rear brake fluid level........................................ 98

Adding brake fluid to the rear brake circuit ...................... 99

Changing the rear brake fluid.......................................... 99

30/ENGINE..................................................................... 101

Removing the engine ................................................... 101

Installing the engine .................................................... 106

30/DISASSEMBLING THE ENGINE................................... 112

Preparations................................................................ 112

Removing the shift lever............................................... 112

Draining the engine oil ................................................. 112

Removing the oil filter.................................................. 112

Removing the spark plug .............................................. 113

Removing the valve cover ............................................. 113

Removing the starter motor .......................................... 113

Removing the alternator cover....................................... 113

Removing the torque limiter and starter idler gear........... 114

Positioning the engine at ignition top dead center

(TDC) ......................................................................... 114

Removing the camshaft................................................ 115

Removing the timing chain tensioner............................. 115

Removing the double wheel .......................................... 116

Removing the cylinder head.......................................... 116

Removing the water pump cover ................................... 117

Removing the clutch cover ........................................... 117

Removing the piston .................................................... 118

Removing the timing chain rails.................................... 118

Removing the timing chain........................................... 118

Removing the ignition pulse generator ........................... 119

Removing the rotor ...................................................... 119

Removing the drive wheel of the balancer gear ...............

Removing the force pump ............................................

Removing the spacer ...................................................

Removing the outer clutch hub .....................................

Removing the primary gear ...........................................

Removing the suction pump .........................................

Removing the shift shaft ..............................................

Removing the shift drum locating unit ...........................

Removing the locking lever...........................................

Removing the left section of the engine case..................

Removing the shift rails ...............................................

Removing the shift drum ..............................................

Removing the shift forks ..............................................

Removing the transmission shafts .................................

Removing the crankshaft ..............................................

30/ENGINE - WORK ON THE INDIVIDUAL PARTS .............

Working on the right section of the engine case ..............

Working on the left section of the engine case................

Removing the water pump ............................................

Changing the shaft seal ring of the water pump ..............

Installing the water pump.............................................

Removing the crankshaft seal ring in the clutch cover .....

Installing the crankshaft seal ring in the clutch cover......

Removing the stator.....................................................

Installing the stator .....................................................

Removing the oil pressure regulator valve.......................

Checking spring length of oil pressure regulator valve......

Installing the oil pressure regulator valve .......................

Checking the lubrication system....................................

Removing the crankshaft bearing inner race ...................

Installing the crankshaft bearing inner race....................

Changing connecting rod, conrod bearing and crank

pin.............................................................................

Checking crankshaft run-out at bearing pin ....................

Measuring the crankshaft end play ................................

Cylinder - Nikasil

coating ............................................

Checking/measuring cylinder ........................................

Checking/measuring the piston .....................................

Measuring piston/cylinder mounting clearance................

Checking the piston ring end gap ..................................

Changing the camshaft bearing.....................................

Checking the autodecompressor....................................

Checking camshafts.....................................................

Checking the radial clearance of the camshaft

bearings .....................................................................

Checking the camshaft bearing bridges..........................

Removing the valves ....................................................

Checking the valves .....................................................

Checking the valve springs ...........................................

Checking valve spring seat............................................

Checking the cam levers ..............................................

Checking cylinder head ................................................

Installing the valves .....................................................

Removing the freewheel ...............................................

Checking the freewheel ................................................

Installing the free wheel ...............................................

Checking the starter drive.............................................

Checking the timing assembly ......................................

Preparing the timing chain tensioner for installation .......

Disassembling the antihopping clutch ...........................

Preassembling the antihopping clutch ...........................

Checking the clutch.....................................................

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