KTM 2013 450 Rally Factory Replica, Owner'S Manual

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TABLE OF CONTENTS
3
11.12 Checking the steering head bearing play............ 46
11.13 Adjusting the play of the steering head
bearing x ..................................................... 46
11.14 Greasing the steering head bearing x .............. 47
11.15 Removing the seat .......................................... 48
11.16 Mounting the seat ........................................... 48
11.17 Removing the air filter
x
................................ 48
11.18 Installing the air filter
x
................................. 49
11.19 Removing the main silencer ............................. 49
11.20 Installing the main silencer.............................. 50
11.21 Changing the glass fiber yarn filling of the
main silencer
x
............................................. 50
11.22 Removing the fuel tank toward the front............ 50
11.23 Installing the fuel tank at the front ................... 51
11.24 Checking the chain for dirt accumulation .......... 51
11.25 Cleaning the chain .......................................... 52
11.26 Checking the chain tension .............................. 52
11.27 Adjusting the chain tension.............................. 53
11.28 Checking the chain, rear sprocket, engine
sprocket, and chain guide................................ 53
11.29 Checking the frame
x
.................................... 55
11.30 Checking the swingarm
x
............................... 55
11.31 Checking the rubber grip ................................. 55
11.32 Additionally securing the rubber grip................. 56
11.33 Adjusting the basic position of the clutch
lever .............................................................. 56
11.34 Checking the fluid level of the hydraulic
clutch ............................................................ 56
11.35 Changing the hydraulic clutch fluid
x
.............. 56
11.36 Removing the trim .......................................... 57
11.37 Mounting the trim ........................................... 57
12 BRAKE SYSTEM ........................................................ 59
12.1 Checking the free travel on the hand brake
lever .............................................................. 59
12.2 Adjusting the free travel of the hand brake
lever .............................................................. 59
12.3 Checking the brake discs ................................. 59
12.4 Checking the front brake fluid level .................. 60
12.5 Adding front brake fluid
x
.............................. 60
12.6 Checking the front brake linings ....................... 61
12.7 Changing the front brake linings
x
.................. 61
12.8 Checking the free travel of the foot brake
lever .............................................................. 63
12.9 Adjusting the free travel of the foot brake
lever
x ......................................................... 63
12.10 Checking the rear brake fluid level.................... 64
12.11 Adding rear brake fluid
x
............................... 64
12.12 Checking the rear brake linings ........................ 65
12.13 Changing the rear brake linings
x
................... 65
13 WHEELS, TIRES ........................................................ 67
13.1 Removing the front wheel
x
........................... 67
13.2 Mounting the front wheel
x
............................ 67
13.3 Removing the rear wheel
x
............................. 68
13.4 Installing the rear wheel
x
.............................. 69
13.5 Checking the rear hub rubber dampers
x
......... 70
13.6 Checking the tire condition .............................. 70
13.7 Checking the tire air pressure........................... 71
13.8 Checking the spoke tension.............................. 71
14 ELECTRICAL SYSTEM ................................................ 73
14.1 Removing the battery
x
.................................. 73
14.2 Installing the battery
x
.................................. 73
14.3 Recharging the battery
x
................................ 73
14.4 Changing the main fuse................................... 74
14.5 Changing fuses of individual power
consumers...................................................... 75
14.6 Checking the headlight setting ......................... 75
14.7 Adjusting the headlight range........................... 76
15 COOLING SYSTEM ..................................................... 77
15.1 Cooling system ............................................... 77
15.2 Checking the antifreeze and coolant level .......... 77
15.3 Checking the coolant level ............................... 77
15.4 Draining the coolant
x
................................... 78
15.5 Refilling coolant
x
......................................... 78
16 TUNING THE ENGINE................................................ 80
16.1 Checking the play in the throttle cable .............. 80
16.2 Adjusting the play in the throttle cable
x
......... 80
16.3 Carburetor - idle.............................................. 80
16.4 Carburetor - adjusting the idle speed x ............ 81
16.5 Emptying the carburetor float chamber x ......... 82
16.6 Checking the basic position of the shift lever ..... 83
16.7 Adjusting the basic position of the shift
lever
x ......................................................... 83
17 SERVICE WORK ON THE ENGINE ............................... 84
17.1 Checking the engine oil level............................ 84
17.2 Changing the engine oil and oil filter, cleaning
the oil screen
x
............................................. 84
17.3 Adding engine oil............................................ 86
18 CLEANING, CARE ...................................................... 88
18.1 Cleaning motorcycle ........................................ 88
18.2 Checks and maintenance steps for winter
operation........................................................ 89
19 STORAGE.................................................................. 90
19.1 Storage .......................................................... 90
19.2 Preparing for use after storage.......................... 90
20 TECHNICAL DATA...................................................... 91
20.1 Engine ........................................................... 91
20.2 Engine tightening torques ................................ 91
20.3 Capacities ...................................................... 93
20.3.1 Engine oil .................................................. 93
20.3.2 Coolant ...................................................... 93
20.3.3 Fuel .......................................................... 93
20.4 Chassis .......................................................... 93
20.5 Electrical system............................................. 94
20.6 Tires .............................................................. 94
20.7 Fork............................................................... 94
20.8 Shock absorber ............................................... 95
20.9 Chassis tightening torques ............................... 95
20.10 Carburetor with carburetor configuration
(carburetor sheets) .......................................... 97
21 WIRING DIAGRAM ..................................................... 98
21.1 Page 1 of 9 .................................................... 98
21.2 Page 2 of 9 .................................................. 100
21.3 Page 3 of 9 .................................................. 102
21.4 Page 4 of 9 .................................................. 104
21.5 Page 5 of 9 .................................................. 106
21.6 Page 6 of 9 .................................................. 108
21.7 Page 7 of 9 .................................................. 110
21.8 Page 8 of 9 .................................................. 112
21.9 Page 9 of 9 .................................................. 114
22 SUBSTANCES ......................................................... 116
23 AUXILIARY SUBSTANCES ........................................ 118
24 STANDARDS ........................................................... 120
INDEX ............................................................................ 121