KTM 2013 450 Rally Factory Replica Owner'S Manual Download

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SERVICE WORK ON THE ENGINE

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 ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.

–

Start the engine and check that it is oil-tight.

Finishing work

–

Check the engine oil level. (

p. 84)

Summary of Contents for 2013 450 Rally Factory Replica

Page 1: ...OWNER S MANUAL 2013 450 Rally Factory Replica Art no 3211865en ...

Page 2: ......

Page 3: ...cifica 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...

Page 4: ...e of conditions and menu activation 20 6 12 Fuel tank 20 6 13 Fuel tap 20 6 14 Choke 21 6 15 Shift lever 21 6 16 Foot brake lever 22 6 17 Side stand 22 6 18 Steering lock 22 6 19 Locking the steering 22 6 20 Unlocking the steering 23 7 PREPARING FOR USE 24 7 1 Advice on first use 24 7 2 Running in the engine 25 8 RIDING INSTRUCTIONS 26 8 1 Checks and maintenance when preparing for use 26 8 2 Start...

Page 5: ... 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 f...

Page 6: ...standing 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 Identif...

Page 7: ...arning 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 environ...

Page 8: ... 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...

Page 9: ... 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...

Page 10: ...w of vehicle front left 601285 10 1 Choke p 21 2 Kill switch p 12 2 Light switch p 12 2 Turn signal switch p 13 2 Horn button p 13 3 Clutch lever p 12 4 Steering lock p 22 5 Shift lever p 21 6 Side stand p 22 7 Seat release strap ...

Page 11: ...4 VIEW OF VEHICLE 9 4 2 View of vehicle rear right 601286 10 1 Ignition switch p 13 2 Overview p 14 3 Throttle grip p 12 4 Fuel tap p 20 5 Foot brake lever p 22 6 Hand brake lever p 12 ...

Page 12: ... fixed to the right of the steering head 5 3 Engine number 601288 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket 5 4 Key number 500125 10 The key number 1 for the steering lock is stamped onto the key connector 5 5 Fork part number 601289 10 The fork part number 1 is stamped on the inner side of the fork stub ...

Page 13: ...5 SERIAL NUMBERS 11 5 6 Shock absorber part number 601327 10 Shock absorber part number 1 is attached to the lower part of the shock absorber at the rear opposite to the direction of travel ...

Page 14: ...ar 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 Light switch 601292 12 The light switch 1 is fitted on the left side of the handlebar Possible states Light off Light switch is turn...

Page 15: ...sic position Electric starter button pressed In this position the electric starter is actuated 6 9 Indicator lamp overview 601298 01 Possible states High beam indicator lamp lights up blue High beam is switched on Turn signal indicator light flashes green Turn signal is switched on The oil pressure warning lamp lights up red The oil pressure is too low The temperature warning lamp lights up red Th...

Page 16: ... WS is displayed briefly Info The number 2205 equals the circumference of the 21 front wheel with stan dard tires The display then changes to the last selected mode 6 11 3 Tripmaster switch Option Tripmaster switch The tripmaster switch is used to control the functions of the speedometer from the handlebar Info The trip master is an optional accessory 6 11 4 Setting kilometers or miles Info If you...

Page 17: ...d and the Setup menu is closed Info If no button is pressed for 20 seconds or if no impulse comes from the wheel speed sensor the settings are automatically saved and the Setup menu is closed 6 11 6 Adjusting the speedometer functions Info When the vehicle is delivered only the SPEED H and SPEED ODO display modes are activated Condition The motorcycle is stationary 400318 01 Press the button brief...

Page 18: ... is displayed in the SPEED display mode The current speed can be displayed in Km h or Mph Info Making the setting according to the country When an impulse comes from the front wheel the left side of the speedometer display changes to the SPEED mode and the current speed is shown 6 11 9 Display mode SPEED H operating hours 400316 01 Condition The motorcycle is stationary Press the button briefly an...

Page 19: ...he next lap Press the button for 3 5 seconds The stop watch and the lap time are reset Press the button briefly Next display mode 6 11 12 Display mode SPEED ODO odometer 400317 01 Press the button briefly and repeatedly until ODO appears at the bottom right of the display The total distance traveled is displayed in the ODO display mode Press the button No function Press the button No function Pres...

Page 20: ... repeatedly until A1 appears at the top right of the display A1 average speed 1 shows the average speed calculated on the basis of TR1 trip mas ter 1 and S1 stop watch 1 The calculation of this value is activated by the first impulse of the wheel speed sensor and ends 3 seconds after the last impulse Press the button No function Press the button No function Press the button for 3 5 seconds The TR1...

Page 21: ...the button Press the button for 3 5 seconds Press the button briefly Display mode SPEED H operating hours No function No function The display changes to the Setup menu of the speedometer functions Next display mode Display mode SPEED CLK clock No function No function The display changes to the Setup menu of the clock Next display mode Display mode SPEED LAP lap time Starts or stops the clock Stops...

Page 22: ...ntrolled by a fuel tap Two fuel tanks are located in front of the seat and one fuel tank is located beneath the seat 601303 10 The right fuel tank is filled via filler cap 1 and the left fuel tank is filled via filler cap 2 601304 10 The rear fuel tank is filled via filler cap 3 6 13 Fuel tap 601305 10 Fuel tap 1 is located on the right over the pivot point of the swingarm The fuel tap can be used...

Page 23: ...handlebar Activating the choke function frees an opening through which the engine can draw extra fuel This creates a richer fuel air mixture as is required for a cold start Info If the engine is warm the choke function must be deactivated Possible states Choke function activated The choke lever is pulled to the stop Choke function deactivated The choke lever is pushed back to the stop 6 15 Shift l...

Page 24: ... is used to park the motorcycle Info When you are riding the side stand 1 must be folded up and secured with the rubber band 2 6 18 Steering lock 601300 10 The steering lock 1 is fitted on the left of the steering head The steering lock is used to lock the steering Steering and therefore riding is no longer possible 6 19 Locking the steering Note Danger of damage The parked vehicle may roll away o...

Page 25: ...ess it in and turn it to the right Remove the key Steering is no longer possible Info Never leave the key in the steering lock 6 20 Unlocking the steering 400731 01 Insert the key in the steering lock turn it to the left pull it out and turn it to the right Remove the key You can now steer the bike again Info Never leave the key in the steering lock ...

Page 26: ...re not braking Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permissible weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons Info When using your motorcycle remember that others may feel disturbed by excessive noise Make sure t...

Page 27: ... 882 lb Maximum permissible front axle load 190 kg 419 lb Maximum permissible rear axle load 250 kg 551 lb Run in the engine p 25 7 2 Running in the engine During the running in 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 hours 75 Avoid fully op...

Page 28: ...screws nuts and hose clamps regularly for tightness Check the fuel reserves 8 2 Starting 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 Note Engine failure Hig...

Page 29: ...gine has warmed up After reaching maximum speed by fully opening the throttle grip turn the throttle back so it is open This will barely reduce the speed but fuel consumption will be considerably lower Always open the throttle only as much as the engine can handle abrupt throttle opening increases fuel consumption To shift down brake and close the throttle at the same time Pull the clutch lever an...

Page 30: ... vehicle components become very hot when the vehicle is operated Do not park the vehicle near flammable or explosive substances Do not place objects on the vehicle while it is still warm from being run Always let the vehicle cool first Note Material damage Damage and destruction of components by excessive load The side stand is designed for the weight of the motorcycle only Do not sit on the motor...

Page 31: ...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 ground water the ground or the sewage system Switch off the engine Unscrew the filler cap 601328 10 Fill the fuel tank with fuel up to measurement A Guideline Measurement of A 45 mm 1 77 in Fuel tan...

Page 32: ...e all moving parts e g hand lever chain and check for smooth operation x Check the fluid level of the hydraulic clutch p 56 Check the front brake fluid level p 60 Check the free travel on the hand brake lever p 59 Check the steering head bearing play p 46 Check the valve clearance x Check the clutch x Change the absorbing elements in the outer clutch hub x Check all hoses e g fuel cooling bleeder ...

Page 33: ... conditions x Check measure the cylinder x Check the cylinder head x Change the valves valve springs and valve spring seats x Check the camshaft and cam lever x Change the connecting rod conrod bearing and crank pin x Change the crankshaft bearing x Check the transmission and shift mechanism x Check the oil pressure x Check the oil pressure regulator valve x Check the oil pumps and lubrication sys...

Page 34: ...suspension and not to the vehicle speed The high speed setting for example has an effect on the landing after a jump the rear wheel suspension compresses more quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses more slowly These two ranges can be adjusted separately although the transition between high speed and low speed...

Page 35: ...ounterclockwise to reduce damp ing 10 5 Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help 601330 10 Turn adjusting screw 1 clockwise up to the last perceptible click Turn back c...

Page 36: ...rcycle the rider wearing full protective cloth ing sits on the seat in a normal sitting position feet on footrests and bounces up and down a few times The rear wheel suspension levels out Another person now measures the distance between the rear axle and a fixed point Note down the value as dimension C Info The riding sag is the difference between measurements A and C Check the riding sag Riding s...

Page 37: ...e riding sag x Preparatory work Remove the shock absorber x After removing the shock absorber clean it thoroughly B00292 10 Main work Choose and mount a suitable spring Guideline Spring rate Weight of rider 75 85 kg 165 187 lb 80 N mm 457 lb in Info The spring rate is shown on the outside of the spring Finishing work Install the shock absorber x Check the static sag of the shock absorber p 34 Chec...

Page 38: ... rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior 601332 10 Remove protection caps 1 Turn adjusting screws 2 clockwise all the way Info Adjusting screws 2 are located at the bottom end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline Rebound d...

Page 39: ...ount the front fender p 41 Remove the fork legs x p 42 Remove the lower triple clamp x p 43 0 0 1 1 0 0 1 1 401200 10 Main work Remove screws 1 Remove the steering stem Rotate the steering stem 180 and insert into the triple clamp Mount and tighten screws 1 Guideline Screw steering stem bot tom M8 25 Nm 18 4 lbf ft Loctite 243 Finishing work Install the lower triple clamp x p 44 Check that the wir...

Page 40: ...it will cause material fatigue and the handlebar can break Always replace handle bar 0 0 3 3 0 0 2 2 0 0 1 1 0 0 4 4 0 0 5 5 0 0 6 6 0 0 7 7 0 0 8 8 0 0 9 9 400343 10 Remove the four screws 1 Remove handlebar clamps 2 with rubber washers 3 and elastomers 4 Remove the handlebar and lay it to one side Info Protect the motorcycle and its attachments against damage by covering them Do not bend the cab...

Page 41: ...bber washers 3 and elastomers 4 Elastomer kit green soft quality SXS05125203 Elastomer kit yellow medium quality standard SXS05125204 Elastomer kit red hard quality SXS05125205 Info The elastomers are available in different versions Mount and evenly tighten the four screws 1 Guideline Screw handlebar clamp M8 16 Nm 11 8 lbf ft Info Make sure the gap width is even ...

Page 42: ...d vehicle may roll away or fall over Always place the vehicle on a firm and even surface 601699 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press the side stand 1 with your foot to the ground and lean the motorcycle on it Info When you are riding the side stand must be folded up and secured with the rubber band 11 3 Bleeding the fork legs Preparatory w...

Page 43: ...ccidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray p 119 Press the dust boots back into their normal position Remove excess oil Finishing work Install the front fender p 41 Remove the moto...

Page 44: ...01338 10 Remove cable binder 2 Loosen screws 3 Take out the left fork leg Loosen screws 4 Take out the right fork leg 11 8 Removing the fork legs x Preparatory work Raise the motorcycle with the lift stand p 40 Remove the front wheel x p 67 Dismount the front fender p 41 601339 10 Main work Remove screws 1 Allow the brake caliper and brake line to hang tension free to the side 601338 10 Remove cab...

Page 45: ...er 4 601339 11 Position the brake caliper Mount and tighten screws 5 Guideline Screw front brake caliper M8 30 Nm 22 1 lbf ft Loctite 243 Finishing work Install the front fender p 41 Mount the front wheel x p 67 11 10 Removing the lower triple clamp x Preparatory work Raise the motorcycle with the lift stand p 40 Remove the front wheel x p 67 Dismount the front fender p 41 Remove the fork legs x p...

Page 46: ... triple clamp with the steering stem Remove the upper steering head bearing 11 11 Installing the lower triple clamp x 401211 10 Main work Clean the bearing and sealing elements check for damage and grease High viscosity grease p 118 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing Check whether the top steering head seal 1 is correctly positioned Slide on ...

Page 47: ...r 8 601385 10 Mount and tighten screws 9 Guideline Screw brake line holder on bottom triple clamp M5 2 Nm 1 5 lbf ft 601386 10 Tighten nut bk Guideline Nut upper steering head M20x1 12 Nm 8 9 lbf ft Lock screw bl with nut bk Guideline Screw top steering head M20x1 12 Nm 8 9 lbf ft Tighten screw bm Guideline Screw top steering stem M8 20 Nm 14 8 lbf ft 601338 13 Tighten screws bn Guideline Screw bo...

Page 48: ...fo If the bike is ridden with play in the steering head bearing the bearing and the bearing seats in the frame can become dam aged over time Preparatory work Raise the motorcycle with the lift stand p 40 400738 11 Main work Move the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel No play should be noticeable in the steering head bearing If there is...

Page 49: ...tem M8 20 Nm 14 8 lbf ft Tighten screws 6 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft 601337 10 Position steering damper 3 Mount and tighten screws 2 Guideline Screw steering damper M6 15 Nm 11 1 lbf ft Remove the cable binders and place the handlebar onto the handlebar clamp base Mount the holding plate with the handlebar clamps and position the handlebar Mount and tighten screws 1 Guid...

Page 50: ...t at the rear and take it off 11 16 Mounting the seat 601348 10 Let the locking pin of the seat engage in lock housing 1 Lock the seat at the front with quick release 2 Make sure that the seat is correctly locked in 11 17 Removing the air filter x Preparatory work Remove the seat p 48 601349 10 Main work Remove screws 1 Take off air filter box lid 2 ...

Page 51: ...air filter 1 Info The air filter must lie flush against the air filter box along the entire sealing surface Hook air filter box lid 2 into the front of the air filter box and swing down 601349 11 Mount and tighten screws 3 Guideline Screw air filter box top M6 2 Nm 1 5 lbf ft Finishing work Mount the seat p 48 11 19 Removing the main silencer Warning Danger of burns The exhaust system gets very ho...

Page 52: ... the inner tube Remove the adhesive tape from the inner tube Slide the outer tube over the glass fiber yarn filling Insert the locking cap into the outer tube Position the steel bands and mount the rivets Finishing work Install the main silencer p 50 11 22 Removing the fuel tank toward the front Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigare...

Page 53: ...cap 11 23 Installing the fuel tank at the front 601355 11 Main work Position the fuel tank Mount and tighten screws 1 Guideline Screw front fuel tank M8 8 Nm 5 9 lbf ft Clean quick release of fuel line 2 and connect it Repeat the operation on the opposite side 601354 11 Mount and tighten screws 3 Guideline Screw front fuel tank M8 8 Nm 5 9 lbf ft Connect the hoses 4 of the fuel tank breather witho...

Page 54: ...ccidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bear ings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On the other hand if the chain is loose it can fall off...

Page 55: ... Chain tension 5 mm Turn adjusting screws 3 on the left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks A The rear wheel is then correctly aligned Tighten nuts 2 Make sure that chain adjusters 4 are fitted correctly on adjusting screws 3 Tighten nut 1 Guideline Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Info The wi...

Page 56: ...rocket should also be changed New chains wear out faster on old worn sprockets 601358 10 Check the chain sliding guard for wear If the bottom edge of the chain bolt is in line with or below the chain sliding guard Change the chain sliding guard x Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the chain sliding guard Guideline Screw chain sliding gua...

Page 57: ...f the frame exhibits cracks or deformation due to a mechanical impact Change the frame x Info A frame that has been damaged due to a mechanical impact must always be changed Repair of the frame is not authorized by KTM 11 30 Checking the swingarm x 601608 01 Check the swingarm for damage cracking and deformation If the swingarm shows signs of damage cracking or deformation Change the swingarm x In...

Page 58: ...and do not apply any force Do not make any adjustments while riding 11 34 Checking the fluid level of the hydraulic clutch Info The fluid level rises with increased wear of the clutch lining discs Do not use brake fluid 600112 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 Check the fluid level Fluid level under t...

Page 59: ...ylinder reservoir Remove the bleeding syringe Mount and tighten the bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level under top level of container 4 mm 0 16 in Position the cover with the membrane Mount and tighten the screws 11 36 Removing the trim 601352 10 Detach the plug in connectors on the turn signal cables Open quick releases 1 Remove the trim toward the f...

Page 60: ...11 SERVICE WORK ON THE CHASSIS 58 601352 11 Position the trim and attach it with quick releases 3 ...

Page 61: ... moves away from the handlebar Turn the adjusting screw counterclockwise to increase free travel The pres sure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 12 3 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc s Chan...

Page 62: ... system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warn...

Page 63: ... 12 7 Changing the front brake linings x Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brak...

Page 64: ...uid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid is corrosive Use only clean brake fluid from a sealed container 601364 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 600039 11 Press the brak...

Page 65: ...ach the spring from the foot brake lever 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 A Guideline Free travel at the foot brake lever 3 5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the free travel of the foot brake lever x p 63 Attach the spring to the foot brake lever 12 9 Adjusting...

Page 66: ...n irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid...

Page 67: ...d of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents Reduced braking efficiency due to use of non approved brake lin...

Page 68: ... remove bolt 4 toward the left by striking it and remove the brake linings Clean the brake caliper and brake caliper support 400419 10 Check that leaf spring 5 in the brake caliper and sliding plate 6 in the brake caliper support are seated correctly 100289 01 Insert the brake linings insert the bolt and mount the cotter pin Operate the foot brake lever repeatedly until the brake linings are in co...

Page 69: ...3 10 Remove spacer 4 13 2 Mounting the front wheel x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary 600033 11 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the wheel bearing x Clean and grease shaft seal rin...

Page 70: ... on to the brake disc in order to press back the brake piston Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut 1 Remove chain adjuster 2 Withdraw wheel spindle 3 only enough to allow the rear wheel to be pushed for ward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket Holding the rear wheel...

Page 71: ...ce of the spacer in the rear sprocket carrier Insert the rear sprocket carrier 2 into the rear hub 601369 10 Lift the rear wheel into the swingarm position it and insert wheel spindle 3 Attach the chain Position chain adjuster 4 Mount nut 5 but do not tighten it yet Check the chain tension p 52 Make sure that the chain adjusters are fitted correctly on the adjusting screws Tighten nut 5 Guideline ...

Page 72: ...ay on the outside of the rear sprocket Play in rubber dampers rear wheel 5 mm 0 2 in If play A is larger than the specified value Change all rubber dampers in the rear hub Finishing work Install the rear wheel x p 69 Remove the motorcycle from the lift stand p 40 13 6 Checking the tire condition Info Only mount tires approved and or recommended by KTM Other tires could have a negative effect on ri...

Page 73: ... 5 bar 22 psi If the tire pressure does not meet specifications Correct the tire air pressure Fit the dust cap 13 8 Checking the spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that the spoke tension is correct Your authorized KTM workshop will be glad to help Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes If the s...

Page 74: ...13 WHEELS TIRES 72 Torque wrench with various accessories in set 58429094000 ...

Page 75: ...e battery holder Lithium ion battery p 94 Reconnect rubber band 1 Connect positive cable 2 Guideline Nut cable on battery M6 5 Nm 3 7 lbf ft Attach negative cable 3 Guideline Nut cable on battery M6 5 Nm 3 7 lbf ft Finishing work Mount the seat p 48 14 3 Recharging the battery x Warning Environmental hazard The battery contains elements that are harmful to the environment Do not discard batteries ...

Page 76: ...work Mount the seat p 48 14 4 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Info The main fuse protects all power consumers of the vehicle It is located in the starter relay housing under the seat Preparatory work Switch off all power consumers and switch off t...

Page 77: ...defective fuse is shown by a burned out fuse wire A Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Use spare fuses with the correct rating only Fuse 58011109105 p 94 Fuse 58011109110 p 94 Fuse 58011109115 p 94 Check that the power consumer is functioning properly Close the fuse box co...

Page 78: ... the trim p 57 601382 10 Main work Loosen screw 1 Adjust the headlight range by moving the headlight Guideline The boundary between light and dark must be exactly on the lower mark for an operational motorcycle with a rider to prepare the mark see Checking the head light setting Info A change in weight on the vehicle may require a correction of the headlight range Tighten screw 1 Finishing work Mo...

Page 79: ...tact a doctor immedi ately Change clothes that have come into contact with coolants Keep coolant out of the reach of children Condition The engine is cold 400243 10 Stand the motorcycle upright on a horizontal surface Remove the radiator cap Check the coolant antifreeze 25 45 C 13 49 F If the coolant antifreeze does not meet specifications Correct the coolant antifreeze Check the coolant level in ...

Page 80: ...immediately with soap and water If coolant is swallowed contact a doctor immedi ately Change clothes that have come into contact with coolants Keep coolant out of the reach of children Condition The engine is cold 601374 10 Stand the motorcycle upright Place a suitable container under the water pump cover Remove screw 1 Remove radiator cap 2 Completely drain the coolant Mount and tighten screw 1 w...

Page 81: ...15 COOLING SYSTEM 79 Mount the radiator cap Take a short test ride Check the coolant level p 77 ...

Page 82: ...ove the trim p 57 Remove the seat p 48 Remove the fuel tank toward the front p 50 Check the throttle cable routing 601376 10 Main work Move the handlebar to the straight ahead position Push back sleeves 1 Loosen nut 2 Turn adjusting screw 3 in as far as possible Loosen nut 4 Turn adjusting screw 5 so that there is play in the throttle cable at the throttle grip Guideline Play in throttle cable 3 5...

Page 83: ...c and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Adjust the idle speed with adjusting screw 2 Guideline Choke function deactivated The choke lever is pushed back to the stop p 21 Idle speed 1 550 1 650 rpm Tur...

Page 84: ... 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...

Page 85: ...ust the basic position of the shift lever x p 83 16 7 Adjusting the basic position of the shift lever x 601380 10 Remove screw 1 and take off shift lever 2 601381 10 Clean gear teeth A of the shift lever and shift shaft Mount the shift lever on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into contact with any...

Page 86: ...ng the oil screen x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable ...

Page 87: ... ring 601323 10 Pull oil filter 6 out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing area 601323 11 Oil O ring 7 and mount on the oil filter cover 601322 10 Position the lower oil filter cover 5 Mount and tighten screws 4 Guideline Screw oil filter cover M5 6 Nm 4 4 lbf ft 601325 10 Remove screws 8 Remove the uppe...

Page 88: ...il filler plug 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 ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight Finishing work Check the engine oil level p 84 1...

Page 89: ...esult in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight Finishing work Check the engine oil level p 84 ...

Page 90: ... cleaner and then clean with a paintbrush Motorcycle cleaner p 118 Info Use warm water containing normal motorcycle cleaner and a soft sponge After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the closure on the exhaust system Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a dirty or wet brake system b...

Page 91: ...brake system Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts are cooled down and while they are installed After riding on salted roads thoroughly wash the motorcycle with cold water and dry it well Treat the engine swingarm and all other bright and zinc plated parts except for the brake...

Page 92: ...level p 77 Add fuel additive the last time you refuel before taking the motorcycle out of service Fuel additive p 118 Drain the fuel from the fuel tanks into a suitable container Empty the carburetor float chamber x p 82 Check the tire air pressure p 71 Remove the battery x p 73 Recharge the battery x p 73 Guideline Storage temperature of battery without direct sunshine 0 35 C 32 95 F Charging lev...

Page 93: ...d gear 19 30 4th gear 21 28 5th gear 23 26 Alternator 12 V 200 W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Spark plug NGK CR 9 EKB Spark plug electrode gap 0 7 mm 0 028 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid Electric starter 20 2 Engine tightening torques Jet engine case breather M4 On block Loctite 243...

Page 94: ...1 14 Nm 10 3 lbf ft Screw engine case M7x1 14 Nm 10 3 lbf ft Plug crankshaft location M8 20 Nm 14 8 lbf ft Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701 Spark plug M10 10 12 Nm 7 4 8 9 lbf ft Plug cam lever axle M10x1 10 Nm 7 4 lbf ft Plug oil channel M10x1 10 Nm 7 4 lbf ft Screw camshaft gear M10x1 50 Nm 36 9 lbf ft Lubricated with engine oil Screw rotor M10x1 80 Nm 59 lbf ft Lubricate...

Page 95: ...al Super unleaded ROZ 95 RON 95 PON 91 p 117 Rear fuel tank approx 18 0 l 4 76 US gal Super unleaded ROZ 95 RON 95 PON 91 p 117 Total fuel capacity approx 36 0 l 9 51 US gal Super unleaded ROZ 95 RON 95 PON 91 p 117 20 4 Chassis Frame Lattice frame of chromium molybdenum steel tubes powder coated Suspension travel Front 300 mm 11 81 in Rear 310 mm 12 2 in Fork offset Mark 1 visible 20 mm 0 79 in N...

Page 96: ...ht W5W socket W2 1x9 5d 12 V 5 W Indicator lamps W1 2W socket W2x4 6d 12 V 1 2 W Turn signal RY10W socket BAU15s 12 V 10 W Brake tail light LED License plate lamp W5W socket W2 1x9 5d 12 V 5 W 20 6 Tires Front tires Rear tires 90 90 21 54S TT Michelin T63 130 80 18 66S TT Michelin T63 Additional information is available in the Service section under http www ktm com 20 7 Fork Fork part number 14 18...

Page 97: ...Nm 3 7 4 4 lbf ft Remaining nuts chassis M5 5 Nm 3 7 lbf ft Remaining screws chassis M5 5 Nm 3 7 lbf ft Screw additional tail light M5 2 Nm 1 5 lbf ft Screw air baffle M5 1 Nm 0 7 lbf ft Screw brake line holder on bottom triple clamp M5 2 Nm 1 5 lbf ft Screw foot brake lever foothold M5 6 Nm 4 4 lbf ft Loctite 243 Screw fuel tank closure flange M5 2 5 Nm 1 84 lbf ft Screw fuel tap on frame M5 5 Nm...

Page 98: ...Screw front brake caliper M8 30 Nm 22 1 lbf ft Loctite 243 Screw front fuel tank M8 8 Nm 5 9 lbf ft Screw fuel tank bracket M8 15 Nm 11 1 lbf ft Screw handlebar clamp M8 16 Nm 11 8 lbf ft Screw license plate holder top M8 20 Nm 14 8 lbf ft Screw motor guard M8 25 Nm 18 4 lbf ft Screw rear fuel tank top M8 25 Nm 18 4 lbf ft Loctite 243 Screw side stand bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw...

Page 99: ... with carburetor configuration carburetor sheets Carburetor type KEIHIN FCR MX 41 Carburetor identification number 4100D Needle position 3 th position from top Idle mixture adjusting screw Open 1 5 turns Main jet 185 Jet needle OBDVT OBDTQ Idling jet 42 Idle air jet 100 Cold start jet 85 ...

Page 100: ... 3 1 2 4 0 2 G 0 1 G 2 3 EN 3 1 S15 1 2 X300 10A F4 12 4 5A F2 10 2 T20 BI 2 EM 3 1 2 3 2 1 X301 1 1 AF 4 X3 2 AU 2 X4 2 FP 1 X5 1 3 e AF 4 X3 4 d b c FP 1 X9 1 a X302 3 A1 A15 2 3 BU 18 X1 2 3 FH 16 X6 2 FH 16 X6 10 FH 16 X6 4 FH 16 X6 12 br br bl bl bl bl ye rd ye rd ye rd ye rd ye rd ye rd bl br wh rd gr gn rd gn br br br ye rd gn gn br wh rd gr gn rd gn 601401 01 ...

Page 101: ...21 WIRING DIAGRAM 99 Components A15 CDI controller F2 Fuse F4 Fuse G10 Battery G20 Alternator K10 Starter relay with main fuse M10 Starter motor T20 Voltage regulator S15 Ignition switch ...

Page 102: ...9 1 2 1 BL 2 X20 2 1 BL 2 X21 2 1 BL 2 X22 2 10A F5 13 6 C1 5 FH 16 5 FH 16 13 AD 12 X7 1 BD 12 X8 1 b BD 12 X8 8 AD 12 X7 8 c AD 12 X7 7 BD 12 X8 7 a a M14 BI 2 BI 2 1 2 B33 2 1 FP 1 X17 1 FP 1 X54 1 AU 2 X55 1 10A F7 15 7 FH 16 X6 7 FH 16 X6 15 AU 2 X55 2 e br bl rd bl rd pk pk gn rd gn rd gn bl bl gn bl rd br br br br bl rd bl rd gr gn rd br wh bl wh bl br gn gr gn rd br br gn br 601402 01 ...

Page 103: ...21 WIRING DIAGRAM 101 Components B33 Radiator fan temperature switch F5 Fuse F7 Fuse M14 Radiator fan ...

Page 104: ...B 9 X15 3 BB 9 X16 3 AC 6 X24 2 CJ 2 X26 1 e e AB 9 X15 1 BB 9 X16 1 2 6 BB 9 X16 4 AB 9 X15 4 AF 4 X12 1 CJ 2 X26 2 4 15A F3 11 3 AF 4 X12 3 CR 1 X48 1 CR 1 X46 1 3 AC 6 X24 5 g AC 6 X24 1 a a h f g 1 A4 A15 9 A3 9 BA 1 X27 1 BU 18 X1 9 FH 16 X6 3 FH 16 X6 11 BD 12 X8 2 AD 12 X7 2 gn or gn or gn or gn or gn bu rd ye rd wh ye gn gn rd ye br gn or gn or gn br ye ye gn ye wh br ye gn gn bu rd ye ye ...

Page 105: ...21 WIRING DIAGRAM 103 Components A15 CDI controller E11 Low beam F3 Fuse K14 Low beam relay P15 Horn S22 Light switch horn button kill switch ...

Page 106: ... F1 3 B8 3 B8 4 9 450 RALLY Factory Replica e e e e f P23 2 1 FO 2 X35 2 FO 2 X35 1 K13 2 4 3 1 4 AB 9 X15 5 BB 9 X16 5 CJ 2 X25 2 AF 4 X11 1 CJ 2 X25 1 2 AF 4 X11 3 AB 9 X15 2 BB 9 X16 2 g AB 9 X15 7 BB 9 X16 7 E12 2 1 bu rd bu bu bu or bu or rd bu ye br bu bu br rd bu br br br br br bu rd br ye br br 601404 01 ...

Page 107: ...21 WIRING DIAGRAM 105 Components E12 High beam K13 High beam relay P23 High beam indicator light ...

Page 108: ...p Down Mode 4 E8 8 E1 3 E8 5 9 450 RALLY Factory Replica 3 2 1 2 1 4 3 2 1 CZ 3 CX 2 DB 4 P13 B70 1 2 CW 2 S36 4 1 DA 4 2 3 e 1 2 2 1 1 2 CY 3 X34 3 h h AH 2 X31 1 AH 2 X32 1 AK 2 X33 2 AH 2 X30 2 AH 2 X10 1 AH 2 X10 2 P35 AK 2 AK 2 1 2 br br br br br wh wh wh wh br wh br wh wh br br wh 601405 01 ...

Page 109: ...21 WIRING DIAGRAM 107 Components B70 Wheel speed sensor front P13 Speedometer P35 Parking light S36 Tripmaster switch ...

Page 110: ... CW 2 P46 1 CW 2 2 CW 2 P42 1 CW 2 2 CW 2 P21 2 1 K20 1 2 CX 2 X37 2 CX 2 X38 2 CX 2 X39 2 CX 2 X40 2 BL 2 X23 1 AH 2 X56 1 i AH 2 X56 2 BT 3 X49 1 2 CX 2 X37 1 CX 2 X38 1 FO 2 X2 1 BT 3 X49 3 CX 2 X39 1 CX 2 X40 1 2 CD 2 X36 2 e P22 2 1 FO 2 X57 1 AD 12 X7 4 FO 2 X57 2 CD 2 X36 1 BL 2 X23 2 ye bu or pu pu pu pu bl bl bl br br br br ye bu ye bu or ye bu bl ye bu bl gn bl gn br br 601406 01 ...

Page 111: ...mponents K20 Turn signal relay P21 Turn signal indicator light P22 Idling speed indicator lamp P41 Front left turn signal P42 Front right turn signal P45 Rear left turn signal P46 Rear right turn signal S25 Turn signal switch ...

Page 112: ... 7 6 5 4 3 2 1 P 3 E8 t 7 9 450 RALLY Factory Replica B35 1 P27 2 1 FO 2 X45 2 g P26 2 1 FO 2 X43 2 AB 9 X15 8 BB 9 X16 8 FP 1 X42 1 FO 2 X45 1 B39 AY 1 X41 1 BJ 1 X29 1 BB 9 X16 9 AB 9 X15 9 FO 2 X43 1 gn gr gn gr bl ye bl ye bl ye bl ye ye ye gn gr gn gr bl ye bl ye ye 601407 01 ...

Page 113: ...21 WIRING DIAGRAM 111 Components B35 Oil pressure sensor B39 Temperature switch indicator lamp P26 Temperature warning lamp P27 Oil pressure warning lamp ...

Page 114: ...13 2 DI 2 X44 2 AH 2 X58 1 i 10A F6 14 6 FH 16 X6 6 FH 16 X6 14 BD 12 X8 10 AD 12 X7 10 AH 2 X52 1 AH 2 X52 2 BD 12 X8 3 AD 12 X7 3 AH 2 X58 2 5A F1 9 1 DI 2 X44 1 BC 6 X13 5 3 3 AB 9 X15 6 BB 9 X16 6 h a a BC 6 X13 1 CB 6 X14 1 BV 2 X28 1 BV 2 X28 2 AJ 3 X18 3 AJ 3 X18 2 1 FH 16 X6 1 FH 16 X6 9 ye bu wh gn wh gn wh wh gn gn br ye bu wh gn br wh gn wh gn wh ye wh ye wh wh ye bu ye bu ye bu wh gn g...

Page 115: ...21 WIRING DIAGRAM 113 Components B76 Front brake light switch B77 Rear brake light switch E60 License plate lamp F1 Fuse F6 Fuse P36 Brake tail light ...

Page 116: ...8 16 8 FH 16 X6 8 FH 16 X6 16 BD 12 X8 6 AD 12 X7 6 BR 4 X53 4 a B10 1 3 2 AR 3 B37 1 2 AT 2 R51 1 12 2 13 1 BU 18 X1 14 AM 3 X47 3 11 1 BU 18 X1 10 AL 2 X50 2 BU 18 X1 1 CR 1 X51 1 12 13 10 11 14 1 BU 18 X1 5 BU 18 X1 7 BF 1 X280 1 BA 1 X281 1 CB 6 X14 4 BC 6 X13 4 CB 6 X14 6 BC 6 X13 6 7 5 or wh rd wh rd bl or bl or gn bu ye bl gn rd bl bu or bu ye bl gn rd bl bu or or or wh rd bl or bl or gn wh...

Page 117: ... B37 Pulse generator F8 Fuse R51 Ignition coil cylinder 1 S23 Emergency OFF switch electric starter button X280 Connector ignition curve X281 Connector ignition curve Cable colors bl Black br Brown bu Blue gn Green gr Gray lbu Light blue or Orange pk Pink pu Violet rd Red wh White ye Yellow ...

Page 118: ...orrosion inhibitor antifreeze 50 distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Supplier Motorex COOLANT G48 Engine oil SAE 10W 60 00062010035 According to JASO T903 MA p 120 SAE p 120 SAE 10W 60 KTM LC4 2007 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corre sponding properties KTM recommends Moto...

Page 119: ... recommends Motorex products Supplier Motorex Hydraulic Fluid 75 Shock absorber oil SAE 2 5 50180342S1 According to SAE p 120 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel...

Page 120: ...ilizer High viscosity grease Guideline KTM recommends SKF products Supplier SKF LGHB 2 Long life grease Guideline KTM recommends Motorex products Supplier Motorex Bike Grease 2000 Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Off road chain spray Guideline KTM recommends Motorex products Supplier Motorex Chainlube Offroad Paint cleaner and polish for ...

Page 121: ...23 AUXILIARY SUBSTANCES 119 Rubber grip adhesive 00062030051 Supplier KTM Sportmotorcycle AG GRIP GLUE Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Synthetic ...

Page 122: ...rvice intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils...

Page 123: ...king 56 fluid changing 56 Clutch lever 12 basic position adjusting 56 Compression damping fork adjusting 36 Compression damping high speed shock absorber adjusting 32 Compression damping low speed shock absorber adjusting 33 Coolant draining 78 refilling 78 Coolant level checking 77 Cooling system 77 Customer service 7 E Electric starter button 13 Engine running in 25 Engine number 10 Engine oil a...

Page 124: ... checks and maintenance when preparing for use 26 Protective clothing 6 R Rear hub rubber dampers checking 70 Rear sprocket checking 53 Rear wheel installing 69 removing 68 Rebound damping fork adjusting 36 shock absorber adjusting 33 Refueling fuel 29 Riding sag adjusting 35 Rubber grip checking 55 securing 56 S Safe operation 6 Seat mounting 48 removing 48 Service 7 Service schedule 30 31 Shift ...

Page 125: ...e condition checking 70 Transport 28 Trim mounting 57 removing 57 Turn signal switch 13 Type label 10 U Use definition 5 V View of vehicle front left 8 rear right 9 W Warranty 7 Winter operation checks and maintenance steps 89 Wiring diagram page 1 of 9 98 page 2 of 9 100 page 3 of 9 102 page 4 of 9 104 page 5 of 9 106 page 6 of 9 108 page 7 of 9 110 page 8 of 9 112 page 9 of 9 114 Work rules 6 ...

Page 126: ... 3211865en 3211865en 06 2012 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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KTM 2013 450 Rally Factory Replica, Owner'S Manual

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