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SERVICE WORK ON THE CHASSIS

52

9.32

Checking the rubber grip

401197-01

–

Check the rubber grips on the handlebar for damage, wear, and looseness.
» If a rubber grip is damaged, worn, or loose:

–

Change and secure the rubber grip.

Rubber grip adhesive (00062030051) (

9.33

Additionally securing the rubber grip

–

Check the rubber grip. (

401198-01

–

Secure the rubber grip at two points using the securing wire.

Securing wire (54812016000)
Wire twister forceps (U6907854)

The twisted wire ends face away from the hands and are bent toward the rub-
ber grip.

9.34

Adjusting the basic position of the clutch lever

601290-11

–

Adjust the basic setting of the clutch lever to your hand size by turning adjusting
screw



.

Info

Turn the adjusting screw clockwise to increase the distance between the
clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the clutch lever and 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!

9.35

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



.

–

Remove cover



with membrane



.

–

Check the fluid level.

Fluid level under top level of container

4 mm (0.16 in)

» If the fluid level does not meet specifications:

–

Correct the fluid level of the hydraulic clutch.

Hydraulic fluid (15) (

–

Position the cover with the membrane. Mount and tighten the screws.

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Содержание 450 Rally Factory Replica

Страница 1: ...OWNER S MANUAL 2012 450 Rally Factory Replica Art no 3211726en ...

Страница 2: ......

Страница 3: ...elow Chassis number p 8 Dealer s stamp Engine number p 8 Key number p 8 2011 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...

Страница 4: ...bsorber 30 Adjusting the low speed compression damping of the shock absorber 31 Adjusting the rebound damping of the shock absorber 31 Measuring the unloaded rear wheel sag 31 Checking the static sag of the shock absorber 32 Checking the riding sag of the shock absorber 32 Adjusting the spring preload of the shock absorber x 32 Adjusting the riding sag x 33 Checking the basic setting of the fork 3...

Страница 5: ...ING SYSTEM 71 Cooling system 71 Checking the antifreeze and coolant level 71 Checking the coolant level 71 Draining the coolant x 72 Refilling coolant x 72 TUNING THE ENGINE 74 Checking the play in the throttle cable 74 Adjusting the play in the throttle cable x 74 Carburetor idle 74 Carburetor adjusting the idle speed x 75 Emptying the carburetor float chamber x 76 Checking the basic position of ...

Страница 6: ... You should use the fuels oils and greases according to specifications as listed in the owner s manual Spare parts accessories For your own safety only use spare parts and accessory products that have been 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 Some spare parts and accesso...

Страница 7: ...us 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 ...

Страница 8: ... of vehicle front left 601285 10 1 Choke p 19 2 Kill switch p 10 2 Light switch p 10 2 Turn signal switch p 11 2 Horn button p 11 3 Clutch lever p 10 4 Steering lock p 20 5 Shift lever p 19 6 Side stand p 20 7 Seat release strap ...

Страница 9: ...VIEW OF VEHICLE 7 2 2 View of vehicle rear right 601286 10 1 Ignition switch p 11 2 Speedometer p 12 3 Throttle grip p 10 4 Fuel tap p 18 5 Foot brake lever p 20 6 Hand brake lever p 10 ...

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

Страница 11: ...SERIAL NUMBERS 9 3 6 Shock absorber part number 601327 10 Shock absorber part number is attached to the lower part of the shock absorber at the rear opposite to the direction of travel ...

Страница 12: ...ossible 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 4 5 Light switch 601292 12 The light switch is fitted on the left side of the handlebar Possible states Light off Light switch is turned to ...

Страница 13: ... position Electric starter button pressed In this position the electric starter is actuated 4 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 The c...

Страница 14: ... 2205 mm equals the circumference of the 21 front wheel with a series production tire The display then changes to the last selected mode 4 13 Tripmaster switch Option Tripmaster switch You can use the trip master switch to control the functions of the speedometer from the handlebar Info The trip master is an optional accessory 4 14 Setting kilometers or miles Info If you change the unit of measure...

Страница 15: ...menu is closed Info If no button is pressed for 20 seconds or if a pulse arrives from the wheel speed sensor the settings are stored automatically and the Setup menu is closed 4 16 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 briefly and repeatedly ...

Страница 16: ...splayed 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 4 19 Display mode SPEED H operating hours 400316 01 Condition The motorcycle is stationary Press the button briefly and repeat...

Страница 17: ...e 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 4 22 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 Press th...

Страница 18: ...epeatedly 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 A...

Страница 19: ...perating 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 the current lap time and saves it and the stop watch starts the next lap The stop watch an...

Страница 20: ...anks 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 and the left fuel tank is filled via filler cap 601304 10 The rear fuel tank is filled via filler cap 4 30 Fuel tap 601305 10 Fuel tap is located on the right over the pivot point of the swingarm The fuel tap can be used to control the individual fuel tanks The...

Страница 21: ...ndlebar Activating the choke function frees an opening through which the engine can draw extra fuel This gives a richer fuel air mixture which is needed 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 4 32 Shift leve...

Страница 22: ...ring lock 601300 10 The steering lock 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 4 36 Locking the steering Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 400732 01 Park the vehicle Turn the handlebar as far as possible to the ri...

Страница 23: ...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 ...

Страница 24: ...t 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 that t...

Страница 25: ...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 23 5 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 ope...

Страница 26: ...rews nuts and hose clamps regularly for tightness Check the fuel reserves 6 2 Starting Danger Danger of poisoning Exhaust gases are poisonous 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 H...

Страница 27: ... the engine 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 l...

Страница 28: ... 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 motorcycle when it is supported by the side stand only The side stand and or the frame could be damaged and the motorcycle could fall over Brake the motorcycle Shift gear to neutral With the engine idling flip the ignition switch up until the en...

Страница 29: ...N 95 PON 91 p 115 Fuel tank half front right approx 9 0 l 2 38 US gal Super unleaded ROZ 95 RON 95 PON 91 p 115 Rear fuel tank approx 18 0 l 4 76 US gal Super unleaded ROZ 95 RON 95 PON 91 p 115 Total fuel capacity approx 36 0 l 9 51 US gal Super unleaded ROZ 95 RON 95 PON 91 p 115 Replace the filler cap and turn clockwise until the fuel tank is tightly closed Info Run the fuel tank breather hoses...

Страница 30: ... all moving parts e g hand lever chain and check for smooth operation x Check the fluid level of the hydraulic clutch p 52 Check the front brake fluid level p 55 Check the free travel on the hand brake lever p 54 Check the steering head bearing play p 42 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 d...

Страница 31: ...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 syst...

Страница 32: ...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...

Страница 33: ...e damping turn counterclockwise to reduce damp ing 8 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 clockwise up to the last perceptible clic...

Страница 34: ...rson holding the motorcycle 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 Info The riding sag is the difference between measurements and Check the ridi...

Страница 35: ...the riding sag x Remove the shock absorber x After removing the shock absorber clean it thoroughly B00292 10 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 Install the shock absorber x Check the static sag of the shock absorber p 32 Check the riding sag of the shock absorber p...

Страница 36: ...bound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior 601332 10 Remove protection caps Turn adjusting screws clockwise all the way Info Adjusting screws 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 damping St...

Страница 37: ...iple clamp Mount and tighten screws Guideline Screw steering stem bot tom M8 25 Nm 18 4 lbf ft Loctite 243 Install the lower triple clamp x p 40 8 16 Handlebar position 0 0 B B 0 0 A A 400361 10 On the upper triple clamp there are 2 holes at a distance to each other Distance between holes 15 mm 0 59 in The holes on the handlebar support are placed at a distance of from the center Distance between ...

Страница 38: ...the handlebar support Place the handlebar support in the required position Mount and tighten the two screws Guideline Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Condition Spacer mounted Use a M10x35 screw Condition Without a spacer Use a M10x25 screw Info Position the left and right handlebar supports evenly Insert rubber cones and clamp bar Insert lower shells Position the handleba...

Страница 39: ...rk the motorcycle press the side stand 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 9 3 Bleeding the fork legs Raise the motorcycle with the lift stand p 37 601334 10 Remove bleeder screws briefly Any excess pressure escapes from the interior of the fork Mount and tighten the bleeder screws Rem...

Страница 40: ...nstall the front fender p 38 Remove the motorcycle from the lift stand p 37 9 5 Dismounting the front fender 600109 10 Remove screws Remove front fender 9 6 Installing the front fender 600109 10 Position front fender Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 9 7 Removing the fork legs x Remove the front wheel x p 62 Dismount the front fender p 38 601339 10 Rem...

Страница 41: ... triple clamp M8 12 Nm 8 9 lbf ft Secure the brake line with cable binder 601339 11 Position the brake caliper Mount and tighten screws Guideline Screw front brake caliper M8 30 Nm 22 1 lbf ft Loctite 243 Install the front fender p 38 Mount the front wheel x p 62 9 9 Removing the lower triple clamp x Remove the fork legs x p 38 601389 10 Remove screw Allow the brake caliper and brake line to hang ...

Страница 42: ... with the steering stem Remove the upper steering head bearing 9 10 Installing the lower triple clamp x 0 0 2 2 0 0 1 1 0 0 3 3 401211 10 Clean the bearing and sealing elements check for damage and grease High viscosity grease p 116 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing Check whether the top steering head seal is correctly positioned Slide on pr...

Страница 43: ...le binder 601385 10 Mount and tighten screws Guideline Screw brake line holder on bottom triple clamp M5 2 Nm 1 5 lbf ft 601386 10 Tighten nut Guideline Nut upper steering head M20x1 12 Nm 8 9 lbf ft Lock screw with nut Guideline Screw top steering head M20x1 12 Nm 8 9 lbf ft Tighten screw Guideline Screw top steering stem M8 20 Nm 14 8 lbf ft 601338 13 Tighten screws Guideline Screw bottom triple...

Страница 44: ...ke is ridden with play in the steering head bearing the bearing and the bearing seats in the frame can become dam aged over time Raise the motorcycle with the lift stand p 37 400738 11 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 noticeable play present Adjust the pla...

Страница 45: ...20 Nm 14 8 lbf ft Tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft 601337 10 Position steering damper Mount and tighten screws 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 Guideline Screw han...

Страница 46: ...me lift the seat at the rear and take it off 9 15 Mounting the seat 601348 10 Let the locking pin of the seat engage in lock housing Lock the seat at the front with quick release Make sure that the seat is correctly locked in 9 16 Removing the air filter x Remove the seat p 44 601349 10 Remove screws Take off air filter box lid ...

Страница 47: ...ng the entire sealing surface Hook air filter box lid into the front of the air filter box and swing down 601349 11 Mount and tighten screws Guideline Screw air filter box top M6 2 Nm 1 5 lbf ft Mount the seat p 44 9 18 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down Do not touch hot components 601...

Страница 48: ...ocking cap and outer tube Pull the glass fiber yarn filling from inner tube Clean the parts that are to be reinstalled Wind adhesive tape around the end of the inner tube Mount the new glass fiber yarn filling on 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 ...

Страница 49: ...kin 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 Remove the t...

Страница 50: ... the chain is very dirty Clean the chain p 48 9 26 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material 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 Warni...

Страница 51: ...ing Danger of accidents 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 ...

Страница 52: ...istance of 18 chain links in the lower chain section Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance at the longest chain section 272 mm 10 71 in If the distance is greater than the specified measurement Replace the chain x Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains w...

Страница 53: ...If the chain guide is loose Tighten the chain guide Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Remaining nuts chassis M6 10 Nm 7 4 lbf ft Remove the motorcycle from the lift stand p 37 9 30 Checking the frame x 601609 01 Check the frame for cracks and deformation If the frame exhibits cracks or deformation due to a mechanical impact Change the frame x Info A frame that has been damaged...

Страница 54: ...urn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and 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 9 35 Checking the fluid level of the hydraulic ...

Страница 55: ... Fill bleeding syringe with the appropriate fluid Bleed syringe 50329050000 Hydraulic fluid 15 p 115 On the slave cylinder remove bleeder screw and mount bleeding syringe 400247 10 Inject the fluid into the system until it escapes from hole of the master cylinder without bubbles To prevent overflow drain the fluid occasionally from the master cylinder reservoir Remove the bleeding syringe Mount an...

Страница 56: ...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 10 3 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc s Change the ...

Страница 57: ...stem 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 Warning...

Страница 58: ...ing 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 brake fluid com...

Страница 59: ...ke fluid 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 Remove cover with membrane 600039 11 Press the brake...

Страница 60: ...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 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 58 Attach the spring to the foot brake lever 10 9 Adjusting the f...

Страница 61: ...ritation 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 effect caused by old brake fluid Change the brake fluid of t...

Страница 62: ...e 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 linings Br...

Страница 63: ...ve bolt 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 in the brake caliper and sliding plate 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 contact with ...

Страница 64: ...acer 11 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 ring and bearing su...

Страница 65: ...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 Remove chain adjuster Withdraw wheel spindle 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 withdraw wheel s...

Страница 66: ...it and insert wheel spindle Attach the chain Position chain adjuster Mount nut but do not tighten it yet Check the chain tension p 49 Make sure that the chain adjusters are fitted correctly on the adjusting screws Tighten nut Guideline Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Info The wide adjustment range of the chain adjusters enables different sec ondary ratios with the same chain lengt...

Страница 67: ...and air pressure of the tires all have an important impact on the riding behavior of the motorcycle The tires mounted on the front and rear wheels must have a similar profile Worn tires have a negative effect on riding behavior especially on wet surfaces 400602 10 Examine the front and rear tires for cuts foreign bodies and other damage If you find cuts foreign bodies or other damage on a tire Cha...

Страница 68: ... 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 spokes are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle 400694 01 Briefly strike each spoke with a screwdriver blade Info The frequency of the tone is a function of ...

Страница 69: ...ect rubber band Connect positive cable Guideline Nut cable on battery M6 5 Nm 3 7 lbf ft Attach negative cable Guideline Nut cable on battery M6 5 Nm 3 7 lbf ft Mount the seat p 44 12 3 Recharging the battery x Warning Environmental hazard The battery contains elements that are harmful to the environment Do not discard batteries with the household trash Dispose of a defective battery in an environ...

Страница 70: ...nging 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 Switch off all power consumers and switch off the engine Remove the seat p 44 601371 10 Remove pr...

Страница 71: ...fuse is shown by a burned out fuse wire 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 89 Fuse 58011109110 p 89 Fuse 58011109115 p 90 Check that the power consumer is functioning properly Close the fuse box cover Mount th...

Страница 72: ...move the trim p 46 601382 10 Loosen screw 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 Mount the trim p 46 ...

Страница 73: ...edi 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 the radiator Cool...

Страница 74: ...nd 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 Remove radiator cap Completely drain the coolant Mount and tighten screw with a new seal ring Guideline...

Страница 75: ...COOLING SYSTEM 73 Take a short test ride Check the coolant level p 71 ...

Страница 76: ...throttle cable x Remove the fuel tank toward the front p 47 Check the throttle cable routing 601376 10 Move the handlebar to the straight ahead position Push back sleeves Loosen nut Turn adjusting screw in as far as possible Loosen nut Turn adjusting screw so that there is play in the throttle cable at the throttle grip Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Tighten nut Press and hold...

Страница 77: ...sition and turn the idle adjusting screw slowly counterclockwise until the idle speed falls Adjust to the point between these two positions with the highest idle speed Info If there is a big engine speed rise reduce the idle speed to a normal level and repeat the above steps The extreme sport motorcyclist will set the mixture about of a turn back from this ideal value leaner in a clockwise directi...

Страница 78: ...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 Info Carry out this work with a cold engine 601378 11 Direct the hose of the float...

Страница 79: ...er 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 other vehicle compo nents during the shift procedure Mount and tighten the screw Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 ...

Страница 80: ...r cleaning 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 app...

Страница 81: ... ring 601323 10 Pull oil filter 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 and mount on the oil filter cover 601322 10 Position the lower oil filter cover Mount and tighten screws Guideline Screw oil filter cover M5 6 Nm 4 4 lbf ft 601325 10 Remove screws Remove the upper oil filt...

Страница 82: ...n the oil filler plug Danger Danger of poisoning Exhaust gases are poisonous 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 Check the engine oil level p 78 15 3 ...

Страница 83: ...em 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 Check the engine oil level p 78 ...

Страница 84: ...cycle cleaner p 116 Info Clean the vehicle with 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 Empty the carburetor float chamber x p 76 Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently After cleaning ...

Страница 85: ...e brakes 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 dis...

Страница 86: ... oil screen x p 78 Check the antifreeze and coolant level p 71 Drain the fuel from the fuel tanks into a suitable container Empty the carburetor float chamber x p 76 Check the tire air pressure p 66 Remove the battery x p 67 Recharge the battery x p 67 Guideline Storage temperature of battery without direct sunshine 0 35 C 32 95 F Charging level of the battery for storage 50 75 Place the vehicle o...

Страница 87: ...Forged light alloy Engine lubrication Pressure circulation lubrication with 3 rotor pumps Primary transmission 29 74 Clutch Multidisc clutch in oil bath hydraulically activated Transmission ratio 1st gear 14 35 2nd gear 17 33 3rd 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 ...

Страница 88: ...M6 6 Nm 4 4 lbf ft Loctite 243 Screw alternator cover M6 10 Nm 7 4 lbf ft Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch slave cylinder M6 10 Nm 7 4 lbf ft Screw clutch spring M6 10 Nm 7 4 lbf ft Screw engine case M6 10 Nm 7 4 lbf ft Screw exhaust flange M6 10 Nm 7 4 lbf ft Loctite 243 Screw ignition pulse generator cable holder M6 10 Nm 7 4 lbf ft Loctite 243 Screw oil pump casing M6 10 Nm 7...

Страница 89: ... rail for timing chain M14x1 15 Nm 11 1 lbf ft Axle tension rail for timing chain M14x1 15 Nm 11 1 lbf ft Nut compensating sprocket M14x1 20 Nm 14 8 lbf ft Loctite 243 Oil suction pipe M14x1 15 Nm 11 1 lbf ft Loctite 243 Oil pressure regulator valve plug M14x1 5 18 Nm 13 3 lbf ft Nut inner clutch hub M18x1 5 80 Nm 59 lbf ft Loctite 243 Plug timing chain tensioner M24x1 5 25 Nm 18 4 lbf ft Screw al...

Страница 90: ...uretor 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 ...

Страница 91: ... 46 48 49 50 51 Chain 5 8 x 1 4 Wheelbase 1 535 10 mm 60 43 0 39 in Steering head angle 62 5 Seat height unloaded 980 mm 38 58 in Ground clearance unloaded 320 mm 12 6 in Weight without fuel approx 145 kg 320 lb Maximum permissible front axle load 190 kg 419 lb Maximum permissible rear axle load 250 kg 551 lb Maximum permissible overall weight 400 kg 882 lb Standard rider weight 80 kg 176 lb 21 1 ...

Страница 92: ...n under http www ktm com 21 3 Capacity fuel Fuel tank capacity Fuel tank half front left approx 9 0 l 2 38 US gal Super unleaded ROZ 95 RON 95 PON 91 p 115 Fuel tank half front right approx 9 0 l 2 38 US gal Super unleaded ROZ 95 RON 95 PON 91 p 115 Rear fuel tank approx 18 0 l 4 76 US gal Super unleaded ROZ 95 RON 95 PON 91 p 115 Total fuel capacity approx 36 0 l 9 51 US gal Super unleaded ROZ 95...

Страница 93: ...ng length with preload spacer s 492 mm 19 37 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 6 N mm 26 3 lb in Weight of rider standard 75 85 kg 165 187 lb 4 8 N mm 27 4 lb in Weight of rider hard 75 85 kg 165 187 lb 5 0 N mm 28 6 lb in Gas pressure 1 2 bar 17 psi Fork length 950 mm 37 4 in Oil capacity fork leg without cartridge 400 ml 13 52 fl oz Fork oil SAE 5 p 115 ...

Страница 94: ...n damping high speed Standard 1 5 turns Rebound damping Standard 18 clicks Spring preload Standard 17 mm Spring rate Weight of rider 75 85 kg 165 187 lb 80 N mm 457 lb in Spring length 250 mm 9 84 in Gas pressure 10 bar 145 psi Static sag 36 mm 1 42 in Riding sag 100 mm 3 94 in Fitted length 432 mm 17 01 in Shock absorber oil Shock absorber oil SAE 2 5 50180342S1 p 115 ...

Страница 95: ...t Loctite 243 Screw connection voltage regulator M6 8 Nm 5 9 lbf ft Loctite 243 Screw air filter box top M6 2 Nm 1 5 lbf ft Screw bottom radiator bracket M6 5 Nm 3 7 lbf ft Screw brake fluid reservoir of rear brake M6 5 Nm 3 7 lbf ft Screw cable on starter relay M6 5 Nm 3 7 lbf ft Screw chain sliding guard M6 6 Nm 4 4 lbf ft Loctite 243 Screw engine guard bracket on engine bearer M6 15 Nm 11 1 lbf...

Страница 96: ...rews chassis M10 45 Nm 33 2 lbf ft Screw connection engine mounting bracket M10 45 Nm 33 2 lbf ft Loctite 243 Screw connection shock absorber bot tom M10 45 Nm 33 2 lbf ft Loctite 243 Screw connection shock absorber top M10 45 Nm 33 2 lbf ft Loctite 243 Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Screw side stand M10 35 Nm 25 8 lbf ft Loctite 243 Banjo bolt M10x1 12 Nm 8 9 lbf ft Nut...

Страница 97: ...95 ...

Страница 98: ...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 ...

Страница 99: ...WIRING DIAGRAM 97 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 ...

Страница 100: ...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 ...

Страница 101: ...WIRING DIAGRAM 99 Components B33 Radiator fan temperature switch F5 Fuse F7 Fuse M14 Radiator fan ...

Страница 102: ... 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 b...

Страница 103: ...WIRING DIAGRAM 101 Components A15 CDI controller E11 Low beam F3 Fuse K14 Low beam relay P15 Horn S22 Light switch horn button kill switch ...

Страница 104: ...1 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 ...

Страница 105: ...WIRING DIAGRAM 103 Components E12 High beam K13 High beam relay P23 High beam indicator light ...

Страница 106: ... 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 ...

Страница 107: ...WIRING DIAGRAM 105 Components B70 Wheel speed sensor front P13 Speedometer P35 Parking light S36 Tripmaster switch ...

Страница 108: ...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 ...

Страница 109: ...ponents 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 ...

Страница 110: ...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 ...

Страница 111: ...WIRING DIAGRAM 109 Components B35 Oil pressure sensor B39 Temperature switch indicator lamp P26 Temperature warning lamp P27 Oil pressure warning lamp ...

Страница 112: ...3 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 gn...

Страница 113: ...WIRING DIAGRAM 111 Components B76 Front brake light switch B77 Rear brake light switch E60 License plate lamp F1 Fuse F6 Fuse P36 Brake tail light ...

Страница 114: ...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 r...

Страница 115: ...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 ...

Страница 116: ...n inhibitor antifreeze 50 distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Supplier Motorex Anti Freeze Engine oil SAE 10W 60 00062010035 According to JASO T903 MA p 118 SAE p 118 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 Motorex pro...

Страница 117: ...re sponding properties KTM recommends Motorex products Supplier Motorex Hydraulic Fluid 75 Shock absorber oil SAE 2 5 50180342S1 According to SAE p 118 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 On...

Страница 118: ... 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 high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommen...

Страница 119: ...AUXILIARY SUBSTANCES 117 Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Synthetic ...

Страница 120: ...ice intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines With 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...

Страница 121: ...amping fork adjusting 34 Compression damping high speed shock absorber adjusting 30 Compression damping low speed shock absorber adjusting 31 Coolant draining 72 refilling 72 Coolant level checking 71 Cooling system 71 E Electric starter button 11 Engine running in 23 Engine number 8 Engine oil adding 80 changing 78 Engine oil level checking 78 Engine sprocket checking 50 Environment 5 F Foot brak...

Страница 122: ...ound damping fork adjusting 34 shock absorber adjusting 31 Refueling fuel 26 Riding sag adjusting 33 Rubber grip checking 52 securing 52 S Seat mounting 44 removing 44 Service 4 Service schedule 28 29 Shift lever 19 basic position adjusting 76 basic position checking 76 Shock absorber compression damping general 30 riding sag checking 32 spring preload adjusting 32 static sag checking 32 Side stan...

Страница 123: ...se definition 4 V View of vehicle front left 6 rear right 7 W Warranty 4 Winter operation checks and maintenance steps 83 Wiring diagram page 1 of 9 96 page 2 of 9 98 page 3 of 9 100 page 4 of 9 102 page 5 of 9 104 page 6 of 9 106 page 7 of 9 108 page 8 of 9 110 page 9 of 9 112 Work rules 4 ...

Страница 124: ... 3211726en 3211726en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 05 2011 Photo Mitterbauer ...

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