KTM 450 EXC - Service Work on the Chassis; Bleeding the Fork Legs

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11 TUNING THE CHASSIS 49

–

Position the handlebar clamps. Mount and tighten screws



evenly.

Guideline

Screw, handlebar clamp M8 20 Nm

(14.8 lbf ft)

Info

Make sure the gap width is even.

Table of Contents

Default Chapter4
- Table of Contents4
1 Means of Representation7
- Symbols Used7
- Formats Used7
2 Safety Advice8
- Use Definition - Intended Use8
- Degrees of Risk and Symbols8
- Tampering Warning8
- Safe Operation9
- Protective Clothing9
- Work Rules9
- Environment9
- Owner's Manual10
3 Important Notes11
- Guarantee, Warranty11
- Operating and Auxiliary Substances11
- Spare Parts, Accessories11
- Service11
- Figures11
- Customer Service11
4 View of Vehicle12
- View of Vehicle, Front Left (Example)12
- View of Vehicle, Rear Right (Example)13
5 Serial Numbers14
- Chassis Number14
- Type Label14
- Key Number (All EXC Models)14
- Engine Number14
- Fork Part Number14
- Shock Absorber Part Number15
6 Controls16
- Clutch Lever16
- Hand Brake Lever16
- Throttle Grip16
- Kill Switch (All EXC Models)16
- Kill Switch (XC-W)16
- Horn Button (All EXC Models)17
- Light Switch (All EXC Models)17
- Light Switch (XC-W)17
- Turn Signal Switch (All EXC Models)17
- Emergency off Switch (EXC AU)17
- Electric Starter Button (EXC EU, EXC SIX DAYS, XC-W)18
- Electric Starter Button (EXC AU)18
- Overview of Indicator Lamps (All EXC Models)18
- Overview of Indicator Lamps (XC-W)18
- Opening Filler Cap18
- Closing Filler Cap19
- Idle Speed Adjusting Screw19
- Shift Lever20
- Kick Starter20
- Foot Brake Lever20
- Side Stand20
- Steering Lock (All EXC Models)21
- Locking the Steering (All EXC Models)21
- Unlocking the Steering (All EXC Models)21
7 Speedometer22
- Speedometer Overview22
- Activation and Test22
- Setting Kilometers or Miles22
- Setting the Speedometer Functions23
- Setting the Clock23
- Viewing the Lap Time23
- Display Mode SPEED (Speed)24
- Display Mode SPEED/H (Service Hours)24
- Setup Menu25
- Setting the Unit of Measurement25
- Display Mode SPEED/CLK (Time)26
- Setting the Clock26
- Display Mode SPEED/LAP (Lap Time)26
- Viewing the Lap Time27
- Display Mode SPEED/ODO (Odometer)27
- Display Mode SPEED/TR1 (Trip Master 1)27
- Display Mode SPEED/TR2 (Trip Master 2)28
- Setting TR2 (Trip Master 2)28
- Display Mode SPEED/A1 (Average Speed 1)28
- Display Mode SPEED/A2 (Average Speed 2)29
- Display Mode SPEED/S1 (Stop Watch 1)29
- Display Mode SPEED/S2 (Stop Watch 2)29
- Table of Functions30
- Table of Conditions and Menu Activation31
8 Preparing for Use32
- Advice on First Use32
- Running-In the Engine33
- Preparing the Vehicle for Difficult Riding Conditions33
- Preparing for Rides on Dry Sand34
- Preparing for Rides on Wet Sand34
- Preparing for Rides on Wet and Muddy Surfaces35
- Preparing for Rides at High Temperature and Slow Speed35
- Preparing for Rides at Low Temperature or in Snow35
9 Riding Instructions36
- Checks and Maintenance Work When Preparing for Use36
- Starting36
- Starting off37
- Shifting, Riding37
- Braking37
- Stopping, Parking38
- Transport38
- Refueling39
10 Service Schedule40
- Service Work (as Additional Order)41
11 Tuning the Chassis42
- Checking the Basic Suspension Setting against the Rider's Weight42
- Compression Damping of Shock Absorber42
- Adjusting the Low-Speed Compression Damping of the Shock Absorber42
- Adjusting the High-Speed Compression Damping of the Shock Absorber43
- Adjusting the Rebound Damping of the Shock Absorber43
- Measuring Rear Wheel Sag Unloaded44
- Checking the Static Sag of the Shock Absorber44
- Checking the Riding Sag of the Shock Absorber44
- Adjusting the Spring Preload of the Shock Absorber45
- Adjusting the Riding Sag45
- Checking Basic Setting of Fork46
- Adjusting the Compression Damping of the Fork46
- Adjusting the Rebound Damping of the Fork47
- Adjusting the Spring Preload of the Fork (EXC EU/AU, XC-W)48
- Handlebar Position49
- Adjusting Handlebar Position50
12 Service Work on the Chassis52
- Raising the Motorcycle with the Lift Stand52
- Removing the Motorcycle from the Lift Stand52
- Bleeding the Fork Legs52
- Cleaning the Dust Boots of the Fork Legs53
- Removing the Fork Legs53
- Installing the Fork Legs54
- Removing the Fork Protector56
- Installing the Fork Protector56
- Removing the Lower Triple Clamp (All EXC Models)56
- Removing the Lower Triple Clamp (XC-W)57
- Installing the Lower Triple Clamp (All EXC Models)58
- Installing the Lower Triple Clamp (XC-W)61
- Checking the Steering Head Bearing Play62
- Adjusting the Play of the Steering Head Bearing (All EXC Models)63
- Adjusting the Play of the Steering Head Bearing (XC-W)64
- Greasing the Steering Head Bearing64
- Removing the Front Fender64
- Installing the Front Fender65
- Removing the Shock Absorber65
- Installing the Shock Absorber65
- Removing the Seat66
- Mounting the Seat66
- Removing the Air Filter Box Cover66
- Installing the Air Filter Box Cover66
- Removing the Air Filter67
- Installing the Air Filter67
- Cleaning the Air Filter and Air Filter Box67
- Sealing the Air Filter Box68
- Removing Main Silencer68
- Installing the Main Silencer68
- Cleaning Spark Arrestor (XC-W)69
- Changing Glass Fiber Yarn Filling in the Main Silencer70
- Removing the Fuel Tank71
- Installing the Fuel Tank72
- Checking for Chain Dirt Accumulation74
- Cleaning the Chain74
- Checking the Chain Tension75
- Adjusting the Chain Tension75
- Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide76
- Checking the Frame78
- Checking the Swingarm78
- Checking Throttle Cable Routing78
- Checking the Rubber Grip79
- Additionally Securing the Rubber Grip79
- Adjusting the Basic Position of the Clutch Lever79
- Checking/Correcting the Fluid Level of the Hydraulic Clutch79
- Changing the Hydraulic Clutch Fluid80
- Removing the Engine Guard (All EXC Models)80
- Installing the Engine Guard (All EXC Models)80
13 Brake System81
- Checking Free Travel of Hand Brake Lever81
- Adjusting Free Travel of Hand Brake Lever (All EXC Models)81
- Adjusting the Basic Position of the Hand Brake Lever (XC-W)81
- Checking the Brake Discs82
- Checking the Brake Fluid Level of the Front Brake82
- Adding Front Brake Fluid82
- Checking the Front Brake Linings83
- Changing the Front Brake Linings84
- Checking the Free Travel of Foot Brake Lever85
- Adjusting the Basic Position of the Foot Brake Lever85
- Checking the Rear Brake Fluid Level86
- Adding Rear Brake Fluid86
- Checking the Rear Brake Linings87
- Changing the Rear Brake Linings88
14 Wheels, Tires90
- Removing the Front Wheel90
- Installing the Front Wheel90
- Removing the Rear Wheel91
- Installing the Rear Wheel92
- Checking the Tire Condition92
- Checking the Tire Air Pressure93
- Checking Spoke Tension93
15 Electrical System95
- Removing the Battery95
- Installing the Battery95
- Charging the Battery96
- Changing the Main Fuse97
- Changing the Fuses of Individual Power Consumers98
- Removing Headlight Mask with Headlight98
- Refitting the Headlight Mask with the Headlight99
- Changing the Headlight Bulb100
- Changing the Turn Signal Bulb (All EXC Models)100
- Checking the Headlight Setting101
- Adjusting the Headlight Range101
- Changing the Speedometer Battery102
16 Cooling System103
- Checking the Antifreeze and Coolant Level103
- Checking the Coolant Level103
- Draining the Coolant104
- Refilling Coolant104
17 Tuning the Engine106
- Checking the Play in the Throttle Cable106
- Adjusting the Play in the Throttle Cable106
- Adjusting the Idle Speed107
- Checking the Basic Position of the Shift Lever107
- Adjusting the Basic Position of the Shift Lever107
18 Service Work on the Engine109
- Changing the Fuel Screen109
- Checking the Engine Oil Level109
- Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens110
- Adding Engine Oil112
19 Cleaning, Care113
- Cleaning the Motorcycle113
- Checks and Maintenance Steps for Winter Operation114
20 Storage115
- Preparing for Use after Storage115
21 Troubleshooting116
22 Blink Code118
23 Technical Data120
- Engine120
- Engine Tightening Torques120
- Capacities122
- Engine Oil122
- Coolant122
- Fuel122
- Chassis122
- Electrical System123
- Tires123
- Fork123
- Exc Eu/Au, XC-W123
- EXC Six Days124
- Shock Absorber124
- Chassis Tightening Torques125
24 Substances127
25 Auxiliary Substances128
26 Standards130
27 List of Abbreviations131
28 Lisy of Symbols132
- Yellow and Orange Symbols132
- Green and Blue Symbols132
- Index133

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