KTM 450 Rally Factory Replica 2021 User Manual

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OWNER'S MANUAL 2021

450 RALLY Factory Replica

Art. no. 3214230en

Default Chapter4
- Table of Contents4
1 Means of Representation8
- Symbols Used8
- Formats Used8
2 Safety Advice 29
- Use Definition - Intended Use9
- Degrees of Risk and Symbols9
- Tampering Warning9
- Safe Operation10
- Protective Clothing10
- Work Rules11
- Environment11
- Owner's Manual11
3 Important Notes12
- Manufacturer Warranty, Implied Warranty12
- Fuel, Auxiliary Substances12
- Spare Parts, Accessories12
- Service12
- Figures12
- Customer Service12
4 View of Vehicle 413
- View of Vehicle, Front Left13
- View of Vehicle, Rear Right Side14
5 Serial Numbers 515
- Vehicle Identification Number15
- Type Label15
- Engine Number15
- Key Number15
- Fork Part Number16
- Shock Absorber Article Number16
6 Controls 617
- Clutch Lever17
- Hand Brake Lever17
- Throttle Grip17
- Stop Button17
- Light Switch18
- Turn Signal Switch18
- Horn Button18
- Start Button18
- Emergency off Switch19
- Overview of Indicator Lamps19
- Fuel Pump Switch19
- Fuel Tank20
- Opening Fuel Tank Filler Caps20
- Closing Fuel Tank Filler Caps21
- Cold Start Button22
- Idle Speed Adjusting Screw22
- Shift Lever23
- Foot Brake Lever23
- Side Stand23
- Steering Lock24
- Locking the Steering24
- Unlocking the Steering24
7 Combination Instrument25
- Combination Instrument 725
- Combination Instrument Overview25
- Activation and Test25
- Setting Kilometers or Miles25
- Adjusting Combination Instrument Function26
- Setting Clock27
- Viewing the Lap Time27
- Display Mode SPEED (Speed)28
- Display Mode SPEED/H (Operating Hours)28
- Setup Menu28
- Adjusting the Unit of Measurement29
- Display Mode SPEED/CLK (Time)30
- Setting the Clock30
- Display Mode SPEED/LAP (Lap Time)30
- Viewing the Lap Time31
- Display Mode SPEED/ODO (Odometer)31
- Display Mode SPEED/TR1 (Trip Master 1)32
- Display Mode SPEED/TR2 (Trip Master 2)32
- Setting TR2 (Trip Master 2)32
- Display Mode SPEED/A1 (Average Speed 1)33
- Display Mode SPEED/A2 (Average Speed 2)33
- Display Mode SPEED/S1 (Stop Watch 1)34
- Display Mode SPEED/S2 (Stop Watch 2)34
- Table of Functions35
- Table of Conditions and Menu Activation36
8 Preparing for Use37
- Preparing for Use 837
- Advice on Preparing for First Use37
- Running in the Engine38
9 Riding Instructions 939
- Checks and Maintenance When Preparing for Use39
- Starting39
- Starting off40
- Shifting, Riding40
- Braking41
- Stopping, Parking41
- Transporting42
- Refueling42
10 Service Schedule44
- Additional Information44
- Required Work44
- Recommended Work45
11 Tuning the Chassis 1147
- Checking Basic Chassis Setting with Rider's Weight47
- Compression Damping of the Shock Absorber47
- Adjusting the Low-Speed Compression Damping of the Shock Absorber47
- Adjusting the High-Speed Compression Damping of the Shock Absorber48
- Adjusting the Rebound Damping of the Shock Absorber49
- Measuring the Dimension of the Rear Wheel Unloaded49
- Checking Static Sag of the Shock Absorber49
- Checking Riding Sag of the Shock Absorber50
- Adjusting the Spring Preload of the Shock Absorber51
- Adjusting the Riding Sag52
- Checking the Basic Setting of the Fork53
- Adjusting the Compression Damping of the Fork53
- Adjusting the Rebound Damping of the Fork53
- Handlebar Position54
- Adjusting the Handlebar Position55
12 Service Work on the Chassis 1257
- Raising the Motorcycle with a Lift Stand57
- Removing Motorcycle from Lift Stand57
- Bleeding the Fork Legs57
- Cleaning the Dust Boots of the Fork Legs58
- Removing Fork Protector58
- Installing the Fork Protector59
- Removing Fork Legs59
- Installing the Fork Legs60
- Removing the Lower Triple Clamp60
- Installing the Lower Triple Clamp62
- Checking Steering Head Bearing Play64
- Adjusting the Steering Head Bearing Play64
- Greasing the Steering Head Bearing66
- Removing the Shock Absorber66
- Installing the Shock Absorber67
- Removing Front Fender68
- Installing the Front Fender68
- Removing the Seat69
- Mounting the Seat69
- Removing the Activated Carbon Filter69
- Installing the Activated Carbon Filter69
- Removing the Air Filter70
- Cleaning the Air Filter and Air Filter Box70
- Installing the Air Filter71
- Removing the Main Silencer72
- Installing the Main Silencer72
- Changing the Glass Fiber Yarn Filling of the Main Silencer72
- Removing Front Left Fuel Tank73
- Removing Front Right Fuel Tank75
- Installing the Front Left Fuel Tank76
- Installing the Front Right Fuel Tank77
- Changing the Fuel Screen77
- Checking the Chain for Dirt Accumulation79
- Cleaning the Chain79
- Checking Chain Tension80
- Adjusting the Chain Tension80
- Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide81
- Checking the Frame83
- Checking Swingarm84
- Checking the Throttle Cable Routing84
- Checking the Rubber Grip85
- Adjusting the Basic Position of the Clutch Lever85
- Checking/Correcting the Fluid Level of the Hydraulic Clutch85
- Changing the Hydraulic Clutch Fluid87
- Removing Side Cover88
- Mounting Side Cover89
- Removing Front Fairing90
- Mounting Front Fairing90
- Removing the Engine Guard90
- Installing the Engine Guard91
13 Brake System92
- Adjusting the Basic Position of the Hand Brake Lever92
14 Wheels, Tires 14103
- Removing Front Wheel103
- Installing the Front Wheel103
- Removing Rear Wheel104
- Installing the Rear Wheel106
- Checking Rear Hub Damping Rubber Pieces107
- Checking Tire Condition107
- Checking Tire Pressure108
- Checking Spoke Tension109
15 Electrical System110
- Removing the 12-V Battery110
- Installing the 12-V Battery110
- Charging the 12-V Battery111
- Changing Main Fuse112
- Changing the Fuses of Individual Electrical Power Consumers113
16 Cooling System 16115
- Checking the Antifreeze and Coolant Level115
- Checking the Coolant Level116
- Draining the Coolant116
- Refilling with Coolant117
- Changing the Coolant118
17 Tuning the Engine120
- Checking the Play in the Throttle Cable120
- Adjusting the Play in the Throttle Cable120
- Adjusting the Idle Speed121
- Checking Basic Position of the Shift Lever122
- Adjusting the Basic Position of the Shift Lever122
18 Service Work on the Engine123
- Service Work on the Engine 18123
- Checking the Engine Oil Level123
- Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens123
- Adding Engine Oil127
19 Cleaning, Care128
- Cleaning the Motorcycle128
- Checks and Maintenance Steps for Winter Operation129
- 20 Storage130
20 Storage131
- Preparing for Use after Storage131
21 Troubleshooting132
22 Blink Code 22135
23 Technical Data 23137
- Engine137
- Engine Tightening Torques138
- Capacities139
- Engine Oil139
- Coolant139
- Fuel140
- Chassis140
- Electrical System141
- Tires141
- Fork141
- Shock Absorber142
- Chassis Tightening Torques143
24 Wiring Diagram146
- 144146
- 146148
- 148150
- 150152
- 152154
- 154156
- 156158
- 158160
- 160162
- 162164
25 Substances166
26 Auxiliary Substances168
27 Standards170
- Index of Special Terms 28171
29 List of Abbreviations172
30 List of Symbols 30173
- Red Symbols173
- Yellow and Orange Symbols173

Questions and Answers:

J
Jacqueline ThompsonSep 12, 2025
Why is the brake light not working on my KTM 450 Rally Factory Replica 2021 Motorcycle?
- J
  Jeremy JohnsonSep 12, 2025
  If the brake light is not working on your KTM Motorcycle, fuse 5 is likely blown. Change the fuses of individual electrical power consumers.

KTM 450 Rally Factory Replica 2021 Specifications

General

Engine Type	Single cylinder, 4-stroke
Bore x Stroke	95 mm x 63.4 mm
Starter	Electric starter
Transmission	6-speed
Fuel System	Electronic Fuel Injection
Displacement	449.3 cc
Front Brake	Disc brake
Rear Brake	Disc brake
Dry Weight	139 kg
Seat Height	960 mm
Ground Clearance	310 mm
Frame	Chromium-Molybdenum steel frame