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450 Rally Factory Replica
KTM 450 Rally Factory Replica User Manual
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OWNER'S
MANUAL
2013
450
Rally
Factory
Replica
Art.
no.
3211865en
2
Table of Contents
Default Chapter
4
Table of Contents
4
1 Means of Representation
6
Symbols Used
6
Formats Used
6
2 Safety Advice
7
Use Definition - Intended Use
7
Degrees of Risk and Symbols
7
Tampering Warning
7
Safe Operation
8
Protective Clothing
8
Work Rules
8
Environment
8
Owner's Manual
8
3 Important Notes
9
Guarantee, Warranty
9
Operating and Auxiliary Substances
9
Spare Parts, Accessories
9
Service
9
Figures
9
Customer Service
9
4 View of Vehicle
10
View of Vehicle, Front Left
10
View of Vehicle, Rear Right
11
5 Serial Numbers
12
Chassis Number
12
Type Label
12
Engine Number
12
Key Number
12
Fork Part Number
12
Shock Absorber Part Number
13
6 Controls
14
Clutch Lever
14
Hand Brake Lever
14
Throttle Grip
14
Kill Switch
14
Light Switch
14
Turn Signal Switch
15
Horn Button
15
Electric Starter Button
15
Indicator Lamp Overview
15
Ignition Switch
15
Speedometer
16
Overview
16
Activation and Test
16
Tripmaster Switch
16
Setting Kilometers or Miles
16
Setting the Clock
17
Adjusting the Speedometer Functions
17
Querying Lap Time
18
Display Mode SPEED (Speed)
18
Display Mode SPEED/H (Operating Hours)
18
Display Mode SPEED/CLK (Clock)
19
Display Mode SPEED/LAP (Lap Time)
19
Display Mode SPEED/ODO (Odometer)
19
Display Mode SPEED/TR1 (Trip Master 1)
19
Display Mode SPEED/TR2 (Trip Master 2)
20
Display Mode SPEED/A1 (Average Speed 1)
20
Display Mode SPEED/A2 (Average Speed 2)
20
Display Mode SPEED/S1 (Stop Watch 1)
21
Display Mode SPEED/S2 (Stop Watch 2)
21
6.11.19 Table of Functions
21
6.11.20 Table of Conditions and Menu Activation
22
Fuel Tank
22
Fuel Tap
22
Choke
23
Shift Lever
23
Foot Brake Lever
24
Side Stand
24
Steering Lock
24
Locking the Steering
24
Unlocking the Steering
25
7 Preparing for Use
26
Advice on First Use
26
Running in the Engine
27
8 Riding Instructions
28
Checks and Maintenance When Preparing for Use
28
Starting
28
Starting off
29
Shifting, Riding
29
Braking
29
Stopping, Parking
30
Transport
30
Refueling
31
9 Service Schedule
32
Service Work (as Additional Order)
33
10 Tuning the Chassis
34
Checking the Basic Chassis Setting with the Rider's Weight
34
Compression Damping of the Shock Absorber
34
Adjusting the High-Speed Compression Damping of the Shock Absorber
34
Adjusting the Low-Speed Compression Damping of the Shock Absorber
35
Adjusting the Rebound Damping of the Shock Absorber
35
Measuring the Unloaded Rear Wheel Sag
35
Checking the Static Sag of the Shock Absorber
36
Checking the Riding Sag of the Shock Absorber
36
Adjusting the Spring Preload of the Shock Absorber
36
Adjusting the Riding Sag
37
Checking the Basic Setting of the Fork
37
Adjusting the Compression Damping of the Fork
38
Adjusting the Rebound Damping of the Fork
38
Fork Offset
38
Setting the Fork Offset
39
Handlebar Position
40
Adjusting the Handlebar Position
40
11 Service Work on the Chassis
42
Raising the Motorcycle with the Lift Stand
42
Removing the Motorcycle from the Lift Stand
42
Bleeding the Fork Legs
42
Cleaning the Dust Boots of the Fork Legs
43
Dismounting the Front Fender
43
Installing the Front Fender
43
Removing the Fork Legs
44
Removing the Fork Legs X
44
Installing the Fork Legs
45
Removing the Lower Triple Clamp
45
Installing the Lower Triple Clamp
46
Main Work
46
Position the Fork Legs
47
Position Bleeder Screws Toward the Front
47
Tighten Screws
47
Screw, Top Triple Clamp 17 Nm
47
Tighten Screws 3 . Guideline
47
Screw, Bottom Triple Clamp M8
47
Nm (8.9 Lbf Ft)
47
Checking the Steering Head Bearing Play
48
Adjusting the Play of the Steering Head Bearing
48
Greasing the Steering Head Bearing
49
Removing the Seat
50
Mounting the Seat
50
Removing the Air Filter
50
Installing the Air Filter
51
Removing the Main Silencer
51
Installing the Main Silencer
52
Changing the Glass Fiber Yarn Filling of the Main Silencer
52
Removing the Fuel Tank Toward the Front
52
Installing the Fuel Tank at the Front
53
Checking the Chain for Dirt Accumulation
53
Cleaning the Chain
54
Checking the Chain Tension
54
Adjusting the Chain Tension
55
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide
55
Nm Loctite (22.1 Lbf Ft)
56
Checking the Frame
57
Checking the Swingarm
57
Checking the Rubber Grip
57
Additionally Securing the Rubber Grip
58
Adjusting the Basic Position of the Clutch Lever
58
Checking the Fluid Level of the Hydraulic Clutch
58
Changing the Hydraulic Clutch Fluid
58
Removing the Trim
59
Mounting the Trim
59
12 Brake System
61
Checking the Free Travel on the Hand Brake Lever
61
Adjusting the Free Travel of the Hand Brake Lever
61
Checking the Brake Discs
61
Checking the Front Brake Fluid Level
62
Adding Front Brake Fluid
62
Checking the Front Brake Linings
63
Changing the Front Brake Linings
63
Checking the Free Travel of the Foot Brake Lever
65
Adjusting the Free Travel of the Foot Brake Lever
65
Checking the Rear Brake Fluid Level
66
Adding Rear Brake Fluid
66
Checking the Rear Brake Linings
67
Changing the Rear Brake Linings
67
13 Wheels, Tires
69
Removing the Front Wheel
69
Mounting the Front Wheel
69
Removing the Rear Wheel
70
Installing the Rear Wheel
71
Checking the Rear Hub Rubber Dampers X
72
Checking the Tire Condition
72
Checking the Tire Air Pressure
73
Checking the Spoke Tension
73
14 Electrical System
75
Removing the Battery
75
Installing the Battery
75
Recharging the Battery
75
Changing the Main Fuse
76
Changing Fuses of Individual Power Consumers
77
Checking the Headlight Setting
77
Adjusting the Headlight Range
78
15 Cooling System
79
Checking the Antifreeze and Coolant Level
79
Checking the Coolant Level
79
Draining the Coolant
80
Refilling Coolant
80
16 Tuning the Engine
82
Checking the Play in the Throttle Cable
82
Adjusting the Play in the Throttle Cable
82
Carburetor - Idle
82
Carburetor - Adjusting the Idle Speed
83
Emptying the Carburetor Float Chamber
84
Checking the Basic Position of the Shift Lever
85
Adjusting the Basic Position of the Shift Lever
85
17 Service Work on the Engine
86
Checking the Engine Oil Level
86
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen
86
Adding Engine Oil
88
18 Cleaning, Care
90
Cleaning Motorcycle
90
Checks and Maintenance Steps for Winter Operation
91
19 Storage
92
Preparing for Use after Storage
92
20 Technical Data
93
Engine
93
Engine Tightening Torques
93
Capacities
95
Engine Oil
95
Coolant
95
Fuel
95
Chassis
95
Electrical System
96
Tires
96
Fork
96
Shock Absorber
97
Chassis Tightening Torques
97
Carburetor with Carburetor Configuration (Carburetor Sheets)
99
21 Wiring Diagram
100
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112
Page 7 of
112
112
114
Page 8 of
114
114
116
Page 9 of
116
22 Substances
118
23 Auxiliary Substances
120
24 Standards
122
Index
123
4
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KTM 450 Rally Factory Replica Specifications
General
Brand
KTM
Model
450 Rally Factory Replica
Category
Motorcycle
Language
English
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