KTM 450 EXC-R EU Repair Manual page 5

CONTENTS
Add front brake fluid...................................................... 48
Changing the front brake fluid ........................................ 48
Checking rear brake linings ............................................ 49
Removing the rear brake linings ...................................... 49
Installing the rear brake linings....................................... 50
Changing the rear brake linings....................................... 50
Checking free play of foot brake lever .............................. 51
Adjusting basic position of footbrake lever ....................... 51
Checking rear brake fluid level........................................ 52
Adding rear brake fluid .................................................. 52
Changing the rear brake fluid.......................................... 52
14/LIGHT SYSTEM, INSTRUMENTS ................................... 54
Adjusting speedometer functions .................................... 54
Setting kilometers or miles ............................................. 54
Setting the clock ........................................................... 55
30/ENGINE....................................................................... 56
Removing the engine ..................................................... 56
Installing the engine ...................................................... 57
30/DISASSEMBLING ENGINE ............................................ 59
Preparations.................................................................. 59
Draining the engine oil................................................... 59
Removing the oil filter.................................................... 59
Draining gear oil, cleaning gear oil screen ........................ 59
Removing the starter engine ........................................... 60
Removing the valve cover ............................................... 60
Removing the shift lever................................................. 60
Removing the spark plug ................................................ 60
Removing the generator cover ......................................... 61
Setting the engine to ignition top dead center .................. 61
Removing the timing chain tensioner............................... 62
Removing the camshaft.................................................. 62
Removing the cylinder head............................................ 62
Removing the piston ...................................................... 62
Removing the rotor ........................................................ 63
Removing the balance weight ......................................... 63
Removing the timing chain guide rail .............................. 63
Removing the timing chain tensioning rail........................ 64
Removing the timing chain securing guide ....................... 64
Removing the timing chain............................................. 64
Removing the ignition pulse generator ............................. 64
Removing the suction pump ........................................... 64
Removing the kickstarter................................................ 65
Removing the water pump cover ..................................... 65
Removing the clutch cover ............................................. 65
Removing the clutch discs.............................................. 66
Removing the primary gear nut ....................................... 66
Removing the outer clutch hub ....................................... 66
Removing the balancer shaft .......................................... 67
Removing the torque limiter ........................................... 67
Removing the starter idler gear ....................................... 67
Removing the kickstarter shaft........................................ 67
Removing the kickstarter idler gear ................................. 67
Removing the shift shaft ................................................ 68
Removing the shift drum locating.................................... 68
Removing the locking lever............................................. 68
removing the oil pump gears........................................... 68
Removing the oil pumps................................................. 69
Removing the primary gear with the free-wheel-gear.......... 69
Removing the left section of the engine case.................... 69
Removing the shift rails ................................................. 70
Removing the shift roller ................................................ 70
Removing the shift forks ................................................ 71
Removing the transmission shaft..................................... 71
Removing the crankshaft................................................ 71
30/ENGINE - WORK ON INDIVIDUAL PARTS....................... 72
Work on the right section of the engine case .................... 72
Work on the left section of the engine case ...................... 73
removing the oil pressure regulator valve.......................... 75
Checking the spring length of the oil pressure regulator
valve ............................................................................ 75
Installing the oil pressure regulator valve ......................... 75
Removing the crankshaft seal ring in the clutch cover ....... 76
Fitting the crankshaft seal ring into the clutch cover ......... 76
Removing the water pump .............................................. 76
Installing the water pump............................................... 77
Checking the balancer shaft ........................................... 78
Removing the timing chain sprocket................................ 78
Installing the timing chain sprocket................................. 78
Changing the conrod bearing .......................................... 78
Checking the crankshaft run-out on the bearing pin .......... 80
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Cylinder - Nikasil coating.............................................. 80
Checking/measuring the cylinder..................................... 80
Checking/measuring the piston ....................................... 81
Checking the piston ring end gap .................................... 81
Checking piston/cylinder mounting clearance ................... 82
Checking the oil pumps for wear ..................................... 82
Checking the lubrication system...................................... 82
Disassembling the autodecompressor .............................. 83
Assembling the autodecompressor................................... 83
Checking the camshaft................................................... 84
Checking the timing assembly ........................................ 84
Preparing the timing chain tensioner for installation ......... 84
Removing the rocker arm................................................ 85
Removing the valves ...................................................... 85
Replacing the camshaft bearing ...................................... 86
Checking the valves ....................................................... 87
Checking the valve springs ............................................. 87
Checking the lower valve spring retainer .......................... 87
Checking the cylinder head ............................................ 88
Installing valves ............................................................ 88
Installing the rocker arm ................................................ 89
Checking the clutch....................................................... 89
Checking the shift mechanism ........................................ 90
Preassembling the shift shaft.......................................... 91
Dismantling the main shaft ............................................ 91
Assembling the main shaft ............................................. 91
Dismantling the countershaft.......................................... 92
Assembling the countershaft........................................... 92
Checking the transmission.............................................. 93
Checking electric starter operation .................................. 94
Removing the free-wheel ................................................ 94
Checking the free-wheel ................................................. 95
Installing the free-wheel................................................. 95
30/ASSEMBLING ENGINE ................................................. 96
Installing the crankshaft................................................. 96
Installing the transmission shaft ..................................... 96
Installing the shift forks ................................................. 96
Installing the shift roller................................................. 97
Installing the shift rails .................................................. 97
Installing the left engine case ......................................... 97
Installing the primary gear with the free-wheel-gear .......... 98
Installing the oil pumps ................................................. 98
Installing the oil pump gears .......................................... 99
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