KTM 450 EXC-R EU Repair Manual page 6

CONTENTS
Installing the locking lever.............................................. 99
Installing the shift drum locating .................................... 99
Installing the shift shaft ................................................. 99
Installing the kickstarter idler gear ................................ 100
Installing the kickstarter shaft ...................................... 100
Installing the starter idler gear ...................................... 100
Installing the torque limiter .......................................... 100
Installing the balancer shaft ......................................... 101
Installing the outer clutch hub...................................... 101
Installing the primary gear nut ...................................... 101
Installing the clutch discs ............................................ 102
Installing the clutch cover ............................................ 102
Installing the water pump cover .................................... 103
Installing the kickstarter............................................... 103
Installing the suction pump .......................................... 103
Installing the ignition pulse generator............................ 104
Installing the timing chain............................................ 104
Installing the timing chain securing guide...................... 104
Installing the timing chain tensioning rail ...................... 104
Installing the timing chain guide rail ............................. 105
Installing the balance weight ........................................ 105
Installing the rotor ....................................................... 105
Installing the piston..................................................... 105
Installing the cylinder head .......................................... 107
Installing the camshaft ................................................ 108
Installing the timing chain tensioner ............................. 108
Checking the valve clearance ........................................ 109
Adjusting the valve clearance........................................ 109
Installing the generator cover........................................ 109
Installing the shift lever ............................................... 110
Installing the valve cover .............................................. 110
Installing the spark plug............................................... 110
Installing the starter motor ........................................... 111
Mounting oil filter........................................................ 111
Filling up with engine oil.............................................. 111
Filling up with gear oil ................................................. 112
Removing the engine from the universal mounting
rack ........................................................................... 112
31/CARBURETOR ........................................................... 113
Choke (EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA,
XCR-W) ...................................................................... 113
Choke (EXC-R EU) ....................................................... 113
Checking the choke Bowden cable routing (EXC-R EU).... 113
Checking the choke Bowden cable for play (EXC-R EU) ... 113
Adjusting the choke Bowden cable play (EXC-R EU)........ 113
Checking gas Bowden cable route ................................. 114
Checking play in the gas Bowden cable ......................... 114
Adjusting the gas Bowden cable play............................. 114
Removing the carburetor .............................................. 115
Disassembling the carburetor........................................ 115
Checking the carburetor components............................. 118
Checking/adjusting the accelerator pump....................... 118
Checking the choke slide.............................................. 119
Checking the jet needle................................................ 119
Checking the throttle slide............................................ 119
Checking the needle jet................................................ 120
Checking the float needle valve..................................... 120
Checking/adjusting the float level.................................. 120
Checking/adjusting the throttle slide opening ................. 120
Checking throttle valve sensor TPS ................................ 121
Adjusting the position of throttle valve sensor TPS .......... 121
Assembling the carburetor............................................ 122
Installing the carburetor ............................................... 125
Carburetor - adjusting idle ............................................ 126
Emptying the carburetor float chamber .......................... 127
32/CLUTCH .................................................................... 129
Checking fluid level of hydraulic clutch ......................... 129
Changing fluid level of hydraulic clutch ......................... 129
33/TRANSMISSION......................................................... 131
Removing the engine sprocket ...................................... 131
Installing the engine sprocket ....................................... 131
35/WATER PUMP, COOLING SYSTEM .............................. 132
Checking antifreeze and coolant level ............................ 132
Checking the coolant level............................................ 132
Draining coolant .......................................................... 133
Refilling coolant .......................................................... 133
38/LUBRICATION SYSTEM .............................................. 134
Oil cycle ..................................................................... 134
Checking engine oil level.............................................. 134
Changing engine oil and oil filter, cleaning engine oil
screen ........................................................................ 135
Draining engine oil, cleaning engine oil screen ............... 135
Removing the oil filter.................................................. 135
Mounting oil filter........................................................ 136
Filling up with engine oil.............................................. 136
Topping up engine oil .................................................. 137
Checking the engine oil pressure................................... 137
Checking gear oil level ................................................. 138
Changing gear oil, cleaning gear oil screen..................... 138
Draining gear oil, cleaning gear oil screen ...................... 138
Filling up with gear oil ................................................. 139
Topping up with gear oil............................................... 139
TROUBLESHOOTING....................................................... 140
TECHNICAL DATA - ENGINE ............................................ 142
Capacity- engine oil ..................................................... 142
Capacity - gear oil........................................................ 142
Capacity - coolant........................................................ 143
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF
ENGINE ......................................................................... 144
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ 145
TECHNICAL DATA - CARBURETOR................................... 147
450 EXC-R EU, 450 EXC-R AUS/UK (3900I) ................. 147
450 EXC-R SIX DAYS, 450 EXC-R USA, 450 XCR-W
(3900L) ..................................................................... 147
530 EXC-R EU, 530 EXC-R AUS/UK (3900J)................. 148
530 EXC-R SIX DAYS, 530 EXC-R USA, 530 XCR-W
(3900M) .................................................................... 148
TECHNICAL DATA - CARBURETOR TIGHTENING
TORQUES....................................................................... 149
TECHNICAL DATA - CHASSIS .......................................... 150
Lighting equipment ..................................................... 151
Tires .......................................................................... 151
Capacity - fuel............................................................. 151
TECHNICAL DATA - FORK................................................ 152
TECHNICAL DATA - SHOCK ABSORBER ........................... 153
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 154
CLEANING...................................................................... 155
Cleaning motorcycle .................................................... 155
STORAGE ....................................................................... 156
Storage....................................................................... 156
Putting into operation after storage ............................... 156
GREASING AND SERVICE TABLE ..................................... 157
Important maintenance work to be carried out by an
authorized KTM workshop. ........................................... 157
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