KTM 450 EXC EU 2013 Repair Manual page 3

TABLE OF CONTENTS
9.21 Assembling the rebound adjuster ...................... 74
9.22 Assembling the seal ring retainer ...................... 74
9.23 Assembling the piston rod ................................ 75
9.24 Assembling the damper ................................... 76
9.25 Bleeding and filling the damper ....................... 79
9.26 Filling the damper with nitrogen ....................... 81
9.27 Installing the spring ........................................ 82
9.28 Changing the heim jOint ................................... 83
10 EXHAUST .................................................................. 85
10.1 Removing the manifold .................................... 85
10.2 Installing the manifold .................................... 85
10.3 Removing main silencer ................................... 86
10.4 Installing the main silencer .............................. 86
10.5 Changing the glass fiber yarn filling of the
main silencer .................................................. 86
11 AIR FILTER ............................................................... 88
11.1 Removing the air filter box lid .......................... 88
11.2 Installing the air filter box lid ........................... 88
11.3 Removing the air filter ..................................... 88
11.4 Installing the air filter ...................................... 88
11.5 Cleaning the air filter and air filter box .............. 89
12 FUEL TANK, SEAT, TRIM ........................................... 90
12.1 Opening filler cap ........................................... 90
12.2 Closing filler cap ............................................. 90
12.3 Removing the seat .......................................... 90
12.4 Mounting the sea!.. ......................................... 91
12.5 Removing the fuel tank .................................... 91
12.6 Installing the fuel tank .................................... 92
12.7 Changing the fuel screen ................................. 93
12.8 Changing the fuel filter .................................... 94
12.9 Changing the fuel pump .................................. 96
12.10 Checking the fuel pressure ............................... 97
13 MASK, FENDER ......................................................... 99
13.1 Removing the front fender ............................... 99
13.2 Installing the front fender ................................ 99
13.3 Removing headlight mask with headligh!.. ......... 99
13.4 Refitting the headlight mask with the
headlight.. ...................................................... 99
14 WHEELS ................................................................. 101
14.1 Checking the tire air pressure ......................... 101
14.2 Checking the tire condition ............................ 101
14.3 Checking the brake discs ............................... 102
14.4 Checking spoke tension ................................. 102
14.5 Front wheel .................................................. 103
14.5.1 Removing the front wheel .......................... 103
14.5.2 Installing the front wheel ........................... 103
14.5.3 Removing the front brake disc .................... 104
14.5.4 Installing the front brake disc .................... 104
14.6 Rear wheel ................................................... 104
14.6.1 Removing the rear wheel ........................... 104
14.6.2 Installing the rear wheel ............................ 105
14.6.3 Removing the rear brake disc ..................... 106
14.6.4 Installing the rear brake disc ...................... 106
14.6.5 Checking the chain tension ........................ 107
14.6.6 Adjusting the chain tension ....................... 107
14.6.7 Adjusting the chain guide .......................... 108
14.6.8 Checking the chain, rear sprocket, engine
sprocket and chain guide ........................... 108
14.6.9 Checking for chain dirt accumulation .......... 110
14.6.10 Cleaning the chain .................................... 110
15 WIRING HARNESS, BATTERy ................................... 112
15.1 Changing the main fuse ................................. 112
15.2 Changing the fuses of individual power
consumers ................................................... .
15.3 Changing the fuse of the radiator fan ............ ..
15.4 Removi ng the battery .................................. ..
15.5 Installing the battery .................................... .
15.6 Charging the battery .................................... ..
16 BRAKE SYSTEM .................................................... ..
3
113
113
114
115
115
117
16.1
16.2
Checking the front brake linings ..................... 117
Changing the front brake linings ..................... 117
16.3 Checking free travel of hand brake lever .......... 119
16.4 Adjusting the basic position of the hand
brake lever (all XC-W models) ......................... 119
16.5 Adjusting free travel of hand brake lever (All
EXC models).......... ...... ........ ...... ...... ........ ..... 119
16.6
16.7
Checking the front brake fluid level ................ 120
Adding front brake fluid ................................. 120
16.8 Changing the front brake fluid ........................ 121
16.9 Checking the rear brake linings ...................... 122
16.10 Changing the rear brake linings ...................... 122
16.11 Checking the free travel of foot brake lever ...... 124
16.12 Adjusting the basic position of the foot brake
lever ............................................................ 124
16.13 Checking the rear brake fluid level .................. 125
16.14 Adding brake fluid to the rear brake circui!.. .... 125
16.15 Changing the rear brake fluid ......................... 126
17 LIGHTING SYSTEM, INSTRUMENTS ......................... 128
17.1 Adjusting the speedometer functions .............. 128
17.2 Setting kilometers or miles ............................. 128
17.3 Activating the additional functions .................. 129
17.4 Setting the wheel circumference .................... 129
17.5 Setting the clock ........................................... 130
17.6 Checking the headlight setting ....................... 130
17.7 Adjusting the headlight range ......................... 131
18 ENGINE .................................................................. 132
18.1 Removing the engine ..................................... 132
18.2 Installing the engine ...................................... 136
18.3 Engine disassembly ....................................... 140
18.3.1 Preparations ............................................. 140
18.3.2 Draining the engine oil .............................. 140
18.3.3 Removing the clutch push rod .................... 141
18.3.4 Removing the oil filter ............................... 141
18.3.5 Removing the starter motor ........................ 141
18.3.6 Removing the spark plug ........................... 141
18.3.7 Removing the valve cover........................... 142
18.3.8 Removing the alternator cover .................... 142
18.3.9 Positioning the engine at ignition top dead
18.3.10
18.3.11
18.3.12
center ...................................................... 142
Removing the timing chain tensioner .......... 143
Removing the camshaft ............................. 143
Removing the cylinder head ....................... 144
18.3.13 Removing the piston ................................. 144
18.3.14 Removing the rotor .................................... 144
18.3.15 Removing the timing chain guide rail .......... 145
18.3.16 Removing the timing chain tensioning
rail .......................................................... 145
18.3.17 Removing the timing chain securing
guide ....................................................... 145
18.3.18 Removing the timing chain ........................ 145
18.3.19 Removing the ignition pulse generator ........ 145
18.3.20 Removing the suction pump ....................... 146
18.3.21 Removing the water pump cover ................. 146
18.3.22 Removing the clutch cover ......................... 146