KTM 450 EXC EU 2013 Repair Manual page 4

TABLE OF CONTENTS
18.3.23 Removing the clutch discs ......................... 147
18.3.24 Removing the primary gear nut. .................. 148
18.3.25 Removing the outer clutch hub .................. 148
18.3.26 Removing the torque limiter ....................... 149
18.3.27 Removing the starter idler gear ................... 149
18.3.28 Removing the kickstarter idler gear ............. 149
18.3.29 Removing the kickstarter idler gear ............. 149
18.3.30 Removing the shift shaft... ......................... 149
18.3.31 Removing the shift drum locating unit ........ 150
18.3.32 Removing the locking lever ........................ 150
18.3.33 Removing the oil pump gear wheels ............ 150
18.3.34 Removing the force pump .......................... 151
18.3.35 Removing the primary gear ........................ 151
18.3.36 Removing the free wheel gear .................... 151
18.3.37 Removing the left engine case section ........ 151
18.3.38 Removing the shift rails ............................. 152
18.3.39 Removing the shift drum ........................... 152
18.3.40 Removing the shift lorks ............................ 153
18.3.41 Removing the transmission shafts ............... 153
18.3.42 Removing the crankshaft ........................... 153
18.4 Work on individual parts ................................ 154
18.4.1 Work on the right section of the engine
18.4.2
18.4.3
18.4.4
18.4.5
18.4.6
18.4.7
18.4.8
18.4.9
18.4.10
18.4.11
18.4.12
18.4.13
18.4.14
18.4.15
18.4.16
18.4.17
18.4.18
18.4.19
18.4.20
18.4.21
18.4.22
18.4.23
18.4.24
18.4.25
18.4.26
18.4.27
18.4.28
18.4.29
18.4.30
18.4.31
18.4.32
18.4.33
case ........................................................ 154
Work on the left section of the engine
case ........................................................ 155
Removing the oil pressure regulator valve .... 156
Checking spring length of oil pressure
regulator valve .......................................... 156
Installing the oil pressure regulator valve ..... 157
Removing the crankshaft seal ring in the
clutch cover ............................................. 157
Installing the crankshaft seal ring in the
clutch cover ............................................. 157
Removing the water pump ......................... 157
Installing the water pump .......................... 158
Removing the timing chain sprocket ........... 159
Installing the timing chain sprocket ............ 159
Changing the connecting rod, conrod
bearing. and crank pin .............................. 159
Checking crankshaft run-out at bearing
pin .......................................................... 161
Cylinder - Nikasil" coating ......................... 161
Checking/measuring the cylinder ................ 161
Checking/measuring the piston ................... 162
Checking the piston ring end gap ............... 162
Measuring the piston/cylinder mounting
clearance ................................................. 163
Checking the oil pumps ............................. 163
Disassembling the autodecompressor .......... 163
Assembling the autodecompressor .............. 164
Checking camshaft ................................... 165
Checking the timing assembly .................... 165
Removing the rocker arm ........................... 166
Removing the valves .................................. 166
Changing camshaft bearing ........................ 167
Checking the valves .................................. 167
Checking valve springs .............................. 168
Checking valve spring seal.. ....................... 168
Checking the cylinder head ........................ 168
Checking the rocker arm shafts .................. 169
Installing the valves .................................. 169
Install i ng the rocker arm.... .............. .......... 170
4
18.4.34 Checking the clutch .................................. 170
18.4.35 Checking the shift mechanism ................... 172
18.4.36 Preassembling the shift shaft ..................... 173
18.4.37 Disassembling the main shaft .................... 173
18.4.38 Assembling the main shaft ......................... 174
18.4.39 Disassembling the countershaft .................. 175
18.4.40 Assembling the countershaft ...................... 175
18.4.41 Checking the transmission ......................... 176
18.4.42 Premountingthe kickstarter shaft ............... 178
18.4.43 Checking the starter drive .......................... 179
18.4.44 Removing the Ireewheel ............................ 179
18.4.45 Checking the freewheel ............................. 180
18.4.46 Installing the free wheel ............................ 180
18.5 Engine assembly ........................................... 181
18.5.1 Installing the crankshaft ............................ 181
18.5.2 Installing the transmission shafts ............... 181
18.5.3 Installing the shift lorks ............................. 181
18.5.4 Installing the shift drum ............................ 182
18.5.5 Installing the shift rails ............................. 182
18.5.6 Installing the left engine case .................... 182
18.5.7 Installing the free wheel gear ..................... 183
18.5.8 Installing the primary gear ......................... 183
18.5.9 Installing the lorce pump ........................... 183
18.5.10 Installing the oil pump gear wheels ............. 184
18.5.11 Installing the locking lever ......................... 184
18.5.12 Installing the shift drum locating unit ......... 184
18.5.13 Installing the shift shaft ............................ 185
18.5.14 Installing the kickstarter idler gear .............. 185
18.5.15 Installing the kickstarter shaft .................... 185
18.5.16 Installing the starter idler gear ................... 185
18.5.17 Installing the torque limiter ....................... 186
18.5.18 Installing the outer clutch hub ................... 186
18.5.19 Installing the primary gear nut ................... 187
18.5.20 Installing the clutch discs .......................... 187
18.5.21 Installing the clutch cover ......................... 188
18.5.22 Installing the water pump cover .................. 189
18.5.23 Installing the suction pump ....................... 189
18.5.24 Installing the ignition pulse generator ......... 190
18.5.25 Installing the timing chain ......................... 190
18.5.26 Installing the timing chain securing guide ... 190
18.5.27 Installing the timing chain tensioning rail .... 191
18.5.28 Installing the timing chain guide rail ........... 191
18.5.29 Installing the rotor .................................... 191
18.5.30 Installing the piston .................................. 191
18.5.31 Installing the cylinder head ........................ 193
18.5.32 Installing the camshaft .............................. 194
18.5.33 Installing the timing chain tensioner ........... 194
18.5.34 Checking the valve clearance ..................... 194
18.5.35 Adjusting the valve clearance ..................... 195
18.5.36 Installing the alternator cover ..................... 195
18.5.37 Installing the valve cover ........................... 196
18.5.38 Installing the spark plug ............................ 196
18.5.39 Installing the starter motor ......................... 196
18.5.40 Installing the oil filter ................................ 196
18.5.41 Installing the clutch push rod .................... 197
18.5.42 Installing the oil screen ............................. 197
18.5.43 Removing the engine lrom the engine
assembly stand ......................................... 198
19 CLUTCH .................................................................. 199
19.1 Checking/correcting the fluid level of the
hydraulic clutch ............................................ 199
19.2 Changing the hydraulic clutch fluid ................ 199