KTM 450 XC 2008 Repair Manual page 5

CONTENTS
Checking the brake fluid level of the front brake ............... 75
Adding brake fluid for the front brake .............................. 75
Checking the front brake linings...................................... 76
Removing the front brake linings..................................... 76
Mounting front brake linings........................................... 76
Changing the front brake linings ..................................... 77
Checking free play of foot brake lever .............................. 77
Adjusting basic position of footbrake lever ....................... 78
Checking the brake fluid level of the rear brake ................ 78
Adding brake fluid for the rear brake ............................... 79
Checking the rear brake linings ....................................... 79
Removing the rear brake linings ...................................... 80
Mounting rear brake linings ............................................ 80
Changing the rear brake linings....................................... 81
30/ENGINE....................................................................... 82
Removing the engine ..................................................... 82
Installing the engine ...................................................... 84
30/DISASSEMBLING THE ENGINE..................................... 87
Preparations.................................................................. 87
Draining the engine oil ................................................... 87
Removing the oil filter.................................................... 87
Removing the starter motor ............................................ 87
Removing the shift lever................................................. 88
Removing the clutch cover ............................................. 88
Removing the clutch discs.............................................. 88
Removing the outer clutch hub ....................................... 89
Removing the starter idler gear/torque limiter ................... 90
Removing the shift shaft ................................................ 90
Removing the shift drum locating.................................... 90
Removing the locking lever ............................................. 90
Removing the oil pump gear ........................................... 90
Removing the primary gear with the free-wheel-gear.......... 91
Removing the spark plug ................................................ 91
Removing the generator cover ......................................... 91
Installing the crankshaft locking bolt ............................... 91
Removing the ignition pulse generator ............................. 92
Removing the rotor ........................................................ 92
Removing the oil pumps................................................. 93
Removing the oil line ..................................................... 93
Removing the timing chain tensioner............................... 94
Removing the water pump cover ..................................... 94
Removing the cylinder head top section........................... 94
Removing the camshaft.................................................. 94
Removing the cylinder head............................................ 95
Removing the cylinder ................................................... 95
Removing the piston ...................................................... 96
Removing the timing chain............................................. 96
Removing the timing chain sprocket................................ 96
Removing the locking shaft lever..................................... 96
Removing the gear sensor............................................... 97
Taking off the left section of the engine case ................... 97
Remove the shift rails and forks. ..................................... 98
Removing the shift drum ................................................ 98
Removing the transmission shaft..................................... 99
Removing the balancer shaft .......................................... 99
Removing the crankshaft ................................................ 99
30/ENGINE - WORK ON INDIVIDUAL PARTS..................... 100
Work on the right section of the engine case .................. 100
Removing the oil pressure regulator valve....................... 101
Checking the spring length of the oil pressure regulator
valve .......................................................................... 101
Installing the oil pressure regulator valve ....................... 101
Work on the left section of the engine case .................... 102
Changing the crankshaft seal ring in the clutch cover...... 102
Disassembling the autodecompressor ............................ 103
Assembling the autodecompressor................................. 104
Changing the camshaft bearing..................................... 105
Checking the rocker arms and rocker arm shafts ............. 106
Removing the valves .................................................... 107
Checking the valves ..................................................... 108
Checking the valve springs ........................................... 108
Checking the lower valve spring retainer ........................ 108
Checking the cylinder head .......................................... 109
Installing the valves ..................................................... 109
Checking the timing assembly ...................................... 110
Preparing the timing chain tensioner for installation ....... 110
Changing the conrod bearing ........................................ 110
Checking the crankshaft run-out on the bearing pin ........ 111
Measuring the axial clearance of the crankshaft.............. 112
Correcting the axial clearance of the crankshaft.............. 112
cylinder - Nikasil ® coating ............................................ 113
Checking/measuring the cylinder................................... 113
Checking/measuring the piston ..................................... 114
Checking the piston ring end gap .................................. 114
Checking the piston/cylinder mounting clearance............ 115
Checking the oil pumps for wear ................................... 115
Checking the shift mechanism ...................................... 116
Disassembling the shift shaft........................................ 117
Preassembling the shift shaft........................................ 118
Checking the clutch..................................................... 118
Disassembling the main shaft ....................................... 119
Checking the main shaft .............................................. 120
Assembling the main shaft ........................................... 121
Disassembling the countershaft .................................... 122
Checking the countershaft ............................................ 123
Assembling the countershaft......................................... 124
Checking/premounting the reverse gear shaft.................. 125
Checking electric starter operation ................................ 126
Removing the free-wheel .............................................. 127
Checking the free-wheel ............................................... 127
Installing the free-wheel............................................... 127
30/ASSEMBLING THE ENGINE ........................................ 128
Installing the crankshaft............................................... 128
Installing the balancer shaft ......................................... 128
Installing the transmission shaft ................................... 128
Installing the shift forks ............................................... 129
Installing the shift drum............................................... 129
Installing the shift rails ................................................ 129
Installing the left engine case ....................................... 129
Installing the timing chain sprocket............................... 131
Installing the timing chain rails..................................... 131
Installing the piston..................................................... 131
Installing the cylinder .................................................. 132
Installing the cylinder head .......................................... 132
Installing the camshaft ................................................ 133
Installing the cylinder head top section.......................... 134
Installing the timing chain tensioner ............................. 135
Installing the rotor ....................................................... 135
Checking the valve clearance ........................................ 135
Adjusting the valve clearance........................................ 136
Installing the valve cover .............................................. 136
Installing the water pump cover .................................... 136
Installing the oil line.................................................... 136
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