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450 EXC EU 2013
Repair manual
KTM 450 EXC EU 2013 Repair Manual
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Also See for 450 EXC EU 2013
:
Setup instructions
(20 pages)
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Contents
Table of Contents
Bookmarks
Table of Contents
Table of Contents
1 Means of Representation
Symbols Used
Formats Used
2 SAFETY Advice
Repair Manual
Degrees of Risk and Symbols
Work Rules
3 Important Notes
Guarantee, Warranty
Operating and Auxiliary Substances
Spare Parts, Accessories
Figures
4 Serial Numbers
Chassis Number
Type Label
Key Number
Engine Number
Fork Part Number
Shock Absorber Part Number
5 Motorcycle
Raising the Motorcycle with the Lift Stand
Removing the Motorcycle from the Lift Stand
Starting
Starting the Motorcycle for a Check
Adjusting the Compression Damping of the Fork
Adjusting the Rebound Damping of the Fork
Adjusting the Spring Preload of the Fork
6 Fork, Triple Clamp
Bleeding Fork Legs
Cleaning the Dust Boots of the Fork Legs
Exc Eu/Aus/Usa, XC-W
Loosening the Fork Protector
Positioning the Fork Protection
Removing the Fork Legs
Installing the Fork Legs
Removing the Fork Protector
Installing the Fork Protector
Performing a Fork Service
Disassembling the Fork Legs
Cartridge Disassembly
Disassembling the Compression Damping Fitting
Checking the Fork Legs
Assembling the Compression Damping Fitting
Assembling the Cartridge
Assembling the Fork Legs
Greasing the Steering Head Bearing
Removing the Lower Triple Clamp
Installing the Lower Triple Clamp
Checking the Steering Head Bearing Play
Adjusting the Play of the Steering Head Bearing
Exc Six Days
Adjusting the Compression Damping of the Fork
Adjusting the Rebound Damping of the Fork
Bleeding Fork Legs
Cleaning the Dust Boots of the Fork Legs
Loosening the Fork Protector
Positioning the Fork Protection
Removing the Fork Legs
Installing the Fork Legs
Removing the Fork Protector
Installing the Fork Protector
Performing a Fork Service
Disessembling the Fork Legs
Removing the Spring
Disassembling the Cartridge
Disassembling the Piston Rod
Disassembling the Hydrostop Unit
Disassembling the Seal Ring Retainer
Checki Ng the Fork Legs
Assembling the Seal Ring Retainer
Assembling the Hydrostop Unit
Assembling the Piston Rod
Assembling the Cartridge
Assembling the Fork Legs
Greasing the Steering Head Bearing
Removing the Lower Triple Clamp
Installing the Lower Triple Clamp
Bearing
Checking the Steering Head Bearing Play
7 Handlebar, Controls
Handlebar Position
Adjusting Handlebar Position
Adjusting the Basic Position of the Clutch Lever
Checking the Throttle Cable Routing
Checking the Play in the Throttle Cable
Adjusting the Play in the Throttle Cable
8 Frame
Removing the Engine Guard
EXC Ausl
Installing the Engine Guard
9 Shock Absorber, Swingarm
Adjusting the High-Speed Compression Damping of the Shock Absorber
Adjusting the Low-Speed Compression Damping of the Shock Absorber
Adjusting the Rebound Damping of the Shock Absorber
Measuring Rear Wheel Sag Unloaded
Checking the Static Sag of the Shock Absorber
Checking the Riding Sag of the Shock Absorber
Absorber
Adjusting the Riding Sag
Removing the Shock Absorber
Installing the Shock Absorber
Servicing the Shock Absorber
Removing the Spring
Disassembling the Damper
Disassembling the Piston Rod
Disassembling the Seal Ring Retainer
Replacing the Pilot Bushing
Checking the Damper
Disassembling the Rebound Adjuster
Removing the Heim Join
Installing the Heim Join
Assembling the Rebound Adjuster
Assembling the Seal Ring Retainer
Assembling the Piston Rod
Assembling the Damper
Bleeding and Filling the Damper
Filling the Damper with Nitrogen
Installing the Spring
Changing the Heim Joint
10 Exhaust
Removing the Manifold
Installing the Manifold
Removing Main Silencer
Installing the Main Silencer
Changing the Glass Fiber Yarn Filling of the Main Silencer
11 Air Filter
Removing the Air Filter Box Lid
Installing the Air Filter Box Lid
Removing the Air Filter
Installing the Air Filter
Cleaning the Air Filter and Air Filter Box
Opening Filler Cap
Closing Filler Cap
Removing the Seat
12 Fuel Tank, Seat, Trim
Mounting the Sea
Removing the Fuel Tank
Installing the Fuel Tank
Changing the Fuel Screen
Changing the Fuel Filter
Changing the Fuel Pump
Checking the Fuel Pressure
13 Mask, Fender
Removing the Front Fender
Installing the Front Fender
Removing Headlight Mask with Headligh
Headlight
14 Wheels
Checking the Tire Air Pressure
Checking the Tire Condition
Checking the Brake Discs
Checking Spoke Tension
Front Wheel
Removing the Front Wheel
Installing the Front Wheel
Removing the Front Brake Disc
Installing the Front Brake Disc
Rear Wheel
Removing the Rear Wheel
Installing the Rear Wheel
Removing the Rear Brake Disc
Installing the Rear Brake Disc
Checking the Chain Tension
Adjusting the Chain Tension
Adjusting the Chain Guide
Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide
Checking for Chain Dirt Accumulation
14.6.10 Cleaning the Chain
15 WIRING HARNESS, Battery
Changing the Main Fuse
Changing the Fuses of Individual Power Consumers
Changing the Fuse of the Radiator Fan
Removi Ng the Battery
Installing the Battery
Charging the Battery
16 Brake System
Checking the Front Brake Linings
Changing the Front Brake Linings
Checking Free Travel of Hand Brake Lever
Brake Lever (All XC-W Models)
Adjusting Free Travel of Hand Brake Lever (All EXC Models)
Checking the Front Brake Fluid Level
Adding Front Brake Fluid
Changing the Front Brake Fluid
Checking the Rear Brake Linings
Changing the Rear Brake Linings
Checking the Free Travel of Foot Brake Lever
Adjusting the Basic Position of the Foot Brake Lever
Checking the Rear Brake Fluid Level
Adding Brake Fluid to the Rear Brake Circui
Changing the Rear Brake Fluid
17 Lighting System, Instruments
Adjusting the Speedometer Functions
Setting Kilometers or Miles
Activating the Additional Functions
Setting the Wheel Circumference
Setting the Clock
Checking the Headlight Setting
Adjusting the Headlight Range
18 Engine
Removing the Engine
Installing the Engine
Engine Disassembly
Preparations
Draining the Engine Oil
Removing the Clutch Push Rod
Removing the Oil Filter
Removing the Starter Motor
Removing the Spark Plug
Removing the Valve Cover
Removing the Alternator Cover
Positioning the Engine at Ignition Top Dead Center
Removing the Timing Chain Tensioner
Removing the Camshaft
Removing the Cylinder Head
Removing the Piston
Removing the Rotor
Removing the Timing Chain Guide Rail
Removing the Timing Chain Tensioning Rail
Removing the Timing Chain Securing Guide
Removing the Timing Chain
Removing the Ignition Pulse Generator
Removing the Suction Pump
Removing the Water Pump Cover
Removing the Clutch Cover
Removing the Clutch Discs
Removing the Primary Gear Nut
Removing the Outer Clutch Hub
Removing the Torque Limiter
Removing the Starter Idler Gear
Removing the Kickstarter Idler Gear
Removing the Shift Shaft
Removing the Shift Drum Locating Unit
Removing the Locking Lever
Removing the Oil Pump Gear Wheels
Removing the Force Pump
Removing the Primary Gear
Removing the Free Wheel Gear
Removing the Left Engine Case Section
Removing the Shift Rails
Removing the Shift Drum
Removing the Shift Lorks
Removing the Transmission Shafts
Removing the Crankshaft
Work on Individual Parts
Work on the Right Section of the Engine Case
Work on the Left Section of the Engine Case
Removing the Oil Pressure Regulator Valve
Checking Spring Length of Oil Pressure Regulator Valve
Installing the Oil Pressure Regulator Valve
Removing the Crankshaft Seal Ring in the Clutch Cover
Installing the Crankshaft Seal Ring in the Clutch Cover
Removing the Water Pump
Installing the Water Pump
Removing the Timing Chain Sprocket
Installing the Timing Chain Sprocket
Changing the Connecting Rod, Conrod Bearing. and Crank Pin
18.4.13 Checking Crankshaft Run-Out at Bearing Pin
Cylinder - Nikasil" Coating
Checking/Measuring the Cylinder
Checking/Measuring the Piston
Checking the Piston Ring End Gap
18.4.18 Measuring the Piston/Cylinder Mounting Clearance
Checking the Oil Pumps
18.4.20 Disassembling the Autodecompressor
Assembling the Autodecompressor
Checking Camshaft
Checking the Timing Assembly
Removing the Rocker Arm
Removing the Valves
Changing Camshaft Bearing
Checking the Valves
Checking Valve Springs
Checking Valve Spring Seal
Checking the Cylinder Head
Checking the Rocker Arm Shafts
Installing the Valves
Install I Ng the Rocker Arm
Checking the Clutch
18.4.35 Checking the Shift Mechanism
Preassembling the Shift Shaft
Disassembling the Main Shaft
Assembling the Main Shaft
Disassembling the Countershaft
Assembling the Countershaft
Checking the Transmission
Premountingthe Kickstarter Shaft
18.4.43 Checking the Starter Drive
Removing the Ireewheel
Checking the Freewheel
Installing the Free Wheel
Engine Assembly
Installing the Crankshaft
Installing the Transmission Shafts
Installing the Shift Lorks
Installing the Shift Drum
Installing the Shift Rails
Installing the Left Engine Case
Installing the Free Wheel Gear
Installing the Primary Gear
Installing the Lorce Pump
18.5.10 Installing the Oil Pump Gear Wheels
Installing the Locking Lever
Installing the Shift Drum Locating Unit
18.5.13 Installing the Shift Shaft
Installing the Kickstarter Idler Gear
Installing the Kickstarter Shaft
Installing the Starter Idler Gear
18.5.17 Installing the Torque Limiter
Installing the Outer Clutch Hub
18.5.19 Installing the Primary Gear Nut
Installing the Clutch Discs
Installing the Clutch Cover
18.5.22 Installing the Water Pump Cover
18.5.23 Installing the Suction Pump
18.5.24 Installing the Ignition Pulse Generator
18.5.25 Installing the Timing Chain
18.5.28 Installing the Timing Chain Securing Guide
Installing the Timing Chain Tensioning Rail
Installing the Timing Chain Guide Rail
18.5.29 Installing the Rotor
Installing the Piston
Installing the Cylinder Head
18.5.32 Installing the Camshaft
Installing the Timing Chain Tensioner
Checking the Valve Clearance
Adjusting the Valve Clearance
Installing the Alternator Cover
Installing the Valve Cover
Installing the Spark Plug
Installing the Starter Motor
Installing the Oil Filter
18.5.41 Installing the Clutch Push Rod
Installing the Oil Screen
Removing the Engine Lrom the Engine Assembly Stand
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REPAIR MANUAL
2013
''l'MWI:ii~8ijIIM
450 EXC EU
450 EXC AUS
450 EXC SIX DAYS EU
450 XC-W USA
500 EXC EU
500 EXC AUS
500 EXC SIX DAYS EU
500 EXC USA
500 XC-W USA
Art. no. 32D6152en
Table of
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