KTM 450 EXC-F 2017 Repair Manual page 5

TABLE OF CONTENTS
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9 .3 1 Installing the swingarm .......... .. ........................ 89 15 WIRING HARNESS, BATTERY ...... .. .................... .. ..... 134
9 .32 Changi ng the swingarm bearing ........................ 9 1 15. 1 Changingthemainfuse .......................... .. ..... 134
10 EXHAU ST .................. ... ................... ... .................. ... .. 93 15.2 Changing the fuses of individual power
10.1 Removing the manifol d .......... .. ........................ 93
consumers .................................................... 134
10.2 Installing the manifold .......... .. ........................ 93
15.3 Removing the battery .................................... 136
10.3 Removing main si lencer ................................... 94
15.4 Installing the battery ..................................... 136
10.4 Installing the main si lencer .............................. 95
15.5 Recharging the battery .................................. 137
10.5 Changing the glass fiber yarn filling in the
15.6 Checking the charging voltage ........................ 138
main silencer .................................................. 95 15.7 Checking the quiescent current ...................... 138
10.6 Cleaning the spark arrestor (All US models) ....... 96 15.8 Checking the starter relay .............................. 138
11 AIR FILTER ............................................................... 98 16 BRAKE SYSTEM ...................................................... 139
11.1 Removing the air filter box cover ...................... 98 16.1 Checking the front brake lini ngs ..................... 139
11.2 Installing the air filter box cover ....................... 98 16.2 Changing the front brake linings ..................... 139
11.3 Sealing the air fi lter box .................................. 98 16.3 Checking free travel of hand brake lever .......... 141
11.4 Removing the air filter ..................................... 99 16.4 Adjusting free trave l of hand brake lever .......... 141
11.5 Installing the air filter ...................................... 99 16.5 Checking the brake fluid leve l of the front
11.6 Cleaning the air filter and air fi lter box .............. 99
brake ........................................................... 141
11.7 Checking the inlet membrane (All US
16.6 Adding front brake f luid ................................. 142
models) ........................................................ 100
16.7 Changing the front brake fluid ........................ 143
12 FUEL TANK , SEAT, TRIM ......................................... 101 16.8 Checking the rear brake lini ngs ...................... 144
12.1 Opening the filler cap .................................... 101 16.9 Changing the rear brake linings ...................... 144
12.2 Closing the filler cap ..................................... 101 16.10 Checking the free travel of foot brake lever ...... 146
12.3 Removing the seat ............ .. .......................... 101 16.11 Adjusting the basic position of the foot brake
12.4 Mounting the seat ......................................... 102
lever ............................................................ 147
12.5 Removing the fuel tank ...... .. .......................... 102
16.12 Checking the rear brake fluid level .................. 14 7
12.6 Installing the fuel tank .................................. 104
16.13 Adding rear brake f luid .................................. 148
12.7 Changing the fuel screen ............................... 105
16. 14 Changing the rear brake fluid .................. .. ..... 149
12.8 Changing the fuel filter .................................. 106
17 LIGHTING SYSTEM, INSTRUMENTS .................. .. ..... 151
12.9 Changing the fuel pump ................................ 109
1 7. 1 Checking the head I ight setting .. .. .. .. .. .. .. .. .. .. .. . 151
12.10 Checkingthefuel pressure ............................. 111
17.2 Adjusting the head I ight range .................. .. ..... 151
13 MASK , FENDER ....................................................... 113
17.3 Speedomet eroverview ...... .. .................... .. ..... 151
13.1 Removing the front fender ............................. 11 3
17.4 Activation and test ................................ .. ...... 151
13.2 Installing the front fender .............................. 113
17.5 Settingki lometersormi les ............................. 152
13.3 Removing the headlight mask with the
17.6 Setting the speedometer functions .................. 152
headlight.. .................................................... 114 17.7 Settingtheclock ........................................... 153
13.4 Installing the head light mask with the 17.8 Activating additional functions ....................... 153
headlight ...................................................... 115
17.9 Setting the wheel circu mference .................... 154
14 WHEELS ................................................................. 117
17.10 Viewingthelaptime ...................................... 154
14.1 Checking the tire air pressure ......................... 117
18 ENGINE .................................................................. 155
14.2 Checking the tire cond ition ............................ 11 7
18. 1 Removing the engine ..................................... 155
14.3 Checking the wheel bearing f or play ................ 118
18.2 Inst alling the engine ...................................... 160
14.4 Checking the brake discs ............................... 118
18.3 Engine disassembly ....................................... 165
14.5 Checking spoke tension ................................. 119
18.3. 1 Preparations ............................................. 165
14.6 Checking the rim run-out ............................... 119
18.3.2 Drain ing the engine oil .............................. 166
14.7 Front whee l .................................................. 120
18.3.3 Removing the clutch push rod .................... 166
14.7 . 1 Removing the front whee l .......................... 120
18.3.4 Removing the oi l filter ............................... 167
14.7.2 Installing the front wheel ........................... 120
18.3.5 Removing the starter motor ........................ 167
14.7 .3 Changing the front brake discs ................... 121
18.3.6 Removing the spark plug ........................... 168
14.7 .4 Changing the front wheel bearing ............... 121
18.3.7 Removing the valve cover ........................... 168
14.8 Rear wheel ................................................... 123
18.3.8 Removing the alternator cover .................... 168
14.8.1 Removing the rear whee l ........................... 123
18.3.9 Positioning the engine at ignition top dead
14.8.2 Installing the rear wheel ............................ 123 center ...................................................... 169
14.8.3 Changing the rear brake d isc ...................... 124 18.3.10 Removing the timing chain t ensioner .. .. ...... 169
14.8.4 Changing the rear wheel bearing .............. .. . 125 18.3. 11 Removing the camshaft ...................... .. ..... 170
14.8.5 Checking the chain tension .. ...................... 126 18.3. 12 Removing the cyl inder head ................ .. ..... 171
14.8.6 Adjusting the chain tension .................... .. . 127
18.3. 13 Removing the piston .......................... .. ..... 171
14.8.7 Checking the chain , rear sprocket , motor 18.3. 14 Removing the rotor ........ .. .................. .. ...... 173
sprocket, and chain guide .......................... 128
18.3. 15 Removing the timing chain ................ .. ...... 173
14.8.8 Checking for chain dirt accumulation .......... 129
18.3. 16 Removing suction pump .................... .. ...... 174
14.8.9 Cleaning the chain .................................... 129
18.3.17 Removing the gear position sensor .............. 17 4
14.8.10 Changing the drivetrain kit ......................... 130
18.3.18 Removing the water pump cover ................. 17 4
18.3.19 Removing the clutch cover ......................... 175