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450 EXC AUS 2013
KTM 450 EXC AUS 2013 Manuals
Manuals and User Guides for KTM 450 EXC AUS 2013. We have
2
KTM 450 EXC AUS 2013 manuals available for free PDF download: Repair Manual, Setup Instructions
KTM 450 EXC AUS 2013 Repair Manual (313 pages)
Brand:
KTM
| Category:
Motorcycle
| Size: 84.12 MB
Table of Contents
Table of Contents
2
1 Means of Representation
6
Symbols Used
6
Formats Used
6
2 SAFETY Advice
7
Repair Manual
7
Degrees of Risk and Symbols
7
Work Rules
7
3 Important Notes
8
Guarantee, Warranty
8
Operating and Auxiliary Substances
8
Spare Parts, Accessories
8
Figures
8
4 Serial Numbers
9
Chassis Number
9
Type Label
9
Key Number
10
Engine Number
10
Fork Part Number
10
Shock Absorber Part Number
10
5 Motorcycle
12
Raising the Motorcycle with the Lift Stand
12
Removing the Motorcycle from the Lift Stand
12
Starting
12
Starting the Motorcycle for a Check
13
Adjusting the Compression Damping of the Fork
14
Adjusting the Rebound Damping of the Fork
14
Adjusting the Spring Preload of the Fork
14
6 Fork, Triple Clamp
15
Bleeding Fork Legs
15
Cleaning the Dust Boots of the Fork Legs
15
Exc Eu/Aus/Usa, XC-W
16
Loosening the Fork Protector
16
Positioning the Fork Protection
16
Removing the Fork Legs
16
Installing the Fork Legs
17
Removing the Fork Protector
17
Installing the Fork Protector
18
Performing a Fork Service
18
Disassembling the Fork Legs
18
Cartridge Disassembly
21
Disassembling the Compression Damping Fitting
23
Checking the Fork Legs
23
Assembling the Compression Damping Fitting
25
Assembling the Cartridge
25
Assembling the Fork Legs
27
Greasing the Steering Head Bearing
31
Removing the Lower Triple Clamp
31
Installing the Lower Triple Clamp
32
Checking the Steering Head Bearing Play
34
Adjusting the Play of the Steering Head Bearing
34
Exc Six Days
35
Adjusting the Compression Damping of the Fork
35
Adjusting the Rebound Damping of the Fork
35
Bleeding Fork Legs
35
Cleaning the Dust Boots of the Fork Legs
36
Loosening the Fork Protector
36
Positioning the Fork Protection
37
Removing the Fork Legs
37
Installing the Fork Legs
37
Removing the Fork Protector
38
Installing the Fork Protector
38
Performing a Fork Service
38
Disessembling the Fork Legs
39
Removing the Spring
41
Disassembling the Cartridge
42
Disassembling the Piston Rod
43
Disassembling the Hydrostop Unit
44
Disassembling the Seal Ring Retainer
44
Checki Ng the Fork Legs
45
Assembling the Seal Ring Retainer
46
Assembling the Hydrostop Unit
46
Assembling the Piston Rod
47
Assembling the Cartridge
48
Assembling the Fork Legs
49
Greasing the Steering Head Bearing
53
Removing the Lower Triple Clamp
53
Installing the Lower Triple Clamp
54
Bearing
54
Checking the Steering Head Bearing Play
55
7 Handlebar, Controls
57
Handlebar Position
57
Adjusting Handlebar Position
57
Adjusting the Basic Position of the Clutch Lever
57
Checking the Throttle Cable Routing
58
Checking the Play in the Throttle Cable
58
Adjusting the Play in the Throttle Cable
59
8 Frame
61
Removing the Engine Guard
61
EXC Ausl
61
Installing the Engine Guard
61
9 Shock Absorber, Swingarm
62
Adjusting the High-Speed Compression Damping of the Shock Absorber
62
Adjusting the Low-Speed Compression Damping of the Shock Absorber
62
Adjusting the Rebound Damping of the Shock Absorber
63
Measuring Rear Wheel Sag Unloaded
63
Checking the Static Sag of the Shock Absorber
63
Checking the Riding Sag of the Shock Absorber
64
Absorber
65
Adjusting the Riding Sag
65
Removing the Shock Absorber
65
Installing the Shock Absorber
65
Servicing the Shock Absorber
66
Removing the Spring
66
Disassembling the Damper
67
Disassembling the Piston Rod
68
Disassembling the Seal Ring Retainer
69
Replacing the Pilot Bushing
70
Checking the Damper
71
Disassembling the Rebound Adjuster
71
Removing the Heim Join
72
Installing the Heim Join
73
Assembling the Rebound Adjuster
74
Assembling the Seal Ring Retainer
74
Assembling the Piston Rod
75
Assembling the Damper
76
Bleeding and Filling the Damper
79
Filling the Damper with Nitrogen
81
Installing the Spring
82
Changing the Heim Joint
83
10 Exhaust
85
Removing the Manifold
85
Installing the Manifold
85
Removing Main Silencer
86
Installing the Main Silencer
86
Changing the Glass Fiber Yarn Filling of the Main Silencer
86
11 Air Filter
88
Removing the Air Filter Box Lid
88
Installing the Air Filter Box Lid
88
Removing the Air Filter
88
Installing the Air Filter
88
Cleaning the Air Filter and Air Filter Box
89
Opening Filler Cap
90
Closing Filler Cap
90
Removing the Seat
90
12 Fuel Tank, Seat, Trim
91
Mounting the Sea
91
Removing the Fuel Tank
91
Installing the Fuel Tank
92
Changing the Fuel Screen
93
Changing the Fuel Filter
94
Changing the Fuel Pump
96
Checking the Fuel Pressure
97
13 Mask, Fender
99
Removing the Front Fender
99
Installing the Front Fender
99
Removing Headlight Mask with Headligh
99
Headlight
99
14 Wheels
101
Checking the Tire Air Pressure
101
Checking the Tire Condition
101
Checking the Brake Discs
102
Checking Spoke Tension
102
Front Wheel
103
Removing the Front Wheel
103
Installing the Front Wheel
103
Removing the Front Brake Disc
104
Installing the Front Brake Disc
104
Rear Wheel
104
Removing the Rear Wheel
104
Installing the Rear Wheel
105
Removing the Rear Brake Disc
106
Installing the Rear Brake Disc
106
Checking the Chain Tension
107
Adjusting the Chain Tension
107
Adjusting the Chain Guide
108
Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide
108
Checking for Chain Dirt Accumulation
110
14.6.10 Cleaning the Chain
110
15 WIRING HARNESS, Battery
112
Changing the Main Fuse
112
Changing the Fuses of Individual Power Consumers
113
Changing the Fuse of the Radiator Fan
113
Removi Ng the Battery
114
Installing the Battery
115
Charging the Battery
115
16 Brake System
117
Checking the Front Brake Linings
117
Changing the Front Brake Linings
117
Checking Free Travel of Hand Brake Lever
119
Brake Lever (All XC-W Models)
119
Adjusting Free Travel of Hand Brake Lever (All EXC Models)
119
Checking the Front Brake Fluid Level
120
Adding Front Brake Fluid
120
Changing the Front Brake Fluid
121
Checking the Rear Brake Linings
122
Changing the Rear Brake Linings
122
Checking the Free Travel of Foot Brake Lever
124
Adjusting the Basic Position of the Foot Brake Lever
124
Checking the Rear Brake Fluid Level
125
Adding Brake Fluid to the Rear Brake Circui
125
Changing the Rear Brake Fluid
126
17 Lighting System, Instruments
128
Adjusting the Speedometer Functions
128
Setting Kilometers or Miles
128
Activating the Additional Functions
129
Setting the Wheel Circumference
129
Setting the Clock
130
Checking the Headlight Setting
131
Adjusting the Headlight Range
131
18 Engine
132
Removing the Engine
132
Installing the Engine
136
Engine Disassembly
140
Preparations
140
Draining the Engine Oil
140
Removing the Clutch Push Rod
141
Removing the Oil Filter
141
Removing the Starter Motor
141
Removing the Spark Plug
141
Removing the Valve Cover
142
Removing the Alternator Cover
142
Positioning the Engine at Ignition Top Dead Center
142
Removing the Timing Chain Tensioner
143
Removing the Camshaft
143
Removing the Cylinder Head
144
Removing the Piston
144
Removing the Rotor
144
Removing the Timing Chain Guide Rail
145
Removing the Timing Chain Tensioning Rail
145
Removing the Timing Chain Securing Guide
145
Removing the Timing Chain
145
Removing the Ignition Pulse Generator
145
Removing the Suction Pump
146
Removing the Water Pump Cover
146
Removing the Clutch Cover
146
Removing the Clutch Discs
147
Removing the Primary Gear Nut
148
Removing the Outer Clutch Hub
148
Removing the Torque Limiter
149
Removing the Starter Idler Gear
149
Removing the Kickstarter Idler Gear
149
Removing the Shift Shaft
149
Removing the Shift Drum Locating Unit
150
Removing the Locking Lever
150
Removing the Oil Pump Gear Wheels
150
Removing the Force Pump
151
Removing the Primary Gear
151
Removing the Free Wheel Gear
151
Removing the Left Engine Case Section
151
Removing the Shift Rails
152
Removing the Shift Drum
152
Removing the Shift Lorks
153
Removing the Transmission Shafts
153
Removing the Crankshaft
153
Work on Individual Parts
154
Work on the Right Section of the Engine 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
18.4.13 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
18.4.18 Measuring the Piston/Cylinder Mounting Clearance
163
Checking the Oil Pumps
163
18.4.20 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
Checking the Clutch
170
18.4.35 Checking the Shift Mechanism
172
Preassembling the Shift Shaft
173
Disassembling the Main Shaft
173
Assembling the Main Shaft
174
Disassembling the Countershaft
175
Assembling the Countershaft
175
Checking the Transmission
176
Premountingthe Kickstarter Shaft
178
18.4.43 Checking the Starter Drive
179
Removing the Ireewheel
179
Checking the Freewheel
180
Installing the Free Wheel
180
Engine Assembly
181
Installing the Crankshaft
181
Installing the Transmission Shafts
181
Installing the Shift Lorks
181
Installing the Shift Drum
182
Installing the Shift Rails
182
Installing the Left Engine Case
182
Installing the Free Wheel Gear
183
Installing the Primary Gear
183
Installing the Lorce Pump
183
18.5.10 Installing the Oil Pump Gear Wheels
184
Installing the Locking Lever
184
Installing the Shift Drum Locating Unit
184
18.5.13 Installing the Shift Shaft
185
Installing the Kickstarter Idler Gear
185
Installing the Kickstarter Shaft
185
Installing the Starter Idler Gear
185
18.5.17 Installing the Torque Limiter
186
Installing the Outer Clutch Hub
186
18.5.19 Installing the Primary Gear Nut
187
Installing the Clutch Discs
187
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
18.5.28 Installing the Timing Chain Securing Guide
190
Installing the Timing Chain Tensioning Rail
191
Installing the Timing Chain Guide Rail
191
18.5.29 Installing the Rotor
191
Installing the Piston
191
Installing the Cylinder Head
193
18.5.32 Installing the Camshaft
194
Installing the Timing Chain Tensioner
194
Checking the Valve Clearance
194
Adjusting the Valve Clearance
195
Installing the Alternator Cover
195
Installing the Valve Cover
196
Installing the Spark Plug
196
Installing the Starter Motor
196
Installing the Oil Filter
196
18.5.41 Installing the Clutch Push Rod
197
Installing the Oil Screen
197
Removing the Engine Lrom the Engine Assembly Stand
198
19 Clutch
199
Checking/Correcting the Fluid Level of the Hydraulic Clutch
199
Changing the Hydraulic Clutch Fluid
199
20 Water Pump, Cooling System
201
Cooling System
201
Checking the Antifreeze and Coolant Level
201
Checking the Coolant Level
202
Draining the Coolanl
202
Refilling Coolant
203
21 LUBRICATION System
204
Oil Circui
204
Checking the Engine Oil Level
204
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens
204
Adding Engine Oil
207
Checking the Engine Oil Pressure
208
22 IGNITION System
209
Ignition Coil - Checking the Secondary Winding
209
Checking the Spark Plug Connector
209
Alternator - Checking the Stator Winding
209
Removing the Stator
210
Installing the Stator
210
23 Electric Starter
211
Checking the Starter Motor
211
24 THROTILE VALVE Body
212
Adjusting the Idle Speed
212
Throttle Position Sensor Circuit a - Checking
212
Throttle Position Sensor - Adjusting the Basic Settings
212
25 Technical Data
214
Engine
214
Engine Tolerance, Wear Limits
214
Engine Tightening Torques
215
Capacities
217
Engine Oil
217
Coolant
217
Fuel
217
Chassis
217
Electrical System
218
Tires
218
Fork
219
EXC Euiaus/Usa, XC-W
219
EXC SIX Days
219
Shock Absorber
220
Chassis Tightening Torques
220
26 Cleaning, Care
222
Cleaning the Motorcycle
222
Checks and Maintenance Steps for Winter Operation
223
27 Storage
224
Preparing for Use after Storage
224
28 Service Schedule
225
Service Work (as Additional Order)
226
29 Wiring Diagram
228
EXC EU, EXC SIX Days)
228
Exc Eu, Exc Six Days)
230
Exc Eu, Exc Six Days)
232
Exc Eu, Exc Six Days)
234
Exc Eu, Exc Six Days)
236
Exc Eu, Exc Six Days)
238
Exc Eu, Exc Six Days)
240
Exc Eu, Exc Six Days)
242
Exc Aus)
244
Exc Aus)
246
Exc Aus)
248
Exc Aus)
250
Exc Aus)
252
Exc Aus)
254
Exc Aus)
256
Exc Aus)
258
Exc Usa)
260
Exc Usa)
262
Exc Usa)
264
Exc Usa)
266
Exc Usa)
268
Exc Usa)
270
Exc Usa)
272
Exc Usa)
274
All XC-W Models)
276
All XC-W Models)
278
All XC-W Models)
280
All XC-W Models)
282
All XC-W Models)
284
All XC-W Models)
286
All XC-W Models)
288
30 Substances
290
31 Auxiliary Substances
292
32 Special Tools
294
33 Standards
308
Index
309
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KTM 450 EXC AUS 2013 Setup Instructions (20 pages)
Brand:
KTM
| Category:
Motorcycle
| Size: 1.03 MB
Table of Contents
Means of Representation
4
Checking the Headlight Setting
11
Closing Filler Cap
15
Technical Data - Tightening Torques for Chassis
17
Auxiliary Substances
19
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