KTM 450 EXC-R AUS/UK Manuals

Manuals and User Guides for KTM 450 EXC-R AUS/UK. We have 1 KTM 450 EXC-R AUS/UK manual available for free PDF download: Repair Manual

KTM 450 EXC-R AUS/UK Repair Manual

KTM 450 EXC-R AUS/UK Repair Manual (191 pages)

Brand: KTM | Category: Motorcycle | Size: 11 MB

Table of Contents

Table of Contents
4
Means of Representation
8
Important Notes
9
Motorcycle
10
- Jacking up the Motorcycle
  10
- Removing the Motorcycle from the Work Stand
  10
01/Fork, Triple Clamp
11
03/Frame
21
- Removing the Engine Sprocket Cover
  21
- Installing the Engine Sprocket Cover
  21
04/Shock Absorber, Swingarm
22
05/Exhaust
27
- Removing Main Silencer
  27
- Fitting the Main Silencer
  27
- Removing the Manifold
  27
- Installing the Manifold
  27
Installing the Air Filter
28
Removing the Air Filter
28
Installing the Air Filter Box Lid
28
Dismounting the Air Filter Box Lid
28
06/Air Filter
28
07/Fuel Tank, Seat, Trim
30
- Opening Filler Cap
  30
- Closing Filler Cap
  30
- Removing the Seat
  30
- Mounting the Seat
  30
- Dismounting the Fuel Tank
  30
- Installing the Fuel Tank
  31
- Fuel Tap
  32
08/Mask, Fender
33
09/Front Wheel
35
- Removing Front Wheel
  35
- Fitting Front Wheel
  35
- Checking Brake Discs
  36
- Removing the Front Brake Disc
  36
- Installing the Front Brake Disc
  36
- Tire Condition Checking
  37
- Checking Tire Air Pressure
  37
- Checking Spoke Tension
  37
10/Rear Wheel
38
11/Wiring Harness, Battery
44
- Removing a Fuse
  44
- Replacing the Fuse
  44
- Removing the Battery
  44
- Installing the Battery
  45
- Recharging the Battery
  45
13/Brake System
47
14/Light System, Instruments
56
30/Engine
58
- Removing the Engine
  58
- Installing the Engine
  59
30/Disassembling Engine
61
30/Engine - Work on Individual Parts
74
30/Assembling Engine
98
- Installing the Crankshaft
  98
- Installing the Transmission Shaft
  98
- Installing the Shift Forks
  98
- Installing the Shift Roller
  99
- Installing the Shift Rails
  99
- Installing the Left Engine Case
  99
- Installing the Primary Gear with the Free-Wheel-Gear
  100
- Installing the Oil Pumps
  100
- Installing the Oil Pump Gears
  101
- Installing the Locking Lever
  101
- Installing the Shift Drum Locating
  101
- Installing the Shift Shaft
  101
- Installing the Kickstarter Idler Gear
  102
- Installing the Kickstarter Shaft
  102
- Installing the Starter Idler Gear
  102
- Installing the Torque Limiter
  102
- Installing the Balancer Shaft
  103
- Installing the Outer Clutch Hub
  103
- Installing the Primary Gear Nut
  103
- Installing the Clutch Discs
  104
- Installing the Clutch Cover
  104
- Installing the Water Pump Cover
  105
- Installing the Kickstarter
  105
- Installing the Suction Pump
  105
- Installing the Ignition Pulse Generator
  106
- Installing the Timing Chain
  106
- Installing the Timing Chain Securing Guide
  106
- Installing the Timing Chain Tensioning Rail
  106
- Installing the Timing Chain Guide Rail
  107
- Installing the Balance Weight
  107
- Installing the Rotor
  107
- Installing the Piston
  107
- Installing the Cylinder Head
  109
- Installing the Camshaft
  110
- Installing the Timing Chain Tensioner
  110
- Checking the Valve Clearance
  111
- Adjusting the Valve Clearance
  111
- Installing the Generator Cover
  111
- Installing the Shift Lever
  112
- Installing the Valve Cover
  112
- Installing the Spark Plug
  112
- Installing the Starter Motor
  113
- Mounting Oil Filter
  113
- Filling up with Engine Oil
  113
- Filling up with Gear Oil
  114
- Removing the Engine from the Universal Mounting Rack
  114
31/Carburetor
115
32/Clutch
131
- Checking Fluid Level of Hydraulic Clutch
  131
- Changing Fluid Level of Hydraulic Clutch
  131
33/Transmission
133
- Removing the Engine Sprocket
  133
- Installing the Engine Sprocket
  133
35/Water Pump, Cooling System
134
- Checking Antifreeze and Coolant Level
  134
- Checking the Coolant Level
  134
- Draining Coolant
  135
- Refilling Coolant
  135
38/Lubrication System
136
- Oil Cycle
  136
- Checking Engine Oil Level
  136
- Changing Engine Oil and Oil Filter, Cleaning Engine Oil Screen
  137
- Draining Engine Oil, Cleaning Engine Oil Screen
  137
- Removing the Oil Filter
  137
- Mounting Oil Filter
  138
- Filling up with Engine Oil
  138
- Topping up Engine Oil
  139
- Checking the Engine Oil Pressure
  139
- Checking Gear Oil Level
  140
- Changing Gear Oil, Cleaning Gear Oil Screen
  140
- Draining Gear Oil, Cleaning Gear Oil Screen
  140
- Filling up with Gear Oil
  141
- Topping up with Gear Oil
  141
Troubleshooting
142
Technical Data - Engine
144
- Capacity- Engine Oil
  144
- Capacity - Gear Oil
  144
- Capacity - Coolant
  145
Technical Data - Tolerance, Wear Limits of Engine
146
Technical Data - Engine Tightening Torques
147
Technical Data - Carburetor
149
Technical Data - Carburetor Tightening Torques
151
Technical Data - Chassis
152
- Lighting Equipment
  153
- Tires
  153
- Capacity - Fuel
  153
Technical Data - Fork
154
Technical Data - Shock Absorber
155
Technical Data - Chassis Tightening Torques
156
Cleaning
157
- Cleaning Motorcycle
  157
Storage
158
Wiring Diagram
162
- Wiring Diagram (EXC-R EU)
  162
- Wiring Diagram (EXC-R AUS/UK)
  164
- Wiring Diagram (EXC-R USA)
  166
- Wiring Diagram (EXC-R SIX DAYS)
  170
- Wiring Diagram (XCR-W USA)
  172
- Wiring Diagram (XCR-W ZA)
  174
Substances
176
Auxiliary Substances
177
Special Tools
179
Standards
186
Index
187

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