450 Rally Replica

KTM 450 Rally Replica User Manual

KTM 450 Rally Replica

124 pages

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OWNER'S MANUAL 2012

450 Rally Factory Replica

Art. no. 3211726en

Table of Contents

Table of Contents4
Important Information6
View of Vehicle8
- View of Vehicle, Front Left8
- View of Vehicle, Rear Right9
Serial Numbers10
- Chassis Number10
- Type Label10
- Engine Number10
- Key Number10
- Fork Part Number10
- Shock Absorber Part Number11
Controls12
- Clutch Lever12
- Hand Brake Lever12
- Throttle Grip12
- Kill Switch12
- Light Switch12
- Turn Signal Switch13
- Horn Button13
- Electric Starter Button13
- Indicator Lamp Overview13
- Ignition Switch13
- Speedometer14
- Speedometer Activation and Test14
- Tripmaster Switch14
- Setting Kilometers or Miles14
- Setting the Clock15
- Adjusting the Speedometer Functions15
- Querying Lap Time16
- Display Mode SPEED (Speed)16
- Display Mode SPEED/H (Operating Hours)16
- Display Mode SPEED/CLK (Clock)17
- Display Mode SPEED/LAP (Lap Time)17
- Display Mode SPEED/ODO (Odometer)17
- Display Mode SPEED/TR1 (Trip Master 1)17
- Display Mode SPEED/TR2 (Trip Master 2)18
- Display Mode SPEED/A1 (Average Speed 1)18
- Display Mode SPEED/A2 (Average Speed 2)18
- Display Mode SPEED/S1 (Stop Watch 1)19
- Display Mode SPEED/S2 (Stop Watch 2)19
- Fuel Tank20
- Fuel Tap20
- Choke21
- Shift Lever21
- Foot Brake Lever22
- Side Stand22
- Steering Lock22
- Locking the Steering22
- Unlocking the Steering23
Preparing for Use24
- Advice on First Use24
- Running in the Engine25
Riding Instructions26
- Checks and Maintenance When Preparing for Use26
- Starting26
- Starting off27
- Shifting, Riding27
- Braking27
- Stop, Park28
- Refueling28
Service Schedule30
- Service Work (as Additional Order)31
Tuning the Chassis32
- Checking the Basic Chassis Setting with the Rider's Weight32
- Compression Damping of the Shock Absorber32
- Adjusting the High-Speed Compression Damping of the Shock Absorber32
- Adjusting the Low-Speed Compression Damping of the Shock Absorber33
- Adjusting the Rebound Damping of the Shock Absorber33
- Measuring the Unloaded Rear Wheel Sag33
- Checking the Static Sag of the Shock Absorber34
- Checking the Riding Sag of the Shock Absorber34
- Adjusting the Spring Preload of the Shock Absorber34
- Adjusting the Riding Sag35
- Checking the Basic Setting of the Fork35
- Adjusting the Compression Damping of the Fork36
- Adjusting the Rebound Damping of the Fork36
- Fork Offset36
- Setting the Fork Offset37
- Handlebar Position37
- Adjusting the Handlebar Position38
Service Work on the Chassis39
- Raising the Motorcycle with the Lift Stand39
- Removing the Motorcycle from the Lift Stand39
- Bleeding the Fork Legs39
- Cleaning the Dust Boots of the Fork Legs39
- Dismounting the Front Fender40
- Installing the Front Fender40
- Removing the Fork Legs40
- Installing the Fork Legs41
- Removing the Lower Triple Clamp41
- Installing the Lower Triple Clamp42
- Checking the Steering Head Bearing Play44
- Adjusting the Play of the Steering Head Bearing44
- Greasing the Steering Head Bearing45
- Removing the Seat46
- Mounting the Seat46
- Removing the Air Filter46
- Installing the Air Filter47
- Removing the Main Silencer47
- Installing the Main Silencer47
- Changing the Glass Fiber Yarn Filling of the Main Silencer48
- Removing the Trim48
- Mounting the Trim48
- Removing the Fuel Tank Toward the Front49
- Installing the Fuel Tank at the Front50
- Checking the Chain for Dirt Accumulation50
- Cleaning the Chain50
- Checking the Chain Tension51
- Adjusting the Chain Tension51
- Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide52
- Checking the Frame53
- Checking the Swingarm53
- Checking the Rubber Grip54
- Additionally Securing the Rubber Grip54
- Adjusting the Basic Position of the Clutch Lever54
- Checking the Fluid Level of the Hydraulic Clutch54
- Changing the Hydraulic Clutch Fluid55
Brakes56
- Checking the Free Travel on the Hand Brake Lever56
- Adjusting the Free Travel of the Hand Brake Lever56
- Checking the Brake Discs56
- Checking the Front Brake Fluid Level57
- Adding Front Brake Fluid57
- Checking the Front Brake Linings58
- Changing the Front Brake Linings58
- Checking the Free Travel of the Foot Brake Lever60
- Adjusting the Free Travel of the Foot Brake Lever60
- Checking the Rear Brake Fluid Level61
- Adding Rear Brake Fluid61
- Checking the Rear Brake Linings62
- Changing the Rear Brake Linings62
Wheels, Tires64
- Removing the Front Wheel64
- Mounting the Front Wheel64
- Removing the Rear Wheel65
- Installing the Rear Wheel66
- Checking the Rear Hub Rubber Dampers66
- Checking the Tire Condition67
- Checking the Tire Air Pressure68
- Checking the Spoke Tension68
Electrical System69
- Removing the Battery69
- Installing the Battery69
- Recharging the Battery69
- Changing the Main Fuse70
- Changing Fuses of Individual Power Consumers71
- Checking the Headlight Setting71
- Adjusting the Headlight Range72
Cooling System73
- Checking the Antifreeze and Coolant Level73
- Checking the Coolant Level73
- Draining the Coolant74
- Refilling Coolant74
Tuning the Engine76
- Checking the Play in the Throttle Cable76
- Adjusting the Play in the Throttle Cable76
- Carburetor - Idle76
- Carburetor - Adjusting the Idle Speed77
- Emptying the Carburetor Float Chamber78
- Checking the Basic Position of the Shift Lever78
- Adjusting the Basic Position of the Shift Lever78
Service Work on the Engine80
- Checking the Engine Oil Level80
- Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen80
- Adding Engine Oil82
Cleaning, Care84
- Cleaning Motorcycle84
- Checks and Maintenance Steps for Winter Operation85
Storage86
- Preparing for Use after Storage86
Technical Data - Engine87
- Capacity - Engine Oil87
- Capacity - Coolant87
Technical Data - Engine Tightening Torques88
Technical Data - Carburetor90
Technical Data - Chassis91
- Lighting Equipment91
- Tires92
- Capacity - Fuel92
Technical Data - Fork93
Technical Data - Shock Absorber94
Technical Data - Tightening Torques for Chassis95
Wiring Diagram98
- Page 2 of100
- 100102
- 102104
- 104106
- 106108
- 108110
- 110112
- 112114
Substances116
Auxiliary Substances118
Standards120
Index121

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KTM 450 Rally Replica Specifications

General

Brand	KTM
Model	450 Rally Replica
Category	Motorcycle
Language	English

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