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KTM 450 Rally Replica User Manual

KTM 450 Rally Replica
124 pages
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SERIAL NUMBERS 8
3.1Chassis number
601287-10
Chassis number is embossed in the steering head at the right.
3.2Type label
601287-11
Type label is fixed to the right of the steering head.
3.3Engine number
601288-10
The engine number is stamped on the left side of the engine under the engine
sprocket.
3.4Key number
500125-10
The key number for the steering lock is stamped onto the key connector.
3.5Fork part number
601289-10
The fork part number is stamped on the inner side of the fork stub.

Table of Contents

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KTM 450 Rally Replica Specifications

General IconGeneral
Engine TypeSingle-cylinder, 4-stroke
Displacement449.3 cc
CoolingLiquid cooled
Fuel SystemKeihin EFI, throttle body 44 mm
Transmission6-speed
StarterElectric starter
Bore x Stroke95 mm x 63.4 mm
Compression Ratio12.75:1
ABSNo
Seat Height960 mm
Dry Weight139 kg
FrameChromoly steel central-tube frame
Front SuspensionWP XACT PRO 48 mm, closed cartridge
Rear SuspensionWP XACT PRO with Trax technology
Front Brake300 mm
Rear BrakeSingle disc, 240 mm

Summary

Important Information

Use Definition

Defines KTM sport motorcycles' design for competitive use and adherence to regulations.

Service

Prerequisite for operation and prevention of wear through proper service and tuning.

Warranty

Details warranty conditions and voiding for work not done by authorized KTM workshops.

Work Rules

Outlines special tools, non-reusable parts replacement, and thread locker usage.

Transport

Provides notes on safe transport, danger of damage, and fire hazard precautions.

Environment

Emphasizes responsible motorcycling for environmental consciousness and respect for others.

Notes and Warnings

Instructs to pay close attention to information and warning labels affixed to the vehicle.

Grades of Risks

Defines risk levels: Danger, Warning, Caution, and Note with corresponding injury potentials.

Owner's Manual

Highlights the importance of reading the manual for operation, handling, and servicing information.

Controls

Locking the Steering

Provides step-by-step instructions on how to lock the motorcycle's steering.

Unlocking the Steering

Details the procedure for unlocking the motorcycle's steering mechanism.

Preparing for Use

Advice on First Use

Offers safety advice, pre-ride checks, and handling tips for new riders.

Running in the Engine

Guides on engine break-in procedures, specifying speed and performance limits.

Riding Instructions

Checks and Maintenance When Preparing for Use

Lists essential pre-trip checks for safe vehicle operation, including fluids and tires.

Starting

Provides safety warnings for starting the engine and advice on cold engine starting.

Starting Off

Details the procedure for starting off, including clutch and throttle control.

Shifting, Riding

Explains gear shifting, safe riding practices, and clutch usage.

Braking

Offers advice on effective braking, adapting to conditions and avoiding wheel lock-up.

Stop, Park

Provides instructions on stopping, parking safely, and securing the vehicle.

Refueling

Details safety precautions for refueling, including fire and poisoning hazards.

Service Schedule

Service Schedule

Presents a table of regular checks and maintenance tasks based on operating hours.

Service Work (as Additional Order)

Lists service tasks recommended as additional orders based on operating hours or time.

Tuning the Chassis

Checking the Basic Chassis Setting with the Rider's Weight

Explains how to adjust suspension components to match the rider's weight.

Compression Damping of the Shock Absorber

Describes high-speed and low-speed compression damping ranges for the shock absorber.

Adjusting the High-Speed Compression Damping of the Shock Absorber

Details the procedure for adjusting shock absorber high-speed compression damping.

Adjusting the Low-Speed Compression Damping of the Shock Absorber

Provides steps for adjusting shock absorber low-speed compression damping.

Adjusting the Rebound Damping of the Shock Absorber

Explains how to adjust the rebound damping on the shock absorber.

Measuring the Unloaded Rear Wheel Sag

Guides on measuring rear wheel sag with the motorcycle on a lift stand.

Checking the Static Sag of the Shock Absorber

Describes how to check the static sag of the shock absorber.

Checking the Riding Sag of the Shock Absorber

Details how to check the riding sag of the shock absorber with rider weight.

Adjusting the Spring Preload of the Shock Absorber

Provides instructions for adjusting the shock absorber's spring preload.

Adjusting the Riding Sag

Explains how to adjust the riding sag by changing the spring.

Checking the Basic Setting of the Fork

Discusses fork settings, spring preload, and heavier springs for overloaded forks.

Adjusting the Compression Damping of the Fork

Details how to adjust the compression damping on the fork legs.

Adjusting the Rebound Damping of the Fork

Explains how to adjust the rebound damping on the fork legs.

Service Work on the Chassis

Checking the Steering Head Bearing Play

Describes how to check for play in the steering head bearing.

Adjusting the Play of the Steering Head Bearing

Provides steps for adjusting the steering head bearing play.

Checking the Chain Tension

Guides on checking chain tension and its importance for drivetrain components.

Adjusting the Chain Tension

Provides steps for adjusting chain tension using adjusters and nuts.

Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide

Explains how to check wear on the chain, sprockets, and chain guide.

Checking the Frame

Instructs on checking the frame for cracks or deformation due to mechanical impact.

Checking the Swingarm

Details how to check the swingarm for damage, cracking, or deformation.

Checking the Fluid Level of the Hydraulic Clutch

Details how to check the hydraulic clutch fluid level.

Changing the Hydraulic Clutch Fluid

Provides instructions for changing the hydraulic clutch fluid.

Brakes

Checking the Free Travel on the Hand Brake Lever

Explains how to check free travel on the hand brake lever to prevent system failure.

Adjusting the Free Travel of the Hand Brake Lever

Details how to adjust hand brake lever free travel using an adjusting screw.

Checking the Brake Discs

Guides on checking brake disc thickness and for damage, cracks, or deformation.

Checking the Front Brake Fluid Level

Instructs how to check the front brake fluid level and identify leaks.

Adding Front Brake Fluid

Provides steps for adding front brake fluid, emphasizing correct type and safety.

Checking the Front Brake Linings

Explains how to check front brake lining minimum thickness and for damage.

Changing the Front Brake Linings

Details the procedure for changing the front brake linings.

Checking the Free Travel of the Foot Brake Lever

Guides on checking free travel of the foot brake lever to prevent overheating.

Adjusting the Free Travel of the Foot Brake Lever

Provides steps for adjusting foot brake lever free travel using a screw.

Checking the Rear Brake Fluid Level

Instructs how to check the rear brake fluid level and identify leaks.

Adding Rear Brake Fluid

Provides steps for adding rear brake fluid, emphasizing correct type and safety.

Checking the Rear Brake Linings

Explains how to check rear brake lining minimum thickness and for damage.

Changing the Rear Brake Linings

Details the procedure for changing the rear brake linings.

Wheels, Tires

Electrical System

Cooling System

Tuning the Engine

Service Work on the Engine

Checking the Engine Oil Level

Explains how to check the engine oil level when the engine is cold or warm.

Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen

Details the procedure for changing engine oil, oil filter, and cleaning the oil screen.

Adding Engine Oil

Provides instructions for adding engine oil, emphasizing correct type and level.

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