KTM 450 Rally Replica User Manual

SERVICE WORK ON THE CHASSIS 39
9.8Installing the fork legs x
601334-10
– Position the fork legs.
Info
The upper triple clamp must be flush with the upper edge of the fork legs.
Position bleeder screws  toward the front.
601338-11
– Tighten screws .
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
– Tighten screws .
Guideline
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
– Secure the brake line with cable binder .
601339-11
– Position the brake caliper. Mount and tighten screws .
Guideline
Screw, front brake caliper M8 30 Nm
(22.1 lbf ft)
Loctite
®
243™
– Install the front fender. ( p. 38)
–
Mount the front wheel. x ( p. 62)
9.9Removing the lower triple clamp x
–
Remove the fork legs. x ( p. 38)
601389-10
– Remove screw .
– Allow the brake caliper and brake line to hang tension-free to the side.
601342-10
– Remove screws . Remove the holding plate with handlebar clamps.
– Remove screws . Remove steering damper .

KTM 450 Rally Replica Specifications

General

Engine Type	Single-cylinder, 4-stroke
Displacement	449.3 cc
Cooling	Liquid cooled
Fuel System	Keihin EFI, throttle body 44 mm
Transmission	6-speed
Starter	Electric starter
Bore x Stroke	95 mm x 63.4 mm
Compression Ratio	12.75:1
ABS	No
Seat Height	960 mm
Dry Weight	139 kg
Frame	Chromoly steel central-tube frame
Front Suspension	WP XACT PRO 48 mm, closed cartridge
Rear Suspension	WP XACT PRO with Trax technology
Front Brake	300 mm
Rear Brake	Single disc, 240 mm