KTM 450 Rally Replica User Manual

SERVICE WORK ON THE CHASSIS 40
601344-10
– Fix handlebar  onto the instrument support with cable binders .
601343-10
– Loosen screws  and .
– Remove screw  and secure against falling out under triple clamp .
601390-10
– Remove O-ring . Remove protective ring  and take off the seal ring beneath it.
– Take out the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.
9.10Installing the lower triple clamp x
0
0
22
0
0
11
0
0
33
401211-10
– Clean the bearing and sealing elements, check for damage, and grease.
High viscosity grease ( p. 116)
– Insert the lower triple clamp with the steering stem. Mount the upper steering head
bearing.
– Check whether the top steering head seal  is correctly positioned.
– Slide on protective ring  and O-ring .
601383-10
– Position the upper triple clamp.
– Mount nut  with screw  but do not tighten yet.

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