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KTM 450 Rally Replica User Manual

KTM 450 Rally Replica
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SERVICE WORK ON THE CHASSIS 52
9.32Checking the rubber grip
401197-01
Check the rubber grips on the handlebar for damage, wear, and looseness.
» If a rubber grip is damaged, worn, or loose:
Change and secure the rubber grip.
Rubber grip adhesive (00062030051) ( p. 116)
9.33Additionally securing the rubber grip
Check the rubber grip. ( p. 52)
401198-01
Secure the rubber grip at two points using the securing wire.
Securing wire (54812016000)
Wire twister forceps (U6907854)
The twisted wire ends face away from the hands and are bent toward the rub-
ber grip.
9.34Adjusting the basic position of the clutch lever
601290-11
Adjust the basic setting of the clutch lever to your hand size by turning adjusting
screw .
Info
Turn the adjusting screw clockwise to increase the distance between the
clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the clutch lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
9.35Checking the fluid level of the hydraulic clutch
Info
The fluid level rises with increased wear of the clutch lining discs.
Do not use brake fluid.
600112-10
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws .
Remove cover with membrane .
Check the fluid level.
Fluid level under top level of container 4 mm (0.16 in)
» If the fluid level does not meet specifications:
Correct the fluid level of the hydraulic clutch.
Hydraulic fluid (15) ( p. 115)
Position the cover with the membrane. Mount and tighten the screws.

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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

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