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KTM 450 Rally Replica User Manual

KTM 450 Rally Replica
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BRAKES 58
601365-10
Operate the hand brake lever repeatedly until the brake linings are in contact with
the brake disc and there is a pressure point.
Add brake fluid to level .
Guideline
Measurement of 5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 114)
Position cover with membrane .
Mount and tighten screws .
Info
Clean up overflowed or spilt brake fluid immediately with water.
10.8Checking the free travel of the foot brake lever
Warning
Danger of accidentsBrake system failure.
If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust free travel on foot brake lever according to specifications.
601319-11
Detach the spring from the foot brake lever.
Move the foot brake lever back and forth between the end stop and the contact to
the foot brake cylinder piston and check free travel .
Guideline
Free travel at the foot brake lever 3… 5 mm (0.12… 0.2 in)
» If the free travel does not meet specifications:
Adjust the free travel of the foot brake lever. x ( p. 58)
Attach the spring to the foot brake lever.
10.9Adjusting the free travel of the foot brake lever x
Warning
Danger of accidentsBrake system failure.
If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust free travel on foot brake lever according to specifications.
601319-10
Loosen nut and use screw to adjust free travel .
Guideline
Free travel at the foot brake lever 3… 5 mm (0.12… 0.2 in)
Hold screw and tighten nut .
Guideline
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft)

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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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