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KTM 450 Rally Replica User Manual

KTM 450 Rally Replica
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TUNING THE ENGINE 74
14.1Checking the play in the throttle cable
400192-10
Check the throttle grip for smooth operation.
Move the handlebar to the straight-ahead position. Move the throttle grip back-
wards and forwards to ascertain the play in the throttle cable.
Play in throttle cable 3… 5 mm (0.12… 0.2 in)
» If the throttle cable play does not meet specifications:
Adjust the play in the throttle cable. x ( p. 74)
Danger
Danger of poisoningExhaust gases are poisonous and inhaling them may
result in unconsciousness and/or death.
When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
Start the engine and let it run idle. Move the handlebar to and fro over the entire
steering range.
The idle speed must not change.
» If the idle speed changes:
Adjust the play in the throttle cable. x ( p. 74)
14.2Adjusting the play in the throttle cable x
Remove the fuel tank toward the front. ( p. 47)
Check the throttle cable routing.
601376-10
Move the handlebar to the straight-ahead position.
Push back sleeves .
Loosen nut . Turn adjusting screw in as far as possible.
Loosen nut . Turn adjusting screw so that there is play in the throttle cable at
the throttle grip.
Guideline
Play in throttle cable 3… 5 mm (0.12… 0.2 in)
Tighten nut .
Press and hold the throttle grip in the closed setting. Turn out adjusting screw
until there is no play in the upper throttle cable.
Tighten nut .
Push sleeves on. Check the throttle grip for smooth operation.
Install the fuel tank at the front. ( p. 48)
Check the play in the throttle cable. ( p. 74)
14.3Carburetor - idle
The idle setting of the carburetor has a big influence on the starting behavior, stable
idling, and the response to throttle opening. That means that an engine with a correctly
set idle speed is easier to start than if the idle is set wrongly.
Info
The carburetor and its components are subject to increased wear caused by
engine vibration. Wear can result in malfunctioning.
601378-10
The idle mixture is adjusted with the idle adjusting screw .

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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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