KTM 450 EXC-R EU User Manual
Page 5
CONTENTS
3
Removing the lower triple clamp
b
x
(EXC-R
bEU,
EXC-R
bAUS/UK, EXC-RbUSA, XCR-WbZA) ......................... 44
Installing the lower triple clamp
b
x
(EXC-R
bSIXbDAYS,
XCR-W
bUSA) ................................................................. 44
Installing the lower triple clamp
b
x
(EXC-R
bEU,
EXC-R
bAUS/UK, EXC-RbUSA, XCR-WbZA) ......................... 45
Greasing the steering head bearing
b
x
............................. 46
Dismounting the front fender .......................................... 46
Installing the front fender............................................... 46
Removing headlight mask with headlight (EXC-R
bEU,
EXC-R
bAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA,
XCR-W
bZA).................................................................... 46
Refitting the headlight mask with the headlight
(EXC-R
bEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS,
EXC-R
bUSA, XCR-WbZA) ................................................. 47
Dismount the start number plate (XCR-W
bUSA) ................ 47
Fitting the start number plate (XCR-W
bUSA)..................... 47
Handlebar position ........................................................ 47
Adjusting handlebar position
b
x
...................................... 48
Checking gas Bowden cable route ................................... 49
Checking play in the gas Bowden cable ........................... 50
Adjusting the gas Bowden cable play
b
x
.......................... 50
Checking chain dirt ....................................................... 50
Cleaning the chain......................................................... 50
Checking the chain tension ............................................ 51
Checking the chain tension when fitting rear wheel........... 51
Checking the rear sprocket / engine sprocket for wear ....... 52
Checking chain wear ...................................................... 52
Adjusting the chain tension ............................................ 52
Adjusting chain tension - after checking .......................... 53
Adjusting chain tension - fitting rear wheel ...................... 54
Adjusting chain guide
b
x
............................................... 54
Brake fluid reservoir....................................................... 54
Brake calipers ............................................................... 55
Checking brake discs ..................................................... 55
Checking free play of hand brake lever............................. 55
Adjusting basic position of handbrake lever (Every XCR-W
models) ........................................................................ 56
Adjusting free travel of handbrake lever (Every EXC-R
models) ........................................................................ 56
Checking the front brake fluid level ................................. 56
Topping up the front brake fluid
b
x
................................. 56
Checking the front brake linings...................................... 57
Removing front brake linings
b
x
...................................... 58
Installing the front brake linings
b
x
................................. 58
Changing the front brake linings
b
x
................................. 59
Checking free play of foot brake lever .............................. 59
Adjusting basic position of footbrake lever
b
x
................... 60
Checking the rear brake fluid level .................................. 60
Adding rear brake fluid
b
x
.............................................. 61
Checking rear brake linings ............................................ 61
Removing rear brake linings
b
x
....................................... 62
Installing the rear brake linings
b
x
.................................. 62
Changing the rear brake linings
b
x
.................................. 63
Removing front wheel
b
x
................................................ 63
Fitting front wheel
b
x
.................................................... 64
Removing rear wheel
b
x
................................................. 65
Fitting rear wheel
b
x
...................................................... 65
Tire condition checking.................................................. 66
Checking tire air pressure............................................... 66
Checking spoke tension.................................................. 67
Removing the battery
b
x
................................................ 67
Installing the battery
b
x
................................................. 67
Recharging the battery
b
x
.............................................. 68
Removing a fuse............................................................ 69
Replacing the fuse......................................................... 69
Removing the seat ......................................................... 69
Mounting the seat ......................................................... 69
Dismounting the fuel tank
b
x
......................................... 70
Installing the fuel tank
b
x
.............................................. 70
Cooling system .............................................................. 71
Checking antifreeze and coolant level .............................. 71
Checking the coolant level.............................................. 72
Draining coolant
b
x
....................................................... 72
Refilling coolant
b
x
....................................................... 73
Glass fiber yarn filling of main silencer ............................ 73
Removing main silencer ................................................. 73
Fitting the main silencer ................................................ 74
Dismounting the air filter box lid ..................................... 74
Installing the air filter box lid.......................................... 74
Removing the air filter
b
x
............................................... 74
Installing the air filter
b
x
............................................... 75
Cleaning air filter
b
x
...................................................... 75
Adjusting basic position of clutch lever............................ 75
Checking fluid level of hydraulic clutch ........................... 75
Changing fluid level of hydraulic clutch
b
x
...................... 76
Carburetor - idle ............................................................ 77
Carburetor - adjusting idle
b
x
......................................... 77
Emptying the carburetor float chamber
b
x
....................... 78
Checking engine oil level................................................ 79
Changing engine oil and oil filter, cleaning engine oil
screen
b
x
..................................................................... 79
Draining engine oil, cleaning engine oil screen
b
x
............ 79
Removing the oil filter
b
x
............................................... 80
Mounting oil filter
b
x
..................................................... 80
Filling up with engine oil
b
x
........................................... 81
Topping up engine oil .................................................... 81
Checking gear oil level ................................................... 81
Changing gear oil, cleaning gear oil screen
b
x
.................. 82
Draining gear oil, cleaning gear oil screen
b
x
................... 82
Filling up with gear oil
b
x
............................................... 83
Topping up with gear oil
b
x
............................................ 83
TROUBLESHOOTING......................................................... 84
CLEANING........................................................................ 86
Cleaning motorcycle ...................................................... 86
STORAGE ......................................................................... 87
Storage......................................................................... 87
Putting into operation after storage ................................. 87
TECHNICAL DATA - ENGINE .............................................. 88
Capacity - engine oil ...................................................... 88
Capacity - gear oil.......................................................... 88
Capacity - coolant.......................................................... 89
TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 90
TECHNICAL DATA - CARBURETOR..................................... 92
450
bEXC-RbEU, 450bEXC-RbAUS/UK (3900I) ................... 92
450
bEXC-RbSIXbDAYS, 450bEXC-RbUSA, 450bXCR-W
(3900L) ....................................................................... 92
530
bEXC-RbEU, 530bEXC-RbAUS/UK (3900J)................... 93
530
bEXC-RbSIXbDAYS, 530bEXC-RbUSA, 530bXCR-W
(3900M) ...................................................................... 93
TECHNICAL DATA - CHASSIS ............................................ 94
Lighting equipment ....................................................... 95
Tires ............................................................................ 95