2013r Repair manual.pdf

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REPAIR MANUAL
2013
450 SMR
Art. no. 3206144en
INTRODUCTION
It is important that you read this repair manual carefully and completely before starting work.
INTRODUCTION
1
This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified
experts.
The repair manual was written to correspond to the most current state of this model series. We reserve the right to make changes in
the interest of technical advancement without, at the same time, updating this repair manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that repair work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not belong to the regular scope of supply.
© 2013 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS
TABLE OF CONTENTS
2
Adjusting the handlebar position ......................
Adjusting the basic position of the clutch
lever ..............................................................
7.4
Checking the throttle cable routing ...................
7.5
Checking the play in the throttle cable ..............
7.6
Adjusting the play in the throttle cable..............
8
SHOCK ABSORBER, SWINGARM ................................
8.1
Adjusting the high-speed compression
damping of the shock absorber.........................
8.2
Adjusting the low-speed compression damping
of the shock absorber ......................................
8.3
Adjusting the rebound damping of the shock
absorber.........................................................
8.4
Measuring rear wheel sag unloaded...................
8.5
Checking static sag of shock absorber ...............
8.6
Checking riding sag of shock absorber...............
8.7
Adjusting the spring preload of the shock
absorber.........................................................
8.8
Adjusting the riding sag ...................................
8.9
Removing the shock absorber ...........................
8.10 Installing the shock absorber............................
8.11 Checking the shock absorber linkage.................
8.12 Servicing the shock absorber............................
8.13 Removing the spring........................................
8.14 Disassembling the damper ...............................
8.15 Disassembling the piston rod ...........................
8.16 Disassembling the seal ring retainer..................
8.17 Changing the pilot bushing ..............................
8.18 Checking the damper ......................................
8.19 Removing the heim joint..................................
8.20 Installing the heim joint...................................
8.21 Assembling the seal ring retainer ......................
8.22 Assembling the piston rod................................
8.23 Assembling the damper ...................................
8.24 Bleeding and filling the damper .......................
8.25 Filling the damper with nitrogen .......................
8.26 Installing the spring ........................................
9
EXHAUST ..................................................................
9.1
Removing the manifold....................................
9.2
Installing the manifold ....................................
9.3
Removing the main silencer .............................
9.4
Installing the main silencer..............................
9.5
Changing the glass fiber yarn filling of the
main silencer..................................................
10 AIR FILTER ...............................................................
10.1 Removing the air filter box lid ..........................
10.2 Installing the air filter box lid ...........................
10.3 Removing the air filter .....................................
10.4 Installing the air filter......................................
10.5 Cleaning the air filter and air filter box ..............
10.6 Sealing the air filter box ..................................
10.7 Securing the air filter box lid............................
11 FUEL TANK, SEAT, TRIM ...........................................
11.1 Opening the filler cap......................................
11.2 Closing the filler cap .......................................
11.3 Removing the seat ..........................................
11.4 Mounting the seat ...........................................
11.5 Removing the fuel tank....................................
11.6 Installing the fuel tank ....................................
11.7 Checking the fuel pressure...............................
11.8 Changing the fuel pump ..................................
11.9 Changing the fuel filter....................................
7.2
7.3
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MEANS OF REPRESENTATION ..................................... 6
1.1
Symbols used ................................................... 6
1.2
Formats used.................................................... 6
SAFETY ADVICE........................................................... 7
2.1
Repair Manual .................................................. 7
2.2
Safety advice.................................................... 7
2.3
Degrees of risk and symbols ............................... 7
2.4
Work rules........................................................ 7
IMPORTANT NOTES..................................................... 8
3.1
Guarantee, warranty .......................................... 8
3.2
Operating and auxiliary substances ..................... 8
3.3
Spare parts, accessories .................................... 8
3.4
Figures ............................................................ 8
SERIAL NUMBERS ...................................................... 9
4.1
Chassis number ................................................ 9
4.2
Type label ........................................................ 9
4.3
Engine number ................................................. 9
4.4
Fork part number .............................................. 9
4.5
Shock absorber part number .............................. 9
MOTORCYCLE ........................................................... 10
5.1
Raising the motorcycle with the lift stand.......... 10
5.2
Removing the motorcycle from the lift stand...... 10
5.3
Starting.......................................................... 10
5.4
Starting the motorcycle for checking ................. 11
FORK, TRIPLE CLAMP ............................................... 12
6.1
Adjusting the compression damping of the
fork ............................................................... 12
6.2
Adjusting the rebound damping of the fork ........ 12
6.3
Bleeding the fork legs...................................... 12
6.4
Cleaning the dust boots of the fork legs............. 13
6.5
Removing the fork legs .................................... 13
6.6
Installing the fork legs ..................................... 14
6.7
Removing the fork protector ............................. 14
6.8
Installing the fork protector.............................. 14
6.9
Conducting major fork service .......................... 15
6.10 Conducting minor fork service .......................... 15
6.11 Disassembling the fork legs.............................. 16
6.12 Disassembling the cartridge ............................. 18
6.13 Disassembling the piston rod ........................... 20
6.14 Disassembling the screw cap with the
membrane holder............................................ 21
6.15 Disassembling the screw sleeve ........................ 23
6.16 Checking the fork legs ..................................... 23
6.17 Checking the fork legs - during a minor fork
service ........................................................... 25
6.18 Changing the pilot bushing .............................. 26
6.19 Assembling the screw sleeve ............................ 27
6.20 Assembling the screw cap with the membrane
holder ............................................................ 27
6.21 Assembling the piston rod................................ 28
6.22 Assembling the cartridge ................................. 29
6.23 Assembling the fork legs.................................. 31
6.24 Bleeding and filling the cartridge...................... 34
6.25 Filling the cartridge with nitrogen ..................... 36
6.26 Greasing the steering head bearing ................... 36
6.27 Removing the lower triple clamp....................... 37
6.28 Installing the lower triple clamp ....................... 37
6.29 Checking the steering head bearing play............ 39
6.30 Adjusting the play of the steering head
bearing .......................................................... 39
HANDLEBAR, CONTROLS........................................... 41
7.1
Handlebar position.......................................... 41
TABLE OF CONTENTS
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11.10 Changing the fuel screen ................................. 80
MASK, FENDER......................................................... 82
12.1 Removing the front fender ............................... 82
12.2 Installing the front fender ................................ 82
12.3 Removing the start number plate ...................... 82
12.4 Installing the start number plate....................... 82
WHEELS ................................................................... 83
13.1 Checking the tire air pressure........................... 83
13.2 Checking the tire condition .............................. 83
13.3 Checking the brake discs ................................. 83
13.4 Checking the spoke tension.............................. 84
13.5 Front wheel .................................................... 84
13.5.1
Removing the front wheel ............................ 84
13.5.2
Installing the front wheel ............................. 85
13.5.3
Removing the brake disc of the front brake.... 86
13.5.4
Installing the brake disc of the front brake .... 86
13.6 Rear wheel ..................................................... 86
13.6.1
Removing the rear wheel ............................. 86
13.6.2
Installing the rear wheel .............................. 87
13.6.3
Removing the brake disc of the rear brake ..... 88
13.6.4
Installing the brake disc of the rear brake...... 88
13.6.5
Checking the chain tension.......................... 88
13.6.6
Adjusting the chain tension ......................... 89
13.6.7
Adjusting the chain guide ............................ 90
13.6.8
Checking the chain, rear sprocket, engine
sprocket and chain guide............................. 90
13.6.9
Checking for chain dirt accumulation............ 92
13.6.10 Cleaning the chain ...................................... 92
WIRING HARNESS, BATTERY..................................... 93
14.1 Changing the main fuse ................................... 93
14.2 Removing the battery ...................................... 94
14.3 Installing the battery ....................................... 94
14.4 Charging the battery ........................................ 94
14.5 Checking the charging voltage .......................... 95
14.6 Checking the quiescent current ........................ 96
14.7 Checking the capacitor .................................... 96
14.8 Checking the starter relay ................................ 97
BRAKE SYSTEM ........................................................ 99
15.1 Checking the front brake linings ....................... 99
15.2 Changing the front brake linings ....................... 99
15.3 Checking the free travel of the hand brake
lever ............................................................ 100
15.4 Adjusting the basic position of the hand
brake lever ................................................... 101
15.5 Checking the brake fluid level of the front
brake ........................................................... 101
15.6 Adding front brake fluid................................. 101
15.7 Changing the front brake fluid ........................ 102
15.8 Checking the rear brake linings ...................... 103
15.9 Changing the rear brake linings ...................... 103
15.10 Checking the free travel of foot brake lever ...... 104
15.11 Adjusting the basic position of the foot brake
lever ............................................................ 105
15.12 Checking the rear brake fluid level.................. 105
15.13 Adding rear brake fluid .................................. 106
15.14 Changing the rear brake fluid ......................... 106
ENGINE .................................................................. 108
16.1 Removing the engine..................................... 108
16.2 Installing the engine...................................... 112
16.3 Engine disassembly....................................... 117
16.3.1
Preparations ............................................. 117
16.3.2
Draining the engine oil .............................. 118
Removing the clutch push rod....................
Removing the oil filter ...............................
Removing the starter motor........................
Removing the spark plug ...........................
Removing the valve cover...........................
Removing the alternator cover ....................
Positioning the engine at ignition top dead
center......................................................
16.3.10 Removing the timing chain tensioner ..........
16.3.11 Removing the camshaft .............................
16.3.12 Removing the cylinder head .......................
16.3.13 Removing the piston .................................
16.3.14 Removing the rotor....................................
16.3.15 Removing the timing chain ........................
16.3.16 Removing the ignition pulse generator ........
16.3.17 Removing the suction pump.......................
16.3.18 Removing the water pump cover.................
16.3.19 Removing the clutch cover.........................
16.3.20 Removing the clutch discs .........................
16.3.21 Removing the outer clutch hub ..................
16.3.22 Removing the torque limiter.......................
16.3.23 Removing the starter idler gear...................
16.3.24 Removing the shift shaft............................
16.3.25 Removing the shift drum locating unit ........
16.3.26 Removing the locking lever ........................
16.3.27 Removing the force pump..........................
16.3.28 Removing the primary gear ........................
16.3.29 Removing the freewheel gear .....................
16.3.30 Removing the left engine case section ........
16.3.31 Removing the shift rails.............................
16.3.32 Removing the shift drum ...........................
16.3.33 Removing the shift forks............................
16.3.34 Removing the transmission shafts...............
16.3.35 Removing the crankshaft ...........................
16.4 Work on individual parts ................................
16.4.1
Work on the right section of the engine
case ........................................................
16.4.2
Work on the left section of the engine
case ........................................................
16.4.3
Removing the oil pressure regulator valve ....
16.4.4
Checking spring length of oil pressure
regulator valve ..........................................
16.4.5
Installing the oil pressure regulator valve.....
16.4.6
Changing the crankshaft seal ring in the
clutch cover .............................................
16.4.7
Removing the water pump .........................
16.4.8
Installing the water pump ..........................
16.4.9
Removing the timing chain sprocket ...........
16.4.10 Installing the timing chain sprocket ............
16.4.11 Changing the connecting rod, conrod
bearing, and crank pin ..............................
16.4.12 Checking crankshaft run-out at bearing
pin ..........................................................
16.4.13 Cylinder - Nikasil
®
coating .........................
16.4.14 Checking/measuring the cylinder ................
16.4.15 Checking/measuring the piston...................
16.4.16 Checking the piston ring end gap ...............
16.4.17 Measuring the piston/cylinder mounting
clearance .................................................
16.4.18 Checking the oil pumps .............................
16.4.19 Disassembling the autodecompressor..........
16.4.20 Assembling the autodecompressor ..............
16.3.3
16.3.4
16.3.5
16.3.6
16.3.7
16.3.8
16.3.9
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