KTM 450 EXC 2003 Manual

KTM 450 EXC · 2003 · manual · 167 pages

KTM 450 EXC
2003
Manual
167 pages
Powersport

Technical data

Numbers below were extracted automatically from the document. Verify them against the original manual before you order parts or apply torque.

Tightening torque

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
Screw, shock	5 N·m	3.7 ft·lb	p. 55
Screw, handle	40 N·m	29.5 ft·lb	p. 59
Screw, frame protec	3 N·m	2.2 ft·lb	p. 63
Triple clamp (EXC1F Six Days)	15 N·m	11.1 ft·lb	p. 64
Screw, top steering	12 N·m	8.9 ft·lb	p. 67
Clamp (EXC1F Six Days)	20.1 N·m	14.8 ft·lb	p. 67
Screw, sub	30 N·m	22.1 ft·lb	p. 72
Screw, air filter box	3 N·m	2.2 ft·lb	p. 74
Screws on main	7 N·m	5.2 ft·lb	p. 78
Nut, wheel spindle	80 N·m	59 ft·lb	p. 84
Screw, chain slid	15 N·m		p. 86
Screw, front wheel	35 N·m	25.8 ft·lb	p. 106
Screw, fork stub	15 N·m	11.1 ft·lb	p. 106
Screw, battery hold	6 N·m	4.4 ft·lb	p. 113
Screw, battery termi	2.5 N·m		p. 113
Mounted under screws 5	2.5 N·m	1.84 ft·lb	p. 113
Screw, throttle grip	5 N·m	3.7 ft·lb	p. 129
Oil drain plug	20 N·m	14.8 ft·lb	p. 136
Screw, oil filter cover	10 N·m	7.4 ft·lb	p. 136
Hose clip, intake flange	3 N·m	2.2 ft·lb	p. 147
Oil nozzle for conrod bearing lubri	2 N·m	1.5 ft·lb	p. 147
Oil nozzle for main bearing lubrica	2 N·m	1.5 ft·lb	p. 147
Screw, oil nozzle bent for piston	2.5 N·m	1.84 ft·lb	p. 147
Alternator cover grub screw	2 N·m	1.5 ft·lb	p. 147
Locking screw for bearing	6 N·m	4.4 ft·lb	p. 147
Screw, bearing bolt, oil pump idler	6 N·m	4.4 ft·lb	p. 147
Screw, clutch spring retainer	6 N·m	4.4 ft·lb	p. 147
Screw, locking lever	6 N·m	4.4 ft·lb	p. 147
Screw, oil pump cover	6 N·m	4.4 ft·lb	p. 147
Screw, stator	6 N·m	4.4 ft·lb	p. 147
Nut, cylinder head	10 N·m	7.4 ft·lb	p. 147
Nut, water pump impeller	6 N·m	4.4 ft·lb	p. 147
Screw, alternator cover	10 N·m	7.4 ft·lb	p. 147
Screw, clutch slave cylinder	10 N·m	7.4 ft·lb	p. 147
Screw, engine case	10 N·m	7.4 ft·lb	p. 147
Screw, exhaust flange	10 N·m	7.4 ft·lb	p. 147
Screw, fuel vapor retention system	5 N·m	3.7 ft·lb	p. 147
Screw, guide rail	10 N·m	7.4 ft·lb	p. 148
Screw, outer clutch cover	10 N·m	7.4 ft·lb	p. 148
Screw, shift drum locating	10 N·m	7.4 ft·lb	p. 148
Screw, shift lever	14 N·m	10.3 ft·lb	p. 148
Screw, starter motor - intermediate	10 N·m	7.4 ft·lb	p. 148
Screw, timing chain failure protec	10 N·m	7.4 ft·lb	p. 148
Screw, valve cover	8 N·m	5.9 ft·lb	p. 148
Screw, water pump cover	10 N·m	7.4 ft·lb	p. 148
Stud, cylinder head	6 N·m	4.4 ft·lb	p. 148
Crankshaft locking bolt	8 N·m	5.9 ft·lb	p. 148
Screw, tensioning rail	15 N·m	11.1 ft·lb	p. 148
Screw, rotor	70 N·m	51.6 ft·lb	p. 148
Tensioner Spark plug	12 N·m	8.9 ft·lb	p. 148
Screw, cylinder head	20 N·m	14.8 ft·lb	p. 149
Stud, cylinder head	20 N·m	14.8 ft·lb	p. 149
Screw plug, oil pressure control	20 N·m	14.8 ft·lb	p. 149
Oil drain plug	15 N·m	11.1 ft·lb	p. 149
Nut, inner clutch hub	100 N·m	73.8 ft·lb	p. 149
Nut, primary gear wheel	120 N·m	88.5 ft·lb	p. 149
Screw plug, oil screen	15 N·m	11.1 ft·lb	p. 149
Plug, timing chain tensioner	40 N·m	29.5 ft·lb	p. 149
Screw, alternator cover	18 N·m	13.3 ft·lb	p. 149
Screw, combination switch (EXC1F Six Days)	2 N·m	1.5 ft·lb	p. 152
Screw, emergency OFF switch	2 N·m	1.5 ft·lb	p. 152
Screw, fuel pump	2 N·m	1.5 ft·lb	p. 152
Screw, fuel pump	2.5 N·m	1.84 ft·lb	p. 152
Screw, intake air temperature sensor	0.7 N·m	0.52 ft·lb	p. 152
Screw, pressure regulator	2.3 N·m	1.7 ft·lb	p. 152
Screw, radiator hoses clip	2.4 N·m	1.77 ft·lb	p. 152
Screw, seat fixing	2.5 N·m	1.84 ft·lb	p. 152
Screw, fixed grip	5 N·m	3.7 ft·lb	p. 152
Screw, hose clip, throttle valve	5 N·m	3.7 ft·lb	p. 152
Spoke nipple, front wheel	6 N·m	4.4 ft·lb	p. 152
Spoke nipple, rear wheel	6 N·m	4.4 ft·lb	p. 152
Screw, battery terminal	2.5 N·m	1.84 ft·lb	p. 153
Screw, light switch	1 N·m	0.7 ft·lb	p. 153
Screw, throttle valve body cover	2.6 N·m	1.92 ft·lb	p. 153
Screw, turn signal switch	1 N·m	0.7 ft·lb	p. 153
Nut, starter motor	4 N·m	3 ft·lb	p. 153
Nut, throttle cable on throttle valve	3 N·m	2.2 ft·lb	p. 153
Screw, ball joint of push rod	10 N·m	7.4 ft·lb	p. 153
Screw, battery holding bracket	6 N·m	4.4 ft·lb	p. 153
Screw, brake line guide on link	4.5 N·m	3.32 ft·lb	p. 153
Screw, chain sliding guard	6 N·m	4.4 ft·lb	p. 153
Screw, fender	12 N·m	8.9 ft·lb	p. 153
Screw, front brake disc	14 N·m	10.3 ft·lb	p. 153
Screw, fuel tank spoiler on radiator	6 N·m	4.4 ft·lb	p. 153
Screw, ground wire on frame	10 N·m	7.4 ft·lb	p. 153
Screw, hand lever	5 N·m	3.7 ft·lb	p. 153
Screw, rear brake disc	14 N·m	10.3 ft·lb	p. 153
Screw, seat fixing	8 N·m	5.9 ft·lb	p. 153
Nut, foot brake lever stop	20 N·m	14.8 ft·lb	p. 153
Nut, rear sprocket screw	35 N·m	25.8 ft·lb	p. 153
Nut, rim lock	12 N·m	8.9 ft·lb	p. 153
Oot brake lever stop	20 N·m	14.8 ft·lb	p. 153
Screw, bottom triple clamp (EXC1F Six Days)	12 N·m	8.9 ft·lb	p. 153
Screw, bottom triple clamp	15 N·m	11.1 ft·lb	p. 153
Screw, chain sliding piece	15 N·m	11.1 ft·lb	p. 153
Screw, engine brace on engine	25 N·m	18.4 ft·lb	p. 153
Screw, engine brace on frame	25 N·m	18.4 ft·lb	p. 153
Screw, front brake caliper	25 N·m	18.4 ft·lb	p. 154
Screw, handlebar clamp	20 N·m	14.8 ft·lb	p. 154
Screw, manifold	15 N·m	11.1 ft·lb	p. 154
Screw, side stand attachment	33 N·m	24.3 ft·lb	p. 154
Screw, subframe bottom	30 N·m	22.1 ft·lb	p. 154
Screw, subframe top	35 N·m	25.8 ft·lb	p. 154
Screw, top steering stem	20 N·m	14.8 ft·lb	p. 154
Screw, top triple clamp (EXC1F Six Days)	17 N·m	12.5 ft·lb	p. 154
Screw, top triple clamp	20 N·m	14.8 ft·lb	p. 154
Engine attachment bolt	60 N·m	44.3 ft·lb	p. 154
Screw, handlebar holder	40 N·m	29.5 ft·lb	p. 154

Spark plugs

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
Spark plug	1 mm		p. 146
M10	—		p. 148

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