KTM 400 EXC (2009) manual

OWN ER'S MAN UAL 2009 400 EXC EU 400 EXC AUS 400 XC-W USA 450 EXC EU 450 EXC AUS 450 EXC SIX DAYS EU 450 XC-W USA 450 XC-W ZA 530 EXC EU 530 EXC AUS 530 EXC SIX DAYS EU 530 XC-W USA 530 XC-W ZA ART. NO. 32113 55en[...]

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DEAR KTM CUSTOME R 1 DEAR KTMCUSTOME R Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-ar t sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. We wish you great pleasure riding the vehicle! Enter the serial numbers of your vehicle below. Chassis n[...]

CONTENTS 2 CONTENTS MEANS OF REPRESENTAT ION ............................ ................ 4 IMPORTANT NOTES ............................ .............................. .. 5 VIEW OF VEHICLE .................................................... ........... 7 View of the vehicle from the left front (example) ..... ............ 7 View of the vehicle fr[...]

CONTENTS 3 Dismount the start number plate (XC ‑ W USA)................... 48 Installing the start number plate (XC ‑ W USA) ................... 48 Handlebar position ................................................. ....... 48 Adjusting handlebar position x ........................... ........... 48 Checking gas Bowden cable route ............[...]

MEANS OF REPRESEN TATION 4 1 MEANS OFREPRESEN TATION Symbols used The symbols used are explained in the following. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). All work marked with this symbol requires specialist knowledge and technical understanding. In th[...]

IMPORTAN T NOTES 5 2 IMPORTANT NOTES Use definition (al l EXC models) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply with currently valid regulations and categories of the top international motorsport organizations. Info The motorcycle is authorized for public r[...]

IMPORTAN T NOTES 6 – Turn handle  of the fuel tap to the OFF position. (Figure 500137-10 p. 20) – Use straps or other suitable devices to secure the motorcycle against accidents or falling over. Environment Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a poten[...]

VIEW OF V EHICLE 7 3 VIEW OFVEHICLE 3.1 View of the vehi cle from the left fr ont (example) 800014-10 1 Side stand 2 Shift lever 3 Chain guide 4 Fuel tap 5 Air filter box lid 6 Clutch lever 7 Hand brake lever[...]

VIEW OF V EHICLE 8 3.2 View of the veh icle from the righ t rear (example) 800013-10 1 Level viewer for brake fluid, rear 2 Fork compression adjustment 3 Foot brake pedal 4 Kickstarter 5 Horn 6 Filler cap 7 Fork rebound adjustment 8 Electric starter button 9 Speedometer 10 Short circuit button 11 Shock absorber compression adjustment 12 Shock absor[...]

LOCATION OF SERIAL NUMBERS 9 4 LOCATION OFSERIA L NUMBERS 4.1 Chassis number 500127-10 The chassis number  is stamped on the steering head on the right. 4.2 Type label 500128-10 The type label  is fixed to the front of the steering head. 4.3 Key number (a ll EXC models) 500125-10 The key number  is stamped on the key strap. 4.4 Engine numb[...]

LOCATION OF SERIAL NUMBERS 10 4.6 Shock absorbe r part number 500129-10 The shock absorber part number  is stamped on the top of the shock absorber above the adjusting ring on the engine side.[...]

OPERATIN G ELEMEN TS 11 5 OPERATING ELEMENTS 5.1 Clutch lever 500133-10 The clutch lever  is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 5.2 Hand brake lev er 400196-10 Hand brake lever  is located on the right side of the handlebar. The hand brake lever is used to activate the front brak[...]

OPERATIN G ELEMEN TS 12 5.6 Electric starter b utton (EXC EU, E XC SIX DAYS, XC-W) 400198-10 The electric starter button  is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position • Electric starter button pressed – In this position, the electric starter is actuated. 5.7 Electric starter b ut[...]

OPERATIN G ELEMEN TS 13 5.11 Flasher switch (a ll EXC models) 500145-10 Flasher switch  is fitted on the left side of the handlebar. Possible states Flasher light off – Flasher switch is in the central position. Flasher light, left, on – Flasher switch turned to the left. Flasher light, right, on – Flasher switch turned to the right. 5.12 [...]

OPERATIN G ELEMEN TS 14 5.15 Tripmaster switc h (Option: Tripmast er switch) You can use the trip master switch to control the functions of the speedometer from the handlebar. Info The trip master is an optional accessory. 5.16 Setting kilomete rs or miles Info If you change the unit, the value ODO is retained and converted accordingly. The values [...]

OPERATIN G ELEMEN TS 15 5.18 Adjusting the spe edometer functio ns Info Upon delivery, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is standing. 400318-01 – Press the button briefly and repeatedly until H appears at the bottom right of the display. – Press the button for 3 - 5 seconds. The Setup menu open[...]

OPERATIN G ELEMEN TS 16 5.20 SPEED display m ode (speed) 400317-02 – Press the button briefly and repeatedly until SPEED appears on the left side of the display. The current speed is displayed in the SPEED display mode. The current speed can be displayed in Km/h or Mph . Info Making the setting according to the country. When an impulse comes from[...]

OPERATIN G ELEMEN TS 17 Press the button briefly. next display mode 5.24 SPEED/ODO dis play mode (odom eter) 400317-01 – Press the button briefly and repeatedly until ODO appears at the bottom right of the display. The total number of kilometers ridden is shown in the ODO display mode. Press the button . No function Press the button . No function[...]

OPERATIN G ELEMEN TS 18 5.27 SPEED/A1 displ ay mode (averag e speed 1) 400325-01 – Press the button briefly and repeatedly until A1 appears at the top right of the display. A1 (average speed 1) shows the average speed calculated on the basis of TR1 (trip mas- ter 1) and S1 (stop watch 1). The calculation of this value is activated by the first im[...]

OPERATIN G ELEMEN TS 19 Table of function s Display Press the button . Press the button . Press the button for 3 - 5 seconds. Press the button briefly. SPEED/H display mode (service hours) No function No function The display changes to the Setup menu of the speedometer functions. next display mode SPEED/CLK display mode (time) No function No functi[...]

OPERATIN G ELEMEN TS 20 5.31 Fuel tap 500137-10 The fuel tap is on the left of the fuel tank. With the tap handle  on the fuel tap, you can open or close the supply of fuel to the carburetor. Possible states • Fuel supply closed OFF – No fuel can flow from the tank to the carburetor. • Fuel supply open ON – Fuel can flow from the tank to[...]

OPERATIN G ELEMEN TS 21 5.35 Choke (EXC EU, EXC SIX D AYS) 500136-10 The flasher switch  is fitted on the left side of the handlebar. Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start. Info If the engine is warm, the choke function m[...]

OPERATIN G ELEMEN TS 22 5.39 Side stand 500140-10 Note Danger of damag e   Danger of damage by the vehicle running away or falling over. – Always place the vehicle on a firm and even surface. Note Material damage   Damage and destruction of components by excessive load. – The side stand is designed for the weight of the motorcycle only. Do [...]

OPERATIN G ELEMEN TS 23 5.42 Unlocking the ste ering (all EXC m odels) – Insert the key in the steering lock, turn it to the left, pull it out and turn it to the right. Remove the key. You can now steer the bike again. Info Never leave the key in the steering lock.[...]

GENERAL TIPS AND H INTS ON P UTTING IN TO OPERAT ION 24 6 GENERAL TIPSAND HINTS ONPUTTING INTO OPERATION 6.1 Advice on first u se Danger Danger of accide nts   Danger from insufficien t traffic competence. – Do not use the vehicle if you are not fit to deal with traffic or if you have consumed alcohol and/or medicaments or drugs. Warning Risk o[...]

GENERAL TIPS AND H INTS ON P UTTING IN TO OPERAT ION 25 – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis- tribution between the front and rear wheels. Info Motorcycles react sensitively to any changes of weight distribution. – Do not exceed the overall maximum [...]

RIDING INS TRUCTION S 26 7 RIDING INSTRUCTIONS 7.1 Checks before putting into o peration Info Make sure that the motorcycle is in a perfect technical condition before use. Info In the interests of riding safety, make a habit of making a general check before you ride. – Check the engine oil level. ( p. 79) – Check the chain tension. ( p. 52) –[...]

RIDING INS TRUCTION S 27 7.3 Starting up Info If your bike has lights, switch them on before riding. You will then be seen earlier by other motorists. When you are riding, the side stand must be folded up and secured with the rubber band. – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttl[...]

RIDING INS TRUCTION S 28 7.6 Stopping, park ing Warning Risk of misapprop riation   Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns   Some vehicle components get very hot when the machine is driven. – Do not touch hot compon[...]

A A RIDING INS TRUCTION S 29 400382-10 – Fill the fuel tank with fuel up to measurement  . Guideline Measurement of  35 mm (1.38 in) Total fuel tank capacity, approx. (EXC, EXC SIX DAYS, XC ‑ W ZA) 9.0 l (2.38 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. 106) Total fuel tank capacity, approx. (XC ‑ W USA) 9.2 l (2.43 US gal) S[...]

SERVICE S CHEDULE 30 8 SERVICE SCHEDULE 8.1 Important maint enance work to b e carried out by an authorize d KTM workshop . S3N S15A S30A Engine Change the engine oil and oil filter and clean the engine oil screen. x ( p. 80) • • • Change the gear oil and clean the gear oil screen. x ( p. 82) • • • Replace spark plug. • Check the valv[...]

SERVICE S CHEDULE 31 8.2 Important main tenance work to be carried o ut by an authoriz ed KTM worksho p. (as additional order) Competition use Hobby use J1A J2A S15A S30A S 45A S30A S60 A S90A Carry out a complete fork service. x • • Carry out a complete shock absorber service. x • Grease the steering head bearing. x ( p. 46) • • Treat el[...]

SERVICE S CHEDULE 32 NB1A Clean the chain. ( p. 51) • Check the chain tension. ( p. 52) • Check the chain wear. ( p. 53) • Check the rear sprocket / engine sprocket for wear. ( p. 52) • Clean the air filter. x ( p. 75) • Check the tire air pressure. ( p. 67) • Check the tire condition. ( p. 66) • Check the coolant level. ( p. 72) • [...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 33 9 MAINTENANCE WORK ON CHASSISAND ENGINE 9.1 Jacking up the m otorcycle 500074-01 Note Danger of damag e   Danger of damage by the vehicle running away or falling over. – Always place the vehicle on a firm and even surface. – Jack up the motorcycle underneath the engine. The wheels must no longer to[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 34 400208-10 – Turn the adjusting screw  clockwise with a ring wrench until it stops. Info Do not loosen nut  ! – Turn back counterclockwi se the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1 turn Info[...]

0 0 A A 0 0 0 B B 0 0 A A MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 35 400210-10 – Turn the adjusting screw  clockwise until it stops. Info Do not loosen nut  ! – Turn back counterclockwi se the number of clicks corresponding to the shock absorber type. Guideline Rebound damping Comfort 26 clicks Standard 24 clicks Sport 22 clicks Info Tu[...]

C C 0 0 A A A A 2 2 1 1 MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 36 9.10 Checking the rid ing sag of the sho ck absorber 400222-10 – Measure distance  of rear wheel unloaded. ( p. 35) – With another person holding the motorcycle, sit on the saddle with full protective clothing in a normal sitting position (feet on footrests) and bounce up a[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 37 9.12 Adjusting riding s ag x – Remove shock absorber. x ( p. 37) – After removing the shock absorber, clean it thoroughly. – Choose and mount a suitable spring. Guideline Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 69 N/mm (394 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 72 N[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 38 9.15 Checking basic setting of fork Info For various reasons, no exact riding sag can be determined for the forks. 400189-01 – As with the shock absorber, smaller weight differences can be compensated by the spring preload. – However, if your fork is often overloaded (hard end stop on compression), y[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 39 – Turn back counterclockwi se the number of clicks corresponding to the fork type. Guideline Rebound damping Comfort 24 clicks Standard 22 clicks Sport 22 clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce sus- pension damping. 9.18 Adjusting spring preload of th e fork 800[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 40 Warning Danger of accide nts   Reduced braking due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. – Clean and oil the dust boots and inner fork tube of both fork legs. Universal oil spray ( p. 108) – Pre[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 41 – Move the handlebar to and fro over the entire steering range. The handlebar must be able to move easily over the entire steering range. No resting locations should be noticeable. » If click positions are noticeable: (EXC SIX DAYS, XC ‑ W USA) – Adjust play of the steering head bearing. x ( p. 41[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 42 9.26 Removing the fo rk legs – Remove the front wheel. x ( p. 64) 500093-10 – Remove screws  and take off clamp. – Remove cable clip  , remove screw  and take off the brake caliper. – Hang the brake caliper and the brake line loosely to the side. 500094-10 (EXC SIX DAYS, XC ‑ W USA) ?[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 43 100023-10 (EXC EU, EXC AUS, X C ‑ W ZA) – Fully tighten screw  . Guideline Screw, top triple clamp M8 20 Nm (14.8 lbf ft) – Fully tighten screw  . Guideline Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) 500093-11 – Position brake caliper, mount and tighten screws  . Guideline Screw, [...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 44 500099-10 – Remove screws  and hang the CDI control unit to the side. Info Do not unplug the CDI control unit. – Remove screw  . Remove screw  , take off top triple clamp with the handlebar and place it on one side. Info Protect the motorcycle and its attachments from damage by covering them[...]

0 0 2 2 0 0 1 1 0 0 3 3 MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 45 9.32 Installing the low er triple clamp x (EXC SIX DAYS, X C ‑ W USA) 500098-10 – Clean the bearing and sealing elements, check for damage, and grease. Long-life grease ( p. 107) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. I[...]

0 0 2 2 0 0 1 1 MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 46 9.33 Installing the low er triple clamp x (EXC EU, EXC AUS , XC ‑ W ZA) 500151-10 – Clean the bearing and sealing elements, check for damage, and grease. Long-life grease ( p. 107) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. Info Ch[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 47 9.35 Dismounting the front fender 500092-10 – Remove screws  . Remove the front fender. – Make sure that the distance bushings remain in place. 9.36 Installing the fron t fender 500092-10 – Ensure that the spacing sleeves are mounted in the fender. – Position the front fender. Mount and tighte[...]

0 0 B B 0 0 B B 0 0 A A 0 0 A A 0 0 2 2 0 0 1 1 0 0 2 2 0 0 1 1 MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 48 800018-11 – Position the headlight mask and fix it with the rubber band  . Info Take care with the contact of the holding lug at the fender. – Position the brake line and cable harness. Put the clamp on, mount and tighten screw  . [...]

0 0 3 3 0 0 2 2 0 0 1 1 0 0 4 4 0 0 5 5 0 0 6 6 0 0 7 7 0 0 8 8 0 0 9 9 MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 49 – Place the handlebar support in the required position. Fit and tighten the two screws  . Guideline Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite ® 243™ Info Position the left and right handlebar supports evenly. ?[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 50 – Position the handlebar clamps  with rubber washers  and elastomers  . Elastomer kit green - soft quality (SXS05125203) Elastomer kit yellow - medium quality (standard) (SXS05125204) Elastomer kit red - hard quality (SXS05125 205) Info The elastomers are available in different versions. – F[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 51 500153-10 – Move the handlebar to the straight-ahead position. – Push back bellows  . – Loosen nut  . Turn adjusting screw  in as far as possible. – Loosen nut  . Turn adjusting screw  so that there is play in the gas Bowden cable at the throttle grip. Guideline Play in gas Bowden [...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 52 9.48 Checking the ch ain tension Warning Danger of accide nts   Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel) are under additional load. Apart[...]

0 0 0 B B 0 0 A A 1 2 3 1 6 1 7 1 8 MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 53 9.51 Checking chain wear – Jack up the motorcycle. ( p. 33) 400226-10 – Shift gear to neutral. – Pull the upper chain section with the specified weight  . Guideline Weight of chain wear measuremen t 10… 15 kg (22… 33 lb.) – Measure distance  of 18 cha[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 54 400225-10 – Loosen nut  . – Loosen nuts  . – Adjust the chain tension by turning the left and right adjusting screws  . Guideline Chain tension 8… 10 mm (0.31… 0.39 in) Turn the left and right adjusting screws  so that the markings on the left and right chain adjusters are in the sa[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 55 9.54 Adjusting chain t ension - fitting rea r wheel 400225-11 – Loosen nuts  . – Adjust the chain tension by turning the adjusting screws  left and right. Guideline Chain tension 8… 10 mm (0.31… 0.39 in) Turn the adjusting screws  left and right so that the markings on the left and right[...]

A A MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 56 400257-10 – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement  . Info Wear reduces the thickness of the brake disc around the area used by the brake linings. Wear limit of brake discs Front 2.5 mm (0.098 in) Rear 3.5 mm (0.13[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 57 9.59 Adjusting free tra vel of handbrak e lever (all EXC m odels) 400196-12 – Adjust the free travel of the handbrake lever with the adjustment screw  . Info Turn the adjustment screw clockwise to reduce free travel. The pressure point moves away from the handlebar. Turn the adjustment screw counter[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 58 600706-10 – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws  . – Remove cover  with membrane  . – Add brake fluid to level  . Guideline Measurement of  5 mm (0.2 in) Brake fluid DOT 4 / DOT 5.1 ( p. 106) – Position the cover with [...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 59 9.64 Mounting front b rake linings x Warning Danger of accide nts   Reduced braking due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Danger of accide nts   Reduced braking due to use of non-appro[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 60 600706-10 – Remove the front brake linings. x ( p. 58) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws  . – Remove cover  with membrane  . – Press the brake piston back to its basic position and make sure that no brake fluid overflows[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 61 – Hold screw  and tighten nut  . Guideline Remaining nuts, chassis M8 30 Nm (22.1 lbf ft) – Hold push rod  and tighten nut  . Guideline Remaining nuts, chassis M6 15 Nm (11.1 lbf ft) – Reconnect spring  . 9.68 Checking the re ar brake fluid leve l Warning Danger of accide nts   Bra[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 62 400233-10 – Stand the vehicle upright. – Remove screw cap  with membrane  and the O-ring. – Add brake fluid to level  . Brake fluid DOT 4 / DOT 5.1 ( p. 106) – Mount the screw cap with the membrane and the O-ring. Info Clean up overflowed or spilt brake fluid immediately with water. 9.70[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 63 500122-10 – Check that leaf spring  in the brake caliper and sliding plate  in the brake caliper support are seated correctly. Info The arrow on the leaf spring points in the rotation direction of the brake disc. 400237-10 – Fit the brake pads, insert bolt  , and mount locking split pins [...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 64 9.74 Removing the fro nt wheel x – Jack up the motorcycle. ( p. 33) 500089-10 – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes. 500084-10 – R[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 65 500084-11 – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw  . Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc. – Re[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 66 400260-10 – Clean and grease shaft seal rings  and bearing surface  of the spacing sleeves. Long-life grease ( p. 107) – Insert the spacing sleeves. 400259-10 – Lift the rear wheel into the swing arm, position it, and insert the wheel spindle  . – Put the chain on. 400225-12 – Position[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 67 9.79 Checking tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire. Correct tire air pressure ensures optimal riding comfort and maximum tire service life. 400241-01 – Remove dust cap. – Check tire air pressure when tires are cold. Tire air pressure off road[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 68 500069-10 – Disconnect the negative (minus) cable  of the battery. – Pull back the plus pole cover  and disconnect the positive (plus) cable of the bat- tery. – Hang the rubber band  out to the bottom. – Lift the battery up. 9.82 Installing the batt ery x 500069-11 – Place the battery [...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 69 400240-10 – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the battery, and to test the generator. With this device, you cannot overcharge the bat- tery. Info Nev[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 70 9.87 Mounting the sea t 500068-01 – Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear and simultaneously push it forward. – Make sure that the seat is correctly locked in. – Mount and tighten the screw of the seat fixing. Guideline Remaining screws, chassis M[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 71 9.89 Installing the fuel tank x Danger Fire hazard   Fuel can easily catch fire. – Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. – Fue[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 72 9.91 Checking antifre eze and coolant level Warning Danger of scaldin g   The coolant gets very hot when the motorcycle is driven and is under high pressure. – Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to co[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 73 9.93 Draining coolan t x Warning Danger of scaldin g   The coolant gets very hot when the motorcycle is driven and is under high pressure. – Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. If you sca[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 74 9.96 Removing main silencer Warning Danger of burns   The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. 800020-10 – Disconnect spring  . – Remove screws  and take off main silencer. 9.97 Installing the mai n si[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 75 9.100 Removing the ai r filter x Note Engine failure   U nfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Warning Environmental ha zard   Problem mat[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 76 9.103 Adjusting basic p osition of clutch l ever 500133-11 – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw  . Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw counterclock[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 77 400339-10 – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws  . – Remove cover  with membrane  . 500158-10 – Fill bleeding syringe  with the appropriate hydraulic fluid. Bleed syringe (503290500 00) Brake fluid DOT 4 / DOT 5.1 ( p. 106[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 78 9.107 Carburetor - adju sting idle x 400341-10 – Screw in the idle adjusting screw  until it stops and then to the prescribed basic setting. Guideline Idle mixture adjusting screw (400 EXC) Open 0.75 turn Idle mixture adjusting screw (530 EXC, 530 EXC SIX DAYS, 450 XC-W ZA, 530 XC-W ZA) Open 1.5 tur[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 79 – Adjust the idle speed with adjusting screw  . Guideline Choke function deactivated – The choke lever is pushed in to the stop. (EXC AUS, XC ‑ W) ( p. 20) Choke function deactivated – The choke lever is pushed back to the stop. (EXC EU, EXC SIX DAYS) ( p. 21) Idle speed 1,550… 1,650 rpm Inf[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 80 200119-10 Condition Engine is cold. – Check the engine oil level. The engine oil must be between the halfway mark and the top of the oil level viewer  . » If the engine oil level is below the specified level: – Top up the engine oil. ( p. 82) 9.110 Changing engine oil and oil filter, cleanin g en[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 81 200113-10 – Remove screws  . Remove oil filter cover  with O-ring. 200114-10 – Pull the oil filter insert  out of the oil filter casing. Circlip pliers reverse (51012011000) – Completely drain the engine oil. – Thoroughly clean parts and sealing area. 9.113 Mounting oil filte r x 200114-[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 82 9.115 Topping up engi ne oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. 200115-10 – Remove the screw cap  on the generator cover and fill up with engine oil. Engine oil (SAE 10W/50) ( p. 106) – Mount and tighten screw cap  . Danger Danger of p[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 83 500159-10 – Place a suitable container under the engine. – Remove the gear oil drain plug  . – Plug - remove the gear oil screen  . – Completely drain the gear oil. – Thoroughly clean the gear oil drain plug with a magnet. – Thoroughly clean the drain plug and gear oil screen with a mag[...]

MAINTENA NCE WOR K ON CHA SSIS AND ENGINE 84 200118-11 – Remove screw cap  . Stand the vehicle upright. – Add gear oil until it flows out of the bore of the gear oil level screw. Engine oil (SAE 10W/50) ( p. 106) – Mount and tighten the gear oil level check screw. Guideline Screw, gear oil level check M6 8 Nm (5.9 lbf ft) – Mount and tig[...]

TROUBLES HOOTING 85 10 TROUBLESHOOTING Faults Possible cause Action The engine cannot be cranked (electric starter). Operating error – Go through the steps of starting the engine. ( p. 26) Battery discharged – Recharge the battery. x ( p. 68) – Check the charging voltage. x – Check the closed current. x – Check the generator. x Fuse blown[...]

TROUBLES HOOTING 86 Faults Possible cause Action Engine has too little power. Fuel feed interrupted – Check the fuel tank breather. – Clean the fuel tap. – Check/adjust the carburetor compo- nents. x Air filter very dirty – Clean the air filter. x ( p. 75) Exhaust system leaky, deformed or too lit- tle glass fiber yarn filling in main silen[...]

CLEANING 87 11 CLEANING 11.1 Cleaning motorc ycle Note Material damage   Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, connects, Bowden cables, and bearings, etc., and c[...]

STORAGE 88 12 STORAGE 12.1 Storage Warning Danger of poison ing   Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi- ately with water and contact a doctor. Wash affected skin areas immediate ly with soap and water. If fuel is swal[...]

TECHNICA L DATA - E NGINE 89 13 TECHNICAL DATA- ENGINE Design 1-cylinder 4-stroke engine, water-cooled Displacement (all 400 models) 393.4 cm³ (24.007 cu in) Displacement (all 450 models) 449.3 cm³ (27.418 cu in) Displacement (all 530 models) 510.4 cm³ (31.147 cu in) Stroke (all 400 models) 55.5 mm (2.185 in) Stroke (all 450 models) 63.4 mm (2.4[...]

TECHNICA L DATA - E NGINE 90 13.2 Capacity - gear oil Gear oil 0.90 l (0.95 qt.) Engine oil (SAE 10W/50) ( p. 106) 13.3 Capacity - coola nt Coolant 0.95 l (1 qt.) Coolant ( p. 106) Coolant (mixed ready to use) ( p. 106)[...]

TECHNICA L DATA - E NGINE TIG HTENING T ORQUES 91 14 TECHNICAL DATA- ENGINE TIGHTENINGTO RQUES Screw, cable holder in generator cover M4 4 Nm (3 lbf ft) Loctite ® 243™ Oil jet, rocker arm lubrication M5 2 Nm (1.5 lbf ft) Loctite ® 243™ Oil jet, piston cooling M5 2 Nm (1.5 lbf ft) Loctite ® 243™ Screw, locking lever M5 6 Nm (4.4 lbf ft) Loc[...]

TECHNICA L DATA - E NGINE TIG HTENING T ORQUES 92 Screw, cylinder head M10x1.25 Tightenin g sequence: Tighten diagonally, begin- ning with the rear screw on the chain shaft. Step 1 10 Nm (7.4 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 50 Nm (36.9 lbf ft) lubricated with engine oil Nut, rotor M12x1 60 Nm (44.3 lbf ft) – Spark plug M12x1.25 15… 20[...]

TECHNICA L DATA - C ARBURET OR 93 15 TECHNICAL DATA- CARBURETOR 15.1 400 EXC Carburetor type KEIHIN FCR-MX 39 Carburetor identification number 3900N Needle position 5th position from top Idle mixture adjusting screw Open 0.75 turn Pump membrane stop 2.15 mm (0.0846 in) Main jet 180 Jet needle OBDYU (OBDTQ) Idling jet 42 Idle air jet 100 Cold start [...]

TECHNICA L DATA - C ARBURET OR 94 15.4 450 XC-W Carburetor type KEIHIN FCR-MX 39 Carburetor identfication number 3900L Needle position (450 XC-W USA) 1st position from top Needle position (450 XC-W ZA) 4th position from top Idle mixture adjusting screw (450 XC-W ZA) Open 1.5 turns Idle mixture adjusting screw (450 XC-W USA) Open 1.75 turns Pump mem[...]

TECHNICA L DATA - C HASSIS 95 16 TECHNICAL DATA- CHASSIS Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Susp ension 4860 MXMA PA Suspension travel Front 300 mm (11.81 in) Rear 335 mm (13.19 in) Fork offset (EXC SIX DAYS, XC ‑ W USA) 19 mm (0.75 in) Fork offset (EXC EU, EXC AUS, XC ‑ W ZA) 20 mm (0.79 in) Shock absorber [...]

TECHNICA L DATA - C HASSIS 96 Licence plate lamp (all EXC models) W 2,1x9,5d 12 V 5 W 16.2 Tires Validity Front tire Rear ti re (all EXC models) 90/90 - 21 M/C 54M M+S TT Metzeler MCE 6 DAYS EXTREME 140/80 - 18 M/C 70M M+S TT Metzeler MCE 6 DAYS EXTREME (all XC ‑ W models) 80/100 - 21 51M TT Bridgestone M59 110/100 - 18 64M TT Bridgestone M402 Fo[...]

TECHNICA L DATA - F ORK 97 17 TECHNICAL DATA- FORK Fork part number 14.18.7E.06 Fork WP Susp ension 4860 MXMA PA Compression damping Comfort 26 clicks Standard 22 clicks Sport 20 clicks Rebound damping Comfort 24 clicks Standard 22 clicks Sport 22 clicks Spring length with preload spacer(s) 510 mm (20.08 in) Spring rate Weight of rider: 65… 75 kg[...]

TECHNICA L DATA - S HOCK ABS ORBER 98 18 TECHNICAL DATA- SHOCK ABSORBER Shock absorber part number 12.18.7E.06 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 18 clicks Standard 15 clicks Sport 12 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1 turn Rebound damping Comfort 26 clicks[...]

TECHNICA L DATA - C HASSIS T IGHTENING TORQUES 99 19 TECHNICAL DATA- CHASSIS TIGHTENINGTO RQUES Spoke nipple, front wheel M4,5 5 Nm (3.7 lbf ft) – Spoke nipple, rear wheel M5 5 Nm (3.7 lbf ft) – Screw, spoiler on fuel tank (XC ‑ W USA) M5x12 1.5 Nm (1.11 lbf ft) – Remaining nuts, chassis M6 15 Nm (11.1 lbf ft) – Remaining screws, chassis [...]

BT/3 BG/3 AH/2 AK/2 12 BV/2 BO/2 AH1/2 AK1/2 BF/1 BA/1 AC/6 BC/6 BA1/1 BF1/1 G AH2/2 AJ1/3 BG1/3 v BA2/1 U CE/4 CA/4 BU/18 CW/2 CX/2 CW1/2 CX1/2 CW2/2 CX2/2 CW3/2 CX3/2 EI/1 EH/1 1 2.1 BK/4 BR/4 1 2 3 4 5A t M AJ/3 BG/3 BV/2 BS/2 1 2 3 2.1 2.2 1 2 DI/2 CY/3 CZ/3 DA/4 DB/4 CW/2 CX/2 BP/4 DG/4 M A 10 AF/4 4 3 2 AM/3 AR/3 G 3 3 2 2 2 1 AT/2 1 1 AT1/2 [...]

WIRING DI AGRAM 101 Components A6 CDI controller B1 Throttle position sensor B3 Wheel speed sensor E6 Thermoswitch (EXC SIX DAYS) G1 Battery G2 Generator H1 Right rear flasher H2 Left front flasher H3 Left rear flasher H4 Right front flasher H5 Brake/tail light H7 Parking light H9 License plate lamp H11 Low/high beam H13 Horn H14 Radiator fan (EXC [...]

WIRING DI AGRAM 102 ye Yellow ye-bl Yellow-black ye-re Yellow-red[...]

WIRING DI AGRAM 103[...]

G 3 v M A 0 1 bl U 2 / V B _ C A 5 t M e r - e y e y h w r b h w r b wh ye re-wh re-bl gn re re gn re-bl re-wh bu-wh br ye-bl bu-wh br br ye r b e r - e y r b l b - e y l b l b e r u b h w r b bu ye bl bl ye bu ye-re wh-re wh-re ye-re br ye-re br wh ye-bl h w h w gr gr bl-wh bl br br br bl br bl H7 H11 B3 P1 S5 S9 S6 S 10 E6 H 14 M1 K1 G1 N2 H5 G2 [...]

WIRING DI AGRAM 105 Components A6 CDI controller B1 Throttle position sensor B3 Wheel speed sensor E6 Thermoswitch (XC-W ZA) G1 Battery G2 Generator H5 Brake/tail light (XC-W ZA) H7 Parking light (XC-W ZA) H11 Low/high beam (XC-W ZA) H14 Radiator fan (XC-W ZA) K1 Starter relay with main fuse L1 Pulse generator L2 Ignition coil M1 Star ter motor N2 [...]

SUBSTAN CES 106 21 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 According to – DOT Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Castrol and Motorex ® products. Supplier Castrol – RESPONSE BRAKE FLU ID SUPER DOT 4 M[...]

AUXILIARY SUBSTAN CES 107 22 AUXILIARY SUBSTANCES Air filter cleaner Specification – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Dirt Bio Re mover Chain cleaner Specification – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean 611 Cleaning and po lishing materials for metal, ru bber and plastic Spe[...]

AUXILIARY SUBSTAN CES 108 Oil for foam air f ilter Specification – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Liquid Bi o Power Universal oil spr ay Specification – KTM recommends Motorex ® products. Supplier Motorex ® – Joker 440 Universa l[...]

STANDAR DS 109 23 STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard.Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification.Whereas long service intervals are demande[...]

INDEX 110 INDEX A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Air filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 A[...]

INDEX 111 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Front wheel installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Fuel tank installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 re[...]

INDEX 112 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 T Technical data Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93-94 chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-96 chassis tightening torques . . . . . . . . . . . . . . . . . . . . . 99 Engine . . . [...]

*321 1355 en* 3211355en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com 05/2008 Photo Mitterbauer[...]