KTM 400, 450, 530, EXC, XC-W, SIX DAYS - Service Manual - Wiring Diagrams - Owners Manual

KTM 400, 450, 530, EXC, XC-W, SIX DAYS - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - OWNERS MANUAL

- English Service Manual, Owners Manual and Wiring Diagrams, to motorcycles KTM KTM 400, 450, 530, EXC, XC-W, SIX DAYS.

 

CONTENTS:


SERVICE MANUAL

Home
Means Of Representation
Important Notes
Location Of Serial Numbers
- Chassis number
- Type label
- Key number (all EXC models)
- Engine number
- Fork part number
- Shock absorber part number
Motorcycle
- Jacking up the motorcycle
- Removing the motorcycle from the work stand
- Starting
- Starting the motorcycle for checking
01/Fork, Triple Clamp
- Adjusting compression damping of fork
- Adjusting rebound damping of fork
- Adjusting spring preload of the fork
- Bleeding fork legs
- Cleaning the dust boots of the fork legs
- Loosening the fork protection
- Positioning the fork protection
- Removing the fork legs
- Installing fork legs
- Removing the fork protector
- Installing the fork protector
- Performing a fork service
- Disassembling the fork legs
- cartridge, disassembling
- Disassembling the compression damping fitting
- Checking the fork legs
- Assembling the compression damping fitting
- Assembling the cartridge
- Assembling the fork legs
- Greasing the steering head bearing
- Removing the lower triple clamp (EXC SIX DAYS, XC W USA, EXC USA)
- Installing the lower triple clamp (EXC SIX DAYS, XC W USA, EXC USA)
- Removing the lower triple clamp (EXC EU, EXC AUS, XC W ZA)
- Installing the lower triple clamp (EXC EU, EXC AUS, XC W ZA)
- Checking the play of the steering head bearing
- Adjusting play of steering head bearing (EXC SIX DAYS, XC W USA, EXC USA)
- Adjusting play of steering head bearing (EXC EU, EXC AUS, XC W ZA)
02/Handlebar, Instruments
- Handlebar position
- Adjusting handlebar position
- Adjusting basic position of clutch lever
- Checking the choke cable routing (EXC EU, EXC SIX DAYS)
- Checking the choke cable play (EXC EU, EXC SIX DAYS)
- Adjusting the choke cable play (EXC EU, EXC SIX DAYS)
- Checking of the routing of the throttle cable
- Checking the play in the throttle cable
- Adjusting the play in the throttle cable
03/Frame
- Removing the engine sprocket cover
- Installing the engine sprocket cover
04/Shock Absorber, Swingarm
- Adjusting high-speed compression damping of the shock absorber
- Adjusting the low-speed compression damping of the shock absorber
- Adjusting rebound damping of shock absorber
- Measuring rear wheel sag unloaded
- Checking static sag of shock absorber
- Checking riding sag of shock absorber
- Adjusting spring preload of the shock absorber
- Adjusting riding sag
- Removing the shock absorber
- Installing the shock absorber
- Performing a shock absorber service
- Removing the spring
- Disassembling the shock absorber
- Disassembling the piston rod
- Disassembling the seal ring retainer
- Replacing the pilot bushing
- Checking the shock absorber
- Disassembling the rebound adjuster
- Removing the heim joint
- Installing the heim joint
- Assembling the rebound adjuster
- Assembling the seal ring retainer
- piston rod, assembling
- Assembling the damper
- Bleeding and filling the damper
- Filling the damper with nitrogen
- Installing the spring
05/Exhaust
- Removing main silencer
- Installing the main silencer
- Removing the manifold
- Installing the manifold
06/Air Filter
- Dismounting the air filter box lid
- Installing the air filter box lid
- Removing the air filter
- Installing the air filter
- Cleaning air filter
- Removing the carburetor connection boot
- Installing the carburetor connection boot
07/Fuel Tank, Seat, Trim
- Opening filler cap
- Closing filler cap
- Removing the seat
- Mounting the seat
- Dismounting the fuel tank
- Installing the fuel tank
- Fuel tap
08/Mask, Fender
- Removing the front fender
- Installing the front fender
- Removing headlight mask with headlight (EXC EU, EXC AUS, EXC SIX DAYS, EXC USA, XC W ZA)
- Refitting the headlight mask with the headlight (EXC EU, EXC AUS, EXC SIX DAYS, EXC USA, XC W ZA)
- Removing the start number plate (XC W USA)
- Installing the start number plate (XC W USA)
09/Front Wheel
- Removing the front wheel
- Installing the front wheel
- Checking the brake discs
- Removing the front brake disc
- Installing the front brake disc
- Checking the tire condition
- Checking tire air pressure
- Checking spoke tension
10/Rear Wheel
- Removing the rear wheel
- Installing the rear wheel
- Removing the rear brake disc
- Installing the rear brake disc
- Checking chain tension when fitting rear wheel
- Adjusting chain tension - fitting rear wheel
- Checking the chain tension
- Adjusting chain tension - after checking
- Adjusting the chain tension
- Adjusting chain guide
- Checking the rear sprocket / engine sprocket for wear
- Checking chain wear
- Checking for chain dirt accumulation
- Cleaning the chain
11/Wiring Harness, Battery
- Removing a fuse
- Installing the fuse
- Removing the battery
- Installing the battery
- Recharging the battery
- Checking the closed current
- Checking the charging voltage
- Checking the voltage regulator
- Checking the charging current
- Checking the starter relay
13/Brake System
- Checking the front brake linings
- Removing front brake linings
- Mounting front brake linings
- Changing the front brake linings
- Checking free travel of hand brake lever
- Adjusting basic position of handbrake lever (all XC W models)
- Adjusting free travel of handbrake lever (all EXC models)
- Checking the brake fluid level of the front brake
- Adding front brake fluid
- Changing the front brake fluid
- Checking rear brake linings
- Removing rear brake linings
- Mounting rear brake linings
- Changing the rear brake linings
- Checking free travel of foot brake lever
- Adjusting basic position of foot brake lever
- Checking the brake fluid level of the rear brake
- Adding rear brake fluid
- Changing the rear brake fluid
14/Lighting System, Instruments
- Adjusting the speedometer functions
- kilometers or miles, setting
- Activating the additional functions
- Setting the wheel circumference
- Setting the clock
- Checking the headlamp setting (EXC EU, EXC AUS, EXC SIX DAYS, EXC USA, XC W ZA)
- Adjusting the beam width of the headlight (EXC EU, EXC AUS, EXC SIX DAYS, EXC USA, XC W ZA)
30/Engine
- Removing the engine
- Installing the engine
30/Disassembling The Engine
- Preparations
- Draining the engine oil
- Removing the oil filter
- Draining the gear oil, removing the gear oil screen
- Removing the starter engine
- Removing the spark plug
- Removing the valve cover
- Removing the shift lever
- Removing the generator cover
- Setting the engine to ignition top dead center
- Removing the timing chain tensioner
- Removing the camshaft
- Removing the cylinder head
- Removing the piston
- Removing the rotor
- Removing the balance weight
- Removing the timing chain guide rail
- Removing the timing chain tensioning rail
- Removing the timing chain securing guide
- Removing the timing chain
- Removing the ignition pulse generator
- Removing the suction pump
- Removing the kickstarter
- Removing the water pump cover
- Removing the clutch cover
- Disassembling the clutch disks
- Removing the primary gear nut
- Removing the outer clutch hub
- Removing the balancer shaft
- Removing the torque limiter
- Removing the starter idler gear
- Removing the kickstarter shaft
- Removing the kickstarter idler gear
- Removing the shift shaft
- Removing the shift drum locating
- Removing the locking lever
- Removing the oil pump gears
- Removing the oil pumps
- Removing the primary gear
- Removing the free wheel gear
- Removing the left section of the engine case
- Removing the shift rails
- Removing the shift drum
- Removing the shift forks
- Removing the transmission shafts
- Removing the crankshaft
30/Engine - Work On The Individual Parts
- Working on the right section of the engine case
- Working on the left section of the engine case
- Removing the oil pressure regulator valve
- Checking spring length of oil pressure regulator valve
- Installing the oil pressure regulator valve
- Removing the crankshaft seal ring in the clutch cover
- Fitting the crankshaft seal ring into the clutch cover
- Removing the water pump
- Installing the water pump
- Checking the balancer shaft
- Removing the timing chain sprocket
- Installing the timing chain sprocket
- Changing the connecting rod, conrod bearing and crank pin
- Checking crankshaft run-out at bearing pin
- cylinder - Nikasil® coating
- Checking/measuring cylinder
- Checking/measuring the piston
- Checking the piston ring
- Piston/cylinder - determining the mounting clearance
- Checking the oil pumps for wear
- Disassembling the autodecompressor
- Assembling the autodecompressor
- Checking camshaft
- Checking the timing assembly
- Preparing the timing chain tensioner for installation
- Removing the rocker arm
- Removing the valves
- Changing camshaft bearing
- Checking valves
- Checking valve springs
- Checking valve spring seat
- Checking the cylinder head
- Checking the rocker arm shafts
- Installing valves
- Installing the rocker arm
- Checking clutch
- Checking shift mechanism
- Preassembling the shift shaft
- Dismantling the main shaft
- Assembling the main shaft
- Dismantling the countershaft
- Assembling the countershaft
- Checking the transmission
- Premounting the kickstarter shaft
- Checking the electric starter mode
- Removing the freewheel
- Checking the freewheel
- Installing the free-wheel
30/Engine Assembly
- Installing the crankshaft
- Installing the transmission shaft
- Installing the shift forks
- Installing the shift drum
- Installing the shift rails
- Installing the left engine case
- Installing the free wheel gear
- Installing the primary gear
- Installing the oil pumps
- Installing the oil pump gears
- Installing the locking lever
- Installing the shift drum locating
- Installing the shift shaft
- Installing the kickstarter idler gear
- Installing the kickstarter shaft
- Installing the starter idler gear
- Installing the torque limiter
- Installing the balancer shaft
- Installing the outer clutch hub
- Installing the primary gear nut
- Installing the clutch discs
- Installing the clutch cover
- Installing the water pump cover
- Installing the kickstarter
- Installing the suction pump
- Installing the ignition pulse generator
- Installing the timing chain
- Installing the timing chain securing guide
- Installing the timing chain tensioning rail
- Installing the timing chain guide rail
- Installing the balance weight
- Installing the rotor
- Installing the piston
- Installing the cylinder head
- Installing the camshaft
- Installing the timing chain tensioner
- Checking the valve clearance
- Adjusting the valve clearance
- Installing the generator cover
- Installing the shift lever
- Installing the valve cover
- Installing the spark plug
- Installing the starter motor
- Mounting oil filter
- Filling up with engine oil
- Filling up with gear oil
- Removing the engine from the work stand
31/Carburetor
- Choke (EXC AUS, XC W, EXC USA)
- Choke (EXC EU, EXC SIX DAYS)
- Removing the carburetor
- Disassembling the carburetor
- Checking/adjusting the carburetor components
- Checking/adjusting the accelerator pump
- Checking the choke slide
- Checking the jet needle
- Checking the throttle slide
- Checking the needle jet
- Checking the float needle valve
- Checking/adjusting the float level
- Checking/setting the throttle slide opening
- Checking the throttle valve sensor
- Adjusting the position of the throttle position sensor
- Assembling the carburetor
- Installing the carburetor
- Carburetor - adjusting idle
- Emptying the carburetor float chamber
32/Clutch
- Checking fluid level of hydraulic clutch
- Changing the hydraulic clutch fluid
33/Transmission
- Removing the engine sprocket
- Installing the engine sprocket
35/Water Pump, Cooling System
- Cooling system
- Checking the antifreeze and coolant level
- Checking the coolant level
- Draining coolant
- Refilling coolant
38/Lubrication System
- Oil circuit
- Checking engine oil level
- Changing engine oil and oil filter, cleaning engine oil screen
- Draining engine oil, cleaning engine oil screen
- Removing the oil filter
- Mounting oil filter
- Filling up with engine oil
- Topping up engine oil
- Checking the engine oil pressure
- Checking the gear oil level
- Changing gear oil, cleaning gear oil screen
- Draining gear oil, cleaning gear oil screen
- Filling up with gear oil
- Adding gear oil
39/Ignition System
- Checking the ignition system
- Checking the ignition coil
- Checking the spark plug connector
- Checking the CDI controller
- Checking the ignition pulse generator
- Checking the generator
- Removing the stator
- Mounting the stator
40/Electrostarter
- Checking the starter motor
Troubleshooting
Technical Data - Engine
- Capacity - engine oil
- Capacity - gear oil
- Capacity - coolant
Technical Data - Engine Tolerances, Wear Limits
Technical Data - Engine Tightening Torques
Technical Data - Carburetor
- 400 EXC
- 400 XC-W USA
- 450 EXC EU/AUS, 450 EXC SIX DAYS
- 450 EXC USA
- 450 XC-W
- 530 EXC EU/AUS, 530 EXC SIX DAYS
- 530 EXC USA
- 530 XC W
Technical Data - Carburetor Tightening Torques
Technical Data - Chassis
- Lighting equipment
- Tires
- Capacity - fuel
Technical Data - Fork
Technical Data - Shock Absorber
Technical Data - Tightening Torques For Chassis
Cleaning
- Cleaning motorcycle
Storage
- Storage
- Putting into operation after storage
Service Schedule
- Important maintenance work to be carried out by an authorized KTM workshop.
- Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)
- Important checks and maintenance work to be carried out by the rider.
Wiring Diagram
- Wiring diagram (EXC EU, EXC AUS, EXC R SIX DAYS)
- Wiring diagram (EXC USA)
- Wiring diagram (all XC W models)
Operating Substances
Auxiliary Substances
Special Tools
Standards
Index


SETUP INSTRUCTIONS

Means Of Representation
Set Up
- Unpacking and setting up the vehicle
Work
- Removing the seat
- Mounting the seat
- Installing the front wheel
- Recharging the battery
- Installing the battery
- Installing the front fender
- Opening filler cap
- Closing filler cap
- Refueling
- Installing the shock absorber
Technical Data - Chassis Tightening Torques
Substances
Auxiliary Substances


OWNERS MANUAL

Means Of Representation
Important Information
View Of Vehicle
- View of the vehicle from the left front (example)
- View of the vehicle from the right rear (example)
Serial Numbers
- Chassis number
- Type label
- Engine number
- Key number (All EXC models)
- Fork part number
- Shock absorber part number
Controls
- Clutch lever
- Choke (EXC EU, EXC Factory Edition, EXC SIX DAYS)
- Hand brake lever
- Throttle grip
- Short circuit button (XC W SIX DAYS)
- Short circuit button (All EXC models)
- Light switch (All EXC models)
- Turn signal switch (All EXC models)
- Horn button (All EXC models)
- Emergency OFF switch (EXC AUS)
- Electric starter button (EXC AUS)
- Electric starter button (EXC EU, EXC Factory Edition, EXC SIX DAYS, XC W SIX DAYS)
- Light switch (XC W SIX DAYS)
- Overview of indicator lamps (All EXC models)
- Speedometer
- Speedometer activation and test
- Tripmaster switch
- Setting kilometers or miles
- Setting the clock
- Adjusting the speedometer functions
- Querying the lap time
- Display mode SPEED (speed)
- Display mode SPEED/H (service hours)
- Display mode SPEED/CLK (clock)
- Display mode SPEED/LAP (lap time)
- Display mode SPEED/ODO (odometer)
- Display mode SPEED/TR1 (trip master 1)
- Display mode SPEED/TR2 (trip master 2)
- Display mode SPEED/A1 (average speed 1)
- Display mode SPEED/A2 (average speed 2)
- Display mode SPEED/S1 (stop watch 1)
- Display mode SPEED/S2 (stop watch 2)
- Opening filler cap
- Closing filler cap
- Fuel tap
- Choke (EXC AUS, XC W SIX DAYS)
- Shift lever
- Kick starter
- Foot brake lever
- Side stand
- Steering lock (All EXC models)
- Locking the steering (All EXC models)
- Unlocking the steering (All EXC models)
Putting Into Operation
- Advice on first use
- Running-in the engine
- Preparing vehicle for arduous riding conditions
- Preparations for riding on dry sand
- Preparations for riding on wet sand
- Preparing for rides on wet and muddy surfaces
- Preparing for rides at high temperature and slow speed
- Preparing for rides at low temperatures or in snow
Riding Instructions
- Checks and maintenance before putting into operation
- Starting
- Starting up
- Shifting, riding
- Braking
- Stopping, parking
- Refueling
Service Schedule
- Service schedule
- Service work (as additional order)
Tuning The Chassis
- Checking the basic suspension setting against the rider's weight
- Compression damping of shock absorber
- Adjusting high-speed compression damping of the shock absorber
- Adjusting the low-speed compression damping of the shock absorber
- Adjusting rebound damping of the shock absorber
- Measuring rear wheel sag unloaded
- Checking the static sag of the shock absorber
- Checking the riding sag of the shock absorber
- Adjusting the spring preload of the shock absorber x
- Adjusting the riding sag x
- Checking basic setting of fork
- Adjusting the compression damping of the fork
- Adjusting the rebound damping of the fork
- Adjusting spring preload of the fork
- Fork offset (XC W SIX DAYS)
- Setting the fork offset x (XC W SIX DAYS)
- Handlebar position
- Adjusting handlebar position x
Service Work On The Chassis
- Raising the motorcycle with the lift stand
- Removing the motorcycle from the lift stand
- Bleeding fork legs
- Cleaning the dust boots of the fork legs
- Loosening the fork protector
- Positioning the fork protector
- Removing the fork legs x
- Installing fork legs x
- Removing the fork protector x
- Installing the fork protector x
- Removing the lower triple clamp x (EXC Factory Edition, EXC SIX DAYS, XC W SIX DAYS)
- Installing the lower triple clamp x (EXC Factory Edition, EXC SIX DAYS, XC W SIX DAYS)
- Removing the lower triple clamp x (EXC EU/AUS)
- Installing the lower triple clamp x (EXC EU/AUS)
- Checking the steering head bearing play
- Adjusting play of steering head bearing x (EXC Factory Edition, EXC SIX DAYS, XC W SIX DAYS)
- Adjusting play of steering head bearing x (EXC EU/AUS)
- Greasing the steering head bearing x
- Removing the shock absorber x
- Installing the shock absorber x
- Removing the front fender
- Installing the front fender
- Removing the seat
- Mounting the seat
- Removing the air filter box lid
- Installing the air filter box lid
- Removing the air filter x
- Installing the air filter x
- Cleaning the air filter and air filter box x
- Removing main silencer
- Installing the main silencer
- Changing the glass fiber yarn filling of the main silencer x
- Removing the fuel tank x
- Installing the fuel tank x
- Checking for chain dirt accumulation
- Cleaning the chain
- Checking the chain tension
- Adjusting the chain tension
- Checking the chain, rear sprocket, engine sprocket and chain guide
- Adjusting chain guide x
- Checking the throttle cable routing
- Adjusting the basic position of the clutch lever
- Checking the fluid level of hydraulic clutch
- Changing the hydraulic clutch fluid x
Brakes
- Checking free travel of hand brake lever
- Adjusting the basic position of the hand brake lever (XC W SIX DAYS)
- Adjusting free travel of hand brake lever (All EXC models)
- Checking the brake discs
- Checking the brake fluid level of the front brake
- Adding front brake fluid x
- Checking the front brake linings
- Changing the front brake linings x
- Checking the free travel of the foot brake lever
- Adjusting the basic position of the foot brake lever x
- Checking rear brake fluid level
- Adding brake fluid to the rear brake circuit x
- Checking rear brake linings
- Changing the rear brake linings x
Wheels, Tires
- Removing front wheel x
- Installing the front wheel x
- Removing the rear wheel x
- Installing the rear wheel x
- Checking the tire condition
- Checking tire air pressure
- Checking spoke tension
Electrical System
- Removing the battery x
- Installing the battery x
- Recharging the battery x
- Removing the main fuse
- Installing the main fuse
- Changing the fuse of the radiator fan (EXC SIX DAYS, XC W SIX DAYS)
- Removing headlight mask with headlight
- Refitting the headlight mask with the headlight
- Changing the headlight bulb
- Checking the headlight adjustment
- Adjusting the headlight range
- Changing the speedometer battery
Cooling System
- Cooling system
- Checking the anti-freeze and coolant level
- Checking the coolant level
- Draining coolant x
- Refilling coolant x
Tuning The Engine
- Checking the play in the throttle cable
- Adjusting the play in the throttle cable x
- Carburetor - idle
- Carburetor - adjusting the idle speed x
- Emptying the carburetor float chamber x
- Checking the basic position of the shift lever
- Adjusting the basic position of the shift lever x
Service Work On The Engine
- Checking engine oil level
- Changing engine oil and oil filter, cleaning engine oil screen x
- Draining engine oil, cleaning engine oil screen x
- Removing the oil filter x
- Installing the oil filter x
- Filling up with engine oil x
- Adding engine oil
- Checking the gear oil level
- Changing gear oil, cleaning gear oil screen x
- Draining gear oil, cleaning gear oil screen x
- Filling up with gear oil x
- Adding gear oil x
Cleaning, Care
- Cleaning the motorcycle
- Protection for winter operation
Storage
- Storage
- Putting into operation after storage
Troubleshooting
Technical Data - Engine
- Capacity - engine oil
- Capacity - transmission oil
- Capacity - coolant
Technical Data - Engine Tightening Torques
Technical Data - Carburetor
- All 400 models
- 450 EXC EU/AUS, 450 EXC SIX DAYS, 450 EXC Factory Edition EU
- 450 XC-W SIX DAYS USA
- All 530 EXC models
- 530 XC-W SIX DAYS USA
Technical Data - Chassis
- Lighting equipment
- Tires
- Capacity - fuel
Technical Data - Fork
Technical Data - Shock Absorber
Technical Data - Tightening Torques For Chassis
Substances
Auxiliary Substances
Standards
Index