KTM 400, 450, 530, EXC, XC-W, SIX DAYS
KTM 400, 450, 530, EXC, XC-W, SIX DAYS - SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - OWNERS MANUAL
KTM 400, 450, 530, EXC, XC-W, SIX DAYS - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - OWNERS MANUAL - English Workshop Manual, Owners Manual and Wiring Diagrams, to motorcycles KTM KTM 400, 450, 530, EXC, XC-W, SIX DAYS. CONTENTS: WORKSHOP MANUAL - MEANS OF REPRESENTATION 6 - IMPORTANT NOTES 7 - MOTORCYCLE 8 - Jacking up the motorcycle 8 - Removing the motorcycle from the work stand 8 - 01/FORK, TRIPLE CLAMP 9 - Fork part number 9 - Adjusting spring preload of the fork 9 - Adjusting compression damping of fork 9 - Adjusting rebound damping of fork 10 - Cleaning dust boots of fork legs 10 - Removing the fork legs 11 - Installing the fork legs 11 - Bleeding fork legs 12 - Removing the fork protector 12 - Installing the fork protector 13 - Loosening the fork protection 13 - Positioning the fork protection 13 - Removing the lower triple clamp (EXC-R SIX DAYS, XCR-W USA) 13 - Installing the lower triple clamp (EXC-R SIX DAYS, XCR-W USA) 14 - Removing the lower triple clamp (EXC-R EU, - EXC-R AUS/UK, EXC-R USA, XCR-W ZA) 15 - Installing the lower triple clamp (EXC-R EU, - EXC-R AUS/UK, EXC-R USA, XCR-W ZA) 15 - Fork offset (EXC-R SIX DAYS, XCR-W USA) 16 - Setting the fork offset (EXC-R SIX DAYS, XCR-W USA) 16 - Checking play of steering head bearing 16 - Adjusting play of steering head bearing (EXC-R SIX DAYS, XCR-W USA) 17 - Adjusting play of steering head bearing (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA) 17 - Greasing the steering head bearing 18 - 03/FRAME 19 - Removing the engine sprocket cover 19 - Installing the engine sprocket cover 19 - 04/SHOCK ABSORBER, SWINGARM 20 - Shock absorber part number 20 - Adjusting high-speed compression damping of the shock absorber 20 - Adjusting the low-speed compression damping of the shock absorber 20 - Adjusting rebound damping of the shock absorber 21 - Measuring rear wheel sag unloaded 21 - Checking static sag of the shock absorber 22 - Checking the riding sag of the shock absorber 22 - Adjusting spring preload of the shock absorber 22 - Adjusting riding sag 23 - Removing the shock absorber 23 - Installing shock absorber 24 - 05/EXHAUST 25 - Removing main silencer 25 - Fitting the main silencer 25 - Removing the manifold 25 - Installing the manifold 25 - 06/AIR FILTER 26 - Dismounting the air filter box lid 26 - Installing the air filter box lid 26 - Removing the air filter 26 - Installing the air filter 26 - Cleaning air filter 27 - Removing the carburetor connection boot 27 - Installing the carburetor connection boot 27 - 07/FUEL TANK, SEAT, TRIM 28 - Opening filler cap 28 - Closing filler cap 28 - Removing the seat 28 - Mounting the seat 28 - Dismounting the fuel tank 28 - Installing the fuel tank 29 - Fuel tap 30 - 08/MASK, FENDER 31 - Dismounting the front fender 31 - Installing the front fender 31 - Removing headlight mask with headlight (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W ZA) 31 - Refitting the headlight mask with the headlight (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W ZA) 31 - Dismount the start number plate (XCR-W USA) 32 - Fitting the start number plate (XCR-W USA) 32 - 09/FRONT WHEEL 33 - Removing front wheel 33 - Fitting front wheel 33 - Checking brake discs 34 - Removing the front brake disc 34 - Installing the front brake disc 34 - Tire condition checking 35 - Checking tire air pressure 35 - Checking spoke tension 35 - 10/REAR WHEEL 36 - Removing rear wheel 36 - Fitting rear wheel 36 - Removing the rear brake disc 37 - Installing the rear brake disc 37 - Checking the chain tension when fitting rear wheel 37 - Adjusting chain tension - fitting rear wheel 38 - Checking the chain tension 38 - Adjusting chain tension - after checking 39 - Adjusting the chain tension 39 - Adjusting chain guide 40 - Checking the rear sprocket / engine sprocket for wear 40 - Checking chain wear 41 - Checking chain dirt 41 - Cleaning the chain 41 - 11/WIRING HARNESS, BATTERY 42 - Removing a fuse 42 - Replacing the fuse 42 - Removing the battery 42 - Installing the battery 43 - Recharging the battery 43 - 13/BRAKE SYSTEM 45 - Checking the front brake linings 45 - Removing the front brake linings 45 - Installing the front brake linings 45 - Changing the front brake linings 46 - Adjusting basic position of handbrake lever (Every XCR-W models) 46 - Checking free play of hand brake lever 47 - Adjusting free travel of handbrake lever (Every EXC-R models) 47 - Checking the front brake fluid level 47 - Add front brake fluid 48 - Changing the front brake fluid 48 - Checking rear brake linings 49 - Removing the rear brake linings 49 - Installing the rear brake linings 50 - Changing the rear brake linings 50 - Checking free play of foot brake lever 51 - Adjusting basic position of footbrake lever 51 - Checking rear brake fluid level 52 - Adding rear brake fluid 52 - Changing the rear brake fluid 52 - 14/LIGHT SYSTEM, INSTRUMENTS 54 - Adjusting speedometer functions 54 - Setting kilometers or miles 54 - Setting the clock 55 - 30/ENGINE 56 - Removing the engine 56 - Installing the engine 57 - 30/DISASSEMBLING ENGINE 59 - Preparations 59 - Draining the engine oil 59 - Removing the oil filter 59 - Draining gear oil, cleaning gear oil screen 59 - Removing the starter engine 60 - Removing the valve cover 60 - Removing the shift lever 60 - Removing the spark plug 60 - Removing the generator cover 61 - Setting the engine to ignition top dead center 61 - Removing the timing chain tensioner 62 - Removing the camshaft 62 - Removing the cylinder head 62 - Removing the piston 62 - Removing the rotor 63 - Removing the balance weight 63 - Removing the timing chain guide rail 63 - Removing the timing chain tensioning rail 64 - Removing the timing chain securing guide 64 - Removing the timing chain 64 - Removing the ignition pulse generator 64 - Removing the suction pump 64 - Removing the kickstarter 65 - Removing the water pump cover 65 - Removing the clutch cover 65 - Removing the clutch discs 66 - Removing the primary gear nut 66 - Removing the outer clutch hub 66 - Removing the balancer shaft 67 - Removing the torque limiter 67 - Removing the starter idler gear 67 - Removing the kickstarter shaft 67 - Removing the kickstarter idler gear 67 - Removing the shift shaft 68 - Removing the shift drum locating 68 - Removing the locking lever 68 - removing the oil pump gears 68 - Removing the oil pumps 69 - Removing the primary gear with the free-wheel-gear 69 - Removing the left section of the engine case 69 - Removing the shift rails 70 - Removing the shift roller 70 - Removing the shift forks 71 - Removing the transmission shaft 71 - Removing the crankshaft 71 - 30/ENGINE - WORK ON INDIVIDUAL PARTS 72 - Work on the right section of the engine case 72 - Work on the left section of the engine case 73 - removing the oil pressure regulator valve 75 - Checking the spring length of the oil pressure regulator valve 75 - Installing the oil pressure regulator valve 75 - Removing the crankshaft seal ring in the clutch cover 76 - Fitting the crankshaft seal ring into the clutch cover 76 - Removing the water pump 76 - Installing the water pump 77 - Checking the balancer shaft 78 - Removing the timing chain sprocket 78 - Installing the timing chain sprocket 78 - Changing the conrod bearing 78 - Checking the crankshaft run-out on the bearing pin 80 - Cylinder - Nikasil? coating 80 - Checking/measuring the cylinder 80 - Checking/measuring the piston 81 - Checking the piston ring end gap 81 - Checking piston/cylinder mounting clearance 82 - Checking the oil pumps for wear 82 - Checking the lubrication system 82 - Disassembling the autodecompressor 83 - Assembling the autodecompressor 83 - Checking the camshaft 84 - Checking the timing assembly 84 - Preparing the timing chain tensioner for installation 84 - Removing the rocker arm 85 - Removing the valves 85 - Replacing the camshaft bearing 86 - Checking the valves 87 - Checking the valve springs 87 - Checking the lower valve spring retainer 87 - Checking the cylinder head 88 - Installing valves 88 - Installing the rocker arm 89 - Checking the clutch 89 - Checking the shift mechanism 90 - Preassembling the shift shaft 91 - Dismantling the main shaft 91 - Assembling the main shaft 91 - Dismantling the countershaft 92 - Assembling the countershaft 92 - Checking the transmission 93 - Checking electric starter operation 94 - Removing the free-wheel 94 - Checking the free-wheel 95 - Installing the free-wheel 95 - 30/ASSEMBLING ENGINE 96 - Installing the crankshaft 96 - Installing the transmission shaft 96 - Installing the shift forks 96 - Installing the shift roller 97 - Installing the shift rails 97 - Installing the left engine case 97 - Installing the primary gear with the free-wheel-gear 98 - Installing the oil pumps 98 - Installing the oil pump gears 99 - Installing the locking lever 99 - Installing the shift drum locating 99 - Installing the shift shaft 99 - Installing the kickstarter idler gear 100 - Installing the kickstarter shaft 100 - Installing the starter idler gear 100 - Installing the torque limiter 100 - Installing the balancer shaft 101 - Installing the outer clutch hub 101 - Installing the primary gear nut 101 - Installing the clutch discs 102 - Installing the clutch cover 102 - Installing the water pump cover 103 - Installing the kickstarter 103 - Installing the suction pump 103 - Installing the ignition pulse generator 104 - Installing the timing chain 104 - Installing the timing chain securing guide 104 - Installing the timing chain tensioning rail 104 - Installing the timing chain guide rail 105 - Installing the balance weight 105 - Installing the rotor 105 - Installing the piston 105 - Installing the cylinder head 107 - Installing the camshaft 108 - Installing the timing chain tensioner 108 - Checking the valve clearance 109 - Adjusting the valve clearance 109 - Installing the generator cover 109 - Installing the shift lever 110 - Installing the valve cover 110 - Installing the spark plug 110 - Installing the starter motor 111 - Mounting oil filter 111 - Filling up with engine oil 111 - Filling up with gear oil 112 - Removing the engine from the universal mounting rack 112 - 31/CARBURETOR 113 - Choke (EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W) 113 - Choke (EXC-R EU) 113 - Checking the choke Bowden cable routing (EXC-R EU) 113 - Checking the choke Bowden cable for play (EXC-R EU) 113 - Adjusting the choke Bowden cable play (EXC-R EU) 113 - Checking gas Bowden cable route 114 - Checking play in the gas Bowden cable 114 - Adjusting the gas Bowden cable play 114 - Removing the carburetor 115 - Disassembling the carburetor 115 - Checking the carburetor components 118 - Checking/adjusting the accelerator pump 118 - Checking the choke slide 119 - Checking the jet needle 119 - Checking the throttle slide 119 - Checking the needle jet 120 - Checking the float needle valve 120 - Checking/adjusting the float level 120 - Checking/adjusting the throttle slide opening 120 - Checking throttle valve sensor TPS 121 - Adjusting the position of throttle valve sensor TPS 121 - Assembling the carburetor 122 - Installing the carburetor 125 - Carburetor - adjusting idle 126 - Emptying the carburetor float chamber 127 - 32/CLUTCH 129 - Checking fluid level of hydraulic clutch 129 - Changing fluid level of hydraulic clutch 129 - 33/TRANSMISSION 131 - Removing the engine sprocket 131 - Installing the engine sprocket 131 - 35/WATER PUMP, COOLING SYSTEM 132 - Checking antifreeze and coolant level 132 - Checking the coolant level 132 - Draining coolant 133 - Refilling coolant 133 - 38/LUBRICATION SYSTEM 134 - Oil cycle 134 - Checking engine oil level 134 - Changing engine oil and oil filter, cleaning engine oil screen 135 - Draining engine oil, cleaning engine oil screen 135 - Removing the oil filter 135 - Mounting oil filter 136 - Filling up with engine oil 136 - Topping up engine oil 137 - Checking the engine oil pressure 137 - Checking gear oil level 138 - Changing gear oil, cleaning gear oil screen 138 - Draining gear oil, cleaning gear oil screen 138 - Filling up with gear oil 139 - Topping up with gear oil 139 - TROUBLESHOOTING 140 - TECHNICAL DATA - ENGINE 142 - Capacity- engine oil 142 - Capacity - gear oil 142 - Capacity - coolant 143 - TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE 144 - TECHNICAL DATA - ENGINE TIGHTENING TORQUES 145 - TECHNICAL DATA - CARBURETOR 147 - 450 EXC-R EU, 450 EXC-R AUS/UK (3900I) 147 - 450 EXC-R SIX DAYS, 450 EXC-R USA, 450 XCR-W (3900L) 147 - 530 EXC-R EU, 530 EXC-R AUS/UK (3900J) 148 - 530 EXC-R SIX DAYS, 530 EXC-R USA, 530 XCR-W (3900M) 148 - TECHNICAL DATA - CARBURETOR TIGHTENING TORQUES 149 - TECHNICAL DATA - CHASSIS 150 - Lighting equipment 151 - Tires 151 - Capacity - fuel 151 - TECHNICAL DATA - FORK 152 - TECHNICAL DATA - SHOCK ABSORBER 153 - TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 154 - CLEANING 155 - Cleaning motorcycle 155 - STORAGE 156 - Storage 156 - Putting into operation after storage 156 - GREASING AND SERVICE TABLE 157 - Important maintenance work to be carried out by an authorized KTM workshop 157 - Important maintenance work to be carried out by an authorized KTM workshop (as additional order) 158 - Important checks and maintenance work to be carried out by the rider 158 - WIRING DIAGRAM 160 - Wiring diagram (EXC-R EU) 160 - Wiring diagram (EXC-R AUS/UK) 162 - Wiring diagram (EXC-R USA) 164 - Wiring diagram (EXC-R SIX DAYS) 168 - Wiring diagram (XCR-W USA) 170 - Wiring diagram (XCR-W ZA) 172 - SUBSTANCES 174 - AUXILIARY SUBSTANCES 175 - SPECIAL TOOLS 177 - STANDARDS 184 - INDEX 185 OWNERS MANUAL - MEANS OF REPRESENTATION 5 - IMPORTANT NOTES 6 - LOCATION OF SERIAL NUMBERS 8 - Chassis number 8 - Type label 8 - Key number (EXC-R EU, EXC-R AUS/UK, EXC-R USA) 8 - Engine number 8 - Fork part number 8 - Shock absorber part number 9 - OPERATING ELEMENTS 10 - Clutch lever 10 - Hand brake lever 10 - Short circuit button (EVERY XCR-W MODELS) 10 - Short circuit button (EXC-R EU, EXC-R AUS/UK, - EXC-R SIX DAYS) 10 - Emergency OFF switch (EXC-R AUS/UK) 10 - Emergency OFF switch (EXC-R USA) 11 - Ignition switch (EXC-R USA) 11 - Electric starter button (EXC-R EU, EXC-R SIX DAYS, - EXC-R USA, XCR-W) 11 - Electric starter button (EXC-R AUS/UK) 11 - Light switch (EXC-R EU, EXC-R AUS/UK, - EXC-R SIX DAYS) 11 - Light switch (EVERY XCR-W MODELS) 12 - Light switch (EXC-R USA) 12 - Headlight flasher switch (EXC-R USA) 12 - Horn (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS) 12 - Horn (EXC-R USA) 12 - Flasher switch (EXC-R EU, EXC-R AUS/UK) 13 - Flasher switch (EXC-R USA) 13 - Overview of indicator lamps (EXC-R EU, EXC-R AUS/UK, - EXC-R USA) 13 - Overview of indicator lamps (EXC-R SIX DAYS) 13 - Speedometer 13 - Speedometer activation and test 14 - Tripmaster switch 14 - Setting kilometers or miles 14 - Setting the clock 15 - Adjusting speedometer functions 15 - Querying lap time 16 - Display mode SPEED 16 - Display mode SPEED/H (service hours) 16 - Display mode SPEED / CLK (time) 17 - Display mode SPEED/LAP (lap time) 17 - Display mode SPEED/ODO (odometer) 17 - Display mode SPEED/TR1 (trip master 1) 17 - Display mode SPEED/TR2 (trip master 2) 18 - Disply mode SPEED/A1 (average speed 1) 18 - Display mode SPEED/A2 (average speed 2) 18 - Display mode SPEED/S1 (stop watch 1) 19 - Display mode SPEED/S2 (stop watch 2) 19 - Fuel tap 20 - Opening filler cap 20 - Closing filler cap 20 - Choke (EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, - XCR-W) 21 - Choke (EXC-R EU) 21 - Shift lever 21 - Foot brake pedal 21 - Kickstarter 22 - Side stand 22 - Steering lock (EXC-R EU, EXC-R AUS/UK, EXC-R USA) 22 - Locking the steering (EXC-R EU, EXC-R AUS/UK, - EXC-R USA) 22 - Unlocking the steering (EXC-R EU, EXC-R AUS/UK, - EXC-R USA) 23 - GENERAL TIPS AND HINTS ON PUTTING INTO - OPERATION 24 - Advice on first use 24 - Running in the engine 25 - RIDING INSTRUCTIONS 26 - Checks before putting into operation 26 - Starting 26 - Starting up 27 - Shifting, riding 27 - Braking 27 - Stopping, parking 28 - Refueling 28 - GREASING AND SERVICE TABLE 29 - Important maintenance work to be carried out by an - authorized KTM workshop 29 - Important maintenance work to be carried out by an - authorized KTM workshop (as additional order) 30 - Important checks and maintenance work to be carried - out by the rider 30 - MAINTENANCE WORK ON CHASSIS AND ENGINE 32 - Jacking up the motorcycle 32 - Removing the motorcycle from the work stand 32 - Checking the basic chassis setting with the rider's - weight 32 - Compression damping of shock absorber 32 - Adjusting high-speed compression damping of the shock - absorber 32 - Adjusting the low-speed compression damping of the - shock absorber 33 - Adjusting rebound damping of the shock absorber 33 - Measuring rear wheel sag unloaded 34 - Checking static sag of the shock absorber 34 - Checking the riding sag of the shock absorber 35 - Adjusting spring preload of the shock absorber 35 - Adjusting riding sag 36 - Removing the shock absorber 36 - Installing shock absorber 36 - Checking basic setting of fork 37 - Adjusting compression damping of fork 37 - Adjusting rebound damping of fork 37 - Adjusting spring preload of the fork 38 - Bleeding fork legs 38 - Cleaning dust boots of fork legs 39 - Loosening the fork protection 39 - Positioning the fork protection 39 - Checking play of steering head bearing 39 - Adjusting play of steering head bearing (EXC-R EU, - EXC-R AUS/UK, EXC-R USA, XCR-W ZA) 40 - Adjusting play of steering head bearing - (EXC-R SIX DAYS, XCR-W USA) 40 - Fork offset (EXC-R SIX DAYS, XCR-W USA) 41 - Setting the fork offset (EXC-R SIX DAYS, - XCR-W USA) 41 - Removing the fork legs 41 - Installing the fork legs 42 - Removing the fork protector 43 - Installing the fork protector 43 - Removing the lower triple clamp (EXC-R SIX DAYS, - XCR-W USA) 43 - Removing the lower triple clamp (EXC-R EU, - EXC-R AUS/UK, EXC-R USA, XCR-W ZA) 44 - Installing the lower triple clamp (EXC-R SIX DAYS, - XCR-W USA) 44 - Installing the lower triple clamp (EXC-R EU, - EXC-R AUS/UK, EXC-R USA, XCR-W ZA) 45 - Greasing the steering head bearing 46 - Dismounting the front fender 46 - Installing the front fender 46 - Removing headlight mask with headlight (EXC-R EU, - EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, - XCR-W ZA) 46 - Refitting the headlight mask with the headlight - (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS, - EXC-R USA, XCR-W ZA) 47 AND MORE...
KTM 400, 450, 530, EXC, XC-W, SIX DAYS - Repair, Workshop Manual, Wiring Diagrams and Owners Manual
inicio - index
coche - car
moto
4x4
quad - buggy
cami?n - truck
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