KTM 400 EXC EU Owner's Manual
2009 year
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Also See for 400 EXC EU:
- Owner's manual (123 pages) ,
- Repair manual (12 pages) ,
- Setup instructions (16 pages)
Related Manuals for KTM 400 EXC EU
Summary of Contents for KTM 400 EXC EU
- Page 1 OWNER'S MANUAL 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...
- Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors.
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Page 4: Table Of Contents
Key number (all EXC models) ........... 9 Important maintenance work to be carried out by an Engine number..............9 authorized KTM workshop. (as additional order)....31 Fork part number............. 9 Important checks and maintenance work to be carried Shock absorber part number........... 10 out by the rider. - Page 5 CONTENTS Dismount the start number plate (XC‑W USA)....48 Dismounting the air filter box lid........74 Installing the start number plate (XC‑W USA) ....48 Installing the air filter box lid.......... 74 Handlebar position ............48 Removing the air filter ..........
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Page 6: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required. -
Page 7: Important Notes
Warranty The work prescribed in the service schedule must be carried out in an authorized KTM workshop and confirmed in the customer's ser- vice record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle. - Page 8 IMPORTANT NOTES – 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- tial problem for the environment and can lead to conflicts with other persons.
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Page 9: View Of Vehicle
VIEW OF VEHICLE 3 V IEW OF VEHICLE View of the vehicle from the left front (example) 800014-10 Side stand Shift lever Chain guide Fuel tap Air filter box lid Clutch lever Hand brake lever... -
Page 10: View Of The Vehicle From The Right Rear (Example)
VIEW OF VEHICLE View of the vehicle from the right rear (example) 800013-10 Level viewer for brake fluid, rear Fork compression adjustment Foot brake pedal Kickstarter Horn Filler cap Fork rebound adjustment Electric starter button Speedometer Short circuit button Shock absorber compression adjustment Shock absorber rebound adjustment... -
Page 11: Location Of Serial Numbers
LOCATION OF SERIAL NUMBERS 4 L OCATION OF SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. 500127-10 Type label The type label is fixed to the front of the steering head. ... -
Page 12: Shock Absorber Part Number
LOCATION OF SERIAL NUMBERS Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side. 500129-10... -
Page 13: Operating Elements
OPERATING ELEMENTS 5 O PERATING ELEMENTS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 500133-10 Hand brake lever Hand brake lever is located on the right side of the handlebar. ... -
Page 14: Electric Starter Button (Exc Eu, Exc Six Days, Xc-W)
OPERATING ELEMENTS Electric starter button (EXC EU, EXC SIX DAYS, XC-W) The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position pressed – In this position, the electric starter is actuated. •... -
Page 15: Flasher Switch (All Exc Models)
OPERATING ELEMENTS Flasher switch (all EXC models) 5.11 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 –... -
Page 16: Tripmaster Switch
OPERATING ELEMENTS Tripmaster switch 5.15 (Option: Tripmaster 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. Setting kilometers or miles 5.16 Info If you change the unit, the value ODO is retained and converted accordingly. The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed. -
Page 17: Adjusting The Speedometer Functions
OPERATING ELEMENTS Adjusting the speedometer functions 5.18 Info Upon delivery, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is standing. – briefly and repeatedly until H appears at the bottom right of the Press the button display. -
Page 18: Speed Display Mode (Speed)
OPERATING ELEMENTS SPEED display mode (speed) 5.20 – 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. -
Page 19: Speed/Odo Display Mode (Odometer)
OPERATING ELEMENTS Press the button next display mode briefly. SPEED/ODO display mode (odometer) 5.24 – briefly and repeatedly until ODO appears at the bottom right of Press the button the display. The total number of kilometers ridden is shown in the ODO display mode. Press the button . -
Page 20: Speed/A1 Display Mode (Average Speed 1)
OPERATING ELEMENTS SPEED/A1 display mode (average speed 1) 5.27 – 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). - Page 21 OPERATING ELEMENTS Table of functions Display Press the button Press the button Press the button for 3 - Press the button 5 seconds. briefly. SPEED/H display mode No function No function The display changes to next display mode (service hours) the Setup menu of the speedometer functions.
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Page 22: Fuel Tap
OPERATING ELEMENTS Fuel tap 5.31 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. •... -
Page 23: Choke (Exc Eu, Exc Six Days)
OPERATING ELEMENTS Choke (EXC EU, EXC SIX DAYS) 5.35 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 must be deactivated. -
Page 24: Side Stand
OPERATING ELEMENTS Side stand 5.39 Note Danger of damage 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. –... -
Page 25: Unlocking The Steering (All Exc Models)
OPERATING ELEMENTS Unlocking the steering (all EXC models) 5.42 – 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. -
Page 26: General Tips And Hints On Putting Into Operation
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover. -
Page 27: Running In The Engine
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION – 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. -
Page 28: Riding Instructions
RIDING INSTRUCTIONS 7 R IDING INSTRUCTIONS Checks before putting into operation 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. –... -
Page 29: Starting Up
Do not change into a low gear at high engine speed. The engine races and the rear wheel can block. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines. -
Page 30: Stopping, Parking
RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation 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. –... - Page 31 RIDING INSTRUCTIONS – Fill the fuel tank with fuel up to measurement Guideline Measurement of 35 mm (1.38 in) Total fuel tank 9.0 l Super unleaded (ROZ 95 / RON 95 / capacity, (2.38 US gal) PON 91) ( p.
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Page 32: Service Schedule
SERVICE SCHEDULE 8 S ERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop. S15A S30A Engine Change the engine oil and oil filter and clean the engine oil screen. p. 80) • • • Change the gear oil and clean the gear oil screen. -
Page 33: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop. (As Additional Order)
SERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) Competition use Hobby use S15A S30A S45A S30A S60A S90A • • Carry out a complete fork service. Carry out a complete shock absorber service. - Page 34 SERVICE SCHEDULE 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. p.
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Page 35: Maintenance Work On Chassis And Engine
For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swing arm and frame, the basic set- tings of the suspension components must match your body weight. – As delivered, KTM offroad motorcycles are adjusted for a standard rider weight (with full protective clothing). Guideline Standard rider weight 75…... -
Page 36: Adjusting The Low-Speed Compression Damping Of The Shock Absorber
MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn the adjusting screw clockwise with a ring wrench until it stops. Info Do not loosen nut – Turn back counterclockwise the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-speed 400208-10... -
Page 37: Measuring Rear Wheel Sag Unloaded
MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn the adjusting screw clockwise until it stops. Info Do not loosen nut – Turn back counterclockwise the number of clicks corresponding to the shock absorber type. Guideline Rebound damping 400210-10 Comfort 26 clicks Standard... -
Page 38: Checking The Riding Sag Of The Shock Absorber
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the riding sag of the shock absorber 9.10 – 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 and down a few times until the rear suspension levels out. -
Page 39: Adjusting Riding Sag
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting riding sag 9.12 – Remove shock absorber. 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…... -
Page 40: Checking Basic Setting Of Fork
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking basic setting of fork 9.15 Info For various reasons, no exact riding sag can be determined for the forks. – As with the shock absorber, smaller weight differences can be compensated by the spring preload. -
Page 41: Adjusting Spring Preload Of The Fork
MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn back counterclockwise 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. -
Page 42: Loosening The Fork Protection
Danger of accidents Unsafe riding behavior due to incorrect steering head bearing play. – The steering head bearing play should be adjusted immediately in an authorized KTM workshop. Info If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time. -
Page 43: Adjusting Play Of Steering Head Bearing (Exc Eu, Exc Aus, Xc-W Za)
MAINTENANCE WORK ON CHASSIS AND ENGINE – 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) –... -
Page 44: Removing The Fork Legs
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the fork legs 9.26 – Remove the front wheel. p. 64) – Remove screws and take off clamp. – Remove cable clip , remove screw and take off the brake caliper. ... -
Page 45: Removing The Fork Protector
MAINTENANCE WORK ON CHASSIS AND ENGINE (EXC EU, EXC AUS, XC‑W ZA) – Fully tighten screw Guideline Screw, top triple clamp 20 Nm (14.8 lbf ft) – Fully tighten screw Guideline Screw, bottom triple clamp 15 Nm 100023-10 (11.1 lbf ft) –... -
Page 46: Removing The Lower Triple Clamp (Exc Eu, Exc Aus, Xc-W Za)
MAINTENANCE WORK ON CHASSIS AND ENGINE – 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 ... -
Page 47: Installing The Lower Triple Clamp (Exc Six Days, Xc-W Usa)
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the lower triple clamp (EXC SIX DAYS, XC‑W USA) 9.32 – Clean the bearing and sealing elements, check for damage, and grease. Long-life grease ( p. 107) 0 0 3 – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. -
Page 48: Installing The Lower Triple Clamp (Exc Eu, Exc Aus, Xc-W Za)
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the lower triple clamp (EXC EU, EXC AUS, XC‑W ZA) 9.33 – 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. -
Page 49: Dismounting The Front Fender
MAINTENANCE WORK ON CHASSIS AND ENGINE Dismounting the front fender 9.35 – Remove screws . Remove the front fender. – Make sure that the distance bushings remain in place. 500092-10 Installing the front fender 9.36 – Ensure that the spacing sleeves are mounted in the fender. –... -
Page 50: Dismount The Start Number Plate (Xc-W Usa)
MAINTENANCE WORK ON CHASSIS AND ENGINE – 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 ... - Page 51 MAINTENANCE WORK ON CHASSIS AND ENGINE – Place the handlebar support in the required position. Fit and tighten the two screws Guideline Loctite ® 243™ Screw, handlebar support M10 40 Nm (29.5 lbf ft) Info Position the left and right handlebar supports evenly. –...
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Page 52: Checking Gas Bowden Cable Route
MAINTENANCE WORK ON CHASSIS AND ENGINE – 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 (SXS05125205) Info The elastomers are available in different versions. -
Page 53: Checking For Chain Dirt Accumulation
MAINTENANCE WORK ON CHASSIS AND ENGINE – 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 ... -
Page 54: Checking The Chain Tension
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the chain tension 9.48 Warning Danger of accidents 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. -
Page 55: Checking Chain Wear
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking chain wear 9.51 – Jack up the motorcycle. ( p. 33) – Shift gear to neutral. – Pull the upper chain section with the specified weight Guideline 0 0 A Weight of chain wear measurement 10…... -
Page 56: Adjusting Chain Tension - After Checking
MAINTENANCE WORK ON CHASSIS AND ENGINE – 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 ... -
Page 57: Adjusting Chain Tension - Fitting Rear Wheel
Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 400252-10 Checking the brake discs 9.56 Warning Danger of accidents Reduced braking due to worn brake discs. – Worn brake discs should be replaced immediately in an authorized KTM workshop. -
Page 58: Checking Free Travel Of Hand Brake Lever
MAINTENANCE WORK ON CHASSIS AND ENGINE – 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. -
Page 59: Adjusting Free Travel Of Handbrake Lever (All Exc Models)
Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. -
Page 60: Checking The Front Brake Linings
Warning Danger of accidents Improper brake maintenance and repair. – Always have your brake system maintained and repaired in an authorized KTM workshop. – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons. -
Page 61: Mounting Front Brake Linings
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license. -
Page 62: Checking Free Travel Of Foot Brake Lever
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove the front brake linings. 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 from the brake fluid reservoir. -
Page 63: Checking The Rear Brake Fluid Level
Have the brake system checked in an authorized KTM workshop, and do not ride any further. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. – Stand the vehicle upright. –... -
Page 64: Checking The Rear Brake Linings
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license. -
Page 65: Changing The Rear Brake Linings
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –... -
Page 66: Removing The Front Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the front wheel 9.74 – Jack up the motorcycle. ( p. 33) – 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. -
Page 67: Removing Rear Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE – 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. -
Page 68: Tire Condition Checking
9.78 Info Only mount tires approved or recommended by KTM. Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle. -
Page 69: Checking Tire Air Pressure
Danger of accidents Unstable riding behavior due to loose spokes. – If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop. Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time. -
Page 70: Installing The Battery
MAINTENANCE WORK ON CHASSIS AND ENGINE – 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. ... -
Page 71: Removing A Fuse
Replace a burned-out fuse only by an equivalent fuse. If the new fuse burns out, contact an authorized KTM workshop. – Replace the protection cover. 400273-10 – Install the air filter box lid. ( p. -
Page 72: Mounting The Seat
MAINTENANCE WORK ON CHASSIS AND ENGINE Mounting the seat 9.87 – 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. –... -
Page 73: Installing The Fuel Tank
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the fuel tank 9.89 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. -
Page 74: Checking Antifreeze And Coolant Level
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking antifreeze and coolant level 9.91 Warning Danger of scalding 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. -
Page 75: Draining Coolant
MAINTENANCE WORK ON CHASSIS AND ENGINE Draining coolant 9.93 Warning Danger of scalding 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. -
Page 76: Removing Main Silencer
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing main silencer 9.96 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. – Disconnect spring ... -
Page 77: Removing The Air Filter
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the air filter 9.100 Note Engine failure Unfiltered 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 hazard Problem materials cause environmental damage. -
Page 78: Adjusting Basic Position Of Clutch Lever
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting basic position of clutch lever 9.103 – 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. -
Page 79: Carburetor - Idle
MAINTENANCE WORK ON CHASSIS AND ENGINE – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane 400339-10 – Fill bleeding syringe with the appropriate hydraulic fluid. ... -
Page 80: Carburetor - Adjusting Idle
MAINTENANCE WORK ON CHASSIS AND ENGINE Carburetor - adjusting idle 9.107 – 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 turns... -
Page 81: Emptying The Carburetor Float Chamber
MAINTENANCE WORK ON CHASSIS AND ENGINE – 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. -
Page 82: Changing Engine Oil And Oil Filter, Cleaning Engine Oil Screen
MAINTENANCE WORK ON CHASSIS AND ENGINE 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: –... -
Page 83: Mounting Oil Filter
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screws . Remove oil filter cover with O-ring. 200113-10 – Pull the oil filter insert out of the oil filter casing. Circlip pliers reverse (51012011000) – Completely drain the engine oil. –... -
Page 84: Topping Up Engine Oil
MAINTENANCE WORK ON CHASSIS AND ENGINE Topping up engine oil 9.115 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – Remove the screw cap on the generator cover and fill up with engine oil. ... -
Page 85: Filling Up With Gear Oil
MAINTENANCE WORK ON CHASSIS AND ENGINE – 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. –... - Page 86 MAINTENANCE WORK ON CHASSIS AND ENGINE – 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) –...
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Page 87: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (electric Operating error Go through the steps of starting the starter). engine. ( p. 26) – Battery discharged Recharge the battery. p. 68) – Check the charging voltage. –... - Page 88 TROUBLESHOOTING 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. – Air filter very dirty Clean the air filter. p. 75) –...
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Page 89: Cleaning
CLEANING CLEANING Cleaning motorcycle 11.1 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 can damage or destroy these parts. Warning Environmental hazard Problem materials cause environmental damage. -
Page 90: Storage
Storage temperature of battery without direct sunshine. 0… 35 °C (32… 95 °F) – The storage place should be dry and not subject to large temperature differences. Info KTM recommends propping up the motorcycle. – Jack up the motorcycle. ( p. 33) –... -
Page 91: Technical Data - Engine
TECHNICAL DATA - ENGINE 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) -
Page 92: Capacity - Gear Oil
TECHNICAL DATA - ENGINE Capacity - gear oil 13.2 Gear oil 0.90 l (0.95 qt.) Engine oil (SAE 10W/50) ( p. 106) Capacity - coolant 13.3 Coolant 0.95 l (1 qt.) Coolant ( p. 106) Coolant (mixed ready to use) ( p. -
Page 93: Technical Data - Engine Tightening Torques
TECHNICAL DATA - ENGINE TIGHTENING TORQUES TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Screw, cable holder in generator cover 4 Nm (3 lbf ft) Loctite 243™ ® Oil jet, rocker arm lubrication 2 Nm (1.5 lbf ft) Loctite 243™ ® Oil jet, piston cooling 2 Nm (1.5 lbf ft) Loctite... - Page 94 TECHNICAL DATA - ENGINE TIGHTENING TORQUES Screw, cylinder head M10x1.25 Tightening sequence: lubricated with engine oil 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) –...
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Page 95: Technical Data - Carburetor
TECHNICAL DATA - CARBURETOR TECHNICAL DATA - CARBURETOR 400 EXC 15.1 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 Jet needle OBDYU (OBDTQ) -
Page 96: 450 Xc-W
TECHNICAL DATA - CARBURETOR 450 XC-W 15.4 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) -
Page 97: Technical Data - Chassis
TECHNICAL DATA - CHASSIS TECHNICAL DATA - CHASSIS Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Suspension 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) -
Page 98: Tires
80/100 - 21 51M TT 110/100 - 18 64M TT Bridgestone M59 Bridgestone M402 For further information, see the Service section under: http://www.ktm.com Capacity - fuel 16.3 Total fuel tank capacity, 9.0 l (2.38 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. -
Page 99: Technical Data - Fork
TECHNICAL DATA - FORK TECHNICAL DATA - FORK Fork part number 14.18.7E.06 Fork WP Suspension 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... -
Page 100: Technical Data - Shock Absorber
TECHNICAL DATA - SHOCK ABSORBER 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... -
Page 101: Technical Data - Chassis Tightening Torques
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Spoke nipple, front wheel M4,5 5 Nm (3.7 lbf ft) – Spoke nipple, rear wheel 5 Nm (3.7 lbf ft) – Screw, spoiler on fuel tank (XC‑W USA) M5x12 1.5 Nm (1.11 lbf ft) –... -
Page 102: Wiring Diagram
WIRING DIAGRAM WIRING DIAGRAM Wiring diagram (all EXC models) 20.1 CX/2 CZ/3 DB/4 CW/2 DA/4 CY/3 AK1/2 DG/4 CW2/2 CW3/2 AH1/2 BP/4 CX2/2 CX3/2 ye-bl bl-wh bu-wh ye-re ye-re ye-re bu-wh ye-bl re-wh re-bl BA2/1 ye-bl ye-re ye-re wh-re re-bl re-wh CR/1 CR1/1... - Page 103 WIRING DIAGRAM Components CDI controller Throttle position sensor Wheel speed sensor Thermoswitch (EXC SIX DAYS) Battery Generator Right rear flasher Left front flasher Left rear flasher Right front flasher Brake/tail light Parking light License plate lamp Low/high beam Horn Radiator fan (EXC SIX DAYS) Flasher indicator light High beam indicator light Starter relay with main fuse...
- Page 104 WIRING DIAGRAM Yellow ye-bl Yellow-black ye-re Yellow-red...
- Page 105 WIRING DIAGRAM...
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Page 106: Wiring Diagram (All Xc-W Models)
WIRING DIAGRAM Wiring diagram (all XC‑W models) 20.2 bl-wh ye-bl bu-wh bu-wh ye-bl re-wh re-bl ye-re wh-re ye-re re-bl wh-re re-wh ye-re 500248-10... - Page 107 WIRING DIAGRAM Components CDI controller Throttle position sensor Wheel speed sensor Thermoswitch (XC-W ZA) Battery Generator Brake/tail light (XC-W ZA) Parking light (XC-W ZA) Low/high beam (XC-W ZA) Radiator fan (XC-W ZA) Starter relay with main fuse Pulse generator Ignition coil Starter motor Voltage regulator/rectifier Speedometer...
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Page 108: Substances
– 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 FLUID SUPER DOT 4 ®... -
Page 109: Auxiliary Substances
AUXILIARY SUBSTANCES AUXILIARY SUBSTANCES Air filter cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Chain cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Cleaning and polishing materials for metal, rubber and plastic Specification –... - Page 110 AUXILIARY SUBSTANCES Oil for foam air filter Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Liquid Bio Power Universal oil spray Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Joker 440 Universal...
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Page 111: Standards
STANDARDS 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 demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle and ATV engines.With most motorcycles and ATVs, the gearbox and the clutch are lubricated with the same oil as the engine. -
Page 112: Index
INDEX Clutch lever ........11 INDEX adjusting basic position ..... . . 76 Accessories . - Page 113 INDEX removing ....... . . 47 Front wheel Play in gas Bowden cable installing .
- Page 114 INDEX Storage ........88 Technical data Carburetor .
- Page 115 *3211355en* 3211355en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...