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KTM Manuals
Motorcycle
400 EXC AUS 2011
Repair manual
KTM 400 EXC AUS 2011 Repair Manual
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Also See for 400 EXC AUS 2011
:
Setup instructions
(16 pages)
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Contents
Table of Contents
Bookmarks
Table of Contents
Table of Contents
Means of Representation
Important Notes
Serial Numbers
Chassis Number
Type Label
Key Number (All EXC Models)
Engine Number
Fork Part Number
Shock Absorber Part Number
Motorcycle
Raising the Motorcycle with the Lift Stand
Removi Ng the Motorcycle from the I Ift Stand
Starting
Starting the Motorcycle for a Check
Ollfork, TRIPLE CLAMP
Adjusting the Compression Damping of the Fork
Adjusling Ihe Rebound Damping of Ihe Fork
Adjusling Spring Preload of Ihe Fork
Bleeding Fork Legs
Cleaning the Dust Bools of Ihe Fork Legs
Loosening the Fork Protector
Positioning the Fork Protector
Removing the Fork Legs
Inslalling Fork Legs
Removing the Fork Proteclor
Inslalling Ihe Fork Protector
Performing a Fork Service
Disassembling the Fork Legs
Cartridge Disassembly
Disassembling the Compression Damping Fitting
Checking the Fork Legs
Assembling Ihe Compression Damping Fitting
Assembling Ihe Cartridge
Assembling the Fork Legs
Greasing the Steering Head Bearing
Removing the Lower Triple Clamp (EXC USA, All SIX DAYS Models)
Inslalling Ihe Lower Triple Clamp (EXC USA, All SIX DAYS Models)
Removing the Lower Triple Clamp (EXC EU/AUS)
Installing the Lower Triple Clamp (EXC Euiaus)
Fork Offset (XC-W SIX DAYS)
Setting the Fork Offset (XC-W SIX DAYS)
Checking the Steering Head Bearing Play
SIX DAYS Models)
Adjusling Play of Steering Head Bearing (EXC EU/AUS)
02/Handlebar, Instruments
Handlebar Position
Adjusting Handlebar Position
Adjusling the Basic Position of Ihe Clulch Lever
Checking the Choke Cable Routing
Exc Six Days)
Checking the Choke Cable Play (EXC EU, EXC SIX DAYS)
Adjusting the Choke Cable Play (EXC EU, EXC SIX DAYS)
Checking the Throttle Cable Routing
Checking the Play in Ihe Throttle Cable
Adjusling 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 Ihe Shock Absorber
Adjusting Rebound Damping of the Shock Absorber
Measuring Rear Wheel Sag Unloaded
Checking the Static Sag of the Shock Absorber
Checking Ihe Riding Sag of Ihe Shock Absorber
Adjusting the Spring Preload of the Shock Absorber
Adjusting the Riding Sag
Removi Ng the Shock Absorber
Installing the Shock Absorber
Perform a Shock Absorber Service
Removing the Spring
Disassembling the Damper
Disassembling the Pislon Rod
Disassembling the Seal Ring Retainer
Replacing the Pilot Bushing
Checking the Damper
Disassembling the Rebound Adjuster
Removing the Heim Joint
Installing the Heim Joint
Assembling the Rebound Adjuster
Assembling the Seal Ring Retainer
Assembling the Piston Rod
Assembling the Damper
Bleeding and Filling the Damper
Filling Ihe Damper Wilh Nitrogen
Installing the Spring
Changing the Heim Joint
05/Exhaust
Removing the Manifold
Installing the Manifold
Removi Ng Mai N si Lencer
Installing the Main Silencer
Changing the Glass Fiber Yarn Filling of the Main Silencer
06/Air Filter
Removing the Air Filter Box Lid
Installing the Air Filter Box Lid
Removing the Air Filter
Installing the Air Filter
Cleaning the Air Filter and Air Filler Box
Removing the Carburetor Connection Boot
Installing the Carburetor Connection Boot
07/Fuel Tank, Seat, Trim
Opening Filler Cap
Closing Filler Cap
Removi Ng the Seal
Mounting the Seal
Removing the Fuel Tank
Installing the Fuel Tank
Fuel Tap
08!Mask, Fender
Removi Ng the Front Fender
Install I Ng the Front Fender
Removing Headlight Mask with Headlight
Refitting the Headlight Mask with the Headlight
09/Front Wheel
Removi Ng Front Wheel
Checking the Brake Discs
Removing the Iront Brake Disc
Install I Ng the Front Wheel
Installing the Front Brake Disc
Checking the Tire Condition
Checking Tire Air Pressure
Checking Spoke Tension
Lo/Rear WHEEL
Removing the Rear Wheel
Installing the Rear Wheel
Removing the Rear Brake Disc
Installing the Rear Brake Disc
Checking the Chain Tension
Adjusting the Chain Tension
Adjusting Chain Guide
Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide
Checking for Chain Dirt Accumulation
Clean I Ng the Chai N
11IWIRING HARNESS, Battery
Removing the Main Fuse
Installing the Main Fuse
XC-W Six Days)
Removi Ng the Battery
Installing the Battery
Rechargi Ng the Battery
Checking the Quiescent Current
Checking the Charging Voltage
Checking the Voltage Regulator
Checking the Starter Relay
13/Brake System
Checking the Front Brake Linings
Removing Front Brake Linings
Installing the Front Brake Linings
Changing the Front Brake Linings
Checking Free Travel of Hand Brake Lever
(XC-W SIX Days)
Models)
Checking the Brake Iluid Level of the Iront Brake
Adding Iront Brake Iluid
Changing the Iront Brake Iluid
Checking Rear Brake Linings
Removing Rear Brake Linings
Mounting Rear Brake Linings
Changing the Rear Brake Linings
Checking the Iree Travel of the Loot Brake Lever
Adjusting the Basic Position 01 the Loot Brake Lever
Checking Rear Brake Iluid Level
Adding Brake Fluid to the Rear Brake Circuit
Changing the Rear Brake Iluid
14/Lighting SYSTEM, INSTRUMENTS
Adjusting the Speedometer Lunctions
Setting Kilometers or Miles
Activating the Additional Lunctions
Setting the Wheel Circumference
Setting the Clock
Checking the Headlight Adjustment
Adjusting the Headlight Range
Engine
Removing the Engine
Installing the Engine
Disassembling the Engine
Preparations
Draining the Engine Oil
Removing the Oil Lilter
Draining the Gear Oil, Removing the Gear Oil Screen
Removi Ng the Starter Motor
Removi Ng the Spark Pi Ug
Removing the Valve Cover
Removing the Shift Lever
Removi Ng the Alternator Cover
Positioning the Engine at Ignition Top Dead Center
Removing the Timing Chain Tensioner
Removing the Camshaft
Removing the Cylinder Head
Removing the Piston
Removi Ng 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
Disassembling the Clutch Disks
Removi Ng the Pri Mary Gear Nut
Removing the Outer Clutch Hub
Removing the Balancer Shaft
Removing the Torque Limiter
Removing the Starter Idler Gear
Removing the Kickstarter Idler Gear
Removing the Kickstarter Idler Gear
Removing the Shift Shaft
Removing the Shift Drum Locating Unit
Removing the Locking Lever
Removing the Oil Pump Gears
Removing the Oil Pumps
Removing the Primary Gear
Removing the Iree Wheel Gear
Removi Ng the Left Section 01 the Engi Ne Case
Removing the Shift Rails
Removing the Shift Drum
Removing the Shift Lorks
Removing the Transmission Shafts
Removing the Crankshaft
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
Installing the Crankshaft Seal Ring in 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, Conrad 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 End Gap
Piston/Cylinder - Determining the Mounting Clearance
Checking the Oil Pumps
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 the Valves
Installing the Rocker Arm
Checking the Clutch
Checking Shift Mechanism
Preassembling the Shift Shaft
Disassembling the Main Shaft
Assembling the Main Shaft
Disassembling 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 Shafts
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 Uni
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 Timing Chain Tensioner
Installing the Camshaft
Checking the Valve Clearance
Adjusting the Valve Clearance
Installing the Alternator Cover
Installing the Shift Lever
Installing the Valve Cover
Installing the Spark Plug
Installing the Starter Motor
Installing the Oil Filter
Filling up with Engine Oil
Filling up with Gear Oil
Removing the Engine from the Work Stand
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400 EXC EU
400 EXC AUS
450 EXC EU
450 EXC AUS
450 EXC SIX DAYS EU
450 EXC USA
450 XC-W SIX DAYS USA
530 EXC EU
530 EXC AUS
530 EXC SIX DAYS EU
530 EXC USA
530 XC-W SIX DAYS USA
Art. no. 320609gen
400 EXC EU
400 EXC AUS
450 EXC EU
450 EXC AUS
450 EXC SIX DAYS EU
450 EXC USA
450 XC-W SIX DAYS USA
530 EXC EU
530 EXC AUS
530 EXC SIX DAYS EU
530 EXC USA
530 XC-W SIX DAYS USA
Art. no. 320609gen
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This manual is also suitable for:
450 exc aus 2011
400 exc eu 2011
450 exc six days eu 2011
450 exc usa 2011
450 xc-w six days usa 2011
530 exc eu 2011
...
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530 exc aus 2011
530 exc six days eu 2011
530 exc usa 2011
530 xc-w six days usa 2011
450 exc eu 2011
530 xc-w za 2009
400 exc eu 2009
400 xc-w usa 2009
450 exc aus 2009
450 exc eu 2009
450 exc six days eu 2009
450 exc usa 2009
450 xc-w usa 2009
530 exc eu 2009
450 xc-w za 2009
530 exc six days eu 2009
530 exc aus 2009
530 xc-w usa 2009
530 exc usa 2009
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