Table Of Contents - KTM 400 EXC AUS 2011 Repair Manual

TABLE OF CONTENTS
2
MEANS OF REPRESENTATION ............................................ 6
Installing the engine sprocket cover ................................. 39
IMPORTANT NOTES ............................................................ 7
04/sHOCK ABSORBER, SWINGARM ................................... 40
SERIAL NUMBERS .............................................................. 8
Adjusting high-speed compression damping of the shock
Chassis number ............................................................... 8
absorber.......... ....... .................... .................... .............. 40
Type label ....................................................................... 8
Key number (all EXC models) ........................................... 8
Engine number ................................................................ 9
Fork part number ............................................................. 9
Shock absorber part number ............................................. 9
MOTORCyCLE ................................................................... 10
Adjusting the low-speed compression damping of Ihe
shock absorber .............................................................. 40
Adjusting rebound damping of the shock absorber ............ 41
Measuring rear wheel sag unloaded ................................. 41
Checking the static sag of the shock absorber .................. 41
Checking Ihe riding sag of Ihe shock absorber .................. 42
Raising the motorcycle with the lift stand ........................ 10
Removi ng the motorcycle from the I ift stand .. ....... ....... .... 10
Starting ........................................................................ 10
Starting the motorcycle for a check ................................. 11
OllFORK, TRIPLE CLAMP .................................................. 12
Adjusting the compression damping of the fork ................ 12
Adjusling Ihe rebound damping of Ihe fork ....................... 12
Adjusling spring preload of Ihe fork ................................. 12
Bleeding fork legs .......................................................... 13
Cleaning the dust bools of Ihe fork legs ........................... 13
Loosening the fork protector ........................................... 13
Positioning the fork protector .......................................... 14
Removing the fork legs ................................................... 14
Inslalling fork legs ......................................................... 14
Removing the fork proteclor ............................................ 15
Inslalling Ihe fork protector ............................................ 15
Performing a fork service ................................................ 16
Disassembling the fork legs ............................................ 16
Cartridge disassembly .................................................... 19
Disassembling the compression damping fitting ............... 21
Checking the fork legs .................................................... 21
Assembling Ihe compression damping fitting .................... 22
Assembling Ihe cartridge ................................................ 23
Assembling the fork legs ................................................ 25
Greasing the steering head bearing .................................. 29
Removing the lower triple clamp (EXC USA, all SIX DAYS
models) ........................................................................ 29
Adjusting the spring preload of the shock absorber ........... 42
Adjusting the riding sag ................................................. 43
Removi ng the shock absorber .............. ...... .............. ....... 43
Installing the shock absorber .......................................... 43
Perform a shock absorber service.. ...... ........ ...... .............. 44
Removing the spring ...................................................... 44
Disassembling the damper ............................................. 45
Disassembling the pislon rod .......................................... 46
Disassembling the seal ring retainer ................................ 47
Replacing the pilot bushing ............................................ 48
Checking the damper ..................................................... 48
Disassembling the rebound adjuster ................................ 49
Removing the heim joint ................................................ 50
Installing the heim joint ................................................. 50
Assembling the rebound adjuster .................................... 51
Assembling the seal ring retainer .................................... 52
Assembling the piston rod .............................................. 52
Assembling the damper .................................................. 54
Bleeding and filling the damper ...................................... 56
Filling Ihe damper wilh nitrogen ..................................... 58
Installing the spring ....................................................... 59
Changing the heim joint ................................................. 60
05/EXHAUST .................................................................... 62
Removing the manifold .................................................. 62
Installing the manifold ................................................... 62
Removi ng mai n si lencer .. ...... .............. ...... .............. ....... 62
Installing the main silencer ............................................ 62
Inslalling Ihe lower triple clamp (EXC USA, all SIX DAYS
Changing the glass fiber yarn filling of the main silencer ... 63
models) ........................................................................ 29
06/AIR FILTER .................................................................. 64
Removing the lower triple clamp (EXC EU/AUS) ............... 31
Removing the air filter box lid ......................................... 64
Installing the lower triple clamp (EXC EUiAUS) ................ 32
Installing the air filter box lid .......................................... 64
Fork offset (XC-W SIX DAYS) .......................................... 33
Removing the air filter ................................................... 64
Setting the fork offset (XC-W SIX DAYS) .......................... 34
Installing the air filter .................................................... 64
Checking the steering head bearing play .......................... 34
Cleaning the air filter and air filler box ............................ 65
Adjusling play of steering head bearing (EXC USA, all
Removing the carburetor connection boot ........................ 65
SIX DAYS models) ......................................................... 34
Installing the carburetor connection boot ......................... 65
Adjusling play of steering head bearing (EXC EU/AUS) ...... 35
07/FUEL TANK, SEAT, TRIM .............................................. 66
02/HANDLEBAR, INSTRUMENTS ....................................... 36 Opening filler cap .......................................................... 66
Handlebar position ........................................................ 36 Closing filler cap ........................................................... 66
Adjusting handlebar position .......................................... 36 Removi ng the seal... .................... ....... ............. ....... ....... 66
Adjusling the basic position of Ihe clulch lever ................. 36 Mounting the seal ......................................................... 66
Checking the choke cable routing (EXC EU,
Removing the fuel tank .................................................. 66
EXC SIX DAYS) ............................................................. 37
Installing the fuel tank ................................................... 67
Checking the choke cable play (EXC EU,
EXC SIX DAYS) ............................................................. 37
Fuel tap ........................................................................ 68
08!MASK, FENDER ........................................................... 69
Adjusting the choke cable play (EXC EU,
EXC SIX DAYS) ............................................................. 37
Checking the throttle cable routing .................................. 37
Checking the play in Ihe throttle cable ............................. 38
Adjusling the play in the throttle cable ............................ 38
03/FRAM E...... .................... .................... .................... ...... 39
Removing the engine sprocket cover ................................ 39
Removi ng the front fender ............ ...... .............. ...... ........ 69
Install i ng the front fender...... ...... ........ ...... ...... ........ ....... 69
Removing headlight mask with headlight ......................... 69
Refitting the headlight mask with the headlight. ............... 69
09/FRONT WHEEL ............................................................ 71
Removi ng front wheel.... .............. ...... .............. ...... ........ 71
Install i ng the front wheeL...... ...... ........ ...... ...... ........ ....... 71
TABLE OF CONTENTS
2
MEANS OF REPRESENTATION ............................................ 6
Installing the engine sprocket cover ................................. 39
IMPORTANT NOTES ............................................................ 7
04/sHOCK ABSORBER, SWINGARM ................................... 40
SERIAL NUMBERS .............................................................. 8
Adjusting high-speed compression damping of the shock
Chassis number ............................................................... 8
absorber.......... ....... .................... .................... .............. 40
Type label ....................................................................... 8
Key number (all EXC models) ........................................... 8
Engine number ................................................................ 9
Fork part number ............................................................. 9
Shock absorber part number ............................................. 9
MOTORCyCLE ................................................................... 10
Adjusting the low-speed compression damping of Ihe
shock absorber .............................................................. 40
Adjusting rebound damping of the shock absorber ............ 41
Measuring rear wheel sag unloaded ................................. 41
Checking the static sag of the shock absorber .................. 41
Checking Ihe riding sag of Ihe shock absorber .................. 42
Raising the motorcycle with the lift stand ........................ 10
Removi ng the motorcycle from the I ift stand .. ....... ....... .... 10
Starting ........................................................................ 10
Starting the motorcycle for a check ................................. 11
OllFORK, TRIPLE CLAMP .................................................. 12
Adjusting the compression damping of the fork ................ 12
Adjusling Ihe rebound damping of Ihe fork ....................... 12
Adjusling spring preload of Ihe fork ................................. 12
Bleeding fork legs .......................................................... 13
Cleaning the dust bools of Ihe fork legs ........................... 13
Loosening the fork protector ........................................... 13
Positioning the fork protector .......................................... 14
Removing the fork legs ................................................... 14
Inslalling fork legs ......................................................... 14
Removing the fork proteclor ............................................ 15
Inslalling Ihe fork protector ............................................ 15
Performing a fork service ................................................ 16
Disassembling the fork legs ............................................ 16
Cartridge disassembly .................................................... 19
Disassembling the compression damping fitting ............... 21
Checking the fork legs .................................................... 21
Assembling Ihe compression damping fitting .................... 22
Assembling Ihe cartridge ................................................ 23
Assembling the fork legs ................................................ 25
Greasing the steering head bearing .................................. 29
Removing the lower triple clamp (EXC USA, all SIX DAYS
models) ........................................................................ 29
Adjusting the spring preload of the shock absorber ........... 42
Adjusting the riding sag ................................................. 43
Removi ng the shock absorber .............. ...... .............. ....... 43
Installing the shock absorber .......................................... 43
Perform a shock absorber service.. ...... ........ ...... .............. 44
Removing the spring ...................................................... 44
Disassembling the damper ............................................. 45
Disassembling the pislon rod .......................................... 46
Disassembling the seal ring retainer ................................ 47
Replacing the pilot bushing ............................................ 48
Checking the damper ..................................................... 48
Disassembling the rebound adjuster ................................ 49
Removing the heim joint ................................................ 50
Installing the heim joint ................................................. 50
Assembling the rebound adjuster .................................... 51
Assembling the seal ring retainer .................................... 52
Assembling the piston rod .............................................. 52
Assembling the damper .................................................. 54
Bleeding and filling the damper ...................................... 56
Filling Ihe damper wilh nitrogen ..................................... 58
Installing the spring ....................................................... 59
Changing the heim joint ................................................. 60
05/EXHAUST .................................................................... 62
Removing the manifold .................................................. 62
Installing the manifold ................................................... 62
Removi ng mai n si lencer .. ...... .............. ...... .............. ....... 62
Installing the main silencer ............................................ 62
Inslalling Ihe lower triple clamp (EXC USA, all SIX DAYS
Changing the glass fiber yarn filling of the main silencer ... 63
models) ........................................................................ 29
06/AIR FILTER .................................................................. 64
Removing the lower triple clamp (EXC EU/AUS) ............... 31
Removing the air filter box lid ......................................... 64
Installing the lower triple clamp (EXC EUiAUS) ................ 32
Installing the air filter box lid .......................................... 64
Fork offset (XC-W SIX DAYS) .......................................... 33
Removing the air filter ................................................... 64
Setting the fork offset (XC-W SIX DAYS) .......................... 34
Installing the air filter .................................................... 64
Checking the steering head bearing play .......................... 34
Cleaning the air filter and air filler box ............................ 65
Adjusling play of steering head bearing (EXC USA, all
Removing the carburetor connection boot ........................ 65
SIX DAYS models) ......................................................... 34
Installing the carburetor connection boot ......................... 65
Adjusling play of steering head bearing (EXC EU/AUS) ...... 35
07/FUEL TANK, SEAT, TRIM .............................................. 66
02/HANDLEBAR, INSTRUMENTS ....................................... 36 Opening filler cap .......................................................... 66
Handlebar position ........................................................ 36 Closing filler cap ........................................................... 66
Adjusting handlebar position .......................................... 36 Removi ng the seal... .................... ....... ............. ....... ....... 66
Adjusling the basic position of Ihe clulch lever ................. 36 Mounting the seal ......................................................... 66
Checking the choke cable routing (EXC EU,
Removing the fuel tank .................................................. 66
EXC SIX DAYS) ............................................................. 37
Installing the fuel tank ................................................... 67
Checking the choke cable play (EXC EU,
EXC SIX DAYS) ............................................................. 37
Fuel tap ........................................................................ 68
08!MASK, FENDER ........................................................... 69
Adjusting the choke cable play (EXC EU,
EXC SIX DAYS) ............................................................. 37
Checking the throttle cable routing .................................. 37
Checking the play in Ihe throttle cable ............................. 38
Adjusling the play in the throttle cable ............................ 38
03/FRAM E...... .................... .................... .................... ...... 39
Removing the engine sprocket cover ................................ 39
Removi ng the front fender ............ ...... .............. ...... ........ 69
Install i ng the front fender...... ...... ........ ...... ...... ........ ....... 69
Removing headlight mask with headlight ......................... 69
Refitting the headlight mask with the headlight. ............... 69
09/FRONT WHEEL ............................................................ 71
Removi ng front wheel.... .............. ...... .............. ...... ........ 71
Install i ng the front wheeL...... ...... ........ ...... ...... ........ ....... 71