Related Manuals for KTM 400 EXC EU 2010
Summary of Contents for KTM 400 EXC EU 2010
- Page 1 OWNER'S MANUAL 2010 400 EXC EU 400 EXC AUS 400 XC-W USA 450 EXC EU 450 EXC AUS 450 EXC SIX DAYS EU 450 XC-W SIX DAYS USA 450 XC-W ZA 530 EXC EU 530 EXC AUS 530 EXC SIX DAYS EU 530 XC-W SIX DAYS USA 530 XC-W ZA Art.
- Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as for printing and other errors.
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Page 4: Table Of Contents
Hand brake lever ............11 Important maintenance work to be carried out by an Short circuit button (all XC‑W models)......11 authorized KTM workshop. (as additional order)....34 Short circuit button (all EXC models)....... 11 Important checks and maintenance work to be carried Emergency OFF switch (EXC AUS) ........ - Page 5 TABLE OF CONTENTS Handlebar position ............48 Removing the air filter ..........75 Adjusting handlebar position ........48 Installing the air filter ..........75 Checking throttle cable route .......... 48 Cleaning air filter ............75 Checking the play in the throttle cable......49 Adjusting basic position of clutch lever......
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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 Information
Warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record; otherwise, all warranty claims will be void. No warranty claim can be honored for damage resulting from manipulation and/or other changes to the vehicle. - Page 8 IMPORTANT INFORMATION Transport Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances.
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Page 9: View Of Vehicle
VIEW OF VEHICLE View of the vehicle from the left front (example) 100799-10 Hand brake lever Clutch lever Air filter box lid Fuel tap Chain guide Side stand Shift lever... -
Page 10: View Of The Vehicle From The Right Rear (Example)
VIEW OF VEHICLE View of the vehicle from the right rear (example) 100800-10 Filler cap Short circuit button Speedometer Electric starter button Fork rebound adjustment Horn Fork compression adjustment Shock absorber rebound adjustment Level viewer for brake fluid, rear Shock absorber compression adjustment Foot brake pedal Kick starter... -
Page 11: Location Of Serial Numbers
LOCATION 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. 500128-10 Key number (all EXC models) The key number is stamped on the key strap. -
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: Controls
CONTROLS 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. The hand brake lever is used to activate the front brake. -
Page 14: Electric Starter Button (Exc Eu, Exc Six Days, Xc-W, Xc-W Six Days)
CONTROLS Electric starter button (EXC EU, EXC SIX DAYS, XC-W, XC‑W SIX DAYS) 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)
CONTROLS Flasher switch (all EXC models) 5.11 The 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
CONTROLS 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
CONTROLS Adjusting the speedometer functions 5.18 Info Upon delivery, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is stationary. – briefly and repeatedly until H appears at the bottom right of the Press the button display. –... -
Page 18: Speed Display Mode (Speed)
CONTROLS 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: Display Mode Speed/Odo (Odometer)
CONTROLS Press the button The stop watch and the lap time are reset. for 3 - 5 seconds. Press the button Next display mode briefly. Display mode SPEED/ODO (odometer) 5.24 – Press the button briefly and repeatedly until ODO appears at the bottom right of the display. -
Page 20: Disply Mode Speed/A1 (Average Speed 1)
CONTROLS Disply mode SPEED/A1 (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 using TR1 (trip master 1) and S1 (stop watch 1). - Page 21 CONTROLS Table of functions Display Press the button Press the button Press the button for 3 - Press the button 5 seconds. briefly. Display mode SPEED/H 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
CONTROLS Fuel tap 5.31 The fuel tap is on the left of the fuel tank. With tap handle on the fuel tap, you can open or close the supply of fuel to the car- buretor. Possible states Fuel supply closed OFF – No fuel flows from the tank to the carburetor. •... -
Page 23: Choke (Exc Eu, Exc Six Days)
CONTROLS Choke (EXC EU, EXC SIX DAYS) 5.35 The flasher switch is fitted on the left side of the handlebar. Activating the choke opens a drilling which supplies the engine with extra fuel. This enriches the 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
CONTROLS Side stand 5.39 Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. Note Material damage Damage and destruction of components by excessive load. – The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand only. -
Page 25: Unlocking The Steering (All Exc Models)
CONTROLS 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: Preparing For Riding On Wet Sand
Sand protection device for air filter (59006022000) Info See the KTM PowerParts fitting instructions. – Adjust the carburetor jetting and settings. Info 600871-01 Your authorized KTM workshop has the recommended carburetor tuning set- tings. – Clean the chain. Chain cleaner ( p. 110) –... -
Page 29: Preparing For Riding On Wet And Muddy Surfaces
Waterproofing device for air filter (59006021000) Info See the KTM PowerParts fitting instructions. – Adjust the carburetor jetting and settings. Info 600870-01 Your authorized KTM workshop has the recommended carburetor tuning set- tings. – Clean the chain. Chain cleaner ( p. 110) –... -
Page 30: Preparing For Rides At High Temperature And Slow Speed
Fit a waterproofing device on the air filter. Waterproofing device for air filter (59006021000) Info See the KTM PowerParts fitting instructions. – Adjust the carburetor jetting and settings. Info 600870-01 Your authorized KTM workshop has the recommended carburetor tuning set- tings. -
Page 31: Riding Instructions
RIDING 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. – Check the engine oil level. -
Page 32: Starting Up
Do not change into a low gear at high engine speed. The engine overspeeds 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 33: 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 vehicle is in use. –... - Page 34 RIDING INSTRUCTIONS – Fill the fuel tank with fuel up to measurement Guideline Measurement of 35 mm (1.38 in) Total fuel tank 9.5 l Super unleaded (ROZ 95 / RON 95 / capacity, (2.51 US gal) PON 91) ( p.
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Page 35: Service Schedule
SERVICE 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 36: 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 S15N S45A S15A S30A S45A S30A S60A S90A • • Perform a fork service. Perform a shock absorber service. -
Page 37: Important Checks And Maintenance Work To Be Carried Out By The Rider
SERVICE SCHEDULE Important checks and maintenance work to be carried out by the rider. NB1A Check the engine oil level. ( p. 80) • Check the brake fluid level of the front brake. ( p. 55) • Check the rear brake fluid level. ( p. -
Page 38: Maintenance Work On Chassis And Engine
Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber. -
Page 39: Adjusting The Low-Speed Compression Damping Of The Shock Absorber
Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. -
Page 40: Measuring Rear Wheel Sag Unloaded
MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn adjusting screw clockwise up to the last perceptible click. Info Do not loosen nut – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping 400210-10 Comfort... -
Page 41: Checking Riding Sag Of Shock Absorber
Danger Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. -
Page 42: Adjusting Riding Sag
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting riding sag 9.12 – Remove shock absorber. p. 40) – After removing the shock absorber, clean it thoroughly. – Choose and fit 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 43: 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 44: Adjusting Spring Preload Of The Fork
MAINTENANCE WORK ON CHASSIS AND ENGINE Info Turn clockwise to increase damping, turn counterclockwise to reduce sus- pension damping. Adjusting spring preload of the fork 9.18 – Turn adjusting screws counterclockwise until they stop. Info Make sure the setting is identical on both fork legs. –... -
Page 45: Loosening The Fork Protector
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) 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 46: Adjusting Play Of Steering Head Bearing (Exc Eu, Exc Aus, Xc-W Za)
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting play of steering head bearing (EXC EU, EXC AUS, XC‑W ZA) 9.24 – Jack up the motorcycle. ( p. 36) – Loosen screws – Loosen and retighten screw Guideline Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft) –... -
Page 47: Installing Fork Legs
MAINTENANCE WORK ON CHASSIS AND ENGINE (EXC EU, EXC AUS, XC‑W ZA) – Unscrew screws . Take out the left fork leg. – Unscrew screws . Take out the right fork leg. 100804-10 Installing fork legs 9.27 – Position the fork legs. -
Page 48: Removing The Fork Protector
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the fork protector 9.28 – Remove the fork legs. p. 44) – Remove screws on the left fork leg. Remove the fork protector upwards. – Remove the screws on the right fork leg. Remove the fork protector upwards. 600878-10 Installing the fork protector 9.29... -
Page 49: Refitting The Headlight Mask With The Headlight (All Exc Models, All 450/530 Xc-W Models)
MAINTENANCE WORK ON CHASSIS AND ENGINE – Pull out the electric plug connector and remove the headlight mask with the headlight. 600702-10 Refitting the headlight mask with the headlight (all EXC models, all 450/530 XC-W models) 9.33 – Connect the electric plug connector ... -
Page 50: Handlebar Position
MAINTENANCE WORK ON CHASSIS AND ENGINE Handlebar position 9.36 On the upper triple clamp, there are 2 holes at a distance of to each other. Distance between holes 15 mm (0.59 in) The holes on the handlebar support are placed at a distance of from the center. -
Page 51: Checking The Play In The Throttle Cable
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the play in the throttle cable 9.39 – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3…... -
Page 52: Cleaning The Chain
MAINTENANCE WORK ON CHASSIS AND ENGINE Cleaning the chain 9.42 Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. –... -
Page 53: Checking Chain Tension When Fitting Rear Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking chain tension when fitting rear wheel 9.44 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 54: Adjusting Chain Tension
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting chain tension 9.47 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: Adjusting Chain Tension - After Checking
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting chain tension - after checking 9.48 – Loosen nut – Loosen nuts – Adjust the chain tension by turning the adjusting screws left and right. Guideline Chain tension 8… 10 mm (0.31… 0.39 in) Turn the adjusting screws left and right so that the markings on the left and ... -
Page 56: Adjusting Chain Guide
Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disk to see if it conforms to measurement ... -
Page 57: Adjusting Basic Position Of Hand Brake Lever (All Xc-W Models)
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) -
Page 58: Topping Up The Front Brake Fluid
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 59: Checking The Front Brake Linings
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. - Page 60 MAINTENANCE WORK ON CHASSIS AND ENGINE – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons.
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Page 61: Checking Free Play Of Foot Brake Lever
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) -
Page 62: Adding Brake Fluid To The Rear Brake Circuit
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 63: Changing Rear Brake Linings
Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. -
Page 64: Removing Front Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove locking split pins , withdraw bolt , and take out the brake pads. – Clean brake caliper and brake caliper support. 100808-10 – Check that anti-squeal shim in the brake caliper and anti-rattle shim in the ... -
Page 65: Fitting Front Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. Info Do not operate the hand brake lever when the front wheel is removed. Always lay the wheel down in such a way that the brake disc is not dam- aged. -
Page 66: Removing The Rear Wheel
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the rear wheel 9.67 – Jack up the motorcycle. ( p. 36) – Press the brake caliper by hand onto the brake disc in order to retract the brake piston. Info Make sure when retracting the brake piston that you do not press the brake caliper against the spokes. -
Page 67: Checking The Tire Condition
DOT marking. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. KTM recommends that the tires are changed regardless of the actual wear, at the latest after 5 years. »... -
Page 68: Checking Tire Air Pressure
Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time. -
Page 69: Removing The Battery
– Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 70: Removing A Fuse
MAINTENANCE WORK ON CHASSIS AND ENGINE Info Even if there is no load on the battery, it loses power every day. The charge state and the type of charge are very important for the service life of the battery. Fast recharging with a high charge current shortens the battery's service life. If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes. -
Page 71: Checking The Headlight Adjustment (All Exc Models, All 450/530 Xc-W Models)
MAINTENANCE WORK ON CHASSIS AND ENGINE – Insert the fuse. Fuse (58011109110) Info A reserve fuse is located in the starter relay. Replace a blown fuse only by an equivalent fuse. – Replace the protection cover. – Install the air filter box lid. ( p. -
Page 72: Mounting The Seat
MAINTENANCE WORK ON CHASSIS AND ENGINE Mounting the seat 9.80 – 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 9.82 Danger Fire hazard Fuel is highly flammable. – Never refuel 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. Clean up spilt fuel immediately. –... -
Page 74: Checking The Anti-Freeze And Coolant Level
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the anti-freeze and coolant level 9.84 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, 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 Alternative 2 Coolant (mixed ready to use) ( p. 108) – Mount the radiator cap. Draining coolant 9.86 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. -
Page 76: Glass Fiber Yarn Filling Of Main Silencer
MAINTENANCE WORK ON CHASSIS AND ENGINE Glass fiber yarn filling of main silencer 9.88 The main silencer is filled with glass fiber yarn. Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out". Not only is the noise level higher, the performance characteristic changes. -
Page 77: Removing The Air Filter
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the air filter 9.93 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 Hazardous substances cause environmental damage. -
Page 78: Adjusting Basic Position Of Clutch Lever
MAINTENANCE WORK ON CHASSIS AND ENGINE – Oil the dry air filter with a high/quality filter oil. Oil for foam air filter ( p. 110) – Clean the air filter box. – Check carburetor connection boot for damage and tightness. –... -
Page 79: Checking The Basic Position Of The Shift Lever
MAINTENANCE WORK ON CHASSIS AND ENGINE Info The fluid level rises with increasing wear of the clutch lining disc. Avoid contact between brake fluid and painted parts. Brake fluid is corrosive! Use only clean brake fluid from a sealed container! –... -
Page 80: Carburetor - Idle
MAINTENANCE WORK ON CHASSIS AND ENGINE – Clean the teeth of the shift shaft and the shift lever. – Place the shift lever in desired position and slide it onto the shift shaft and engag- ing the teeth. – Mount and tighten screw. -
Page 81: Emptying The Carburetor Float Chamber
MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn the idle adjusting screw slowly until the idle speed begins to fall. – Note the position and turn the idle adjusting screw slowly counterclockwise until the idle speed falls. – Adjust to the point between these two positions with the highest idle speed. Info If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps. -
Page 82: Checking Engine Oil Level
MAINTENANCE WORK ON CHASSIS AND ENGINE – Direct the hose of the float chamber into a suitable container. Info Water in the float chamber results in malfunctioning. – Undo the screw (turn it counterclockwise) a few turns and drain the fuel from ... -
Page 83: Removing The Oil Filter
MAINTENANCE WORK ON CHASSIS AND ENGINE – Place a suitable container under the engine. – Remove engine oil plug screen – Completely drain the engine oil. – Thoroughly clean the plug and engine oil screen. – Clean the sealing surface on the engine. –... -
Page 84: Filling Up With Engine Oil
MAINTENANCE WORK ON CHASSIS AND ENGINE – Refit the oil filter cover – Mount and tighten screws Guideline Screw, oil filter cover 10 Nm (7.4 lbf ft) – Stand the motorcycle upright. 200113-11 Filling up with engine oil 9.109 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. -
Page 85: Checking The Gear Oil Level
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the gear oil level 9.111 Info The gear oil level should only be checked when the engine is cold. – Stand the motorcycle upright on a horizontal surface. Condition Engine is cold. – Remove gear oil level check screw . -
Page 86: Filling Up With Gear Oil
MAINTENANCE WORK ON CHASSIS AND ENGINE – Place a suitable container under the engine. – Remove the gear oil drain plug – Remove the gear oil screen plug – Completely drain the gear oil. – Thoroughly clean the gear oil drain plug with a magnet. –... - Page 87 MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screw cap . Stand the vehicle upright. – Top up with gear oil until it flows out of the bore of the gear oil level screw. Engine oil (SAE 10W/50) ( p.
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Page 88: Troubleshooting
TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Go through the steps of starting procedure. tric starter). p. 29) – Battery discharged Recharge the battery. p. 67) – Check the charging voltage. – Check the stall current. –... - Page 89 TROUBLESHOOTING Faults Possible cause Action – Engine has a lack of power Air filter severly contaminated Clean the air filter. p. 75) – Exhaust system leaky, deformed or Check exhaust system for damage. too little glass fiber yarn filling in –...
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Page 90: Cleaning
CLEANING Cleaning the 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, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 91: Storage
Storage temperature of battery (not placed in direct sunshine) 0… 35 °C (32… 95 °F) – Place the vehicle on a dry storage place that is not subject to large temperature variations. Info KTM recommends jacking up the motorcycle. – Jack up the motorcycle. ( p. 36) –... -
Page 92: 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) 63.4 mm (2.496 in) -
Page 93: 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. 108) Capacity - coolant 13.3 Coolant 0.95 l (1 qt.) Coolant ( p. 108) Coolant (mixed ready to use) ( p. -
Page 94: Technical Data - Engine Tightening Torques
TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Screw, cable holder in generator cover 4 Nm (3 lbf ft) Loctite 243™ ® Locking screw for bearing 6 Nm (4.4 lbf ft) Loctite 243™ ® Oil jet, piston cooling 2 Nm (1.5 lbf ft) Loctite 243™... - Page 95 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 96: Technical Data - Carburetor
TECHNICAL DATA - CARBURETOR 400 EXC EU/AUS 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 diaphragm stop 2.15 mm (0.0846 in) Main jet Jet needle OBDYU (OBDTQ) Idling jet Idle air jet... -
Page 97: 450 Xc-W Za, 450 Xc-W Six Days
TECHNICAL DATA - CARBURETOR 450 XC‑W ZA, 450 XC‑W SIX DAYS 15.4 Carburetor type KEIHIN FCR-MX 39 Carburetor identfication number 3900L Needle position (450 XC-W SIX DAYS 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... -
Page 98: Technical Data - Chassis
TECHNICAL DATA - CHASSIS Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Suspension Up Side Down 4860 MXMA PA Suspension travel Front 300 mm (11.81 in) Rear 335 mm (13.19 in) Fork offset (EXC SIX DAYS, XC‑W 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 99: Tires
80/100 - 21 51M TT 110/100 - 18 64M TT Bridgestone M59 Bridgestone M402 Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 16.3 Total fuel tank capacity, 9.5 l (2.51 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. -
Page 100: Technical Data - Fork
TECHNICAL DATA - FORK Fork part number 14.18.7J.06 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 26 clicks Standard 22 clicks Sport 18 clicks Rebound damping Comfort 24 clicks Standard 20 clicks Sport 20 clicks Spring length with preload spacer(s) 510 mm (20.08 in) Spring rate Weight of rider: 65…... -
Page 101: Technical Data - Shock Absorber
TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 12.18.7J.06 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 22 clicks Standard 20 clicks Sport 15 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1.25 turns Rebound damping Comfort 26 clicks... -
Page 102: Technical Data - Chassis Tightening Torques
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Screw, spoiler on fuel tank (XC‑W USA, M5x12 1.5 Nm (1.11 lbf ft) XC‑W SIX DAYS) – Spoke nipple, rear wheel 5…... -
Page 104: Wiring Diagram
WIRING DIAGRAM Wiring diagram (all EXC models) 20.1 CX/2 CZ/3 DB/4 CW/2 CY/3 DA/4 AK1/2 DG/4 CW2/2 CW3/2 AH1/2 CX3/2 BP/4 CX2/2 ye-bl bl-wh bu-wh ye-re ye-re ye-re bu-wh ye-bl re-wh re-bl ye-re ye-re wh-re ye-bl re-bl re-wh CR/1 CR1/1 wh-gn wh-re BG1/3... - Page 105 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 106 WIRING DIAGRAM Yellow ye-bl Yellow-black ye-re Yellow-red...
- Page 107 WIRING DIAGRAM...
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Page 108: 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 109 WIRING DIAGRAM Components CDI controller Throttle position sensor Wheel speed sensor Thermoswitch (XC-W ZA, XC-W SIX DAYS) Battery Generator Brake/tail light (XC-W ZA) Parking light (XC-W ZA, XC-W SIX DAYS) Low beam/high beam (XC-W ZA, XC-W SIX DAYS) Radiator fan (XC-W ZA, XC-W SIX DAYS) Starter relay with main fuse Pulse generator Ignition coil...
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Page 110: 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 111 SUBSTANCES Super unleaded (ROZ 95 / RON 95 / PON 91) according to – DIN EN 228 (ROZ 95 / RON 95 / PON 91)
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Page 112: Auxiliary Substances
AUXILIARY SUBSTANCES Air filter cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Cleaning and polishing materials for metal, rubber and plastic Guideline –... - Page 113 AUXILIARY SUBSTANCES Universal oil spray Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Joker 440 Universal...
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Page 114: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation. -
Page 115: Index
INDEX Chassis number ....... . 9 INDEX Choke ........20-21 Accessories . - Page 116 INDEX removing ....... . . 46 Front fender Oil filter installing .
- Page 117 INDEX Steering locking ........22 unlocking ....... . 23 Steering head bearing play adjusting .
- Page 118 *3211467en* 3211467en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...