KTM 450 EXC AUS 2009 Manuals

Manuals and User Guides for KTM 450 EXC AUS 2009. We have 2 KTM 450 EXC AUS 2009 manuals available for free PDF download: Repair Manual, Setup Instructions

KTM 450 EXC AUS 2009 Repair Manual

KTM 450 EXC AUS 2009 Repair Manual (272 pages)

Brand: KTM | Category: Motorcycle | Size: 82.98 MB

Table of Contents

Table of Contents
2
Means of Representation
6
Important Notes
7
Serial Numbers
8
- Chassis Number
  8
- Type Label
  8
- Key Number (All EXC Models)
  8
- Engine Number
  9
- Fork Part Number
  9
- Shock Absorber Part Number
  9
Motorcycle
10
Ollfork, TRIPLE CLAMP
12
02/Handlebar, Instruments
36
03/Frame
39
- Removing the Engine Sprocket Cover
  39
- Installing the Engine Sprocket Cover
  39
04/Shock ABSORBER, SWINGARM
40
05/Exhaust
62
06/Air Filter
64
07/Fuel Tank, Seat, Trim
66
- Opening Filler Cap
  66
- Closing Filler Cap
  66
- Removi Ng the Seal
  66
- Mounting the Seal
  66
- Removing the Fuel Tank
  66
- Installing the Fuel Tank
  67
- Fuel Tap
  68
08!Mask, Fender
69
09/Front Wheel
71
- Removi Ng Front Wheel
  71
- Checking the Brake Discs
  72
- Removing the Iront Brake Disc
  72
- Install I Ng the Front Wheel
  73
- Installing the Front Brake Disc
  73
- Checking the Tire Condition
  73
- Checking Tire Air Pressure
  73
- Checking Spoke Tension
  74
Lo/Rear WHEEL
75
11IWIRING HARNESS, Battery
81
- Removing the Main Fuse
  81
- Installing the Main Fuse
  81
- XC-W Six Days)
  81
- Removi Ng the Battery
  82
- Installing the Battery
  82
- Rechargi Ng the Battery
  82
- Checking the Quiescent Current
  83
- Checking the Charging Voltage
  83
- Checking the Voltage Regulator
  84
- Checking the Starter Relay
  85
13/Brake System
86
14/Lighting SYSTEM, INSTRUMENTS
98
Engine
101
- Removing the Engine
  101
Installing the Engine
102
Disassembling the Engine
104
- Preparations
  104
- Draining the Engine Oil
  104
- Removing the Oil Lilter
  104
- Draining the Gear Oil, Removing the Gear Oil Screen
  104
- Removi Ng the Starter Motor
  105
- Removi Ng the Spark Pi Ug
  105
- Removing the Valve Cover
  105
- Removing the Shift Lever
  105
- Removi Ng the Alternator Cover
  106
- Positioning the Engine at Ignition Top Dead Center
  106
- Removing the Timing Chain Tensioner
  107
- Removing the Camshaft
  107
- Removing the Cylinder Head
  107
- Removing the Piston
  107
- Removi Ng the Rotor
  108
- Removing the Balance Weight
  108
- Removing the Timing Chain Guide Rail
  108
- Removing the Timing Chain Tensioning Rail
  109
- Removing the Timing Chain Securing Guide
  109
- Removing the Timing Chain
  109
- Removing the Ignition Pulse Generator
  109
- Removing the Suction Pump
  109
- Removing the Kickstarter
  110
- Removing the Water Pump Cover
  110
- Disassembling the Clutch Disks
  111
- Removi Ng the Pri Mary Gear Nut
  111
- Removing the Outer Clutch Hub
  111
- Removing the Balancer Shaft
  112
- Removing the Torque Limiter
  112
- Removing the Starter Idler Gear
  112
- Removing the Kickstarter Idler Gear
  112
- Removing the Kickstarter Idler Gear
  113
- Removing the Shift Shaft
  113
- Removing the Shift Drum Locating Unit
  113
- Removing the Locking Lever
  113
- Removing the Oil Pump Gears
  113
- Removing the Oil Pumps
  114
- Removing the Primary Gear
  114
- Removing the Iree Wheel Gear
  114
- Removi Ng the Left Section 01 the Engi Ne Case
  115
- Removing the Shift Rails
  116
- Removing the Shift Drum
  116
- Removing the Shift Lorks
  116
- Removing the Transmission Shafts
  116
- Removing the Crankshaft
  117
Engine - Work on the Individual Parts
118
- Working on the Right Section of the Engine Case
  118
- Working on the Left Section of the Engine Case
  119
- Removing the Oil Pressure Regulator Valve
  121
- Checking Spring Length of Oil Pressure Regulator Valve
  121
- Installing the Oil Pressure Regulator Valve
  121
- Removing the Crankshaft Seal Ring in the Clutch Cover
  121
- Installing the Crankshaft Seal Ring in the Clutch Cover
  121
- Removing the Water Pump
  122
- Installing the Water Pump
  122
- Checking the Balancer Shaft
  123
- Removing the Timing Chain Sprocket
  123
- Installing the Timing Chain Sprocket
  124
- Changing the Connecting Rod, Conrad Bearing and Crank Pin
  124
- Checking Crankshaft Run-Out at Bearing Pin
  126
- Cylinder - Nikasil" Coating
  126
- Checking/Measuring Cylinder
  126
- Checking/Measuring the Piston
  127
- Checking the Piston Ring End Gap
  127
- Piston/Cylinder - Determining the Mounting Clearance
  128
- Checking the Oil Pumps
  128
- Disassembling the Autodecompressor
  128
- Assembling the Autodecompressor
  129
- Checking Camshaft
  129
- Checking the Timing Assembly
  130
- Preparing the Timing Chain Tensioner for Installation
  130
- Removing the Rocker Arm
  131
- Removing the Valves
  131
- Changing Camshaft Bearing
  132
- Checking Valves
  132
- Checking Valve Springs
  133
- Checking Valve Spring Seat
  133
- Checking the Cylinder Head
  133
- Checking the Rocker Arm Shafts
  134
- Installing the Valves
  134
- Installing the Rocker Arm
  135
- Checking the Clutch
  135
- Checking Shift Mechanism
  136
- Preassembling the Shift Shaft
  137
- Disassembling the Main Shaft
  137
- Assembling the Main Shaft
  138
- Disassembling the Countershaft
  138
- Assembling the Countershaft
  139
- Checking the Transmission
  139
- Premounting the Kickstarter Shaft
  140
- Checking the Electric Starter Mode
  141
- Removing the Freewheel
  142
- Checking the Freewheel
  142
- Installing the Free Wheel
  142
30/ENGINE Assembly
144
- Installing the Crankshaft
  144
- Installing the Transmission Shafts
  144
- Installing the Shift Forks
  144
- Installing the Shift Drum
  145
- Installing the Shift Rails
  145
- Installing the Left Engine Case
  145
- Installing the Free Wheel Gear
  146
- Installing the Primary Gear
  146
- Installing the Oil Pumps
  146
- Installing the Oil Pump Gears
  147
- Installing the Locking Lever
  147
- Installing the Shift Drum Locating Uni
  147
- Installing the Shift Shaft
  147
- Installing the Kickstarter Idler Gear
  148
- Installing the Kickstarter Shaft
  148
- Installing the Starter Idler Gear
  148
- Installing the Torque Limiter
  148
- Installing the Balancer Shaft
  149
- Installing the Outer Clutch Hub
  149
- Installing the Primary Gear Nut
  150
- Installing the Clutch Discs
  150
- Installing the Clutch Cover
  150
- Installing the Water Pump Cover
  151
- Installing the Kickstarter
  151
- Installing the Suction Pump
  151
- Installing the Ignition Pulse Generator
  152
- Installing the Timing Chain
  152
- Installing the Timing Chain Securing Guide
  152
- Installing the Timing Chain Tensioning Rail
  152
- Installing the Timing Chain Guide Rail
  153
- Installing the Balance Weight
  153
- Installing the Rotor
  153
- Installing the Piston
  153
- Installing the Cylinder Head
  155
- Installing the Timing Chain Tensioner
  156
- Installing the Camshaft
  157
- Checking the Valve Clearance
  157
- Adjusting the Valve Clearance
  157
- Installing the Alternator Cover
  157
- Installing the Shift Lever
  158
- Installing the Valve Cover
  158
- Installing the Spark Plug
  158
- Installing the Starter Motor
  158
- Installing the Oil Filter
  159
- Filling up with Engine Oil
  159
- Filling up with Gear Oil
  159
- Removing the Engine from the Work Stand
  160
31/Carburetor
161
- Choke (EXC AUS/USA, XC.W SIX DAYS)
  161
- Choke (EXC EU, EXC SIX DAYS)
  161
- Carburetor - Adjusting the Idle Speed
  161
- Emptying the Carburetor Float Chamber
  162
- Removing the Carburetor
  163
- Installing the Carburetor
  163
- Checking/Adjusting the Carburetor Components
  164
- Checking the Throttle Valve Sensor
  165
- Disassembling the Carburetor
  165
- Checking the Choke Slide
  168
- Checking the Jet Needle
  168
- Checking the Throttle Slide
  168
- Checking the Needle Jet
  169
- Checking the Float Needle Valve
  169
- Assembling the Carburetor
  169
- Checking/Adjusting the Float Level
  172
- Checking/Setting the Throttle Slide Opening
  172
- Checking/Adjusting the Accelerator Pump
  173
- Adjusting the Position of the Throttle Position Sensor
  173
321Clutch
175
- Checking the Fluid Level of Hydraulic Clutch
  175
- Changing the Hydraulic Clutch Fluid
  175
Removing the Engine Sprocket
177
Installing the Engine Sprocket
177
33Ftransmission
177
Checking the Anti-Freeze and Coolant Level
178
Cooling System
178
35Iwater Pump, Cooling System
178
Checking the Coolant Level
179
Draining Coolant
179
Refilling Coolant
180
Oil Circuit
181
- Checking Engine Oil Level
  181
- Changing Engine Oil and Oil Filter, Cleaning Engine Oil Screen
  182
- Draining Engine Oil, Cleaning Engine Oil Screen
  182
- Removing the Oil Filter
  182
- Installing the Oil Filte
  183
- Filling up with Engine Oil
  183
- Adding Engine Oil
  184
- Checking the Engine Oil P'essu'e
  184
- Checking the Gea, Oil Level
  185
- Changing Gear Oil, Cleaning Gear Oil Screen
  185
- Draining Gear Oil, Cleaning Gear Oil Screen
  185
- Filling up with Gea, Oil
  186
- Adding Gea, Oil
  186
381Lubrication System
181
39/1Gnition System
188
40/Electric Starter
193
- Checking the Starte' Mota
  193
Technical Data - Engine
194
- Gapacity - Engine Oil
  194
- Gapacity - Transmission Oil
  195
- Gapacity - Coolant
  195
Technical Data - Tolerance, Wear Limits of Engine
196
Technical Data - Engine Tightening Torques
197
Technical Data - Carburetor
199
- All 400 Models
  199
- Exc Eu/Aus, 450 Exc Six Days
  199
- Exc Usa
  199
- 450 XC-W Six Days Usa
  200
- Exc Eu/Aus, 530 Exc Six Days
  200
- Exc Usa
  200
- 530 XC-W Six Days Usa
  201
Technical Data - Carburetor Tightening Torques
202
Technical Data - Chassis
203
- Lighting Equipment
  204
- Ti,Es
  204
- Gapacity - Fuel
  204
Technical Data - Fork
205
Technical Data - Shock Absorber
206
Technical Data - Chassis Tightening Torques
207
Cleaning
208
- Clean I Ng the Motorcycle
  208
Storage
209
- Sto'age
  209
- Putting into Ope,Ation Afie, Sto,Age
  209
Service Schedule
210
- Service Wo,K (as Additional O'de')
  211
Wiring Diagram
212
- EXC EU, EXC SIX Days)
  212
- EXC EU, EXC SIX Days)
  214
- EXC EU, EXC SIX Days)
  216
- EXC EU, EXC SIX Days)
  218
- EXC EU, EXC SIX Days)
  220
- Exc Aus)
  222
- Exc Aus)
  224
- Exc Aus)
  226
- Exc Aus)
  228
- Exc Aus)
  230
- Exc Usa)
  232
- Exc Usa)
  234
- Exc Usa)
  236
- Exc Usa)
  238
- Exc Usa)
  240
- XC-W Six Days)
  242
- XC-W Six Days)
  244
- XC-W Six Days)
  246
- XC-W Six Days)
  248
Substances
250
Auxiliary Substances
252
Special Tools
254
Standards
267
Index
268

Advertisement

KTM 450 EXC AUS 2009 Setup Instructions

KTM 450 EXC AUS 2009 Setup Instructions (14 pages)

Brand: KTM | Category: Motorcycle | Size: 0.46 MB

Table of Contents

Advertisement

Related Products

KTM Categories

Motorcycle Motorcycle Accessories Offroad Vehicle Engine Bicycle Accessories

More KTM Manuals