KTM 450 EXC USA 2009 Off-Road Motorcycle Manuals

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

KTM 450 EXC USA 2009 Repair Manual

KTM 450 EXC USA 2009 Repair Manual (272 pages)

Brand: KTM | Category: Motorcycle | Size: 82 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

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KTM 450 EXC USA 2009 Setup Instructions

KTM 450 EXC USA 2009 Setup Instructions (14 pages)

Brand: KTM | Category: Motorcycle | Size: 0 MB

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