2011r repair manual.pdf

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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
TABLE OF CONTENTS
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
Raising the motorcycle with the lift stand ........................ 10
Removi ng the motorcycle from the Iift 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
Inslalling Ihe lower triple clamp (EXC USA, all SIX DAYS
models) ........................................................................ 29
Removing the lower triple clamp (EXC EU/AUS) ............... 31
Installing the lower triple clamp (EXC EUiAUS) ................ 32
Fork offset (XC-W SIX DAYS) .......................................... 33
Setting the fork offset (XC-W SIX DAYS) .......................... 34
Checking the steering head bearing play .......................... 34
Adjusling play of steering head bearing (EXC USA, all
SIX DAYS models) ......................................................... 34
Adjusling play of steering head bearing (EXC EU/AUS) ...... 35
02/HANDLEBAR, INSTRUMENTS ....................................... 36
Handlebar position ........................................................ 36
Adjusting handlebar position .......................................... 36
Adjusling the basic position of Ihe clulch lever ................. 36
Checking the choke cable routing (EXC EU,
EXC SIX DAYS) ............................................................. 37
Checking the choke cable play (EXC EU,
EXC SIX DAYS) ............................................................. 37
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
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 ing the front fender...... ...... ........ ...... ...... ........ .......
Removing headlight mask with headlight .........................
Refitting the headlight mask with the headlight. ...............
09/FRONT WHEEL ............................................................
Removi ng front wheel.... .............. ...... .............. ...... ........
Install ing the front wheeL...... ...... ........ ...... ...... ........ .......
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71
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TABLE OF CONTENTS
Checking the brake discs ................................................ 72
Removing the Iront brake disc ........................................ 72
Installing the front brake disc ......................................... 73
Checking the tire condition ............................................. 73
Checking tire air pressure ............................................... 73
Checking spoke tension .................................................. 74
lO/REAR WHEEL .............................................................. 75
Removing the rear wheel ................................................ 75
Installing the rear wheel ................................................. 75
Removing the rear brake disc .......................................... 76
Installing the rear brake disc .......................................... 76
Checking the chain tension ............................................ 76
Adjusting the chain tension ............................................ 77
Adjusting chain guide .................................................... 78
Checking the chain, rear sprocket, engine sprocket and
chain guide ................................................................... 78
Checking for chain dirt accumulation .............................. 80
Clean ing the chai n.... .............. ...... .............. ...... ............. 80
11IWIRING HARNESS, BATTERy ....................................... 81
Removing the main fuse ................................................. 81
Installing the main fuse ................................................. 81
Changing the fuse
of
the radiator Ian (EXC SIX DAYS,
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
Checking the front brake linings ...................................... 86
Removing front brake linings .......................................... 86
Installing the front brake linings ..................................... 86
Changing the front brake linings ..................................... 87
Checking free travel of hand brake lever ........................... 88
Adjusting the basic position of the hand brake lever
(XC-W SIX DAyS) ........................................................... 89
Adjusting free travel of hand brake lever (all EXC
models) ........................................................................ 89
Checking the brake Iluid level
of
the Iront brake ............... 89
Adding Iront brake Iluid ................................................. 90
Changing the Iront brake Iluid ........................................ 90
Checking rear brake linings ............................................ 91
Removing rear brake linings ............................................ 92
Mounting rear brake linings ............................................ 92
Changing the rear brake linings ....................................... 93
Checking the Iree travel
of
the loot brake lever ................. 94
Adjusting the basic position
01
the loot brake lever ........... 94
Checking rear brake Iluid level ........................................ 95
Adding brake fluid to the rear brake circuit ...................... 95
Changing the rear brake Iluid .......................................... 96
14/LiGHTING SYSTEM, INSTRUMENTS ............................. 98
Adjusting the speedometer lunctions ............................... 98
Setting kilometers or miles ............................................. 98
Activating the additional lunctions .................................. 99
Setting the wheel circumference ..................................... 99
Setting the clock ......................................................... 100
Checking the headlight adjustment ............................... 100
Adjusting the headlight range ....................................... 100
3D/ENGINE ..................................................................... 101
Removing the engine ................................................... 101
Installing the engine ....................................................
3D/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 ...................................
Removi ng the cl utch 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 ..............................................
3D/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 ...............................
3
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TABLE OF CONTENTS
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 .........................................
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 ...............................................
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Installing the
Installing the
Installing the
Installing the
Installing the
Installing the
Installing the
Installing the
Installing the
Installing the
suction pump ..........................................
ignition pulse generator ............................
timing chain ............................................
timing chain securing guide ......................
timing chain guide rail .............................
balance weight ........................................
rotor .......................................................
piston .....................................................
cylinder head ..........................................
camshaft ................................................
4
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Installing the timing chain tensioning rail ...................... 152
Installing the timing chain tensioner ............................. 156
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 ......................
31/CARBURETOR ...........................................................
Choke (EXC AUS/USA, XC.W SIX DAYS) ........................
Choke (EXC EU, EXC SIX DAYS) ...................................
Carburetor - adjusting the idle speed .............................
Emptying the carburetor float chamber ..........................
Removing the carburetor ..............................................
Installing the carburetor ...............................................
Checking/adjusting the carburetor components ...............
Checking the throttle valve sensor .................................
Disassembling the carburetor ........................................
Checking the choke slide ..............................................
Checking the jet needle ................................................
Checking the throttle slide ............................................
Checking the needle jet ................................................
Checking the float needle valve .....................................
Assembling the carburetor ............................................
Checking/adjusting the float level ..................................
Checking/setting the throttle slide opening .....................
Checking/adjusting the accelerator pump .......................
Adjusting the position of the throttle position sensor .......
321CLUTCH ....................................................................
Checking the fluid level of hydraulic clutch ....................
Changing the hydraulic clutch fluid ...............................
33fTRANSMISSION .........................................................
Removing the engine sprocket ......................................
Installing the engine sprocket .......................................
35IWATER PUMP, COOLING SYSTEM ..............................
Cooling system ............................................................
Checking the anti-freeze and coolant level .....................
Checking the coolant level ............................................
Draining coolant ..........................................................
Refilling coolant ..........................................................
381LUBRICATION SYSTEM ..............................................
Oil circuit ...................................................................
Checking engine oil level ..............................................
Checking the transmission ............................................ 139
Changing engine oil and oil filter, cleaning engine oil
screen ........................................................................ 182
Draining engine oil, cleaning engine oil screen ............... 182
Removing the oil filter .................................................. 182
TABLE OF CONTENTS
Installing the oil filte, ..................................................
Filling up with engine oil ..............................................
Adding engine oil ........................................................
Checking the engine oil p'essu'e ...................................
Checking the gea, oil leveL ...........................................
Changing gear oil, cleaning gear oil screen .....................
Draining gear oil, cleaning gear oil screen ......................
Filling up with gea, oil .................................................
Adding gea, oil ............................................................
39/1GNITION SYSTEM .....................................................
Checking the ignition system ........................................
Ignition coil - checking the p,imary winding ...................
Ignition coil - checking the secondary winding ................
Checking the spa,k plug connecto' ................................
Alternato, - checking the cha,ging coil of the ignition ......
Alternato, - checking the light and battery winding .........
Checking the ignition pulse gene,ato, ............................
Removi ng the stato,... ....... ....... ...... ....... ....... ...... ..........
Installing the stato, .....................................................
40/ELECTRIC STARTER ...................................................
Checking the starte' mota, ...........................................
TECHNICAL DATA - ENGINE ............................................
Gapacity - engine oil ....................................................
Gapacity - transmission oiL ...........................................
Gapacity - coolant ........................................................
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF
ENGINE .........................................................................
TECHNICAL DATA - ENGINE TIGHTENING TORQUES ........
TECHNICAL DATA - CARBURETOR ...................................
all 400 models ............................................................
450 EXC EU/AUS, 450 EXC SIX DAYS ..........................
450 EXC USA .............................................................
450 XC-W SIX DAYS USA ............................................
530 EXC EU/AUS, 530 EXC SIX DAYS ..........................
530 EXC USA .............................................................
530 XC-W SIX DAYS USA ............................................
TECHNICAL DATA - CARBURETOR TIGHTENING
TORQU ES ....... .................... .................... ........................
TECHNICAL DATA - CHASSIS ..........................................
Lighting equipment .....................................................
Ti,es ..........................................................................
Gapacity - fuel.... ...... .............. ...... .............. ...... ...........
TECHNICAL DATA - FORK ................................................
TECHNICAL DATA - SHOCK ABSORBER ...........................
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......
CLEAN I NG...... .................... ....... ............. ....... .................
Clean ing the motorcycle................. ....... ............. ..........
STORAGE .......................................................................
Sto'age .......................................................................
Putting into ope,ation afie, sto,age ...............................
SERVICE SCHEDULE .......................................................
Service schedule .........................................................
Service wo,k (as additional o'de') ..................................
WIRING DIAGRAM ..........................................................
Page 1 of 5 (EXC EU, EXC SIX DAyS) ............................
Page 2 of 5 (EXC EU, EXC SIX DAyS) ............................
Page 3 of 5 (EXC EU, EXC SIX DAyS) ............................
Page 4 of 5 (EXC EU, EXC SIX DAyS) ............................
Page 5 of 5 (EXC EU, EXC SIX DAyS) ............................
Page 1 of 5 (EXC AUS) ................................................
Page 2 of 5 (EXC AUS) ................................................
Page 3 of 5 (EXC AUS) ................................................
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Page 4 of 5 (EXC AUS) ................................................
Page 5 of 5 (EXC AUS) ................................................
Page 1 of 5 (EXC USA) ................................................
Page 2 of 5 (EXC USA) ................................................
Page 3 of 5 (EXC USA) ................................................
Page 4 of 5 (EXC USA) ................................................
Page 5 of 5 (EXC USA) ................................................
Page 1 of 4 (XC-W SIX DAYS) .......................................
Page 2 of 4 (XC-W SIX DAYS) .......................................
Page 3 of 4 (XC-W SIX DAYS) .......................................
Page 4 of 4 (XC-W SIX DAYS) .......................................
SUBSTANCES .................................................................
AUXILIARY SUBSTANCES ................................................
SPECIAL TOOLS ..............................................................
STANDARDS ...................................................................
INDEX ............................................................................
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268

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