2010r Repair manual.pdf

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REPAIR MANUAL

2010

400 EXC EU

400 EXC AUS

400 XC-W USA

450 EXC EU

450 EXC Champions Edition EU

450 EXC AUS

450 EXC SIX DAYS EU

450 EXC USA

450 EXC Champions Edition USA

450 XC-W SIX DAYS USA

450 XC‑W Champions Edition USA

450 XC-W ZA

530 EXC EU

530 EXC Champions Edition EU

530 EXC AUS

530 EXC SIX DAYS EU

530 EXC USA

530 EXC Champions Edition USA

530 XC-W SIX DAYS USA

530 XC-W ZA

Art. no. 3206080en

INTRODUCTION

It is important that you read this repair manual carefully and completely before the start of work.

INTRODUCTION

Only use

ORIGINAL KTM SPARE PARTS.

This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified

experts.

The repair manual was written to correspond to the most current state of this model series. We reserve the right to make changes in

the interest of technical advancement without, at the same time, updating this repair manual.

We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.

It is assumed that repair work will be performed by a fully trained mechanic.

All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-

tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt

these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for deliv-

ery options, deviations from illustrations and descriptions, as well as for printing and other errors. The models portrayed partly contain

special equipment that does not belong to the regular scope of delivery.

Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright

owner.

ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead

to the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM-Sportmotorcycle AG

5230 Mattighofen, Austria

TABLE OF CONTENTS

Adjusting the play in the throttle cable ............................

03/FRAME........................................................................

Removing the engine sprocket cover................................

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 the

shock absorber ..............................................................

Adjusting rebound damping of the shock absorber ............

Measuring rear wheel sag unloaded .................................

Checking the static sag of the shock absorber ..................

Checking the riding sag of the shock absorber ..................

Adjusting the spring preload of the shock absorber ...........

Adjusting the riding sag .................................................

Removing the shock absorber .........................................

Installing the shock absorber ..........................................

Perform a shock absorber service ....................................

Removing the spring ......................................................

Disassembling the damper .............................................

Disassembling the piston 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 (All Champions Edition models) ...

Assembling the damper (EXC EU/AUS/USA,

EXC SIX DAYS, XC-W, XC‑W SIX DAYS) ...........................

Bleeding and filling the damper ......................................

Filling the damper with nitrogen .....................................

Installing the spring.......................................................

Changing the heim joint .................................................

05/EXHAUST ....................................................................

Removing the manifold ..................................................

Installing the manifold ...................................................

Removing main silencer .................................................

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 filter box ............................

Removing the carburetor connection boot ........................

Installing the carburetor connection boot .........................

07/FUEL TANK, SEAT, TRIM..............................................

Opening filler cap ..........................................................

Closing filler cap ...........................................................

Removing the seat .........................................................

Mounting the seat .........................................................

Removing the fuel tank ..................................................

Installing the fuel tank ...................................................

Fuel tap........................................................................

08/MASK, FENDER ...........................................................

Removing the front fender ..............................................

Installing the front fender...............................................

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

Removing the motorcycle from the lift stand .................... 10

Starting ........................................................................ 10

Starting the motorcycle for a check ................................. 11

01/FORK, TRIPLE CLAMP.................................................. 12

Adjusting the compression damping of the fork ................ 12

Adjusting the rebound damping of the fork....................... 12

Adjusting spring preload of the fork................................. 13

Bleeding fork legs.......................................................... 13

Cleaning the dust boots of the fork legs ........................... 13

Loosening the fork protector ........................................... 14

Positioning the fork protector.......................................... 14

Removing the fork legs................................................... 14

Installing fork legs ......................................................... 15

Removing the fork protector............................................ 15

Installing the fork protector ............................................ 16

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 the compression damping fitting.................... 22

Assembling the cartridge ................................................ 23

Assembling the fork legs (All Champions Edition

models) ........................................................................ 25

Assembling the fork legs (EXC EU/AUS/USA,

EXC SIX DAYS, XC-W, XC‑W SIX DAYS) ........................... 29

Greasing the steering head bearing.................................. 33

Removing the lower triple clamp (EXC SIX DAYS, all USA

models) ........................................................................ 33

Installing the lower triple clamp (EXC SIX DAYS, all USA

models) ........................................................................ 34

Removing the lower triple clamp (EXC Champions

Edition EU, EXC EU/AUS, XC‑W ZA)................................ 35

Installing the lower triple clamp (EXC Champions

Edition EU, EXC EU/AUS, XC‑W ZA)................................ 36

Checking the steering head bearing play .......................... 37

Adjusting play of steering head bearing (EXC SIX DAYS,

all USA models) ............................................................ 38

Adjusting play of steering head bearing (EXC Champions

Edition EU, EXC EU/AUS, XC‑W ZA)................................ 38

02/HANDLEBAR, INSTRUMENTS....................................... 39

Handlebar position ........................................................ 39

Adjusting handlebar position .......................................... 39

Adjusting the basic position of the clutch lever................. 39

Checking the choke cable routing (EXC Champions

Edition EU, EXC EU, EXC SIX DAYS)............................... 40

Checking the choke cable play (EXC Champions

Edition EU, EXC EU, EXC SIX DAYS)............................... 40

Adjusting the choke cable play (EXC Champions

Edition EU, EXC EU, EXC SIX DAYS)............................... 40

Checking the throttle cable routing.................................. 40

Checking the play in the throttle cable............................. 41

TABLE OF CONTENTS

Removing headlight mask with headlight (All EXC

models, XC‑W SIX DAYS, XC‑W ZA) ................................. 75

Refitting the headlight mask with the headlight (All EXC

models, XC‑W SIX DAYS, XC‑W ZA) ................................. 75

Removing the start number plate (XC‑W Champions

Edition USA, 400 XC-W USA)......................................... 76

Installing the start number plate (XC‑W Champions

Edition USA, 400 XC-W USA)......................................... 76

09/FRONT WHEEL ............................................................ 77

Removing front wheel .................................................... 77

Installing the front wheel................................................ 77

Checking the brake discs................................................ 78

Removing the front brake disc ........................................ 78

Installing the front brake disc ......................................... 79

Checking the tire condition............................................. 79

Checking tire air pressure ............................................... 79

Checking spoke tension.................................................. 80

10/REAR WHEEL .............................................................. 81

Removing the rear wheel ................................................ 81

Installing the rear wheel ................................................. 81

Removing the rear brake disc.......................................... 82

Installing the rear brake disc .......................................... 82

Checking the chain tension ............................................ 82

Adjusting the chain tension ............................................ 83

Adjusting chain guide .................................................... 84

Checking the chain, rear sprocket, engine sprocket and

chain guide................................................................... 84

Checking for chain dirt accumulation .............................. 86

Cleaning the chain......................................................... 86

11/WIRING HARNESS, BATTERY ....................................... 87

Removing the main fuse................................................. 87

Installing the main fuse ................................................. 87

Changing the fuse of the radiator fan (All SIX DAYS

models, XC-W ZA).......................................................... 87

Removing the battery ..................................................... 88

Installing the battery...................................................... 88

Recharging the battery ................................................... 88

Checking the quiescent current....................................... 89

Checking the charging voltage ........................................ 89

Checking the voltage regulator ........................................ 90

Checking the starter relay ............................................... 91

13/BRAKE SYSTEM........................................................... 92

Checking the front brake linings...................................... 92

Removing front brake linings .......................................... 92

Installing the front brake linings ..................................... 92

Changing the front brake linings ..................................... 93

Checking free travel of hand brake lever........................... 94

Adjusting the basic position of the hand brake lever (all

XC‑W models) ............................................................... 95

Adjusting free travel of hand brake lever (all EXC

models) ........................................................................ 95

Checking the brake fluid level of the front brake ............... 95

Adding front brake fluid ................................................. 96

Changing the front brake fluid ........................................ 96

Checking rear brake linings ............................................ 97

Removing rear brake linings............................................ 98

Mounting rear brake linings ............................................ 98

Changing the rear brake linings....................................... 99

Checking the free travel of the foot brake lever ............... 100

Adjusting the basic position of the foot brake lever ......... 100

Checking rear brake fluid level...................................... 101

Adding brake fluid to the rear brake circuit .................... 101

Changing the rear brake fluid........................................

14/LIGHTING SYSTEM, INSTRUMENTS ...........................

Adjusting the speedometer functions.............................

Setting kilometers or miles ...........................................

Activating the additional functions ................................

Setting the wheel circumference ...................................

Setting the clock .........................................................

Checking the headlight adjustment (All EXC models,

XC‑W SIX DAYS, XC‑W ZA) ...........................................

Adjusting the headlight range (All EXC models,

XC‑W SIX DAYS, XC‑W ZA) ...........................................

30/ENGINE.....................................................................

Removing the engine ...................................................

Installing the engine ....................................................

30/DISASSEMBLING THE ENGINE...................................

Preparations................................................................

Draining the engine oil .................................................

Removing the oil filter..................................................

Draining the gear oil, removing the gear oil screen ..........

Removing the starter motor ..........................................

Removing the spark plug ..............................................

Removing the valve cover .............................................

Removing the shift lever...............................................

Removing 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 ....................................................

Removing 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 ...................................

Removing the clutch cover ...........................................

Disassembling the clutch disks .....................................

Removing the primary 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 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 free wheel gear .......................................

Removing the left section of the engine case..................

Removing the shift rails ...............................................

Removing the shift drum ..............................................

Removing the shift forks ..............................................

Removing the transmission shafts .................................

Removing the crankshaft ..............................................

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