2009 KTM 400 450 530 SERVICE WORKSHOP REPAIR MANUAL

MORE THAN YOU EVER NEEDED TO KNOW ABOUT THE SERVICE AND REPAIR OF YOUR NEW 2009 KTM MODELS LISTED BELOW

400 EXC EU
400 EXC AUS
400 XC-W USA
450 EXC EU
450 EXC AUS
450 EXC SIX DAYS EU
450 XC-W USA
450 XC-W ZA
530 EXC EU
530 EXC AUS
530 EXC SIX DAYS EU
530 XC-W USA
530 XC-W ZA
450 EXC USA
530 EXC USA

MASSIVE MANUAL ;-) ALL SET OUT IN SECTIONS SO YOU CAN QUICKLY GET TO WHAT YOU NEED TO KNOW:

CONTENTS 2
CONTENTS MEANS OF REPRESENTATION ............................................ 6
IMPORTANT NOTES ............................................................ 7
LOCATION OF 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
Jacking up the motorcycle .............................................. 10
Removing the motorcycle from the work stand.................. 10
Starting ........................................................................ 10
Starting the motorcycle for checking ............................... 11
01/FORK, TRIPLE CLAMP.................................................. 12
Adjusting compression damping of fork ........................... 12
Adjusting rebound damping of fork.................................. 12
Adjusting spring preload of the fork................................. 12
Bleeding fork legs.......................................................... 13
Cleaning the dust boots of the fork legs ........................... 13
Loosening the fork protection.......................................... 13
Positioning the fork protection ........................................ 14
Removing the fork legs................................................... 14
Installing fork legs ......................................................... 14
Removing the fork protector............................................ 15
Installing the fork protector ............................................ 15
Performing a fork service................................................ 16
Disassembling the fork legs ............................................ 16
cartridge, disassembling................................................. 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 ................................................ 25
Greasing the steering head bearing.................................. 29
Removing the lower triple clamp (EXC SIX DAYS,
XC‑W USA, EXC USA) .................................................... 29
Installing the lower triple clamp (EXC SIX DAYS,
XC‑W USA, EXC USA) .................................................... 30
Removing the lower triple clamp (EXC EU, EXC AUS,
XC‑W ZA)...................................................................... 30
Installing the lower triple clamp (EXC EU, EXC AUS,
XC‑W ZA)...................................................................... 31
Checking the play of the steering head bearing................. 32
Adjusting play of steering head bearing (EXC SIX DAYS,
XC‑W USA, EXC USA) .................................................... 32
Adjusting play of steering head bearing (EXC EU,
EXC AUS, XC‑W ZA)....................................................... 33
02/HANDLEBAR, INSTRUMENTS....................................... 34
Handlebar position ........................................................ 34
Adjusting handlebar position .......................................... 34
Adjusting basic position of clutch lever............................ 36
Checking the choke cable routing (EXC EU,
EXC SIX DAYS) ............................................................. 36
Checking the choke cable play (EXC EU,
EXC SIX DAYS) ............................................................. 36
Adjusting the choke cable play (EXC EU,
EXC SIX DAYS) ............................................................. 36
Checking of the routing of the throttle cable..................... 37
Checking the play in the throttle cable............................. 37
Adjusting the play in the throttle cable ............................ 37
03/FRAME ........................................................................ 38
Removing the engine sprocket cover................................ 38
Installing the engine sprocket cover................................. 38
04/SHOCK ABSORBER, SWINGARM................................... 39
Adjusting high-speed compression damping of the shock
absorber ....................................................................... 39
Adjusting the low-speed compression damping of the
shock absorber .............................................................. 39
Adjusting rebound damping of shock absorber.................. 40
Measuring rear wheel sag unloaded ................................. 40
Checking static sag of shock absorber.............................. 40
Checking riding sag of shock absorber ............................. 41
Adjusting spring preload of the shock absorber ................. 41
Adjusting riding sag ....................................................... 42
Removing the shock absorber ......................................... 42
Installing the shock absorber .......................................... 42
Performing a shock absorber service................................ 43
Removing the spring ...................................................... 43
Disassembling the shock absorber................................... 44
Disassembling the piston rod .......................................... 45
Disassembling the seal ring retainer ................................ 46
Replacing the pilot bushing ............................................ 47
Checking the shock absorber .......................................... 47
Disassembling the rebound adjuster ................................ 48
Removing the heim joint ................................................ 49
Installing the heim joint ................................................. 49
Assembling the rebound adjuster .................................... 50
Assembling the seal ring retainer .................................... 51
piston rod, assembling ................................................... 51
Assembling the damper.................................................. 53
Bleeding and filling the damper ...................................... 55
Filling the damper with nitrogen ..................................... 57
Installing the spring....................................................... 58
05/EXHAUST .................................................................... 60
Removing main silencer ................................................. 60
Installing the main silencer ............................................ 60
Removing the manifold .................................................. 60
Installing the manifold ................................................... 60
06/AIR FILTER.................................................................. 61
Dismounting the air filter box lid..................................... 61
Installing the air filter box lid.......................................... 61
Removing the air filter ................................................... 61
Installing the air filter .................................................... 61
Cleaning air filter........................................................... 62
Removing the carburetor connection boot ........................ 62
Installing the carburetor connection boot ......................... 62
07/FUEL TANK, SEAT, TRIM.............................................. 63
Opening filler cap .......................................................... 63
Closing filler cap ........................................................... 63
Removing the seat ......................................................... 63
Mounting the seat ......................................................... 63
Dismounting the fuel tank .............................................. 63
Installing the fuel tank ................................................... 64
Fuel tap........................................................................ 65
08/MASK, FENDER ........................................................... 66
Removing the front fender .............................................. 66
Installing the front fender............................................... 66
Removing headlight mask with headlight (EXC EU,
EXC AUS, EXC SIX DAYS, EXC USA, XC‑W ZA)................. 66
Refitting the headlight mask with the headlight (EXC EU,
EXC AUS, EXC SIX DAYS, EXC USA, XC‑W ZA)................. 66
Removing the start number plate (XC‑W USA) .................. 67
CONTENTS 3
Installing the start number plate (XC‑W USA) ................... 67
09/FRONT WHEEL ............................................................ 68
Removing the front wheel ............................................... 68
Installing the front wheel................................................ 68
Checking the brake discs................................................ 69
Removing the front brake disc ........................................ 69
Installing the front brake disc ......................................... 70
Checking the tire condition............................................. 70
Checking tire air pressure ............................................... 70
Checking spoke tension.................................................. 71
10/REAR WHEEL .............................................................. 72
Removing the rear wheel ................................................ 72
Installing the rear wheel ................................................. 72
Removing the rear brake disc.......................................... 73
Installing the rear brake disc .......................................... 73
Checking chain tension when fitting rear wheel ................ 73
Adjusting chain tension - fitting rear wheel ...................... 74
Checking the chain tension ............................................ 74
Adjusting chain tension - after checking .......................... 75
Adjusting the chain tension ............................................ 75
Adjusting chain guide .................................................... 76
Checking the rear sprocket / engine sprocket for wear ....... 76
Checking chain wear ...................................................... 77
Checking for chain dirt accumulation .............................. 77
Cleaning the chain......................................................... 77
11/WIRING HARNESS, BATTERY ....................................... 78
Removing a fuse............................................................ 78
Installing the fuse ......................................................... 78
Removing the battery ..................................................... 78
Installing the battery...................................................... 79
Recharging the battery ................................................... 79
Checking the closed current ........................................... 80
Checking the charging voltage ........................................ 80
Checking the voltage regulator ........................................ 81
Checking the charging current ........................................ 82
Checking the starter relay ............................................... 82
13/BRAKE SYSTEM........................................................... 84
Checking the front brake linings...................................... 84
Removing front brake linings .......................................... 84
Mounting front brake linings........................................... 84
Changing the front brake linings ..................................... 85
Checking free travel of hand brake lever........................... 86
Adjusting basic position of handbrake lever (all XC‑W
models) ........................................................................ 86
Adjusting free travel of handbrake lever (all EXC
models) ........................................................................ 86
Checking the brake fluid level of the front brake ............... 87
Adding front brake fluid ................................................. 87
Changing the front brake fluid ........................................ 88
Checking rear brake linings ............................................ 89
Removing rear brake linings............................................ 89
Mounting rear brake linings ............................................ 89
Changing the rear brake linings....................................... 90
Checking free travel of foot brake lever ............................ 91
Adjusting basic position of foot brake lever ...................... 91
Checking the brake fluid level of the rear brake ................ 91
Adding rear brake fluid .................................................. 92
Changing the rear brake fluid.......................................... 92
14/LIGHTING SYSTEM, INSTRUMENTS ............................. 94
Adjusting the speedometer functions............................... 94
kilometers or miles, setting............................................. 94
Activating the additional functions .................................. 95
Setting the wheel circumference ..................................... 95
Setting the clock ........................................................... 96
Checking the headlamp setting (EXC EU, EXC AUS,
EXC SIX DAYS, EXC USA, XC‑W ZA)................................ 96
Adjusting the beam width of the headlight (EXC EU,
EXC AUS, EXC SIX DAYS, EXC USA, XC‑W ZA)................. 96
30/ENGINE....................................................................... 98
Removing the engine ..................................................... 98
Installing the engine ...................................................... 99
30/DISASSEMBLING THE ENGINE................................... 101
Preparations................................................................ 101
Draining the engine oil ................................................. 101
Removing the oil filter.................................................. 101
Draining the gear oil, removing the gear oil screen .......... 101
Removing the starter engine ......................................... 102
Removing the spark plug .............................................. 102
Removing the valve cover ............................................. 102
Removing the shift lever............................................... 102
Removing the generator cover ....................................... 103
Setting the engine to ignition top dead center ................ 103
Removing the timing chain tensioner............................. 104
Removing the camshaft................................................ 104
Removing the cylinder head.......................................... 104
Removing the piston .................................................... 104
Removing the rotor ...................................................... 105
Removing the balance weight ....................................... 105
Removing the timing chain guide rail ............................ 105
Removing the timing chain tensioning rail...................... 106
Removing the timing chain securing guide ..................... 106
Removing the timing chain........................................... 106
Removing the ignition pulse generator ........................... 106
Removing the suction pump ......................................... 106
Removing the kickstarter .............................................. 107
Removing the water pump cover ................................... 107
Removing the clutch cover ........................................... 107
Disassembling the clutch disks ..................................... 108
Removing the primary gear nut ..................................... 108
Removing the outer clutch hub ..................................... 108
Removing the balancer shaft ........................................ 109
Removing the torque limiter ......................................... 109
Removing the starter idler gear ..................................... 109
Removing the kickstarter shaft...................................... 109
Removing the kickstarter idler gear ............................... 110
Removing the shift shaft .............................................. 110
Removing the shift drum locating.................................. 110
Removing the locking lever ........................................... 110
Removing the oil pump gears........................................ 110
Removing the oil pumps............................................... 111
Removing the primary gear ........................................... 111
Removing the free wheel gear ....................................... 111
Removing the left section of the engine case.................. 112
Removing the shift rails ............................................... 113
Removing the shift drum .............................................. 113
Removing the shift forks .............................................. 113
Removing the transmission shafts ................................. 113
Removing the crankshaft .............................................. 114
30/ENGINE - WORK ON THE INDIVIDUAL PARTS ............. 115
Working on the right section of the engine case .............. 115
Working on the left section of the engine case................ 116
Removing the oil pressure regulator valve....................... 118
Checking spring length of oil pressure regulator valve...... 118
Installing the oil pressure regulator valve ....................... 118
CONTENTS 4
Removing the crankshaft seal ring in the clutch cover ..... 118
Fitting the crankshaft seal ring into the clutch cover ....... 118
Removing the water pump ............................................ 119
Installing the water pump............................................. 119
Checking the balancer shaft ......................................... 120
Removing the timing chain sprocket.............................. 120
Installing the timing chain sprocket............................... 121
Changing the connecting rod, conrod bearing and crank
pin............................................................................. 121
Checking crankshaft run-out at bearing pin .................... 123
cylinder - Nikasil® coating ............................................ 123
Checking/measuring cylinder ........................................ 123
Checking/measuring the piston ..................................... 124
Checking the piston ring end gap .................................. 124
Piston/cylinder - determining the mounting clearance ..... 125
Checking the oil pumps for wear ................................... 125
Disassembling the autodecompressor ............................ 125
Assembling the autodecompressor................................. 126
Checking camshaft ...................................................... 126
Checking the timing assembly ...................................... 127
Preparing the timing chain tensioner for installation ....... 127
Removing the rocker arm.............................................. 128
Removing the valves .................................................... 128
Changing camshaft bearing .......................................... 129
Checking valves........................................................... 129
Checking valve springs ................................................. 130
Checking valve spring seat............................................ 130
Checking the cylinder head .......................................... 130
Checking the rocker arm shafts ..................................... 131
Installing valves .......................................................... 131
Installing the rocker arm .............................................. 132
Checking clutch .......................................................... 132
Checking shift mechanism ........................................... 133
Preassembling the shift shaft........................................ 134
Dismantling the main shaft .......................................... 134
Assembling the main shaft ........................................... 135
Dismantling the countershaft........................................ 135
Assembling the countershaft......................................... 136
Checking the transmission............................................ 136
Premounting the kickstarter shaft.................................. 137
Checking the electric starter mode ................................ 138
Removing the freewheel ............................................... 139
Checking the freewheel ................................................ 139
Installing the free-wheel............................................... 139
30/ENGINE ASSEMBLY ................................................... 141
Installing the crankshaft............................................... 141
Installing the transmission shaft ................................... 141
Installing the shift forks ............................................... 141
Installing the shift drum............................................... 142
Installing the shift rails ................................................ 142
Installing the left engine case ....................................... 142
Installing the free wheel gear ........................................ 143
Installing the primary gear............................................ 143
Installing the oil pumps ............................................... 143
Installing the oil pump gears ........................................ 144
Installing the locking lever............................................ 144
Installing the shift drum locating .................................. 144
Installing the shift shaft ............................................... 144
Installing the kickstarter idler gear ................................ 145
Installing the kickstarter shaft ...................................... 145
Installing the starter idler gear ...................................... 145
Installing the torque limiter .......................................... 145
Installing the balancer shaft ......................................... 146
Installing the outer clutch hub...................................... 146
Installing the primary gear nut ...................................... 147
Installing the clutch discs ............................................ 147
Installing the clutch cover ............................................ 147
Installing the water pump cover .................................... 148
Installing the kickstarter............................................... 148
Installing the suction pump .......................................... 148
Installing the ignition pulse generator............................ 149
Installing the timing chain............................................ 149
Installing the timing chain securing guide...................... 149
Installing the timing chain tensioning rail ...................... 149
Installing the timing chain guide rail ............................. 150
Installing the balance weight ........................................ 150
Installing the rotor ....................................................... 150
Installing the piston..................................................... 150
Installing the cylinder head .......................................... 152
Installing the camshaft ................................................ 153
Installing the timing chain tensioner ............................. 153
Checking the valve clearance ........................................ 154
Adjusting the valve clearance........................................ 154
Installing the generator cover........................................ 154
Installing the shift lever ............................................... 155
Installing the valve cover .............................................. 155
Installing the spark plug............................................... 155
Installing the starter motor ........................................... 155
Mounting oil filter........................................................ 156
Filling up with engine oil.............................................. 156
Filling up with gear oil ................................................. 156
Removing the engine from the work stand...................... 157
31/CARBURETOR ........................................................... 158
Choke (EXC AUS, XC‑W, EXC USA) ............................... 158
Choke (EXC EU, EXC SIX DAYS) ................................... 158
Removing the carburetor .............................................. 158
Disassembling the carburetor........................................ 159
Checking/adjusting the carburetor components............... 161
Checking/adjusting the accelerator pump....................... 162
Checking the choke slide.............................................. 162
Checking the jet needle................................................ 162
Checking the throttle slide............................................ 163
Checking the needle jet................................................ 163
Checking the float needle valve..................................... 163
Checking/adjusting the float level.................................. 164
Checking/setting the throttle slide opening..................... 164
Checking the throttle valve sensor ................................. 164
Adjusting the position of the throttle position sensor ....... 165
Assembling the carburetor ............................................ 166
Installing the carburetor ............................................... 168
Carburetor - adjusting idle ............................................ 169
Emptying the carburetor float chamber .......................... 170
32/CLUTCH .................................................................... 172
Checking fluid level of hydraulic clutch ......................... 172
Changing the hydraulic clutch fluid ............................... 172
33/TRANSMISSION......................................................... 174
Removing the engine sprocket ...................................... 174
Installing the engine sprocket ....................................... 174
35/WATER PUMP, COOLING SYSTEM .............................. 175
Cooling system ............................................................ 175
Checking the antifreeze and coolant level ...................... 175
Checking the coolant level............................................ 176
Draining coolant .......................................................... 176
CONTENTS 5
Refilling coolant .......................................................... 177
38/LUBRICATION SYSTEM .............................................. 178
Oil circuit ................................................................... 178
Checking engine oil level.............................................. 178
Changing engine oil and oil filter, cleaning engine oil
screen ........................................................................ 179
Draining engine oil, cleaning engine oil screen ............... 179
Removing the oil filter.................................................. 179
Mounting oil filter........................................................ 180
Filling up with engine oil.............................................. 180
Topping up engine oil .................................................. 181
Checking the engine oil pressure................................... 181
Checking the gear oil level............................................ 182
Changing gear oil, cleaning gear oil screen..................... 182
Draining gear oil, cleaning gear oil screen ...................... 182
Filling up with gear oil ................................................. 183
Adding gear oil ............................................................ 183
39/IGNITION SYSTEM ..................................................... 185
Checking the ignition system ........................................ 185
Checking the ignition coil ............................................. 186
Checking the spark plug connector................................ 187
Checking the CDI controller .......................................... 187
Checking the ignition pulse generator ............................ 187
Checking the generator ................................................ 188
Removing the stator..................................................... 190
Mounting the stator ..................................................... 190
40/ELECTROSTARTER..................................................... 191
Checking the starter motor ........................................... 191
TROUBLESHOOTING....................................................... 192
TECHNICAL DATA - ENGINE ............................................ 194
Capacity - engine oil .................................................... 194
Capacity - gear oil........................................................ 195
Capacity - coolant........................................................ 195
TECHNICAL DATA - ENGINE TOLERANCES, WEAR
LIMITS ........................................................................... 196
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ 197
TECHNICAL DATA - CARBURETOR................................... 199
400 EXC..................................................................... 199
400 XC-W USA ........................................................... 199
450 EXC EU/AUS, 450 EXC SIX DAYS .......................... 199
450 EXC USA ............................................................. 200
450 XC-W................................................................... 200
530 EXC EU/AUS, 530 EXC SIX DAYS .......................... 200
530 EXC USA ............................................................. 201
530 XC‑W................................................................... 201
TECHNICAL DATA - CARBURETOR TIGHTENING
TORQUES....................................................................... 202
TECHNICAL DATA - CHASSIS .......................................... 203
Lighting equipment ..................................................... 204
Tires .......................................................................... 204
Capacity - fuel............................................................. 204
TECHNICAL DATA - FORK................................................ 205
TECHNICAL DATA - SHOCK ABSORBER ........................... 206
TECHNICAL DATA - TIGHTENING TORQUES FOR
CHASSIS ........................................................................ 207
CLEANING...................................................................... 208
Cleaning motorcycle .................................................... 208
STORAGE ....................................................................... 209
Storage....................................................................... 209
Putting into operation after storage ............................... 209
SERVICE SCHEDULE....................................................... 210
Important maintenance work to be carried out by an
authorized KTM workshop. ........................................... 210
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order).............. 211
Important checks and maintenance work to be carried
out by the rider. .......................................................... 212
WIRING DIAGRAM .......................................................... 214
Wiring diagram (EXC EU, EXC AUS, EXC‑R SIX DAYS) .... 214
Wiring diagram (EXC USA) ........................................... 218
Wiring diagram (all XC‑W models) ................................. 222
OPERATING SUBSTANCES .............................................. 224
AUXILIARY SUBSTANCES................................................ 226
SPECIAL TOOLS.............................................................. 228
STANDARDS................................................................... 240

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