Ktm 400 450 530 EXC EXC Six-Days XC-W Six-Days WorkShop Service Repair Manual 2010-2011
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This Workshop Service repair manual offers detailed servicing instructions and will give you complete step by step information on repair, servicing, preventative maintenance & troubleshooting procedures for your Ktm.
This comprehensive service manual features photos and illustrations along with step-by-step instructions that will guide you through the entire repair process. This manual contains all you need to know to keep your Motorcycle working correctly.
Models covered :
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
Table Of Contents:
MEANS OF REPRESENTATION …………………………………….. 6 Installing the engine sprocket cover …………………………… 39
IMPORTANT NOTES …………………………………………………… 7 04/sHOCK ABSORBER, SWINGARM …………………………….. 40
SERIAL NUMBERS …………………………………………………….. 8 Adjusting high-speed compression damping of the shock
Chassis number ……………………………………………………… 8 absorber………. ……. ……………….. ……………….. ………….. 40
Type label …………………………………………………………….. 8
Key number (all EXC models) ……………………………………. 8
Engine number ………………………………………………………. 9
Fork part number ……………………………………………………. 9
Shock absorber part number ……………………………………… 9
MOTORCyCLE …………………………………………………………. 10
Adjusting the low-speed compression damping of Ihe
shock absorber …………………………………………………….. 40
Adjusting rebound damping of the shock absorber ………… 41
Measuring rear wheel sag unloaded …………………………… 41
Checking the static sag of the shock absorber ……………… 41
Checking Ihe riding sag of Ihe shock absorber ……………… 42
Raising the motorcycle with the lift stand …………………… 10
Removi ng the motorcycle from the I ift 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
Adjusting the spring preload of the shock absorber ……….. 42
Adjusting the riding sag …………………………………………. 43
Removi ng the shock absorber ………….. …… ………….. ……. 43
Installing the shock absorber …………………………………… 43
Perform a shock absorber service.. …… …….. …… ………….. 44
Removing the spring ……………………………………………… 44
Disassembling the damper ……………………………………… 45
Disassembling the pislon rod …………………………………… 46
Disassembling the seal ring retainer ………………………….. 47
Replacing the pilot bushing …………………………………….. 48
Checking the damper …………………………………………….. 48
Disassembling the rebound adjuster ………………………….. 49
Removing the heim joint ………………………………………… 50
Installing the heim joint …………………………………………. 50
Assembling the rebound adjuster ……………………………… 51
Assembling the seal ring retainer ……………………………… 52
Assembling the piston rod ………………………………………. 52
Assembling the damper ………………………………………….. 54
Bleeding and filling the damper ……………………………….. 56
Filling Ihe damper wilh nitrogen ………………………………. 58
Installing the spring ………………………………………………. 59
Changing the heim joint …………………………………………. 60
05/EXHAUST ………………………………………………………….. 62
Removing the manifold ………………………………………….. 62
Installing the manifold …………………………………………… 62
Removi ng mai n si lencer .. …… ………….. …… ………….. ……. 62
Installing the main silencer …………………………………….. 62
Inslalling Ihe lower triple clamp (EXC USA, all SIX DAYS Changing the glass fiber yarn filling of the main silencer … 63
models) ……………………………………………………………… 29 06/AIR FILTER ………………………………………………………… 64
Removing the lower triple clamp (EXC EU/AUS) …………… 31 Removing the air filter box lid ………………………………….. 64
Installing the lower triple clamp (EXC EUiAUS) ……………. 32 Installing the air filter box lid …………………………………… 64
Fork offset (XC-W SIX DAYS) …………………………………… 33 Removing the air filter …………………………………………… 64
Setting the fork offset (XC-W SIX DAYS) …………………….. 34 Installing the air filter ……………………………………………. 64
Checking the steering head bearing play …………………….. 34 Cleaning the air filter and air filler box ………………………. 65
Adjusling play of steering head bearing (EXC USA, all Removing the carburetor connection boot …………………… 65
SIX DAYS models) ………………………………………………… 34 Installing the carburetor connection boot ……………………. 65
Adjusling play of steering head bearing (EXC EU/AUS) …… 35 07/FUEL TANK, SEAT, TRIM ………………………………………. 66
02/HANDLEBAR, INSTRUMENTS ………………………………… 36 Opening filler cap …………………………………………………. 66
Handlebar position ……………………………………………….. 36 Closing filler cap ………………………………………………….. 66
Adjusting handlebar position …………………………………… 36 Removi ng the seal… ……………….. ……. …………. ……. ……. 66
Adjusling the basic position of Ihe clulch lever …………….. 36 Mounting the seal ………………………………………………… 66
Checking the choke cable routing (EXC EU, Removing the fuel tank ………………………………………….. 66
EXC SIX DAYS) ……………………………………………………. 37 Installing the fuel tank …………………………………………… 67
Checking the choke cable play (EXC EU,
EXC SIX DAYS) ……………………………………………………. 37
Fuel tap ……………………………………………………………… 68
08!MASK, FENDER ………………………………………………….. 69
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
Removi ng the front fender ………… …… ………….. …… …….. 69
Install i ng the front fender…… …… …….. …… …… …….. ……. 69
Removing headlight mask with headlight ……………………. 69
Refitting the headlight mask with the headlight. …………… 69
09/FRONT WHEEL …………………………………………………… 71
Removi ng front wheel…. ………….. …… ………….. …… …….. 71
Install i ng the front wheeL…… …… …….. …… …… …….. ……. 71
Checking the brake discs ………………………………………… 72 Installing the engine ……………………………………………. 102
Removing the Iront brake disc …………………………………. 72 3D/DISASSEMBLING THE ENGINE …………………………….. 104
Installing the front brake disc ………………………………….. 73 Preparations ………………………………………………………. 104
Checking the tire condition ……………………………………… 73 Draining the engine oil …………………………………………. 104
Checking tire air pressure ……………………………………….. 73 Removing the oil lilter ………………………………………….. 104
Checking spoke tension ………………………………………….. 74 Draining the gear oil, removing the gear oil screen ………. 104
lO/REAR WHEEL …………………………………………………….. 75 Removi ng the starter motor………. …… ………….. ……. ….. 105
Removing the rear wheel ………………………………………… 75 Removi ng the spark pi ug ………….. …… ………….. …… …… 105
Installing the rear wheel …………………………………………. 75 Removing the valve cover ……………………………………… 105
Removing the rear brake disc …………………………………… 76 Removing the shift lever ……………………………………….. 105
Installing the rear brake disc …………………………………… 76 Removi ng the alternator cover. ……. …… ……. ……. …… ….. 106
Checking the chain tension …………………………………….. 76 Positioning the engine at ignition top dead center ……….. 106
Adjusting the chain tension …………………………………….. 77 Removing the timing chain tensioner ……………………….. 107
Adjusting chain guide ……………………………………………. 78 Removing the camshaft ………………………………………… 107
Checking the chain, rear sprocket, engine sprocket and Removing the cylinder head …………………………………… 107
chain guide …………………………………………………………. 78 Removing the piston ……………………………………………. 107
Checking for chain dirt accumulation ………………………… 80 Removi ng the rotor.. …… ………….. …… ………….. ……. ….. 108
Clean i ng the chai n…. ………….. …… ………….. …… …………. 80 Removing the balance weight ………………………………… 108
11IWIRING HARNESS, BATTERy ………………………………… 81 Removing the timing chain guide rail ………………………. 108
Removing the main fuse …………………………………………. 81 Removing the timing chain tensioning rail.. ……………….. 109
Installing the main fuse …………………………………………. 81 Removing the timing chain securing guide ………………… 109
Changing the fuse of the radiator Ian (EXC SIX DAYS, Removing the timing chain ……………………………………. 109
XC-W SIX DAYS) …………………………………………………… 81 Removing the ignition pulse generator ……………………… 109
Removi ng the battery ………….. …… ………….. …… …………. 82 Removing the suction pump ………………………………….. 109
Installing the battery ……………………………………………… 82 Removing the kickstarter ………………………………………. 110
Rechargi ng the battery ………… …… ………….. …… …………. 82 Removing the water pump cover …………………………….. 110
Checking the quiescent current ………………………………… 83 Removi ng the cl utch cover …. ………….. …… ………….. ….. 11 0
Checking the charging voltage …………………………………. 83 Disassembling the clutch disks ………………………………. 111
Checking the voltage regulator …………………………………. 84 Removi ng the pri mary gear nut ………… …… ………….. ….. 111
Checking the starter relay ……………………………………….. 85 Removing the outer clutch hub ………………………………. 111
13/BRAKE SYSTEM ………………………………………………….. 86 Removing the balancer shaft …………………………………. 112
Checking the front brake linings ……………………………….. 86 Removing the torque limiter ………………………………….. 112
Removing front brake linings …………………………………… 86 Removing the starter idler gear ………………………………. 112
Installing the front brake linings ………………………………. 86 Removing the kickstarter idler gear …………………………. 112
Changing the front brake linings ………………………………. 87 Removing the kickstarter idler gear …………………………. 113
Checking free travel of hand brake lever ……………………… 88 Removing the shift shaft ………………………………………. 113
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
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
3D/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 Installing the suction pump …………………………………… 151
pin ………………………………………………………………….. 124 Installing the ignition pulse generator ………………………. 152
Checking crankshaft run-out at bearing pin ……………….. 126 Installing the timing chain …………………………………….. 152
Cylinder – Nikasil” coating …………………………………….. 126 Installing the timing chain securing guide …………………. 152
Checking/measuring cylinder …………………………………. 126 Installing the timing chain tensioning rail …………………. 152
Checking/measuring the piston ………………………………. 127 Installing the timing chain guide rail ……………………….. 153
Checking the piston ring end gap ……………………………. 127 Installing the balance weight …………………………………. 153
Piston/cylinder – determining the mounting clearance ….. 128 Installing the rotor ………………………………………………. 153
Checking the oil pumps ………………………………………… 128 Installing the piston …………………………………………….. 153
Disassembling the autodecompressor ………………………. 128 Installing the cylinder head …………………………………… 155
Assembling the autodecompressor …………………………… 129 Installing the camshaft ………………………………………… 156
Checking camshaft ……………………………………………… 129 Installing the timing chain tensioner ……………………….. 156
Checking the timing assembly ……………………………….. 130 Checking the valve clearance …………………………………. 157
Preparing the timing chain tensioner for installation ……. 130 Adjusting the valve clearance …………………………………. 157
Removing the rocker arm ………………………………………. 131 Installing the alternator cover ………………………………… 157
Removing the valves ……………………………………………. 131 Installing the shift lever ……………………………………….. 158
Changing camshaft bearing …………………………………… 132 Installing the valve cover ………………………………………. 158
Checking valves ………………………………………………….. 132 Installing the spark plug ……………………………………….. 158
Checking valve springs …………………………………………. 133 Installing the starter motor ……………………………………. 158
Checking valve spring seat …………………………………….. 133 Installing the oil filter ………………………………………….. 159
Checking the cylinder head …………………………………… 133 Filling up with engine oil ………………………………………. 159
Checking the rocker arm shafts ………………………………. 134 Filling up with gear oil …………………………………………. 159
Installing the valves …………………………………………….. 134 Removing the engine from the work stand …………………. 160
Installing the rocker arm ………………………………………. 135 31/CARBURETOR ………………………………………………….. 161
Checking the clutch …………………………………………….. 135 Choke (EXC AUS/USA, XC.W SIX DAYS) …………………… 161
Checking shift mechanism ……………………………………. 136 Choke (EXC EU, EXC SIX DAYS) …………………………….. 161
Preassembling the shift shaft …………………………………. 137 Carburetor – adjusting the idle speed ……………………….. 161
Disassembling the main shaft ………………………………… 137 Emptying the carburetor float chamber …………………….. 162
Assembling the main shaft ……………………………………. 138 Removing the carburetor ………………………………………. 163
Disassembling the countershaft ……………………………… 138 Installing the carburetor ……………………………………….. 163
Assembling the countershaft ………………………………….. 139 Checking/adjusting the carburetor components …………… 164
Checking the transmission …………………………………….. 139 Checking the throttle valve sensor …………………………… 165
Premounting the kickstarter shaft ……………………………. 140 Disassembling the carburetor …………………………………. 165
Checking the electric starter mode ………………………….. 141 Checking the choke slide ………………………………………. 168
Removing the freewheel ……………………………………….. 142 Checking the jet needle ………………………………………… 168
Checking the freewheel ………………………………………… 142 Checking the throttle slide …………………………………….. 168
Installing the free wheel ……………………………………….. 142 Checking the needle jet ………………………………………… 169
30/ENGINE ASSEMBLy …………………………………………… 144 Checking the float needle valve ………………………………. 169
Installing the crankshaft ……………………………………….. 144 Assembling the carburetor …………………………………….. 169
Installing the transmission shafts ……………………………. 144 Checking/adjusting the float level ……………………………. 172
Installing the shift forks ……………………………………….. 144 Checking/setting the throttle slide opening ………………… 172
Installing the shift drum ……………………………………….. 145 Checking/adjusting the accelerator pump ………………….. 173
Installing the shift rails ………………………………………… 145 Adjusting the position of the throttle position sensor ……. 173
Installing the left engine case ………………………………… 145 321CLUTCH ………………………………………………………….. 175
Installing the free wheel gear …………………………………. 146 Checking the fluid level of hydraulic clutch ……………….. 175
Installing the primary gear …………………………………….. 146 Changing the hydraulic clutch fluid …………………………. 175
Installing the oil pumps ……………………………………….. 146 33fTRANSMISSION ………………………………………………… 177
Installing the oil pump gears …………………………………. 147 Removing the engine sprocket ……………………………….. 177
Installing the locking lever …………………………………….. 147 Installing the engine sprocket ………………………………… 177
Installing the shift drum locating uni!.. …………………….. 147 35IWATER PUMP, COOLING SYSTEM ………………………… 178
Installing the shift shaft ……………………………………….. 147 Cooling system …………………………………………………… 178
Installing the kickstarter idler gear ………………………….. 148 Checking the anti-freeze and coolant level ………………… 178
Installing the kickstarter shaft ……………………………….. 148 Checking the coolant level …………………………………….. 179
Installing the starter idler gear ……………………………….. 148 Draining coolant …………………………………………………. 179
Installing the torque limiter …………………………………… 148 Refilling coolant …………………………………………………. 180
Installing the balancer shaft ………………………………….. 149 381LUBRICATION SYSTEM ………………………………………. 181
Installing the outer clutch hub ……………………………….. 149 Oil circuit …………………………………………………………. 181
Installing the primary gear nut ……………………………….. 150 Checking engine oil level ………………………………………. 181
Installing the clutch discs …………………………………….. 150 Changing engine oil and oil filter, cleaning engine oil
Installing the clutch cover …………………………………….. 150 screen ……………………………………………………………… 182
Installing the water pump cover ……………………………… 151 Draining engine oil, cleaning engine oil screen …………… 182
Installing the kickstarter ……………………………………….. 151 Removing the oil filter ………………………………………….. 182
Installing the oil filte, ………………………………………….. 183 Page 4 of 5 (EXC AUS) ………………………………………… 228
Filling up with engine oil ………………………………………. 183 Page 5 of 5 (EXC AUS) ………………………………………… 230
Adding engine oil ……………………………………………….. 184 Page 1 of 5 (EXC USA) ………………………………………… 232
Checking the engine oil p’essu’e …………………………….. 184 Page 2 of 5 (EXC USA) ………………………………………… 234
Checking the gea, oil leveL ……………………………………. 185 Page 3 of 5 (EXC USA) ………………………………………… 236
Changing gear oil, cleaning gear oil screen ………………… 185 Page 4 of 5 (EXC USA) ………………………………………… 238
Draining gear oil, cleaning gear oil screen …………………. 185 Page 5 of 5 (EXC USA) ………………………………………… 240
Filling up with gea, oil …………………………………………. 186 Page 1 of 4 (XC-W SIX DAYS) ………………………………… 242
Adding gea, oil …………………………………………………… 186 Page 2 of 4 (XC-W SIX DAYS) ………………………………… 244
39/1GNITION SYSTEM …………………………………………….. 188 Page 3 of 4 (XC-W SIX DAYS) ………………………………… 246
Checking the ignition system …………………………………. 188 Page 4 of 4 (XC-W SIX DAYS) ………………………………… 248
Ignition coil – checking the p,imary winding ………………. 189 SUBSTANCES ……………………………………………………….. 250
Ignition coil – checking the secondary winding ……………. 189 AUXILIARY SUBSTANCES ………………………………………… 252
Checking the spa,k plug connecto’ ………………………….. 190 SPECIAL TOOLS …………………………………………………….. 254
Alternato, – checking the cha,ging coil of the ignition …… 190 STANDARDS …………………………………………………………. 267
Alternato, – checking the light and battery winding ……… 190 INDEX …………………………………………………………………. 268
Checking the ignition pulse gene,ato, ………………………. 191
Removi ng the stato,… ……. ……. …… ……. ……. …… ………. 192
Installing the stato, …………………………………………….. 192
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
450 EXC EU/AUS, 450 EXC SIX DAYS …………………….. 199
450 EXC USA ……………………………………………………. 199
450 XC-W SIX DAYS USA …………………………………….. 200
530 EXC EU/AUS, 530 EXC SIX DAYS …………………….. 200
530 EXC USA ……………………………………………………. 200
530 XC-W SIX DAYS USA …………………………………….. 201
TECHNICAL DATA – CARBURETOR TIGHTENING
TORQU ES ……. ……………….. ……………….. …………………… 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
CLEAN I NG…… ……………….. ……. …………. ……. …………….. 208
Clean i ng the motorcycle…………….. ……. …………. ………. 208
STORAGE …………………………………………………………….. 209
Sto’age …………………………………………………………….. 209
Putting into ope,ation afie, sto,age …………………………. 209
SERVICE SCHEDULE ………………………………………………. 210
Service schedule ………………………………………………… 210
Service wo,k (as additional o’de’) ……………………………. 211
WIRING DIAGRAM …………………………………………………. 212
Page 1 of 5 (EXC EU, EXC SIX DAyS) ………………………. 212
Page 2 of 5 (EXC EU, EXC SIX DAyS) ………………………. 214
Page 3 of 5 (EXC EU, EXC SIX DAyS) ………………………. 216
Page 4 of 5 (EXC EU, EXC SIX DAyS) ………………………. 218
Page 5 of 5 (EXC EU, EXC SIX DAyS) ………………………. 220
Page 1 of 5 (EXC AUS) ………………………………………… 222
Page 2 of 5 (EXC AUS) ………………………………………… 224
Page 3 of 5 (EXC AUS) ………………………………………… 226
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