Ktm 400 450 530 EXC \ EXC Six-Days \ XC-W  WorkShop Service Repair Manual 2008-2009

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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
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

Table Of Contents:

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
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

And Much More ...

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