2009 KTM Motorcycle Service Manual 400 450 530 EXC XC-W Six Days

Description

This 248 page, 2009 KTM Service Manual for KTM 400 450 530 EXC XC-W and Six Days motorcycles is an authorized reproduction of the original classic KTM motorcycle manual that is no longer in print.

This KTM Service Manual works for the following KTM motorcycles:

2009 KTM 400 EXC EU
2009 KTM 400 EXC AUS
2009 KTM 400 XC-W USA
2009 KTM 450 EXC EU
2009 KTM 450 EXC AUS
2009 KTM 450 EXC SIX DAYS EU
2009 KTM 450 XC-W USA
2009 KTM 450 XC-W ZA
2009 KTM 530 EXC EU
2009 KTM 530 EXC AUS
2009 KTM 530 EXC SIX DAYS EU
2009 KTM 530 XC-W USA
2009 KTM 530 XC-W ZA
2009 KTM 450 EXC USA
2009 KTM 530 EXC USA

This 2009 KTM Service Manual 400 450 530 EXC XC-W Six Days includes the following repair information:

MEANS OF REPRESENTATION
IMPORTANT NOTES
LOCATION OF SERIAL NUMBERS
Chassis number
Type label
Key number (all EXC models)
Engine number
Fork part number
Shock absorber part number
MOTORCYCLE
Jacking up the motorcycle
Removing the motorcycle from the work stand
Starting
Starting the motorcycle for checking
Ol/FORK, TRIPLE CLAMP
Adjusting compression damping of fork
Adjusting rebound damping of fork
Adjusting spring preload of the fork
Bleeding fork legs
Cleaning the dust boots of the fork legs
Loosening the fork protection
Positioning the fork protection
Removing the fork legs
Installing fork legs
Removing the fork protector
Installing the fork protector
Performing a fork service
Disassembling the fork legs
cartridge, disassembling
Disassembling the compression damping fitting
Checking the fork legs
Assembling the compression damping fitting
Assembling the cartridge
Assembling the fork legs
Greasing the steering head bearing
Removing the lower triple clamp (EXC SIX DAYS,XC-W USA, EXC USA)
Installing the lower triple clamp (EXC SIX DAYS,XC-W USA, EXC USA)
Removing the lower triple clamp (EXC EU, EXC AUS,XC-W ZA)
Installing the lower triple clamp (EXC EU, EXC AUS,XC-W ZA)
Checking the play of the steering head bearing
Adjusting play of steering head bearing (EXC SIX DAYS,XC-W USA, EXC USA)
Adjusting play of steering head bearing (EXC EU,EXC AUS, XC-W ZA)
02/HANDLEBAR, INSTRUMENTS
Handlebar position
Adjusting handlebar position
Adjusting basic position of clutch lever
Checking the choke cable routing (EXC EU,EXC SIX DAYS)
Checking the choke cable play (EXC EU,EXC SIX DAYS)
Adjusting the choke cable play (EXC EU,EXC SIX DAYS)
Checking of the routing of the throttle cable
Checking the play in the throttle cable
Adjusting the play in the throttle cable
03/FRAME
Removing the engine sprocket cover
Installing the engine sprocket cover
04/SH0CK 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 shock absorber
Measuring rear wheel sag unloaded
Checking static sag of shock absorber
Checking riding sag of shock absorber
Adjusting spring preload of the shock absorber
Adjusting riding sag
Removing the shock absorber
Installing the shock absorber
Performing a shock absorber service
Removing the spring
Disassembling the shock absorber
Disassembling the piston rod
Disassembling the seal ring retainer
Replacing the pilot bushing
Checking the shock absorber
Disassembling the rebound adjuster
Removing the heim joint
Installing the heim joint
Assembling the rebound adjuster
Assembling the seal ring retainer
piston rod, assembling
Assembling the damper
Bleeding and filling the damper
Filling the damper with nitrogen
Installing the spring
05/EXHAUST
Removing main silencer
Installing the main silencer
Removing the manifold
Installing the manifold
06/AIR FILTER
Dismounting the air filter box lid
Installing the air filter box lid
Removing the air filter
Installing the air filter
Cleaning air filter
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
Dismounting the fuel tank
Installing the fuel tank
Fuel tap
08/MASK, FENDER
Removing the front fender
Installing the front fender
Removing headlight mask with headlight (EXC EU,EXC AUS, EXC SIX DAYS, EXC USA, XC-W ZA)
Refitting the headlight mask with the headlight (EXC EU,EXC AUS, EXC SIX DAYS, EXC USA, XC-W ZA)
Removing the start number plate (XC-W USA)
Installing the start number plate (XC-W USA)
09/FR0NT WHEEL
Removing the front wheel
Installing the front wheel
Checking the brake discs
Removing the front brake disc
Installing the front brake disc
Checking the tire condition
Checking tire air pressure
Checking spoke tension
10/REAR WHEEL
Removing the rear wheel
Installing the rear wheel
Removing the rear brake disc
Installing the rear brake disc
Checking chain tension when fitting rear wheel
Adjusting chain tension – fitting rear wheel
Checking the chain tension
Adjusting chain tension – after checking
Adjusting the chain tension
Adjusting chain guide
Checking the rear sprocket / engine sprocket for wear
Checking chain wear
Checking for chain dirt accumulation
Cleaning the chain
11/WIRING HARNESS, BATTERY
Removing a fuse
Installing the fuse
Removing the battery
Installing the battery
Recharging the battery
Checking the closed current
Checking the charging voltage
Checking the voltage regulator
Checking the charging current
Checking the starter relay
13/BRAKE SYSTEM
Checking the front brake linings
Removing front brake linings
Mounting front brake linings
Changing the front brake linings
Checking free travel of hand brake lever
Adjusting basic position of handbrake lever (all XC-W models)
Adjusting free travel of handbrake lever (all EXC
models)
Checking the brake fluid level of the front brake
Adding front brake fluid
Changing the front brake fluid
Checking rear brake linings
Removing rear brake linings
Mounting rear brake linings
Changing the rear brake linings
Checking free travel of foot brake lever
Adjusting basic position of foot brake lever
Checking the brake fluid level of the rear brake
Adding rear brake fluid
Changing the rear brake fluid
14/LIGHTING SYSTEM, INSTRUMENTS
Adjusting the speedometer functions
kilometers or miles, setting
Activating the additional functions
Setting the wheel circumference
Setting the clock
Checking the headlamp setting (EXC EU, EXC AUS,EXC SIX DAYS, EXC USA, XC-W ZA)
Adjusting the beam width of the headlight (EXC EU,EXC AUS, EXC SIX DAYS, EXC USA, 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 engine
Removing the spark plug
Removing the valve cover
Removing the shift lever
Removing the generator cover
Setting the engine to 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 shaft
Removing the kickstarter idler gear
Removing the shift shaft
Removing the shift drum locating
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
30/ENGINE – WORK ON THE INDIVIDUAL PARTS
Working on the right section of the engine case
Working on the left section of the engine case
Removing the oil pressure regulator valve
Checking spring length of oil pressure regulator valve
Installing the oil pressure regulator valve
Removing the crankshaft seal ring in the clutch cover
Fitting the crankshaft seal ring into the clutch cover
Removing the water pump
Installing the water pump
Checking the balancer shaft
Removing the timing chain sprocket
Installing the timing chain sprocket
Changing the connecting rod, conrod bearing and crank
pin
Checking crankshaft run-out at bearing pin
cylinder – Nikasil® coating
Checking/measuring cylinder
Checking/measuring the piston
Checking the piston ring end gap
Piston/cylinder – determining the mounting clearance
Checking the oil pumps for wear
Disassembling the autodecompressor
Assembling the autodecompressor
Checking camshaft
Checking the timing assembly
Preparing the timing chain tensioner for installation
Removing the rocker arm
Removing the valves
Changing camshaft bearing
Checking valves
Checking valve springs
Checking valve spring seat
Checking the cylinder head
Checking the rocker arm shafts
Installing valves
Installing the rocker arm
Checking clutch
Checking shift mechanism
Preassembling the shift shaft
Dismantling the main shaft
Assembling the main shaft
Dismantling the countershaft
Assembling the countershaft
Checking the transmission
Premounting the kickstarter shaft
Checking the electric starter mode
Removing the freewheel
Checking the freewheel
Installing the free-wheel
30/ENGIINE ASSEMBLY
Installing the crankshaft
Installing the transmission shaft
Installing the shift forks
Installing the shift drum
Installing the shift rails
Installing the left engine case
Installing the free wheel gear
Installing the primary gear
Installing the oil pumps
Installing the oil pump gears
Installing the locking lever
Installing the shift drum locating
Installing the shift shaft
Installing the kickstarter idler gear
Installing the kickstarter shaft
Installing the starter idler gear
Installing the torque limiter
Installing the balancer shaft
Installing the outer clutch hub
Installingtheprimary gear nut
Installing the clutch discs
Installing the clutch cover
Installing the water pump cover
Installing the kickstarter
Installing the suction pump
Installing the ignition pulse generator
Installing the timing chain
Installing the timing chain securing guide
Installing the timing chain tensioning rail
Installing the timing chain guide rail
Installing the balance weight
Installing the rotor
Installing the piston
Installing the cylinder head
Installing the camshaft
Installing the timing chain tensioner
Checking the valve clearance
Adjusting the valve clearance
Installing the generator cover
Installing the shift lever
Installing the valve cover
Installing the spark plug
Installing the starter motor
Mounting oil filter
Filling up with engine oil
Filling up with gear oil
Removing the engine from the work stand
31/CARBURETOR
Choke (EXC AUS, XC-W, EXC USA)
Choke (EXC EU, EXC SIX DAYS)
Removing the carburetor
Disassembling the carburetor
Checking/adjusting the carburetor components
Checking/adjusting the accelerator pump
Checking the choke slide
Checking the jet needle
Checking the throttle slide
Checking the needle jet
Checking the float needle valve
Checking/adjusting the float level
Checking/setting the throttle slide opening
Checking the throttle valve sensor
Adjusting the position of the throttle position sensor
Assembling the carburetor
Installing the carburetor
Carburetor – adjusting idle
Emptying the carburetor float chamber
32/CLUTCH
Checking fluid level of hydraulic clutch
Changing the hydraulic clutch fluid
33/TRANSMISSION
Removing the engine sprocket
Installing the engine sprocket
35/WATER PUMP, COOLING SYSTEM
Cooling system
Checking the antifreeze and coolant level
Checking the coolant level
Draining coolant
Refilling coolant
38/LUBRICATION SYSTEM
Oil circuit
Checking engine oil level
Changing engine oil and oil filter, cleaning engine oil
screen
Draining engine oil, cleaning engine oil screen
Removing the oil filter
Mounting oil filter
Filling up with engine oil
Topping up engine oil
Checking the engine oil pressure
Checking the gear oil level
Changing gear oil, cleaning gear oil screen
Draining gear oil, cleaning gear oil screen
Filling up with gear oil
Adding gear oil
39/IGNITION SYSTEM
Checking the ignition system
Checking the ignition coil
Checking the spark plug connector
Checking the CDI controller
Checking the ignition pulse generator
Checking the generator
Removing the stator
Mounting the stator
40/ELECTR0STARTER
Checking the starter motor
TROUBLESHOOTING
TECHNICAL DATA – ENGINE
Capacity – engine oil
Capacity – gear oil
Capacity – coolant
TECHNICAL DATA – ENGINE TOLERANCES, WEAR
LIMITS
TECHNICAL DATA – ENGINE TIGHTENING TORQUES
TECHNICAL DATA – CARBURETOR
400 EXC
400 XC-W USA
450 EXC EU/AUS, 450 EXC SIX DAYS
450 EXC USA
450 XC-W
530 EXC EU/AUS, 530 EXC SIX DAYS
530 EXC USA
530 XC-W
TECHNICAL DATA – CARBURETOR TIGHTENING
TORQUES
TECHNICAL DATA – CHASSIS
Lighting equipment
Tires
Capacity – fuel
TECHNICAL DATA – FORK
TECHNICAL DATA – SHOCK ABSORBER
TECHNICAL DATA – TIGHTENING TORQUES FOR
CHASSIS
CLEANING
Cleaning motorcycle
STORAGE
Putting into operation after storage
SERVICE SCHEDULE
Important maintenance work to be carried out by an
authorized KTM workshop
Important maintenance work to be carried out by an
authorized KTM workshop, (as additional order)
Important checks and maintenance work to be carried
out by the rider
WIRING DIAGRAM
Wiring diagram (EXC EU, EXC AUS, EXC-R SIX DAYS)
Wiring diagram (EXC USA)
Wiring diagram (all XC-W models)
OPERATING SUBSTANCES
AUXILIARY SUBSTANCES
SPECIAL TOOLS
STANDARDS
INDEX