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2009 KTM 400 EXC, 400 XC-W, 450 XC-W, 530 EXC, 530 XC-W Motorcycle Workshop Repair Service Manual
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 is a COMPLETE Service and Repair Manual for your 2009 KTM 400 EXC, 400 XC-W, 450 XC-W, 530 EXC, 530 XC-W Motorcycle. It covers every single detail.
This QUALITY manual is 100 percents COMPLETE and INTACT, no MISSING/CORRUPT pages/sections to freak you out! Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure. This manual for 2009 KTM 400 EXC, 400 XC-W, 450 XC-W, 530 EXC, 530 XC-W Motorbike can be viewed on any computer, as well as zoomed and printed. All repair procedures are covered A-Z. Save yourself Big money by doing your own repairs! This manual makes any repair job easy to do with very easy to follow step-by-step instructions & pictures on all areas of repair. This high quality manual covers everything: For example: General Information, Body, Frame & Mounting, Engine, Suspension, Driveline, Brake System, Transmission/Transaxle, Clutch, Chains, Exhaust, Fuel, Steering, Shocks, Climate Control, Instrumentation & Warnings Systems, Battery & Charging Systems, Audio, Lighting, Electrical Distribution, Wiring, Plus Lots More Etc
Fixing problems in your vehicle is a do-it-approach with the this Repair Manual for 2009 KTM 400 EXC, 400 XC-W, 450 XC-W, 530 EXC, 530 XC-W Motorcycle as they contain comprehensive instructions and procedures on how to fix the problems in your ride. Repair Manuals can come in handy especially when you have to do immediate repair. The durability of your vehicle/bike is unquestionable but you also know that no matter how tough they are, constant use can cause them to deteriorate. When this happens, and ultimately it will, you will have to replace them. Some car/bike parts are very simple to mount and do not require professional help. By having a trusty repair manual you not only save money but you also get to experience the fun of do-it-yourself projects. A repair manual comes with comprehensive details regarding technical data, diagrams, a complete list of car parts and pictures. Even the most novice can easily follow the step-by-step guides which are made simple by the illustrations and drawings. You can find a complete list of accessories that can further enhance the performance of your engine. This Repair Manual can save you a lot of time. These packages are complete with all the information needs. You will surely enjoy browsing through the pages and learning how to repair the different parts. It makes you up-to-date and more knowledge. Now, you dont have to rely on your mechanic for the simplest repair. You can do it at the comfort of your garage. All pages are printable, so print off what you need and take it with you into the garage or workshop. This manual will never get dirty and rip as you can keep it safely on your PC and print the pages you need in matter of seconds.
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Format: PDF
System: All Versions of Windows, Mac, iOS, BB, Android, etc..
Requirements: PDF Reader.
Printable: Yes
2009 KTM 400 EXC, 400 XC-W, 450 XC-W, 530 EXC, 530 XC-W Motorcycle
===========
REPAIR MANUAL 2009
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
Article no. 3206064en
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............
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 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/FRONT 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 ....... 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 ... 118CONTENTS
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/ENGINE 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........
Installing the primary 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 ........
176CONTENTS
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/ELECTROSTARTER.............
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 ...........
Storage...........
Putting into operation after storage ...........
---------------------------------
And A LOT MORE..
---------------------------------
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