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2008 450-540 exc Workshop Servcie Repair Manual.pdf
2008 KTM 450 530 EXC-R XCR-W Manual Model Coverage
2008 KTM 450 EXC-R EU
2008 KTM 450 EXC-R AUS/UK
2008 KTM 450 EXC-R SIX DAYS
2008 KTM 450 EXC-R USA
2008 KTM 450 XCR-W USA
2008 KTM 450 XCR-W ZA
2008 KTM 530 EXC-R EU
2008 KTM 530 EXC-R AUS/UK
2008 KTM 530 EXC-R SIX DAYS
2008 KTM 530 EXC-R USA
2008 KTM 530 XCR-W USA
2008 KTM 530 XCR-W ZA
Table of Contents
MEANS OF REPRESENTATION
IMPORTANT NOTES
MOTORCYCLE
Jacking up the motorcycle
Removing the motorcycle from the work stand
FORK, TRIPLE CLAMP
Fork part number
Adjusting spring preload of the fork
Adjusting compression damping of fork
Adjusting rebound damping of fork
Cleaning dust boots of fork legs
Removing the fork legs
Installing the fork legs
Bleeding fork legs
Removing the fork protector
Installing the fork protector
Loosening the fork protection
Positioning the fork protection
Removing the lower triple clamp (EXC-R SIX DAYS, XCR-W USA)
Installing the lower triple clamp (EXC-R SIX DAYS, XCR-W USA)
Removing the lower triple clamp (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA)
Installing the lower triple clamp (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA)
Fork offset (EXC-R SIX DAYS, XCR-W USA)
Setting the fork offset (EXC-R SIX DAYS, XCR-W USA)
Checking play of steering head bearing
Adjusting play of steering head bearing
(EXC-R SIX DAYS, XCR-W USA)
Adjusting play of steering head bearing (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA)
Greasing the steering head bearing
FRAME
Removing the engine sprocket cover
Installing the engine sprocket cover
SHOCK ABSORBER, SWINGARM
Shock absorber part number
Adjusting high-speed compression damping of the shock
absorber
Adjusting the low-speed compression damping of the
shock absorber
Adjusting rebound damping of the shock absorber
Measuring rear wheel sag unloaded
Checking static sag of the shock absorber
Checking the riding sag of the shock absorber
Adjusting spring preload of the shock absorber
Adjusting riding sag
Removing the shock absorber
Installing shock absorber
EXHAUST
Removing main silencer
Fitting the main silencer
Removing the manifold
Installing the manifold
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
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
MASK, FENDER
Dismounting the front fender
Installing the front fender
Removing headlight mask with headlight (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W ZA)
Refitting the headlight mask with the headlight (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W ZA)
Dismount the start number plate (XCR-W USA)
Fitting the start number plate (XCR-W USA)
FRONT WHEEL
Removing front wheel
Fitting front wheel
Checking brake discs
Removing the front brake disc
Installing the front brake disc
Tire condition checking
Checking tire air pressure
Checking spoke tension
REAR WHEEL
Removing rear wheel
Fitting rear wheel
Removing the rear brake disc
Installing the rear brake disc
Checking the 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 chain dirt
Cleaning the chain
WIRING HARNESS, BATTERY
Removing a fuse
Replacing the fuse
Removing the battery
Installing the battery
Recharging the battery
BRAKE SYSTEM
Checking the front brake linings
Removing the front brake linings
Installing the front brake linings
Changing the front brake linings
Adjusting basic position of handbrake lever (Every XCR-W motorcycles)
Checking free play of hand brake lever
Adjusting free travel of handbrake lever (Every EXC-R motorcycles)
Checking the front brake fluid level
Add front brake fluid
Changing the front brake fluid
Checking rear brake linings
Removing the rear brake linings
Installing the rear brake linings
Changing the rear brake linings
Checking free play of foot brake lever
Adjusting basic position of footbrake lever
Checking rear brake fluid level
Adding rear brake fluid
Changing the rear brake fluid
LIGHT SYSTEM, INSTRUMENTS
Adjusting speedometer functions
Setting kilometers or miles
Setting the clock
ENGINE
Removing the engine
Installing the engine
DISASSEMBLING ENGINE
Preparations
Draining the engine oil
Removing the oil filter
Draining gear oil, cleaning gear oil screen
Removing the starter engine
Removing the valve cover
Removing the shift lever
Removing the spark plug
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
Removing the clutch discs
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 with the free-wheel-gear
Removing the left section of the engine case
Removing the shift rails
Removing the shift roller
Removing the shift forks
Removing the transmission shaft
Removing the crankshaft
ENGINE – WORK ON INDIVIDUAL PARTS
Work on the right section of the engine case
Work on the left section of the engine case
removing the oil pressure regulator valve
Checking the spring length of the 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 conrod bearing
Checking the crankshaft run-out on the bearing pin
Cylinder – Nikasil® coating
Checking/measuring the cylinder
Checking/measuring the piston
Checking the piston ring end gap
Checking piston/cylinder mounting clearance
Checking the oil pumps for wear
Checking the lubrication system
Disassembling the autodecompressor
Assembling the autodecompressor
Checking the camshaft
Checking the timing assembly
Preparing the timing chain tensioner for installation
Removing the rocker arm
Removing the valves
Replacing the camshaft bearing
Checking the valves
Checking the valve springs
Checking the lower valve spring retainer
Checking the cylinder head
Installing valves
Installing the rocker arm
Checking the clutch
Checking the shift mechanism
Preassembling the shift shaft
Dismantling the main shaft
Assembling the main shaft
Dismantling the countershaft
Assembling the countershaft
Checking the transmission
Checking electric starter operation
Removing the free-wheel
Checking the free-wheel
Installing the free-wheel
ASSEMBLING ENGINE
Installing the crankshaft
Installing the transmission shaft
Installing the shift forks
Installing the shift roller
Installing the shift rails
Installing the left engine case
Installing the primary gear with the free-wheel-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 universal mounting rack
CARBURETOR
Choke (EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W)
Choke (EXC-R EU)
Checking the choke Bowden cable routing (EXC-R EU)
Checking the choke Bowden cable for play (EXC-R EU)
Adjusting the choke Bowden cable play (EXC-R EU)
Checking gas Bowden cable route
Checking play in the gas Bowden cable
Adjusting the gas Bowden cable play
Removing the carburetor
Disassembling the carburetor
Checking 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/adjusting the throttle slide opening
Checking throttle valve sensor TPS
Adjusting the position of throttle valve sensor TPS
Assembling the carburetor
Installing the carburetor
Carburetor – adjusting idle
Emptying the carburetor float chamber
CLUTCH
Checking fluid level of hydraulic clutch
Changing fluid level of hydraulic clutch
TRANSMISSION
Removing the engine sprocket
Installing the engine sprocket
WATER PUMP, COOLING SYSTEM
Checking antifreeze and coolant level
Checking the coolant level
Draining coolant
Refilling coolant
LUBRICATION SYSTEM
Oil cycle
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 gear oil level
Changing gear oil, cleaning gear oil screen
Draining gear oil, cleaning gear oil screen
Filling up with gear oil
Topping up with gear oil
TROUBLESHOOTING
TECHNICAL DATA – ENGINE
Capacity- engine oil
Capacity – gear oil
Capacity – coolant
TECHNICAL DATA – TOLERANCE, WEAR LIMITS OF
ENGINE
TECHNICAL DATA – ENGINE TIGHTENING TORQUES
TECHNICAL DATA – CARBURETOR
450 EXC-R EU, 450 EXC-R AUS/UK (39001)
450 EXC-R SIX DAYS, 450 EXC-R USA, 450 XCR-W (3900L)
530 EXC-R EU, 530 EXC-R AUS/UK (3900J)
530 EXC-R SIX DAYS, 530 EXC-R USA, 530 XCR-W (3900M)
TECHNICAL DATA – CARBURETOR TIGHTENING
TORQUES
TECHNICAL DATA – CHASSIS
Lighting equipment
Tires
Capacity – fuel
TECHNICAL DATA – FORK
TECHNICAL DATA – SHOCK ABSORBER
TECHNICAL DATA – CHASSIS TIGHTENING TORQUES
CLEANING
Cleaning motorcycle
STORAGE
Storage
Putting into operation after storage
GREASING AND SERVICE TABLE
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-R EU)
Wiring diagram (EXC-R AUS/UK)
Wiring diagram (EXC-R USA)
Wiring diagram (EXC-R SIX DAYS)
Wiring diagram (XCR-W USA)
Wiring diagram (XCR-W ZA)
SUBSTANCES
AUXILIARY SUBSTANCES
SPECIAL TOOLS
STANDARDS
INDEX
File Data