450 XCR-W USA

KTM 450 XCR-W USA User Manual

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REPAIR MANUAL 2008

450EXC-REU

450EXC-RAUS/UK

450EXC-RSIXDAYS

450EXC-RUSA

450XCR-WUSA

450XCR-WZA

530EXC-REU

530EXC-RAUS/UK

530EXC-RSIXDAYS

530EXC-RUSA

530XCR-WUSA

530XCR-WZA

ART. NO. 3206054en

Table of Contents

Table of Contents4
Means of Representation8
Important Notes9
Motorcycle10
- Jacking up the Motorcycle10
- Removing the Motorcycle from the Work Stand10
01/Fork, Triple Clamp11
- Fork Part Number11
- Adjusting Spring Preload of the Fork11
- Adjusting Compression Damping of Fork11
- Adjusting Rebound Damping of Fork12
- Cleaning Dust Boots of Fork Legs12
- Removing the Fork Legs13
- Installing the Fork Legs13
- Bleeding Fork Legs14
- Removing the Fork Protector14
- Installing the Fork Protector15
- Loosening the Fork Protection15
- Positioning the Fork Protection15
- Removing the Lower Triple Clamp (EXC-R SIX DAYS, XCR-W USA)15
- Installing the Lower Triple Clamp (EXC-R SIX DAYS, XCR-W USA)16
- Removing the Lower Triple Clamp (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA)17
- Installing the Lower Triple Clamp (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA)17
- Fork Offset (EXC-R SIX DAYS, XCR-W USA)18
- Setting the Fork Offset (EXC-R SIX DAYS, XCR-W USA)18
- Checking Play of Steering Head Bearing18
- Adjusting Play of Steering Head Bearing (EXC-R SIX DAYS, XCR-W USA)19
- Adjusting Play of Steering Head Bearing (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA)19
- Greasing the Steering Head Bearing20
03/Frame21
- Removing the Engine Sprocket Cover21
- Installing the Engine Sprocket Cover21
04/Shock Absorber, Swingarm22
- Shock Absorber Part Number22
- Adjusting High-Speed Compression Damping of the Shock Absorber22
- Adjusting the Low-Speed Compression Damping of the Shock Absorber22
- Adjusting Rebound Damping of the Shock Absorber23
- Measuring Rear Wheel Sag Unloaded23
- Checking Static Sag of the Shock Absorber24
- Checking the Riding Sag of the Shock Absorber24
- Adjusting Spring Preload of the Shock Absorber24
- Adjusting Riding Sag25
- Removing the Shock Absorber25
- Installing Shock Absorber26
05/Exhaust27
- Removing Main Silencer27
- Fitting the Main Silencer27
- Removing the Manifold27
- Installing the Manifold27
Installing the Air Filter28
- Cleaning Air Filter29
- Removing the Carburetor Connection Boot29
- Installing the Carburetor Connection Boot29
Removing the Air Filter28
Installing the Air Filter Box Lid28
Dismounting the Air Filter Box Lid28
06/Air Filter28
07/Fuel Tank, Seat, Trim30
- Opening Filler Cap30
- Closing Filler Cap30
- Removing the Seat30
- Mounting the Seat30
- Dismounting the Fuel Tank30
- Installing the Fuel Tank31
- Fuel Tap32
08/Mask, Fender33
- Dismounting the Front Fender33
- Installing the Front Fender33
- Removing Headlight Mask with Headlight (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W ZA)33
- Refitting the Headlight Mask with the Headlight (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W ZA)33
- Dismount the Start Number Plate (XCR-W USA)34
- Fitting the Start Number Plate (XCR-W USA)34
09/Front Wheel35
- Removing Front Wheel35
- Fitting Front Wheel35
- Checking Brake Discs36
- Removing the Front Brake Disc36
- Installing the Front Brake Disc36
- Tire Condition Checking37
- Checking Tire Air Pressure37
- Checking Spoke Tension37
10/Rear Wheel38
- Removing Rear Wheel38
- Fitting Rear Wheel38
- Removing the Rear Brake Disc39
- Installing the Rear Brake Disc39
- Checking the Chain Tension When Fitting Rear Wheel39
- Adjusting Chain Tension - Fitting Rear Wheel40
- Checking the Chain Tension40
- Adjusting Chain Tension - after Checking41
- Adjusting the Chain Tension41
- Adjusting Chain Guide42
- Checking the Rear Sprocket / Engine Sprocket for Wear42
- Checking Chain Wear43
- Checking Chain Dirt43
- Cleaning the Chain43
11/Wiring Harness, Battery44
- Removing a Fuse44
- Replacing the Fuse44
- Removing the Battery44
- Installing the Battery45
- Recharging the Battery45
13/Brake System47
- Checking the Front Brake Linings47
- Removing the Front Brake Linings47
- Installing the Front Brake Linings47
- Changing the Front Brake Linings48
- Adjusting Basic Position of Handbrake Lever (Every XCR-W Models)48
- Checking Free Play of Hand Brake Lever49
- Adjusting Free Travel of Handbrake Lever (Every EXC-R Models)49
- Checking the Front Brake Fluid Level49
- Add Front Brake Fluid50
- Changing the Front Brake Fluid50
- Checking Rear Brake Linings51
- Removing the Rear Brake Linings51
- Installing the Rear Brake Linings52
- Changing the Rear Brake Linings52
- Checking Free Play of Foot Brake Lever53
- Adjusting Basic Position of Footbrake Lever53
- Checking Rear Brake Fluid Level54
- Adding Rear Brake Fluid54
- Changing the Rear Brake Fluid54
14/Light System, Instruments56
- Adjusting Speedometer Functions56
- Setting Kilometers or Miles56
- Setting the Clock57
30/Engine58
- Removing the Engine58
- Installing the Engine59
30/Disassembling Engine61
- Preparations61
- Draining the Engine Oil61
- Removing the Oil Filter61
- Draining Gear Oil, Cleaning Gear Oil Screen61
- Removing the Starter Engine62
- Removing the Valve Cover62
- Removing the Shift Lever62
- Removing the Spark Plug62
- Removing the Generator Cover63
- Setting the Engine to Ignition Top Dead Center63
- Removing the Timing Chain Tensioner64
- Removing the Camshaft64
- Removing the Cylinder Head64
- Removing the Piston64
- Removing the Rotor65
- Removing the Balance Weight65
- Removing the Timing Chain Guide Rail65
- Removing the Timing Chain Tensioning Rail66
- Removing the Timing Chain Securing Guide66
- Removing the Timing Chain66
- Removing the Ignition Pulse Generator66
- Removing the Suction Pump66
- Removing the Kickstarter67
- Removing the Water Pump Cover67
- Removing the Clutch Cover67
- Removing the Clutch Discs68
- Removing the Primary Gear Nut68
- Removing the Outer Clutch Hub68
- Removing the Balancer Shaft69
- Removing the Torque Limiter69
- Removing the Starter Idler Gear69
- Removing the Kickstarter Shaft69
- Removing the Kickstarter Idler Gear69
- Removing the Shift Shaft70
- Removing the Shift Drum Locating70
- Removing the Locking Lever70
- Removing the Oil Pump Gears70
- Removing the Oil Pumps71
- Removing the Primary Gear with the Free-Wheel-Gear71
- Removing the Left Section of the Engine Case71
- Removing the Shift Rails72
- Removing the Shift Roller72
- Removing the Shift Forks73
- Removing the Transmission Shaft73
- Removing the Crankshaft73
30/Engine - Work on Individual Parts74
- Work on the Right Section of the Engine Case74
- Work on the Left Section of the Engine Case75
- Removing the Oil Pressure Regulator Valve77
- Checking the Spring Length of the Oil Pressure Regulator Valve77
- Installing the Oil Pressure Regulator Valve77
- Removing the Crankshaft Seal Ring in the Clutch Cover78
- Fitting the Crankshaft Seal Ring into the Clutch Cover78
- Removing the Water Pump78
- Installing the Water Pump79
- Checking the Balancer Shaft80
- Removing the Timing Chain Sprocket80
- Installing the Timing Chain Sprocket80
- Changing the Conrod Bearing80
- Checking the Crankshaft Run-Out on the Bearing Pin82
- Cylinder - Nikasil Coating82
- Checking/Measuring the Cylinder82
- Checking/Measuring the Piston83
- Checking the Piston Ring End Gap83
- Checking Piston/Cylinder Mounting Clearance84
- Checking the Oil Pumps for Wear84
- Checking the Lubrication System84
- Disassembling the Autodecompressor85
- Assembling the Autodecompressor85
- Checking the Camshaft86
- Checking the Timing Assembly86
- Preparing the Timing Chain Tensioner for Installation86
- Removing the Rocker Arm87
- Removing the Valves87
- Replacing the Camshaft Bearing88
- Checking the Valves89
- Checking the Valve Springs89
- Checking the Lower Valve Spring Retainer89
- Checking the Cylinder Head90
- Installing Valves90
- Installing the Rocker Arm91
- Checking the Clutch91
- Checking the Shift Mechanism92
- Preassembling the Shift Shaft93
- Dismantling the Main Shaft93
- Assembling the Main Shaft93
- Dismantling the Countershaft94
- Assembling the Countershaft94
- Checking the Transmission95
- Checking Electric Starter Operation96
- Removing the Free-Wheel96
- Checking the Free-Wheel97
- Installing the Free-Wheel97
30/Assembling Engine98
- Installing the Crankshaft98
- Installing the Transmission Shaft98
- Installing the Shift Forks98
- Installing the Shift Roller99
- Installing the Shift Rails99
- Installing the Left Engine Case99
- Installing the Primary Gear with the Free-Wheel-Gear100
- Installing the Oil Pumps100
- Installing the Oil Pump Gears101
- Installing the Locking Lever101
- Installing the Shift Drum Locating101
- Installing the Shift Shaft101
- Installing the Kickstarter Idler Gear102
- Installing the Kickstarter Shaft102
- Installing the Starter Idler Gear102
- Installing the Torque Limiter102
- Installing the Balancer Shaft103
- Installing the Outer Clutch Hub103
- Installing the Primary Gear Nut103
- Installing the Clutch Discs104
- Installing the Clutch Cover104
- Installing the Water Pump Cover105
- Installing the Kickstarter105
- Installing the Suction Pump105
- Installing the Ignition Pulse Generator106
- Installing the Timing Chain106
- Installing the Timing Chain Securing Guide106
- Installing the Timing Chain Tensioning Rail106
- Installing the Timing Chain Guide Rail107
- Installing the Balance Weight107
- Installing the Rotor107
- Installing the Piston107
- Installing the Cylinder Head109
- Installing the Camshaft110
- Installing the Timing Chain Tensioner110
- Checking the Valve Clearance111
- Adjusting the Valve Clearance111
- Installing the Generator Cover111
- Installing the Shift Lever112
- Installing the Valve Cover112
- Installing the Spark Plug112
- Installing the Starter Motor113
- Mounting Oil Filter113
- Filling up with Engine Oil113
- Filling up with Gear Oil114
- Removing the Engine from the Universal Mounting Rack114
31/Carburetor115
- Choke (EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W)115
- Choke (EXC-R EU)115
- Checking the Choke Bowden Cable Routing (EXC-R EU)115
- Checking the Choke Bowden Cable for Play (EXC-R EU)115
- Adjusting the Choke Bowden Cable Play (EXC-R EU)115
- Checking Gas Bowden Cable Route116
- Checking Play in the Gas Bowden Cable116
- Adjusting the Gas Bowden Cable Play116
- Removing the Carburetor117
- Disassembling the Carburetor117
- Checking the Carburetor Components120
- Checking/Adjusting the Accelerator Pump120
- Checking the Choke Slide121
- Checking the Jet Needle121
- Checking the Throttle Slide121
- Checking the Needle Jet122
- Checking the Float Needle Valve122
- Checking/Adjusting the Float Level122
- Checking/Adjusting the Throttle Slide Opening122
- Checking Throttle Valve Sensor TPS123
- Adjusting the Position of Throttle Valve Sensor TPS123
- Assembling the Carburetor124
- Installing the Carburetor127
- Carburetor - Adjusting Idle128
- Emptying the Carburetor Float Chamber129
32/Clutch131
- Checking Fluid Level of Hydraulic Clutch131
- Changing Fluid Level of Hydraulic Clutch131
33/Transmission133
- Removing the Engine Sprocket133
- Installing the Engine Sprocket133
35/Water Pump, Cooling System134
- Checking Antifreeze and Coolant Level134
- Checking the Coolant Level134
- Draining Coolant135
- Refilling Coolant135
38/Lubrication System136
- Oil Cycle136
- Checking Engine Oil Level136
- Changing Engine Oil and Oil Filter, Cleaning Engine Oil Screen137
- Draining Engine Oil, Cleaning Engine Oil Screen137
- Removing the Oil Filter137
- Mounting Oil Filter138
- Filling up with Engine Oil138
- Topping up Engine Oil139
- Checking the Engine Oil Pressure139
- Checking Gear Oil Level140
- Changing Gear Oil, Cleaning Gear Oil Screen140
- Draining Gear Oil, Cleaning Gear Oil Screen140
- Filling up with Gear Oil141
- Topping up with Gear Oil141
Troubleshooting142
Technical Data - Engine144
- Capacity- Engine Oil144
- Capacity - Gear Oil144
- Capacity - Coolant145
Technical Data - Tolerance, Wear Limits of Engine146
Technical Data - Engine Tightening Torques147
Technical Data - Carburetor149
- Exc-R Eu, 450 Exc-R Aus/Uk (3900I)149
- Exc-R Six Days, 450 Exc-R Usa, 450 Xcr-W (3900L)149
- Exc-R Eu, 530 Exc-R Aus/Uk (3900J)150
- Exc-R Six Days, 530 Exc-R Usa, 530 Xcr-W (3900M)150
Technical Data - Carburetor Tightening Torques151
Technical Data - Chassis152
- Lighting Equipment153
- Tires153
- Capacity - Fuel153
Technical Data - Fork154
Technical Data - Shock Absorber155
Technical Data - Chassis Tightening Torques156
Cleaning157
- Cleaning Motorcycle157
Storage158
- Putting into Operation after Storage158
- Greasing and Service Table159
- Important Maintenance Work to be Carried out by an Authorized KTM Workshop159
- Important Maintenance Work to be Carried out by an Authorized KTM Workshop. (as Additional Order)160
- Important Checks and Maintenance Work to be Carried out by the Rider160
Wiring Diagram162
- Wiring Diagram (EXC-R EU)162
- Wiring Diagram (EXC-R AUS/UK)164
- Wiring Diagram (EXC-R USA)166
- Wiring Diagram (EXC-R SIX DAYS)170
- Wiring Diagram (XCR-W USA)172
- Wiring Diagram (XCR-W ZA)174
Substances176
Auxiliary Substances177
Special Tools179
Standards186
Index187

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KTM 450 XCR-W USA Specifications

General

Brand	KTM
Model	450 XCR-W USA
Category	Motorcycle
Language	English

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