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WIRING DIAGRAM 171

Components

1 Battery

2 Generator

3 Ignition coil

4 Pulse generator

5 Voltage regulator/rectifier

6 Electric starter button

7 Starter relay with fuse

8 Starter motor

9 Short circuit button

10 Throttle valve sensor TPS

11 Ignition curve plug connection

12 CDI controller

13 Light switch

14 Speedometer

15 Wheel speed sensor

16 Tripmaster switch (optional)

17 Plug connector for radiator fan (optional)

18 Plug connector, headlight (optional)

19 Plug connector, brake / tail light (optional)

21 Thermoswitch

Cable colors

bl black

bl-wh black-white

br brown

bu blue

bu-wh blue-white

gn green

gr gray

re red

re-bl red-black

re-wh red-white

wh white

wh-re white-red

ye yellow

ye-bl yellow-black

ye-re yellow-red

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

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

KTM 450 XCR-W USA User Manual

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KTM 450 XCR-W USA Specifications

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