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KTM
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450 XCR-W USA
KTM 450 XCR-W USA User Manual
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WIRING
DIAGRAM
173
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
Headlight
14
Parking
light
15
Brake
/
tail
light
16
Light
switch
17
Speedometer
18
Wheel
speed
sensor
19
Tripmaster
switch
(optional)
20
Radiator
fan
21
Thermoswitch
22
Fuse,
radiator
fan
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
174
176
Table of Contents
Table of Contents
4
Means of Representation
8
Important Notes
9
Motorcycle
10
Jacking up the Motorcycle
10
Removing the Motorcycle from the Work Stand
10
01/Fork, Triple Clamp
11
Fork Part Number
11
Adjusting Spring Preload of the Fork
11
Adjusting Compression Damping of Fork
11
Adjusting Rebound Damping of Fork
12
Cleaning Dust Boots of Fork Legs
12
Removing the Fork Legs
13
Installing the Fork Legs
13
Bleeding Fork Legs
14
Removing the Fork Protector
14
Installing the Fork Protector
15
Loosening the Fork Protection
15
Positioning the Fork Protection
15
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 Bearing
18
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 Bearing
20
03/Frame
21
Removing the Engine Sprocket Cover
21
Installing the Engine Sprocket Cover
21
04/Shock Absorber, Swingarm
22
Shock Absorber Part Number
22
Adjusting High-Speed Compression Damping of the Shock Absorber
22
Adjusting the Low-Speed Compression Damping of the Shock Absorber
22
Adjusting Rebound Damping of the Shock Absorber
23
Measuring Rear Wheel Sag Unloaded
23
Checking Static Sag of the Shock Absorber
24
Checking the Riding Sag of the Shock Absorber
24
Adjusting Spring Preload of the Shock Absorber
24
Adjusting Riding Sag
25
Removing the Shock Absorber
25
Installing Shock Absorber
26
05/Exhaust
27
Removing Main Silencer
27
Fitting the Main Silencer
27
Removing the Manifold
27
Installing the Manifold
27
Installing the Air Filter
28
Cleaning Air Filter
29
Removing the Carburetor Connection Boot
29
Installing the Carburetor Connection Boot
29
Removing the Air Filter
28
Installing the Air Filter Box Lid
28
Dismounting the Air Filter Box Lid
28
06/Air Filter
28
07/Fuel Tank, Seat, Trim
30
Opening Filler Cap
30
Closing Filler Cap
30
Removing the Seat
30
Mounting the Seat
30
Dismounting the Fuel Tank
30
Installing the Fuel Tank
31
Fuel Tap
32
08/Mask, Fender
33
Dismounting the Front Fender
33
Installing the Front Fender
33
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 Wheel
35
Removing Front Wheel
35
Fitting Front Wheel
35
Checking Brake Discs
36
Removing the Front Brake Disc
36
Installing the Front Brake Disc
36
Tire Condition Checking
37
Checking Tire Air Pressure
37
Checking Spoke Tension
37
10/Rear Wheel
38
Removing Rear Wheel
38
Fitting Rear Wheel
38
Removing the Rear Brake Disc
39
Installing the Rear Brake Disc
39
Checking the Chain Tension When Fitting Rear Wheel
39
Adjusting Chain Tension - Fitting Rear Wheel
40
Checking the Chain Tension
40
Adjusting Chain Tension - after Checking
41
Adjusting the Chain Tension
41
Adjusting Chain Guide
42
Checking the Rear Sprocket / Engine Sprocket for Wear
42
Checking Chain Wear
43
Checking Chain Dirt
43
Cleaning the Chain
43
11/Wiring Harness, Battery
44
Removing a Fuse
44
Replacing the Fuse
44
Removing the Battery
44
Installing the Battery
45
Recharging the Battery
45
13/Brake System
47
Checking the Front Brake Linings
47
Removing the Front Brake Linings
47
Installing the Front Brake Linings
47
Changing the Front Brake Linings
48
Adjusting Basic Position of Handbrake Lever (Every XCR-W Models)
48
Checking Free Play of Hand Brake Lever
49
Adjusting Free Travel of Handbrake Lever (Every EXC-R Models)
49
Checking the Front Brake Fluid Level
49
Add Front Brake Fluid
50
Changing the Front Brake Fluid
50
Checking Rear Brake Linings
51
Removing the Rear Brake Linings
51
Installing the Rear Brake Linings
52
Changing the Rear Brake Linings
52
Checking Free Play of Foot Brake Lever
53
Adjusting Basic Position of Footbrake Lever
53
Checking Rear Brake Fluid Level
54
Adding Rear Brake Fluid
54
Changing the Rear Brake Fluid
54
14/Light System, Instruments
56
Adjusting Speedometer Functions
56
Setting Kilometers or Miles
56
Setting the Clock
57
30/Engine
58
Removing the Engine
58
Installing the Engine
59
30/Disassembling Engine
61
Preparations
61
Draining the Engine Oil
61
Removing the Oil Filter
61
Draining Gear Oil, Cleaning Gear Oil Screen
61
Removing the Starter Engine
62
Removing the Valve Cover
62
Removing the Shift Lever
62
Removing the Spark Plug
62
Removing the Generator Cover
63
Setting the Engine to Ignition Top Dead Center
63
Removing the Timing Chain Tensioner
64
Removing the Camshaft
64
Removing the Cylinder Head
64
Removing the Piston
64
Removing the Rotor
65
Removing the Balance Weight
65
Removing the Timing Chain Guide Rail
65
Removing the Timing Chain Tensioning Rail
66
Removing the Timing Chain Securing Guide
66
Removing the Timing Chain
66
Removing the Ignition Pulse Generator
66
Removing the Suction Pump
66
Removing the Kickstarter
67
Removing the Water Pump Cover
67
Removing the Clutch Cover
67
Removing the Clutch Discs
68
Removing the Primary Gear Nut
68
Removing the Outer Clutch Hub
68
Removing the Balancer Shaft
69
Removing the Torque Limiter
69
Removing the Starter Idler Gear
69
Removing the Kickstarter Shaft
69
Removing the Kickstarter Idler Gear
69
Removing the Shift Shaft
70
Removing the Shift Drum Locating
70
Removing the Locking Lever
70
Removing the Oil Pump Gears
70
Removing the Oil Pumps
71
Removing the Primary Gear with the Free-Wheel-Gear
71
Removing the Left Section of the Engine Case
71
Removing the Shift Rails
72
Removing the Shift Roller
72
Removing the Shift Forks
73
Removing the Transmission Shaft
73
Removing the Crankshaft
73
30/Engine - Work on Individual Parts
74
Work on the Right Section of the Engine Case
74
Work on the Left Section of the Engine Case
75
Removing the Oil Pressure Regulator Valve
77
Checking the Spring Length of the Oil Pressure Regulator Valve
77
Installing the Oil Pressure Regulator Valve
77
Removing the Crankshaft Seal Ring in the Clutch Cover
78
Fitting the Crankshaft Seal Ring into the Clutch Cover
78
Removing the Water Pump
78
Installing the Water Pump
79
Checking the Balancer Shaft
80
Removing the Timing Chain Sprocket
80
Installing the Timing Chain Sprocket
80
Changing the Conrod Bearing
80
Checking the Crankshaft Run-Out on the Bearing Pin
82
Cylinder - Nikasil Coating
82
Checking/Measuring the Cylinder
82
Checking/Measuring the Piston
83
Checking the Piston Ring End Gap
83
Checking Piston/Cylinder Mounting Clearance
84
Checking the Oil Pumps for Wear
84
Checking the Lubrication System
84
Disassembling the Autodecompressor
85
Assembling the Autodecompressor
85
Checking the Camshaft
86
Checking the Timing Assembly
86
Preparing the Timing Chain Tensioner for Installation
86
Removing the Rocker Arm
87
Removing the Valves
87
Replacing the Camshaft Bearing
88
Checking the Valves
89
Checking the Valve Springs
89
Checking the Lower Valve Spring Retainer
89
Checking the Cylinder Head
90
Installing Valves
90
Installing the Rocker Arm
91
Checking the Clutch
91
Checking the Shift Mechanism
92
Preassembling the Shift Shaft
93
Dismantling the Main Shaft
93
Assembling the Main Shaft
93
Dismantling the Countershaft
94
Assembling the Countershaft
94
Checking the Transmission
95
Checking Electric Starter Operation
96
Removing the Free-Wheel
96
Checking the Free-Wheel
97
Installing the Free-Wheel
97
30/Assembling Engine
98
Installing the Crankshaft
98
Installing the Transmission Shaft
98
Installing the Shift Forks
98
Installing the Shift Roller
99
Installing the Shift Rails
99
Installing the Left Engine Case
99
Installing the Primary Gear with the Free-Wheel-Gear
100
Installing the Oil Pumps
100
Installing the Oil Pump Gears
101
Installing the Locking Lever
101
Installing the Shift Drum Locating
101
Installing the Shift Shaft
101
Installing the Kickstarter Idler Gear
102
Installing the Kickstarter Shaft
102
Installing the Starter Idler Gear
102
Installing the Torque Limiter
102
Installing the Balancer Shaft
103
Installing the Outer Clutch Hub
103
Installing the Primary Gear Nut
103
Installing the Clutch Discs
104
Installing the Clutch Cover
104
Installing the Water Pump Cover
105
Installing the Kickstarter
105
Installing the Suction Pump
105
Installing the Ignition Pulse Generator
106
Installing the Timing Chain
106
Installing the Timing Chain Securing Guide
106
Installing the Timing Chain Tensioning Rail
106
Installing the Timing Chain Guide Rail
107
Installing the Balance Weight
107
Installing the Rotor
107
Installing the Piston
107
Installing the Cylinder Head
109
Installing the Camshaft
110
Installing the Timing Chain Tensioner
110
Checking the Valve Clearance
111
Adjusting the Valve Clearance
111
Installing the Generator Cover
111
Installing the Shift Lever
112
Installing the Valve Cover
112
Installing the Spark Plug
112
Installing the Starter Motor
113
Mounting Oil Filter
113
Filling up with Engine Oil
113
Filling up with Gear Oil
114
Removing the Engine from the Universal Mounting Rack
114
31/Carburetor
115
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 Route
116
Checking Play in the Gas Bowden Cable
116
Adjusting the Gas Bowden Cable Play
116
Removing the Carburetor
117
Disassembling the Carburetor
117
Checking the Carburetor Components
120
Checking/Adjusting the Accelerator Pump
120
Checking the Choke Slide
121
Checking the Jet Needle
121
Checking the Throttle Slide
121
Checking the Needle Jet
122
Checking the Float Needle Valve
122
Checking/Adjusting the Float Level
122
Checking/Adjusting the Throttle Slide Opening
122
Checking Throttle Valve Sensor TPS
123
Adjusting the Position of Throttle Valve Sensor TPS
123
Assembling the Carburetor
124
Installing the Carburetor
127
Carburetor - Adjusting Idle
128
Emptying the Carburetor Float Chamber
129
32/Clutch
131
Checking Fluid Level of Hydraulic Clutch
131
Changing Fluid Level of Hydraulic Clutch
131
33/Transmission
133
Removing the Engine Sprocket
133
Installing the Engine Sprocket
133
35/Water Pump, Cooling System
134
Checking Antifreeze and Coolant Level
134
Checking the Coolant Level
134
Draining Coolant
135
Refilling Coolant
135
38/Lubrication System
136
Oil Cycle
136
Checking Engine Oil Level
136
Changing Engine Oil and Oil Filter, Cleaning Engine Oil Screen
137
Draining Engine Oil, Cleaning Engine Oil Screen
137
Removing the Oil Filter
137
Mounting Oil Filter
138
Filling up with Engine Oil
138
Topping up Engine Oil
139
Checking the Engine Oil Pressure
139
Checking Gear Oil Level
140
Changing Gear Oil, Cleaning Gear Oil Screen
140
Draining Gear Oil, Cleaning Gear Oil Screen
140
Filling up with Gear Oil
141
Topping up with Gear Oil
141
Troubleshooting
142
Technical Data - Engine
144
Capacity- Engine Oil
144
Capacity - Gear Oil
144
Capacity - Coolant
145
Technical Data - Tolerance, Wear Limits of Engine
146
Technical Data - Engine Tightening Torques
147
Technical Data - Carburetor
149
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 Torques
151
Technical Data - Chassis
152
Lighting Equipment
153
Tires
153
Capacity - Fuel
153
Technical Data - Fork
154
Technical Data - Shock Absorber
155
Technical Data - Chassis Tightening Torques
156
Cleaning
157
Cleaning Motorcycle
157
Storage
158
Putting into Operation after Storage
158
Greasing and Service Table
159
Important Maintenance Work to be Carried out by an Authorized KTM Workshop
159
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 Rider
160
Wiring Diagram
162
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
Substances
176
Auxiliary Substances
177
Special Tools
179
Standards
186
Index
187
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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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