KTM 450 XC-W SIX DAYS USA 2010 Page 103 Owner'S Manual Download

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Summary of Contents for 450 XC-W SIX DAYS USA 2010

Page 1: ...L 2010 400 EXC EU 400 EXC AUS 400 XC W USA 450 EXC EU 450 EXC AUS 450 EXC SIX DAYS EU 450 XC W SIX DAYS USA 450 XC W ZA 530 EXC EU 530 EXC AUS 530 EXC SIX DAYS EU 530 XC W SIX DAYS USA 530 XC W ZA Art...

Page 2: ......

Page 3: ...y or delete technical spec ifications prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to...

Page 4: ...ces 27 Preparing for rides at high temperature and slow speed 28 Preparing for rides at low temperatures or in snow 28 RIDING INSTRUCTIONS 29 Checks before putting into operation 29 Starting 29 Starti...

Page 5: ...ystem 71 Checking the anti freeze and coolant level 72 Checking the coolant level 72 Draining coolant x 73 Refilling coolant x 73 Glass fiber yarn filling of main silencer 74 Removing main silencer 74...

Page 6: ...erstanding In the interest of your own safety have these jobs done in an authorized KTM workshop There your motorcycle will be serviced optimally by specially trained experts using the specialist tool...

Page 7: ...vice schedule is reached Pay careful attention to the prescribed running in period inspection and maintenance intervals Observing these rules will vastly increase the service life of your motorcycle W...

Page 8: ...to the notes warnings Info Various information and warning labels are affixed to the vehicle Do not remove information warning labels If they are miss ing you or others may not recognize potential haz...

Page 9: ...VIEW OF VEHICLE 7 3 1 View of the vehicle from the left front example 100799 10 1 Hand brake lever 2 Clutch lever 3 Air filter box lid 4 Fuel tap 5 Chain guide 6 Side stand 7 Shift lever...

Page 10: ...ller cap 2 Short circuit button 3 Speedometer 4 Electric starter button 5 Fork rebound adjustment 6 Horn 7 Fork compression adjustment 8 Shock absorber rebound adjustment 9 Level viewer for brake flui...

Page 11: ...type label is fixed to the front of the steering head 4 3 Key number all EXC models 500125 10 The key number is stamped on the key strap 4 4 Engine number 500072 10 The engine number is stamped on th...

Page 12: ...LOCATION OF SERIAL NUMBERS 10 4 6 Shock absorber part number 500129 10 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side...

Page 13: ...t is interrupted a running engine stops and a non running engine will not start 5 4 Short circuit button all EXC models 500134 10 The short circuit button is fitted on the left side of the handlebar P...

Page 14: ...ght In this position the light is switched off Low beam on Light switch is in the central position In this position the low beam and tail light are switched on High beam on Light switch is turned to t...

Page 15: ...key to change the display mode or change to one of the setup menus Press the button to control different functions Press the button to control different functions Info In its condition at delivery the...

Page 16: ...on for 3 5 seconds The settings are stored and the setup menu closed Info If no button is actuated for 20 seconds or there is no signal from the wheel speed sensor then the settings are automatically...

Page 17: ...lay changes to the next function Activate or deactivate all functions accordingly Press the button for 3 5 seconds The settings are saved and the Setup menu closed Info If no button is pressed for 20...

Page 18: ...ly changes to the ODO display mode The H display mode is suppressed during the journey Press the button No function Press the button No function Press the button for 3 5 seconds The display changes to...

Page 19: ...average speed 1 and S1 stop watch 1 Info If 999 9 is exceeded the values of TR1 A1 and S1 are automaticallt reset to 0 0 Press the button No function Press the button No function Press the button for...

Page 20: ...on No function Press the button No function Press the button for 3 5 seconds Press the button briefly Next display mode 5 29 Display mode SPEED S1 stop watch 1 400327 01 Press the button briefly and r...

Page 21: ...y mode Display mode SPEED TR2 trip master 2 Increases value of TR2 Reduces value of TR2 Deletes value of TR2 Next display mode Disply mode SPEED A1 average speed 1 No function No function Displays of...

Page 22: ...tton turn filler cap counterclockwise and lift it upwards and remove 5 33 Closing filler cap 400199 11 Replace the filler cap and turn clockwise until the release button locks in place Info Route the...

Page 23: ...to the stop 5 36 Shift lever 500138 10 Shift lever is mounted on the left side of the engine 500138 11 The gear positions can be seen in the photograph The neutral or idle position is between the fir...

Page 24: ...an the motorcycle on it 500141 10 When you are riding side stand must be folded up and secured with rubber band 5 40 Steering lock all EXC models 500126 10 Steering lock is fitted on the left side of...

Page 25: ...cking the steering all EXC models Insert the key in the steering lock turn it to the left pull it out and turn it to the right Remove the key You can now steer the bike again Info Never leave the key...

Page 26: ...foot off the foot brake lever if you do not want to brake Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permissible weight and axle loads Warning Risk of misappropria...

Page 27: ...ours 75 Avoid fully opening the throttle 6 3 Preparing vehicle for arduous riding conditions Using a motorcycle in arduous conditions can lead to excessive wear of components such as the power train o...

Page 28: ...in cleaner p 110 Fit the steel sprocket Tip Do not grease the chain Clean radiator fins Straighten bent radiator fins carefully 6 5 Preparing for riding on wet sand 600872 10 Check the radiator cap Va...

Page 29: ...Straighten bent radiator fins carefully 6 6 Preparing for riding on wet and muddy surfaces Seal the air filter box x Tip Seal the air filter box along the edges to prevent the ingress of dirt Clean th...

Page 30: ...e air filter x p 75 Info Check the air filter approx every 30 minutes 600868 01 Adjust the secondary drive to the road conditions Info The engine oil quickly gets hot if the clutch has to be operated...

Page 31: ...art or run the engine in an enclosed space without an effective exhaust extraction system Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engin...

Page 32: ...ays open the throttle only as much as the engine can handle abrupt throttle opening increases fuel consumption To shift down brake and close the throttle at the same time Pull the clutch lever and shi...

Page 33: ...er Brake the motorcycle Shift transmission to neutral all XC W models Press and hold the short circuit button while the engine is idling until the engine stops all EXC models Press and hold the short...

Page 34: ...ine Measurement of 35 mm 1 38 in Total fuel tank capacity approx EXC EXC SIX DAYS XC W ZA 9 5 l 2 51 US gal Super unleaded ROZ 95 RON 95 PON 91 p 109 Total fuel tank capacity approx XC W USA XC W SIX...

Page 35: ...roperly Check the headlight adjustment all EXC models all 450 530 XC W models p 69 Brakes Check the front brake linings p 57 Check the rear brake linings p 60 Check the brake discs p 54 Check the brak...

Page 36: ...eat x Check the cylinder head x Check the valves x Check the valve springs x Check the radial clearance of the rocker arm rollers x Check the timing chain tensioner function x Check the balancer shaft...

Page 37: ...s p 42 Clean the dust boots of the fork legs p 42 Clean the chain p 50 Check the chain tension p 50 Check the chain wear p 51 Check rear sprocket engine sprocket for wear p 51 Clean the air filter x p...

Page 38: ...es are adjusted for a standard rider weight with full protective clothing Guideline Standard rider weight 75 85 kg 165 187 lb If your weight is above or below the standard range you have to adjust the...

Page 39: ...description provided Your authorized KTM workshop will be glad to help Info The low speed setting can be seen during the slow to normal compression of the shock absorber 400209 10 Turn adjusting screw...

Page 40: ...stance as vertical as possible between the rear axle and a fixed point for example a mark on the side cover Make a note of the value as measurement Remove the motorcycle from the work stand p 36 9 9 C...

Page 41: ...er x Danger Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM works...

Page 42: ...absorber p 37 9 13 Removing the shock absorber x Jack up the motorcycle p 36 800023 10 Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel Fix t...

Page 43: ...g screws are located at the bottom end of the fork legs Make sure the setting is identical on both fork legs Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline...

Page 44: ...ad 9 19 Bleeding fork legs Jack up the motorcycle p 36 100021 10 Remove bleeder screws briefly Any excess pressure escapes from the interior of the fork Mount and tighten bleeder screws Remove the mot...

Page 45: ...teering head bearing play without delay Your authorized KTM workshop will be glad to help Info If the bike is driven for a longer time with play in the steering head bearing the bearing and the bearin...

Page 46: ...Jack up the motorcycle p 36 800022 10 Loosen screw Remove screw Loosen and retighten screw Guideline Screw top steering head M20x1 5 10 Nm 7 4 lbf ft Using a plastic hammer tap lightly on the upper t...

Page 47: ...SIX DAYS XC W USA Fully tighten screw Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws Guideline Screw bottom triple clamp M8 12 Nm 8 9 lbf ft 100804 11 EXC EU EXC AUS XC W ZA Ful...

Page 48: ...rews chassis M6 10 Nm 7 4 lbf ft Install the fork legs x p 45 9 30 Removing the front fender 600692 10 Remove screws Remove the front fender Pay attention to the location of the distance bushings 9 31...

Page 49: ...e brake line and wiring harness Put the clamp on mount and tighten screw Check the headlight adjustment p 69 9 34 Removing the start number plate 400 XC W USA 500101 10 Remove screw and remove the cla...

Page 50: ...clamps Remove the handlebar and lay it to one side Info Protect the motorcycle and its attachments against damage by covering them Do not bend the cables and lines Remove the two screws Remove the ha...

Page 51: ...the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable x p 49 9 40 Adjusting the play in the throttle cable x Remove the fuel tank x p...

Page 52: ...Warning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bear ings in tran...

Page 53: ...ons Adjust the chain tension when fitting rear wheel p 53 9 45 Checking the rear sprocket engine sprocket for wear 400227 01 Check rear sprocket engine sprocket for wear If the rear sprocket engine sp...

Page 54: ...the chain guide to measure the chain ten sion Info The upper chain section must be taut Chain wear is not always even so you should repeat this measurement at different chain positions 400225 10 Loos...

Page 55: ...are fitted correctly on the adjusting screws Tighten nut Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm enables different secondar...

Page 56: ...help A A 400257 10 Check the thickness of the front and rear brake discs at several places on the disk to see if it conforms to measurement Info Wear reduces the thickness of the brake disc around th...

Page 57: ...ting screw by hand only and do not apply any force Do not make any adjustments while riding 9 54 Adjusting free travel of hand brake lever all EXC models 400196 12 Check the free travel of the hand br...

Page 58: ...immediately Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brakes according to the service schedule Your authorized KTM works...

Page 59: ...ront and rear brakes according to the service schedule Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs...

Page 60: ...it pins withdraw bolt and take out the brake pads Clean brake caliper and brake caliper support 0 0 7 7 0 0 6 6 0 0 100397 01 Check that anti squeal shim in the brake caliper and anti rattle shim in t...

Page 61: ...according to specifications 500154 10 Detach spring Loosen nut and with push rod turn it back until you have maximum free travel To adjust the basic position of the foot brake lever individually loose...

Page 62: ...used by old brake fluid Change the brake fluid of the front and rear brakes according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous s...

Page 63: ...ith brake cleaner when necessary Warning Danger of accidents Reduced braking efficiency due to use of non approved brake linings Brake linings available from accessory suppliers are often not tested a...

Page 64: ...until the brake linings lie on the brake disc and there is a noticeable pressure point 400233 10 Correct the brake fluid reservoir level to the marking Brake fluid DOT 4 DOT 5 1 p 108 Mount the screw...

Page 65: ...and grease and clean them with brake cleaner when necessary 500086 11 Clean and grease shaft seal rings and bearing surface of the spacing sleeves Long life grease p 110 Insert the spacing sleeves 500...

Page 66: ...rear wheel withdraw the wheel spindle Take the rear wheel out of the swing arm Info Do not operate the foot brake when the rear wheel is removed Always lay the wheel down in such a way that the brake...

Page 67: ...ll have an important impact on the riding behavior of the motorcycle The front and rear wheels must be mounted with tires with similar profiles Worn tires have a negative effect on riding behavior esp...

Page 68: ...oke tension Ensure that the spoke tension is correct Your authorized KTM workshop will be glad to help Info A loose spoke can cause wheel imbalance which leads to more loose spokes in a short time If...

Page 69: ...ery YTX5L BS p 96 Reconnect the rubber band Attach the plus cable and replace the plus pole cover Attach the minus cable Mount the seat p 70 9 74 Recharging the battery x Warning Risk of injury Batter...

Page 70: ...tor cycle s electronics 400240 10 Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 You can also use the battery charger to test the open circuit vol...

Page 71: ...t on the footrests Guideline Distance 5 m 16 ft Switch on low beam Check the headlight adjustment The border between light and dark must be exactly at the lower mark when the motorcycle is operational...

Page 72: ...ng Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immedi ately with water a...

Page 73: ...67 01 Position the fuel tank and fit the two spoilers to the side of the radiator fixing Make sure that no cables are trapped or damaged 800019 11 Mount the fuel tank vent hose Mount and tighten with...

Page 74: ...he radiator Coolant level above radiator fins 10 mm 0 39 in If the level of the coolant does not meet specifications Correct the coolant level Alternative 1 Coolant p 108 Alternative 2 Coolant mixed r...

Page 75: ...the reach of children Condition Engine is cold 400335 11 Stand the motorcycle upright Place a suitable container under the water pump cover Remove screw Remove the radiator cap Completely drain the c...

Page 76: ...very hot when the vehicle is driven Allow the exhaust system to cool down Do not touch hot components 800020 10 Disconnect spring Remove screws and take off main silencer 9 90 Installing the main sile...

Page 77: ...air filter x 301262 10 Mount the clean air filter onto the air filter support Apply grease to the section of the air filter Long life grease p 110 500107 10 Put in both parts together position them a...

Page 78: ...with water and contact a doctor immediately Info The fluid level rises with increasing wear of the clutch lining disc Avoid contact between brake fluid and painted parts Brake fluid is corrosive Use o...

Page 79: ...without bubbles To prevent overflow drain fluid occasionally from the master cylinder reservoir Remove the bleeding syringe Mount and tighten screws bleeder screw Correct the fluid level of the hydra...

Page 80: ...nt screw 9 102 Carburetor adjusting idle x 400341 10 Screw in the idle adjusting screw until it stops and then to the prescribed basic setting Guideline Idle mixture adjusting screw 400 EXC EU AUS Ope...

Page 81: ...activated The choke lever is pushed back to the stop EXC EU EXC SIX DAYS p 21 Idle speed 1 550 1 650 rpm Info Following extreme air temperature or altitude changes adjust the idle speed again 9 103 Em...

Page 82: ...evel Top up the engine oil p 82 9 105 Changing engine oil and oil filter cleaning engine oil screen x 301489 10 Drain the engine oil and clean the engine oil screen x p 80 Remove the oil filter x p 81...

Page 83: ...mmediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in appl...

Page 84: ...the engine and let it run idle for 30 seconds Stop the engine and check that it is oil tight 301454 10 Stand the motorcycle upright on a horizontal surface Remove the screw connection on the generato...

Page 85: ...bf ft 9 112 Changing gear oil cleaning gear oil screen x 301490 10 Drain the gear oil and clean the gear oil screen x p 83 Fill up with gear oil x p 84 9 113 Draining gear oil cleaning gear oil screen...

Page 86: ...Filling up with gear oil x Info Too little gear oil or poor quality oil results in premature wear to the transmission 200118 10 Remove the screw cap and fill up with gear oil Gear oil 0 90 l 0 95 qt...

Page 87: ...l check screw Guideline Screw gear oil level check M6 8 Nm 5 9 lbf ft Mount and tighten screw cap Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness...

Page 88: ...the ignition system x Short circuit cable in cable harness frayed short circuit button or emer gency OFF switch defective Check the wiring harness visual check Check the electrical system Plug connect...

Page 89: ...witch off engine when stationary Radiator fins very dirty Clean radiator fins Foam formation in cooling system Drain the coolant x p 73 Refill the coolant x p 73 Bent radiator hose Change the radiator...

Page 90: ...cle cleaner and a soft sponge After rinsing the motorcycle with a gentle water spray allow it to dry thoroughly Empty the carburetor float chamber x p 79 Warning Danger of accidents Reduced braking du...

Page 91: ...lter and clean the engine oil screen x p 80 Change the gear oil and clean the gear oil screen x p 83 Check the anti freeze and coolant level p 72 Drain the fuel from the tanks into a suitable containe...

Page 92: ...10 0 15 mm 0 0039 0 0059 in Crankshaft bearing 2 grooved ball bearings Conrod bearing Needle bearing Piston pin bearing No bearing bushes DLC plated piston pins Pistons Forged light alloy Piston rings...

Page 93: ...TECHNICAL DATA ENGINE 91 13 2 Capacity gear oil Gear oil 0 90 l 0 95 qt Engine oil SAE 10W 50 p 108 13 3 Capacity coolant Coolant 0 95 l 1 qt Coolant p 108 Coolant mixed ready to use p 108...

Page 94: ...gear oil level check M6 8 Nm 5 9 lbf ft Screw idler M6 10 Nm 7 4 lbf ft Loctite 243 Screw kickstarter spring hanger M6 10 Nm 7 4 lbf ft Screw kickstarter stop M6 10 Nm 7 4 lbf ft Loctite 243 Screw oi...

Page 95: ...t Spark plug M12x1 25 15 20 Nm 11 1 14 8 lbf ft Gear oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Oil pressure control valve plug M12x1 5 20 Nm 14 8 lbf ft Plug SLS M12x1 5 20 Nm 14 8 lbf ft P...

Page 96: ...X 39 Carburetor identification number 3900W Needle position 1st position from top Idle mixture adjusting screw Open 1 75 turns Pump diaphragm stop 2 15 mm 0 0846 in Main jet 180 Jet needle OBDTQ Idlin...

Page 97: ...N FCR MX 39 Carburetor identfication number 3900J Needle position 5th position from top Idle mixture adjusting screw Open 1 5 turns Pump membrane stop 2 15 mm 0 0846 in Main jet 180 Jet needle OBDZT O...

Page 98: ...ZA 530 XC W SIX DAYS 13 50 Final drive 530 EXC EU AUS 530 EXC SIX DAYS 15 45 13 50 Chain 5 8 x 1 4 Rear sprockets available 38 40 42 45 48 49 50 51 52 Steering head angle 63 5 Wheelbase 1 475 10 mm 5...

Page 99: ...ME all XC W models 80 100 21 51M TT Bridgestone M59 110 100 18 64M TT Bridgestone M402 Additional information is available in the Service section under http www ktm com 16 3 Capacity fuel Total fuel t...

Page 100: ...g length with preload spacer s 510 mm 20 08 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 4 N mm 25 1 lb in Weight of rider 75 85 kg 165 187 lb 4 6 N mm 26 3 lb in Weight of rider 85 95 kg 187...

Page 101: ...rns Rebound damping Comfort 26 clicks Standard 24 clicks Sport 22 clicks Spring preload 9 mm 0 35 in Spring rate Weight of rider 65 75 kg 143 165 lb 69 N mm 394 lb in Weight of rider 75 85 kg 165 187...

Page 102: ...t Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw side stand fixing M8 40 Nm 29 5 lbf ft Loctite 243 Screw subframe M8 35 Nm 25 8 lbf ft Loc...

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Page 104: ...2 6 2 5 1 1 3 1 1 1 1 2 2 1 2 2 2 2 CR1 1 CR 1 1 1 1 2 3 3 H2 L2 A6 B1 L1 G2 H3 H9 H5 H1 N2 G1 K1 S1 M1 S10 S10 S11 E6 H14 S8 K2 H13 H11 H4 S2 H18 H15 B3 P1 S5 S6 S7 4 4 3 3 3 2 1 4 1 2 5 6 7 11 10 1...

Page 105: ...K1 Starter relay with main fuse K2 Flasher relay L1 Pulse generator L2 Ignition coil M1 Starter motor N2 Voltage regulator rectifier P1 Speedometer S1 Rear brake light switch S2 Front brake light swi...

Page 106: ...WIRING DIAGRAM 104 ye Yellow ye bl Yellow black ye re Yellow red...

Page 107: ...WIRING DIAGRAM 105...

Page 108: ...b h w r b wh ye re wh re bl gn re re gn re bl re wh bu wh br ye bl bu wh br br ye r b e r e y r b l b e y l b l b e r u b h w r b bu ye bl bl ye bu ye re wh re wh re ye re br ye re br wh ye bl h w h w...

Page 109: ...n XC W ZA XC W SIX DAYS K1 Starter relay with main fuse L1 Pulse generator L2 Ignition coil M1 Starter motor N2 Voltage regulator rectifier P1 Speedometer S5 Tripmaster switch optional S6 Light switch...

Page 110: ...to use Antifreeze 40 C 40 F Supplier Motorex Anti Freeze Engine oil SAE 10W 50 according to JASO T903 MA p 112 SAE p 112 SAE 10W 50 Guideline Use only engine oils that comply with the specified stand...

Page 111: ...SUBSTANCES 109 Super unleaded ROZ 95 RON 95 PON 91 according to DIN EN 228 ROZ 95 RON 95 PON 91...

Page 112: ...products Supplier Motorex Protect Shine 645 Contact spray Guideline KTM recommends Motorex products Supplier Motorex Accu Contact Long life grease Guideline KTM recommends Motorex products Supplier Mo...

Page 113: ...AUXILIARY SUBSTANCES 111 Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Universal...

Page 114: ...ce intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated wi...

Page 115: ...hain cleaning 50 Chain guide adjusting 54 Chain tension adjusting 52 checking 50 Chain wear checking 51 Chassis number 9 Choke 20 21 Cleaning 88 Clutch fluid level checking 76 fluid changing 76 Clutch...

Page 116: ...Oil filter changing 80 installing 81 removing 81 Overview of indicator lamps 13 Owner s manual 6 P Play in throttle cable adjusting 49 checking 49 Putting into operation advice on first use 24 after s...

Page 117: ...97 chassis tightening torques 100 engine 90 91 engine tightening torques 92 93 fork 98 shock absorber 99 Throttle cable route checking 48 Tire condition checking 65 Tire pressure checking 66 Transpor...

Page 118: ...3211467en 3211467en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 05 2009 Photo Mitterbauer...

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