KTM 450 XC-W SIX DAYS USA 2010, Owner'S Manual

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TABLE OF CONTENTS
3
Handlebar position ........................................................ 48
Adjusting handlebar position
x ...................................... 48
Checking throttle cable route .......................................... 48
Checking the play in the throttle cable............................. 49
Adjusting the play in the throttle cable
x
....................... 49
Checking for chain dirt accumulation .............................. 49
Cleaning the chain......................................................... 50
Checking the chain tension ............................................ 50
Checking chain tension when fitting rear wheel ................ 51
Checking the rear sprocket/engine sprocket for wear ......... 51
Checking chain wear...................................................... 51
Adjusting chain tension.................................................. 52
Adjusting chain tension - after checking .......................... 53
Adjusting chain tension - fitting rear wheel ...................... 53
Adjusting chain guide
x
............................................... 54
Checking brake discs ..................................................... 54
Checking free travel of hand brake lever........................... 54
Adjusting basic position of hand brake lever (all XC
‑
W
models) ........................................................................ 55
Adjusting free travel of hand brake lever (all EXC
models) ........................................................................ 55
Checking the brake fluid level of the front brake............... 55
Topping up the front brake fluid
x
................................. 56
Checking the front brake linings...................................... 57
Changing the front brake linings
x ................................. 57
Checking free play of foot brake lever .............................. 59
Adjusting basic position of foot brake lever
x
.................. 59
Checking rear brake fluid level........................................ 59
Adding brake fluid to the rear brake circuit
x
................. 60
Checking rear brake linings ............................................ 60
Changing rear brake linings
x
....................................... 61
Removing front wheel
x
................................................ 62
Fitting front wheel
x
.................................................... 63
Removing the rear wheel
x
........................................... 64
Fitting rear wheel
x
...................................................... 64
Checking the tire condition............................................. 65
Checking tire air pressure............................................... 66
Checking spoke tension.................................................. 66
Removing the battery
x
................................................ 67
Installing the battery x ................................................. 67
Recharging the battery x .............................................. 67
Removing a fuse............................................................ 68
Installing the fuse ......................................................... 68
Checking the headlight adjustment (all EXC models, all
450/530 XC-W models) ................................................. 69
Adjusting the beam width of the headlight (all EXC
models, all 450/530 XC-W models)................................. 69
Removing the seat ......................................................... 69
Mounting the seat ......................................................... 70
Removing the fuel tank
x
............................................. 70
Installing the fuel tank
x
.............................................. 71
Cooling system .............................................................. 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
Installing the main silencer ............................................ 74
Removing the air filter box lid......................................... 74
Installing the air filter box lid.......................................... 74
Removing the air filter
x
............................................... 75
Installing the air filter
x
............................................... 75
Cleaning air filter
x
...................................................... 75
Adjusting basic position of clutch lever............................ 76
Checking the fluid level of hydraulic clutch...................... 76
Changing the hydraulic clutch fluid
x ............................ 76
Checking the basic position of the shift lever.................... 77
Adjusting the basic position of the shift lever
x
.............. 77
Carburetor - idle ............................................................ 78
Carburetor - adjusting idle
x
......................................... 78
Emptying the carburetor float chamber
x
....................... 79
Checking engine oil level................................................ 80
Changing engine oil and oil filter, cleaning engine oil
screen
x
..................................................................... 80
Draining engine oil, cleaning engine oil screen x ............ 80
Removing the oil filter x ............................................... 81
Installing the oil filter x ............................................... 81
Filling up with engine oil
x
........................................... 82
Topping up engine oil .................................................... 82
Checking the gear oil level.............................................. 83
Changing gear oil, cleaning gear oil screen
x
.................. 83
Draining gear oil, cleaning gear oil screen
x
................... 83
Filling up with gear oil
x
.............................................. 84
Adding gear oil x ......................................................... 84
TROUBLESHOOTING......................................................... 86
CLEANING........................................................................ 88
Cleaning the motorcycle ................................................. 88
STORAGE ......................................................................... 89
Storage......................................................................... 89
Putting into operation after storage ................................. 89
TECHNICAL DATA - ENGINE.............................................. 90
Capacity - engine oil ...................................................... 90
Capacity - gear oil.......................................................... 91
Capacity - coolant.......................................................... 91
TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 92
TECHNICAL DATA - CARBURETOR..................................... 94
400 EXC EU/AUS.......................................................... 94
400 XC-W USA ............................................................. 94
450 EXC EU/AUS, 450 EXC SIX DAYS ............................ 94
450 XC
‑
W ZA, 450 XC
‑
W SIX DAYS ................................ 95
530 EXC EU/AUS, 530 EXC SIX DAYS ............................ 95
530 XC
‑
W ZA, 530 XC
‑
W SIX DAYS ................................ 95
TECHNICAL DATA - CHASSIS ............................................ 96
Lighting equipment ....................................................... 96
Tires ............................................................................ 97
Capacity - fuel............................................................... 97
TECHNICAL DATA - FORK.................................................. 98
TECHNICAL DATA - SHOCK ABSORBER ............................. 99
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 100
WIRING DIAGRAM .......................................................... 102
Wiring diagram (all EXC models) ................................... 102
Wiring diagram (all XC
‑
W models) ................................. 106
SUBSTANCES................................................................. 108
AUXILIARY SUBSTANCES................................................ 110
STANDARDS................................................................... 112
INDEX ............................................................................ 113