KTM 450 EXC-R EU Repair Manual
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KTM 450 EXC-R EU Repair 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

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  • Page 1 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...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors.

  • Page 4: Table Of Contents

    CONTENTS Removing the carburetor connection boot ......27 MEANS OF REPRESENTATION ..........6 Installing the carburetor connection boot ......27 IMPORTANT NOTES ............7 07/FUEL TANK, SEAT, TRIM..........28 MOTORCYCLE..............8 Opening filler cap............28 Jacking up the motorcycle ..........8 Closing filler cap ............
  • Page 5 CONTENTS Add front brake fluid............48 Removing the shift forks ..........71 Changing the front brake fluid ........48 Removing the transmission shaft........71 Checking rear brake linings ..........49 Removing the crankshaft..........71 Removing the rear brake linings ........49 30/ENGINE - WORK ON INDIVIDUAL PARTS.......
  • Page 6 ................112 TECHNICAL DATA - CARBURETOR........147 31/CARBURETOR ............113 450 EXC-R EU, 450 EXC-R AUS/UK (3900I) ....147 Choke (EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W) ..............113 450 EXC-R SIX DAYS, 450 EXC-R USA, 450 XCR-W (3900L) ..............
  • Page 7 CONTENTS Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)....158 Important checks and maintenance work to be carried out by the rider............158 WIRING DIAGRAM ............160 Wiring diagram (EXC-R EU) .......... 160 Wiring diagram (EXC-R AUS/UK)........

  • Page 8: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. 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 tools required.

  • Page 9: Important Notes

    You should use the fuels, oils and greases according to specifications as listed in the owner's manual. Spare parts, accessories For your own safety, use only spare parts and accessories approved by KTM. KTM accepts no liability for other products and any re- sulting damage or loss.

  • Page 10: Motorcycle

    MOTORCYCLE Jacking up the motorcycle Note Danger of damage Danger of damage by the vehicle running away or falling over. Always place the vehicle on a firm and even surface. Jack up the motorcycle underneath the engine. The wheels must no longer touch the ground.

  • Page 11: 01/Fork, Triple Clamp

    01/FORK, TRIPLE CLAMP Fork part number The fork part number is stamped on the inner side of the fork stub. 500082-10 Adjusting spring preload of the fork Turn adjusting screws counterclockwise until they stop. Info Make the same adjustment on both fork legs. Turn back clockwise the number of turns corresponding to the fork type.

  • Page 12: Adjusting Rebound Damping Of Fork

    01/FORK, TRIPLE CLAMP Turn back counterclockwise the number of clicks corresponding to the fork type. Specification Compression damping (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W) Comfort 24 clicks Standard 20 clicks Sport 18 clicks Compression damping (EXC-R SIX DAYS) Comfort 24 clicks Standard 22 clicks...

  • Page 13: Removing The Fork Legs

    01/FORK, TRIPLE CLAMP Warning Danger of accidents Reduced braking due to oil or grease on the brake discs. Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Clean and oil the dust boots and inner fork tube of both fork legs. Universal oil spray ( P.

  • Page 14: Bleeding Fork Legs

    01/FORK, TRIPLE CLAMP (EXC-R SIX DAYS, XCR-W USA) Fully tighten screw Specification Screw, top triple clamp 17 Nm (12.54 lbf ft) Fully tighten screw Specification Screw, bottom triple clamp 12 Nm (8.85 lbf ft) 500094-11 (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA) Fully tighten screw Specification Screw, top triple clamp...

  • Page 15: Installing The Fork Protector

    01/FORK, TRIPLE CLAMP Installing the fork protector Check parts for damage and wear. Replace damaged or worn parts. Position the fork protection on the left fork leg. Mount and tighten screws Specification Remaining screws, chassis 10 Nm (7.38 lbf ft) Position the fork protection on the right fork leg.

  • Page 16: Installing The Lower Triple Clamp (Exc-R Six Days, Xcr-W Usa)

    01/FORK, TRIPLE CLAMP Remove o-ring . Remove protector ring Remove the lower triple clamp with the steering stem. Remove the upper steering head bearing. 500100-10 Installing the lower triple clamp (EXC-R SIX DAYS, XCR-W USA) Clean the bearing and sealing elements, check for damage, and grease. Long-life grease ( P.

  • Page 17: Removing The Lower Triple Clamp (Exc-R Eu, Exc-R Aus/Uk, Exc-R Usa, Xcr-W Za)

    01/FORK, TRIPLE CLAMP Removing the lower triple clamp (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA) Remove the fork legs. ( P. 11) Remove the headlight mask with the headlight. ( P. 31) Dismount the front fender. ( P. 31) Remove screws and hang the CDI control unit to the side.

  • Page 18: Fork Offset (Exc-R Six Days, Xcr-W Usa)

    01/FORK, TRIPLE CLAMP Tighten screw Specification Screw, top steering stem 20 Nm (14.75 lbf ft) Check the cable harness, cable, brake and clutch line for free movement and free laying. Check play of steering head bearing. 100022-11 Fork offset (EXC-R SIX DAYS, XCR-W USA) You can see the currently set offset if you remove screw The fork offset has an impact on the handling of the vehicle.

  • Page 19: Adjusting Play Of Steering Head Bearing (Exc-R Six Days, Xcr-W Usa)

    01/FORK, TRIPLE CLAMP Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: (EXC-R SIX DAYS, XCR-W USA) Adjust play of the steering head bearing.

  • Page 20: Greasing The Steering Head Bearing

    01/FORK, TRIPLE CLAMP Greasing the steering head bearing (EXC-R SIX DAYS, XCR-W USA) Remove the lower triple clamp. ( P. 13) Install the lower triple clamp. ( P. 14) (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA) Remove the lower triple clamp. ( P.

  • Page 21: 03/Frame

    03/FRAME Removing the engine sprocket cover Remove screw Remove screw . Take off the engine sprocket cover. 500113-10 Installing the engine sprocket cover Check parts for damage and wear. Replace damaged or worn parts. Position the engine sprocket cover. Mount and tighten screw Specification Remaining screws, chassis 25 Nm...

  • Page 22: 04/Shock Absorber, Swingarm

    04/SHOCK ABSORBER, SWINGARM Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side. 500129-10 Adjusting high-speed compression damping of the shock absorber Danger Danger of accidents The shock absorber is under high pressure. The shock absorber is filled with high density nitrogen.

  • Page 23: Adjusting Rebound Damping Of The Shock Absorber

    04/SHOCK ABSORBER, SWINGARM Turn back counterclockwise the number of clicks corresponding to the shock ab- sorber type. Specification Compression damping, low-speed Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce sus- pension damping.

  • Page 24: Checking Static Sag Of The Shock Absorber

    04/SHOCK ABSORBER, SWINGARM Checking static sag of the shock absorber Measure distance of rear wheel unloaded. ( P. 21) Ask someone to help you by holding the motorcycle upright. Measure the distance between the rear axle and the fixed point again. 0 0 A Make a note of the value as measurement Info...

  • Page 25: Adjusting Riding Sag

    04/SHOCK ABSORBER, SWINGARM Loosen screw Turn adjusting ring until the spring is no longer under tension. Hook wrench (T106S) Measure the overall spring length when not under tension. Tighten the spring by turning adjusting ring to measurement Specification Spring preload Standard 9 mm Info...

  • Page 26: Installing Shock Absorber

    04/SHOCK ABSORBER, SWINGARM Installing shock absorber Check parts for damage and wear. Replace damaged or worn parts. Push splash protector to the side and position the shock absorber. Mount and tighten screw Specification ® Screw, top shock absorber 80 Nm Loctite 243™...

  • Page 27: 05/Exhaust

    05/EXHAUST Removing main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. Allow the exhaust system to cool down. Do not touch hot components. Disconnect spring Remove screws and take off main silencer. 400337-10 Fitting the main silencer Check parts for damage and wear.

  • Page 28: 06/Air Filter

    06/AIR FILTER Dismounting the air filter box lid Pull off the air filter box lid in area to the side and remove to the front. 400338-10 Installing the air filter box lid Insert the air filter box lid into the rear area and clip it into the front area 400338-11 Removing the air filter...

  • Page 29: Cleaning Air Filter

    06/AIR FILTER Cleaning air filter Warning Environmental hazard Problem materials cause environmental damage. Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info Do not clean the air filter with fuel or petroleum since these substances attack the foam. Remove the air filter.

  • Page 30: 07/Fuel Tank, Seat, Trim

    07/FUEL TANK, SEAT, TRIM Opening filler cap Press release button , turn filler cap counterclockwise and lift it free. 400199-10 Closing filler cap Replace the filler cap and turn clockwise until the release button locks in place. Info Run the fuel tank breather hose without kinks.

  • Page 31: Installing The Fuel Tank

    07/FUEL TANK, SEAT, TRIM Warning 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 imme- diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately.

  • Page 32: Fuel Tap

    07/FUEL TANK, SEAT, TRIM Check parts for damage and wear. Replace damaged or worn parts. Position the fuel tank and fit the two spoilers to the side of the radiator fixing. Make sure that no cables or Bowden cables are trapped or damaged. 500067-01 Mount the fuel tank vent hose.

  • Page 33: 08/Mask, Fender

    08/MASK, FENDER Dismounting the front fender Remove screws . Remove the front fender. Make sure that the distance bushings remain in place. 500092-10 Installing the front fender Check parts for damage and wear. Replace damaged or worn parts. Make sure that the distance bushings are mounted in the fender. Position the front fender.

  • Page 34: Dismount The Start Number Plate (Xcr-W Usa)

    08/MASK, FENDER Position the headlight mask and fix it with the rubber band Info Take care with the contact of the holding lug at the fender. Position the brake line and cable harness. Put the clamp on, mount and tighten screw Check the headlamp setting.

  • Page 35: 09/Front Wheel

    09/FRONT WHEEL Removing front wheel Jack up the motorcycle. ( P. 8) Press the brake caliper by hand on to the brake disc in order to press back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.

  • Page 36: Checking Brake Discs

    09/FRONT WHEEL Lift the front wheel into the fork, position it, and insert the wheel spindle. Mount and tighten screw Specification Screw, front wheel spindle M24x1,5 40 Nm (29.5 lbf ft) Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc.

  • Page 37: Tire Condition Checking

    Tire condition checking Info Fit only tires approved by KTM. Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.

  • Page 38: 10/Rear Wheel

    10/REAR WHEEL Removing rear wheel Jack up the motorcycle. ( P. 8) Press the brake caliper by hand on to the brake disc in order to press back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.

  • Page 39: Removing The Rear Brake Disc

    10/REAR WHEEL Position the chain adjuster . Fit nut , but do not tighten it yet. Check the chain tension when fitting rear wheel. ( P. 37) Make sure that the chain adjusters are fitted correctly on the adjusting screws Tighten nut Specification Nut, rear wheel spindle...

  • Page 40: Adjusting Chain Tension - Fitting Rear Wheel

    10/REAR WHEEL Make sure that the chain adjusters are fitted correctly on the adjusting screws. Push the chain at the end of the chain sliding component upwards to measure chain tension Info The upper chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 41: Adjusting Chain Tension - After Checking

    10/REAR WHEEL Adjusting chain tension - after checking Loosen nut Loosen nuts Adjust the chain tension by turning the adjusting screws left and right. Specification Chain tension 8… 10 mm (0.31… 0.39 in) Turn the adjusting screws left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks The rear wheel is then correctly aligned.

  • Page 42: Adjusting Chain Guide

    10/REAR WHEEL Loosen nut Loosen nuts Adjust the chain tension by turning the left and right adjusting screws Specification Chain tension 8… 10 mm (0.31… 0.39 in) Turn the left and right adjusting screws so that the markings on the left and right chain adjusters are in the same position relative to the reference marks The rear wheel is then correctly aligned.

  • Page 43: Checking Chain Wear

    10/REAR WHEEL Checking chain wear Jack up the motorcycle. ( P. 8) Shift to neutral and pull the upper chain length with the specified tension Specification Chain tension 10… 15 kg (22.05… 33.07 lb.) 0 0 A Measure distance of 18 chain links in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 44: 11/Wiring Harness, Battery

    Refit the fuse. Fuse (58011109110) Info 400273-10 If the new fuse burns out, contact an authorized KTM workshop. Replace the protection cover. Install the air filter box lid. ( P. 26) Removing the battery Warning Risk of injury Battery acid and battery gases cause serious cauterization.

  • Page 45: Installing The Battery

    11/WIRING HARNESS, BATTERY Installing the battery Check parts for damage and wear. Replace damaged or worn parts. Place the battery in the battery holder. 4Ah battery (YTX5L-BS) ( P. 150) Reconnect the rubber band Attach the plus cable and replace the plus pole cover Attach the minus cable Mount the seat.
  • Page 46 11/WIRING HARNESS, BATTERY Mount the seat. ( P. 28)

  • Page 47: 13/Brake System

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

  • Page 48: Changing The Front Brake Linings

    Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info ® KTM recommends brake fluid DOT 5.1 from Motorex . This brake fluid has a higher wet boiling point than brake fluid DOT 4 and offers more protection under high load.

  • Page 49: Checking Free Play Of Hand Brake Lever

    13/BRAKE SYSTEM Checking free play of hand brake lever Warning Danger of accidents Brake system failure. If there is no free travel on the hand brake lever, pressure builds up on the front brake in the brake system. The front brake can fail due to overheating.

  • Page 50: Add Front Brake Fluid

    Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info ® KTM recommends brake fluid DOT 5.1 from Motorex . This brake fluid has a higher wet boiling point than brake fluid DOT 4 and offers more protection under high load.

  • Page 51: Checking Rear Brake Linings

    13/BRAKE SYSTEM Move the brake fluid reservoir mounted on the handlebar to a horizontal position. Remove screws Remove cover with membrane Extract the old brake fluid from the brake fluid reservoir with a syringe and add new brake fluid. Bleed syringe (50329050000) ( P.

  • Page 52: Installing The Rear Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

  • Page 53: Checking Free Play Of Foot Brake Lever

    13/BRAKE SYSTEM Remove the rear brake linings. Stand the vehicle upright. Remove screw cap with membrane and the O-ring. Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir. Install the rear brake linings.

  • Page 54: Checking Rear Brake Fluid Level

    Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info ® KTM recommends brake fluid DOT 5.1 from Motorex . This brake fluid has a higher wet boiling point than brake fluid DOT 4 and offers more protection under high load.
  • Page 55 13/BRAKE SYSTEM Stand the vehicle upright. Remove screw cap with membrane and the O-ring. Extract the old brake fluid from the brake fluid reservoir with a syringe and add new brake fluid. Bleed syringe (50329050000) ( P. 177) Brake fluid DOT 5.1 ( P.

  • Page 56: 14/Light System, Instruments

    14/LIGHT SYSTEM, INSTRUMENTS Adjusting speedometer functions Info In the condition at delivery, only the SPEED / H display mode and SPEED / ODO are active. Condition The motorcycle is standing. Press the button briefly and repeatedly until H appears at the bottom right of the display.

  • Page 57: Setting The Clock

    14/LIGHT SYSTEM, INSTRUMENTS Setting the clock Condition The motorcycle is standing. Press the button briefly and repeatedly until CLK appears at the bottom right of the display. Press the button for 3 - 5 seconds. The hour display flashes. Set the hour display with the button "+" and/or button " ". Press the button briefly.

  • Page 58: 30/Engine

    30/ENGINE Removing the engine Drain the coolant. ( P. 133) Remove the carburetor. ( P. 115) Remove the engine sprocket. ( P. 131) Jack up the motorcycle. ( P. 8) Disconnect the negative (minus) cable of the battery. Remove screws .

  • Page 59: Installing The Engine

    30/ENGINE Remove the cable binder and disconnect all connectors of the engine wiring har- ness in area Remove screws . Take off the slave cylinder of the clutch and hang it to one side. Info To not kink the clutch line. Do not activate the clutch lever if the slave cylinder of the clutch has been removed.
  • Page 60 30/ENGINE Position the manifold and mount springs Mount and tighten screw Specification Remaining screws, chassis 25 Nm (18.44 lbf ft) Fit the main silencer. ( P. 25) 500076-14 Position the swingarm, shock absorber and rear wheel together. Insert the swingarm pivot.

  • Page 61: 30/Disassembling Engine

    30/DISASSEMBLING ENGINE Preparations Thoroughly clean the outside of the engine and attach it to the universal mounting rack using the special tool. Engine holder (78029002000) ( P. 182) Universal mounting rack (56012001000) ( P. 178) Place a container suitable for draining oil beneath the engine. 700020-01 Draining the engine oil Remove engine oil plug screen...

  • Page 62: Removing The Starter Engine

    30/DISASSEMBLING ENGINE Plug - remove the gear oil screen Completely drain the gear oil. 700024-10 Removing the starter engine Remove screws and take off the starter engine. 200064-10 Removing the valve cover Remove screws . Take off the valve cover with the valve cover seal. 700013-10 Removing the shift lever Remove screw...

  • Page 63: Removing The Generator Cover

    30/DISASSEMBLING ENGINE Removing the generator cover Remove screws . Take off the generator cover. 700011-10 Remove centering pins . Take off generator cover seal and dispose of it. 700010-10 Setting the engine to ignition top dead center Align camshaft marking with marking on the cylinder head.

  • Page 64: Removing The Timing Chain Tensioner

    30/DISASSEMBLING ENGINE Removing the timing chain tensioner Remove screw . Take off seal ring Pull out timing chain tensioner . Remove O-ring 200074-10 Removing the camshaft Remove screw . Take off camshaft bracket 200076-10 Pull the camshaft out of the bearing seats. Take the timing chain off of the camshaft gear.

  • Page 65: Removing The Rotor

    30/DISASSEMBLING ENGINE Remove dowels and cylinder base gasket 200090-11 Removing the rotor Remove nut with the spring washer. 200100-10 Attach special tool to the rotor. Apply counterpressure with the special tool and pull off the rotor by turning in the screw. Extractor (58012009000) ( P.

  • Page 66: Removing The Timing Chain Tensioning Rail

    30/DISASSEMBLING ENGINE Removing the timing chain tensioning rail Remove screw . Remove the timing chain guide rail toward the top. 700005-10 Removing the timing chain securing guide Remove screws . Remove the timing chain securing guide. 700026-10 Removing the timing chain Take off the timing chain.

  • Page 67: Removing The Kickstarter

    30/DISASSEMBLING ENGINE Remove internal rotor with pin and external rotor Remove O-ring 200129-10 Removing the kickstarter Remove screw . Take off the kickstarter. 200067-10 Removing the water pump cover Remove screws . Take off the water pump cover. Take off the water pump cover seal and dispose of it. 200071-10 Removing the clutch cover Remove crankshaft fixation element...

  • Page 68: Removing The Clutch Discs

    30/DISASSEMBLING ENGINE Removing the clutch discs Undo screws and remove them with the washers and springs. Take off the pressure cap. 200093-10 Take out clutch discs entirely. 200094-11 Removing the primary gear nut Block the outer clutch hub and primary gear using special tool Gear segment (80029004000) ( P.

  • Page 69: Removing The Balancer Shaft

    30/DISASSEMBLING ENGINE Removing the balancer shaft Pull balancer shaft out of the bearing seats and remove it. 700029-10 Removing the torque limiter Remove the screw with the washer. Take off torque limiter 200120-11 Removing the starter idler gear Remove the lock ring. Take off the washer. Take off starter idler gear 200121-12 Removing the kickstarter shaft Apply counterpressure to kickstarter spring...

  • Page 70: Removing The Shift Shaft

    30/DISASSEMBLING ENGINE Removing the shift shaft Press sliding plate away from the shift drum locating. Remove shift shaft with the washer. 200109-10 Removing the shift drum locating Remove screw Press locking lever away from shift drum locating and take off the shift drum locating.

  • Page 71: Removing The Oil Pumps

    30/DISASSEMBLING ENGINE Removing the oil pumps Remove screws Take off oil pump covers of the force pumps. 200125-10 Remove oil pump shaft of the gear oil force pump together with pin , internal rotor and external rotor Remove internal rotor and external rotor of the engine oil force pump.

  • Page 72: Removing The Shift Rails

    30/DISASSEMBLING ENGINE Mount special tool with suitable screws. Extractor (75029048000) ( P. 180) Info Use the bore labeled 780. Pull off the engine case section. Info Do not warp the engine case section. 200138-10 Remove the special tool. Remove distance bushing Take off the left section of the engine case.

  • Page 73: Removing The Shift Forks

    30/DISASSEMBLING ENGINE Removing the shift forks Take shift forks out of the shift grooves. Info Make sure not to misplace shift drums 200144-10 Removing the transmission shaft Place the engine in an upright position. Remove lock ring 200145-10 Pull both transmission shafts out of the bearing seats together. Info Make sure not to misplace the washers.

  • Page 74: 30/Engine - Work On Individual Parts

    30/ENGINE - WORK ON INDIVIDUAL PARTS Work on the right section of the engine case Remove the oil pressure regulator valve. ( P. 75) Remove oil jet Remove the bearing retainer of crankshaft bearing , drive shaft bearing , coun- tershaft bearing and shift drum bearing Remove any sealing mass remnants and clean the engine case section thoroughly.

  • Page 75: Work On The Left Section Of The Engine Case

    30/ENGINE - WORK ON INDIVIDUAL PARTS Mount and tighten oil jet Specification ® Oil jet, piston cooling 2 Nm Loctite 243™ (1.48 lbf ft) Mount and tighten oil jet Specification ® Oil jet, conrod lubrication M6x0,75 4 Nm Loctite 243™ (2.95 lbf ft) 400368-01 Blow though all oil holes with compressed air and check that they are clear.
  • Page 76 30/ENGINE - WORK ON INDIVIDUAL PARTS Treat the new shaft seal ring of the crankshaft and the seat of the shaft seal ring in the engine case section with activator. ® Loctite 7471 ® Loctite 7649 Apply adhesive to the outside of the shaft seal ring. ®...

  • Page 77: Removing The Oil Pressure Regulator Valve

    30/ENGINE - WORK ON INDIVIDUAL PARTS 400367-01 Blow though all oil holes with compressed air and check that they are clear. removing the oil pressure regulator valve Remove plug with sealing disc Remove preload spring and ball 200154-10 Checking the spring length of the oil pressure regulator valve Remove the oil pressure regulator valve.

  • Page 78: Removing The Crankshaft Seal Ring In The Clutch Cover

    30/ENGINE - WORK ON INDIVIDUAL PARTS Removing the crankshaft seal ring in the clutch cover Remove the crankshaft seal ring in clutch cover 200194-10 Fitting the crankshaft seal ring into the clutch cover Check parts for damage and wear. Replace damaged or worn parts. Press crankshaft seal ring into the clutch cover with the open side facing in- wards until it is flush.

  • Page 79: Installing The Water Pump

    30/ENGINE - WORK ON INDIVIDUAL PARTS Press out bearing of the water pump shaft using a suitable tool. Info Support the clutch cover as necessary when pressing it out. 200198-10 Installing the water pump Check parts for damage and wear. Replace damaged or worn parts. Press in bearing of the water pump shaft using a suitable tool until it is flush.

  • Page 80: Checking The Balancer Shaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the balancer shaft Check bearing surface of the balancer shaft for pitting corrosion. » If there is pitting corrosion: Change the balancer shaft. Check the remaining areas of the balancer shaft for damage and wear. »...
  • Page 81 30/ENGINE - WORK ON INDIVIDUAL PARTS When the crank pin is pressed in, oil hole must be aligned with oil hole Marking is opposite from oil hole and must be on the outside after mounting. Info If the oil holes are not correctly aligned, the conrod bearing will not be pro- vided with oil.

  • Page 82: Checking The Crankshaft Run-Out On The Bearing Pin

    30/ENGINE - WORK ON INDIVIDUAL PARTS Measure the external dimensions of the crankshaft - crank web. Crankshaft - external crank web dimen- 63 0.05 mm (2.48 0.002 in) sion » If the specified value is not reached: Correct to the specified value. Check the crankshaft run-out on the bearing pin.

  • Page 83: Checking/Measuring The Piston

    30/ENGINE - WORK ON INDIVIDUAL PARTS Check the sealing area of the cylinder head for distortion using a straight edge and the special tool. Feeler gauge (59029041000) ( P. 179) Cylinder/cylinder head - sealing area 0.1 mm ( 0.0039 in) distortion »...

  • Page 84: Checking Piston/Cylinder Mounting Clearance

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking piston/cylinder mounting clearance Check/measure the cylinder. ( P. 80) Check/measure the piston. ( P. 81) The smallest piston/cylinder mounting clearance is the result of the smallest cylinder bore diameter minus the largest piston diam- eter.

  • Page 85: Disassembling The Autodecompressor

    30/ENGINE - WORK ON INDIVIDUAL PARTS Check the spring length of the oil pressure regulator valve. ( P. 75) Disassembling the autodecompressor Take lock ring off of the autodecompressor shaft and dispose of it. 200166-10 Pull autodecompression shaft out of the camshaft. 200167-10 Detach autodecompression spring and remove it.

  • Page 86: Checking The Camshaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS Mount a new lock ring Check for correct functioning. » The autodecompression spring does not turn the autodecompression shaft fully back to the stop: Tighten the autodecompression spring or replace it. 200166-11 Checking the camshaft Check the camshaft for damage and wear.

  • Page 87: Removing The Rocker Arm

    30/ENGINE - WORK ON INDIVIDUAL PARTS Place 2 spacing washers or similar aids next to the piston of the timing chain ten- sioner. This should ensure that when pushed down, the piston does not fully with- draw. Specification Thickness of spacers 2…...

  • Page 88: Replacing The Camshaft Bearing

    30/ENGINE - WORK ON INDIVIDUAL PARTS Remove the spring retainer and spring. Pull the valve downward out of the valve guide, pry off the valve stem seal and re- move the lower valve spring retainer. 200188-10 Mark the valve to indicate the installation position. Info Place the valve into a box according to the installation position and label the box.

  • Page 89: Checking The Valves

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the valves Info The valve stem is chrome-hardened, and wear normally takes place in the valve guide. Check for valve retainer run-out. Valve Run-out on valve plate 0.05 mm ( 0.002 in) » If the measured value does not equal the specified value: Change the valve.

  • Page 90: Checking The Cylinder Head

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the cylinder head Check the exhaust valve guides using special tool Limit plug gauge (59029026006) ( P. 179) » If the special tool is easy to insert into the valve guide: Change the valve guide and valve. Check the intake valve guides using the special tool.

  • Page 91: Installing The Rocker Arm

    30/ENGINE - WORK ON INDIVIDUAL PARTS Mount the valve keys. Info When mounting the valve keys, check that they are seated correctly; prefer- ably, fix the valve keys to the valve with a little grease. Place the shims in the valve spring retainers according to their position in the en- gine.

  • Page 92: Checking The Shift Mechanism

    30/ENGINE - WORK ON INDIVIDUAL PARTS Check intermediate discs for damage and wear. » If the intermediate discs are not level and have pittings: Change all intermediate discs. Check clutch facing discs for discoloration and scoring. » If there is discoloration or scoring: Change all clutch facing discs.

  • Page 93: Preassembling The Shift Shaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS Check clearance between sliding plate and shift quadrant. Shift shaft - play in sliding plate/shift 0.4… 0.8 mm (0.02… 0.03 in) quadrant 0 0 0 A » If the measured value does not equal the specified value: Change the sliding plate.

  • Page 94: Dismantling The Countershaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS 0 0 4 0 0 5 0 0 7 0 0 9 0 0 6 0 0 8 0 0 b k 0 0 b l 0 0 2 0 0 1 0 0 3 200178-01 Fix the main shaft in the vise with the geared end facing downwards.

  • Page 95: Checking The Transmission

    30/ENGINE - WORK ON INDIVIDUAL PARTS 0 0 b o 0 0 b p 0 0 b n 0 0 b k 0 0 9 0 0 8 0 0 2 0 0 7 0 0 5 0 0 4 0 0 1 0 0 b s 0 0 b q...

  • Page 96: Checking Electric Starter Operation

    30/ENGINE - WORK ON INDIVIDUAL PARTS Check the tooth faces of idler gears and fixed gears for damage and wear. » If there is damage or wear: Change the idler/fixed gear pair. Check the tooth profiles of fixed gears for damage and wear. »...

  • Page 97: Checking The Free-Wheel

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the free-wheel Place the free-wheel gear in primary pinion while rotating the primary pinion clockwise, but do not tilt it! Check the locking action of free-wheel gear » The primary pinion cannot be rotated clockwise or does not block counterclock- wise: Remove the free-wheel.

  • Page 98: 30/Assembling Engine

    30/ASSEMBLING ENGINE Installing the crankshaft Check parts for damage and wear. Replace damaged or worn parts. Clamp the right section of the engine case into the engine work stand. Heat the inner ring of the crankshaft bearing. Specification 80 °C (176 °F) Info Do not damage the seal ring.

  • Page 99: Installing The Shift Roller

    30/ASSEMBLING ENGINE Installing the shift roller Check parts for damage and wear. Replace damaged or worn parts. Slide shift roller into the bearing seat. Hang the shift forks into the shift roller. Info Make sure not to misplace the shift drums. 200142-11 Installing the shift rails Check parts for damage and wear.

  • Page 100: Installing The Primary Gear With The Free-Wheel-Gear

    30/ASSEMBLING ENGINE Mount collar and needle bearing 200136-12 Installing the primary gear with the free-wheel-gear Oil the free-wheel in the primary gear. Slide primary gear with the free-wheel onto free-wheel-gear and mount them both on crankshaft Info The free-wheel-gear must rotate counterclockwise when it is mounted. 700004-01 Installing the oil pumps Check parts for damage and wear.

  • Page 101: Installing The Oil Pump Gears

    30/ASSEMBLING ENGINE Installing the oil pump gears Check parts for damage and wear. Replace damaged or worn parts. Insert pins 200127-11 Position oil pump gears Info Ensure that the pins are seated correctly. Position washers Mount shaft retainer Crank the oil pump gears and check that they can be easily moved. 200124-11 Installing the locking lever Check parts for damage and wear.

  • Page 102: Installing The Kickstarter Idler Gear

    30/ASSEMBLING ENGINE Installing the kickstarter idler gear Check parts for damage and wear. Replace damaged or worn parts. Slide on kickstarter idler gear with the collar facing the engine case. Slide on the washer. Mount the lock ring. 200120-12 Installing the kickstarter shaft Check parts for damage and wear.

  • Page 103: Installing The Balancer Shaft

    30/ASSEMBLING ENGINE Installing the balancer shaft Check parts for damage and wear. Replace damaged or worn parts. Slide balancer shaft into the bearing seats. Align the marking on balance weight with the marking on primary pinion 200134-11 Installing the outer clutch hub Check parts for damage and wear.

  • Page 104: Installing The Clutch Discs

    30/ASSEMBLING ENGINE Installing the clutch discs Check parts for damage and wear. Replace damaged or worn parts. Oil the clutch facing discs well. Engine oil (SAE 10W/50) ( P. 174) Insert support ring into the outer clutch hub. Insert pretension ring with the open side facing outward.

  • Page 105: Installing The Water Pump Cover

    30/ASSEMBLING ENGINE Installing the water pump cover Check parts for damage and wear. Replace damaged or worn parts. Fit the water pump cover seal. Install the water pump cover. Mount screw with the seal washer and tighten it after all screws of the water pump cover have been mounted. Specification Screw, water pump cover M6x25...

  • Page 106: Installing The Ignition Pulse Generator

    30/ASSEMBLING ENGINE Installing the ignition pulse generator Check parts for damage and wear. Replace damaged or worn parts. Position the ignition pulse generator. Info Use the outermost pair of drill holes. Mount and tighten screws Specification ® Screw, ignition pulse gen- 6 Nm Loctite 243™...

  • Page 107: Installing The Timing Chain Guide Rail

    30/ASSEMBLING ENGINE Installing the timing chain guide rail Check parts for damage and wear. Replace damaged or worn parts. Thread timing chain guide rail from above. Mount and tighten screws Specification ® Screw, timing chain guide 10 Nm Loctite 243™ rail (7.38 lbf ft) 700006-11...
  • Page 108 30/ASSEMBLING ENGINE Carefully knock the piston into the cylinder using the hammer shaft. Info The piston tension band must press the piston rings together firmly and must be flush with the cylinder; the piston rings should not catch or else they will be damaged.

  • Page 109: Installing The Cylinder Head

    30/ASSEMBLING ENGINE Insert the special tool and firmly press it toward the piston. Turn the special tool counterclockwise, thereby pressing the piston pin retainer into the groove. Insert for piston pin retainer (77329030100) ( P. 181) 200084-10 Remove the cloth. Keep the timing chain tensioned. Push the cylinder down carefully and let the dowels engage.

  • Page 110: Installing The Camshaft

    30/ASSEMBLING ENGINE Installing the camshaft Check parts for damage and wear. Replace damaged or worn parts. Place the timing chain over the camshaft. Slide the camshaft into the bearing seats. The markings on camshaft and cylinder head must be aligned. Info Ensure that the crankshaft is located at top dead center.

  • Page 111: Checking The Valve Clearance

    30/ASSEMBLING ENGINE Checking the valve clearance Remove special tool Crank the engine several times. Set the engine to ignition top dead center. ( P. 61) 200062-11 On all valves, check valve clearance between the valve and rocker arm. Specification Valve clearance Outfeed at: 20 °C (68 °F) 0.12…...

  • Page 112: Installing The Shift Lever

    30/ASSEMBLING ENGINE Position the generator cover. Mount screws and tighten them after all screws of the generator cover have been mounted. Specification Screw generator cover M6x25 10 Nm (7.38 lbf ft) Mount screws and tighten all screws in a crisscross pattern. Specification Screw generator cover M6x40...

  • Page 113: Installing The Starter Motor

    30/ASSEMBLING ENGINE Installing the starter motor Check parts for damage and wear. Replace damaged or worn parts. Grease the O-ring. Mount the starter engine. Long-life grease ( P. 175) Mount and tighten screws Specification Screw, starter motor 10 Nm (7.38 lbf ft) 200064-10 Mounting oil filter Tilt the engine sideways and fill the oil filter housing to about 1/3 full with engine...

  • Page 114: Filling Up With Gear Oil

    30/ASSEMBLING ENGINE Filling up with gear oil Thoroughly clean the plug, gear oil screen and gear oil drain plug. Check parts for damage and wear. Replace damaged or worn parts. Clean the sealing surfaces on the engine. Refit gear oil drain plug with seal ring and tighten it. Specification Gear oil drain plug with magnet M12x1,5...

  • Page 115: 31/Carburetor

    31/CARBURETOR Choke (EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W) The choke is fitted on the left side of the carburetor. Activating the choke function frees an opening through which the engine can draw ex- tra fuel. This gives a richer fuel-air mixture, which is needed for a cold start. Info If the engine is warm, the choke function must be deactivated.

  • Page 116: Checking Gas Bowden Cable Route

    31/CARBURETOR Push bellows Checking gas Bowden cable route The two gas Bowden cables must run parallel behind the handlebar down to the frame. They must be routed directly on the frame above the tank bearing to the car- buretor. 500152-10 Checking play in the gas Bowden cable Move the handlebar to the straight-ahead position.

  • Page 117: Removing The Carburetor

    31/CARBURETOR Removing the carburetor Dismount the fuel tank. ( P. 28) Remove the carburetor connection boot. ( P. 27) Remove screw . Remove the carburetor cover. Push back bellows 500109-10 Undo nuts , detach the Bowden cables and hang them to one side. Undo hose clip Pull engine vent hose off of the carburetor.
  • Page 118 31/CARBURETOR Remove screws with the spring and washer and slide stop Pull the jet needle out of the throttle slide. Remove screw 700036-10 Pull up throttle slide arm . Take throttle slide out of the carburetor along with throttle slide roller and the throttle slide plate.
  • Page 119 31/CARBURETOR Remove idling jet , cold start jet , needle jet and buffer plate Screw in mixture control screw to the stop, counting and noting down the num- ber of rotations. Remove the mixture control screw with the spring, washer and O-ring. 700045-10 Screws should not be removed.

  • Page 120: Checking The Carburetor Components

    31/CARBURETOR Checking the carburetor components 700073-01 Disassemble the carburetor. ( P. 115) Check/adjust the accelerator pump. ( P. 118) Check the choke slide. ( P. 119) Check the jet needle. ( P. 119) Check the throttle slide. ( P. 119) Check the needle jet.

  • Page 121: Checking The Choke Slide

    31/CARBURETOR Check/adjust the throttle slide opening. ( P. 120) Info Adjusting the play of the accelerator pump changes the time at which injec- tion starts and does not influence the injection rate or the intensity of the accelerator pump. Check piston rod overhang Specification Piston rod overhang 0.9…...

  • Page 122: Checking The Needle Jet

    31/CARBURETOR Checking the needle jet Use a new jet needle as a gauge. Apply a marking on the jet needle above step at a distance of Specification Distance 3 mm (0.12 in) Info The marking should come off completely when cleaned away. 700053-10 Insert the marked jet needle into the needle jet being tested.

  • Page 123: Checking Throttle Valve Sensor Tps

    31/CARBURETOR Check the throttle slide opening using a wire or a drill shank. Throttle slide opening 1 mm (0.04 in) » If the throttle slide opening does not equal the specified value: Adjust the throttle slide opening with adjusting screw 700062-10 Checking throttle valve sensor TPS Info...

  • Page 124: Assembling The Carburetor

    31/CARBURETOR Multiply the total resistance R of the throttle valve sensor by 0.17. This gen- erates the variable resistance R for the setting of the throttle valve sensor. x 0.17 = R (tolerance 0.05 k ) 700064-10 Connect the positive wire of the multimeter to the yellow (ye) cable and the ground wire to the black (bl) cable of the connector of throttle valve sensor TPS.
  • Page 125 1 turn Idle mixture adjusting screw (XCR-W ZA, 530 EXC-R EU, 530 EXC-R AUS/UK) Open 1.5 turns Idle mixture adjusting screw (450 EXC-R EU, 450 EXC-R AUS/UK, 450 EXC- R USA) Open 1.75 turns Idle mixture adjusting screw (530 EXC-R USA)
  • Page 126 Jet needle (OBDTQ) (530 XCR-W, 530 EXC-R SIX DAYS) Jet needle (OBDTR) (450 EXC-R USA) Jet needle (OBDYU) (450 EXC-R EU, 450 EXC-R AUS/UK) Jet needle (OBDYU (OBDTQ)) (530 EXC-R USA) Jet needle (OBDZT) (530 EXC-R EU, 530 EXC-R AUS/UK) Jet needle (OBDZT (OBDTR)) Insert the jet needle.

  • Page 127: Installing The Carburetor

    31/CARBURETOR Check/adjust the accelerator pump. ( P. 118) Position seal ring , membrane and spring Info The label on the membrane must be visible when mounted. 700060-11 Position seal ring in the accelerator pump cover with the rounded side facing outward.

  • Page 128: Carburetor - Adjusting Idle

    Idle mixture adjusting screw (XCR-W ZA, 530 EXC-R EU, 530 EXC-R AUS/UK) 400341-10 Open 1.5 turns Idle mixture adjusting screw (450 EXC-R EU, 450 EXC-R AUS/UK, 450 EXC- R USA) Open 1.75 turns Idle mixture adjusting screw (530 EXC-R USA)

  • Page 129: Emptying The Carburetor Float Chamber

    31/CARBURETOR Note the position and turn the idle adjusting screw slowly counterclockwise until the idle speed falls. Adjust to the point between these two positions with the highest idle speed. Info If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps.
  • Page 130 31/CARBURETOR Guide the hose coming down behind the engine into a suitable container. Info Water in the float chamber results in malfunctioning. Undo the screw (turn it counterclockwise) a few turns and drain the fuel from the float chamber. Tighten screw 400341-11...

  • Page 131: 32/Clutch

    32/CLUTCH Checking fluid level of hydraulic clutch Warning Skin irritations Brake fluid can cause skin irritation on contact. Avoid contact with skin and eyes, and keep out of the reach of children. If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Info The fluid level rises with increasing wear of the clutch lining disc.
  • Page 132 32/CLUTCH Fill the bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) ( P. 177) Brake fluid DOT 5.1 ( P. 174) On the slave cylinder, remove the bleeder screw and fit the bleeding syringe 500158-10 Inject the liquid into the system until it escapes from the bore hole of the mas- ter cylinder without bubbles.

  • Page 133: 33/Transmission

    33/TRANSMISSION Removing the engine sprocket Remove the engine sprocket cover. ( P. 19) Press the rear brake and remove screw with spring washer. Pull the engine sprocket with the chain off of the countershaft. Remove the engine sprocket. 500115-10 Installing the engine sprocket Check parts for damage and wear.

  • Page 134: 35/Water Pump, Cooling System

    35/WATER PUMP, COOLING SYSTEM Checking antifreeze and coolant level Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure. Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 135: Draining Coolant

    35/WATER PUMP, COOLING SYSTEM Draining coolant Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure. Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 136: 38/Lubrication System

    38/LUBRICATION SYSTEM Oil cycle 400283-10 engine oil screen Engine oil force pump Oil pressure regulator valve Oil filter insert Oil jet, conrod lubrication Oil jet, piston cooling Timing chain tensioner Lubrication, rocker arm shaft Oil jet, rocker arm lubrication Gear oil screen Gear oil force pump Oil channel, transmission lubrication Lubrication, clutch push rod...

  • Page 137: Changing Engine Oil And Oil Filter, Cleaning Engine Oil Screen

    38/LUBRICATION SYSTEM Condition Engine is cold. Check the engine oil level. The engine oil must be between the halfway mark and the top of the oil level viewer » If the engine oil level is below the specified level: Top up the engine oil. ( P.

  • Page 138: Mounting Oil Filter

    38/LUBRICATION SYSTEM Remove screws . Remove oil filter cover with O-ring. 200113-10 Pull the oil filter insert out of the oil filter casing. Circlip pliers reverse (51012011000) Completely drain the engine oil. Thoroughly clean parts and sealing area. 200114-10 Mounting oil filter Check parts for damage and wear.

  • Page 139: Topping Up Engine Oil

    38/LUBRICATION SYSTEM Topping up engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. Remove the screw cap on the generator cover and fill up with engine oil. Engine oil (SAE 10W/50) ( P.

  • Page 140: Checking Gear Oil Level

    38/LUBRICATION SYSTEM Checking gear oil level Info The gear oil level must be checked when the engine is cold. Stand the motorcycle upright on a horizontal surface. Condition Engine is cold. Remove gear oil level check screw . Stand the vehicle upright. Check the gear oil level.

  • Page 141: Filling Up With Gear Oil

    38/LUBRICATION SYSTEM Filling up with gear oil Info Too little gear oil or poor-quality oil results in premature wear to the transmission. Remove the screw cap and fill up with gear oil. Gear oil 0.9 l (0.95 qt.) Engine oil (SAE 10W/50) ( P.

  • Page 142: Troubleshooting

    Low external temperature Start the engine with the kickstarter. Recharge the battery. Establish the reason for discharging or have it checked in a KTM workshop. Engine turns but does not start. Operating error Perform the steps necessary to start the engine.
  • Page 143 TROUBLESHOOTING Faults Possible cause Measure Engine turns but does not start. Water in carburetor or jets blocked Clean carburetor. Engine has no idle. Idling jet blocked Clean carburetor. Adjusting screws on carburetor distorted Have the carburetor adjusted. Spark plug defective Change spark plug.

  • Page 144: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 1-cyliner 4-stroke engine, water-cooled Displacement (Every 450 models) 449.3 cm³ (27.42 cu in) Displacement (Every 530 models) 510.4 cm³ (31.15 cu in) Stroke (Every 450 models) 63.4 mm (2.5 in) Stroke (Every 530 models) 72 mm (2.83 in) Bore 95 mm (3.74 in) Compression ratio...

  • Page 145: Capacity - Coolant

    TECHNICAL DATA - ENGINE Capacity - coolant Coolant 0.95 l (1 qt.) Coolant ( P. 174) Coolant (mixed ready to use) ( P. 174)

  • Page 146: Technical Data - Tolerance, Wear Limits Of Engine

    TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE Camshaft - cam height Intake 33… 33.2 mm (1.3… 1.31 in) Camshaft - cam height (Every 450 models) Exhaust 33.9… 34.1 mm (1.33… 1.34 in) Camshaft - cam height (Every 530 models) Exhaust 34.2…...

  • Page 147: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Screw, cable holder in generator cover 4 Nm (2.95 lbf ft) Loctite 243™ ® Oil jet, rocker arm lubrication 2 Nm (1.48 lbf ft) Loctite 243™ ® Oil jet, piston cooling 2 Nm (1.48 lbf ft) Loctite 243™...
  • Page 148 TECHNICAL DATA - ENGINE TIGHTENING TORQUES Screw, cylinder head M10x1,25 Tightening sequence: Engine oil (any) Tighten diagonally, begin- ning with the rear screw on the chain shaft. Step 1 10 Nm (7.38 lbf ft) Step 2 30 Nm (22.13 lbf ft) Step 3 50 Nm (36.88 lbf ft) Gear oil drain plug with magnet...

  • Page 149: Technical Data - Carburetor

    TECHNICAL DATA - CARBURETOR 450 EXC-R EU, 450 EXC-R AUS/UK (3900I) Carburetor type KEIHIN FCR-MX 39 Carburetor identification number 3900I Needle position 4th position from top Idle mixture adjusting screw Open 1.75 turns Pump membrane stop 2.15 mm (0.08 in)

  • Page 150: Exc-R Eu, 530 Exc-R Aus/Uk (3900J)

    TECHNICAL DATA - CARBURETOR 530 EXC-R EU, 530 EXC-R AUS/UK (3900J) Carburetor type KEIHIN 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 (0.08 in) Main jet Jet needle OBDZT (OBDTR)

  • Page 151: Technical Data - Carburetor Tightening Torques

    TECHNICAL DATA - CARBURETOR TIGHTENING TORQUES Leakage nozzle M4x0,7 2 Nm (1.48 lbf ft) ® Screw, throttle slide arm 2 Nm (1.48 lbf ft) Loctite 243™ ® Screw, hose connection 2 Nm (1.48 lbf ft) Loctite 243™ Other screws, carburetor 2 Nm (1.48 lbf ft) Idle air jet M4,5x0,75...

  • Page 152: Technical Data - Chassis

    Road tire pressure (Every EXC-R models) front 1.5 bar (21.76 psi) Rear 2 bar (29.01 psi) Rear wheel gearing (450 EXC-R EU, 450 EXC-R AUS/UK, 15:45 (14:52) 450 EXC-R USA) Rear wheel gearing (450 EXC-R SIX DAYS, XCR-W ZA) 14:52...

  • Page 153: Lighting Equipment

    80/100 - 21 51 M TT 110/100 - 18 64 M TT Bridgestone M59 Bridgestone M402 For further information, see: http://www.ktm.com Capacity - fuel Tank capacity (EXC-R EU, 9 l (2.38 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( P.

  • Page 154: Technical Data - Fork

    TECHNICAL DATA - FORK Fork part number (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR- 14.18.7D.06 Fork part number (EXC-R SIX DAYS) 14.18.7D.35 Fork WP 4860 MXMA PA Compression damping (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W) Comfort 24 clicks Standard 20 clicks Sport 18 clicks...

  • Page 155: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number (EXC-R EU, EXC-R AUS/UK, EXC- 12.18.7D.06 R USA, XCR-W) Shock absorber part number (EXC-R SIX DAYS) 12.18.7D.35 Shock absorber WP PDS 5018 DCC Compression damping, low-speed Comfort 18 clicks Standard 15 clicks Sport 12 clicks Compression damping, high-speed...

  • Page 156: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES Spoke nipple, front wheel M4,5 5 Nm (3.69 lbf ft) Spoke nipple, rear wheel 5 Nm (3.69 lbf ft) Remaining nuts, chassis 15 Nm (11.06 lbf ft) Remaining screws, chassis 10 Nm (7.38 lbf ft) Screw, rear brake disc 14 Nm (10.33 lbf ft) Screw, front brake disc...

  • Page 157: Cleaning

    CLEANING Cleaning motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 158: Storage

    STORAGE Storage Warning 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 imme- diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately.

  • Page 159: Greasing And Service Table

    GREASING AND SERVICE TABLE Important maintenance work to be carried out by an authorized KTM workshop. S15A S30A Engine Change the engine oil and oil filter and clean the engine oil screen. ( P. 135) • • Change the gear oil and clean the gear oil screen. ( P.

  • Page 160: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop. (As Additional Order)

    GREASING AND SERVICE TABLE Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) Competition use Hobby use S15A S30A S45A S30A S60A S90A Carry out a complete fork service. • Carry out a complete shock absorber service.
  • Page 161 GREASING AND SERVICE TABLE NB1A Clean dust boots of fork legs. ( P. 10) • Clean the chain. ( P. 41) • Check the chain tension. ( P. 38) • Check the chain wear. ( P. 41) • Check the rear sprocket / engine sprocket for wear. ( P.

  • Page 162: Wiring Diagram

    WIRING DIAGRAM Wiring diagram (EXC-R EU) C_CX/2 C_CZ/3 C_DB/4 C_CW/2 C_CY/3 C_DA/4 C_AK1/2 C_DG/4 C_CW2/2 C_CW3/2 C_AH1/2 C_CX2/2 C_CX3/2 C_BP/4 ye-bl bl-wh C_BA/1 bu-wh C_BF/1 bu-wh ye-re ye-re ye-re ye-bl re-wh re-bl C_BA2/1 ye-bl ye-re wh-re ye-re re-bl wh-re re-wh ye-re C_CR/1 C_CR1/1...
  • Page 163 WIRING DIAGRAM Components Battery Generator Ignition coil Pulse generator Voltage regulator/rectifier Electric starter button Starter relay with fuse Starter motor Light switch, horn button, short circuit button Throttle valve sensor TPS Ignition curve plug connection CDI controller Headlight Parking light Brake / tail light Licence plate lamp Speedometer...

  • Page 164: Wiring Diagram (Exc-R Aus/Uk)

    WIRING DIAGRAM Wiring diagram (EXC-R AUS/UK) C_CX/2 C_CZ/3 C_DB/4 C_CW/2 C_CY/3 C_DA/4 C_AK1/2 C_CW2/2 C_DG/4 C_CW3/2 C_AH1/2 C_CX2/2 C_CX3/2 C_BP/4 ye-bl bl-wh C_BA/1 bu-wh C_BF/1 bu-wh ye-re ye-re ye-re ye-bl re-wh re-bl C_BA2/1 ye-bl ye-re wh-re ye-re re-bl wh-re re-wh ye-re C_CR/1 C_CR1/1...
  • Page 165 WIRING DIAGRAM Components Battery Generator Ignition coil Pulse generator Voltage regulator/rectifier Flasher switch Starter relay with fuse Starter motor Light switch, horn button, short circuit button Throttle valve sensor TPS Ignition curve plug connection CDI controller Headlight Parking light Brake / tail light Licence plate lamp Electric starter button, emergency OFF switch Flasher relay...

  • Page 166: Wiring Diagram (Exc-R Usa)

    WIRING DIAGRAM Wiring diagram (EXC-R USA) C_CX/2 C_CZ/3 C_DB/4 C_CW/2 C_CY/3 C_DA/4 C_AK1/2 C_CW2/2 C_CW3/2 C_DG/4 C_AH1/2 C_CX2/2 C_CX3/2 C_BP/4 bl-wh bu-wh bu-wh ye-re ye-re ye-re ye-bl re-wh re-bl ye-re black C_BF/1 ye-re ye-re ye-bl C_BA/1 ye-bl re-bl wh-re re-wh ye-re C_CR/1 C_CR1/1...
  • Page 167 WIRING DIAGRAM Components Battery Generator Ignition coil Pulse generator Voltage regulator/rectifier Electric starter button Starter relay with fuse Starter motor Emergency OFF switch Throttle valve sensor TPS Ignition curve plug connection CDI controller Headlight Parking light Brake / tail light Light switch Flasher switch Flasher relay...
  • Page 168 WIRING DIAGRAM yellow ye-bl yellow-black ye-re yellow-red...
  • Page 169 WIRING DIAGRAM...

  • Page 170: Wiring Diagram (Exc-R Six Days)

    WIRING DIAGRAM Wiring diagram (EXC-R SIX DAYS) C_CX/2 C_CZ/3 C_DB/4 C_CW/2 C_CY/3 C_DA/4 C_AK1/2 C_DG/4 C_AH1/2 C_BP/4 ye-bl bl-wh C_BA/1 bu-wh C_BF/1 bu-wh ye-re C_BA2/1 ye-bl ye-bl ye-re re-wh wh-re re-bl ye-re re-bl wh-re re-wh ye-re C_CR/1 C_CR1/1 wh-gn C_CA/4 C_CE/4 C_AJ/3 C_BG/3...
  • Page 171 WIRING DIAGRAM Components Battery Generator Ignition coil Pulse generator Voltage regulator/rectifier Electric starter button Starter relay with fuse Starter motor Light switch, horn button, short circuit button Throttle valve sensor TPS Ignition curve plug connection CDI controller Headlight Parking light Brake / tail light Thermoswitch Speedometer...

  • Page 172: Wiring Diagram (Xcr-W Usa)

    WIRING DIAGRAM Wiring diagram (XCR-W USA) bl-wh ye-bl bu-wh bu-wh ye-bl re-wh re-bl ye-re wh-re ye-re re-bl wh-re re-wh ye-re 400310-10...
  • Page 173 WIRING DIAGRAM Components Battery Generator Ignition coil Pulse generator Voltage regulator/rectifier Electric starter button Starter relay with fuse Starter motor Short circuit button Throttle valve sensor TPS Ignition curve plug connection CDI controller Light switch Speedometer Wheel speed sensor Tripmaster switch (optional) Plug connector for radiator fan (optional) Plug connector, headlight (optional) Plug connector, brake / tail light (optional)

  • Page 174: Wiring Diagram (Xcr-W Za)

    WIRING DIAGRAM Wiring diagram (XCR-W ZA) bl-wh ye-bl bu-wh bu-wh ye-bl re-wh re-bl ye-re wh-re ye-re re-bl wh-re re-wh ye-re 400311-10...
  • Page 175 WIRING DIAGRAM Components Battery Generator Ignition coil Pulse generator Voltage regulator/rectifier Electric starter button Starter relay with fuse Starter motor Short circuit button Throttle valve sensor TPS Ignition curve plug connection CDI controller Headlight Parking light Brake / tail light Light switch Speedometer Wheel speed sensor...

  • Page 176: Substances

    SUBSTANCES Brake fluid DOT 5.1 according to Specification Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier Motorex ® Motorex Brake Fluid DOT 5.1...

  • Page 177: Auxiliary Substances

    AUXILIARY SUBSTANCES Universal oil spray Specification ® KTM recommends Motorex products. Supplier Motorex ® Motorex Joker 440 Universal Long-life grease Specification ® KTM recommends Motorex products. Supplier Motorex ® Motorex Long Therm 2000 Cleaning substance for foam air filter Specification ®...
  • Page 178 AUXILIARY SUBSTANCES Cleaning and polishing materials for metal, rubber and plastic Specification ® KTM recommends Motorex products. Supplier Motorex ® Motorex Protect & Shine 645 High-luster polish for paint Specification ® KTM recommends Motorex products. Supplier Motorex ® Motorex Moto Polish...

  • Page 179: Special Tools

    SPECIAL TOOLS Crankshaft locking bolt ART. NO.: 113080802 400035-01 Bearing puller ART. NO.: 15112017000 400037-01 Insert for bearing puller ART. NO.: 15112018100 Feature 18… 23 mm (0.71… 0.91 in) 400038-01 Bleed syringe ART. NO.: 50329050000 400058-01 Circlip pliers reverse ART. NO.: 51012011000 400059-01...
  • Page 180 SPECIAL TOOLS Clutch holder ART. NO.: 51129003000 400289-01 Work stand ART. NO.: 54829055000 500071-01 Universal mounting rack ART. NO.: 56012001000 400067-01 Extractor ART. NO.: 58012009000 400073-01 Valve spring mounter ART. NO.: 59029019000 400101-01...
  • Page 181 SPECIAL TOOLS Limit plug gauge ART. NO.: 59029026006 400104-01 Feeler gauge ART. NO.: 59029041000 400110-01 Piston ring mounting tool ART. NO.: 60029015000 400123-01 Pressure testing tool ART. NO.: 61029094000 400149-01 Push-in drift ART. NO.: 75029044010 500163-01...
  • Page 182 SPECIAL TOOLS Push-in drift ART. NO.: 75029044020 500162-01 Press drift ART. NO.: 75029047000 400185-01 Extractor ART. NO.: 75029048000 400162-01 Clamping plate ART. NO.: 75029050000 400163-01 Push-out drift ART. NO.: 75029051000 400164-01...
  • Page 183 SPECIAL TOOLS Protection cover ART. NO.: 75029090000 400167-01 Spark plug wrench ART. NO.: 75029172000 400170-01 Limit plug gauge ART. NO.: 77029026000 400104-01 Oil pressure adapter ART. NO.: 77329006000 400176-01 Insert for piston pin retainer ART. NO.: 77329030100 400160-01...
  • Page 184 SPECIAL TOOLS Adjustment tool for mixture control screw ART. NO.: 77329034000 400274-01 Release device for timing chain tensioner ART. NO.: 77329051000 400181-01 Engine holder ART. NO.: 78029002000 500161-01 Mounting sleeve ART. NO.: 78029005000 500167-01 Plate - Pressing device ART. NO.: 78029008000 500170-01...
  • Page 185 SPECIAL TOOLS Separator plate ART. NO.: 78029009000 500169-01 Extractor ART. NO.: 78029033100 500166-01 Press-out device ART. NO.: 78029049100 500168-01 Valve spring mounting device ART. NO.: 78029060000 500165-01 Gear segment ART. NO.: 80029004000 500164-01...

  • Page 186: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation.

  • Page 187: Index

    INDEX Carburetor components checking ....... . 118 Accessories ........7 Carburetor connection boot Air filter installing .
  • Page 188 INDEX checking the lubrication system ....82 installing the rotor ......105 checking the oil pumps for wear .
  • Page 189 INDEX removing the torque limiter ....67 gear oil removing the transmission shaft ....71 changing .
  • Page 190 INDEX of shock absorber, adjusting ....21 Riding sag adjusting ....... . . 23 Seat mounting .
  • Page 191 *3206054en* 3206054en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

This manual is also suitable for:

450 exc-r aus/uk450 exc-r six days450 xcr-w za530 exc-r eu530 exc-r aus/uk530 exc-r six days ... Show all

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