KTM 400 XC-W USA (2009), 450 EXC SIX DAYS EU (2009), 400 EXC AUS (2009), 450 EXC AUS (2009), 450 EXC EU (2009) Setup Instructions

SETUP INSTRUCTIONS 2009

400 EXC EU

400 EXC AUS

400 XC-W USA

450 EXC EU

450 EXC AUS

450 EXC SIX DAYS EU

450 EXC USA

450 XC-W USA

450 XC-W ZA

530 EXC EU

530 EXC AUS

530 EXC SIX DAYS EU

530 EXC USA

530 XC-W USA

530 XC-W ZA

ART. NO. 3211421en

INTRODUCTION 1

INTRODUCTION

The work described in these setup instructions must be performed before the vehicle is delivered to the customer.

Read the setup instructions in their entirety before beginning work.

Print out the current PDI form found on the KTM DEALER.NET.

These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter­est of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that the work will be performed by a fully trained mechanic.

All specifications are non-binding. KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifica­tions, 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 stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe­cial equipment that does not belong to the regular scope of delivery.

© 2008 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service

KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

MEANS OF REPRESENTATION 2

Symbols used

The symbols used are explained in the following.

Indicates an expected reaction (e.g. of a work step or a function).

Indicates an unexpected reaction (e.g. of a work step or a function).

Identifies a page reference (more information is provided on the specified page).

Formats used

The typographical and other formats used are explained in the following.

Own name Indicates a proprietary name.

®

Name

Brand™ Identifies a brand in merchandise traffic.

Identifies a protected name.

SET‑UP 3

2.1Unpacking and setting up the vehicle

– Remove the box and the plastic packaging.

Info

To avoid damaging the motorcycle during the setup, leave the protective foil
on the the vehicle until you have finished.

– Check the vehicle for transport damage.
– Unpack the separate enclosure and check its contents on the basis of the enclosure

list.

800030-10

– Position the operating elements on the right half of the handlebar.

Info

The routing of cables and Bowden cables can be seen in the figure.

– Mount the handlebar.

800034-10

– Position the handlebar.

The mark 1 of the scale on the handlebar should be in the center of the han­dlebar clamp.

– Position the handlebar clamps. Fit and evenly tighten the four screws.

Guideline

100305-10

Screw, handlebar clamp (EXC EU, EXC
AUS, EXC USA, XC‑W)

Screw, handlebar clamp
(EXC SIX DAYS)

– Mount the footrests with the springs and bolts. Secure the bolts using the washers

and pins.

M8 20 Nm

(14.8 lbf ft)

M8 16 Nm

(11.8 lbf ft)

800042-10

Plier for footrest spring (58429083000)

– Remove the protective plastic.
– Carefully loosen and remove the tensioning belt over the link fork.

Info

An assistant prevents the motorcycle from falling over.

– Carefully loosen and remove the tensioning belts around the lower triple clamp.

The vehicle is released at the front.

– Set up the work stand.

Work stand (54829055000)

– Together with an assistant, take the vehicle off the palette.
– Install the front wheel. ( p. 5)

SET‑UP 4

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep the battery away from sparks or open fire. Charge only in well-

ventilated rooms.

800035-10

– Fill the battery.

– Recharge the battery. ( p. 6)
– Install the battery. ( p. 6)
– Install the front fender. ( p. 7)

(EXC AUS, EXC SIX DAYS)

– In the event of skin contact, rinse with large amounts of water. If battery

acid gets in the eyes, rinse with water for at least 15 minutes and con­tact a physician.

Info

Read the notes in the battery package.

– Fit the engine guard.

800041-10

Info

Read the accompanying KTM PowerParts installation instructions.

– Fit the frame protector.

Info

Read the accompanying KTM PowerParts installation instructions.

(all EXC models)

– Mount and tighten the rear mirror adapter and rear mirror on both sides.
– Position all operating elements exactly on the handlebar. Tighten all screws.
– Mount the reflector.

(EXC AUS, EXC SIX DAYS, XC‑W USA)

– Fit the hand guard.

Info

Read the accompanying KTM PowerParts installation instructions.

(EXC SIX DAYS)

– Fit the handlebar cushion.
– Fill up with fuel. ( p. 8)
– Print out the current PDI form found on KTM DEALER.NET and perform the delivery

inspection.

WORK 5

3.1Removing the seat

– Remove screw . Lift up the seat at the rear, pull it back and then remove from

above.

500080-10

3.2Mounting the seat

– Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear

and simultaneously push it forward.

– Make sure that the seat is correctly locked in.
– Mount and tighten the screw of the seat fixing.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

500068-01

3.3Installing the front wheel

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 grease shaft seal rings  and bearing surface  of the spacing sleeves.

Long-life grease ( p. 11)

– Insert the spacing sleeves.

500086-11

– Lift the front wheel into the fork, position it, and insert the wheel spindle.
– Mount and tighten screw .

Guideline

Screw, front wheel spindle M24x1.5 45 Nm

(33.2 lbf ft)

500084-11

– Operate the hand brake lever several times until the brake pads are lying correctly

on the brake disc.

– Remove the motorcycle from the work stand.
– Pull the front wheel brake and push down hard on the fork several times to align

the fork legs.
– Fully tighten screw .

Guideline

Screw, fork stub M8 15 Nm

(11.1 lbf ft)

WORK 6

3.4Installing the battery

– Place the battery in the battery holder.

4Ah battery (YTX5L-BS)

– Reconnect the rubber band .
– Attach the plus cable and replace the plus pole cover .
– Attach the minus cable .
– Mount the seat. ( p. 5)

500069-11

3.5Recharging the battery

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep the battery away from sparks or open fire. Charge only in well-ventilated rooms.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least

15 minutes and contact a physician.

Warning

Environmental hazard Components and battery acid are a danger to the environment.

– Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.

Warning

Environmental hazard Problem materials cause environmental damage.

– Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Even if there is no load on the battery, it loses power every day.
The charge state and the type of charge are very important for the service life of the battery.
Fast recharging with a high charge current shortens the battery's service life.
If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes.
The battery capacity is then reduced.
If the battery is discharged from starting, it must be recharged immediately.
If it stands for a long time in a discharged state, the battery becomes over-discharged and sulfated, and then it is destroyed.
The battery is maintenance-free, i.e., the acid level does not have to be checked.

– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 5)
– Disconnect the minus (negative) cable of the battery to avoid damage to the motor-

cycle's electronics.
– Connect the battery charger to the battery. Switch on the battery charger.

400240-10

Battery charger (58429074000)

You can also use the battery charger to test rest potential and start potential of the

battery, and to test the generator. With this device, you cannot overcharge the bat-

tery.

Info

Never remove the lid .
Charge the battery with at most 10% of the capacity specified on the bat­tery .

WORK 7

– Switch off the charger after charging. Disconnect the battery.

Guideline

The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the

motorcycle is not in use.

– Mount the seat. ( p. 5)

3.6Installing the battery

– Place the battery in the battery holder.

4Ah battery (YTX5L-BS)

– Reconnect the rubber band .
– Attach the plus cable and replace the plus pole cover .
– Attach the minus cable .
– Mount the seat. ( p. 5)

500069-11

3.7Installing the front fender

– Ensure that the spacing sleeves are mounted in the fender.
– Position the front fender. Mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

3 months

3.8Opening filler cap

3.9Closing filler cap

Info

Take care with the contact between the holding lugs and the start number
plate or headlight mask.

500092-10

– Press release button , turn filler cap counterclockwise and lift it free.

400199-10

– Replace the filler cap and turn clockwise until the release button  locks in place.

Info

Run the fuel tank breather hose  without kinks.

400199-11

AA

WORK 8

3.10Refueling

Danger

Fire hazard Fuel can easily catch fire.

– Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no

fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.

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. Change clothing that has come into contact with fuel.

Warning

Environmental hazard Improper handling of fuel is a danger to the environment.

– Do not allow fuel to get into the ground water, the ground, or the sewage system.

– Switch off the engine.
– Open the filler cap. ( p. 7)
– Fill the fuel tank with fuel up to measurement .

Guideline

Measurement of  35 mm (1.38 in)

400382-10

Total fuel tank
capacity,
approx. (EXC,
EXC SIX DAYS,
XC‑W ZA)

Total fuel tank
capacity, approx.
(EXC USA,
XC‑W USA)

– Close the filler cap. ( p. 7)

9.0 l
(2.38 US gal)

9.2 l
(2.43 US gal)

Super unleaded (ROZ 95 / RON 95 /
PON 91) ( p. 10)

Super unleaded (ROZ 95 / RON 95 /
PON 91) ( p. 10)

TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS 9

Spoke nipple, front wheel M4.5 5 Nm (3.7 lbf ft) –
Screw, spoiler on fuel tank (EXC USA,

XC‑W USA)
Spoke nipple, rear wheel M5 5 Nm (3.7 lbf ft) –
Remaining nuts, chassis M6 15 Nm (11.1 lbf ft) –
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –
Screw, ball joint of push rod on foot-

brake cylinder
Screw, front brake disc M6 14 Nm (10.3 lbf ft) –
Screw, rear brake disc M6 14 Nm (10.3 lbf ft) –
Screw, shock absorber adjusting ring M6 5 Nm (3.7 lbf ft) –
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft)
Nut, rim lock M8 10 Nm (7.4 lbf ft) –
Remaining nuts, chassis M8 30 Nm (22.1 lbf ft) –
Remaining screws, chassis M8 25 Nm (18.4 lbf ft) –
Screw, bottom triple clamp (EXC USA,

XC‑W USA, EXC SIX DAYS)
Screw, bottom triple clamp (EXC EU,

EXC AUS, XC‑W ZA)
Screw, engine brace M8 33 Nm (24.3 lbf ft) –
Screw, fork stub M8 15 Nm (11.1 lbf ft) –
Screw, front brake caliper M8 25 Nm (18.4 lbf ft)
Screw, handlebar clamp (EXC EU, EXC

AUS, EXC USA, XC‑W)
Screw, handlebar clamp

(EXC SIX DAYS)
Screw, side stand fixing M8 40 Nm (29.5 lbf ft)
Screw, subframe M8 35 Nm (25.8 lbf ft)
Screw, top steering stem (EXC USA,

XC‑W USA, EXC SIX DAYS)
Screw, top steering stem (EXC EU,

EXC AUS, XC‑W ZA)
Screw, top triple clamp (EXC USA,

XC‑W USA, EXC SIX DAYS)
Screw, top triple clamp (EXC EU,

EXC AUS, XC‑W ZA)
Engine carrying screw M10 60 Nm (44.3 lbf ft) –
Remaining nuts, chassis M10 50 Nm (36.9 lbf ft) –
Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –
Screw, handlebar support M10 40 Nm (29.5 lbf ft)
Screw, bottom shock absorber M12 80 Nm (59 lbf ft)
Screw, top shock absorber M12 80 Nm (59 lbf ft)
Nut, seat fixing M12x1 20 Nm (14.8 lbf ft) –
Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) –
Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft) –
Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft) –
Screw-in nozzles, cooling system M20x1.5 12 Nm (8.9 lbf ft)
Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) –

M5x12 1.5 Nm (1.11 lbf ft) –

M6 10 Nm (7.4 lbf ft) –

M8 12 Nm (8.9 lbf ft) –

M8 15 Nm (11.1 lbf ft) –

M8 20 Nm (14.8 lbf ft) –

M8 16 Nm (11.8 lbf ft) –

M8 17 Nm (12.5 lbf ft)

M8 20 Nm (14.8 lbf ft) –

M8 17 Nm (12.5 lbf ft) –

M8 20 Nm (14.8 lbf ft) –

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

SUBSTANCES 10

Super unleaded (ROZ 95 / RON 95 / PON 91)

According to

– DIN EN 228 (ROZ 95 / RON 95 / PON 91)

AUXILIARY SUBSTANCES 11

Long-life grease

Specification

–

KTM recommends Motorex®products.

Supplier

®

Motorex
– Fett 2000

*3211421en*

3211421en

KTM-Sportmotorcycle AG

5230 Mattighofen/Austria

http://www.ktm.com

07/2008

Photo: Mitterbauer