User manual KTM 450 XC-W USA 2009

[. . . ] OWNER'S MANUAL 2009 400 EXC EU 400 EXC AUS 400 XC-W USA 450 EXC EU 450 EXC AUS 450 EXC SIX DAYS EU 450 XC-W USA 450 XC-W ZA 530 EXC EU 530 EXC AUS 530 EXC SIX DAYS EU 530 XC-W USA 530 XC-W ZA ART. 3211355en DEAR KTM CUSTOMER DEAR KTM CUSTOMER 1 Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. We wish you great pleasure riding the vehicle! Enter the serial numbers of your vehicle below. [. . . ] Mount the upper steering head bearing. 2 0 1 0 ­ Info Check whether the top steering head seal is correctly positioned. Push on protective ring . 500151-10 ­ ­ Position the upper triple clamp with the steering. Guideline Screw, top steering head M20x1. 5 10 Nm (7. 4 lbf ft) ­ Position the clutch line, wiring harness and CDI control unit. 42) 10 Nm (7. 4 lbf ft) 500149-11 ­ ­ ­ ­ Install the front fender. Guideline Screw, top steering stem Refit the headlight mask with the headlight. ( x( M8 20 Nm (14. 8 lbf ft) ­ ­ 100022-11 Check the cable harness, cable, brake and clutch line for free movement and free laying. 40) Greasing the steering head bearing 9. 34 x (EXC SIX DAYS, XCW USA) ­ Remove the lower triple clamp. x ( p. 46) 800010-10 MAINTENANCE WORK ON CHASSIS AND ENGINE Dismounting the front fender 9. 35 47 ­ ­ Remove screws . Make sure that the distance bushings remain in place. 500092-10 Installing the front fender 9. 36 ­ ­ Ensure that the spacing sleeves are mounted in the fender. Guideline Remaining screws, chassis M6 10 Nm (7. 4 lbf ft) Info Take care with the contact between the holding lugs and the start number plate or headlight mask. 500092-10 Removing headlight mask with headlight (EXC, EXC SIX DAYS, XCW ZA) 9. 37 ­ ­ ­ Switch off all electrical equipment. Push up the headlight mask and swing it forwards. 800018-10 ­ Pull out the electric plug connector and remove the headlight mask with the headlight. 500156-10 Refitting the headlight mask with the headlight (EXC, EXC SIX DAYS, XCW ZA) 9. 38 ­ Connect the electric plug connector . 500156-11 MAINTENANCE WORK ON CHASSIS AND ENGINE ­ Position the headlight mask and fix it with the rubber band . 48 Info Take care with the contact of the holding lug at the fender. Check the headlamp setting. Dismount the start number plate (XCW USA) 9. 39 ­ ­ Remove screw and take off clamp. Remove the start number plate. 500101-10 Installing the start number plate (XCW USA) 9. 40 ­ Position the start number plate. Guideline Remaining screws, chassis M6 10 Nm (7. 4 lbf ft) Info Take care with the contact of the holding lug at the fender. 500101-11 ­ Position the brake line and cable harness. Put the clamp on, mount and tighten screw . Handlebar position 9. 41 On the upper triple clamp, there are 2 holes at a distance of to each other. Distance between holes 15 mm (0. 59 in) The holes on the handlebar support are placed at a distance of from the center. 0 A B 0 A 0 B 0 400223-11 Distance between holes 3. 5 mm (0. 138 in) The handlebar supports can be mounted in 4 different positions. (EXC SIX DAYS) The handlebar supports can also be mounted at 2 different heights (with and without spacer). Thick spacer 9 mm (0. 35 in) Adjusting handlebar position 9. 42 x 1 0 2 0 (EXC EU, EXC AUS, XCW) ­ Remove the four screws . Remove the handlebar and lay it to one side. 1 0 2 0 Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines. 400223-10 ­ Remove the two screws . Remove the handlebar support. MAINTENANCE WORK ON CHASSIS AND ENGINE ­ Place the handlebar support in the required position. Guideline Screw, handlebar support M10 40 Nm (29. 5 lbf ft) Loctite® 243TM 49 Info Position the left and right handlebar supports evenly. [. . . ] 106) TECHNICAL DATA - FORK TECHNICAL DATA - FORK 17 97 Fork part number Fork Compression damping Comfort Standard Sport Rebound damping Comfort Standard Sport Spring length with preload spacer(s) Spring rate Weight of rider: 65. . . 209 lb. ) Air chamber length Spring preload - Preload Adjuster Comfort Standard Sport Fork length FORK OIL 14. 18. 7E. 06 WP Suspension 4860 MXMA PA 26 clicks 22 clicks 20 clicks 24 clicks 22 clicks 22 clicks 510 mm (20. 08 in) 4. 4 N/mm (25. 1 lb/in) 4. 6 N/mm (26. 3 lb/in) 4. 8 N/mm (27. 4 lb/in) 110+20 mm (4. 33+0. 79 in) -30 -1. 18 2 turns 2 turns 4 turns 940 mm (37. 01 in) Fork oil (SAE 5) ( p. 106) TECHNICAL DATA - SHOCK ABSORBER TECHNICAL DATA - SHOCK ABSORBER 18 98 Shock absorber part number Shock absorber Compression damping, low-speed Comfort Standard Sport Compression damping, high-speed Comfort Standard Sport Rebound damping Comfort Standard Sport Spring preload Spring rate Weight of rider: 65. . . 209 lb. ) Spring length Gas pressure Static sag Riding sag Fitted length 12. 18. 7E. 06 WP Suspension PDS 5018 DCC 18 clicks 15 clicks 12 clicks 2 turns 1. 5 turns 1 turn 26 clicks 24 clicks 22 clicks 9 mm (0. 35 in) 69 N/mm (394 lb/in) 72 N/mm (411 lb/in) 76 N/mm (434 lb/in) 250 mm (9. 84 in) 10 bar (145 psi) 35 mm (1. 38 in) 105 mm (4. 13 in) 411 mm (16. 18 in) TECHNICAL DATA - CHASSIS TIGHTENING TORQUES TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 19 99 ­ ­ ­ ­ ­ ­ ­ ­ ­ Loctite® 243TM ­ ­ ­ Loctite® 243TM ­ ­ ­ ­ ­ Loctite® 243TM ­ ­ ­ ­ Loctite® 243TM Loctite® 243TM ­ ­ ­ Loctite® 243TM ­ Loctite® 243TM Loctite® 243TM ­ Loctite® 243TM ­ ­ ­ Spoke nipple, front wheel Spoke nipple, rear wheel Screw, spoiler on fuel tank (XCW USA) Remaining nuts, chassis Remaining screws, chassis Screw, rear brake disc Screw, front brake disc Screw, shock absorber adjusting ring Screw, ball joint of push rod on footbrake cylinder Nut, rear sprocket screw Nut, rim lock Remaining nuts, chassis Remaining screws, chassis Screw, front brake caliper Screw, top triple clamp (EXC SIX DAYS, XCW USA) Screw, top triple clamp (EXC EU, EXC AUS, XCW ZA) Screw, bottom triple clamp (EXC SIX DAYS, XCW USA) Screw, bottom triple clamp (EXC EU, EXC AUS, XCW ZA) Screw, fork stub Screw, top steering stem (EXC SIX DAYS, XCW USA) Screw, top steering stem (EXC EU, EXC AUS, XCW ZA) Screw, handlebar clamp (EXC EU, EXC AUS, XCW) Screw, handlebar clamp (EXC SIX DAYS) Screw, engine brace Screw, subframe Screw, side stand fixing Engine carrying screw Remaining nuts, chassis Remaining screws, chassis Screw, handlebar support Nut, seat fixing Screw, top shock absorber Screw, bottom shock absorber Nut, swingarm pivot Screw-in nozzles, cooling system Nut, rear wheel spindle Screw, top steering head Screw, front wheel spindle M4, 5 M5 M5x12 M6 M6 M6 M6 M6 M6 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M10 M10 M10 M10 M12x1 M12 M12 M16x1. 5 M20x1. 5 M20x1. 5 M20x1. 5 M24x1. 5 5 Nm (3. 7 lbf ft) 5 Nm (3. 7 lbf ft) 1. 5 Nm (1. 11 lbf ft) 15 Nm (11. 1 lbf ft) 10 Nm (7. 4 lbf ft) 14 Nm (10. 3 lbf ft) 14 Nm (10. 3 lbf ft) 5 Nm (3. 7 lbf ft) 10 Nm (7. 4 lbf ft) 35 Nm (25. 8 lbf ft) 10 Nm (7. 4 lbf ft) 30 Nm (22. 1 lbf ft) 25 Nm (18. 4 lbf ft) 25 Nm (18. 4 lbf ft) 17 Nm (12. 5 lbf ft) 20 Nm (14. 8 lbf ft) 12 Nm (8. 9 lbf ft) 15 Nm (11. 1 lbf ft) 15 Nm (11. 1 lbf ft) 17 Nm (12. 5 lbf ft) 20 Nm (14. 8 lbf ft) 20 Nm (14. 8 lbf ft) 16 Nm (11. 8 lbf ft) 33 Nm (24. 3 lbf ft) 35 Nm (25. 8 lbf ft) 40 Nm (29. 5 lbf ft) 60 Nm (44. 3 lbf ft) 50 Nm (36. 9 lbf ft) 45 Nm (33. 2 lbf ft) 40 Nm (29. 5 lbf ft) 20 Nm (14. 8 lbf ft) 80 Nm (59 lbf ft) 80 Nm (59 lbf ft) 100 Nm (73. 8 lbf ft) 12 Nm (8. 9 lbf ft) 80 Nm (59 lbf ft) 10 Nm (7. 4 lbf ft) 45 Nm (33. 2 lbf ft) WIRING DIAGRAM WIRING DIAGRAM 20 20. 1 100 Wiring diagram (all EXC models) H18 H2 H4 H15 P1 bu br H7 H11 bl pu CX/2 CW/2 CZ/3 CY/3 DB/4 DA/4 S2 AK1/2 CW3/2 CX3/2 DG/4 BP/4 CW2/2 CX2/2 AH1/2 1 3 2 1 2 3 1 2 4 v B3 br-bl bu re br br ye-re wh S5 bl bl 1 2 1 bl 2 br 1 pu 2 br bl-wh br bu-wh 1 gn X1 EH/1 3 wh 2. 1 4 br EI/1 2 bu gr ye S6 3 wh bu gn ye re br ye-bl BC/6 AC/6 wh-gn 64 5 12 1 BF1/1 BA1/1 S7 ye-bl BA/1 BF/1 re K2 ye-re ye-bl H13 ye-re br ye-re BO/2 BV/2 L2 bu-wh br gr ye-bl re-wh ye-re or 1 2 4 5 7 6 11 10 12 13 14 2 2 AH2/2 G BU/18 br 1 1 S8 3 re-bl gn re bu ye bl BL/2 CV/2 or pu bl ye-bl br bl BT/3 BG/3 2 1 BA2/1 E6 M br H14 t A6 br bl 5A bl ye bu ye-re br bl br BS/2 3 2 1 BV/2 AM/3 AR/3 S10 ye-re BR/4 BK/4 1 2 wh-re B1 br 3 bl 4 S10 2 1 re BR/4 BK/4 AL/2 AT/2 1 gn 2 br S11 L1 3 4 M1 3 G G2 CX1/2 CW1/2 re-bl re-wh ye 2 1 AT1/2 CR/1 CR1/1 AL1/2 M K1 wh bl ye wh-re ye-re 43 BG1/3 AJ1/3 pu 2 bl 3 AF/4 br 12 AH/2 AK/2 1 bl br wh-gn 10 A 2 S1 G1 br ye-re 1 ye wh 2 4 3 pu 1 br CA/4 br 1 2 wh-gn wh CE/4 2 3 CX/2 2 1 AJ/3 BG/3 CW/2 2. 2 2. 1 wh br 2 DI/2 BV/2 BS/2 1 H5 U H9 H3 H1 N2 500247-10 WIRING DIAGRAM Components A6 B1 B3 E6 G1 G2 H1 H2 H3 H4 H5 H7 H9 H11 H13 H14 H15 H18 K1 K2 L1 L2 M1 N2 P1 S1 S2 S5 S6 S7 S8 S10 S11 X1 Cable colors bl bl-wh br br-bl bu bu-wh gn gr or pu re re-bl re-wh wh wh-gn wh-re Black Black-white Brown Brown-black Blue Blue-white Green Gray Orange Violet Red Red-black Red-white White White-green White-red CDI controller Throttle position sensor Wheel speed sensor Thermoswitch (EXC SIX DAYS) Battery Generator Right rear flasher Left front flasher Left rear flasher Right front flasher Brake/tail light Parking light License plate lamp Low/high beam Horn Radiator fan (EXC SIX DAYS) Flasher indicator light High beam indicator light Starter relay with main fuse Flasher relay Pulse generator Ignition coil Starter motor Voltage regulator/rectifier Speedometer Rear brake light switch Front brake light switch Tripmaster switch (optional) Light switch Horn button, short circuit button Flasher switch Electric starter button Emergency OFF switch (EXC-R AUS) Ignition curve plug connection 101 WIRING DIAGRAM ye ye-bl ye-re Yellow Yellow-black Yellow-red 102 WIRING DIAGRAM 103 WIRING DIAGRAM Wiring diagram (all XCW models) 20. 2 104 P1 H11 H7 v S5 re bu wh br bl bl br ye-re B3 wh br wh X1 bl-wh br gr ye-bl bu-wh L2 S9 bu-wh br gr ye-bl re-wh re-bl gn re bu ye bl ye-bl wh ye S6 ye-re wh-re S10 bl br bl ye bu br bl H14 A6 B1 L1 M br t br bl E6 5A ye-re br bl br M1 re M gn K1 re-bl re-wh ye wh br wh-re 3 G G2 10 A ye-re G1 br ye-re ye wh br wh C_BV/2 U N2 H5 500248-10 WIRING DIAGRAM Components A6 B1 B3 E6 G1 G2 H5 H7 H11 H14 K1 L1 L2 M1 N2 P1 S5 S6 S9 S10 X1 Cable colors bl bl-wh br bu bu-wh gn gr re re-bl re-wh wh wh-re ye ye-bl ye-re Black Black-white Brown Blue Blue-white Green Gray Red Red-black Red-white White White-red Yellow Yellow-black Yellow-red CDI controller Throttle position sensor Wheel speed sensor Thermoswitch (XC-W ZA) Battery Generator Brake/tail light (XC-W ZA) Parking light (XC-W ZA) Low/high beam (XC-W ZA) Radiator fan (XC-W ZA) Starter relay with main fuse Pulse generator Ignition coil Starter motor Voltage regulator/rectifier Speedometer Tripmaster switch (optional) Light switch Short circuit button Electric starter button Ignition curve plug connection 105 SUBSTANCES SUBSTANCES 21 106 Brake fluid DOT 4 / DOT 5. 1 According to ­ DOT Guideline ­ Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. 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