KTM 450 EXC-R 450 XCR-W 530 EXC-R 530 XCR-W - Repair, Service Manual, Wiring Diagrams and Owners Manual

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KTM 450 EXC-R, 450 XCR-W, 530 EXC-R, 530 XCR-W - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - OWNERS MANUAL

- English Service Manual, Owners Manual and Wiring Diagrams, for motorcycles KTM 450 EXC-R 450 XCR-W 530 EXC-R 530 XCR-W.

 
CONTENTS:

SERVICE MANUAL

- MEANS OF REPRESENTATION  6
- IMPORTANT NOTES 7
- MOTORCYCLE 8
- Jacking up the motorcycle 8
- Removing the motorcycle from the work stand 8
- 01/FORK, TRIPLE CLAMP 9
- Fork part number 9
- Adjusting spring preload of the fork 9
- Adjusting compression damping of fork  9
- Adjusting rebound damping of fork 10
- Cleaning dust boots of fork legs  10
- Removing the fork legs 11
- Installing the fork legs  11
- Bleeding fork legs 12
- Removing the fork protector 12
- Installing the fork protector  13
- Loosening the fork protection 13
- Positioning the fork protection  13
- Removing the lower triple clamp (EXC-R SIX DAYS, XCR-W USA)  13
- Installing the lower triple clamp (EXC-R SIX DAYS, XCR-W USA)  14
- Removing the lower triple clamp (EXC-R EU,
- EXC-R AUS/UK, EXC-R USA, XCR-W ZA)  15
- Installing the lower triple clamp (EXC-R EU,
- EXC-R AUS/UK, EXC-R USA, XCR-W ZA)  15
- Fork offset (EXC-R SIX DAYS, XCR-W USA)  16
- Setting the fork offset (EXC-R SIX DAYS, XCR-W USA) 16
- Checking play of steering head bearing 16
- Adjusting play of steering head bearing (EXC-R SIX DAYS, XCR-W USA)  17
- Adjusting play of steering head bearing (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA)  17
- Greasing the steering head bearing 18
- 03/FRAME 19
- Removing the engine sprocket cover 19
- Installing the engine sprocket cover 19
- 04/SHOCK ABSORBER, SWINGARM 20
- Shock absorber part number 20
- Adjusting high-speed compression damping of the shock absorber  20
- Adjusting the low-speed compression damping of the shock absorber  20
- Adjusting rebound damping of the shock absorber  21
- Measuring rear wheel sag unloaded  21
- Checking static sag of the shock absorber  22
- Checking the riding sag of the shock absorber  22
- Adjusting spring preload of the shock absorber 22
- Adjusting riding sag  23
- Removing the shock absorber  23
- Installing shock absorber 24
- 05/EXHAUST  25
- Removing main silencer  25
- Fitting the main silencer  25
- Removing the manifold  25
- Installing the manifold 25
- 06/AIR FILTER 26
- Dismounting the air filter box lid 26
- Installing the air filter box lid 26
- Removing the air filter  26
- Installing the air filter  26
- Cleaning air filter 27
- Removing the carburetor connection boot  27
- Installing the carburetor connection boot  27
- 07/FUEL TANK, SEAT, TRIM 28
- Opening filler cap 28
- Closing filler cap  28
- Removing the seat  28
- Mounting the seat  28
- Dismounting the fuel tank  28
- Installing the fuel tank 29
- Fuel tap 30
- 08/MASK, FENDER  31
- Dismounting the front fender 31
- Installing the front fender 31
- Removing headlight mask with headlight (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W ZA) 31
- Refitting the headlight mask with the headlight (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W ZA)  31
- Dismount the start number plate (XCR-W USA)  32
- Fitting the start number plate (XCR-W USA) 32
- 09/FRONT WHEEL  33
- Removing front wheel  33
- Fitting front wheel  33
- Checking brake discs  34
- Removing the front brake disc  34
- Installing the front brake disc  34
- Tire condition checking 35
- Checking tire air pressure 35
- Checking spoke tension 35
- 10/REAR WHEEL  36
- Removing rear wheel 36
- Fitting rear wheel  36
- Removing the rear brake disc 37
- Installing the rear brake disc  37
- Checking the chain tension when fitting rear wheel 37
- Adjusting chain tension - fitting rear wheel  38
- Checking the chain tension  38
- Adjusting chain tension - after checking  39
- Adjusting the chain tension  39
- Adjusting chain guide  40
- Checking the rear sprocket / engine sprocket for wear  40
- Checking chain wear 41
- Checking chain dirt  41
- Cleaning the chain 41
- 11/WIRING HARNESS, BATTERY  42
- Removing a fuse 42
- Replacing the fuse 42
- Removing the battery  42
- Installing the battery 43
- Recharging the battery  43
- 13/BRAKE SYSTEM 45
- Checking the front brake linings 45
- Removing the front brake linings 45
- Installing the front brake linings  45
- Changing the front brake linings  46
- Adjusting basic position of handbrake lever (Every XCR-W models)  46
- Checking free play of hand brake lever 47
- Adjusting free travel of handbrake lever (Every EXC-R models)  47
- Checking the front brake fluid level  47
- Add front brake fluid 48
- Changing the front brake fluid  48
- Checking rear brake linings  49
- Removing the rear brake linings  49
- Installing the rear brake linings 50
- Changing the rear brake linings 50
- Checking free play of foot brake lever  51
- Adjusting basic position of footbrake lever  51
- Checking rear brake fluid level 52
- Adding rear brake fluid  52
- Changing the rear brake fluid 52
- 14/LIGHT SYSTEM, INSTRUMENTS  54
- Adjusting speedometer functions  54
- Setting kilometers or miles  54
- Setting the clock  55
- 30/ENGINE 56
- Removing the engine  56
- Installing the engine  57
- 30/DISASSEMBLING ENGINE 59
- Preparations 59
- Draining the engine oil 59
- Removing the oil filter 59
- Draining gear oil, cleaning gear oil screen  59
- Removing the starter engine  60
- Removing the valve cover  60
- Removing the shift lever 60
- Removing the spark plug  60
- Removing the generator cover  61
- Setting the engine to ignition top dead center  61
- Removing the timing chain tensioner 62
- Removing the camshaft 62
- Removing the cylinder head 62
- Removing the piston  62
- Removing the rotor  63
- Removing the balance weight  63
- Removing the timing chain guide rail  63
- Removing the timing chain tensioning rail 64
- Removing the timing chain securing guide  64
- Removing the timing chain 64
- Removing the ignition pulse generator  64
- Removing the suction pump  64
- Removing the kickstarter 65
- Removing the water pump cover  65
- Removing the clutch cover  65
- Removing the clutch discs 66
- Removing the primary gear nut  66
- Removing the outer clutch hub  66
- Removing the balancer shaft  67
- Removing the torque limiter  67
- Removing the starter idler gear  67
- Removing the kickstarter shaft 67
- Removing the kickstarter idler gear  67
- Removing the shift shaft  68
- Removing the shift drum locating 68
- Removing the locking lever 68
- removing the oil pump gears 68
- Removing the oil pumps 69
- Removing the primary gear with the free-wheel-gear 69
- Removing the left section of the engine case 69
- Removing the shift rails  70
- Removing the shift roller  70
- Removing the shift forks  71
- Removing the transmission shaft 71
- Removing the crankshaft 71
- 30/ENGINE - WORK ON INDIVIDUAL PARTS 72
- Work on the right section of the engine case  72
- Work on the left section of the engine case  73
- removing the oil pressure regulator valve 75
- Checking the spring length of the oil pressure regulator valve  75
- Installing the oil pressure regulator valve  75
- Removing the crankshaft seal ring in the clutch cover  76
- Fitting the crankshaft seal ring into the clutch cover  76
- Removing the water pump 76
- Installing the water pump 77
- Checking the balancer shaft  78
- Removing the timing chain sprocket 78
- Installing the timing chain sprocket 78
- Changing the conrod bearing  78
- Checking the crankshaft run-out on the bearing pin  80
- Cylinder - Nikasil® coating 80
- Checking/measuring the cylinder 80
- Checking/measuring the piston  81
- Checking the piston ring end gap  81
- Checking piston/cylinder mounting clearance  82
- Checking the oil pumps for wear  82
- Checking the lubrication system 82
- Disassembling the autodecompressor  83
- Assembling the autodecompressor 83
- Checking the camshaft 84
- Checking the timing assembly  84
- Preparing the timing chain tensioner for installation  84
- Removing the rocker arm 85
- Removing the valves  85
- Replacing the camshaft bearing 86
- Checking the valves  87
- Checking the valve springs  87
- Checking the lower valve spring retainer  87
- Checking the cylinder head  88
- Installing valves  88
- Installing the rocker arm  89
- Checking the clutch 89
- Checking the shift mechanism 90
- Preassembling the shift shaft 91
- Dismantling the main shaft  91
- Assembling the main shaft  91
- Dismantling the countershaft 92
- Assembling the countershaft 92
- Checking the transmission 93
- Checking electric starter operation  94
- Removing the free-wheel  94
- Checking the free-wheel  95
- Installing the free-wheel 95
- 30/ASSEMBLING ENGINE  96
- Installing the crankshaft 96
- Installing the transmission shaft  96
- Installing the shift forks  96
- Installing the shift roller 97
- Installing the shift rails  97
- Installing the left engine case 97
- Installing the primary gear with the free-wheel-gear  98
- Installing the oil pumps  98
- Installing the oil pump gears  99
- Installing the locking lever 99
- Installing the shift drum locating  99
- Installing the shift shaft  99
- Installing the kickstarter idler gear  100
- Installing the kickstarter shaft  100
- Installing the starter idler gear  100
- Installing the torque limiter  100
- Installing the balancer shaft  101
- Installing the outer clutch hub 101
- Installing the primary gear nut  101
- Installing the clutch discs  102
- Installing the clutch cover  102
- Installing the water pump cover  103
- Installing the kickstarter 103
- Installing the suction pump 103
- Installing the ignition pulse generator 104
- Installing the timing chain 104
- Installing the timing chain securing guide 104
- Installing the timing chain tensioning rail  104
- Installing the timing chain guide rail  105
- Installing the balance weight  105
- Installing the rotor  105
- Installing the piston 105
- Installing the cylinder head  107
- Installing the camshaft  108
- Installing the timing chain tensioner  108
- Checking the valve clearance 109
- Adjusting the valve clearance 109
- Installing the generator cover 109
- Installing the shift lever  110
- Installing the valve cover  110
- Installing the spark plug 110
- Installing the starter motor  111
- Mounting oil filter 111
- Filling up with engine oil 111
- Filling up with gear oil  112
- Removing the engine from the universal mounting rack  112
- 31/CARBURETOR  113
- Choke (EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W)  113
- Choke (EXC-R EU)  113
- Checking the choke Bowden cable routing (EXC-R EU) 113
- Checking the choke Bowden cable for play (EXC-R EU)  113
- Adjusting the choke Bowden cable play (EXC-R EU) 113
- Checking gas Bowden cable route  114
- Checking play in the gas Bowden cable  114
- Adjusting the gas Bowden cable play 114
- Removing the carburetor  115
- Disassembling the carburetor 115
- Checking the carburetor components 118
- Checking/adjusting the accelerator pump 118
- Checking the choke slide 119
- Checking the jet needle 119
- Checking the throttle slide 119
- Checking the needle jet 120
- Checking the float needle valve 120
- Checking/adjusting the float level 120
- Checking/adjusting the throttle slide opening  120
- Checking throttle valve sensor TPS 121
- Adjusting the position of throttle valve sensor TPS 121
- Assembling the carburetor 122
- Installing the carburetor  125
- Carburetor - adjusting idle  126
- Emptying the carburetor float chamber  127
- 32/CLUTCH  129
- Checking fluid level of hydraulic clutch  129
- Changing fluid level of hydraulic clutch  129
- 33/TRANSMISSION 131
- Removing the engine sprocket  131
- Installing the engine sprocket  131
- 35/WATER PUMP, COOLING SYSTEM  132
- Checking antifreeze and coolant level  132
- Checking the coolant level 132
- Draining coolant  133
- Refilling coolant  133
- 38/LUBRICATION SYSTEM 134
- Oil cycle  134
- Checking engine oil level 134
- Changing engine oil and oil filter, cleaning engine oil screen  135
- Draining engine oil, cleaning engine oil screen  135
- Removing the oil filter 135
- Mounting oil filter 136
- Filling up with engine oil 136
- Topping up engine oil  137
- Checking the engine oil pressure 137
- Checking gear oil level  138
- Changing gear oil, cleaning gear oil screen 138
- Draining gear oil, cleaning gear oil screen  138
- Filling up with gear oil  139
- Topping up with gear oil 139
- TROUBLESHOOTING 140
- TECHNICAL DATA - ENGINE 142
- Capacity- engine oil  142
- Capacity - gear oil 142
- Capacity - coolant 143
- TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE  144
- TECHNICAL DATA - ENGINE TIGHTENING TORQUES 145
- TECHNICAL DATA - CARBURETOR 147
- 450 EXC-R EU, 450 EXC-R AUS/UK (3900I)  147
- 450 EXC-R SIX DAYS, 450 EXC-R USA, 450 XCR-W (3900L)  147
- 530 EXC-R EU, 530 EXC-R AUS/UK (3900J) 148
- 530 EXC-R SIX DAYS, 530 EXC-R USA, 530 XCR-W (3900M)  148
- TECHNICAL DATA - CARBURETOR TIGHTENING TORQUES 149
- TECHNICAL DATA - CHASSIS  150
- Lighting equipment  151
- Tires  151
- Capacity - fuel 151
- TECHNICAL DATA - FORK 152
- TECHNICAL DATA - SHOCK ABSORBER  153
- TECHNICAL DATA - CHASSIS TIGHTENING TORQUES  154
- CLEANING 155
- Cleaning motorcycle  155
- STORAGE  156
- Storage 156
- Putting into operation after storage  156
- GREASING AND SERVICE TABLE 157
- Important maintenance work to be carried out by an authorized KTM workshop  157
- 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) 162
- Wiring diagram (EXC-R USA)  164
- Wiring diagram (EXC-R SIX DAYS) 168
- Wiring diagram (XCR-W USA)  170
- Wiring diagram (XCR-W ZA)  172
- SUBSTANCES 174
- AUXILIARY SUBSTANCES 175
- SPECIAL TOOLS 177
- STANDARDS 184
- INDEX  185


OWNERS MANUAL

- MEANS OF REPRESENTATION  5
- IMPORTANT NOTES 6
- LOCATION OF SERIAL NUMBERS 8
- Chassis number 8
- Type label 8
- Key number (EXC-R EU, EXC-R AUS/UK, EXC-R USA)  8
- Engine number 8
- Fork part number 8
- Shock absorber part number 9
- OPERATING ELEMENTS 10
- Clutch lever  10
- Hand brake lever  10
- Short circuit button (EVERY XCR-W MODELS) 10
- Short circuit button (EXC-R EU, EXC-R AUS/UK,
- EXC-R SIX DAYS)  10
- Emergency OFF switch (EXC-R AUS/UK) 10
- Emergency OFF switch (EXC-R USA)  11
- Ignition switch (EXC-R USA) 11
- Electric starter button (EXC-R EU, EXC-R SIX DAYS,
- EXC-R USA, XCR-W)  11
- Electric starter button (EXC-R AUS/UK)  11
- Light switch (EXC-R EU, EXC-R AUS/UK,
- EXC-R SIX DAYS)  11
- Light switch (EVERY XCR-W MODELS)  12
- Light switch (EXC-R USA)  12
- Headlight flasher switch (EXC-R USA)  12
- Horn (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS)  12
- Horn (EXC-R USA)  12
- Flasher switch (EXC-R EU, EXC-R AUS/UK)  13
- Flasher switch (EXC-R USA)  13
- Overview of indicator lamps (EXC-R EU, EXC-R AUS/UK,
- EXC-R USA)  13
- Overview of indicator lamps (EXC-R SIX DAYS)  13
- Speedometer 13
- Speedometer activation and test  14
- Tripmaster switch  14
- Setting kilometers or miles  14
- Setting the clock  15
- Adjusting speedometer functions  15
- Querying lap time  16
- Display mode SPEED 16
- Display mode SPEED/H (service hours) 16
- Display mode SPEED / CLK (time) 17
- Display mode SPEED/LAP (lap time)  17
- Display mode SPEED/ODO (odometer)  17
- Display mode SPEED/TR1 (trip master 1)  17
- Display mode SPEED/TR2 (trip master 2)  18
- Disply mode SPEED/A1 (average speed 1)  18
- Display mode SPEED/A2 (average speed 2) 18
- Display mode SPEED/S1 (stop watch 1)  19
- Display mode SPEED/S2 (stop watch 2) 19
- Fuel tap 20
- Opening filler cap 20
- Closing filler cap  20
- Choke (EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA,
- XCR-W)  21
- Choke (EXC-R EU)  21
- Shift lever 21
- Foot brake pedal  21
- Kickstarter 22
- Side stand  22
- Steering lock (EXC-R EU, EXC-R AUS/UK, EXC-R USA) 22
- Locking the steering (EXC-R EU, EXC-R AUS/UK,
- EXC-R USA)  22
- Unlocking the steering (EXC-R EU, EXC-R AUS/UK,
- EXC-R USA)  23
- GENERAL TIPS AND HINTS ON PUTTING INTO
- OPERATION 24
- Advice on first use 24
- Running in the engine 25
- RIDING INSTRUCTIONS  26
- Checks before putting into operation  26
- Starting  26
- Starting up  27
- Shifting, riding 27
- Braking  27
- Stopping, parking  28
- Refueling 28
- GREASING AND SERVICE TABLE 29
- Important maintenance work to be carried out by an
- authorized KTM workshop  29
- Important maintenance work to be carried out by an
- authorized KTM workshop (as additional order) 30
- Important checks and maintenance work to be carried
- out by the rider  30
- MAINTENANCE WORK ON CHASSIS AND ENGINE 32
- Jacking up the motorcycle 32
- Removing the motorcycle from the work stand 32
- Checking the basic chassis setting with the rider's
- weight  32
- Compression damping of shock absorber 32
- Adjusting high-speed compression damping of the shock
- absorber  32
- Adjusting the low-speed compression damping of the
- shock absorber  33
- Adjusting rebound damping of the shock absorber  33
- Measuring rear wheel sag unloaded  34
- Checking static sag of the shock absorber  34
- Checking the riding sag of the shock absorber  35
- Adjusting spring preload of the shock absorber 35
- Adjusting riding sag 36
- Removing the shock absorber 36
- Installing shock absorber 36
- Checking basic setting of fork  37
- Adjusting compression damping of fork  37
- Adjusting rebound damping of fork 37
- Adjusting spring preload of the fork 38
- Bleeding fork legs 38
- Cleaning dust boots of fork legs  39
- Loosening the fork protection 39
- Positioning the fork protection  39
- Checking play of steering head bearing 39
- Adjusting play of steering head bearing (EXC-R EU,
- EXC-R AUS/UK, EXC-R USA, XCR-W ZA)  40
- Adjusting play of steering head bearing
- (EXC-R SIX DAYS, XCR-W USA)  40
- Fork offset (EXC-R SIX DAYS, XCR-W USA)  41
- Setting the fork offset (EXC-R SIX DAYS,
- XCR-W USA)  41
- Removing the fork legs 41
- Installing the fork legs 42
- Removing the fork protector 43
- Installing the fork protector 43
- Removing the lower triple clamp (EXC-R SIX DAYS,
- XCR-W USA)  43
- Removing the lower triple clamp (EXC-R EU,
- EXC-R AUS/UK, EXC-R USA, XCR-W ZA)  44
- Installing the lower triple clamp (EXC-R SIX DAYS,
- XCR-W USA)  44
- Installing the lower triple clamp (EXC-R EU,
- EXC-R AUS/UK, EXC-R USA, XCR-W ZA)  45
- Greasing the steering head bearing 46
- Dismounting the front fender 46
- Installing the front fender 46
- Removing headlight mask with headlight (EXC-R EU,
- EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA,
- XCR-W ZA) 46
- Refitting the headlight mask with the headlight
- (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS,
- EXC-R USA, XCR-W ZA)  47
- Dismount the start number plate (XCR-W USA)  47
- Fitting the start number plate (XCR-W USA) 47
- Handlebar position  47
- Adjusting handlebar position 48
- Checking gas Bowden cable route  49
- Checking play in the gas Bowden cable  50
- Adjusting the gas Bowden cable play 50
- Checking chain dirt  50
- Cleaning the chain 50
- Checking the chain tension  51
- Checking the chain tension when fitting rear wheel 51
- Checking the rear sprocket / engine sprocket for wear  52
- Checking chain wear 52
- Adjusting the chain tension  52
- Adjusting chain tension - after checking  53
- Adjusting chain tension - fitting rear wheel  54
- Adjusting chain guide 54
- Brake fluid reservoir 54
- Brake calipers  55
- Checking brake discs  55
- Checking free play of hand brake lever 55
- Adjusting basic position of handbrake lever (Every XCR-W
- models)  56
- Adjusting free travel of handbrake lever (Every EXC-R
- models)  56
- Checking the front brake fluid level  56
- Topping up the front brake fluid 56
- Checking the front brake linings 57
- Removing front brake linings 58
- Installing the front brake linings 58
- Changing the front brake linings 59
- Checking free play of foot brake lever  59
- Adjusting basic position of footbrake lever 60
- Checking the rear brake fluid level  60
- Adding rear brake fluid 61
- Checking rear brake linings  61
- Removing rear brake linings 62
- Installing the rear brake linings 62
- Changing the rear brake linings 63
- Removing front wheel 63
- Fitting front wheel 64
- Removing rear wheel 65
- Fitting rear wheel 65
- Tire condition checking 66
- Checking tire air pressure 66
- Checking spoke tension 67
- Removing the battery 67
- Installing the battery 67
- Recharging the battery 68
- Removing a fuse 69
- Replacing the fuse 69
- Removing the seat  69
- Mounting the seat  69
- Dismounting the fuel tank 70
- Installing the fuel tank 70
- Cooling system  71
- Checking antifreeze and coolant level  71
- Checking the coolant level 72
- Draining coolant 72
- Refilling coolant 73
- Glass fiber yarn filling of main silencer  73
- Removing main silencer  73
- Fitting the main silencer  74
- Dismounting the air filter box lid 74
- Installing the air filter box lid 74
- Removing the air filter 74
- Installing the air filter 75
- Cleaning air filter 75
- Adjusting basic position of clutch lever 75
- Checking fluid level of hydraulic clutch  75
- Changing fluid level of hydraulic clutch 76
- Carburetor - idle  77
- Carburetor - adjusting idle 77
- Emptying the carburetor float chamber 78
- Checking engine oil level 79
- Changing engine oil and oil filter, cleaning engine oil
- screen 79
- Draining engine oil, cleaning engine oil screen 79
- Removing the oil filter 80
- Mounting oil filter 80
- Filling up with engine oil 81
- Topping up engine oil  81
- Checking gear oil level  81
- Changing gear oil, cleaning gear oil screen 82
- Draining gear oil, cleaning gear oil screen 82
- Filling up with gear oil 83
- Topping up with gear oil 83
- TROUBLESHOOTING 84
- CLEANING 86
- Cleaning motorcycle  86
- STORAGE  87
- Storage 87
- Putting into operation after storage  87
- TECHNICAL DATA - ENGINE 88
- Capacity - engine oil  88
- Capacity - gear oil 88
- Capacity - coolant 89

AND MORE.....