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Ktm 450 Exc R 2009

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450 EXC EU 2009

KTM 450 EXC EU 2009 Manuals

Manuals and User Guides for KTM 450 EXC EU 2009. We have 2 KTM 450 EXC EU 2009 manuals available for free PDF download: Repair Manual, Setup Instructions

KTM 450 EXC EU 2009 Repair Manual

KTM 450 EXC EU 2009 Repair Manual (272 pages)

Brand: KTM | Category: Motorcycle | Size: 82.98 MB

2

Table of Contents
6

Means of Representation
7

Important Notes
8

Serial Numbers
- 8
  
  Chassis Number
- 8
  
  Type Label
- 8
  
  Key Number (All EXC Models)
- 9
  
  Engine Number
- 9
  
  Fork Part Number
- 9
  
  Shock Absorber Part Number
10

Motorcycle
- 10
  
  Raising the Motorcycle with the Lift Stand
- 10
  
  Removi Ng the Motorcycle From the I Ift Stand
- 10
  
  Starting
- 11
  
  Starting the Motorcycle for a Check
12

Ollfork, TRIPLE CLAMP
- 12
  
  Adjusting the Compression Damping of the Fork
- 12
  
  Adjusling Ihe Rebound Damping of Ihe Fork
- 12
  
  Adjusling Spring Preload of Ihe Fork
- 13
  
  Bleeding Fork Legs
- 13
  
  Cleaning the Dust Bools of Ihe Fork Legs
- 13
  
  Loosening the Fork Protector
- 14
  
  Positioning the Fork Protector
- 14
  
  Removing the Fork Legs
- 14
  
  Inslalling Fork Legs
- 15
  
  Removing the Fork Proteclor
- 15
  
  Inslalling Ihe Fork Protector
- 16
  
  Performing a Fork Service
- 16
  
  Disassembling the Fork Legs
- 19
  
  Cartridge Disassembly
- 21
  
  Disassembling the Compression Damping Fitting
- 21
  
  Checking the Fork Legs
- 22
  
  Assembling Ihe Compression Damping Fitting
- 23
  
  Assembling Ihe Cartridge
- 25
  
  Assembling the Fork Legs
- 29
  
  Greasing the Steering Head Bearing
- 29
  
  Removing the Lower Triple Clamp (EXC USA, All SIX DAYS Models)
- 29
  
  Inslalling Ihe Lower Triple Clamp (EXC USA, All SIX DAYS Models)
- 31
  
  Removing the Lower Triple Clamp (EXC EU/AUS)
- 32
  
  Installing the Lower Triple Clamp (EXC Euiaus)
- 33
  
  Fork Offset (XC-W SIX DAYS)
- 34
  
  Setting the Fork Offset (XC-W SIX DAYS)
- 34
  
  Checking the Steering Head Bearing Play
- 34
  
  SIX DAYS Models)
- 35
  
  Adjusling Play of Steering Head Bearing (EXC EU/AUS)
36

02/Handlebar, Instruments
- 36
  
  Handlebar Position
- 36
  
  Adjusting Handlebar Position
- 36
  
  Adjusling the Basic Position of Ihe Clulch Lever
- 37
  
  Checking the Choke Cable Routing
- 37
  
  Exc Six Days)
- 37
  
  Checking the Choke Cable Play (EXC EU, EXC SIX DAYS)
- 37
  
  Adjusting the Choke Cable Play (EXC EU, EXC SIX DAYS)
- 37
  
  Checking the Throttle Cable Routing
- 38
  
  Checking the Play in Ihe Throttle Cable
- 38
  
  Adjusling the Play in the Throttle Cable
39

03/Frame
- 39
  
  Removing the Engine Sprocket Cover
- 39
  
  Installing the Engine Sprocket Cover
40

04/Shock ABSORBER, SWINGARM
- 40
  
  Adjusting High-Speed Compression Damping of the Shock Absorber
- 40
  
  Adjusting the Low-Speed Compression Damping of Ihe Shock Absorber
- 41
  
  Adjusting Rebound Damping of the Shock Absorber
- 41
  
  Measuring Rear Wheel Sag Unloaded
- 41
  
  Checking the Static Sag of the Shock Absorber
- 42
  
  Checking Ihe Riding Sag of Ihe Shock Absorber
- 42
  
  Adjusting the Spring Preload of the Shock Absorber
- 43
  
  Adjusting the Riding Sag
- 43
  
  Removi Ng the Shock Absorber
- 43
  
  Installing the Shock Absorber
- 44
  
  Perform a Shock Absorber Service
- 44
  
  Removing the Spring
- 45
  
  Disassembling the Damper
- 46
  
  Disassembling the Pislon Rod
- 47
  
  Disassembling the Seal Ring Retainer
- 48
  
  Replacing the Pilot Bushing
- 48
  
  Checking the Damper
- 49
  
  Disassembling the Rebound Adjuster
- 50
  
  Removing the Heim Joint
- 50
  
  Installing the Heim Joint
- 51
  
  Assembling the Rebound Adjuster
- 52
  
  Assembling the Seal Ring Retainer
- 52
  
  Assembling the Piston Rod
- 54
  
  Assembling the Damper
- 56
  
  Bleeding and Filling the Damper
- 58
  
  Filling Ihe Damper Wilh Nitrogen
- 59
  
  Installing the Spring
- 60
  
  Changing the Heim Joint
62

05/Exhaust
- 62
  
  Removing the Manifold
- 62
  
  Installing the Manifold
- 62
  
  Removi Ng Mai N Si Lencer
- 62
  
  Installing the Main Silencer
- 63
  
  Changing the Glass Fiber Yarn Filling of the Main Silencer
64

06/Air Filter
- 64
  
  Removing the Air Filter Box Lid
- 64
  
  Installing the Air Filter Box Lid
- 64
  
  Removing the Air Filter
- 64
  
  Installing the Air Filter
- 65
  
  Cleaning the Air Filter and Air Filler Box
- 65
  
  Removing the Carburetor Connection Boot
- 65
  
  Installing the Carburetor Connection Boot
66

07/Fuel Tank, Seat, Trim
- 66
  
  Opening Filler Cap
- 66
  
  Closing Filler Cap
- 66
  
  Removi Ng the Seal
- 66
  
  Mounting the Seal
- 66
  
  Removing the Fuel Tank
- 67
  
  Installing the Fuel Tank
- 68
  
  Fuel Tap
69

08!Mask, Fender
- 69
  
  Removi Ng the Front Fender
- 69
  
  Install I Ng the Front Fender
- 69
  
  Removing Headlight Mask with Headlight
- 69
  
  Refitting the Headlight Mask with the Headlight
71

09/Front Wheel
- 71
  
  Removi Ng Front Wheel
- 72
  
  Checking the Brake Discs
- 72
  
  Removing the Iront Brake Disc
- 73
  
  Install I Ng the Front Wheel
- 73
  
  Installing the Front Brake Disc
- 73
  
  Checking the Tire Condition
- 73
  
  Checking Tire Air Pressure
- 74
  
  Checking Spoke Tension
75

Lo/Rear WHEEL
- 75
  
  Removing the Rear Wheel
- 75
  
  Installing the Rear Wheel
- 76
  
  Removing the Rear Brake Disc
- 76
  
  Installing the Rear Brake Disc
- 76
  
  Checking the Chain Tension
- 77
  
  Adjusting the Chain Tension
- 78
  
  Adjusting Chain Guide
- 78
  
  Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide
- 80
  
  Checking for Chain Dirt Accumulation
- 80
  
  Clean I Ng the Chai N
81

11IWIRING HARNESS, Battery
- 81
  
  Removing the Main Fuse
- 81
  
  Installing the Main Fuse
- 81
  
  XC-W Six Days)
- 82
  
  Removi Ng the Battery
- 82
  
  Installing the Battery
- 82
  
  Rechargi Ng the Battery
- 83
  
  Checking the Quiescent Current
- 83
  
  Checking the Charging Voltage
- 84
  
  Checking the Voltage Regulator
- 85
  
  Checking the Starter Relay
86

13/Brake System
- 86
  
  Checking the Front Brake Linings
- 86
  
  Removing Front Brake Linings
- 86
  
  Installing the Front Brake Linings
- 87
  
  Changing the Front Brake Linings
- 88
  
  Checking Free Travel of Hand Brake Lever
- 89
  
  (XC-W SIX Days)
- 89
  
  Models)
- 89
  
  Checking the Brake Iluid Level of the Iront Brake
- 90
  
  Adding Iront Brake Iluid
- 90
  
  Changing the Iront Brake Iluid
- 91
  
  Checking Rear Brake Linings
- 92
  
  Removing Rear Brake Linings
- 92
  
  Mounting Rear Brake Linings
- 93
  
  Changing the Rear Brake Linings
- 94
  
  Checking the Iree Travel of the Loot Brake Lever
- 94
  
  Adjusting the Basic Position 01 the Loot Brake Lever
- 95
  
  Checking Rear Brake Iluid Level
- 95
  
  Adding Brake Fluid to the Rear Brake Circuit
- 96
  
  Changing the Rear Brake Iluid
98

14/Lighting SYSTEM, INSTRUMENTS
- 98
  
  Adjusting the Speedometer Lunctions
- 98
  
  Setting Kilometers or Miles
- 99
  
  Activating the Additional Lunctions
- 99
  
  Setting the Wheel Circumference
- 100
  
  Setting the Clock
- 100
  
  Checking the Headlight Adjustment
- 100
  
  Adjusting the Headlight Range
101

Engine
- 101
  
  Removing the Engine
- 102
  
  Installing the Engine
104

Disassembling the Engine
- 104
  
  Preparations
- 104
  
  Draining the Engine Oil
- 104
  
  Removing the Oil Lilter
- 104
  
  Draining the Gear Oil, Removing the Gear Oil Screen
- 105
  
  Removi Ng the Starter Motor
- 105
  
  Removi Ng the Spark Pi Ug
- 105
  
  Removing the Valve Cover
- 105
  
  Removing the Shift Lever
- 106
  
  Removi Ng the Alternator Cover
- 106
  
  Positioning the Engine at Ignition Top Dead Center
- 107
  
  Removing the Timing Chain Tensioner
- 107
  
  Removing the Camshaft
- 107
  
  Removing the Cylinder Head
- 107
  
  Removing the Piston
- 108
  
  Removi Ng the Rotor
- 108
  
  Removing the Balance Weight
- 108
  
  Removing the Timing Chain Guide Rail
- 109
  
  Removing the Timing Chain Tensioning Rail
- 109
  
  Removing the Timing Chain Securing Guide
- 109
  
  Removing the Timing Chain
- 109
  
  Removing the Ignition Pulse Generator
- 109
  
  Removing the Suction Pump
- 110
  
  Removing the Kickstarter
- 110
  
  Removing the Water Pump Cover
- 111
  
  Disassembling the Clutch Disks
- 111
  
  Removi Ng the Pri Mary Gear Nut
- 111
  
  Removing the Outer Clutch Hub
- 112
  
  Removing the Balancer Shaft
- 112
  
  Removing the Torque Limiter
- 112
  
  Removing the Starter Idler Gear
- 112
  
  Removing the Kickstarter Idler Gear
- 113
  
  Removing the Kickstarter Idler Gear
- 113
  
  Removing the Shift Shaft
- 113
  
  Removing the Shift Drum Locating Unit
- 113
  
  Removing the Locking Lever
- 113
  
  Removing the Oil Pump Gears
- 114
  
  Removing the Oil Pumps
- 114
  
  Removing the Primary Gear
- 114
  
  Removing the Iree Wheel Gear
- 115
  
  Removi Ng the Left Section 01 the Engi Ne Case
- 116
  
  Removing the Shift Rails
- 116
  
  Removing the Shift Drum
- 116
  
  Removing the Shift Lorks
- 116
  
  Removing the Transmission Shafts
- 117
  
  Removing the Crankshaft
118

Engine - Work On the Individual Parts
- 118
  
  Working On the Right Section of the Engine Case
- 119
  
  Working On the Left Section of the Engine Case
- 121
  
  Removing the Oil Pressure Regulator Valve
- 121
  
  Checking Spring Length of Oil Pressure Regulator Valve
- 121
  
  Installing the Oil Pressure Regulator Valve
- 121
  
  Removing the Crankshaft Seal Ring in the Clutch Cover
- 121
  
  Installing the Crankshaft Seal Ring in the Clutch Cover
- 122
  
  Removing the Water Pump
- 122
  
  Installing the Water Pump
- 123
  
  Checking the Balancer Shaft
- 123
  
  Removing the Timing Chain Sprocket
- 124
  
  Installing the Timing Chain Sprocket
- 124
  
  Changing the Connecting Rod, Conrad Bearing and Crank Pin
- 126
  
  Checking Crankshaft Run-Out at Bearing Pin
- 126
  
  Cylinder - Nikasil" Coating
- 126
  
  Checking/Measuring Cylinder
- 127
  
  Checking/Measuring the Piston
- 127
  
  Checking the Piston Ring End Gap
- 128
  
  Piston/Cylinder - Determining the Mounting Clearance
- 128
  
  Checking the Oil Pumps
- 128
  
  Disassembling the Autodecompressor
- 129
  
  Assembling the Autodecompressor
- 129
  
  Checking Camshaft
- 130
  
  Checking the Timing Assembly
- 130
  
  Preparing the Timing Chain Tensioner for Installation
- 131
  
  Removing the Rocker Arm
- 131
  
  Removing the Valves
- 132
  
  Changing Camshaft Bearing
- 132
  
  Checking Valves
- 133
  
  Checking Valve Springs
- 133
  
  Checking Valve Spring Seat
- 133
  
  Checking the Cylinder Head
- 134
  
  Checking the Rocker Arm Shafts
- 134
  
  Installing the Valves
- 135
  
  Installing the Rocker Arm
- 135
  
  Checking the Clutch
- 136
  
  Checking Shift Mechanism
- 137
  
  Preassembling the Shift Shaft
- 137
  
  Disassembling the Main Shaft
- 138
  
  Assembling the Main Shaft
- 138
  
  Disassembling the Countershaft
- 139
  
  Assembling the Countershaft
- 139
  
  Checking the Transmission
- 140
  
  Premounting the Kickstarter Shaft
- 141
  
  Checking the Electric Starter Mode
- 142
  
  Removing the Freewheel
- 142
  
  Checking the Freewheel
- 142
  
  Installing the Free Wheel
144

30/ENGINE Assembly
- 144
  
  Installing the Crankshaft
- 144
  
  Installing the Transmission Shafts
- 144
  
  Installing the Shift Forks
- 145
  
  Installing the Shift Drum
- 145
  
  Installing the Shift Rails
- 145
  
  Installing the Left Engine Case
- 146
  
  Installing the Free Wheel Gear
- 146
  
  Installing the Primary Gear
- 146
  
  Installing the Oil Pumps
- 147
  
  Installing the Oil Pump Gears
- 147
  
  Installing the Locking Lever
- 147
  
  Installing the Shift Drum Locating Uni
- 147
  
  Installing the Shift Shaft
- 148
  
  Installing the Kickstarter Idler Gear
- 148
  
  Installing the Kickstarter Shaft
- 148
  
  Installing the Starter Idler Gear
- 148
  
  Installing the Torque Limiter
- 149
  
  Installing the Balancer Shaft
- 149
  
  Installing the Outer Clutch Hub
- 150
  
  Installing the Primary Gear Nut
- 150
  
  Installing the Clutch Discs
- 150
  
  Installing the Clutch Cover
- 151
  
  Installing the Water Pump Cover
- 151
  
  Installing the Kickstarter
- 151
  
  Installing the Suction Pump
- 152
  
  Installing the Ignition Pulse Generator
- 152
  
  Installing the Timing Chain
- 152
  
  Installing the Timing Chain Securing Guide
- 152
  
  Installing the Timing Chain Tensioning Rail
- 153
  
  Installing the Timing Chain Guide Rail
- 153
  
  Installing the Balance Weight
- 153
  
  Installing the Rotor
- 153
  
  Installing the Piston
- 155
  
  Installing the Cylinder Head
- 156
  
  Installing the Timing Chain Tensioner
- 157
  
  Installing the Camshaft
- 157
  
  Checking the Valve Clearance
- 157
  
  Adjusting the Valve Clearance
- 157
  
  Installing the Alternator Cover
- 158
  
  Installing the Shift Lever
- 158
  
  Installing the Valve Cover
- 158
  
  Installing the Spark Plug
- 158
  
  Installing the Starter Motor
- 159
  
  Installing the Oil Filter
- 159
  
  Filling Up with Engine Oil
- 159
  
  Filling Up with Gear Oil
- 160
  
  Removing the Engine From the Work Stand
161

31/Carburetor
- 161
  
  Choke (EXC AUS/USA, XC.W SIX DAYS)
- 161
  
  Choke (EXC EU, EXC SIX DAYS)
- 161
  
  Carburetor - Adjusting the Idle Speed
- 162
  
  Emptying the Carburetor Float Chamber
- 163
  
  Removing the Carburetor
- 163
  
  Installing the Carburetor
- 164
  
  Checking/Adjusting the Carburetor Components
- 165
  
  Checking the Throttle Valve Sensor
- 165
  
  Disassembling the Carburetor
- 168
  
  Checking the Choke Slide
- 168
  
  Checking the Jet Needle
- 168
  
  Checking the Throttle Slide
- 169
  
  Checking the Needle Jet
- 169
  
  Checking the Float Needle Valve
- 169
  
  Assembling the Carburetor
- 172
  
  Checking/Adjusting the Float Level
- 172
  
  Checking/Setting the Throttle Slide Opening
- 173
  
  Checking/Adjusting the Accelerator Pump
- 173
  
  Adjusting the Position of the Throttle Position Sensor
175

321Clutch
- 175
  
  Checking the Fluid Level of Hydraulic Clutch
- 175
  
  Changing the Hydraulic Clutch Fluid
177

33Ftransmission
- 177
  
  Removing the Engine Sprocket
- 177
  
  Installing the Engine Sprocket
178

35Iwater Pump, Cooling System
- 178
  
  Cooling System
- 178
  
  Checking the Anti-Freeze and Coolant Level
- 179
  
  Checking the Coolant Level
- 179
  
  Draining Coolant
- 180
  
  Refilling Coolant
181

381Lubrication System
- 181
  
  Oil Circuit
- 181
  
  Checking Engine Oil Level
- 182
  
  Changing Engine Oil and Oil Filter, Cleaning Engine Oil Screen
- 182
  
  Draining Engine Oil, Cleaning Engine Oil Screen
- 182
  
  Removing the Oil Filter
- 183
  
  Installing the Oil Filte
- 183
  
  Filling Up with Engine Oil
- 184
  
  Adding Engine Oil
- 184
  
  Checking the Engine Oil P'essu'e
- 185
  
  Checking the Gea, Oil Level
- 185
  
  Changing Gear Oil, Cleaning Gear Oil Screen
- 185
  
  Draining Gear Oil, Cleaning Gear Oil Screen
- 186
  
  Filling Up with Gea, Oil
- 186
  
  Adding Gea, Oil
188

39/1Gnition System
- 188
  
  Checking the Ignition System
- 189
  
  Ignition Coil - Checking the P,Imary Winding
- 189
  
  Ignition Coil - Checking the Secondary Winding
- 190
  
  Checking the Spa,K Plug Connecto
- 190
  
  Alternato, - Checking the Cha,Ging Coil of the Ignition
- 190
  
  Alternato, - Checking the Light and Battery Winding
- 191
  
  Checking the Ignition Pulse Gene,Ato
- 192
  
  Removi Ng the Stato
- 192
  
  Installing the Stato
193

40/Electric Starter
- 193
  
  Checking the Starte' Mota
194

Technical Data - Engine
- 194
  
  Gapacity - Engine Oil
- 195
  
  Gapacity - Transmission Oil
- 195
  
  Gapacity - Coolant
196

Technical Data - Tolerance, Wear Limits of Engine
197

Technical Data - Engine Tightening Torques
199

Technical Data - Carburetor
- 199
  
  All 400 Models
- 199
  
  Exc Eu/Aus, 450 Exc Six Days
- 199
  
  Exc Usa
- 200
  
  450 XC-W Six Days Usa
- 200
  
  Exc Eu/Aus, 530 Exc Six Days
- 200
  
  Exc Usa
- 201
  
  530 XC-W Six Days Usa
202

Technical Data - Carburetor Tightening Torques
203

Technical Data - Chassis
- 204
  
  Lighting Equipment
- 204
  
  Ti,Es
- 204
  
  Gapacity - Fuel
205

Technical Data - Fork
206

Technical Data - Shock Absorber
207

Technical Data - Chassis Tightening Torques
208

Cleaning
- 208
  
  Clean I Ng the Motorcycle
209

Storage
- 209
  
  Sto'age
- 209
  
  Putting Into Ope,Ation Afie, Sto,Age
210

Service Schedule
- 211
  
  Service Wo,K (As Additional O'de')
212

Wiring Diagram
- 212
  
  EXC EU, EXC SIX Days)
- 214
  
  EXC EU, EXC SIX Days)
- 216
  
  EXC EU, EXC SIX Days)
- 218
  
  EXC EU, EXC SIX Days)
- 220
  
  EXC EU, EXC SIX Days)
- 222
  
  Exc Aus)
- 224
  
  Exc Aus)
- 226
  
  Exc Aus)
- 228
  
  Exc Aus)
- 230
  
  Exc Aus)
- 232
  
  Exc Usa)
- 234
  
  Exc Usa)
- 236
  
  Exc Usa)
- 238
  
  Exc Usa)
- 240
  
  Exc Usa)
- 242
  
  XC-W Six Days)
- 244
  
  XC-W Six Days)
- 246
  
  XC-W Six Days)
- 248
  
  XC-W Six Days)
250

Substances
252

Auxiliary Substances
254

Special Tools
267

Standards
268

Index

KTM 450 EXC EU 2009 Setup Instructions

KTM 450 EXC EU 2009 Setup Instructions (14 pages)

Brand: KTM | Category: Motorcycle | Size: 0.46 MB

4

Means of Representation
8

Installing the Battery
8

Recharging the Battery
11

Technical Data - Tightening Torques for Chassis
13

Auxiliary Substances

KTM Categories

Motorcycle Motorcycle Accessories Offroad Vehicle Engine Industrial Equipment

More KTM Manuals

Ktm 450 Exc R 2009

Source: https://www.manualslib.com/products/Ktm-450-Exc-Eu-2009-10638441.html

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Ktm 450 Exc R 2009

Ktm 450 Exc R 2009

KTM 450 EXC EU 2009 Manuals

Manuals and User Guides for KTM 450 EXC EU 2009. We have 2 KTM 450 EXC EU 2009 manuals available for free PDF download: Repair Manual, Setup Instructions

KTM 450 EXC EU 2009 Repair Manual (272 pages)

Table of Contents

KTM 450 EXC EU 2009 Setup Instructions (14 pages)

Table of Contents

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KTM Categories

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