KTM 450 XCR-W USA User manual

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

INTRODUCTION 1

,1752'8&7,21

Read the repair manual before beginning work.

Only use ORGINALKTM SPARE PARTS.

The engine will only be able to meet the demands placed on it if the specified service work is performed regularly and properly.

This repair manual was 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 will not be specified

here. It is assumed that the repair work will be performed by a fully trained mechanic.

All specifications are not binding. KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifica-

tions, 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 printing and other errors. The models portrayed partly contain special

equipment that does not belong to the regular scope of delivery.

Reproduction, even in part, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)

Within the meaning of 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

CONTENTS 2

&217(176

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

CONTENTS 3

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

CONTENTS 4

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

CONTENTS 5

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

MEANS OF REPRESENTATION 6

0($16 2)5(35(6(17$7,21

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).

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.

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.

Specific name Identifies a specific name.

Name

®

Identifies a protected name.

Brand™ Identifies a brand in merchandise traffic.

IMPORTANT NOTES 7

,03257$17 127(6

Warranty

The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed

in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for

damage resulting from manipulations and alterations to the motorcycle.

Fuel, oils, etc.

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.

MOTORCYCLE 8

02725&<&/(



Jacking up the motorcycle

500074-01

Note

Danger of damageಗDanger of damage by the vehicle running away or falling over.

ಥ Always place the vehicle on a firm and even surface.

ಥ Jack up the motorcycle underneath the engine. The wheels must no longer touch

the ground.

Work stand (54829055000) ( P. 178)

ಥ Secure the motorcycle against falling over.

Removing the motorcycle from the work stand

Note

Danger of damageಗDanger of damage by the vehicle running away or falling over.

ಥ Always place the vehicle on a firm and even surface.

ಥ Remove the motorcycle from the work stand.

ಥ Remove the work stand.

01/FORK, TRIPLE CLAMP 9

)25. 75,3/( &/$03



Fork part number

500082-10

The fork part number is stamped on the inner side of the fork stub.

Adjusting spring preload of the fork

100025-10

ಥ Turn adjusting screws counterclockwise until they stop.

Info

Make the same adjustment on both fork legs.

ಥ Turn back clockwise the number of turns corresponding to the fork type.

Specification

Spring preload - PreloadAdjuster (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-

W)

Comfort 2turns

Standard 4turns

Sport 7turns

Spring preload - PreloadAdjuster (EXC-RSIXDAYS)

Comfort 2turns

Standard 2turns

Sport 7turns

Info

Turn clockwise to increase spring preload, turn counterclockwise to reduce

spring preload.

Adjusting the spring preload has no influence on the absorption setting of

the rebound damping.

Basically, however, you should set the rebound damping higher with a

higher spring preload.

Adjusting compression damping of fork

Info

The hydraulic compression damping determines the fork suspension behavior.

100020-10

ಥ Remove protection covers.

ಥ Turn adjusting screws

 clockwise until they stop.

Info

The adjusting screws are located at the bottom end of the fork legs.

Make the same adjustment on both fork legs.

01/FORK, TRIPLE CLAMP 10

ಥ 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

Sport 18clicks

Info

Turn clockwise to increase damping, turn counterclockwise to reduce sus-

pension damping.

ಥ Mount protection covers

.

Adjusting rebound damping of fork

Info

The hydraulic rebound damping determines the fork suspension behavior.

100019-10

ಥ Turn adjusting screws clockwise until they stop.

Info

The adjusting screws are located at the top end of the fork legs.

Make the same adjustment on both fork legs.

ಥ Turn back counterclockwise the number of clicks corresponding to the fork type.

Specification

Rebound damping (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-W)

Comfort 20clicks

Standard 18clicks

Sport 18clicks

Rebound damping (EXC-RSIXDAYS)

Comfort 20clicks

Standard 20clicks

Sport 18clicks

Info

Turn clockwise to increase damping, turn counterclockwise to reduce sus-

pension damping.

Cleaning dust boots of fork legs

ಥ Jack up the motorcycle. ( P. 8)

ಥ Loosen the fork protection. ( P. 13)

500088-10

ಥ Push dust boots of both fork legs downwards.

Info

The dust boots should remove dust and coarse dirt particles from the fork

tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not

removed, the oil seals behind can start to leak.

01/FORK, TRIPLE CLAMP 11

Warning

Danger of accidentsಗReduced braking due to oil or grease on the brake

discs.

ಥ Always keep the brake discs free of oil and grease, and clean them with

brake cleaner when necessary.

ಥ Clean and oil the dust boots and inner fork tube of both fork legs.

Universal oil spray ( P. 175)

ಥ Press the dust boots back into their normal position.

ಥ Remove excess oil.

ಥ Position the fork protection. ( P. 13)

ಥ Remove the motorcycle from the work stand. ( P. 8)

Removing the fork legs

ಥ Remove front wheel. ( P. 33)

500093-10

ಥ Remove screws and take off clamp.

ಥ Remove cable clip

, remove screw and take off the brake caliper.

ಥ Hang the brake caliper and the brake line loosely to the side.

500094-10

(EXC-RSIXDAYS, XCR-WUSA)

ಥ Loosen screw

. Remove the fork leg on the left.

ಥ Loosen screw

. Remove the fork leg on the right.

100023-11

(EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-WZA)

ಥ Loosen screw

. Remove the fork leg on the left.

ಥ Loosen screw

. Remove the fork leg on the right.

Installing the fork legs

100021-10

ಥ Check parts for damage and wear. Replace damaged or worn parts.

ಥ Position the fork legs.

Info

The topmost sunk nut in the fork leg must be flush to the upper edge of the

upper triple clamp.

Position the bleeder screw

 to the front.

01/FORK, TRIPLE CLAMP 12

500094-11

(EXC-RSIXDAYS, XCR-WUSA)

ಥ Fully tighten screw

.

Specification

Screw, top triple clamp M8 17Nm

(12.54lbfft)

ಥ Fully tighten screw

.

Specification

Screw, bottom triple clamp M8 12Nm

(8.85lbfft)

100023-10

(EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-WZA)

ಥ Fully tighten screw

.

Specification

Screw, top triple clamp M8 20Nm

(14.75lbfft)

ಥ Fully tighten screw

.

Specification

Screw, bottom triple clamp M8 15Nm

(11.06lbfft)

500093-11

ಥ Position brake caliper, mount and tighten screws.

Specification

Screw, front brake caliper M8 25Nm

(18.44lbfft)

Loctite

®

243™

ಥ Fit cable clip

.

ಥ Position the brake line and cable harness. Put the clamp on, mount and tighten

screws

.

ಥ Fit front wheel. ( P. 33)

Bleeding fork legs

ಥ Jack up the motorcycle. ( P. 8)

100021-10

ಥ Remove bleeder screws briefly.

Any excess pressure escapes from the interior of the fork.

ಥ Mount and tighten bleeder screws.

ಥ Remove the motorcycle from the work stand. ( P. 8)

Removing the fork protector

ಥ Remove the fork legs. ( P. 11)

500105-10

ಥ Remove screws on the left fork leg. Remove the fork protector upwards.

ಥ Remove the screws on the right fork leg. Remove the fork protector upwards.

01/FORK, TRIPLE CLAMP 13

Installing the fork protector

500105-10

ಥ Check parts for damage and wear. Replace damaged or worn parts.

ಥ Position the fork protection on the left fork leg. Mount and tighten screws

.

Specification

Remaining screws, chassis M6 10Nm

(7.38lbfft)

ಥ Position the fork protection on the right fork leg. Mount and tighten screws.

Specification

Remaining screws, chassis M6 10Nm

(7.38lbfft)

ಥ Install the fork legs. ( P. 11)

Loosening the fork protection

500087-11

ಥ Remove screws and take off clamp.

ಥ Remove screws

 on left fork leg. Push the fork protection downwards.

ಥ Remove the screws on the right fork leg. Push the fork protection downwards.

Positioning the fork protection

500087-10

ಥ Position the fork protection on the left fork leg. Mount and tighten screws.

Specification

Remaining screws, chassis M6 10Nm

(7.38lbfft)

ಥ Position the brake line and cable harness. Put the clamp on, mount and tighten

screws

.

ಥ Position the fork protection on the right fork leg. Mount and tighten screws.

Specification

Remaining screws, chassis M6 10Nm

(7.38lbfft)

Removing the lower triple clamp (EXC-RSIXDAYS, XCR-WUSA)

ಥ Remove the fork legs. ( P. 11)

(XCR-WUSA)

ಥ Dismount the start number plate. ( P. 32)

(EXC-RSIXDAYS)

ಥ Remove the headlight mask with the headlight. ( P. 31)

ಥ Dismount the front fender. ( P. 31)

500099-10

ಥ Remove screws and hang the CDI control unit to the side.

Info

Do not unplug the CDI control unit.

ಥ Remove screw

. Remove screw, take off top triple clamp with the handlebar

and place it on one side.

Info

Protect the motorcycle and its attachments from damage by covering them.

Do not bend the cables and lines.

0022

0011

0033

01/FORK, TRIPLE CLAMP 14

500100-10

ಥ Remove o-ring. Remove protector ring.

ಥ Remove the lower triple clamp with the steering stem.

ಥ Remove the upper steering head bearing.

Installing the lower triple clamp (EXC-RSIXDAYS, XCR-WUSA)

500098-10

ಥ Clean the bearing and sealing elements, check for damage, and grease.

Long-life grease ( P. 175)

ಥ Insert the lower triple clamp with the steering stem. Mount the upper steering head

bearing.

Info

Check whether the top steering head seal is correctly positioned.

ಥ Push up protective ring

 and o-ring.

500099-11

ಥ Position the upper triple clamp with the steering.

ಥ Mount and tighten screw

.

Specification

Screw, top steering head M20x1,5 10Nm

(7.38lbfft)

ಥ Position the clutch line, wiring harness and CDI control unit. Mount and tighten

screws

.

Specification

Remaining screws, chassis M6 10Nm

(7.38lbfft)

ಥ Install the front fender. ( P. 31)

(XCR-WUSA)

ಥ Fit the start number plate. ( P. 32)

(EXC-RSIXDAYS)

ಥ Refit the headlight mask with the headlight. ( P. 31)

ಥ Install the fork legs. ( P. 11)

500103-10

ಥ Mount and tighten screw.

Specification

Screw, top steering stem M8 17Nm

(12.54lbfft)

Loctite

®

243™

ಥ Check the cable harness, cable, brake and clutch line for free movement and free

laying.

ಥ Check play of steering head bearing.

0022

0011

01/FORK, TRIPLE CLAMP 15

Removing the lower triple clamp (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-WZA)

ಥ Remove the fork legs. ( P. 11)

ಥ Remove the headlight mask with the headlight. ( P. 31)

ಥ Dismount the front fender. ( P. 31)

500149-10

ಥ Remove screws and hang the CDI control unit to the side.

Info

Do not unplug the CDI control unit.

ಥ Remove screw

. Loosen screw. Take off top triple clamp with the handlebar

and place it on one side.

Info

Protect the motorcycle and its attachments from damage by covering them.

Do not bend the cables and lines.

500150-10

ಥ Remove protector ring.

ಥ Remove the lower triple clamp with the steering stem.

ಥ Remove the upper steering head bearing.

Installing the lower triple clamp (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-WZA)

500151-10

ಥ Clean the bearing and sealing elements, check for damage, and grease.

Long-life grease ( P. 175)

ಥ Insert the lower triple clamp with the steering stem. Mount the upper steering head

bearing.

Info

Check whether the top steering head seal is correctly positioned.

ಥ Push on protective ring

.

500149-11

ಥ Position the upper triple clamp with the steering.

ಥ Mount and tighten screw

.

Specification

Screw, top steering head M20x1,5 10Nm

(7.38lbfft)

ಥ Position the clutch line, wiring harness and CDI control unit. Mount and tighten

screws

.

Specification

Remaining screws, chassis M6 10Nm

(7.38lbfft)

ಥ Install the front fender. ( P. 31)

ಥ Refit the headlight mask with the headlight. ( P. 31)

ಥ Install the fork legs. ( P. 11)

0011

00BB

00AA

01/FORK, TRIPLE CLAMP 16

100022-11

ಥ Tighten screw.

Specification

Screw, top steering stem M8 20Nm

(14.75lbfft)

ಥ Check the cable harness, cable, brake and clutch line for free movement and free

laying.

ಥ Check play of steering head bearing.

Fork offset (EXC-RSIXDAYS, XCR-WUSA)

400188-10

You can see the currently set offset if you remove screw.

The fork offset

 has an impact on the handling of the vehicle. It is calculated from

the center of the fork leg to the center of the steering head bearing.

The fork offset can optionally be adjusted.

Marking

 to the front gives greater stability on fast racetracks.

Fork offset

Front marking 18mm (0.71in)

Marking

 to the rear (condition at delivery) gives better handling in bends.

Fork offset

Rear marking 20mm (0.79in)

Setting the fork offset (EXC-RSIXDAYS, XCR-WUSA)

ಥ Remove the lower triple clamp. ( P. 13)

500104-10

ಥ Remove screw. Remove the steering stem.

ಥ Clean the parts and check for damage.

ಥ Rotate the steering stem 180° and insert into the triple clamp. Mount and tighten

screw

.

Specification

Screw, bottom steering

head

M20x1,5 60Nm

(44.26lbfft)

Loctite

®

243™

ಥ Install the lower triple clamp. ( P. 14)

Checking play of steering head bearing

Info

If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can

be damaged after time.

ಥ Jack up the motorcycle. ( P. 8)

01/FORK, TRIPLE CLAMP 17

400189-10

ಥ 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)

ಥ Adjust play of the steering head bearing. ( P. 17)

(EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-WZA)

ಥ Adjust play of the steering head bearing. ( P. 17)

ಥ Move the handlebar to and fro over the entire steering range.

The handlebar must be able to move easily over the entire steering range. No

resting locations should be noticeable.

» If click positions are noticeable:

(EXC-RSIXDAYS, XCR-WUSA)

ಥ Adjust play of the steering head bearing. ( P. 17)

(EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-WZA)

ಥ Adjust play of the steering head bearing. ( P. 17)

ಥ Check the steering head bearing and replace if required.

ಥ Remove the motorcycle from the work stand. ( P. 8)

Adjusting play of steering head bearing (EXC-RSIXDAYS, XCR-WUSA)

ಥ Jack up the motorcycle. ( P. 8)

500103-11

ಥ Loosen screw. Remove screw.

ಥ Loosen and retighten screw

.

Specification

Screw, top steering head M20x1,5 10Nm

(7.38lbfft)

ಥ Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.

ಥ Fully tighten screw

.

Specification

Screw, top triple clamp M8 17Nm

(12.54lbfft)

ಥ Mount and tighten screw

.

Specification

Screw, top steering stem M8 17Nm

(12.54lbfft)

Loctite

®

243™

ಥ Check play of steering head bearing.

Adjusting play of steering head bearing (EXC-REU, EXC-RAUS/UK, EXC-RUSA, XCR-WZA)

ಥ Jack up the motorcycle. ( P. 8)

100022-10

ಥ Loosen screws and.

ಥ Loosen and retighten screw

.

Specification

Screw, top steering head M20x1,5 10Nm

(7.38lbfft)

ಥ Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.

ಥ Fully tighten screw

.

Specification

Screw, top triple clamp M8 20Nm

(14.75lbfft)

ಥ Tighten screw

.

Specification

Screw, top steering stem M8 20Nm

(14.75lbfft)

ಥ Check play of steering head bearing.

01/FORK, TRIPLE CLAMP 18

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. 15)

Install the lower triple clamp. ( P. 15)

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KTM 450 XCR-W USA User manual

KTM 450 XCR-W USA User manual

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