2008 KTM 450 EXC-R, 450 EXC-R SIX DAYS, 450 EX SIX DAYSC-R, 450 XCR-W, 530 EXC-R, 530 XCR-W Motorcycle also Covers Engine Servic

400 EXC EU 400 EXC AUS 450 EXC EU 450 EXC AUS 450 EXC SIX DAYS EU 450 EXC USA 450 XC-W SIX DAYS USA 530 EXC EU 530 EXC AUS 530 EXC SIX DAYS EU 530 EXC USA 530 XC-W SIX DAYS USA Art. no. 320609gen 400 EXC EU 400 EXC AUS 450 EXC EU 450 EXC AUS 450 EXC SIX DAYS EU 450 EXC USA 450 XC-W SIX DAYS USA 530 EXC EU 530 EXC AUS 530 EXC SIX DAYS EU 530 EXC USA 530 XC-W SIX DAYS USA Art. no. 320609gen

TABLE OF CONTENTS 2 MEANS OF REPRESENTATION ............................................ 6 Installing the engine sprocket cover ................................. 39 IMPORTANT NOTES ............................................................ 7 04/sHOCK ABSORBER, SWINGARM ................................... 40 SERIAL NUMBERS .............................................................. 8 Adjusting high-speed compression damping of the shock Chassis number ............................................................... 8 absorber.......... ....... .................... .................... .............. 40 Type label ....................................................................... 8 Key number (all EXC models) ........................................... 8 Engine number ................................................................ 9 Fork part number ............................................................. 9 Shock absorber part number ............................................. 9 MOTORCyCLE ................................................................... 10 Adjusting the low-speed compression damping of Ihe shock absorber .............................................................. 40 Adjusting rebound damping of the shock absorber ............ 41 Measuring rear wheel sag unloaded ................................. 41 Checking the static sag of the shock absorber .................. 41 Checking Ihe riding sag of Ihe shock absorber .................. 42 Raising the motorcycle with the lift stand ........................ 10 Removi ng the motorcycle from the Iift stand .. ....... ....... .... 10 Starting ........................................................................ 10 Starting the motorcycle for a check ................................. 11 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 ................................. 12 Bleeding fork legs .......................................................... 13 Cleaning the dust bools of Ihe fork legs ........................... 13 Loosening the fork protector ........................................... 13 Positioning the fork protector .......................................... 14 Removing the fork legs ................................................... 14 Inslalling fork legs ......................................................... 14 Removing the fork proteclor ............................................ 15 Inslalling Ihe fork protector ............................................ 15 Performing a fork service ................................................ 16 Disassembling the fork legs ............................................ 16 Cartridge disassembly .................................................... 19 Disassembling the compression damping fitting ............... 21 Checking the fork legs .................................................... 21 Assembling Ihe compression damping fitting .................... 22 Assembling Ihe cartridge ................................................ 23 Assembling the fork legs ................................................ 25 Greasing the steering head bearing .................................. 29 Removing the lower triple clamp (EXC USA, all SIX DAYS models) ........................................................................ 29 Adjusting the spring preload of the shock absorber ........... 42 Adjusting the riding sag ................................................. 43 Removi ng the shock absorber .............. ...... .............. ....... 43 Installing the shock absorber .......................................... 43 Perform a shock absorber service.. ...... ........ ...... .............. 44 Removing the spring ...................................................... 44 Disassembling the damper ............................................. 45 Disassembling the pislon rod .......................................... 46 Disassembling the seal ring retainer ................................ 47 Replacing the pilot bushing ............................................ 48 Checking the damper ..................................................... 48 Disassembling the rebound adjuster ................................ 49 Removing the heim joint ................................................ 50 Installing the heim joint ................................................. 50 Assembling the rebound adjuster .................................... 51 Assembling the seal ring retainer .................................... 52 Assembling the piston rod .............................................. 52 Assembling the damper .................................................. 54 Bleeding and filling the damper ...................................... 56 Filling Ihe damper wilh nitrogen ..................................... 58 Installing the spring ....................................................... 59 Changing the heim joint ................................................. 60 05/EXHAUST .................................................................... 62 Removing the manifold .................................................. 62 Installing the manifold ................................................... 62 Removi ng mai n si lencer .. ...... .............. ...... .............. ....... 62 Installing the main silencer ............................................ 62 Inslalling Ihe lower triple clamp (EXC USA, all SIX DAYS Changing the glass fiber yarn filling of the main silencer ... 63 models) ........................................................................ 29 06/AIR FILTER .................................................................. 64 Removing the lower triple clamp (EXC EU/AUS) ............... 31 Removing the air filter box lid ......................................... 64 Installing the lower triple clamp (EXC EUiAUS) ................ 32 Installing the air filter box lid .......................................... 64 Fork offset (XC-W SIX DAYS) .......................................... 33 Removing the air filter ................................................... 64 Setting the fork offset (XC-W SIX DAYS) .......................... 34 Installing the air filter .................................................... 64 Checking the steering head bearing play .......................... 34 Cleaning the air filter and air filler box ............................ 65 Adjusling play of steering head bearing (EXC USA, all Removing the carburetor connection boot ........................ 65 SIX DAYS models) ......................................................... 34 Installing the carburetor connection boot ......................... 65 Adjusling play of steering head bearing (EXC EU/AUS) ...... 35 07/FUEL TANK, SEAT, TRIM .............................................. 66 02/HANDLEBAR, INSTRUMENTS ....................................... 36 Opening filler cap .......................................................... 66 Handlebar position ........................................................ 36 Closing filler cap ........................................................... 66 Adjusting handlebar position .......................................... 36 Removi ng the seal... .................... ....... ............. ....... ....... 66 Adjusling the basic position of Ihe clulch lever ................. 36 Mounting the seal ......................................................... 66 Checking the choke cable routing (EXC EU, Removing the fuel tank .................................................. 66 EXC SIX DAYS) ............................................................. 37 Installing the fuel tank ................................................... 67 Checking the choke cable play (EXC EU, EXC SIX DAYS) ............................................................. 37 Fuel tap ........................................................................ 68 08!MASK, FENDER ........................................................... 69 Adjusting the choke cable play (EXC EU, EXC SIX DAYS) ............................................................. 37 Checking the throttle cable routing .................................. 37 Checking the play in Ihe throttle cable ............................. 38 Adjusling the play in the throttle cable ............................ 38 03/FRAM E...... .................... .................... .................... ...... 39 Removing the engine sprocket cover ................................ 39 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. ............... 69 09/FRONT WHEEL ............................................................ 71 Removi ng front wheel.... .............. ...... .............. ...... ........ 71 Install i ng the front wheeL...... ...... ........ ...... ...... ........ ....... 71 TABLE OF CONTENTS 2 MEANS OF REPRESENTATION ............................................ 6 Installing the engine sprocket cover ................................. 39 IMPORTANT NOTES ............................................................ 7 04/sHOCK ABSORBER, SWINGARM ................................... 40 SERIAL NUMBERS .............................................................. 8 Adjusting high-speed compression damping of the shock Chassis number ............................................................... 8 absorber.......... ....... .................... .................... .............. 40 Type label ....................................................................... 8 Key number (all EXC models) ........................................... 8 Engine number ................................................................ 9 Fork part number ............................................................. 9 Shock absorber part number ............................................. 9 MOTORCyCLE ................................................................... 10 Adjusting the low-speed compression damping of Ihe shock absorber .............................................................. 40 Adjusting rebound damping of the shock absorber ............ 41 Measuring rear wheel sag unloaded ................................. 41 Checking the static sag of the shock absorber .................. 41 Checking Ihe riding sag of Ihe shock absorber .................. 42 Raising the motorcycle with the lift stand ........................ 10 Removi ng the motorcycle from the Iift stand .. ....... ....... .... 10 Starting ........................................................................ 10 Starting the motorcycle for a check ................................. 11 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 ................................. 12 Bleeding fork legs .......................................................... 13 Cleaning the dust bools of Ihe fork legs ........................... 13 Loosening the fork protector ........................................... 13 Positioning the fork protector .......................................... 14 Removing the fork legs ................................................... 14 Inslalling fork legs ......................................................... 14 Removing the fork proteclor ............................................ 15 Inslalling Ihe fork protector ............................................ 15 Performing a fork service ................................................ 16 Disassembling the fork legs ............................................ 16 Cartridge disassembly .................................................... 19 Disassembling the compression damping fitting ............... 21 Checking the fork legs .................................................... 21 Assembling Ihe compression damping fitting .................... 22 Assembling Ihe cartridge ................................................ 23 Assembling the fork legs ................................................ 25 Greasing the steering head bearing .................................. 29 Removing the lower triple clamp (EXC USA, all SIX DAYS models) ........................................................................ 29 Adjusting the spring preload of the shock absorber ........... 42 Adjusting the riding sag ................................................. 43 Removi ng the shock absorber .............. ...... .............. ....... 43 Installing the shock absorber .......................................... 43 Perform a shock absorber service.. ...... ........ ...... .............. 44 Removing the spring ...................................................... 44 Disassembling the damper ............................................. 45 Disassembling the pislon rod .......................................... 46 Disassembling the seal ring retainer ................................ 47 Replacing the pilot bushing ............................................ 48 Checking the damper ..................................................... 48 Disassembling the rebound adjuster ................................ 49 Removing the heim joint ................................................ 50 Installing the heim joint ................................................. 50 Assembling the rebound adjuster .................................... 51 Assembling the seal ring retainer .................................... 52 Assembling the piston rod .............................................. 52 Assembling the damper .................................................. 54 Bleeding and filling the damper ...................................... 56 Filling Ihe damper wilh nitrogen ..................................... 58 Installing the spring ....................................................... 59 Changing the heim joint ................................................. 60 05/EXHAUST .................................................................... 62 Removing the manifold .................................................. 62 Installing the manifold ................................................... 62 Removi ng mai n si lencer .. ...... .............. ...... .............. ....... 62 Installing the main silencer ............................................ 62 Inslalling Ihe lower triple clamp (EXC USA, all SIX DAYS Changing the glass fiber yarn filling of the main silencer ... 63 models) ........................................................................ 29 06/AIR FILTER .................................................................. 64 Removing the lower triple clamp (EXC EU/AUS) ............... 31 Removing the air filter box lid ......................................... 64 Installing the lower triple clamp (EXC EUiAUS) ................ 32 Installing the air filter box lid .......................................... 64 Fork offset (XC-W SIX DAYS) .......................................... 33 Removing the air filter ................................................... 64 Setting the fork offset (XC-W SIX DAYS) .......................... 34 Installing the air filter .................................................... 64 Checking the steering head bearing play .......................... 34 Cleaning the air filter and air filler box ............................ 65 Adjusling play of steering head bearing (EXC USA, all Removing the carburetor connection boot ........................ 65 SIX DAYS models) ......................................................... 34 Installing the carburetor connection boot ......................... 65 Adjusling play of steering head bearing (EXC EU/AUS) ...... 35 07/FUEL TANK, SEAT, TRIM .............................................. 66 02/HANDLEBAR, INSTRUMENTS ....................................... 36 Opening filler cap .......................................................... 66 Handlebar position ........................................................ 36 Closing filler cap ........................................................... 66 Adjusting handlebar position .......................................... 36 Removi ng the seal... .................... ....... ............. ....... ....... 66 Adjusling the basic position of Ihe clulch lever ................. 36 Mounting the seal ......................................................... 66 Checking the choke cable routing (EXC EU, Removing the fuel tank .................................................. 66 EXC SIX DAYS) ............................................................. 37 Installing the fuel tank ................................................... 67 Checking the choke cable play (EXC EU, EXC SIX DAYS) ............................................................. 37 Fuel tap ........................................................................ 68 08!MASK, FENDER ........................................................... 69 Adjusting the choke cable play (EXC EU, EXC SIX DAYS) ............................................................. 37 Checking the throttle cable routing .................................. 37 Checking the play in Ihe throttle cable ............................. 38 Adjusling the play in the throttle cable ............................ 38 03/FRAM E...... .................... .................... .................... ...... 39 Removing the engine sprocket cover ................................ 39 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. ............... 69 09/FRONT WHEEL ............................................................ 71 Removi ng front wheel.... .............. ...... .............. ...... ........ 71 Install i ng the front wheeL...... ...... ........ ...... ...... ........ ....... 71

TABLE OF CONTENTS 3 Checking the brake discs ................................................ 72 Installing the engine .................................................... 102 Removing the Iront brake disc ........................................ 72 3D/DISASSEMBLING THE ENGINE ................................... 104 Installing the front brake disc ......................................... 73 Preparations ................................................................ 104 Checking the tire condition ............................................. 73 Draining the engine oil ................................................. 104 Checking tire air pressure ............................................... 73 Removing the oil lilter.................................................. 104 Checking spoke tension .................................................. 74 Draining the gear oil, removing the gear oil screen .......... 104 lO/REAR WHEEL .............................................................. 75 Removi ng the starter motor.......... ...... .............. ....... ..... 105 Removing the rear wheel ................................................ 75 Removi ng the spark pi ug .............. ...... .............. ...... ...... 105 Installing the rear wheel ................................................. 75 Removing the valve cover ............................................. 105 Removing the rear brake disc .......................................... 76 Removing the shift lever ............................................... 105 Installing the rear brake disc .......................................... 76 Removi ng the alternator cover. ....... ...... ....... ....... ...... ..... 106 Checking the chain tension ............................................ 76 Positioning the engine at ignition top dead center ........... 106 Adjusting the chain tension ............................................ 77 Removing the timing chain tensioner ............................. 107 Adjusting chain guide .................................................... 78 Removing the camshaft ................................................ 107 Checking the chain, rear sprocket, engine sprocket and Removing the cylinder head .......................................... 107 chain guide ................................................................... 78 Removing the piston .................................................... 107 Checking for chain dirt accumulation .............................. 80 Removi ng the rotor.. ...... .............. ...... .............. ....... ..... 108 Clean i ng the chai n.... .............. ...... .............. ...... ............. 80 Removing the balance weight ....................................... 108 11IWIRING HARNESS, BATTERy ....................................... 81 Removing the timing chain guide rail ............................ 108 Removing the main fuse ................................................. 81 Removing the timing chain tensioning rail .. .................... 109 Installing the main fuse ................................................. 81 Removing the timing chain securing guide ..................... 109 Changing the fuse of the radiator Ian (EXC SIX DAYS, Removing the timing chain ........................................... 109 XC-W SIX DAYS) ............................................................ 81 Removing the ignition pulse generator ........................... 109 Removi ng the battery .............. ...... .............. ...... ............. 82 Removing the suction pump ......................................... 109 Installing the battery ...................................................... 82 Removing the kickstarter .............................................. 110 Rechargi ng the battery ............ ...... .............. ...... ............. 82 Removing the water pump cover ................................... 110 Checking the quiescent current ....................................... 83 Removi ng the cl utch cover .... .............. ...... .............. ..... 11 0 Checking the charging voltage ........................................ 83 Disassembling the clutch disks ..................................... 111 Checking the voltage regulator ........................................ 84 Removi ng the pri mary gear nut ............ ...... .............. ..... 111 Checking the starter relay ............................................... 85 Removing the outer clutch hub ..................................... 111 13/BRAKE SYSTEM ........................................................... 86 Removing the balancer shaft ........................................ 112 Checking the front brake linings ...................................... 86 Removing the torque limiter ......................................... 112 Removing front brake linings .......................................... 86 Removing the starter idler gear ..................................... 112 Installing the front brake linings ..................................... 86 Removing the kickstarter idler gear ............................... 112 Changing the front brake linings ..................................... 87 Removing the kickstarter idler gear ............................... 113 Checking free travel of hand brake lever ........................... 88 Removing the shift shaft .............................................. 113 Adjusting the basic position of the hand brake lever (XC-W SIX DAyS) ........................................................... 89 Adjusting free travel of hand brake lever (all EXC models) ........................................................................ 89 Checking the brake Iluid level of the Iront brake ............... 89 Adding Iront brake Iluid ................................................. 90 Changing the Iront brake Iluid ........................................ 90 Checking rear brake linings ............................................ 91 Removing rear brake linings............................................ 92 Mounting rear brake linings ............................................ 92 Changing the rear brake linings ....................................... 93 Checking the Iree travel of the loot brake lever ................. 94 Adjusting the basic position 01 the loot brake lever ........... 94 Checking rear brake Iluid level ........................................ 95 Adding brake fluid to the rear brake circuit ...................... 95 Changing the rear brake Iluid .......................................... 96 14/LiGHTING SYSTEM, INSTRUMENTS ............................. 98 Adjusting the speedometer lunctions ............................... 98 Setting kilometers or miles ............................................. 98 Activating the additional lunctions .................................. 99 Setting the wheel circumference ..................................... 99 Setting the clock ......................................................... 100 Checking the headlight adjustment ............................... 100 Adjusting the headlight range ....................................... 100 3D/ENGINE ..................................................................... 101 Removing the engine ................................................... 101 Removing the shift drum locating unit ........................... 113 Removing the locking lever ........................................... 113 Removing the oil pump gears ........................................ 113 Removing the oil pumps ............................................... 114 Removing the primary gear ........................................... 114 Removing the Iree wheel gear ....................................... 114 Removi ng the left section 01 the engi ne case ...... ............ 115 Removing the shift rails ............................................... 116 Removing the shift drum .............................................. 116 Removing the shift lorks .............................................. 116 Removing the transmission shafts ................................. 116 Removing the crankshaft .............................................. 117 3D/ENGINE - WORK ON THE INDIVIDUAL PARTS ............. 118 Working on the right section of the engine case .............. 118 Working on the left section of the engine case ................ 119 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 ...... 121 Removing the water pump ............................................ 122 Installing the water pump ............................................. 122 Checking the balancer shaft ......................................... 123 Removing the timing chain sprocket .............................. 123 Installing the timing chain sprocket ............................... 124 TABLE OF CONTENTS 3 Checking the brake discs ................................................ 72 Installing the engine .................................................... 102 Removing the Iront brake disc ........................................ 72 3D/DISASSEMBLING THE ENGINE ................................... 104 Installing the front brake disc ......................................... 73 Preparations ................................................................ 104 Checking the tire condition ............................................. 73 Draining the engine oil ................................................. 104 Checking tire air pressure ............................................... 73 Removing the oil lilter.................................................. 104 Checking spoke tension .................................................. 74 Draining the gear oil, removing the gear oil screen .......... 104 lO/REAR WHEEL .............................................................. 75 Removi ng the starter motor.......... ...... .............. ....... ..... 105 Removing the rear wheel ................................................ 75 Removi ng the spark pi ug .............. ...... .............. ...... ...... 105 Installing the rear wheel ................................................. 75 Removing the valve cover ............................................. 105 Removing the rear brake disc .......................................... 76 Removing the shift lever ............................................... 105 Installing the rear brake disc .......................................... 76 Removi ng the alternator cover. ....... ...... ....... ....... ...... ..... 106 Checking the chain tension ............................................ 76 Positioning the engine at ignition top dead center ........... 106 Adjusting the chain tension ............................................ 77 Removing the timing chain tensioner ............................. 107 Adjusting chain guide .................................................... 78 Removing the camshaft ................................................ 107 Checking the chain, rear sprocket, engine sprocket and Removing the cylinder head .......................................... 107 chain guide ................................................................... 78 Removing the piston .................................................... 107 Checking for chain dirt accumulation .............................. 80 Removi ng the rotor.. ...... .............. ...... .............. ....... ..... 108 Clean i ng the chai n.... .............. ...... .............. ...... ............. 80 Removing the balance weight ....................................... 108 11IWIRING HARNESS, BATTERy ....................................... 81 Removing the timing chain guide rail ............................ 108 Removing the main fuse ................................................. 81 Removing the timing chain tensioning rail .. .................... 109 Installing the main fuse ................................................. 81 Removing the timing chain securing guide ..................... 109 Changing the fuse of the radiator Ian (EXC SIX DAYS, Removing the timing chain ........................................... 109 XC-W SIX DAYS) ............................................................ 81 Removing the ignition pulse generator ........................... 109 Removi ng the battery .............. ...... .............. ...... ............. 82 Removing the suction pump ......................................... 109 Installing the battery ...................................................... 82 Removing the kickstarter .............................................. 110 Rechargi ng the battery ............ ...... .............. ...... ............. 82 Removing the water pump cover ................................... 110 Checking the quiescent current ....................................... 83 Removi ng the cl utch cover .... .............. ...... .............. ..... 11 0 Checking the charging voltage ........................................ 83 Disassembling the clutch disks ..................................... 111 Checking the voltage regulator ........................................ 84 Removi ng the pri mary gear nut ............ ...... .............. ..... 111 Checking the starter relay ............................................... 85 Removing the outer clutch hub ..................................... 111 13/BRAKE SYSTEM ........................................................... 86 Removing the balancer shaft ........................................ 112 Checking the front brake linings ...................................... 86 Removing the torque limiter ......................................... 112 Removing front brake linings .......................................... 86 Removing the starter idler gear ..................................... 112 Installing the front brake linings ..................................... 86 Removing the kickstarter idler gear ............................... 112 Changing the front brake linings ..................................... 87 Removing the kickstarter idler gear ............................... 113 Checking free travel of hand brake lever ........................... 88 Removing the shift shaft .............................................. 113 Adjusting the basic position of the hand brake lever (XC-W SIX DAyS) ........................................................... 89 Adjusting free travel of hand brake lever (all EXC models) ........................................................................ 89 Checking the brake Iluid level of the Iront brake ............... 89 Adding Iront brake Iluid ................................................. 90 Changing the Iront brake Iluid ........................................ 90 Checking rear brake linings ............................................ 91 Removing rear brake linings............................................ 92 Mounting rear brake linings ............................................ 92 Changing the rear brake linings ....................................... 93 Checking the Iree travel of the loot brake lever ................. 94 Adjusting the basic position 01 the loot brake lever ........... 94 Checking rear brake Iluid level ........................................ 95 Adding brake fluid to the rear brake circuit ...................... 95 Changing the rear brake Iluid .......................................... 96 14/LiGHTING SYSTEM, INSTRUMENTS ............................. 98 Adjusting the speedometer lunctions ............................... 98 Setting kilometers or miles ............................................. 98 Activating the additional lunctions .................................. 99 Setting the wheel circumference ..................................... 99 Setting the clock ......................................................... 100 Checking the headlight adjustment ............................... 100 Adjusting the headlight range ....................................... 100 3D/ENGINE ..................................................................... 101 Removing the engine ................................................... 101 Removing the shift drum locating unit ........................... 113 Removing the locking lever ........................................... 113 Removing the oil pump gears ........................................ 113 Removing the oil pumps ............................................... 114 Removing the primary gear ........................................... 114 Removing the Iree wheel gear ....................................... 114 Removi ng the left section 01 the engi ne case ...... ............ 115 Removing the shift rails ............................................... 116 Removing the shift drum .............................................. 116 Removing the shift lorks .............................................. 116 Removing the transmission shafts ................................. 116 Removing the crankshaft .............................................. 117 3D/ENGINE - WORK ON THE INDIVIDUAL PARTS ............. 118 Working on the right section of the engine case .............. 118 Working on the left section of the engine case ................ 119 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 ...... 121 Removing the water pump ............................................ 122 Installing the water pump ............................................. 122 Checking the balancer shaft ......................................... 123 Removing the timing chain sprocket .............................. 123 Installing the timing chain sprocket ............................... 124

TABLE OF CONTENTS 4 Changing the connecting rod, conrad bearing and crank Installing the suction pump .......................................... 151 pin ............................................................................. 124 Installing the ignition pulse generator ............................ 152 Checking crankshaft run-out at bearing pin .................... 126 Installing the timing chain ............................................ 152 Cylinder - Nikasil" coating ............................................ 126 Installing the timing chain securing guide ...................... 152 Checking/measuring cylinder ........................................ 126 Installing the timing chain tensioning rail ...................... 152 Checking/measuring the piston ..................................... 127 Installing the timing chain guide rail ............................. 153 Checking the piston ring end gap .................................. 127 Installing the balance weight ........................................ 153 Piston/cylinder - determining the mounting clearance ..... 128 Installing the rotor ....................................................... 153 Checking the oil pumps ................................................ 128 Installing the piston ..................................................... 153 Disassembling the autodecompressor ............................ 128 Installing the cylinder head .......................................... 155 Assembling the autodecompressor ................................. 129 Installing the camshaft ................................................ 156 Checking camshaft ...................................................... 129 Installing the timing chain tensioner ............................. 156 Checking the timing assembly ...................................... 130 Checking the valve clearance ........................................ 157 Preparing the timing chain tensioner for installation ....... 130 Adjusting the valve clearance ........................................ 157 Removing the rocker arm .............................................. 131 Installing the alternator cover ....................................... 157 Removing the valves .................................................... 131 Installing the shift lever ............................................... 158 Changing camshaft bearing .......................................... 132 Installing the valve cover .............................................. 158 Checking valves ........................................................... 132 Installing the spark plug ............................................... 158 Checking valve springs ................................................. 133 Installing the starter motor ........................................... 158 Checking valve spring seat ............................................ 133 Installing the oil filter .................................................. 159 Checking the cylinder head .......................................... 133 Filling up with engine oil .............................................. 159 Checking the rocker arm shafts ..................................... 134 Filling up with gear oil ................................................. 159 Installing the valves ..................................................... 134 Removing the engine from the work stand ...................... 160 Installing the rocker arm .............................................. 135 31/CARBURETOR ........................................................... 161 Checking the clutch ..................................................... 135 Choke (EXC AUS/USA, XC.W SIX DAYS) ........................ 161 Checking shift mechanism ........................................... 136 Choke (EXC EU, EXC SIX DAYS) ................................... 161 Preassembling the shift shaft ........................................ 137 Carburetor - adjusting the idle speed ............................. 161 Disassembling the main shaft ....................................... 137 Emptying the carburetor float chamber .......................... 162 Assembling the main shaft ........................................... 138 Removing the carburetor .............................................. 163 Disassembling the countershaft .................................... 138 Installing the carburetor ............................................... 163 Assembling the countershaft ......................................... 139 Checking/adjusting the carburetor components ............... 164 Checking the transmission ............................................ 139 Checking the throttle valve sensor ................................. 165 Premounting the kickstarter shaft .................................. 140 Disassembling the carburetor ........................................ 165 Checking the electric starter mode ................................ 141 Checking the choke slide .............................................. 168 Removing the freewheel ............................................... 142 Checking the jet needle................................................ 168 Checking the freewheel ................................................ 142 Checking the throttle slide ............................................ 168 Installing the free wheel ............................................... 142 Checking the needle jet ................................................ 169 30/ENGINE ASSEMBLy ................................................... 144 Checking the float needle valve ..................................... 169 Installing the crankshaft ............................................... 144 Assembling the carburetor ............................................ 169 Installing the transmission shafts .................................. 144 Checking/adjusting the float level .................................. 172 Installing the shift forks ............................................... 144 Checking/setting the throttle slide opening ..................... 172 Installing the shift drum ............................................... 145 Checking/adjusting the accelerator pump ....................... 173 Installing the shift rails ................................................ 145 Adjusting the position of the throttle position sensor ....... 173 Installing the left engine case ....................................... 145 321CLUTCH .................................................................... 175 Installing the free wheel gear ........................................ 146 Checking the fluid level of hydraulic clutch .................... 175 Installing the primary gear ............................................ 146 Changing the hydraulic clutch fluid ............................... 175 Installing the oil pumps ............................................... 146 33fTRANSMISSION ......................................................... 177 Installing the oil pump gears ........................................ 147 Removing the engine sprocket ...................................... 177 Installing the locking lever............................................ 147 Installing the engine sprocket ....................................... 177 Installing the shift drum locating uni! .. .......................... 147 35IWATER PUMP, COOLING SYSTEM .............................. 178 Installing the shift shaft ............................................... 147 Cooling system ............................................................ 178 Installing the kickstarter idler gear ................................ 148 Checking the anti-freeze and coolant level ..................... 178 Installing the kickstarter shaft ...................................... 148 Checking the coolant level ............................................ 179 Installing the starter idler gear ...................................... 148 Draining coolant .......................................................... 179 Installing the torque limiter .......................................... 148 Refilling coolant .......................................................... 180 Installing the balancer shaft ......................................... 149 381LUBRICATION SYSTEM .............................................. 181 Installing the outer clutch hub ...................................... 149 Oil circuit ................................................................... 181 Installing the primary gear nut ...................................... 150 Checking engine oil level .............................................. 181 Installing the clutch discs ............................................ 150 Changing engine oil and oil filter, cleaning engine oil Installing the clutch cover ............................................ 150 screen ........................................................................ 182 Installing the water pump cover .................................... 151 Draining engine oil, cleaning engine oil screen ............... 182 Installing the kickstarter ............................................... 151 Removing the oil filter .................................................. 182 TABLE OF CONTENTS 4 Changing the connecting rod, conrad bearing and crank Installing the suction pump .......................................... 151 pin ............................................................................. 124 Installing the ignition pulse generator ............................ 152 Checking crankshaft run-out at bearing pin .................... 126 Installing the timing chain ............................................ 152 Cylinder - Nikasil" coating ............................................ 126 Installing the timing chain securing guide ...................... 152 Checking/measuring cylinder ........................................ 126 Installing the timing chain tensioning rail ...................... 152 Checking/measuring the piston ..................................... 127 Installing the timing chain guide rail ............................. 153 Checking the piston ring end gap .................................. 127 Installing the balance weight ........................................ 153 Piston/cylinder - determining the mounting clearance ..... 128 Installing the rotor ....................................................... 153 Checking the oil pumps ................................................ 128 Installing the piston ..................................................... 153 Disassembling the autodecompressor ............................ 128 Installing the cylinder head .......................................... 155 Assembling the autodecompressor ................................. 129 Installing the camshaft ................................................ 156 Checking camshaft ...................................................... 129 Installing the timing chain tensioner ............................. 156 Checking the timing assembly ...................................... 130 Checking the valve clearance ........................................ 157 Preparing the timing chain tensioner for installation ....... 130 Adjusting the valve clearance ........................................ 157 Removing the rocker arm .............................................. 131 Installing the alternator cover ....................................... 157 Removing the valves .................................................... 131 Installing the shift lever ............................................... 158 Changing camshaft bearing .......................................... 132 Installing the valve cover .............................................. 158 Checking valves ........................................................... 132 Installing the spark plug ............................................... 158 Checking valve springs ................................................. 133 Installing the starter motor ........................................... 158 Checking valve spring seat ............................................ 133 Installing the oil filter .................................................. 159 Checking the cylinder head .......................................... 133 Filling up with engine oil .............................................. 159 Checking the rocker arm shafts ..................................... 134 Filling up with gear oil ................................................. 159 Installing the valves ..................................................... 134 Removing the engine from the work stand ...................... 160 Installing the rocker arm .............................................. 135 31/CARBURETOR ........................................................... 161 Checking the clutch ..................................................... 135 Choke (EXC AUS/USA, XC.W SIX DAYS) ........................ 161 Checking shift mechanism ........................................... 136 Choke (EXC EU, EXC SIX DAYS) ................................... 161 Preassembling the shift shaft ........................................ 137 Carburetor - adjusting the idle speed ............................. 161 Disassembling the main shaft ....................................... 137 Emptying the carburetor float chamber .......................... 162 Assembling the main shaft ........................................... 138 Removing the carburetor .............................................. 163 Disassembling the countershaft .................................... 138 Installing the carburetor ............................................... 163 Assembling the countershaft ......................................... 139 Checking/adjusting the carburetor components ............... 164 Checking the transmission ............................................ 139 Checking the throttle valve sensor ................................. 165 Premounting the kickstarter shaft .................................. 140 Disassembling the carburetor ........................................ 165 Checking the electric starter mode ................................ 141 Checking the choke slide .............................................. 168 Removing the freewheel ............................................... 142 Checking the jet needle................................................ 168 Checking the freewheel ................................................ 142 Checking the throttle slide ............................................ 168 Installing the free wheel ............................................... 142 Checking the needle jet ................................................ 169 30/ENGINE ASSEMBLy ................................................... 144 Checking the float needle valve ..................................... 169 Installing the crankshaft ............................................... 144 Assembling the carburetor ............................................ 169 Installing the transmission shafts .................................. 144 Checking/adjusting the float level .................................. 172 Installing the shift forks ............................................... 144 Checking/setting the throttle slide opening ..................... 172 Installing the shift drum ............................................... 145 Checking/adjusting the accelerator pump ....................... 173 Installing the shift rails ................................................ 145 Adjusting the position of the throttle position sensor ....... 173 Installing the left engine case ....................................... 145 321CLUTCH .................................................................... 175 Installing the free wheel gear ........................................ 146 Checking the fluid level of hydraulic clutch .................... 175 Installing the primary gear ............................................ 146 Changing the hydraulic clutch fluid ............................... 175 Installing the oil pumps ............................................... 146 33fTRANSMISSION ......................................................... 177 Installing the oil pump gears ........................................ 147 Removing the engine sprocket ...................................... 177 Installing the locking lever............................................ 147 Installing the engine sprocket ....................................... 177 Installing the shift drum locating uni! .. .......................... 147 35IWATER PUMP, COOLING SYSTEM .............................. 178 Installing the shift shaft ............................................... 147 Cooling system ............................................................ 178 Installing the kickstarter idler gear ................................ 148 Checking the anti-freeze and coolant level ..................... 178 Installing the kickstarter shaft ...................................... 148 Checking the coolant level ............................................ 179 Installing the starter idler gear ...................................... 148 Draining coolant .......................................................... 179 Installing the torque limiter .......................................... 148 Refilling coolant .......................................................... 180 Installing the balancer shaft ......................................... 149 381LUBRICATION SYSTEM .............................................. 181 Installing the outer clutch hub ...................................... 149 Oil circuit ................................................................... 181 Installing the primary gear nut ...................................... 150 Checking engine oil level .............................................. 181 Installing the clutch discs ............................................ 150 Changing engine oil and oil filter, cleaning engine oil Installing the clutch cover ............................................ 150 screen ........................................................................ 182 Installing the water pump cover .................................... 151 Draining engine oil, cleaning engine oil screen ............... 182 Installing the kickstarter ............................................... 151 Removing the oil filter .................................................. 182

TABLE OF CONTENTS 5 Installing the oil filte, .................................................. 183 Page 4 of 5 (EXC AUS) ................................................ 228 Filling up with engine oil .............................................. 183 Page 5 of 5 (EXC AUS) ................................................ 230 Adding engine oil ........................................................ 184 Page 1 of 5 (EXC USA) ................................................ 232 Checking the engine oil p'essu'e ................................... 184 Page 2 of 5 (EXC USA) ................................................ 234 Checking the gea, oil leveL ........................................... 185 Page 3 of 5 (EXC USA) ................................................ 236 Changing gear oil, cleaning gear oil screen ..................... 185 Page 4 of 5 (EXC USA) ................................................ 238 Draining gear oil, cleaning gear oil screen ...................... 185 Page 5 of 5 (EXC USA) ................................................ 240 Filling up with gea, oil ................................................. 186 Page 1 of 4 (XC-W SIX DAYS) ....................................... 242 Adding gea, oil ............................................................ 186 Page 2 of 4 (XC-W SIX DAYS) ....................................... 244 39/1GNITION SYSTEM ..................................................... 188 Page 3 of 4 (XC-W SIX DAYS) ....................................... 246 Checking the ignition system ........................................ 188 Page 4 of 4 (XC-W SIX DAYS) ....................................... 248 Ignition coil - checking the p,imary winding ................... 189 SUBSTANCES ................................................................. 250 Ignition coil - checking the secondary winding ................ 189 AUXILIARY SUBSTANCES ................................................ 252 Checking the spa,k plug connecto' ................................ 190 SPECIAL TOOLS .............................................................. 254 Alternato, - checking the cha,ging coil of the ignition ...... 190 STANDARDS ................................................................... 267 Alternato, - checking the light and battery winding ......... 190 INDEX ............................................................................ 268 Checking the ignition pulse gene,ato, ............................ 191 Removi ng the stato,... ....... ....... ...... ....... ....... ...... .......... 192 Installing the stato, ..................................................... 192 40/ELECTRIC STARTER ................................................... 193 Checking the starte' mota, ........................................... 193 TECHNICAL DATA - ENGINE ............................................ 194 Gapacity - engine oil .................................................... 194 Gapacity - transmission oiL ........................................... 195 Gapacity - coolant ........................................................ 195 TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE ......................................................................... 196 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ........ 197 TECHNICAL DATA - CARBURETOR ................................... 199 all 400 models ............................................................ 199 450 EXC EU/AUS, 450 EXC SIX DAYS .......................... 199 450 EXC USA ............................................................. 199 450 XC-W SIX DAYS USA ............................................ 200 530 EXC EU/AUS, 530 EXC SIX DAYS .......................... 200 530 EXC USA ............................................................. 200 530 XC-W SIX DAYS USA ............................................ 201 TECHNICAL DATA - CARBURETOR TIGHTENING TORQU ES ....... .................... .................... ........................ 202 TECHNICAL DATA - CHASSIS .......................................... 203 Lighting equipment ..................................................... 204 Ti,es .......................................................................... 204 Gapacity - fuel.... ...... .............. ...... .............. ...... ........... 204 TECHNICAL DATA - FORK ................................................ 205 TECHNICAL DATA - SHOCK ABSORBER ........................... 206 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 207 CLEAN I NG...... .................... ....... ............. ....... ................. 208 Clean i ng the motorcycle................. ....... ............. .......... 208 STORAGE ....................................................................... 209 Sto'age ....................................................................... 209 Putting into ope,ation afie, sto,age ............................... 209 SERVICE SCHEDULE ....................................................... 210 Service schedule ......................................................... 210 Service wo,k (as additional o'de') .................................. 211 WIRING DIAGRAM .......................................................... 212 Page 1 of 5 (EXC EU, EXC SIX DAyS) ............................ 212 Page 2 of 5 (EXC EU, EXC SIX DAyS) ............................ 214 Page 3 of 5 (EXC EU, EXC SIX DAyS) ............................ 216 Page 4 of 5 (EXC EU, EXC SIX DAyS) ............................ 218 Page 5 of 5 (EXC EU, EXC SIX DAyS) ............................ 220 Page 1 of 5 (EXC AUS) ................................................ 222 Page 2 of 5 (EXC AUS) ................................................ 224 Page 3 of 5 (EXC AUS) ................................................ 226 TABLE OF CONTENTS 5 Installing the oil filte, .................................................. 183 Page 4 of 5 (EXC AUS) ................................................ 228 Filling up with engine oil .............................................. 183 Page 5 of 5 (EXC AUS) ................................................ 230 Adding engine oil ........................................................ 184 Page 1 of 5 (EXC USA) ................................................ 232 Checking the engine oil p'essu'e ................................... 184 Page 2 of 5 (EXC USA) ................................................ 234 Checking the gea, oil leveL ........................................... 185 Page 3 of 5 (EXC USA) ................................................ 236 Changing gear oil, cleaning gear oil screen ..................... 185 Page 4 of 5 (EXC USA) ................................................ 238 Draining gear oil, cleaning gear oil screen ...................... 185 Page 5 of 5 (EXC USA) ................................................ 240 Filling up with gea, oil ................................................. 186 Page 1 of 4 (XC-W SIX DAYS) ....................................... 242 Adding gea, oil ............................................................ 186 Page 2 of 4 (XC-W SIX DAYS) ....................................... 244 39/1GNITION SYSTEM ..................................................... 188 Page 3 of 4 (XC-W SIX DAYS) ....................................... 246 Checking the ignition system ........................................ 188 Page 4 of 4 (XC-W SIX DAYS) ....................................... 248 Ignition coil - checking the p,imary winding ................... 189 SUBSTANCES ................................................................. 250 Ignition coil - checking the secondary winding ................ 189 AUXILIARY SUBSTANCES ................................................ 252 Checking the spa,k plug connecto' ................................ 190 SPECIAL TOOLS .............................................................. 254 Alternato, - checking the cha,ging coil of the ignition ...... 190 STANDARDS ................................................................... 267 Alternato, - checking the light and battery winding ......... 190 INDEX ............................................................................ 268 Checking the ignition pulse gene,ato, ............................ 191 Removi ng the stato,... ....... ....... ...... ....... ....... ...... .......... 192 Installing the stato, ..................................................... 192 40/ELECTRIC STARTER ................................................... 193 Checking the starte' mota, ........................................... 193 TECHNICAL DATA - ENGINE ............................................ 194 Gapacity - engine oil .................................................... 194 Gapacity - transmission oiL ........................................... 195 Gapacity - coolant ........................................................ 195 TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE ......................................................................... 196 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ........ 197 TECHNICAL DATA - CARBURETOR ................................... 199 all 400 models ............................................................ 199 450 EXC EU/AUS, 450 EXC SIX DAYS .......................... 199 450 EXC USA ............................................................. 199 450 XC-W SIX DAYS USA ............................................ 200 530 EXC EU/AUS, 530 EXC SIX DAYS .......................... 200 530 EXC USA ............................................................. 200 530 XC-W SIX DAYS USA ............................................ 201 TECHNICAL DATA - CARBURETOR TIGHTENING TORQU ES ....... .................... .................... ........................ 202 TECHNICAL DATA - CHASSIS .......................................... 203 Lighting equipment ..................................................... 204 Ti,es .......................................................................... 204 Gapacity - fuel.... ...... .............. ...... .............. ...... ........... 204 TECHNICAL DATA - FORK ................................................ 205 TECHNICAL DATA - SHOCK ABSORBER ........................... 206 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 207 CLEAN I NG...... .................... ....... ............. ....... ................. 208 Clean i ng the motorcycle................. ....... ............. .......... 208 STORAGE ....................................................................... 209 Sto'age ....................................................................... 209 Putting into ope,ation afie, sto,age ............................... 209 SERVICE SCHEDULE ....................................................... 210 Service schedule ......................................................... 210 Service wo,k (as additional o'de') .................................. 211 WIRING DIAGRAM .......................................................... 212 Page 1 of 5 (EXC EU, EXC SIX DAyS) ............................ 212 Page 2 of 5 (EXC EU, EXC SIX DAyS) ............................ 214 Page 3 of 5 (EXC EU, EXC SIX DAyS) ............................ 216 Page 4 of 5 (EXC EU, EXC SIX DAyS) ............................ 218 Page 5 of 5 (EXC EU, EXC SIX DAyS) ............................ 220 Page 1 of 5 (EXC AUS) ................................................ 222 Page 2 of 5 (EXC AUS) ................................................ 224 Page 3 of 5 (EXC AUS) ................................................ 226

MEANS OF REPRESENTATION 6 ~ balsus.d The symbols used are explained in the following. Identifies an expected reaction (e.g. of a work step or a function). x Identifies an unexpected reaction (e.g. of a work step or a function). Identifies a page reference (more information is provided on the specified page). • I Indicates information with more details or tips . » Indicates the result of a testing step. v Identifies a voltage measurement. A Identifies a current measurement. Identifies a resistance measurement. Fannaa used The typographical formals used in this document are explained below. Specific name Identifies a specific name. Identifies a protected name. Identifies a brand available on the open market. MEANS OF REPRESENTATION 6 ~ balsus.d The symbols used are explained in the following. Identifies an expected reaction (e.g. of a work step or a function). x Identifies an unexpected reaction (e.g. of a work step or a function). Identifies a page reference (more information is provided on the specified page). • I Indicates information with more details or tips . » Indicates the result of a testing step. v Identifies a voltage measurement. A Identifies a current measurement. Identifies a resistance measurement. Fannaa used The typographical formals used in this document are explained below. Specific name Identifies a specific name. Identifies a protected name. Identifies a brand available on the open market.

IMPORTANT NOTES 7 WalTl!!IJ The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM deller.net; otherwise, all warranty claims will be void. No warranty claim can be honored for damage resulting from manipulation and/or other changes to the vehicle. FUll, 0111, etc. You should use the fuels, oils and greases according to specifications as listed in the repair manual. SJI!!re Jl!!rtI accessories Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any resulting damage or loss. You will find the current KIM PDwerPiris for your vehicle on the KTM website. International KTM Website, httpdlwww.ktm.com Work rules Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in parentheses. Ex, valve spring compressor (59029019000) During assembly, non·reusable parts (e.g. self·locking screws and nuts, seals and seal rings, O'rings, pins, lock washers) must be replaced by new parts. If thread lock (e.g. Loctite e ) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its usage. Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or worn parts. Following repairs or servicing, the vehicle must be checked for roadworthiness. NDtIIIwaml!IP Pay close attention to the noteslwarnings. • Info I Various information and warning labels are affixed to the vehicle. Do not remove informationlWarning labels. If they are miss- ing, you or others may not recognize potential hazards and may therefore be injured. Grades 01 risks n Danger W Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken. Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken. * Warning 'f1" Identifies a danger that will lead to environmental damage if the appropriate measures are not taken. RIJI!!lr manual - It is imperative that you read this owner's manual carefully and completely before the start of work. It contains useful information and many tips on how to repair and maintain your vehicle. - This manual assumes that the necessary special KTM tools and workplace and workshop equipment are available. IMPORTANT NOTES 7 WalTl!!IJ The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM deller.net; otherwise, all warranty claims will be void. No warranty claim can be honored for damage resulting from manipulation and/or other changes to the vehicle. FUll, 0111, etc. You should use the fuels, oils and greases according to specifications as listed in the repair manual. SJI!!re Jl!!rtI accessories Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any resulting damage or loss. You will find the current KIM PDwerPiris for your vehicle on the KTM website. International KTM Website, httpdlwww.ktm.com Work rules Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in parentheses. Ex, valve spring compressor (59029019000) During assembly, non·reusable parts (e.g. self·locking screws and nuts, seals and seal rings, O'rings, pins, lock washers) must be replaced by new parts. If thread lock (e.g. Loctite e ) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its usage. Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or worn parts. Following repairs or servicing, the vehicle must be checked for roadworthiness. NDtIIIwaml!IP Pay close attention to the noteslwarnings. • Info I Various information and warning labels are affixed to the vehicle. Do not remove informationlWarning labels. If they are miss- ing, you or others may not recognize potential hazards and may therefore be injured. Grades 01 risks n Danger W Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken. Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken. * Warning 'f1" Identifies a danger that will lead to environmental damage if the appropriate measures are not taken. RIJI!!lr manual - It is imperative that you read this owner's manual carefully and completely before the start of work. It contains useful information and many tips on how to repair and maintain your vehicle. - This manual assumes that the necessary special KTM tools and workplace and workshop equipment are available.

SERIAL NUMBERS B The chassis number. is stamped on the steering head on the right. (EXC ElIfAUS, all SIX DAYS models) The type label 0 is fixed to the front of the steering head. (EXC USA) The type label USA. is fixed to the front of the steering head. (EXC USA) The type label Canada. is fixed to the front of the front pipe. K~ number (all EXC madllS) The key number. for the steering lock is stamped onto the key connector. 50012!>-10 SERIAL NUMBERS B The chassis number. is stamped on the steering head on the right. (EXC ElIfAUS, all SIX DAYS models) The type label 0 is fixed to the front of the steering head. (EXC USA) The type label USA. is fixed to the front of the steering head. (EXC USA) The type label Canada. is fixed to the front of the front pipe. K~ number (all EXC madllS) The key number. for the steering lock is stamped onto the key connector. 50012!>-10

SERIAL NUMBERS 300397-10 (EXC USA) The key number. for the ignition lock is shown on the KEYCODECARD. • Info I You need the key number to order a replacement key. Keep the KEYCODE- CARD in a safe place. The engine number. is stamped on the left side of the engine under the engine sprocket. The fork part number. is stamped on the inner side of the fork stub. The shock absorber part number 0 is stamped on the top of the shock absorber above the adjusting ring on the engine side. 9 SERIAL NUMBERS 300397-10 (EXC USA) The key number. for the ignition lock is shown on the KEYCODECARD. • Info I You need the key number to order a replacement key. Keep the KEYCODE- CARD in a safe place. The engine number. is stamped on the left side of the engine under the engine sprocket. The fork part number. is stamped on the inner side of the fork stub. The shock absorber part number 0 is stamped on the top of the shock absorber above the adjusting ring on the engine side. 9

MOTORCYCLE Note Danger 01 damage The parked vehicle may roll away or fall over. - Always place the vehicle on a firm and even surface. - Raise the motorcycle at the frame underneath the engine. I Lift stand (54829055000) ( .. p. 255) ,/ The wheels should no longer touch the ground. - Secure the motorcycle against falling over. RlmDYinllll1 mDta ~11 from 1111 lift stand Note Danger 01 damage The parked vehicle may roll away or fall over. - Always place the vehicle on a firm and even surface. - Remove the motorcycle from the lift stand. - Remove the lift stand. - To park the motorcycle, press the side stand. to the ground with your foot and lean the motorcycle on it. • Info 10 I When you are riding, the side stand must be folded up and secured with the rubber band. ~ Danpr W Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness andlor death. Note - When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine. - Always warm up the engine at low engine speeds. • Info I If the motorcycle is unwilling to start, the cause may be old fuel in the float chamber. The flammable elements of the fuel evaporate after a long time of standing. If the float chamber is filled with fresh fuel, the engine starts immediately. Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again. Motorcycle has been out of use lor more than 1 week - Empty the carburetor float chamber. ( .. p. 162) - Turn handle. of the fuel tap to the ON position. (Figure 500137-10" p. 68) ,/ Fuel can flow from the fuel tank to the carburetor. - Raise the motorcycle off of the stand and secure the stand with rubber band •. - Shift transmission to neutral. (EXC USA) - Turn the key in the ignition lock to the position O. (EXC USA) - Turn the emergency OFF switch to the position O. MOTORCYCLE Note Danger 01 damage The parked vehicle may roll away or fall over. - Always place the vehicle on a firm and even surface. - Raise the motorcycle at the frame underneath the engine. I Lift stand (54829055000) ( .. p. 255) ,/ The wheels should no longer touch the ground. - Secure the motorcycle against falling over. RlmDYinllll1 mDta ~11 from 1111 lift stand Note Danger 01 damage The parked vehicle may roll away or fall over. - Always place the vehicle on a firm and even surface. - Remove the motorcycle from the lift stand. - Remove the lift stand. - To park the motorcycle, press the side stand. to the ground with your foot and lean the motorcycle on it. • Info 10 I When you are riding, the side stand must be folded up and secured with the rubber band. ~ Danpr W Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness andlor death. Note - When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine. - Always warm up the engine at low engine speeds. • Info I If the motorcycle is unwilling to start, the cause may be old fuel in the float chamber. The flammable elements of the fuel evaporate after a long time of standing. If the float chamber is filled with fresh fuel, the engine starts immediately. Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again. Motorcycle has been out of use lor more than 1 week - Empty the carburetor float chamber. ( .. p. 162) - Turn handle. of the fuel tap to the ON position. (Figure 500137-10" p. 68) ,/ Fuel can flow from the fuel tank to the carburetor. - Raise the motorcycle off of the stand and secure the stand with rubber band •. - Shift transmission to neutral. (EXC USA) - Turn the key in the ignition lock to the position O. (EXC USA) - Turn the emergency OFF switch to the position O.

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2008 KTM 450 EXC-R, 450 EXC-R SIX DAYS, 450 EX SIX DAYSC-R, 450 XCR-W, 530 EXC-R, 530 XCR-W Motorcycle also Covers Engine Servic

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