KTM 400 EXC EU User Manual

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OWNER'S MANUAL 2011

400 EXC EU

400 EXC Factory Edition EU

400 EXC AUS

450 EXC EU

450 EXC Factory Edition EU

450 EXC AUS

450 EXC SIX DAYS EU

450 XC-W SIX DAYS USA

530 EXC EU

530 EXC Factory Edition EU

530 EXC AUS

530 EXC SIX DAYS EU

530 XC-W SIX DAYS USA

Art. no. 3211690en

Table of Contents4
Means of Representation7
Important Information8
View of Vehicle10
- View of the Vehicle from the Left Front (Example)10
- View of the Vehicle from the Right Rear (Example)11
Serial Numbers12
- Chassis Number12
- Type Label12
- Engine Number12
- Key Number (All EXC Models)12
- Fork Part Number12
- Shock Absorber Part Number13
Controls14
- Clutch Lever14
- Choke (EXC EU, EXC Factory Edition, EXC SIX DAYS)14
- Hand Brake Lever14
- Throttle Grip14
- Short Circuit Button (XC-W SIX DAYS)14
- Short Circuit Button (All EXC Models)15
- Light Switch (All EXC Models)15
- Turn Signal Switch (All EXC Models)15
- Horn Button (All EXC Models)15
- Emergency off Switch (EXC AUS)15
- Electric Starter Button (EXC AUS)16
- Electric Starter Button (EXC EU, EXC Factory Edition, EXC SIX DAYS, XC-W SIX DAYS)16
- Light Switch (XC-W SIX DAYS)16
- Overview of Indicator Lamps (All EXC Models)16
- Speedometer16
- Speedometer Activation and Test17
- Tripmaster Switch17
- Setting Kilometers or Miles17
- Setting the Clock18
- Adjusting the Speedometer Functions18
- Querying the Lap Time19
- Display Mode SPEED (Speed)19
- Display Mode SPEED/H (Service Hours)19
- Display Mode SPEED/CLK (Clock)20
- Display Mode SPEED/LAP (Lap Time)20
- Display Mode SPEED/ODO (Odometer)20
- Display Mode SPEED/TR1 (Trip Master 1)20
- Display Mode SPEED/TR2 (Trip Master 2)21
- Display Mode SPEED/A1 (Average Speed 1)21
- Display Mode SPEED/A2 (Average Speed 2)21
- Display Mode SPEED/S1 (Stop Watch 1)22
- Display Mode SPEED/S2 (Stop Watch 2)22
- Opening Filler Cap23
- Closing Filler Cap23
- Fuel Tap24
- Choke (EXC AUS, XC-W SIX DAYS)24
- Shift Lever24
- Kick Starter25
- Foot Brake Lever25
- Side Stand25
- Steering Lock (All EXC Models)25
- Locking the Steering (All EXC Models)26
- Unlocking the Steering (All EXC Models)26
Putting into Operation27
- Advice on First Use27
- Running-In the Engine28
- Preparing Vehicle for Arduous Riding Conditions28
- Preparations for Riding on Dry Sand28
- Preparations for Riding on Wet Sand29
- Preparing for Rides on Wet and Muddy Surfaces30
- Preparing for Rides at High Temperature and Slow Speed31
- Preparing for Rides at Low Temperatures or in Snow31
Riding Instructions32
- Checks and Maintenance before Putting into Operation32
- Starting32
- Starting up33
- Shifting, Riding33
- Braking33
- Stopping, Parking34
- Refueling34
Service Schedule36
- Service Work (as Additional Order)37
Tuning the Chassis38
- Checking the Basic Suspension Setting against the Rider's Weight38
- Compression Damping of Shock Absorber38
- Adjusting High-Speed Compression Damping of the Shock Absorber38
- Adjusting the Low-Speed Compression Damping of the Shock Absorber39
- Adjusting Rebound Damping of the Shock Absorber39
- Measuring Rear Wheel Sag Unloaded40
- Checking the Static Sag of the Shock Absorber40
- Checking the Riding Sag of the Shock Absorber40
- Adjusting the Spring Preload of the Shock Absorber41
- Adjusting the Riding Sag41
- Checking Basic Setting of Fork42
- Adjusting the Compression Damping of the Fork42
- Adjusting the Rebound Damping of the Fork42
- Adjusting Spring Preload of the Fork43
- Fork Offset (XC-W SIX DAYS)43
- Setting the Fork Offset X (XC-W SIX DAYS)43
- Handlebar Position44
- Adjusting Handlebar Position44
Service Work on the Chassis45
- Raising the Motorcycle with the Lift Stand45
- Removing the Motorcycle from the Lift Stand45
- Bleeding Fork Legs45
- Cleaning the Dust Boots of the Fork Legs45
- Loosening the Fork Protector46
- Positioning the Fork Protector46
- Removing the Fork Legs46
- Installing Fork Legs47
- Removing the Fork Protector47
- Installing the Fork Protector48
- Removing the Lower Triple Clamp48
- (EXC Factory Edition, EXC SIX DAYS, XC-W SIX DAYS)48
- Installing the Lower Triple Clamp (EXC Factory Edition, EXC SIX DAYS, XC-W SIX DAYS)48
- Removing the Lower Triple Clamp (EXC EU/AUS)50
- Installing the Lower Triple Clamp (EXC EU/AUS)51
- Checking the Steering Head Bearing Play52
- (EXC Factory Edition, EXC SIX DAYS, XC-W SIX DAYS)53
- Adjusting Play of Steering Head Bearing (EXC EU/AUS)53
- Greasing the Steering Head Bearing53
- Removing the Shock Absorber54
- Installing the Shock Absorber54
- Removing the Front Fender54
- Installing the Front Fender54
- Removing the Seat55
- Mounting the Seat55
- Removing the Air Filter Box Lid55
- Installing the Air Filter Box Lid55
- Removing the Air Filter55
- Installing the Air Filter56
- Cleaning the Air Filter and Air Filter Box56
- Removing Main Silencer57
- Installing the Main Silencer57
- Changing the Glass Fiber Yarn Filling of the Main Silencer57
- Removing the Fuel Tank58
- Installing the Fuel Tank59
- Checking for Chain Dirt Accumulation60
- Cleaning the Chain60
- Checking the Chain Tension60
- Adjusting the Chain Tension61
- Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide61
- Adjusting Chain Guide63
- Checking the Throttle Cable Routing63
- Adjusting the Basic Position of the Clutch Lever64
- Checking the Fluid Level of Hydraulic Clutch64
- Changing the Hydraulic Clutch Fluid64
Brakes66
- Checking Free Travel of Hand Brake Lever66
- Adjusting the Basic Position of the Hand Brake Lever (XC-W SIX DAYS)66
- Adjusting Free Travel of Hand Brake Lever (All EXC Models)66
- Checking the Brake Discs67
- Checking the Brake Fluid Level of the Front Brake67
- Adding Front Brake Fluid67
- Checking the Front Brake Linings68
- Changing the Front Brake Linings69
- Checking the Free Travel of the Foot Brake Lever70
- Adjusting the Basic Position of the Foot Brake Lever70
- Checking Rear Brake Fluid Level71
- Adding Brake Fluid to the Rear Brake Circuit71
- Checking Rear Brake Linings72
- Changing the Rear Brake Linings72
Wheels, Tires75
- Removing Front Wheel75
- Installing the Front Wheel75
- Removing the Rear Wheel76
- Installing the Rear Wheel76
- Checking the Tire Condition77
- Checking Tire Air Pressure78
- Checking Spoke Tension78
Electrical System80
- Removing the Battery80
- Installing the Battery80
- Recharging the Battery80
- Removing the Main Fuse81
- Installing the Main Fuse81
- Changing the Fuse of the Radiator Fan (EXC SIX DAYS, XC-W SIX DAYS)82
- Removing Headlight Mask with Headlight82
- Refitting the Headlight Mask with the Headlight83
- Changing the Headlight Bulb83
- Checking the Headlight Adjustment84
- Adjusting the Headlight Range84
- Changing the Speedometer Battery84
Cooling System86
- Checking the Anti-Freeze and Coolant Level86
- Checking the Coolant Level86
- Draining Coolant87
- Refilling Coolant87
Tuning the Engine89
- Checking the Play in the Throttle Cable89
- Adjusting the Play in the Throttle Cable89
- Carburetor - Idle89
- Carburetor - Adjusting the Idle Speed90
- Emptying the Carburetor Float Chamber91
- Checking the Basic Position of the Shift Lever91
- Adjusting the Basic Position of the Shift Lever92
Service Work on the Engine93
- Checking Engine Oil Level93
- Changing Engine Oil and Oil Filter, Cleaning Engine Oil Screen93
- Draining Engine Oil, Cleaning Engine Oil Screen93
- Removing the Oil Filter94
- Installing the Oil Filter94
- Filling up with Engine Oil95
- Adding Engine Oil95
- Checking the Gear Oil Level96
- Changing Gear Oil, Cleaning Gear Oil Screen96
- Draining Gear Oil, Cleaning Gear Oil Screen96
- Filling up with Gear Oil97
- Adding Gear Oil97
Cleaning, Care99
- Cleaning the Motorcycle99
- Protection for Winter Operation100
Storage101
- Putting into Operation after Storage101
Troubleshooting102
Technical Data - Engine104
- Capacity - Engine Oil104
- Capacity - Transmission Oil105
- Capacity - Coolant105
Technical Data - Engine Tightening Torques106
Technical Data - Carburetor108
- All 400 Models108
- 450 EXC EU/AUS, 450 EXC SIX DAYS, 450 EXC Factory Edition EU108
- 450 XC-W Six Days Usa108
- All 530 EXC Models109
- 530 XC-W Six Days Usa109
Technical Data - Chassis110
- Lighting Equipment111
- Tires111
- Capacity - Fuel111
Technical Data - Fork112
Technical Data - Shock Absorber113
Technical Data - Tightening Torques for Chassis114
Substances115
Auxiliary Substances117

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KTM 400 EXC EU Specifications

General

Cooling	Liquid cooled
Transmission	6-speed
Front Brake	Disc brake
Rear Brake	Disc brake
Bore x Stroke	89 mm x 64 mm
Starter	Electric starter
Ground Clearance	355 mm
ABS	No
Engine Type	Single-cylinder, 4-stroke
Displacement	398.6 cc
Fuel System	Keihin carburetor
Front Suspension	WP USD forks
Rear Suspension	WP shock absorber
Fuel Tank Capacity	8.5 l
Frame	Central double-cradle type 25CrMo4 steel