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KTM 400 EXC - User Manual

KTM 400 EXC
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250 SX-F
250 EXC RACING
400 EXC RACING
450 SX, XC, EXC RACING
525 SX, XC, EXC RACING
OWNER’S MANUAL 2006
ART. NR. 3.211.73EN
ENGLISH

Table of Contents

Questions and Answers

  • B
    Benjamin RosalesAug 14, 2025
    Why does my KTM 400 EXC Motorcycle engine get too hot?
    • G
      Gloria StricklandAug 15, 2025
      If your KTM Motorcycle engine is overheating, several factors could be the cause. First, check and refill the cooling liquid, also inspect the cooling system for any leaks. Ensure there's adequate airflow while riding; consider retrofitting an electric fan if needed. Make sure the cooling system is properly bled and the radiators are clean. If foam is present in the cooling system, replace the coolant with a brand-name antifreeze liquid. Inspect cooling hoses for bends and replace if necessary. Check the thermostat for proper operation (opening temperature 70°C or 158°F). If you have an XC Desert model, check and replace the fan fuse if blown.
  • P
    Peter KelleyAug 18, 2025
    Why my KTM 400 EXC Motorcycle engine will not reach full power?
    • C
      Craig TrujilloAug 18, 2025
      If your KTM Motorcycle isn't reaching its full power, start by checking the fuel system and carburetor for dirt or blockages, and clean them if necessary. Replace the float if it leaks. Ensure the air filter is clean; if it's very dirty, clean or replace it. Inspect the exhaust system for damage and ensure it's tight; replace the glass fiber yarn in the exhaust silencer if needed. Also, check and adjust the valve gap. Finally, check the setting of the hand decompression cable.
  • J
    James TurnerAug 25, 2025
    How to fix KTM 400 EXC Motorcycle when engine doesn’t crank?
    • A
      Anna PerkinsAug 25, 2025
      If your KTM Motorcycle engine doesn't crank with the E-starter, the issue might be a blown fuse. To resolve this, dismount the left paneling and the filter box cover and replace the fuse in the starter relay. Another possibility is a discharged battery; recharge it and investigate the causes of the discharge. Also, ensure the emergency-OFF switch is turned on (Australia only).
  • J
    Joshua WashingtonAug 28, 2025
    What causes a KTM 400 EXC engine to fail to idle?
    • M
      Melissa MorganAug 28, 2025
      If your KTM Motorcycle engine fails to idle, the problem could be a clogged idling jet. Disassemble the carburetor and clean the jets. Also, the spark plug may be defective and require replacement.
  • M
    Miss Michelle AllenAug 31, 2025
    What to do if KTM Motorcycle engine stops or splutters in carburetor?
    • S
      Shane LopezAug 31, 2025
      If your KTM Motorcycle engine stops or sputters in the carburetor, it could be due to insufficient fuel. Clean and check the fuel system and carburetor. Also, check the rubber sleeve and carburetor for a tight fit, as the engine might be taking in air uncontrollably.
  • J
    jacobsloriSep 3, 2025
    Why does my KTM Motorcycle have high oil consumption?
    • N
      nicholasfloresSep 3, 2025
      If your KTM Motorcycle has high oil consumption, check if the hose of the engine ventilation is bent. If it is, dislocate or replace it with a non-buckling ventilation hose. Also, check the engine oil level and correct it if it's too high. If the motor oil is too thin, use a thicker engine oil.
  • M
    Melanie ChenSep 7, 2025
    What to do if horn, flasher lights and E-starter do not work on KTM 400 EXC Motorcycle?
    • A
      Angela BrewerSep 7, 2025
      If the horn, flasher lights, and E-starter on your KTM Motorcycle aren't working, it may be due to a blown fuse in the starter relay. To fix this, dismount the left side paneling and filter box cover, then replace the fuse.
  • K
    Kyle SmithSep 10, 2025
    Why KTM Motorcycle engine does not rev high?
    • S
      Scott EllisSep 10, 2025
      If your KTM Motorcycle engine does not rev high, the carburetor fuel level might be too high because the float needle valve is dirty or worn out. Dismount the carburetor and check if it's worn out. Also, tighten the jets.
  • M
    monicajonesNov 20, 2025
    What to do if KTM 400 EXC Motorcycle engine cranks but doesn’t start?
    • K
      Keith MarshallNov 20, 2025
      If your KTM Motorcycle engine cranks but doesn't start, or won't start with the kickstarter, consider these potential issues. If the motorcycle has been out of operation for more than a week, drain the old fuel from the float chamber. Ensure the fuel tap is open, there's fuel in the tank, and the choke is engaged. If the engine is flooded, 'pump the engine free' by pulling the hand decompression lever, fully revving up the engine, and actuating the kickstarter 5 to 10 times or the E-starter 2 times for 5 seconds each. Clean or replace a sooty or wet spark plug. Adjust the spark plug electrode gap to 0.6 mm. Check for a strong spark at the spark plug by dismounting the spark plug, connecting the ignition cable, and holding it to ground while actuating the starter. If there's no spark, repla...

Summary

Important Information and Introduction

Safety Warnings and Cautions

Key warnings and cautions for safe operation and motorcycle care.

Warranty and Guarantee Information

Details on limited warranty and guarantee terms for the motorcycle.

Introduction to Your KTM Motorcycle

Welcome and advice on using and maintaining the KTM motorcycle.

Operation Instruments

Motorcycle Controls and Levers

Explanation of clutch, brake levers, and handlebar controls.

Starting and Engine Controls

Operation of hot start, decompression, choke, and starter mechanisms.

Electronic Speedometer Functions

Overview of the digital speedometer, its modes, and settings.

Suspension and Steering Adjustments

Guidance on adjusting front fork and rear shock absorber damping and steering.

Driving Instructions

Pre-Ride Checks and Starting Procedures

Essential checks before starting, cold/warm engine starting, and basic riding.

Braking and Stopping

Proper braking techniques and procedures for stopping and parking the motorcycle.

Maintenance

Periodic Maintenance Schedule

Recommended maintenance tasks for rider and workshop based on usage intervals.

Chassis and Engine Maintenance

Detailed procedures for maintaining suspension, brakes, chain, engine, and other components.

Technical Data

Engine Specifications

Detailed specifications for the engine, including oil, settings, and torques.

Chassis Specifications

Technical data for the chassis, including suspension, frame, and tightening torques.

Troubleshooting, Cleaning, and Storage

Troubleshooting Common Issues

Guide to identifying and resolving common engine, electrical, and operational problems.

Motorcycle Cleaning and Storage

Instructions for cleaning the motorcycle and preparing it for storage.

Wiring Diagrams

CDI and Harness Wiring

Electrical diagrams for the CDI unit and associated wiring harnesses.

Main Electrical System Wiring

Comprehensive wiring diagram for the EXC Racing models.

KTM 400 EXC Specifications

General IconGeneral
Displacement398cc
Bore x Stroke89mm x 64mm
Transmission6-speed
Fuel SystemKeihin FCR-MX 39 carburetor
Front BrakeSingle 260mm disc
Rear BrakeSingle 220mm disc
Cooling SystemLiquid-cooled
StarterElectric starter
Rear SuspensionWP Xplor shock absorber

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