Name: KTM 400 XC-W USA 2009
Brand: KTM
Rating: 5 (1 reviews)

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Table of Contents2
Means of Representation6
Important Notes7
Serial Numbers8
- Chassis Number8
- Type Label8
- Key Number (All EXC Models)8
- Engine Number9
- Fork Part Number9
- Shock Absorber Part Number9
Motorcycle10
- Raising the Motorcycle with the Lift Stand10
- Removi Ng the Motorcycle from the I Ift Stand10
- Starting10
- Starting the Motorcycle for a Check11
Ollfork, TRIPLE CLAMP12
- Adjusting the Compression Damping of the Fork12
- Adjusling Ihe Rebound Damping of Ihe Fork12
- Adjusling Spring Preload of Ihe Fork12
- Bleeding Fork Legs13
- Cleaning the Dust Bools of Ihe Fork Legs13
- Loosening the Fork Protector13
- Positioning the Fork Protector14
- Removing the Fork Legs14
- Inslalling Fork Legs14
- Removing the Fork Proteclor15
- Inslalling Ihe Fork Protector15
- Performing a Fork Service16
- Disassembling the Fork Legs16
- Cartridge Disassembly19
- Disassembling the Compression Damping Fitting21
- Checking the Fork Legs21
- Assembling Ihe Compression Damping Fitting22
- Assembling Ihe Cartridge23
- Assembling the Fork Legs25
- Greasing the Steering Head Bearing29
- Removing the Lower Triple Clamp (EXC USA, All SIX DAYS Models)29
- Inslalling Ihe Lower Triple Clamp (EXC USA, All SIX DAYS Models)29
- Removing the Lower Triple Clamp (EXC EU/AUS)31
- Installing the Lower Triple Clamp (EXC Euiaus)32
- Fork Offset (XC-W SIX DAYS)33
- Setting the Fork Offset (XC-W SIX DAYS)34
- Checking the Steering Head Bearing Play34
- SIX DAYS Models)34
- Adjusling Play of Steering Head Bearing (EXC EU/AUS)35
02/Handlebar, Instruments36
- Handlebar Position36
- Adjusting Handlebar Position36
- Adjusling the Basic Position of Ihe Clulch Lever36
- Checking the Choke Cable Routing37
- Exc Six Days)37
- Checking the Choke Cable Play (EXC EU, EXC SIX DAYS)37
- Adjusting the Choke Cable Play (EXC EU, EXC SIX DAYS)37
- Checking the Throttle Cable Routing37
- Checking the Play in Ihe Throttle Cable38
- Adjusling the Play in the Throttle Cable38
03/Frame39
- Removing the Engine Sprocket Cover39
- Installing the Engine Sprocket Cover39
04/Shock ABSORBER, SWINGARM40
- Adjusting High-Speed Compression Damping of the Shock Absorber40
- Adjusting the Low-Speed Compression Damping of Ihe Shock Absorber40
- Adjusting Rebound Damping of the Shock Absorber41
- Measuring Rear Wheel Sag Unloaded41
- Checking the Static Sag of the Shock Absorber41
- Checking Ihe Riding Sag of Ihe Shock Absorber42
- Adjusting the Spring Preload of the Shock Absorber42
- Adjusting the Riding Sag43
- Removi Ng the Shock Absorber43
- Installing the Shock Absorber43
- Perform a Shock Absorber Service44
- Removing the Spring44
- Disassembling the Damper45
- Disassembling the Pislon Rod46
- Disassembling the Seal Ring Retainer47
- Replacing the Pilot Bushing48
- Checking the Damper48
- Disassembling the Rebound Adjuster49
- Removing the Heim Joint50
- Installing the Heim Joint50
- Assembling the Rebound Adjuster51
- Assembling the Seal Ring Retainer52
- Assembling the Piston Rod52
- Assembling the Damper54
- Bleeding and Filling the Damper56
- Filling Ihe Damper Wilh Nitrogen58
- Installing the Spring59
- Changing the Heim Joint60
05/Exhaust62
- Removing the Manifold62
- Installing the Manifold62
- Removi Ng Mai N si Lencer62
- Installing the Main Silencer62
- Changing the Glass Fiber Yarn Filling of the Main Silencer63
06/Air Filter64
- Removing the Air Filter Box Lid64
- Installing the Air Filter Box Lid64
- Removing the Air Filter64
- Installing the Air Filter64
- Cleaning the Air Filter and Air Filler Box65
- Removing the Carburetor Connection Boot65
- Installing the Carburetor Connection Boot65
07/Fuel Tank, Seat, Trim66
- Opening Filler Cap66
- Closing Filler Cap66
- Removi Ng the Seal66
- Mounting the Seal66
- Removing the Fuel Tank66
- Installing the Fuel Tank67
- Fuel Tap68
08!Mask, Fender69
- Removi Ng the Front Fender69
- Install I Ng the Front Fender69
- Removing Headlight Mask with Headlight69
- Refitting the Headlight Mask with the Headlight69
09/Front Wheel71
- Removi Ng Front Wheel71
- Checking the Brake Discs72
- Removing the Iront Brake Disc72
- Install I Ng the Front Wheel73
- Installing the Front Brake Disc73
- Checking the Tire Condition73
- Checking Tire Air Pressure73
- Checking Spoke Tension74
Lo/Rear WHEEL75
- Removing the Rear Wheel75
- Installing the Rear Wheel75
- Removing the Rear Brake Disc76
- Installing the Rear Brake Disc76
- Checking the Chain Tension76
- Adjusting the Chain Tension77
- Adjusting Chain Guide78
- Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide78
- Checking for Chain Dirt Accumulation80
- Clean I Ng the Chai N80
11IWIRING HARNESS, Battery81
- Removing the Main Fuse81
- Installing the Main Fuse81
- XC-W Six Days)81
- Removi Ng the Battery82
- Installing the Battery82
- Rechargi Ng the Battery82
- Checking the Quiescent Current83
- Checking the Charging Voltage83
- Checking the Voltage Regulator84
- Checking the Starter Relay85
13/Brake System86
- Checking the Front Brake Linings86
- Removing Front Brake Linings86
- Installing the Front Brake Linings86
- Changing the Front Brake Linings87
- Checking Free Travel of Hand Brake Lever88
- (XC-W SIX Days)89
- Models)89
- Checking the Brake Iluid Level of the Iront Brake89
- Adding Iront Brake Iluid90
- Changing the Iront Brake Iluid90
- Checking Rear Brake Linings91
- Removing Rear Brake Linings92
- Mounting Rear Brake Linings92
- Changing the Rear Brake Linings93
- Checking the Iree Travel of the Loot Brake Lever94
- Adjusting the Basic Position 01 the Loot Brake Lever94
- Checking Rear Brake Iluid Level95
- Adding Brake Fluid to the Rear Brake Circuit95
- Changing the Rear Brake Iluid96
14/Lighting SYSTEM, INSTRUMENTS98
- Adjusting the Speedometer Lunctions98
- Setting Kilometers or Miles98
- Activating the Additional Lunctions99
- Setting the Wheel Circumference99
- Setting the Clock100
- Checking the Headlight Adjustment100
- Adjusting the Headlight Range100
Engine101
- Removing the Engine101
Installing the Engine102
Disassembling the Engine104
- Preparations104
- Draining the Engine Oil104
- Removing the Oil Lilter104
- Draining the Gear Oil, Removing the Gear Oil Screen104
- Removi Ng the Starter Motor105
- Removi Ng the Spark Pi Ug105
- Removing the Valve Cover105
- Removing the Shift Lever105
- Removi Ng the Alternator Cover106
- Positioning the Engine at Ignition Top Dead Center106
- Removing the Timing Chain Tensioner107
- Removing the Camshaft107
- Removing the Cylinder Head107
- Removing the Piston107
- Removi Ng the Rotor108
- Removing the Balance Weight108
- Removing the Timing Chain Guide Rail108
- Removing the Timing Chain Tensioning Rail109
- Removing the Timing Chain Securing Guide109
- Removing the Timing Chain109
- Removing the Ignition Pulse Generator109
- Removing the Suction Pump109
- Removing the Kickstarter110
- Removing the Water Pump Cover110
- Disassembling the Clutch Disks111
- Removi Ng the Pri Mary Gear Nut111
- Removing the Outer Clutch Hub111
- Removing the Balancer Shaft112
- Removing the Torque Limiter112
- Removing the Starter Idler Gear112
- Removing the Kickstarter Idler Gear112
- Removing the Kickstarter Idler Gear113
- Removing the Shift Shaft113
- Removing the Shift Drum Locating Unit113
- Removing the Locking Lever113
- Removing the Oil Pump Gears113
- Removing the Oil Pumps114
- Removing the Primary Gear114
- Removing the Iree Wheel Gear114
- Removi Ng the Left Section 01 the Engi Ne Case115
- Removing the Shift Rails116
- Removing the Shift Drum116
- Removing the Shift Lorks116
- Removing the Transmission Shafts116
- Removing the Crankshaft117
Engine - Work on the Individual Parts118
- Working on the Right Section of the Engine Case118
- Working on the Left Section of the Engine Case119
- Removing the Oil Pressure Regulator Valve121
- Checking Spring Length of Oil Pressure Regulator Valve121
- Installing the Oil Pressure Regulator Valve121
- Removing the Crankshaft Seal Ring in the Clutch Cover121
- Installing the Crankshaft Seal Ring in the Clutch Cover121
- Removing the Water Pump122
- Installing the Water Pump122
- Checking the Balancer Shaft123
- Removing the Timing Chain Sprocket123
- Installing the Timing Chain Sprocket124
- Changing the Connecting Rod, Conrad Bearing and Crank Pin124
- Checking Crankshaft Run-Out at Bearing Pin126
- Cylinder - Nikasil" Coating126
- Checking/Measuring Cylinder126
- Checking/Measuring the Piston127
- Checking the Piston Ring End Gap127
- Piston/Cylinder - Determining the Mounting Clearance128
- Checking the Oil Pumps128
- Disassembling the Autodecompressor128
- Assembling the Autodecompressor129
- Checking Camshaft129
- Checking the Timing Assembly130
- Preparing the Timing Chain Tensioner for Installation130
- Removing the Rocker Arm131
- Removing the Valves131
- Changing Camshaft Bearing132
- Checking Valves132
- Checking Valve Springs133
- Checking Valve Spring Seat133
- Checking the Cylinder Head133
- Checking the Rocker Arm Shafts134
- Installing the Valves134
- Installing the Rocker Arm135
- Checking the Clutch135
- Checking Shift Mechanism136
- Preassembling the Shift Shaft137
- Disassembling the Main Shaft137
- Assembling the Main Shaft138
- Disassembling the Countershaft138
- Assembling the Countershaft139
- Checking the Transmission139
- Premounting the Kickstarter Shaft140
- Checking the Electric Starter Mode141
- Removing the Freewheel142
- Checking the Freewheel142
- Installing the Free Wheel142
30/ENGINE Assembly144
- Installing the Crankshaft144
- Installing the Transmission Shafts144
- Installing the Shift Forks144
- Installing the Shift Drum145
- Installing the Shift Rails145
- Installing the Left Engine Case145
- Installing the Free Wheel Gear146
- Installing the Primary Gear146
- Installing the Oil Pumps146
- Installing the Oil Pump Gears147
- Installing the Locking Lever147
- Installing the Shift Drum Locating Uni147
- Installing the Shift Shaft147
- Installing the Kickstarter Idler Gear148
- Installing the Kickstarter Shaft148
- Installing the Starter Idler Gear148
- Installing the Torque Limiter148
- Installing the Balancer Shaft149
- Installing the Outer Clutch Hub149
- Installing the Primary Gear Nut150
- Installing the Clutch Discs150
- Installing the Clutch Cover150
- Installing the Water Pump Cover151
- Installing the Kickstarter151
- Installing the Suction Pump151
- Installing the Ignition Pulse Generator152
- Installing the Timing Chain152
- Installing the Timing Chain Securing Guide152
- Installing the Timing Chain Tensioning Rail152
- Installing the Timing Chain Guide Rail153
- Installing the Balance Weight153
- Installing the Rotor153
- Installing the Piston153
- Installing the Cylinder Head155
- Installing the Timing Chain Tensioner156
- Installing the Camshaft157
- Checking the Valve Clearance157
- Adjusting the Valve Clearance157
- Installing the Alternator Cover157
- Installing the Shift Lever158
- Installing the Valve Cover158
- Installing the Spark Plug158
- Installing the Starter Motor158
- Installing the Oil Filter159
- Filling up with Engine Oil159
- Filling up with Gear Oil159
- Removing the Engine from the Work Stand160
31/Carburetor161
- Choke (EXC AUS/USA, XC.W SIX DAYS)161
- Choke (EXC EU, EXC SIX DAYS)161
- Carburetor - Adjusting the Idle Speed161
- Emptying the Carburetor Float Chamber162
- Removing the Carburetor163
- Installing the Carburetor163
- Checking/Adjusting the Carburetor Components164
- Checking the Throttle Valve Sensor165
- Disassembling the Carburetor165
- Checking the Choke Slide168
- Checking the Jet Needle168
- Checking the Throttle Slide168
- Checking the Needle Jet169
- Checking the Float Needle Valve169
- Assembling the Carburetor169
- Checking/Adjusting the Float Level172
- Checking/Setting the Throttle Slide Opening172
- Checking/Adjusting the Accelerator Pump173
- Adjusting the Position of the Throttle Position Sensor173
321Clutch175
- Checking the Fluid Level of Hydraulic Clutch175
- Changing the Hydraulic Clutch Fluid175
Removing the Engine Sprocket177
Installing the Engine Sprocket177
33Ftransmission177
Checking the Anti-Freeze and Coolant Level178
Cooling System178
35Iwater Pump, Cooling System178
Checking the Coolant Level179
Draining Coolant179
Refilling Coolant180
Oil Circuit181
- Checking Engine Oil Level181
- Changing Engine Oil and Oil Filter, Cleaning Engine Oil Screen182
- Draining Engine Oil, Cleaning Engine Oil Screen182
- Removing the Oil Filter182
- Installing the Oil Filte183
- Filling up with Engine Oil183
- Adding Engine Oil184
- Checking the Engine Oil P'essu'e184
- Checking the Gea, Oil Level185
- Changing Gear Oil, Cleaning Gear Oil Screen185
- Draining Gear Oil, Cleaning Gear Oil Screen185
- Filling up with Gea, Oil186
- Adding Gea, Oil186
381Lubrication System181
39/1Gnition System188
- Checking the Ignition System188
- Ignition Coil - Checking the P,Imary Winding189
- Ignition Coil - Checking the Secondary Winding189
- Checking the Spa,K Plug Connecto190
- Alternato, - Checking the Cha,Ging Coil of the Ignition190
- Alternato, - Checking the Light and Battery Winding190
- Checking the Ignition Pulse Gene,Ato191
- Removi Ng the Stato192
- Installing the Stato192
40/Electric Starter193
- Checking the Starte' Mota193
Technical Data - Engine194
- Gapacity - Engine Oil194
- Gapacity - Transmission Oil195
- Gapacity - Coolant195
Technical Data - Tolerance, Wear Limits of Engine196
Technical Data - Engine Tightening Torques197
Technical Data - Carburetor199
- All 400 Models199
- Exc Eu/Aus, 450 Exc Six Days199
- Exc Usa199
- 450 XC-W Six Days Usa200
- Exc Eu/Aus, 530 Exc Six Days200
- Exc Usa200
- 530 XC-W Six Days Usa201
Technical Data - Carburetor Tightening Torques202
Technical Data - Chassis203
- Lighting Equipment204
- Ti,Es204
- Gapacity - Fuel204
Technical Data - Fork205
Technical Data - Shock Absorber206
Technical Data - Chassis Tightening Torques207
Cleaning208
- Clean I Ng the Motorcycle208
Storage209
- Sto'age209
- Putting into Ope,Ation Afie, Sto,Age209
Service Schedule210
- Service Wo,K (as Additional O'de')211
Wiring Diagram212
- EXC EU, EXC SIX Days)212
- EXC EU, EXC SIX Days)214
- EXC EU, EXC SIX Days)216
- EXC EU, EXC SIX Days)218
- EXC EU, EXC SIX Days)220
- Exc Aus)222
- Exc Aus)224
- Exc Aus)226
- Exc Aus)228
- Exc Aus)230
- Exc Usa)232
- Exc Usa)234
- Exc Usa)236
- Exc Usa)238
- Exc Usa)240
- XC-W Six Days)242
- XC-W Six Days)244
- XC-W Six Days)246
- XC-W Six Days)248
Substances250
Auxiliary Substances252
Special Tools254
Standards267
Index268

KTM 400 XC-W USA 2009 User Manual

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Brand	KTM
Model	400 XC-W USA 2009
Category	Motorcycle
Language	English