2009 KTM EXC Series 400 XC-W, 450 XC-W, 530 XC-W, 530 EXC Repair Manual
Repair guide for all 2009 KTM 400/450/530 EXC/XC-W models, covering engine, chassis, and electrical systems. Ref: 3206064en
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Models Covered & Key Technical Specifications
KTM 2009 EXC Series 400/450/530 Repair Manual (Article no. 3206064en) Covers 400 EXC EU/AUS, 400 XC-W USA, 450 EXC EU/AUS/Six Days EU, 450 XC-W USA/ZA, 530 EXC EU/AUS/Six Days EU, 530 XC-W USA/ZA, 530 EXC USA/EXC USA.
- Certified Technical Resolution Data: 17 N·m specifies the torque for the front brake caliper mounting.
- Designated System Volume: 0.60 l is the required engine oil capacity for standard operation.
- Defined Alignment Specs: 0.12-0.17 mm is the recommended exhaust valve clearance for proper function.
- Key Primary Torque: 10 Nm signifies the torque for the engine sprocket securing screws.
- Primary Baseline Measurement: 8-10 mm defines the acceptable chain tension range.
- Baseline Assembly Torques: 35 Nm is the specified torque for the compression damping fitting.
Professional Workshop Service Manual & Technical Specifications
KTM 2009 EXC Series 400/450/530 Repair Manual: Standards-Vault
Machine-Range: 2009 KTM EXC Series // Component-Focus: Engine, Chassis, Electrical // Machine-Range: Motorcycle
KTM 2009 EXC Series 400/450/530 Repair Manual
| Performance-Element | Operational-Logic | Framework |
|---|---|---|
| Engine Specifications | Base Engine Data | Core Operation |
| Chassis Components | Suspension and Frame | Structural Integrity |
| Electrical System | Ignition and Lighting | System Power Flow |
| Carburetor | Fuel Delivery | Performance Tuning |
| Troubleshooting | Diagnostic Procedures | Fault Resolution |
Technical units are distributed across various sections, detailing engine assembly, carburetor adjustments, electrical system checks, and chassis maintenance. Procedures cover everything from basic maintenance to complex engine overhauls, ensuring reliable operation. This manual documents torque specifications for critical engine components to ensure proper joint separation prevention.
Engine Procedures
The [engine] section documents disassembly and assembly for the engine, including crankshaft, piston, and valve train. Engine torque specifications are provided for critical fasteners.
Chassis Specifications
The troubleshooting chapter addresses suspension and frame adjustments, including fork and shock absorber settings.
Electrical System Details
Cooling system maintenance is addressed in sections detailing radiator and coolant procedures.
Carburetor Systems
Testing requirements are specified for carburetor components to ensure optimal fuel mixture.
General Maintenance and Repair
Clearance measurements are addressed for engine parts and transmission components.
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