KTM 400 EXC FACTORY EDITION EU Operating instructions

REPAIR MANUAL 2009
400 EXC EU
400 EXC AUS
400 XC-W USA
450 EXC EU
450 EXC AUS
450 EXC SIX DAYS EU
450 XC-W USA
450 XC-W ZA
530 EXC EU
530 EXC AUS
530 EXC SIX DAYS EU
530 XC-W USA
530 XC-W ZA
450 EXC USA
530 EXC USA
Article no. 3206064en

INTRODUCTION 1
INTRODUCTION
It is important that you read this owner's manual carefully and completely before the start of work.
Only use ORGINAL KTM SPARE PARTS.
This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified
experts.
The repair manual was written to correspond to the most current state of this model series. We reserve the right to make changes in
the interest of technical advancement without, at the same time, updating this repair manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that repair work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special
equipment that does not belong to the regular scope of delivery.
© 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

CONTENTS 2
CONTENTS
MEANS OF REPRESENTATION ............................................ 6
IMPORTANT NOTES............................................................ 7
LOCATION OF SERIAL NUMBERS ........................................ 8
Chassis number............................................................... 8
Type label....................................................................... 8
Key number (all EXC models) ........................................... 8
Engine number................................................................ 9
Fork part number............................................................. 9
Shock absorber part number............................................. 9
MOTORCYCLE................................................................... 10
Jacking up the motorcycle.............................................. 10
Removing the motorcycle from the work stand.................. 10
Starting ........................................................................ 10
Starting the motorcycle for checking ............................... 11
01/FORK, TRIPLE CLAMP.................................................. 12
Adjusting compression damping of fork ........................... 12
Adjusting rebound damping of fork.................................. 12
Adjusting spring preload of the fork................................. 12
Bleeding fork legs.......................................................... 13
Cleaning the dust boots of the fork legs ........................... 13
Loosening the fork protection.......................................... 13
Positioning the fork protection ........................................ 14
Removing the fork legs................................................... 14
Installing fork legs......................................................... 14
Removing the fork protector............................................ 15
Installing the fork protector ............................................ 15
Performing a fork service................................................ 16
Disassembling the fork legs ............................................ 16
cartridge, disassembling................................................. 19
Disassembling the compression damping fitting ............... 21
Checking the fork legs.................................................... 21
Assembling the compression damping fitting.................... 22
Assembling the cartridge................................................ 23
Assembling the fork legs ................................................ 25
Greasing the steering head bearing.................................. 29
Removing the lower triple clamp (EXC SIX DAYS,
XC‑W USA, EXC USA) .................................................... 29
Installing the lower triple clamp (EXC SIX DAYS,
XC‑W USA, EXC USA) .................................................... 30
Removing the lower triple clamp (EXC EU, EXC AUS,
XC‑W ZA)...................................................................... 30
Installing the lower triple clamp (EXC EU, EXC AUS,
XC‑W ZA)...................................................................... 31
Checking the play of the steering head bearing................. 32
Adjusting play of steering head bearing (EXC SIX DAYS,
XC‑W USA, EXC USA) .................................................... 32
Adjusting play of steering head bearing (EXC EU,
EXC AUS, XC‑W ZA)....................................................... 33
02/HANDLEBAR, INSTRUMENTS....................................... 34
Handlebar position ........................................................ 34
Adjusting handlebar position .......................................... 34
Adjusting basic position of clutch lever............................ 36
Checking the choke cable routing (EXC EU,
EXC SIX DAYS) ............................................................. 36
Checking the choke cable play (EXC EU,
EXC SIX DAYS) ............................................................. 36
Adjusting the choke cable play (EXC EU,
EXC SIX DAYS) ............................................................. 36
Checking of the routing of the throttle cable..................... 37
Checking the play in the throttle cable............................. 37
Adjusting the play in the throttle cable ............................ 37
03/FRAME........................................................................ 38
Removing the engine sprocket cover................................ 38
Installing the engine sprocket cover................................. 38
04/SHOCK ABSORBER, SWINGARM................................... 39
Adjusting high-speed compression damping of the shock
absorber ....................................................................... 39
Adjusting the low-speed compression damping of the
shock absorber .............................................................. 39
Adjusting rebound damping of shock absorber.................. 40
Measuring rear wheel sag unloaded ................................. 40
Checking static sag of shock absorber.............................. 40
Checking riding sag of shock absorber ............................. 41
Adjusting spring preload of the shock absorber................. 41
Adjusting riding sag....................................................... 42
Removing the shock absorber ......................................... 42
Installing the shock absorber .......................................... 42
Performing a shock absorber service................................ 43
Removing the spring ...................................................... 43
Disassembling the shock absorber................................... 44
Disassembling the piston rod.......................................... 45
Disassembling the seal ring retainer ................................ 46
Replacing the pilot bushing............................................ 47
Checking the shock absorber .......................................... 47
Disassembling the rebound adjuster ................................ 48
Removing the heim joint ................................................ 49
Installing the heim joint................................................. 49
Assembling the rebound adjuster .................................... 50
Assembling the seal ring retainer .................................... 51
piston rod, assembling ................................................... 51
Assembling the damper.................................................. 53
Bleeding and filling the damper ...................................... 55
Filling the damper with nitrogen ..................................... 57
Installing the spring....................................................... 58
05/EXHAUST .................................................................... 60
Removing main silencer ................................................. 60
Installing the main silencer ............................................ 60
Removing the manifold .................................................. 60
Installing the manifold................................................... 60
06/AIR FILTER.................................................................. 61
Dismounting the air filter box lid..................................... 61
Installing the air filter box lid.......................................... 61
Removing the air filter ................................................... 61
Installing the air filter .................................................... 61
Cleaning air filter........................................................... 62
Removing the carburetor connection boot ........................ 62
Installing the carburetor connection boot ......................... 62
07/FUEL TANK, SEAT, TRIM.............................................. 63
Opening filler cap.......................................................... 63
Closing filler cap ........................................................... 63
Removing the seat......................................................... 63
Mounting the seat ......................................................... 63
Dismounting the fuel tank .............................................. 63
Installing the fuel tank................................................... 64
Fuel tap........................................................................ 65
08/MASK, FENDER ........................................................... 66
Removing the front fender.............................................. 66
Installing the front fender............................................... 66
Removing headlight mask with headlight (EXC EU,
EXC AUS, EXC SIX DAYS, EXC USA, XC‑W ZA)................. 66
Refitting the headlight mask with the headlight (EXC EU,
EXC AUS, EXC SIX DAYS, EXC USA, XC‑W ZA)................. 66
Removing the start number plate (XC‑W USA) .................. 67

CONTENTS 3
Installing the start number plate (XC‑W USA)................... 67
09/FRONT WHEEL ............................................................ 68
Removing the front wheel............................................... 68
Installing the front wheel................................................ 68
Checking the brake discs................................................ 69
Removing the front brake disc ........................................ 69
Installing the front brake disc ......................................... 70
Checking the tire condition............................................. 70
Checking tire air pressure............................................... 70
Checking spoke tension.................................................. 71
10/REAR WHEEL .............................................................. 72
Removing the rear wheel ................................................ 72
Installing the rear wheel................................................. 72
Removing the rear brake disc.......................................... 73
Installing the rear brake disc .......................................... 73
Checking chain tension when fitting rear wheel ................ 73
Adjusting chain tension - fitting rear wheel ...................... 74
Checking the chain tension ............................................ 74
Adjusting chain tension - after checking .......................... 75
Adjusting the chain tension ............................................ 75
Adjusting chain guide .................................................... 76
Checking the rear sprocket / engine sprocket for wear ....... 76
Checking chain wear...................................................... 77
Checking for chain dirt accumulation .............................. 77
Cleaning the chain......................................................... 77
11/WIRING HARNESS, BATTERY ....................................... 78
Removing a fuse............................................................ 78
Installing the fuse ......................................................... 78
Removing the battery..................................................... 78
Installing the battery...................................................... 79
Recharging the battery................................................... 79
Checking the closed current ........................................... 80
Checking the charging voltage ........................................ 80
Checking the voltage regulator ........................................ 81
Checking the charging current ........................................ 82
Checking the starter relay............................................... 82
13/BRAKE SYSTEM........................................................... 84
Checking the front brake linings...................................... 84
Removing front brake linings .......................................... 84
Mounting front brake linings........................................... 84
Changing the front brake linings ..................................... 85
Checking free travel of hand brake lever........................... 86
Adjusting basic position of handbrake lever (all XC‑W
models) ........................................................................ 86
Adjusting free travel of handbrake lever (all EXC
models) ........................................................................ 86
Checking the brake fluid level of the front brake............... 87
Adding front brake fluid ................................................. 87
Changing the front brake fluid ........................................ 88
Checking rear brake linings ............................................ 89
Removing rear brake linings............................................ 89
Mounting rear brake linings ............................................ 89
Changing the rear brake linings....................................... 90
Checking free travel of foot brake lever ............................ 91
Adjusting basic position of foot brake lever ...................... 91
Checking the brake fluid level of the rear brake ................ 91
Adding rear brake fluid .................................................. 92
Changing the rear brake fluid.......................................... 92
14/LIGHTING SYSTEM, INSTRUMENTS ............................. 94
Adjusting the speedometer functions............................... 94
kilometers or miles, setting............................................. 94
Activating the additional functions .................................. 95
Setting the wheel circumference ..................................... 95
Setting the clock ........................................................... 96
Checking the headlamp setting (EXC EU, EXC AUS,
EXC SIX DAYS, EXC USA, XC‑W ZA)................................ 96
Adjusting the beam width of the headlight (EXC EU,
EXC AUS, EXC SIX DAYS, EXC USA, XC‑W ZA)................. 96
30/ENGINE....................................................................... 98
Removing the engine ..................................................... 98
Installing the engine ...................................................... 99
30/DISASSEMBLING THE ENGINE................................... 101
Preparations................................................................ 101
Draining the engine oil................................................. 101
Removing the oil filter.................................................. 101
Draining the gear oil, removing the gear oil screen .......... 101
Removing the starter engine ......................................... 102
Removing the spark plug.............................................. 102
Removing the valve cover ............................................. 102
Removing the shift lever............................................... 102
Removing the generator cover ....................................... 103
Setting the engine to ignition top dead center ................ 103
Removing the timing chain tensioner............................. 104
Removing the camshaft................................................ 104
Removing the cylinder head.......................................... 104
Removing the piston .................................................... 104
Removing the rotor ...................................................... 105
Removing the balance weight ....................................... 105
Removing the timing chain guide rail ............................ 105
Removing the timing chain tensioning rail...................... 106
Removing the timing chain securing guide..................... 106
Removing the timing chain........................................... 106
Removing the ignition pulse generator ........................... 106
Removing the suction pump ......................................... 106
Removing the kickstarter.............................................. 107
Removing the water pump cover ................................... 107
Removing the clutch cover ........................................... 107
Disassembling the clutch disks ..................................... 108
Removing the primary gear nut ..................................... 108
Removing the outer clutch hub ..................................... 108
Removing the balancer shaft ........................................ 109
Removing the torque limiter ......................................... 109
Removing the starter idler gear ..................................... 109
Removing the kickstarter shaft...................................... 109
Removing the kickstarter idler gear ............................... 110
Removing the shift shaft .............................................. 110
Removing the shift drum locating.................................. 110
Removing the locking lever........................................... 110
Removing the oil pump gears........................................ 110
Removing the oil pumps............................................... 111
Removing the primary gear ........................................... 111
Removing the free wheel gear ....................................... 111
Removing the left section of the engine case.................. 112
Removing the shift rails ............................................... 113
Removing the shift drum.............................................. 113
Removing the shift forks .............................................. 113
Removing the transmission shafts ................................. 113
Removing the crankshaft.............................................. 114
30/ENGINE - WORK ON THE INDIVIDUAL PARTS ............. 115
Working on the right section of the engine case.............. 115
Working on the left section of the engine case................ 116
Removing the oil pressure regulator valve....................... 118
Checking spring length of oil pressure regulator valve...... 118
Installing the oil pressure regulator valve ....................... 118

CONTENTS 4
Removing the crankshaft seal ring in the clutch cover ..... 118
Fitting the crankshaft seal ring into the clutch cover ....... 118
Removing the water pump............................................ 119
Installing the water pump............................................. 119
Checking the balancer shaft ......................................... 120
Removing the timing chain sprocket.............................. 120
Installing the timing chain sprocket............................... 121
Changing the connecting rod, conrod bearing and crank
pin............................................................................. 121
Checking crankshaft run-out at bearing pin .................... 123
cylinder - Nikasil®coating ............................................ 123
Checking/measuring cylinder ........................................ 123
Checking/measuring the piston ..................................... 124
Checking the piston ring end gap .................................. 124
Piston/cylinder - determining the mounting clearance ..... 125
Checking the oil pumps for wear ................................... 125
Disassembling the autodecompressor ............................ 125
Assembling the autodecompressor................................. 126
Checking camshaft ...................................................... 126
Checking the timing assembly ...................................... 127
Preparing the timing chain tensioner for installation ....... 127
Removing the rocker arm.............................................. 128
Removing the valves .................................................... 128
Changing camshaft bearing .......................................... 129
Checking valves........................................................... 129
Checking valve springs ................................................. 130
Checking valve spring seat............................................ 130
Checking the cylinder head .......................................... 130
Checking the rocker arm shafts..................................... 131
Installing valves .......................................................... 131
Installing the rocker arm .............................................. 132
Checking clutch .......................................................... 132
Checking shift mechanism ........................................... 133
Preassembling the shift shaft........................................ 134
Dismantling the main shaft .......................................... 134
Assembling the main shaft ........................................... 135
Dismantling the countershaft........................................ 135
Assembling the countershaft......................................... 136
Checking the transmission............................................ 136
Premounting the kickstarter shaft.................................. 137
Checking the electric starter mode ................................ 138
Removing the freewheel ............................................... 139
Checking the freewheel ................................................ 139
Installing the free-wheel............................................... 139
30/ENGINE ASSEMBLY ................................................... 141
Installing the crankshaft............................................... 141
Installing the transmission shaft ................................... 141
Installing the shift forks ............................................... 141
Installing the shift drum............................................... 142
Installing the shift rails ................................................ 142
Installing the left engine case....................................... 142
Installing the free wheel gear........................................ 143
Installing the primary gear............................................ 143
Installing the oil pumps ............................................... 143
Installing the oil pump gears ........................................ 144
Installing the locking lever............................................ 144
Installing the shift drum locating .................................. 144
Installing the shift shaft............................................... 144
Installing the kickstarter idler gear ................................ 145
Installing the kickstarter shaft ...................................... 145
Installing the starter idler gear ...................................... 145
Installing the torque limiter .......................................... 145
Installing the balancer shaft ......................................... 146
Installing the outer clutch hub...................................... 146
Installing the primary gear nut ...................................... 147
Installing the clutch discs ............................................ 147
Installing the clutch cover ............................................ 147
Installing the water pump cover .................................... 148
Installing the kickstarter............................................... 148
Installing the suction pump.......................................... 148
Installing the ignition pulse generator............................ 149
Installing the timing chain............................................ 149
Installing the timing chain securing guide...................... 149
Installing the timing chain tensioning rail ...................... 149
Installing the timing chain guide rail ............................. 150
Installing the balance weight ........................................ 150
Installing the rotor....................................................... 150
Installing the piston..................................................... 150
Installing the cylinder head .......................................... 152
Installing the camshaft ................................................ 153
Installing the timing chain tensioner ............................. 153
Checking the valve clearance........................................ 154
Adjusting the valve clearance........................................ 154
Installing the generator cover........................................ 154
Installing the shift lever ............................................... 155
Installing the valve cover .............................................. 155
Installing the spark plug............................................... 155
Installing the starter motor ........................................... 155
Mounting oil filter........................................................ 156
Filling up with engine oil.............................................. 156
Filling up with gear oil ................................................. 156
Removing the engine from the work stand...................... 157
31/CARBURETOR ........................................................... 158
Choke (EXC AUS, XC‑W, EXC USA) ............................... 158
Choke (EXC EU, EXC SIX DAYS) ................................... 158
Removing the carburetor .............................................. 158
Disassembling the carburetor........................................ 159
Checking/adjusting the carburetor components............... 161
Checking/adjusting the accelerator pump....................... 162
Checking the choke slide.............................................. 162
Checking the jet needle................................................ 162
Checking the throttle slide............................................ 163
Checking the needle jet................................................ 163
Checking the float needle valve..................................... 163
Checking/adjusting the float level.................................. 164
Checking/setting the throttle slide opening..................... 164
Checking the throttle valve sensor ................................. 164
Adjusting the position of the throttle position sensor....... 165
Assembling the carburetor............................................ 166
Installing the carburetor............................................... 168
Carburetor - adjusting idle............................................ 169
Emptying the carburetor float chamber .......................... 170
32/CLUTCH .................................................................... 172
Checking fluid level of hydraulic clutch ......................... 172
Changing the hydraulic clutch fluid............................... 172
33/TRANSMISSION......................................................... 174
Removing the engine sprocket ...................................... 174
Installing the engine sprocket ....................................... 174
35/WATER PUMP, COOLING SYSTEM .............................. 175
Cooling system ............................................................ 175
Checking the antifreeze and coolant level ...................... 175
Checking the coolant level............................................ 176
Draining coolant .......................................................... 176

CONTENTS 5
Refilling coolant .......................................................... 177
38/LUBRICATION SYSTEM .............................................. 178
Oil circuit ................................................................... 178
Checking engine oil level.............................................. 178
Changing engine oil and oil filter, cleaning engine oil
screen ........................................................................ 179
Draining engine oil, cleaning engine oil screen ............... 179
Removing the oil filter.................................................. 179
Mounting oil filter........................................................ 180
Filling up with engine oil.............................................. 180
Topping up engine oil .................................................. 181
Checking the engine oil pressure................................... 181
Checking the gear oil level............................................ 182
Changing gear oil, cleaning gear oil screen..................... 182
Draining gear oil, cleaning gear oil screen ...................... 182
Filling up with gear oil ................................................. 183
Adding gear oil............................................................ 183
39/IGNITION SYSTEM ..................................................... 185
Checking the ignition system ........................................ 185
Checking the ignition coil............................................. 186
Checking the spark plug connector................................ 187
Checking the CDI controller.......................................... 187
Checking the ignition pulse generator............................ 187
Checking the generator ................................................ 188
Removing the stator..................................................... 190
Mounting the stator ..................................................... 190
40/ELECTROSTARTER..................................................... 191
Checking the starter motor ........................................... 191
TROUBLESHOOTING....................................................... 192
TECHNICAL DATA - ENGINE............................................ 194
Capacity - engine oil .................................................... 194
Capacity - gear oil........................................................ 195
Capacity - coolant........................................................ 195
TECHNICAL DATA - ENGINE TOLERANCES, WEAR
LIMITS........................................................................... 196
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ 197
TECHNICAL DATA - CARBURETOR................................... 199
400 EXC..................................................................... 199
400 XC-W USA ........................................................... 199
450 EXC EU/AUS, 450 EXC SIX DAYS .......................... 199
450 EXC USA ............................................................. 200
450 XC-W................................................................... 200
530 EXC EU/AUS, 530 EXC SIX DAYS .......................... 200
530 EXC USA ............................................................. 201
530 XC‑W................................................................... 201
TECHNICAL DATA - CARBURETOR TIGHTENING
TORQUES....................................................................... 202
TECHNICAL DATA - CHASSIS .......................................... 203
Lighting equipment ..................................................... 204
Tires .......................................................................... 204
Capacity - fuel............................................................. 204
TECHNICAL DATA - FORK................................................ 205
TECHNICAL DATA - SHOCK ABSORBER ........................... 206
TECHNICAL DATA - TIGHTENING TORQUES FOR
CHASSIS ........................................................................ 207
CLEANING...................................................................... 208
Cleaning motorcycle .................................................... 208
STORAGE ....................................................................... 209
Storage....................................................................... 209
Putting into operation after storage ............................... 209
SERVICE SCHEDULE....................................................... 210
Important maintenance work to be carried out by an
authorized KTM workshop. ........................................... 210
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order).............. 211
Important checks and maintenance work to be carried
out by the rider. .......................................................... 212
WIRING DIAGRAM .......................................................... 214
Wiring diagram (EXC EU, EXC AUS, EXC‑R SIX DAYS) .... 214
Wiring diagram (EXC USA) ........................................... 218
Wiring diagram (all XC‑W models) ................................. 222
OPERATING SUBSTANCES.............................................. 224
AUXILIARY SUBSTANCES................................................ 226
SPECIAL TOOLS.............................................................. 228
STANDARDS................................................................... 240
INDEX ............................................................................ 241

MEANS OF REPRESENTATION 6
Symbols used
The symbols used are explained in the following.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained in the following.
Own name Indicates a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a brand in merchandise traffic.

IMPORTANT NOTES 7
Warranty
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; 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.
Fuel, oils, etc.
The fuels and lubricants named in the owner's manual must be used according to specifications.
Spare parts, 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 KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.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®) 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.
notes/warnings
Be sure to pay attention to the notes and warnings given here.
Info
Various notes and warning stickers are attached to the vehicle. Do not remove any notes and warning stickers. If they are miss-
ing, you or others may not recognize sources of danger and may therefore be injured.
Grades of risks
Danger
Indicates immediate danger that will invariably lead to severe or even fatal injury if the appropriate measures are not taken.
Warning
Indicates immediate danger that may lead to severe or even fatal injury 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
Indicates immediate danger that will invariably lead to environmental damage if the appropriate measures are not taken.
Repair 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.

LOCATION OF SERIAL NUMBERS 8
3.1Chassis number
500127-10
The chassis number is stamped on the steering head on the right.
3.2Type label
500128-10
(EXC EU, EXC AUS, EXC SIX DAYS, XCR‑W)
The type label is fixed to the front of the steering head.
300402-10
(EXC USA)
The type label USA is fixed to the front of the steering head.
300403-10
(EXC USA)
The type label Canada is fixed to the front of the front pipe.
3.3Key number (all EXC models)
500125-10
(EXC EU, EXC AUS, EXC‑R SIX DAYS)
The key number is stamped on the key strap.

LOCATION OF SERIAL NUMBERS 9
300397-10
(EXC USA)
The key number is provided on the KEYCODECARD.
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a
safe place.
3.4Engine number
500072-10
The engine number is stamped on the left side of the engine under the engine
sprocket.
3.5Fork part number
500082-10
The fork part number is stamped on the inner side of the fork stub.
3.6Shock absorber part number
500129-10
The shock absorber part number is stamped on the top of the shock absorber above
the adjusting ring on the engine side.

MOTORCYCLE 10
4.1Jacking up the motorcycle
500074-01
Note
Danger of damage The parked vehicle can roll away or fall over.
–Always place the vehicle on a firm and even surface.
–Jack up the motorcycle underneath the engine. The wheels must no longer touch
the ground.
Work stand (54829055000) ( p. 229)
–Secure the motorcycle against falling over.
4.2Removing the motorcycle from the work stand
Note
Danger of damage The parked vehicle can roll away or fall over.
–Always place the vehicle on a firm and even surface.
–Remove the motorcycle from the work stand.
–Remove the work stand.
4.3Starting
Danger
Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death.
–When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed
space without an effective exhaust extraction system.
Note
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
If the motorcycle is unwilling to start, the cause can 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 until trying again.
Motorcycle has been out of use for more than 1 week
–Empty the carburetor float chamber. ( p. 170)
–Turn handle of the fuel tap to the ON position. (Figure 500137-10 p. 65)
Fuel can flow from the fuel tank to the carburetor.
–Remove the motorcycle from the stand.
–Shift gear to neutral.
(EXC USA)
–Turn the key in the ignition switch to the position .
(EXC USA)
–Turn the emergency OFF switch to the position .
(EXC AUS)
–Turn the emergency OFF switch to the position .
Engine cold
(EXC AUS, XC‑W, EXC USA)
–Pull the choke lever out as far as possible.
(EXC EU, EXC SIX DAYS)
–Pull the choke lever to the stop.
–Press the electric starter button or press the kickstarter robustly through its full range.
Info
Don't open the throttle.