This workshop service manual is designed for the KTM 400 EXC XC-W for the years 2008, 2009, 2010, and 2011. It is intended for use by mechanical technicians familiar with service procedures for BRP products.
The manual covers repair and overhaul procedures specific to the KTM 400 EXC XC-W and assumes the technician's familiarity with general automobile practices. It includes instructions on components manufactured for the vehicle and provides information for routine maintenance, servicing, and diagnostic and repair procedures.
Whether you are a professional mechanic or a DIY enthusiast, this manual aims to help you get the best value from your KTM 400 EXC XC-W. It contains specifications and procedures available in an authorized KTM dealer service department and emphasizes particular information denoted by the wording and symbols: WARNING, CAUTION, NOTE.
For those intending to perform maintenance and repairs, safety equipment and precautions must be observed, including the use of a torque wrench to ensure that fasteners are tightened according to specifications. The manual also refers to special tools recommended or required for adjustments or repairs, often identified by their KTM 400 EXC XC-W special tool number and illustrated.
This comprehensive service manual contains all necessary instructions for tune-ups, maintenance, removal and installation procedures, assemblies and disassemblies, fuel system, ignition, lubrication system, exhaust, electrical system, body, and more extensive repairs involving engine and transmission disassembly.
It is important to note that this is an electronic delivery via email and is printable. The content of the manual depicts parts and procedures applicable to the particular product at the time of writing.
General Information
Maintenance
Lubrication
Heating
Ventilation
Air Conditioning
Suspension
Front Suspension
Rear Suspension
Wheel
Tire System
Differential
Driveline
Drive Shaft
Transfer Case
Brakes
Engine
Engine Mechanical
Engine Cooling
Engine Fuel
Engine Electrical
Ignition System
Starting
Charging System
Emissions
Engine Exhaust
Engine Lubrication
Engine Speed Control System
Clutch
Cooling
Electronic Control Modules
Engine Systems
Heated Systems
Horn
Ignition Control
Instrument Cluster
Lamps
Power Systems
Restraints
Speed Control
Transmission
Exhaust System
Body Structure
Seats
Security and Locks
Air Bag System
Exterior Trim
Interior Trim
Frame
Bumpers
Fuel System
Steering
Transmission and Transfer Case
Tires
Wheels
Body
Heating
Air Conditioning
Emissions Control
Engine Removal
Engine Installation
Final Drive
Electrical System
Air cleaner element renewal
Air cleaner temperature control check
Auxiliary drivebelt check
Battery electrolyte level check
Battery terminal check
Brake hydraulic fluid renewal
Brake hydraulic system seal and hose renewal
Brake pipe and hose check
Choke adjustment check
Contact breaker point renewal and distributor lubrication
