Model:
400 EXC, 450 EXC, 530 EXC, 400 XC-W, 450 XC-W, 530 XC-W
Engine Codes:
LC4 (specific variants for 400, 450, 530cc)
Category:
High-performance off-road motorcycles (Enduro/Cross-Country).
Competitors:
Yamaha WR series, Honda CRF-X series, Suzuki RM-Z series, Kawasaki KX series.
Features:
Powerful LC4 engines, advanced WP suspension, robust chassis, designed for demanding off-road conditions. Available in different displacements to cater to various rider preferences and regulations.
Engine:
Complete engine disassembly, assembly, tuning, troubleshooting, internal components (crankshaft, pistons, cylinders, valves), oil system, cooling system.
Transmission:
Clutch system, gearbox operation, maintenance, repair, troubleshooting.
Chassis And Suspension:
Frame, front forks (WP Suspension), rear shock absorber (WP Suspension), swingarm, wheel bearings, steering head bearings.
Brakes:
Front and rear brake systems (hydraulic disc brakes), brake fluid specifications, bleeding procedures, caliper maintenance, master cylinder repair.
Electrical System:
Ignition system, charging system (stator, regulator/rectifier), starter motor, battery maintenance, lighting system, wiring diagrams, troubleshooting electrical faults.
Fuel System:
Fuel tank, fuel pump, fuel injection system (EFI), throttle body, injectors, troubleshooting fuel delivery issues.
Emission Control:
Emission control systems (where applicable for specific markets), charcoal canister, air injection systems (if present).
Cooling System:
Radiator, coolant types and capacities, fan operation, troubleshooting overheating.
Maintenance:
Routine maintenance checks, oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement, valve clearance checks and adjustment.
Troubleshooting:
Comprehensive diagnostic procedures for engine performance, electrical issues, starting problems, and general operational faults.
Repair:
Step-by-step instructions for major component overhauls and repairs, including engine rebuilds, transmission overhauls, suspension component replacement, and electrical system repairs.
Disassembly Assembly:
Complete tear-down and reassembly instructions for all major motorcycle systems.
Depth:
Factory-level detail, suitable for both DIY enthusiasts and professional mechanics. Includes detailed illustrations, torque specifications, clearances, and diagnostic procedures.
Engine Type:
Single-cylinder, 4-stroke, liquid-cooled (LC4 variant).
Displacement:
400cc, 450cc, 530cc (specific models).
Horsepower And Torque:
Specific figures vary by exact model and displacement; manual provides detailed specifications and tuning data.
Fuel Delivery:
Electronic Fuel Injection (EFI).
Oil Change Interval:
Typically every 10-15 hours of riding or annually. Manual provides specific recommendations based on usage.
Valve Clearance Check:
Recommended at intervals such as 100-200 hours of riding. Manual details the exact procedure and specifications.
Engine Oil:
Specific viscosity grade (e.g., Motorex Power Synt 4T 10W-50 or equivalent) and capacity provided in the manual.
Coolant:
Ethylene glycol-based coolant with corrosion inhibitors. Capacity and type specified in the manual.
Brake Fluid:
DOT 4 recommended. Manual specifies type and procedure for replacement/bleeding.
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, wheel bearings, fork seals. Manual provides guidance on inspection and replacement.
Engine Component Wear:
Piston rings, valve guides, and cam chains can experience wear with high mileage or aggressive use. Manual guides on checking tolerances and replacement.
