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Related Manuals for KTM 450 EXC-F 2017
Summary of Contents for KTM 450 EXC-F 2017
- Page 1 OWNER'S MANUAL 2017 450 EXC‑F 500 EXC‑F Art. no. 3213482en...
- Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.
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Page 4: Table Of Contents
TABLE OF CONTENTS Setup menu ........... 24 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 7.10 Setting the unit of measurement ...... 24 Symbols used ........... 5 7.11 Display mode SPEED/CLK (time) ...... 25 Formats used............ 5 7.12 Setting the clock..........25 SAFETY ADVICE............ - Page 5 TABLE OF CONTENTS 11.10 Adjusting the riding sag ....... 47 12.44 Adjusting the basic position of the clutch lever .............. 76 11.11 Checking the basic setting of the fork ....47 12.45 Checking/correcting the fluid level of the 11.12 Adjusting the compression damping of the hydraulic clutch..........
- Page 6 TABLE OF CONTENTS 17.6 Teaching the throttle valve position....106 17.7 Checking the basic position of the shift lever ... 107 17.8 Adjusting the basic position of the shift lever ............107 18 SERVICE WORK ON THE ENGINE ......108 18.1 Changing the fuel screen ......
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Page 7: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required. -
Page 8: Safety Advice
SAFETY ADVICE Use definition - intended use KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply with currently valid regulations and categories of the top international motorsport organizations. -
Page 9: Safe Operation
– Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren- theses. -
Page 10: Owner's Manual
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer. -
Page 11: Important Notes
Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the warranty. -
Page 12: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) H01693-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Filler cap Shift lever ( p. 18) Engine number ( p. 12) Side stand ( p. 19) -
Page 13: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) H01692-10 Kill switch ( p. 14) Horn button ( p. 14) Light switch ( p. 15) Turn signal switch ( p. 15) Emergency OFF switch ( p. 15) Electric starter button ( p. -
Page 14: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. 401945-10 Type label The type label is fixed to the front of the steering head. 401946-10 Key number The key number for the steering lock is stamped onto the key connector. -
Page 15: Shock Absorber Article Number
SERIAL NUMBERS Shock absorber article number Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 0 0 1 401948-10... -
Page 16: Controls
CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. S01305-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. The hand brake lever is used to activate the front brake. -
Page 17: Light Switch
CONTROLS Light switch The light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is in the central position. In this position, the low beam and tail light are switched on. High beam on –... -
Page 18: Combination Switch (Exc-F Six Days)
CONTROLS 6.10 Combination switch (EXC‑F Six Days) The combination switch is fitted on the left side of the handlebar. Possible states STANDARD – STANDARD mapping is activated when LED 1 lights up. STANDARD with TC – STANDARD mapping with traction control is acti- vated when LED 1 and TC light up. -
Page 19: Closing The Filler Cap
CONTROLS – Press release button , turn the filler cap counterclockwise, and lift it off. M01472-10 6.13 Closing the filler cap – Fit the filler cap and turn clockwise until release button locks in place. Info Route fuel tank breather hose without kinks. -
Page 20: Idle Speed Adjusting Screw
CONTROLS 6.15 Idle speed adjusting screw The idle setting of the throttle valve body has a big influence on the vehicle's starting behavior, on stable idling, and on vehicle response when the throttle is opened. An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly. -
Page 21: Side Stand
CONTROLS 6.18 Side stand The side stand is attached to the left side of the vehicle. 401943-10 The side stand is used to park the motorcycle. Info When you are riding, the side stand must be folded up and secured with the ... -
Page 22: Unlocking The Steering
CONTROLS 6.21 Unlocking the steering – Insert the key in the steering lock ( p. 19), turn it to the left, pull it out, and turn it to the right. Remove the key. You can now steer the bike again. Info Never leave the key in the steering lock. -
Page 23: Speedometer
SPEEDOMETER Speedometer overview – Press the button to control different functions. – Press the button to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. 401761-01 Activation and test Activating the speedometer The speedometer is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor. -
Page 24: Setting The Speedometer Functions
SPEEDOMETER Setting the speedometer functions Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is stationary. – Repeatedly press the button briefly until H appears at the bottom right of the display. -
Page 25: Display Mode Speed (Speed)
SPEEDOMETER – Repeatedly press the button briefly until LAP appears at the bottom right of the display. – Briefly press the button LAP 1 appears on the left side of the display. – The laps 1–10 can be viewed with the button –... -
Page 26: Setup Menu
SPEEDOMETER Setup menu Condition • The motorcycle is stationary. – Repeatedly press the button briefly until H appears at the bottom right of the display. – Press the button for 2–3 seconds. The Setup menu displays the active functions. Info Repeatedly press the button briefly until the desired function is reached. -
Page 27: Display Mode Speed/Clk (Time)
SPEEDOMETER 7.11 Display mode SPEED/CLK (time) – Repeatedly press the button briefly until CLK appears at the bottom right of the display. The time is shown in display mode CLK. Press the button The display changes to the Setup menu of the clock. for 2–3 seconds. -
Page 28: Viewing The Lap Time
SPEEDOMETER 7.14 Viewing the lap time Condition • The motorcycle is stationary. – Repeatedly press the button briefly until LAP appears at the bottom right of the display. – Briefly press the button Press the button The stop watch and the lap time are reset. for 2–3 seconds. -
Page 29: Display Mode Speed/Tr2 (Trip Master 2)
SPEEDOMETER 7.17 Display mode SPEED/TR2 (trip master 2) – Repeatedly press the button briefly until TR2 appears at the top right of the dis- play. TR2 (trip master 2) runs constantly and counts up to 999.9. Press the button Clears the values TR2 and A2. for 2–3 seconds. -
Page 30: Display Mode Speed/A2 (Average Speed 2)
SPEEDOMETER 7.20 Display mode SPEED/A2 (average speed 2) – Repeatedly press the button briefly until A2 appears at the top right of the dis- play. A2 (average speed 2) shows the average speed on the basis of the current speed if the stop watch S2 (stop watch 2) is running. -
Page 31: Table Of Functions
SPEEDOMETER 7.23 Table of functions Display Press the but- Briefly press the Press the but- Briefly press the Wait 3–5 sec- Wait 10–12 sec- for 2–3 button for 2–3 button onds onds seconds. seconds. Display mode The display Next display No function No function SPEED/H (service... -
Page 32: Table Of Conditions And Menu Activation
SPEEDOMETER 7.24 Table of conditions and menu activation Display The motorcycle is Menu can be acti- stationary. vated Display mode SPEED/H (service hours) • Setup menu • Setting the unit of measurement • Setting the clock • Display mode SPEED/LAP (lap time) •... -
Page 33: Preparing For Use
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover. -
Page 34: Running-In The Engine
PREPARING FOR USE – Try also to ride as slowly as possible and in a standing position to get a better feeling for the motorcycle. – Do not make any off-road trips that exceed your ability and experience. – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. –... -
Page 35: Preparing For Rides On Dry Sand
Preparing for rides on dry sand – Fit a dust cover on the air filter. Dust cover for air filter (79006920000) Info See the KTM PowerParts fitting instructions. 102136-01 – Fit a sand cover on the air filter. Sand cover for air filter (79006922000) Info See the KTM PowerParts fitting instructions. -
Page 36: Preparing For Rides On Wet And Muddy Surfaces
Preparing for rides on wet and muddy surfaces – Fit a waterproofing device on the air filter. Waterproofing device for air filter (79006921000) Info See the KTM PowerParts fitting instructions. 102137-01 – Fit the steel sprocket. – Clean the motorcycle. ( p. -
Page 37: Preparing For Rides At High Temperature And Slow Speed
– Check the coolant level. ( p. 102) Preparing for rides at low temperature or in snow – Fit a waterproofing device on the air filter. Waterproofing device for air filter (79006921000) Info See the KTM PowerParts fitting instructions. 102137-01... -
Page 38: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –... -
Page 39: Activating Launch Control (Exc-F Six Days)
RIDING INSTRUCTIONS – Press the electric starter button. Info Press the electric starter button for a maximum of 5 seconds. Wait for 30 seconds before a further attempt at starting. At temperatures below 15 °C (60 °F), several attempts at starting may be necessary to warm-up the lithium-ion battery and thereby increase the start- ing power. -
Page 40: Starting Off
Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system. -
Page 41: Stopping, Parking
RIDING INSTRUCTIONS – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. – Make use of the braking effect of the engine when driving down long downhill stretches. To do so, shift back one or two gears, but do not overrev the engine. -
Page 42: Refueling
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Improper handling of fuel is a danger to the environment. -
Page 43: Service Schedule
Final check: Check the vehicle is roadworthy and take a test ride. ○ ● ● Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. -
Page 44: Recommended Work
SERVICE SCHEDULE ○ One-time interval ● Periodic interval 10.3 Recommended work Annually Every 135 operating hours Every 70 operating hours when used for motorsports Every 45 operating hours/every 10 operating hours when used for motorsports Once after 10 operating hours ●... -
Page 45: Tuning The Chassis
The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber. -
Page 46: Adjusting The High-Speed Compression Damping Of The Shock Absorber
The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber. -
Page 47: Measuring The Rear Wheel Dimension Unloaded
TUNING THE CHASSIS 11.6 Measuring the rear wheel dimension unloaded Preparatory work – Raise the motorcycle with the lift stand. ( p. 52) Main work – Position the sag gauge in the rear axle and measure the distance to marking SAG on the rear fender. -
Page 48: Checking The Riding Sag Of The Shock Absorber
The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. -
Page 49: Adjusting The Riding Sag
TUNING THE CHASSIS – Remove the motorcycle from the lift stand. ( p. 52) 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with the lift stand. ( p. 52) – Remove shock absorber. p. 63) – After removing the shock absorber, clean it thoroughly. Main work –... -
Page 50: Adjusting The Rebound Damping Of The Fork
TUNING THE CHASSIS – Turn counterclockwise by the number of clicks corresponding to the fork type. Guideline Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. (EXC‑F Six Days) –... -
Page 51: Adjusting The Spring Preload Of The Fork (Exc-F Six Days)
TUNING THE CHASSIS (EXC‑F Six Days) – Turn red adjusting screw clockwise as far as it will go. Info Adjusting screw is located at the upper end of the right fork leg. The rebound damping is located in right fork leg REB (red adjusting screw). -
Page 52: Handlebar Position
TUNING THE CHASSIS 11.15 Handlebar position (EXC‑F EU/AU) On the upper triple clamp, there are 2 holes at a distance of to each other. 15 mm (0.59 in) Hole distance The holes on the handlebar supports are placed at a distance of from the cen- ter. - Page 53 TUNING THE CHASSIS (EXC‑F EU/AU) – Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against damage. Do not kink the cables and lines. –...
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Page 54: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (78129955100) Neither wheel is in contact with the ground. -
Page 55: Removing The Fork Legs
SERVICE WORK ON THE CHASSIS Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –... -
Page 56: Installing The Fork Legs
SERVICE WORK ON THE CHASSIS 12.6 Installing the fork legs Main work (EXC‑F EU/AU) – Position the fork legs. Bleeder screws are positioned toward the front. Info The rebound damping is located in right fork leg REB (red adjusting screw). -
Page 57: Removing The Fork Protector
SERVICE WORK ON THE CHASSIS 12.7 Removing the fork protector – Remove screws and take off the clamp. – Remove screws on the left fork leg and take off the left fork protector. – Remove screws on the right fork leg and take off the right fork protector. V00332-10 12.8 Installing the fork protector... -
Page 58: Removing The Lower Triple Clamp (Exc-F Six Days)
SERVICE WORK ON THE CHASSIS 12.10 Removing the lower triple clamp (EXC‑F Six Days) Preparatory work – Remove the headlight mask with the headlight. ( p. 97) – Raise the motorcycle with the lift stand. ( p. 52) – Remove the front wheel. p. - Page 59 SERVICE WORK ON THE CHASSIS – Position the upper triple clamp with the handlebar. – Mount screw but do not tighten yet. – Secure wiring harness and clutch line with cable holder. – Position the voltage regulator, and mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft)
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Page 60: Installing The Lower Triple Clamp (Exc-F Six Days)
SERVICE WORK ON THE CHASSIS Finishing work – Mount the handlebar cushion. – Install the front fender. ( p. 62) – Install the front wheel. p. 88) – Install the headlight mask with the headlight. ( p. 97) – Check that the wiring harness, throttle cables, and brake and clutch lines can move freely and are routed correctly. - Page 61 SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, bottom triple clamp 15 Nm (11.1 lbf ft) V00466-10 – Tighten screw Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) E00387-10 – Mount and tighten screw Guideline Screw, top steering stem 17 Nm...
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Page 62: Checking The Play Of The Steering Head Bearing
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time. -
Page 63: Adjusting The Steering Head Bearing Play (Exc-F Six Days)
SERVICE WORK ON THE CHASSIS 12.15 Adjusting the steering head bearing play (EXC‑F Six Days) Preparatory work – Raise the motorcycle with the lift stand. ( p. 52) Main work – Loosen screws – Remove screw – Loosen and retighten screw Guideline Screw, top steering head... -
Page 64: Installing The Front Fender
SERVICE WORK ON THE CHASSIS (EXC‑F Six Days) – Remove screws K00576-10 – Remove screws . Remove the front fender. S01321-10 12.18 Installing the front fender Main work (EXC‑F EU/AU) – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm... -
Page 65: Removing The Shock Absorber
SERVICE WORK ON THE CHASSIS Finishing work – Install the headlight mask with the headlight. ( p. 97) – Check the headlight setting. ( p. 99) 12.19 Removing the shock absorber Preparatory work – Raise the motorcycle with the lift stand. ( p. -
Page 66: Mounting The Seat
SERVICE WORK ON THE CHASSIS 12.22 Mounting the seat – Mount the front of the seat on the collar bushing of the fuel tank, lower the seat at the rear, and push the seat forward. – Make sure that the seat is correctly locked in. V00343-10 –... -
Page 67: Removing The Air Filter
SERVICE WORK ON THE CHASSIS Condition The air filter box cover is secured. – Mount and tighten screw Guideline Screw, air filter box cover EJOT PT ® 3 Nm (2.2 lbf ft) K60x20-Z K00554-10 12.25 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine. -
Page 68: Cleaning The Air Filter And Air Filter Box
SERVICE WORK ON THE CHASSIS 12.27 Cleaning the air filter and air filter box Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu- lations. -
Page 69: Removing Main Silencer
SERVICE WORK ON THE CHASSIS Finishing work – Install the air filter box cover. ( p. 64) 12.30 Removing main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. –... -
Page 70: Removing The Fuel Tank
SERVICE WORK ON THE CHASSIS Main work – Remove screws – Take off silencer cap with O-ring – Remove old glass fiber yarn filling. – Clean the parts that need to be reinstalled and check for damage. –... -
Page 71: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! – Disconnect the plug-in connection of the fuel line. –... -
Page 72: Checking For Chain Dirt Accumulation
SERVICE WORK ON THE CHASSIS Main work – Check throttle cable routing. ( p. 75) – Position the fuel tank and fit the two spoilers to the sides in front of the radiator bracket. – Make sure that no cables or throttle cables are trapped or damaged. –... -
Page 73: Cleaning The Chain
SERVICE WORK ON THE CHASSIS 12.36 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. – Remove the lubricant from the tires using a suitable cleaning agent. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –... -
Page 74: Adjusting The Chain Tension
SERVICE WORK ON THE CHASSIS Main work – Pull the chain at the end of the chain sliding component upwards to measure chain tension Info The lower chain section must be taut. When the chain guard is mounted, it must be possible to pull up the chain ... -
Page 75: Checking The Chain, Rear Sprocket, Motor Sprocket, And Chain Guide
SERVICE WORK ON THE CHASSIS Finishing work – Remove the motorcycle from the lift stand. ( p. 52) 12.39 Checking the chain, rear sprocket, motor sprocket, and chain guide Preparatory work – Raise the motorcycle with the lift stand. ( p. -
Page 76: Checking The Frame
If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by KTM. S01316-10... -
Page 77: Checking The Swingarm
» If the swingarm shows signs of damage, cracking, or deformation: – Change the swingarm. Info Always change a damaged swingarm. Repair of the swingarm is not authorized by KTM. S01317-10 12.42 Checking throttle cable routing Preparatory work – Remove the seat. ( p. -
Page 78: Adjusting The Basic Position Of The Clutch Lever
SERVICE WORK ON THE CHASSIS 12.44 Adjusting the basic position of the clutch lever – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. -
Page 79: Changing The Hydraulic Clutch Fluid
SERVICE WORK ON THE CHASSIS 12.46 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. –... -
Page 80: Removing The Engine Guard (Exc-F Six Days, Exc-F Au)
SERVICE WORK ON THE CHASSIS 12.47 Removing the engine guard (EXC‑F Six Days, EXC‑F AU) – Remove screws and engine guard. H01638-10 12.48 Installing the engine guard (EXC‑F Six Days, EXC‑F AU) – Attach the engine guard on the frame at the rear and swing up at the front. –... -
Page 81: Brake System
Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disk ... -
Page 82: Checking The Brake Fluid Level Of The Front Brake
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect. -
Page 83: Checking The Front Brake Linings
Changing the front brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation. –... - Page 84 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
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Page 85: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM – Correct the brake fluid quantity to level Guideline 5 mm (0.2 in) Level (brake fluid level below reser- voir rim) Brake fluid DOT 4 / DOT 5.1 ( p. 124) – Position the cover with the membrane. Mount and tighten the screws. Info K00574-12 Clean up overflowed or spilled brake fluid immediately with water. -
Page 86: Checking The Rear Brake Fluid Level
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect. -
Page 87: Checking The Rear Brake Linings
85) E00349-10 13.13 Changing the rear brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.) - Page 88 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
- Page 89 BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. E00352-10 – Insert the new brake linings, insert the pin, and mount the cotter pins. Info Always change the brake linings in pairs.
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Page 90: Wheels, Tires
WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 52) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. -
Page 91: Removing The Rear Wheel
WHEELS, TIRES – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw Guideline Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) – Operate the hand brake lever several times until the brake linings are seated cor- rectly against the brake disc. -
Page 92: Installing The Rear Wheel
WHEELS, TIRES 14.4 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Main work –... -
Page 93: Checking The Tire Condition
DOT number. The first two digits indi- cate the week of manufacture and the last two digits the year of manufac- ture. KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear. H01144-01 »... -
Page 94: Checking Spoke Tension
Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.) – Strike each spoke briefly using a screwdriver blade. -
Page 95: Electrical System
ELECTRICAL SYSTEM 15.1 Removing the battery Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batteries. – Only charge batteries in well-ventilated rooms. – Maintain a minimum clearance from inflammable materials when charging batteries. -
Page 96: Recharging The Battery
ELECTRICAL SYSTEM 15.3 Recharging the battery Warning Environmental hazard Batteries contain environmentally-hazardous materials. – Do not dispose of batteries as household waste. – Dispose of batteries at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu- lations. -
Page 97: Changing The Main Fuse
ELECTRICAL SYSTEM Info If the charging current, charging voltage, or charging time are exceeded, the battery will be destroyed. If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfated, destroying the battery. The battery is maintenance-free. -
Page 98: Changing The Fuses Of Individual Power Consumers
ELECTRICAL SYSTEM – Take off protection caps – Remove faulty main fuse Info You can recognize a defective fuse by a burned-out fuse wire A spare fuse is located in the starter relay. – Install a new main fuse. Fuse (58011109120) ( p. -
Page 99: Removing The Headlight Mask With The Headlight
ELECTRICAL SYSTEM Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. – Use spare fuses with the correct rating only. Fuse (75011088010) ( p. 120) Fuse (58011109105) ( p. -
Page 100: Changing The Headlight Bulb
ELECTRICAL SYSTEM Finishing work – Check the headlight setting. ( p. 99) 15.8 Changing the headlight bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting. -
Page 101: Checking The Headlight Setting
ELECTRICAL SYSTEM Main work – Remove the screw on the rear of the turn signal housing. – Carefully remove diffuser – Lightly squeeze orange cap in the area of the holding lugs and take it off. – Press the turn signal bulb carefully into the socket, turn it counterclockwise by about 30°, and take it out of the socket. -
Page 102: Changing The Speedometer Battery
ELECTRICAL SYSTEM 15.12 Changing the speedometer battery Preparatory work – Remove the headlight mask with the headlight. ( p. 97) Main work – Remove screws with the washers. – Pull the speedometer upward out of the holder. V00370-10 – ... -
Page 103: Cooling System
COOLING SYSTEM 16.1 Cooling system The water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions. -
Page 104: Checking The Coolant Level
COOLING SYSTEM 16.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature. -
Page 105: Refilling Coolant
COOLING SYSTEM Main work – Position the motorcycle upright. – Place a suitable container under the water pump cover. – Remove screw . Take off radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring. -
Page 106: Tuning The Engine
TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3…... -
Page 107: Setting The Characteristic Map Of The Throttle Response
TUNING THE ENGINE 17.3 Setting the characteristic map of the throttle response Info On the throttle grip, the characteristic map of the throttle response is changed by changing the guide plate. A guide plate with a different characteristic map is supplied. Main work –... -
Page 108: Adjusting The Idle Speed
Danger of accidents The engine may go out spontaneously if the idle speed is set too low. – Set the idle speed to the specified value. (Your authorized KTM workshop will be glad to help.) – Run the engine until warm. -
Page 109: Checking The Basic Position Of The Shift Lever
TUNING THE ENGINE – Allow the vehicle to idle. The malfunction indicator lamp stops flashing once teaching is completed. Info If the engine becomes too hot, perform a cool-down ride at medium revs. Then do not switch off the engine after this, but leave it running at idle speed until teaching is completed. 17.7 Checking the basic position of the shift lever Info... -
Page 110: Service Work On The Engine
SERVICE WORK ON THE ENGINE 18.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –... -
Page 111: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens
SERVICE WORK ON THE ENGINE Main work – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level. The engine oil is at a level between lower edge and the middle of level ... - Page 112 SERVICE WORK ON THE ENGINE – Mount and tighten screw plug with the short oil screen and the O-rings. Guideline Screw plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) H01706-10 – Position long oil screen with the O-rings on a pin wrench. –...
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Page 113: Adding Engine Oil
SERVICE WORK ON THE ENGINE – Remove filler plug with the O-ring from the clutch cover and fill up with engine oil. Engine oil 1.2 l (1.3 qt.) Engine oil (SAE 10W/50) ( p. 124) Info Too little engine oil or poor-quality engine oil results in premature wear of the engine. -
Page 114: Cleaning, Care
CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –... -
Page 115: Checks And Maintenance Steps For Winter Operation
CLEANING, CARE 19.2 Checks and maintenance steps for winter operation Info If you use the vehicle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt. -
Page 116: Storage
– Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 52) – Preferably cover the vehicle with a tarp or similar cover that is permeable to air. -
Page 117: Troubleshooting
– Check the electrical system. switch defective – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. - Page 118 – Check the cabling for damage and the electri- cal plug-in connectors for corrosion and dam- age. – Read out the fault memory using the KTM diag- nostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary.
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Page 119: Technical Data
TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement (All 450 models) 449.9 cm³ (27.455 cu in) Displacement (All 500 models) 510.9 cm³ (31.177 cu in) Stroke (All 450 models) 63.4 mm (2.496 in) Stroke (All 500 models) 72 mm (2.83 in) Bore 95 mm (3.74 in) Compression ratio... -
Page 120: Capacities
TECHNICAL DATA – Screw, alternator cover 10 Nm (7.4 lbf ft) Screw, bearing bolt, torque limiter 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, camshaft support plate 10 Nm (7.4 lbf ft) Loctite ® 243™ – Screw, clutch cover 10 Nm (7.4 lbf ft) –... -
Page 121: Fuel
TECHNICAL DATA 22.3.3 Fuel Total fuel tank capacity, 8.5 l (2.25 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 124) approx. Fuel reserve, approx. 1.5 l (1.6 qt.) 22.4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing WP Performance Systems MXMA 4860 upside down Fork (EXC‑F EU/AU) Fork (EXC‑F Six Days) -
Page 122: Electrical System
(EXC‑F Six Days) Metzeler MCE 6 Days Extreme Metzeler MCE 6 Days Extreme The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork 22.7.1 EXC‑F EU/AU Fork article number 14.18.8Q.69... -
Page 123: Exc-F Six Days
TECHNICAL DATA 22.7.2 EXC‑F Six Days Fork article number 14.15.8Q.69 Fork WP Performance SystemsXplor 48 Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring preload - Preload Adjuster Comfort Standard Sport... -
Page 124: Chassis Tightening Torques
TECHNICAL DATA Gas pressure 10 bar (145 psi) Static sag 35 mm (1.38 in) Riding sag 110 mm (4.33 in) Fitted length 415 mm (16.34 in) Damper oil Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 124) 22.9 Chassis tightening torques –... - Page 125 TECHNICAL DATA – Remaining screws, chassis 45 Nm (33.2 lbf ft) Screw, handlebar holder 40 Nm (29.5 lbf ft) Loctite ® 243™ – Nut, fuel pump fixation 15 Nm (11.1 lbf ft) Screw, bottom shock absorber 80 Nm (59 lbf ft) Loctite ®...
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Page 126: Substances
SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corre- sponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®... -
Page 127: Auxiliary Substances
AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier Motorex ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier Motorex... -
Page 128: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation. -
Page 129: Index Of Special Terms
INDEX OF SPECIAL TERMS On-board diagnosis Vehicle system that monitors emission- and safety-related values... -
Page 130: List Of Abbreviations
LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly... -
Page 131: List Of Symbols
LIST OF SYMBOLS 28.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols. Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an emission- or safety-critical fault. -
Page 132: Index
INDEX Clutch INDEX fluid level, checking/correcting ....76 Accessories ........9 fluid, changing . - Page 133 INDEX Fork legs Light switch ........15 basic setting, checking .
- Page 134 INDEX basic position, checking ..... 107 Troubleshooting ......115-116 Shock absorber Turn signal bulb installing .
- Page 135 *3213482en* 3213482en 07/2016 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...