Related Manuals for KTM 2013 450 EXC SIX DAYS EU
Summary of Contents for KTM 2013 450 EXC SIX DAYS EU
- Page 1 OWNER'S MANUAL 2013 450 EXC EU 450 EXC AUS 450 EXC SIX DAYS EU 450 XC-W USA 500 EXC EU 500 EXC AUS 500 EXC SIX DAYS EU 500 XC-W USA Art. no. 3211864en...
- Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.
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Page 4: Table Of Contents
TABLE OF CONTENTS 6.15.15 Display mode SPEED/A1 (average speed 1) ... 20 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 6.15.16 Display mode SPEED/A2 (average speed 2) ... 20 Symbols used ........... 5 6.15.17 Display mode SPEED/S1 (stop watch 1)..21 Formats used............ - Page 5 TABLE OF CONTENTS 10.14 Adjusting the spring preload of the fork 11.48 Checking/correcting the fluid level of the (EXC EU, EXC AUS, all XC‑W models) ....42 hydraulic clutch..........67 10.15 Handlebar position.......... 42 11.49 Changing the hydraulic clutch fluid ....
- Page 6 TABLE OF CONTENTS 16.5 Adjusting the basic position of the shift lever ............95 17 SERVICE WORK ON THE ENGINE ....... 96 17.1 Changing the fuel screen ......96 17.2 Checking the engine oil level......96 17.3 Changing the engine oil and oil filter, cleaning the oil screens ...........
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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
Use definition - intended use (all EXC models) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations. -
Page 9: Safe Operation
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 10: Important Notes
Guarantee, 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 and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle. -
Page 11: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) 101626-10 Filler cap Air filter box lid Fork compression adjustment Shift lever ( p. 23) Engine number ( p. 11) Side stand ( p. 24) -
Page 12: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) 101627-10 Kill switch ( p. 13) Horn button ( p. 14) Light switch ( p. 14) Turn signal switch ( p. 14) Emergency OFF switch ( p. 14) Electric starter button ( p. -
Page 13: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. 101289-10 Type label The type label is fixed to the front of the steering head. 101290-10 Key number (all EXC models) The key number for the steering lock is stamped onto the key connector. -
Page 14: Shock Absorber Part Number
SERIAL NUMBERS Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side. 601613-10... -
Page 15: Controls
CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 101628-10 Hand brake lever Hand brake lever is located on the right side of the handlebar. The hand brake lever is used to activate the front brake. 101629-10 Throttle grip The throttle grip... -
Page 16: Horn Button (All Exc Models)
CONTROLS Horn button (all EXC models) The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed – The horn is operated in this position. • Horn button 101631-11 Light switch (all EXC models) The light switch is fitted on the left side of the handlebar. -
Page 17: Electric Starter Button (Exc Aus)
CONTROLS 6.11 Electric starter button (EXC AUS) The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position pressed – In this position, the electric starter is actuated. • Electric starter button 101634-11 6.12... -
Page 18: Speedometer
CONTROLS 6.15 Speedometer 6.15.1 Overview – Press the button to change the display mode or change to one of the Setup menus. – 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. -
Page 19: Setting The Clock
CONTROLS Adjusting Mph – Press the button – Press the button for 3 - 5 seconds. The settings are stored and the Setup menu is closed. Info If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu is closed. -
Page 20: Querying Lap Time
CONTROLS Info If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu is closed. 6.15.7 Querying lap time Info This function can be called up only if lap times are measured. Condition The motorcycle is stationary. -
Page 21: Display Mode Speed/Clk (Clock)
CONTROLS 6.15.10 Display mode SPEED/CLK (clock) – Press the button briefly and repeatedly until CLK appears at the bottom right of the display. The time is displayed in CLK display mode. Press the button . No function Press the button . -
Page 22: Display Mode Speed/Tr2 (Trip Master 2)
CONTROLS 6.15.14 Display mode SPEED/TR2 (trip master 2) – Press the button briefly and repeatedly until TR2 appears at the top right of the display. TR2 (trip master 2) runs constantly and counts up to 999.9. The displayed value can be set manually with the button and the button . -
Page 23: Display Mode Speed/S1 (Stop Watch 1)
CONTROLS 6.15.17 Display mode SPEED/S1 (stop watch 1) – Press the button briefly and repeatedly until S1 appears at the top right of the display. S1 (stop watch 1) displays the journey time on the basis of TR1 and continues when an impulse is received from the wheel speed sensor. -
Page 24: 6.15.20 Table Of Conditions And Menu Activation
CONTROLS 6.15.20 Table of conditions and menu activation Display The motorcycle is Menu can be acti- stationary. vated Display mode SPEED/H (operating hours) • Display mode SPEED/CLK (clock) • Display mode SPEED/LAP (lap time) • Display mode SPEED/TR1 (trip master 1) •... -
Page 25: Idle Speed Adjusting Screw
CONTROLS 6.18 Idle speed adjusting screw Idle speed adjusting screw is located on the throttle valve body at the top left. The idle speed adjusting screw has two functions. Turning it controls the idle speed. Pulling it out all the way raises the idle speed during a cold start. Possible states RPM increase activated –... -
Page 26: Foot Brake Lever
CONTROLS 6.21 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 601618-10 6.22 Side stand The side stand is on the left side of the vehicle. C00077-01 The side stand is used to park the motorcycle. -
Page 27: Unlocking The Steering (All Exc Models)
CONTROLS – Park the vehicle. – Turn the handlebar as far as possible to the right. – Insert the key in the steering lock, turn it to the left, press it in and turn it to the right. Remove the key. Steering is no longer possible. -
Page 28: 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 record at vehicle handover. -
Page 29: Running-In The Engine
– KTM recommends that you use the specified engine oil for difficult riding condi- tions and to increase performance. -
Page 30: Preparing For Rides On Dry Sand
– Fit a dust cover on the air filter. Dust protection device for air filter (77206920000) Info See the KTM PowerParts fitting instructions. 600869-01 – Fit a sand cover on the air filter. Sand protection device for air filter (59006022000) Info See the KTM PowerParts fitting instructions. -
Page 31: 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 (77206921000) Info See the KTM PowerParts fitting instructions. 600870-01 – Fit the steel sprocket. – Clean the motorcycle. ( p. -
Page 32: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p. 96) –... -
Page 33: Starting Off
Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines. -
Page 34: Stopping, Parking
RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. –... -
Page 35: 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. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards. -
Page 36: Service Schedule
Final check: Check the vehicle for roadworthiness and take a test ride. • • • Read out the fault memory using the KTM diagnostics tool after a test ride. • • • Make the service entry in KTM DEALER.NET and in the service record. -
Page 37: Service Work (As Additional Order)
SERVICE SCHEDULE Service work (as additional order) S15N S45A S105A Change the front brake fluid. • Change the rear brake fluid. • Change the hydraulic clutch fluid. p. 67) • Grease the steering head bearing. p. 54) • Clean the spark arrestor. (all XC‑W models) •... -
Page 38: Tuning The Chassis
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. -
Page 39: Adjusting The High-Speed Compression Damping Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber. -
Page 40: Measuring Rear Wheel Sag Unloaded
TUNING THE CHASSIS 10.6 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with the lift stand. ( p. 44) Main work – Measure the distance – as vertically as possible – between the rear axle and a fixed point such as a mark on the side cover. -
Page 41: Adjusting The Spring Preload Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to 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 42: Checking Basic Setting Of Fork
TUNING THE CHASSIS Info The spring rate is shown on the outside of the spring. Smaller weight differences can be compensated by changing the spring preload. Finishing work – Install the shock absorber. p. 55) – Remove the motorcycle from the lift stand. ( p. -
Page 43: Adjusting The Rebound Damping Of The Fork
TUNING THE CHASSIS (EXC SIX DAYS) – Turn the white adjusting screw all the way clockwise. Info Adjusting screw is located at the upper end of the left fork leg. The compression damping is located in the left fork leg (white adjusting screw). -
Page 44: Adjusting The Spring Preload Of The Fork (Exc Eu, Exc Aus, All Xc-W Models)
TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 10.14 Adjusting the spring preload of the fork (EXC EU, EXC AUS, all XC‑W models) – Turn the adjusting screws counterclockwise all the way. Info Make the same adjustment on both fork legs. –... - Page 45 TUNING THE CHASSIS Info Position the left and right handlebar supports evenly. – Position the handlebar. Info Make sure cables and wiring are positioned correctly. – Position the handlebar clamps. Fit and evenly tighten the four screws Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) Info...
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Page 46: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (54829055000) The wheels should no longer touch the ground. -
Page 47: Loosening The Fork Protector
SERVICE WORK ON THE CHASSIS Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. – Clean and lubricate the dust boot and inside fork tube on both fork legs. -
Page 48: Installing The Fork Legs
SERVICE WORK ON THE CHASSIS (EXC EU, EXC AUS, all XC‑W models) – Release screws . Take out the left fork leg. – Release screws . Take out the right fork leg. 101323-10 (EXC SIX DAYS) – Release screws . Take out the left fork leg. –... -
Page 49: Removing The Fork Protector
SERVICE WORK ON THE CHASSIS – Position the brake line, wiring harness, and clamp. Mount and tighten screws Finishing work – Install the front wheel. p. 78) 11.9 Removing the fork protector Preparatory work – Remove the headlight mask with the headlight. ( p. -
Page 50: Removing The Lower Triple Clamp (Exc Six Days)
SERVICE WORK ON THE CHASSIS – Remove O-ring . Remove protective ring – Take out the lower triple clamp with the steering stem. – Take out the upper steering head bearing. 101329-10 11.12 Removing the lower triple clamp (EXC SIX DAYS) Preparatory work –... -
Page 51: Installing The Lower Triple Clamp (Exc Eu, Exc Aus, All Xc-W Models)
SERVICE WORK ON THE CHASSIS 11.13 Installing the lower triple clamp (EXC EU, EXC AUS, all XC‑W models) Main work – Clean the bearing and sealing elements, check for damage, and grease. 0 0 3 High viscosity grease ( p. 116) 0 0 2 –... - Page 52 SERVICE WORK ON THE CHASSIS – Tighten screw Guideline Screw, top steering stem 20 Nm (14.8 lbf ft) 101334-11 – Tighten screws Guideline Screw, top triple clamp 20 Nm (14.8 lbf ft) – Secure the wiring harness with cable holder 101333-11 –...
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Page 53: Installing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS 11.14 Installing the lower triple clamp (EXC SIX DAYS) Main work – Clean the bearing and sealing elements, check for damage, and grease. 0 0 3 High viscosity grease ( p. 116) 0 0 2 –... -
Page 54: Checking The Steering Head Bearing Play
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam- aged over time. -
Page 55: Adjusting The Play Of The Steering Head Bearing (Exc Eu, Exc Aus, All Xc-W Models)
SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: (EXC SIX DAYS) –... -
Page 56: Greasing The Steering Head Bearing
SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Screw, top steering stem 17 Nm Loctite ® 243™ (12.5 lbf ft) Finishing work – Check the steering head bearing play. ( p. 52) – Remove the motorcycle from the lift stand. ( p. -
Page 57: Installing The Shock Absorber
SERVICE WORK ON THE CHASSIS 11.22 Installing the shock absorber Main work – Push splash protector to the side and position the shock absorber. Mount and tighten screw Guideline Screw, top shock absorber 80 Nm Loctite ® 2701 (59 lbf ft) –... -
Page 58: Installing The Air Filter Box Lid
SERVICE WORK ON THE CHASSIS 11.26 Installing the air filter box lid – Insert the air filter box lid into the rear area and clip it into the front area 601622-11 11.27 Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. –... -
Page 59: Cleaning The Air Filter And Air Filter Box
SERVICE WORK ON THE CHASSIS 11.29 Cleaning the air filter and air filter box Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Do not clean the air filter with fuel or petroleum since these substances attack the foam. -
Page 60: Installing The Main Silencer
SERVICE WORK ON THE CHASSIS 11.32 Installing the main silencer – Mount the main silencer. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Reconnect spring 101353-11 11.33 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. -
Page 61: Removing The Fuel Tank
SERVICE WORK ON THE CHASSIS (all XC‑W models) – Remove screws of connecting cap – Take off the connecting cap with the perforated pipe, O-ring and glass fiber yarn filling – Remove screws and silencer cap with O-ring – Remove screw and remove insert together with stuffing yarn –... -
Page 62: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS – Remove screws with the collar bushings and horn. 101356-10 – Remove screw with the rubber bushing. 101357-10 – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. 101358-01 11.35 Installing the fuel tank... -
Page 63: Checking For Chain Dirt Accumulation
SERVICE WORK ON THE CHASSIS – Position the horn, and fit and tighten screws with collar bushings. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 101356-11 – Connect the electrical plug-in connection – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Never let dirt enter the fuel line. -
Page 64: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 116) Off-road chain spray ( p. 116) 400725-01 11.38 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. –... -
Page 65: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide
SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55… 58 mm (2.17… 2.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks . - Page 66 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the bottom edge of the chain bolt is in line with or below the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated. »...
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Page 67: Adjusting The Chain Guide
If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by KTM. 401340-01 11.43 Checking the swingarm –... -
Page 68: Checking The Throttle Cable Routing
SERVICE WORK ON THE CHASSIS 11.44 Checking the throttle cable routing Preparatory work – Remove the seat. ( p. 55) – Remove the fuel tank. p. 59) Main work – Check the throttle cable routing. Both throttle cables must be routed side by side behind the handlebars and above the fuel tank bearing to the throttle valve body. -
Page 69: Adjusting The Basic Position Of The Clutch Lever
SERVICE WORK ON THE CHASSIS 11.47 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 70: Removing The Engine Guard (Exc Six Days, Exc Aus)
SERVICE WORK ON THE CHASSIS – Inject the liquid into the system until it escapes from openings of the master cylinder without bubbles. – To prevent overflow, drain fluid occasionally from the master cylinder reservoir. – Remove the bleeding syringe. Mount and tighten screws bleeder screw. –... -
Page 71: Brake System
BRAKE SYSTEM 12.1 Checking free travel of hand brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake may fail due to overheating. -
Page 72: Checking The Brake Discs
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. -
Page 73: Checking The Front Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. - Page 74 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
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Page 75: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM – Insert the brake linings, insert the pin, and mount the cotter pin. – Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. 100398-10 –... -
Page 76: Checking The Rear Brake Fluid Level
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright. -
Page 77: Checking The Rear Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 78: Changing The Rear Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. - Page 79 BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 100407-10 – Insert the brake linings, insert the pin, and mount the cotter pin. – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.
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Page 80: Wheels, Tires
WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 44) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. -
Page 81: Removing The Rear Wheel
WHEELS, TIRES – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc. -
Page 82: Checking The Tire Condition
Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have a significant impact on the handling characteristics of the motorcycle. -
Page 83: Checking Tire Air Pressure
Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time. - Page 84 WHEELS, TIRES Guideline Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) Spoke nipple, rear wheel 5… 6 Nm (3.7… 4.4 lbf ft) Torque wrench with various accessories in set (58429094000)
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Page 85: Electrical System
ELECTRICAL SYSTEM 14.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –... -
Page 86: Changing The Main Fuse
– Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 87: Changing The Fuses Of Individual Power Consumers
ELECTRICAL SYSTEM Main work – Remove screw 101395-10 – Lift rear fairing slightly and pull starter relay out of the holder. 101396-10 – Remove protection caps – Remove the faulty main fuse Info A defective fuse can be identified by the burned-out fuse wire A reserve fuse is located in the starter relay. -
Page 88: Changing The Fuse Of The Radiator Fan
ELECTRICAL SYSTEM – Remove the defective fuse. Guideline Fuse 1 - 10 A - EFI control unit Fuse 2 - 10 A - fuel pump Fuse 3 - 10 A - high beam, low beam, parking light, tail light, license plate lamp Fuse 4 - 10 A - horn, brake light, turn signal, radiator fan Fuse 5 - 10 A - ignition lock (optional) Fuses res - 10 A - spare fuses... -
Page 89: Removing Headlight Mask With Headlight
ELECTRICAL SYSTEM 14.7 Removing headlight mask with headlight – Switch off all electrical equipment. – Remove screw and take off clamp. – Loosen the rubber band . Push up the headlight mask and swing it forwards. 101401-10 – Pull out the electric plug connector and remove the headlight mask with the headlight. -
Page 90: Changing The Turn Signal Bulb
ELECTRICAL SYSTEM Main work – Turn rubber cap together with the underlying lamp socket counterclockwise all the way and remove it. – Pull lamp socket of the parking light out of the reflector. 101403-10 – Press headlight bulb into the lamp socket lightly, turn it counterclockwise all the way and pull it out. -
Page 91: Checking The Headlight Setting
ELECTRICAL SYSTEM 14.11 Checking the headlight setting – Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight. 0 0 A –... - Page 92 ELECTRICAL SYSTEM – Position locking cap and, using a coin, turn it clockwise all the way. – Press any button on the speedometer. The speedometer is activated. – Position the speedometer in the bracket. – Mount and tighten the screws with washers. 101407-10 Finishing work –...
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Page 93: Cooling System
COOLING SYSTEM 15.1 Cooling system 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 tem- perature will not result in a risk of malfunctions. -
Page 94: Checking The Coolant Level
COOLING SYSTEM 15.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. -
Page 95: Refilling Coolant
COOLING SYSTEM 15.5 Refilling coolant Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con- tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi- ately. -
Page 96: Tuning The Engine
TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3…... -
Page 97: Adjusting The Idle Speed
TUNING THE ENGINE 16.3 Adjusting the idle speed – Run the engine warm and push the idle speed adjusting screw all the way in. – Set the desired idle speed by turning the idle speed adjusting screw. Guideline Idle speed 1,800…... -
Page 98: Service Work On The Engine
SERVICE WORK ON THE ENGINE 17.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –... -
Page 99: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens
SERVICE WORK ON THE ENGINE 17.3 Changing the engine oil and oil filter, cleaning the oil screens Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage. - Page 100 SERVICE WORK ON THE ENGINE – Push the engine oil screen with the O-rings onto a pin wrench. – Push the pin wrench through the opening into the drill hole of the opposite engine case wall and push the oil screen as far as possible into the engine case. C00068-10 –...
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Page 101: Adding Engine Oil
SERVICE WORK ON THE ENGINE – Install and tighten the oil filler plug with O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. -
Page 102: Cleaning, Care
CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts. -
Page 103: Checks And Maintenance Steps For Winter Operation
CLEANING, CARE 18.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. 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 104: 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. 44) – Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materi- als since they prevent humidity from escaping, thus causing corrosion. -
Page 105: Troubleshooting
– 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 106 – Check the cabling for damage and the electri- cal plug-in connections 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 107: Blink Code
BLINK CODE Blink code FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Crankshaft position sensor - circuit fault Blink code FI warning lamp (MIL) 06 FI warning lamp (MIL) flashes 6x short Error level condition Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high Blink code FI warning lamp (MIL) - Page 108 BLINK CODE Blink code FI warning lamp (MIL) 45 FI warning lamp (MIL) flashes 4x long, 5x short Error level condition EXC EU, EXC SIX DAYS Lambda sensor heater cylinder 1, sensor 1 - short circuit to ground or open circuit EXC EU, EXC SIX DAYS Lambda sensor heater cylinder 1, sensor 1 - input signal too high...
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Page 109: Technical Data
TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement (All 450 models) 449.3 cm³ (27.418 cu in) Displacement (All 500 models) 510.4 cm³ (31.147 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 110 TECHNICAL DATA ® Nut, water pump impeller 8 Nm (5.9 lbf ft) Loctite 243™ ® Plug, vacuum connection 2.5 Nm (1.84 lbf ft) Loctite 243™ – Screw, alternator cover M6x25 10 Nm (7.4 lbf ft) ® Screw, camshaft bearing support 10 Nm (7.4 lbf ft) Loctite 243™...
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Page 111: Capacities
TECHNICAL DATA – Plug, SLS M12x1.5 20 Nm (14.8 lbf ft) – Plug, rocker arm M14x1.25 20 Nm (14.8 lbf ft) – Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft) ® Nut, primary gear M20LHx1.5 100 Nm (73.8 lbf ft) Loctite 648™... -
Page 112: Electrical System
140/80 - 18 M/C 70R TT MAXXIS MAXX CROSS SI MAXXIS MAXX ENDURO (all XC‑W models) 80/100 - 21 51M TT 110/100 - 18 64M TT Dunlop GEOMAX MX51 Dunlop GEOMAX MX51 Additional information is available in the Service section under: http://www.ktm.com... -
Page 113: Fork
TECHNICAL DATA 22.7 Fork 22.7.1 EXC EU, EXC AUS, all XC‑W models Fork part number 14.18.7L.69 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 22 clicks Standard 20 clicks Sport 18 clicks Rebound damping Comfort 20 clicks Standard 18 clicks Sport... -
Page 114: Shock Absorber
TECHNICAL DATA 22.8 Shock absorber Shock absorber part number 12.18.7L.69 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1.25 turns Rebound damping Comfort 28 clicks... - Page 115 TECHNICAL DATA – Remaining screws, chassis 25 Nm (18.4 lbf ft) – Screw, bottom triple clamp 12 Nm (8.9 lbf ft) (EXC SIX DAYS) – Screw, bottom triple clamp (EXC EU, 15 Nm (11.1 lbf ft) EXC AUS, all XC‑W models) –...
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Page 116: Substances
Brake fluid DOT 4 / DOT 5.1 According to – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Castrol and Motorex ® products. Supplier Castrol –... - Page 117 SUBSTANCES Fork oil (SAE 4) (48601166S1) According to – SAE ( p. 118) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Shock absorber oil (SAE 2.5) (50180342S1) According to –...
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Page 118: Auxiliary Substances
AUXILIARY SUBSTANCES Air filter cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Dirt Bio Remover Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline –... - Page 119 AUXILIARY SUBSTANCES Oil for foam air filter Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Liquid Bio Power Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline – KTM recommends Motorex ®...
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Page 120: 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 121: Index
INDEX Clutch lever ........13 INDEX basic position, adjusting ..... . 67 Accessories . - Page 122 INDEX bleeding ....... . . 44 removing ....... 47-48 dust boots, cleaning .
- Page 123 INDEX removing ....... . . 54 riding sag, checking ......38 View of vehicle spring preload, adjusting .
- Page 124 *3211864en* 3211864en 05/2012 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...