Related Manuals for KTM 450 EXC-R EU
Summary of Contents for KTM 450 EXC-R EU
- Page 1 OWNER'S MANUAL 2008 450 EXC-R EU 450 EXC-R AUS/UK 450 EXC-R SIX DAYS 450 EXC-R USA 450 XCR-W USA 450 XCR-W ZA 530 EXC-R EU 530 EXC-R AUS/UK 530 EXC-R SIX DAYS 530 EXC-R USA 530 XCR-W USA 530 XCR-W ZA...
- Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors.
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Page 4: Table Of Contents
Important maintenance work to be carried out by an authorized KTM workshop..29 Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)... 30 Important checks and maintenance work to be carried out by the rider..30 MAINTENANCE WORK ON CHASSIS AND ENGINE... - Page 5 Capacity - coolant... 89 TECHNICAL DATA - ENGINE TIGHTENING TORQUES... 90 TECHNICAL DATA - CARBURETOR... 92 450 EXC-R EU, 450 EXC-R AUS/UK (3900I) ... 92 450 EXC-R SIX DAYS, 450 EXC-R USA, 450 XCR-W (3900L) ... 92 530 EXC-R EU, 530 EXC-R AUS/UK (3900J)... 93 530 EXC-R SIX DAYS, 530 EXC-R USA, 530 XCR-W (3900M) ...
- Page 6 CONTENTS Capacity - fuel... 95 TECHNICAL DATA - FORK... 96 TECHNICAL DATA - SHOCK ABSORBER ... 97 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ... 98 WIRING DIAGRAM ... 100 Wiring diagram (EXC-R EU) ... 100 Wiring diagram (EXC-R AUS/UK)... 102 Wiring diagram (EXC-R USA) ...
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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 done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required. -
Page 8: Important Notes
You should use the fuels, oils and greases according to specifications as listed in the owner's manual. Spare parts, accessories For your own safety, use only spare parts and accessories approved by KTM. KTM accepts no liability for other products and any re- sulting damage or loss. - Page 9 But if you use your motorcycle responsibly, you can en- sure that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your mo- torcycle legally, display environmental consciousness, and respect the rights of others.
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Page 10: Location Of Serial Numbers
LOCATION OF SERIAL NUMBERS Chassis number 500127-10 Type label 500128-10 Key number (EXC-R EU, EXC-R AUS/UK, EXC-R USA) 500125-10 Engine number 500072-10 Fork part number 500082-10 The chassis number is stamped on the steering head on the right. The type label is fixed to the front of the steering head. -
Page 11: Shock Absorber Part Number
LOCATION OF 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. 500129-10... -
Page 12: Operating Elements
OPERATING ELEMENTS Clutch lever 500133-10 Hand brake lever 400196-10 Short circuit button (EVERY XCR-W MODELS) 500132-10 Short circuit button (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS) 500134-10 Emergency OFF switch (EXC-R AUS/UK) 500131-10 The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. -
Page 13: Emergency Off Switch (Exc-R Usa)
OPERATING ELEMENTS Emergency OFF switch (EXC-R USA) 500144-10 Ignition switch (EXC-R USA) 500130-10 Electric starter button (EXC-R EU, EXC-R SIX DAYS, EXC-R USA, XCR-W) 400198-10 Electric starter button (EXC-R AUS/UK) 500131-11 Light switch (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS) 500134-12 The emergency OFF switch is fitted on the left side of the handlebar. -
Page 14: Light Switch (Every Xcr-W Models)
OPERATING ELEMENTS Light switch (EVERY XCR-W MODELS) 500146-10 Light switch (EXC-R USA) 500142-10 Headlight flasher switch (EXC-R USA) 500143-10 Horn (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS) 500134-11 Horn (EXC-R USA) 500142-11 The light switch is on the right of the speedometer. Possible states (XCR-W ZA) •... -
Page 15: Flasher Switch (Exc-R Eu, Exc-R Aus/Uk)
OPERATING ELEMENTS Flasher switch (EXC-R EU, EXC-R AUS/UK) 500145-10 Flasher switch (EXC-R USA) 500142-12 Overview of indicator lamps (EXC-R EU, EXC-R AUS/UK, EXC-R USA) 500147-01 Overview of indicator lamps (EXC-R SIX DAYS) 500160-01 Speedometer 400312-01 The flasher switch is fitted on the left side of the handlebar. Possible states Flasher light off Flasher switch is in the central position. -
Page 16: Speedometer Activation And Test
2205 mm corresponds to the size of the 21" front wheel with a series produc- tion tire. The display then changes to the last selected mode. Condition The motorcycle is standing. Press the button briefly and repeatedly until H appears at the bottom right of the display. -
Page 17: Setting The Clock
In the condition at delivery, only the SPEED / H display mode and SPEED / ODO are active. 400318-01 Condition The motorcycle is standing. Press the button briefly and repeatedly until CLK appears at the bottom right of the display. -
Page 18: Querying Lap Time
400321-01 Display mode SPEED 400317-02 Display mode SPEED/H (service hours) 400316-01 Condition The motorcycle is standing. Press the button briefly and repeatedly until LAP appears at the bottom right of the display. Press the button briefly. The LAP 1 is displayed on the left of the display. -
Page 19: Display Mode Speed / Clk (Time)
OPERATING ELEMENTS Display mode SPEED / CLK (time) 400319-01 Display mode SPEED/LAP (lap time) 400320-01 Display mode SPEED/ODO (odometer) 400317-01 Display mode SPEED/TR1 (trip master 1) 400323-01 Press the button briefly and repeatedly until CLK appears at the bottom right of the display. -
Page 20: Display Mode Speed/Tr2 (Trip Master 2)
OPERATING ELEMENTS Display mode SPEED/TR2 (trip master 2) 400324-01 Disply mode SPEED/A1 (average speed 1) 400325-01 Display mode SPEED/A2 (average speed 2) 400326-01 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 "+"... -
Page 21: Display Mode Speed/S1 (Stop Watch 1)
Next display mode next display mode Next display mode Next display mode Next display mode Next display mode Next display mode Next display mode Next display mode Next display mode The motorcycle is Menu can be en- standing abled • •... -
Page 22: Fuel Tap
Press release button , turn filler cap counterclockwise and lift it free. Replace the filler cap and turn clockwise until the release button Info Run the fuel tank breather hose The motorcycle is Menu can be en- standing abled •... -
Page 23: Choke (Exc-R Aus/Uk, Exc-R Six Days, Exc-R Usa, Xcr-W)
OPERATING ELEMENTS Choke (EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W) 500135-10 Choke (EXC-R EU) 500136-10 Shift lever 500138-10 500138-11 Foot brake pedal 500139-10 The choke is fitted on the left side of the carburetor. Activating the choke function frees an opening through which the engine can draw ex- tra fuel. -
Page 24: Kickstarter
Material damage Damage and destruction of components by excessive load. The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over. -
Page 25: Unlocking The Steering (Exc-R Eu, Exc-R Aus/Uk, Exc-R Usa)
OPERATING ELEMENTS 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. Info Never leave the key in the steering lock. Unlocking the steering (EXC-R EU, EXC-R AUS/UK, EXC-R USA) Insert the key in the steering lock, turn it to the left, pull it out and turn it to the right. -
Page 26: General Tips And Hints On Putting Into Operation
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 27: Running In The Engine
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis- tribution between the front and rear wheels. Info Motorcycles react sensitively to any changes of weight distribution. -
Page 28: Riding Instructions
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. -
Page 29: Starting Up
Do not change into a low gear at high engine speed. The engine races and the rear wheel can block. 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 30: Stopping, Parking
Push the emergency off switch at engine indling speed to the position . Turn the handle of the fuel tap to the OFF position. (Figure 500137-10 Stand the motorcycle on a hard surface. Refueling Danger Fire hazard Fuel can easily catch fire. -
Page 31: Greasing And Service Table
GREASING AND SERVICE TABLE Important maintenance work to be carried out by an authorized KTM workshop. Engine Change the engine oil and oil filter and clean the engine oil screen. ( Change the gear oil and clean the gear oil screen. ( Replace spark plug. -
Page 32: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop. (As Additional Order)
GREASING AND SERVICE TABLE Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) Carry out a complete fork service. Carry out a complete shock absorber service. Grease the steering head bearing. ( Clean and adjust carburetor. - Page 33 GREASING AND SERVICE TABLE Clean the chain. ( P. 50) Check the chain tension. ( P. 51) Check the chain wear. ( P. 52) Check the rear sprocket / engine sprocket for wear. ( Clean the air filter. ( P. 75) Checking the tire air pressure.
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Page 34: Maintenance Work On Chassis And Engine
For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swing arm and frame, the basic set- tings of the suspension components must match your body weight. As delivered, KTM offroad motorcycles are adjusted for a standard rider weight (with full protective clothing). Specification... -
Page 35: Adjusting The Low-Speed Compression Damping Of The Shock Absorber
MAINTENANCE WORK ON CHASSIS AND ENGINE 400208-10 Adjusting the low-speed compression damping of the shock absorber Danger Danger of accidents The shock absorber is under high pressure. The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main- tenance on it yourself. -
Page 36: Measuring Rear Wheel Sag Unloaded
Remove the motorcycle from the work stand. ( Measure distance of rear wheel unloaded. ( Ask someone to help you by holding the motorcycle upright. Measure the distance between the rear axle and the fixed point again. Make a note of the value as measurement... -
Page 37: Checking The Riding Sag Of The Shock Absorber
Measure distance of rear wheel unloaded. ( With another person holding the motorcycle, sit on the saddle with full protective clothing in a normal sitting position (feet on footrests) and bounce up and down a few times until the rear suspension levels out. -
Page 38: Adjusting Riding Sag
The heim joint for the shock absorber at the swing arm is Teflon coated. It must not be greased with grease or with other lubricants. Lubricants dis- solve the Teflon coating, thereby drastically reducing the service life. Remove the motorcycle from the work stand. ( to the side, and remove the shock ab- ®... -
Page 39: Checking Basic Setting Of Fork
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking basic setting of fork Info For various reasons, no exact riding sag can be determined for the forks. 400189-01 Adjusting compression damping of fork Info The hydraulic compression damping determines the fork suspension behavior. 100020-10 Adjusting rebound damping of fork Info... -
Page 40: Adjusting Spring Preload Of The Fork
Jack up the motorcycle. ( P. 32) Remove bleeder screws briefly. Any excess pressure escapes from the interior of the fork. Mount and tighten bleeder screws. Remove the motorcycle from the work stand. ( 20 clicks 18 clicks 18 clicks 20 clicks 20 clicks... -
Page 41: Cleaning Dust Boots Of Fork Legs
Warning Danger of accidents Unsafe riding behavior due to incorrect steering head bearing play. The steering head bearing play should be adjusted immediately in an authorized KTM workshop. Info If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time. -
Page 42: Adjusting Play Of Steering Head Bearing (Exc-R Eu, Exc-R Aus/Uk, Exc-R Usa, Xcr-W Za)
(EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA) Adjust play of the steering head bearing. ( Check the steering head bearing and replace if required. Remove the motorcycle from the work stand. ( (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA) Jack up the motorcycle. ( P. -
Page 43: Fork Offset (Exc-R Six Days, Xcr-W Usa)
MAINTENANCE WORK ON CHASSIS AND ENGINE Fork offset (EXC-R SIX DAYS, XCR-W USA) 0 0 B 0 0 A 0 0 1 400188-10 Setting the fork offset (EXC-R SIX DAYS, XCR-W USA) 500104-10 Removing the fork legs 500093-10 500094-10 You can see the currently set offset if you remove screw The fork offset has an impact on the handling of the vehicle. -
Page 44: Installing The Fork Legs
MAINTENANCE WORK ON CHASSIS AND ENGINE 100023-11 Installing the fork legs 100021-10 500094-11 100023-10 500093-11 (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA) Loosen screw . Remove the fork leg on the left. Loosen screw . Remove the fork leg on the right. Check parts for damage and wear. -
Page 45: Removing The Fork Protector
Remove screw . Remove screw and place it on one side. Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines. Remove o-ring . Remove protector ring Remove the lower triple clamp with the steering stem. -
Page 46: Removing The Lower Triple Clamp (Exc-R Eu, Exc-R Aus/Uk, Exc-R Usa, Xcr-W Za)
. Loosen screw and place it on one side. Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines. Remove protector ring Remove the lower triple clamp with the steering stem. -
Page 47: Installing The Lower Triple Clamp (Exc-R Eu, Exc-R Aus/Uk, Exc-R Usa, Xcr-W Za)
MAINTENANCE WORK ON CHASSIS AND ENGINE 500103-10 Installing the lower triple clamp 0 0 2 0 0 1 500151-10 500149-11 100022-11 (EXC-R SIX DAYS) Refit the headlight mask with the headlight. ( Install the fork legs. ( P. 42) Mount and tighten screw Specification Screw, top steering stem Check the cable harness, cable, brake and clutch line for free movement and free... -
Page 48: Greasing The Steering Head Bearing
MAINTENANCE WORK ON CHASSIS AND ENGINE Greasing the steering head bearing (EXC-R SIX DAYS, XCR-W USA) Remove the lower triple clamp. ( Install the lower triple clamp. ( P. 44) (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA) Remove the lower triple clamp. ( Install the lower triple clamp. -
Page 49: Refitting The Headlight Mask With The Headlight (Exc-R Eu, Exc-R Aus/Uk, Exc-R Six Days, Exc-R Usa, Xcr-W Za)
MAINTENANCE WORK ON CHASSIS AND ENGINE Refitting the headlight mask with the headlight (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W ZA) 500156-11 500155-11 Dismount the start number plate (XCR-W USA) 500101-10 Fitting the start number plate (XCR-W USA) 500101-11 Handlebar position 0 0 A... -
Page 50: Adjusting Handlebar Position
Remove the four screws . Remove the handlebar clamp. Remove the handle- bar and lay it to one side. Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines. Remove the two screws . -
Page 51: Checking Gas Bowden Cable Route
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking gas Bowden cable route 500152-10 Place the handlebar support in the required position. Fit and tighten the two screws Specification Screw, handlebar support M10 Condition Spacer fitted: Use a M10x35 screw Condition without a spacer Use a M10x25 screw Info Position the left and right handlebar supports evenly. -
Page 52: Checking Play In The Gas Bowden Cable
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking play in the gas Bowden cable 400192-10 Adjusting the gas Bowden cable play 500153-10 Checking chain dirt Check the chain for coarse dirt accumulation. » If the chain is very dirty: Clean the chain. ( P. -
Page 53: Checking The Chain Tension
If the chain tension does not meet specifications: Adjusting chain tension - after checking. ( Remove the motorcycle from the work stand. ( Make sure that the chain adjusters are fitted correctly on the adjusting screws. Push the chain at the end of the chain sliding component upwards to measure... -
Page 54: Checking The Rear Sprocket / Engine Sprocket For Wear
When you replace the chain, you should also replace the rear and engine sprockets. New chains wear out faster on old, worn sprockets. Remove the motorcycle from the work stand. ( Jack up the motorcycle. ( P. 32) Push the chain at the end of the chain sliding component upwards to measure... -
Page 55: Adjusting Chain Tension - After Checking
The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length. Chain adjusters can be turned by 180°. Remove the motorcycle from the work stand. ( Loosen nut Loosen nuts Adjust the chain tension by turning the adjusting screws... -
Page 56: Adjusting Chain Tension - Fitting Rear Wheel
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further. The brake fluid reservoirs of the front and rear brakes are dimensioned so that they do not need topping up with brake fluid even if the brake linings are worn. -
Page 57: Brake Calipers
The lateral compensation ensures an optimal position of the brake pad in relation to the brake disc. Checking brake discs Warning Danger of accidents Reduced braking due to worn brake discs. Worn brake discs should be replaced immediately by an authorized KTM workshop. 400257-10 Checking free play of hand brake lever Warning Danger of accidents Brake system failure. -
Page 58: Adjusting Basic Position Of Handbrake Lever (Every Xcr-W Models)
Have the brake system checked in an authorized KTM workshop, and do not ride any further. Warning Danger of accidents Reduced braking due to old brake fluid. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. 400231-10 Topping up the front brake fluid Warning Danger of accidents Brake system failure. -
Page 59: Checking The Front Brake Linings
MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of accidents Reduced braking due to old brake fluid. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. -
Page 60: Removing Front Brake Linings
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license. -
Page 61: Changing The Front Brake Linings
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. -
Page 62: Adjusting Basic Position Of Footbrake Lever
Have the brake system checked in an authorized KTM workshop, and do not ride any further. Warning Danger of accidents Reduced braking due to old brake fluid. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. 400234-10 Disconnect spring... -
Page 63: Adding Rear Brake Fluid
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. -
Page 64: Removing Rear Brake Linings
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license. -
Page 65: Changing The Rear Brake Linings
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. -
Page 66: Fitting Front Wheel
Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc. Remove the motorcycle from the work stand. ( Pull the front wheel brake and push down hard on the fork several times to align the fork legs. -
Page 67: Removing Rear Wheel
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. 400260-10 400259-10 Jack up the motorcycle. ( P. 32) Press the brake caliper by hand on to the brake disc in order to press back the brake piston. -
Page 68: Tire Condition Checking
Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle. The front and rear wheels must be fitted with tires with similar profiles. -
Page 69: Checking Spoke Tension
Warning Danger of accidents Unstable riding behavior due to loose spokes. If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop. Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time. -
Page 70: Recharging The Battery
Switch off the charger after charging. Disconnect the battery. Specification The charge current, charge voltage and charge time must not be exceeded. Charge the battery regularly when the motorcycle is not in use. Mount the seat. ( P. 69) on the battery casing. -
Page 71: Removing A Fuse
Replace a burned-out fuse only by an equivalent fuse. Refit the fuse. Fuse (58011109110) Info If the new fuse burns out, contact an authorized KTM workshop. Replace the protection cover. Install the air filter box lid. ( P. 74) Remove screw . -
Page 72: Dismounting The Fuel Tank
MAINTENANCE WORK ON CHASSIS AND ENGINE Dismounting the fuel tank Danger Fire hazard Fuel can easily catch fire. Never fill up 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. -
Page 73: Cooling System
Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure. Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. -
Page 74: Checking The Coolant Level
Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure. Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. -
Page 75: Refilling Coolant
MAINTENANCE WORK ON CHASSIS AND ENGINE 400335-11 Refilling coolant Warning Danger of poisoning Coolants are poisonous and a health hazard. Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. -
Page 76: Fitting The Main Silencer
MAINTENANCE WORK ON CHASSIS AND ENGINE Fitting the main silencer 400337-11 Dismounting the air filter box lid 400338-10 Installing the air filter box lid 400338-11 Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. -
Page 77: Installing The Air Filter
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the air filter 500107-10 Cleaning air filter Warning Environmental hazard Problem materials cause environmental damage. Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info Do not clean the air filter with fuel or petroleum since these substances attack the foam. Remove the air filter. -
Page 78: Changing Fluid Level Of Hydraulic Clutch
MAINTENANCE WORK ON CHASSIS AND ENGINE 400339-10 Changing fluid level of hydraulic clutch Warning Skin irritations Brake fluid can cause skin irritation on contact. Avoid contact with skin and eyes, and keep out of the reach of children. If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Environmental hazard Problem materials cause environmental damage. -
Page 79: Carburetor - Idle
Idle mixture adjusting screw (EXC-R SIX DAYS) Open Idle mixture adjusting screw (XCR-W ZA, 530 EXC-R EU, 530 EXC-R AUS/UK) Open Idle mixture adjusting screw (450 EXC-R EU, 450 EXC-R AUS/UK, 450 EXC- R USA) Open Idle mixture adjusting screw (530 EXC-R USA) -
Page 80: Emptying The Carburetor Float Chamber
MAINTENANCE WORK ON CHASSIS AND ENGINE Emptying the carburetor float chamber Danger Fire hazard Fuel can easily catch fire. Never fill up 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. -
Page 81: Checking Engine Oil Level
The engine oil must be between the halfway mark and the top of the oil level viewer » If the engine oil level is below the specified level: Top up the engine oil. ( P. 79) Stand the motorcycle on its side stand on a horizontal surface. P. 20) P. 81) -
Page 82: Removing The Oil Filter
Thoroughly clean parts and sealing area. Check parts for damage and wear. Replace damaged or worn parts. Lay the motorcycle on its side and fill the oil filter housing to about 1/3 full with engine oil. Fill the oil filter with engine oil and place it in the oil filter container. -
Page 83: Filling Up With Engine Oil
Start the engine and check that it is oil-tight. Check the engine oil level. ( P. 79) Stand the motorcycle upright on a horizontal surface. 6 Nm (4.4 lbf ft) Engine oil (SAE 10W/50) ( P. 114) -
Page 84: Changing Gear Oil, Cleaning Gear Oil Screen
Mount and tighten the gear oil level check screw. Specification Screw, gear oil level check P. 82) Stand the motorcycle on its side stand on a horizontal surface. Place a suitable container under the engine. Remove the gear oil drain plug Remove the gear oil screen plug Completely drain the gear oil. -
Page 85: Filling Up With Gear Oil
MAINTENANCE WORK ON CHASSIS AND ENGINE Filling up with gear oil Info Too little gear oil or poor-quality oil results in premature wear to the transmission. 200118-10 Topping up with gear oil Info Too little gear oil or poor-quality oil results in premature wear to the transmission. 200116-10 200118-11 Remove the screw cap... -
Page 86: Troubleshooting
Replace the fuse. ( P. 69) Start the engine with the kickstarter. Recharge the battery. Establish the reason for discharging or have it checked in a KTM workshop. Carry out instructions on starting. P. 26) Empty the carburetor float chamber. P. 78) Check tank vent. - Page 87 TROUBLESHOOTING Faults Engine turns but does not start. Engine has no idle. Engine does not speed up. Engine has too little power. Engine stalls or is popping into the carbu- retor Engine overheats. High oil consumption Battery discharged Speedometer values deleted (time, stop watch, lap times) Possible cause Water in carburetor or jets blocked...
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Page 88: Cleaning
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info If you clean the motorcycle regularly, its value and appearance are maintained over a long period. Avoid direct sunshine on the motorcycle during cleaning. -
Page 89: Storage
KTM recommends propping up the motorcycle. Jack up the motorcycle. ( P. 32) Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Info Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust. -
Page 90: Technical Data - Engine
TECHNICAL DATA - ENGINE Design Displacement (Every 450 models) Displacement (Every 530 models) Stroke (Every 450 models) Stroke (Every 530 models) Bore Compression ratio Idle speed Control Valve diameter, intake Valve diameter, exhaust Valve clearance Outfeed at: 20 °C (68 °F) Infeed at: 20 °C (68 °F) Crankshaft bearing Conrod bearing... -
Page 91: Capacity - Coolant
TECHNICAL DATA - ENGINE Capacity - coolant Coolant 0.95 l (1 qt.) Coolant ( P. 114) Coolant (mixed ready to use) ( P. 114) -
Page 92: Technical Data - Engine Tightening Torques
TECHNICAL DATA - ENGINE TIGHTENING TORQUES Screw, cable holder in generator cover Oil jet, rocker arm lubrication Oil jet, piston cooling Screw, locking lever Screw, ignition pulse generator Screw, clutch spring Locking screw for bearing Screw, oil filter cover Screw, oil pump cover Oil jet, conrod lubrication Nut, water-pump wheel Screw, kickstarter stop... - Page 93 TECHNICAL DATA - ENGINE TIGHTENING TORQUES Screw, cylinder head Gear oil drain plug with magnet Ignition rotor nut Plug, SLS Oil pressure control valve plug Spark plug Plug, rocker arm Plug, gear oil screen Plug, engine oil screen Nut, inner clutch hub Nut, primary gear Plug, timing chain tensioner M10x1,25...
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Page 94: Technical Data - Carburetor
TECHNICAL DATA - CARBURETOR 450 EXC-R EU, 450 EXC-R AUS/UK (3900I) Carburetor type Carburetor identification number Needle position Idle mixture adjusting screw Open Pump membrane stop Main jet Jet needle Idling jet Main air jet Idle air jet Cold start jet... -
Page 95: Exc-R Eu, 530 Exc-R Aus/Uk (3900J)
TECHNICAL DATA - CARBURETOR 530 EXC-R EU, 530 EXC-R AUS/UK (3900J) Carburetor type Carburetor identfication number Needle position Idle mixture adjusting screw Open Pump membrane stop Main jet Jet needle Idling jet Main air jet Idle air jet Cold start jet Leakage nozzle Throttle slide Slide stop... -
Page 96: Technical Data - Chassis
Rear Road tire pressure (Every EXC-R models) front Rear Rear wheel gearing (450 EXC-R EU, 450 EXC-R AUS/UK, 450 EXC-R USA) Rear wheel gearing (450 EXC-R SIX DAYS, XCR-W ZA) Rear wheel gearing (530 EXC-R SIX DAYS, XCR-W USA) Rear wheel gearing (530 EXC-R EU, 530 EXC-R AUS/UK) -
Page 97: Lighting Equipment
Licence plate lamp (EXC-R EU, EXC- R AUS/UK) Tires Validity (Every EXC-R models) (Every XCR-W models) For further information, see: http://www.ktm.com Capacity - fuel Tank capacity (EXC-R EU, 9 l (2.4 US gal) EXC-R AUS/UK, EXC-R SIX DAYS, XCR-W ZA) Tank capacity (EXC-R USA, 9.2 l (2.43 US gal) -
Page 98: Technical Data - Fork
TECHNICAL DATA - FORK Fork part number (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR- Fork part number (EXC-R SIX DAYS) Fork Compression damping (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W) Comfort Standard Sport Compression damping (EXC-R SIX DAYS) Comfort Standard Sport Rebound damping (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W) Comfort... -
Page 99: Technical Data - Shock Absorber
TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number (EXC-R EU, EXC-R AUS/UK, EXC- R USA, XCR-W) Shock absorber part number (EXC-R SIX DAYS) Shock absorber Compression damping, low-speed Comfort Standard Sport Compression damping, high-speed Comfort Standard Sport Rebound damping Comfort Standard Sport... -
Page 100: Technical Data - Chassis Tightening Torques
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES Spoke nipple, front wheel Spoke nipple, rear wheel Remaining nuts, chassis Remaining screws, chassis Screw, rear brake disc Screw, front brake disc Screw, shock absorber adjusting ring Screw, ball joint of push rod on foot- brake cylinder Nut, rear sprocket screw Nut, rim lock... -
Page 102: Wiring Diagram
WIRING DIAGRAM Wiring diagram (EXC-R EU) C_DG/4 C_CW3/2 C_CX3/2 C_BP/4 bl-wh bu-wh bu-wh ye-bl re-wh re-bl re-bl re-wh C_CR/1 C_CR1/1 C_CX1/2 C_CW1/2 C_DI/2 C_AK1/2 C_CW2/2 C_AH1/2 C_CX2/2 C_BA/1 C_BF/1 ye-re wh-gn C_BG1/3 C_AJ1/3 C_CX/2 C_CW/2 C_AJ/3 C_BG/3 C_CX/2 C_CZ/3 C_DB/4 C_CW/2 C_CY/3 C_DA/4... - Page 103 WIRING DIAGRAM Components Battery Generator Ignition coil Pulse generator Voltage regulator/rectifier Electric starter button Starter relay with fuse Starter motor Light switch, horn button, short circuit button Throttle valve sensor TPS Ignition curve plug connection CDI controller Headlight Parking light Brake / tail light Licence plate lamp Speedometer...
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Page 104: Wiring Diagram (Exc-R Aus/Uk)
WIRING DIAGRAM Wiring diagram (EXC-R AUS/UK) C_DG/4 C_CW3/2 C_CX3/2 C_BP/4 bl-wh bu-wh bu-wh ye-bl re-wh re-bl re-bl re-wh C_CR/1 C_CR1/1 C_CX1/2 C_CW1/2 C_DI/2 C_AK1/2 C_CW2/2 C_AH1/2 C_CX2/2 C_BA/1 C_BF/1 ye-re wh-gn C_BG1/3 C_AJ1/3 C_CX/2 C_CW/2 C_AJ/3 C_BG/3 C_CX/2 C_CZ/3 C_DB/4 C_CW/2 C_CY/3 C_DA/4... - Page 105 WIRING DIAGRAM Components Battery Generator Ignition coil Pulse generator Voltage regulator/rectifier Flasher switch Starter relay with fuse Starter motor Light switch, horn button, short circuit button Throttle valve sensor TPS Ignition curve plug connection CDI controller Headlight Parking light Brake / tail light Licence plate lamp Electric starter button, emergency OFF switch Flasher relay...
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Page 106: Wiring Diagram (Exc-R Usa)
WIRING DIAGRAM Wiring diagram (EXC-R USA) C_CW3/2 C_DG/4 C_CX3/2 C_BP/4 bl-wh bu-wh bu-wh ye-bl re-wh re-bl re-bl re-wh C_CR/1 C_CR1/1 C_CX1/2 C_CW1/2 C_AK1/2 C_CW2/2 C_AH1/2 C_CX2/2 ye-re C_BF/1 C_BA/1 wh-gn C_BG1/3 C_AJ1/3 C_CX/2 C_AJ/3 C_CW/2 C_BG/3 C_CX/2 C_CZ/3 C_DB/4 C_CW/2 C_CY/3 C_DA/4 ye-re... - Page 107 WIRING DIAGRAM Components Battery Generator Ignition coil Pulse generator Voltage regulator/rectifier Electric starter button Starter relay with fuse Starter motor Emergency OFF switch Throttle valve sensor TPS Ignition curve plug connection CDI controller Headlight Parking light Brake / tail light Light switch Flasher switch Flasher relay...
- Page 108 WIRING DIAGRAM yellow ye-bl yellow-black ye-re yellow-red...
- Page 109 WIRING DIAGRAM...
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Page 110: Wiring Diagram (Exc-R Six Days)
WIRING DIAGRAM Wiring diagram (EXC-R SIX DAYS) C_DG/4 C_BP/4 bl-wh bu-wh bu-wh ye-bl re-wh re-bl re-bl re-wh C_CR/1 C_CR1/1 C_AK1/2 C_AH1/2 C_BA/1 C_BF/1 ye-re wh-gn C_AJ/3 C_BG/3 C_CX/2 C_CZ/3 C_DB/4 C_CW/2 C_CY/3 C_DA/4 ye-bl C_BA2/1 ye-bl ye-re wh-re ye-re wh-re ye-re C_CA/4 C_CE/4... - Page 111 WIRING DIAGRAM Components Battery Generator Ignition coil Pulse generator Voltage regulator/rectifier Electric starter button Starter relay with fuse Starter motor Light switch, horn button, short circuit button Throttle valve sensor TPS Ignition curve plug connection CDI controller Headlight Parking light Brake / tail light Thermoswitch Speedometer...
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Page 112: Wiring Diagram (Xcr-W Usa)
WIRING DIAGRAM Wiring diagram (XCR-W USA) bl-wh bu-wh bu-wh ye-bl re-wh re-bl re-bl re-wh ye-bl ye-re wh-re ye-re wh-re ye-re 400310-10... - Page 113 WIRING DIAGRAM Components Battery Generator Ignition coil Pulse generator Voltage regulator/rectifier Electric starter button Starter relay with fuse Starter motor Short circuit button Throttle valve sensor TPS Ignition curve plug connection CDI controller Light switch Speedometer Wheel speed sensor Tripmaster switch (optional) Plug connector for radiator fan (optional) Plug connector, headlight (optional) Plug connector, brake / tail light (optional)
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Page 114: Wiring Diagram (Xcr-W Za)
WIRING DIAGRAM Wiring diagram (XCR-W ZA) bl-wh bu-wh bu-wh ye-bl re-wh re-bl re-bl re-wh ye-bl ye-re wh-re ye-re wh-re ye-re 400311-10... - Page 115 WIRING DIAGRAM Components Battery Generator Ignition coil Pulse generator Voltage regulator/rectifier Electric starter button Starter relay with fuse Starter motor Short circuit button Throttle valve sensor TPS Ignition curve plug connection CDI controller Headlight Parking light Brake / tail light Light switch Speedometer Wheel speed sensor...
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Page 116: Substances
DIN EN 228 (ROZ 95 / RON 95 / PON 91) Brake fluid DOT 5.1 according to Specification Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Motorex Supplier Motorex ® Motorex Brake Fluid DOT 5.1... -
Page 117: Auxiliary Substances
AUXILIARY SUBSTANCES Universal oil spray Specification ® KTM recommends Motorex products. Supplier Motorex ® Motorex Joker 440 Universal Long-life grease Specification ® KTM recommends Motorex products. Supplier Motorex ® Motorex Long Therm 2000 Chain cleaner Specification ® KTM recommends Motorex products. - Page 118 AUXILIARY SUBSTANCES High-luster polish for paint Specification ® KTM recommends Motorex products. Supplier Motorex ® Motorex Moto Polish Contact spray Specification ® KTM recommends Motorex products. Supplier Motorex ® Motorex Accu Contact...
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Page 119: Standards
Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the fore- ground for motorcycle engines. With most motorcycles, the gearbox and the clutch are lubricated with the oil as the engine. The JASO MA Standard meets these special requirements. -
Page 120: Consumer Information (Exc-R Usa)
CONSUMER INFORMATION (EXC-R USA) Type label USA Chain tension EAVP Before you go for the first ride Type label CAN Noise emission Green sticker... - Page 121 NOISE EMISSION WARRANTY KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise stan- dards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.
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Page 122: Index
INDEX Accessories ........6 Air filter cleaning . - Page 123 ....... . . 73 Maintenance ........6 Motorcycle cleaning .
- Page 124 INDEX removing ....... . . 47 Starting ........26 steering locking .
- Page 125 *3211254en* 3211254en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...