KTM 450 EXC Owner's Manual
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KTM 450 EXC Owner's Manual

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OWNER'S MANUAL
2016
450 EXC EU
450 EXC AU
450 EXC Six Days EU
450 XC-W US
500 EXC EU
500 EXC AU
500 EXC Six Days EU
500 XC-W US
Art. no. 3213338en

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Summary of Contents for KTM 450 EXC

  • Page 1 OWNER'S MANUAL 2016 450 EXC EU 450 EXC AU 450 EXC Six Days EU 450 XC-W US 500 EXC EU 500 EXC AU 500 EXC Six Days EU 500 XC-W US Art. no. 3213338en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, misprints, and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Setting the clock..........21 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 Viewing the lap time........21 Symbols used ........... 5 Display mode SPEED (speed) ......22 Formats used............ 5 Display mode SPEED/H (service hours) ..... 22 SAFETY ADVICE............
  • Page 5 TABLE OF CONTENTS 11.12 Adjusting the compression damping of the 12.48 Removing the engine guard (All EXC models)..78 fork ............... 44 12.49 Installing the engine guard (All EXC models) ..78 11.13 Adjusting the rebound damping of the fork ..45 13 BRAKE SYSTEM ............
  • Page 6 TABLE OF CONTENTS 18.4 Adding engine oil .......... 110 19 CLEANING, CARE ............ 111 19.1 Cleaning the motorcycle ........ 111 19.2 Checks and maintenance steps for winter operation............112 20 STORAGE ..............113 20.1 Storage ............113 20.2 Preparing for use after storage......113 21 TROUBLESHOOTING ..........

  • 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

    Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements. 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.

  • 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

    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 & Warranty Booklet and in the KTM Dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 12: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) S00813-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Filler cap Shift lever ( p. 18) Engine number ( p. 12) Side stand ( p. 18)

  • Page 13: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) S00812-10 Kill switch ( p. 14) Horn button ( p. 15) 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 (All EXC models)  The key number for the steering lock is stamped onto the key connector.

  • Page 15: 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. 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. M00083-10 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: 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 102044-11 Light switch (All EXC models) The light switch ...

  • Page 18: Electric Starter Button (Exc Eu, Exc Six Days, Xc-W)

    CONTROLS 6.11 Electric starter button (EXC EU, EXC SIX DAYS, XC-W)  The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position pressed – the electric starter is actuated in this position. •...

  • Page 19: Closing Filler Cap

    CONTROLS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water.

  • Page 20: Shift Lever

    CONTROLS 6.18 Shift lever  The shift lever is fitted on the left side of the engine. 401950-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.19 Kick starter ...

  • Page 21: Steering Lock (All Exc Models)

    CONTROLS 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  rubber band 401944-10 6.22 Steering lock (All EXC models) Steering lock  is fitted on the left side of the steering head.

  • Page 22: 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 23: 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 24: 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 25: 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 26: 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 27: 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 28: 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 29: 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 30: 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 31: 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 32: 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 33: Running-In The Engine

    PREPARING FOR USE – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. – If you carry any baggage, make sure you fix it firmly as close as possible to the center of the vehicle and ensure even weight distri- bution between the front and rear wheels.

  • Page 34: Preparing For Rides On Dry Sand

    – Fit a dust cover on the air filter. Dust protection device for air filter (77206920100) Info See the KTM PowerParts fitting instructions. M00999-01 – Fit a sand cover on the air filter. Sand protection device for air filter (59006922000) Info See the KTM PowerParts fitting instructions.

  • Page 35: 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 (77206921100) Info See the KTM PowerParts fitting instructions. M01001-01 – Fit the steel sprocket. – Clean the motorcycle. ( p.

  • Page 36: 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. 107) –...

  • Page 37: 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 unusual noises occur 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 38: 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 39: 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 40: Service Schedule

    ● ● Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval...

  • Page 41: Service Work (As Additional Order)

    SERVICE SCHEDULE 10.2 Service work (as additional order) Annually Every 135 operating hours/every 70 operating hours when used for motorsports Every 45 operating hours Once after 15 operating hours ● Change the front brake fluid. ● Change the rear brake fluid. ●...

  • Page 42: 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 43: 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 44: Measuring Rear Wheel Sag Unloaded

    TUNING THE CHASSIS 11.6 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with the lift stand. ( p. 50) 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 45: 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 46: 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. 63) – Remove the motorcycle from the lift stand. ( p.

  • Page 47: 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 COMP (white adjusting screw).

  • Page 48: Adjusting The Spring Preload Of The Fork (Exc Eu/Au, Xc-W)

    TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. (EXC Six Days) –  Turn the red adjusting screw all the way clockwise. Info  Adjusting screw is located at the upper end of the right fork leg. The rebound damping is located in the right fork leg REB (red adjusting screw).

  • Page 49: Handlebar Position

    TUNING THE CHASSIS Info Turn clockwise to increase the spring preload; turn counterclockwise to reduce the spring preload. Adjusting the spring preload has no influence on the absorption setting of the rebound damping. Basically, however, you should set the rebound damping higher with a higher spring preload.

  • Page 50: Adjusting Handlebar Position

    TUNING THE CHASSIS 11.16 Adjusting handlebar position Warning Danger of accidents Handlebar breakage. – If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle- bar. (All EXC models) –  Remove screws .
  • Page 51 TUNING THE CHASSIS –  Position the handlebar clamps. Mount and tighten screws evenly. Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) Info Make sure the gap width is even.

  • Page 52: 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 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 (78129955100) Neither wheel is in contact with the ground.

  • Page 53: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS (EXC Six Days) –  Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws. S00636-10 Finishing work – Remove the motorcycle from the lift stand. ( p.

  • Page 54: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS (EXC EU/AU) –  Release screws . Take out the left fork leg. –  Release screws . Take out the right fork leg. K00086-10 (XC‑W) –  Release screws . Take out the left fork leg. –...
  • Page 55 SERVICE WORK ON THE CHASSIS (XC‑W) – Position the fork legs. Bleeder screws  are positioned toward the front. Info Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from the top) must be flush with the top edge of the upper triple clamp.

  • Page 56: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS – Refit the headlight mask with the headlight. ( p. 97) – Check the headlight setting. ( p. 99) 12.7 Removing the fork protector –  Remove screws and take off the clamp. –  Remove screws on the left fork leg.

  • Page 57: Removing The Lower Triple Clamp (Xc-W)

    SERVICE WORK ON THE CHASSIS (EXC Six Days) – Open the cable holder in front of the right radiator and detach the wiring har- ness. –  Remove screws and hang the voltage regulator to the side. –   Remove screw .

  • Page 58: Installing The Lower Triple Clamp (All Exc Models)

    SERVICE WORK ON THE CHASSIS 12.11 Installing the lower triple clamp (All EXC models) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 126) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.
  • Page 59 SERVICE WORK ON THE CHASSIS –  Mount and tighten screw Guideline Screw, top steering stem 17 Nm Loctite ® 243™ (12.5 lbf ft) K00092-10 –  Tighten screws Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) – ...
  • Page 60 SERVICE WORK ON THE CHASSIS –  Mount and tighten screw Guideline Screw, top steering stem 17 Nm Loctite ® 243™ (12.5 lbf ft) B01233-10 –  Tighten screws Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) – ...

  • Page 61: Installing The Lower Triple Clamp (Xc-W)

    SERVICE WORK ON THE CHASSIS 12.12 Installing the lower triple clamp (XC‑W) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 126) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

  • Page 62: 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 63: Adjusting The Play Of The Steering Head Bearing (All Exc 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: (All EXC models) –...

  • Page 64: Adjusting The Play Of The Steering Head Bearing (Xc-W)

    SERVICE WORK ON THE CHASSIS Finishing work – Check the steering head bearing play. ( p. 60) – Remove the motorcycle from the lift stand. ( p. 50) 12.15 Adjusting the play of the steering head bearing (XC‑W) Preparatory work –...

  • Page 65: Installing The Front Fender

    SERVICE WORK ON THE CHASSIS –  Remove screws . Remove the front fender. K00073-10 12.18 Installing the front fender Main work –  Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) K00072-10 –...

  • Page 66: Removing The Seat

    SERVICE WORK ON THE CHASSIS Guideline Screw, bottom shock 80 Nm Loctite ® 2701™ absorber (59 lbf ft) Info The heim joint for the shock absorber at the swingarm 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.

  • Page 67: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 12.25 Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to increased wear. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 68: Sealing The Air Filter Box

    SERVICE WORK ON THE CHASSIS Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 126) Info Only press the air filter to dry it, never wring it out. –...

  • Page 69: Cleaning Spark Arrestor (Xc-W)

    SERVICE WORK ON THE CHASSIS 12.31 Cleaning spark arrestor (XC‑W) Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. Info Soot particles accumulate on the screen of the spark arrestor over time. This changes the performance characteristics.

  • Page 70: Changing Glass Fiber Yarn Filling In The Main Silencer

    SERVICE WORK ON THE CHASSIS 12.32 Changing glass fiber yarn filling in the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. Info Over time, the fibers of the glass fiber yarn escape and the damper "burns"...

  • Page 71: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS –  Position the silencer cap with O-ring in the outer tube. –  Mount and tighten screws Guideline Screws on the main silencer 7 Nm (5.2 lbf ft) Finishing work – Install the main silencer. ( p.

  • Page 72: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS (EXC Six Days) – Disconnect the connector of the horn. – Remove screws  with the collar bushings and horn. M01023-10 (XC‑W) –  Remove screws with the collar bushings. K00146-10 –  Remove screw with the rubber bushing.
  • Page 73 SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water.

  • Page 74: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS –  Plug in connector of the fuel pump. – Remove the wash cap set. – 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.

  • Page 75: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 12.37 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear- ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases.

  • Page 76: 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 ...
  • Page 77 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. »...

  • Page 78: 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. 401340-01 12.41 Checking the swingarm –...

  • Page 79: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS 12.43 Checking the rubber grip – Check the rubber grips on the handlebar for damage and wear and to ensure they are firmly seated. » If a rubber grip is damaged, worn or loose: – Change and secure the rubber grip.

  • Page 80: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 12.47 Changing the hydraulic clutch fluid 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. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...

  • Page 81: Brake System

    BRAKE SYSTEM 13.1 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 can fail due to overheating.

  • Page 82: 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 83: 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 84: Changing 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 Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.

  • Page 85: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM –   Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 100397-01 – Insert the new brake linings, insert the pin, and mount the cotter pins. Info Always change the brake linings in pairs.

  • Page 86: 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 87: 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 88: 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 89 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 new brake linings, insert the pin, and mount the cotter pins. Info Always change the brake linings in pairs.

  • Page 90: Wheels, Tires

    WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 50) 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 (EXC Six Days) –   Align the brake disc guard so that gaps are the same size. M01022-10 –  Mount and tighten screw Guideline Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) – Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc.

  • Page 92: Installing The Rear Wheel

    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 93: Checking The 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 94 WHEELS, TIRES – Tap each spoke with a screwdriver. Info The sound frequency depends on the length and thickness of the spoke. If there are different sound frequencies in spokes with the same length and thickness, this indicates different spoke tensions. You should hear a high note.

  • Page 95: Electrical System

    ELECTRICAL SYSTEM 15.1 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 96: Charging The Battery

    – Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 97: Changing The Main Fuse

    ELECTRICAL SYSTEM 15.4 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box cover.

  • Page 98: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM 15.5 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat.

  • Page 99: Refitting The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM –  Detach plug-in connectors and take off the headlight mask with the head- light. K00118-10 (XC‑W) – Switch off all power consumers and switch off the engine. –  Remove screw and take off the clamp. – ...

  • Page 100: Changing The Headlight Bulb

    ELECTRICAL SYSTEM –  Position the headlight mask and fix it with rubber straps Info Ensure the holding lugs engage in the fender. – Position the brake line and wiring harness. Put the clamp on and mount and  tighten screw K00151-11 Finishing work –...

  • 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. 96) Main work –  Remove screws – Pull the speedometer upward out of the holder. K00122-10 –  Using a coin, turn protection cap all the way counterclockwise and remove it.

  • 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: Draining The Coolant

    COOLING SYSTEM – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the coolant level in the radiator. 10 mm (0.39 in)  Coolant level above radiator fins. » If the coolant level does not meet specifications: –...
  • Page 105 COOLING SYSTEM – Refit the radiator cap. Finishing work (All EXC models) – Install the engine guard. ( p. 78) – Take a short test ride. – Check the coolant level. ( p. 101)

  • 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. Move the throttle grip back and  forth slightly to ascertain play in the throttle cable. Play in throttle cable 3…...

  • Page 107: Adjusting The Idle Speed

    TUNING THE ENGINE 17.3 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 1,950…...
  • Page 108 TUNING THE ENGINE –  Mount and tighten screw with the washers. Guideline Screw, shift lever 14 Nm Loctite ® 243™ (10.3 lbf ft)

  • Page 109: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 18.1 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 110: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens

    SERVICE WORK ON THE ENGINE 18.3 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 111 SERVICE WORK ON THE ENGINE –  Position oil screen with the O-rings on a pin wrench. – Position the pin wrench through the drill hole of the screw plug in the opposite sec- tion of the engine case. – Push the oil screen all the way into the engine case.

  • Page 112: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 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 113: Cleaning, Care

    CLEANING, CARE 19.1 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 114: 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 115: 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. 50) – Preferably cover the vehicle with a tarp or similar cover that is permeable to air.

  • Page 116: 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 117 – 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.

  • Page 118: 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 119 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...

  • Page 120: Technical Data

    TECHNICAL DATA 23.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement (all 450 models) 449.3 cm³ (27.418 cu in) Displacement (alle 500 Modelle) 510.4 cm³ (31.147 cu in) Stroke (all 450 models) 63.4 mm (2.496 in) Stroke (alle 500 Modelle) 72 mm (2.83 in) Bore 95 mm (3.74 in) Compression ratio...
  • Page 121 TECHNICAL DATA Loctite ® 243™ Plug, vacuum connection 2.5 Nm (1.84 lbf ft) Screw plug EVAP 5 Nm (3.7 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 ®...

  • Page 122: Capacities

    1.0 bar (15 psi) Road tire pressure (All EXC models) Front 1.5 bar (22 psi) Rear 1.5 bar (22 psi) Final drive (all 450 EXC models) 14:52 (13:52) Final drive (alle 500 EXC Modelle) 14:50 (13:50) Final drive (450 XC-W US) 13:52...

  • Page 123: Electrical System

    Seat height unloaded 970 mm (38.19 in) Ground clearance unloaded 345 mm (13.58 in) Homologated weight without fuel, approx. (all 450 EXC models) 111.0 kg (244.7 lb.) Homologated weight without fuel, approx. (alle 500 EXC Mod- 111.5 kg (245.8 lb.) elle) Weight without fuel, approx.

  • Page 124: Exc Six Days

    TECHNICAL DATA Spring preload - Preload Adjuster Comfort 0 turns Standard 0 turns Sport 1 turn Spring length with preload spacer(s) Weight of rider: 65… 75 kg (143… 165 lb.) 510 mm (20.08 in) Weight of rider: 75… 85 kg (165… 187 lb.) 510 mm (20.08 in) Weight of rider: 85…...

  • Page 125: Chassis Tightening Torques

    TECHNICAL DATA Comfort 9 mm (0.35 in) Standard 9 mm (0.35 in) Sport 9 mm (0.35 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 69 N/mm (394 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 72 N/mm (411 lb/in) Weight of rider: 85…...
  • Page 126 TECHNICAL DATA – Screw, top triple clamp (All EXC mod- 17 Nm (12.5 lbf ft) els) – Screw, top triple clamp (XC‑W) 20 Nm (14.8 lbf ft) – Engine attachment bolt 60 Nm (44.3 lbf ft) – Remaining nuts, chassis 45 Nm (33.2 lbf ft) –...

  • Page 127: 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 128: Auxiliary Substances

    Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Grip adhesive (00062030051) Recommended supplier KTM Motorrad AG – GRIP GLUE High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier Motorex ®...
  • Page 129 AUXILIARY SUBSTANCES Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic...

  • Page 130: 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 131: 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 132: Lisy Of Symbols

    LISY 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. EFI warning lamp (MIL) lights up/flashes orange – The OBD has detected an emission- or safety-critical fault. The low fuel warning lamp lights up orange –...

  • Page 133: Index

    INDEX fluid, changing ......78 INDEX Clutch lever ........14 Accessories .
  • Page 134 INDEX bleeding ....... . . 50 dust boots, cleaning ......51 Main fuse installing .
  • Page 135 INDEX removing ....... . . 63 riding sag, checking ......42 View of vehicle spring preload, adjusting .
  • Page 136 *3213338en* 3213338en 04/2015 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

This manual is also suitable for:

500 exc500 xc-w500 exc six days

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