KTM 530 EXC Owner's Manual
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KTM 530 EXC Owner's Manual

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OWNER'S MANUAL
2009
450 EXC USA
530 EXC USA
ART. NO. 3211356en

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Summary of Contents for KTM 530 EXC

  • Page 1 OWNER'S MANUAL 2009 450 EXC USA 530 EXC USA ART. NO. 3211356en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors.

  • Page 4: Table Of Contents

    LOCATION OF SERIAL NUMBERS ........12 Important maintenance work to be carried out by an Chassis number............. 12 authorized KTM workshop. (as additional order)....32 Type label..............12 Important checks and maintenance work to be carried Key number ..............12 out by the rider.
  • Page 5 Installing the rear brake linings ........58 450 EXC USA ............... 88 Changing the rear brake linings ........59 530 EXC USA ............... 88 Removing the front wheel .......... 60 TECHNICAL DATA - CHASSIS ..........89 Installing the front wheel ...........

  • Page 6: 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 7: Important Notes

    Warranty The work prescribed in the service schedule must be carried out in an authorized KTM workshop and confirmed in the customer's ser- vice record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 8: Overview Of Labels

    IMPORTANT NOTES Environment Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a poten- tial problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such problems and conflicts do not have to occur.
  • Page 9 IMPORTANT NOTES 500251-01 Type label for the USA Fuel evaporative system information 500254-01 Chain tension information 500255-01 Information on putting into operation 700210-01 500252-01 Emission control information...
  • Page 10 Noise emission warranty KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable US EPA Federal noise standards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.
  • Page 11 Consumer rights Warranty claims should be directed to a KTM workshop. If you wish to make a complaint, please contact: KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA Telephone: (440) 985–3553...

  • Page 12: View Of Vehicle

    VIEW OF VEHICLE 3 V IEW OF VEHICLE View of the vehicle from the left front (example) 300399-10 Side stand Shift lever Chain guide Fuel tap Air filter box lid Clutch lever Light switch, headlight flasher button, flasher switch, horn button Hand brake lever...

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

    VIEW OF VEHICLE View of the vehicle from the right rear (example) 300398-10 Level viewer for brake fluid, rear Fork compression adjustment Foot brake pedal Kickstarter Horn Ignition switch Fork rebound adjustment Filler cap Shock absorber compression adjustment Shock absorber rebound adjustment...

  • Page 14: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS 4 L OCATION OF SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right.  500127-10 Type label The type label USA is fixed to the front of the steering head. ...

  • Page 15: Fork Part Number

    LOCATION OF SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub.  500082-10 Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above ...

  • Page 16: Controls

    CONTROLS 5 C ONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar.  The clutch is hydraulically operated and self-adjusting. 500133-10 Hand brake lever Hand brake lever is located on the right side of the handlebar. ...

  • Page 17: Light Switch

    CONTROLS Light switch Light switch is fitted on the left side of the handlebar.  Possible states Low beam on – Light switch is turned downward. In this position, the low beam and tail light are switched on. High beam on – Light switch is turned upward. In this position, the high beam and tail light are switched on.

  • Page 18: Speedometer

    CONTROLS Speedometer 5.11 – Press the key 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 In its condition at delivery, the display mode SPEED/H and SPEED/ODO is acti- vated.

  • Page 19: Setting The Clock

    CONTROLS – Press the button for 3 - 5 seconds. The settings are saved and the Setup menu 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 The Lap Time

    CONTROLS – Press the button for 3 - 5 seconds. The settings are saved and the Setup menu 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 21: Speed/Clk Display Mode (Time)

    CONTROLS Press the button next display mode briefly. SPEED/CLK display mode (time) 5.20 – Press the button briefly and repeatedly until CLK appears at the bottom right of the display. The time is displayed in the CLK display mode. Press the button .

  • Page 22: Speed/Tr2 Display Mode (Trip Master 2)

    CONTROLS Press the button The TR1, A1 and S1 displays are reset to 0.0. for 3 - 5 seconds. Press the button next display mode briefly. SPEED/TR2 display mode (trip master 2) 5.24 – Press the button briefly and repeatedly until TR2 appears at the top right of the display.

  • Page 23: Speed/S1 Display Mode (Stop Watch 1)

    CONTROLS SPEED/S1 display mode (stop watch 1) 5.27 – Press the button briefly and repeatedly until S1 appears at the top right of the display. S1 (stop watch 1) shows the trip time on the basis of TR1 and continues running when an impulse is received from the wheel speed sensor.

  • Page 24: Fuel Tap

    CONTROLS Table of conditions and activability Display Vehicle at a stand- Menu can be acti- still vated SPEED/CLK display mode (time) • SPEED/LAP display mode (lap time) • SPEED/TR1 display mode (trip master 1) • SPEED/TR2 display mode (trip master 2) •...

  • Page 25: Choke

    CONTROLS Choke 5.32 Choke is fitted on the left side of the carburetor.  Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start. Info If the engine is warm, the choke function must be deactivated.

  • Page 26: Side Stand

    CONTROLS Side stand 5.36 Note Danger of damage Danger of damage by the vehicle running away or falling over. – Always place the vehicle on a firm and even surface. Note Material damage Damage and destruction of components by excessive load. – The side stand is designed for the weight of the motorcycle only.

  • Page 27: Unlocking The Steering

    CONTROLS Unlocking the steering 5.39 – Insert the key in the steering lock, turn it to the left, pull it out and turn it to the right. Remove the key. You can now steer the bike again. Info Never leave the key in the steering lock.

  • Page 28: 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 29: Running In The Engine

    GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION – Do not exceed the overall maximum permitted weight and the axle loads. Guideline Maximum permissible overall weight 335 kg (739 lb.) Maximum permissible front axle load 145 kg (320 lb.) Maximum permissible rear axle load 190 kg (419 lb.) –...

  • Page 30: Riding Instructions

    RIDING INSTRUCTIONS 7 R IDING INSTRUCTIONS Checks before putting into operation Info Make sure that the motorcycle is in a perfect technical condition before use. Info In the interests of riding safety, make a habit of making a general check before you ride. –...

  • Page 31: 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 32: 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 get very hot when the machine is driven. –...

  • Page 33: Service Schedule

    SERVICE SCHEDULE 8 S ERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop. S15A S30A Engine Change the engine oil and oil filter and clean the engine oil screen. p. 75) • • • Change the gear oil and clean the gear oil screen.

  • Page 34: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop. (As Additional Order)

    SERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) Competition use Hobby use S15A S30A S45A S30A S60A S90A • • Carry out a complete fork service. Carry out a complete shock absorber service.
  • Page 35 SERVICE SCHEDULE NB1A Clean the chain. ( p. 48) • Check the chain tension. ( p. 48) • Check the chain wear. ( p. 49) • Check the rear sprocket / engine sprocket for wear. ( p. 49) • Clean the air filter. p.

  • Page 36: 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). Guideline Standard rider weight 75…...

  • Page 37: Adjusting The Low-Speed Compression Damping Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn the adjusting screw clockwise with a ring wrench until it stops.  Info Do not loosen nut  – Turn back counterclockwise the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-speed 400208-10...

  • Page 38: Measuring Rear Wheel Sag Unloaded

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn the adjusting screw clockwise until it stops.  Info Do not loosen nut  – Turn back counterclockwise the number of clicks corresponding to the shock absorber type. Guideline Rebound damping 400210-10 Comfort 26 clicks Standard...

  • Page 39: Checking The Riding Sag Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the riding sag of the shock absorber 9.10 – Measure distance of rear wheel unloaded. ( p. 36)  – 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 40: Adjusting Riding Sag

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting riding sag 9.12 – Remove shock absorber. p. 38) – After removing the shock absorber, clean it thoroughly. – Choose and mount a suitable spring. Guideline Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 69 N/mm (394 lb/in) Weight of rider: 75…...

  • Page 41: Checking Basic Setting Of Fork

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking basic setting of fork 9.15 Info For various reasons, no exact riding sag can be determined for the forks. – As with the shock absorber, smaller weight differences can be compensated by the spring preload.

  • Page 42: Adjusting Spring Preload Of The Fork

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn back counterclockwise the number of clicks corresponding to the fork type. Guideline Rebound damping Comfort 24 clicks Standard 22 clicks Sport 22 clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce sus- pension damping.

  • Page 43: Loosening The Fork Protection

    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 44: Adjusting Play Of Steering Head Bearing

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Move the handlebar to and fro over the entire steering range. The handlebar must be able to move easily over the entire steering range. No resting locations should be noticeable. » If click positions are noticeable: –...

  • Page 45: Installing The Fork Legs

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the fork legs 9.26 – Position the fork legs. Info The topmost sunk nut in the fork leg must be flush to the upper edge of the upper triple clamp. Position the bleeder screw to the front.

  • Page 46: Removing The Lower Triple Clamp

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the lower triple clamp 9.29 – Remove the fork legs. ( p. 42) – Remove the headlight mask with the headlight. ( p. 45) – Dismount the front fender. ( p. 45) – Remove screws and hang the CDI control unit to the side.

  • Page 47: Greasing The Steering Head Bearing

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount and tighten screw  Guideline Screw, top steering stem 17 Nm Loctite ® 243™ (12.5 lbf ft) – Check the cable harness, cable, brake and clutch line for free movement and free laying.

  • Page 48: Refitting The Headlight Mask With The Headlight

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Pull out the electric plug connector and remove the headlight mask with the  headlight. 500156-10 Refitting the headlight mask with the headlight 9.35 – Connect the electric plug connector  500156-11 – Position the headlight mask and fix it with the rubber band ...

  • Page 49: Checking Gas Bowden Cable Route

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the handlebar. Info Make sure cables and wiring are positioned correctly. – Position the handlebar clamp. Mount and evenly tighten the four screws  Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) Info Make sure the gap width is even.

  • Page 50: Checking For Chain Dirt Accumulation

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Push bellows on. Check the throttle grip for smooth operation.  – Install the fuel tank. p. 67) – Check play in the gas Bowden cable. ( p. 47) Checking for chain dirt accumulation 9.41 –...

  • Page 51: Checking The Chain Tension When Fitting Rear Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the chain tension when fitting rear wheel 9.44 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel) are under additional load.

  • Page 52: Adjusting The Chain Tension

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the chain tension 9.47 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel) are under additional load.

  • Page 53: Adjusting Chain Tension - After Checking

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting chain tension - after checking 9.48 – Loosen nut  – Loosen nuts  – Adjust the chain tension by turning the adjusting screws left and right.  Guideline Chain tension 8… 10 mm (0.31… 0.39 in) Turn the adjusting screws left and right so that the markings on the left and ...

  • Page 54: Adjusting Chain Guide

    Warning Danger of accidents Reduced braking due to worn brake discs. – Worn brake discs should be replaced immediately in an authorized KTM workshop. – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement ...

  • Page 55: Adjusting Free Travel Of Handbrake Lever

    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. – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 56: Checking The Front Brake Linings

    Warning Danger of accidents Improper brake maintenance and repair. – Always have your brake system maintained and repaired in an authorized KTM workshop. – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons.

  • Page 57: Mounting 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 58: Checking Free Travel Of Foot Brake Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove the front brake linings. p. 54) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws  – Remove cover with membrane   – Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir.

  • Page 59: Checking The Rear Brake Fluid Level

    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. – Stand the vehicle upright. –...

  • Page 60: Checking The 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 61: 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 62: Removing The Front Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the front wheel 9.68 – Jack up the motorcycle. ( p. 34) – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.

  • Page 63: Removing Rear Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE – 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) – Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc.

  • Page 64: Tire Condition Checking

    9.72 Info Only mount tires approved or recommended by KTM. 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.

  • Page 65: Checking Tire Air Pressure

    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 66: Installing The Battery

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Disconnect the negative (minus) cable of the battery.  – Pull back the plus pole cover and disconnect the positive (plus) cable of the bat-  tery. – Hang the rubber band out to the bottom. ...

  • Page 67: Removing A Fuse

     Replace a burned-out fuse only by an equivalent fuse.  If the new fuse burns out, contact an authorized KTM workshop. – Replace the protection cover. 400273-10 – Install the air filter box lid. ( p.

  • Page 68: Mounting The Seat

    MAINTENANCE WORK ON CHASSIS AND ENGINE Mounting the seat 9.81 – Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear and simultaneously push it forward. – Make sure that the seat is correctly locked in. –...

  • Page 69: Installing The Fuel Tank

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the fuel tank 9.83 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 70: Checking Antifreeze And Coolant Level

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking antifreeze and coolant level 9.85 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 71: Draining Coolant

    MAINTENANCE WORK ON CHASSIS AND ENGINE Draining coolant 9.87 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 72: Installing The Main Silencer

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Disconnect spring  – Remove screws and take off main silencer.  800020-10 Installing the main silencer 9.91 – Mount the main silencer. Mount and tighten screws  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) –...

  • Page 73: Installing The Air Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Hang the air filter holder out to the bottom and swing it to the side. Remove the  air filter with the air filter support. – Remove the air filter from the air filter support. 500107-10 Installing the air filter 9.95...

  • Page 74: Checking The Fluid Level Of Hydraulic Clutch

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the fluid level of hydraulic clutch 9.98 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.

  • Page 75: Carburetor - Idle

     setting. Guideline Idle mixture adjusting screw (450 EXC USA) Open 1.75 turns Idle mixture adjusting screw (530 EXC USA) Open 2.0 turns Adjustment tool for mixture control screw (77329034000) 400341-10 – Run the engine until warm.

  • Page 76: Emptying The Carburetor Float Chamber

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn the idle adjusting screw slowly until the idle speed begins to fall.  – Note the position and turn the idle adjusting screw slowly counterclockwise until the idle speed falls. – Adjust to the point between these two positions with the highest idle speed. Info If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps.

  • Page 77: Checking Engine Oil Level

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Direct the hose of the float chamber into a suitable container. Info Water in the float chamber results in malfunctioning. – Undo the screw (turn it counterclockwise) a few turns and drain the fuel from ...

  • Page 78: Removing The Oil Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the oil filter 9.106 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. – Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 79: Filling Up With Engine Oil

    MAINTENANCE WORK ON CHASSIS AND ENGINE Filling up with engine oil 9.108 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – Remove the screw cap on the generator cover and fill up with engine oil. ...

  • Page 80: Changing Gear Oil, Cleaning Gear Oil Screen

    MAINTENANCE WORK ON CHASSIS AND ENGINE Changing gear oil, cleaning gear oil screen 9.111 – Drain the gear oil and clean the gear oil screen. p. 78) – Fill up with gear oil. p. 78) Draining gear oil, cleaning gear oil screen 9.112 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven.

  • Page 81: Adding Gear Oil

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adding gear oil 9.114 Info Too little gear oil or poor-quality oil results in premature wear to the transmission. – Remove gear oil level check screw  200116-10 – Remove screw cap . Stand the vehicle upright. ...

  • Page 82: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Go through the steps of starting the engine. tric starter). p. 28) – Battery discharged Recharge the battery. p. 64) – Check the charging voltage. –...
  • Page 83 TROUBLESHOOTING Faults Possible cause Action – Engine has too little power. Air filter very dirty Clean the air filter. p. 71) – Exhaust system leaky, deformed or Check exhaust system for damage. too little glass fiber yarn filling in – Change glass fiber yarn filling of main main silencer silencer.

  • Page 84: Cleaning

    CLEANING CLEANING Cleaning motorcycle 11.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 85: Storage

    Storage temperature of battery without direct sunshine. 0… 35 °C (32… 95 °F) – The storage place should be dry and not subject to large temperature differences. Info KTM recommends propping up the motorcycle. – Jack up the motorcycle. ( p. 34) –...

  • Page 86: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 1-cyliner 4-stroke engine, water-cooled Displacement (450 EXC USA) 449.3 cm³ (27.418 cu in) Displacement (530 EXC USA) 510.4 cm³ (31.147 cu in) Stroke (450 EXC USA) 63.4 mm (2.496 in) Stroke (530 EXC USA) 72 mm (2.83 in) Bore 95 mm (3.74 in)

  • Page 87: Capacity - Coolant

    TECHNICAL DATA - ENGINE Capacity - coolant 13.3 Coolant 0.95 l (1 qt.) Coolant ( p. 97) Coolant (mixed ready to use) ( p. 97)

  • Page 88: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Screw, cable holder in generator cover 4 Nm (3 lbf ft) Loctite 243™ ® Oil jet, rocker arm lubrication 2 Nm (1.5 lbf ft) Loctite 243™ ® Oil jet, piston cooling 2 Nm (1.5 lbf ft) Loctite...
  • Page 89 TECHNICAL DATA - ENGINE TIGHTENING TORQUES Screw, cylinder head M10x1.25 Tightening sequence: lubricated with engine oil Tighten diagonally, begin- ning with the rear screw on the chain shaft. Step 1 10 Nm (7.4 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 50 Nm (36.9 lbf ft) –...

  • Page 90: Technical Data - Carburetor

    2.15 mm (0.0846 in) Main jet Jet needle OBDYU Idling jet Idle air jet Cold start jet Leakage nozzle 530 EXC USA 15.2 Carburetor type KEIHIN FCR-MX 39 Carburetor identification number 3900Y Needle position 3rd position from top Idle mixture adjusting screw Open 2.0 turns...

  • Page 91: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS TECHNICAL DATA - CHASSIS Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Suspension 4860 MXMA PA Suspension travel Front 300 mm (11.81 in) Rear 335 mm (13.19 in) Fork offset 19 mm (0.75 in) WP Suspension PDS 5018 DCC Shock absorber Brake system...

  • Page 92: Tires

    90/90 - 21 M/C 54M M+S TT 140/80 - 18 M/C 70M M+S TT Metzeler MCE 6 DAYS EXTREME Metzeler MCE 6 DAYS EXTREME For further information, see the Service section under: http://www.ktm.com Capacity - fuel 16.3 Total fuel tank capacity, 9.2 l (2.43 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p.

  • Page 93: Technical Data - Fork

    TECHNICAL DATA - FORK TECHNICAL DATA - FORK Fork part number 14.18.7E.06 Fork WP Suspension 4860 MXMA PA Compression damping Comfort 26 clicks Standard 22 clicks Sport 20 clicks Rebound damping Comfort 24 clicks Standard 22 clicks Sport 22 clicks Spring length with preload spacer(s) 510 mm (20.08 in) Spring rate...

  • Page 94: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 12.18.7E.06 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 18 clicks Standard 15 clicks Sport 12 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport...

  • Page 95: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Spoke nipple, front wheel M4,5 5 Nm (3.7 lbf ft) – Spoke nipple, rear wheel 5 Nm (3.7 lbf ft) – Screw, spoiler on fuel tank M5x12 1.5 Nm (1.11 lbf ft) –...

  • Page 96: Wiring Diagram

    WIRING DIAGRAM WIRING DIAGRAM Wiring diagram 20.1 CX/2 CZ/3 DB/4 CW/2 CY/3 DA/4 AK1/2 CW2/2 CW3/2 DG/4 AH1/2 CX2/2 CX3/2 BP/4 bl-wh bu-wh bu-wh ye-re ye-re ye-re ye-bl re-wh re-bl ye-re black BF/1 ye-re ye-re ye-bl BA/1 ye-bl re-bl wh-re re-wh ye-re CR/1...
  • Page 97 WIRING DIAGRAM Components CDI controller Throttle position sensor Wheel speed sensor Battery Generator Right rear flasher Left front flasher Left rear flasher Right front flasher Brake/tail light Parking light Low/high beam Horn Flasher indicator light High beam indicator light Starter relay with main fuse Flasher relay Pulse generator Ignition coil...
  • Page 98 WIRING DIAGRAM Yellow ye-bl Yellow-black ye-re Yellow-red...

  • Page 99: Substances

    – Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...

  • Page 100: Auxiliary Substances

    AUXILIARY SUBSTANCES AUXILIARY SUBSTANCES Air filter cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Chain cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Cleaning and polishing materials for metal, rubber and plastic Specification –...
  • Page 101 AUXILIARY SUBSTANCES Oil for foam air filter Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Liquid Bio Power Universal oil spray Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Joker 440 Universal...

  • Page 102: Standards

    STANDARDS STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard.Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification.Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle and ATV engines.With most motorcycles and ATVs, the gearbox and the clutch are lubricated with the same oil as the engine.

  • Page 103: Index

    INDEX Clutch lever ........14 INDEX adjusting basic position ..... . . 71 Accessories .
  • Page 104 INDEX removing ....... . . 45 Overview of indicator lamps .
  • Page 105 INDEX Technical data carburetor ....... . 88 chassis ....... . 89-90 chassis tightening torques .
  • Page 106 *3211356en* 3211356en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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