KTM workshop..........29 Chassis number............... 9 Important maintenance work to be carried out by an Type label............... 9 authorized KTM workshop. (as additional order)....30 Key number (EXC EU)............9 Important checks and maintenance work to be carried Engine number..............9 out by the rider.
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TECHNICAL DATA - ENGINE TIGHTENING TORQUES..88 Changing the rear brake linings ........60 TECHNICAL DATA - CARBURETOR........90 Removing the front wheel .......... 61 450 EXC EU ..............90 Installing the front wheel ........... 61 XC‑W USA ..............90 Removing rear wheel ..........62 530 EXC EU ..............
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.
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.
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IMPORTANT NOTES Transport Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. Note Fire hazard Some vehicle components get very hot when the machine is driven. – Do not place the vehicle where there are flammable or explosive substances.
VIEW OF VEHICLE View of the vehicle from the left front (example) 800014-10 Side stand Shift lever Chain guide Fuel tap Air filter box lid Clutch lever Hand brake lever...
VIEW OF VEHICLE View of the vehicle from the right rear (example) 800013-10 Level viewer for brake fluid, rear Fork compression adjustment Foot brake pedal Kickstarter Horn Filler cap Fork rebound adjustment Electric starter button Speedometer Short circuit button Shock absorber compression adjustment Shock absorber rebound adjustment...
LOCATION OF SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. 500127-10 Type label The type label is fixed to the front of the steering head. 500128-10 Key number (EXC EU) The key number is stamped on the key strap.
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...
CONTROLS 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. The hand brake lever is used to activate the front brake.
CONTROLS Light switch (EXC EU) The light switch is fitted on the left side of the handlebar. Possible states Light off – Light switch is turned to the right. In this position, the light is switched off. Low beam on – Light switch is in the central position. In this position, the low beam and tail light are switched on.
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.
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 closed.
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.
CONTROLS Press the button Next display mode briefly. Display mode SPEED/CLK (clock) 5.20 – Press the button briefly and repeatedly until CLK appears at the bottom right of the display. The time is displayed in CLK display mode. Press the button .
CONTROLS Press the button . No function Press the button Displays of TR1, A1 and S1 are reset to 0,0. for 3 - 5 seconds. Press the button Next display mode briefly. Display mode SPEED/TR2 (trip master 2) 5.24 – Press the button briefly and repeatedly until TR2 appears at the top right of the display.
CONTROLS Display mode SPEED/S1 (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) displays the journey time on the basis of TR1 and continues when an impulse is received from the wheel speed sensor.
CONTROLS Choke (XC‑W USA) 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.
CONTROLS Kickstarter 5.36 Kickstarter is fitted on the right of the engine. The engine can be started with either the kickstarter or the electric starter. The upper part of the kickstarter can be swung out. Info Before riding, swing the upper part of the kickstarter inward toward the engine. 500148-10 Side stand 5.37...
CONTROLS – 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 EU) 5.40 –...
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.
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.
RIDING 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. – Check the engine oil level.
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.
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. –...
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RIDING INSTRUCTIONS – Fill the fuel tank with fuel up to measurement Guideline Measurement of 35 mm (1.38 in) Total fuel tank 9.0 l Super unleaded (ROZ 95 / RON 95 / capacity, approx. (2.38 US gal) PON 91) ( p.
SERVICE 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. 77) Change the gear oil and clean the gear oil screen.
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.
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SERVICE SCHEDULE NB1A Clean the chain. ( p. 49) • Check the chain tension. ( p. 49) • Check the chain wear. ( p. 50) • Check the rear sprocket / engine sprocket for wear. ( p. 50) • Clean the air filter. p.
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…...
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...
MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn adjusting screw clockwise up to the last perceptible click. Info Do not loosen nut – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping 400210-10 Comfort...
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking riding sag of shock absorber 9.10 – Measure distance of rear wheel unloaded. ( p. 34) – With another person holding the motorcycle, the rider should 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting riding sag 9.12 – Remove shock absorber. p. 36) – 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…...
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.
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.
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.
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: (XC‑W USA) –...
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the fork legs 9.26 – Remove the front wheel. p. 61) – Remove screws and take off clamp. – Remove cable clip , remove screw and take off the brake caliper. ...
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove o-ring . Remove protector ring – Remove the lower triple clamp with the steering stem. – Remove the upper steering head bearing. 500100-10 Removing the lower triple clamp (EXC EU) 9.31 –...
MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the upper triple clamp with the steering. – Mount and tighten screw Guideline Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft) – Position the clutch line, wiring harness and CDI control unit. Mount and tighten screws ...
MAINTENANCE WORK ON CHASSIS AND ENGINE – Tighten screw Guideline Screw, top steering stem 20 Nm (14.8 lbf ft) – Check the cable harness, cable, brake and clutch line for free movement and free laying. – Check the steering head bearing play. ( p.
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 (EXC EU) 9.38 – Connect the electric plug connector 500156-11 –...
MAINTENANCE WORK ON CHASSIS AND ENGINE Handlebar position 9.41 On the upper triple clamp, there are 2 holes at a distance of to each other. Distance between holes 15 mm (0.59 in) The holes on the handlebar support are placed at a distance of from the center.
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking play in gas Bowden cable 9.44 – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the gas Bowden cable. Play in gas Bowden cable 3…...
MAINTENANCE WORK ON CHASSIS AND ENGINE Cleaning the chain 9.47 Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking due to oil or grease on the brake discs. –...
MAINTENANCE WORK ON CHASSIS AND ENGINE – Make sure that the chain adjusters are mounted correctly on the adjusting screws. – Push the chain at the end of the chain sliding component upwards to measure the chain tension Info The upper chain section must be taut.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Push the chain at the end of the chain sliding component upwards to measure chain tension Info The upper chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions.
Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 400252-10 Check brake discs 9.56 Warning Danger of accidents Reduced braking due to worn brake discs. – Worn brake discs should be replaced immediately in an authorized KTM workshop.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement Info Wear reduces the thickness of the brake disc around the area used by the brake linings.
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.
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.
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.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove the front brake linings. p. 55) – 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.
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. –...
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.
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 Hazardous substances cause environmental damage. –...
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the front wheel 9.74 – Jack up the motorcycle. ( p. 32) – 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.
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.
9.78 Info Only mount tires approved and/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.
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.
Environmental hazard Battery parts and acid are harmful to the environment. – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries.
MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Even if there is no load on the battery, it loses power every day. The charge state and the type of charge are very important for the service life of the battery.
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.
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the seat 9.88 – Remove screw . Lift up the seat at the rear, pull it back and then remove from above. 500080-10 Mounting the seat 9.89 – 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Pull both spoilers to the side of the radiator bracket and take the fuel tank away upwards. 500067-10 Installing the fuel tank 9.91 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE Cooling system 9.92 The water pump in the engine forces the coolant to flow. The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap .
MAINTENANCE WORK ON CHASSIS AND ENGINE – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the coolant level in the radiator. Coolant level above radiator fins. 10 mm (0.39 in) » If the level of the coolant does not meet specifications: –...
MAINTENANCE WORK ON CHASSIS AND ENGINE Glass fiber yarn filling of main silencer 9.97 The main silencer is filled with glass fiber yarn. Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out". Not only is the noise level higher, the performance characteristic changes.
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the air filter 9.102 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. Warning Environmental hazard Hazardous substances cause environmental damage.
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting basic position of clutch lever 9.105 – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.
setting. Guideline Idle mixture adjusting screw (530 EXC EU) Open 1.5 turns Idle mixture adjusting screw (XC‑W USA, 450 EXC EU) Open 1.75 turns Adjustment tool for mixture control screw (77329034000) 400341-10 – Run the engine until warm.
MAINTENANCE WORK ON CHASSIS AND ENGINE Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon- sciousness and/or death. – When running the engine, always make sure there is sufficient venti- lation, and do not start or run the engine in a closed space without an effective exhaust extraction system.
MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. Info Carry out this work with a cold engine. –...
MAINTENANCE WORK ON CHASSIS AND ENGINE – Place a suitable container under the engine. – Remove engine oil plug screen – Completely drain the engine oil. – Thoroughly clean the plug and gear oil screen. – Clean the sealing area on the engine. –...
MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount oil filter cover – Mount and tighten screws Guideline Screw, oil filter cover 10 Nm (7.4 lbf ft) – Stand the motorcycle up. 200113-11 Filling up with engine oil 9.116 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine.
MAINTENANCE WORK ON CHASSIS AND ENGINE Condition Engine is cold. – Remove gear oil level check screw . Stand the vehicle upright. – Check the gear oil level. A small amount of gear oil should flow out. » If no gear oil flows out: –...
MAINTENANCE WORK ON CHASSIS AND ENGINE Filling up with gear oil 9.121 Info Too little gear oil or poor-quality oil results in premature wear to the transmission. – Remove the screw cap and fill up with gear oil. Gear oil 0.90 l (0.95 qt.) Engine oil (SAE 10W/50) ( p.
TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Go through the steps of starting the engine. tric starter). p. 25) – Battery discharged Recharge the battery. p. 65) – Check the charging voltage. – Check the closed current.
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TROUBLESHOOTING Faults Possible cause Action – Engine has too little power. Air filter very dirty Clean the air filter. p. 73) – 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.
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, plug connectors, Bowden cables and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
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. 32) –...
TECHNICAL DATA - CARBURETOR 450 EXC EU 15.1 Carburetor type KEIHIN FCR-MX 39 Carburetor identification number 3900I Needle position 4th position from top Idle mixture adjusting screw Open 1.75 turns Pump membrane stop 2.15 mm (0.0846 in) Main jet Jet needle...
Rear 1.0 bar (15 psi) Road tire pressure (EXC EU) Front 1.5 bar (22 psi) Rear 2.0 bar (29 psi) Final drive (450 EXC EU) 15:45 (13:52) Final drive (XC‑W USA) 13:52 Final drive (530 EXC EU) 15:45 (14:52) Chain 5/8 x 1/4"...
80/100 - 21 51M TT 110/100 - 18 64M TT Bridgestone M59 Bridgestone M402 Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 16.3 Total fuel tank capacity, 9.0 l (2.38 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p.
TECHNICAL DATA - FORK Fork part number 14.18.7E.06 Fork WP Suspension Up Side Down 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 Weight of rider: 65…...
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WIRING DIAGRAM CDI controller Throttle position sensor Wheel speed sensor Thermoswitch (EXC SIX DAYS) Battery Generator Right rear flasher Left front flasher Left rear flasher Right front flasher Brake/tail light Parking light License plate lamp Low/high beam Horn Radiator fan (EXC SIX DAYS) Flasher indicator light High beam indicator light Starter relay with main fuse...
– 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 ®...
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.