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

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OWNER'S MANUAL
2011
450 EXC USA
530 EXC USA
Art. no. 3211602en

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Summary of Contents for KTM 450 EXC

  • Page 1 OWNER'S MANUAL 2011 450 EXC USA 530 EXC USA Art. no. 3211602en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Preparing for rides at low temperatures or in snow .... 30 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........4 RIDING INSTRUCTIONS ............ 31 IMPORTANT INFORMATION ..........5 Checks and maintenance before putting into operation..31 Overview of labels............6 Starting ................
  • Page 5 TECHNICAL DATA - ENGINE TIGHTENING TORQUES..100 Changing rear brake linings ........68 TECHNICAL DATA - CARBURETOR........102 WHEELS, TIRES ............... 70 450 EXC USA ............. 102 Removing front wheel ..........70 530 EXC USA ............. 102 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 Information

    Warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claim can be honored for damage resulting from manipulation and/or other changes to the vehicle.

  • Page 8: Overview Of Labels

    IMPORTANT INFORMATION – Turn handle of the fuel tap to the OFF position. (Figure 500137-10 p. 22)  – Use straps or other suitable devices to secure the motorcycle against accidents or falling over. Environment Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the environment and can lead to conflicts with other persons.
  • Page 9 IMPORTANT INFORMATION 500251-01 Type label for the USA Fuel evaporative system information 100873-01 Chain tension information 500255-01 Information on putting into operation 700210-01 100840-01 Emission control information...
  • Page 10 If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc. If NHTSA receives similar complaints, it may open an investigation. If it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
  • Page 11 IMPORTANT INFORMATION Noise emission warranty KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise stan- dards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.

  • Page 12: View Of Vehicle

    VIEW OF VEHICLE View of the vehicle from the left front (example) 100868-10 Side stand Shift lever Chain guide Fuel tap Air filter box lid Clutch lever Light switch, headlight flasher switch, turn signal 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) 100869-10 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: Serial Numbers

    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.  300402-10 The type label Canada is fixed to the front of the front pipe. ...

  • Page 15: Fork Part Number

    SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub.  100801-10 Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above ...

  • 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. 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.

  • 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 key to control different functions. – Press the key to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.

  • Page 19: Setting The Clock

    CONTROLS – Press the button for 3 - 5 seconds. The settings are stored and the Setup menu is closed. Info If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu is closed.

  • Page 20: Querying The Lap Time

    CONTROLS Info If no button is pressed for 20 seconds, or if a pulse arrives from the wheel speed sensor, the settings are stored automatically and the Setup menu is closed. Querying the lap time 5.17 Info This function can be called only if lap times are measured. Condition The motorcycle is stationary.

  • Page 21: Display Mode Speed/Clk (Clock)

    CONTROLS 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 . No function Press the button .

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

    CONTROLS 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. TR2 (trip master 2) runs constantly and counts up to 999.9. The displayed value can be set manually with the button and the button .

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

    CONTROLS 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.

  • Page 24: Opening Filler Cap

    CONTROLS Table of conditions and menu activation Display The motorcycle is Menu can be acti- stationary. vated Display mode SPEED/CLK (clock) • Display mode SPEED/LAP (lap time) • Display mode SPEED/TR1 (trip master 1) • Display mode SPEED/TR2 (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 The parked vehicle may roll away or fall 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. Do not sit on the motorcycle when it is supported by the side stand 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. 400731-01...

  • Page 28: 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

    PUTTING INTO OPERATION Info Motorcycles react sensitively to any changes of weight distribution. – 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: Preparing For Riding On Wet Sand

    Sand protection device for air filter (59006022000) Info See the KTM PowerParts fitting instructions. – Adjust the carburetor jetting and settings. Info 600871-01 Your authorized KTM workshop has the recommended carburetor tuning set- tings. – Clean the chain. Chain cleaner ( p. 110) –...

  • Page 31: Preparing For Riding On Wet And Muddy Surfaces

    Waterproofing device for air filter (59006021000) Info See the KTM PowerParts fitting instructions. – Adjust the carburetor jetting and settings. Info 600870-01 Your authorized KTM workshop has the recommended carburetor tuning set- tings. – Clean the chain. Chain cleaner ( p. 110) –...

  • Page 32: Preparing For Rides At High Temperature And Slow Speed

    Fit a waterproofing device on the air filter. Waterproofing device for air filter (59006021000) Info See the KTM PowerParts fitting instructions. – Adjust the carburetor jetting and settings. Info 600870-01 Your authorized KTM workshop has the recommended carburetor tuning set- tings.

  • Page 33: Riding Instructions

    RIDING INSTRUCTIONS Checks and maintenance before putting into operation Info The motorcycle must always be in perfect technical condition before use. Before every trip, check the condition of the vehicle and ensure that it is safe to operate. – Check the engine oil level. ( p.

  • Page 34: Starting Up

    Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines.

  • Page 35: Stopping, Parking

    RIDING INSTRUCTIONS – On sandy, wet or slippery surfaces, use the rear brake. – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. – On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine. In this way, you have to brake far less and the brakes do not overheat.
  • Page 36 RIDING INSTRUCTIONS – Fill the fuel tank with fuel up to measurement  Guideline Measurement of 35 mm (1.38 in)  Total fuel tank 9.2 l Super unleaded (ROZ 95 / RON 95 / capacity, approx. (2.43 US gal) PON 91) ( p.

  • Page 37: Service Schedule

    Check idle. Final check: Check the vehicle for roadworthiness and take a test ride. • • • Make the service entry in KTM DEALER.NET and in the service record. • • • S1N: Once after one operating hour S15A: Every 15 operating hours...

  • Page 38: Service Work (As Additional Order)

    SERVICE SCHEDULE Service work (as additional order) S15N S45A S90A • Change the front brake fluid. Change the rear brake fluid. • Change the foot brake cylinder seals. • Change the hydraulic clutch fluid. p. 60) • Grease the steering head bearing. p.

  • Page 39: 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 high-speed setting can be seen during the fast compression of the shock absorber.

  • Page 40: Adjusting The Low-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 low-speed setting can be seen during the slow to normal compression of the shock absorber.

  • Page 41: Measuring Rear Wheel Sag Unloaded

    TUNING THE CHASSIS Measuring rear wheel sag unloaded – Raise the motorcycle with the lift stand. ( p. 44) – Measure the distance – as vertically as possible – between the rear axle and a fixed point, such as a mark on the side cover. –...

  • Page 42: Adjusting 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 43: Checking Basic Setting Of Fork

    TUNING THE CHASSIS Checking basic setting of fork 9.11 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. – However, if your fork is often overloaded (hits the bump stops on compression), it is recommended to fit stiffer springs to avoid damage to the fork and frame.

  • Page 44: Adjusting Spring Preload Of The Fork

    TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. Adjusting spring preload of the fork 9.14 – Turn adjusting screws counterclockwise until they stop. Info Make sure the setting is identical on both fork legs. –...
  • Page 45 TUNING THE CHASSIS – 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 46: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS Raising the motorcycle with the lift stand 10.1 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (54829055000) The wheels should no longer touch the ground.

  • Page 47: Loosening The Fork Protector

    SERVICE WORK ON THE CHASSIS Loosening the fork protector 10.5 – Remove screws and remove the clamp.  – Remove screws on the left fork leg. Push the fork protector downwards.  – Remove the screws on the right fork leg. Push the fork protector downwards. 600875-11 Positioning the fork protector 10.6...

  • Page 48: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS – Fully tighten screw  Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) – Tighten screws  Guideline Screw, bottom triple clamp 12 Nm (8.9 lbf ft) 100803-11 – Position brake caliper, mount and tighten screws ...

  • Page 49: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS – Remove o-ring . Remove protector ring   – Remove the lower triple clamp with the steering stem. – Remove the upper steering head bearing. 500100-10 Installing the lower triple clamp 10.12 – Clean the bearing and sealing elements, check for damage, and grease. Long-life grease ( p.

  • Page 50: Checking 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 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 51: Removing The Shock Absorber

    SERVICE WORK ON THE CHASSIS Removing the shock absorber 10.16 – Raise the motorcycle with the lift stand. ( p. 44) – Remove screw and lower the rear wheel with the swing arm as far as possible  without blocking the rear wheel. Fix the rear wheel in this position. –...

  • Page 52: Removing The Seat

    SERVICE WORK ON THE CHASSIS Removing the seat 10.20 – Remove screw . Lift up the seat at the rear, pull it back and then remove from  above. 500080-10 Mounting the seat 10.21 – 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.

  • Page 53: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS – Detach air filter holder at the bottom and swing it to one 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 10.25 –...

  • Page 54: Removing Main Silencer

    SERVICE WORK ON THE CHASSIS Removing main silencer 10.27 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. – Disconnect spring  –...

  • Page 55: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS Removing the fuel tank 10.30 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 56: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS – Position the fuel tank and fit the two spoilers to the sides of the radiator bracket. – Make sure that no cables are trapped or damaged. 500067-01 – Mount the fuel tank vent hose. –...

  • Page 57: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 110) Off-road chain spray ( p. 110) 400725-01 Checking the chain tension 10.34 Warning Danger of accidents Danger caused by incorrect chain tension. –...

  • Page 58: Adjusting Chain Tension

    SERVICE WORK ON THE CHASSIS Adjusting chain tension 10.36 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. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break.

  • Page 59: Adjusting Chain Tension - After Checking

    SERVICE WORK ON THE CHASSIS Adjusting chain tension - after checking 10.37 – 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 60 SERVICE WORK ON THE CHASSIS – Pull on the upper part of the chain with the specified weight  Guideline Weight of chain wear measurement 10… 15 kg (22… 33 lb.) 0 0 A – Measure the distance of 18 chain links in the lower chain section. ...

  • Page 61: Adjusting Chain Guide

    SERVICE WORK ON THE CHASSIS – Check the chain guide for wear. Info Wear is visible on the front of the chain guide. » If the light part of the chain guide is worn: – Change the chain guide. 400985-01 –...

  • Page 62: Adjusting Basic Position Of Clutch Lever

    SERVICE WORK ON THE CHASSIS Adjusting basic position of clutch lever 10.42 – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw  Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.
  • Page 63 SERVICE WORK ON THE CHASSIS – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws  – Remove cover with membrane   400339-10 – Fill bleeding syringe with the appropriate hydraulic fluid. ...

  • Page 64: Brakes

    Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disk to see if it conforms to measurement ...

  • Page 65: Checking The Brake Fluid Level Of The Front Brake

    Warning Danger of accidents Reduced braking effect caused by 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 66: Checking The Front Brake Linings

    Warning Danger of accidents Reduced braking effect caused by 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 67 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 68: Checking The Free Travel Of The Foot Brake Lever

    BRAKES – Correct the brake fluid reservoir level to the marking  Guideline Measurement of 5 mm (0.2 in)  Brake fluid DOT 4 / DOT 5.1 ( p. 108) – Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water.

  • Page 69: Checking Rear Brake Fluid Level

    Warning Danger of accidents Reduced braking effect caused by 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 70: Checking Rear Brake Linings

    Warning Danger of accidents Reduced braking effect caused by 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 71 BRAKES – Stand the vehicle upright. – Remove screw cap with membrane and the O-ring.   – Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.

  • Page 72: Wheels, Tires

    WHEELS, TIRES Removing front wheel 12.1 – Raise the motorcycle with the lift stand. ( p. 44) – 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 73: Removing The Rear Wheel

    WHEELS, TIRES – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw  Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc.

  • Page 74: Tire Condition Checking

    12.5 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 75: Checking Tire Air Pressure

    Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.
  • Page 76 WHEELS, TIRES Torque wrench with various accessories in set (58429094000)

  • Page 77: Electrical System

    – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 78: Removing The Main Fuse

    ELECTRICAL SYSTEM 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. Fast recharging with a high charge current shortens the battery's service life. If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes.

  • Page 79: Removing Headlight Mask With Headlight

    ELECTRICAL SYSTEM – Insert the main fuse. Fuse (58011109110) ( p. 103) Info A reserve fuse is located in the starter relay.  Replace a faulty fuse by an equivalent fuse only.  – Replace the protection cover. – Install the air filter box lid. ( p.

  • Page 80: Changing The Headlight Bulb

    ELECTRICAL SYSTEM Changing the headlight bulb 13.8 Note Damage to reflector Reduced luminance. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting. –...

  • Page 81: Adjusting The Beam Width Of The Headlight

    ELECTRICAL SYSTEM Adjusting the beam width of the headlight 13.10 – Check the headlight adjustment. ( p. 78) – Loosen screw  – Adjust the light range by swiveling the headlight. Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with a rider (mark is applied under: Checking the headlight adjust- ment).

  • Page 82: Cooling System

    COOLING SYSTEM Cooling system 14.1 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 . This ensures that operating the vehicle at the specified coolant ...

  • Page 83: Draining Coolant

    COOLING SYSTEM Condition The engine is cold. – Stand the motorcycle upright on a horizontal surface. – Remove radiator cap. – Check the coolant level in the radiator. Coolant level above the radiator fins. 10 mm (0.39 in)  » If the coolant level does not meet specifications: –...
  • Page 84 COOLING SYSTEM – Refit the radiator cap. – Make a short test ride. – Check the coolant level. ( p. 80)

  • Page 85: Tuning The Engine

    TUNING THE ENGINE Checking the play in the throttle cable 15.1 – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3… 5 mm (0.12… 0.2 in) »...

  • Page 86: Carburetor - Adjusting Idle

    – Screw in the idle adjusting screw until it stops and then to the prescribed basic  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 –...

  • Page 87: Emptying The Carburetor Float Chamber

    TUNING THE ENGINE Emptying the carburetor float chamber 15.5 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 88 TUNING THE ENGINE – Clean gear teeth of the shift lever and shift shaft.  – Mount the shift lever on the shift shaft in the required position and engage the gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle compo- nents during the shift procedure.

  • Page 89: Service Work On The Engine

    SERVICE WORK ON THE ENGINE Checking engine oil level 16.1 Info The engine oil level must be checked when the engine is cold. – Stand the motorcycle upright on a horizontal surface. Condition Engine is cold. – Check the engine oil level. The engine oil must be between the halfway mark and the top of the oil level viewer ...

  • Page 90: Removing The Oil Filter

    SERVICE WORK ON THE ENGINE Removing the oil filter 16.4 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 91: Filling Up With Engine Oil

    SERVICE WORK ON THE ENGINE Filling up with engine oil 16.6 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 92: Checking The Gear Oil Level

    SERVICE WORK ON THE ENGINE Checking the gear oil level 16.8 Info The gear oil level should only be checked when the engine is cold. – Stand the motorcycle upright on a horizontal surface. Condition Engine is cold. – Remove gear oil level check screw .

  • Page 93: Filling Up With Gear Oil

    SERVICE WORK ON THE ENGINE – Place a suitable container under the engine. – Remove the gear oil drain plug  – Remove the gear oil screen plug  – Completely drain the gear oil. – Thoroughly clean the gear oil drain plug with a magnet. –...
  • Page 94 SERVICE WORK ON THE ENGINE – Remove screw cap . Stand the motorcycle upright.  – Add gear oil until it flows out of the bore of the gear oil level screw. Engine oil (SAE 10W/50) ( p. 108) – Mount and tighten the gear oil level check screw.

  • Page 95: Cleaning, Care

    CLEANING, CARE Cleaning the motorcycle 17.1 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, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 96 CLEANING, CARE – Clean the chain. ( p. 54)

  • Page 97: Storage

    0… 35 °C (32… 95 °F) – Place the vehicle on a dry storage place that is not subject to large temperature variations. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 44) –...

  • Page 98: 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. 31) – Battery discharged Recharge the battery. p. 75) – Check the charging voltage. – Check the stall current.
  • Page 99 TROUBLESHOOTING Faults Possible cause Action – Engine has a lack of power Exhaust system leaky, deformed or Check exhaust system for damage. too little glass fiber yarn filling in – Change the glass fiber yarn filling of the main main silencer silencer.

  • Page 100: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 1-cylinder 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 101: Capacity - Coolant

    TECHNICAL DATA - ENGINE Capacity - coolant 20.3 Coolant 0.95 l (1 qt.) Coolant ( p. 108) Coolant (mixed ready to use) ( p. 108)

  • Page 102: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Screw, cable holder in generator cover 4 Nm (3 lbf ft) Loctite 243™ ® Locking screw for bearing 6 Nm (4.4 lbf ft) Loctite 243™ ® Oil jet, piston cooling 2 Nm (1.5 lbf ft) Loctite 243™...
  • Page 103 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 104: Technical Data - Carburetor

    TECHNICAL DATA - CARBURETOR 450 EXC USA 22.1 Carburetor type KEIHIN FCR-MX 39 Carburetor identification number 3900Z 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...

  • Page 105: Technical Data - Chassis

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

  • Page 106: Tires

    140/80 - 18 M/C 70M M+S TT Metzeler MCE 6 DAYS EXTREME Metzeler MCE 6 DAYS EXTREME Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 23.3 Total fuel tank capacity, 9.2 l (2.43 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p.

  • Page 107: Technical Data - Fork

    TECHNICAL DATA - FORK Fork part number 14.18.7J.06 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 26 clicks Standard 22 clicks Sport 18 clicks Rebound damping Comfort 24 clicks Standard 20 clicks Sport 20 clicks Spring length with preload spacer(s) 510 mm (20.08 in) Spring rate Weight of rider: 65…...

  • Page 108: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 12.18.7J.06 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 22 clicks Standard 20 clicks Sport 15 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1.25 turns Rebound damping Comfort 26 clicks...

  • Page 109: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Screw, spoiler on fuel tank M5x12 1.5 Nm (1.11 lbf ft) – Spoke nipple, rear wheel 5… 6 Nm (3.7… 4.4 lbf ft) –...

  • Page 110: Substances

    – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 111 SUBSTANCES Super unleaded (ROZ 95 / RON 95 / PON 91) According to – DIN EN 228 (ROZ 95 / RON 95 / PON 91)

  • Page 112: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline –...
  • Page 113 AUXILIARY SUBSTANCES Universal oil spray Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Joker 440 Synthetic...

  • Page 114: 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 115: Index

    INDEX Cleaning ........93-94 INDEX Clutch Accessories ........5 fluid level, checking .
  • Page 116 INDEX Front fender Main silencer installing ....... . . 49 glass fiber yarn filling, changing .
  • Page 117 INDEX function description ......16 kilometers or miles, setting ....16 Spoke tension checking .
  • Page 118 *3211602en* 3211602en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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