KTM 450 EXC-F 2020 Owner's Manual
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KTM 450 EXC-F 2020 Owner's Manual

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OWNER'S MANUAL
2020
450 EXC‑F
450 EXC‑F Six Days
500 EXC‑F
500 EXC‑F Six Days
500 XCF‑W
Art. no. 3214012en

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Summary of Contents for KTM 450 EXC-F 2020

  • Page 1 OWNER'S MANUAL 2020 450 EXC‑F 450 EXC‑F Six Days 500 EXC‑F 500 EXC‑F Six Days 500 XCF‑W Art. no. 3214012en...
  • Page 3 KTM accepts no liability for delivery options, deviations from fig- ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 6.14 Opening fuel tank filler cap....20 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 6 6.15 Closing the fuel tank filler cap... 20 Symbols used ........6 6.16 Cold start button......21 Formats used........6 6.17 Idle speed adjusting screw ....21 SAFETY ADVICE..........
  • Page 5 TABLE OF CONTENTS Preparing the vehicle for riding on 11.14 Adjusting the spring preload of the dry sand.......... 39 fork (All EXC-F Six Days)....60 Preparing the vehicle for riding on 11.15 Handlebar position......61 wet sand ......... 40 11.16 Adjusting the handlebar position ..
  • Page 6 TABLE OF CONTENTS 12.35 Checking for chain dirt 15 ELECTRICAL SYSTEM ....... 121 accumulation........89 15.1 Removing the 12-V battery ..121 12.36 Cleaning the chain ......89 15.2 Installing the 12-V battery ... 122 12.37 Checking the chain tension ....90 15.3 Charging the 12-V battery ...
  • Page 7 TABLE OF CONTENTS 20 STORAGE ..........150 20.1 Storage ......... 150 20.2 Preparing for use after storage..151 21 TROUBLESHOOTING ........ 152 22 TECHNICAL DATA........155 22.1 Engine .......... 155 22.2 Engine tightening torques ....156 22.3 Capacities ........157 22.3.1 Engine oil .........

  • Page 8: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary tools required.

  • Page 9: Safety Advice 2

    SAFETY ADVICE 2 Use definition – intended use (All EU models) This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations. Info This vehicle is only authorized for operation on public roads in the homologated (restricted) version.

  • Page 10: Degrees Of Risk And Symbols

    2 SAFETY ADVICE Degrees of risk and symbols Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

  • Page 11: Protective Clothing

    – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks.

  • Page 12: Owner's Manual

    The Owner's Manual is an important component of the vehicle and must be handed over to the new owner if the vehicle is sold. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. International KTM Website: http://www.ktm.com...

  • Page 13: Important Notes 3

    Manufacturer and implied warranty The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con- firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

  • Page 14: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) V01746-10 Clutch lever ( p. 16) Fuel tank filler cap Air filter box cover Side stand ( p. 22) Engine number ( p. 14) Shift lever ( p. 22)

  • Page 15: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) V01747-10 Switch-off button ( p. 16) Horn button ( p. 17) (All EU models) Light switch ( p. 17) (All EU models) Turn signal switch ( p. 18) (All EU models) Start button ( p.

  • Page 16: Serial Numbers

    5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Type label (All EU models) The Europe type label is fixed to the front of the steering head. The Canada type label is fixed to the front of the chest tube.

  • Page 17: Fork Part Number

    SERIAL NUMBERS 5 Fork part number The fork part number is stamped on the inner side of the fork stub. 401947-10 Shock absorber article number Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. H02222-10...

  • Page 18: Controls

    6 CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. E00817-10 Hand brake lever The hand brake lever is fitted on the right side of the handle- bar.

  • Page 19: Horn Button (All Eu Models)

    CONTROLS 6 (XCF‑W) Switch-off button is fitted on the left side of the handle- bar. Possible states is in the basic position – In this • The switch-off button position, the ignition circuit is closed and the engine can be started.

  • Page 20: Turn Signal Switch (All Eu Models)

    6 CONTROLS Turn signal switch (All EU models) The turn signal switch is fitted on the left side of the handle- bar. Possible states Turn signal off – Turn signal switch is in the central position. Turn signal, left, on – The turn signal switch is turned to the left.

  • Page 21: Combination Switch (All Exc-F Six Days, Xcf-W)

    Possible states Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle elec- tronics. Stop and contact an authorized KTM work- shop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

  • Page 22: Opening Fuel Tank Filler Cap

    6 CONTROLS 6.14 Opening fuel tank filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 23: Cold Start Button

    CONTROLS 6 6.16 Cold start button The cold start button is fitted to the bottom of the throttle valve body. The electronic fuel injection system extends the injection time if the engine is cold and the ambient temperature is low. To help the engine burn the increased fuel quantity, it must be supplied with additional oxygen by pushing the cold start button.

  • Page 24: Shift Lever

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

  • Page 25: Steering Lock (All Eu Models)

    CONTROLS 6 The side stand is used for parking the motorcycle. Info When you are riding, side stand must be folded up and secured with rubber strap 401944-10 6.21 Steering lock (All EU models) Steering lock is fitted on the left side of the steering head. The steering lock is used to lock the steering.

  • Page 26: Unlocking The Steering (All Eu Models)

    6 CONTROLS 6.23 Unlocking the steering (All EU models) – Insert the key for the steering lock into the steering lock p. 23), turn it to the left, pull it out, and turn it to the right. Pull out the key for the steering lock. The handlebar can now be moved again.

  • Page 27: Combination Instrument 7

    COMBINATION INSTRUMENT 7 Combination instrument overview – Press the button to control different functions. – Press the button to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. V00799-01 Activation and test Activating combination instrument The combination instrument is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor.

  • Page 28: Setting The Combination Instrument

    7 COMBINATION INSTRUMENT – Wait 3 - 5 seconds. The settings are stored. Info If no button is pressed for 10–12 seconds, or if an impulse comes from the wheel speed sensor, the settings are automatically saved and the setup menu is closed.

  • Page 29: Setting The Clock

    COMBINATION INSTRUMENT 7 Setting the clock Condition The motorcycle is stationary. – Repeatedly press the button briefly until CLK appears at the bottom right of the display. – Press the button for 2–3 seconds. The hour display flashes. – Adjust the hour display with the button and/or button –...

  • Page 30: Display Mode Speed (Speed)

    7 COMBINATION INSTRUMENT Display mode SPEED (speed) – Repeatedly press the button briefly until SPEED appears on the left side of the display. The current speed is displayed in the SPEED display mode. The current speed can be displayed in Km/h or Mph. Info Make the setting according to the country.

  • Page 31: Adjusting The Unit Of Measurement

    COMBINATION INSTRUMENT 7 Info Repeatedly press the button briefly until the desired function is reached. If no button is pressed for 20 seconds, the settings are automatically saved. Briefly press Activates the flashing display and changes to the button the next display Press the but- No function for 2–3...

  • Page 32: Display Mode Speed/Clk (Time)

    7 COMBINATION INSTRUMENT 7.11 Display mode SPEED/CLK (time) – Repeatedly press the button briefly until CLK appears at the bottom right of the display. The time is shown in display mode CLK. Press the but- The display changes to the Setup menu of the for 2–3 clock.

  • Page 33: Viewing The Lap Time

    COMBINATION INSTRUMENT 7 Press the but- The stop watch and the lap time are reset. for 2–3 seconds. Briefly press Next display mode the button Press the but- Stops the clock. for 2–3 seconds. Briefly press Starts the stop watch or stop the current lap the button time measurement, stores it and the stop watch starts the next lap.

  • Page 34: Display Mode Speed/Tr1 (Trip Master 1)

    7 COMBINATION INSTRUMENT 7.16 Display mode SPEED/TR1 (trip master 1) – Repeatedly press the button briefly until TR1 appears at the top right of the display. TR1 (trip master 1) runs constantly and counts up to 999.9. You can use it to measure trips or the distance between refueling stops.

  • Page 35: Display Mode Speed/A1 (Average Speed 1)

    COMBINATION INSTRUMENT 7 Info The TR2 value can also be corrected manually during the journey with the button and the button If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0. Press the but- Increases value of TR2. for 2–3 seconds.

  • Page 36: Display Mode Speed/S1 (Stop Watch 1)

    7 COMBINATION INSTRUMENT Press the but- No function for 2–3 seconds. Press the but- No function for 2–3 seconds. Briefly press No function the button 7.21 Display mode SPEED/S1 (stop watch 1) – Repeatedly press the button briefly until S1 appears at the top right of the display.

  • Page 37: Table Of Functions

    COMBINATION INSTRUMENT 7 7.23 Table of functions Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12 for 2–3 the button for 2–3 the button seconds. seconds. seconds. seconds. Display mode The display Next display No function...

  • Page 38: Table Of Conditions And Menu Activation

    7 COMBINATION INSTRUMENT Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12 for 2–3 the button for 2–3 the button seconds. seconds. seconds. seconds. Setting TR2 Increases Increases Reduces Reduces Stores and (trip master 2) value of TR2.

  • Page 39: Preparing For Use 8

    When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-sales inspection work has been carried out by an authorized KTM workshop. You will receive a delivery certificate when the vehicle is handed over.

  • Page 40: Running-In The Engine

    8 PREPARING FOR USE (All EU models) – Adjust the free travel of the handbrake lever. ( p. 100) (XCF‑W) – Adjust the basic position of the hand brake lever. ( p. 101) – Adjust the basic position of the foot brake lever. p.

  • Page 41: Starting Power Of Lithium-Ion Batteries At Low Temperatures

    – Riding at low temperatures and in snow. ( p. 42) Preparing the vehicle for riding on dry sand – Mount the air filter dust cover. Air filter dust cover (79006920000) Info Observe the fitting instructions for KTM PowerParts. 102136-01...

  • Page 42: Preparing The Vehicle For Riding On Wet Sand

    8 PREPARING FOR USE – Mount the air filter sand cover. Air filter sand cover (79006922000) Info Observe the fitting instructions for KTM PowerParts. 102138-01 – Clean the chain. Chain cleaner ( p. 166) – Mount the steel sprocket. –...

  • Page 43: Preparing The Vehicle For Riding On Wet And Muddy Circuits

    Preparing the vehicle for riding on wet and muddy circuits – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the fitting instructions for KTM PowerParts. 102137-01 – Mount the steel sprocket. – Clean motorcycle. ( p.

  • Page 44: Preparing The Vehicle For Low Temperatures Or Snow

    Straighten the bent radiator fins carefully. – Check the coolant level. ( p. 134) Preparing the vehicle for low temperatures or snow – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the fitting instructions for KTM PowerParts. 102137-01...

  • Page 45: Riding Instructions 9

    RIDING INSTRUCTIONS 9 Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 46: Activating Traction Control (All Exc-F Six Days, Xcf-W)

    9 RIDING INSTRUCTIONS – Take the motorcycle off side stand and secure the side stand with rubber strap – Shift the transmission into neutral. – Turn the emergency OFF switch to the position Condition Ambient temperature: < 20 °C (< 68 °F) –...

  • Page 47: Starting Off

    Warning Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)

  • Page 48: Stopping, Parking

    9 RIDING INSTRUCTIONS Warning Danger of accidents Moisture and dirt impair the brake system. – Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs. – On sandy, wet or slippery surfaces, use the rear brake. –...

  • Page 49: Transporting

    In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.)
  • Page 50 9 RIDING INSTRUCTIONS Note Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to enter the groundwater, the soil, or the sewage system. – Switch off engine. – Open fuel tank filler cap. ( p.

  • Page 51: Service Schedule 10

    Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.

  • Page 52: Recommended Work

    Final check: Check the vehicle is roadworthy and take a test ride. ○ ● ● ● ● Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● ● Make a service entry in KTM Dealer.net.
  • Page 53 SERVICE SCHEDULE 10 Every 135 operating hours Every 70 operating hours when used for motorsports After 20 operating hours After 10 operating hours every 12 months ● ● Perform engine service including removing and installing the engine. (Change the spark plug and spark plug connector.

  • Page 54: 11 Tuning The Chassis

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock...

  • Page 55: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the high-speed compression adjuster can be seen in fast compression of the shock absorber.

  • Page 56: Adjusting The Rebound Damping Of The Shock Absorber

    Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.

  • Page 57: Checking The Static Sag Of The Shock Absorber

    TUNING THE CHASSIS 11 11.7 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 54) – Hold the motorcycle upright with aid of an assistant. – Measure the distance again between the rear axle and mark- ing SAG on the rear fender using the sag gage.

  • Page 58: Adjusting The Spring Preload Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow 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 spring length.

  • Page 59: Adjusting The Riding Sag

    TUNING THE CHASSIS 11 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with the lift stand. ( p. 64) – Remove the shock absorber. p. 78) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 60: Adjusting The Compression Damping Of The Fork

    11 TUNING THE CHASSIS 11.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. (EXC‑F EU, XCF‑W) – Turn white adjuster clockwise as far as it will go. Info Adjuster is located at the upper end of the left fork leg.

  • Page 61: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS 11 11.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. (EXC‑F EU, XCF‑W) – Turn red adjuster clockwise as far as it will go. Info Adjuster is located at the upper end of the right fork leg.

  • Page 62: Adjusting The Spring Preload Of The Fork (All Exc-F Six Days)

    11 TUNING THE CHASSIS 11.14 Adjusting the spring preload of the fork (All EXC-F Six Days) Preparatory work – Raise the motorcycle with the lift stand. ( p. 64) Main work – Turn T-grips counterclockwise all the way. The marking +0 aligns with the right wing. Info Make the adjustment by hand only.

  • Page 63: Handlebar Position

    TUNING THE CHASSIS 11 11.15 Handlebar position (EXC‑F EU, XCF‑W) On the upper triple clamp, there are 2 holes at a distance to each other. 15 mm (0.59 in) Hole distance The holes on the handlebar supports are placed at a distance from the center.
  • Page 64 11 TUNING THE CHASSIS (EXC‑F EU, XCF‑W) – Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against dam- age. Do not kink the cables and lines. –...
  • Page 65 TUNING THE CHASSIS 11 (All EXC-F Six Days) – Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against dam- age. Do not kink the cables and lines. –...

  • Page 66: 12 Service Work On The Chassis

    12 SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (78129955100) Neither wheel is in contact with the ground.

  • Page 67: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS 12 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 64) – Remove the fork protector. ( p. 65) Main work – Push dust boots of both fork legs downward.

  • Page 68: Installing The Fork Protector

    12 SERVICE WORK ON THE CHASSIS 12.6 Installing the fork protector – Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position the brake line, wiring harness, and clamp. Mount and tighten screws –...

  • Page 69: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS 12 (All EXC-F Six Days) – Loosen screws . Remove the left fork leg. – Loosen screws . Remove the right fork leg. V01784-10 12.8 Installing the fork legs Main work (EXC‑F EU, XCF‑W) – Position the fork legs.

  • Page 70: Removing The Lower Triple Clamp (Exc-F Eu, Xcf-W)

    12 SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, top triple 17 Nm clamp (12.5 lbf ft) – Tighten screws Guideline Screw, bottom 15 Nm triple clamp (11.1 lbf ft) V01784-11 – Position the brake caliper, and mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft)

  • Page 71: (All Exc-F Six Days)

    SERVICE WORK ON THE CHASSIS 12 – Remove O-ring and protective ring – Take off the lower triple clamp with the steering stem. – Remove the upper steering head bearing. V01757-10 12.10 Removing the lower triple clamp (All EXC-F Six Days) Preparatory work –...

  • Page 72: Installing The Lower Triple Clamp (Exc-F Eu, Xcf-W)

    12 SERVICE WORK ON THE CHASSIS 12.11 Installing the lower triple clamp (EXC‑F EU, XCF‑W) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 166) – Insert the lower triple clamp with the steering stem. Mount upper steering head bearing.
  • Page 73 SERVICE WORK ON THE CHASSIS 12 – Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head – Tighten screw Guideline Screw, top steering 20 Nm (14.8 lbf ft) stem V01789-10 – Tighten screws Guideline Screw, top triple 20 Nm (14.8 lbf ft) clamp V01790-11...

  • Page 74: Installing The Lower Triple Clamp (All Exc-F Six Days)

    12 SERVICE WORK ON THE CHASSIS 12.12 Installing the lower triple clamp (All EXC-F Six Days) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 166) – Position the lower triple clamp with the steering stem. Mount upper steering head bearing.

  • Page 75: Checking Steering Head Bearing Play

    129) 12.13 Checking steering head bearing play Warning Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam- ages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.)

  • Page 76: Adjusting Steering Head Bearing Play (Exc-F Eu, Xcf-W)

    12 SERVICE WORK ON THE CHASSIS Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time. Preparatory work – Raise the motorcycle with the lift stand.

  • Page 77: Adjusting Steering Head Bearing Play (All Exc-F Six Days)

    SERVICE WORK ON THE CHASSIS 12 Guideline Screw, top steering 20 Nm stem (14.8 lbf ft) Finishing work – Check steering head bearing play. ( p. 73) – Remove the motorcycle from the lift stand. ( p. 64) 12.15 Adjusting steering head bearing play (All EXC-F Six Days) Preparatory work –...

  • Page 78: Removing Front Fender

    12 SERVICE WORK ON THE CHASSIS 12.17 Removing front fender Preparatory work – Press and hold the switch-off button while the engine is idling until the engine stops. – Remove the headlight mask with the headlight. ( p. 127) Main work (EXC‑F EU, XCF‑W) –...

  • Page 79: Installing Front Fender

    SERVICE WORK ON THE CHASSIS 12 12.18 Installing front fender Main work (EXC‑F EU, XCF‑W) – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00340-10 – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00341-10...

  • Page 80: Removing The Shock Absorber

    12 SERVICE WORK ON THE CHASSIS 12.19 Removing the shock absorber Preparatory work – Raise the motorcycle with the lift stand. ( p. 64) Main work – Remove screw and lower the rear wheel with the link fork as far as possible without blocking the rear wheel. Secure the rear wheel in this position.

  • Page 81: Mounting The Seat

    SERVICE WORK ON THE CHASSIS 12 – Raise the rear of the seat, pull the seat back, and lift it off. H02218-10 12.22 Mounting the seat – Mount the front of the seat on the collar bushings of the fuel tank, lower the seat at the rear, and push the seat forward.

  • Page 82: Installing The Air Filter Box Cover

    12 SERVICE WORK ON THE CHASSIS – Pull off the air filter box cover in area laterally and take it off at the front. V01759-11 Condition The air filter box cover is not secured. – Pull off the air filter box cover in area laterally and take it off at the front.

  • Page 83: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 12 12.25 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter. – Never start to use the vehicle without an air filter. Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 84: Cleaning The Air Filter And Air Filter Box

    12 SERVICE WORK ON THE CHASSIS 12.27 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Do not clean the air filter with fuel or petroleum since these substances attack the foam.

  • Page 85: Removing The Main Silencer

    SERVICE WORK ON THE CHASSIS 12 12.29 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. –...
  • Page 86 12 SERVICE WORK ON THE CHASSIS V01736-10 Main work – Remove screws and take off silencer cap with O-ring Info Do not remove the glass fiber yarn filling. Caution Danger to health Soot particles irritate the eyes and mucuous membranes. – Wear suitable breathing and eye protection when cleaning the main silencer and carbon screen.

  • Page 87: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    SERVICE WORK ON THE CHASSIS 12 12.32 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. Info Over time, the fibers of the glass fiber yarn escape and the damper “burns”...

  • Page 88: Removing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS Finishing work – Install the main silencer. ( p. 83) 12.33 Removing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. –...

  • Page 89: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 12 (All EU models) – Remove screws – Hang the horn and horn bracket to one side. V01764-10 (XCF‑W) – Remove screws V01765-10 – Remove screw with the rubber bushing. – Remove the hose from the fuel tank breather. V01766-10 –...
  • Page 90 12 SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. –...

  • Page 91: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS 12 – Plug in connector for the fuel pump. – Remove the wash cap set. – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line.

  • Page 92: Checking The Chain Tension

    12 SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with the lift stand. ( p. 64) Main work – Rinse off loose dirt with a soft jet of water. – Remove old grease residue with chain cleaner. Chain cleaner ( p.

  • Page 93: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 12 12.38 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 94: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    12 SERVICE WORK ON THE CHASSIS 12.39 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with the lift stand. ( p. 64) Main work – Shift the transmission into neutral. – Check the rear sprocket and engine sprocket for wear. »...
  • Page 95 SERVICE WORK ON THE CHASSIS 12 – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with, or below, the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated.

  • Page 96: Checking The Frame

    » If the link fork exhibits damage, cracking, or deformation: – Change the link fork. Info Always replace a damaged link fork. Repairing the link fork is not authorized by KTM. S01317-10 12.42 Checking throttle cable routing Preparatory work –...

  • Page 97: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS 12 Main work – Check throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars and above the fuel tank bracket, to the throttle valve body. Both throttle cables must be secured behind the rubber strap of the fuel tank support.

  • Page 98: Adjusting The Basic Position Of The Clutch Lever

    12 SERVICE WORK ON THE CHASSIS (XCF‑W) – Check that screw is firmly seated. Guideline Screw, fixed 5 Nm (3.7 lbf ft) Loctite ® 243™ grip Diamond must be positioned visibly as shown in the figure. V01768-10 12.44 Adjusting the basic position of the clutch lever –...

  • Page 99: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 12 – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Check the fluid level. Fluid level below container 4 mm (0.16 in) »...

  • Page 100: Removing The Engine Guard (All Exc-F Six Days, Xcf-W)

    12 SERVICE WORK ON THE CHASSIS – Move the hydraulic clutch fluid reservoir mounted on the han- dlebar into a horizontal position. – Remove screws – Take off cover with membrane V00456-10 – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 101: Installing The Engine Guard (All Exc-F Six Days, Xcf-W)

    SERVICE WORK ON THE CHASSIS 12 12.48 Installing the engine guard (All EXC-F Six Days, XCF‑W) – Attach the engine guard on the frame at the rear and swing up at the front. – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis H01638-10...

  • Page 102: 13 Brake System

    13 BRAKE SYSTEM 13.1 Checking the free travel of the hand brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. –...

  • Page 103: Adjusting The Basic Position Of The Hand Brake Lever (Xcf-W)

    Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the front and rear brake disc thickness at multiple...

  • Page 104: Checking The Front Brake Fluid Level

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) (All EU models) –...
  • Page 105 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 106: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 107 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 108 13 BRAKE SYSTEM Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons. – Remove cotter pin , pull out pin , and remove the brake linings. – Clean the brake caliper and the brake caliper bracket. E00344-10 –...
  • Page 109 BRAKE SYSTEM 13 – Correct the brake fluid quantity to level Guideline 5 mm (0.2 in) Level (brake fluid level below reservoir rim) Brake fluid DOT 4 / DOT 5.1 ( p. 164) – Position cover with membrane . Mount and tighten screws Info Immediately clean up any brake fluid that has over-...

  • Page 110: Checking The Free Travel Of Foot Brake Lever

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

  • Page 111: Adjusting The Basic Position Of The Foot Brake Lever

    BRAKE SYSTEM 13 – Disconnect spring – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in) »...

  • Page 112: Checking The Rear Brake Fluid Level

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.

  • Page 113: Checking The Rear Brake Linings

    Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...

  • Page 114: Changing The Rear Brake Linings

    Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 115 BRAKE SYSTEM 13 – Stand the vehicle upright. – Remove screw cap with membrane and the O-ring. – Press the brake piston back into the basic position and ensure that brake fluid does not flow out of the brake fluid reservoir; extract some if necessary.
  • Page 116 13 BRAKE SYSTEM – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 164) – Mount screw cap with membrane and O-ring. Info Clean up overflowed or spilled brake fluid immediately with water. K01347-10...

  • Page 117: Wheels, Tires 14

    WHEELS, TIRES 14 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 64) Main work – Manually press the brake caliper toward the brake disc to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons.

  • Page 118: Installing The Front Wheel

    14 WHEELS, TIRES 14.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –...

  • Page 119: Installing The Rear Wheel

    WHEELS, TIRES 14 Main work – Manually press the brake caliper toward the brake disc to push back the brake piston. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston. –...
  • Page 120 14 WHEELS, TIRES Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surface of the spacers. Long-life grease ( p.

  • Page 121: Checking The Tire Condition

    DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. KTM recommends that the tires be changed after 5 H01144-01 years at the latest, regardless of the actual state of wear.

  • Page 122: Checking Spoke Tension

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.) –...

  • Page 123: Electrical System 15

    ELECTRICAL SYSTEM 15 15.1 Removing the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V batteries. – Only charge 12 V batteries in well-ventilated rooms.

  • Page 124: Installing The 12-V Battery

    15 ELECTRICAL SYSTEM – Remove screw and detach the battery compartment. – Lift out the 12-V battery. V01779-10 15.2 Installing the 12-V battery Main work – Insert the 12 V battery into the battery compartment with the terminals facing forward and secure with holding bracket 12-V battery (HJTZ5S-FP‑C) ( p.

  • Page 125: Charging The 12-V Battery

    ELECTRICAL SYSTEM 15 – Connect the positive cable to the 12-V battery. Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) Info Contact disk must be mounted under screw cable lug with the claws toward the battery termi- nal. – Slide positive terminal cover over the positive terminal.
  • Page 126 15 ELECTRICAL SYSTEM Main work Warning Risk of injury 12 V batteries contain harmful sub- stances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V bat- teries. – Only charge 12 V batteries in well-ventilated S00863-10 rooms.

  • Page 127: Changing The Main Fuse

    It is also impossible to overcharge the 12-V battery with this battery charger. The charging time may be longer at low temperatures. This battery charger is only suitable for lithium iron phosphate batteries. Read the accompanying KTM Pow- erParts instructions. Info Never remove cover –...

  • Page 128: Changing The Fuses Of Individual Power Consumers

    15 ELECTRICAL SYSTEM – Take off protection caps – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the starter relay. – Install a new main fuse. Fuse (58011109120) ( p.

  • Page 129: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 15 (XCF‑W) Fuse 1 ‑ 10 A - EFI control unit, combination instru- ment, combination switch (optional), electronic fuel injection, diagnostics connector, evaporate emission control system, fuse 4 Fuse 2 - 10 A - low beam, position light, tail light Fuse 3 - 10 A - radiator fan Fuse 4 - 5 A - fuel pump Fuses res - 10 A - spare fuse...

  • Page 130: Installing The Headlight Mask With The Headlight

    15 ELECTRICAL SYSTEM (All EU models) – Detach plug-in connectors and take off the headlight mask with the headlight. S01328-10 (XCF‑W) – Disconnect plug-in connector and take off the head- light mask together with the headlight. V01802-10 15.7 Installing the headlight mask with the headlight Main work (All EU models) –...

  • Page 131: Changing The Headlight Bulb

    ELECTRICAL SYSTEM 15 15.8 Changing the headlight bulb Note Damage to reflector Grease on the reflector reduces the light intensity. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. – Clean and degrease the bulbs before mounting. –...

  • Page 132: Adjusting The Headlight Range

    15 ELECTRICAL SYSTEM – The rider now sits down on the motorcycle. – Switch on the low beam. – Check the headlight setting. The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider. »...

  • Page 133: Changing The Combination Instrument Battery

    ELECTRICAL SYSTEM 15 Main work – Remove the screw on the rear of the turn signal housing. – Carefully remove turn signal glass – Lightly squeeze together the orange cap in the area of the holding lugs and take it off. –...

  • Page 134: Diagnostics Connector

    15 ELECTRICAL SYSTEM – Position protection cap and turn all the way clockwise using a coin. – Press any button on the combination instrument. The combination instrument is activated. – Position the combination instrument in the holder. – Mount and tighten the screws with washers. V00372-10 Finishing work –...

  • Page 135: Cooling System 16

    COOLING SYSTEM 16 16.1 Cooling system (All EU models) Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 136: Checking The Coolant Level

    16 COOLING SYSTEM – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: –...

  • Page 137: Draining The Coolant

    COOLING SYSTEM 16 16.4 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 138: Refilling Coolant

    16 COOLING SYSTEM 16.5 Refilling coolant Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. –...

  • Page 139: Tuning The Engine 17

    TUNING THE ENGINE 17 17.1 Checking the throttle cable play – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Throttle cable play 3 …...

  • Page 140: Adjusting The Characteristic Map Of The Throttle Response

    17 TUNING THE ENGINE Main work – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut – Push cold start button all the way to the stop. –...

  • Page 141: Changing The Mapping (All Exc-F Six Days, Xcf-W)

    TUNING THE ENGINE 17 – Remove guide plate from handle tube – Position the required guide plate on the grip tube. Guideline The label OUTSIDE must be visible. Marking must be positioned at marking Grey guide plate (79002014000) Alternative 1 Black guide plate (79002014100) Info The gray guide plate opens the throttle valve more...

  • Page 142: Adjusting The Idle Speed

    Danger of accidents The engine may go out spontaneously if the idle speed is set too low. – Set the idle speed to the specified value. (Your authorized KTM workshop will be glad to help.) – Run the engine until warm.

  • Page 143: Teaching The Throttle Valve Position

    TUNING THE ENGINE 17 17.6 Teaching the throttle valve position Info If the control unit detects that the throttle valve position at idle speed needs to be retaught, then the mal- function indicator lamp flashes 2x per second. Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death.

  • Page 144: Adjusting The Basic Position Of The Shift Lever

    17 TUNING THE ENGINE 17.8 Adjusting the basic position of the shift lever – Remove screw with the washers and take off shift lever 401950-12 – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage gearing.

  • Page 145: Service Work On The Engine 18

    SERVICE WORK ON THE ENGINE 18 18.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 146: Checking The Engine Oil Level

    18 SERVICE WORK ON THE ENGINE 18.2 Checking the engine oil level Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level.
  • Page 147 SERVICE WORK ON THE ENGINE 18 – Remove screw plug with the short oil screen and the O- rings. Info Do not remove screw H01704-10 – Remove screw plug with the long oil screen and the O- rings. – Allow the engine oil to drain completely. –...
  • Page 148 18 SERVICE WORK ON THE ENGINE – Remove screws . Remove the oil filter cover with the O-ring. H01709-10 – Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) – Allow the engine oil to drain completely. –...

  • Page 149: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 18 Finishing work (All EXC-F Six Days, XCF‑W) – Install the engine guard. ( p. 99) – Check the engine oil level. ( p. 144) 18.4 Adding engine oil Info Too little engine oil or poor-quality engine oil will result in premature wear of the engine. Main work –...

  • Page 150: 19 Cleaning, Care

    19 CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...

  • Page 151: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE 19 – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p. 166) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 152: 20 Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the lift stand. ( p. 64) – Preferably cover the motorcycle with a tarp or similar cover that is permeable to air.

  • Page 153: Preparing For Use After Storage

    STORAGE 20 Info Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and the exhaust system to rust. 20.2 Preparing for use after storage –...

  • Page 154: 21 Troubleshooting

    Check the electrical system. faulty – Error in the electronic fuel Read out the fault memory using the injection KTM diagnostics tool. – Engine does not speed up Error in the electronic fuel Read out the fault memory using the injection KTM diagnostics tool.
  • Page 155 Check wiring for damage and electrical plug-in connectors for corrosion and damage. – Read out the fault memory using the KTM diagnostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary.
  • Page 156 21 TROUBLESHOOTING Faults Possible cause Action – The horn, brake light, turn sig- Fuse 3 blown Change the fuses of individual power nal, and radiator fan are not consumers. ( p. 126) working...

  • Page 157: Technical Data 22

    TECHNICAL DATA 22 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement (All 450 models) 449.9 cm³ (27.455 cu in) Displacement (All 500 models) 510.9 cm³ (31.177 cu in) Stroke (All 450 models) 63.4 mm (2.496 in) Stroke (All 500 models) 72 mm (2.83 in) Bore 95 mm (3.74 in)

  • Page 158: Engine Tightening Torques

    22 TECHNICAL DATA 22.2 Engine tightening torques Oil jet, piston cooling 2 Nm (1.5 lbf ft) Loctite ® 243™ Crankshaft speed sensor screw and 6 Nm (4.4 lbf ft) Loctite ® 243™ cable retainer Oil nozzle for clutch lubrication 2 Nm (1.5 lbf ft) Loctite ®...

  • Page 159: Capacities

    TECHNICAL DATA 22 Screw, torque governor 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, valve cover 10 Nm (7.4 lbf ft) Screw, water pump cover 10 Nm (7.4 lbf ft) Oil nozzle for conrod bearing lubri- M6x0.75 2 Nm (1.5 lbf ft) cation Plug, oil channel 9 Nm (6.6 lbf ft)

  • Page 160: Chassis

    22 TECHNICAL DATA Total fuel tank capacity, approx. 8.5 l (2.25 US gal) Super unleaded (ROZ 95/RON (XCF‑W) 95/PON 91) ( p. 165) Fuel reserve, approx. 1.5 l (1.6 qt.) 22.4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork (EXC‑F EU, XCF‑W) WP SuspensionXplor 5348...

  • Page 161: Electrical System

    140/80 - 18 M/C 70M M+S TT Metzeler MCE 6 Days Extreme Metzeler MCE 6 Days Extreme The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork 22.7.1 EXC‑F EU, XCF‑W Fork article number 14.18.8T.69...

  • Page 162: All Exc-F Six Days

    22 TECHNICAL DATA Sport 12 clicks Spring length with preload spacer(s) 477 mm (18.78 in) Spring rate Weight of rider: 65 … 75 kg (143 … 165 lb.) 4.0 N/mm (22.8 lb/in) Weight of rider: 75 … 85 kg (165 … 187 lb.) 4.2 N/mm (24 lb/in) Weight of rider: 85 …...

  • Page 163: Chassis Tightening Torques

    TECHNICAL DATA 22 Sport 1 turn Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring preload 8 mm (0.31 in) Spring rate Weight of rider: 65 … 75 kg (143 … 165 lb.) 60 … 66 N/mm (343 … 377 lb/in) Weight of rider: 75 …...
  • Page 164 22 TECHNICAL DATA Screw, front brake disc 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, rear brake disc 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, throttle grip 5 Nm (3.7 lbf ft) Fuel connection on fuel pump 10 Nm (7.4 lbf ft) Nut, foot brake lever stop 20 Nm (14.8 lbf ft)
  • Page 165 TECHNICAL DATA 22 Screw, top shock absorber 80 Nm (59 lbf ft) Loctite ® 2701™ Nut, fork pivot M16x1.5 100 Nm (73.8 lbf ft) Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft) Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft)

  • Page 166: 23 Substances

    23 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX ®...
  • Page 167 SUBSTANCES 23 Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 168) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –...

  • Page 168: 24 Auxiliary Substances

    24 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier MOTOREX ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier...
  • Page 169 AUXILIARY SUBSTANCES 24 Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier MOTOREX ® – Quick Cleaner Universal oil spray Recommended supplier MOTOREX ® – Joker 440 Synthetic...

  • Page 170: 25 Standards

    25 STANDARDS JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 171: Index Of Special Terms 26

    INDEX OF SPECIAL TERMS 26 On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics...

  • Page 172: 27 List Of Abbreviations

    27 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 173: List Of Symbols 28

    Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized KTM workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

  • Page 174: Index

    INDEX Chain guide INDEX checking ......92 12-V battery Chain tension charging ......123 adjusting .
  • Page 175 INDEX Engine oil free travel, checking ....100 adding ......147 Handlebar position .
  • Page 176 INDEX raising with lift stand ....64 Start button ......18 Starting .
  • Page 177 INDEX Vehicle identification number ....14 View of vehicle front left ......12 rear right .
  • Page 178 *3214012en* 3214012en 05/2019 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

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