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KTM 450 EXC Six Days Setup Instructions
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KTM 450 EXC Six Days Setup Instructions

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SETUP INSTRUCTIONS
2016
450 EXC Six Days
450 XC‑W
500 EXC Six Days
500 XC‑W
Art. no. 3213434en
450 EXC
500 EXC

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Summary of Contents for KTM 450 EXC Six Days

  • Page 1 SETUP INSTRUCTIONS 2016 450 EXC 450 EXC Six Days 450 XC‑W 500 EXC 500 EXC Six Days 500 XC‑W Art. no. 3213434en...
  • Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.

  • Page 4: Means Of Representation

    MEANS OF REPRESENTATION Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips.
  • Page 5 SETUP Unpacking and setting up the vehicle Package 2 – Remove the box and the plastic packaging. Info To avoid damaging the motorcycle during the setup, leave the protective film on the vehicle until you have finished. – Remove the separate enclosure and unpack it. Check that the scope of supply is complete on the basis of the enclosed packing list.
  • Page 6 SETUP (EXC EU, EXC Six Days EU, EXC AU) – Position the fork legs and tighten the screws of the triple clamp. Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) Screw, bottom triple clamp 15 Nm (11.1 lbf ft) Info The rebound damping is located in right fork leg REB (red adjusting screw).
  • Page 7 SETUP (EXC EU, EXC Six Days EU, EXC AU, 500 EXC US) – Insert the indicator lamp with the black and violet cable colors into  socket 102049-11 (XC‑W) –  Connect pull switch with the yellow and white cables. –...
  • Page 8 SETUP – Position the turn signal on each side and mount and tighten nuts. – Connect the plug-in connection of the right turn signal using the black and brown cable colors. – Connect the plug-in connection of the left turn signal using the violet and brown cable colors.
  • Page 9 Set the clock. ( p. 24) – Refuel. ( p. 22) – Position all controls in their exact positions on the handlebar. Tighten all screws. – Prepare the vehicle according to the specifications in the KTM Dealer.net for han- dover to the customer.
  • Page 10 WORK Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (78129955100) Neither wheel is in contact with the ground.
  • Page 11 WORK –  Detach plug-in connectors and take off the headlight mask with the head- light. M00189-10 (XC‑W) – Switch off all power consumers and switch off the engine. –  Remove screw and take off the clamp. –  Release rubber straps .

  • Page 12: Checking The Headlight Setting

    WORK –  Position the headlight mask and fix it with rubber straps Info Ensure the holding lugs engage in the fender. – Position the brake line and wiring harness. Put the clamp on and mount and  tighten screw M00188-11 (XC‑W) –...
  • Page 13 WORK Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 10) Main work (EXC EU, EXC Six Days EU, EXC AU) –  Loosen screw – Adjust the headlight range by pivoting the headlight. Guideline The boundary between light and dark must be exactly on the lower marking for a motorcycle with rider (instructions on how to apply the marking: Check- ing the headlight setting).
  • Page 14 WORK Info The heim joint for the shock absorber at the swingarm is Teflon-coated. It must not be greased with grease or with other lubricants. Lubricants dis- solve the Teflon coating, thereby drastically reducing the service life. Finishing work – Remove the motorcycle from the lift stand.
  • Page 15 WORK Installing the front wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. – Check the wheel bearing for damage and wear.
  • Page 16 WORK –  Press out bearing using a suitable tool. Info  Spacing tube can be pushed aside. – Remove spacing tube  B03358-10 –  Press out bearing using a suitable tool. –  Press in the new bearing all the way using a suitable tool.
  • Page 17 WORK –  Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) K00073-10 Finishing work – Refit the headlight mask with the headlight. ( p. 9) – Check the headlight setting. ( p. 10) 3.12 Removing the seat –...
  • Page 18 – Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 19 WORK Finishing work – Mount the seat. ( p. 15) 3.16 Installing the air filter box cover (EXC AU, EXC EU, EXC SIX DAYS, XC-W) –   Insert the air filter box cover into rear area and clip it into front area K00076-11 (500 EXC US) –...
  • Page 20 WORK –  Mount the wash cap set Wash cap set (81212016100) (500 EXC US) – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve.
  • Page 21 WORK (EXC Six Days) – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. M01025-01 3.18 Installing the fuel tank 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.

  • Page 22: Checking Throttle Cable Routing

    WORK (EXC Six Days) – Position collar bushings between the spoiler and radiator shield. – Position the horn, and fit and tighten screws  with washers. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Connect the connector of the horn. M01023-11 (XC‑W, 500 EXC US) –...
  • Page 23 WORK Main work (EXC EU, EXC Six Days EU, EXC AU) – Check throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handle- bars and above the fuel tank bracket, to the throttle valve body. »...
  • Page 24 WORK Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. (EXC EU, EXC Six Days EU, EXC AU) –  Press release button , turn the filler cap counterclockwise, and lift it off.
  • Page 25 WORK Note Material damage Premature clogging of the fuel filter. – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Only refuel with clean fuel that meets the specified standards. Warning Environmental hazard Improper handling of fuel is a danger to the environment.

  • Page 26: Setting The Clock

    WORK 3.24 Setting the speedometer functions Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is stationary. – Repeatedly press the button briefly until H appears at the bottom right of the display.

  • Page 27: Technical Data

    TECHNICAL DATA Chassis tightening torques – EJOT PT ® Screw, pressure regulator K60x25‑Z 3 Nm (2.2 lbf ft) – Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft) – Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft) –...
  • Page 28 TECHNICAL DATA – 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) Screw-in nozzles, cooling system M20x1.5 12 Nm (8.9 lbf ft) Loctite ®...
  • Page 29 SUBSTANCES Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification – DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e.

  • Page 30: Auxiliary Substances

    AUXILIARY SUBSTANCES Long-life grease Recommended supplier Motorex ® – Bike Grease 2000...
  • Page 31 *3213434en* 3213434en 11/2015 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

This manual is also suitable for:

450 exc500 exc six days500 xc-w450 xc-w500 exc