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KTM 450 EXC-F 2023 Owner's Manual

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OWNER'S MANUAL
2023
450 EXC‑F
450 EXC-F SIX DAYS
450 XCF‑W
500 EXC‑F
500 EXC-F SIX DAYS
Art. no. 3214649en

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Summary of Contents for KTM 450 EXC-F 2023

  • Page 1 OWNER'S MANUAL 2023 450 EXC‑F 450 EXC-F SIX DAYS 450 XCF‑W 500 EXC‑F 500 EXC-F SIX DAYS Art. no. 3214649en...
  • 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 6.13 Overview of indicator lamps TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 6 (XCF‑W) .......... 19 Symbols used ........6 6.14 Opening fuel tank filler cap....20 Formats used........6 6.15 Closing the fuel tank filler cap... 20 6.16 Cold start button......
  • Page 5 TABLE OF CONTENTS Preparing the vehicle for difficult 11.13 Adjusting the rebound damping of operating conditions......39 the fork........... 58 Preparing the vehicle for riding on 11.14 Adjusting the spring preload of the dry sand.......... 39 fork ..........59 Preparing the vehicle for riding on 11.15 Handlebar position......
  • Page 6 TABLE OF CONTENTS 12.34 Installing the fuel tank ....86 15.4 Changing main fuse ....... 123 12.35 Checking for chain dirt 15.5 Changing the fuses of individual accumulation........88 electrical power consumers ..... 124 12.36 Cleaning the chain ......88 15.6 Removing the headlight mask with the headlight .........
  • Page 7 TABLE OF CONTENTS 20.2 Preparing for use after storage..150 21 TROUBLESHOOTING ........ 151 22 BLINK CODE ..........154 23 TECHNICAL DATA........156 23.1 Engine .......... 156 23.2 Engine tightening torques ....157 23.3 Capacities ........158 23.3.1 Engine oil ......... 158 23.3.2 Coolant ........

  • Page 8: Means Of Representation

    Indicates work that requires expert knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be cared for there to the highest degree by specially trained experts using the special 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 Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key).

  • Page 12: Owner's Manual

    The Owner's Manual can be downloaded several times using the QR code or the link on the delivery certificate. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. A printed copy can also be ordered from your authorized KTM dealer.

  • Page 13: Important Notes 3

    Manufacturer warranty, 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) A01150-10 Clutch lever ( p. 16) Fuel tank filler cap Air filter box cover Side stand ( p. 22) Engine number ( p. 15) Shift lever ( p. 22)

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

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) A01151-10 Stop 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: Key Number (All Eu Models)

    SERIAL NUMBERS 5 Key number (All EU models) The key number for the steering lock is stamped onto the key connector. 402247-10 Engine number Engine number is embossed on the left side of the engine behind the shift lever. H00940-10 Fork part number The fork part number is stamped on the inner side of the fork...

  • 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) The stop button is fitted on the left side of the handlebar. Possible states is in the basic position – In this position, • The stop button the ignition circuit is closed and the engine can be started. pressed –...

  • 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 (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 fuel 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 Shift lever is mounted on the left of the engine. 401950-10 The gear positions can be seen in the figure. The neutral or idle position is between the first and second gears. 401950-11 6.19 Foot brake lever Foot brake lever is located in front of the right footrest.

  • 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: Viewing The Lap Time

    COMBINATION INSTRUMENT 7 – 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 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. Briefly press No function the button 7.21 Display mode SPEED/S1 (stop watch 1) – briefly until S1 appears at the Repeatedly press the button top right of the display. S1 (Stop watch 1) shows the riding time based on TR1 and contin- ues running as soon as an impulse arrives from the wheel speed sensor.
  • Page 37 COMBINATION INSTRUMENT 7 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. Setup menu No function Activates No function Deactivates Changes to Setup menu...

  • 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. Display mode Displays of Next display No function No function SPEED/S1 (stop...

  • 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 – Adjust the basic position of the foot brake lever. p. 107) – Adjust the basic position of the shift lever. p. 141) – Get used to the handling characteristics of the motorcycle on a suitable surface before undertaking more chal- lenging trips.

  • 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 the motorcycle. ( p.

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

    Straighten the bent radiator fins carefully. – Check the coolant level. ( p. 132) 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 (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 48 months every 12 months Every 135 operating hours Every 70 operating hours when used for motorsports After 20 operating hours After 10 operating hours ● ● 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 the 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. 63) – Remove the shock absorber. p. 76) – 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. – 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 Spring Preload Of The Fork

    TUNING THE CHASSIS 11 Info Turn clockwise to increase the damping; turn counter- clockwise to reduce damping when the shock absorber rebounds. 11.14 Adjusting the spring preload of the fork Preparatory work – Raise the motorcycle with the lift stand. ( p.

  • Page 62: Handlebar Position

    11 TUNING THE CHASSIS 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 63 TUNING THE CHASSIS 11 (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 64 11 TUNING THE CHASSIS Info Make sure the cables and wiring are positioned cor- rectly. – Position the handlebar clamps. Mount screws tighten evenly. Guideline Screw, handlebar 20 Nm clamp (14.8 lbf ft) Info Make sure the gap widths are even.

  • Page 65: Service Work On The Chassis 12

    SERVICE WORK ON THE CHASSIS 12 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 66: Cleaning The Dust Boots Of The Fork Legs

    12 SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 63) – Remove the fork protector. ( p. 64) Main work – Push dust boots of both fork legs downward.

  • Page 67: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS 12 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 68: Installing The Fork Legs

    12 SERVICE WORK ON THE CHASSIS 12.8 Installing the fork legs Main work (EXC‑F EU, XCF‑W) – Position the fork legs. Bleeder screws are positioned toward the front. Info The rebound damping is located in right fork leg REB (red adjusting screw). The compression damping is located in left fork leg COMP (white adjusting screw).

  • Page 69: (Exc-F Eu, Xcf-W)

    SERVICE WORK ON THE CHASSIS 12 – Position the brake caliper, and mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) brake caliper Loctite ® 243™ – Mount the cable tie. – Position the brake line, wiring harness, and clamp. Mount and tighten screws K00546-10 Finishing work...

  • Page 70: (Exc-F Six Days Eu)

    12 SERVICE WORK ON THE CHASSIS 12.10 Removing the lower triple clamp (EXC‑F SIX DAYS EU) Preparatory work – Remove the headlight mask with the headlight. ( p. 125) – Raise the motorcycle with the lift stand. ( p. 63) –...
  • Page 71 SERVICE WORK ON THE CHASSIS 12 – Position the upper triple clamp with the handlebar. – Mount screw , but do not tighten yet. – Secure the wiring harness and the clutch line with the cable holder. V01785-11 – Position the fork legs. Bleeder screws are positioned toward the front.

  • Page 72: Installing The Lower Triple Clamp (Exc-F Six Days Eu)

    12 SERVICE WORK ON THE CHASSIS – Position the brake caliper, and mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) brake caliper Loctite ® 243™ – Mount the cable ties. – Position the brake line, the wiring harness, and the clamp. Mount and tighten screws V01792-10 Finishing work...
  • Page 73 SERVICE WORK ON THE CHASSIS 12 – Position the upper triple clamp with the handlebar. – Mount screw , but do not tighten yet. – Secure the wiring harness and the clutch line with the cable holder. V01787-11 – Position the fork legs. Bleeder screws are positioned toward the front.

  • Page 74: Checking Steering Head Bearing Play

    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.) 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.

  • Page 75: Adjusting The Steering Head Bearing Play (Exc-F Eu, Xcf-W)

    SERVICE WORK ON THE CHASSIS 12 (EXC‑F EU, XCF‑W) – Adjust the steering head bearing play. p. 73) (EXC‑F SIX DAYS EU) – Adjust the steering head bearing play. p. 73) – Check the steering head bearing and replace if neces- sary.

  • Page 76: Lubricating The Steering Head Bearing

    12 SERVICE WORK ON THE CHASSIS Guideline Screw, top triple 17 Nm (12.5 lbf ft) clamp – Mount and tighten screw Guideline Screw, top 17 Nm (12.5 lbf ft) steering stem Loctite ® 243™ Finishing work – Check steering head bearing play. ( p.

  • Page 77: Installing Front Fender

    SERVICE WORK ON THE CHASSIS 12 – Remove screws . Take off front fender. V00341-10 (EXC‑F SIX DAYS EU) – Remove screws K00576-10 – Remove screws . Take off front fender. S01321-10 12.18 Installing front fender Main work (EXC‑F EU, XCF‑W) –...

  • Page 78: Removing The Shock Absorber

    12 SERVICE WORK ON THE CHASSIS (EXC‑F SIX DAYS EU) – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis K00576-10 – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis S01321-10 Finishing work...

  • Page 79: Removing The Seat

    SERVICE WORK ON THE CHASSIS 12 Info The heim joint for the shock absorber on the link fork is Teflon coated. It must not be lubricated with grease, nor with any other lubricants. Lubricants dissolve the Teflon coating, thereby drastically reducing the service life.

  • Page 80: Removing The Air Filter Box Cover

    12 SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis S03480-10 12.23 Removing the air filter box cover Condition The air filter box cover is secured. – Remove the seat. ( p.

  • Page 81: Installing The Air Filter Box Cover

    SERVICE WORK ON THE CHASSIS 12 12.24 Installing the air filter box cover Condition The air filter box cover is secured. – Insert the air filter box cover in area and clip it into area V01759-12 – Mount and tighten screw Guideline Screw, air filter box EJOT PT...

  • Page 82: Installing The Air Filter

    12 SERVICE WORK ON THE CHASSIS Main work – Detach retaining tab . Remove air filter with air filter sup- port. – Remove air filter from air filter support. K01338-10 12.26 Installing the air filter Main work – Mount the clean air filter on the air filter support. –...

  • Page 83: Preparing Air Filter Box Cover For Securing

    SERVICE WORK ON THE CHASSIS 12 Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 166) Info Only press the air filter to dry it, never wring it out. –...

  • Page 84: Installing The Main Silencer

    12 SERVICE WORK ON THE CHASSIS – Remove screws and take off the main silencer. 12.30 Installing the main silencer (All EU models) – Position the catalytic converter in the main silencer. S02101-10 – Position the main silencer. Mount screws , but do not tighten yet.
  • Page 85 SERVICE WORK ON THE CHASSIS 12 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 86: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    12 SERVICE WORK ON THE CHASSIS 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 filling escape and the damper "burns"...

  • Page 87: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 12 Finishing work – Install the main silencer. ( p. 82) 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 88: Installing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS (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 89 SERVICE WORK ON THE CHASSIS 12 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 90: Checking For Chain Dirt Accumulation

    12 SERVICE WORK ON THE CHASSIS – Plug in connector for the fuel pump. – Remove the wash cap set. – Clean the quick release coupling thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line.

  • Page 91: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 12 Preparatory work – Raise the motorcycle with the lift stand. ( p. 63) Main work – Rinse off loose dirt with a soft jet of water. – Remove old grease residue with chain cleaner. Chain cleaner ( p.

  • Page 92: Adjusting The Chain Tension

    12 SERVICE WORK ON THE CHASSIS 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 93: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 12 12.39 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with the lift stand. ( p. 63) Main work – Shift the transmission into neutral. – Check the rear sprocket and engine sprocket for wear. »...
  • Page 94 12 SERVICE WORK ON THE CHASSIS – 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 95: 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 the throttle cable routing Warning Danger of accidents The throttle cable can become kinked, trapped or blocked if it is not routed cor- rectly.

  • Page 96: Checking The Rubber Grip

    12 SERVICE WORK ON THE CHASSIS Main work – Check the 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 97: Adjusting The Basic Position Of The Clutch Lever

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

  • Page 98: Changing The Hydraulic Clutch Fluid

    12 SERVICE WORK ON THE CHASSIS – 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 99: Removing The Engine Guard (Exc-F Six Days, Xcf-W)

    SERVICE WORK ON THE CHASSIS 12 – 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 100: Installing The Engine Guard (Exc-F Six Days, Xcf-W)

    12 SERVICE WORK ON THE CHASSIS 12.48 Installing the engine guard (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 101: Brake System 13

    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 102: 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 103 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 104: 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 105 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 106 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 107 BRAKE SYSTEM 13 – Correct the brake fluid level 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 Use water to immediately clean up any brake fluid...

  • Page 108: Checking The Free Travel Of Foot Brake Lever

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

  • Page 109: 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 110: 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 111: 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 112: 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 113 BRAKE SYSTEM 13 – Position the vehicle vertically. – 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 114 13 BRAKE SYSTEM – Correct brake fluid level to marking Brake fluid DOT 4 / DOT 5.1 ( p. 164) – Mount screw cap with membrane and O-ring. Info Use water to immediately clean up any brake fluid that has overflowed or spilled. K01347-10...

  • Page 115: Wheels, Tires 14

    WHEELS, TIRES 14 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 63) 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 116: 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 117: 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 118 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 surfaces of the spacers. Long-life grease ( p.

  • Page 119: 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 years at the latest, regardless of the actual state of H01144-01 wear.

  • Page 120: 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 121: 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 122: 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 123: 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 124 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.

  • Page 125: Changing Main Fuse

    ELECTRICAL SYSTEM 15 Info Never remove cover – Switch off the battery charger after charging and disconnect it from the 12-V battery. Finishing work – Install the 12-V battery. p. 120) – Mount the seat. ( p. 77) 15.4 Changing main fuse Warning Fire hazard Incorrect fuses overload the electrical system.

  • Page 126: Changing The Fuses Of Individual Electrical 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. – Insert a new main fuse. Fuse (58011109120) ( p.

  • Page 127: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 15 Warning Fire hazard Incorrect fuses overload the electrical sys- tem. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. – Insert the spare fuse with the correct rating. Fuse (75011088010) ( p.

  • Page 128: Installing The Headlight Mask With The Headlight

    15 ELECTRICAL SYSTEM 15.7 Installing the headlight mask with the headlight Main work (All EU models) – Join plug-in connectors S01328-11 (XCF‑W) – Join plug-in connector V01802-11 – Position the headlight mask and secure it with rubber straps The holding lugs engage in the fender. –...

  • Page 129: Checking The Headlight Setting

    ELECTRICAL SYSTEM 15 Main work – Turn protection cap together with the underlying bulb socket counterclockwise all the way and remove it. – Pull bulb socket of the position light out of the reflector. V01783-10 – Pull out headlight bulb –...

  • Page 130: Adjusting The Headlight Range

    15 ELECTRICAL SYSTEM 15.10 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 127) Main work – Loosen screw – Adjust the headlight range by pivoting the headlight. Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider (instructions on how to apply the mark: Checking the headlight setting).

  • Page 131: Changing The Combination Instrument Battery

    ELECTRICAL SYSTEM 15 15.12 Changing the combination instrument battery Preparatory work – Remove the headlight mask with the headlight. ( p. 125) Main work – Remove screws with the washers. – Pull the combination instrument upward out of the holder. V01807-10 –...

  • Page 132: Diagnostics Connector

    15 ELECTRICAL SYSTEM 15.13 Diagnostics connector Diagnostics connector is located under the seat. H00933-12...

  • Page 133: Cooling System 16

    COOLING SYSTEM 16 16.1 Cooling system (XCF‑W) 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 134: 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 135: 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 136: Refilling Coolant

    16 COOLING SYSTEM 16.5 Refilling coolant Warning Danger of poisoning Coolant is harmful to health. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed.
  • Page 137 COOLING SYSTEM 16 Preparatory work (EXC-F SIX DAYS, XCF-W) – Remove the engine guard. ( p. 97) Main work (XCF‑W) – Position the motorcycle upright. – Place an appropriate container under the water pump cover. – Remove screw . Take off radiator cap –...

  • Page 138: 17 Tuning The Engine

    17 TUNING THE ENGINE 17.1 Checking the play in the throttle cable – 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 Play in throttle cable 3 …...

  • Page 139: Adjusting The Characteristic Map Of The Throttle Response

    TUNING THE ENGINE 17 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 140: Changing The Mapping (Exc-F Six Days, Xcf-W)

    17 TUNING THE ENGINE – 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 141: 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 142: Teaching The Throttle Valve Position

    17 TUNING THE ENGINE 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 143: Adjusting The Basic Position Of The Shift Lever

    TUNING THE ENGINE 17 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 144: 18 Service Work On The Engine

    18 SERVICE WORK ON THE ENGINE 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 fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 145: Checking The Engine Oil Level

    SERVICE WORK ON THE ENGINE 18 Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.
  • Page 146 18 SERVICE WORK ON THE ENGINE Main work – Position an appropriate container under the engine. – Remove oil drain plug with the magnet and seal ring. H01703-10 – Remove screw plug with the short oil screen and the O- rings.
  • Page 147 SERVICE WORK ON THE ENGINE 18 – Mount and tighten screw plug with the O-ring. Guideline Screw plug, oil M20x1.5 15 Nm (11.1 lbf ft) screen – Mount and tighten oil drain plug with the magnet and a new seal ring. Guideline Oil drain plug with M12x1.5...

  • Page 148: Adding Engine Oil

    164) Info In order to achieve optimal engine oil performance, it is not advisable to mix different engine oils. KTM recommends changing the engine oil. – Mount and tighten the filler plug together with the O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death.

  • Page 149: Cleaning, Care 19

    CLEANING, CARE 19 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 150: Checks And Maintenance Steps For Winter Operation

    19 CLEANING, CARE – 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 151: Storage 20

    – 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. 63) – Preferably cover the motorcycle with a tarp or similar cover that is permeable to air.

  • Page 152: Preparing For Use After Storage

    20 STORAGE 20.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 63) – Install the 12-V battery. p. 120) – Perform checks and maintenance measures when preparing for use. ( p. 43) – Take a test ride.

  • Page 153: Troubleshooting 21

    Check the electrical system. – 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 154 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 155 TROUBLESHOOTING 21 Faults Possible cause Action – The horn, brake light, turn sig- Fuse 3 blown Change the fuses of individual electri- nal, and radiator fan are not cal power consumers. ( p. 124) working...

  • Page 156: 22 Blink Code

    22 BLINK CODE Info The blink codes are only displayed by the derestricted version of the vehicle. Blink code for malfunction indicator lamp 02a Malfunction indicator lamp flashes 2x per second Error level condition Teaching of throttle valve position required Blink code for malfunction indicator lamp 02 Malfunction indicator lamp flashes 2x short...
  • Page 157 BLINK CODE 22 Blink code for malfunction indicator lamp 22 Malfunction indicator lamp flashes 2x long, 2x short Error level condition Gear position sensor - input voltage too high Gear position sensor - input voltage too low Blink code for malfunction indicator lamp 33 Malfunction indicator lamp flashes 3x long, 3x short Error level condition...

  • Page 158: 23 Technical Data

    23 TECHNICAL DATA 23.1 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 159: Engine Tightening Torques

    TECHNICAL DATA 23 23.2 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) cable retainer Loctite ® 243™ Oil nozzle for clutch lubrication 2.5 Nm (1.84 lbf ft) Oil nozzle for piston cooling 2.5 Nm (1.84 lbf ft) Oil nozzle for rocker arm lubrica-...

  • Page 160: Capacities

    23 TECHNICAL DATA 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 2.5 Nm (1.84 lbf ft) cation Plug, oil channel 9 Nm (6.6 lbf ft)

  • Page 161: Chassis

    TECHNICAL DATA 23 Total fuel tank capacity, approx. 8.5 l (2.25 US gal) Super unleaded (ROZ 95) (XCF‑W) p. 165) Fuel reserve, approx. 1.5 l (1.6 qt.) 23.4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork WPXPLOR OC Suspension travel front...

  • Page 162: Electrical System

    The tires specified represent one of the possible series production tires. For alternative manufacturers, if any, contact an authorized dealer or qualified tire dealership. If local road approval regulations apply, these and the respective technical specifications must be observed. Additional information is available in the Service section under: KTM.COM 23.7 Fork Fork article number...

  • Page 163: Shock Absorber

    TECHNICAL DATA 23 Sport 12 clicks Spring preload – preload adjuster Comfort Standard Sport Spring length with preload spacer(s) 474 mm (18.66 in) Spring rate Weight of rider: 65 … 75 kg (143 … 165 lb.) 4.4 N/mm (25.1 lb/in) Weight of rider: 75 …...

  • Page 164: Chassis Tightening Torques

    23 TECHNICAL DATA 23.9 Chassis tightening torques EJOT PT Remaining screws, chassis ® K60x25‑Z 2 Nm (1.5 lbf ft) EJOT PT Screw, combination switch (EXC- ® K50x18 2 Nm (1.5 lbf ft) F SIX DAYS, XCF-W) Screw, intake air temperature sen- EJOT DELTA PT ®...
  • Page 165 TECHNICAL DATA 23 Screw, engine brace on frame M8x15 25 Nm (18.4 lbf ft) Loctite ® 2701™ Screw, fork stub 15 Nm (11.1 lbf ft) Screw, front brake caliper 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, handlebar clamp 20 Nm (14.8 lbf ft) Screw, manifold 15 Nm (11.1 lbf ft)

  • Page 166: 24 Substances

    24 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 24 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: 25 Auxiliary Substances

    25 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 25 Silicone spray Recommended supplier MOTOREX ® – Silicone Spray 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: 26 Standards

    26 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 27

    INDEX OF SPECIAL TERMS 27 On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics...

  • Page 172: 28 List Of Abbreviations

    28 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 29

    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 ......91 12-V battery Chain tension charging ......121 adjusting .
  • Page 175 INDEX Engine oil Handlebar position ..... . 60 adding ......146 adjusting .
  • Page 176 INDEX Spoke tension checking ......118 Oil filter Start button ......18 changing .
  • Page 177 INDEX rear right ......13 Winter operation checks and maintenance steps ..148 Work rules .
  • Page 178 *3214649en* 3214649en 07.04.2022 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.COM...

This manual is also suitable for:

450 exc-f six days 2023450 xcf-w 2023500exc-f 2023500 exc-f six days 2023

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