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

2014
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OWNER'S MANUAL
2014
450 EXC EU
450 EXC AUS
450 EXC SIX DAYS EU
450 XC-W USA
500 EXC EU
500 EXC AUS
500 EXC SIX DAYS EU
500 XC-W USA
Art. no. 3213037en

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Summary of Contents for KTM 450 EXC EU

  • Page 1 OWNER'S MANUAL 2014 450 EXC EU 450 EXC AUS 450 EXC SIX DAYS EU 450 XC-W USA 500 EXC EU 500 EXC AUS 500 EXC SIX DAYS EU 500 XC-W USA Art. no. 3213037en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 7.1.2 Activation and test ........21 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 7.1.3 Setting kilometers or miles ......21 Symbols used ........... 5 7.1.4 Adjusting the speedometer functions .... 22 Formats used............ 5 7.1.5 Setting the clock ........22 SAFETY ADVICE............
  • Page 5 TABLE OF CONTENTS RIDING INSTRUCTIONS..........42 12.19 Removing the front fender ....... 66 Checks and maintenance work when preparing 12.20 Installing the front fender ........ 66 for use ............42 12.21 Removing the shock absorber ...... 67 Starting............42 12.22 Installing the shock absorber .......
  • Page 6 TABLE OF CONTENTS 14.5 Checking the tire condition ......92 25 AUXILIARY SUBSTANCES ........128 14.6 Checking the tire air pressure......93 26 STANDARDS ............130 14.7 Checking spoke tension ........93 INDEX ................131 15 ELECTRICAL SYSTEM ..........95 15.1 Removing the battery ........

  • Page 7: 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. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required.

  • Page 8: Safety Advice

    Use definition - intended use (all EXC models) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations.

  • Page 9: Safe Operation

    Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements. 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 10: Owner's Manual

    Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.

  • Page 11: Important Notes

    Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 12: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) L00701-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Filler cap Shift lever ( p. 18) Engine number ( p. 12) Side stand ( p. 19)

  • Page 13: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) L00700-10 Kill switch ( p. 14) Horn button ( p. 15) Light switch ( p. 15) Turn signal switch ( p. 15) Emergency OFF switch ( p. 15) Electric starter button ( p.

  • Page 14: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. B01492-10 Type label The type label is fixed to the front of the steering head. B01492-11 Key number (all EXC models) The key number for the steering lock is stamped onto the key connector.

  • Page 15: Shock Absorber Part Number

    SERIAL NUMBERS Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side. B01495-10...

  • Page 16: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. B01496-10 Hand brake lever Hand brake lever is located on the right side of the handlebar. The hand brake lever is used to activate the front brake. B01497-10 Throttle grip The throttle grip...

  • Page 17: Horn Button (All Exc Models)

    CONTROLS Horn button (all EXC models) The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed – the horn is actuated in this position. • Horn button B01585-11 Light switch (all EXC models) The light switch is fitted on the left side of the handlebar.

  • Page 18: Electric Starter Button (Exc Aus)

    CONTROLS 6.11 Electric starter button (EXC AUS) The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position pressed – the electric starter is actuated in this position. • Electric starter button B01501-10 6.12...

  • Page 19: Opening Filler Cap

    CONTROLS 6.16 Opening filler cap Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 20: Idle Speed Adjusting Screw

    CONTROLS 6.18 Idle speed adjusting screw The idle speed adjusting screw is located on the throttle valve body at the top left. The idle speed adjusting screw has two functions. Turning it controls the idle speed. Pulling it out all the way raises the idle speed during a cold start. Possible states RPM increase activated –...

  • Page 21: Foot Brake Lever

    CONTROLS 6.21 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. L00708-10 6.22 Side stand The side stand is on the left side of the vehicle. L00706-10 The side stand is used to park the motorcycle.

  • Page 22: Unlocking The Steering (All Exc Models)

    CONTROLS – Park the vehicle. – Turn the handlebar as far as possible to the right. – Insert the key in the steering lock, turn it to the left, press it in and turn it to the right. Remove the key. Steering is no longer possible.

  • Page 23: Speedometer

    SPEEDOMETER EXC EU, EXC AUS, all XC‑W models 7.1.1 Speedometer overview – Press the button to change the display mode or change to one of the Setup menus. – Press the button to control different functions. – Press the button to control different functions.

  • Page 24: Adjusting The Speedometer Functions

    SPEEDOMETER 7.1.4 Adjusting 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. – briefly and repeatedly until H appears at the bottom right of the Press the button display.

  • Page 25: Display Mode Speed (Speed)

    SPEEDOMETER Condition The motorcycle is stationary. – Press the button briefly and repeatedly until LAP appears at the bottom right of the display. – Press the button briefly. LAP 1 appears on the left side of the display. – Laps 1-10 can be displayed by pressing the button –...

  • Page 26: Unit Of Measurement Menu

    SPEEDOMETER Press the button . Activates the flashing display Press the button . Deactivates the flashing display Press the button Changes to the next display without changes briefly. Press the button Setup menu starts, stores the settings, and changes to H or for 3 - 5 seconds.

  • Page 27: Display Mode Speed/Lap (Lap Time)

    SPEEDOMETER 7.1.13 Display mode SPEED/LAP (lap time) – Press the button briefly and repeatedly until LAP appears at the bottom right of the display. In the LAP display mode, up to 10 lap times can be timed with the stop watch. Info If the lap time continues running after the button is pressed, 9 memory loca-...

  • Page 28: Display Mode Speed/Tr2 (Trip Master 2)

    SPEEDOMETER Press the button Next display mode briefly. 7.1.17 Display mode SPEED/TR2 (trip master 2) – Press the button briefly and repeatedly until TR2 appears at the top right of the display. TR2 (trip master 2) runs constantly and counts up to 999.9. The displayed value can be set manually with the button and the button .

  • Page 29: Display Mode Speed/A2 (Average Speed 2)

    SPEEDOMETER 7.1.20 Display mode SPEED/A2 (average speed 2) – Press the button briefly and repeatedly until A2 appears at the top right of the display. A2 (average speed 2) shows the average speed on the basis of the current speed if the stop watch S2 (stop watch 2) is running.

  • Page 30: Table Of Conditions And Menu Activation

    SPEEDOMETER Display Press the button Press the button Press the button for 3 - Press the button 5 seconds. briefly. Setting the clock Increases the value Reduces the value Starts and exits the Changes to the next SETUP menu value Display mode SPEED/LAP Starts or stops the Times the current lap...

  • Page 31: Activation And Test

    SPEEDOMETER 7.2.2 Activation and test Activating the speedometer The speedometer is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor. Display test To enable you to check that the display is functioning properly, all display segments light up briefly.

  • Page 32: Setting The Clock

    SPEEDOMETER – Repeatedly press the button briefly until H appears at the bottom right of the display. – Press the button for 2–3 seconds. The Setup menu is displayed and the active functions are shown. Info If no button is pressed for 10–12 seconds, the settings are automatically stored.

  • Page 33: Display Mode Speed (Speed)

    SPEEDOMETER 7.2.7 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 Making the setting according to the country.

  • Page 34: Setting The Unit Of Measurement

    SPEEDOMETER 7.2.10 Setting the unit of measurement Condition • The motorcycle is stationary. – briefly until H appears at the bottom right of the Repeatedly press the button display. – Press the button for 2–3 seconds. – Repeatedly press the button briefly until Km/h/Mph flashes.

  • Page 35: Display Mode Speed/Lap (Lap Time)

    SPEEDOMETER 7.2.13 Display mode SPEED/LAP (lap time) – Repeatedly press the button briefly until LAP appears at the bottom right of the display. In the LAP display mode, up to 10 lap times can be timed with the stop watch. Info If the lap time continues running after the button is pressed, 9 memory loca-...

  • Page 36: Display Mode Speed/Tr2 (Trip Master 2)

    SPEEDOMETER Displays of TR1, A1 and S1 are reset to 0,0. Press the button for 2–3 seconds. Briefly press the Next display mode button Press the button No function for 2–3 seconds. Briefly press the No function button 7.2.17 Display mode SPEED/TR2 (trip master 2) –...

  • Page 37: Display Mode Speed/A2 (Average Speed 2)

    SPEEDOMETER Press the button No function for 2–3 seconds. Briefly press the No function button 7.2.20 Display mode SPEED/A2 (average speed 2) – briefly until A2 appears at the top right of the dis- Repeatedly press the button play. A2 (average speed 2) shows the average speed on the basis of the current speed if the stop watch S2 (stop watch 2) is running.

  • Page 38: Table Of Functions

    SPEEDOMETER 7.2.23 Table of functions Display Press the but- Briefly press the Press the but- Briefly press the Wait 3–5 sec- Wait 10–12 sec- for 2–3 button for 2–3 button onds onds seconds. seconds. Display mode The display Next display No function No function SPEED/H (service...

  • Page 39: Table Of Conditions And Menu Activation

    SPEEDOMETER 7.2.24 Table of conditions and menu activation Display The motorcycle is Menu can be acti- stationary. vated Display mode SPEED/H (service hours) • Setup menu • Setting the unit of measurement • Setting the clock • Display mode SPEED/LAP (lap time) •...

  • Page 40: Preparing For Use

    When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover.

  • Page 41: Running-In The Engine

    For this reason, it may be neces- sary to inspect or replace parts before the next scheduled service. – KTM recommends that you use the specified engine oil for difficult riding conditions and to increase performance. Engine oil (SAE 10W/60) (00062010035) ( p. 126) –...

  • Page 42: Preparing For Rides On Dry Sand

    – Fit a dust cover on the air filter. Dust protection device for air filter (77206920000) Info See the KTM PowerParts fitting instructions. 600869-01 – Fit a sand cover on the air filter. Sand protection device for air filter (59006022000) Info See the KTM PowerParts fitting instructions.

  • Page 43: Preparing For Rides On Wet And Muddy Surfaces

    Preparing for rides on wet and muddy surfaces – Fit a waterproofing device on the air filter. Waterproofing device for air filter (77206921000) Info See the KTM PowerParts fitting instructions. 600870-01 – Fit the steel sprocket. – Clean the motorcycle. ( p.

  • Page 44: Riding Instructions

    RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p. 108) –...

  • Page 45: Starting Off

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

  • Page 46: Stopping, Parking

    RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. –...

  • Page 47: Refueling

    – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards.

  • Page 48: Service Schedule

    Final check: Check the vehicle for roadworthiness and take a test ride. ○ ● ● Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● ● Make the service entry in KTM DEALER.NET and in the service record.

  • Page 49: Service Work (As Additional Order)

    SERVICE SCHEDULE ● Periodic interval 10.2 Service work (as additional order) Annually Every 135 operating hours/every 70 operating hours when used for motorsports Every 45 operating hours Once after 15 operating hours ● Change the front brake fluid. ● Change the rear brake fluid. ●...

  • Page 50: Tuning The Chassis

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber.

  • Page 51: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber.

  • Page 52: Measuring Rear Wheel Sag Unloaded

    TUNING THE CHASSIS 11.6 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with the lift stand. ( p. 56) Main work – Measure the distance – as vertically as possible – between the rear axle and a fixed point such as a mark on the side cover.

  • Page 53: Adjusting The Spring Preload Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.

  • Page 54: Checking Basic Setting Of Fork

    TUNING THE CHASSIS Info The spring rate is shown on the outside of the spring. Smaller weight differences can be compensated by changing the spring preload. Finishing work – Install the shock absorber. p. 67) – Remove the motorcycle from the lift stand. ( p.

  • Page 55: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS (EXC SIX DAYS) – Turn the white adjusting screw all the way clockwise. Info Adjusting screw is located at the upper end of the left fork leg. The compression damping is located in the left fork leg COMP (white adjusting screw).

  • Page 56: Adjusting The Spring Preload Of The Fork (Exc Eu, Exc Aus, All Xc-W Models)

    TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 11.14 Adjusting the spring preload of the fork (EXC EU, EXC AUS, all XC‑W models) – Turn the adjusting screws counterclockwise all the way. Info Make the same adjustment on both fork legs. –...
  • Page 57 TUNING THE CHASSIS – Position the handlebar. Info Make sure cables and wiring are positioned correctly. – Position the handlebar clamps. Fit and evenly tighten the four screws Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) Info Make sure the gap width is even.

  • Page 58: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 12.1 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 (54829055000) The wheels should no longer touch the ground.

  • Page 59: Loosening The Fork Protector

    SERVICE WORK ON THE CHASSIS 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. – Clean and lubricate the dust boot and inside fork tube on both fork legs.

  • Page 60: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS (EXC EU, EXC AUS, all XC‑W models) – Release screws . Take out the left fork leg. – Release screws . Take out the right fork leg. B01516-10 (EXC SIX DAYS) – Release screws . Take out the left fork leg. –...

  • Page 61: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS – Position the brake caliper and mount and tighten screws Guideline Screw, front brake caliper 25 Nm Loctite ® 243™ (18.4 lbf ft) – Mount cable binder – Position the brake line, wiring harness, and clamp. Mount and tighten screws 101326-10 Finishing work –...

  • Page 62: Removing The Lower Triple Clamp (Exc Six Days)

    SERVICE WORK ON THE CHASSIS Main work – Open the cable holder in front of the right radiator and detach the wiring harness. – Remove screws and hang the voltage regulator to one side. – Release screw and remove screw .

  • Page 63: Installing The Lower Triple Clamp (Exc Eu, Exc Aus, All Xc-W Models)

    SERVICE WORK ON THE CHASSIS 12.13 Installing the lower triple clamp (EXC EU, EXC AUS, all XC‑W models) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 128) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.
  • Page 64 SERVICE WORK ON THE CHASSIS – Tighten screw Guideline Screw, top steering stem 20 Nm (14.8 lbf ft) B01522-11 – Tighten screws Guideline Screw, top triple clamp 20 Nm (14.8 lbf ft) – Secure the wiring harness with cable holder B01521-11 –...

  • Page 65: Installing The Lower Triple Clamp (Exc Six Days)

    SERVICE WORK ON THE CHASSIS 12.14 Installing the lower triple clamp (EXC SIX DAYS) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 128) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

  • Page 66: Checking The Steering Head Bearing Play

    Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam- aged over time.

  • Page 67: Adjusting The Play Of The Steering Head Bearing (Exc Eu, Exc Aus, All Xc-W Models)

    SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: (EXC SIX DAYS) –...

  • Page 68: Greasing The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Screw, top steering stem 17 Nm Loctite ® 243™ (12.5 lbf ft) Finishing work – Check the steering head bearing play. ( p. 64) – Remove the motorcycle from the lift stand. ( p.

  • Page 69: Removing The Shock Absorber

    SERVICE WORK ON THE CHASSIS – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) B01603-11 Finishing work – Refit the headlight mask with the headlight. ( p. 99) – Check the headlight setting. ( p. 100) 12.21 Removing the shock absorber Preparatory work...

  • Page 70: Mounting The Seat

    SERVICE WORK ON THE CHASSIS 12.24 Mounting the seat – Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear and simultaneously push it forward. – Make sure that the seat is correctly locked in. –...

  • Page 71: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 12.28 Installing the air filter Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area Long-life grease ( p. 128) 101351-10 – Insert both parts together, position them and fasten them using air filter holder The arrow of marking UP faces up.

  • Page 72: Sealing The Air Filter Box

    SERVICE WORK ON THE CHASSIS 12.30 Sealing the air filter box – Seal the air filter box in the marked area 401527-10 12.31 Removing main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. –...

  • Page 73: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS Main work (all EXC models) – Remove screws of connecting cap – Take off the connecting cap with the perforated pipe, O-ring , and glass fiber yarn filling – Remove screws and take off silencer cap with O-ring and stuffing yarn...

  • Page 74: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS Main work – Disconnect electric plug-in connection of the fuel pump. – Remove the tube from the fuel tank breather. B01529-10 – 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 75: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water.

  • Page 76: Cleaning The Chain

    SERVICE WORK ON THE CHASSIS 12.37 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. –...

  • Page 77: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS Finishing work – Remove the motorcycle from the lift stand. ( p. 56) 12.39 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear- ings in the transmission and in the rear wheel) will be under additional load.
  • Page 78 SERVICE WORK ON THE CHASSIS – Pull on the upper part of the chain with the specified weight Guideline Weight of chain wear measurement 10… 15 kg (22… 33 lb.) – Measure the distance of 18 chain links in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 79: Checking The Frame

    If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by KTM. 401340-01 12.42 Checking the swingarm –...

  • Page 80: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS Main work – Check the throttle cable routing. Both throttle cables must be routed side by side behind the handlebars and above the fuel tank bearing to the throttle valve body. » If the throttle cable is not routed as specified: –...

  • Page 81: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS 12.47 Checking/correcting the fluid level of the hydraulic clutch Info The fluid level rises with increased wear of the clutch lining discs. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...

  • Page 82: Removing The Engine Guard (Exc Six Days, Exc Aus)

    SERVICE WORK ON THE CHASSIS 12.49 Removing the engine guard (EXC SIX DAYS, EXC AUS) – Turn quick release counterclockwise until it disengages. Remove the engine guard. L00723-10 12.50 Installing the engine guard (EXC SIX DAYS, EXC AUS) – Attach the engine guard on the frame at the rear and swing up at the front. –...

  • Page 83: Brake System

    BRAKE SYSTEM 13.1 Checking free travel of hand brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating.

  • Page 84: Checking The Brake Discs

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 85: Checking The Front Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 86: Changing The Front Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.

  • Page 87: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 100397-01 – Insert the brake linings, insert the pin, and mount the cotter pin. – Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

  • Page 88: Checking The Rear Brake Fluid Level

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.

  • Page 89: Checking The Rear Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 90: Changing The Rear Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
  • Page 91 BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 100407-10 – Insert the brake linings, insert the pin, and mount the cotter pin. – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

  • Page 92: Wheels, Tires

    WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 56) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

  • Page 93: Removing The Rear Wheel

    WHEELS, TIRES – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc.

  • Page 94: Installing The Rear Wheel

    Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have a significant impact on the handling characteristics of the motorcycle.

  • Page 95: Checking The Tire Air Pressure

    Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.
  • Page 96 WHEELS, TIRES – Tap each spoke with a screwdriver. Info The sound frequency depends on the length and thickness of the spoke. If there are different sound frequencies in spokes with the same length and thickness, this indicates different spoke tensions. You should hear a high note.

  • Page 97: Electrical System

    ELECTRICAL SYSTEM 15.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...

  • Page 98: Charging The Battery

    – Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible 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 99: Changing The Main Fuse

    ELECTRICAL SYSTEM 15.4 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box cover.

  • Page 100: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM 15.5 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat.

  • Page 101: Refitting The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM – Pull out the electric plug connector and remove the headlight mask with the headlight. B01561-10 15.7 Refitting the headlight mask with the headlight Main work – Connect the electric plug connector B01561-11 – Position the headlight mask and fix it with the rubber band Info Ensure that the retaining lugs engage in the fender.

  • Page 102: Changing The Turn Signal Bulb

    ELECTRICAL SYSTEM – Pull out headlight bulb – Insert the new headlight bulb. Headlight (HS1 / socket PX43t) ( p. 122) – Insert the protection cap with the bulb socket into the reflector and turn it clock- wise all the way. Info Ensure that O-ring is seated properly.

  • Page 103: Adjusting The Headlight Range

    ELECTRICAL SYSTEM » If the light-dark border does not meet specifications: – Adjust the headlight range. ( p. 101) 15.11 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 100) Main work – Loosen screw – Adjust the headlight range of the headlight by moving it up or down.
  • Page 104 ELECTRICAL SYSTEM (EXC SIX DAYS) – Remove screws – Pull the speedometer upward out of the holder. B01599-10 – Using a coin, turn protection cap all the way counterclockwise and remove – Remove speedometer battery – Insert the new battery with the label facing upward. Speedometer battery (CR 2430) ( p.

  • Page 105: Cooling System

    COOLING SYSTEM 16.1 Cooling system Water pump in the engine circulates 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 tem- perature will not result in a risk of malfunctions.

  • Page 106: Draining The Coolant

    COOLING SYSTEM Condition The engine is cold. – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the coolant level in the radiator. Coolant level above radiator fins. 10 mm (0.39 in) » If the coolant level does not meet specifications: –...
  • Page 107 COOLING SYSTEM Coolant 1.2 l (1.3 qt.) Coolant (mixed ready to use) p. 126) – Refit the radiator cap. Finishing work – Take a short test ride. – Check the coolant level. ( p. 103)

  • Page 108: Tuning The Engine

    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. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3…...

  • Page 109: Adjusting The Idle Speed

    TUNING THE ENGINE 17.3 Adjusting the idle speed – Run the engine warm and push the idle speed adjusting screw all the way in. – Set the desired idle speed by turning the idle speed adjusting screw. Guideline Idle speed 1,950…...

  • Page 110: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 18.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 111: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens

    SERVICE WORK ON THE ENGINE 18.3 Changing the engine oil and oil filter, cleaning the oil screens Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 112 SERVICE WORK ON THE ENGINE – Push the engine oil screen with the O-rings onto a pin wrench. – Push the pin wrench through the opening into the drill hole of the opposite engine case wall and push the oil screen as far as possible into the engine case. L00735-10 –...

  • Page 113: Adding Engine Oil

    SERVICE WORK ON THE ENGINE – Install and tighten the oil filler plug with O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 114: Cleaning, Care

    CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts.

  • Page 115: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE 19.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

  • Page 116: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 56) – Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materi- als since they prevent humidity from escaping, thus causing corrosion.

  • Page 117: Troubleshooting

    – Check the electrical system. switch defective – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool.
  • Page 118 – Check the cabling for damage and the electri- cal plug-in connections for corrosion and dam- age. – Read out the fault memory using the KTM diag- nostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary.

  • Page 119: Blink Code

    BLINK CODE Blink code FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Crankshaft position sensor - circuit fault Blink code FI warning lamp (MIL) 06 FI warning lamp (MIL) flashes 6x short Error level condition Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high Blink code FI warning lamp (MIL)
  • Page 120 BLINK CODE Blink code FI warning lamp (MIL) 45 FI warning lamp (MIL) flashes 4x long, 5x short Error level condition EXC EU, EXC SIX DAYS Lambda sensor heater cylinder 1, sensor 1 - short circuit to ground or open circuit Lambda sensor heater cylinder 1, sensor 1 - input signal too high...

  • Page 121: Technical Data

    TECHNICAL DATA 23.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement (all 450 models) 449.3 cm³ (27.418 cu in) Displacement (all 500 models) 510.4 cm³ (31.147 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) Compression ratio...
  • Page 122 TECHNICAL DATA ® Nut, water pump impeller 8 Nm (5.9 lbf ft) Loctite 243™ ® Plug, vacuum connection 2.5 Nm (1.84 lbf ft) Loctite 243™ – Screw, alternator cover M6x25 10 Nm (7.4 lbf ft) ® Screw, camshaft bearing support 10 Nm (7.4 lbf ft) Loctite 243™...

  • Page 123: Capacities

    TECHNICAL DATA – Nut, inner clutch hub M18x1.5 80 Nm (59 lbf ft) ® Nut, primary gear M20LHx1.5 100 Nm (73.8 lbf ft) Loctite 648™ – Screw plug, engine oil screen M20x1.5 15 Nm (11.1 lbf ft) – Screw plug, gear oil screen M20x1.5 15 Nm (11.1 lbf ft) 23.3...

  • Page 124: Electrical System

    (all XC‑W models) 80/100 - 21 51M TT 110/100 - 18 64M TT Dunlop GEOMAX MX51FA Dunlop GEOMAX MX51 Additional information is available in the Service section under: http://www.ktm.com 23.7 Fork 23.7.1 EXC EU, EXC AUS, all XC‑W models Fork part number 14.18.7L.69...

  • Page 125: Exc Six Days

    TECHNICAL DATA Standard 2 turns Sport 2 turns Spring length with preload spacer(s) Weight of rider: 65… 75 kg (143… 165 lb.) 513 mm (20.2 in) Weight of rider: 75… 85 kg (165… 187 lb.) 513 mm (20.2 in) Weight of rider: 85… 95 kg (187… 209 lb.) 513 mm (20.2 in) Spring rate Weight of rider: 65…...

  • Page 126: Chassis Tightening Torques

    TECHNICAL DATA Sport 9 mm (0.35 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 69 N/mm (394 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 72 N/mm (411 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 76 N/mm (434 lb/in) Spring length 250 mm (9.84 in)
  • Page 127 TECHNICAL DATA – Screw, top triple clamp (EXC EU, 20 Nm (14.8 lbf ft) EXC AUS, all XC‑W models) – Engine attachment bolt 60 Nm (44.3 lbf ft) – Remaining nuts, chassis 45 Nm (33.2 lbf ft) – Remaining screws, chassis 45 Nm (33.2 lbf ft) ®...

  • Page 128: Substances

    Brake fluid DOT 4 / DOT 5.1 According to – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Castrol and Motorex ® products. Supplier Castrol –...
  • Page 129 SUBSTANCES Fork oil (SAE 4) (48601166S1) According to – SAE ( p. 130) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Shock absorber oil (SAE 2.5) (50180342S1) According to –...
  • Page 130 AUXILIARY SUBSTANCES Air filter cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Dirt Bio Remover Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline –...
  • Page 131 AUXILIARY SUBSTANCES Oil for foam air filter Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Liquid Bio Power Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline – KTM recommends Motorex ®...
  • Page 132 STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation.
  • Page 133 INDEX Clutch lever ........14 INDEX basic position, adjusting ..... . 78 Accessories .
  • Page 134 INDEX bleeding ....... . . 56 dust boots, cleaning ......56 Main fuse installing .
  • Page 135 INDEX riding sag, checking ......50 spring preload, adjusting ..... . 51 View of vehicle static sag, checking .
  • Page 136 *3213037en* 3213037en 04/2013 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

This manual is also suitable for:

450 exc aus450 exc six days eu450 xc-w usa500 exc aus500 exc six days eu500 exc usa ... Show all

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