KTM 400 EXC EU Owner's Manual
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KTM 400 EXC EU Owner's Manual

2011
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OWNER'S MANUAL
400 EXC Factory Edition EU
450 EXC Factory Edition EU
450 EXC SIX DAYS EU
450 XC-W SIX DAYS USA
530 EXC Factory Edition EU
530 EXC SIX DAYS EU
530 XC-W SIX DAYS USA
2011
400 EXC EU
400 EXC AUS
450 EXC EU
450 EXC AUS
530 EXC EU
530 EXC AUS
Art. no. 3211690en

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Summary of Contents for KTM 400 EXC EU

  • Page 1 OWNER'S MANUAL 2011 400 EXC EU 400 EXC Factory Edition EU 400 EXC AUS 450 EXC EU 450 EXC Factory Edition EU 450 EXC AUS 450 EXC SIX DAYS EU 450 XC-W SIX DAYS USA 530 EXC EU 530 EXC Factory Edition EU...
  • 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 Preparations for riding on dry sand ........26 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........5 Preparations for riding on wet sand ......... 27 IMPORTANT INFORMATION ..........6 Preparing for rides on wet and muddy surfaces....28 VIEW OF VEHICLE...............
  • Page 5 TABLE OF CONTENTS Refitting the headlight mask with the headlight....81 Installing the shock absorber ........52 Removing the front fender ..........52 Changing the headlight bulb........... 81 Checking the headlight adjustment ......... 82 Installing the front fender..........52 Adjusting the headlight range ......... 82 Removing the seat ............
  • Page 6 TABLE OF CONTENTS AUXILIARY SUBSTANCES..........115 STANDARDS..............117 INDEX ................118...

  • 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 done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.

  • Page 8: Important Information

    Warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claim can be honored for damage resulting from manipulation and/or other changes to the vehicle.
  • Page 9 IMPORTANT INFORMATION Transport Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances.

  • Page 10: View Of Vehicle

    VIEW OF VEHICLE View of the vehicle from the left front (example) 100853-10 Hand brake lever Clutch lever Air filter box lid Fuel tap Chain guide Side stand Shift lever...

  • Page 11: View Of The Vehicle From The Right Rear (Example)

    VIEW OF VEHICLE View of the vehicle from the right rear (example) 100854-10 Filler cap Short circuit button Speedometer Electric starter button Fork rebound adjustment Horn Fork compression adjustment Shock absorber rebound adjustment Level viewer for brake fluid, rear Shock absorber compression adjustment Foot brake lever Kick starter...

  • Page 12: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right.  500127-10 Type label The type label is fixed to the front of the steering head.  500128-10 Engine number The engine number is stamped on the left side of the engine under the engine ...

  • Page 13: 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. 500129-10...

  • Page 14: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar.  The clutch is hydraulically operated and self-adjusting. 500133-10 Choke (EXC EU, EXC Factory Edition, EXC SIX DAYS) The choke lever is fitted on the left side of the handlebar. ...

  • Page 15: Short Circuit Button (All Exc Models)

    CONTROLS Short circuit button (All EXC models) The short circuit button is fitted on the left side of the handlebar.  Possible states in basic position – In this position, the ignition circuit is • Short circuit button closed, and the engine can be started. pressed –...

  • Page 16: Electric Starter Button (Exc Aus)

    CONTROLS Electric starter button (EXC AUS) 5.11 The electric starter button is fitted on the right side of the handlebar.  Possible states • Electric starter button in basic position pressed – In this position, the electric starter is actuated. •...

  • Page 17: Speedometer Activation And Test

    CONTROLS Speedometer activation and test 5.16 Activating the speedometer The speedometer is activated when one of the keys is pressed or an impulse comes from the wheel speed sensor. Display test For the function test of the display, all display segments light up briefly. 400313-01 WS (wheel size) After the display function test, the wheel size WS is displayed briefly.

  • Page 18: Setting The Clock

    CONTROLS Setting the clock 5.19 Condition The motorcycle is stationary. – Press the button briefly and repeatedly until CLK appears at the bottom right of the display. – Press the button for 3 - 5 seconds. The hour display flashes. –...

  • Page 19: Querying The Lap Time

    CONTROLS Querying the lap time 5.21 Info This function can be called only if lap times are measured. Condition The motorcycle is stationary. – briefly and repeatedly until LAP appears at the bottom right of Press the button the display. –...

  • Page 20: Display Mode Speed/Clk (Clock)

    CONTROLS Display mode SPEED/CLK (clock) 5.24 – Press the button briefly and repeatedly until CLK appears at the bottom right of the display. The time is displayed in CLK display mode. Press the button . No function Press the button .

  • Page 21: Display Mode Speed/Tr2 (Trip Master 2)

    CONTROLS Press the button Next display mode briefly. Display mode SPEED/TR2 (trip master 2) 5.28 – 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 22: Display Mode Speed/S1 (Stop Watch 1)

    CONTROLS Display mode SPEED/S1 (stop watch 1) 5.31 – Press the button briefly and repeatedly until S1 appears at the top right of the display. S1 (stop watch 1) displays the journey time on the basis of TR1 and continues when an impulse is received from the wheel speed sensor.

  • Page 23: Opening Filler Cap

    CONTROLS Table of conditions and menu activation Display The motorcycle is Menu can be acti- stationary. vated Display mode SPEED/CLK (clock) • Display mode SPEED/LAP (lap time) • Display mode SPEED/TR1 (trip master 1) • Display mode SPEED/TR2 (trip master 2) •...

  • Page 24: Fuel Tap

    CONTROLS Fuel tap 5.35 The fuel tap is on the left of the fuel tank. With tap handle on the fuel tap, you can open or close the supply of fuel to the car-  buretor. Possible states Fuel supply closed OFF – No fuel flows from the tank to the carburetor. •...

  • Page 25: Kick Starter

    CONTROLS Kick starter 5.38 The kick starter is fitted on the right of the engine.  The engine can be started with either the kick starter or the electric starter. The upper part of the kick starter can be swung out. Info Before riding, swing the upper part of the kick starter inwards towards the engine.

  • Page 26: Locking The Steering (All Exc Models)

    CONTROLS Locking the steering (All EXC models) 5.42 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Park the vehicle. – Turn the handlebar as far as possible to the right. –...

  • Page 27: Putting Into Operation

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

  • Page 28: Running-In The Engine

    PUTTING INTO OPERATION – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis- tribution between the front and rear wheels.

  • Page 29: Preparations For Riding On Wet Sand

    – Mount the dust cover for the air filter. Dust protection device for air filter (59006019000) Info Read the KTM PowerParts installation instructions. 600869-01 – Mount the dust cover for the air filter for sand. Sand protection device for air filter (59006022000) Info Read the KTM PowerParts installation instructions.

  • Page 30: Preparing For Rides On Wet And Muddy Surfaces

    Waterproofing device for air filter (59006021000) Info See the KTM PowerParts fitting instructions. – Adjust the carburetor jetting and settings. Info 600870-01 Your authorized KTM workshop has the recommended carburetor tuning set- tings. – Fit the steel sprocket. – Clean the motorcycle. ( p. 97) –...

  • Page 31: Preparing For Rides At High Temperature And Slow Speed

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

  • Page 32: Riding Instructions

    RIDING INSTRUCTIONS Checks and maintenance before putting into operation 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 used. – Check the engine oil level. ( p.

  • Page 33: Starting Up

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

  • Page 34: Stopping, Parking

    RIDING INSTRUCTIONS – On sandy, wet or slippery surfaces, use the rear brake. – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. – On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine. In this way, you have to brake far less and the brakes do not overheat.
  • Page 35 RIDING INSTRUCTIONS – Fill the fuel tank with fuel up to measurement  Guideline Measurement of 35 mm (1.38 in)  Total fuel tank 9.5 l Super unleaded (ROZ 95 / RON 95 / capacity, approx. (2.51 US gal) PON 91) ( p.

  • Page 36: Service Schedule

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

  • Page 37: Service Work (As Additional Order)

    SERVICE SCHEDULE Service work (as additional order) S15N S45A S90A • Change the front brake fluid. Change the rear brake fluid. • Change the foot brake cylinder seals. • Change the hydraulic clutch fluid. p. 62) • Grease the steering head bearing. p.

  • Page 38: Tuning The Chassis

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

  • Page 39: Adjusting The Low-Speed Compression Damping Of The Shock Absorber

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

  • Page 40: Measuring Rear Wheel Sag Unloaded

    TUNING THE CHASSIS Measuring rear wheel sag unloaded – Raise the motorcycle with the lift stand. ( p. 43) – Measure the distance – as vertically as possible – between the rear axle and a fixed point, such as a mark on the side cover. –...

  • Page 41: 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 42: Checking Basic Setting Of Fork

    TUNING THE CHASSIS Checking basic setting of fork 9.11 Info For various reasons, no exact riding sag can be determined for the forks. – As with the shock absorber, smaller differences in the rider's weight can be com- pensated by the spring preload. –...

  • Page 43: Adjusting Spring Preload Of The Fork

    TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. Adjusting spring preload of the fork 9.14 – Turn the adjusting screws counterclockwise until they stop. Info Make the same adjustment on both fork legs. –...

  • Page 44: Handlebar Position

    TUNING THE CHASSIS Handlebar position 9.17 On the upper triple clamp, there are 2 holes at a distance of to each other.  Distance between holes 15 mm (0.59 in)  The holes on the handlebar support are placed at a distance of from the center.

  • Page 45: Service Work On The Chassis

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

  • Page 46: Loosening The Fork Protector

    SERVICE WORK ON THE CHASSIS – Press the dust boots back into their normal position. – Remove excess oil. – Position the fork protector. ( p. 44) – Remove the motorcycle from the lift stand. ( p. 43) Loosening the fork protector 10.5 –...

  • Page 47: Installing Fork Legs

    SERVICE WORK ON THE CHASSIS Installing fork legs 10.8 – Position the fork legs. Info The topmost milled groove in the fork leg must be flush to the upper edge of the upper triple clamp. Position bleeder screws toward the front. ...

  • Page 48: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS Installing the fork protector 10.10 – Position the fork protection on the left fork leg. Mount and tighten screws  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the fork protection on the right fork leg. Mount and tighten the screws. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft)
  • Page 49 SERVICE WORK ON THE CHASSIS – Position the upper triple clamp with the steering. – Mount screw but do not tighten yet.  – Position the clutch line, wiring harness, and CDI control unit. Mount and tighten screws  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 201470-11...

  • Page 50: Removing The Lower Triple Clamp (Exc Eu/Aus)

    SERVICE WORK ON THE CHASSIS – Position the brake caliper. 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 ...

  • Page 51: Installing The Lower Triple Clamp (Exc Eu/Aus)

    SERVICE WORK ON THE CHASSIS Installing the lower triple clamp (EXC EU/AUS) 10.14 – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 115) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

  • Page 52: 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 53: (Exc Factory Edition, Exc Six Days, Xc-W Six Days)

    SERVICE WORK ON THE CHASSIS (EXC Factory Edition, EXC SIX DAYS, XC‑W SIX DAYS) – Adjust play of the steering head bearing. p. 51) (EXC EU/AUS) – Adjust play of the steering head bearing. p. 51) – Check the steering head bearing and replace if required. –...

  • Page 54: Removing The Shock Absorber

    SERVICE WORK ON THE CHASSIS Removing the shock absorber 10.19 – Raise the motorcycle with the lift stand. ( p. 43) – Remove screw and lower the rear wheel with the swing arm as far as possible  without blocking the rear wheel. Fix the rear wheel in this position. –...

  • Page 55: Removing The Seat

    SERVICE WORK ON THE CHASSIS Removing the seat 10.23 – Remove screw  – Lift up the seat at the rear, pull it back and then remove it from above. 500080-10 Mounting the seat 10.24 – Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear and simultaneously push it forward.

  • Page 56: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS – Detach air filter holder at the bottom and swing it to one side. Remove the air  filter with the air filter support. – Remove the air filter from the air filter support. 500107-10 Installing the air filter 10.28 –...

  • Page 57: Removing Main Silencer

    SERVICE WORK ON THE CHASSIS Removing main silencer 10.30 Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. – Disconnect spring  –...

  • Page 58: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS (XC‑W SIX DAYS) – Remove screws of connecting cap   – Remove the connecting cap, perforated pipe and glass fiber yarn filling   – Remove screws and end cap   – Remove screws and take off spark arrestor with stuffing yarn ...

  • Page 59: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS – Pull both spoilers to the side of the radiator bracket and take the fuel tank away  upward. 500067-10 Installing the fuel tank 10.34 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components.

  • Page 60: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS Checking for chain dirt accumulation 10.35 – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 58) 400678-01 Cleaning the chain 10.36 Warning Danger of accidents Oil or grease on the tires reduces their grip. –...

  • Page 61: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS » If the chain tension does not meet specifications: – Adjust the chain tension. ( p. 59) – Remove the motorcycle from the lift stand. ( p. 43) Adjusting the chain tension 10.38 Warning Danger of accidents Danger caused by incorrect chain tension. –...
  • Page 62 SERVICE WORK ON THE CHASSIS – Pull on the upper part of the chain with the specified weight  Guideline Weight of chain wear measurement 10… 15 kg (22… 33 lb.) 0 0 A – Measure the distance of 18 chain links in the lower chain section. ...

  • Page 63: Adjusting Chain Guide

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

  • Page 64: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS Adjusting the basic position of the clutch lever 10.42 – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw  Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.
  • Page 65 SERVICE WORK ON THE CHASSIS – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws  – Remove cover with membrane   400339-10 – Fill bleeding syringe with the appropriate hydraulic fluid. ...

  • Page 66: Brakes

    BRAKES Checking free travel of hand brake lever 11.1 Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up in the front brake circuit. The front brake can fail due to overheating.

  • Page 67: Checking The Brake Discs

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

  • Page 68: Checking The Front Brake Linings

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

  • Page 69: Changing The Front Brake Linings

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

  • Page 70: Checking The Free Travel Of The Foot Brake Lever

    BRAKES – Check that leaf spring in the brake caliper and sliding plate in the brake   caliper support are seated correctly. 0 0 6 100397-01 – Fit the brake linings, insert the bolt, and mount the locking split pins. –...

  • Page 71: Checking Rear Brake Fluid Level

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

  • Page 72: Checking Rear Brake Linings

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 73 Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
  • Page 74 BRAKES – Correct the brake fluid reservoir level to the marking  Brake fluid DOT 4 / DOT 5.1 ( p. 113) – Mount the screw cap with the membrane and the O-ring.   Info Clean up overflowed or spilt brake fluid immediately with water. 400233-10...

  • Page 75: Wheels, Tires

    WHEELS, TIRES Removing front wheel 12.1 – Raise the motorcycle with the lift stand. ( p. 43) – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.

  • Page 76: Removing The Rear Wheel

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

  • Page 77: Checking The Tire Condition

    12.5 Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.

  • Page 78: Checking Tire Air Pressure

    Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.
  • Page 79 WHEELS, TIRES Torque wrench with various accessories in set (58429094000)

  • Page 80: Electrical System

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

  • Page 81: Removing The Main Fuse

    ELECTRICAL SYSTEM Info Even when there is no load on the battery, it still loses power steadily. The charge state and the type of charge are very important for the service life of the battery. Rapid recharging with a high charging current shortens the battery's service life. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves.

  • Page 82: Changing The Fuse Of The Radiator Fan (Exc Six Days, Xc-W Six Days)

    ELECTRICAL SYSTEM – Insert the main fuse. Fuse (58011109110) ( p. 108) Info A reserve fuse is located in the starter relay.  Replace a faulty fuse by an equivalent fuse only.  – Replace the protection cover. – Install the air filter box lid. ( p.

  • Page 83: Refitting The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM Refitting the headlight mask with the headlight 13.8 – Connect the electric plug connector  600702-11 – Position the headlight mask and fix it with the rubber band  Info Ensure that the retaining lugs engage in the fender. –...

  • Page 84: Checking The Headlight Adjustment

    ELECTRICAL SYSTEM Checking the headlight adjustment 13.10 – Stand the vehicle upright on a horizontal surface in front of a light wall and make a 0 0 A mark at the height of the center of the low beam headlight. –...
  • Page 85 ELECTRICAL SYSTEM – Position locking cap and, using a coin, turn it clockwise all the way.  – Press any button on the speedometer. The speedometer is activated. – Position the speedometer in the bracket. – Mount and tighten the screws with washers. –...

  • Page 86: Cooling System

    COOLING SYSTEM Cooling system 14.1 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- ...

  • Page 87: Draining Coolant

    COOLING SYSTEM Condition The engine is cold. – Stand the motorcycle upright on a horizontal surface. – Remove radiator cap. – Check the coolant level in the radiator. Coolant level above the radiator fins. 10 mm (0.39 in)  » If the coolant level does not meet specifications: –...
  • Page 88 COOLING SYSTEM – Refit the radiator cap. – Make a short test ride. – Check the coolant level. ( p. 84)

  • Page 89: Tuning The Engine

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

  • Page 90: Carburetor - Adjusting The Idle Speed

    TUNING THE ENGINE Carburetor - adjusting the idle speed 15.4 – Screw in idle adjusting screw all the way and then turn it to the prescribed basic  setting. Guideline Idle mixture adjusting screw (All 400 models) Open 0.75 turn Idle mixture adjusting screw (All 530 EXC models) Open 1.5 turns...

  • Page 91: Emptying The Carburetor Float Chamber

    TUNING THE ENGINE Info Following extreme air temperature or altitude changes, adjust the idle speed again. Emptying the carburetor float chamber 15.5 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components.

  • Page 92: Adjusting The Basic Position Of The Shift Lever

    TUNING THE ENGINE Adjusting the basic position of the shift lever 15.7 – Remove screw and take off shift lever   B00427-10 – Clean gear teeth of the shift lever and shift shaft.  – Mount the shift lever on the shift shaft in the required position and engage the gearing.

  • Page 93: Service Work On The Engine

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

  • Page 94: Removing The Oil Filter

    SERVICE WORK ON THE ENGINE Removing the oil filter 16.4 Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 95: Filling Up With Engine Oil

    SERVICE WORK ON THE ENGINE Filling up with engine oil 16.6 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – Remove the screw cap on the alternator cover and fill up with engine oil. ...

  • Page 96: Checking The Gear Oil Level

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

  • Page 97: Filling Up With Gear Oil

    SERVICE WORK ON THE ENGINE – Place a suitable container under the engine. – Remove the gear oil drain plug  – Remove the gear oil screen plug  – Completely drain the gear oil. – Thoroughly clean the gear oil drain plug with a magnet. –...
  • Page 98 SERVICE WORK ON THE ENGINE – Remove screw cap . Stand the motorcycle upright.  – Add gear oil until it flows out of the bore of the gear oil level screw. Engine oil (SAE 10W/50) ( p. 113) – Mount and tighten the gear oil level check screw.

  • Page 99: Cleaning, Care

    CLEANING, CARE Cleaning the motorcycle 17.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 100: Protection For Winter Operation

    CLEANING, CARE Protection for winter operation 17.2 Info If you use the motorcycle in the winter, you can expect to encounter salt on the roads. Precautions need to be taken against road salt corrosion. If the vehicle has been used on salted roads, clean it with cold water. Warm water intensifies the effects of salt. –...

  • Page 101: Storage

    – Place the vehicle on a dry storage place that is not subject to large temperature variations. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 43) – Cover the vehicle with an air-permeable cover or blanket.

  • Page 102: Troubleshooting

    TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Go through the steps of starting the engine. tric starter). p. 30) – Battery discharged Recharge the battery. p. 78) – Check the charging voltage. – Check the closed current.
  • Page 103 TROUBLESHOOTING Faults Possible cause Action – Engine stalls or pops back into the The intake system has an air leak Check rubber sleeves and carburetor for tight- carburetor ness. – Engine overheats Coolant level low in cooling system Check the cooling system for leaks. –...

  • Page 104: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 1-cylinder 4-stroke engine, water-cooled Displacement (All 400 models) 393.4 cm³ (24.007 cu in) Displacement (All 450 models) 449.3 cm³ (27.418 cu in) Displacement (All 530 models) 510.4 cm³ (31.147 cu in) Stroke (All 400 models) 55.5 mm (2.185 in) Stroke (All 450 models) 63.4 mm (2.496 in)

  • Page 105: Capacity - Transmission Oil

    TECHNICAL DATA - ENGINE Capacity - transmission oil 20.2 Gear oil 0.90 l (0.95 qt.) Engine oil (SAE 10W/50) ( p. 113) Capacity - coolant 20.3 Coolant 0.95 l (1 qt.) Coolant ( p. 113) Coolant (mixed ready to use) ( p.

  • Page 106: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Screw, cable holder in alternator cover 4 Nm (3 lbf ft) Loctite 243™ ® Locking screw for bearing 6 Nm (4.4 lbf ft) Loctite 243™ ® Oil jet, piston cooling 2 Nm (1.5 lbf ft) Loctite 243™...
  • Page 107 TECHNICAL DATA - ENGINE TIGHTENING TORQUES Screw, cylinder head M10x1.25 Tightening sequence: Lubricated with engine oil Tighten diagonally, begin- ning with the rear screw on the chain shaft. Step 1 10 Nm (7.4 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 50 Nm (36.9 lbf ft) –...

  • Page 108: Technical Data - Carburetor

    TECHNICAL DATA - CARBURETOR All 400 models 22.1 Carburetor type KEIHIN FCR-MX 39 Carburetor identification number 3900N Needle position 5th position from top Idle mixture adjusting screw Open 0.75 turn Pump diaphragm stop 2.15 mm (0.0846 in) Main jet Jet needle OBDYU (OBDTQ) Idling jet Idle air jet...

  • Page 109: All 530 Exc Models

    TECHNICAL DATA - CARBURETOR All 530 EXC models 22.4 Carburetor type KEIHIN FCR-MX 39 Carburetor identification number 3900J Needle position 5th position from top Idle mixture adjusting screw Open 1.5 turns Pump membrane stop 2.15 mm (0.0846 in) Main jet Jet needle OBDZT (OBDTR) Idling jet...

  • Page 110: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Suspension Up Side Down 4860 MXMA PA Suspension travel Front 300 mm (11.81 in) Rear 335 mm (13.19 in) Fork offset (EXC EU/AUS) 20 mm (0.79 in) Fork offset (EXC Factory Edition, EXC SIX DAYS) 19 mm (0.75 in) Fork offset (XC‑W SIX DAYS)

  • Page 111: Lighting Equipment

    80/100 - 21 51M TT 110/100 - 18 64M TT Bridgestone M59 Bridgestone M402 Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 23.3 Total fuel tank capacity, 9.5 l (2.51 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p.

  • Page 112: Technical Data - Fork

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

  • Page 113: Technical Data - Shock Absorber

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

  • Page 114: Technical Data - Tightening Torques For Chassis

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

  • Page 115: Substances

    – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 116 SUBSTANCES Super unleaded (ROZ 95 / RON 95 / PON 91) According to – DIN EN 228 (ROZ 95 / RON 95 / PON 91)

  • Page 117: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline –...
  • Page 118 AUXILIARY SUBSTANCES Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Clean & Polish Universal oil spray Guideline – ® KTM recommends Motorex products.
  • Page 119 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 120 INDEX Clutch lever ........12 INDEX basic position, adjusting ..... . 62 Accessories .
  • Page 121 INDEX Fork offset ........41 adjusting ....... . . 41 Main fuse Fork protector installing .
  • Page 122 INDEX Spare parts ........6 Speedometer adjusting .
  • Page 123 *3211690en* 3211690en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

This manual is also suitable for:

400 exc aus450 exc eu450 exc aus450 exc six days eu450 xc-w six days usa530 exc eu ... Show all

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