450 EXC-R AUS - Moto tout-terrain KTM - Free user manual and instructions

USER MANUAL 450 EXC-R AUS KTM

Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly.

We wish you great pleasure riding the vehicle!

Enter the serial numbers of your vehicle below.

Chassis number (% P. 8) Dealer's stamp

Engine number (*% P. 8)

Key number (EXC-R EU, EXC-R AUS/UK, EXC-R USA) (% P. 8)

The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing development and design of our motorcycles can however not be completely excluded.

All specifications are not binding. KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifica- tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop prudction of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery.

© 2007 by KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, is permitted only with the express written permission of the copyright owner.

F ISO 9001(12 100 6061) ÉN Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes JU that lead to the maximum possible quality of the products.

Issued by: TÜV Management Service

EXC-R USA). Overview of indicator lamps (EXC-R six DAYS) Speedometer… Speedometer activation and test Tripmaster switch... Setting kilometers or mile: Setting the clock Adjusting speedometer functions Querying lap time … Display mode SPEED Display mode SPEED/H (service hours) Display mode SPEED / CLK (time)... Display mode SPEED/LAP (lap time) Display mode SPEED/ODO (odometer) . Display mode SPEED/TR1 (trip master 1) Display mode SPEED/TR2 (trip master 2) Disply mode SPEED/A1 (average speed 1 Display mode SPEED/A2 (average speed 2). Display mode SPEED/S1 (stop watch 1). Display mode SPEED/S2 (stop watch 2 Fuel tap…..….. Opening filer ca Closing filler cap … Choke (EXC-R AUS/UK, “EXC. R SIX DAYS, EXC-R USA, XCR-W) Choke (EXCR EU). Shift lever. Foot brake pedal Kickstarte: Side stand Steering lock (EXC-R EU, EXC-R AUS/UK, EXC-R USA)... 22

Locking the steering (EXC-R EU, EXC-R AUS/UK, EXC-R USA) Unlocking the steering (EXC-R EU, EXC-R AUS/UK, EXC-R USA) GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION Advice on first use … Running in the engine. RIDING INSTRUCTIONS Checks before putting into operation . 26 Starting Starting up Shifting, ridin: Braking Stopping, parking. Refueling. GREASING AND SERVICE TABLE. Important maintenance work to be carried out by an authorized KTM workshop. . Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)... 30 Important checks and maintenance work to be carried out by the rider. … MAINTENANCE WORK ON CHASSIS AND ENGINE. Jacking up the motorcycle …. Removing the motorcycle from the work stan:

Checking the basic chassis setting with the rider's weight Compression damping of shock absorber Adjusting high-speed compression damping of the shock absorber

Adjusting the low-speed compression damping of the shock absorber

Adjusting rebound damping of the shock absorbe Measuring rear wheel sag unloaded . Checking static sag of the shock absorber. Checking the riding sag of the shock absorbe Adjusting spring preload of the shock absorber À Adjusting riding sag À Removing the shock absorber À Installing shock absorber À . Checking basic setting of fork… Adjusting compression damping of fork . Adjusting rebound damping of fork Adjusting spring preload of the fork. Bleeding fork legs... Cleaning dust boots of fork legs Loosening the fork protection Positioning the fork protection … Checking play of steering head bearing Adjusting play of steering head bearing À (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA) Adjusting play of steering head bearing À (EXC-R SIX DAYS, XCR-W USA) Fork offset (EXC-R SIX DAYS, XCR-W USA) Setting the fork offset À (EXC-R SIX DAYS, XCR-W USA) Removing the fork legs Installing the fork legs À Removing the fork protector À. Installing the fork protector À

Removing the lower triple clamp À (EXC-R SIX DAYS, XCR-W USA)

CONTENTS Removing the lower triple clamp À (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA) Installing the lower triple clamp À (EXC-R SIX DAYS, XCR-W USA). Installing the lower triple clamp À (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA) Greasing the steering head bearing À Dismounting the front fender Installing the front fender... Removing headlight mask with headlight (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W ZA). Refitting the headlight mask with the headlight (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W ZA) Dismount the start number plate (CR: m USA). Fitting the start number plate (XCR-W USA) Handlebar position ….. Adjusting handlebar position Checking gas Bowden cable route Checking play in the gas Bowden cable Adjusting the gas Bowden cable play À Checking chain dirt Cleaning the chain. Checking the chain tension . Checking the chain tension when fitting rear whee Checking the rear sprocket / engine sprocket for wear . Checking chain wear. Adjusting the chain tension … Adjusting chain tension - after checking . Adjusting chain tension - fitting rear wheel . Adjusting chain guide À Brake fluid reservoir. Brake calipers Checking brake discs Checking free play of hand brake lever... Adjusting basic position of handbrake lever (Every XCR- We models) ..

Adjusting free travel of handbrake lever (Every EXC- R models)

Checking the front brake fluid level Topping up the front brake fluid À Checking the front brake linings. Removing front brake linings à. Installing the front brake linings À Changing the front brake linings à... Checking free play of foot brake lever Adjusting basic position of footbrake lever À. Checking the rear brake fluid level Adding rear brake fluid À... Checking rear brake linings … Removing rear brake linings À Installing the rear brake linings À Changing the rear brake linings À Removing front wheel À. Fitting front wheel À Removing rear wheel À Fitting rear wheel À. Tire condition checking Checking tire air pressure Checking spoke tension Removing the battery À ….

Installing the battery À. Recharging the battery À . Removing a fuse… Replacing the fuse Removing the seat Mounting the seat Dismounting the fuel tank À Installing the fuel tank À Cooling system Checking antifreeze and coolant level. Checking the coolant level …. Draining coolant À . Refilling coolant à . Glass fiber yarn filling of main silencer Removing main silencer. Fitting the main silencer Dismounting the air filter box lid Installing the air filter box lid.….. Removing the air filter À... Installing the air filter À Cleaning air filter À

Adjusting basic position of clutch leve: . Checking fluid level of hydraulic clutch . ..75 Changing fluid level of hydraulic clutch À 76

Carburetor - idle … Carburetor - adjusting idle À … Emptying the carburetor float chamber À Checking engine oil level.

Changing engine oil and oil filter, cleaning engine oil screen À

Draining engine oil, cleaning engine oil screen À Removing the oil filter À. Mounting oil filter À. Filling up with engine oil À Topping up engine oil . Checking gear oil level Changing gear oil, cleaning gear oil screen À

Draining gear oil, cleaning gear oil screen À . 82 Filling up with gear oil À . 83 Topping up with gear oil À . 83

TROUBLESHOOTING. CLEANING Cleaning motorcycle STORAGE Storage Putting into operation after storage . TECHNICAL DATA - ENGINE. Capacity - engine oil Capacity - gear oil. Capacity - coolant. TECHNICAL DATA - ENGINE TIGHTENING TORQUES TECHNICAL DATA - CARBURETOR 450 EXC-R EU, 450 EXC-R AUS/UK (39001) 450 EXC-R SIX DAYS, 450 EXC-R USA, 450 XCR-W (39001) . 530 EXC-R EU, 530 exc. R AUS/UK (39004) 530 EXC-R SIX DAYS, 530 EXC-R USA, 530 XCR-W (3900M) TECHNICAL DATA - CHASSIS Lighting equipment . Tires

MEANS OF REPRESENTATION F]

The symbols used are explained in the following.

Indicates an expected reaction (e.g. of a work step or a function).

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.

X Indicates an unexpected reaction (e.g. of a work step or a function).

Identifies a page reference (more information is provided on the specified page).

The typographical and other formats used are explained in the following.

Specific name Identifies a specific name. Name® Identifies a protected name.

Brand'M Identifies a brand in merchandise traffic.

KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply with currently valid regulations and categories of the top international motorsport organizations.

e Info [ The motorcycle is authorized for public road traffic in the homologous (reduced) version only. In the derestricted version, the motorcycle must be used only on secluded property remote from public road traffic. The motorcycle is designed for off-road sport endurance competition (Enduro) and not for the predominant motocross use.

KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply with currently valid regulations and categories of the top international motorsport organizations.

e Info The motorcycle must be used only on secluded property remote from public road traffic. The motorcycle is designed for off-road sport endurance competition (Enduro) and not for the predominant motocross use.

A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and break- age of components.

Using the motorcycle in extreme conditions such as very muddy or wet terrain can lead to above-average wear of components such as the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the greasing and service table is reached.

Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will ensure à much longer service life for your motorcycle.

The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for damage resulting from manipulations and alterations to the motorcycle.

You should use the fuels, oils and greases according to specifications as listed in the owner's manual.

For your own safety, use only spare parts and accessories approved by KTM. KTM accepts no liability for other products and any re- sulting damage or loss.

Note Danger of damage Danger of damage by the vehicle running away or falling over.

— Always place the vehicle on a firm and even surface. Note Fire hazard Some components (engine, radiator and exhaust system) get very hot when the engine is running.

— Do not place the vehicle where there are flammable or explosive substances.

— switch off engine. — Turn the handle @ of the fuel tap to the OFF position. (Figure 500137-10 ® P. 20) — Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a poten- tial problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can en- sure that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your mo- torcycle legally, display environmental consciousness, and respect the rights of others.

In your own interest, read the specified warning notes.

Various warning labels are attached to your vehicle. Do not remove any warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured.

Danger Danger that leads immediately and certainly to severe and permanent injury or death.

Warning Danger that will probably lead to severe and permanent injury or death.

Note Danger of serious damage to machine or material.

Warning Risk of environmental damage.

Read this owner's manual carefully and completely before making your first trip. It contains a lot of information and tips to help you operate and handle your motorcycle. Only then will you find out how to customize the motorcycle ideally for your own use and how you can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.

The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.

LOCATION OF SERIAL NUMBERS 8

The chassis number @ is stamped on the steering head on the right.

The type label @ is fixed to the front of the steering head.

The key number @ is stamped on the key strap.

The engine number @ is stamped on the left side of the engine under the engine sprocket.

The fork part number @ is stamped on the inner side of the fork stub.

LOCATION OF SERIAL NUMBERS The shock absorber part number @ is stamped on the top of the shock absorber above the adjusting ring on the engine side.

OPERATING ELEMENTS 10

] The clutch lever @ is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting.

The hand brake lever @ is located on the right side of the handlebar and operates the front wheel brake.

The short circuit button @ is mounted on the left side of the handlebar.

+ Short circuit button EX in basic position — In this position, the ignition circuit is closed, and the engine can be started.

+ Short circuit button Æ pressed — In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.

a The short circuit button @ is fitted on the left side of the handlebar.

+ Short circuit button & in basic position — In this position, the ignition circuit is closed, and the engine can be started.

+ Short circuit button © pressed — In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.

The emergency OFF switch @ is fitted on the left side of the handlebar. Possible states

lgnition off — In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.

lgnition on — In this position, the ignition circuit is closed, and the en- gine can be started.

OPERATING ELEMENTS ii

Emergency OFF switch (EXC-R USA)

The emergency OFF switch @ is fitted on the left side of the handlebar.

Possible states lgnition off — In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.

lgnition on — In this position, the ignition circuit is closed, and the en- gine can be started.

Ignition switch (EXC-R USA)

ŒU The ignition switch @ is on the right behind the headlight mask.

Possible states lgnition off — In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.

lgnition on — In this position, the ignition circuit is closed, and the en- gine can be started.

Electric starter button (EXC-R EU, EXC-R SIX DAYS, EXC-R USA, XCR-W) The electric starter button @ is fitted on the right side of the handlebar.

Possible states + Electric starter button ® in basic position + Electric starter button ® pressed — In this position, the electric starter is actuated.

Electric starter button (EXC-R AUS/UK)

The electric starter button @ is fitted on the right side of the handlebar.

Possible states + Electric starter button © in basic position + Electric starter button ® pressed — In this position, the electric starter is actuated.

Light switch (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS) The light switch @ is fitted on the left side of the handlebar.

Possible states Light off - Light switch is turned to the right. In this position, the light is e switched off.

20 Low beam on - Light switch is in the central position. In this position, £ the low beam and tail light are switched on.

High beam on — Light switch is turned to the left. In this position, the O high beam and the tail light are switched on.

OPERATING ELEMENTS 12

The light switch @ is on the right of the speedometer.

Possible states (XCR-W ZA) + Light off - Light switch is pressed in up to the stop. In this position, the light is switched off. + Light on - Light switch is pulled out to the stop. In this position, the low beam and tail light are switched on.

(XCR-W USA) + The light switch has no function when delivered. — It can be used if lighting is fitted later.

The light switch @ is fitted on the left side of the handlebar.

D) Low beam on - Light switch is turned downwards. In this position, the

Z low beam and tail light are switched on.

= High beam on — Light switch is turned upwards. In this position, the high 20 beam and the tail light are switched on.

The headlight flasher switch @ is fitted on the left side of the handlebar.

+ Headlight flasher switch in neutral position

+ Headlight flasher switch pressed -— In this position, the headlight flasher (high beam) is actuated.

The horn button @ is fitted on the left side of the handlebar.

Possible states + Horn button * in neutral position + Horn button pressed - The horn is operated in this position.

The horn button @ is fitted on the left side of the handlebar.

Possible states + Horn button in neutral position + Horn button *- pressed - The horn is operated in this position.

OPERATING ELEMENTS 13

The flasher switch @ is fitted on the left side of the handlebar.

Possible states Flasher light off - Flasher switch is in the central position. « Flasher light, left, on — Flasher switch turned to the left.

L 2 Flasher light, right, on — Flasher switch turned to the right.

The flasher switch @ is fitted on the left side of the handlebar.

Possible states Flasher light off Flasher light, left, on — Flasher switch pressed to the right. The flasher switch returns automatically to the central position after use.

Flasher light, right, on — Flasher switch pressed to the right. The flasher switch returns automatically to the central position after use.

To switch off the flasher light, press the flasher switch towards the switch case.

Possible states High beam indicator lamp lights up blue — High beam is switched on.

Flasher indicator lamp flashes green - Flasher light is switched on.

Possible states High beam indicator lamp lights up blue — High beam is switched on.

— Press the key O© to change the display mode or change to one of the setup menus. — Press the key "+" to control different functions. — Press the key "-" to control different functions.

In its condition at delivery, the disply mode SPEED/H and SPEED/0D0 is acti- vated.

14 Speedometer activation and test 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 LP 0008 TR TR M RSS For the function test of the display, all display segments light up briefly. ma 0 56:06:58 SPEED WS Kmh Mph Miles | 0D0 LP CK H 400313-01 WS (wheel size) After the function test of the display, the wheel size WS is displayed. Ya] e Info 222 6 2205 mm corresponds to the size of the 21" front wheel with a series produc- tion tire. ws The display then changes to the last selected mode. 400314-01

(Option: Tripmaster switch)

You can use the trip master switch to control the functions of the speedometer from the handlebar.

The trip master is an optional accessory.

Setting kilometers or miles

If you change the unit, the ODO value is retained and converted accordingly. The values TR1, TR2, A1, A2 and S1 are deleted at the changeover.

Van ELUUR ES 000 LP CKH

Condition The motorcycle is standing.

— Press the button © briefly and repeatedly until H appears at the bottom right of the display.

— Press the button O for 3 - 5 seconds. The Setup menu opens and the active functions are displayed. — Press the button O repeatedly until the Km/h / Mphdisplay flashes.

Setting Km/h — Press the button "+". Setting Mph — Press the button "-". — Press the button O for 3 - 5 seconds.

7 The settings are saved and the Setup menu closed.

e Info ll If no button is pressed for 20 seconds, or if no impulse comes from the

wheel speed sensor, the settings are automatically saved and the Setup menu closed.

OPERATING ELEMENTS 15

Condition The motorcycle is standing.

— Press the button © briefly and repeatedly until CLK appears at the bottom right of the display. — Press the button O for 3 - 5 seconds.

[a] \/ 7 The hour display flashes.

[a] -0 & 18447 — Set the hour display with the button "+" and/or button "-". /A\ x — Press the button O briefly.

7 The next segment of the display flashes and can be set.

— You can set the following segments in the same way as the hours by pressing the 400830-01 button "+" and the button "-".

e Info The seconds can only be set to zero.

— Press the button O for 3 - 5 seconds. 7 The settings are saved and the Setup menu closed.

(l If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu closed.

Adjusting speedometer functions

e Info In the condition at delivery, only the SPEED / H display mode and SPEED / ODO are active.

The motorcycle is standing.

— Press the button © briefly and repeatedly until H appears at the bottom right of the display.

— Press the button O for 3 - 5 seconds.

Sem A1 A2 51 82 7 The Setup menu opens and the active functions are displayed. 7 — Switch to the function you require by briefly pressing the button ©. MW LI CAL 7 The selected function flashes.

Activating a function — Press the button "+".

Deactivating a function — Press the button "-".

7 The icon disappears from the display and the display changes to the next function.

— Activate or deactivate all functions accordingly. — Press the button O for 3 - 5 seconds. 7 The settings are saved and the Setup menu closed.

ll If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu closed.

OPERATING ELEMENTS UV ap He

e Info This function can be called only if lap times are measured.

Condition The motorcycle is standing.

— Press the button O briefly and repeatedly until LAP appears at the bottom right of the display.

— Press the button © briefly.

7 The LAP 1 is displayed on the left of the display. — _ Laps 1-10 can be displayed by pressing the button "+" — button "-" no function — Press the button O briefly.

e Info If an impulse is received from the wheel speed sensor, the left side of the display changes back to SPEED mode.

— Press the button O briefly and repeatedly until SPEED appears on the left of the display.

In the SPEED display mode, the current speed is displayed.

The current speed can be displayed in Km/h or in Mph.

(l Making the setting according to the country. When an impulse comes from the front wheel, the left side of the speedometer display changes to the SPEED mode and the current speed is shown.

The motorcycle is standing

— Press the button © briefly and repeatedly until H appears at the bottom right of the display.

In display mode H, the service hours of the engine are displayed.

The service hour counter stores the total traveling time.

(l The service hour counter is necessary for ensuring that maintenance work is car- ried out at the right intervals. If the speedometer is in H display mode at the start of the journey, it automati- cally changes to the ODO display mode. The H display mode is suppressed during the journey.

Press the button "+". No function

Press the button "-". No function Press the button © The display changes to the Setup menu of the speedometer for 3-5 seconds. functions.

Press the button © briefly.

— Press the button © briefly and repeatedly until CLK appears at the bottom right of

The time is displayed in CLK display mode.

Press the button O for 3 - 5 seconds. Press the button ©

— Press the button O 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.

e Info If the lap time continues after you press the button "-", 9 memory locations are already occupied. Lap 10 must be timed with the button "+".

Press the button "+". Starts or stops the clock.

Press the button "-". Stops the current lap time and saves it, and the stop watch starts the next lap.

Press the button © The stop watch and the lap time are reset.

— Press the button O briefly and repeatedly until 0DO appears at the bottom right of the display.

In 0D0 display mode, the total number of kilometers ridden is displayed.

Press the button "+". No function

Press the button © Next display mode briefly.

— Press the button O briefly and repeatedly until TR1 appears at the top right of the display.

TRI (trip master 1) runs constantly and counts up to 999.9.

It can be used to measure the distance covered during trips or between two refueling

TRI is coupled with A1 (average speed 1) and S1 (stop watch 1).

1f 999.9 is exceeded, the values of TR1, A1 and S1 are automaticallt reset to 0.0.

Press the button "+". No function

Press the button "-". No function

Press the button © Displays of TR1, A1 and S1 are reset to 0,0. for 3 - 5 seconds. Press the button © briefly.

— 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 "-". A very practical function for rides by the road book.

e Info The TR2 value can also be corrected manually during the journey with the but- ton "+" and the button "-". 1f 999.9 is exceeded, the value of TR2 is automatically reset to 0.0.

Press the button "+". Increases value of TR2. Press the button "-". Reduces value of TR2. Press the button © Deletes value of TR2. for 3 - 5 seconds. Press the button O briefly.

— Press the button © briefly and repeatedly until A1 appears at the top right of the display.

A1 (average speed 1) shows the average speed calculated using TR1 (trip master 1) and

The calculation of this value is activated by the first impulse of the wheel sensor and

ends 3 seconds after the last impulse.

Press the button "+". No function

Press the button "-". No function

Press the button © Displays of TR1, A1 and S1 are reset to 0,0. for 3 - 5 seconds.

Press the button © Next display mode

— 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.

The displayed value can differ from the actual average speed if S2 was not timed after the ride.

Press the button © Next display mode briefly.

OPERATING ELEMENTS Display mode SPEED/S1 (stop watch 1)

— 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 TRI and continues when an

impulse is received from the wheel sensor.

The calculation of this value starts with the first impulse of the wheel sensor and ends

3 seconds after the last impulse.

Press the button "+". No function Press the button "-". No function Press the button © Displays of TR1, A1 and S1 are reset to 0,0.

Display mode SPEED/S2 (stop watch 2)

for 3 - 5 seconds. Press the button © Next display mode briefly.

Press the button © briefly and repeatedly until S2 appears at the top right of the

S2 (stop watch 2) is a manual stop watch. If S2 is running in the background, the S2 display flashes in the speedometer display.

Press the button "+". Starts or stops S2. Press the button "-". Press the button © Displays of S2 and A2 are reset to O.0. for 3 - 5 seconds. Press the button © Next display mode briefly.

Overview of speedomer functions

Press the button "+".

Press the button "-".

Press the button © for 3 - 5 seconds.

Press the button © briefly.

Display mode SPEED/H No function No function The display changes to | Next display mode (service hours) the Setup menu of the

speedometer functions. Display mode no function no function The display changes to | next display mode

the Setup menu of the clock.

Display mode SPEED/LAP (lap time)

Starts or stops the clock.

Stops the current lap time and saves it, and the stop watch starts

The stop watch and the lap time are reset.

the next lap. Display mode No function No function - Next display mode SPEED/0D0 (odometer) Display mode SPEED/TR1 | No function No function Displays of TRI, A1 and | Next display mode

S1 are reset to 0,0.

Display mode SPEED/TR2 (trip master 2)

increases value of TR2.

Reduces value of TR2.

Deletes value of TR2.

Disply mode SPEED/A1 No function No function Displays of TRI, A1 and | Next display mode (average speed 1) S1 are reset to 0,0.

Display mode SPEED/S1 | No function No function Displays of TRI, A1 and | Next display mode (stop watch 1) S1 are reset to 0,0.

Overview of conditions and ability to be enabled

The motorcycle is standing

Menu can be en- abled

Display mode SPEED Display mode SPEED/H (service hours)

Overview of conditions and ability to be enabled Display The motorcycle is Menu can be en- standing abled Display mode SPEED/LAP (lap time) . Display mode SPEED/0D0 (odometer) Display mode SPEED/TR1 (trip master 1) . Display mode SPEED/TR2 (trip master 2) . Disply mode SPEED/A1 (average speed 1) . Display mode SPEED/A2 (average speed 2) . Display mode SPEED/S1 (stop watch 1) . Display mode SPEED/S2 (stop watch 2) . Fuel tap

The fuel tap is on the left of the fuel tank.

With the tap handle @ on the fuel tap, you can open or close the supply of fuel to the

+ Fuel supply closed OFF - No fuel can flow from the tank to the carburetor.

+ Fuel supply open ON - Fuel can flow from the tank to the carburetor. The fuel tank empties down to the reserve.

+ __ Reserve fuel supply open RES - Fuel can flow from the tank to the carburetor. The fuel tank empties completely.

— Press release button ©, turn filler cap counterclockwise and lift it free.

— Replace the filler cap and turn clockwise until the release button @ locks in place.

e Info Run the fuel tank breather hose @ without kinks.

OPERATING ELEMENTS 21

The choke @ is fitted on the left side of the carburetor. Activating the choke function frees an opening through which the engine can draw ex- tra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.

e Info If the engine is warm, the choke function must be deactivated.

Possible states + Choke function activated - The choke lever is pulled out to the stop. + Choke function deactivated - The choke lever is pushed in to the stop.

The flasher switch @ is fitted on the left side of the handlebar. Activating the choke function frees an opening through which the engine can draw ex- tra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.

e Info If the engine is warm, the choke function must be deactivated.

Possible states + Choke function activated - The choke lever is pulled to the stop. + Choke function deactivated - The choke lever is pushed back to the stop.

The shift lever @ is mounted on the left side of the engine.

The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears.

The foot brake pedal @ is located in front of the right footrest and operates the rear wheel brake.

OPERATING ELEMENTS 22

7 The kickstarter @ is fitted on the right of the engine. The engine can be started with either the kickstarter or the electric starter.

The upper part of the kickstarter can be swung out.

e Info Before riding, swing the upper part of the kickstarter inwards towards the en- gine. Note

Danger of damage Danger of damage by the vehicle running away or falling over. — Always place the vehicle on a firm and even surface.

Material damage Damage and destruction of components by excessive load.

— The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over.

To park the motorcycle, press the side stand @ with your foot to the ground and lean the motorcycle on it.

When you are riding, the side stand @ must be folded up and secured with the rubber band @.

Steering lock (EXC-R EU, EXC-R AUS/UK, EXC-R USA)

The steering lock @ is fitted on the left of the steering head. The steering lock is used to lock the steering. Steering, and therefore riding, is no longer possible.

Locking the steering (EXC-R EU, EXC-R AUS/UK, EXC-R USA)

Note Danger of damage Danger of damage by the vehicle running away or falling over.

— Always place the vehicle on a firm and even surface.

— _ Parkthe motorcycle. — 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. 7 Steering is no longer possible.

e Info Never leave the key in the steering lock.

Unlocking the steering (EXC-R EU, EXC-R AUS/UK, EXC-R USA) — Insert the key in the steering lock, turn it to the left, pull it out and turn it to the right. Remove the key. 7 You can now steer the bike again.

e Info Never leave the key in the steering lock.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION Advi

Danger Danger of accidents Danger from inadequate traffic experience.

— Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs.

Warning Risk of injury Risk of injury by missing/inadequate protective clothing.

— Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle.

Warning Danger of crashing Impairment of riding behavior due to different tire tread patterns on front and rear wheels.

— The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.

Warning Danger of accidents Critical riding behavior due to inappropriate riding.

— Adapt your riding speed to the road conditoins and your riding ability.

Warning Danger of accidents Accident risk caused by presence of a passenger.

— Your vehicle is not designed to carry passengers. Do not ride with a passenger.

Warning Danger of accidents Brake system failure.

— _lfthe foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take

your foot off the foot brake pedal if you do not want to brake.

Warning Danger of accidents Unstable riding behavior.

— Do not exceed the maximum permitted weight and axle loads. 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.

Info 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.

— Before your first trip, read the entire operating instructions carefully. — Get to know the operating elements. — adjust the basic position of clutch lever. (® P. 75)

EXC-R models) Adjust the free travel of the handbrake lever. (® P. 56)

Adjust the basic position of the footbrake lever. (% P. 60) Get used to handling the motorcycle on a suitable piece of land before making a longer trip.

e Info Offroad, you should be accompanied by another person on another machine so that you can help each other.

— Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.

— Do not make any offroad trips that over-stress your ability and experience. — Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. — Do not make any changes to the motorcycle, and use only KTM approved parts.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 25

— 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.

e Info Motorcycles react sensitively to any changes of weight distribution.

— Do not exceed the overall maximum permitted weight and the axle loads. Specification

Maximum permissible overall weight 335 kg (739 Ib.) Maximum permissible front axle load 145 kg (320 Ib.) Maximum permissible rear axle load 190 kg (419 Ib.)

Running in the engine

— During the running-in phase, do not exceed the specified engine speed and engine performance. Specification

Maximum engine speed

During the first 3 service hours 7000 rpm Maximum engine performance during the running-in period

During the first 3 service hours <50%

During the next 12 service hours <75%

— Avoid fully opening the throttle!

Checks before putting into operation

e Info Make sure that the motorcycle is in a perfect technical condition before use.

e Info In the interests of riding safety, make a habit of making a general check before you ride.

— Check the engine oil level. (# P. 79)

— Check the chain tension. (* P. 51)

— Check the chain dirt accumulation. (% P. 50)

— Check the tire condition. (% P. 66)

— Check that all operating elements are correctly adjusted and free to move. — Check the functioning of the electrical equipment.

Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death.

— When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.

Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.

— Always warm up the engine at low engine speeds.

e Info If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel evaporate after a long time of standing. If the float chamber is filled with fresh fuel, the engine starts immediately. Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds until trying again.

Conditions Motorcycle standing still: 2 1 week

— Empty the carburetor float chamber. (* P. 78) — Turn the handle @ of the fuel tap to the ON position. (Figure 500137-10 # P. 20) 7 Fuel can flow from the tank to the carburetor. — Remove the motorcycle from the stand. — Shift gear to neutral. (EXC-R USA) — Turn the key in the ignition switch to the position O. — Turn the emergency OFF switch to the position ©. (EXC-R AUS/UK) — Turn the emergency OFF switch to the position ©. Conditions Engine cold (EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W) — Pull choke lever out as far as possible.

(EXC-R EU) — Pull the choke lever to the stop.

RIDING INSTRUCTIONS 21

— Press the electric starter button or press the kickstarter robustly through its full range.

e Info Don't open the throttle.

Conditions Engine hot and running

— Push back the hot start lever to the stop with the engine running.

e Info If your bike has lights, switch them on before riding. You will then be seen earlier by other motorists. When you are riding, the side stand must be folded up and secured with the rubber band.

— Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.

û Warning Danger of accidents 1f you change down at high engine speed, the rear wheel can lock up.

— Do not change into a low gear at high engine speed. The engine races and the rear wheel can block.

e 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.

— When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simulta- neously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.

— _lfthe choke function was activated, deactivate it after the engine has warmed up.

— When you reach maximum speed after fully opening the throttle, turn back the throttle to about 3/4 of its range; the speed hardly drops, but the fuel consumption falls considerably.

— Always open the throttle only as much as the engine can handle — abrupt throttle opening increases fuel consumption. — To shift down, brake if necessary and close the throttle at the same time. — Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again. — Switch off the engine if you expect to be standing for a long time. Specification 22 min

— Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and the cooling system. — Ride with a lower engine speed instead of with a high engine speed and a slipping clutch.

û Warning Danger of accidents 1f you brake too hard, the wheels can lock.

— Adapt your braking to the traffic situation and the road conditions.

à Warning Danger of accidents Reduced braking caused by spongy pressure point of front or rear brake.

— Have the brake system checked in an authorized KTM workshop, and do not ride any further.

û Warning Danger of accidents Reduced braking due to wet or dirty brakes. — Clean or dry dirty or wet brakes by riding and braking gently.

— 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.

RIDING INSTRUCTIONS 28

û Warning Danger of burns Some vehicle components get very hot when the machine is driven.

— Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these compo- nents to cool down before starting work on them.

Note Danger of damage Danger of damage by the vehicle running away or falling over.

— Always place the vehicle on a firm and even surface.

Note Fire hazard Some components (engine, radiator and exhaust system) get very hot when the engine is running.

— Do not place the vehicle where there are flammable or explosive substances.

— _Brake the motorcycle. — Shift gear to neutral.

(Every XCR-W models) — Press the short circuit button X at engine idling speed until the engine stops.

(EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS) — Press the short circuit button X at engine idling speed until the engine stops.

(EXC-R USA) — Push the emergency off switch at engine indling speed to the position Xi.

— Turn the handle @ of the fuel tap to the OFF position. (Figure 500137-10 ® P. 20) — Stand the motorcycle on a hard surface.

Danger Fire hazard Fuel can easily catch fire.

— Never fill up 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.

— Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.

û Warning Danger of poisoning Fuel is poisonous and a health hazard.

— Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. |f fuel gets into your eyes, rinse imme- diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel.

Warning Environmental hazard Improper handling of fuel is a danger to the environment.

— Do not allow fuel to get into the ground water, the ground, or the sewage system.

— Open the filler cap. (# P. 20) — Fillthe fuel tank with fuel up to measurement @. Specification

[Measurement of @ [35 mm (1.38 in) Tank capacity 91(2.4 US gal) Super unleaded (ROZ 95 / RON 95 / (EXC-R EU, EXC- PON 91) (+ P.114)

R AUS/UK, EXC- R SIX DAYS, XCR-

Important maintenance work to be carried out by an authorized KTM workshop.

S3N S15A S30A Engine

Change the engine oil and oil filter and clean the engine oil screen. (% P. 79)

Change the gear oil and clean the gear oil screen. (% P. 82)

Check and adjust valve clearance.

Check engine mounting screws for tightness.

Clean spark plug connectors and check for tightness.

Check that the screws in the shift lever and the kickstarter are tight.

Check carburetor connection boots for cracks and leakage.

Check vent hoses for damage and routing without sharp bends.

Check the cooling system for leakage.

Check the antifreeze and coolant level. (* P.71)

Check the exhaust system for leakage and looseness.

Check Bowden cables for damage, smooth operation and routing without sharp bends.

Check the fluid level of the hydraulic clutch. (# P.75)

Clean the air filter. (% P. 75)

Check cables for damage and routing without sharp bends.

Check that the electrical equipment is functioning properly.

Check the headlamp setting.

Check the front brake linings. (# P. 57)

Check the rear brake linings. (# P. 61)

Check the brake discs. (# P. 55)

Check the front brake fluid level. (® P. 56)

Check brake lines for damage and leakage.

Check the free play of the hand brake lever. (® P. 55)

Check the free play of the foot brake lever. (% P. 59)

Check brake system function.

Check screws and guide bolts of brake system for tightness.

Check shock absorber and fork for leakage and functioning.

Clean dust boots of fork legs. (% P. 39)

Bleed fork legs. (% P. 38)

Check swingarm bearing.

Check play of steering head bearing. (* P. 39)

Check all screws to see if they are tight.

Check the chain wear. (® P. 52)

Check the chain tension. (# P. 51)

Clean the chain. (% P. 50)

Check wheel bearing for play.

Clean and grease adjusting screws of chain adjuster.

S3N: After 3 service hours S15A: Every 15 service hours / after every race S30A: Every 30 service hours

GREASING AND SERVICE TABLE

30 Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) Competition use Hobby use J1A J2A S15A | S30A | S45A | S30A | S60A | S90A Carry out a complete fork service. . Q Carry out a complete shock absorber service. . Grease the steering head bearing. (® P. 46) . ° Clean and adjust carburetor. . Q Treat electric contacts with contact spray. . . Change hydraulic clutch fluid. (# P. 76) . ° Change the front brake fluid. . Q Change the rear brake fluid. . Q Clean spark arrestor. (EXC-R USA, XCR-W USA) . . Check wear of clutch discs. . . . . . . Check the clutch. . . Check/measure the cylinder. . . Change the piston. . . Check the camshaft. . . Change the camshaft bearing. . . Check the lower valve spring retainer. . . Check the cylinder head. . . Check the valves. . . Check the valve springs. . . Check the radial clearance of the rocker arm rollers. . . Check the timing chain tensioner function. . . Check the balancer shaft. . . Check the crankshaft run-out on the bearing pin. . . Change conrod bearing. . . Change the crankshaft main bearing. . . Check the transmission. . . Check the shift mechanism. . . Check the spring length of the oil pressure regulator . . valve. Change glass fiber yarn filling of main silencer. . . Replace foot brake cylinder seals. . . Check the carburetor components. . . S15A: Every 15 service hours / after every race S30A: Every 30 service hours S45A: Every 45 service hours S60A: Every 60 service hours S90A: Every 90 service hours JA: annually J2A: every 2 years Important checks and maintenance work to be carried out by the rider.

NB1A Check the engine oil level. (# P. 79)

Check the front brake fluid level. (® P. 56)

Check the rear brake fluid level. (# P. 60)

Check the front brake linings. (® P. 57)

Check the rear brake linings. (% P. 61)

Check and adjust Bowden cables.

Bleed fork legs. (# P. 38)

Clean dust boots of fork legs. (# P. 39)

GREASING AND SERVICE TABLE NB1A Clean the chain. (% P. 50)

Check the chain tension. (# P. 51)

Check the chain wear. (# P. 52)

Check that all operating elements for smooth operation.

Check all screws, nuts and hose clamps regularly for tightness.

NB1A: Depending on conditions of use according to requirements.

MAINTENANCE WORK ON CHASSIS AND ENGINE 3

PS Note Danger of damage Danger of damage by the vehicle running away or falling over.

— Always place the vehicle on a firm and even surface.

— Jack up the motorcycle underneath the engine. The wheels must no longer touch the ground.

[Work stand (54829055000)

500074.01| — Secure the motorcycle against falling over.

Note Danger of damage Danger of damage by the vehicle running away or falling over.

— Always place the vehicle on a firm and even surface.

— Remove the motorcycle from the work stand. — Remove the work stand.

e Info When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.

For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swing arm and frame, the basic set- tings of the suspension components must match your body weight.

As delivered, KTM offroad motorcycles are adjusted for a standard rider weight (with full protective clothing). Specification Standard rider weight [ 75... 85 kg (165... 187 Ib.)

If your weight is above or below the standard range, you have to adjust the basic setting of the suspension components accord- ingly.

Small weight differences can be compensated by adjusting the spring preload, but in the case of large weight differences, the springs must be replaced.

The shock absorber can regulate compression damping in low- and high-speed range separately (Dual Compression Control).

The term low and high speed refers to the movement of the shock absorber during compression and not the riding speed of the motor- cycle.

The low- and high-speed technology works non-specifically.

Danger Danger of accidents The shock absorber is under high pressure.

— The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main- tenance on it yourself.

e Info The high-speed setting can be seen during the fast compression of the shock absorber.

MAINTENANCE WORK ON CHASSIS AND ENGINE

Turn the adjusting screw @ clockwise with a ring wrench until it stops.

e Info Do not loosen nut @!

Turn back counterclockwise the number of turns corresponding to the shock ab-

sorber type. Specification

Compression damping, high-speed Comfort 2turns Standard 1.5 turns Sport l'turn

Turn clockwise to increase damping, turn counterclockwise to reduce sus-

Adjusting the low-speed compression damping of the shock absorber

Danger of accidents The shock absorber is under high pressure.

— The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-

tenance on it yourself.

The low-speed setting can be seen during the slow to normal compression of the shock absorber.

Turn the adjusting screw @ clockwise with a screwdriver until it stops.

e Info Do not loosen nut @!

Turn back counterclockwise the number of clicks corresponding to the shock ab-

sorber type. Specification

Compression damping, low-speed Comfort 18 clicks Standard 15 clicks Sport 12 clicks e Info

Turn clockwise to increase damping, turn counterclockwise to reduce sus-

Adjusting rebound damping of the shock absorber

Danger Danger of accidents The shock absorber is under high pressure.

— The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-

tenance on it yourself.

MAINTENANCE WORK ON CHASSIS AND ENGINE 34

Measuring rear wheel sag unloaded

urn the adjusting screw @ clockwise until it stops.

e Info Do not loosen nut @!

Turn back counterclockwise the number of clicks corresponding to the shock ab- sorber type. Specification Rebound damping Comfort 24 clicks Standard 22 clicks Sport 20 clicks e Info Turn clockwise to increase damping, turn counterclockwise to reduce sus- pension damping. Jack up the motorcycle. (# P. 32)

Measure the distance — as vertical as possible - between the rear axle and a fixed

oint, for example, à mark on the side cover.

Make a note of the value as measurement @. Remove the motorcycle from the work stand. (® P. 32)

Measure distance @ of rear wheel unloaded. (% P. 34)

Ask someone to help you by holding the motorcycle upright.

Measure the distance between the rear axle and the fixed point again. Make a note of the value as measurement @.

e Info The static sag is the difference between measurements @ and @.

Check the static sag.

MAINTENANCE WORK ON CHASSIS AND ENGINE 35

Checking the riding sag of the shock absorber

Measure distance @ of rear wheel unloaded. (% P. 34)

With another person holding the motorcycle, sit on the saddle with full protective clothing in a normal sitting position (feet on footrests) and bounce up and down a few times until the rear suspension levels out.

The other person now has to measure the distance between the rear axle and a fixed point.

Make a note of the value as measurement @.

e Info The riding sag is the difference between measurements @ and @.

Check the riding sag.

» _ Ifthe riding sag differs from the specified measurement: — Adjust the riding sag. (* P. 36)

Adjusting spring preload of the shock absorber à

Danger of accidents The shock absorber is under high pressure.

— The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-

tenance on it yourself.

Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.

Remove shock absorber. (% P. 36)

After removing the shock absorber, clean it thoroughly.

Turn adjusting ring @ until the spring is no longer under tension. Combination wrench (50329080000) Hook wrench (T106S)

Measure the overall spring length when not under tension.

Tighten the spring by turning adjusting ring @ to measurement @.

e Info Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload.

Tighten screw ©. Specification

Screw, shock absorber adjusting ring M6 5 Nm (3.7 Ibf ft)

Installing shock absorber. (% P. 36)

MAINTENANCE WORK ON CHASSIS AND ENGINE 35

Adjusting riding sag À — Remove shock absorber. (# P. 36) — After removing the shock absorber, clean it thoroughly. — Choose and fit a suitable spring. Specification

Spring rate Weight of rider: 65... 75 kg (143... 165 Ib.) 69 N/mm (394 Ib/in) Weight of rider: 75... 85 kg (165... 187 Ib.) 72 N/mm (411 Ib/in) Weight of rider: 85... 95 kg (187... 209 Ib.) 76 N/mm (434 Ib/in)

The spring rate is shown on the outside of the spring. Smaller weight differences can be compensated by changing the spring preload.

— Check the static sag of the shock absorber. (# P. 34)

— Adjust the rebound damping of the shock absorber. (% P. 33)

Removing the shock absorber à

— Jack up the motorcycle. (# P. 32)

— 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.

— Remove screw @, push splash protector @ to the side, and remove the shock ab- sorber.

— Check parts for damage and wear. Replace damaged or worn parts.

— Push splash protector @ to the side and position the shock absorber. Mount and tighten screw @.

Screw, top shock absorber | M12 80 Nm Loctite® 243TM (59 Ibf ft)

— Mount and tighten screw ©. Specification

D 50005 1 Screw, bottom shock ab- M12 80 Nm Loctite® 243TM sorber (59 Ibf ft) e Info

The heim joint for the shock absorber at the swing arm is Teflon coated. lt must not be greased with grease or with other lubricants. Lubricants dis- solve the Teflon coating, thereby drastically reducing the service life.

— Remove the motorcycle from the work stand. (*# P. 32)

MAINTENANCE WORK ON CHASSIS AND ENGINE 31

Checking basic setting of fork

e Info For various reasons, no exact riding sag can be determined for the forks.

— As with the shock absorber, smaller weight differences can be compensated by the spring preload.

— However, if your fork is often overloaded (hard end stop on compression), you must fit harder springs to avoid damage to the fork and frame.

Adjusting compression damping of fork

e Info The hydraulic compression damping determines the fork suspension behavior.

Remove protection covers @. — Turn adjusting screws @ clockwise until they stop.

The adjusting screws @ are located at the bottom end of the fork legs. Make the same adjustment on both fork legs.

Turn back counterclockwise the number of clicks corresponding to the fork type. Specification

Compression damping (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W) Comfort 24 clicks Standard 20 clicks Sport 18 clicks Compression damping (EXC-R SIX DAYS) Comfort 24 clicks Standard 22 clicks Sport 18 clicks e Info

Turn clockwise to increase damping, turn counterclockwise to reduce sus- pension damping.

Mount protection covers @.

Adjusting rebound damping of fork

e Info The hydraulic rebound damping determines the fork suspension behavior.

— Turn adjusting screws @ clockwise until they stop.

The adjusting screws @ are located at the top end of the fork legs. Make the same adjustment on both fork legs.

MAINTENANCE WORK ON CHASSIS AND ENGINE Bleeding fork legs

— Turn back counterclockwise the number of clicks corresponding to the fork type.

Rebound damping (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W) Comfort 20 clicks Standard 18 clicks Sport 18 clicks Rebound damping (EXC-R SIX DAYS) Comfort 20 clicks Standard 20 clicks Sport 18 clicks e Info

Turn clockwise to increase damping, turn counterclockwise to reduce sus-

— Turn adjusting screws counterclockwise until they stop.

Make the same adjustment on both fork legs.

— Turn back clockwise the number of turns corresponding to the fork type.

Adjusting the spring preload has no influence on the absorption setting of

the rebound damping. Basically, however, you should set higher spring preload.

the rebound damping higher with a

Turn clockwise to increase spring preload, turn counterclockwise to reduce

— Jack up the motorcycle. (# P. 32) — Remove bleeder screws @ briefly.

7 Any excess pressure escapes from the interior of the fork.

— Mount and tighten bleeder screws.

— Remove the motorcycle from the work stand. (# P. 32)

MAINTENANCE WORK ON CHASSIS AND ENGINE 39

Cleaning dust boots of fork legs

— Jack up the motorcycle. (# P. 32) — Loosen the fork protection. (# P. 39) — Push dust boots @ of both fork legs downwards.

ll The dust boots should remove dust and coarse dirt particles from the fork tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not

[1] removed, the oil seals behind can start to leak.

n Warning Danger of accidents Reduced braking due to oil or grease on the brake 500088-10 discs.

— Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

— Clean and oil the dust boots and inner fork tube of both fork legs.

Universal oil spray (% P. 115)

— Press the dust boots back into their normal position.

— Remove excess oil.

— Position the fork protection. (* P. 39)

— Remove the motorcycle from the work stand. (# P. 32)

Loosening the fork protection

— Remove screws @ and take off clamp. — Remove screws @ on left fork leg. Push the fork protection downwards. — Remove the screws on the right fork leg. Push the fork protection downwards.

Positioning the fork protection r ] — Position the fork protection on the left fork leg. Mount and tighten screws @. p , Specification

[ Remaining screws, chassis M6 I 10 Nm (7.4 Ibf ft) |

— Position the brake line and cable harness. Put the clamp on, mount and tighten screws @.

— Position the fork protection on the right fork leg. Mount and tighten screws. Specification [ Remaining screws, chassis M6 I 10 Nm (7.4 Ibf ft) |

Checking play of steering head bearing

û Warning Danger of accidents Unsafe riding behavior due to incorrect steering head bearing play.

— The steering head bearing play should be adjusted immediately in an authorized KTM workshop.

If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time.

— Jack up the motorcycle. (# P. 32)

MAINTENANCE WORK ON CHASSIS AND ENGINE 20

— 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-R SIX DAYS, XCR-W USA) — Adjust play of the steering head bearing. (% P. 40)

(EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA) — Adjust play of the steering head bearing. (% P. 40)

— Move the handlebar to and fro over the entire steering range.

The handlebar must be able to move easily over the entire steering range. No resting locations should be noticeable.

» If click positions are noticeable:

(EXC-R SIX DAYS, XCR-W USA) — Adjust play of the steering head bearing. (% P. 40)

(EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA) — Adjust play of the steering head bearing. (% P. 40)

— Check the steering head bearing and replace if required. — Remove the motorcycle from the work stand. (# P. 32)

Adjusting play of steering head bearing à (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA) — Jack up the motorcycle. (# P. 32) — Loosen screws @ and @. — Loosen and retighten screw @. Specification [ Screw, top steering head M20x1,5 I 10 Nm (7.4 Ibf ft) |

— Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. — Fully tighten screw @. Specification

Screw, top triple clamp M8 20 Nm (14.8 Ibf ft)

— Tighten screw @. Specification

Screw, top steering stem M8 20 Nm (14.8 Ibf ft)

— Check play of steering head bearing. (# P. 39)

Adjusting play of steering head bearing À (EXC-R SIX DAYS, XCR-W USA) — Jack up the motorcycle. (# P. 32) — Loosen screw @. Remove screw @. — Loosen and retighten screw @. Specification [ Screw, top steering head M20x1,5 I 10 Nm (7.4 Ibf ft) |

— Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. — Fully tighten screw @. Specification

Screw, top triple clamp M8 17 Nm (12.5 Ibf ft)

— Mount and tighten screw @. Specification

Screw, top steering stem M8 17 Nm Loctite® 2437M (2.5 lbf ft)

— Check play of steering head bearing. (* P. 39)

MAINTENANCE WORK ON CHASSIS AND ENGINE at

Fork offset (EXC-R SIX DAYS, XCR-W USA)

You can see the currently set offset if you remove screw @.

The fork offset @ has an impact on the handling of the vehicle. It is calculated from the center of the fork leg to the center of the steering head bearing.

The fork offset can optionally be adjusted.

Marking @ to the front gives greater stability on fast racetracks.

Front marking Ï 18 mm (0.71 in)

Marking @ to the rear (condition at delivery) gives better handling in bends.

Rear marking I 20 mm (0.79 in)

Setting the fork offset À (EXC-R SIX DAYS, XCR-W USA) — Remove the lower triple clamp. (* P. 43) — Remove screw @. Remove the steering stem.

— Clean the parts and check for damage. — _ Rotate the steering stem 180° and insert into the triple clamp. Mount and tighten

— Install the lower triple clamp. (* P. 44)

Removing the fork legs

— Remove front wheel. (% P. 63)

— Remove screws @ and take off clamp.

— Remove cable clip @, remove screw © and take off the brake caliper.

— Hang the brake caliper and the brake line loosely to the side. 500093-10

à (EXC-R SIX DAYS, XCR-W USA)

— Loosen screw @. Remove the fork leg on the left. — Loosen screw @. Remove the fork leg on the right.

(EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA) — Loosen screw @. Remove the fork leg on the left.

— Loosen screw @. Remove the fork leg on the right.

— Check parts for damage and wear. Replace damaged or worn parts. — Position the fork legs.

The topmost sunk nut in the fork leg must be flush to the upper edge of the upper triple clamp. Position the bleeder screw @ to the front.

(EXC-R SIX DAYS, XCR-W USA) — Fully tighten screw @.

Screw, top triple clamp M8 17 Nm (12.5 Ibf ft)

— Fullytighten screw ©. Specification

— Fullytighten screw ©. Specification

Screw, bottom triple clamp M8 15 Nm (1.1 1bfft)

— Position brake caliper, mount and tighten screws ©. Specification

Screw, front brake caliper | M8 25 Nm Loctite® 243TM (8.4 lbf ft)

— Position the brake line and cable harness. Put the clamp on, mount and tighten screws ©.

— Fit front wheel. ( P. 64)

MAINTENANCE WORK ON CHASSIS AND ENGINE

43 — Remove the fork legs. (# P. 41) — Remove screws @ on the left fork leg. Remove the fork protector upwards. — Remove the screws on the right fork leg. Remove the fork protector upwards. ; 500105-10 — Check parts for damage and wear. Replace damaged or worn parts. — Position the fork protection on the left fork leg. Mount and tighten screws @. Specification [ Remaining screws, chassis I M6 I 10 Nm (7.4 Ibf ft) |

Position the fork protection on the right fork leg. Mount and tighten screws. Specification

[ Remaining screws, chassis I M6 I 10 Nm (7.4 lbf ft) |

Install the fork legs. (* P. 42)

— Remove the fork legs. (% P. 41)

(XCR-W USA) — Dismount the start number plate. (* P.47)

(EXC-R SIX DAYS) — Remove the headlight mask with the headlight. (% P. 46)

— Dismount the front fender. (* P. 46) — Remove screws @ and hang the CDI control unit to the side.

e Info Do not unplug the CDI control unit.

— Remove screw @. Remove screw ©, take off top triple clamp with the handlebar and place it on one side.

e Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines.

— Remove o-ring @. Remove protector ring @. — Remove the lower triple clamp with the steering stem. — Remove the upper steering head bearing.

MAINTENANCE WORK ON CHASSIS AND ENGINE aa

Removing the lower triple clamp à (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA)

— Remove the fork legs. (# P. 41)

— Remove the headlight mask with the headlight. (® P. 46) — Dismount the front fender. (* P. 46)

— Remove screws @ and hang the CDI control unit to the side.

e Info Do not unplug the CDI control unit.

— Remove screw @. Loosen screw ©. Take off top triple clamp with the handlebar and place it on one side.

e Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines.

— Remove protector ring @. — Remove the lower triple clamp with the steering stem. — Remove the upper steering head bearing.

Installing the lower triple clamp À (EXC-R SIX DAYS, XCR-W USA)

— Clean the bearing and sealing elements, check for damage, and grease.

[ Long-life grease (® P. 115)

— Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

e Info Check whether the top steering head seal @ is correctly positioned.

— Push up protective ring @ and o-ring @.

Position the upper triple clamp with the steering. — Mount and tighten screw @. Specification Screw, top steering head M20x1,5 10 Nm (7.4 Ibf ft)

Position the clutch line, wiring harness and CDI control unit. Mount and tighten screws ©.

Specification [ Remaining screws, chassis I M6 I 10 Nm (7.4 Ibf ft) |

— Install the front fender. (% P. 46)

MAINTENANCE WORK ON CHASSIS AND ENGINE 35

(EXC-R SIX DAYS) — Refit the headlight mask with the headlight. (# P. 47)

— Install the fork legs. (® P. 42) — Mount and tighten screw @. Specification

Screw, top steering stem M8 17 Nm Loctite® 2437M (2.5 lbf ft) — Check the cable harness, cable, brake and clutch line for free movement and free laying.

— Check play of steering head bearing. (* P. 39)

Installing the lower triple clamp À (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA)

— Clean the bearing and sealing elements, check for damage, and grease.

I [ Long-life grease (% P. 115)

H — Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

e Info Check whether the top steering head seal @ is correctly positioned.

— Push on protective ring @.

— Position the upper triple clamp with the steering. — Mount and tighten screw ©. Specification

Screw, top steering head M20x1,5 I 10 Nm (7.4 Ibf ft) | — Position the clutch line, wiring harness and CDI control unit. Mount and tighten screws @. Specification [ Remaining screws, chassis I M6 I 10 Nm (7.4 Ibf ft) |

— Install the front fender. (% P. 46) — Refit the headlight mask with the headlight. (# P. 47) — Install the fork legs. (# P. 42) — _ Tighten screw ©. Specification

Screw, top steering stem M8 20 Nm (14.8 Ibf ft)

— Check the cable harness, cable, brake and clutch line for free movement and free laying. — Check play of steering head bearing. (* P. 39)

Remove the lower triple clamp. (® P. 44) Install the lower triple clamp. (# P.45)

Dismounting the front fender

Removing headlight mask with headlight

— Remove screws @. Remove the front fender. — Make sure that the distance bushings remain in place.

— Check parts for damage and wear. Replace damaged or worn parts. — Make sure that the distance bushings are mounted in the fender. — Position the front fender. Mount and tighten screws @.

Specification [ Remaining screws, chassis M6 I 10 Nm (7.4 Ibf ft) |

Ensure that there is contact between the holding lugs and the start number plate or headlight mask.

(EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W ZA)

— Switch off all electrical equipment. — Remove screw @ and take off clamp. — Loosen the rubber band @. Push up the headlight mask and swing it forwards.

— Pull out the electric plug connector @ and remove the headlight mask with the

MAINTENANCE WORK ON CHASSIS AND ENGINE 41

— Check parts for damage and wear. Replace damaged or worn parts. — Connect the electric plug connector @.

— Position the headlight mask and fix it with the rubber band @.

e Info Take care with the contact of the holding lug at the fender.

— Position the brake line and cable harness. Put the clamp on, mount and tighten screw ©.

— Check the headlamp setting.

— Remove screw @ and take off clamp. — Remove screw @ with distance bushing. Remove the start number plate.

— Check parts for damage and wear. Replace damaged or worn parts.

— Position the start number plate. Fit and tighten screw @ with distance bushing. Specification [ Remaining screws, chassis M6 I 10 Nm (7.4 Ibf ft) ]

e Info Take care with the contact of the holding lug at the fender.

— Position the brake line and cable harness. Put the clamp on, mount and tighten

screw @. î : On the upper triple clamp, there are 2 holes at a distance of @ to each other. ë Ê [ Distance @ between holes I 15 mm (0.59 in) ] <i The holes on the handlebar support are placed at a distance of @ from the center. O° [Distance @ between holes | 3.5 mm (0.138 in) ]

1 ® The handlebar supports can be mounted in 4 different positions. (EXC-R SIX DAYS) The handlebar supports can also be mounted at 2 different heights (with and with-

400223-11 out spacer).

(EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W)

Remove the four screws @. Remove the handlebar clamp. Remove the handle- bar and lay it to one side.

e Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines.

Remove the two screws @. Remove the handlebar support. Check parts for damage and wear. Replace damaged or worn parts.

Place the handlebar support in the required position. Fit and tighten the two screws @.

Screw, handlebar support | M10 40 Nm Loctite® 2437 (29.5 lbf ft)

e Info Position the left and right handlebar supports evenly.

Position the handlebar.

e Info Make sure cables and wiring are positioned correctly.

Position the handlebar clamp. Fit and evenly tighten the four screws @. Specification

Screw, handlebar clamp M8 20 Nm (14.8 Ibf ft)

e Info Make sure the gap width is even.

Remove the four screws @. Remove the handlebar clamps @ with rubber wash- ers © and elastomers @.

Remove the handlebar and lay it to one side.

e Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines.

Remove the lower shells ©.

Remove the clamp bar @ with the rubber cones @.

Remove the two screws @. Remove the handlebar support.

Check parts for damage and wear. Replace damaged or worn parts.

MAINTENANCE WORK ON CHASSIS AND ENGINE 4

Checking gas Bowden cable route

— Place the handlebar support in the required position. Fit and tighten the two screws ©.

Screw, handlebar support | M10 40 Nm Loctite® 2437 (29.5 lbf ft)

Condition © Spacer fitted:

Condition without a spacer @:

e Info Position the left and right handlebar supports evenly.

— Fitthe rubber cones @ and clamp bar @. — Fitthe lower shells @. — Position the handlebar.

e Info Make sure cables and wiring are positioned correctly.

— Position the handlebar clamps @ with rubber washers @ and elastomers @. Elastomer kit green - soft quality (SXS05125203)

Elastomer kit yellow - medium quality (standard) (SXS05125204) Elastomer kit red - hard quality (SXSO05125205)

e Info The elastomeres are available in different versions.

— Fit and evenly tighten the four screws @. Specification

Screw, handlebar clamp M8 16 Nm (1.8 Ibf ft)

e Info Make sure the gap width is even.

The two gas Bowden cables must run parallel behind the handlebar down to the frame. They must be routed directly on the frame above the tank bearing to the car- buretor.

MAINTENANCE WORK ON CHASSIS AND ENGINE 50

— Move the handlebar to the straight-ahead position. Move the throttle grip back and forth slightly to ascertain the play in the gas Bowden cable.

[ Play in gas Bowden cable Ï 3... 5 mm (0.12... O.2 in) |

» _lfthe gas Bowden cable play does not meet specifications: — Adjust the gas Bowden cable play. (* P. 50)

Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon- 400192-10 sciousness and/or death.

— When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in a closed space.

— Start the engine and let it run idle. Move the handlebar to and fro over the entire steering range.

[ The idle speed must not change. |

» _lfthe idle speed changes: — _ Adjust the gas Bowden cable play. (* P. 50)

— Dismount the fuel tank. (* P. 70)

— Move the handlebar to the straight-ahead position.

— Push back bellows @.

— Loosen nut @. Turn adjusting screw © in as far as possible.

— Loosen nut @. Turn adjusting screw © so that there is play in the gas Bowden ca- ble at the throttle grip.

Specification [ Play in gas Bowden cable 3... 5 mm (0.12... O.2 in)

— Press and hold the throttle grip in the closed setting. Turn adjusting screw @ out until there is no play in the Bowden cable @.

— Push bellows @ on. Check the throttle grip for smooth operation. — Install the fuel tank. (% P. 70)

— Check play in the gas Bowden cable. (% P. 50)

— Check the chain for coarse dirt accumulation. »__lfthe chain is very dirty: — Clean the chain. (* P. 50)

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 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. Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

MAINTENANCE WORK ON CHASSIS AND ENGINE st

e Info The service life of the chain depends largely on its maintenance.

— Clean the chain regularly and then treat with chain spray.

Chain cleaner (% P. 115) Offroad chain spray (# P. 115)

Checking the chain tension

À Warning Danger of accidents Danger caused by incorrect chain tension.

— _lfthe chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary.

— Jack up the motorcycle. (# P. 32) — Push the chain at the end of the chain sliding component upwards to measure the chain tension @.

(l The upper chain section @ must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions.

[ Chain tension | 8... 10 mm (0.31... 0.39 in)

» If the chain tension does not meet specifications: — Adjusting chain tension - after checking. (® P. 53) — Remove the motorcycle from the work stand. (* P. 32)

Checking the chain tension when fitting rear wheel

û Warning Danger of accidents Danger caused by incorrect chain tension.

— _lfthe chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if

— Make sure that the chain adjusters are fitted correctly on the adjusting screws.

— Push the chain at the end of the chain sliding component upwards to measure chain tension @.

D The upper chain section @ must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions.

[ Chain tension 8... 10 mm (0.31... 0.39 in)

» If the chain tension does not meet specifications: — Adjust the chain tension when fitting rear wheel. (# P. 54)

MAINTENANCE WORK ON CHASSIS AND ENGINE 52

Checking the rear sprocket / engine sprocket for wear

— Check the rear sprocket / engine sprocket for wear. ——— » _Ifthe rear sprocket / engine sprocket are worn: — Replace rear sprocket / engine sprocket.

e Info KZ ll When fitting the chain joint, always make sure that the closed side NY ÿ # of the joint faces forward (riding direction). À The engine sprocket, rear sprocket and chain should always be re- ù placed together.

— Check that the chain guide is firmly seated and not worn.

Checking chain wear — Jack up the motorcycle. (* P. 32) — Shift to neutral and pull the upper chain length with the specified tension @. Specification [Chain tension I 10... 15 kg (22... 331b.)

— Measure distance @ of 18 chain links in the lower chain section.

Chain wear is not always even, so you should repeat this measurement at different chain positions.

Maximum distance @ at the longest 272 mm (10.71 in) chain section

» If distance @ is greater than the specified measurement: — Replace the chain.

e Info When you replace the chain, you should also replace the rear and engine sprockets. New chains wear out faster on old, worn sprockets.

16 17 18 400226-10] — Remove the motorcycle from the work stand. (# P. 32)

Adjusting the chain tension

û Warning Danger of accidents Danger caused by incorrect chain tension.

— _lfthe chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary.

— Jack up the motorcycle. (% P. 32)

— Push the chain at the end of the chain sliding component upwards to measure chain tension @.

(l The upper chain section @ must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions.

MAINTENANCE WORK ON CHASSIS AND ENGINE 53

— Loosen nut @. — _Loosen nuts @. — Adjust the chain tension by turning the left and right adjusting screws @. Specification Chain tension 8... 10 mm (0.31... 0.39 in)

Turn the left and right adjusting screws @ so that the markings on the left and right chain adjusters are in the same position relative to the reference marks @. The rear wheel is then correctly aligned.

— Tighten nuts @. — Make sure that chain adjusters @ are fitted correctly on the adjusting screws @. — Tighten nut @.

[ Nut, rear wheel spindle M20x1,5 80 Nm (59 Ibf ft)

e Info The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length. Chain adjusters © can be turned by 180°.

— Remove the motorcycle from the work stand. (# P. 32)

— _ Loosen nut @. — _Loosen nuts @. — Adjust the chain tension by turning the adjusting screws © left and right. Specification Chain tension 8... 10 mm (0.31... 0.39 in)

Turn the adjusting screws © left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks @. The rear wheel is then correctly aligned.

— Make sure that the chain adjusters @ are fitted correctly on the adjusting screws ©.

— Tighten nut @. Specification [ Nut, rear wheel spindle M20x1,5 80 Nm (59 Ibf ft)

D The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length. The chain adjusters @ can be turned by 180°.

MAINTENANCE WORK ON CHASSIS AND ENGINE sa

— _ Loosen nuts @. — Adjust the chain tension by turning the adjusting screws @ left and right. Specification

Chain tension 8... 10 mm (0.31... 0.39 in)

Turn the adjusting screws @ left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks @. The rear wheel is then correctly aligned.

— Remove screws @ and @. Take off the chain guide.

Conditions Number of teeth: < 44 teeth

— Insert nut @ in hole @. Position the chain guide. — Mount and tighten screws @ and @. Specification

Remaining screws, chassis M6 10 Nm (7.4 Ibf ft)

Conditions Number of teeth: z 45 teeth

— Insert nut @ in hole @. Position the chain guide. — Mount and tighten screws @ and @. Specification

Remaining screws, chassis M6 10 Nm (7.4 Ibf ft)

Warning Danger of accidents Brake system failure.

— _lfthe brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.

The brake fluid reservoirs of the front and rear brakes are dimensioned so that they do not need topping up with brake fluid even if the brake linings are worn.

MAINTENANCE WORK ON CHASSIS AND ENGINE 55

The brake calipers of this series are "floating", which means that they are not fixed to the brake caliper support. The lateral compensation ensures an optimal position of the brake pad in relation to the brake disc.

Checking brake discs

û Warning Danger of accidents Reduced braking due to worn brake discs.

— Worn brake discs should be replaced immediately by an authorized KTM workshop.

— Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement @.

Wear reduces the thickness of the brake disc around the area used by the brake linings.

Wear limit of brake discs front 2.5 mm (0.098 in) 400257-10 Rear 3.5 mm (0.138 in)

» The brake disc thickness is less than the specified value. — Replace the brake disc.

Checking free play of hand brake lever

û Warning Danger of accidents Brake system failure.

— _lfthere is no free travel on the hand brake lever, pressure builds up on the front brake in the brake system. The front brake can fail due to overheating. Adjust free travel on hand brake lever according to specifications.

\ (Every XCR-W models) a] — Push the hand brake lever forwards and check free play. @.

[Free play of hand brake lever [23 mm @ 0.12 in)

» _lfthe free travel does not meet specifications: — adjust the basic position of handbrake lever. (# P. 56)

(Every EXC-R models) Le — Push the hand brake to the handlebar and check free play @. de

[ Free play of hand brake lever I 23 mm (20.12 in)

» _lfthe free travel does not meet specifications: — Adjust the free travel of the handbrake lever. (# P. 56)

MAINTENANCE WORK ON CHASSIS AND ENGINE 55

Adjusting basic position of handbrake lever (Every XCR-W models) — Adjust the basic setting of the handbrake lever to your hand size by turning adjust- ing screw ©.

(l Turn the adjusting screw clockwise to increase the distance between the handbrake lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the handbrake lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force. Do not make any adjustments while riding!

— Check the free play of the hand brake lever. (# P. 55)

Adjusting free travel of handbrake lever (Every EXC-R models)

— Adjust the free travel of the handbrake lever with the adjustment screw @.

s af (| Turn the adjustment screw clockwise to reduce free travel. The pressure point moves away from the handlebar.

Turn the adjustment screw counterclockwise to increase free travel. The pressure point moves towards the handlebar.

The range of adjustment is limited.

Turn the adjusting screw by hand only, and do not apply any force.

iding! 00196-12 Do not make any adjustments while riding!

— Check the free play of the hand brake lever. (# P. 55)

Checking the front brake fluid level

û Warning Danger of accidents Brake system failure.

— _lfthe brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.

û Warning Danger of accidents Reduced braking due to old brake fluid.

— Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

— Move the brake fluid reservoir mounted on the handlebar to a horizontal position. — Check the brake fluid level in the viewer @. »__lfthe brake fluid is below the MIN mark: — Top up the brake fluid of the front brake. (# P. 56)

Topping up the front brake fluid à

û Warning Danger of accidents Brake system failure.

— _lfthe brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Skin irritations Brake fluid can cause skin irritation on contact.

— Avoid contact with skin and eyes, and keep out of the reach of children. — If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

MAINTENANCE WORK ON CHASSIS AND ENGINE 57

û Warning Danger of accidents Reduced braking due to old brake fluid.

— Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

I KTM recommends DOT 5.1 brake fluid from Motorex®. This has a higher wet boiling point than DOT 4 brake fluid and provides greater safety for high demands. Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container!

— Move the brake fluid reservoir mounted on the handlebar to a horizontal position. — Remove screws @. — Remove the cover @ with membrane @. — Top up brake fluid to level @. Specification [Measurement of @ [5 mm (0.2 in) |

[ Brake fluid DOT 5.1 (* P. 114) |

— Check parts for damage and wear. Replace damaged or worn parts. — Position the cover with membrane. Mount and tighten screws.

e Info Clean up overflowed or spilt brake fluid immediately with water.

Checking the front brake linings

û Warning Danger of accidents Reduced braking due to worn brake linings.

— Worn brake linings should be replaced immediately in an authorized KTM workshop.

— Check the brake linings for minimum thickness @.

» Minimum thickness @: z 1 mm (> 0.04 in) If the minimum thickness is less than specified:

— Change the front brake linings. (# P. 59)

MAINTENANCE WORK ON CHASSIS AND ENGINE 58

Removing front brake linings à

û Warning Danger of accidents Improper brake maintenance and repair.

— Always have your brake system maintained and repaired in an authorized KTM workshop.

— Press the brake caliper by hand on to the brake disc in order to press back the brake pistons.

Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.

— Remove the locking split pins @, withdraw the bolt @, and take out the brake pads.

— Remove cable clip @. Remove screws @ and take off brake caliper. — Clean brake caliper and brake caliper support.

Installing the front brake linings à

û Warning Danger of accidents Reduced braking 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.

à Warning Danger of accidents Reduced braking due to use of non-approved brake linings.

— _ 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. lf brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

— Checkthe brake discs. (% P. 55) — Check parts for damage and wear. Replace damaged or worn parts.

— Check that leaf spring @ in the brake caliper and sliding plate @ in the brake caliper support are seated correctly.

e Info The arrow on the leaf spring points in the rotation direction of the brake disc.

— Fitthe brake linings, insert bolt ©, and mount locking split pins @. — Position brake caliper, mount and tighten screws @. Specification

Screw, front brake caliper | M8 25 Nm Loctite® 243TM (8.4 lbf ft)

— Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot.

MAINTENANCE WORK ON CHASSIS AND ENGINE 59

Changing the front brake linings à

Warning Skin irritations Brake fluid can cause skin irritation on contact.

— Avoid contact with skin and eyes, and keep out of the reach of children. — If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

û Warning Danger of accidents Reduced braking due to old brake fluid.

— Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

KTM recommends brake fluid DOT 5.1 from Motorex®. This brake fluid has a higher wet boiling point than brake fluid DOT 4 and offers more protection under high load.

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!

Use only clean brake fluid from a sealed container!

— Remove the front brake linings. (® P. 58)

— Move the brake fluid reservoir mounted on the handlebar to a horizontal position. — Remove screws @.

— Remove cover @ with membrane @.

— Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir.

— Install the front brake linings. (# P. 58) — Add brake fluid to level @. Specification [Measurement of @ [5 mm (0.2 in)

[ Brake fluid DOT 5.1 (* P. 114)

— Check parts for damage and wear. Replace damaged or worn parts.

Position the cover with the membrane. Mount and tighten the screws.

e Info Clean up overflowed or spilt brake fluid immediately with water.

Checking free play of foot brake lever

û Warning Danger of accidents Brake system failure.

— _lfthere is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can fail due to overheating. Adjust free travel on foot brake pedal according to specifications.

— Disconnect spring @.

— Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free play @.

Specification [ Free play at foot brake lever 3... 5 mm (0.12... O.2 in)

» _ Ifthe free travel does not meet specifications: — Adjust the basic position of the footbrake lever. (# P. 60) — Reconnect spring @.

MAINTENANCE WORK ON CHASSIS AND ENGINE 60

û Warning Danger of accidents Brake system failure.

— _lfthere is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can fail due to overheating. Adjust free travel on foot brake pedal according to specifications.

— Disconnect spring @. — Loosen nut @ and with push rod ©, turn it back until you have maximum free play.

— To adjust the basic position of the footbrake lever individually, lossen nut @ and turn screw @ accordingly.

e Info The range of adjustment is limited.

— Turn push rod @ accordingly until you have free play @. If necessary, adjust the basic position of the footbrake lever.

Specification Free play at foot brake lever 3... 5 mm (0.12... O.2 in)

— Hold screw @ and tighten nut @. Specification

Remaining nuts, chassis M8 30 Nm (22.1 Ibf ft)

— Hold push rod @ and tighten nut @. Specification

Remaining nuts, chassis M6 15 Nm (1.1 1bfft)

— Reconnect spring @.

û Warning Danger of accidents Brake system failure.

— _lfthe brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.

à Warning Danger of accidents Reduced braking due to old brake fluid.

— Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

— Stand the vehicle upright. — Check the brake fluid level in the viewer @. » When in the viewer @ an air bubble is visible: — Add rear brake fluid. ( P.61)

MAINTENANCE WORK ON CHASSIS AND ENGINE st

à Warning Danger of accidents Brake system failure.

— _lfthe brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning Skin irritations Brake fluid can cause skin irritation on contact.

— Avoid contact with skin and eyes, and keep out of the reach of children. — If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

û Warning Danger of accidents Reduced braking due to old brake fluid.

— Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

[ KTM recommends brake fluid DOT 5.1 from Motorex®. This brake fluid has a higher wet boiling point than brake fluid DOT 4 and offers more protection under high load. Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container!

— Stand the vehicle upright. — Remove screw cap @ with membrane @ and the O-ring. — Add brake fluid to level @.

Î Brake fluid DOT 5.1 (* P. 114)

— Check parts for damage and wear. Replace damaged or worn parts. — Mount the screw cap with the membrane and the O-ring.

e Info Clean up overflowed or spilt brake fluid immediately with water.

à Warning Danger of accidents Reduced braking due to worn brake linings.

— Worn brake linings should be replaced immediately in an authorized KTM workshop.

— Check the brake linings for minimum thickness @. » Minimum thickness @: z 1 mm (2 0.04 in) If the minimum thickness is less than specified: — Change the rear brake linings. (# P. 63)

MAINTENANCE WORK ON CHASSIS AND ENGINE 62

Removing rear brake linings à

û Warning Danger of accidents Improper brake maintenance and repair.

— Always have your brake system maintained and repaired in an authorized KTM workshop.

— Press the brake caliper by hand on to the brake disc in order to press back the brake piston.

Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.

— Remove the locking split pins @, withdraw the bolt @, and take out the brake pads.

— Clean brake caliper and brake caliper support.

Installing the rear brake linings à

à Warning Danger of accidents Reduced braking 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.

û Warning Danger of accidents Reduced braking due to use of non-approved brake linings.

— _ 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. lf brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

— Checkthe brake discs. (% P. 55) — Check parts for damage and wear. Replace damaged or worn parts.

— Check that leaf spring @ in the brake caliper and sliding plate @ in the brake caliper support are seated correctly.

The arrow on the leaf spring points in the rotation direction of the brake disc.

— Fitthe brake linings, insert bolt ©, and mount locking split pins @.

e Info Make sure that the decoupling plate @ is mounted on the piston side of the brake pad.

— Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot.

MAINTENANCE WORK ON CHASSIS AND ENGINE 63

tions Brake fluid can cause skin irritation on contact.

— Avoid contact with skin and eyes, and keep out of the reach of children. — If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning Danger of accidents Reduced braking due to old brake fluid.

— Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

KTM recommends brake fluid DOT 5.1 from Motorex®. This brake fluid has a higher wet boiling point than brake fluid DOT 4 and offers more protection under high load.

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!

Use only clean brake fluid from a sealed container!

— Remove the rear brake linings. (* P. 62) — Stand the vehicle upright. — Remove screw cap @ with membrane @ and the O-ring.

— Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir.

— Install the rear brake linings. (# P. 62) — Add brake fluid to level @.

Brake fluid DOT 5.1 (* P. 114)

— Check parts for damage and wear. Replace damaged or worn parts. — Mount the screw cap with the membrane and the O-ring.

e Info Clean up overflowed or spilt brake fluid immediately with water.

— Jack up the motorcycle. (* P. 32)

— Press the brake caliper by hand on to the brake disc in order to press back the brake pistons.

Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.

Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork.

e Info Do not pull the hand brake lever when the front wheel is removed. Always lay the wheel down in such a way that the brake disc is not dam- aged.

Remove distance bushing ©.

à Warning Danger of accidents Reduced braking due to oil or grease on the brake discs.

— Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Check parts for damage and wear. Replace damaged or worn parts. Clean and grease shaft seal rings @ and bearing surface @ of the distance bush- ings.

[ Long-life grease (% P. 115)

Fit the distance bushings.

Lift the front wheel into the fork, position it, and insert the wheel spindle. Mount and tighten screw @. Specification

Screw, front wheel spindle M24x1,5 40 Nm (29.5 Ibf ft)

Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc.

Remove the motorcycle from the work stand. (% P. 32)

Pull the front wheel brake and push down hard on the fork several times to align the fork legs.

Fully tighten screw ©. Specification

Screw, fork stub M8 15 Nm (1.1 1bfft)

MAINTENANCE WORK ON CHASSIS AND ENGINE 65

ROME FEAT MES Jack up the motorcycle. (# P. 32)

Press the brake caliper by hand on to the brake disc in order to press back the brake piston.

Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.

Remove chain adjuster @. Withdraw the wheel spindle © only enough to allow the rear wheel to be pushed forward.

Push the rear wheel forward as far as possible. Remove the chain from the rear sprocket.

Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of the swing arm.

e Info Do not operate the foot brake when the rear wheel is removed. Always lay the wheel down in such a way that the brake disc is not dam- aged.

Remove the spacing sleeves @.

û Warning Danger of accidents Reduced braking due to oil or grease on the brake discs.

— Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Check parts for damage and wear. Replace damaged or worn parts. Clean and grease shaft seal rings @ and bearing surface @ of the spacing sleeves.

[ Long-life grease (% P. 115)

Fit the spacing sleeves.

Lift the rear wheel into the swing arm, position it, and insert the wheel spindle @. Put the chain on.

MAINTENANCE WORK ON CHASSIS AND ENGINE 65

— Position the chain adjuster @. Fit nut ©, but do not tighten it yet. — Check the chain tension when fitting rear wheel. (# P. 51)

— Make sure that the chain adjusters © are fitted correctly on the adjusting screws ©.

— Tighten nut @. Specification [Nut, rear wheel spindle M20x1,5 [80 Nm 69 Ibf ft) |

D The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length. The chain adjusters @ can be turned by 180°.

— Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot.

— Remove the motorcycle from the work stand. (# P. 32)

e Info D Fitonty tires approved 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. The front and rear wheels must be fitted with tires with similar profiles. Worn tires have a negative effect on riding behavior, especially on wet surfaces.

— Examine the tires for cuts, foreign bodies and other damage. — Check the depth of the tread.

e Info Note local national regulations concerning the minimum tread depth.

Minimum tread depth: 2 2 mm (2 0.08 in) If the minimum tread depth is insufficient:

— Replace the tire(s).

Low tire air pressure leads to abnormal wear and overheating of the tire. Correct tire air pressure ensures optimal riding comfort and maximum tire service life.

Remove dust cap. — Check tire air pressure when tires are cold.

Tire air pressure off road front 1.0 bar (15 psi) Rear 1.0 bar (15 psi) Road tire pressure (Every EXC-R models) front 1.5 bar (22 psi) Rear 2.0 bar (29 psi)

» _lfthe tire pressure does not meet specifications: — Correct tire pressure. — Mount dust cap.

MAINTENANCE WORK ON CHASSIS AND ENGINE 67

Checking spoke tension

û Warning Danger of accidents Unstable riding behavior due to loose spokes.

— If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop.

A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time. If the spokes are too tight, they can break due to local overload.

Check the spoke tension regularly, especially on a new motorcycle.

— To check spoke tension, tap each spoke with a screwdriver. Specification

[ You should hear a high note.

Spoke nipple, front wheel M4,5 5 Nm (3.7 Ibf ft) Spoke nipple, rear wheel M5 5 Nm (3.7 Ibf ft) e Info

If you hear different tone frequencies from different spokes, this is an indi- cation of different spoke tensions.

Removing the battery à

û Warning Risk of injury Battery acid and battery gases cause serious cauterization.

— Keep batteries out of the reach of children.

— Wear suitable protective clothing and goggles.

— Avoid contact with battery acid and battery gases.

— Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.

— In the event of skin contact, rinse with large amounts of water. lf battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a doctor.

— Switch off all power-consuming components and switch off the engine. — Remove the seat. (# P. 69) — Disconnect the negative (minus) cable @ of the battery.

— Pull back the plus pole cover @ and disconnect the positive (plus) cable of the bat- tery.

— Hang the rubber band @ out to the bottom. — Lift the battery up.

— Check parts for damage and wear. Replace damaged or worn parts. — Place the battery in the battery holder.

Risk of injury Battery acid and battery gases cause serious cauterization.

— Keep batteries out of the reach of children.

— Wear suitable protective clothing and goggles.

— Avoid contact with battery acid and battery gases. — Keep the battery away from sparks or open fire. Charge only in well ventilated rooms. — In the event of skin contact, rinse with large amounts of water. lf battery acid gets in the eyes, rinse with water for at least

15 minutes and contact a doctor.

Environmental hazard Components and battery acid are a danger to the environment.

— Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.

Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Even if there is no load on the battery, it loses power every day. The charge state and the type of charge are very important for the service life of the battery. Fast recharging with a high charge current shortens the battery's service life.

If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes. The battery capacity is then reduced.

If the battery is discharged from starting, it must be recharged immediately.

If it stands for a long time in a discharged state, the battery becomes over-discharged and sulfated, and then it is destroyed.

The battery is maintenance-free, i.e., the acid level does not have to be checked.

Switch off all power-consuming components and switch off the engine.

Remove the seat. (# P. 69)

Disconnect the minus (negative) cable of the battery to avoid damage to the motor-

cycle's electronics.

Connect the battery charger to the battery. Switch on the battery charger.

[ Battery charger (58429074000)

You can also use the battery charger to test rest potential and start potential of the battery, and to test the generator. With this device, you cannot overcharge the bat-

e Info Never remove the lid @.

Charge the battery according to the instructions @ on the battery casing.

Switch off the charger after charging. Disconnect the battery.

The charge current, charge voltage and charge time must not be exceeded.

Charge the battery regularly when the motorcycle is not in use.

— Switch off all power-consuming components and switch off the engine. — Dismount the air filter box lid. (# P. 74) — Remove the protection cover @.

e Info D The fuse @ is located in the starter relay © under the filter box cover.

— Remove the fuse @.

û Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses.

— Use only fuses with the prescribed amperage. Never by-pass or repair fuses.

Check parts for damage and wear. Replace damaged or worn parts.

A reserve fuse @ is located in the starter relay. Replace a burned-out fuse @ only by an equivalent fuse.

Refit the fuse. [Fuse (568011109110)

400273-10 e Info If the new fuse burns out, contact an authorized KTM workshop.

— _Replace the protection cover. — Install the air filter box lid. (* P. 74)

— Remove screw @. Lift up the seat at the rear, pull it back and then remove from above.

— Check parts for damage and wear. Replace damaged or worn parts.

— Hook the front of the seat into the flange adapter of the fuel tank, lower the rear of the seat and simultaneously push it forwards.

— Make sure that the seat is correctly locked in. — Mount and tighten the screw of the seat fixing. Specification [ Remaining screws, chassis M6 I 10 Nm (7.4 Ibf ft) |

MAINTENANCE WORK ON CHASSIS AND ENGINE 70

Dismounting the fuel tank À

Fire hazard Fuel can easily catch fire.

— Never fill up 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.

— Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.

û Warning Danger of poisoning Fuel is poisonous and a health hazard.

— Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. |f fuel gets into your eyes, rinse imme- diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister ac- cording to regulations and keep it out of the reach of children.

— Remove the seat. (# P. 69) — Turn the handle @ of the fuel tap to the OFF position. (Figure 500137-10 ® P. 20) — Pull off the fuel hose.

e Info Remaining fuel may run out of the fuel hose.

— Remove screws @ with collar sleeve.

(Every EXC-R models) — Hang the horn and horn bracket to one side.

— Remove screw @ with collar sleeve. — Remove the tube from the fuel tank vent line.

— Pull both spoilers to the side of the radiator bracket @ and take the fuel tank away upwards.

Installing the fuel tank à

Danger Fire hazard Fuel can easily catch fire.

— Never fill up 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.

— Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.

û Warning Danger of poisoning Fuel is poisonous and a health hazard.

— Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. |f fuel gets into your eyes, rinse imme- diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel.

MAINTENANCE WORK ON CHASSIS AND ENGINE n

— Check parts for damage and wear. Replace damaged or worn parts. — Position the fuel tank and fit the two spoilers to the side of the radiator fixing. — Make sure that no cables or Bowden cables are trapped or damaged.

500067-01 — Mount the fuel tank vent hose. — Fit and tighten screw @ with collar sleeve. Specification [ Remaining screws, chassis M6 I 10 Nm (7.4 Ibf ft) |

(Every EXC-R models) — Position horn with horn bracket.

— Fit and tighten screws @ with collar sleeve. Specification [ Remaining screws, chassis M6 10 Nm (7.4 Ibf ft)

— Connect fuel hose. — Mountthe seat. (+ P. 69)

The water pump @ in the engine forces the coolant to flow.

The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap @. The specified coolant temperature is therefore permissible with- out danger of function problems.

Coolant (# P.114) Cooling is effected by the air stream. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cool- ing effect. (EXC-R SIX DAYS, XCR-W ZA) The radiator fan provides extra cooling. lt is controlled by a thermoswitch.

Checking antifreeze and coolant level

Warning À Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure.

— Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.

à Warning Danger of poisoning Coolants are poisonous and a health hazard.

— Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. 1f coolant is swallowed, contact a doctor im- mediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

MAINTENANCE WORK ON CHASSIS AND ENGINE 72

— Stand the motorcycle upright on a horizontal surface.

— — Remove the radiator cap. (—] ' — Check antifreeze of coolant. o —25... -45 °C (-13... -49 °F)

» If the antifreeze of the cooling liquid does not meet specifications: — Correct antifreeze of coolant. — Check the coolant level in the radiator.

400243-10 Coolant level @ above radiator fins. 10 mm (0.39 in)

» If the level of the cooling liquid does not meet specifications: — Correct the coolant level.

Alternative 1 Coolant (# P.114)

Alternative 2 Coolant (mixed ready to use) (* P. 114)

— _ Refit the radiator cap.

Checking the coolant level

Warning À Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure.

— Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.

à Warning Danger of poisoning Coolants are poisonous and a health hazard.

— Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. 1f coolant is swallowed, contact a doctor im- mediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

— Stand the motorcycle upright on a horizontal surface. + — Remove the radiator cap. (—] ' — Check the coolant level in the radiator.

i LU Coolant level @ above radiator fins. 10 mm (0.39 in)

» If the level of the cooling liquid does not meet specifications: — Correct the coolant level.

Alternative 1 Coolant (# P.114)

Alternative 2 Coolant (mixed ready to use) (% P. 114)

— _ Refit the radiator cap.

Warning À Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure.

— Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.

û Warning Danger of poisoning Coolants are poisonous and a health hazard.

— Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. 1f coolant is swallowed, contact a doctor im- mediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

MAINTENANCE WORK ON CHASSIS AND ENGINE 13

— Stand the vehicle upright. — Place a suitable container under the water pump cover. — Remove screw @. Remove the radiator cap @. — Completely drain the coolant. — Fit screw @ with a new seal and tighten it. Specification [ Screw, water pump cover I M6x25 I 10 Nm (7.4 Ibf ft) |

û Warning Danger of poisoning Coolants are poisonous and a health hazard.

— Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. 1f coolant is swallowed, contact a doctor im- mediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

— Make sure that the screw @ is tightened.

7 — Stand the vehicle upright. — Pour coolant in up to measurement @ above the radiator fins. LA] Specification [10 mm (0.39 in) Coolant 0.951 (1 qt.) Coolant (* P.114) Coolant (mixed ready to use) 400244-10 CT P.114)

— _ Refit the radiator cap. — Make a short test ride. — Check the coolant level. (* P.72)

The main silencer is filled with glass fiber yarn. Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out". Not only is the noise level higher, the performance characteristic changes.

ni 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 @. — Remove screws @ and take off main silencer.

MAINTENANCE WORK ON CHASSIS AND ENGINE 74

Fitting the main silencer

— Check parts for damage and wear. Replace damaged or worn parts. — Mount the main silencer. Mount and tighten screws @. Specification [ Remaining screws, chassis M6 I 10 Nm (7.4 Ibf ft) |

— Reconnect spring @.

— Pull off the air filter box lid in area @ to the side and remove to the front.

— Check parts for damage and wear. Replace damaged or worn parts. — Insert the air filter box lid into the rear area @ and clip it into the front area @.

Removing the air filter à

Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine.

— Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

— Dismount the air filter box lid. (* P. 74)

— Hangthe air filter holder @ out to the bottom and swing it to the side. Remove the air filter with the air filter support.

— Remove the air filter from the air filter support.

MAINTENANCE WORK ON CHASSIS AND ENGINE 15

— Check parts for damage and wear. Replace damaged or worn parts. — Mount the clean air filter onto the air filter support. — Put in both parts together, position them and fix them with the air filter support @.

ll If the air filter is not correctly mounted, dust and dirt can penetrate into the engine and can cause damage.

— Install the air filter box lid. (® P. 74)

Cleaning air filter À

Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

e Info Do not clean the air filter with fuel or petroleum since these substances attack the foam.

— Remove the air filter. (# P. 74) — Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.

[Air filter cleaner (# P. 115)

e Info Only press the air filter to dry it, never wring it out.

Oil the dry air filter with a high/quality filter oil. [Oil for foam air filter (9 P. 115)

— Clean the air filter box.

— Check carburetor connection boot for damage and tightness. Install the air filter. (+ P. 75)

Adjusting basic position of clutch lever

— Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw ©.

(l Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force. Do not make any adjustments while riding!

Checking fluid level of hydraulic clutch

û Warning Skin irritations Brake fluid can cause skin irritation on contact.

— Avoid contact with skin and eyes, and keep out of the reach of children. — If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

The fluid level rises with increasing wear of the clutch lining disc.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container!

MAINTENANCE WORK ON CHASSIS AND ENGINE 15

— Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. — Remove screws @.

— Take off cover @ with membrane ©.

— Check the fluid level.

[ Fluid level under top level of container. Ï 4 mm (0.16 in) |

» If the level of the cooling liquid does not meet specifications: — Correct the fluid level of the hydraulic clutch. [ Brake fluid DOT 5.1 (* P. 114) |

— Check parts for damage and wear. Replace damaged or worn parts. — Position the cover with the membrane. Mount and tighten screws.

e Info Clean up overflowed or spilt fluid immediately with water.

Changing fluid level of hydraulic clutch à

à Warning Skin irritations Brake fluid can cause skin irritation on contact.

— Avoid contact with skin and eyes, and keep out of the reach of children. — If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

The fluid level rises with increasing wear of the clutch lining disc.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container!

— Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. — Remove screws @. — Take off cover @ with membrane ©.

— Fillthe bleeding syringe @ with the appropriate hydraulic fluid.

Bleed syringe (50329050000) Brake fluid DOT 5.1 (* P. 114)

Inject the liquid into the system until it escapes from the bore hole @ of the mas- ter cylinder without bubbles.

— To prevent overflow, drain fluid occasionally from the master cylinder reservoir. — Remove the bleeding syringe. Mount and tighten screws bleeder screw. — Correct the fluid level of the hydraulic clutch. Specification Fluid level under top level of container. Ï 4 mm (0.16 in)

— Check parts for damage and wear. Replace damaged or worn parts. Position the cover with the membrane. Mount and tighten screws.

e Info Clean up overflowed or spilt fluid immediately with water.

The idle setting of the carburetor has a big influence on the starting behavior, stable idling and the response to throttle opening. That means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly.

The carburetor and its components are subject to increased wear caused by en- gine vibration. Wear can result in malfunctioning.

The idle speed is adjusted with the adjustment screw @. The idle mixture is adjusted with the idle mixture adjustment screw @.

— Screw in the idle adjusting screw @ until it stops and then to the prescribed basic setting.

Specification Idle mixture adjusting screw (XCR-W USA) Open Ï 0.5 turn Idle mixture adjusting screw (EXC-R SIX DAYS) Open Ï 1.0 turn Idle mixture adjusting screw (XCR-W ZA, 530 EXC-R EU, 530 EXC-R AUS/UK) Open Ï 1.5turns

Idle mixture adjusting screw (450 EXC-R EU, 450 EXC-R AUS/UK, 450 EXC- R USA)

Open Ï 1.75 turns Idle mixture adjusting screw (530 EXC-R USA) Open Ï 2.0 turns

[ Adjustment tool for mixture control screw (77329034000) - Runthe engine until warm.

[Warm-up time E 5 min

MAINTENANCE WORK ON CHASSIS AND ENGINE 18

Emptying the carburetor float chamber À

Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon- sciousness and/or death.

— When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in a closed space.

Adijust the idle speed with the adjusting screw @. Specification

Choke function deactivated — The choke lever is pushed in to the stop. (9 P.21)

Choke function deactivated — The choke lever is pushed back to the stop. (9 P.21)

Idle speed 1550... 1650 rpm

Turn the idle adjusting screw @ slowly until the idle speed begins to fall.

Note the position and turn the idle adjusting screw slowly counterclockwise until the idle speed falls.

Adjust to the point between these two positions with the highest idle speed.

ll If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps. The extremely sporty rider will set the mixture about 1/4 of a turn back from this ideal value (leaner, in a clockwise direction) since the engine becomes hotter in sporting use. If the procedure described here does not lead to satisfactory results, the cause may be a wrongly dimensioned idling jet. If you can turn the idle adjusting screw to the end without any change of engine speed, you have to fit a smaller idling jet. The idle adjusting screw must not be opened more than two turns. If more than two turns are necessary (rich mixture), use a larger idling jet. After changing the idling jet, start from the beginning with the adjusting steps.

Adijust the idle speed with the adjusting screw @. Specification

Choke function deactivated — The choke lever is pushed in to the stop. (# P.21)

Choke function deactivated — The choke lever is pushed back to the stop. (9 P.21)

Idle speed 1550... 1650 rpm

e Info Following extreme air temperature or altitude changes, adjust the idle speed again.

Danger Fire hazard Fuel can easily catch fire.

Never fill up 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.

Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.

û Warning Danger of poisoning Fuel is poisonous and a health hazard.

Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme- diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister ac- cording to regulations and keep it out of the reach of children.

MAINTENANCE WORK ON CHASSIS AND ENGINE 19

Warning Environmental hazard Improper handling of fuel is a danger to the environment.

— Do not allow fuel to get into the ground water, the ground, or the sewage system.

e Info Carry out this work with a cold engine.

— Turn the handle @ of the fuel tap to the OFF position. (Figure 500137-10 # P. 20) 7 No more fuel flows from the tank to the carburetor. — Guide the hose coming down behind the engine into a suitable container.

e Info ll Water in the float chamber results in malfunctioning.

— Undo the screw @ (turn it counterclockwise) a few turns and drain the fuel from the float chamber.

Checking engine oil level

e 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 @.

» _ lfthe engine oil level is below the specified level: — Top up the engine oil. (* P. 81)

Changing engine oil and oil filter, cleaning engine oil screen À — Drain the engine oil and clean the engine oil screen. (® P. 79)

— Remove the oil filter. (% P. 80)

— Mount the oil filter. (% P. 80)

— Fill up with engine oil. (# P. 81)

Draining engine oil, cleaning engine oil screen à

û Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven.

— Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info Drain the engine oil only when the engine is warm.

— Stand the motorcycle on its side stand on a horizontal surface.

MAINTENANCE WORK ON CHASSIS AND ENGINE 80

Place a suitable container under the engine.

Remove engine oil plug screen @.

Completely drain the engine oil.

Thoroughly clean the plug and gear oil screen.

Clean the sealing area on the engine.

Check parts for damage and wear. Replace damaged or worn parts. Fit plug @ for the engine oil screen and tighten it.

Plug, engine oil screen M17x1,5 20 Nm (14.8 Ibf ft)

û Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven.

— Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Place a suitable container under the engine. Remove screws @. Remove oil filter cover @ with O-ring.

Pull the oil filter insert @ out of the oil filter casing. [ Circlip pliers reverse (5101201 1000)

Completely drain the engine oil. Thoroughly clean parts and sealing area.

Check parts for damage and wear. Replace damaged or worn parts.

Lay the motorcycle on its side and fill the oil filter housing to about 1/3 full with engine oil.

Fill the oil filter @ with engine oil and place it in the oil filter container. Lubricate the O/ring @ of the oil filter cover.

MAINTENANCE WORK ON CHASSIS AND ENGINE st

— _ Refit the oil filter cover ©. — Mount and tighten screws @. Specification [Screw, oil filter cover M5 [ENmta4lbf |

— Stand the motorcycle up.

e Info Too little engine oil or poor-quality engine oil results in premature wear to the engine.

— Remove the screw cap @ on the generator cover and fill up with engine oil. [ Engine oil I 0.61 (0.6 at.) Ï Engine oil (SAE 10W/50) (+ P. 114) |

— Mount and tighten screw cap @.

Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon- sciousness and/or death.

— When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in a closed space.

— Start the engine and check that it is oil-tight. — Check the engine oil level. (* P. 79)

e Info I Too little engine oil or poor-quality engine oil results in premature wear to the engine.

— Remove the screw cap @ on the generator cover and fill up with engine oil.

[ Engine oil (SAE 10W/50) (# P. 114)

— Mount and tighten screw cap @.

Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon- sciousness and/or death.

— When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in a closed space.

— Start the engine and check that it is oil-tight. — Check the engine oil level. (* P. 79)

e Info The gear oil level must be checked when the engine is cold.

— Stand the motorcycle upright on a horizontal surface.

MAINTENANCE WORK ON CHASSIS AND ENGINE 82

Condition Engine is cold.

— Remove gear oil level check screw @. Stand the vehicle upright. — Check the gear oil level.

A small amount of gear oil should flow out.

» _ |f no gear oil flows out: — Top up with gear oil. (# P. 83) — Mount and tighten the gear oil level check screw. Specification

Screw, gear oil level check M6 10 Nm (7.4 lbf ft)

— Drain the gear oil and clean the gear oil screen. (* P. 82) — Fill up with gear oil. (# P. 83)

Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven.

— Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

e Info I Drain the gear oil only when the engine is warm.

— Stand the motorcycle on its side stand on a horizontal surface.

— 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.

— Thoroughly clean the drain plug and gear oil screen with a magnet.

— Clean the sealing surface on the engine.

— Check parts for damage and wear. Replace damaged or worn parts.

— Refit gear oil drain plug @ with seal ring and tighten it. Specification

Gear oil drain plug with magnet M12x1,5 20 Nm (14.8 Ibf ft)

— Fitthe plug @ for the gear oil screen and tighten it. Specification

Plug, gear oil screen M16x1,5 20 Nm (14.8 Ibf ft)

MAINTENANCE WORK ON CHASSIS AND ENGINE 83

Filing up with gear oil à

e Info Too little gear oil or poor-quality oil results in premature wear to the transmission.

\ — Remove the screw cap @ and fill up with gear oil.

[ Gear oil 0.91 (1 qt.) Engine oil (SAE 10W/50) (# P. 114) R a Q s M Ce { _ ur

Topping up with gear oil À

— Mount and tighten screw cap @.

Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon- sciousness and/or death.

— When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in a closed space.

— Start the engine and check that it is oil-tight. — Check the gear oil level. (® P. 81)

e Info Too little gear oil or poor-quality oil results in premature wear to the transmission.

— Remove gear oil level check screw @.

\ — Remove screw cap @. Stand the vehicle upright. — Top up with gear oil until it flows out of the bore of the gear oil level screw.

[Engine oil (SAE 10W/50) (+ P. 114) |

— Mount and tighten the gear oil level check screw.

A, à 1) a - ' |. Specification h [ Screw, gear oil level check I M6 I 10 Nm (7.4 Ibf ft) | Le 4 + é— — Mount and tighten screw cap @. À EE. 4

Danger of poisoning Exhaust gases are poisonous and can result in uncon- sciousness and/or death.

— When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in a closed space.

— Start the engine and check that it is oil-tight.

The engine cannot be cranked (electric starter).

— Carry out instructions on starting. (9 P.26)

— Recharge the battery. (® P. 68) — Check the cause of discharging.

— Remove the fuse. (* P. 69) — Replace the fuse. (# P. 69)

Low external temperature

— Start the engine with the kickstarter.

— Recharge the battery. Establish the reason for discharging or have it checked in a KTM workshop.

Engine turns but does not start.

— Carry out instructions on starting. (9 P.26)

Motorcycle was out of use for a long time and there is old fuel in the float chamber

- Empty the carburetor float chamber. (9 P.78)

Fuel feed interrupted

Spark plug oily or wet

— Clean and dry spark plug or replace if necessary.

Electrode distance (plug gap) of spark plug too wide

— Adjust plug gap. Specification Spark plug electrode gap 0.8... 0.9 mm (0.031... 0.035 in)

Spark plug connector or spark plug defec- tive

Warning Risk of injury The ignition sys- tem is under high voltage.

— Do not touch parts of the ig- nition system. Have work on the ignition system carried out in an authorized KTM workshop.

— Remove spark plug, connect ignition cable, hold spark plug to ground (bare metal area on engine), and try to start the engine.

Specification You should see a strong spark on the spark plug.

— _lfthere is no spark, change the spark plug.

— _Ifthere is still no spark, remove the spark plug cap from the ignition cable, hold it at the specified distance from the ground contact, and try to start the engine.

Specification 5 mm (O.2 in)

— If you now have a spark, replace the spark plug connector.

— _lfthere is no spark, have the ignition system checked.

Short-circuit cable in cable harness frayed, short-circuit button or emergency OFF switch defective

— Check wiring harness. (visual check) — Check electrical system.

Socket connector of CDI control device, pulse generator or ignition coil oxidized.

— Clean socket connector and treat it with contact spray.

Engine turns but does not start.

Water in carburetor or jets blocked

Adjusting screws on carburetor distorted

Have the carburetor adjusted.

Spark plug defective

lgnition system defective

Have ignition system checked.

Engine does not speed up.

Carburetor running over because float needle dirty or worn

Have carburetor checked.

Loose carburetor jets

Have carburetor checked.

Electronic ignition adjustment defective

Have ignition system checked.

Engine has too little power.

Fuel feed interrupted

Check tank vent. Clean fuel tap. Clean carburetor.

Air filter very dirty

Clean the air filter. (# P. 75)

Exhaust system leaky, deformed or too lit- tle glass fiber yarn filling in main silencer

Check exhaust system for damage.

Change glass fiber yarn filling of main silencer.

Valve clearance too little

Have valve clearance adjusted.

Electronic ignition adjustment defective

Have ignition system checked.

Engine stalls or is popping into the carbu- retor

Clean and check the fuel system and carburetor.

Engine takes in bad air

Check rubber sleeves and carburetor for tightness.

Too little coolant in cooling system

Check the cooling system for leakage. Check the coolant level. (* P. 72)

Too little air stream

Switch off engine when standing.

Radiator fins very dirty

Clean radiator fins.

Foam formation in cooling system

Replace the radiator hose.

Thermostat defective

Have thermostat removed and checked.

Specification Opening temperature: 70 °C (158 °F)

Defect in radiator fan system (EXC-R SIX DAYS, XCR-W ZA)

Have the radiator fan system checked.

High oil consumption

Engine vent hose bent

Route the vent hose without bends or replace it if necessary.

Engine oil level too high

Check the engine oil level. (# P. 79)

Engine oil too thin (low viscosity)

Change the engine oil and oil filter and clean the engine oil screen. (% P. 79)

Battery is not charged by generator

Check electrical system.

Speedometer values deleted (time, stop watch, lap times)

The battery in the speedometer ist empty.

Change the battery in the speedometer.

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, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts.

Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

e Info If you clean the motorcycle regularly, its value and appearance are maintained over a long period. Avoid direct sunshine on the motorcycle during cleaning.

— Before you clean the motocycle, seal the exhaust system to prevent penetration by water. — First remove coarse dirt particles with a gentle water spray. — Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush.

[ Motorcycle cleaner (% P. 115)

e Info Use warm water containing normal motorcycle cleaner and a soft sponge.

— After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly. — Empty the carburetor float chamber. (* P. 78)

û Warning Danger of accidents Reduced braking due to wet or dirty brakes. — Clean or dry dirty or wet brakes by riding and braking gently.

— After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes.

e Info The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.

— Push back the protection covers on the handlebar instruments to allow water to evaporate.

— After the motorcycle has cooled off, oil or grease all moving parts and bearings.

— Clean the chain. (* P. 50)

— Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.

[ Cleaning and polishing materials for metal, rubber and plastic (® P.115)

Treat all painted parts with a mild paint polish.

[ High-luster polish for paint (% P. 116)

To prevent electrical problems, treat electric contacts and switches with contact spray.

[ Contact spray (% P. 116)

(EXC-R EU, EXC-R AUS/UK, EXC-R USA) — _ Lubricate the steering lock.

[ Universal oil spray (% P.115)

û Warning Danger of poisoning Fuel is poisonous and a health hazard.

— Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. |f fuel gets into your eyes, rinse imme- diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister ac- cording to regulations and keep it out of the reach of children.

Info If you want to garage the motorcycle for a longer period, take the following actions. Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you

should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season.

— Clean the motorcycle. (% P. 86) — Change the engine oil and oil filter and clean the engine oil screen. (* P. 79) — Change the gear oil and clean the gear oil screen. (# P. 82) — Check the antifreeze and coolant level. (# P. 71) — Drain the fuel from the tanks into a suitable container. — Empty the carburetor float chamber. (* P. 78) — Checking the tire air pressure. (® P. 66) — Remove the battery. (# P. 67) — Recharge the battery. (# P. 68) Specification [ Storage temperature of battery without direct sunshine. 0... 35 °C (32... 95 °F)

— The storage place should be dry and not subject to large temperature differences.

e Info KTM recommends propping up the motorcycle.

— Jack up the motorcycle. (# P. 32)

— Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.

Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust.

Putting into operation after storage

— Remove the motorcycle from the work stand. (*# P. 32) — Installthe battery. (# P. 67)

— Fill up with fuel. (# P. 28)

— Checks before putting into operation (* P. 26)

1-cyliner 4-stroke engine, water-cooled

Stroke (Every 450 models)

Stroke (Every 530 models)

4 valves controlled via rocker arm, drive via tooth/wheel chain

not a bearing bush - DLC-plated piston pins

1 compression ring, 1 oil scraper ring

Pressure circulation lubrication with 2 rotor pumps (engine) / 1 rotor pump (transmission)

Primary transmission

Multidisc clutch in oil bath / hydraulically activated

1st gear 14:36 2nd gear 17:32 3rd gear 19:28 Ath gear 22:26 Bth gear 24:23 6th gear 26:21 Generator 12V,150W lgnition Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan Spark plug NGK LK AR 8A -9 Spark plug electrode gap 0.8... 0.9 mm (0.031... 0.035 in) Cooling Water cooling, permanent circulation of coolant by water pump Starting aid Electric starter / kickstarter

Capacity - engine oil

[ Engine oil Ï 0.61 (0.6 qt.)

Ï Engine oil (SAE 10W/50) (+ P. 114)

[ Gear oil [0.910 at)

90 Screw, cable holder in generator cover | M4 4 Nm (3 Ibf ft) Loctite® 243TM Oil jet, rocker arm lubrication M5 2 Nm (1.5 Ibfft) Loctite® 2437M Oil jet, piston cooling M5 2 Nm (1.5 Ibfft) Loctite® 2437M Screw, locking lever M5 6 Nm (4.4 Ibf ft) Loctite® 243TM Screw, ignition pulse generator M5 6 Nm (4.4 Ibf ft) Loctite® 2437M Screw, clutch spring M6 10 Nm (7.4 Ibf ft) - Locking screw for bearing M5 6 Nm (4.4 Ibf ft) Loctite® 2437M Screw, oil filter cover M5 6 Nm (4.4 Ibf ft) _- Screw, oil pump cover M5 6 Nm (4.4 Ibf ft) Loctite® 222 Oil jet, conrod lubrication M6x0,75 4 Nm (3 lbf ft) Loctite® 2437M Nut, water-pump wheel M6 6 Nm (4.4 Ibf ft) Loctite® 648TM Screw, kickstarter stop M6 10 Nm (7.4 Ibf ft) Loctite® 243TM Screw, timing chain securing guide M6 10 Nm (7.4 Ibf ft) Loctite® 2437M Screw, exhaust flange M6 10 Nm (7.4 Ibf ft) _- Screw, torque governor M6 10 Nm (7.4 Ibf ft) Loctite® 243TM Screw, starter motor M6 10 Nm (7.4 Ibf ft) _- Screw, kickstarter spring hanger M6 10 Nm (7.4 Ibf ft) - Screw, timing chain guide rail M6 10 Nm (7.4 Ibf ft) Loctite® 2437M Screw generator cover M6x25 10 Nm (7.4 Ibf ft) - Screw generator cover M6x40 10 Nm (7.4 Ibf ft) - Screw, gear oil level check M6 10 Nm (7.4 Ibf ft) _- Screw, clutch cover M6x25 10 Nm (7.4 Ibf ft) _- Screw, clutch cover M6x30 10 Nm (7.4 Ibf ft) _- Screw, clutch cover M6x55 10 Nm (7.4 Ibf ft) _- Screw, engine housing M6x65 10 Nm (7.4 Ibf ft) - Screw, engine housing M6x80 10 Nm (7.4 Ibf ft) - Screw, camshaft bearing support M6 10 Nm (7.4 Ibf ft) Loctite® 2437M Screw, shift drum locating M6 10 Nm (7.4 Ibf ft) Loctite® 243TM Screw, shift lever M6 10 Nm (7.4 Ibf ft) Loctite® 243TM Screw, timing chain tensioning rail M6 10 Nm (7.4 Ibf ft) Loctite® 2437M Screw, stator bracket M6 10 Nm (7.4 Ibf ft) Loctite® 243TM Screw, valve cover M6 10 Nm (7.4 Ibf ft) _- Screw, water pump cover M6x25 10 Nm (7.4 Ibf ft) _- Screw, water pump cover M6x55 10 Nm (7.4 Ibf ft) _- Screw, idler M6 10 Nm (7.4 Ibf ft) Loctite® 243TM Screw, cylinder head M6 10 Nm (7.4 Ibf ft) _- Screw, rocker arm bearing M7x1 15 Nm (11.1 1lbfft) _- Plug, oil channel M7 9 Nm (6.6 Ibf ft) Loctite® 2437M Screw, kickstarter M8 25 Nm (18.4 Ibf ft) Loctite® 243TM Plug, crankshaft location M8 10 Nm (7.4 Ibf ft) - Balancer shaft nut M10x1 40 Nm (29.5 Ibf ft) — Screw, unlocking of timing chain ten- | M10x1 10 Nm (7.4 Ibf ft) - sioner

Screw, engine sprocket M10 60 Nm (44.3 Ibf ft) Loctite® 2437M Plug, oil channel M10 15 Nm (11.1 Ibf ft) Loctite® 2437M TECHNICAL DATA - ENGINE TIGHTENING TORQUES Screw, cylinder head M10x1,25 Tightening sequence: Engine oil (any)

Tighten diagonally, begin-

ning with the rear screw on

Ath position from top

Idle mixture adjusting screw

Jet needle OBDYU (OBDTQ) ldling jet 40

1st position from top

Needle position (450 EXC-R SIX DAYS)

3rd position from top

Needle position (450 EXC-R USA, 450 XCR-W ZA)

Ath position from top

Idle mixture adjusting screw (450 XCR-W USA)

Open I 0.5 turn Idle mixture adjusting screw (450 EXC-R SIX DAYS)

Open Ï 1.0 turn Idle mixture adjusting screw (450 XCR-W ZA)

Open Ï 1.5turns Idle mixture adjusting screw (450 EXC-R USA)

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 180 Jet needle OBDZT (OBDTR) ldling jet 40 Main air jet 200 ldle air jet 100 Cold start jet 65 (85) Leakage nozzle 40 Throttle slide 15 Slide stop present

1st position from top

Needle position (530 EXC-R SIX DAYS, 530 EXC-R USA)

3rd position from top

Needle position (530 XCR-W ZA)

Ath position from top

Idle mixture adjusting screw (530 XCR-W USA)

Open I 0.5 turn Idle mixture adjusting screw (530 EXC-R SIX DAYS)

Open Ï 1.0 turn Idle mixture adjusting screw (530 XCR-W ZA)

Open Ï 1.5turns Idle mixture adjusting screw (530 EXC-R USA)

Open 2.0 turns Pump membrane stop 2.15 mm (0.0846 in) Main jet (530 EXC-R SIX DAYS, 530 EXC-R USA, 530 XCR- 180 W USA)

TECHNICAL DATA - CHASSIS Frame Central tube frame made of chrome molybdenum steel tubing Fork WP 4860 MXMA PA Suspension travel

front 300 mm (11.81 in)

Rear 335 mm (13.19 in)

WP PDS 5018 DCC Brake system

Disc brakes, brake calipers on floating bearings

Diameter of brake discs

Wear limit of brake discs

front 2.5 mm (0.098 in)

Rear 3.5 mm (0.138 in) Tire air pressure off road

front 1.0 bar (15 psi)

Rear 1.0 bar (15 psi)

Road tire pressure (Every EXC-R models)

Rear wheel gearing (450 EXC-R SIX DAYS, XCR-W ZA) 14:52

Seat height unloaded

Ground clearance unloaded

Weight without fuel (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS)

113.9 kg (251.1 Ib.)

Weight without fuel (XCR-W USA)

112.2 kg (247.4 Ib.)

Weight without fuel (XCR-W ZA)

Weight without fuel (EXC-R USA)

Maximum permissible overall weight

(Every EXC-R models)

90/90 - 21 48 M+S MTT Metzeler MCE 6 DAYS EXTREME

140/80 - 18 70 M+S M TT Metzeler MCE 6 DAYS EXTREME

(Every XCR-W models)

80/100 - 21 51 MTT Bridgestone M59

110/100 - 18 64 MTT Bridgestone M402

For further information, see: http://www.ktm.com

Tank capacity (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS, XCR-W ZA)

WP PDS 5018 DCC Compression damping, low-speed

Sport 12 clicks Compression damping, high-speed

Spoke nipple, rear wheel M5 5 Nm (3.7 lbf ft) -

Remaining nuts, chassis M6 15 Nm (11.1 1lbfft) _-

Remaining screws, chassis M6 10 Nm (7.4 Ibf ft) _-

Screw, rear brake disc M6 14 Nm (10.3 Ibf ft) _

Screw, front brake disc M6 14 Nm (10.3 Ibf ft) _

Screw, shock absorber adjusting ring M6 5 Nm (3.7 lbf ft) _-

Screw, ball joint of push rod on foot- M6 10 Nm (7.4 Ibf ft) _-

Screw, handlebar clamp (EXC-R EU, M8 20 Nm (14.8 Ibf ft) _

Screw, handlebar clamp M8 16 Nm (11.8 Ibf ft) _

Screw, engine brace M8 33 Nm (24.3 Ibf ft) _

Screw, subframe M8 35 Nm (25.8 Ibf ft) Loctite® 2437" Screw, side stand fixing M8 40 Nm (29.5 Ibf ft) Loctite® 243TM Engine carrying screw M10 60 Nm (44.3 Ibf ft) -

Remaining nuts, chassis M10 50 Nm (36.9 Ibf ft) _-

Remaining screws, chassis M10 45 Nm (33.2 Ibf ft) _-

Screw, handlebar support M10 40 Nm (29.5 Ibf ft) Loctite® 243TM Nut, seat fixing M12x1 20 Nm (14.8 Ibf ft) _

Screw, top shock absorber M12 80 Nm (59 Ibf ft) Loctite® 243TM Screw, bottom shock absorber M12 80 Nm (59 Ibf ft) Loctite® 243TM Nut, swingarm pivot M16x1,5 100 Nm (73.8 Ibf ft) _

7 Starter relay with fuse

9 Light switch, horn button, short circuit button 10 Throttle valve sensor TPS 11 lgnition curve plug connection 12 CDI controller

Wiring diagram (EXC-R AUS/UK)

7 Starter relay with fuse

9 Light switch, horn button, short circuit button 10 Throttle valve sensor TPS 11 lgnition curve plug connection 12 CDI controller

7 Starter relay with fuse

9 Emergency OFF switch 10 Throttle valve sensor TPS 11 lgnition curve plug connection 12 CDI controller

ye yellow ye-bl yellow-black ye-re yellow-red

109 Components 1 Battery 2 Generator 3 lgnition coil 4 Pulse generator 5 Voltage regulator/rectifier 6 Electric starter button 7 Starter relay with fuse 8 Starter motor 9 Light switch, horn button, short circuit button 10 Throttle valve sensor TPS 11 lgnition curve plug connection 12 CDI controller 13 Headlight 14 Parking light 15 Brake / tail light 16 Thermoswitch 17 Speedometer 18 Wheel speed sensor 19 Tripmaster switch (optional) 20 Horn 21 Front brake light switch 22 Rear brake light switch 23 High beam indicator light 24 Radiator fan 25 Plug connector for flasher cable harness (optional) 26 Fuse, radiator fan Cable colors bl black bl-wh black-white br brown br-bl brown-black bu blue bu-wh blue-white gn green g gray re red re-bl red-black re-wh red-white wh white wh-gn white-green wh-re white-red ye yellow ye-bl yellow-black

111 Components 1 Battery 2 Generator 3 lgnition coil 4 Pulse generator 5 Voltage regulator/rectifier 6 Electric starter button 7 Starter relay with fuse 8 Starter motor 9 Short circuit button 10 Throttle valve sensor TPS 11 lgnition curve plug connection 12 CDI controller 13 Light switch 14 Speedometer 15 Wheel speed sensor 16 Tripmaster switch (optional) 17 Plug connector for radiator fan (optional) 18 Plug connector, headlight (optional) 19 Plug connector, brake / tail light (optional) 21 Thermoswitch Cable colors bl black bl-wh black-white br brown bu blue bu-wh blue-white gn green g gray re red re-bl red-black re-wh red-white wh white wh-re white-red ye yellow ye-bl yellow-black ye-re yellow-red

7 Starter relay with fuse

9 Short circuit button

10 Throttle valve sensor TPS 11 lgnition curve plug connection 12 CDI controller

— Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Motorex® products.

Specification — Use only suitable coolant (even in countries with high temperatures). Using inferior antifreeze can result in corrosion and foaming. KTM recommends Motorex® products.

— Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre- sponding properties. KTM recommends Motorex® products.

Synthetic engine oil

Supplier Motorex — Motorex® Cross Power 4T

— Use only oils that comply with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex® products.

Specification — _ KTM recommends Motorex® products.

— Motorex® Joker 440 Universal

Specification — _ KTM recommends Motorex® products.

—_ Motorex® Long Therm 2000

Specification — _ KTM recommends Motorex® products.

— Motorex® Chain Clean 611

Specification — _ KTM recommends Motorex® products.

— Motorex® Chain Lube 622

Specification — _ KTM recommends Motorex® products.

— Motorex® Twin Air Dirt Bio Remover

Specification — _ KTM recommends Motorex® products.

— Motorex® Twin Air Liquid Power

Specification — _ KTM recommends Motorex® products.

— Motorex® Moto Clean 900

Specification — _ KTM recommends Motorex® products.

AUXILIARY SUBSTANCES 116

— __KTM recommends Motorex® products. Supplier

— Motorex® Moto Polish

— _ KTM recommends Motorex® products. Supplier

— Motorex® Accu Contact

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. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the fore- ground for motorcycle engines. With most motorcycles, the gearbox and the clutch are lubricated with the oil as the engine. The JASO MA Standard meets these special requirements.

The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis- cosity. The viscosity describes only one property of oil and says nothing about quality.

_____CONSUMER INFORMATION (EXC-R USA) 54e

REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect which could cause an accident resulting in injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc.

If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remady campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or KTM North America, Inc.

To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-888-327-4236 or visit the website www.nhtsa.dot.gov, or write to: NHTSA Headquarters, 1200 New Jersey Avenue, SE, West Buildding, Washington, DC 20590. You can also obtain other information about motor vehicle safety from the Hotline.

NOISE EMISSION WARRANTY KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise stan- dards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.

Warranty claims should be directed to:

KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001,

Phone: (440) 985-3553

TAMPERING WARNING TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED. FEDERAL LAW PROHIBITS THE FOLLOWING ACTS OR CAUSING THEREOF:

1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or

2) The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW.

1) Removal of, or puncturing the muffler, baffles, header pipes or any other components which conducts exhaust gases.

2) Removal or puncturing of any part of the intake system.

3) Lack of proper maintenance.

4) Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.

WARNING STATEMENT This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalties under state and local ordinances.

CONSUMER RIGHTS Limited Warranty claims should be directed to an authorized KTM dealer. If you are not satisfied, please contact: KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001,

Phone: (440) 985-3553

Your rights may vary, please refer to the applicable state laws.

Aïr filter cleaning fitting ... removing

Air filter box lid fitting .. removing .

Basic chassis setting

checking with rider's weight 32 Battery

of rear brake, adding Topping up brake fluid of front brake Brake fluid level of front brake, checking of rear brake, checking Brake linings of front brake, changing of front brake, checking of front brake, installing of front brake, removing of rear brake, changing of rear brake, checking of rear brake, installing of rear brake, removing Le EN Carburetor adjusting idle emptying the float chamber

Chain wear checking ...

Chassis number Choke

CLEANING Clutch changing fluid checking fluid level ..

Clutch lever adjusting basic position . Compression damping fork, adjusting Compression damping, high-speed of shock absorber, adjusting Compression damping, low-speed of shock absorber, adjusting Coolant draining refilling ... Coolant level checking ..

Electric starter button Emergency OFF switch Engine running in Engine number Engine oil changing .. draining refilling ... topping up . Engine oil level checking

engine oil screen cleaning Engine oil screen cleaning

Filler cap closing opening ...

Flasher switch Foot brake pedal adjusting basic position . checking free play Fork checking basic setting Fork legs bleeding fitting .... removing .. Fork offset . ... adjusting ..

121 Fork protector TEMOVINS 73 fitting cossoreresiieeeceeeeeereettte 43 Maintenance 6 removing 43 Motorcycle Front fender cleaning 86 installing ... removing ... NN Front wheel Oil filter | fitting changing nu removing . fitting . removing Fuel tank installing ... Overview of indicator lamps 13 removing . OWNER'S MANUAL 7 Fuel tap a

Fuel, oils, etc. Fuse fitting ... removing .

Gas Bowden cable route checking

Gear oil draining refilling topping up ..

gear oil level checking

gear oil screen cleaning

Gear oil screen cleaning

Hand brake lever adjusting basic position adjusting free travel checking free play

Putting into operation Advice on first use after storage .. Checks before putting into operation

Rear sprocket / engine sprocket checking for wear

Rear wheel fitting removing

Rebound damping fork, adjusting of shock absorber, adjusting 33

Riding sag adjusting

Seat mounting removing ..

of shock absorber, adjusting 35 Start number plate

unlocking Steering head bearing

greasing 46 Steering head bearing play