450 XC-W USA - Moto tout-terrain KTM - Free user manual and instructions

USER MANUAL 450 XC-W USA 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. 9) Dealer's stamp

Engine number (® p. 9)

Key number (all EXC models) (# p. 9)

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 specifically 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 production 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.

© 2008 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.

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

Issued by: TÜV Management Service

KTM-Sportmotorcycle AG 5230 Mattighofen, Austria

CONTENTS MEANS OF REPRESENTATION IMPORTANT NOTES VIEW OF VEHICLE.. View of the vehicle from the left front (example) View of the vehicle from the right rear (example) LOCATION OF SERIAL NUMBERS. Chassis number Type label. Key number (all EXC models) . Engine number.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION...

Advice on first use. Running in the engin RIDING INSTRUCTIONS Checks before putting into operation

Starting. Starting up Shifting, riding. Braking Stopping, parking. Refueling SERVICE SCHEDULE 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). 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 absorbet Measuring rear wheel sag unloaded Checking static sag of the shock absorber . Checking the riding sag of the shock absorber … Adjusting spring preload of the shock absorber À Adjusting riding sag À Removing the shock absorber Installing the 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 protectio: Checking play of steering head bearing Adjusting play of steering head bearing À (EXC EU, EXC AUS, XC-W ZA). Adjusting play of steering head bearing À (EXC SIX DAYS, XC-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 SIX DAYS, XC-W USA) Removing the lower triple clamp À (EXC EU, EXC AUS, XC-W ZA) en Installing the lower triple clamp À (EXC SIX DAYS,

XC-W USA) en Installing the lower triple clamp À (EXC EU, EXC AUS, XC-W ZA) Greasing the steering head bearing À Dismounting the front fender …. Installing the front fender. Removing headlight mask with headlight (EXC, EXC SIX DAYS, XC-W ZA). Refitting the headlight mask with the headlight (EXC, EXC SIX DAYS, XC-W ZA) ….

CONTENTS Dismount the start number plate (XC-W USA). Installing the start number plate (XC-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 for chain dirt accumulation 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 Checking the brake discs. Checking free travel of hand brake leve:

Adjusting basic position of handbrake lever (all XC-W models) .

Adjusting free travel of handbrake lever (all EXC models)

Checking the front brake fluid level Adding front brake fluid À . Checking the front brake linings. Removing front brake linings À Mounting front brake linings À . Changing the front brake linings À Checking free travel of foot brake lever Adjusting basic position of footbrake lever À. Checking the rear brake fluid level Adding brake fluid for the rear brake À . Checking the rear brake linings Removing rear brake linings À Installing the rear brake linings À Changing the rear brake linings À Removing the front wheel À Installing the front wheel À Removing rear wheel À Installing the 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. Installing 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 Installing 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 the fluid level of hydraulic clutch Changing the hydraulic clutch fluid À 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 oi 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 Filling up with gear oil À …. Adding gear oil À 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 400 EXC 400 XC-W USA 450 EXC, 450 EXC SIX DAYS

530 EXC, 530 EXC SIX DAYS

530 XC-W TECHNICAL DATA - CHASSIS Lighting equipment Tires … Capacity - fuel TECHNICAL DATA - FORK TECHNICAL DATA - SHOCK ABSORBER TECHNICAL DATA - CHASSIS TIGHTENING TORQUES . WIRING DIAGRAM … Wiring diagram (all EXC models Wiring diagram (all XC-W models) SUBSTANCES AUXILIARY SUBSTANCES. STANDARDS

100 . 100 . 104 . 106 . 107 109 . 110

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.

Brandt Identifies a brand in merchandise traffic.

____ IMPORTANT NOTES

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 I 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.

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 service schedule is reached.

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

The work prescribed in the service schedule must be carried out in an authorized KTM workshop and confirmed in the customer's ser- vice record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.

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

For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.

The current KTM PowerParts for your vehicle can be found on the KTM website. International KTM Website: http://www.ktm.com

When the vehicle is assembled, non-reusable parts (e.g., self-locking screws and nuts, gaskets, seal rings, O-rings, splints, lock wash- ers) must be replaced with new parts.

Where thread lockers are used on screw connections (e.g., Loctite®), follow the instructions for use from the manufacturer.

After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or worn parts.

After you complete the repair or maintenance work, check the roadworthiness of the vehicle.

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

Always place the vehicle on a firm and even surface.

ote 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.

____ IMPORTANT NOTES

— Turn 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 ensure that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.

Be sure to pay attention to the notes and warnings given here.

e Info Various notes and warning stickers are attached to the vehicle. Do not remove any notes and warning stickers. If they are miss- ing, 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.

It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful infor- mation and many tips on how to operate and handle your motorcycle. Only then will you find out how to best customize the motor- cycle 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.

NO B| WIN Hand brake lever

Level viewer for brake fluid, rear

Fork compression adjustment

Fork rebound adjustment

Shock absorber compression adjustment

D Shock absorber rebound adjustment

____ LOCATION OF SERIAL NUMBERS 9

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 10

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

_____ OPERATING ELEMENTS nl

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

Hand brake lever @ is located on the right side of the handlebar. The hand brake lever is used to activate the front brake.

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 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 run-

so ning engine stops, and a non-running engine will not start. lgnition on — In this position, the ignition circuit is closed, and the engine can be started.

_____ OPERATING ELEMENTS 12

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

+ Electric starter button @ in basic position

+ Electric starter button @ pressed — In this position, the electric starter is actuated.

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.

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 ° switched off.

D) Low beam on -— Light switch is in the central position. In this position, A the low beam and tail light are switched on.

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

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

Possible states (XC-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 the tail light are switched on.

(XC-W USA) (G) C4 + The light switch has no function when delivered. — It can be used if lighting is ao 10] fited later.

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 12

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.

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

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

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

— Press the key © to change the display mode or change to one of the setup menus. — Press the button # to control different functions. — Press the button Æ to control different functions.

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

Activating the speedometer:

The speedometer is activated when one of the keys is pressed or an impulse comes from the wheel speed sensor.

WS (wheel size) After the display function test, the wheel size WS is displayed briefly.

e Info 2025 (| 2205 mm corresponds to the size of the 21" front wheel with a series produc- tion tire.

_____ OPERATING ELEMENTS 14

(Option: Tripmaster switch) You can use the trip master switch to control the functions of the speedometer from the handlebar.

e Info The trip master is an optional accessory.

e Info If you change the unit, the value ODO is retained and converted accordingly. The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed.

Condition The motorcycle is standing.

— Press the button © briefly and repeatedly until H appears at the bottom right of the display. — Press the button © for 3 - 5 seconds. TR TR2 A A2 St S2 The Setup menu opens and the active functions are displayed. WW — Press the button © repeatedly until the Kn/h/Mph display flashes. Skmh MZ O0 LP CK H Km/hadjusting A — Press the button Æ. Mphadjusting 400329-01 — Press the button =. — Press the button © for 3 - 5 seconds. AJ The settings are saved and the Setup menu closed. e Info (| 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.

Condition The motorcycle is standing.

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

— Press the button © for 3 - 5 seconds.

n \/ The hour display flashes. L 2 18.441 — Set the hour display with the button Æ and/or button &. ck — Press the button © briefly. 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 400330-01 the button # and the button E.

e Info (| The seconds can only be set to zero.

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

(| 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

Adjusting the speedometer functions

e Info Upon delivery, only the SPEED/H and SPEED/OD0 display modes are activated.

Condition The motorcycle is standing.

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

— Press the button © for 3 - 5 seconds.

Rem M A2 Si 92 The Setup menu opens and the active functions are displayed. — Switch to the function you require by briefly pressing the button ©. Kmh Mph 00 UP CKH 4 The selected function flashes.

Activating a function

Deactivating a function — Press the button =.

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

— Activate or deactivate all functions accordingly. — Press the button © for 3 - 5 seconds. 4 The settings are saved and the Setup menu closed.

(| 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 is closed.

Querying the lap time

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

Condition The motorcycle is standing.

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

the display. up nl — Press the button © briefly. 0 00:00:39 J LAP 1 appears on the left side of the display. LAP — Laps 1-10 can be displayed by pressing the button +.

— The # button has no function — Press the button © briefly. 7 Next display mode

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

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

The current speed is displayed in the SPEED display mode.

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

(| 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.

Condition + Vehicle at a standstill

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

The number of service hours of the engine is shown in the H display mode.

The service hour counter stores the total traveling time.

(| The service hour counter is necessary for ensuring that maintenance work is car- ried out at the right intervals. If the speedometer is in the H display mode at the start of the trip, it automati- cally changes to the OD0 display mode. The H display mode is suppressed during travel.

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 display. The time is displayed in the CLK display mode.

Press the button #. No function

Press the button =. No function

Press the button © The display changes to the Setup menu of the clock. for 3 - 5 seconds. Press the button © briefly.

— Press the button © briefly and repeatedly until LAP appears at the bottom right of the display. In the LAP display mode, up to ten laps 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 #. Press the button =.

Starts or stops the clock.

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.

_____ OPERATING ELEMENTS 17

Press the button © next display mode briefly.

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

The total number of kilometers ridden is shown in the ODO display mode.

Press the button #. No function 54 HA 63 pl Press the button =. No function SD Knn Press the button © —

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

— Press the button © briefly and repeatedly until TR1 appears at the top right of the

display. TR1 (trip master 1) runs constantly and counts to 999.9. mt You can use it to measure trips or the distance between refueling stops. 55 1 TR1 is coupled with A1 (average speed 1) and S1 (stop watch 1). SPEED ' 033 Kmh e Info (l 1f 999.9 is exceeded, the values of TR1, A1 and S1 are automatically reset to 0.0.

Press the button #. No function

Press the button © The TR1, A1 and S1 displays are reset to 0.0. for 3 - 5 seconds.

Press the button © next display mode

— Press the button © briefly and repeatedly until TR2 appears at the top right of the display.

TR2 (trip master 2) runs constantly and counts to 999.9.

The displayed value can be set manually with the button Æ and the button =. A very

6e | “39 u practical function for rides by the road book.

The TR2 value can also be corrected manually during the trip using the but- ton # and the button =.

400324-01 1f 999.9 is exceeded, TR2 is automatically reset to 0.0.

Press the button #. Increases value TR2. Press the button =. Decreases value TR2. Press the button © Clears value TR2.

Press the button © next display mode briefly.

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

A (average speed 1) shows the average speed calculated on the basis of TR1 (trip mas-

ter 1) and S1 (stop watch 1).

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

and ends 3 seconds after the last impulse.

Press the button #. No function Press the button =. No function

Press the button © The TRI, A1 and S1 displays are reset to 0.0. for 3 - 5 seconds.

Press the button © briefly.

— 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.

(l The displayed value can differ from the actual average speed if S2 is not stopped after the ride.

Press the button #. No function Press the button =. No function Press the button © —

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

— Press the button © briefly and repeatedly until S1 appears at the top right of the display.

S1 (stop watch 1) shows the trip time on the basis of TR1 and continues running when

an impulse is received from the wheel speed sensor.

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

ends three seconds after the last impulse.

Press the button #. Press the button =. Press the button © for 3 - 5 seconds. Press the button © briefly.

No function No function The TRI, A1 and S1 displays are reset to 0.0.

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

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 #. Press the button =. Press the button © for 3 - 5 seconds. Press the button © briefly.

Starts or stops $2. No function The S2 and A2 displays are reset to O.0.

Press the button © for 3 - 5 seconds.

Press the button © briefly.

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

speedometer functions. SPEED/CLK display mode | No function No function The display changes to | next display mode

the Setup menu of the clock.

SPEED/LAP display mode | Starts or stops the

Stops the current lap

The stop watch and the

(lap time) clock. time and saves it, and lap time are reset. the stop watch starts the next lap. SPEED/0D0 display mode | No function No function - next display mode (odometer) SPEED/TR1 display mode | No function No function The TR1, A1 and S1 dis- | next display mode

plays are reset to O.0.

SPEED/TR2 display mode | Increases value TR2.

Decreases value TR2.

SPEED/S1 display mode | No function No function The TR1, A1 and S1 dis- | next display mode (stop watch 1) plays are reset to 0.0.

Table of conditions and activability

Vehicle at a stand- | Menu can be acti-

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.

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

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

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

Choke (EXC AUS, XC-W)

Choke @ is fitted on the left side of the carburetor. Activating the choke function frees an opening through which the engine can draw extra 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.

n | Possible states TRE + Choke function activated — The choke lever is pulled out to the stop. SEX roro) + Choke function deactivated - The choke lever is pushed in to the stop.

_____ OPERATING ELEMENTS 21

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 extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.

e Info (l 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.

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.

Foot brake pedal @ is located in front of the right footrest. The foot brake pedal is used to activate the rear brake.

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 inward toward the engine.

_____ OPERATING ELEMENTS

Locking the steering (all EXC models)

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

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

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

— Park the 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.

J Steering is no longer possible.

Never leave the key in the steering lock.

_____ OPERATING ELEMENTS 2

— Insert the key in the steering lock, turn it to the left, pull it out and turn it to the right. Remove the key. 4 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 2

Danger Danger of accidents Danger from insufficient traffic competence.

— Do not use the vehicle if you are not fit to deal with traffic or if you have consumed alcohol and/or medicaments or drugs.

à Warning Risk ofinjury 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. Always wear protective clothing, which must be in perfect condition and meet legal requirements.

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 conditions 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.

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.

e Info I 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 controls.

— Adjust the basic position of clutch lever. (# p. 76)

(all XC-W models) — adjust the basic position of handbrake lever. (# p. 56)

{all EXC models) — Adjust the free travel of the handbrake lever. (® p. 57)

Adjust the basic position of the footbrake lever. À (# 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.

____ GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 2

— 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.

Guideline 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.

Guideline Maximum engine speed During the first 3 service hours 7,000 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 I Make sure that the motorcycle is in a perfect technical condition before use.

e Info I 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. 52)

— Check for chain dirt accumulation. (# p. 51)

— 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.

I 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.

Motorcycle has been out of use for more than 1 week — Empty the carburetor float chamber. À (# p. 79)

— Turn handle @ of the fuel tap to the ON position. (Figure 500137-10% p. 20) Fuel can flow from the fuel tank to the carburetor.

— Remove the motorcycle from the stand.

— Shift gear to neutral.

(EXC AUS) — Turn the emergency OFF switch to the position Q. Engine cold

(EXC AUS, XC-W) — Pull the choke lever out as far as possible.

(EXC EU, EXC SIX DAYS) — Pull the choke lever to the stop.

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

e Info Don't open the throttle.

____ RIDING INSTRUCTIONS 21

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.

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.

I 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.

If the 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 %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 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.

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.

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

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

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.

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 2

û Warning Risk of misappropriation Usage by unauthorized persons. — Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.

Warning Danger of burns Some vehicle components 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. Note 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.

— Brake the motorcycle. — Shift gear to neutral.

(ll XC-W models) — Press and hold the short circuit button & while the engine is idling until the engine stops.

(all EXC models) — Press and hold the short circuit button & while the engine is idling until the engine stops.

— Turn handle @ of the fuel tap to the OFF position. (Figure 500137-10% p. 20) — Park the motorcycle on firm ground.

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.

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.

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.

— Switch off the engine. — Open the filler cap. (* p. 20)

Fill the fuel tank with fuel up to measurement @.

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. À (# p. 80) . ° ° Change the gear oil and clean the gear oil screen. À (+ p. 82) . . . Replace spark plug. . Check the valve clearance. À . . . 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. . . . Carburetor Check carburetor connection boots for cracks and leakage. Q . Check vent hoses for damage and routing without sharp bends. . 0 . Check idle. . . . Attachments Check the cooling system for leakage. . . . Check the antifreeze and coolant level. (# p. 72) . . . Check the exhaust system for leakage and looseness. Q . Check Bowden cables for damage, smooth operation and routing without sharp . . . bends. Check the fluid level of the hydraulic clutch. (# p. 76) . . . Clean the air filter. À (# p.75) . . . Check cables for damage and routing without sharp bends. Q . Check that the electrical equipment is functioning properly. . . . Check the headlamp setting. Q . Brakes Check the front brake linings. (# p. 58) . . . Check the rear brake linings. (# p. 62) . . . Check the brake discs. (# p. 55) . . . Check the front brake fluid level. (# p. 57) . . . Check the rear brake fluid level. (# p. 61) . . . Check brake lines for damage and leakage. . . . Check the free travel of the hand brake lever. (# p. 56) . . . Check the free travel of the foot brake lever. (# p. 60) . . . Check brake system function. . . . Check screws and guide bolts of brake system for tightness. . 0 . Chassis Check shock absorber and fork for leakage and functioning. À . . . Clean dust boots of fork legs. (# p. 39) . . Bleed fork legs. (# p. 39) . . Check the swingarm bearing. À Q . Check play of steering head bearing. (# p. 40) . . . Check all screws to see if they are tight. . . . Wheels Check the spoke tension. (# p. 67) . . . Check rim run-out. . . . Check the tire condition. (# p. 66) . . . Check the tire air pressure. (# p. 67) . . . Check the chain wear. (# p. 53) . . . Check the chain tension. (# p. 52) . . . Clean the chain. (# p. 51) . . . Check the wheel bearing for play. À . Q . 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

Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)

Competition use Hobby use JA J2A S15A | S30A | S45A | S30A | S60A | S90A Carry out a complete fork service. À . . Carry out a complete shock absorber service. À . Grease the steering head bearing. À (# p. 46) . . Treat electric contacts with contact spray. . . Change the hydraulic clutch fluid. À (# p. 76) . . Change the front brake fluid. À . . Change the rear brake fluid. À . . Clean the spark arrestor. À (XC-W USA) . ° Check wear of clutch discs. À . . . . . . Check the clutch. à . . Check/measure the cylinder. À . . Change the piston. À . . Check the camshaft. À . . Change the camshaft bearing. À . . Check the valve spring seat. À . . Check the cylinder head. À . . Check the valves. À . . Check the valve springs. À . . Check the radial clearance of the rocker arm rollers. À . . Check the timing-chain tensioner function. À . . Check the balancer shaft. À . . Check the crankshaft run-out at the bearing pin. À . . Change the conrod bearing. À . . Change the crankshaft main bearing. À . . Check the transmission. À . . Check the shift mechanism. À . . Check the spring length of the oil pressure regulator . . valve. à Change glass fiber yarn filling of main silencer. À . Q Replace foot brake cylinder seals. À . . Check/adjust the carburetor components. À . Q . .

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

Important checks and maintenance work to be carried out by the rider.

Clean the chain. (# p. 51)

Check the chain wear. (# p. 53)

Clean the air filter. À (# p. 75)

Check the tire condition. (* p. 66)

Check the coolant level. (# p. 72)

Empty the carburetor float chamber. À (# p. 79)

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 ss

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 (5482905500) |

50007401 | — 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).

Guideline Standard rider weight 75... 85 kg (165... 187 lb.)

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 separately in the low-speed and high-speed ranges (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-speed 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.

— 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 absorber type.

Compression damping, high-speed

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

Adjusting the low-speed compression 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.

e Info 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 absorber type.

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

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

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 Measuring rear wheel sag unloaded

Turn the adjusting screw @ clockwise until it stops.

e Info D Do not loosen nut @!

Turn back counterclockwise the number of clicks corresponding to the shock absorber type.

Guideline Rebound damping Comfort 26 clicks Standard 24 clicks Sport 22 clicks e Info

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

Jack up the motorcycle. (# p. 33)

Measure the distance — as vertical as possible — between the rear axle and a fixed point, for example, a mark on the side cover.

Make a note of the value as measurement @. Remove the motorcycle from the work stand. (# p. 33)

Measure distance @ of rear wheel unloaded. (* p. 35)

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.

Checking the riding sag of the shock absorber

Measure distance @ of rear wheel unloaded. (® p. 35)

With another person holding the motorcycle, sit on the saddie 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

Make a note of the value as measurement @.

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

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. À (# p. 37) After removing the shock absorber, clean Loosen screw @.

Turn adjusting ring @ until the spring is no longer under tension.

Combination wrench (50329080000)

Measure the overall spring length when not under tension. Tighten the spring by turning adjusting ring @ to measurement @.

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

Tighten screw @. Guideline

Screw, shock absorber adjusting ring

— After removing the shock absorber, clean it thoroughly. — Choose and mount a suitable spring.

Guideline 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)

e Info The spring rate is shown on the outside of the spring.

Smaller weight differences can be compensated by changing the spring preload.

— Install the shock absorber. À (+ p. 37)

— Check the static sag of the shock absorber. (# p. 35)

— Check the riding sag of the shock absorber. (# p. 36)

— Adjust the rebound damping of the shock absorber. (# p. 34)

Removing the shock absorber à

— Jack up the motorcycle. (# p. 33)

— 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

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

Guideline Screw, top shock absorber | M12 80 Nm Loctite® 2437M (59 Ibf ft) — Mount and tighten screw ©. Guideline Screw, bottom shock M12 80 Nm Loctite® 2437" absorber (59 Ibf ft)

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

— Remove the motorcycle from the work stand. (# p. 33)

e Info I 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.

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

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

e Info (| 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.

Guideline Compression damping Comfort 26 clicks Standard 22 clicks Sport 20 clicks e Info

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

— Mount protection covers @.

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

— Turn adjusting screws @ clockwise until they stop.

e Info (| 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 3e

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

Guideline Rebound damping Comfort 24 clicks Standard 22 clicks Sport 22 clicks e Info

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

— Turn adjusting screws counterclockwise until they stop.

e Info (| Make the same adjustment on both fork legs.

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

Guideline Spring preload - Preload Adjuster Comfort 2 turns Standard 2 turns Sport 4 turns Info

Turn clockwise to increase spring preload, turn counterclockwise to reduce spring preload.

Adjusting the spring preload has no influence on the absorption setting of the rebound damping.

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

— Jack up the motorcycle. (# p. 33) — Remove bleeder screws @ briefly.

4 Any excess pressure escapes from the interior of the fork. — Mount and tighten bleeder screws. — Remove the motorcycle from the work stand. (# p. 33)

— Jack up the motorcycle. (# p. 33) — Loosen the fork protection. (# p. 40) — Push dust boots @ of both fork legs downwards.

(| 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 removed, the oil seals behind can start to leak.

Checking play of steering head bearing

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.

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

Universal oil spray (* p. 108)

Press the dust boots back into their normal position. Remove excess oil.

Position the fork protection. (# p. 40)

Remove the motorcycle from the work stand. (# p. 33)

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.

Position the fork protection on the left fork leg. Mount and tighten screws @. Guideline

[ Remaining screws, chassis M6 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. Guideline

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

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. 33)

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.

» _ lfthere is noticeable play present: (EXC SIX DAYS, XC-W USA) — Adjust play of the steering head bearing. À (# p. 41)

(EXC EU, EXC AUS, XC-W ZA) — Adjust play of the steering head bearing. À (# p. 41)

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE ai

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 SIX DAYS, XC-W USA) — Adjust play of the steering head bearing. À (+ p. 41)

(EXC EU, EXC AUS, XC-W ZA) — Adjust play of the steering head bearing. À (# p. 41)

— Check the steering head bearing and replace if required. Remove the motorcycle from the work stand. (# p. 33)

Adjusting play of steering head bearing à (EXC EU, EXC AUS, XC-W ZA)

Jack up the motorcycle. (# p. 33)

Loosen screws @ and @.

Loosen and retighten screw ©.

[ Screw, top steering head M20x1.5 10 Nm (7.4 Ibf ft)

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

Adjusting play of steering head bearing À (EXC SIX DAYS, XC-W USA)

Guideline Screw, top triple clamp M8 20 Nm (14.8 lbf ft) Tighten screw @. Guideline Screw, top steering stem M8 20 Nm (14.8 lbf ft) Check play of steering head bearing. (* p. 40) Jack up the motorcycle. (# p. 33) Loosen screw @. Remove screw @. Loosen and retighten screw ©. Guideline [ Screw, top steering head M20x1.5 10 Nm (7.4 Ibf ft)

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

Guideline Screw, top triple clamp M8 17 Nm (2.5 lbf ft) Mount and tighten screw @. Guideline Screw, top steering stem M8 17 Nm Loctite® 2437M (12.5 lbf ft)

Check play of steering head bearing. (* p. 40)

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE 42

Removing the fork legs

— Remove the front wheel. À (+ p. 64)

— 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.

(EXC SIX DAYS, XC-W USA) — Loosen screw @. Remove the fork leg on the left.

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

(EXC EU, EXC AUS, XC-W ZA) — Loosen screw @. Remove the fork leg on the left.

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

— Position the fork legs.

e Info 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 SIX DAYS, XC-W USA) — Fullytighten screw @.

(EXC EU, EXC AUS, XC-W ZA) — Fullytighten screw @.

Guideline Screw, top triple clamp M8 20 Nm (14.8 Ibf ft) — Fullytighten screw ©. Guideline Screw, bottom triple clamp M8 15 Nm (1.1 Ibf ft) — Position brake caliper, mount and tighten screws ©. Guideline Screw, front brake caliper | M8 25 Nm Loctite® 2437M (18.4 lbf ft)

— Mount cable clip @.

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

— Install the front wheel. À (+ p. 64)

— Remove the fork legs. (# p. 42) — 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.

— Position the fork protection on the left fork leg. Mount and tighten screws @. Guideline

[ Remaining screws, chassis I M6

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

[10 Nm (7.4 Ibf fo |

[ Remaining screws, chassis

[M6 [10 Nm (7.4 Ibf fo |

— Remove the fork legs. (# p. 42)

(XC-W USA) — Dismount the start number plate. (# p. 48)

(EXC SIX DAYS) — Remove the headlight mask with the headlight. (# p. 47)

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.

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.

Removing the lower triple clamp à (EXC EU, EXC AUS, XC-W ZA)

Remove the fork legs. (# p. 42)

Remove the headlight mask with the headlight. (# p. 47) Dismount the front fender. (# p. 47)

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.

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.

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

[ Long-life grease (# p. 107)

— 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 @. Guideline 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 ©.

Guideline Remaining screws, chassis M6 10 Nm (7.4 Ibf ft) — Install the front fender. (# p.47) (XC-W USA) — Install the start number plate. (* p. 48) (EXC SIX DAYS)

— _ Refit the headlight mask with the headlight. (# p. 47) — Install the fork legs. À (# p.42) — Mount and tighten screw @.

Screw, top steering stem M8 17 Nm Loctite® 2437M (12.5 lbf ft)

— Check the cable harness, cable, brake and clutch line for free movement and free laying. — Check play of steering head bearing. (# p. 40)

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

[ Long-life grease (# p. 107)

— 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 ©. Guideline

[ 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 @.

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

— Check the cable harness, cable, brake and clutch line for free movement and free laying. Check play of steering head bearing. (# p. 40)

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE 41

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

— Ensure that the spacing sleeves are mounted in the fender. — Position the front fender. Mount and tighten screws @. Guideline [ Remaining screws, chassis M6 10 Nm (7.4 Ibf ft)

e Info Take care with the contact between the holding lugs and the start number plate or headlight mask.

— 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 headlight.

— 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.

— Position the start number plate. Mount and tighten screw @ with the distance bushing.

Guideline [ Remaining screws, chassis M6

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 @.

On the upper triple clamp, there are 2 holes at a distance of @ to each other.

[ Distance @ between holes I 15 mm (0.59 in) |

The holes on the handlebar support are placed at a distance of @ from the center.

[ Distance ® between holes I 3.5 mm (0.138 in) |

The handlebar supports can be mounted in 4 different positions.

(EXC SIX DAYS) The handlebar supports can also be mounted at 2 different heights (with and with- out spacer).

[Thick spacer [9 mm (0.35 in) |

(EXC EU, EXC AUS, XC-W) — Remove the four screws @. Remove the handlebar clamp. Remove the handle- bar and lay it to one side.

e Info I 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.

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE 4

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

Guideline Screw, handlebar support | M10 40 Nm Loctite® 2437M (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 @. Guideline

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.

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

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

[ Use a M10x25 screw |

e Info Position the left and right handlebar supports evenly.

Fit the rubber cones @ and clamp bar @. Fit the lower shells ©. Position the handlebar.

e Info Make sure cables and wiring are positioned correctly.

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE so

— 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 (SXS05125205)

e Info The elastomers are available in different versions.

— Fit and evenly tighten the four screws @. Guideline

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

e Info I 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.

— 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 I 3... 5 mm (0.12... 0.2 in) |

» __lfthe gas Bowden cable play does not meet specifications: — Adjust the gas Bowden cable play. À (# p. 50)

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 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. À (# p. 50)

— 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 cable at the throttle grip.

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. À (æ p. 71)

— Check play in the gas Bowden cable. (# p. 50)

Checking for chain dirt accumulation

gl \ ZA, — Check the chain for coarse dirt accumulation. » _lfthe chain is very dirty: — Clean the chain. (# p. 51)

û Warning Danger of accidents Oil or grease on the tires reduces their grip.

— Remove oil and grease with a suitable cleaning material.

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.

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

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

Chain cleaner (# p. 107)

Offroad chain spray (# p. 107)

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE 52

Checking the chain tension

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

If the 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

— Jack up the motorcycle. (# p. 33) Push the chain at the end of the chain sliding component upwards to measure the chain tension @.

e Info (| 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)

» _ lfthe chain tension does not meet specifications: — Adjusting chain tension - after checking. (# p. 54) — Remove the motorcycle from the work stand. (® p. 33)

Checking the chain tension when fitting rear wheel

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

If the 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 @.

e Info (| 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)

» _ lfthe chain tension does not meet specifications: — Adjust the chain tension when fitting rear wheel. (# p. 55)

» _ lfthe rear sprocket / engine sprocket are worn: — Replace rear sprocket / engine sprocket.

I When fitting the chain joint, always make sure that the closed side of the joint faces forward (riding direction). The engine sprocket, rear sprocket and chain should always be

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

— Jack up the motorcycle. (# p. 33)

— Shift gear to neutral.

— Pull the upper chain section with the specified weight @. Guideline

[ Weight of chain wear measurement 10... 15 kg (22... 33 Ib.)

Measure distance ® of 18 chain links in the lower chain section.

e Info 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

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

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

Adjusting the chain tension

— Remove the motorcycle from the work stand. (# p. 33)

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

— Jack up the motorcycle. (# p. 33)

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

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

— Adjust the chain tension by turning the left and right adjusting screws @. Guideline

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. 33)

— Adjust the chain tension by turning the adjusting screws © left and right. Guideline

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

(l 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°.

lAdjusting chain tension - fin rear Wheel

— Adjust the chain tension by turning the adjusting screws @ left and right. Guideline

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.

Condition Number of teeth: < 44 teeth

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

Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) Condition Number of teeth: 2 45 teeth — Insert nut @ in hole @. Position the chain guide. — Mount and tighten screws @ and @. Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

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

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

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE se

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

e Info 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) 40025710 Rear 3.5 mm (0.138 in)

»_lfthe brake disc thickness is less than the specified value: — Change the brake disc.

Checking free travel of hand brake lever

Danger of accidents Brake system failure.

If there 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.

(all XC-W models) — Push the hand brake lever forwards and check free travel @.

L _# Free travel of hand brake lever 23mm(20.12in)

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

(all EXC models) — Push the hand brake to the handlebar and check free travel @.

Free travel of hand brake lever 23mm(20.12in)

» _lfthe free travel does not meet specifications: — Adjust the free travel of the handbrake lever. (® p. 57)

Adjusting basic position of handbrake lever (all XC-W models) Adjust the basic setting of the handbrake lever to your hand size by turning adjust- ing screw @.

(| 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!

Adjusting free travel of handbrake lever (all EXC models)

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

Call (| 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.

Do not make any adjustments while riding!

— Check the free travel of the hand brake lever. (* p. 56)

Checking the front brake fluid level

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 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: — Add front brake fluid. À (® p. 57)

A F 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. — _lfbrake 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.

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!

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE se

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

[Brake fluid DOT 4 / DOT 5.1 (# p. 106) |

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

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

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 @ [> 1 mm (@ 0.04 in)

» _lfthe minimum thickness is less than specified: — Change the front brake linings. À (# p. 59)

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.

e Info 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.

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE se

Mounting front brake linings à

Warning À 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 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. If 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.

— Check the brake discs. (# p. 55)

— 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.

— Insert the brake pads, insert bolt ©, and mount locking split pins @. — Position brake caliper, mount and tighten screws @. Guideline

Screw, front brake caliper | M8 25 Nm Loctite® 2437M (18.4 lbf ft)

— Mount cable clip @.

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

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. — _lfbrake 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.

I 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!

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE so

— Remove the front brake linings. À (# 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.

— Mount the front brake linings. À (# p. 59) — Add brake fluid to level @. Guideline

[ Measurement of @ I 5 mm (0.2 in)

[ Brake fluid DOT 4 / DOT 5.1 (# p. 106)

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 travel of foot brake lever

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 travel @.

[ Free travel at foot brake lever 3... 5 mm (0.12... O2 in)

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

Adjusting basic position of footbrake lever à

— _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 travel.

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

e Info The range of adjustment is limited.

500154-10| — Turn push rod © accordingly until you have free travel @. If necessary, adjust the basic position of the footbrake lever.

Free travel at foot brake lever 3... 5 mm (0.12... O2 in)

— Hold screw © and tighten nut @.

Guideline Remaining nuts, chassis M8 30 Nm (22.1 lbf ft) — Hold push rod @ and tighten nut @. Guideline Remaining nuts, chassis M6 15 Nm Q1.1 lbf ft)

— Reconnect spring @.

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 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 brake fluid for the rear brake. À (# p. 61)

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. — _lfbrake 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.

e Info 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!

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE &2

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

[ Brake fluid DOT 4 / DOT 5.1 (# p. 106)

— Mount the screw cap with the membrane and the O-ring.

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

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 @ [> 1 mm (@ 0.04 in)

» _lfthe minimum thickness is less than specified: — Change the rear brake linings. À (# p. 63)

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.

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 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. If 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.

— Check the brake discs. (# p. 55)

— 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 pads, 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.

Changing the rear 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. — _lfbrake 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.

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. À (# 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. À (# p. 62) — Add brake fluid to level @.

[ Brake fluid DOT 4 / DOT 5.1 (# p. 106)

— Mount the screw cap with the membrane and the O-ring.

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

___ MAINTENANCE WORK ON CHASSIS AND ENGINE s4 IRemoving he front Wheel À

Jack up the motorcycle. (# p.33)

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

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

Remove screw @. Loosen screw @.

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 spacing sleeves ©.

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.

Clean and grease shaft seal rings @ and bearing surface @ of the spacing sleeves.

[ Long-life grease (# p. 107)

Insert the spacing sleeves.

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE ss

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

Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft)

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. 33)

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

Fully tighten screw ©. Guideline

Screw, fork stub M8 15 Nm Q1.1 lbf ft)

Jack up the motorcycle. (# p.33)

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

e Info (| 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.

(| 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 @.

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.

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE ss

Clean and grease shaft seal rings @ and bearing surface @ of the spacing sleeves.

[ Long-life grease (# p. 107)

Insert the spacing sleeves.

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

Position the chain adjuster @. Mount nut ©, but do not tighten it yet. Check the chain tension when fitting rear wheel. (# p. 52)

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

Tighten nut @. Guideline [ 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. 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. 33)

I Only mount tires approved or recommended by KTM. Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle. The front and rear wheels must be mounted with tires with similar profiles. Worn tires have a negative effect on riding behavior, especially on wet surfaces.

— Examine the front and rear tires for cuts, foreign bodies and other damage.

» If you find cuts, foreign bodies or other damage on a tire:

— Change the tire. — Check the depth of the tread.

Note local national regulations concerning the minimum tread depth.

[ Minimum tread depth

» _Ifthe tread depth is less than the minimum allowable depth:

Checking tire air pressure

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.

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 (all EXC models)

front 1.5 bar (22 psi)

Rear 2.0 bar (29 psi)

Checking spoke tension

» _lfthe tire pressure does not meet specifications:

— Correct tire pressure. Mount dust cap.

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.

I 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.

Removing the battery à

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

[ You should hear a high note.

Spoke nipple, front wheel

Spoke nipple, rear wheel

If you hear different tone frequencies from different spokes, this is an indi-

cation of different spoke tensions.

PIN Risk ofinjury Battery acid and battery gases cause serious chemical burns.

— Keep batteries out of the reach of children.

— Wear suitable protective clothing and goggles.

— Avoid contact with battery acid and battery gases. — 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. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a physician.

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

Remove the seat. (# p. 69)

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE sa

— 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. — _Liftthe battery up.

— Place the battery in the battery holder. AAh battery (YTX5L-BS) (# p. 95)

— Reconnect the rubber band @.

Risk ofinjury Battery acid and battery gases cause serious chemical burns.

— Keep batteries out of the reach of children.

— Wear suitable protective clothing and goggles.

— Avoid contact with battery acid and battery gases.

— 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. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a physician.

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.

Warning 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 consumers 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.

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE sa

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- tery.

e Info Never remove the lid @. Charge the battery with at most 10% of the capacity specified on the bat- tery @.

Switch off the charger after charging. Disconnect the battery. Guideline

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

Charge the battery regularly when the 3 months motorcycle is not in use.

Mount the seat. (# p. 70)

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 The fuse @ is located in the starter relay @ under the filter box cover.

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.

Insert the fuse. [Fuse (58011109110)

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

— Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear and simultaneously push it forward.

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

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.

à 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 immedi- ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con- tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.

— Remove the seat. (# p. 69) Turn 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.

(all EXC 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.

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE 7

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.

à 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.

\ * > Pa 500067-01 = _—

— Position the fuel tank and install the two spoilers to the side of the radiator fixing. — Make sure that no cables or Bowden cables are trapped or damaged.

= — Mount the fuel tank vent hose.

D» — Mount and tighten screw @ with the collar sleeve. : Guideline | Remaining screws, chassis M6 10 Nm (7.4 Ibf ft)

(all EXC models) — Position the horn with the horn bracket.

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

— Connect the fuel hose. — Mount the seat. (# p. 70)

Cooling system Ps = 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. [120 °c (248 °F)

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 SIX DAYS, XC-W ZA) The radiator fan provides extra cooling. It is controlled by a thermoswitch.

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE 72

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. lf fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. 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 antifreeze of coolant.

—25... -45 °C (-13... -49 °F)

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

40024310 Coolant level @ above radiator fins. 10 mm (0.39 in)

» _ lfthe level of the cooling liquid does not meet specifications: — Correct the coolant level. Alternative 1 [ Coolant (# p. 106) | Alternative 2 [ Coolant (mixed ready to use) (# p. 106)

— _ Refit the radiator cap.

Checking the coolant level

Warning 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. lf fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. 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.

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

» _ lfthe level of the cooling liquid does not meet specifications: — Correct the coolant level. Alternative 1 400243-10 [ Coolant (% p. 106)

Alternative 2 [ Coolant (mixed ready to use) (# p. 106)

— _ Refit the radiator cap.

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE 73

Warning 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.

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

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

— Stand the vehicle upright. — Place a suitable container under the water pump cover. — Remove screw @. Remove the radiator cap @. — Completely drain the coolant. — Mount and tight screw @ with a new seal ring. Guideline [ Screw, water pump cover I M6x25 I 10 Nm (7.4 Ibf ft) |

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

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

— Make sure that the screw @ is tightened.

— Stand the vehicle upright.

— Pour coolant in up to measurement @ above the radiator fins. Guideline [10 mm (0.39 in)

Coolant 0.95 1 (1 at.) Coolant (# p. 106)

Coolant (mixed ready to use) (# p. 106)

— _ 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.

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE 14

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.

— Mount the main silencer. Mount and tighten screws @. Guideline [ Remaining screws, chassis I 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.

— Insert the air filter box lid into the rear area @ and clip it into the front area @.

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE 15

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)

— Hang the 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.

— 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 @.

e Info 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. À (æ p. 75) — Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.

[ Aïr filter cleaner (# p. 107)

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 (# p. 108)

— Clean the air filter box. — Check carburetor connection boot for damage and tightness. Install the air filter. À (# p. 75)

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE 76

Adjusting basic position of clutch lever

— Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw @.

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 the fluid level of hydraulic clutch

Skin irritations Brake fluid can cause skin irritation on contact.

— Avoid contact with skin and eyes, and keep out of the reach of children.

— _lfbrake 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!

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

— Remove cover @ with membrane @.

— Check the fluid level.

[ Fluid level under top level of container. | 4 mm (0.16 in) |

» _ lfthe level of the fluid does not meet specifications: — Correct the fluid level of the hydraulic clutch.

[Brake fluid DOT 4 / DOT 5.1 (# p. 106) |

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

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

Changing the hydraulic clutch fluid 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.

— _lfbrake 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!

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE T1

— Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. — Remove screws @. — Remove cover @ with membrane @.

— Fill bleeding syringe @ with the appropriate hydraulic fluid.

Bleed syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 (# p. 106)

— On the slave cylinder, remove bleeder screw @ and mount bleeding syringe @.

— _Inject the liquid into the system until it escapes from bore hole @ of the master 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.

[ Fluid level under top level of container. | 4 mm (0.16 in)

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

e Info The carburetor and its components are subject to increased wear caused by engine 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 @.

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE 78

Carburetor - adjusting idle à

Screw in the idle adjusting screw @ until it stops and then to the prescribed basic setting.

Guideline Idle mixture adjusting screw (400 EXC) Open I 0.75 turn Idle mixture adjusting screw (530 EXC, 530 EXC SIX DAYS, 450 XC-W ZA, 530 XC-W ZA) Open I 1.5 turns

Idle mixture adjusting screw (450 EXC, 450 EXC SIX DAYS, 400 XC-W USA, 450 XC-W USA)

Open I 1.75 turns Idle mixture adjusting screw (530 XC-W USA) Open I 2.0 turns

[ Adjustment tool for mixture control screw (77329034000) |

Run the engine until warm. Guideline

[ Warm-up time 25 min

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 adjusting screw @. Guideline

Choke function deactivated — The choke lever is pushed in to the stop. (EXC AUS, XC-W) (# p. 20)

Choke function deactivated — The choke lever is pushed back to the stop. (EXC EU, EXC SIX DAYS) (# p. 21)

Idle speed 1,550... 1,650 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.

(l If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps. The extreme sport motorcyclist will set the mixture about 14 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 mount 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.

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE 18

— Adjust the idle speed with adjusting screw @.

Guideline Choke function deactivated — The choke lever is pushed in to the stop. (EXC AUS, XC-W) (® p. 20)

Choke function deactivated — The choke lever is pushed back to the stop. (EXC EU, EXC SIX DAYS) (# p. 21)

Idle speed 1,550... 1,650 rpm

e Info Following extreme air temperature or altitude changes, adjust the idle speed again.

Emptying the carburetor float chamber 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 immedi- ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con- tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.

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.

Info Carry out this work with a cold engine.

— Turn handle @ of the fuel tap to the OFF position. (Figure 500137-10% p. 20) No more fuel flows from the tank to the carburetor. — Direct the hose of the float chamber into a suitable container.

e Info 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.

— _ Tighten screw @.

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. 82)

— Drain the engine oil and clean the engine oil screen. À (+ p. 80) — Remove the oil filter. À (* p. 80)

— Mount the oil filter. À (# p. 81)

— Fill up with engine oil. à (# p. 81)

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.

e Info Drain the engine 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 engine oil plug screen @.

— Completely drain the engine oil.

— Thoroughly clean the plug and gear oil screen.

— Clean the sealing area on the engine.

— Mount and tighten the plug of engine oil screen @.

Guideline Plug, engine oil screen M17x1.5 20 Nm 29011210 (14.8 Ibf ft)

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.

— 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.

— Lay the motorcycle on its side and fill the oil filter housing to about ?4 full with engine oil.

— Fillthe oil filter @ with engine oil and place it in the oil filter container. — Lubricate the O-ring @ of the oil filter cover.

— _ Refit the oil filter cover ©. — Mount and tighten screws @. Guideline [ Screw, oil filter cover M6 10 Nm (7.4 Ibf ft)

— 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 0.60 1 (0.63 qt.) | Engine oil (SAE 10W/50) (# p. 106)

— 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 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. 106)

— 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 The gear oil level must be checked when the engine is cold.

— Stand the motorcycle upright on a horizontal surface.

Condition Engine is cold.

— Remove gear oil level check screw @. Stand the vehicle upright. — Check the gear oil level.

A small amount of gear oil should flow out.

» _ |f no gear oil flows out: — Add gear oil. À (+ p. 83)

= — Mount and tighten the gear oil level check screw. Guideline [Screw, gear oil level check I M6 I 8 Nm (5.9 Ibf ft) |

— Drain the gear oil and clean the gear oil screen. À (# p. 82) — Fill up with gear oil. À (# p. 83)

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.

e Info Drain the gear oil only when the engine is warm.

— Stand the motorcycle on its side stand on a horizontal surface.

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE ES

— Place a suitable container under the engine.

— Remove the gear oil drain plug @.

— Plug - remove the gear oil screen @.

— Completely drain the gear oil.

— Thoroughly clean the gear oil drain plug with à magnet.

— Thoroughly clean the drain plug and gear oil screen with a magnet. — Clean the sealing area on the engine.

— Mount and tighten gear oil drain plug @ with the seal ring.

Guideline Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) — Mount and tighten the plug of gear oil screen @. Guideline Plug, gear oil screen M16x1.5 20 Nm (14.8 lbf ft)

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 0.90 1 (0.95 qt.) | Engine oil (SAE 10W/50) (# p. 106)

— 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. 82)

e Info Too little gear oil or poor-quality oil results in premature wear to the transmission.

— Remove gear oil level check screw @.

_____ MAINTENANCE WORK ON CHASSIS AND ENGINE #4

— Remove screw cap @. Stand the vehicle upright. — Add gear oil until it flows out of the bore of the gear oil level screw.

[ Engine oil (SAE 10W/50) (+ p. 106) |

— Mount and tighten the gear oil level check screw. Guideline [ Screw, gear oil level check M6 8 Nm (5.9 Ibf ft) |

— 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.

_____TROUBLESHOOTING

The engine cannot be cranked (electric starter).

Go through the steps of starting the engine. (* p. 26)

Starter relay defective

Check the starter relay. À

Starter motor defective

Check the starter motor. À

Engine turns but does not start.

Go through the steps of starting the engine. (* 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. À (# p. 79)

Fuel feed interrupted

Check the fuel tank breather. Clean the fuel tap.

Check/adjust the carburetor compo- nents. À

Spark plug oily or wet

Clean and dry the spark plug or replace if necessary.

Electrode distance (plug gap) of spark plug too wide

Adjust plug gap. Guideline

Spark plug electrode gap 0.9 mm (0.035 in)

Defect in ignition system

Check the ignition system. À

Short-circuit cable in cable harness frayed, short-circuit button or emergency OFF switch defective

Check the wiring harness (visual check).

Check the electrical system.

Plug connector of CDI control device, pulse generator or ignition coil oxidized.

Clean the plug connector and treat it with contact spray.

Water in carburetor or jets blocked

Check/adjust the carburetor compo- nents. À

Adjusting screws on carburetor distorted

Carburetor - adjust the idle speed. À (9 p. 78)

Spark plug defective

lgnition system defective

Check the CDI unit. À

Check the spark plug connector. À Check the ignition pulse generator. À Check the generator. À

Engine does not speed up.

Carburetor running over because float needle dirty or worn.

Check/adjust the carburetor compo- nents. À

Loose carburetor jets

lgnition system defective

Check the CDI unit. À

_____TROUBLESHOOTING

Engine has too little power.

Fuel feed interrupted

Check the fuel tank breather. Clean the fuel tap.

Check/adjust the carburetor compo- nents. À

Air filter very dirty

Clean the air filter. À (® 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. À

Valve clearance too little

Adjust the valve clearance. À

lgnition system defective

Check the ignition coil. À

Check the CDI unit. À

Engine stalls or is popping into the carbu-

Turn handle @ of the fuel tap to the ON position. (Figure 500137-10% p. 20)

Fill up with fuel. (# p. 28)

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

Thermostat defective

Check the thermostat. À

Guideline Opening temperature: 70 °C (158 °F)

Defect in radiator fan system (EXC SIX DAYS, XC-W ZA)

Check the radiator fan fuse. Check the radiator fan. À Check the thermostat. À

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. À (# p. 80)

Piston or cylinder is worn

Piston/cylinder - determine the mount- ing clearance À

The battery does not charge

Check the charging voltage. À Check the charging current. À Check the generator. À

Undesired power consumer

Check the closed current. À

Speedometer values deleted (time, stop watch, lap times)

The battery in the speedometer is 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. 107)

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. À (# p. 79)

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 I 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. 51)

— 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. 107) |

Treat all painted parts with a mild paint polish.

[ High-luster polish for paint (# p. 107) |

To prevent electrical problems, treat electric contacts and switches with contact spray.

[ Contact spray (# p. 107) |

(all EXC models) — Lubricate the steering lock.

[ Universal oil spray (# p. 108) |

à 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 immedi- ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con- tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.

I 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. 87) — Change the engine oil and oil filter and clean the engine oil screen. À (# p. 80) — Change the gear oil and clean the gear oil screen. À (# p. 82) — Check the antifreeze and coolant level. (# p. 72) — Drain the fuel from the tanks into a suitable container. — Empty the carburetor float chamber. À (# p. 79) — Check the tire air pressure. (# p. 67) — Remove the battery. À (# p. 67) — Recharge the battery. À (# p. 68) Guideline [ 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. 33)

— Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.

e Info 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. 33) — Install the battery. À (# p. 68)

— Fill up with fuel. (# p. 28)

— Checks before putting into operation (* p. 26)

1-cylinder 4-stroke engine, water-cooled

Stroke (all 400 models)

Stroke (all 450 models)

OHC, 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 5th gear 24:23 6th gear 26:21 Generator 12V,150W Ignition Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan Spark plug NGK LKAR 8AI - 9 Spark plug electrode gap 0.9 mm (0.035 in) Cooling Water cooling, permanent circulation of coolant by water pump Starting aid Electric starter / kickstarter

Capacity- engine oil

[ Engine oil I 0.60 1 (0.63 at.)

Engine oil (SAE 10W/50) (# p. 106)

____ TECHNICAL DATA - ENGINE TIGHTENING TORQUES

91 Screw, cable holder in generator cover | M4 4 Nm (3 lbf ft) Loctite® 2437M Oil jet, rocker arm lubrication M5 2 Nm (1.5 Ibf ft) Loctite® 2437M Oil jet, piston cooling M5 2 Nm (1.5 Ibf ft) Loctite® 2437M Screw, locking lever M5 6 Nm (4.4 Ibf ft) Loctite® 2437M Screw, ignition pulse generator M5 6 Nm (4.4 Ibf ft) Loctite® 2437M Locking screw for bearing M5 6 Nm (4.4 Ibf ft) Loctite® 2437M Screw, oil pump cover M5 6 Nm (4.4 Ibf ft) Loctite® 222 Oil jet, conrod lubrication M6x0.75 4 Nm (3 Ibf ft) - Bleeding connection, transmission M6 4 Nm (3 Ibf ft) Loctite® 2437M Nut, water-pump wheel M6 8 Nm (5.9 Ibf ft) Loctite® 2437M Screw, kickstarter stop M6 10 Nm (7.4 Ibf ft) Loctite® 2437M Screw, timing chain securing guide M6 8 Nm (5.9 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® 2437M 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 8 Nm (5.9 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 8 Nm (5.9 Ibf ft) _- Screw, clutch cover M6x25 10 Nm (7.4 Ibf ft) _- Screw, clutch cover M6x30 10 Nm (7.4 Ibf ft) _- Screw, clutch spring M6 10 Nm (7.4 Ibf ft) - Screw, engine housing M6x60 10 Nm (7.4 Ibf ft) - Screw, engine housing M6x75 10 Nm (7.4 Ibf ft) - Screw, camshaft bearing support M6 10 Nm (7.4 Ibf ft) Loctite® 2437M Screw, oil filter cover M6 10 Nm (7.4 Ibf ft) _- Screw, shift drum locating M6 10 Nm (7.4 Ibf ft) Loctite® 2437M Screw, shift lever M6 10 Nm (7.4 Ibf ft) Loctite® 2437M Screw, timing chain tensioning rail M6 8 Nm (5.9 Ibf ft) Loctite® 2437M Screw, stator bracket M6 10 Nm (7.4 Ibf ft) Loctite® 2437M Plug, vacuum connection M6 5 Nm (3.7 Ibf ft) Loctite® 2437M 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® 2437M Screw, cylinder head M6 10 Nm (7.4 Ibf ft) _- Screw, rocker arm bearing M7xl 15 Nm (11.1 lbfft) _- Plug, oil channel M7 9 Nm (6.6 Ibf ft) Loctite® 2437M Screw, kickstarter M8 25 Nm (18.4 lbf ft) Loctite® 2437M 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 lbf ft) Loctite® 2437M

____ TECHNICAL DATA - ENGINE TIGHTENING TORQUES Screw, cylinder head M10x1.25 Tightening sequence: lubricated with engine oil

Tighten diagonally, begin-

ning with the rear screw on

Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Suspension 4860 MXMA PA Suspension travel Front 300 mm (11.81 in) Rear 335 mm (13.19 in) Fork offset (EXC SIX DAYS, XC-W USA) 19 mm (0.75 in) Fork offset (EXC EU, EXC AUS, XC-W ZA) 20 mm (0.79 in)

WP Suspension PDS 5018 DCC Brake system

Disc brakes, brake calipers on floating bearings

Diameter of brake discs

Tire air pressure off road

Road tire pressure (all EXC models)

Final drive (530 XC-W) 14:52

Seat height unloaded

Ground clearance unloaded

Weight without fuel, approx. (all EXC models)

113.9 kg (251.1 Ib.)

Weight without fuel, approx. (XC-W USA)

112.2 kg (247.4 Ib.)

Weight without fuel, approx. (XC-W ZA)

Maximum permissible overall weight

35/35 W Parking light (EXC, EXC SIX DAYS, W2,1x9,5d 12V XC-W ZA) 5W Indicator lights (all EXC models) W2x4,6d 12V

12W Flasher light (all EXC models) BA15s 12V

10W Brake / tail light (EXC, EXC SIX DAYS, LED XC-W ZA)

Metzeler MCE 6 DAYS EXTREME Licence plate lamp (all EXC models) W2,1x9,5d 12V 5W Tires Validity Front tire Rear tire

For further information, see the Service section under:

Total fuel tank capacity, approx. (EXC, EXC SIX DAYS, XC-W ZA)

Super unleaded (ROZ 95 / RON 95 / PON 91) (# p. 106)

Total fuel tank capacity, approx. (XC-W USA)

Super unleaded (ROZ 95 / RON 95 / PON 91) (# p. 106)

Fuel reserve, approx.

Fork WP Suspension 4860 MXMA PA Compression damping

Shock absorber part number 12.18.7E.06 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed

Sport 12 clicks Compression damping, high-speed

Spoke nipple, rear wheel M5 5 Nm (3.7 Ibf ft) -

Screw, spoiler on fuel tank (XC-W USA) | M5x12 1.5 Nm (1.11 lbfft) _-

Remaining nuts, chassis M6 15 Nm (11.1 lbf ft) -

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

Screw, rear brake disc M6 14 Nm (10.3 lbf ft) _-

Screw, front brake disc M6 14 Nm (10.3 lbf ft) _-

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

Screw, ball joint of push rod on foot- M6 10 Nm (7.4 Ibf ft) _-

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

Screw, subframe M8 35 Nm (25.8 lbf ft) Loctite® 2437M Screw, side stand fixing M8 40 Nm (29.5 lbf ft) Loctite® 2437M 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 lbf ft) _-

Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite® 2437M Nut, seat fixing M12x1 20 Nm (14.8 lbf ft) _-

ye Yellow ye-bl Yellow-black ye-re Yellow-red

105 Components A6 CDI controller B1l Throttle position sensor B3 Wheel speed sensor E6 Thermoswitch (XC-W ZA) G1 Battery G2 Generator H5 Brake/tail light (XC-W ZA) H7 Parking light (XC-W ZA) Hil Low/high beam (XC-W ZA) H14 Radiator fan (XC-W ZA) KI Starter relay with main fuse L1 Pulse generator L2 lgnition coil M1 Starter motor N2 Voltage regulator/rectifier P1 Speedometer S5 Tripmaster switch (optional) S6 Light switch S9 Short circuit button S10 Electric starter button X1 lgnition curve plug connection Cable colors bl Black bl-wh Black-white br Brown bu Blue bu-wh Blue-white gn Green æg 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

— Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Castrol and Motorex® products.

Motorex® — Brake Fluid DOT 5.1

— 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

— Cross Power 4T According to - SAE(® p. 109) (SAE 5)

Guideline — Use only oils that comply with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex® products.

According to — DIN EN 228 (ROZ 95 / RON 95 / PON 91)

KTM recommends Motorex® products.

Supplier Motorex® Twin Air Dirt Bio Remover

KTM recommends Motorex® products.

Supplier Motorex® — Chain Clean 611

KTM recommends Motorex® products.

Supplier Motorex® Protect & Shine 645

KTM recommends Motorex® products.

Supplier Motorex® — Accu Contact

KTM recommends Motorex® products.

Supplier Motorex® Moto Polish

KTM recommends Motorex® products.

KTM recommends Motorex® products.

Supplier Motorex® Moto Clean 900

KTM recommends Motorex® products.

____ AUXILIARY SUBSTANCES 108

—_ KTM recommends Motorex® products. Supplier

— Twin Air Liquid Bio Power

—_ KTM recommends Motorex® products. Supplier

— Joker 440 Universal

Different technical development directions required a new specification for 4-stroke motorcycles - the JASO T903 MA Standard.Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification.Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle and ATV engines.With most motorcycles and ATVSs, the gearbox and the clutch are lubricated with the same 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.

Aïr filter cleaning installing ... removing

Air filter box lid installing . removing ...

Antifreeze checking ... ne Basic chassis setting checking with rider's weight

Battery installing ... recharging removing ...

Brake discs checking

Brake fluid front brake, adding rear brake, adding

Brake fluid level of front brake, checking of rear brake, checking

Brake linings front brake, changing front brake, checking front brake, installing of front brake, removing of rear brake, removing rear brake, changing rear brake, checking rear brake, installing .

Carburetor adjusting idle float chamber, emptying ne idle

adjusting 55 Chain tension

checking 52 Chain wear

changing fluid checking fluid level

Compression damping fork, adjusting Compression damping, high-speed of shock absorber, adjusting 33 Compression damping, low-speed shock absorber, adjusting

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

Filler cap closing opening ...

Front fender installing

Front wheel installing ... removing ...

Fuel tank installing ... removing ...

Fuse installing removing

Gas Bowden cable route checking Gear oil adding changing ... draining refilling Gear oil level checking Gear oil screen cleaning

Hand brake lever 11 basic position, adjusting .. 56 free travel, adjusting .. 57 free travel, checking .. 56

Oil filter changing fitting ... removing .

Overview of indicator lamps

OWNER'S MANUAL Play in gas Bowden cable adjusting checking

Putting into operation advice on first use after storage Checks before putting into operation

Rear sprocket / engine sprocket

checking for wear 52 Rear wheel

Rebound damping fork, adjusting of shock absorber, adjusting .

Riding sag adjusting ..

Seat mounting removing ..

Service schedule Shiftlever .... Shock absorber checking static sag . installing removing riding sag, checking Short circuit button Side stand Spare parts Speedometer adjusting function description Setting kilometers or miles . Setting the clock

Spoke tension checking

Spring preload fork, adjusting of shock absorber, adjusting .

Start number plate installing removing ..

Starting steering locking unlocking Steering head bearing greasing Steering head bearing play adjusting checking

chassis chassis tightening torques Engine engine tightening torques Fork

checking 67 Tire condition

checking 66 Transport TROUBLESHOOTING Type label

View of vehicle left front right rear

Warranty Wiring diagram Work rules