Owner`s manual | Cadillac 2011 Escalade ESV Automobile User Manual

OWNER'S MANUAL 2008
450bEXC-RbEU
450bEXC-RbAUS/UK
450bEXC-RbSIXbDAYS
450bEXC-RbUSA
450bXCR-WbUSA
450bXCR-WbZA
530bEXC-RbEU
530bEXC-RbAUS/UK
530bEXC-RbSIXbDAYS
530bEXC-RbUSA
530bXCR-WbUSA
530bXCR-WbZA
ART. NO. 3211254en
DEAR KTM CUSTOMER
1
'($5 .70 &86720(5
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you enormous pleasure if you service and maintain it accordingly.
We wish you great pleasure riding the vehicle!
Enter the serial numbers of your vehicle below.
Chassis number (
P. 8)
Engine number (
P. 8)
Key number (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA) (
Dealer's stamp
P. 8)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing
development and design of our motorcycles can however not be completely excluded.
All specifications are not binding. KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop prudction of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special
equipment that does not belong to the regular scope of delivery.
© 2007 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes
that lead to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
CONTENTS
2
&217(176
MEANS OF REPRESENTATION ............................................ 5
IMPORTANT NOTES ............................................................ 6
LOCATION OF SERIAL NUMBERS ........................................ 8
Chassis number............................................................... 8
Type label....................................................................... 8
Key number (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA) ........ 8
Engine number................................................................ 8
Fork part number............................................................. 8
Shock absorber part number............................................. 9
OPERATING ELEMENTS.................................................... 10
Clutch lever .................................................................. 10
Hand brake lever ........................................................... 10
Short circuit button (EVERY XCR-W MODELS).................. 10
Short circuit button (EXC-RbEU, EXC-RbAUS/UK,
EXC-RbSIXbDAYS) .......................................................... 10
Emergency OFF switch (EXC-RbAUS/UK).......................... 10
Emergency OFF switch (EXC-RbUSA) ............................... 11
Ignition switch (EXC-RbUSA)........................................... 11
Electric starter button (EXC-RbEU, EXC-RbSIXbDAYS,
EXC-RbUSA, XCR-W) ...................................................... 11
Electric starter button (EXC-RbAUS/UK) ........................... 11
Light switch (EXC-RbEU, EXC-RbAUS/UK,
EXC-RbSIXbDAYS) .......................................................... 11
Light switch (EVERY XCR-W MODELS) ............................ 12
Light switch (EXC-RbUSA) .............................................. 12
Headlight flasher switch (EXC-RbUSA) ............................. 12
Horn (EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS) ......... 12
Horn (EXC-RbUSA) ......................................................... 12
Flasher switch (EXC-RbEU, EXC-RbAUS/UK) ..................... 13
Flasher switch (EXC-RbUSA) ........................................... 13
Overview of indicator lamps (EXC-RbEU, EXC-RbAUS/UK,
EXC-RbUSA) .................................................................. 13
Overview of indicator lamps (EXC-RbSIXbDAYS) ................. 13
Speedometer................................................................. 13
Speedometer activation and test ..................................... 14
Tripmaster switch .......................................................... 14
Setting kilometers or miles ............................................. 14
Setting the clock ........................................................... 15
Adjusting speedometer functions .................................... 15
Querying lap time .......................................................... 16
Display mode SPEED ..................................................... 16
Display mode SPEED/H (service hours)............................ 16
Display mode SPEEDb/bCLK (time)................................... 17
Display mode SPEED/LAP (lap time) ............................... 17
Display mode SPEED/ODO (odometer) ............................. 17
Display mode SPEED/TR1 (trip masterb1) ........................ 17
Display mode SPEED/TR2 (trip master 2) ........................ 18
Disply mode SPEED/A1 (average speedb1) ....................... 18
Display mode SPEED/A2 (average speed 2)...................... 18
Display mode SPEED/S1 (stop watch 1) .......................... 19
Display mode SPEED/S2 (stop watchb2)........................... 19
Fuel tap........................................................................ 20
Opening filler cap .......................................................... 20
Closing filler cap ........................................................... 20
Choke (EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA,
XCR-W) ........................................................................ 21
Choke (EXC-RbEU) ......................................................... 21
Shift lever..................................................................... 21
Foot brake pedal ........................................................... 21
Kickstarter.................................................................... 22
Side stand .................................................................... 22
Steering lock (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA) ..... 22
Locking the steering (EXC-RbEU, EXC-RbAUS/UK,
EXC-RbUSA) ..................................................................
Unlocking the steering (EXC-RbEU, EXC-RbAUS/UK,
EXC-RbUSA) ..................................................................
GENERAL TIPS AND HINTS ON PUTTING INTO
OPERATION......................................................................
Advice on first use .........................................................
Running in the engine....................................................
RIDING INSTRUCTIONS ....................................................
Checks before putting into operation ...............................
Starting ........................................................................
Starting up ...................................................................
Shifting, riding..............................................................
Braking ........................................................................
Stopping, parking ..........................................................
Refueling......................................................................
GREASING AND SERVICE TABLE .......................................
Important maintenance work to be carried out by an
authorized KTM workshop. .............................................
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order)................
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 stand..................
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 absorber ............
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 absorberb ............
Adjusting riding sagb ..................................................
Removing the shock absorberb .....................................
Installing shock absorberb ...........................................
Checking basic setting of fork .........................................
Adjusting compression damping of fork ...........................
Adjusting rebound damping of fork..................................
Adjusting spring preload of the fork.................................
Bleeding fork legs..........................................................
Cleaning dust boots of fork legs ......................................
Loosening the fork protection..........................................
Positioning the fork protection ........................................
Checking play of steering head bearing ............................
Adjusting play of steering head bearingb (EXC-RbEU,
EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA) .........................
Adjusting play of steering head bearingb
(EXC-RbSIXbDAYS, XCR-WbUSA) ......................................
Fork offset (EXC-RbSIXbDAYS, XCR-WbUSA) ......................
Setting the fork offsetb (EXC-RbSIXbDAYS,
XCR-WbUSA) .................................................................
Removing the fork legs...................................................
Installing the fork legsb ...............................................
Removing the fork protectorb .......................................
Installing the fork protectorb ........................................
Removing the lower triple clampb (EXC-RbSIXbDAYS,
XCR-WbUSA) .................................................................
x
x
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x
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CONTENTS
3
x
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Removing the lower triple clampb (EXC-RbEU,
EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA) .........................
Installing the lower triple clampb (EXC-RbSIXbDAYS,
XCR-WbUSA) .................................................................
Installing the lower triple clampb (EXC-RbEU,
EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA) .........................
Greasing the steering head bearingb .............................
Dismounting the front fender ..........................................
Installing the front fender...............................................
Removing headlight mask with headlight (EXC-RbEU,
EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA,
XCR-WbZA)....................................................................
Refitting the headlight mask with the headlight
(EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS,
EXC-RbUSA, XCR-WbZA) .................................................
Dismount the start number plate (XCR-WbUSA) ................
Fitting the start number plate (XCR-WbUSA).....................
Handlebar position ........................................................
Adjusting handlebar positionb ......................................
Checking gas Bowden cable route ...................................
Checking play in the gas Bowden cable ...........................
Adjusting the gas Bowden cable playb ..........................
Checking chain dirt .......................................................
Cleaning the chain.........................................................
Checking the chain tension ............................................
Checking the chain tension when fitting rear wheel...........
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 guideb ...............................................
Brake fluid reservoir.......................................................
Brake calipers ...............................................................
Checking brake discs .....................................................
Checking free play of hand brake lever.............................
Adjusting basic position of handbrake lever (Every XCR-W
models) ........................................................................
Adjusting free travel of handbrake lever (Every EXC-R
models) ........................................................................
Checking the front brake fluid level .................................
Topping up the front brake fluidb .................................
Checking the front brake linings......................................
Removing front brake liningsb ......................................
Installing the front brake liningsb .................................
Changing the front brake liningsb .................................
Checking free play of foot brake lever ..............................
Adjusting basic position of footbrake leverb ...................
Checking the rear brake fluid level ..................................
Adding rear brake fluidb ..............................................
Checking rear brake linings ............................................
Removing rear brake liningsb .......................................
Installing the rear brake liningsb ..................................
Changing the rear brake liningsb ..................................
Removing front wheelb ................................................
Fitting front wheelb ....................................................
Removing rear wheelb .................................................
Fitting rear wheelb ......................................................
Tire condition checking..................................................
Checking tire air pressure...............................................
Checking spoke tension..................................................
Removing the batteryb ................................................
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Installing the batteryb .................................................
Recharging the batteryb ..............................................
Removing a fuse............................................................
Replacing the fuse.........................................................
Removing the seat .........................................................
Mounting the seat .........................................................
Dismounting the fuel tankb .........................................
Installing the fuel tankb ..............................................
Cooling system ..............................................................
Checking antifreeze and coolant level ..............................
Checking the coolant level..............................................
Draining coolantb .......................................................
Refilling coolantb .......................................................
Glass fiber yarn filling of main silencer ............................
Removing main silencer .................................................
Fitting the main silencer ................................................
Dismounting the air filter box lid.....................................
Installing the air filter box lid..........................................
Removing the air filterb ...............................................
Installing the air filterb ...............................................
Cleaning air filterb ......................................................
Adjusting basic position of clutch lever............................
Checking fluid level of hydraulic clutch ...........................
Changing fluid level of hydraulic clutchb ......................
Carburetor - idle ............................................................
Carburetor - adjusting idleb .........................................
Emptying the carburetor float chamberb .......................
Checking engine oil level................................................
Changing engine oil and oil filter, cleaning engine oil
screenb .....................................................................
Draining engine oil, cleaning engine oil screenb ............
Removing the oil filterb ...............................................
Mounting oil filterb .....................................................
Filling up with engine oilb ...........................................
Topping up engine oil ....................................................
Checking gear oil level ...................................................
Changing gear oil, cleaning gear oil screenb ..................
Draining gear oil, cleaning gear oil screenb ...................
Filling up with gear oilb ...............................................
Topping up with gear oilb ............................................
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.....................................
450bEXC-RbEU, 450bEXC-RbAUS/UK (3900I) ...................
450bEXC-RbSIXbDAYS, 450bEXC-RbUSA, 450bXCR-W
(3900L) .......................................................................
530bEXC-RbEU, 530bEXC-RbAUS/UK (3900J)...................
530bEXC-RbSIXbDAYS, 530bEXC-RbUSA, 530bXCR-W
(3900M) ......................................................................
TECHNICAL DATA - CHASSIS ............................................
Lighting equipment .......................................................
Tires ............................................................................
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CONTENTS
Capacity - fuel............................................................... 95
TECHNICAL DATA - FORK.................................................. 96
TECHNICAL DATA - SHOCK ABSORBER ............................. 97
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ........ 98
WIRING DIAGRAM .......................................................... 100
Wiring diagram (EXC-RbEU) .......................................... 100
Wiring diagram (EXC-RbAUS/UK)................................... 102
Wiring diagram (EXC-RbUSA) ........................................ 104
Wiring diagram (EXC-RbSIXbDAYS)................................. 108
Wiring diagram (XCR-WbUSA) ....................................... 110
Wiring diagram (XCR-WbZA) .......................................... 112
SUBSTANCES................................................................. 114
AUXILIARY SUBSTANCES................................................ 115
STANDARDS................................................................... 117
CONSUMER INFORMATION (EXC-R USA).......................... 118
INDEX ............................................................................ 120
4
MEANS OF REPRESENTATION
0($16 2) 5(35(6(17$7,21
Symbols used
The symbols used are explained in the following.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected 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.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained in the following.
Specific name
Identifies a specific name.
Name®
Identifies a protected name.
Brand™
Identifies a brand in merchandise traffic.
5
IMPORTANT NOTES
6
,03257$17 127(6
Use definition (Every EXC-R models)
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle is authorized for public road traffic in the homologous (reduced) version only.
In the derestricted version, the motorcycle must be used only on secluded property remote from public road traffic.
The motorcycle is designed for off-road sport endurance competition (Enduro) and not for the predominant motocross use.
Use definition (Every XCR-W models)
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle must be used only on secluded property remote from public road traffic.
The motorcycle is designed for off-road sport endurance competition (Enduro) and not for the predominant motocross use.
Maintenance
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 breakage of components.
Using the motorcycle in extreme conditions such as very muddy or wet terrain can lead to above-average wear of components such as
the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in
the greasing and service table is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will
ensure a much longer service life for your motorcycle.
Warranty
The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed
in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for
damage resulting from manipulations and alterations to the motorcycle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
Spare parts, accessories
For your own safety, use only spare parts and accessories approved by KTM. KTM accepts no liability for other products and any resulting damage or loss.
Transport
Note
Danger of damageಘDanger of damage by the vehicle running away or falling over.
ದ
Always place the vehicle on a firm and even surface.
Note
Fire hazardಘSome components (engine, radiator and exhaust system) get very hot when the engine is running.
ದ
Do not place the vehicle where there are flammable or explosive substances.
ದ
switch off engine.
ದ
Turn the handleb of the fuel tap to the OFF position. (Figureb500137-10b
ದ
Use straps or other suitable devices to secure the motorcycle against accidents or falling over.
P. 20)
IMPORTANT NOTES
7
Environment
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 potential 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.
Warning notes
In your own interest, read the specified warning notes.
Info
Various warning labels are attached to your vehicle. Do not remove any warning labels. If they are missing, you or others may
not recognize dangers and may therefore be injured.
Grades of risks
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.
OWNER'S MANUAL
ದ
Read this owner's manual carefully and completely before making your first trip. It contains a lot of information and tips to help
you operate and handle your motorcycle. Only then will you find out how to customize the motorcycle ideally for your own use and
how you can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.
ದ
The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is
sold.
LOCATION OF SERIAL NUMBERS
/2&$7,21 2) 6(5,$/ 180%(56
Chassis number
The chassis numberb is stamped on the steering head on the right.
500127-10
Type label
The type labelb is fixed to the front of the steering head.
500128-10
Key number (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA)
The key numberb is stamped on the key strap.
500125-10
Engine number
The engine numberb is stamped on the left side of the engine under the engine
sprocket.
500072-10
Fork part number
The fork part numberb is stamped on the inner side of the fork stub.
500082-10
8
LOCATION OF SERIAL NUMBERS
Shock absorber part number
The shock absorber part numberb is stamped on the top of the shock absorber above
the adjusting ring on the engine side.
500129-10
9
OPERATING ELEMENTS
10
23(5$7,1* (/(0(176
Clutch lever
The clutch leverb is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
500133-10
Hand brake lever
The hand brake leverb is located on the right side of the handlebar and operates the
front wheel brake.
400196-10
Short circuit button (EVERY XCR-W MODELS)
The short circuit buttonb is mounted on the left side of the handlebar.
Possible states
• Short circuit button b in basic position ದbIn this position, the ignition circuit is
closed, and the engine can be started.
• Short circuit buttonb pressed ದbIn this position, the ignition circuit is interrupted,
a running engine stops, and a non-running engine will not start.
500132-10
Short circuit button (EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS)
The short circuit buttonb is fitted on the left side of the handlebar.
Possible states
• Short circuit buttonb in basic position ದbIn this position, the ignition circuit is
closed, and the engine can be started.
• Short circuit button b pressed ದbIn this position, the ignition circuit is
interrupted, a running engine stops, and a non-running engine will not start.
500134-10
Emergency OFF switch (EXC-RbAUS/UK)
The emergency OFF switchb is fitted on the left side of the handlebar.
Possible states
Ignition off ದbIn this position, the ignition circuit is interrupted, a running
engine stops, and a non-running engine will not start.
Ignition on ದbIn this position, the ignition circuit is closed, and the engine can be started.
500131-10
OPERATING ELEMENTS
11
Emergency OFF switch (EXC-RbUSA)
The emergency OFF switchb is fitted on the left side of the handlebar.
Possible states
Ignition off ದbIn this position, the ignition circuit is interrupted, a running
engine stops, and a non-running engine will not start.
Ignition on ದbIn this position, the ignition circuit is closed, and the engine can be started.
500144-10
Ignition switch (EXC-RbUSA)
The ignition switchb is on the right behind the headlight mask.
Possible states
Ignition off ದbIn this position, the ignition circuit is interrupted, a running
engine stops, and a non-running engine will not start.
Ignition on ದbIn this position, the ignition circuit is closed, and the engine can be started.
500130-10
Electric starter button (EXC-RbEU, EXC-RbSIXbDAYS, EXC-RbUSA, XCR-W)
The electric starter buttonb is fitted on the right side of the handlebar.
Possible states
• Electric starter buttonb
• Electric starter buttonb
in basic position
pressed ದbIn this position, the electric starter is actuated.
400198-10
Electric starter button (EXC-RbAUS/UK)
The electric starter buttonb is fitted on the right side of the handlebar.
Possible states
• Electric starter buttonb
• Electric starter buttonb
in basic position
pressed ದbIn this position, the electric starter is actuated.
500131-11
Light switch (EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS)
The light switchb is fitted on the left side of the handlebar.
Possible states
Light off ದbLight switch is turned to the right. In this position, the light is
switched off.
Low beam on ದbLight switch is in the central position. In this position,
the low beam and tail light are switched on.
High beam on ದbLight switch is turned to the left. In this position, the
high beam and the tail light are switched on.
500134-12
OPERATING ELEMENTS
12
Light switch (EVERY XCR-W MODELS)
The light switchb is on the right of the speedometer.
Possible states
(XCR-WbZA)
• Light off ದbLight switch is pressed in up to the stop. In this position, the light
is switched off.
• Light on ದbLight switch is pulled out to the stop. In this position, the low beam
and tail light are switched on.
500146-10
(XCR-WbUSA)
• The light switch has no function when delivered. ದbIt can be used if lighting is
fitted later.
Light switch (EXC-RbUSA)
The light switchb is fitted on the left side of the handlebar.
Possible states
Low beam on ದbLight switch is turned downwards. In this position, the
low beam and tail light are switched on.
High beam on ದbLight switch is turned upwards. In this position, the high
beam and the tail light are switched on.
500142-10
Headlight flasher switch (EXC-RbUSA)
The headlight flasher switchb is fitted on the left side of the handlebar.
Possible states
• Headlight flasher switch in neutral position
• Headlight flasher switch pressed ದbIn this position, the headlight flasher (high
beam) is actuated.
500143-10
Horn (EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS)
The horn buttonb is fitted on the left side of the handlebar.
Possible states
• Horn buttonb
• Horn buttonb
in neutral position
pressed ದbThe horn is operated in this position.
500134-11
Horn (EXC-RbUSA)
The horn buttonb is fitted on the left side of the handlebar.
Possible states
• Horn buttonb
• Horn buttonb
500142-11
in neutral position
pressed ದbThe horn is operated in this position.
OPERATING ELEMENTS
13
Flasher switch (EXC-RbEU, EXC-RbAUS/UK)
The flasher switchb is fitted on the left side of the handlebar.
Possible states
Flasher light off ದbFlasher switch is in the central position.
Flasher light, left, on ದbFlasher switch turned to the left.
Flasher light, right, on ದbFlasher switch turned to the right.
500145-10
Flasher switch (EXC-RbUSA)
The flasher switchb is fitted on the left side of the handlebar.
Possible states
Flasher light off
Flasher light, left, on ದbFlasher switch pressed to the right. The flasher
switch returns automatically to the central position after use.
Flasher light, right, on ದbFlasher switch pressed to the right. The flasher
switch returns automatically to the central position after use.
To switch off the flasher light, press the flasher switch towards the switch case.
500142-12
Overview of indicator lamps (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA)
Possible states
High beam indicator lamp lights up blue ದbHigh beam is switched on.
Flasher indicator lamp flashes green ದbFlasher light is switched on.
500147-01
Overview of indicator lamps (EXC-RbSIXbDAYS)
Possible states
High beam indicator lamp lights up blue ದbHigh beam is switched on.
500160-01
Speedometer
ದ
Press the key b
to change the display mode or change to one of the setup menus.
ದ
Press the key b"+" to control different functions.
ದ
Press the key b"ತ" to control different functions.
Info
In its condition at delivery, the disply mode SPEED/H and SPEED/ODO is activated.
400312-01
OPERATING ELEMENTS
14
Speedometer activation and test
Activating the speedometer:
The speedometer is activated when one of the keys is pressed or an impulse comes
from the wheel speed sensor.
Display test
For the function test of the display, all display segments light up briefly.
400313-01
WS (wheel size)
After the function test of the display, the wheel size WS is displayed.
Info
2205 mm corresponds to the size of the 21" front wheel with a series production tire.
The display then changes to the last selected mode.
400314-01
Tripmaster switch
(Option: Tripmaster switch)
You can use the trip master switch to control the functions of the speedometer from the handlebar.
Info
The trip master is an optional accessory.
Setting kilometers or miles
Info
If you change the unit, the ODO value is retained and converted accordingly.
The values TR1, TR2, A1, A2 and S1 are deleted at the changeover.
Condition
The motorcycle is standing.
ದ
Press the buttonb
display.
briefly and repeatedly until H appears at the bottom right of the
ದ
Press the buttonb
for 3 - 5 seconds.
The Setup menu opens and the active functions are displayed.
ದ
Press the button b
repeatedly until the Km/h / Mphdisplay flashes.
Setting Km/h
ದ Press the buttonb"+".
400329-01
Setting Mph
ದ Press the buttonb"ತ".
ದ
Press the buttonb
for 3 - 5 seconds.
The settings are saved and the Setup menu closed.
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.
OPERATING ELEMENTS
15
Setting the clock
Condition
The motorcycle is standing.
ದ
Press the button b
the display.
ದ
Press the buttonb
ದ
Set the hour display with the buttonb"+" and/or buttonb"ತ".
ದ
Press the buttonb
briefly and repeatedly until CLK appears at the bottom right of
for 3 - 5 seconds.
The hour display flashes.
briefly.
The next segment of the display flashes and can be set.
400330-01
ದ
You can set the following segments in the same way as the hours by pressing the
buttonb"+" and the buttonb"ತ".
Info
The seconds can only be set to zero.
ದ
Press the buttonb
for 3 - 5 seconds.
The settings are saved and the Setup menu closed.
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.
Adjusting speedometer functions
Info
In the condition at delivery, only the SPEEDb/bH display mode and SPEEDb/bODO are active.
Condition
The motorcycle is standing.
ದ
Press the buttonb
display.
briefly and repeatedly until H appears at the bottom right of the
ದ
Press the buttonb
for 3 - 5 seconds.
ದ
Switch to the function you require by briefly pressing the buttonb .
The Setup menu opens and the active functions are displayed.
The selected function flashes.
Activating a function
ದ Press the buttonb"+".
400318-01
The icon remains in the display and the display changes to the next function.
Deactivating a function
ದ Press the buttonb"ತ".
The icon disappears from the display and the display changes to the next
function.
ದ
Activate or deactivate all functions accordingly.
ದ
Press the buttonb
for 3 - 5 seconds.
The settings are saved and the Setup menu closed.
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.
OPERATING ELEMENTS
16
Querying lap time
Info
This function can be called only if lap times are measured.
Condition
The motorcycle is standing.
ದ
Press the buttonb
the display.
briefly and repeatedly until LAP appears at the bottom right of
ದ
Press the buttonb
briefly.
The LAPb1 is displayed on the left of the display.
ದ
Laps 1-10 can be displayed by pressing the buttonb"+".
ದ
buttonb"ತ" no function
ದ
Press the buttonb
briefly.
next display mode
400321-01
Info
If an impulse is received from the wheel speed sensor, the left side of the
display changes back to SPEED mode.
Display mode SPEED
ದ
Press the buttonb
display.
briefly and repeatedly until SPEED appears on the left of the
In the SPEED display mode, the current speed is displayed.
The current speed can be displayed in Km/h or in Mph.
Info
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.
400317-02
Display mode SPEED/H (service hours)
Condition
The motorcycle is standing
ದ
Press the buttonb
display.
briefly and repeatedly until H appears at the bottom right of the
In display mode H, the service hours of the engine are displayed.
The service hour counter stores the total traveling time.
Info
400316-01
The service hour counter is necessary for ensuring that maintenance work is carried out at the right intervals.
If the speedometer is in H display mode at the start of the journey, it automatically changes to the ODO display mode.
The H display mode is suppressed during the journey.
Press the buttonb"+".
Press the buttonb"ತ".
Press the buttonb
for 3 - 5 seconds.
Press the buttonb
briefly.
No function
No function
The display changes to the Setup menu of the speedometer
functions.
Next display mode
OPERATING ELEMENTS
17
Display mode SPEEDb/bCLK (time)
ದ
Press the button b
the display.
briefly and repeatedly until CLK appears at the bottom right of
The time is displayed in CLK display mode.
400319-01
Press the buttonb"+".
Press the buttonb"ತ".
Press the buttonb
for 3 - 5 seconds.
Press the buttonb
briefly.
no function
no function
The display changes to the Setup menu of the clock.
next display mode
Display mode SPEED/LAP (lap time)
ದ
Press the buttonb
the display.
briefly and repeatedly until LAP appears at the bottom right of
In the LAP display mode, up to 10 lap times can be timed with the stop watch.
Info
If the lap time continues after you press the buttonb"ತ", 9 memory locations are
already occupied.
Lap 10 must be timed with the buttonb"+".
400320-01
Press the buttonb"+". Starts or stops the clock.
Press the buttonb"ತ". Stops the current lap time and saves it, and the stop watch
starts the next lap.
Press the buttonb
The stop watch and the lap time are reset.
for 3 - 5 seconds.
Press the buttonb
Next display mode
briefly.
Display mode SPEED/ODO (odometer)
ದ
Press the buttonb
the display.
briefly and repeatedly until ODO appears at the bottom right of
In ODO display mode, the total number of kilometers ridden is displayed.
400317-01
Press the buttonb"+".
Press the buttonb"ತ".
Press the buttonb
for 3 - 5 seconds.
Press the buttonb
briefly.
No function
No function
ದ
Next display mode
Display mode SPEED/TR1 (trip masterb1)
ದ
Press the buttonb
display.
briefly and repeatedly until TR1 appears at the top right of the
TR1 (trip masterb1) runs constantly and counts up to 999.9.
It can be used to measure the distance covered during trips or between two refueling
stops.
TR1 is coupled with A1 (average speed 1) and S1 (stop watch 1).
Info
400323-01
If 999.9 is exceeded, the values of TR1, A1 and S1 are automaticallt reset to
0.0.
Press the buttonb"+".
Press the buttonb"ತ".
Press the buttonb
for 3 - 5 seconds.
Press the buttonb
briefly.
No function
No function
Displays of TR1, A1 and S1 are reset to 0,0.
Next display mode
OPERATING ELEMENTS
18
Display mode SPEED/TR2 (trip master 2)
ದ
Press the buttonb
display.
briefly and repeatedly until TR2 appears at the top right of the
TR2 (trip masterb2) runs constantly and counts up to 999.9.
The displayed value can be set manually with the button b"+" and the buttonb"ತ". A very
practical function for rides by the road book.
Info
The TR2 value can also be corrected manually during the journey with the buttonb"+" and the buttonb"ತ".
If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0.
400324-01
Press the buttonb"+".
Press the buttonb"ತ".
Press the buttonb
for 3 - 5 seconds.
Press the buttonb
briefly.
Increases value of TR2.
Reduces value of TR2.
Deletes value of TR2.
Next display mode
Disply mode SPEED/A1 (average speedb1)
ದ
Press the buttonb
display.
briefly and repeatedly until A1 appears at the top right of the
A1 (average speed 1) shows the average speed calculated using TR1 (trip master 1) and
S1 (stop watch 1).
The calculation of this value is activated by the first impulse of the wheel sensor and
ends 3 seconds after the last impulse.
400325-01
Press the buttonb"+".
Press the buttonb"ತ".
Press the buttonb
for 3 - 5 seconds.
Press the buttonb
briefly.
No function
No function
Displays of TR1, A1 and S1 are reset to 0,0.
Next display mode
Display mode SPEED/A2 (average speed 2)
ದ
Press the buttonb
display.
briefly and repeatedly until A2 appears at the top right of the
A2 (average speed 2) shows the average speed on the basis of the current speed if the
stop watch S2 (stop watchb2) is running.
Info
The displayed value can differ from the actual average speed if S2 was not
timed after the ride.
400326-01
Press the buttonb"+".
Press the buttonb"ತ".
Press the buttonb
for 3 - 5 seconds.
Press the buttonb
briefly.
No function
No function
ದ
Next display mode
OPERATING ELEMENTS
19
Display mode SPEED/S1 (stop watch 1)
ದ
Press the buttonb
display.
briefly and repeatedly until S1 appears at the top right of the
S1 (stop watch 1) displays the journey time on the basis of TR1 and continues when an
impulse is received from the wheel sensor.
The calculation of this value starts with the first impulse of the wheel sensor and ends
3 seconds after the last impulse.
400327-01
Press the buttonb"+".
Press the buttonb"ತ".
Press the buttonb
for 3 - 5 seconds.
Press the buttonb
briefly.
No function
No function
Displays of TR1, A1 and S1 are reset to 0,0.
Next display mode
Display mode SPEED/S2 (stop watchb2)
ದ
Press the buttonb
display.
briefly and repeatedly until S2 appears at the top right of the
S2 (stop watch 2) is a manual stop watch.
If S2 is running in the background, the S2 display flashes in the speedometer display.
400328-01
Press the buttonb"+".
Press the buttonb"ತ".
Press the buttonb
for 3 - 5 seconds.
Press the buttonb
briefly.
Starts or stops S2.
No function
Displays of S2 and A2 are reset to 0.0.
Next display mode
Overview of speedomer functions
Display
Press the buttonb"+".
Press the buttonb"ತ".
Press the buttonb
5 seconds.
for 3 -
Press the buttonb
briefly.
Display mode SPEED/H
(service hours)
No function
No function
The display changes to
the Setup menu of the
speedometer functions.
Next display mode
Display mode
SPEEDb/bCLK (time)
no function
no function
The display changes to
the Setup menu of the
clock.
next display mode
Display mode SPEED/LAP
(lap time)
Starts or stops the
clock.
Stops the current lap
time and saves it, and
the stop watch starts
the next lap.
The stop watch and the
lap time are reset.
Next display mode
Display mode
SPEED/ODO (odometer)
No function
No function
ದ
Next display mode
Display mode SPEED/TR1
(trip masterb1)
No function
No function
Displays of TR1, A1 and
S1 are reset to 0,0.
Next display mode
Display mode SPEED/TR2
(trip master 2)
Increases value of TR2.
Reduces value of TR2.
Deletes value of TR2.
Next display mode
Disply mode SPEED/A1
(average speedb1)
No function
No function
Displays of TR1, A1 and
S1 are reset to 0,0.
Next display mode
Display mode SPEED/A2
(average speed 2)
No function
No function
ದ
Next display mode
Display mode SPEED/S1
(stop watch 1)
No function
No function
Displays of TR1, A1 and
S1 are reset to 0,0.
Next display mode
Display mode SPEED/S2
(stop watchb2)
Starts or stops S2.
No function
Displays of S2 and A2
are reset to 0.0.
Next display mode
Overview of conditions and ability to be enabled
Display
The motorcycle is
standing
Menu can be enabled
Display mode SPEED
Display mode SPEED/H (service hours)
Display mode SPEEDb/bCLK (time)
•
•
OPERATING ELEMENTS
20
Overview of conditions and ability to be enabled
Display
The motorcycle is
standing
Menu can be enabled
Display mode SPEED/LAP (lap time)
•
Display mode SPEED/ODO (odometer)
Display mode SPEED/TR1 (trip masterb1)
•
Display mode SPEED/TR2 (trip master 2)
•
Disply mode SPEED/A1 (average speedb1)
•
Display mode SPEED/A2 (average speed 2)
•
Display mode SPEED/S1 (stop watch 1)
•
Display mode SPEED/S2 (stop watchb2)
•
Fuel tap
The fuel tap is on the left of the fuel tank.
With the tap handleb on the fuel tap, you can open or close the supply of fuel to the
carburetor.
Possible states
• Fuel supply closed OFF ದbNo fuel can flow from the tank to the carburetor.
• Fuel supply open ON ದbFuel can flow from the tank to the carburetor. The fuel tank
empties down to the reserve.
• Reserve fuel supply open RES ದbFuel can flow from the tank to the carburetor. The
fuel tank empties completely.
500137-10
Opening filler cap
ದ
Press release buttonb, turn filler cap counterclockwise and lift it free.
ದ
Replace the filler cap and turn clockwise until the release buttonb locks in place.
400199-10
Closing filler cap
Info
Run the fuel tank breather hoseb without kinks.
400199-11
OPERATING ELEMENTS
21
Choke (EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA, XCR-W)
The chokeb 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.
Info
If the engine is warm, the choke function must be deactivated.
500135-10
Possible states
• Choke function activated ದbThe choke lever is pulled out to the stop.
• Choke function deactivated ದbThe choke lever is pushed in to the stop.
Choke (EXC-RbEU)
The flasher switchb 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.
Info
If the engine is warm, the choke function must be deactivated.
500136-10
Possible states
• Choke function activated ದbThe choke lever is pulled to the stop.
• Choke function deactivated ದbThe choke lever is pushed back to the stop.
Shift lever
The shift leverb is mounted on the left side of the engine.
500138-10
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
500138-11
Foot brake pedal
The foot brake pedalb is located in front of the right footrest and operates the rear
wheel brake.
500139-10
OPERATING ELEMENTS
22
Kickstarter
The kickstarterb 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.
Info
Before riding, swing the upper part of the kickstarter inwards towards the engine.
500148-10
Side stand
Note
Danger of damageಘDanger of damage by the vehicle running away or falling over.
ದ
Always place the vehicle on a firm and even surface.
Note
Material damageಘDamage and destruction of components by excessive load.
ದ
500140-10
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 standb with your foot to the ground and lean
the motorcycle on it.
When you are riding, the side standb must be folded up and secured with the rubber
bandb.
500141-10
Steering lock (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA)
The steering lockb is fitted on the left of the steering head.
The steering lock is used to lock the steering. Steering, and therefore riding, is no
longer possible.
500126-10
Locking the steering (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA)
Note
Danger of damageಘDanger of damage by the vehicle running away or falling over.
ದ
Always place the vehicle on a firm and even surface.
ದ
Park the motorcycle.
ದ
Turn the handlebar as far as possible to the right.
OPERATING ELEMENTS
ದ
Insert the key in the steering lock, turn it to the left, press it in and turn it to the right. Remove the key.
Steering is no longer possible.
Info
Never leave the key in the steering lock.
Unlocking the steering (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA)
ದ
Insert the key in the steering lock, turn it to the left, pull it out and turn it to the right. Remove the key.
You can now steer the bike again.
Info
Never leave the key in the steering lock.
23
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION
24
*(1(5$/ 7,36 $1' +,176 21 3877,1* ,172 23(5$7,21
Advice on first use
Danger
Danger of accidentsಘDanger from inadequate traffic experience.
ದ
Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs.
Warning
Risk of injuryಘRisk of injury by missing/inadequate protective clothing.
ದ
Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle.
Warning
Danger of crashingಘImpairment of riding behavior due to different tire tread patterns on front and rear wheels.
ದ
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 accidentsಘCritical riding behavior due to inappropriate riding.
ದ
Adapt your riding speed to the road conditoins and your riding ability.
Warning
Danger of accidentsಘAccident risk caused by presence of a passenger.
ದ
Your vehicle is not designed to carry passengers. Do not ride with a passenger.
Warning
Danger of accidentsಘBrake system failure.
ದ
If the 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 accidentsಘUnstable riding behavior.
ದ
Do not exceed the maximum permitted weight and axle loads.
Warning
Risk of misappropriationಘUsage by unauthorized persons.
ದ
Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.
Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.
ದ
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.
ದ
Before your first trip, read the entire operating instructions carefully.
ದ
Get to know the operating elements.
ದ
adjust the basic position of clutch lever. (
P. 75)
(Every XCR-W models)
ದ adjust the basic position of handbrake lever. (
(Every EXC-R models)
ದ Adjust the free travel of the handbrake lever. (
P. 56)
P. 56)
ದ
Adjust the basic position of the footbrake lever. (
ದ
Get used to handling the motorcycle on a suitable piece of land before making a longer trip.
P. 60)
Info
Offroad, you should be accompanied by another person on another machine so that you can help each other.
ದ
Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.
ದ
Do not make any offroad trips that over-stress your ability and experience.
ದ
Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
ದ
Do not make any changes to the motorcycle, and use only KTM approved parts.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION
ದ
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 distribution between the front and rear wheels.
Info
Motorcycles react sensitively to any changes of weight distribution.
ದ
Do not exceed the overall maximum permitted weight and the axle loads.
Specification
ದ
Maximum permissible overall weight
335bkg (739blb.)
Maximum permissible front axle load
145bkg (320blb.)
Maximum permissible rear axle load
190bkg (419blb.)
Run the engine in.
Running in the engine
ದ
During the running-in phase, do not exceed the specified engine speed and engine performance.
Specification
Maximum engine speed
During the first 3 service hours
7000brpm
Maximum engine performance during the running-in period
ದ
25
During the first 3 service hours
ืb50b%
During the next 12 service hours
ืb75b%
Avoid fully opening the throttle!
RIDING INSTRUCTIONS
26
5,',1* ,16758&7,216
Checks before putting into operation
Info
Make sure that the motorcycle is in a perfect technical condition before use.
Info
In the interests of riding safety, make a habit of making a general check before you ride.
ದ
Check the engine oil level. (
ದ
Check the chain tension. (
ದ
Check the chain dirt accumulation. (
ದ
Check the tire condition. (
ದ
Checking the tire air pressure. (
ದ
Check the front brake fluid level. (
ದ
Check the rear brake fluid level. (
ದ
Check the front brake linings. (
ದ
Check the rear brake linings. (
ದ
Check brake system function.
ದ
Check the coolant level. (
ದ
Check that all operating elements are correctly adjusted and free to move.
ದ
Check the functioning of the electrical equipment.
P. 79)
P. 51)
P. 50)
P. 66)
P. 66)
P. 56)
P. 60)
P. 57)
P. 61)
P. 72)
Starting
Danger
Danger of poisoningಘExhaust gases are poisonous and can result in unconsciousness and/or death.
ದ
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 failureಘHigh engine speeds in cold engines have a negative effect on the service life of the engine.
ದ
Always warm up the engine at low engine speeds.
Info
If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel
evaporate after a long time of standing.
If the float chamber is filled with fresh fuel, the engine starts immediately.
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds until trying again.
Conditions
Motorcycle standing still: ุb1bweek
ದ
ದ
Empty the carburetor float chamber. (
P. 78)
Turn the handleb of the fuel tap to the ON position. (Figureb500137-10b
Fuel can flow from the tank to the carburetor.
ದ
Remove the motorcycle from the stand.
ದ
Shift gear to neutral.
(EXC-RbUSA)
ದ Turn the key in the ignition switch to the positionb .
ದ
Turn the emergency OFF switch to the positionb .
(EXC-RbAUS/UK)
ದ Turn the emergency OFF switch to the positionb .
Conditions
Engine cold
(EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA, XCR-W)
ದ Pull choke lever out as far as possible.
(EXC-RbEU)
ದ Pull the choke lever to the stop.
P. 20)
RIDING INSTRUCTIONS
ದ
27
Press the electric starter button or press the kickstarter robustly through its full range.
Info
Don't open the throttle.
Conditions
Engine hot and running
ದ
Push back the hot start lever to the stop with the engine running.
Starting up
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.
ದ
Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.
Shifting, riding
Warning
Danger of accidentsಘIf you change down at high engine speed, the rear wheel can lock up.
ದ
Do not change into a low gear at high engine speed. The engine races and the rear wheel can block.
Info
If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.
First gear is used for starting off or for steep inclines.
ದ
When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.
ದ
If the choke function was activated, deactivate it after the engine has warmed up.
ದ
When you reach maximum speed after fully opening the throttle, turn back the throttle to about 3/4 of its range; the speed hardly
drops, but the fuel consumption falls considerably.
ದ
Always open the throttle only as much as the engine can handle ದ abrupt throttle opening increases fuel consumption.
ದ
To shift down, brake if necessary and close the throttle at the same time.
ದ
Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again.
ದ
Switch off the engine if you expect to be standing for a long time.
Specification
ุb2bmin
ದ
Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and the cooling system.
ದ
Ride with a lower engine speed instead of with a high engine speed and a slipping clutch.
Braking
Warning
Danger of accidentsಘIf you brake too hard, the wheels can lock.
ದ
Adapt your braking to the traffic situation and the road conditions.
Warning
Danger of accidentsಘReduced braking caused by spongy pressure point of front or rear brake.
ದ
Have the brake system checked in an authorized KTM workshop, and do not ride any further.
Warning
Danger of accidentsಘReduced braking due to wet or dirty brakes.
ದ
Clean or dry dirty or wet brakes by riding and braking gently.
ದ
On sandy, wet or slippery surfaces, use the rear brake.
ದ
Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
ದ
On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine.
In this way, you have to brake far less and the brakes do not overheat.
RIDING INSTRUCTIONS
28
Stopping, parking
Warning
Danger of burnsಘSome vehicle components get very hot when the machine is driven.
ದ
Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these components to cool down before starting work on them.
Note
Danger of damageಘDanger of damage by the vehicle running away or falling over.
ದ
Always place the vehicle on a firm and even surface.
Note
Fire hazardಘSome components (engine, radiator and exhaust system) get very hot when the engine is running.
ದ
Do not place the vehicle where there are flammable or explosive substances.
ದ
Brake the motorcycle.
ದ
Shift gear to neutral.
(Every XCR-W models)
ದ Press the short circuit buttonb
at engine idling speed until the engine stops.
(EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS)
ದ Press the short circuit buttonb at engine idling speed until the engine stops.
(EXC-RbUSA)
ದ Push the emergency off switch at engine indling speed to the positionb .
ದ
Turn the handleb of the fuel tap to the OFF position. (Figureb500137-10b
ದ
Stand the motorcycle on a hard surface.
P. 20)
Refueling
Danger
Fire hazardಘFuel can easily catch fire.
ದ
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.
ದ
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 poisoningಘFuel is poisonous and a health hazard.
ದ
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately 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 hazardಘImproper handling of fuel is a danger to the environment.
ದ
Do not allow fuel to get into the ground water, the ground, or the sewage system.
ದ
Open the filler cap. (
ದ
Fill the fuel tank with fuel up to measurementb.
P. 20)
Specification
Measurement ofb
A
400382-10
ದ
35bmm (1.38bin)
Tank capacity
(EXC-RbEU, EXCRbAUS/UK, EXCRbSIXbDAYS, XCRWbZA)
9bl (2.4bUSbgal)
Super unleaded (ROZ 95 / RON 95 /
PON 91) ( P. 114)
Tank capacity
(EXC-RbUSA, XCRWbUSA)
9.2bl
(2.43bUSbgal)
Super unleaded (ROZ 95 / RON 95 /
PON 91) ( P. 114)
Close the filler cap. (
P. 20)
GREASING AND SERVICE TABLE
29
*5($6,1* $1' 6(59,&( 7$%/(
Important maintenance work to be carried out by an authorized KTM workshop.
Engine
Change the engine oil and oil filter and clean the engine oil screen. (
Change the gear oil and clean the gear oil screen. (
P. 79)
P. 82)
S3N
S15A
S30A
•
•
•
•
•
•
Replace spark plug.
Carburetor
Attachments
•
Check and adjust valve clearance.
•
•
•
Check engine mounting screws for tightness.
•
•
•
Clean spark plug connectors and check for tightness.
•
•
•
Check that the screws in the shift lever and the kickstarter are tight.
•
Check carburetor connection boots for cracks and leakage.
•
•
•
Check idle.
•
•
•
Check the cooling system for leakage.
•
•
•
•
•
•
•
•
P. 71)
Check the exhaust system for leakage and looseness.
Check Bowden cables for damage, smooth operation and routing without sharp
bends.
•
•
•
Check the fluid level of the hydraulic clutch. (
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Clean the air filter. (
P. 75)
P. 75)
Check cables for damage and routing without sharp bends.
Check that the electrical equipment is functioning properly.
•
Check the headlamp setting.
Check the front brake linings. (
Check the rear brake linings. (
Check the brake discs. (
P. 57)
P. 61)
P. 55)
Check the front brake fluid level. (
P. 56)
Check the rear brake fluid level. (
P. 60)
Check brake lines for damage and leakage.
Check the free play of the hand brake lever. (
Check the free play of the foot brake lever. (
Chassis
P. 55)
P. 59)
Check brake system function.
•
•
•
Check screws and guide bolts of brake system for tightness.
•
•
•
Check shock absorber and fork for leakage and functioning.
•
•
•
•
•
•
•
Clean dust boots of fork legs. (
Bleed fork legs. (
P. 39)
P. 38)
Check swingarm bearing.
•
•
•
•
•
Check all screws to see if they are tight.
•
•
•
Check the spoke tension. (
•
•
•
•
•
•
•
•
•
•
•
•
Check play of steering head bearing. (
Wheels
•
•
Check vent hoses for damage and routing without sharp bends.
Check the antifreeze and coolant level. (
Brakes
•
•
P. 39)
P. 67)
Check rim run-out.
Check the tire condition. (
P. 66)
Checking the tire air pressure. (
Check the chain wear. (
P. 52)
Check the chain tension. (
Clean the chain. (
P. 66)
P. 51)
P. 50)
•
•
•
•
•
•
•
•
•
Check wheel bearing for play.
•
•
•
Clean and grease adjusting screws of chain adjuster.
•
•
•
S3N: After 3 service hours
S15A: Every 15 service hours / after every race
S30A: Every 30 service hours
GREASING AND SERVICE TABLE
30
Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)
Competition use
S15A
S30A
Hobby use
S45A
S30A
S60A
J1A
J2A
•
•
S90A
Carry out a complete fork service.
Carry out a complete shock absorber service.
Grease the steering head bearing. (
•
P. 46)
•
•
•
•
Treat electric contacts with contact spray.
•
•
Change hydraulic clutch fluid. (
•
•
Change the front brake fluid.
•
•
Change the rear brake fluid.
•
•
Clean spark arrestor. (EXC-RbUSA, XCR-WbUSA)
•
•
Clean and adjust carburetor.
P. 76)
Check wear of clutch discs.
•
Check the clutch.
•
•
•
•
•
•
•
Check/measure the cylinder.
•
•
Change the piston.
•
•
Check the camshaft.
•
•
Change the camshaft bearing.
•
•
Check the lower valve spring retainer.
•
•
Check the cylinder head.
•
•
Check the valves.
•
•
Check the valve springs.
•
•
Check the radial clearance of the rocker arm rollers.
•
•
Check the timing chain tensioner function.
•
•
Check the balancer shaft.
•
•
Check the crankshaft run-out on the bearing pin.
•
•
Change conrod bearing.
•
•
Change the crankshaft main bearing.
•
•
Check the transmission.
•
•
Check the shift mechanism.
•
•
Check the spring length of the oil pressure regulator
valve.
•
•
Change glass fiber yarn filling of main silencer.
•
•
Replace foot brake cylinder seals.
•
•
Check the carburetor components.
•
•
S15A: Every 15 service hours / after every race
S30A: Every 30 service hours
S45A: Every 45 service hours
S60A: Every 60 service hours
S90A: Every 90 service hours
J1A: annually
J2A: every 2 years
Important checks and maintenance work to be carried out by the rider.
NB1A
Check the engine oil level. (
P. 79)
Check the front brake fluid level. (
Check the rear brake fluid level. (
Check the front brake linings. (
Check the rear brake linings. (
•
P. 56)
P. 60)
P. 57)
P. 61)
Check and adjust Bowden cables.
Bleed fork legs. (
•
•
•
•
P. 38)
Clean dust boots of fork legs. (
•
•
P. 39)
•
GREASING AND SERVICE TABLE
31
NB1A
Clean the chain. (
P. 50)
Check the chain tension. (
Check the chain wear. (
•
P. 51)
•
P. 52)
•
Check the rear sprocket / engine sprocket for wear. (
Clean the air filter. (
P. 52)
P. 75)
Checking the tire air pressure. (
Check the tire condition. (
Check the coolant level. (
•
•
P. 66)
P. 66)
•
P. 72)
Empty the carburetor float chamber. (
•
•
P. 78)
•
Check that all operating elements for smooth operation.
•
Check braking.
•
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
32
0$,17(1$1&( :25. 21 &+$66,6 $1' (1*,1(
Jacking up the motorcycle
Note
Danger of damageಘDanger of damage by the vehicle running away or falling over.
ದ
ದ
Always place the vehicle on a firm and even surface.
Jack up the motorcycle underneath the engine. The wheels must no longer touch
the ground.
Work stand (54829055000)
500074-01
ದ
Secure the motorcycle against falling over.
Removing the motorcycle from the work stand
Note
Danger of damageಘDanger of damage by the vehicle running away or falling over.
ದ
Always place the vehicle on a firm and even surface.
ದ
Remove the motorcycle from the work stand.
ದ
Remove the work stand.
Checking the basic chassis setting with the rider's weight
Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
ದ
For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swing arm and frame, the basic settings of the suspension components must match your body weight.
ದ
As delivered, KTM offroad motorcycles are adjusted for a standard rider weight (with full protective clothing).
Specification
Standard rider weight
75… 85bkg (165… 187blb.)
ದ
If your weight is above or below the standard range, you have to adjust the basic setting of the suspension components accordingly.
ದ
Small weight differences can be compensated by adjusting the spring preload, but in the case of large weight differences, the
springs must be replaced.
Compression damping of shock absorber
The shock absorber can regulate compression damping in low- and high-speed range separately (Dual Compression Control).
The term low and high speed refers to the movement of the shock absorber during compression and not the riding speed of the motorcycle.
The low- and high-speed technology works non-specifically.
Adjusting high-speed compression damping of the shock absorber
Danger
Danger of accidentsಘThe shock absorber is under high pressure.
ದ
The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any maintenance on it yourself.
Info
The high-speed setting can be seen during the fast compression of the shock absorber.
MAINTENANCE WORK ON CHASSIS AND ENGINE
ದ
33
Turn the adjusting screwb clockwise with a ring wrench until it stops.
Info
Do not loosen nutb!
ದ
Turn back counterclockwise the number of turns corresponding to the shock absorber type.
Specification
Compression damping, high-speed
400208-10
Comfort
2bturns
Standard
1.5bturns
Sport
1bturn
Info
Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
Adjusting the low-speed compression damping of the shock absorber
Danger
Danger of accidentsಘThe shock absorber is under high pressure.
ದ
The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any maintenance on it yourself.
Info
The low-speed setting can be seen during the slow to normal compression of the shock absorber.
ದ
Turn the adjusting screwb clockwise with a screwdriver until it stops.
Info
Do not loosen nutb!
ದ
Turn back counterclockwise the number of clicks corresponding to the shock absorber type.
Specification
Compression damping, low-speed
400209-10
Comfort
18bclicks
Standard
15bclicks
Sport
12bclicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
Adjusting rebound damping of the shock absorber
Danger
Danger of accidentsಘThe shock absorber is under high pressure.
ದ
The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any maintenance on it yourself.
MAINTENANCE WORK ON CHASSIS AND ENGINE
ದ
34
Turn the adjusting screwb clockwise until it stops.
Info
Do not loosen nutb!
ದ
Turn back counterclockwise the number of clicks corresponding to the shock absorber type.
Specification
Rebound damping
400210-10
Comfort
24bclicks
Standard
22bclicks
Sport
20bclicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
Measuring rear wheel sag unloaded
A
0
ದ
Jack up the motorcycle. (
ದ
Measure the distance ದ as vertical as possible ದ between the rear axle and a fixed
point, for example, a mark on the side cover.
ದ
Make a note of the value as measurementb.
ದ
Remove the motorcycle from the work stand. (
P. 32)
ದ
Measure distanceb of rear wheel unloaded. (
P. 34)
ದ
Ask someone to help you by holding the motorcycle upright.
ದ
Measure the distance between the rear axle and the fixed point again.
ದ
Make a note of the value as measurementb.
P. 32)
400220-10
Checking static sag of the shock absorber
A
0
Info
The static sag is the difference between measurementsb andb.
ದ
Check the static sag.
Static sag
»
If the static sag is less or more than the specified value:
ದ
B
0
400221-10
35bmm (1.38bin)
Adjust the spring preload of the shock absorber. (
P. 35)
MAINTENANCE WORK ON CHASSIS AND ENGINE
35
Checking the riding sag of the shock absorber
A
0
ದ
Measure distanceb of rear wheel unloaded. (
ದ
With another person holding the motorcycle, sit on the saddle with full protective
clothing in a normal sitting position (feet on footrests) and bounce up and down a
few times until the rear suspension levels out.
ದ
The other person now has to measure the distance between the rear axle and a
fixed point.
ದ
Make a note of the value as measurementb.
P. 34)
Info
The riding sag is the difference between measurementsb andb.
ದ
Check the riding sag.
Riding sag
»
C
105bmm (4.13bin)
If the riding sag differs from the specified measurement:
ದ
Adjust the riding sag. (
P. 36)
400222-10
Adjusting spring preload of the shock absorberb
x
Danger
Danger of accidentsಘThe shock absorber is under high pressure.
ದ
The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any maintenance on it yourself.
Info
Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
2
1
ದ
Remove shock absorber. (
ದ
After removing the shock absorber, clean it thoroughly.
P. 36)
ದ
Loosen screwb.
ದ
Turn adjusting ringb until the spring is no longer under tension.
Combination wrench (50329080000)
Hook wrench (T106S)
A
ದ
ದ
Measure the overall spring length when not under tension.
Tighten the spring by turning adjusting ringb to measurementb.
Specification
Spring preload
Standard
9bmm
Info
Depending on the static sag and/or the riding sag, it may be necessary to
increase or decrease the spring preload.
ದ
Tighten screwb.
Specification
Screw, shock absorber adjusting ring
400216-10
ದ
Installing shock absorber. (
P. 36)
M6
5bNm (3.7blbfbft)
MAINTENANCE WORK ON CHASSIS AND ENGINE
Adjusting riding sagb
36
x
ದ
Remove shock absorber. (
ದ
After removing the shock absorber, clean it thoroughly.
ದ
Choose and fit a suitable spring.
P. 36)
Specification
Spring rate
Weight of rider: 65… 75bkg (143… 165blb.)
69bN/mm (394blb/in)
Weight of rider: 75… 85bkg (165… 187blb.)
72bN/mm (411blb/in)
Weight of rider: 85… 95bkg (187… 209blb.)
76bN/mm (434blb/in)
Info
The spring rate is shown on the outside of the spring.
Smaller weight differences can be compensated by changing the spring preload.
ದ
Installing shock absorber. (
ದ
Check the static sag of the shock absorber. (
P. 34)
ದ
Check the riding sag of the shock absorber. (
P. 35)
ದ
Adjust the rebound damping of the shock absorber. (
P. 36)
Removing the shock absorberb
P. 33)
x
ದ
Jack up the motorcycle. (
ದ
Remove screwb 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.
ದ
Remove screwb, push splash protectorb to the side, and remove the shock absorber.
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Push splash protectorb to the side and position the shock absorber. Mount and
tighten screwb.
P. 32)
500075-10
Installing shock absorberb
x
Specification
Screw, top shock absorber
ದ
M12
80bNm
(59blbfbft)
Loctite® 243™
M12
80bNm
(59blbfbft)
Loctite® 243™
Mount and tighten screwb.
Specification
500075-11
Screw, bottom shock absorber
Info
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 dissolve the Teflon coating, thereby drastically reducing the service life.
ದ
Remove the motorcycle from the work stand. (
P. 32)
MAINTENANCE WORK ON CHASSIS AND ENGINE
37
Checking basic setting of fork
Info
For various reasons, no exact riding sag can be determined for the forks.
ದ
As with the shock absorber, smaller weight differences can be compensated by the
spring preload.
ದ
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.
400189-01
Adjusting compression damping of fork
Info
The hydraulic compression damping determines the fork suspension behavior.
ದ
Remove protection coversb.
ದ
Turn adjusting screwsb clockwise until they stop.
Info
The adjusting screwsb are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
ದ
Turn back counterclockwise the number of clicks corresponding to the fork type.
Specification
100020-10
Compression damping (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)
Comfort
24bclicks
Standard
20bclicks
Sport
18bclicks
Compression damping (EXC-RbSIXbDAYS)
Comfort
24bclicks
Standard
22bclicks
Sport
18bclicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
ದ
Mount protection coversb.
Adjusting rebound damping of fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
ದ
Turn adjusting screwsb clockwise until they stop.
Info
The adjusting screwsb are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
100019-10
MAINTENANCE WORK ON CHASSIS AND ENGINE
ದ
38
Turn back counterclockwise the number of clicks corresponding to the fork type.
Specification
Rebound damping (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)
Comfort
20bclicks
Standard
18bclicks
Sport
18bclicks
Rebound damping (EXC-RbSIXbDAYS)
Comfort
20bclicks
Standard
20bclicks
Sport
18bclicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
Adjusting spring preload of the fork
ದ
Turn adjusting screws counterclockwise until they stop.
Info
Make the same adjustment on both fork legs.
ದ
Turn back clockwise the number of turns corresponding to the fork type.
Specification
Spring preload - PreloadbAdjuster (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCRW)
100025-10
Comfort
2bturns
Standard
4bturns
Sport
7bturns
Spring preload - PreloadbAdjuster (EXC-RbSIXbDAYS)
Comfort
2bturns
Standard
2bturns
Sport
7bturns
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.
Bleeding fork legs
ದ
Jack up the motorcycle. (
ದ
Remove bleeder screwsb briefly.
P. 32)
Any excess pressure escapes from the interior of the fork.
100021-10
ದ
Mount and tighten bleeder screws.
ದ
Remove the motorcycle from the work stand. (
P. 32)
MAINTENANCE WORK ON CHASSIS AND ENGINE
39
Cleaning dust boots of fork legs
ದ
Jack up the motorcycle. (
ದ
Loosen the fork protection. (
ದ
Push dust bootsb of both fork legs downwards.
P. 32)
P. 39)
Info
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.
Warning
Danger of accidentsಘReduced braking due to oil or grease on the brake
discs.
500088-10
ದ
ದ
Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
Clean and oil the dust boots and inner fork tube of both fork legs.
Universal oil spray (
P. 115)
ದ
Press the dust boots back into their normal position.
ದ
Remove excess oil.
ದ
Position the fork protection. (
ದ
Remove the motorcycle from the work stand. (
ದ
Remove screwsb and take off clamp.
ದ
Remove screwsb on left fork leg. Push the fork protection downwards.
ದ
Remove the screws on the right fork leg. Push the fork protection downwards.
ದ
Position the fork protection on the left fork leg. Mount and tighten screwsb.
P. 39)
P. 32)
Loosening the fork protection
500087-11
Positioning the fork protection
Specification
Remaining screws, chassis
M6
10bNm (7.4blbfbft)
ದ
Position the brake line and cable harness. Put the clamp on, mount and tighten
screwsb.
ದ
Position the fork protection on the right fork leg. Mount and tighten screws.
Specification
Remaining screws, chassis
500087-10
M6
10bNm (7.4blbfbft)
Checking play of steering head bearing
Warning
Danger of accidentsಘUnsafe riding behavior due to incorrect steering head bearing play.
ದ
The steering head bearing play should be adjusted immediately in an authorized KTM workshop.
Info
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.
ದ
Jack up the motorcycle. (
P. 32)
MAINTENANCE WORK ON CHASSIS AND ENGINE
ದ
40
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.
»
400189-10
ದ
If there is noticeable play present:
(EXC-RbSIXbDAYS, XCR-WbUSA)
ದ Adjust play of the steering head bearing. (
P. 40)
(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)
ದ Adjust play of the steering head bearing. (
P. 40)
Move the handlebar to and fro over the entire steering range.
The handlebar must be able to move easily over the entire steering range. No
resting locations should be noticeable.
»
If click positions are noticeable:
(EXC-RbSIXbDAYS, XCR-WbUSA)
ದ Adjust play of the steering head bearing. (
P. 40)
(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)
ದ Adjust play of the steering head bearing. (
P. 40)
ದ
ದ
Adjusting play of steering head bearingb
Check the steering head bearing and replace if required.
Remove the motorcycle from the work stand. (
P. 32)
x (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)
ದ
Jack up the motorcycle. (
P. 32)
ದ
Loosen screwsb andb.
ದ
Loosen and retighten screwb.
Specification
Screw, top steering head
M20x1,5
10bNm (7.4blbfbft)
ದ
Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
ದ
Fully tighten screwb.
Specification
Screw, top triple clamp
100022-10
ದ
M8
20bNm
(14.8blbfbft)
M8
20bNm
(14.8blbfbft)
Tighten screwb.
Specification
Screw, top steering stem
ದ
Adjusting play of steering head bearingb
Check play of steering head bearing. (
P. 39)
x (EXC-RbSIXbDAYS, XCR-WbUSA)
ದ
Jack up the motorcycle. (
P. 32)
ದ
Loosen screwb. Remove screwb.
ದ
Loosen and retighten screwb.
Specification
Screw, top steering head
M20x1,5
10bNm (7.4blbfbft)
ದ
Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
ದ
Fully tighten screwb.
Specification
Screw, top triple clamp
500103-11
ದ
M8
17bNm
(12.5blbfbft)
Mount and tighten screwb.
Specification
Screw, top steering stem
ದ
M8
Check play of steering head bearing. (
17bNm
(12.5blbfbft)
P. 39)
Loctite® 243™
MAINTENANCE WORK ON CHASSIS AND ENGINE
41
Fork offset (EXC-RbSIXbDAYS, XCR-WbUSA)
You can see the currently set offset if you remove screwb.
The fork offsetb has an impact on the handling of the vehicle. It is calculated from
the center of the fork leg to the center of the steering head bearing.
The fork offset can optionally be adjusted.
Markingb to the front gives greater stability on fast racetracks.
B
0
A
0
Fork offset
Front marking
18bmm (0.71bin)
Markingb to the rear (condition at delivery) gives better handling in bends.
Fork offset
Rear marking
1
0
20bmm (0.79bin)
400188-10
Setting the fork offsetb
x (EXC-RbSIXbDAYS, XCR-WbUSA)
ದ
Remove the lower triple clamp. (
ದ
Remove screwb. Remove the steering stem.
ದ
Clean the parts and check for damage.
ದ
Rotate the steering stem 180° and insert into the triple clamp. Mount and tighten
screwb.
P. 43)
Specification
Screw, bottom steering
head
M20x1,5
ದ
Install the lower triple clamp. (
ದ
Remove front wheel. (
ದ
Remove screwsb and take off clamp.
60bNm
(44.3blbfbft)
Loctite® 243™
P. 44)
500104-10
Removing the fork legs
P. 63)
ದ
Remove cable clipb, remove screwb and take off the brake caliper.
ದ
Hang the brake caliper and the brake line loosely to the side.
500093-10
(EXC-RbSIXbDAYS, XCR-WbUSA)
ದ Loosen screwb. Remove the fork leg on the left.
ದ
500094-10
Loosen screwb. Remove the fork leg on the right.
MAINTENANCE WORK ON CHASSIS AND ENGINE
42
(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)
ದ Loosen screwb. Remove the fork leg on the left.
ದ
Loosen screwb. Remove the fork leg on the right.
100023-11
Installing the fork legsb
x
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Position the fork legs.
Info
The topmost sunk nut in the fork leg must be flush to the upper edge of the
upper triple clamp.
Position the bleeder screwb to the front.
100021-10
(EXC-RbSIXbDAYS, XCR-WbUSA)
ದ Fully tighten screwb.
Specification
Screw, top triple clamp
ದ
M8
17bNm
(12.5blbfbft)
M8
12bNm
(8.9blbfbft)
M8
20bNm
(14.8blbfbft)
M8
15bNm
(11.1blbfbft)
Fully tighten screwb.
Specification
Screw, bottom triple clamp
500094-11
(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)
ದ Fully tighten screwb.
Specification
Screw, top triple clamp
ದ
Fully tighten screwb.
Specification
Screw, bottom triple clamp
100023-10
ದ
Position brake caliper, mount and tighten screwsb.
Specification
Screw, front brake caliper
500093-11
M8
25bNm
(18.4blbfbft)
Loctite® 243™
ದ
Fit cable clipb.
ದ
Position the brake line and cable harness. Put the clamp on, mount and tighten
screwsb.
ದ
Fit front wheel. (
P. 64)
MAINTENANCE WORK ON CHASSIS AND ENGINE
Removing the fork protectorb
43
x
ದ
Remove the fork legs. (
ದ
Remove screwsb on the left fork leg. Remove the fork protector upwards.
ದ
Remove the screws on the right fork leg. Remove the fork protector upwards.
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Position the fork protection on the left fork leg. Mount and tighten screwsb.
P. 41)
500105-10
Installing the fork protectorb
x
Specification
Remaining screws, chassis
ದ
M6
10bNm (7.4blbfbft)
Position the fork protection on the right fork leg. Mount and tighten screws.
Specification
Remaining screws, chassis
500105-10
Removing the lower triple clampb
ದ
Install the fork legs. (
M6
10bNm (7.4blbfbft)
P. 42)
x (EXC-RbSIXbDAYS, XCR-WbUSA)
ದ
Remove the fork legs. (
P. 41)
(XCR-WbUSA)
ದ Dismount the start number plate. (
P. 47)
(EXC-RbSIXbDAYS)
ದ Remove the headlight mask with the headlight. (
P. 46)
ದ
Dismount the front fender. (
ದ
Remove screwsb and hang the CDI control unit to the side.
P. 46)
Info
Do not unplug the CDI control unit.
ದ
Remove screwb. Remove screwb, take off top triple clamp with the handlebar
and place it on one side.
Info
Protect the motorcycle and its attachments from damage by covering them.
Do not bend the cables and lines.
500099-10
500100-10
ದ
Remove o-ringb. Remove protector ringb.
ದ
Remove the lower triple clamp with the steering stem.
ದ
Remove the upper steering head bearing.
MAINTENANCE WORK ON CHASSIS AND ENGINE
Removing the lower triple clampb
44
x (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)
ದ
Remove the fork legs. (
ದ
Remove the headlight mask with the headlight. (
ದ
Dismount the front fender. (
ದ
Remove screwsb and hang the CDI control unit to the side.
P. 41)
P. 46)
P. 46)
Info
Do not unplug the CDI control unit.
ದ
Remove screwb. Loosen screwb. Take off top triple clamp with the handlebar
and place it on one side.
Info
Protect the motorcycle and its attachments from damage by covering them.
Do not bend the cables and lines.
500149-10
ದ
Remove protector ringb.
ದ
Remove the lower triple clamp with the steering stem.
ದ
Remove the upper steering head bearing.
500150-10
Installing the lower triple clampb
x (EXC-RbSIXbDAYS, XCR-WbUSA)
ದ
Clean the bearing and sealing elements, check for damage, and grease.
Long-life grease (
ದ
3
0
2
0
1
0
P. 115)
Insert the lower triple clamp with the steering stem. Mount the upper steering head
bearing.
Info
Check whether the top steering head sealb is correctly positioned.
ದ
Push up protective ringb and o-ringb.
ದ
Position the upper triple clamp with the steering.
ದ
Mount and tighten screwb.
500098-10
Specification
Screw, top steering head
ದ
M20x1,5
10bNm (7.4blbfbft)
Position the clutch line, wiring harness and CDI control unit. Mount and tighten
screwsb.
Specification
Remaining screws, chassis
500099-11
ದ
Install the front fender. (
M6
P. 46)
(XCR-WbUSA)
ದ Fit the start number plate. (
P. 47)
10bNm (7.4blbfbft)
MAINTENANCE WORK ON CHASSIS AND ENGINE
45
(EXC-RbSIXbDAYS)
ದ Refit the headlight mask with the headlight. (
ದ
Install the fork legs. (
ದ
Mount and tighten screwb.
P. 47)
P. 42)
Specification
Screw, top steering stem
M8
17bNm
(12.5blbfbft)
Loctite® 243™
ದ
Check the cable harness, cable, brake and clutch line for free movement and free
laying.
ದ
Check play of steering head bearing. (
P. 39)
500103-10
Installing the lower triple clampb
x (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)
ದ
Clean the bearing and sealing elements, check for damage, and grease.
Long-life grease (
ದ
2
0
1
0
P. 115)
Insert the lower triple clamp with the steering stem. Mount the upper steering head
bearing.
Info
Check whether the top steering head sealb is correctly positioned.
ದ
Push on protective ringb.
ದ
Position the upper triple clamp with the steering.
ದ
Mount and tighten screwb.
500151-10
Specification
Screw, top steering head
ದ
M20x1,5
10bNm (7.4blbfbft)
Position the clutch line, wiring harness and CDI control unit. Mount and tighten
screwsb.
Specification
Remaining screws, chassis
500149-11
M6
ದ
Install the front fender. (
ದ
Refit the headlight mask with the headlight. (
ದ
Install the fork legs. (
ದ
Tighten screwb.
10bNm (7.4blbfbft)
P. 46)
P. 47)
P. 42)
Specification
Screw, top steering stem
100022-11
M8
20bNm
(14.8blbfbft)
ದ
Check the cable harness, cable, brake and clutch line for free movement and free
laying.
ದ
Check play of steering head bearing. (
P. 39)
MAINTENANCE WORK ON CHASSIS AND ENGINE
Greasing the steering head bearingb
46
x
(EXC-RbSIXbDAYS, XCR-WbUSA)
Remove the lower triple clamp. ( P. 43)
Install the lower triple clamp. ( P. 44)
(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)
Remove the lower triple clamp. ( P. 44)
Install the lower triple clamp. ( P. 45)
Dismounting the front fender
ದ
Remove screwsb. Remove the front fender.
ದ
Make sure that the distance bushings remain in place.
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Make sure that the distance bushings are mounted in the fender.
ದ
Position the front fender. Mount and tighten screwsb.
500092-10
Installing the front fender
Specification
Remaining screws, chassis
M6
10bNm (7.4blbfbft)
Info
Ensure that there is contact between the holding lugs and the start number
plate or headlight mask.
500092-10
Removing headlight mask with headlight (EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA, XCR-WbZA)
ದ
Switch off all electrical equipment.
ದ
Remove screwb and take off clamp.
ದ
Loosen the rubber bandb. Push up the headlight mask and swing it forwards.
ದ
Pull out the electric plug connectorb and remove the headlight mask with the
headlight.
500155-10
500156-10
MAINTENANCE WORK ON CHASSIS AND ENGINE
47
Refitting the headlight mask with the headlight (EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA,
XCR-WbZA)
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Connect the electric plug connectorb.
ದ
Position the headlight mask and fix it with the rubber bandb.
500156-11
Info
Take care with the contact of the holding lug at the fender.
ದ
Position the brake line and cable harness. Put the clamp on, mount and tighten
screwb.
ದ
Check the headlamp setting.
500155-11
Dismount the start number plate (XCR-WbUSA)
ದ
Remove screwb and take off clamp.
ದ
Remove screwb with distance bushing. Remove the start number plate.
500101-10
Fitting the start number plate (XCR-WbUSA)
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Position the start number plate. Fit and tighten screwb with distance bushing.
Specification
Remaining screws, chassis
M6
10bNm (7.4blbfbft)
Info
Take care with the contact of the holding lug at the fender.
500101-11
ದ
Position the brake line and cable harness. Put the clamp on, mount and tighten
screwb.
Handlebar position
On the upper triple clamp, there are 2 holes at a distance ofb to each other.
Distanceb between holes
15bmm (0.59bin)
The holes on the handlebar support are placed at a distance ofb from the center.
A
0
B
0
A
0
B
0
400223-11
Distanceb between holes
3.5bmm (0.138bin)
The handlebar supports can be mounted in 4 different positions.
(EXC-RbSIXbDAYS)
The handlebar supports can also be mounted at 2 different heights (with and without spacer).
Thick spacer
9bmm (0.35bin)
MAINTENANCE WORK ON CHASSIS AND ENGINE
Adjusting handlebar positionb
1
0
2
0
48
x
1
0
2
0
(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)
ದ Remove the four screwsb. Remove the handlebar clamp. Remove the handlebar and lay it to one side.
Info
Protect the motorcycle and its attachments from damage by covering
them.
Do not bend the cables and lines.
400223-10
ದ
Remove the two screwsb. Remove the handlebar support.
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Place the handlebar support in the required position. Fit and tighten the two
screwsb.
Specification
Screw, handlebar support
M10
40bNm
(29.5blbfbft)
Loctite® 243™
Info
Position the left and right handlebar supports evenly.
ದ
Position the handlebar.
Info
Make sure cables and wiring are positioned correctly.
ದ
Position the handlebar clamp. Fit and evenly tighten the four screwsb.
Specification
Screw, handlebar clamp
M8
20bNm
(14.8blbfbft)
Info
Make sure the gap width is even.
(EXC-RbSIXbDAYS)
ದ Remove the four screwsb. Remove the handlebar clampsb with rubber washersb and elastomersb.
0
1
2
0
3
0
4
0
5
0
ದ
Remove the handlebar and lay it to one side.
Info
Protect the motorcycle and its attachments from damage by covering
them.
Do not bend the cables and lines.
6
0
7
0
8
0
9
0
400343-10
ದ
Remove the lower shellsb.
ದ
Remove the clamp barb
with the rubber conesb.
ದ
Remove the two screwsb. Remove the handlebar support.
ದ
Check parts for damage and wear. Replace damaged or worn parts.
MAINTENANCE WORK ON CHASSIS AND ENGINE
ದ
49
Place the handlebar support in the required position. Fit and tighten the two
screwsb.
Specification
Screw, handlebar support
M10
40bNm
(29.5blbfbft)
Loctite® 243™
Condition
Spacer fitted:
Use a M10x35 screw
Condition
without a spacerb:
Use a M10x25 screw
Info
Position the left and right handlebar supports evenly.
ದ
Fit the rubber conesb and clamp barb
.
ದ
Fit the lower shellsb.
ದ
Position the handlebar.
Info
Make sure cables and wiring are positioned correctly.
ದ
Position the handlebar clampsb with rubber washersb and elastomersb.
Elastomer kit green - soft qualityb(SXS05125203)
Elastomer kit yellow - medium quality (standard)b(SXS05125204)
Elastomer kit red - hard qualityb(SXS05125205)
Info
The elastomeres are available in different versions.
ದ
Fit and evenly tighten the four screwsb.
Specification
Screw, handlebar clamp
M8
16bNm
(11.8blbfbft)
Info
Make sure the gap width is even.
Checking gas Bowden cable route
ದ
500152-10
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 carburetor.
MAINTENANCE WORK ON CHASSIS AND ENGINE
50
Checking play in the gas Bowden cable
ದ
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
»
3… 5bmm (0.12… 0.2bin)
If the gas Bowden cable play does not meet specifications:
ದ
Adjust the gas Bowden cable play. (
P. 50)
Danger
Danger of poisoningಘExhaust gases are poisonous and can result in unconsciousness and/or death.
400192-10
ದ
ದ
When running the engine, always make sure there is sufficient ventilation, 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.
»
If the idle speed changes:
ದ
Adjusting the gas Bowden cable playb
Adjust the gas Bowden cable play. (
P. 50)
x
ದ
Dismount the fuel tank. (
ದ
Check gas Bowden cable route. (
ದ
Move the handlebar to the straight-ahead position.
ದ
Push back bellowsb.
ದ
Loosen nutb. Turn adjusting screwb in as far as possible.
ದ
Loosen nutb. Turn adjusting screwb so that there is play in the gas Bowden cable at the throttle grip.
P. 70)
P. 49)
Specification
Play in gas Bowden cable
500153-10
3… 5bmm (0.12… 0.2bin)
ದ
Tighten nutb.
ದ
Press and hold the throttle grip in the closed setting. Turn adjusting screwb out
until there is no play in the Bowden cableb.
ದ
Tighten nutb.
ದ
Push bellowsb on. Check the throttle grip for smooth operation.
ದ
Install the fuel tank. (
ದ
Check play in the gas Bowden cable. (
P. 70)
P. 50)
Checking chain dirt
ದ
Check the chain for coarse dirt accumulation.
»
If the chain is very dirty:
ದ
Clean the chain. (
P. 50)
Cleaning the chain
Warning
Danger of accidentsಘOil or grease on the tires reduces their grip.
ದ
Remove oil and grease with a suitable cleaning material.
Warning
Danger of accidentsಘReduced braking due to oil or grease on the brake discs.
ದ
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Environmental hazardಘProblem materials cause environmental damage.
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
MAINTENANCE WORK ON CHASSIS AND ENGINE
51
Info
The service life of the chain depends largely on its maintenance.
ದ
Clean the chain regularly and then treat with chain spray.
Chain cleaner (
P. 115)
Offroad chain spray (
P. 115)
Checking the chain tension
Warning
Danger of accidentsಘDanger caused by incorrect chain tension.
ದ
If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if
necessary.
ದ
Jack up the motorcycle. (
ದ
Push the chain at the end of the chain sliding component upwards to measure the
chain tensionb.
P. 32)
Info
The upper chain sectionb must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Chain tension
400213-10
»
If the chain tension does not meet specifications:
ದ
ದ
8… 10bmm (0.31… 0.39bin)
Adjusting chain tension - after checking. (
Remove the motorcycle from the work stand. (
P. 53)
P. 32)
Checking the chain tension when fitting rear wheel
Warning
Danger of accidentsಘDanger caused by incorrect chain tension.
ದ
If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if
necessary.
ದ
Make sure that the chain adjusters are fitted correctly on the adjusting screws.
ದ
Push the chain at the end of the chain sliding component upwards to measure
chain tensionb.
Info
The upper chain sectionb must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Chain tension
400213-10
»
8… 10bmm (0.31… 0.39bin)
If the chain tension does not meet specifications:
ದ
Adjust the chain tension when fitting rear wheel. (
P. 54)
MAINTENANCE WORK ON CHASSIS AND ENGINE
52
Checking the rear sprocket / engine sprocket for wear
ದ
Check the rear sprocket / engine sprocket for wear.
»
If the rear sprocket / engine sprocket are worn:
ದ
Replace rear sprocket / engine sprocket.
Info
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 replaced together.
400227-01
ದ
Check that the chain guide is firmly seated and not worn.
ದ
Jack up the motorcycle. (
ದ
Shift to neutral and pull the upper chain length with the specified tensionb.
Checking chain wear
P. 32)
Specification
Chain tension
A
0
ದ
10… 15bkg (22… 33blb.)
Measure distanceb of 18 chain links in the lower chain section.
Info
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Maximum distanceb at the longest
chain section
»
If distanceb is greater than the specified measurement:
ದ
Replace the chain.
Info
B
0
1 2 3
272bmm (10.71bin)
When you replace the chain, you should also replace the rear and
engine sprockets.
New chains wear out faster on old, worn sprockets.
16 17 18
400226-10
ದ
Remove the motorcycle from the work stand. (
P. 32)
Adjusting the chain tension
Warning
Danger of accidentsಘDanger caused by incorrect chain tension.
ದ
If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if
necessary.
ದ
Jack up the motorcycle. (
ದ
Push the chain at the end of the chain sliding component upwards to measure
chain tensionb.
P. 32)
Info
The upper chain sectionb must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
400213-10
MAINTENANCE WORK ON CHASSIS AND ENGINE
53
ದ
Loosen nutb.
ದ
Loosen nutsb.
ದ
Adjust the chain tension by turning the left and right adjusting screwsb.
Specification
Chain tension
8… 10bmm (0.31… 0.39bin)
Turn the left and right adjusting screwsb so that the markings on the left and
right chain adjusters are in the same position relative to the reference marksb.
The rear wheel is then correctly aligned.
ದ
Tighten nutsb.
ದ
Make sure that chain adjustersb are fitted correctly on the adjusting screwsb.
ದ
Tighten nutb.
Specification
Nut, rear wheel spindle
M20x1,5
80bNm (59blbfbft)
Info
The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
Chain adjustersb can be turned by 180°.
400225-10
ದ
Remove the motorcycle from the work stand. (
ದ
Loosen nutb.
ದ
Loosen nutsb.
ದ
Adjust the chain tension by turning the adjusting screwsb left and right.
P. 32)
Adjusting chain tension - after checking
Specification
Chain tension
8… 10bmm (0.31… 0.39bin)
Turn the adjusting screwsb left and right so that the markings on the left and
right chain adjusters are in the same position relative to the reference marksb.
The rear wheel is then correctly aligned.
ದ
Tighten nutsb.
ದ
Make sure that the chain adjustersb are fitted correctly on the adjusting
screwsb.
ದ
Tighten nutb.
Specification
Nut, rear wheel spindle
M20x1,5
80bNm (59blbfbft)
Info
400225-13
The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
The chain adjustersb can be turned by 180°.
MAINTENANCE WORK ON CHASSIS AND ENGINE
54
Adjusting chain tension - fitting rear wheel
ದ
Loosen nutsb.
ದ
Adjust the chain tension by turning the adjusting screwsb left and right.
Specification
Chain tension
8… 10bmm (0.31… 0.39bin)
Turn the adjusting screwsb left and right so that the markings on the left and
right chain adjusters are in the same position relative to the reference marksb.
The rear wheel is then correctly aligned.
ದ
Tighten nutsb.
ದ
Remove screwsb andb. Take off the chain guide.
400225-11
Adjusting chain guideb
x
Conditions
Number of teeth: ืb44bteeth
ದ
Insert nutb in holeb. Position the chain guide.
ದ
Mount and tighten screwsb andb.
Specification
Remaining screws, chassis
M6
10bNm
(7.4blbfbft)
Conditions
Number of teeth: ุb45bteeth
ದ
Insert nutb in holeb. Position the chain guide.
ದ
Mount and tighten screwsb andb.
Specification
Remaining screws, chassis
M6
10bNm
(7.4blbfbft)
400252-10
Brake fluid reservoir
Warning
Danger of accidentsಘBrake system failure.
ದ
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Have the brake system checked in an authorized KTM workshop, and do not ride any further.
The brake fluid reservoirs of the front and rear brakes are dimensioned so that they do not need topping up with brake fluid even if the
brake linings are worn.
MAINTENANCE WORK ON CHASSIS AND ENGINE
55
Brake calipers
The brake calipers of this series are "floating", which means that they are not fixed to the brake caliper support.
The lateral compensation ensures an optimal position of the brake pad in relation to the brake disc.
Checking brake discs
Warning
Danger of accidentsಘReduced braking due to worn brake discs.
ದ
Worn brake discs should be replaced immediately by an authorized KTM workshop.
ದ
Check the thickness of the front and rear brake discs at several places on the disc
to see if it conforms to measurementb.
Info
A
Wear reduces the thickness of the brake disc around the area used by the
brake linings.
Wear limit of brake discs
400257-10
»
front
2.5bmm (0.098bin)
Rear
3.5bmm (0.138bin)
The brake disc thickness is less than the specified value.
ದ
Replace the brake disc.
Checking free play of hand brake lever
Warning
Danger of accidentsಘBrake system failure.
ದ
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.
(Every XCR-W models)
ದ Push the hand brake lever forwards and check free play.b.
Free play of hand brake lever
»
ุb3bmm (ุb0.12bin)
If the free travel does not meet specifications:
ದ
adjust the basic position of handbrake lever. (
P. 56)
400196-11
(Every EXC-R models)
ದ Push the hand brake to the handlebar and check free playb.
Free play of hand brake lever
»
If the free travel does not meet specifications:
ದ
400196-13
ุb3bmm (ุb0.12bin)
Adjust the free travel of the handbrake lever. (
P. 56)
MAINTENANCE WORK ON CHASSIS AND ENGINE
56
Adjusting basic position of handbrake lever (Every XCR-W models)
ದ
Adjust the basic setting of the handbrake lever to your hand size by turning adjusting screwb.
Info
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!
400196-12
ದ
Check the free play of the hand brake lever. (
P. 55)
Adjusting free travel of handbrake lever (Every EXC-R models)
ದ
Adjust the free travel of the handbrake lever with the adjustment screwb.
Info
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!
400196-12
ದ
Check the free play of the hand brake lever. (
P. 55)
Checking the front brake fluid level
Warning
Danger of accidentsಘBrake system failure.
ದ
If the 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 accidentsಘReduced braking due to old brake fluid.
ದ
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.
ದ
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
ದ
Check the brake fluid level in the viewerb.
»
If the brake fluid is below the MIN mark:
ದ
Top up the brake fluid of the front brake. (
P. 56)
400231-10
Topping up the front brake fluidb
x
Warning
Danger of accidentsಘBrake system failure.
ದ
If the 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 irritationsಘBrake fluid can cause skin irritation on contact.
ದ
Avoid contact with skin and eyes, and keep out of the reach of children.
ದ
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
MAINTENANCE WORK ON CHASSIS AND ENGINE
57
Warning
Danger of accidentsಘReduced braking due to old brake fluid.
ದ
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.
Warning
Environmental hazardಘProblem materials cause environmental damage.
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
KTM recommends DOTb5.1 brake fluid from Motorex®. This has a higher wet boiling point than DOTb4 brake fluid and provides
greater safety for high demands.
Never user DOTb5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOTb5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
ದ
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
ದ
Remove screwsb.
ದ
Remove the coverb with membraneb.
ದ
Top up brake fluid to levelb.
Specification
Measurement ofb
Brake fluid DOT 5.1 (
5bmm (0.2bin)
P. 114)
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Position the cover with membrane. Mount and tighten screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
400230-10
Checking the front brake linings
Warning
Danger of accidentsಘReduced braking due to worn brake linings.
ದ
Worn brake linings should be replaced immediately in an authorized KTM workshop.
ದ
Check the brake linings for minimum thicknessb.
»
Minimum thicknessb: ุb1bmm (ุb0.04bin)
If the minimum thickness is less than specified:
ದ
400235-10
Change the front brake linings. (
P. 59)
MAINTENANCE WORK ON CHASSIS AND ENGINE
Removing front brake liningsb
58
x
Warning
Danger of accidentsಘImproper brake maintenance and repair.
ದ
Always have your brake system maintained and repaired in an authorized KTM workshop.
ದ
Press the brake caliper by hand on to the brake disc in order to press back the
brake pistons.
Info
Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.
ದ
500089-11
Installing the front brake liningsb
Remove the locking split pinsb, withdraw the boltb, and take out the brake
pads.
ದ
Remove cable clipb. Remove screwsb and take off brake caliper.
ದ
Clean brake caliper and brake caliper support.
x
Warning
Danger of accidentsಘReduced braking due to oil or grease on the brake discs.
ದ
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidentsಘReduced braking due to use of non-approved brake linings.
ದ
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction 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 original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
ದ
Check the brake discs. (
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Check that leaf springb in the brake caliper and sliding plateb in the brake
caliper support are seated correctly.
P. 55)
Info
The arrow on the leaf spring points in the rotation direction of the brake
disc.
500091-10
ದ
Fit the brake linings, insert boltb, and mount locking split pinsb.
ದ
Position brake caliper, mount and tighten screwsb.
Specification
Screw, front brake caliper
500089-12
M8
25bNm
(18.4blbfbft)
Loctite® 243™
ದ
Fit cable clipb.
ದ
Operate the hand brake lever repeatedly until the brake linings lie on the brake disc
and there is a tight spot.
MAINTENANCE WORK ON CHASSIS AND ENGINE
Changing the front brake liningsb
59
x
Warning
Skin irritationsಘBrake fluid can cause skin irritation on contact.
ದ
Avoid contact with skin and eyes, and keep out of the reach of children.
ದ
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Danger of accidentsಘReduced braking due to old brake fluid.
ದ
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.
Warning
Environmental hazardಘProblem materials cause environmental damage.
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
KTM recommends brake fluid DOTb5.1 from Motorex®. This brake fluid has a higher wet boiling point than brake fluid DOTb4
and offers more protection under high load.
Never user DOTb5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOTb5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
ದ
Remove the front brake linings. (
ದ
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
ದ
Remove screwsb.
P. 58)
ದ
Remove coverb with membraneb.
ದ
Press the brake piston back to its basic position and make sure that no brake fluid
overflows from the brake fluid reservoir.
ದ
Install the front brake linings. (
ದ
Add brake fluid to levelb.
P. 58)
Specification
Measurement ofb
Brake fluid DOT 5.1 (
5bmm (0.2bin)
P. 114)
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
400230-10
Checking free play of foot brake lever
Warning
Danger of accidentsಘBrake system failure.
ದ
If there 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.
ದ
Disconnect springb.
ದ
Move the foot brake lever backwards and forwards between the end stop and the
foot brake cylinder piston bracket and check free playb.
Specification
Free play at foot brake lever
»
If the free travel does not meet specifications:
ದ
500139-11
ದ
3… 5bmm (0.12… 0.2bin)
Adjust the basic position of the footbrake lever. (
Reconnect springb.
P. 60)
MAINTENANCE WORK ON CHASSIS AND ENGINE
Adjusting basic position of footbrake leverb
60
x
Warning
Danger of accidentsಘBrake system failure.
ದ
If there 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.
ದ
Disconnect springb.
ದ
Loosen nutb and with push rodb, turn it back until you have maximum free play.
ದ
To adjust the basic position of the footbrake lever individually, lossen nutb and
turn screwb accordingly.
Info
The range of adjustment is limited.
ದ
500154-10
Turn push rodb accordingly until you have free playb. If necessary, adjust the
basic position of the footbrake lever.
Specification
Free play at foot brake lever
ದ
3… 5bmm (0.12… 0.2bin)
Hold screwb and tighten nutb.
Specification
Remaining nuts, chassis
ದ
M8
30bNm
(22.1blbfbft)
M6
15bNm
(11.1blbfbft)
Hold push rodb and tighten nutb.
Specification
Remaining nuts, chassis
ದ
Reconnect springb.
Checking the rear brake fluid level
Warning
Danger of accidentsಘBrake system failure.
ದ
If the 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 accidentsಘReduced braking due to old brake fluid.
ದ
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.
ದ
Stand the vehicle upright.
ದ
Check the brake fluid level in the viewerb.
»
When in the viewerb an air bubble is visible:
ದ
400234-10
Add rear brake fluid. (
P. 61)
MAINTENANCE WORK ON CHASSIS AND ENGINE
Adding rear brake fluidb
61
x
Warning
Danger of accidentsಘBrake system failure.
ದ
If the 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 irritationsಘBrake fluid can cause skin irritation on contact.
ದ
Avoid contact with skin and eyes, and keep out of the reach of children.
ದ
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Danger of accidentsಘReduced braking due to old brake fluid.
ದ
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.
Warning
Environmental hazardಘProblem materials cause environmental damage.
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
KTM recommends brake fluid DOTb5.1 frombMotorex®. This brake fluid has a higher wet boiling point than brake fluid DOTb4
and offers more protection under high load.
Never user DOTb5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOTb5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
ದ
Stand the vehicle upright.
ದ
Remove screw capb with membraneb and the O-ring.
ದ
Add brake fluid to levelb.
Brake fluid DOT 5.1 (
P. 114)
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Mount the screw cap with the membraneband the O-ring.
Info
400233-10
Clean up overflowed or spilt brake fluid immediately with water.
Checking rear brake linings
Warning
Danger of accidentsಘReduced braking due to worn brake linings.
ದ
Worn brake linings should be replaced immediately in an authorized KTM workshop.
ದ
Check the brake linings for minimum thicknessb.
»
Minimum thicknessb: ุb1bmm (ุb0.04bin)
If the minimum thickness is less than specified:
ದ
400238-10
Change the rear brake linings. (
P. 63)
MAINTENANCE WORK ON CHASSIS AND ENGINE
Removing rear brake liningsb
62
x
Warning
Danger of accidentsಘImproper brake maintenance and repair.
ದ
Always have your brake system maintained and repaired in an authorized KTM workshop.
ದ
Press the brake caliper by hand on to the brake disc in order to press back the
brake piston.
Info
Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.
400236-10
Installing the rear brake liningsb
ದ
Remove the locking split pinsb, withdraw the boltb, and take out the brake
pads.
ದ
Clean brake caliper and brake caliper support.
x
Warning
Danger of accidentsಘReduced braking due to oil or grease on the brake discs.
ದ
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidentsಘReduced braking due to use of non-approved brake linings.
ದ
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction 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 original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
ದ
Check the brake discs. (
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Check that leaf springb in the brake caliper and sliding plateb in the brake
caliper support are seated correctly.
P. 55)
Info
The arrow on the leaf spring points in the rotation direction of the brake
disc.
500122-10
ದ
Fit the brake linings, insert boltb, and mount locking split pinsb.
Info
Make sure that the decoupling plateb is mounted on the piston side of the
brake pad.
ದ
400237-10
Operate the foot brake lever repeatedly until the brake linings lie on the brake disc
and there is a tight spot.
MAINTENANCE WORK ON CHASSIS AND ENGINE
Changing the rear brake liningsb
63
x
Warning
Skin irritationsಘBrake fluid can cause skin irritation on contact.
ದ
Avoid contact with skin and eyes, and keep out of the reach of children.
ದ
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Danger of accidentsಘReduced braking due to old brake fluid.
ದ
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.
Warning
Environmental hazardಘProblem materials cause environmental damage.
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
KTM recommends brake fluid DOTb5.1 from Motorex®. This brake fluid has a higher wet boiling point than brake fluid DOTb4
and offers more protection under high load.
Never user DOTb5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOTb5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
ದ
Remove the rear brake linings. (
ದ
Stand the vehicle upright.
ದ
Remove screw capb with membraneb and the O-ring.
ದ
Press the brake piston back to its basic position and make sure that no brake fluid
overflows from the brake fluid reservoir.
ದ
Install the rear brake linings. (
ದ
Add brake fluid to levelb.
Brake fluid DOT 5.1 (
P. 62)
P. 62)
P. 114)
400233-10
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Mount the screw cap with the membraneband the O-ring.
Info
Clean up overflowed or spilt brake fluid immediately with water.
Removing front wheelb
x
ದ
Jack up the motorcycle. (
ದ
Press the brake caliper by hand on to the brake disc in order to press back the
brake pistons.
P. 32)
Info
Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.
500089-10
500084-10
ದ
Remove screwb.
ದ
Loosen screwb.
MAINTENANCE WORK ON CHASSIS AND ENGINE
ದ
64
Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
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 damaged.
500085-10
ದ
Remove distance bushingb.
500086-10
Fitting front wheelb
x
Warning
Danger of accidentsಘReduced braking due to oil or grease on the brake discs.
ದ
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Clean and grease shaft seal ringsb and bearing surfaceb of the distance bushings.
Long-life grease (
P. 115)
ದ
Fit the distance bushings.
ದ
Lift the front wheel into the fork, position it, and insert the wheel spindle.
ದ
Mount and tighten screwb.
500086-11
Specification
Screw, front wheel spindle
500084-11
M24x1,5
40bNm
(29.5blbfbft)
ದ
Operate the hand brake lever several times until the brake pads are lying correctly
on the brake disc.
ದ
Remove the motorcycle from the work stand. (
ದ
Pull the front wheel brake and push down hard on the fork several times to align
the fork legs.
ದ
Fully tighten screwb.
P. 32)
Specification
Screw, fork stub
M8
15bNm
(11.1blbfbft)
MAINTENANCE WORK ON CHASSIS AND ENGINE
Removing rear wheelb
65
x
ದ
Jack up the motorcycle. (
ದ
Press the brake caliper by hand on to the brake disc in order to press back the
brake piston.
P. 32)
Info
Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.
ದ
Remove nutb.
ದ
Remove chain adjusterb. Withdraw the wheel spindleb only enough to allow the
rear wheel to be pushed forward.
ದ
Push the rear wheel forward as far as possible. Remove the chain from the rear
sprocket.
ದ
Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of the
swing arm.
Info
Do not operate the foot brake when the rear wheel is removed.
Always lay the wheel down in such a way that the brake disc is not damaged.
400258-10
ದ
Remove the spacing sleevesb.
400260-11
Fitting rear wheelb
x
Warning
Danger of accidentsಘReduced braking due to oil or grease on the brake discs.
ದ
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Clean and grease shaft seal ringsb and bearing surfaceb of the spacing sleeves.
Long-life grease (
ದ
P. 115)
Fit the spacing sleeves.
400260-10
400259-10
ದ
Lift the rear wheel into the swing arm, position it, and insert the wheel spindleb.
ದ
Put the chain on.
MAINTENANCE WORK ON CHASSIS AND ENGINE
66
ದ
Position the chain adjusterb. Fit nutb, but do not tighten it yet.
ದ
Check the chain tension when fitting rear wheel. (
ದ
Make sure that the chain adjustersb are fitted correctly on the adjusting
screwsb.
ದ
Tighten nutb.
P. 51)
Specification
Nut, rear wheel spindle
M20x1,5
80bNm (59blbfbft)
Info
The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
The chain adjustersb can be turned by 180°.
ದ
Operate the foot brake lever repeatedly until the brake linings lie on the brake disc
and there is a tight spot.
ದ
Remove the motorcycle from the work stand. (
P. 32)
400225-12
Tire condition checking
Info
Fit only tires approved by KTM.
Other tires could have a negative effect on riding behavior.
The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.
The front and rear wheels must be fitted with tires with similar profiles.
Worn tires have a negative effect on riding behavior, especially on wet surfaces.
ದ
Examine the tires for cuts, foreign bodies and other damage.
ದ
Check the depth of the tread.
»
Info
Note local national regulations concerning the minimum tread depth.
Minimum tread depth: ุb2bmm (ุb0.08bin)
If the minimum tread depth is insufficient:
ದ
Replace the tire(s).
Checking tire air pressure
Info
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.
ದ
Remove dust cap.
ದ
Check tire air pressure when tires are cold.
Tire air pressure off road
front
1.0bbar (15bpsi)
Rear
1.0bbar (15bpsi)
Road tire pressure (Every EXC-R models)
400241-01
»
1.5bbar (22bpsi)
Rear
2.0bbar (29bpsi)
If the tire pressure does not meet specifications:
ದ
ದ
front
Correct tire pressure.
Mount dust cap.
MAINTENANCE WORK ON CHASSIS AND ENGINE
67
Checking spoke tension
Warning
Danger of accidentsಘUnstable riding behavior due to loose spokes.
ದ
If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop.
Info
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.
ದ
To check spoke tension, tap each spoke with a screwdriver.
Specification
You should hear a high note.
Spoke nipple, front wheel
M4,5
5bNm (3.7blbfbft)
Spoke nipple, rear wheel
M5
5bNm (3.7blbfbft)
Info
If you hear different tone frequencies from different spokes, this is an indication of different spoke tensions.
400228-01
Removing the batteryb
x
Warning
Risk of injuryಘBattery acid and battery gases cause serious cauterization.
ದ
Keep batteries out of the reach of children.
ದ
Wear suitable protective clothing and goggles.
ದ
Avoid contact with battery acid and battery gases.
ದ
Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
ದ
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 doctor.
ದ
Switch off all power-consuming components and switch off the engine.
ದ
Remove the seat. (
ದ
Disconnect the negative (minus) cableb of the battery.
ದ
Pull back the plus pole coverb and disconnect the positive (plus) cable of the battery.
P. 69)
ದ
Hang the rubber bandb out to the bottom.
ದ
Lift the battery up.
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Place the battery in the battery holder.
500069-10
Installing the batteryb
x
4Ah batteryb(YTX5L-BS) (
500069-11
P. 94)
ದ
Reconnect the rubber bandb.
ದ
Attach the plus cable and replace the plus pole coverb.
ದ
Attach the minus cableb.
ದ
Mount the seat. (
P. 69)
MAINTENANCE WORK ON CHASSIS AND ENGINE
Recharging the batteryb
68
x
Warning
Risk of injuryಘBattery acid and battery gases cause serious cauterization.
ದ
Keep batteries out of the reach of children.
ದ
Wear suitable protective clothing and goggles.
ದ
Avoid contact with battery acid and battery gases.
ದ
Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
ದ
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 doctor.
Warning
Environmental hazardಘComponents and battery acid are a danger to the environment.
ದ
Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.
Warning
Environmental hazardಘProblem materials cause environmental damage.
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
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.
ದ
Switch off all power-consuming components and switch off the engine.
ದ
Remove the seat. (
ದ
Disconnect the minus (negative) cable of the battery to avoid damage to the motorcycle's electronics.
ದ
Connect the battery charger to the battery. Switch on the battery charger.
P. 69)
Battery chargerb(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 battery.
Info
Never remove the lidb.
Charge the battery according to the instructionsb on the battery casing.
400240-10
ದ
Switch off the charger after charging. Disconnect the battery.
Specification
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use.
ದ
Mount the seat. (
P. 69)
3bmonths
MAINTENANCE WORK ON CHASSIS AND ENGINE
69
Removing a fuse
ದ
Switch off all power-consuming components and switch off the engine.
ದ
Dismount the air filter box lid. (
ದ
Remove the protection coverb.
P. 74)
Info
The fuseb is located in the starter relayb under the filter box cover.
ದ
Remove the fuseb.
400270-10
Replacing the fuse
Warning
Fire hazardಘThe electrical system can be overloaded by the use of incorrect fuses.
ದ
Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
ದ
Check parts for damage and wear. Replace damaged or worn parts.
Info
A reserve fuseb is located in the starter relay.
Replace a burned-out fuseb only by an equivalent fuse.
ದ
Refit the fuse.
Fuseb(58011109110)
Info
400273-10
If the new fuse burns out, contact an authorized KTM workshop.
ದ
Replace the protection cover.
ದ
Install the air filter box lid. (
ದ
Remove screwb. Lift up the seat at the rear, pull it back and then remove from
above.
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Hook the front of the seat into the flange adapter of the fuel tank, lower the rear of
the seat and simultaneously push it forwards.
ದ
Make sure that the seat is correctly locked in.
ದ
Mount and tighten the screw of the seat fixing.
P. 74)
Removing the seat
500080-10
Mounting the seat
Specification
Remaining screws, chassis
500068-01
M6
10bNm (7.4blbfbft)
MAINTENANCE WORK ON CHASSIS AND ENGINE
Dismounting the fuel tankb
70
x
Danger
Fire hazardಘFuel can easily catch fire.
ದ
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.
ದ
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 poisoningಘFuel is poisonous and a health hazard.
ದ
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.
ದ
Remove the seat. (
ದ
Turn the handleb of the fuel tap to the OFF position. (Figureb500137-10b
ದ
Pull off the fuel hose.
P. 69)
P. 20)
Info
Remaining fuel may run out of the fuel hose.
ದ
Remove screwsb with collar sleeve.
(Every EXC-R models)
ದ Hang the horn and horn bracket to one side.
500157-10
ದ
Remove screwb with collar sleeve.
ದ
Remove the tube from the fuel tank vent line.
ದ
Pull both spoilers to the side of the radiator bracketb and take the fuel tank away
upwards.
500066-10
500067-10
Installing the fuel tankb
x
Danger
Fire hazardಘFuel can easily catch fire.
ದ
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.
ದ
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 poisoningಘFuel is poisonous and a health hazard.
ದ
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
MAINTENANCE WORK ON CHASSIS AND ENGINE
71
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Position the fuel tank and fit the two spoilers to the side of the radiator fixing.
ದ
Make sure that no cables or Bowden cables are trapped or damaged.
ದ
Mount the fuel tank vent hose.
ದ
Fit and tighten screwb with collar sleeve.
500067-01
Specification
Remaining screws, chassis
M6
10bNm (7.4blbfbft)
(Every EXC-R models)
ದ Position horn with horn bracket.
500066-11
ದ
Fit and tighten screwsb with collar sleeve.
Specification
Remaining screws, chassis
ದ
Connect fuel hose.
ದ
Mount the seat. (
M6
10bNm (7.4blbfbft)
P. 69)
500157-11
Cooling system
The water pumpb 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 capb. The specified coolant temperature is therefore permissible without danger of function problems.
120b°C (248b°F)
400335-10
Coolant ( P. 114)
Cooling is effected by the air stream.
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect.
(EXC-RbSIXbDAYS, XCR-WbZA)
The radiator fan provides extra cooling. It is controlled by a thermoswitch.
Checking antifreeze and coolant level
Warning
Danger of scaldingಘThe coolant gets very hot when the motorcycle is driven and is under high pressure.
ದ
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 poisoningಘCoolants are poisonous and a health hazard.
ದ
Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and
contact a doctor. Wash affected skin areas immediately with soap and water. 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE
72
ದ
Stand the motorcycle upright on a horizontal surface.
ದ
Remove the radiator cap.
ದ
Check antifreeze of coolant.
෥25… ෥45b°C (෥13… ෥49b°F)
»
If the antifreeze of the cooling liquid does not meet specifications:
ದ
ದ
Correct antifreeze of coolant.
Check the coolant level in the radiator.
400243-10
Coolant levelb above radiator fins.
»
If the level of the cooling liquid does not meet specifications:
ದ
Correct the coolant level.
Alternative 1
Coolant (
P. 114)
Alternative 2
Coolant (mixed ready to use) (
ದ
10bmm (0.39bin)
P. 114)
Refit the radiator cap.
Checking the coolant level
Warning
Danger of scaldingಘThe coolant gets very hot when the motorcycle is driven and is under high pressure.
ದ
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 poisoningಘCoolants are poisonous and a health hazard.
ದ
Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and
contact a doctor. Wash affected skin areas immediately with soap and water. 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.
ದ
Stand the motorcycle upright on a horizontal surface.
ದ
Remove the radiator cap.
ದ
Check the coolant level in the radiator.
Coolant levelb above radiator fins.
»
If the level of the cooling liquid does not meet specifications:
ದ
Correct the coolant level.
Alternative 1
Coolant (
400243-10
P. 114)
Alternative 2
Coolant (mixed ready to use) (
ದ
Draining coolantb
10bmm (0.39bin)
P. 114)
Refit the radiator cap.
x
Warning
Danger of scaldingಘThe coolant gets very hot when the motorcycle is driven and is under high pressure.
ದ
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 poisoningಘCoolants are poisonous and a health hazard.
ದ
Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and
contact a doctor. Wash affected skin areas immediately with soap and water. 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE
73
ದ
Stand the vehicle upright.
ದ
Place a suitable container under the water pump cover.
ದ
Remove screwb. Remove the radiator capb.
ದ
Completely drain the coolant.
ದ
Fit screwb with a new seal and tighten it.
Specification
Screw, water pump cover
M6x25
10bNm (7.4blbfbft)
400335-11
Refilling coolantb
x
Warning
Danger of poisoningಘCoolants are poisonous and a health hazard.
ದ
Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and
contact a doctor. Wash affected skin areas immediately with soap and water. 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.
ದ
Make sure that the screwb is tightened.
ದ
Stand the vehicle upright.
ದ
Pour coolant in up to measurementb above the radiator fins.
Specification
10bmm (0.39bin)
Coolant
0.95bl (1bqt.)
Coolant (
400244-10
ದ
Refit the radiator cap.
ದ
Make a short test ride.
ದ
Check the coolant level. (
P. 72)
Glass fiber yarn filling of main silencer
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.
Removing main silencer
Warning
Danger of burnsಘThe exhaust system gets very hot when the vehicle is driven.
ದ
Allow the exhaust system to cool down. Do not touch hot components.
400337-10
P. 114)
Coolant (mixed ready to use)
( P. 114)
ದ
Disconnect springb.
ದ
Remove screwsb and take off main silencer.
MAINTENANCE WORK ON CHASSIS AND ENGINE
74
Fitting the main silencer
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Mount the main silencer. Mount and tighten screwsb.
Specification
Remaining screws, chassis
M6
10bNm (7.4blbfbft)
ದ
Reconnect springb.
ದ
Pull off the air filter box lid in areab to the side and remove to the front.
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Insert the air filter box lid into the rear areab and clip it into the front areab.
400337-11
Dismounting the air filter box lid
400338-10
Installing the air filter box lid
400338-11
Removing the air filterb
x
Note
Engine failureಘUnfiltered intake air has a negative effect on the service life of the engine.
ದ
Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.
Warning
Environmental hazardಘProblem materials cause environmental damage.
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
500107-10
ದ
Dismount the air filter box lid. (
ದ
Hang the air filter holderb out to the bottom and swing it to the side. Remove the
air filter with the air filter support.
ದ
Remove the air filter from the air filter support.
P. 74)
MAINTENANCE WORK ON CHASSIS AND ENGINE
Installing the air filterb
75
x
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Mount the clean air filter onto the air filter support.
ದ
Put in both parts together, position them and fix them with the air filter supportb.
Info
If the air filter is not correctly mounted, dust and dirt can penetrate into the
engine and can cause damage.
ದ
Install the air filter box lid. (
P. 74)
500107-10
Cleaning air filterb
x
Warning
Environmental hazardಘProblem materials cause environmental damage.
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.
ದ
Remove the air filter. (
ದ
Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.
Air filter cleaner (
P. 74)
P. 115)
Info
Only press the air filter to dry it, never wring it out.
ದ
Oil the dry air filter with a high/quality filter oil.
Oil for foam air filter (
P. 115)
ದ
Clean the air filter box.
ದ
Check carburetor connection boot for damage and tightness.
ದ
Install the air filter. (
P. 75)
Adjusting basic position of clutch lever
ದ
Adjust the basic setting of the clutch lever to your hand size by turning adjusting
screwb.
Info
500133-11
Turn the adjusting screw clockwise to increase the distance between the
clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the clutch lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
Checking fluid level of hydraulic clutch
Warning
Skin irritationsಘBrake fluid can cause skin irritation on contact.
ದ
Avoid contact with skin and eyes, and keep out of the reach of children.
ದ
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Info
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
76
ದ
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
ದ
Remove screwsb.
ದ
Take off coverb with membraneb.
ದ
Check the fluid level.
Fluid level under top level of container.
»
If the level of the cooling liquid does not meet specifications:
ದ
400339-10
4bmm (0.16bin)
Correct the fluid level of the hydraulic clutch.
Brake fluid DOT 5.1 (
P. 114)
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Position the cover with the membrane. Mount and tighten screws.
Info
Clean up overflowed or spilt fluid immediately with water.
Changing fluid level of hydraulic clutchb
x
Warning
Skin irritationsಘBrake fluid can cause skin irritation on contact.
ದ
Avoid contact with skin and eyes, and keep out of the reach of children.
ದ
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Environmental hazardಘProblem materials cause environmental damage.
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
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!
ದ
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
ದ
Remove screwsb.
ದ
Take off coverb with membraneb.
ದ
Fill the bleeding syringeb with the appropriate hydraulic fluid.
400339-10
Bleed syringe (50329050000)
Brake fluid DOT 5.1 (
ದ
500158-10
P. 114)
On the slave cylinder, remove the bleeder screwb and fit the bleeding syringeb.
MAINTENANCE WORK ON CHASSIS AND ENGINE
77
ದ
Inject the liquid into the system until it escapes from the bore holeb of the master cylinder without bubbles.
ದ
To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
ದ
Remove the bleeding syringe. Mount and tighten screws bleeder screw.
ದ
Correct the fluid level of the hydraulic clutch.
Specification
Fluid level under top level of container.
400340-10
4bmm (0.16bin)
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Position the cover with the membrane. Mount and tighten screws.
Info
Clean up overflowed or spilt fluid immediately with water.
Carburetor - idle
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.
Info
The carburetor and its components are subject to increased wear caused by engine vibration. Wear can result in malfunctioning.
400341-10
Carburetor - adjusting idleb
The idle speed is adjusted with the adjustment screwb.
The idle mixture is adjusted with the idle mixture adjustment screwb.
x
ದ
Screw in the idle adjusting screwb until it stops and then to the prescribed basic
setting.
Specification
Idle mixture adjusting screw (XCR-WbUSA)
Open
0.5bturn
Idle mixture adjusting screw (EXC-RbSIXbDAYS)
Open
1.0bturn
Idle mixture adjusting screw (XCR-WbZA, 530bEXC-RbEU, 530bEXC-RbAUS/UK)
400341-10
Open
1.5bturns
Idle mixture adjusting screw (450bEXC-RbEU, 450bEXC-RbAUS/UK, 450bEXCRbUSA)
Open
1.75bturns
Idle mixture adjusting screw (530bEXC-RbUSA)
Open
2.0bturns
Adjustment tool for mixture control screw (77329034000)
ದ
Run the engine until warm.
Specification
Warm-up time
ุb5bmin
MAINTENANCE WORK ON CHASSIS AND ENGINE
78
Danger
Danger of poisoningಘExhaust gases are poisonous and can result in unconsciousness and/or death.
ದ
ದ
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.
Adjust the idle speed with the adjusting screwb.
Specification
Choke function deactivated ದbThe choke lever is pushed in to the stop.
( P. 21)
Choke function deactivated ದbThe choke lever is pushed back to the stop.
( P. 21)
Idle speed
1550… 1650brpm
ದ
Turn the idle adjusting screwb slowly until the idle speed begins to fall.
ದ
Note the position and turn the idle adjusting screw slowly counterclockwise until
the idle speed falls.
ದ
Adjust to the point between these two positions with the highest idle speed.
Info
If there is a big engine speed rise, reduce the idle speed to a normal level
and repeat the above steps.
The extremely sporty rider will set the mixture about 1/4 of a turn back from
this ideal value (leaner, in a clockwise direction) since the engine becomes
hotter in sporting use.
If the procedure described here does not lead to satisfactory results, the
cause may be a wrongly dimensioned idling jet.
If you can turn the idle adjusting screw to the end without any change of
engine speed, you have to fit a smaller idling jet.
The idle adjusting screw must not be opened more than two turns. If more
than two turns are necessary (rich mixture), use a larger idling jet.
After changing the idling jet, start from the beginning with the adjusting
steps.
ದ
Adjust the idle speed with the adjusting screwb.
Specification
Choke function deactivated ದbThe choke lever is pushed in to the stop.
( P. 21)
Choke function deactivated ದbThe choke lever is pushed back to the stop.
( P. 21)
Idle speed
1550… 1650brpm
Info
Following extreme air temperature or altitude changes, adjust the idle speed
again.
Emptying the carburetor float chamberb
x
Danger
Fire hazardಘFuel can easily catch fire.
ದ
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.
ದ
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 poisoningಘFuel is poisonous and a health hazard.
ದ
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.
MAINTENANCE WORK ON CHASSIS AND ENGINE
79
Warning
Environmental hazardಘImproper handling of fuel is a danger to the environment.
ದ
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.
ದ
Turn the handleb of the fuel tap to the OFF position. (Figureb500137-10b
ದ
Guide the hose coming down behind the engine into a suitable container.
P. 20)
No more fuel flows from the tank to the carburetor.
Info
Water in the float chamber results in malfunctioning.
ದ
Undo the screwb (turn it counterclockwise) a few turns and drain the fuel from
the float chamber.
ದ
Tighten screwb.
400341-11
Checking engine oil level
Info
The engine oil level must be checked when the engine is cold.
ದ
Stand the motorcycle upright on a horizontal surface.
Condition
Engine is cold.
ದ
Check the engine oil level.
The engine oil must be between the halfway mark and the top of the oil level
viewerb.
»
If the engine oil level is below the specified level:
ದ
Top up the engine oil. (
P. 81)
200119-10
Changing engine oil and oil filter, cleaning engine oil screenb
ದ
Drain the engine oil and clean the engine oil screen. (
ದ
Remove the oil filter. (
ದ
Mount the oil filter. (
ದ
Fill up with engine oil. (
x
P. 79)
P. 80)
P. 80)
P. 81)
Draining engine oil, cleaning engine oil screenb
x
Warning
Danger of scaldingಘEngine oil and gear oil get very hot when the motocycle is driven.
ದ
Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.
Warning
Environmental hazardಘProblem materials cause environmental damage.
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Drain the engine oil only when the engine is warm.
ದ
Stand the motorcycle on its side stand on a horizontal surface.
MAINTENANCE WORK ON CHASSIS AND ENGINE
80
ದ
Place a suitable container under the engine.
ದ
Remove engine oil plug screenb.
ದ
Completely drain the engine oil.
ದ
Thoroughly clean the plug and gear oil screen.
ದ
Clean the sealing area on the engine.
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Fit plugb for the engine oil screen and tighten it.
Specification
200112-10
Removing the oil filterb
Plug, engine oil screen
M17x1,5
20bNm
(14.8blbfbft)
x
Warning
Danger of scaldingಘEngine oil and gear oil get very hot when the motocycle is driven.
ದ
Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.
Warning
Environmental hazardಘProblem materials cause environmental damage.
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
ದ
Place a suitable container under the engine.
ದ
Remove screwsb. Remove oil filter coverb with O-ring.
ದ
Pull the oil filter insertb out of the oil filter casing.
200113-10
Circlip pliers reverse (51012011000)
ದ
Completely drain the engine oil.
ದ
Thoroughly clean parts and sealing area.
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Lay the motorcycle on its side and fill the oil filter housing to about 1/3 full with
engine oil.
ದ
Fill the oil filterb with engine oil and place it in the oil filter container.
ದ
Lubricate the O/ringb of the oil filter cover.
200114-10
Mounting oil filterb
x
200114-11
MAINTENANCE WORK ON CHASSIS AND ENGINE
ದ
Refit the oil filter coverb.
ದ
Mount and tighten screwsb.
81
Specification
Screw, oil filter cover
ದ
M5
6bNm (4.4blbfbft)
Stand the motorcycle up.
200113-11
Filling up with engine oilb
x
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
ದ
Remove the screw capb on the generator cover and fill up with engine oil.
Engine oil
ದ
0.6bl (0.6bqt.)
Engine oil (SAE 10W/50) (
P. 114)
Mount and tighten screw capb.
Danger
Danger of poisoningಘExhaust gases are poisonous and can result in unconsciousness and/or death.
ದ
200115-10
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.
ದ
Start the engine and check that it is oil-tight.
ದ
Check the engine oil level. (
P. 79)
Topping up engine oil
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
ದ
Remove the screw capb on the generator cover and fill up with engine oil.
Engine oil (SAE 10W/50) (
ದ
P. 114)
Mount and tighten screw capb.
Danger
Danger of poisoningಘExhaust gases are poisonous and can result in unconsciousness and/or death.
ದ
200115-10
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.
ದ
Start the engine and check that it is oil-tight.
ದ
Check the engine oil level. (
P. 79)
Checking gear oil level
Info
The gear oil level must be checked when the engine is cold.
ದ
Stand the motorcycle upright on a horizontal surface.
MAINTENANCE WORK ON CHASSIS AND ENGINE
82
Condition
Engine is cold.
ದ
Remove gear oil level check screwb. Stand the vehicle upright.
ದ
Check the gear oil level.
A small amount of gear oil should flow out.
»
If no gear oil flows out:
ದ
ದ
200116-10
Top up with gear oil. (
P. 83)
Mount and tighten the gear oil level check screw.
Specification
Screw, gear oil level check
Changing gear oil, cleaning gear oil screenb
M6
10bNm
(7.4blbfbft)
x
ದ
Drain the gear oil and clean the gear oil screen. (
ದ
Fill up with gear oil. (
P. 82)
P. 83)
Draining gear oil, cleaning gear oil screenb
x
Warning
Danger of scaldingಘEngine oil and gear oil get very hot when the motocycle is driven.
ದ
Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.
Warning
Environmental hazardಘProblem materials cause environmental damage.
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Drain the gear oil only when the engine is warm.
ದ
Stand the motorcycle on its side stand on a horizontal surface.
ದ
Place a suitable container under the engine.
ದ
Remove the gear oil drain plugb.
ದ
Remove the gear oil screen plugb.
ದ
Completely drain the gear oil.
ದ
Thoroughly clean the gear oil drain plug with a magnet.
ದ
Thoroughly clean the drain plug and gear oil screen with a magnet.
ದ
Clean the sealing surface on the engine.
ದ
Check parts for damage and wear. Replace damaged or worn parts.
ದ
Refit gear oil drain plugb with seal ring and tighten it.
Specification
Gear oil drain plug with magnet
ದ
M12x1,5
20bNm
(14.8blbfbft)
Fit the plugb for the gear oil screen and tighten it.
Specification
Plug, gear oil screen
500159-10
M16x1,5
20bNm
(14.8blbfbft)
MAINTENANCE WORK ON CHASSIS AND ENGINE
Filling up with gear oilb
83
x
Info
Too little gear oil or poor-quality oil results in premature wear to the transmission.
ದ
Remove the screw capb and fill up with gear oil.
Gear oil
ದ
0.9bl (1bqt.)
Engine oil (SAE 10W/50) (
P. 114)
Mount and tighten screw capb.
Danger
Danger of poisoningಘExhaust gases are poisonous and can result in unconsciousness and/or death.
ದ
200118-10
Topping up with gear oilb
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.
ದ
Start the engine and check that it is oil-tight.
ದ
Check the gear oil level. (
P. 81)
x
Info
Too little gear oil or poor-quality oil results in premature wear to the transmission.
ದ
Remove gear oil level check screwb.
200116-10
ದ
Remove screw capb. Stand the vehicle upright.
ದ
Top up with gear oil until it flows out of the bore of the gear oil level screw.
Engine oil (SAE 10W/50) (
ದ
P. 114)
Mount and tighten the gear oil level check screw.
Specification
Screw, gear oil level check
ದ
M6
10bNm (7.4blbfbft)
Mount and tighten screw capb.
200118-11
Danger
Danger of poisoningಘExhaust gases are poisonous and can result in unconsciousness and/or death.
ದ
ದ
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.
Start the engine and check that it is oil-tight.
TROUBLESHOOTING
84
7528%/(6+227,1*
Faults
Possible cause
Measure
The engine cannot be cranked (electric
starter).
Operating error
ದ
Carry out instructions on starting.
( P. 26)
Battery discharged
ದ
Recharge the battery. (
ದ
Check the cause of discharging.
ದ
Remove the fuse. (
P. 69)
ದ
Replace the fuse. (
P. 69)
ದ
Start the engine with the kickstarter.
ದ
Recharge the battery. Establish the
reason for discharging or have it
checked in a KTM workshop.
Operating error
ದ
Carry out instructions on starting.
( P. 26)
Motorcycle was out of use for a long time
and there is old fuel in the float chamber
ದ
Empty the carburetor float chamber.
( P. 78)
Fuel feed interrupted
ದ
Check tank vent.
ದ
Clean fuel tap.
ದ
Clean carburetor.
Engine flooded
ದ
Clean and dry spark plug or replace if
necessary.
Spark plug oily or wet
ದ
Clean and dry spark plug or replace if
necessary.
Electrode distance (plug gap) of spark
plug too wide
ದ
Adjust plug gap.
Fuse blown
Low external temperature
Engine turns but does not start.
P. 68)
Specification
Spark plug electrode gap
0.8… 0.9bmm (0.031… 0.035bin)
Spark plug connector or spark plug defective
Warning
Risk of injuryಘThe ignition system is under high voltage.
ದ
ದ
Do not touch parts of the ignition system. Have work on
the ignition system carried
out in an authorized KTM
workshop.
Remove spark plug, connect ignition
cable, hold spark plug to ground (bare
metal area on engine), and try to start
the engine.
Specification
You should see a strong spark on the
spark plug.
ದ
If there is no spark, change the spark
plug.
ದ
If there is still no spark, remove the
spark plug cap from the ignition cable,
hold it at the specified distance from
the ground contact, and try to start the
engine.
Specification
5bmm (0.2bin)
ದ
If you now have a spark, replace the
spark plug connector.
ದ
If there is no spark, have the ignition
system checked.
Short-circuit cable in cable harness
frayed, short-circuit button or emergency
OFF switch defective
ದ
Check wiring harness. (visual check)
ದ
Check electrical system.
Socket connector of CDI control device,
pulse generator or ignition coil oxidized.
ದ
Clean socket connector and treat it
with contact spray.
TROUBLESHOOTING
85
Faults
Possible cause
Measure
Engine turns but does not start.
Water in carburetor or jets blocked
ದ
Clean carburetor.
Engine has no idle.
Idling jet blocked
ದ
Clean carburetor.
Adjusting screws on carburetor distorted
ದ
Have the carburetor adjusted.
Spark plug defective
ದ
Change spark plug.
Ignition system defective
ದ
Have ignition system checked.
Carburetor running over because float
needle dirty or worn
ದ
Have carburetor checked.
Loose carburetor jets
ದ
Have carburetor checked.
Electronic ignition adjustment defective
ದ
Have ignition system checked.
Fuel feed interrupted
ದ
Check tank vent.
ದ
Clean fuel tap.
ದ
Clean carburetor.
Air filter very dirty
ದ
Clean the air filter. (
Exhaust system leaky, deformed or too little glass fiber yarn filling in main silencer
ದ
Check exhaust system for damage.
ದ
Change glass fiber yarn filling of main
silencer.
Valve clearance too little
ದ
Have valve clearance adjusted.
Engine does not speed up.
Engine has too little power.
Engine stalls or is popping into the carburetor
Engine overheats.
P. 75)
Electronic ignition adjustment defective
ದ
Have ignition system checked.
Lack of fuel
ದ
Clean and check the fuel system and
carburetor.
Engine takes in bad air
ದ
Check rubber sleeves and carburetor
for tightness.
Too little coolant in cooling system
ದ
Check the cooling system for leakage.
ದ
Check the coolant level. (
Too little air stream
ದ
Switch off engine when standing.
Radiator fins very dirty
ದ
Clean radiator fins.
Foam formation in cooling system
ದ
Drain the coolant. (
P. 72)
P. 73)
P. 72)
ದ
Refill the coolant. (
Bent radiator hose
ದ
Replace the radiator hose.
Thermostat defective
ದ
Have thermostat removed and checked.
Specification
Opening temperature: 70b°C (158b°F)
Defect in radiator fan system
(EXC-RbSIXbDAYS, XCR-WbZA)
ದ
Have the radiator fan system checked.
Engine vent hose bent
ದ
Route the vent hose without bends or
replace it if necessary.
Engine oil level too high
ದ
Check the engine oil level. (
Engine oil too thin (low viscosity)
ದ
Change the engine oil and oil filter and
clean the engine oil screen. ( P. 79)
Battery discharged
Battery is not charged by generator
ದ
Check electrical system.
Speedometer values deleted (time, stop
watch, lap times)
The battery in the speedometer ist empty.
ದ
Change the battery in the speedometer.
High oil consumption
P. 79)
CLEANING
86
&/($1,1*
Cleaning motorcycle
Note
Material damageಘDamage and destruction of components by high-pressure cleaning equipment.
ದ
Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts.
Warning
Environmental hazardಘProblem materials cause environmental damage.
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
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.
ದ
Before you clean the motocycle, seal the exhaust system to prevent penetration by water.
ದ
First remove coarse dirt particles with a gentle water spray.
ದ
Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush.
Motorcycle cleaner (
P. 115)
Info
Use warm water containing normal motorcycle cleaner and a soft sponge.
ದ
After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly.
ದ
Empty the carburetor float chamber. (
P. 78)
Warning
Danger of accidentsಘReduced braking due to wet or dirty brakes.
ದ
ದ
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.
Info
The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.
ದ
Push back the protection covers on the handlebar instruments to allow water to evaporate.
ದ
After the motorcycle has cooled off, oil or grease all moving parts and bearings.
ದ
Clean the chain. (
ದ
Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.
P. 50)
Cleaning and polishing materials for metal, rubber and plastic (
ದ
Treat all painted parts with a mild paint polish.
High-luster polish for paint (
ದ
P. 115)
P. 116)
To prevent electrical problems, treat electric contacts and switches with contact spray.
Contact spray (
P. 116)
(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA)
ದ Lubricate the steering lock.
Universal oil spray (
P. 115)
STORAGE
87
6725$*(
Storage
Warning
Danger of poisoningಘFuel is poisonous and a health hazard.
ದ
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.
Info
If you want to garage the motorcycle for a longer period, take the following actions.
Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you
should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the
start of the new season.
ದ
Clean the motorcycle. (
ದ
Change the engine oil and oil filter and clean the engine oil screen. (
ದ
Change the gear oil and clean the gear oil screen. (
ದ
Check the antifreeze and coolant level. (
ದ
Drain the fuel from the tanks into a suitable container.
ದ
Empty the carburetor float chamber. (
ದ
Checking the tire air pressure. (
ದ
Remove the battery. (
ದ
Recharge the battery. (
P. 86)
P. 79)
P. 82)
P. 71)
P. 78)
P. 66)
P. 67)
P. 68)
Specification
Storage temperature of battery without direct sunshine.
ದ
0… 35b°C (32… 95b°F)
The storage place should be dry and not subject to large temperature differences.
Info
KTM recommends propping up the motorcycle.
ದ
Jack up the motorcycle. (
ದ
Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping,
thus causing corrosion.
P. 32)
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
ದ
Remove the motorcycle from the work stand. (
ದ
Install the battery. (
ದ
Fill up with fuel. (
ದ
Checks before putting into operation (
ದ
Make a test ride.
P. 67)
P. 28)
P. 26)
P. 32)
TECHNICAL DATA - ENGINE
88
7(&+1,&$/ '$7$ (1*,1(
Design
1-cyliner 4-stroke engine, water-cooled
Displacement (Every 450 models)
449.3bcm³ (27.418bcubin)
Displacement (Every 530 models)
510.4bcm³ (31.147bcubin)
Stroke (Every 450 models)
63.4bmm (2.496bin)
Stroke (Every 530 models)
72bmm (2.83bin)
Bore
95bmm (3.74bin)
Compression ratio
11,9:1
Idle speed
1550… 1650brpm
Control
4 valves controlled via rocker arm, drive via tooth/wheel chain
Valve diameter, intake
39.5bmm (1.555bin)
Valve diameter, exhaust
31.7bmm (1.248bin)
Valve clearance
Outfeed at: 20b°C (68b°F)
0.12… 0.17bmm (0.0047… 0.0067bin)
Infeed at: 20b°C (68b°F)
0.10… 0.15bmm (0.0039… 0.0059bin)
Crankshaft bearing
2 grooved ball bearings
Conrod bearing
Needle bearing
Piston pin bearing
not a bearing bush - DLC-plated piston pins
Pistons
Forged light alloy
Piston rings
1 compression ring, 1 oil scraper ring
Engine lubrication
Pressure circulation lubrication with 2 rotor pumps (engine) / 1
rotor pump (transmission)
Primary transmission
33:76
Clutch
Multidisc clutch in oil bath / hydraulically activated
Transmission ratio
1st gear
14:36
2nd gear
17:32
3rd gear
19:28
4th gear
22:26
5th gear
24:23
6th gear
26:21
Generator
12bV, 150bW
Ignition
Contactless controlled fully electronic ignition with digital ignition adjustment, type Kokusan
Spark plug
NGK LK AR 8A - 9
Spark plug electrode gap
0.8… 0.9bmm (0.031… 0.035bin)
Cooling
Water cooling, permanent circulation of coolant by water pump
Starting aid
Electric starter / kickstarter
Capacity - engine oil
Engine oil
0.6bl (0.6bqt.)
Engine oil (SAE 10W/50) (
P. 114)
0.9bl (1bqt.)
Engine oil (SAE 10W/50) (
P. 114)
Capacity - gear oil
Gear oil
TECHNICAL DATA - ENGINE
89
Capacity - coolant
Coolant
0.95bl (1bqt.)
Coolant (
P. 114)
Coolant (mixed ready to use) (
P. 114)
TECHNICAL DATA - ENGINE TIGHTENING TORQUES
90
7(&+1,&$/ '$7$ (1*,1( 7,*+7(1,1* 72548(6
Screw, cable holder in generator cover
M4
4bNm (3blbfbft)
Loctite® 243™
Oil jet, rocker arm lubrication
M5
2bNm (1.5blbfbft)
Loctite® 243™
Oil jet, piston cooling
M5
2bNm (1.5blbfbft)
Loctite® 243™
Screw, locking lever
M5
6bNm (4.4blbfbft)
Loctite® 243™
Screw, ignition pulse generator
M5
6bNm (4.4blbfbft)
Loctite® 243™
Screw, clutch spring
M6
10bNm (7.4blbfbft)
ದ
Locking screw for bearing
M5
6bNm (4.4blbfbft)
Loctite® 243™
Screw, oil filter cover
M5
6bNm (4.4blbfbft)
ದ
Screw, oil pump cover
M5
6bNm (4.4blbfbft)
Loctite® 222
Oil jet, conrod lubrication
M6x0,75
4bNm (3blbfbft)
Loctite® 243™
Nut, water-pump wheel
M6
6bNm (4.4blbfbft)
Loctite® 648™
Screw, kickstarter stop
M6
10bNm (7.4blbfbft)
Loctite® 243™
Screw, timing chain securing guide
M6
10bNm (7.4blbfbft)
Loctite® 243™
Screw, exhaust flange
M6
10bNm (7.4blbfbft)
ದ
Screw, torque governor
M6
10bNm (7.4blbfbft)
Loctite® 243™
Screw, starter motor
M6
10bNm (7.4blbfbft)
ದ
Screw, kickstarter spring hanger
M6
10bNm (7.4blbfbft)
ದ
Screw, timing chain guide rail
M6
10bNm (7.4blbfbft)
Loctite® 243™
Screw generator cover
M6x25
10bNm (7.4blbfbft)
ದ
Screw generator cover
M6x40
10bNm (7.4blbfbft)
ದ
Screw, gear oil level check
M6
10bNm (7.4blbfbft)
ದ
Screw, clutch cover
M6x25
10bNm (7.4blbfbft)
ದ
Screw, clutch cover
M6x30
10bNm (7.4blbfbft)
ದ
Screw, clutch cover
M6x55
10bNm (7.4blbfbft)
ದ
Screw, engine housing
M6x65
10bNm (7.4blbfbft)
ದ
Screw, engine housing
M6x80
10bNm (7.4blbfbft)
ದ
Screw, camshaft bearing support
M6
10bNm (7.4blbfbft)
Loctite® 243™
Screw, shift drum locating
M6
10bNm (7.4blbfbft)
Loctite® 243™
Screw, shift lever
M6
10bNm (7.4blbfbft)
Loctite® 243™
Screw, timing chain tensioning rail
M6
10bNm (7.4blbfbft)
Loctite® 243™
Screw, stator bracket
M6
10bNm (7.4blbfbft)
Loctite® 243™
Screw, valve cover
M6
10bNm (7.4blbfbft)
ದ
Screw, water pump cover
M6x25
10bNm (7.4blbfbft)
ದ
Screw, water pump cover
M6x55
10bNm (7.4blbfbft)
ದ
Screw, idler
M6
10bNm (7.4blbfbft)
Loctite® 243™
Screw, cylinder head
M6
10bNm (7.4blbfbft)
ದ
Screw, rocker arm bearing
M7x1
15bNm (11.1blbfbft)
ದ
Plug, oil channel
M7
9bNm (6.6blbfbft)
Loctite® 243™
Screw, kickstarter
M8
25bNm (18.4blbfbft)
Loctite® 243™
Plug, crankshaft location
M8
10bNm (7.4blbfbft)
ದ
Balancer shaft nut
M10x1
40bNm (29.5blbfbft)
ದ
Screw, unlocking of timing chain tensioner
M10x1
10bNm (7.4blbfbft)
ದ
Screw, engine sprocket
M10
60bNm (44.3blbfbft)
Loctite® 243™
Plug, oil channel
M10
15bNm (11.1blbfbft)
Loctite® 243™
TECHNICAL DATA - ENGINE TIGHTENING TORQUES
91
Screw, cylinder head
M10x1,25
Tightening sequence:
Tighten diagonally, beginning with the rear screw on
the chain shaft.
Step 1
10bNm (7.4blbfbft)
Step 2
30bNm (22.1blbfbft)
Step 3
50bNm (36.9blbfbft)
Engine oil (any)
Gear oil drain plug with magnet
M12x1,5
20bNm (14.8blbfbft)
ದ
Ignition rotor nut
M12x1
60bNm (44.3blbfbft)
ದ
Plug, SLS
M12x1,5
20bNm (14.8blbfbft)
ದ
Oil pressure control valve plug
M12x1,5
20bNm (14.8blbfbft)
ದ
Spark plug
M12x1,25
15… 20bNm (11.1…
14.8blbfbft)
ದ
Plug, rocker arm
M14x1,25
20bNm (14.8blbfbft)
ದ
Plug, gear oil screen
M16x1,5
20bNm (14.8blbfbft)
ದ
Plug, engine oil screen
M17x1,5
20bNm (14.8blbfbft)
ದ
Nut, inner clutch hub
M18x1,5
80bNm (59blbfbft)
ದ
Nut, primary gear
M20LHx1,5
150bNm (110.6blbfbft)
Loctite® 648™
Plug, timing chain tensioner
M24x1,5
25bNm (18.4blbfbft)
ದ
TECHNICAL DATA - CARBURETOR
92
7(&+1,&$/ '$7$ &$5%85(725
450bEXC-RbEU, 450bEXC-RbAUS/UK (3900I)
Carburetor type
KEIHIN FCR-MX 39
Carburetor identification number
3900I
Needle position
4th position from top
Idle mixture adjusting screw
Open
Pump membrane stop
1.75bturns
2.15bmm (0.0846bin)
Main jet
180
Jet needle
OBDYU (OBDTQ)
Idling jet
40
Main air jet
200
Idle air jet
100
Cold start jet
65 (85)
Leakage nozzle
40
Throttle slide
15
Slide stop
present
450bEXC-RbSIXbDAYS, 450bEXC-RbUSA, 450bXCR-W (3900L)
Carburetor type
KEIHIN FCR-MX 39
Carburetor identfication number
3900L
Needle position (450bXCR-WbUSA)
1st position from top
Needle position (450bEXC-RbSIXbDAYS)
3rd position from top
Needle position (450bEXC-RbUSA, 450bXCR-WbZA)
4th position from top
Idle mixture adjusting screw (450bXCR-WbUSA)
Open
0.5bturn
Idle mixture adjusting screw (450bEXC-RbSIXbDAYS)
Open
1.0bturn
Idle mixture adjusting screw (450bXCR-WbZA)
Open
1.5bturns
Idle mixture adjusting screw (450bEXC-RbUSA)
Open
1.75bturns
Pump membrane stop
2.15bmm (0.0846bin)
Main jet (450bEXC-RbSIXbDAYS, 450bEXC-RbUSA, 450bXCRWbUSA)
180
Main jet (450bXCR-WbZA)
185
Jet needle (450bXCR-W, 450bEXC-RbSIXbDAYS)
OBDTQ
Jet needle (450bEXC-RbUSA)
OBDYU
Idling jet (450bXCR-W, 450bEXC-RbSIXbDAYS)
40
Idling jet (450bEXC-RbUSA)
48
Main air jet
200
Idle air jet
100
Cold start jet
85
Leakage nozzle
40
Throttle slide
15
TECHNICAL DATA - CARBURETOR
93
530bEXC-RbEU, 530bEXC-RbAUS/UK (3900J)
Carburetor type
KEIHIN FCR-MX 39
Carburetor identfication number
3900J
Needle position
5th position from top
Idle mixture adjusting screw
Open
Pump membrane stop
1.5bturns
2.15bmm (0.0846bin)
Main jet
180
Jet needle
OBDZT (OBDTR)
Idling jet
40
Main air jet
200
Idle air jet
100
Cold start jet
65 (85)
Leakage nozzle
40
Throttle slide
15
Slide stop
present
530bEXC-RbSIXbDAYS, 530bEXC-RbUSA, 530bXCR-W (3900M)
Carburetor type
KEIHIN FCR-MX 39
Carburetor identfication number
3900M
Needle position (530bXCR-WbUSA)
1st position from top
Needle position (530bEXC-RbSIXbDAYS, 530bEXC-RbUSA)
3rd position from top
Needle position (530bXCR-WbZA)
4th position from top
Idle mixture adjusting screw (530bXCR-WbUSA)
Open
0.5bturn
Idle mixture adjusting screw (530bEXC-RbSIXbDAYS)
Open
1.0bturn
Idle mixture adjusting screw (530bXCR-WbZA)
Open
1.5bturns
Idle mixture adjusting screw (530bEXC-RbUSA)
Open
2.0bturns
Pump membrane stop
2.15bmm (0.0846bin)
Main jet (530bEXC-RbSIXbDAYS, 530bEXC-RbUSA, 530bXCRWbUSA)
180
Main jet (530bXCR-WbZA)
185
Jet needle (530bXCR-W, 530bEXC-RbSIXbDAYS)
OBDTR
Jet needle (530bEXC-RbUSA)
OBDZT
Idling jet (530bXCR-W, 530bEXC-RbSIXbDAYS)
40
Idling jet (530bEXC-RbUSA)
48
Main air jet
200
Idle air jet
100
Cold start jet
85
Leakage nozzle
40
Throttle slide
15
TECHNICAL DATA - CHASSIS
94
7(&+1,&$/ '$7$ &+$66,6
Frame
Central tube frame made of chrome molybdenum steel tubing
Fork
WP 4860 MXMA PA
Suspension travel
front
300bmm (11.81bin)
Rear
335bmm (13.19bin)
Fork offset (EXC-RbSIXbDAYS, XCR-WbUSA)
Front marking
18bmm (0.71bin)
Rear marking
20bmm (0.79bin)
Fork offset (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)
20bmm (0.79bin)
Shock absorber
WP PDS 5018 DCC
Brake system
Disc brakes, brake calipers on floating bearings
Diameter of brake discs
front
260bmm (10.24bin)
Rear
220bmm (8.66bin)
Wear limit of brake discs
front
2.5bmm (0.098bin)
Rear
3.5bmm (0.138bin)
Tire air pressure off road
front
1.0bbar (15bpsi)
Rear
1.0bbar (15bpsi)
Road tire pressure (Every EXC-R models)
front
1.5bbar (22bpsi)
Rear
2.0bbar (29bpsi)
Rear wheel gearing (450bEXC-RbEU, 450bEXC-RbAUS/UK,
450bEXC-RbUSA)
15:45 (14:52)
Rear wheel gearing (450bEXC-RbSIXbDAYS, XCR-WbZA)
14:52
Rear wheel gearing (530bEXC-RbSIXbDAYS, XCR-WbUSA)
14:50
Rear wheel gearing (530bEXC-RbEU, 530bEXC-RbAUS/UK)
15:45 (14:50)
Chain
5/8 x 1/4"
Rear sprockets available
38, 40, 42, 45, 48, 49, 50, 51, 52
Steering head angle
63.5°
Wheelbase
1475±10bmm (58.07±0.39bin)
Seat height unloaded
925bmm (36.42bin)
Ground clearance unloaded
380bmm (14.96bin)
Weight without fuel (EXC-RbEU, EXC-RbAUS/UK,
EXC-RbSIXbDAYS)
113.9bkg (251.1blb.)
Weight without fuel (XCR-WbUSA)
112.2bkg (247.4blb.)
Weight without fuel (XCR-WbZA)
113bkg (249blb.)
Weight without fuel (EXC-RbUSA)
114.8bkg (253.1blb.)
Maximum permissible front axle load
145bkg (320blb.)
Maximum permissible rear axle load
190bkg (419blb.)
Maximum permissible overall weight
335bkg (739blb.)
4Ah battery
YTX5L-BS
Battery voltage: 12bV
Nominal capacity: 4bAh
maintenance-free
TECHNICAL DATA - CHASSIS
95
Lighting equipment
Headlight (EXC-RbEU, EXC-RbAUS/UK,
EXC-RbSIXbDAYS, EXC-RbUSA, XCR-WbZA)
BA20d
12bV
35/35bW
Parking light (EXC-RbEU, EXC-RbAUS/UK,
EXC-RbSIXbDAYS, EXC-RbUSA, XCR-WbZA)
W2,1x9,5d
12bV
5bW
Indicator lights (Every EXC-R models)
W2x4,6d
12bV
1.2bW
Flasher light (EXC-RbEU, EXC-RbAUS/UK)
BA15s
12bV
10bW
Flasher light (EXC-RbUSA)
BAU15s
12bV
10bW
Brake / tail light (EXC-RbEU,
EXC-RbAUS/UK, EXC-RbSIXbDAYS,
XCR-WbZA)
LED
Brake / tail light (EXC-RbUSA)
BAY15d
12bV
21/5bW
Licence plate lamp (EXC-RbEU, EXCRbAUS/UK)
W2,1x9,5d
12bV
5bW
Validity
Front tire
Rear tire
(Every EXC-R models)
90/90b-b21b48bM+SbMbTT
Metzeler MCEb6bDAYSbEXTREME
140/80b-b18b70bM+SbMbTT
Metzeler MCEb6bDAYSbEXTREME
(Every XCR-W models)
80/100b-b21b51bMbTT
Bridgestone M59
110/100b-b18b64bMbTT
Bridgestone M402
Tires
For further information, see:
http://www.ktm.com
Capacity - fuel
Tank capacity (EXC-RbEU,
EXC-RbAUS/UK,
EXC-RbSIXbDAYS, XCR-WbZA)
9bl (2.4bUSbgal)
Super unleaded (ROZ 95 / RON 95 / PON 91) (
P. 114)
Tank capacity (EXC-RbUSA,
XCR-WbUSA)
9.2bl (2.43bUSbgal)
Super unleaded (ROZ 95 / RON 95 / PON 91) (
P. 114)
TECHNICAL DATA - FORK
96
7(&+1,&$/ '$7$ )25.
Fork part number (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCRW)
14.18.7D.06
Fork part number (EXC-RbSIXbDAYS)
14.18.7D.35
Fork
WP 4860 MXMA PA
Compression damping (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)
Comfort
24bclicks
Standard
20bclicks
Sport
18bclicks
Compression damping (EXC-RbSIXbDAYS)
Comfort
24bclicks
Standard
22bclicks
Sport
18bclicks
Rebound damping (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)
Comfort
20bclicks
Standard
18bclicks
Sport
18bclicks
Rebound damping (EXC-RbSIXbDAYS)
Comfort
20bclicks
Standard
20bclicks
Sport
18bclicks
Spring length with preload spacer(s)
510bmm (20.08bin)
Spring rate (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)
Weight of rider: 65… 75bkg (143… 165blb.)
4.4bN/mm (25.1blb/in)
Weight of rider: 75… 85bkg (165… 187blb.)
4.6bN/mm (26.3blb/in)
Weight of rider: 85… 95bkg (187… 209blb.)
4.8bN/mm (27.4blb/in)
Spring rate (EXC-RbSIXbDAYS)
Weight of rider: 65… 75bkg (143… 165blb.)
4.6bN/mm (26.3blb/in)
Weight of rider: 75… 85bkg (165… 187blb.)
4.8bN/mm (27.4blb/in)
Air chamber length
100+30
bmm (3.94+1.18
bin)
෥20
෥0.79
Spring preload - PreloadbAdjuster (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)
Comfort
2bturns
Standard
4bturns
Sport
7bturns
Spring preload - PreloadbAdjuster (EXC-RbSIXbDAYS)
Comfort
2bturns
Standard
2bturns
Sport
7bturns
Fork length
Fork oil (
940bmm (37.01bin)
P. 114)
SAE 5
TECHNICAL DATA - SHOCK ABSORBER
7(&+1,&$/ '$7$ 6+2&. $%625%(5
Shock absorber part number (EXC-RbEU, EXC-RbAUS/UK, EXCRbUSA, XCR-W)
12.18.7D.06
Shock absorber part number (EXC-RbSIXbDAYS)
12.18.7D.35
Shock absorber
WP PDS 5018 DCC
Compression damping, low-speed
Comfort
18bclicks
Standard
15bclicks
Sport
12bclicks
Compression damping, high-speed
Comfort
2bturns
Standard
1.5bturns
Sport
1bturn
Rebound damping
Comfort
24bclicks
Standard
22bclicks
Sport
20bclicks
Spring preload
Standard
9bmm
Spring rate
Weight of rider: 65… 75bkg (143… 165blb.)
69bN/mm (394blb/in)
Weight of rider: 75… 85bkg (165… 187blb.)
72bN/mm (411blb/in)
Weight of rider: 85… 95bkg (187… 209blb.)
76bN/mm (434blb/in)
Spring length
250bmm (9.84bin)
Gas pressure
10bbar (145bpsi)
Static sag
35bmm (1.38bin)
Riding sag
105bmm (4.13bin)
Fitted length
411bmm (16.18bin)
97
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES
98
7(&+1,&$/ '$7$ &+$66,6 7,*+7(1,1* 72548(6
Spoke nipple, front wheel
M4,5
5bNm (3.7blbfbft)
ದ
Spoke nipple, rear wheel
M5
5bNm (3.7blbfbft)
ದ
Remaining nuts, chassis
M6
15bNm (11.1blbfbft)
ದ
Remaining screws, chassis
M6
10bNm (7.4blbfbft)
ದ
Screw, rear brake disc
M6
14bNm (10.3blbfbft)
ದ
Screw, front brake disc
M6
14bNm (10.3blbfbft)
ದ
Screw, shock absorber adjusting ring
M6
5bNm (3.7blbfbft)
ದ
Screw, ball joint of push rod on footbrake cylinder
M6
10bNm (7.4blbfbft)
ದ
Nut, rear sprocket screw
M8
35bNm (25.8blbfbft)
Loctite® 243™
Nut, rim lock
M8
10bNm (7.4blbfbft)
ದ
Remaining nuts, chassis
M8
30bNm (22.1blbfbft)
ದ
Remaining screws, chassis
M8
25bNm (18.4blbfbft)
ದ
Screw, front brake caliper
M8
25bNm (18.4blbfbft)
Loctite® 243™
Screw, top triple clamp
(EXC-RbSIXbDAYS, XCR-WbUSA)
M8
17bNm (12.5blbfbft)
ದ
Screw, top triple clamp (EXC-RbEU,
EXC-RbAUS/UK, EXC-RbUSA, XCRWbZA)
M8
20bNm (14.8blbfbft)
ದ
Screw, bottom triple clamp
(EXC-RbSIXbDAYS, XCR-WbUSA)
M8
12bNm (8.9blbfbft)
ದ
Screw, bottom triple clamp (EXC-RbEU,
EXC-RbAUS/UK, EXC-RbUSA, XCRWbZA)
M8
15bNm (11.1blbfbft)
ದ
Screw, fork stub
M8
15bNm (11.1blbfbft)
ದ
Screw, top steering stem
(EXC-RbSIXbDAYS, XCR-WbUSA)
M8
17bNm (12.5blbfbft)
Loctite® 243™
Screw, top steering stem (EXC-RbEU,
EXC-RbAUS/UK, EXC-RbUSA, XCRWbZA)
M8
20bNm (14.8blbfbft)
ದ
Screw, handlebar clamp (EXC-RbEU,
EXC-RbAUS/UK, EXC-RbUSA, XCR-W)
M8
20bNm (14.8blbfbft)
ದ
Screw, handlebar clamp
(EXC-RbSIXbDAYS)
M8
16bNm (11.8blbfbft)
ದ
Screw, engine brace
M8
33bNm (24.3blbfbft)
ದ
Screw, subframe
M8
35bNm (25.8blbfbft)
Loctite® 243™
Screw, side stand fixing
M8
40bNm (29.5blbfbft)
Loctite® 243™
Engine carrying screw
M10
60bNm (44.3blbfbft)
ದ
Remaining nuts, chassis
M10
50bNm (36.9blbfbft)
ದ
Remaining screws, chassis
M10
45bNm (33.2blbfbft)
ದ
Screw, handlebar support
M10
40bNm (29.5blbfbft)
Loctite® 243™
Nut, seat fixing
M12x1
20bNm (14.8blbfbft)
ದ
Screw, top shock absorber
M12
80bNm (59blbfbft)
Loctite® 243™
Screw, bottom shock absorber
M12
80bNm (59blbfbft)
Loctite® 243™
Nut, swingarm pivot
M16x1,5
100bNm (73.8blbfbft)
ದ
Screw-in nozzles, cooling system
M20x1,5
12bNm (8.9blbfbft)
Loctite® 243™
Nut, rear wheel spindle
M20x1,5
80bNm (59blbfbft)
ದ
Screw, top steering head
M20x1,5
10bNm (7.4blbfbft)
ದ
Screw, bottom steering head (EXCRbSIXbDAYS, XCR-WbUSA)
M20x1,5
60bNm (44.3blbfbft)
Loctite® 243™
Screw, front wheel spindle
M24x1,5
40bNm (29.5blbfbft)
ದ
99
br
dk
pu
bl
4
2
wh
bu
re
ye-re
br
1
br
br - bl
1
3
1
bt
bu
gn
1
9
ye
C_BC /6
5
2
C_BF1/1
C _ BA 1 / 1
2
1
ck
C _ BG / 3
C _B T / 3
3
6
C_BK /4
4
3 2 1
C_BR/4
8
M
2
10
A
7
C _A F / 4
4 3
bl
cl
G
1
C_AH2/2
2
wh
br
2
4
3
1
2
3
ye-re
cs
C_AH/2
C _ A K/ 2
1 2
br
bl
pu
1
ye
1
C_CR1/1
6 4
re
C _ A C/ 6
cq
br
3
ye-re
re
C_BS/2
dl
2 1
1
C_A T 1 / 2
2
C _A L 1 / 2
br
bl
1
2
wh-gn
wh
br
2
U
C _B S/ 2
C_BV/2
2.2 2.1
5
C_BG/3
3
2
bl
C_BV/2
C_BO/2
1
br
2
ye-re
br
bl
C_AK1/2
2
ye
y e -b l
1
C _A L / 2
2
C_BG1/3
bs v
bu
1
y e -b l
1
1
wh
wh-gn
2.1
2
C_AM/3
3
br
br
2
br
bl
6 11 10 12 13 14
pu
C_CX/2
C_CX1/2
bl
br
gn
bu
C _ EI / 1
C_BA2/1
ye
7
bu
5
C_A T /2
G
1
2
ye-bl
C_EH/1
1
gr
4
C_AR/ 3
3
ye-re
2
3
2
1
C_CW/2
C_AJ/3
C_CW1/2
ye
ye-re
or
bu-wh
2
ye-bl
bl
C_BU/18
4
wh
C_AJ1/3
C_CA/4
main harness 594.11.075.150
CDI harness 780.39.032.000
wh-gn
ye-re
br
1
bl
bm
bk
re-wh
wh-re
re-bl
1
2
2
wh
br
1
4
br
re
wiring di agr am
ye-re
gn
br
re
br
cr
C_CX2/2
C_DB/4
C_DA/4
bl
bl
bu
3
2
pu
wh
1
br
ct
bo
C_CW2/2
C_BP/4
C_CZ/3
C_CY/3
wh-re
ye
C_BF/1
bu-wh
3
pu
re-bl
ye
C_CR/1
or
gn
ye-bl
re-wh
gr
bl-wh
co
bn
cm
C_DG/4
C_CX3/2
C_AH1/2
C_CW3/2
C_CX/2
C_CW/2
ye-re
bl
100
WIRING DIAGRAM
:,5,1* ',$*5$0
Wiring diagram (EXC-RbEU)
C_BA/1
br
C_CE/4
C_DI/2
cp
cn
bq
bp
400308-10
WIRING DIAGRAM
Components
1
Battery
2
Generator
3
Ignition coil
4
Pulse generator
5
Voltage regulator/rectifier
6
Electric starter button
7
Starter relay with fuse
8
Starter motor
9
Light switch, horn button, short circuit button
10
Throttle valve sensor TPS
11
Ignition curve plug connection
12
CDI controller
13
Headlight
14
Parking light
15
Brake / tail light
16
Licence plate lamp
17
Speedometer
18
Wheel speed sensor
19
Tripmaster switch (optional)
20
Flasher switch
21
Flasher relay
22
Left front flasher
23
Left rear flasher
24
Right front flasher
25
Right rear flasher
26
Horn
27
Front brake light switch
28
Rear brake light switch
29
High beam indicator light
30
Flasher indicator light
31
Plug connector for radiator fan (optional)
Cable colors
bl
black
bl-wh
black-white
br
brown
br-bl
brown-black
bu
blue
bu-wh
blue-white
gn
green
gr
gray
or
orange
pu
violet
re
red
re-bl
red-black
re-wh
red-white
wh
white
wh-gn
white-green
wh-re
white-red
ye
yellow
ye-bl
yellow-black
ye-re
yellow-red
101
cn
1
2
1
3
2
2
4
3
1
bl
bl
ye-re
b r -b l
br
re
bu
wh
br
cp
ye
wh-gn
bu
gn
br
wh
C_BC /6
9
C_BF1/1
C _B A1 /1
cq
ye-bl
bs
G
6
C_BG/3
C _B T/ 3
3 2 1
C_AH2/2
2 1
or
pu
bl
C_AC/6
ye-re
re
ye-bl
C_BV/2
C_BO/2
2 1
C_BA2/1
ye-bl
1 2 4 5 7 6 11 10 12 13 14
C_BU/18
br
C_BK/4
2 1
C_BR/4
4 3
2 1
C_AM/3
3
C_AR/ 3
8
M
C_BS/2
dl
2 1
1
C _A L /2
2
C _ A T /2
4
7
30
A
2
C_ A F /4
4 3
C_A T 1 / 2
2 1
C _A L 1 / 2
3
ye
wh
G
2
1
br
ye-re
ye
wh
cs
C_AH/2
C _ A K/ 2
1 2
br
bl
pu
1
3
2
1
4
3
2
bl
br
br
pu
1
2
br
wh
wh-gn
2
1
U
C_BV/2
C_BS/2
2.2 2.1
5
C_BG/3
3 6 4 5 1 2
2.1
C _E I / 1
bl
ye-bl
C_EH/1
1
C_BA/1
ye-re
or
bm
bk
C_BG1/3
co v
pu
bl
1
2
2
1
4
3
wh
bu
gn
ye
re
br
br
pu
3
wh
br
C_CX/2
C_CX1/2
dk
C_AK1/2
ye-re
re-bl
re-wh
C_CR1/1
C_AJ1/3
C_CA/4
main harness 594.11.075.150
CDI harness 780.39.032.000
C_AJ/3
C_CW/2
3 2 1
C_CW1/2
ye
wh-gn
C_DB/4
C_DA/4
bl
wh-re
C_CR/1
C_BF/1
bu-wh
ye-re
br
ye-re
br
bu-wh
br
gr
ye-bl
re-wh
re-bl
gn
re
bu
ye
bl
w ir ing di agram
gn
ye-re
br
re
1 bl
2 br
2
1
br
bu
br
cr
C_CX2/2
ct
bo
C_CW2/2
C_BP/4
C_CZ/3
C_CY/3
br
bl
ye
bu
gr
bl-wh
cl
bn
bt
C_DG/4
C_CX3/2
C_AH1/2
C_CW3/2
C_CX/2
C_CW/2
ye-re
wh-re
bl
102
WIRING DIAGRAM
Wiring diagram (EXC-RbAUS/UK)
br
C_CE/4
2 1
C_DI/2
cm
ck
bq
bp
400334-10
WIRING DIAGRAM
Components
1
Battery
2
Generator
3
Ignition coil
4
Pulse generator
5
Voltage regulator/rectifier
6
Flasher switch
7
Starter relay with fuse
8
Starter motor
9
Light switch, horn button, short circuit button
10
Throttle valve sensor TPS
11
Ignition curve plug connection
12
CDI controller
13
Headlight
14
Parking light
15
Brake / tail light
16
Licence plate lamp
17
Electric starter button, emergency OFF switch
18
Flasher relay
19
Left front flasher
20
Left rear flasher
21
Right front flasher
22
Right rear flasher
23
Speedometer
24
Wheel speed sensor
25
Tripmaster switch (optional)
26
Horn
27
Front brake light switch
28
Rear brake light switch
29
High beam indicator light
30
Flasher indicator light
31
Plug connector for radiator fan (optional)
Cable colors
bl
black
bl-wh
black-white
br
brown
br-bl
brown-black
bu
blue
bu-wh
blue-white
gn
green
gr
gray
or
orange
pu
violet
re
red
re-bl
red-black
re-wh
red-white
wh
white
wh-gn
white-green
wh-re
white-red
ye
yellow
ye-bl
yellow-black
ye-re
yellow-red
103
cn
dm
4
2
br
wh
bu
re
ye-re
bl
cp
bq cq br
2
3
2
1
bs
6
4 3
C_BR/4
G
1
C_AH2/2
C_BK/4
2
2
1
cs
C_BY/4
C_CV/4
8
3
9
4
M
C _BK/4
2
1
C_BR/4
2
10
A
7
C _A F / 4
4 3
1
C_A T 1 / 2
2
C _A L 1 / 2
wh
br
2
4
3
1
2
3
ye-re
dk
C_AH/2
C _ A K/ 2
1 2
br
bl
pu
1
ye
1
C_CR1/1
C_BG/3
1
br
C_BC/6
5
cr
ye-re
C _B T /3
6 4
br
C_AC/6
3
ye-re
re
C _ B S/ 2
2 1
dn
1
C_A T /2
C _A L /2
2
br
bl
1
2
2
2
1
1
wh
gn-wh 3
br
br
pu
5
C_CW/2
1
br
br - bl
bl
C_BV/2
C_BO/2
1
ye-bl
3
2
3
1
2
2
ye-bl
1
C_AM/3
C_AR/ 3
C_BG1/3
1
ye
ye-bl
br
2
G
wh-gn
co v
1
wh-gn
C_BU/18
3
ye-re
wh
2
ye
pu
bl
2
gn
OFF
ON
C_BF/1
3
ye
6 11 10 12 13 14
bl
7
bl
C_AJ1/3
main harness 594.11.075.244
CDI harness 780.39.032.000
C_CX/2
C_CX1/2
C_AJ/3
C_BG/3
C_CW1/2
bl
br
1
bl
br
bl
5
re-wh
C_ E I /1
br
or
C_EH/1
2.1
gr
4
4
wh-re
re-bl
2
1
wh
br
2
ye-re
gn
bm
ye-re
bk
ye
C_CR/1
or
bu
bl
4
3
1
ye-re
br
ye
re
black
re
re-bl
bu
C_AK1/2
wh
br
bu-wh
C_DB/4
C_DA/4
bu
pu
bu-wh
3
gn
ye-re
or
wiring diagram
re
ye-re
ye-bl
1
2
2
1
gn bu
br
ct
C_CX2/2
br
re-wh
dl
bo
C_CW2/2
C_BP/4
C_CZ/3
C_CY/3
bl
br
cl
bn
bt
C_DG/4
C_CX3/2
C_AH1/2
C_CW3/2
C_CX/2
C_CW/2
pu
gr
bl-wh
ye-bl
C_BA/1
ye
bu
104
WIRING DIAGRAM
Wiring diagram (EXC-RbUSA)
C_CA/4
C_CE/4
U
ck
bp
cm
400309-10
WIRING DIAGRAM
Components
1
Battery
2
Generator
3
Ignition coil
4
Pulse generator
5
Voltage regulator/rectifier
6
Electric starter button
7
Starter relay with fuse
8
Starter motor
9
Emergency OFF switch
10
Throttle valve sensor TPS
11
Ignition curve plug connection
12
CDI controller
13
Headlight
14
Parking light
15
Brake / tail light
16
Light switch
17
Flasher switch
18
Flasher relay
19
Left front flasher
20
Left rear flasher
21
Right front flasher
22
Right rear flasher
23
Speedometer
24
Wheel speed sensor
25
Tripmaster switch (optional)
26
Horn button
27
Horn
28
Ignition switch
29
Front brake light switch
30
Rear brake light switch
31
High beam indicator light
32
Flasher indicator light
33
Plug connector for radiator fan (optional)
Cable colors
bl
black
bl-wh
black-white
br
brown
br-bl
brown-black
bu
blue
bu-wh
blue-white
gn
green
gn-wh
green-white
gr
gray
or
orange
pu
violet
re
red
re-bl
red-black
re-wh
red-white
wh
white
wh-gn
white-green
wh-re
white-red
105
WIRING DIAGRAM
ye
yellow
ye-bl
yellow-black
ye-re
yellow-red
106
WIRING DIAGRAM
107
cn
1
3
2
2
4
3
1
bl
bl
ye-re
b r -b l
br
re
bu
wh
br
bt
ye
wh-gn
9
6
C_BK/4
4 3 2 1
C_BR/4
5
7
br
C_BU/18
6 11 10 12 13 14
M
bq
5A
cq
t
C _ B L /2
C _ C V/ 2
br
co
C_BV/2
C_BS/2
2 1
2 1
C_AR/3
C_AM/3
3
8
M
1
C_A T /2
C _A L /2
2
7
10
A
2
C _A F / 4
4 3
C_A T 1 / 2
2 1
C _A L 1 / 2
3
ye
wh
G
2
1
br
ye-re
ye
wh
cm
C_AH/2
C _ A K/ 2
1 2
1
4
3
2
br
wh
wh-gn
5
C_BG/3
C_BF1/1
4
4
C_AJ/3
C_BC /6
C _ BA 1 / 1
ck
C_BO/2
cp
2 1
2
bk
3 2 1
C_AC/6
ye-re
ye-bl
1
bm
C_CR1/1
bl
ye-re
wh-re
br
bl
br
bl
bl
br
ye-re
br
re
ye-bl
C_BA/1
3 6 4 5 1 2
2.1
C _ EI / 1
C_EH/1
ye-bl
bl
wh
bu
gn
ye
re
br
ye-re
re-bl
re-wh
C_CA/4
main harness 594.11.075.000
CDI harness 780.39.032.000
ye
wh-gn
1
2
bs v
C_AK1/2
bl
wh-re
C_CR/1
1
2
bu
gn
br
wh
3
gn
C_DB/4
C_DA/4
C_BA2/1
ye-bl
ye-re
br
bu-wh
br
gr
ye-bl
re-wh
re-bl
gn
re
bu
ye
bl
wiring di agr am
re
C_BF/1
bu-wh
bu
br
cl
2
1
4
3
1
br
br
bn
bo
C_BP/4
C_CZ/3
C_CY/3
br
ye
bu
gr
bl-wh
C_AH1/2
C_DG/4
C_CX/2
C_CW/2
bl
bl
108
WIRING DIAGRAM
Wiring diagram (EXC-RbSIXbDAYS)
C_CE/4
U
C _B S/ 2
bp
400307-10
WIRING DIAGRAM
Components
1
Battery
2
Generator
3
Ignition coil
4
Pulse generator
5
Voltage regulator/rectifier
6
Electric starter button
7
Starter relay with fuse
8
Starter motor
9
Light switch, horn button, short circuit button
10
Throttle valve sensor TPS
11
Ignition curve plug connection
12
CDI controller
13
Headlight
14
Parking light
15
Brake / tail light
16
Thermoswitch
17
Speedometer
18
Wheel speed sensor
19
Tripmaster switch (optional)
20
Horn
21
Front brake light switch
22
Rear brake light switch
23
High beam indicator light
24
Radiator fan
25
Plug connector for flasher cable harness (optional)
26
Fuse, radiator fan
Cable colors
bl
black
bl-wh
black-white
br
brown
br-bl
brown-black
bu
blue
bu-wh
blue-white
gn
green
gr
gray
re
red
re-bl
red-black
re-wh
red-white
wh
white
wh-gn
white-green
wh-re
white-red
ye
yellow
ye-bl
yellow-black
ye-re
yellow-red
109
WIRING DIAGRAM
110
Wiring diagram (XCR-WbUSA)
bo
v
bl
bl
re
bu
wh
br
bp
bs
bq
br
ye-re
wh
br
wh
bl
gr
bl-wh
br
9
3
ye-bl
bu-wh
ye-bl
wh
bn
bm
ye
ye-re
wh-re
6
wiring diagramm
bu-wh
br
gr
ye-bl
re-wh
re-bl
gn
re
bu
ye
bl
bl
bl
bk
ye
bu
br
8
M
4
gn
br
ye-re
br
re
10
A
G
ye-re
7
3
2
ye
wh
1
br
ye-re
ye
wh
main harness 594.11.075.100
CDI harness 780.39.032.000
br
wh-re
re-bl
re-wh
wh
br
5
bt
U
400310-10
WIRING DIAGRAM
Components
1
Battery
2
Generator
3
Ignition coil
4
Pulse generator
5
Voltage regulator/rectifier
6
Electric starter button
7
Starter relay with fuse
8
Starter motor
9
Short circuit button
10
Throttle valve sensor TPS
11
Ignition curve plug connection
12
CDI controller
13
Light switch
14
Speedometer
15
Wheel speed sensor
16
Tripmaster switch (optional)
17
Plug connector for radiator fan (optional)
18
Plug connector, headlight (optional)
19
Plug connector, brake / tail light (optional)
21
Thermoswitch
Cable colors
bl
black
bl-wh
black-white
br
brown
bu
blue
bu-wh
blue-white
gn
green
gr
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
111
WIRING DIAGRAM
112
Wiring diagram (XCR-WbZA)
br
bn
bo
v
bl
bl
re
bu
wh
br
bs
bt
br
ye-re
wh
br
wh
bl
gr
bl-wh
br
9
3
ye-bl
bu-wh
ye-bl
wh
bq
bm
ye
6
wiring diagramm
bu-wh
br
gr
ye-bl
re-wh
re-bl
gn
re
bu
ye
bl
ye-re
wh-re
bl
br
bl
br
bl
M
br
t
cl
ck
bk
ye
bu
cm
bl
br
5A
ye-re
br
br
bl
8
re
M
4
gn
10
A
G
ye-re
7
3
2
ye
wh
1
br
ye-re
ye
wh
main harness 594.11.075.100
CDI harness 780.39.032.000
br
wh-re
re-bl
re-wh
br
wh
5
C_BS/2
U
bp
400311-10
WIRING DIAGRAM
Components
1
Battery
2
Generator
3
Ignition coil
4
Pulse generator
5
Voltage regulator/rectifier
6
Electric starter button
7
Starter relay with fuse
8
Starter motor
9
Short circuit button
10
Throttle valve sensor TPS
11
Ignition curve plug connection
12
CDI controller
13
Headlight
14
Parking light
15
Brake / tail light
16
Light switch
17
Speedometer
18
Wheel speed sensor
19
Tripmaster switch (optional)
20
Radiator fan
21
Thermoswitch
22
Fuse, radiator fan
Cable colors
bl
black
bl-wh
black-white
br
brown
bu
blue
bu-wh
blue-white
gn
green
gr
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
113
SUBSTANCES
114
68%67$1&(6
Super unleaded (ROZ 95 / RON 95 / PON 91)
according to
ದ DINbENb228 (ROZ 95 / RON 95 / PON 91)
Brake fluid DOT 5.1
according to
ದ DOT
Specification
ದ Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex® products.
Supplier
Motorex
ದ Motorex®bBrakebFluidbDOTb5.1
Coolant
Specification
ದ Use only suitable coolant (even in countries with high temperatures). Using inferior antifreeze can result in corrosion and foaming.
KTM recommends Motorex® products.
Mixture ratio
Antifreeze: ෥25… ෥45b°C (෥13… ෥49b°F)
50b% Anti-corrosion/antifreeze
50b% distilled water
Coolant (mixed ready to use)
෥40b°C (෥40b°F)
Antifreeze
Supplier
Motorex
ದ Motorex®bAntibFreeze
Engine oil (SAE 10W/50)
according to
ದ JASObT903bMA (
ದ
SAE (
P. 117)
P. 117) (SAE 10W/50)
Specification
ದ Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex® products.
Synthetic engine oil
Supplier
Motorex
ದ Motorex®bCrossbPowerb4T
Fork oil (SAE 5)
according to
ದ SAE ( P. 117) (SAE 5)
Specification
ದ Use only oils that comply with the specified standards (see specifications on the container) and that possesses the corresponding
properties. KTM recommends Motorex® products.
Supplier
Motorex
ದ Motorex®bRacingbForkbOil
AUXILIARY SUBSTANCES
$8;,/,$5< 68%67$1&(6
Universal oil spray
Specification
ದ KTM recommends Motorex® products.
Supplier
Motorex
ದ Motorex®bJokerb440bUniversal
Long-life grease
Specification
ದ KTM recommends Motorex® products.
Supplier
Motorex
ದ Motorex®bLongbThermb2000
Chain cleaner
Specification
ದ KTM recommends Motorex® products.
Supplier
Motorex
ದ Motorex®bChainbCleanb611
Offroad chain spray
Specification
ದ KTM recommends Motorex® products.
Supplier
Motorex
ದ Motorex®bChainbLubeb622
Air filter cleaner
Specification
ದ KTM recommends Motorex® products.
Supplier
Motorex
ದ Motorex®bTwinbAirbDirtbBiobRemover
Oil for foam air filter
Specification
ದ KTM recommends Motorex® products.
Supplier
Motorex
ದ Motorex®bTwinbAirbLiquidbPower
Motorcycle cleaner
Specification
ದ KTM recommends Motorex® products.
Supplier
Motorex
ದ Motorex®bMotobCleanb900
Cleaning and polishing materials for metal, rubber and plastic
Specification
ದ KTM recommends Motorex® products.
Supplier
Motorex
ದ Motorex®bProtectb&bShineb645
115
AUXILIARY SUBSTANCES
High-luster polish for paint
Specification
ದ KTM recommends Motorex® products.
Supplier
Motorex
ದ Motorex®bMotobPolish
Contact spray
Specification
ದ KTM recommends Motorex® products.
Supplier
Motorex
ದ Motorex®bAccubContact
116
STANDARDS
117
67$1'$5'6
JASObT903bMA
Different technical development directions required a new specification for 4-stroke motorcycles ದ 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 engines. With most motorcycles, the gearbox and the clutch are lubricated with the oil as the engine. The JASO
MA Standard meets these special requirements.
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity. The viscosity describes only one property of oil and says nothing about quality.
CONSUMER INFORMATION (EXC-R USA)
on upper frame tube
Chain tension
Before you go for the first ride
Type label CAN
Noise emission
Green sticker
on rear fender
on front frame tube
Type label USA
on swing arm LH
inside filter cover LH
on frame tube RH
on steering head tube
118
EAVP
CONSUMER INFORMATION (EXC-R USA)
119
REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect which could cause an accident resulting in injury or death, you should immediately inform
the National Highway Traffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it
may order a recall and remady campaign. However, NHTSA cannot become involved in individual problems between you, your dealer,
or KTM North America, Inc.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1–888–327–4236 or visit the website www.nhtsa.dot.gov,
or write to: NHTSA Headquarters, 1200 New Jersey Avenue, SE, West Buildding, Washington, DC 20590. You can also obtain
other information about motor vehicle safety from the Hotline.
NOISE EMISSION WARRANTY
KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent
buyers.
Warranty claims should be directed to:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001,
Phone: (440) 985–3553
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7
Phone: (450) 441–4451 x 39
www.ktmcanada.com
TAMPERING WARNING
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED. FEDERAL LAW PROHIBITS THE FOLLOWING ACTS OR CAUSING THEREOF:
1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device
or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate
purchaser or while it is in use, or
2) The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW.
1) Removal of, or puncturing the muffler, baffles, header pipes or any other components which conducts exhaust gases.
2) Removal or puncturing of any part of the intake system.
3) Lack of proper maintenance.
4) Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the
manufacturer.
WARNING STATEMENT
This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise,
the owner may become subject to penalties under state and local ordinances.
CONSUMER RIGHTS
Limited Warranty claims should be directed to an authorized KTM dealer. If you are not satisfied, please contact:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001,
Phone: (440) 985–3553
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7
Phone: (450) 441–4451 x 39
www.ktmcanada.com
Your rights may vary, please refer to the applicable state laws.
INDEX
120
,1'(;
A
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 75
Air filter
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Compression damping
fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Air filter box lid
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Compression damping, low-speed
of shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . 33
Antifreeze
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
B
Basic chassis setting
checking with rider's weight . . . . . . . . . . . . . . . . . . . . 32
Battery
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Brake discs
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Brake fluid
of rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . 61
Topping up brake fluid of front brake . . . . . . . . . . . . . . 56
Brake fluid level
of front brake, checking . . . . . . . . . . . . . . . . . . . . . . . 56
of rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . 60
Brake linings
of front brake, changing
of front brake, checking
of front brake, installing
of front brake, removing
of rear brake, changing
of rear brake, checking
of rear brake, installing
of rear brake, removing
.
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59
57
58
58
63
61
62
62
Compression damping, high-speed
of shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . 32
Coolant
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Coolant level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71-72
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
D
Dust boots
cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
E
Electric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Emergency OFF switch . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Engine
running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine oil
changing .
draining .
refilling . .
topping up
.
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79
79
81
81
Engine oil level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
engine oil screen
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Engine oil screen
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
C
F
Carburetor
adjusting idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
emptying the float chamber . . . . . . . . . . . . . . . . . . . . 78
idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Filler cap
closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chain
cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Chain guide
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Chain tension
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Chain wear
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Clutch
changing fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
checking fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Filling up
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 60
checking free play . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Fork
checking basic setting . . . . . . . . . . . . . . . . . . . . . . . . 37
Fork legs
bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Fork offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INDEX
121
Fork protector
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Front fender
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Front wheel
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Fuel tank
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuse
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
G
Gas Bowden cable route
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
gear oil
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Gear oil
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
gear oil level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
gear oil screen
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Gear oil screen
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
H
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
adjusting basic position . . . . . . . . . . . . . . . . . . . . . . .
adjusting free travel . . . . . . . . . . . . . . . . . . . . . . . . .
checking free play . . . . . . . . . . . . . . . . . . . . . . . . . .
10
56
56
55
Handlebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Headlight flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
I
Ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
K
Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
L
Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Lower triple clamp
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-45
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-44
M
Main silencer
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Motorcycle
cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
O
Oil filter
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Overview of indicator lamps . . . . . . . . . . . . . . . . . . . . . . . 13
OWNER'S MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
P
Play in gas Bowden cable
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Putting into operation
Advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . 24
after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Checks before putting into operation . . . . . . . . . . . . . . 26
R
Rear sprocket / engine sprocket
checking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Rear wheel
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Rebound damping
fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
of shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . 33
Riding sag
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
S
Seat
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Shock absorber
checking riding sag
checking static sag
fitting . . . . . . . . .
removing . . . . . . .
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35
34
36
36
Short circuit button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Speedometer
adjusting . . . . . . . . . . . .
Function description . . . .
Setting kilometers or miles
Setting the clock . . . . . .
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15
13
14
15
Spoke tension
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Spring preload
fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
of shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . 35
Start number plate
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INDEX
122
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Starting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
steering
locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Steering head bearing
greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Steering head bearing play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Storage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
T
Technical data
Carburetor . . . . . . . . . . .
Chassis . . . . . . . . . . . . .
Engine . . . . . . . . . . . . .
Fork . . . . . . . . . . . . . . .
Shock absorber . . . . . . .
Tightening torque - chassis
Tightening torque - engine
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. 92-93
. 94-95
. 88-89
. . . 96
. . . 97
. . . 98
. 90-91
Tire air pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 84-85
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-113
*3211254en*
3211254en
10/2007
Photo Mitterbauer
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
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