KTM 530 XC-W USA Owner Manual

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

– Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

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.

Notes/warnings

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

Info

Various notes and warning stickers are attached to the vehicle. Do not remove any notes and warning stickers. 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

– It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful information and many tips on how to operate and handle your motorcycle. Only then will you find out how to best customize the motorcycle for your own use and how you can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.

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

VIEW OF VEHICLE

3VIEW OF VEHICLE

3.1

View of the vehicle from the left front (example)

800014-10

Side stand

Shift lever

Chain guide

Fuel tap

Air filter box lid

Clutch lever

Hand brake lever

VIEW OF VEHICLE

3.2

View of the vehicle from the right rear (example)

Level viewer for brake fluid, rear

Fork compression adjustment

Foot brake pedal

Kickstarter

Horn

Filler cap

Fork rebound adjustment

Electric starter button

Speedometer

Short circuit button

Shock absorber compression adjustment

Shock absorber rebound adjustment

800013-10

LOCATION OF SERIAL NUMBERS

4LOCATION OF SERIAL NUMBERS

4.1

Chassis number

The chassis number

 is stamped on the steering head on the right.

4.2

Type label

500127-10

The type label

 is fixed to the front of the steering head.

4.3

Key number (all EXC models)

500128-10

The key number

 is stamped on the key strap.

4.4

Engine number

500125-10

The engine number sprocket.

 is stamped on the left side of the engine under the engine

4.5

Fork part number

500072-10

The fork part number

 is stamped on the inner side of the fork stub.

500082-10

LOCATION OF SERIAL NUMBERS

4.6

Shock absorber part number

The shock absorber part number

 is stamped on the top of the shock absorber above the adjusting ring on the engine side.

500129-10

OPERATING ELEMENTS

5OPERATING ELEMENTS

5.1

Clutch lever

The clutch lever

 is fitted on the left side of the handlebar.

The clutch is hydraulically operated and self-adjusting.

5.2

Hand brake lever

500133-10

Hand brake lever

 is located on the right side of the handlebar.

The hand brake lever is used to activate the front brake.

400196-10

5.3

Short circuit button (all XC‑W models)

The short circuit button

 is fitted on the left side of the handlebar.

Possible states

• Short circuit button in basic position – In this position, the ignition circuit is closed, and the engine can be started.

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

500132-10

5.4

Short circuit button (all EXC models)

The short circuit button

 is fitted on the left side of the handlebar.

Possible states

• Short circuit button in basic position – In this position, the ignition circuit is closed, and the engine can be started.

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

500134-10

5.5

Emergency OFF switch (EXC AUS)

The emergency OFF switch

 is fitted on the left side of the handlebar.

Possible states

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

Ignition on – In this position, the ignition circuit is closed, and the engine can be started.

500131-10

OPERATING ELEMENTS

5.6

Electric starter button (EXC EU, EXC SIX DAYS, XC-W)

The electric starter button

 is fitted on the right side of the handlebar.

Possible states

• Electric starter button in basic position

• Electric starter button pressed – In this position, the electric starter is actuated.

400198-10

5.7

Electric starter button (EXC AUS)

The electric starter button

 is fitted on the right side of the handlebar.

Possible states

• Electric starter button in basic position

• Electric starter button pressed – In this position, the electric starter is actuated.

5.8

Light switch (all EXC models)

500131-11

The light switch

 is fitted on the left side of the handlebar.

Possible states

Light off – Light switch is turned to the right. In this position, the light is switched off.

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

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

500134-12

5.9

Light switch (all XC‑W models)

500146-10

The light switch

 is on the right of the speedometer.

Possible states

(XC‑W ZA)

• Light off – Light switch is pressed in up to the stop. In this position, the light is switched off.

• Light on – Light switch is pulled out to the stop. In this position, the low beam and the tail light are switched on.

(XC‑W USA)

• The light switch has no function when delivered. – It can be used if lighting is fitted later.

5.10

Horn button (all EXC models)

The horn button

 is fitted on the left side of the handlebar.

Possible states

• Horn button in neutral position

• Horn button pressed – The horn is operated in this position.

500134-11

OPERATING ELEMENTS

5.11

Flasher switch (all EXC models)

Flasher switch

 is fitted on the left side of the handlebar.

Possible states

Flasher light off – Flasher switch is in the central position.

Flasher light, left, on – Flasher switch turned to the left.

Flasher light, right, on – Flasher switch turned to the right.

500145-10

5.12

Overview of indicator lamps (all EXC models)

Possible states

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

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

500147-01

5.13

Speedometer

– Press the key to change the display mode or change to one of the setup menus.

– Press the button to control different functions.

Info

In its condition at delivery, the display mode SPEED/H andSPEED/ODO is activated.

400312-01

5.14

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

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

OPERATING ELEMENTS

5.15

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.

5.16

Setting kilometers or miles

Info

If you change the unit, the value ODO is retained and converted accordingly.

The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed.

400329-01

Condition

The motorcycle is standing.

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

– Press the button for 3 - 5 seconds.

The Setup menu opens and the active functions are displayed.

– Press the button repeatedly until the Km/h/Mph display flashes.

Km/hadjusting

– Press the button .

Mphadjusting

– Press the button .

– Press the button 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.

5.17

Setting the clock

400330-01

Condition

The motorcycle is standing.

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

– Press the button for 3 - 5 seconds.

The hour display flashes.

– Set the hour display with the button and/or button .

– Press the button briefly.

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

– You can set the following segments in the same way as the hours by pressing the button and the button .

Info

The seconds can only be set to zero.

– Press the button 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

5.18

Adjusting the speedometer functions

Info

Upon delivery, only the SPEED/H and SPEED/ODO display modes are activated.

400318-01

Condition

The motorcycle is standing.

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

– Press the button for 3 - 5 seconds.

The Setup menu opens and the active functions are displayed.

– Switch to the function you require by briefly pressing the button .

The selected function flashes.

Activating a function

– Press the button .

The icon remains in the display and the display changes to the next function.

Deactivating a function

– Press the button .

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

– Activate or deactivate all functions accordingly.

– Press the button for 3 - 5 seconds.

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 is closed.

5.19

Querying the lap time

Info

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

Condition

The motorcycle is standing.

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

400321-01

– Press the button briefly.

LAP 1 appears on the left side of the display.

– Laps 1-10 can be displayed by pressing the button .

– The button has no function

– Press the button briefly.

Next display mode

Info

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

OPERATING ELEMENTS

5.20

SPEED display mode (speed)

400316-01

– Press the button briefly and repeatedly until

SPEED appears on the left side of the display.

The current speed is displayed in the

SPEED display mode.

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

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

5.21

SPEED/H display mode (service hours)

Condition

• Vehicle at a standstill

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

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

The service hour counter stores the total traveling time.

Info

The service hour counter is necessary for ensuring that maintenance work is carried out at the right intervals.

If the speedometer is in the H display mode at the start of the trip, it automatically changes to the

ODO display mode.

The H display mode is suppressed during travel.

Press the button . No function

Press the button for 3 - 5 seconds.

The display changes to the Setup menu of the speedometer functions.

Press the button briefly.

next display mode

5.22

SPEED/CLK display mode (time)

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

The time is displayed in the CLK display mode.

Press the button . No function

Press the button for 3 - 5 seconds.

The display changes to the Setup menu of the clock.

Press the button briefly.

next display mode

400319-01

5.23

SPEED/LAP display mode (lap time)

400320-01

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

In the LAP display mode, up to ten laps can be timed with the stop watch.

Info

If the lap time continues after you press the button , 9 memory locations are already occupied.

Lap 10 must be timed with the button .

Press the button . Starts or stops the clock.

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

Press the button for 3 - 5 seconds.

The stop watch and the lap time are reset.

OPERATING ELEMENTS

Press the button briefly.

next display mode

5.24

SPEED/ODO display mode (odometer)

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

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

Press the button . No function

Press the button for 3 - 5 seconds.

–

Press the button briefly.

next display mode

400317-01

5.25

SPEED/TR1 display mode (trip master 1)

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

TR1 (trip master 1) runs constantly and counts to 999.9.

You can use it to measure trips or the distance between refueling stops.

TR1 is coupled with A1 (average speed 1) and S1 (stop watch 1).

Info

If 999.9 is exceeded, the values of

TR1, A1 and S1 are automatically reset to

0.0.

400323-01

Press the button . No function

Press the button for 3 - 5 seconds.

The TR1, A1 and S1 displays are reset to 0.0.

Press the button briefly.

next display mode

5.26

SPEED/TR2 display mode (trip master 2)

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

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

The displayed value can be set manually with the button and the button . A very practical function for rides by the road book.

400324-01

Info

The

TR2 value can also be corrected manually during the trip using the button and the button .

If 999.9 is exceeded, TR2 is automatically reset to 0.0.

Press the button . Increases value TR2.

Press the button . Decreases value TR2.

Press the button for 3 - 5 seconds.

Press the button

Clears value

TR2.

next display mode briefly.

OPERATING ELEMENTS

5.27

SPEED/A1 display mode (average speed 1)

– Press the button briefly and repeatedly until

A1 appears at the top right of the display.

A1 (average speed 1) shows the average speed calculated on the basis of TR1 (trip master 1) and S1 (stop watch 1).

The calculation of this value is activated by the first impulse of the wheel speed sensor and ends 3 seconds after the last impulse.

400325-01

Press the button . No function

Press the button The TR1, A1 and S1 displays are reset to 0.0.

for 3 - 5 seconds.

Press the button briefly.

next display mode

5.28

SPEED/A2 display mode (average speed 2)

– Press the button briefly and repeatedly until A2 appears at the top right of the display.

A2 (average speed 2) shows the average speed on the basis of the current speed if the stop watch

S2 (stop watch 2) is running.

Info

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

400326-01

Press the button . No function

Press the button for 3 - 5 seconds.

–

Press the button briefly.

next display mode

5.29

SPEED/S1 display mode (stop watch 1)

400327-01

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

S1 (stop watch 1) shows the trip time on the basis of TR1 and continues running when an impulse is received from the wheel speed sensor.

The calculation of this value starts with the first impulse of the wheel speed sensor and ends three seconds after the last impulse.

Press the button . No function

Press the button for 3 - 5 seconds.

The

TR1, A1 and S1 displays are reset to 0.0.

Press the button briefly.

next display mode

5.30

SPEED/S2 display mode (stop watch 2)

400328-01

– Press the button briefly and repeatedly until

S2 appears at the top right of the display.

S2 (stop watch 2) is a manual stop watch.

If S2 is running in the background, the S2 display flashes in the speedometer display.

Press the button . Starts or stops S2.

Press the button . No function

Press the button for 3 - 5 seconds.

The S2 and A2 displays are reset to 0.0.

Press the button briefly.

next display mode

OPERATING ELEMENTS

Table of functions

Display Press the button .

SPEED/H display mode

(service hours)

No function

SPEED/CLK display mode

(time)

No function

SPEED/LAP display mode

(lap time)

Starts or stops the clock.

SPEED/ODO display mode

(odometer)

SPEED/TR1 display mode

(trip master 1)

SPEED/TR2 display mode

(trip master 2)

SPEED/A1 display mode

(average speed 1)

SPEED/A2 display mode

(average speed 2)

SPEED/S1 display mode

(stop watch 1)

SPEED/S2 display mode

(stop watch 2)

No function

Increases value TR2.

No function

Starts or stops S2.

Table of conditions and activability

Display

SPEED/H display mode (service hours)

SPEED/CLK display mode (time)

SPEED/LAP display mode (lap time)

SPEED/TR1 display mode (trip master 1)

SPEED/TR2 display mode (trip master 2)

SPEED/A1 display mode (average speed 1)

SPEED/A2 display mode (average speed 2)

SPEED/S1 display mode (stop watch 1)

SPEED/S2 display mode (stop watch 2)

Press the button .

No function

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

No function

Decreases value TR2.

No function

Press the button for 3 -

5 seconds.

The display changes to the Setup menu of the speedometer functions.

The display changes to the Setup menu of the clock.

The stop watch and the lap time are reset.

Press the button briefly.

next display mode next display mode next display mode

– next display mode

The TR1, A1 and S1 displays are reset to 0.0.

Clears value TR2.

next display mode next display mode

The

TR1, A1 and S1 displays are reset to 0.0.

– next display mode next display mode

The TR1, A1 and S1 displays are reset to 0.0.

The S2 and A2 displays are reset to 0.0.

next display mode next display mode

Vehicle at a standstill

•

Menu can be activated

•

OPERATING ELEMENTS

5.31

Fuel tap

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

With the tap handle carburetor.

 on the fuel tap, you can open or close the supply of fuel to the

Possible states

• Fuel supply closed OFF – No fuel can flow from the tank to the carburetor.

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

• Reserve fuel supply open RES – Fuel can flow from the tank to the carburetor. The fuel tank empties completely.

5.32

Opening filler cap

500137-10

– Press release button



, turn filler cap counterclockwise and lift it free.

5.33

Closing filler cap

400199-10

– Replace the filler cap and turn clockwise until the release button

 locks in place.

Info

Run the fuel tank breather hose

 without kinks.

400199-11

5.34

Choke (EXC AUS, XC‑W)

Choke

 is fitted on the left side of the carburetor.

Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.

Info

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

500135-10

Possible states

• Choke function activated – The choke lever is pulled out to the stop.

• Choke function deactivated – The choke lever is pushed in to the stop.

OPERATING ELEMENTS

5.35

Choke (EXC EU, EXC SIX DAYS)

The flasher switch

 is fitted on the left side of the handlebar.

Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.

Info

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

500136-10

Possible states

• Choke function activated – The choke lever is pulled to the stop.

• Choke function deactivated – The choke lever is pushed back to the stop.

5.36

Shift lever

 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.

5.37

Foot brake pedal

500138-11

Foot brake pedal

 is located in front of the right footrest.

The foot brake pedal is used to activate the rear brake.

5.38

Kickstarter

500139-10

Kickstarter

 is fitted on the right of the engine.

The engine can be started with either the kickstarter or the electric starter.

The upper part of the kickstarter can be swung out.

Info

Before riding, swing the upper part of the kickstarter inward toward the engine.

500148-10

OPERATING ELEMENTS

5.39

Side stand

500140-10

Note

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

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

Note

Material damage Damage and destruction of components by excessive load.

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

To park the motorcycle, press the side stand the motorcycle on it.

 with your foot to the ground and lean

When you are riding, the side stand band



 must be folded up and secured with the rubber

500141-10

5.40

Steering lock (all EXC models)

Steering lock

 is fitted on the left side of the steering head.

The steering lock is used to lock the steering. Steering, and therefore riding, is no longer possible.

500126-10

5.41

Locking the steering (all EXC models)

Note

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

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

– Park the motorcycle.

– Turn the handlebar as far as possible to the right.

– Insert the key in the steering lock, turn it to the left, press it in and turn it to the right. Remove the key.

Steering is no longer possible.

Info

Never leave the key in the steering lock.

OPERATING ELEMENTS

5.42

Unlocking the steering (all EXC models)

– 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.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION

6GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION

6.1

Advice on first use

Danger

Danger of accidents Danger from insufficient traffic competence.

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

Warning

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

– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing, which must be in perfect condition and meet legal requirements.

Warning

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

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

Warning

Danger of accidents Critical riding behavior due to inappropriate riding.

– Adapt your riding speed to the road conditions and your riding ability.

Warning

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

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

Warning

Danger of accidents Brake system failure.

– 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 accidents Unstable riding behavior.

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

Warning

Risk of misappropriation Usage by unauthorized persons.

– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.

Info

When using your motorcycle, remember that others may feel disturbed by excessive noise.

– Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.

You receive a delivery certificate and the service record at vehicle handover.

– Before your first trip, read the entire operating instructions carefully.

– Get to know the controls.

(all XC‑W models)

– adjust the basic position of handbrake lever. ( p. 56)

(all EXC models)

– Adjust the free travel of the handbrake lever. ( p. 57)

– Adjust the basic position of the footbrake lever.

x ( p. 60)

– Get used to handling the motorcycle on a suitable piece of land before making a longer trip.

Info

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

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

– Do not make any offroad trips that over-stress your ability and experience.

– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION

– 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.

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

Guideline

Maximum permissible overall weight 335 kg (739 lb.)

Maximum permissible front axle load

Maximum permissible rear axle load

145 kg (320 lb.)

190 kg (419 lb.)

– Run the engine in.

6.2

Running in the engine

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

Guideline

Maximum engine speed

7,000 rpm During the first 3 service hours

Maximum engine performance during the running-in period

During the first 3 service hours

During the next 12 service hours

≤ 50 %

≤ 75 %

– Avoid fully opening the throttle!

RIDING INSTRUCTIONS

7RIDING INSTRUCTIONS

7.1

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.

– Check the chain tension. ( p. 52)

– Check for chain dirt accumulation. ( p. 51)

– Check the tire condition. ( p. 66)

– Check the tire air pressure. ( p. 67)

– Check the front brake fluid level. ( p. 57)

– Check the rear brake fluid level. ( p. 61)

– Check the front brake linings. ( p. 58)

– Check the rear brake linings. ( p. 62)

– Check brake system function.

– Check the coolant level. ( p. 72)

– Check that all operating elements are correctly adjusted and free to move.

– Check the functioning of the electrical equipment.

7.2

Starting

Danger

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

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

Note

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

– Always warm up the engine at low engine speeds.

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.

Motorcycle has been out of use for more than 1 week

– Empty the carburetor float chamber.

ON position. (Figure 500137-10 p. 20)

– Turn handle

 of the fuel tap to the

Fuel can flow from the fuel tank to the carburetor.

– Remove the motorcycle from the stand.

– Shift gear to neutral.

(EXC AUS)

– Turn the emergency OFF switch to the position .

Engine cold

(EXC AUS, XC‑W)

– Pull the choke lever out as far as possible.

(EXC EU, EXC SIX DAYS)

– Pull the choke lever to the stop.

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

Info

Don't open the throttle.

RIDING INSTRUCTIONS

7.3

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.

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

7.4

Shifting, riding

Warning

Danger of accidents If you change down at high engine speed, the rear wheel can lock up.

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

Info

If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.

First gear is used for starting off or for steep inclines.

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

– If the choke function was activated, deactivate it after the engine has warmed up.

– When you reach maximum speed after fully opening the throttle, turn back the throttle to about ¾ of its range; the speed hardly drops, but the fuel consumption falls considerably.

– Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel consumption.

– To shift down, brake and close the throttle at the same time.

– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again.

– Switch off the engine if you expect to be standing for a long time.

Guideline

≥ 2 min

– Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and the cooling system.

– Ride with a lower engine speed instead of with a high engine speed and a slipping clutch.

7.5

Braking

Warning

Danger of accidents If you brake too hard, the wheels can lock.

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

Warning

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

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

Warning

Danger of accidents Reduced braking due to wet or dirty brakes.

– Clean or dry dirty or wet brakes by riding and braking gently.

– On sandy, wet or slippery surfaces, use the rear brake.

– Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.

– On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine.

In this way, you have to brake far less and the brakes do not overheat.

RIDING INSTRUCTIONS

7.6

Stopping, parking

Warning

Risk of misappropriation Usage by unauthorized persons.

– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.

Warning

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

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

Note

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

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

Note

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

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

Note

Material damage Damage and destruction of components by excessive load.

– Brake the motorcycle.

– Shift gear to neutral.

(all XC‑W models)

– Press and hold the short circuit button while the engine is idling until the engine stops.

(all EXC models)

– Press and hold the short circuit button while the engine is idling until the engine stops.

– Turn handle

 of the fuel tap to the

– Park the motorcycle on firm ground.

– Open the filler cap. ( p. 20)

7.7

Refueling

Danger

Fire hazard Fuel can easily catch fire.

– Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

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

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse 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 hazard Improper handling of fuel is a danger to the environment.

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

– Switch off the engine.

RIDING INSTRUCTIONS

400382-10

– Fill the fuel tank with fuel up to measurement



Guideline

Measurement of



35 mm (1.38 in)

Total fuel tank capacity, approx. (EXC,

EXC SIX DAYS,

XC‑W ZA)

Total fuel tank capacity, approx.

(XC‑W USA)

9.0 l

(2.38 US gal)

9.2 l

(2.43 US gal)

– Close the filler cap. ( p. 20)

Super unleaded (ROZ 95 / RON 95 /

PON 91) ( p. 106)

Super unleaded (ROZ 95 / RON 95 /

PON 91) ( p. 106)

SERVICE SCHEDULE

8SERVICE SCHEDULE

8.1

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

Engine

Carburetor

Attachments

Brakes

Chassis

Wheels

S3N S15A S30A

Change the engine oil and oil filter and clean the engine oil screen.

Change the gear oil and clean the gear oil screen.

Replace spark plug.

( p. 82)

Check the antifreeze and coolant level. ( p. 72)

• • •

•

Check the valve clearance.

Check engine mounting screws for tightness.

Clean spark plug connectors and check for tightness.

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

Check carburetor connection boots for cracks and leakage.

Check vent hoses for damage and routing without sharp bends.

Check idle.

Check the cooling system for leakage.

Check the exhaust system for leakage and looseness.

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

Check the fluid level of the hydraulic clutch. ( p. 76)

Clean the air filter.

Check the front brake linings. ( p. 58)

Check cables for damage and routing without sharp bends.

•

Check that the electrical equipment is functioning properly.

Check the headlamp setting.

Check the rear brake linings. ( p. 62)

Check the brake discs. ( p. 55)

Check the front brake fluid level. ( p. 57)

Check the rear brake fluid level. ( p. 61)

Check brake lines for damage and leakage.

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

Check the free travel of the foot brake lever. ( p. 60)

Check brake system function.

Check screws and guide bolts of brake system for tightness.

Check shock absorber and fork for leakage and functioning.

Clean dust boots of fork legs. ( p. 39)

Bleed fork legs. ( p. 39)

Check the swingarm bearing.

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

Check all screws to see if they are tight.

Check the spoke tension. ( p. 67)

Check rim run-out.

Check the tire condition. ( p. 66)

Check the tire air pressure. ( p. 67)

Check the chain wear. ( p. 53)

Check the chain tension. ( p. 52)

Clean the chain. ( p. 51)

Check the wheel bearing for play.

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

SERVICE SCHEDULE

8.2

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

S15A

Competition use

S30A S45A S30A

Hobby use

S60A 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 the hydraulic clutch fluid.

( p. 76)

Change the front brake fluid.

Change the rear brake fluid.

Clean the spark arrestor.

(XC‑W USA)

Check wear of clutch discs.

Check the clutch.

Check/measure the cylinder.

Change the piston.

Check the camshaft.

x x

Change the camshaft bearing.

Check the valve spring seat.

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 at the bearing pin.

Change the 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/adjust 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

•

J1A

•

8.3

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

Check the engine oil level. ( p. 79)

Check the front brake fluid level. ( p. 57)

Check the rear brake fluid level. ( p. 61)

Check the front brake linings. ( p. 58)

Check the rear brake linings. ( p. 62)

Check and adjust Bowden cables.

Bleed fork legs. ( p. 39)

Clean dust boots of fork legs. ( p. 39)

•

NB1A

•

J2A

•

SERVICE SCHEDULE

Clean the chain. ( p. 51)

Check the chain tension. ( p. 52)

Check the chain wear. ( p. 53)

Check the rear sprocket / engine sprocket for wear. ( p. 52)

Clean the air filter.

Check the tire air pressure. ( p. 67)

Check the tire condition. ( p. 66)

Check the coolant level. ( p. 72)

Empty the carburetor float chamber.

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.

•

NB1A

•

MAINTENANCE WORK ON CHASSIS AND ENGINE

9MAINTENANCE WORK ON CHASSIS AND ENGINE

9.1

Jacking up the motorcycle

Note

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

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

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

Work stand (54829055000)

– Secure the motorcycle against falling over.

500074-01

9.2

Removing the motorcycle from the work stand

Note

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

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

– Remove the motorcycle from the work stand.

– Remove the work stand.

9.3

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.

– 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.

– As delivered, KTM offroad motorcycles are adjusted for a standard rider weight (with full protective clothing).

Guideline

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

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

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

9.4

Compression damping of shock absorber

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

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

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

9.5

Adjusting high-speed compression damping of the shock absorber

Danger

Danger of accidents The shock absorber is under high pressure.

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

400208-10

– Turn the adjusting screw

 clockwise with a ring wrench until it stops.

Info

Do not loosen nut



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

Guideline

Compression damping, high-speed

Comfort

Standard

Sport

2 turns

1.5 turns

1 turn

Info

Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

9.6

Adjusting the low-speed compression damping of the shock absorber

Danger

Danger of accidents The shock absorber is under high pressure.

– The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any maintenance on it yourself.

Info

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

400209-10

– Turn the adjusting screw

 clockwise with a screwdriver until it stops.

Info

Do not loosen nut



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

Guideline

Compression damping, low-speed

Comfort

Standard

Sport

18 clicks

15 clicks

12 clicks

Info

Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

9.7

Adjusting rebound damping of the shock absorber

Danger

Danger of accidents The shock absorber is under high pressure.

– The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any maintenance on it yourself.

MAINTENANCE WORK ON CHASSIS AND ENGINE

400210-10

– Turn the adjusting screw

 clockwise until it stops.

Info

Do not loosen nut



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

Guideline

Rebound damping

Comfort

Standard

Sport

26 clicks

24 clicks

22 clicks

Info

Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

9.8

Measuring rear wheel sag unloaded

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

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

– Make a note of the value as measurement



400220-10

9.9

Checking static sag of the shock absorber

– Measure distance



of rear wheel unloaded. ( p. 35)

– Ask someone to help you by holding the motorcycle upright.

– Measure the distance between the rear axle and the fixed point again.

– Make a note of the value as measurement



Info

The static sag is the difference between measurements

 and



– Check the static sag.

Static sag 35 mm (1.38 in)

» If the static sag is less or more than the specified value:

– Adjust the spring preload of the shock absorber.

( p. 36)

400221-10

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.10

Checking the riding sag of the shock absorber

– Measure distance



of rear wheel unloaded. ( p. 35)

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

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

– Make a note of the value as measurement



Info

The riding sag is the difference between measurements

 and



– Check the riding sag.

Riding sag 105 mm (4.13 in)

» If the riding sag differs from the specified measurement:

– Adjust the riding sag.

400222-10

9.11

Adjusting spring preload of the shock absorber

Danger

Danger of accidents The shock absorber is under high pressure.

– The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any 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.

400216-10

– Remove shock absorber.

– After removing the shock absorber, clean it thoroughly.

– Loosen screw



– Turn adjusting ring

 until the spring is no longer under tension.

Combination wrench (50329080000)

Hook wrench (T106S)

– Measure the overall spring length when not under tension.

– Tighten the spring by turning adjusting ring

 to measurement



Guideline

Spring preload 9 mm (0.35 in)

Info

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

– Tighten screw

Guideline



Screw, shock absorber adjusting ring

– Install the shock absorber.

M6 5 Nm (3.7 lbf ft)

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.12

Adjusting riding sag

– Remove shock absorber.

– After removing the shock absorber, clean it thoroughly.

– Choose and mount a suitable spring.

Guideline

Spring rate

Weight of rider: 65… 75 kg (143… 165 lb.)

Weight of rider: 75… 85 kg (165… 187 lb.)

Weight of rider: 85… 95 kg (187… 209 lb.)

69 N/mm (394 lb/in)

72 N/mm (411 lb/in)

76 N/mm (434 lb/in)

Info

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

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

– Install the shock absorber.

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

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

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

9.13

Removing the shock absorber

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

– Remove screw

 and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel. Fix the rear wheel in this position.

– Remove screw absorber.



, push splash protector

 to the side, and remove the shock

800023-10

9.14

Installing the shock absorber

800023-11

– Push splash protector tighten screw



Guideline

 to the side and position the shock absorber. Mount and

Screw, top shock absorber M12 80 Nm

(59 lbf ft)

Loctite ® 243™

– Mount and tighten screw



Guideline

Screw, bottom shock absorber

M12 80 Nm

(59 lbf ft)

Loctite ® 243™

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.

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.15

Checking basic setting of fork

Info

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

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

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

400189-01

9.16

Adjusting compression damping of fork

Info

The hydraulic compression damping determines the fork suspension behavior.

100020-10

– Remove protection covers

– Turn adjusting screws





clockwise until they stop.

Info

The adjusting screws

 are located at the bottom end of the fork legs.

Make the same adjustment on both fork legs.

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

Guideline

Compression damping

Comfort 26 clicks

Standard

Sport

22 clicks

20 clicks

Info

Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

– Mount protection covers



9.17

Adjusting rebound damping of fork

Info

The hydraulic rebound damping determines the fork suspension behavior.

– Turn adjusting screws

 clockwise until they stop.

Info

The adjusting screws

 are located at the top end of the fork legs.

Make the same adjustment on both fork legs.

800017-10

MAINTENANCE WORK ON CHASSIS AND ENGINE

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

Guideline

Rebound damping

Comfort 24 clicks

Standard

Sport

22 clicks

Info

Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

9.18

Adjusting spring preload of the fork

800015-10

– Turn adjusting screws counterclockwise until they stop.

Info

Make the same adjustment on both fork legs.

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

Guideline

Spring preload -

Preload Adjuster

Comfort 2 turns

Standard

Sport

2 turns

4 turns

Info

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

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

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

9.19

Bleeding fork legs

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

– Remove bleeder screws

 briefly.

Any excess pressure escapes from the interior of the fork.

– Mount and tighten bleeder screws.

100021-10

9.20

Cleaning dust boots of fork legs

– Loosen the fork protection. ( p. 40)

– Push dust boots

 of both fork legs downwards.

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.

500088-10

MAINTENANCE WORK ON CHASSIS AND ENGINE

Warning

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

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

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

Universal oil spray ( p. 108)

– Press the dust boots back into their normal position.

– Remove excess oil.

– Position the fork protection. ( p. 40)

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

9.21

Loosening the fork protection

– Remove screws



 and take off clamp.

on left fork leg. Push the fork protection downwards.

– Remove the screws on the right fork leg. Push the fork protection downwards.

500087-11

9.22

Positioning the fork protection

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



Guideline

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

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



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

Guideline

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

500087-10

9.23

Checking play of steering head bearing

Warning

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

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

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.

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

– Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel.

No play should be noticeable in the steering head bearing.

» If there is noticeable play present:

(EXC SIX DAYS, XC‑W USA)

– Adjust play of the steering head bearing.

(EXC EU, EXC AUS, XC‑W ZA)

– Adjust play of the steering head bearing.

( p. 41) x

( p. 41)

400387-10

MAINTENANCE WORK ON CHASSIS AND ENGINE

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

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

» If click positions are noticeable:

(EXC SIX DAYS, XC‑W USA)

– Adjust play of the steering head bearing.

( p. 41)

(EXC EU, EXC AUS, XC‑W ZA)

– Adjust play of the steering head bearing.

( p. 41)

– Check the steering head bearing and replace if required.

9.24

Adjusting play of steering head bearing

(EXC EU, EXC AUS, XC‑W ZA)

– Loosen screws

 and



– Loosen and retighten screw



Guideline

Screw, top steering head

800016-10

M20x1.5

10 Nm (7.4 lbf ft)

– Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.

– Fully tighten screw



Guideline

Screw, top triple clamp M8 20 Nm

(14.8 lbf ft)

– Tighten screw

Guideline



Screw, top steering stem M8 20 Nm

(14.8 lbf ft)

9.25

Adjusting play of steering head bearing

(EXC SIX DAYS, XC‑W USA)

– Loosen screw



. Remove screw



– Loosen and retighten screw



Guideline

Screw, top steering head

800022-10

M20x1.5

10 Nm (7.4 lbf ft)

– Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.

– Fully tighten screw



Guideline

Screw, top triple clamp M8 17 Nm

(12.5 lbf ft)

– Mount and tighten screw



Guideline

Screw, top steering stem M8

– Remove the fork legs. ( p. 42)

17 Nm

(12.5 lbf ft)

Loctite

243™

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.26

Removing the fork legs

– Remove the front wheel.

– Remove screws

( p. 64)

 and take off clamp.

– Remove cable clip



, remove screw

 and take off the brake caliper.

– Hang the brake caliper and the brake line loosely to the side.

500093-10

(EXC SIX DAYS, XC‑W USA)

– Loosen screw



. Remove the fork leg on the left.

– Loosen screw



. Remove the fork leg on the right.

500094-10

(EXC EU, EXC AUS, XC‑W ZA)

– Loosen screw



. Remove the fork leg on the left.

– Loosen screw



. Remove the fork leg on the right.

9.27

Installing the fork legs

100023-11

– 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 screw

 to the front.

100021-10

500094-11

(EXC SIX DAYS, XC‑W USA)

– Fully tighten screw



Guideline

Screw, top triple clamp

– Fully tighten screw



Guideline

Screw, bottom triple clamp

17 Nm

(12.5 lbf ft)

12 Nm

(8.9 lbf ft)

MAINTENANCE WORK ON CHASSIS AND ENGINE

100023-10

(EXC EU, EXC AUS, XC‑W ZA)

– Fully tighten screw



Guideline

Screw, top triple clamp M8 20 Nm

(14.8 lbf ft)

– Fully tighten screw



Guideline

Screw, bottom triple clamp M8 15 Nm

(11.1 lbf ft)

– Position brake caliper, mount and tighten screws



Guideline

Screw, front brake caliper M8 25 Nm

(18.4 lbf ft)

Loctite ® 243™

– Mount cable clip



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



– Install the front wheel.

x ( p. 64)

500093-11

9.28

Removing the fork protector

– Remove screws

 on the left fork leg. Remove the fork protector upwards.

– Remove the screws on the right fork leg. Remove the fork protector upwards.

500105-10

9.29

Installing the fork protector

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



Guideline

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

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

Guideline

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

– Install the fork legs.

( p. 42)

500105-10

9.30

Removing the lower triple clamp

(EXC SIX DAYS, XC‑W USA)

– Remove the fork legs. ( p. 42)

(XC‑W USA)

– Dismount the start number plate. ( p. 48)

(EXC SIX DAYS)

– Remove the headlight mask with the headlight. ( p. 47)

– Dismount the front fender. ( p. 47)

MAINTENANCE WORK ON CHASSIS AND ENGINE

500099-10

– Remove screws

 and hang the CDI control unit to the side.

Info

Do not unplug the CDI control unit.

– Remove screw



. Remove screw and place it on one side.



, take off top triple clamp with the handlebar

Info

Protect the motorcycle and its attachments from damage by covering them.

Do not bend the cables and lines.

– Remove o-ring



. Remove protector ring



– Remove the lower triple clamp with the steering stem.

– Remove the upper steering head bearing.

500100-10

9.31

Removing the lower triple clamp

(EXC EU, EXC AUS, XC‑W ZA)

– Remove the fork legs. ( p. 42)

– Remove the headlight mask with the headlight. ( p. 47)

– Dismount the front fender. ( p. 47)

– Remove screws

 and hang the CDI control unit to the side.

Info

Do not unplug the CDI control unit.

500149-10

– Remove screw



. Loosen screw



. 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.

– Remove protector ring



– Remove the lower triple clamp with the steering stem.

– Remove the upper steering head bearing.

500150-10

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.32

Installing the lower triple clamp

(EXC SIX DAYS, XC‑W USA)

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

– Install the front fender. ( p. 47)

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

Info

Check whether the top steering head seal

 is correctly positioned.

– Push up protective ring

 and o-ring



500098-10

500099-11

– Position the upper triple clamp with the steering.

– Mount and tighten screw



Guideline

Screw, top steering head M20x1.5

10 Nm (7.4 lbf ft)

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



Guideline

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

(XC‑W USA)

– Install the start number plate. ( p. 48)

(EXC SIX DAYS)

– Refit the headlight mask with the headlight. ( p. 47)

– Install the fork legs.

( p. 42)

– Mount and tighten screw



Guideline

Screw, top steering stem M8 17 Nm

(12.5 lbf ft)

Loctite ® 243™

– Check the cable harness, cable, brake and clutch line for free movement and free laying.

500103-10

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.33

Installing the lower triple clamp

(EXC EU, EXC AUS, XC‑W ZA)

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

– Install the front fender. ( p. 47)

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

Info

Check whether the top steering head seal

 is correctly positioned.

– Push on protective ring



500151-10

500149-11

– Position the upper triple clamp with the steering.

– Mount and tighten screw



Guideline

Screw, top steering head M20x1.5

10 Nm (7.4 lbf ft)

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



Guideline

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

– Refit the headlight mask with the headlight. ( p. 47)

– Install the fork legs.

– Tighten screw



( p. 42)

Guideline

Screw, top steering stem M8 20 Nm

(14.8 lbf ft)

– Check the cable harness, cable, brake and clutch line for free movement and free laying.

– Check gas Bowden cable route. ( p. 50)

100022-11

9.34

Greasing the steering head bearing

(EXC SIX DAYS, XC‑W USA)

– Remove the lower triple clamp.

– Install the lower triple clamp.

( p. 43)

( p. 45)

(EXC EU, EXC AUS, XC‑W ZA)

– Remove the lower triple clamp.

( p. 44)

– Install the lower triple clamp.

( p. 46)

800010-10

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.35

Dismounting the front fender

– Remove screws



. Remove the front fender.

– Make sure that the distance bushings remain in place.

500092-10

9.36

Installing the front fender

– Ensure that the spacing sleeves are mounted in the fender.

– Position the front fender. Mount and tighten screws



Guideline

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

Info

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

500092-10

9.37

Removing headlight mask with headlight (EXC, EXC SIX DAYS, XC‑W ZA)

– Switch off all electrical equipment.

– Remove screw

 and take off clamp.

– Loosen the rubber band



. Push up the headlight mask and swing it forwards.

800018-10

– Pull out the electric plug connector headlight.

 and remove the headlight mask with the

500156-10

9.38

Refitting the headlight mask with the headlight (EXC, EXC SIX DAYS, XC‑W ZA)

– Connect the electric plug connector



500156-11

MAINTENANCE WORK ON CHASSIS AND ENGINE

– Position the headlight mask and fix it with the rubber band



Info

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

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



– Check the headlamp setting.

800018-11

9.39

Dismount the start number plate (XC‑W USA)

– Remove screw

 and take off clamp.

 with distance bushing. Remove the start number plate.

500101-10

9.40

Installing the start number plate (XC‑W USA)

– Position the start number plate. Mount and tighten screw bushing.

Guideline

 with the distance

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

500101-11

Info

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

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



9.41

Handlebar position

400223-11

On the upper triple clamp, there are 2 holes at a distance of

 to each other.

Distance

 between holes 15 mm (0.59 in)

The holes on the handlebar support are placed at a distance of

 from the center.

Distance

 between holes 3.5 mm (0.138 in)

The handlebar supports can be mounted in 4 different positions.

(EXC SIX DAYS)

The handlebar supports can also be mounted at 2 different heights (with and without spacer).

Thick spacer 9 mm (0.35 in)

9.42

Adjusting handlebar position

(EXC EU, EXC AUS, XC‑W)

– Remove the four screws



. 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.

– Remove the two screws



. Remove the handlebar support.

400223-10

MAINTENANCE WORK ON CHASSIS AND ENGINE

400343-10

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



Guideline

Screw, handlebar support M10 40 Nm

(29.5 lbf ft)

Loctite ® 243™

Info

Position the left and right handlebar supports evenly.

– Position the handlebar.

Info

Make sure cables and wiring are positioned correctly.

– Position the handlebar clamp. Fit and evenly tighten the four screws



Guideline

Screw, handlebar clamp M8 20 Nm

(14.8 lbf ft)

Info

Make sure the gap width is even.

(EXC SIX DAYS)

– Remove the four screws ers

 and elastomers





. Remove the handlebar clamps

 with rubber wash-

– 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.

– Remove the lower shells

– Remove the clamp bar





with the rubber cones



– Remove the two screws



. Remove the handlebar support.

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



Guideline

Screw, handlebar support M10 40 Nm

(29.5 lbf ft)

Loctite ® 243™

Condition



Spacer fitted:

Use a M10x35 screw

Condition

without a spacer



Use a M10x25 screw

Info

Position the left and right handlebar supports evenly.

– Fit the rubber cones

– Fit the lower shells





and clamp bar



– Position the handlebar.

Info

Make sure cables and wiring are positioned correctly.

MAINTENANCE WORK ON CHASSIS AND ENGINE

– Position the handlebar clamps

 with rubber washers

 and elastomers



Elastomer kit green - soft quality (SXS05125203)

Elastomer kit yellow - medium quality (standard) (SXS05125204)

Elastomer kit red - hard quality (SXS05125205)

Info

The elastomers are available in different versions.

– Fit and evenly tighten the four screws



Guideline

Screw, handlebar clamp M8 16 Nm

(11.8 lbf ft)

Info

Make sure the gap width is even.

9.43

Checking gas Bowden cable route

– 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.

500152-10

9.44

Checking play in the gas Bowden cable

– 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… 5 mm (0.12… 0.2 in)

» If the gas Bowden cable play does not meet specifications:

– Adjust the gas Bowden cable play.

( p. 50)

400192-10

Danger

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

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

– 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:

– Adjust the gas Bowden cable play.

( p. 50)

9.45

Adjusting the gas Bowden cable play

– Dismount the fuel tank.

x ( p. 70)

MAINTENANCE WORK ON CHASSIS AND ENGINE

500153-10

– Move the handlebar to the straight-ahead position.

– Push back bellows



– Loosen nut



. Turn adjusting screw

 in as far as possible.

– Loosen nut



. Turn adjusting screw cable at the throttle grip.

 so that there is play in the gas Bowden

Guideline

Play in gas Bowden cable 3… 5 mm (0.12… 0.2 in)

– Tighten nut



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



– Tighten nut

– Push bellows



 on. Check the throttle grip for smooth operation.

– Install the fuel tank.

( p. 71)

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

 out

9.46

Checking for chain dirt accumulation

– Check the chain for coarse dirt accumulation.

» If the chain is very dirty:

– Clean the chain. ( p. 51)

800012-10

9.47

Cleaning the chain

Warning

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

– Remove oil and grease with a suitable cleaning material.

Warning

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

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

Warning

Environmental hazard Problem materials cause environmental damage.

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

Info

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

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

Chain cleaner ( p. 107)

Offroad chain spray ( p. 107)

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.48

Checking the chain tension

Warning

Danger of accidents Danger caused by incorrect chain tension.

– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, 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.

– Adjusting chain tension - after checking. ( p. 54)

– Push the chain at the end of the chain sliding component upwards to measure the chain tension



Info

The upper chain section

 must be taut.

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

400213-10

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

» If the chain tension does not meet specifications:

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

9.49

Checking the chain tension when fitting rear wheel

Warning

Danger of accidents Danger caused by incorrect chain tension.

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

– Push the chain at the end of the chain sliding component upwards to measure chain tension



Info

The upper chain section

 must be taut.

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

400213-10

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

» If the chain tension does not meet specifications:

– Adjust the chain tension when fitting rear wheel. ( p. 55)

9.50

Checking the rear sprocket / engine sprocket for wear

– Check the rear sprocket / engine sprocket for wear.

» If the rear sprocket / engine sprocket are worn:

– Replace rear sprocket / engine sprocket.

400227-01

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.

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

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.51

Checking chain wear

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

– Shift gear to neutral.

– Pull the upper chain section with the specified weight

Guideline



Weight of chain wear measurement 10… 15 kg (22… 33 lb.)

– Measure distance

 of 18 chain links in the lower chain section.

Info

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

1 2 3 16 17 18

400226-10

Maximum distance chain section

 at the longest 272 mm (10.71 in)

» If the distance

 is greater than the specified measurement:

– Replace the chain.

Info

When you replace the chain, you should also replace the rear sprocket and the engine sprocket.

New chains wear out faster on old, worn sprockets.

9.52

Adjusting the chain tension

Warning

Danger of accidents Danger caused by incorrect chain tension.

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

– Push the chain at the end of the chain sliding component upwards to measure chain tension



Info

The upper chain section

 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

– Loosen nut

– Loosen nuts





– Adjust the chain tension by turning the left and right adjusting screws



Guideline

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

Turn the left and right adjusting screws right chain adjusters are in the same position relative to the reference marks

The rear wheel is then correctly aligned.

 so that the markings on the left and



– Tighten nuts



– Make sure that chain adjusters

– Tighten nut



Guideline

 are fitted correctly on the adjusting screws



Nut, rear wheel spindle M20x1.5

80 Nm (59 lbf ft)

400225-10

Info

The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length.

Chain adjusters

 can be turned by 180°.

9.53

Adjusting chain tension - after checking

– Loosen nut

– Loosen nuts





– Adjust the chain tension by turning the adjusting screws

 left and right.

Guideline

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

Turn the adjusting screws

 left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks

The rear wheel is then correctly aligned.



– Tighten nuts



– Make sure that the chain adjusters screws



 are fitted correctly on the adjusting

– Tighten nut



Guideline

Nut, rear wheel spindle M20x1.5

80 Nm (59 lbf ft)

400225-13

Info

The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length.

The chain adjusters

 can be turned by 180°.

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.54

Adjusting chain tension - fitting rear wheel

– Loosen nuts



– Adjust the chain tension by turning the adjusting screws

 left and right.

Guideline

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

Turn the adjusting screws

 left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks

The rear wheel is then correctly aligned.



– Tighten nuts



9.55

Adjusting chain guide

400225-11

– Remove screws

 and



. Take off the chain guide.

Condition

Number of teeth: ≤ 44 teeth

– Insert nut

 in hole



. Position the chain guide.

– Mount and tighten screws

 and



Guideline

Remaining screws, chassis M6

Condition

Number of teeth: ≥ 45 teeth

– Insert nut

 in hole



. Position the chain guide.

– Mount and tighten screws

 and



Guideline

Remaining screws, chassis M6

400252-10

9.56

Checking the brake discs

Warning

Danger of accidents Reduced braking due to worn brake discs.

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

10 Nm

(7.4 lbf ft)

10 Nm

(7.4 lbf ft)

MAINTENANCE WORK ON CHASSIS AND ENGINE

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



Info

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

400257-10

Wear limit of brake discs

Front

Rear

2.5 mm (0.098 in)

3.5 mm (0.138 in)

» If the brake disc thickness is less than the specified value:

– Change the brake disc.

9.57

Checking free travel of hand brake lever

Warning

Danger of accidents Brake system failure.

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

(all XC‑W models)

– Push the hand brake lever forwards and check free travel



Free travel of hand brake lever

≥ 3 mm (≥ 0.12 in)

» If the free travel does not meet specifications:

– adjust the basic position of handbrake lever. ( p. 56)

400196-11

(all EXC models)

– Push the hand brake to the handlebar and check free travel



Free travel of hand brake lever

≥ 3 mm (≥ 0.12 in)

» If the free travel does not meet specifications:

– Adjust the free travel of the handbrake lever. ( p. 57)

400196-13

9.58

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

– Adjust the basic setting of the handbrake lever to your hand size by turning adjusting screw



400196-12

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!

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

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.59

Adjusting free travel of handbrake lever (all EXC models)

– Adjust the free travel of the handbrake lever with the adjustment screw



400196-12

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!

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

9.60

Checking the front brake fluid level

Warning

Danger of accidents Brake system failure.

– 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 accidents Reduced braking due to old brake fluid.

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

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

– Check the brake fluid level in the viewer



» If the brake fluid is below the MIN mark:

– Add front brake fluid.

( p. 57)

400231-10

9.61

Adding front brake fluid

Warning

Danger of accidents Brake system failure.

– 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 irritations Brake fluid can cause skin irritation on contact.

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

– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking due to old brake fluid.

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

Warning

Environmental hazard Problem materials cause environmental damage.

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

Info

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

DOT 5 brake fluid.

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

Use only clean brake fluid from a sealed container!

MAINTENANCE WORK ON CHASSIS AND ENGINE

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

– Remove screws



– Remove cover

 with membrane

– Add brake fluid to level





Guideline

Measurement of



5 mm (0.2 in)

– Check the brake discs. ( p. 55)

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

Info

Clean up overflowed or spilt brake fluid immediately with water.

600706-10

9.62

Checking the front brake linings

Warning

Danger of accidents Reduced braking due to worn brake linings.

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

– Check the brake linings for minimum thickness



Minimum thickness



≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

– Change the front brake linings.

x ( p. 59)

400235-10

9.63

Removing front brake linings

Warning

Danger of accidents Improper brake maintenance and repair.

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

500089-11

– 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.

– Remove the locking split pins pads.



, withdraw the bolt



, and take out the brake

– Remove cable clip



. Remove screws

 and take off brake caliper.

– Clean brake caliper and brake caliper support.

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.64

Mounting front brake linings

Warning

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

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

Warning

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

– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The 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.

– Check that leaf spring

 in the brake caliper and sliding plate caliper support are seated correctly.

 in the brake

Info

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

500091-10

– Insert the brake pads, insert bolt



, and mount locking split pins

– Position brake caliper, mount and tighten screws





Guideline

Screw, front brake caliper M8 25 Nm

(18.4 lbf ft)

Loctite ® 243™

– Mount cable clip



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

500089-12

9.65

Changing the front brake linings

Warning

Skin irritations Brake fluid can cause skin irritation on contact.

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

– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking due to old brake fluid.

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

Warning

Environmental hazard Problem materials cause environmental damage.

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

Info

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

DOT 5 brake fluid.

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

Use only clean brake fluid from a sealed container!

MAINTENANCE WORK ON CHASSIS AND ENGINE

– Remove the front brake linings.

( p. 58)

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

– Remove screws



– Remove cover

 with membrane



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

– Mount the front brake linings.

( p. 59)

– Add brake fluid to level



Guideline

Measurement of



5 mm (0.2 in)

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

Info

Clean up overflowed or spilt brake fluid immediately with water.

600706-10

9.66

Checking free travel of foot brake lever

Warning

Danger of accidents Brake system failure.

– 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.

– Disconnect spring



– Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free travel



Guideline

Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)

» If the free travel does not meet specifications:

– Adjust the basic position of the footbrake lever.

– Reconnect spring



x ( p. 60)

500139-11

9.67

Adjusting basic position of footbrake lever

Warning

Danger of accidents Brake system failure.

500154-10

– Disconnect spring

– Loosen nut travel.





and with push rod



, turn it back until you have maximum free

– To adjust the basic position of the footbrake lever individually, lossen nut turn screw

 accordingly.

 and

Info

The range of adjustment is limited.

– Turn push rod

 accordingly until you have free travel basic position of the footbrake lever.



. If necessary, adjust the

Guideline

Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)

MAINTENANCE WORK ON CHASSIS AND ENGINE

– Hold screw

 and tighten nut



Guideline

Remaining nuts, chassis M8 30 Nm

(22.1 lbf ft)

– Hold push rod

 and tighten nut



Guideline

Remaining nuts, chassis M6 15 Nm

(11.1 lbf ft)

– Reconnect spring



9.68

Checking the rear brake fluid level

Warning

Danger of accidents Brake system failure.

– 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 accidents Reduced braking due to old brake fluid.

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

– Stand the vehicle upright.

– Check the brake fluid level in the viewer



» When in the viewer

 an air bubble is visible:

– Add brake fluid for the rear brake.

( p. 61)

400234-10

9.69

Adding brake fluid for the rear brake

Warning

Danger of accidents Brake system failure.

– 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 irritations Brake fluid can cause skin irritation on contact.

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

– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking due to old brake fluid.

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

Warning

Environmental hazard Problem materials cause environmental damage.

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

Info

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

DOT 5 brake fluid.

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

Use only clean brake fluid from a sealed container!

MAINTENANCE WORK ON CHASSIS AND ENGINE

– Stand the vehicle upright.

– Remove screw cap

 with membrane

 and the O-ring.

– Add brake fluid to level



– Check the brake discs. ( p. 55)

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

Info

Clean up overflowed or spilt brake fluid immediately with water.

400233-10

9.70

Checking the rear brake linings

Warning

Danger of accidents Reduced braking due to worn brake linings.

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

– Check the brake linings for minimum thickness



Minimum thickness



≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

– Change the rear brake linings.

x ( p. 63)

400238-10

9.71

Removing rear brake linings

Warning

Danger of accidents Improper brake maintenance and repair.

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

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

Info

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

– Remove the locking split pins pads.



, withdraw the bolt

– Clean brake caliper and brake caliper support.



, and take out the brake

400236-10

9.72

Installing the rear brake linings

Warning

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

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

Warning

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

MAINTENANCE WORK ON CHASSIS AND ENGINE

– Check that leaf spring

 in the brake caliper and sliding plate caliper support are seated correctly.

 in the brake

Info

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

500122-10

– Fit the brake pads, insert bolt



, and mount locking split pins



Info

Make sure that the decoupling plate brake pad.

 is mounted on the piston side of the

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

400237-10

9.73

Changing the rear brake linings

Warning

Skin irritations Brake fluid can cause skin irritation on contact.

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

– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking due to old brake fluid.

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

Warning

Environmental hazard Problem materials cause environmental damage.

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

Info

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

DOT 5 brake fluid.

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

Use only clean brake fluid from a sealed container!

400233-10

– Remove the rear brake linings.

( p. 62)

– Stand the vehicle upright.

– Remove screw cap

 with membrane

 and the O-ring.

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

– Install the rear brake linings.

( p. 62)

– Add brake fluid to level



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

Info

Clean up overflowed or spilt brake fluid immediately with water.

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.74

Removing the front wheel

– 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.

500089-10

– Remove screw

– Loosen screw





500084-10

– 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

– Remove spacing sleeves



500086-10

9.75

Installing the front wheel

Warning

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

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

– Clean and grease shaft seal rings

 and bearing surface

 of the spacing sleeves.

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

– Insert the spacing sleeves.

500086-11

MAINTENANCE WORK ON CHASSIS AND ENGINE

500084-11

– Lift the front wheel into the fork, position it, and insert the wheel spindle.

– Mount and tighten screw



Guideline

Screw, front wheel spindle M24x1.5

45 Nm

(33.2 lbf ft)

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

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

– Fully tighten screw



Guideline

Screw, fork stub M8 15 Nm

(11.1 lbf ft)

9.76

Removing rear wheel

– 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.

– Remove nut



– Remove chain adjuster



. Withdraw the wheel spindle rear wheel to be pushed forward.

 only enough to allow the

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

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

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

– Remove the spacing sleeves



400260-11

9.77

Installing the rear wheel

Warning

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

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

MAINTENANCE WORK ON CHASSIS AND ENGINE

– Clean and grease shaft seal rings

 and bearing surface

 of the spacing sleeves.

– Check the chain tension when fitting rear wheel. ( p. 52)

– Insert the spacing sleeves.

400260-10

– Lift the rear wheel into the swing arm, position it, and insert the wheel spindle

– Put the chain on.



400259-10

– Position the chain adjuster



. Mount nut



, but do not tighten it yet.

– Make sure that the chain adjusters screws



 are fitted correctly on the adjusting

– Tighten nut



Guideline

Nut, rear wheel spindle M20x1.5

80 Nm (59 lbf ft)

Info

The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length.

The chain adjusters

 can be turned by 180°.

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

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

400225-12

9.78

Tire condition checking

Info

Only mount tires approved or recommended by KTM.

Other tires could have a negative effect on riding behavior.

The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.

The front and rear wheels must be mounted with tires with similar profiles.

Worn tires have a negative effect on riding behavior, especially on wet surfaces.

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

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

– Change the tire.

– Check the depth of the tread.

Info

Note local national regulations concerning the minimum tread depth.

Minimum tread depth

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

– Change the tire.

≥ 2 mm (≥ 0.08 in)

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.79

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.

400241-01

– Remove dust cap.

– Check tire air pressure when tires are cold.

Tire air pressure off road

Front

Rear

Road tire pressure (all EXC models) front

Rear

1.0 bar (15 psi)

1.5 bar (22 psi)

2.0 bar (29 psi)

» If the tire pressure does not meet specifications:

– Correct tire pressure.

– Mount dust cap.

9.80

Checking spoke tension

Warning

Danger of accidents Unstable riding behavior due to loose spokes.

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

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.

400228-01

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

Guideline

You should hear a high note.

Spoke nipple, front wheel

Spoke nipple, rear wheel

M4,5

5 Nm (3.7 lbf ft)

Info

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

9.81

Removing the battery

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

– Keep batteries out of the reach of children.

– Wear suitable protective clothing and goggles.

– Avoid contact with battery acid and battery gases.

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

– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least

15 minutes and contact a physician.

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

– Remove the seat. ( p. 69)

MAINTENANCE WORK ON CHASSIS AND ENGINE

– Disconnect the negative (minus) cable

– Pull back the plus pole cover tery.



 of the battery.

and disconnect the positive (plus) cable of the bat-

– Hang the rubber band

– Lift the battery up.

 out to the bottom.

500069-10

9.82

Installing the battery

– Place the battery in the battery holder.

4Ah battery (YTX5L-BS) ( p. 95)

– Reconnect the rubber band



– Attach the plus cable and replace the plus pole cover



– Attach the minus cable



– Mount the seat. ( p. 70)

500069-11

9.83

Recharging the battery

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

– Keep batteries out of the reach of children.

– Wear suitable protective clothing and goggles.

– Avoid contact with battery acid and battery gases.

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

– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least

15 minutes and contact a physician.

Warning

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

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

Warning

Environmental hazard Problem materials cause environmental damage.

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

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.

– Switch off all power consumers and switch off the engine.

– Remove the seat. ( p. 69)

– Disconnect the minus (negative) cable of the battery to avoid damage to the motorcycle's electronics.

MAINTENANCE WORK ON CHASSIS AND ENGINE

400240-10

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

Battery charger (58429074000)

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

Info

Never remove the lid



Charge the battery with at most 10% of the capacity specified on the battery



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

Guideline

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

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

3 months

– Mount the seat. ( p. 70)

9.84

Removing a fuse

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

– Dismount the air filter box lid. ( p. 74)

– Remove the protection cover



Info

The fuse

 is located in the starter relay

 under the filter box cover.

– Remove the fuse



400270-10

9.85

Installing the fuse

Warning

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

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

400273-10

– Insert the fuse.

Fuse (58011109110)

Info

A reserve fuse

 is located in the starter relay.

Replace a burned-out fuse

 only by an equivalent fuse.

If the new fuse burns out, contact an authorized KTM workshop.

– Replace the protection cover.

– Install the air filter box lid. ( p. 74)

9.86

Removing the seat

– Remove screw above.



. Lift up the seat at the rear, pull it back and then remove from

500080-10

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.87

Mounting the seat

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

– Make sure that the seat is correctly locked in.

– Mount and tighten the screw of the seat fixing.

Guideline

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

500068-01

9.88

Dismounting the fuel tank

Danger

Fire hazard Fuel can easily catch fire.

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

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

– Remove the seat. ( p. 69)

– Turn handle

 of the fuel tap to the

– Mount the seat. ( p. 70)

– Pull off the fuel hose.

Info

Remaining fuel may run out of the fuel hose.

– Remove screws

 with collar sleeve.

(all EXC models)

– Hang the horn and horn bracket to one side.

500157-10

– Remove screw

 with collar sleeve.

– Remove the tube from the fuel tank vent line.

800019-10

– Pull both spoilers to the side of the radiator bracket upwards.

 and take the fuel tank away

500067-10

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.89

Installing the fuel tank

Danger

Fire hazard Fuel can easily catch fire.

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

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

– Position the fuel tank and install the two spoilers to the side of the radiator fixing.

– Make sure that no cables or Bowden cables are trapped or damaged.

9.90

Cooling system

500067-01

– Mount the fuel tank vent hose.

– Mount and tighten screw

 with the collar sleeve.

Guideline

Remaining screws, chassis M6

(all EXC models)

– Position the horn with the horn bracket.

800019-11

– Mount and tighten screws

 with the collar sleeve.

Guideline

Remaining screws, chassis M6

– Connect the fuel hose.

10 Nm (7.4 lbf ft)

500157-11

400335-10

The water pump

 in the engine forces the coolant to flow.

The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap



. The specified coolant temperature is therefore permissible without danger of function problems.

120 °C (248 °F)

Cooling is effected by the air stream.

The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect.

(EXC SIX DAYS, XC-W ZA)

The radiator fan provides extra cooling. It is controlled by a thermoswitch.

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.91

Checking antifreeze and coolant level

Warning

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

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

Warning

Danger of poisoning Coolants are poisonous and a health hazard.

– Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. 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.

400243-10

– Stand the motorcycle upright on a horizontal surface.

– Remove the radiator cap.

– Check antifreeze of coolant.

−25… −45 °C (−13… −49 °F)

» If the antifreeze of the cooling liquid does not meet specifications:

– Correct antifreeze of coolant.

– Check the coolant level in the radiator.

Coolant level

 above radiator fins.

10 mm (0.39 in)

» If the level of the cooling liquid does not meet specifications:

– Correct the coolant level.

Alternative 1

Coolant ( p. 106)

Alternative 2

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

– Refit the radiator cap.

9.92

Checking the coolant level

Warning

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

Warning

Danger of poisoning Coolants are poisonous and a health hazard.

400243-10

– Stand the motorcycle upright on a horizontal surface.

– Remove the radiator cap.

– Check the coolant level in the radiator.

Coolant level

 above radiator fins.

10 mm (0.39 in)

» If the level of the cooling liquid does not meet specifications:

– Correct the coolant level.

Alternative 1

Coolant ( p. 106)

Alternative 2

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

– Refit the radiator cap.

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.93

Draining coolant

Warning

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

Warning

Danger of poisoning Coolants are poisonous and a health hazard.

– Stand the vehicle upright.

– Place a suitable container under the water pump cover.

– Remove screw



. Remove the radiator cap

– Completely drain the coolant.



– Mount and tight screw

 with a new seal ring.

Guideline

Screw, water pump cover M6x25 10 Nm (7.4 lbf ft)

400335-11

9.94

Refilling coolant

Warning

Danger of poisoning Coolants are poisonous and a health hazard.

400244-10

– Make sure that the screw

– Stand the vehicle upright.

 is tightened.

– Pour coolant in up to measurement

 above the radiator fins.

Guideline

10 mm (0.39 in)

Coolant 0.95 l (1 qt.)

Coolant ( p. 106)

Coolant (mixed ready to use)

( p. 106)

– Refit the radiator cap.

– Make a short test ride.

– Check the coolant level. ( p. 72)

9.95

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.

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.96

Removing main silencer

Warning

Danger of burns The exhaust system gets very hot when the vehicle is driven.

– Allow the exhaust system to cool down. Do not touch hot components.

– Disconnect spring

– Remove screws





and take off main silencer.

9.97

Installing the main silencer

800020-10

– Mount the main silencer. Mount and tighten screws



Guideline

Remaining screws, chassis M6

– Reconnect spring



10 Nm (7.4 lbf ft)

800020-11

9.98

Dismounting the air filter box lid

– Pull off the air filter box lid in area

 to the side and remove to the front.

9.99

Installing the air filter box lid

800021-10

– Insert the air filter box lid into the rear area

 and clip it into the front area



800021-11

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.100

Removing the air filter

Note

Engine failure Unfiltered intake air has a negative effect on the service life of the engine.

– Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.

Warning

Environmental hazard Problem materials cause environmental damage.

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

– Dismount the air filter box lid. ( p. 74)

– Hang the air filter holder

 out to the bottom and swing it to the side. Remove the air filter with the air filter support.

– Remove the air filter from the air filter support.

500107-10

9.101

Installing the air filter

– Mount the clean air filter onto the air filter support.

– Put in both parts together, position them and fix them with the air filter support



Info

If the air filter is not correctly mounted, dust and dirt can penetrate into the engine and can cause damage.

– Install the air filter box lid. ( p. 74)

500107-10

9.102

Cleaning air filter

Warning

Environmental hazard Problem materials cause environmental damage.

– 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.

– Remove the air filter.

Air filter cleaner ( p. 107)

– Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.

Info

Only press the air filter to dry it, never wring it out.

– Oil the dry air filter with a high quality filter oil.

Oil for foam air filter ( p. 108)

– Clean the air filter box.

– Check carburetor connection boot for damage and tightness.

– Install the air filter.

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.103

Adjusting basic position of clutch lever

– Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw



500133-11

Info

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!

9.104

Checking the fluid level of hydraulic clutch

Warning

Skin irritations Brake fluid can cause skin irritation on contact.

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

– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

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!

400339-10

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.

– Remove screws



– Remove cover

 with membrane

– Check the fluid level.



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

» If the level of the fluid does not meet specifications:

– Correct the fluid level of the hydraulic clutch.

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

Info

Clean up overflowed or spilt fluid immediately with water.

9.105

Changing the hydraulic clutch fluid

Warning

Skin irritations Brake fluid can cause skin irritation on contact.

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

– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Environmental hazard Problem materials cause environmental damage.

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

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

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.

– Remove screws



– Remove cover

 with membrane



9.106

Carburetor - idle

400339-10

– Fill bleeding syringe

 with the appropriate hydraulic fluid.

Bleed syringe (50329050000)

(EXC EU, EXC SIX DAYS) ( p. 21)

– On the slave cylinder, remove bleeder screw

 and mount bleeding syringe



500158-10

400340-10

– Inject the liquid into the system until it escapes from bore hole cylinder without bubbles.

 of the master

– To prevent overflow, drain fluid occasionally from the master cylinder reservoir.

– Remove the bleeding syringe. Mount and tighten screws bleeder screw.

– Correct the fluid level of the hydraulic clutch.

Guideline

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

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

Info

Clean up overflowed or spilt fluid immediately with water.

400341-10

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.

The idle speed is adjusted with the adjustment screw



The idle mixture is adjusted with the idle mixture adjustment screw



MAINTENANCE WORK ON CHASSIS AND ENGINE

9.107

Carburetor - adjusting idle

400341-10

– Screw in the idle adjusting screw setting.

 until it stops and then to the prescribed basic

Guideline

Idle mixture adjusting screw (400 EXC)

Open 0.75 turn

Idle mixture adjusting screw (530 EXC, 530 EXC SIX DAYS, 450 XC-W ZA,

530 XC-W ZA)

Open 1.5 turns

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

450 XC-W USA)

Open 1.75 turns

Idle mixture adjusting screw (530 XC-W USA)

Open 2.0 turns

Adjustment tool for mixture control screw (77329034000)

– Run the engine until warm.

Guideline

Warm-up time

≥ 5 min

Danger

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

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

– Adjust the idle speed with adjusting screw

Guideline



Choke function deactivated – The choke lever is pushed in to the stop.

(EXC AUS, XC‑W) ( p. 20)

Choke function deactivated – The choke lever is pushed back to the stop.

Idle speed 1,550… 1,650 rpm

– Turn the idle adjusting screw

 slowly until the idle speed begins to fall.

– Note the position and turn the idle adjusting screw slowly counterclockwise until the idle speed falls.

– Adjust to the point between these two positions with the highest idle speed.

Info

If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps.

The extreme sport motorcyclist will set the mixture about ¼ of a turn back from this ideal value (leaner, in a clockwise direction) since the engine becomes hotter in sporting use.

If the procedure described here does not lead to satisfactory results, the cause may be a wrongly dimensioned idling jet.

If you can turn the idle adjusting screw to the end without any change of engine speed, you have to mount a smaller idling jet.

The idle adjusting screw must not be opened more than two turns. If more than two turns are necessary (rich mixture), use a larger idling jet.

After changing the idling jet, start from the beginning with the adjusting steps.

MAINTENANCE WORK ON CHASSIS AND ENGINE

– Adjust the idle speed with adjusting screw

Guideline



Choke function deactivated – The choke lever is pushed in to the stop.

(EXC AUS, XC‑W) ( p. 20)

Choke function deactivated – The choke lever is pushed back to the stop.

(EXC EU, EXC SIX DAYS) ( p. 21)

Idle speed 1,550… 1,650 rpm

Info

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

9.108

Emptying the carburetor float chamber

Danger

Fire hazard Fuel can easily catch fire.

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

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

Warning

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

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

Info

Carry out this work with a cold engine.

– Turn handle

 of the fuel tap to the

– Top up the engine oil. ( p. 82)

No more fuel flows from the tank to the carburetor.

– Direct the hose of the float chamber into a suitable container.

Info

Water in the float chamber results in malfunctioning.

– Undo the screw

 the float chamber.

(turn it counterclockwise) a few turns and drain the fuel from

– Tighten screw



500256-10

9.109

Checking engine oil level

Info

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

– Stand the motorcycle upright on a horizontal surface.

MAINTENANCE WORK ON CHASSIS AND ENGINE

Condition

Engine is cold.

– Check the engine oil level.

The engine oil must be between the halfway mark and the top of the oil level viewer



» If the engine oil level is below the specified level:

200119-10

9.110

Changing engine oil and oil filter, cleaning engine oil screen

– Drain the engine oil and clean the engine oil screen.

– Remove the oil filter.

– Mount the oil filter.

x ( p. 81)

– Fill up with engine oil.

( p. 81)

x ( p. 80)

9.111

Draining engine oil, cleaning engine oil screen

Warning

Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven.

– Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning

Environmental hazard Problem materials cause environmental damage.

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

Info

Drain the engine oil only when the engine is warm.

200112-10

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

– Place a suitable container under the engine.

– Remove engine oil plug screen

– Completely drain the engine oil.



– Thoroughly clean the plug and gear oil screen.

– Clean the sealing area on the engine.

– Mount and tighten the plug of engine oil screen



Guideline

Plug, engine oil screen M17x1.5

20 Nm

(14.8 lbf ft)

9.112

Removing the oil filter

Warning

Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven.

– Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning

Environmental hazard Problem materials cause environmental damage.

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

– Place a suitable container under the engine.

MAINTENANCE WORK ON CHASSIS AND ENGINE

– Remove screws



. Remove oil filter cover

 with O-ring.

200113-10

– Pull the oil filter insert

 out of the oil filter casing.

Circlip pliers reverse (51012011000)

– Completely drain the engine oil.

– Thoroughly clean parts and sealing area.

9.113

Mounting oil filter

200114-10

– Lay the motorcycle on its side and fill the oil filter housing to about ⅓ full with engine oil.

– Fill the oil filter



– Lubricate the O-ring with engine oil and place it in the oil filter container.

 of the oil filter cover.

200114-11

– Refit the oil filter cover



– Mount and tighten screws



Guideline

Screw, oil filter cover

– Stand the motorcycle up.

M6 10 Nm (7.4 lbf ft)

200113-11

9.114

Filling up with engine oil

Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

200115-10

– Remove the screw cap

 on the generator cover and fill up with engine oil.

Engine oil 0.60 l (0.63 qt.)

– Mount and tighten screw cap



Danger

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

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

– Start the engine and check that it is oil-tight.

MAINTENANCE WORK ON CHASSIS AND ENGINE

9.115

Topping up engine oil

Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

200115-10

– Remove the screw cap

 on the generator cover and fill up with engine oil.

– Mount and tighten screw cap



Danger

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

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

– Start the engine and check that it is oil-tight.

9.116

Checking gear oil level

Info

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

200116-10

– Stand the motorcycle upright on a horizontal surface.

Condition

Engine is cold.

– Remove gear oil level check screw

– Check the gear oil level.



. Stand the vehicle upright.

A small amount of gear oil should flow out.

» If no gear oil flows out:

– Add gear oil.

( p. 83)

– Mount and tighten the gear oil level check screw.

Guideline

Screw, gear oil level check M6 8 Nm (5.9 lbf ft)

9.117

Changing gear oil, cleaning gear oil screen

– Drain the gear oil and clean the gear oil screen.

– Fill up with gear oil.

( p. 83)

( p. 82)

9.118

Draining gear oil, cleaning gear oil screen

Warning

Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven.

– Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning

Environmental hazard Problem materials cause environmental damage.

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

Info

Drain the gear oil only when the engine is warm.

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

MAINTENANCE WORK ON CHASSIS AND ENGINE

– Place a suitable container under the engine.

– Remove the gear oil drain plug



– Plug - remove the gear oil screen

– Completely drain the gear oil.



– Thoroughly clean the gear oil drain plug with a magnet.

– Thoroughly clean the drain plug and gear oil screen with a magnet.

– Clean the sealing area on the engine.

– Mount and tighten gear oil drain plug

 with the seal ring.

Guideline

Gear oil drain plug with magnet M12x1.5

20 Nm

(14.8 lbf ft)

– Mount and tighten the plug of gear oil screen



Guideline

Plug, gear oil screen M16x1.5

20 Nm

(14.8 lbf ft)

500159-10

9.119

Filling up with gear oil

Info

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

200118-10

– Remove the screw cap

 and fill up with gear oil.

Gear oil 0.90 l (0.95 qt.)

– Check the gear oil level. ( p. 82)

– Mount and tighten screw cap



Danger

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

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

– Start the engine and check that it is oil-tight.

9.120

Adding gear oil

Info

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

– Remove gear oil level check screw



200116-10

MAINTENANCE WORK ON CHASSIS AND ENGINE

200118-11

– Remove screw cap



. Stand the vehicle upright.

– Add gear oil until it flows out of the bore of the gear oil level screw.

– Remove the fuse. ( p. 69)

– Mount and tighten the gear oil level check screw.

Guideline

Screw, gear oil level check M6

– Mount and tighten screw cap



8 Nm (5.9 lbf ft)

Danger

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

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

– Start the engine and check that it is oil-tight.

TROUBLESHOOTING

Faults

The engine cannot be cranked (electric starter).

Engine turns but does not start.

Engine has no idle.

Engine does not speed up.

Possible cause

Operating error

Battery discharged

Fuse blown

Starter relay defective

Starter motor defective

Operating error

Motorcycle was out of use for a long time and there is old fuel in the float chamber

Fuel feed interrupted

Engine flooded

Spark plug oily or wet

Electrode distance (plug gap) of spark plug too wide

Defect in ignition system

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

OFF switch defective

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

Water in carburetor or jets blocked

Idling jet blocked

Adjusting screws on carburetor distorted

Spark plug defective

Ignition system defective

Carburetor running over because float needle dirty or worn.

Loose carburetor jets

Ignition system defective

Action

– Go through the steps of starting the

engine. ( p. 26)

– Recharge the battery.

( p. 68)

– Check the charging voltage.

– Check the closed current.

– Check the generator.

– Install the fuse. ( p. 69)

– Check the starter relay.

– Check the starter motor.

x x

– Go through the steps of starting the

engine. ( p. 26)

– Empty the carburetor float chamber.

– Check the fuel tank breather.

– Clean the fuel tap.

– Check/adjust the carburetor components.

– Clean and dry the spark plug or replace if necessary.

– Adjust plug gap.

Guideline

Spark plug electrode gap

0.9 mm (0.035 in)

– Check the ignition system.

– Check the wiring harness (visual check).

– Check the electrical system.

– Clean the plug connector and treat it with contact spray.

– Check/adjust the carburetor components.

– Carburetor - adjust the idle speed.

( p. 78)

– Change spark plug.

– Check the ignition coil.

– Check the CDI unit.

– Check the spark plug connector.

– Check the ignition pulse generator.

– Check the generator.

– Check/adjust the carburetor components.

– Check the ignition coil.

x x

– Check the CDI unit.

– Check the spark plug connector.

– Check the ignition pulse generator.

– Check the generator.

TROUBLESHOOTING

Faults

Engine has too little power.

Engine stalls or is popping into the carburetor

Engine overheats.

High oil consumption

Battery discharged

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

Possible cause Action

Fuel feed interrupted

Air filter very dirty

Exhaust system leaky, deformed or too little glass fiber yarn filling in main silencer

Valve clearance too little

Ignition system defective

Lack of fuel

Engine takes in bad air

Too little coolant in cooling system

Engine oil level too high

Engine oil too thin (low viscosity)

– Check the fuel tank breather.

– Clean the fuel tap.

– Check/adjust the carburetor components.

– Clean the air filter.

– Fill up with fuel. ( p. 28)

– Check exhaust system for damage.

– Change glass fiber yarn filling of main silencer.

– Adjust the valve clearance.

– Check the ignition coil.

– Check the CDI unit.

– Check the spark plug connector.

– Check the ignition pulse generator.

– Check the generator.

– Turn handle

 of the fuel tap to the ON position.

(Figure 500137-10 p. 20)

– Check rubber sleeves and carburetor for tightness.

– Check the cooling system for leakage.

– Check the coolant level. ( p. 72)

– Switch off engine when standing.

Too little air stream

Radiator fins very dirty

Foam formation in cooling system

Bent radiator hose

Thermostat defective

Defect in radiator fan system

(EXC SIX DAYS, XC-W ZA)

Engine vent hose bent

– Clean radiator fins.

– Drain the coolant.

( p. 73)

– Refill the coolant.

( p. 73)

– Change the radiator hose.

– Check the thermostat.

Guideline

Opening temperature: 70 °C (158 °F)

– Check the radiator fan fuse.

– Check the radiator fan.

– Check the thermostat.

– Route the vent hose without bends or replace it if necessary.

– Change the engine oil and oil filter and clean the engine oil screen.

Motorcycle cleaner ( p. 107)

Piston or cylinder is worn

The battery does not charge

– Piston/cylinder - determine the mounting clearance x

– Check the charging voltage.

– Check the charging current.

– Check the generator.

Undesired power consumer

– Check the closed current.

The battery in the speedometer is empty.

– Change the battery in the speedometer.

CLEANING

11.1

Cleaning motorcycle

Note

Material damage Damage and destruction of components by high-pressure cleaning equipment.

– Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts.

Warning

Environmental hazard Problem materials cause environmental damage.

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

Info

If you clean the motorcycle regularly, its value and appearance are maintained over a long period.

Avoid direct sunshine on the motorcycle during cleaning.

– Before you clean the motocycle, seal the exhaust system to prevent penetration by water.

– First remove coarse dirt particles with a gentle water spray.

– Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush.

Info

Use warm water containing normal motorcycle cleaner and a soft sponge.

– After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly.

– Empty the carburetor float chamber.

– Clean the chain. ( p. 51)

Warning

Danger of accidents Reduced braking due to wet or dirty brakes.

– Clean or dry dirty or wet brakes by riding and braking gently.

– After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes.

Info

The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.

– Push back the protection covers on the handlebar instruments to allow water to evaporate.

– After the motorcycle has cooled off, oil or grease all moving parts and bearings.

– Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.

Cleaning and polishing materials for metal, rubber and plastic ( p. 107)

– Treat all painted parts with a mild paint polish.

High-luster polish for paint ( p. 107)

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

Contact spray ( p. 107)

(all EXC models)

– Lubricate the steering lock.

Universal oil spray ( p. 108)

STORAGE

12.1

Storage

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

Info

If you want to garage the motorcycle for a longer period, take the following actions.

Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season.

– Clean the motorcycle. ( p. 87)

– Change the engine oil and oil filter and clean the engine oil screen.

– Change the gear oil and clean the gear oil screen.

– Check the antifreeze and coolant level. ( p. 72)

( p. 82)

– Check the tire air pressure. ( p. 67)

– Drain the fuel from the tanks into a suitable container.

– Empty the carburetor float chamber.

– Remove the battery.

– Recharge the battery.

( p. 67)

x ( p. 68)

Guideline

Storage temperature of battery without direct sunshine.

0… 35 °C (32… 95 °F)

– The storage place should be dry and not subject to large temperature differences.

Info

KTM recommends propping up the motorcycle.