KTM 450 XC-W Six Days US 2011 Cross Country Bike Owner Manual

KTM 450 XC-W Six Days US 2011 Cross Country Bike Owner Manual

OWNER'S MANUAL

2011 400 EXC EU 400 EXC Factory Edition EU 400 EXC AUS 450 EXC EU 450 EXC Factory Edition EU 450 EXC AUS 450 EXC SIX DAYS EU 450 XC-W SIX DAYS USA 530 EXC EU 530 EXC Factory Edition EU 530 EXC AUS 530 EXC SIX DAYS EU 530 XC-W SIX DAYS USA

Art. no. 3211690en

DEAR KTM CUSTOMER

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

We wish you a lot of enjoyment in riding this vehicle!

1

Enter the serial numbers of your vehicle below.

Chassis number ( p. 10) Engine number ( p. 10) Key number (All EXC models) ( p. 10)

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

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

© 2010 KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.

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

Issued by: TÜV Management Service KTM-Sportmotorcycle AG 5230 Mattighofen, Austria

TABLE OF CONTENTS

TABLE OF CONTENTS

MEANS OF REPRESENTATION ............................................ 5

IMPORTANT INFORMATION ................................................ 6

VIEW OF VEHICLE............................................................... 8 View of the vehicle from the left front (example)................. 8

View of the vehicle from the right rear (example) ................ 9

SERIAL NUMBERS............................................................ 10 Chassis number............................................................. 10 Type label..................................................................... 10 Engine number.............................................................. 10 Key number (All EXC models) ......................................... 10 Fork part number........................................................... 10

Shock absorber part number........................................... 11

CONTROLS ....................................................................... 12 Clutch lever .................................................................. 12 Choke (EXC EU, EXC Factory Edition, EXC SIX DAYS) ....... 12 Hand brake lever ........................................................... 12 Throttle grip.................................................................. 12 Short circuit button (XC

EXC SIX DAYS, XC ‑

‑ W SIX DAYS).............................. 12

Short circuit button (All EXC models) .............................. 13 Light switch (All EXC models) ......................................... 13 Turn signal switch (All EXC models) ................................ 13 Horn button (All EXC models) ......................................... 13 Emergency OFF switch (EXC AUS) .................................. 13

Electric starter button (EXC AUS).................................... 14 Electric starter button (EXC EU, EXC Factory Edition, W SIX DAYS) ..................................... 14 Light switch (XC ‑ W SIX DAYS) ........................................ 14 Overview of indicator lamps (All EXC models)................... 14 Speedometer................................................................. 14

Speedometer activation and test ..................................... 15 Tripmaster switch .......................................................... 15 Setting kilometers or miles ............................................. 15

Setting the clock ........................................................... 16 Adjusting the speedometer functions............................... 16

Querying the lap time .................................................... 17 Display mode SPEED (speed) ......................................... 17 Display mode SPEED/H (service hours)............................ 17

Display mode SPEED/CLK (clock) ................................... 18 Display mode SPEED/LAP (lap time) ............................... 18 Display mode SPEED/ODO (odometer) ............................. 18 Display mode SPEED/TR1 (trip master 1) ........................ 18

Display mode SPEED/TR2 (trip master 2) ........................ 19 Display mode SPEED/A1 (average speed 1)...................... 19 Display mode SPEED/A2 (average speed 2)...................... 19

Display mode SPEED/S1 (stop watch 1) .......................... 20 Display mode SPEED/S2 (stop watch 2) .......................... 20

Opening filler cap.......................................................... 21 Closing filler cap ........................................................... 21

Fuel tap........................................................................ 22 Choke (EXC AUS, XC ‑ W SIX DAYS).................................. 22 Shift lever..................................................................... 22

Kick starter................................................................... 23 Foot brake lever............................................................. 23 Side stand .................................................................... 23 Steering lock (All EXC models)........................................ 23

Locking the steering (All EXC models) ............................. 24 Unlocking the steering (All EXC models) .......................... 24

PUTTING INTO OPERATION............................................... 25 Advice on first use......................................................... 25

Running-in the engine ................................................... 26 Preparing vehicle for arduous riding conditions................. 26 Preparations for riding on dry sand .................................. 26

Preparations for riding on wet sand ................................. 27

Preparing for rides on wet and muddy surfaces................. 28

Preparing for rides at high temperature and slow speed..... 29 Preparing for rides at low temperatures or in snow ............ 29

RIDING INSTRUCTIONS .................................................... 30 Checks and maintenance before putting into operation...... 30 Starting ........................................................................ 30

Starting up ................................................................... 31 Shifting, riding.............................................................. 31 Braking ........................................................................ 31

Stopping, parking .......................................................... 32 Refueling...................................................................... 32

SERVICE SCHEDULE......................................................... 34 Service schedule ........................................................... 34

Service work (as additional order).................................... 35

TUNING THE CHASSIS...................................................... 36 Checking the basic suspension setting against the rider's weight .......................................................................... 36 Compression damping of shock absorber.......................... 36 Adjusting high-speed compression damping of the shock absorber ....................................................................... 36

Adjusting the low-speed compression damping of the shock absorber .............................................................. 37 Adjusting rebound damping of the shock absorber ............ 37

Measuring rear wheel sag unloaded ................................. 38 Checking the static sag of the shock absorber .................. 38 Checking the riding sag of the shock absorber .................. 38

Adjusting the spring preload of the shock absorber ...... 39 Adjusting the riding sag x

Fork offset (XC ‑ Setting the fork offset x

x ............................................. 39

Checking basic setting of fork ......................................... 40 Adjusting the compression damping of the fork ................ 40 Adjusting the rebound damping of the fork....................... 40

Adjusting spring preload of the fork................................. 41 W SIX DAYS) .......................................... 41

Removing the fork legs x

(XC

Adjusting handlebar position

x

W SIX DAYS)...................... 41

Handlebar position ........................................................ 42 ...................................... 42

SERVICE WORK ON THE CHASSIS..................................... 43 Raising the motorcycle with the lift stand ........................ 43 Removing the motorcycle from the lift stand .................... 43 Bleeding fork legs.......................................................... 43 Cleaning the dust boots of the fork legs ........................... 43

Loosening the fork protector ........................................... 44 Positioning the fork protector.......................................... 44 .............................................. 44

Installing fork legs x .................................................... 45 Removing the fork protector x ....................................... 45

Installing the fork protector x ....................................... 46 Removing the lower triple clamp x (EXC Factory Edition, EXC SIX DAYS, XC ‑ W SIX DAYS) ..... 46 Installing the lower triple clamp EXC SIX DAYS, XC ‑ x (EXC Factory Edition, W SIX DAYS) ..................................... 46

Removing the lower triple clamp x (EXC EU/AUS)........... 48

Installing the lower triple clamp x (EXC EU/AUS) ........... 49

Checking the steering head bearing play .......................... 50

Adjusting play of steering head bearing x (EXC Factory Edition, EXC SIX DAYS, XC ‑ W SIX DAYS) ..... 51 Adjusting play of steering head bearing (EXC EU/AUS)............................................................... 51 Greasing the steering head bearing x x ............................. 51

Removing the shock absorber x ..................................... 52

2

TABLE OF CONTENTS

Installing the shock absorber x ..................................... 52 Removing the front fender .............................................. 52 Installing the front fender............................................... 52

Removing the seat ......................................................... 53 Mounting the seat ......................................................... 53 Removing the air filter box lid......................................... 53 Installing the air filter box lid.......................................... 53 Removing the air filter x ............................................... 53

Installing the air filter Cleaning the air filter and air filter box

Removing main silencer ................................................. 55 Installing the main silencer ............................................ 55 Changing the glass fiber yarn filling of the main silencer x ................................................................... 55

Removing the fuel tank

x

x

............................................... 54 x ........................ 54

............................................. 56

Installing the fuel tank x .............................................. 57

Checking for chain dirt accumulation .............................. 58 Cleaning the chain......................................................... 58 Checking the chain tension ............................................ 58

Adjusting the chain tension ............................................ 59 Checking the chain, rear sprocket, engine sprocket and chain guide................................................................... 59

Adjusting chain guide

(XC ‑

Adding front brake fluid

Removing front wheel

x

x

x

............................................... 61 Checking the throttle cable routing.................................. 61

Adjusting the basic position of the clutch lever................. 62 Checking the fluid level of hydraulic clutch...................... 62 Changing the hydraulic clutch fluid

BRAKES ........................................................................... 64 Checking free travel of hand brake lever........................... 64 Adjusting the basic position of the hand brake lever W SIX DAYS)........................................................... 64 Adjusting free travel of hand brake lever (All EXC models) ........................................................................ 64

Checking the brake discs................................................ 65 Checking the brake fluid level of the front brake............... 65 ............................................ 65

Checking the front brake linings...................................... 66

Changing the front brake linings

Checking the free travel of the foot brake lever ................. 68 Adjusting the basic position of the foot brake lever

Checking rear brake fluid level........................................ 69 Adding brake fluid to the rear brake circuit

Checking rear brake linings ............................................ 70 Changing the rear brake linings x

x

x ............................ 62

................................. 67

x

x ...... 68

................. 69

.................................. 70

WHEELS, TIRES ............................................................... 73 ................................................ 73 Installing the front wheel

Removing the rear wheel

Installing the battery

x ........................................... 73

x ........................................... 74 Installing the rear wheel

Checking the tire condition............................................. 75

Checking tire air pressure............................................... 76 Checking spoke tension.................................................. 76

ELECTRICAL SYSTEM ....................................................... 78 Removing the battery x

x ............................................ 74

................................................ 78 Recharging the battery x ................................................. 78

Removing the main fuse................................................. 79 Installing the main fuse ................................................. 79

Changing the fuse of the radiator fan (EXC SIX DAYS, XC ‑

x .............................................. 78

W SIX DAYS)............................................................ 80 Removing headlight mask with headlight ......................... 80

Refitting the headlight mask with the headlight................ 81 Changing the headlight bulb........................................... 81

Checking the headlight adjustment ................................. 82 Adjusting the headlight range ......................................... 82 Changing the speedometer battery .................................. 82

COOLING SYSTEM ............................................................ 84 Cooling system .............................................................. 84 Checking the anti-freeze and coolant level ....................... 84 Checking the coolant level.............................................. 84

Draining coolant x ....................................................... 85 Refilling coolant x ....................................................... 85

TUNING THE ENGINE ....................................................... 87 Checking the play in the throttle cable............................. 87 Adjusting the play in the throttle cable Carburetor - idle ............................................................ 87

Carburetor - adjusting the idle speed x

x ....................... 87

.......................... 88

Emptying the carburetor float chamber

screen x

x ....................... 89 Checking the basic position of the shift lever.................... 89

Adjusting the basic position of the shift lever

SERVICE WORK ON THE ENGINE ...................................... 91 Checking engine oil level................................................ 91 Changing engine oil and oil filter, cleaning engine oil ..................................................................... 91 Draining engine oil, cleaning engine oil screen

x

x

.............. 90

............ 91

Removing the oil filter Installing the oil filter x ............................................... 92 x ............................................... 92

Filling up with engine oil x ........................................... 93 Adding engine oil .......................................................... 93

Checking the gear oil level.............................................. 94 Changing gear oil, cleaning gear oil screen x .................. 94 Draining gear oil, cleaning gear oil screen

Filling up with gear oil

x ................... 94

x .............................................. 95 Adding gear oil x ......................................................... 95

CLEANING, CARE ............................................................. 97 Cleaning the motorcycle ................................................. 97

Protection for winter operation ........................................ 98

STORAGE ......................................................................... 99 Storage......................................................................... 99 Putting into operation after storage ................................. 99

TROUBLESHOOTING....................................................... 100

TECHNICAL DATA - ENGINE............................................ 102 Capacity - engine oil .................................................... 102

Capacity - transmission oil............................................ 103 Capacity - coolant........................................................ 103

TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ 104

TECHNICAL DATA - CARBURETOR................................... 106 All 400 models ........................................................... 106 450 EXC EU/AUS, 450 EXC SIX DAYS, 450 EXC Factory Edition EU......................................... 106 450 XC-W SIX DAYS USA ............................................ 106

All 530 EXC models .................................................... 107 530 XC-W SIX DAYS USA ............................................ 107

TECHNICAL DATA - CHASSIS .......................................... 108

Lighting equipment ..................................................... 109 Tires .......................................................................... 109 Capacity - fuel............................................................. 109

TECHNICAL DATA - FORK................................................ 110

TECHNICAL DATA - SHOCK ABSORBER ........................... 111

TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS ........................................................................ 112

SUBSTANCES................................................................. 113

3

TABLE OF CONTENTS

AUXILIARY SUBSTANCES................................................ 115

STANDARDS................................................................... 117

INDEX ............................................................................ 118

4

MEANS OF REPRESENTATION Symbols used

The symbols used are explained in the following.

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

Indicates an unexpected reaction (e.g., to a work step or a function).

All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.

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

Formats used

The typographical and other formats used are explained below.

Proprietary name

Denotes a proprietary name.

Name ®

Denotes a protected name.

Brand™

Denotes a brand available on the open market.

5

IMPORTANT INFORMATION Use definition (All EXC models)

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

Info

The motorcycle is authorized for use on public roads in the homologated (reduced) version only.

In the derestricted version, the motorcycle must be used only on closed off properties remote from public road traffic.

The motorcycle is designed for off-road sport endurance competition (Enduro) and not for the predominant motocross use.

Use definition (XC

W SIX DAYS)

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

Info

The motorcycle may only be used in closed off areas remote from public road traffic.

The motorcycle is designed for off-road sport endurance competition (Enduro) and not for the predominant motocross use.

Service

A prerequisite for perfect operation and prevention of premature wear is that the service, care and tuning work on the engine and chassis is properly carried out as described in the owner's manual. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of components.

Using the vehicle in difficult conditions such as on sand or very muddy or wet terrain can lead to above-average wear of components such as the drive train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached.

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

Warranty

The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the

KTM dealer.net

; otherwise, all warranty claims will be void. No warranty claim can be honored for damage resulting from manipulation and/or other changes to the vehicle.

Fuel, oils, etc.

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

Spare parts, accessories

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

Some spare parts and accessories are specified in brackets in the respective descriptions. Your KTM dealer will be happy to advise you.

You will find the current

KTM PowerParts

for your vehicle on the KTM website.

International KTM Website: http://www.ktm.com

Work rules

Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in parentheses. Ex: valve spring compressor (59029019000) During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts.

If thread lock (e.g.

Loctite ®

) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its usage.

Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or worn parts.

Following repairs or servicing, the vehicle must be checked for roadworthiness.

6

IMPORTANT INFORMATION Transport Note Danger of damage

  The parked vehicle may roll away or fall over.

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

Note Fire hazard

  Some vehicle components become very hot when the vehicle is operated.

– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first.

– – – Switch off engine.

Turn handle  of the fuel tap to the

OFF

position. (Figure 500137-10 p. 22)

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

Environment

Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. 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 prob lems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, dis play environmental consciousness, and respect the rights of others.

Notes/warnings

Pay close attention to the notes/warnings.

Info

Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are miss ing, you or others may not recognize potential hazards and may therefore be injured.

Grades of risks Danger

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.

Warning

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Caution

Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

Note

Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Warning

Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.

– –

Owner's manual

It is important that you read this owner's manual carefully and completely before making your first trip. It contains information and tips to help you operate and handle your motorcycle. Only then will you learn how to best adjust the motorcycle for your own use and how to 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.

7

VIEW OF VEHICLE

3.1

View of the vehicle from the left front (example) 8

100853-10 1 2 3 4 5 6 7 Hand brake lever Clutch lever Air filter box lid Fuel tap Chain guide Side stand Shift lever

VIEW OF VEHICLE

3.2

View of the vehicle from the right rear (example) 9

1 2 3 4 5 6 7 8 9 10 11 12 Filler cap Short circuit button Speedometer Electric starter button Fork rebound adjustment Horn Fork compression adjustment Shock absorber rebound adjustment Level viewer for brake fluid, rear Shock absorber compression adjustment Foot brake lever Kick starter 100854-10

SERIAL NUMBERS

4.1

Chassis number

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

10

4.2

Type label

500127-10 The type label  is fixed to the front of the steering head.

4.3

Engine number

500128-10 The engine number sprocket.

 is stamped on the left side of the engine under the engine 4.4

Key number (All EXC models)

500072-10 The key number  for the steering lock is stamped onto the key connector.

4.5

Fork part number

500125-10 The fork part number  is stamped on the inner side of the fork stub.

100801-10

SERIAL NUMBERS

4.6

Shock absorber part number 11

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

500129-10

CONTROLS

5.1

Clutch lever

The clutch lever  is fitted on the left side of the handlebar.

The clutch is hydraulically operated and self-adjusting.

500133-10 5.2

Choke (EXC EU, EXC Factory Edition, EXC SIX DAYS)

The choke lever  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.

5.3

Hand brake lever

Hand brake lever  is located on the right side of the handlebar.

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

12

5.4

Throttle grip

400196-10 The throttle grip  is fitted on the right side of the handlebar.

100858-10 5.5

Short circuit button (XC

W SIX DAYS)

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

CONTROLS

5.6

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.

13

500134-10 5.7

Light switch (All EXC models)

500134-12 5.8

Turn signal switch (All EXC models)

The light switch

Possible states

 is fitted on the left side of the handlebar.

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.

Turn signal switch 

Possible states

is fitted on the left side of the handlebar.

Turn signal light off – Turn signal switch is in the central position.

Turn signal light, left, on – Turn signal switch turned to the left.

Turn signal light, right, on – Turn signal switch turned to the right.

5.9

Horn button (All EXC models)

500145-10 The horn button

Possible states

• Horn button • Horn button  is fitted on the left side of the handlebar.

in neutral position pressed – The horn is operated in this position.

500134-11 5.10

Emergency OFF switch (EXC AUS)

The emergency OFF switch

Possible states

 is fitted on the right side of the handlebar.

Ignition off – In this position, the ignition circuit is interrupted, a run ning 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

CONTROLS

5.11

Electric starter button (EXC AUS)

The electric starter button

Possible states

• Electric starter button • Electric starter button  is fitted on the right side of the handlebar.

in basic position pressed – In this position, the electric starter is actuated.

14

500131-11 5.12

Electric starter button (EXC EU, EXC Factory Edition, EXC SIX DAYS, XC

W SIX DAYS)

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

Possible states

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

5.15

400198-10 5.13

Light switch (XC

W SIX DAYS)

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

Possible states

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

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

500146-10 5.14

Overview of indicator lamps (All EXC models) Possible states

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

Turn signal indicator lamp flashes green on.

– Turn signal light is switched

Speedometer

500147-01 400312-01 – – – Press the key Press the key Press the key to change the display mode or change to one of the Setup menus.

to control different functions.

to control different functions.

Info

When the vehicle is delivered, only the are activated.

SPEED/H

and

SPEED/ODO

display modes

CONTROLS

5.16

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.

15

400313-01

WS (wheel size)

After the display function test, the wheel size

WS

is displayed briefly.

Info

The number 2205 mm equals the circumference of the 21" front wheel with a series production tire.

The display then changes to the last selected mode.

400314-01 5.17

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.

5.18

Setting kilometers or miles Info

If you change the unit of measure, the The values

TR1

,

TR2

,

A1

,

A2

and

S1 ODO

value is retained and converted accordingly.

are cleared when the unit of measure is changed.

400329-01

Condition

The motorcycle is stationary.

– Press the button display.

briefly and repeatedly until – Press the button for 3 - 5 seconds.

H

appears at the bottom right of the – The Setup menu is displayed and the active functions are shown.

Press the button repeatedly until the

Adjusting Km/h

– Press the button .

Km/h

/

Mph

display flashes.

Adjusting Mph

– Press the button .

– Press the button for 3 - 5 seconds.

The settings are stored and the Setup menu is 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.

CONTROLS

5.19

Setting the clock

400330-01 – –

Condition

The motorcycle is stationary.

– Press the button the display.

briefly and repeatedly until – Press the button for 3 - 5 seconds.

CLK

appears at the bottom right of The hour display flashes.

Set the hour display with the button Press the button briefly.

and/or button .

– 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 stored and the Setup menu is closed.

Info

If no button is pressed for 20 seconds, or if a pulse arrives from the wheel speed sensor, the settings are stored automatically and the Setup menu is closed.

5.20

Adjusting the speedometer functions Info

When the vehicle is delivered, only the

SPEED/H

and

SPEED/ODO

display modes are activated.

400318-01 – –

Condition

The motorcycle is stationary.

– Press the button display.

briefly and repeatedly until – Press the button for 3 - 5 seconds.

H

appears at the bottom right of the – The Setup menu is displayed and the activated functions are shown.

Change to the desired function by pressing the button briefly.

The selected function flashes.

Activating a function

– Press the button .

The symbol remains on the screen and the display changes to the next function.

Deactivating the function

– Press the button .

The symbol on the screen goes out and the display changes to the next function.

All desired functions are activated or deactivated accordingly.

Press the button for 3 - 5 seconds.

The settings are stored and the Setup menu is closed.

Info

If no button is pressed for 20 seconds, or if a pulse arrives from the wheel speed sensor, the settings are stored automatically and the Setup menu is closed.

16

CONTROLS 17

5.21

Querying the lap time Info

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

400321-01 – – –

Condition

The motorcycle is stationary.

– Press the button the display.

briefly and repeatedly until – Press the button briefly.

LAP

appears at the bottom right of

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.

5.22

Display mode SPEED (speed) 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 5.23

Display mode SPEED/H (service hours) Condition

• The motorcycle is stationary.

– Press the button display.

briefly and repeatedly until

H

appears at the bottom right of the In display mode

H

, the service hours of the engine are displayed.

The service hour counter stores the total traveling time.

400316-01 – Press the button the display.

briefly and repeatedly until

SPEED

The current speed is displayed in the The current speed can be displayed in

SPEED Km/h

display mode.

or

Mph

.

appears on the left side of

Info

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

If the speedometer is in

H

display mode at the start of the journey, it automati cally changes to the

ODO

display mode.

The

H

display mode is suppressed during the journey.

Press the button . No function Press the button . No function Press the button for 3 - 5 seconds.

Press the button briefly.

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

Next display mode

CONTROLS

5.24

Display mode SPEED/CLK (clock)

400319-01 – Press the button the display.

The time is displayed in briefly and repeatedly until

CLK

appears at the bottom right of

CLK

display mode.

Press the button . No function 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 5.25

Display mode SPEED/LAP (lap time)

– Press the button the display.

briefly and repeatedly until

LAP

appears at the bottom right of In the

LAP

display mode, up to 10 lap times can be timed with the stop watch.

Info

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

Lap 10 must be timed with the button .

400320-01 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.

Press the button briefly.

Next display mode 5.26

Display mode SPEED/ODO (odometer)

400317-01 – Press the button the display.

briefly and repeatedly until The total distance traveled is displayed in the

ODO ODO

appears at the bottom right of display mode.

Press the button . No function Press the button . No function Press the button for 3 - 5 seconds.

– Press the button briefly.

Next display mode 5.27

Display mode SPEED/TR1 (trip master 1)

– Press the button display.

briefly and repeatedly until

TR1

appears at the top right of the

TR1

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

TR1

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

is coupled with

A1

(average speed 1) and

S1

(stop watch 1).

Info

If 999.9 is exceeded, the values of 0.0.

TR1

,

A1

and

S1

are automatically reset to 400323-01 Press the button . No function Press the button . No function Press the button for 3 - 5 seconds.

The

TR1

,

A1

and

S1

displays are reset to 0.0.

18

CONTROLS 19

400324-01 Press the button briefly.

Next display mode 5.28

Display mode SPEED/TR2 (trip master 2)

– Press the button display.

briefly and repeatedly until

TR2

appears at the top right of the

TR2

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

The displayed value can be set manually with the button and the button . This is a very practical function when riding using the road book.

Info

The

TR2

value can also be corrected manually during the journey with the but ton and the button .

If 999.9 is exceeded, the value of

TR2

is automatically reset to 0.0.

Press the button . Increases value of

TR2

.

Press the button . Reduces value of

TR2

.

Press the button for 3 - 5 seconds.

Deletes value of

TR2

.

Press the button briefly.

Next display mode 5.29

Display mode SPEED/A1 (average speed 1)

– Press the button display.

briefly and repeatedly until

A1

appears at the top right of the

A1

(average speed 1) shows the average speed calculated on the basis of ter 1) and

S1

(stop watch 1).

and ends 3 seconds after the last impulse.

TR1

(trip mas The calculation of this value is activated by the first impulse of the wheel speed sensor 400325-01 Press the button . No function 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

Display mode SPEED/A2 (average speed 2)

– Press the button display.

briefly and repeatedly until

A2

appears at the top right of the

A2

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

S2

(stop watch 2) is running.

Info

The displayed value can differ from the actual average speed if timed after the ride.

S2

was not 400326-01 Press the button . No function Press the button . No function Press the button for 3 - 5 seconds.

– Press the button briefly.

Next display mode

CONTROLS 20

5.31

Display mode SPEED/S1 (stop watch 1)

– Press the button display.

briefly and repeatedly until

S1

appears at the top right of the

S1

(stop watch 1) displays the journey time on the basis of

TR1

and continues when an impulse is received from the wheel speed sensor.

The calculation of this value starts with the first impulse of the wheel speed sensor and ends 3 seconds after the last impulse.

400327-01 Press the button . No function Press the button . No function Press the button for 3 - 5 seconds.

Press the button briefly.

Displays of

TR1

,

A1

and

S1

are reset to 0.0.

Next display mode 5.32

Display mode SPEED/S2 (stop watch 2)

– Press the button display.

briefly and repeatedly until

S2

appears at the top right of the

S2

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

S2

is running in the background, the

S2

display flashes in the speedometer display.

400328-01 Press the button . Starts or stops

S2

.

Press the button . No function Press the button for 3 - 5 seconds.

Press the button briefly.

Displays of

S2

and

A2

are reset to 0.0.

Next display mode

Table of functions Display Press the button .

Display mode (service hours)

SPEED/H

No function Display mode (clock)

SPEED/CLK

No function Display mode (lap time)

SPEED/LAP

Starts or stops the clock.

Press the button .

No function No function Display mode

SPEED/ODO

(odometer) Display mode (trip master 1)

SPEED/TR1

Display mode (trip master 2)

SPEED/TR2

Display mode

SPEED/A1

(average speed 1) Display mode

SPEED/A2

(average speed 2) Display mode (stop watch 1)

SPEED/S1

Display mode (stop watch 2)

SPEED/S2

No function No function Increases value of

TR2

.

No function No function No function Starts or stops

S2

.

Table of conditions and menu activation Display

Display mode

SPEED/H

(service hours) Stops the current lap time and saves it, and the stop watch starts the next lap.

No function No function Reduces value of

TR2

.

No function No function No function No function

Press the button 5 seconds.

for 3 -

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

dis plays are reset to 0.0.

Deletes value of

TR2

.

Next display mode Next display mode The

TR1

,

A1

and

S1

dis plays are reset to 0.0.

– Next display mode Next display mode Displays of

S1 TR1

,

A1

are reset to 0.0.

and Displays of

S2

and are reset to 0.0.

A2

Next display mode Next display mode

The motorcycle is stationary.

Menu can be acti vated

CONTROLS 21 Table of conditions and menu activation Display

Display mode

SPEED/CLK

(clock) Display mode

SPEED/LAP

(lap time) Display mode

SPEED/TR1

(trip master 1) Display mode

SPEED/TR2

(trip master 2) Display mode

SPEED/A1

(average speed 1) Display mode

SPEED/A2

(average speed 2) Display mode

SPEED/S1

(stop watch 1) Display mode

SPEED/S2

(stop watch 2)

The motorcycle is stationary.

Menu can be acti vated

• • • • • • • • 5.33

Opening filler cap Danger Fire hazard

  Fuel is highly flammable.

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

Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

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

Warning Environmental hazard

  Improper handling of fuel is a danger to the environment.

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

– Press release button remove.

 , turn filler cap counterclockwise and lift it upwards and 5.34

Closing filler cap

400199-10 – Replace the filler cap and turn clockwise until the release button  locks in place.

Info

Route the fuel tank breather hose  without kinking.

400199-11

CONTROLS

5.35

Fuel tap 22

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

With tap handle buretor.

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

Possible states

• Fuel supply closed • Fuel supply open

OFF ON

– – No fuel flows from the tank to the carburetor.

Fuel flows from the tank to the carburetor. The fuel tank empties down to the reserve.

• Reserve fuel supply open

RES

fuel tank empties completely.

– Fuel flows from the tank to the carburetor. The 500137-10 5.36

Choke (EXC AUS, XC

W SIX DAYS)

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.

5.37

Shift lever

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.

500138-11

CONTROLS

5.38

Kick starter

5.39

Foot brake lever

500148-10 The kick starter  is fitted on the right of the engine.

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

The upper part of the kick starter can be swung out.

Info

Before riding, swing the upper part of the kick starter inwards towards the engine.

Foot brake lever  is located in front of the right footrest.

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

23

5.40

Side stand

500139-10 The side stand  is on the left side of the vehicle.

500140-10 The side stand is used to park the motorcycle.

Info

When you are riding, side stand band  .

 must be folded up and secured with rubber 500141-10 5.41

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

CONTROLS

5.42

Locking the steering (All EXC models) Note Danger of damage

  The parked vehicle may roll away or fall over.

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

– – – Park the vehicle.

Turn the handlebar as far as possible to the right.

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.

400732-01 5.43

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.

24

400731-01

PUTTING INTO OPERATION

6.1

Advice on first use Danger Danger of accidents

  Danger arising from the rider's judgement being impaired.

– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired.

Warning Risk of injury

  Missing or poor protective clothing present an increased safety risk.

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

Warning Danger of crashing

  Poor vehicle handling 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

  Failure of brake system.

– If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take your foot off the foot brake lever when you are not braking.

Warning Danger of accidents

  Unstable riding behavior.

– Do not exceed the maximum permissible 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.

25 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.

Adjust the basic position of the clutch lever. ( p. 62)

(XC

W SIX DAYS)

Adjust the basic position of the hand brake lever. ( p. 64)

– –

(All EXC models)

Adjust the free travel of the hand brake lever. (

– Adjust the basic position of the foot brake lever.

x (

p. 64)

p. 68)

Adjust the basic position of the shift lever.

x

( p. 90)

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

Info

Off-road, 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 off-road trips that over-stress your ability and experience.

PUTTING INTO OPERATION

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

If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis tribution between the front and rear wheels.

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 Maximum permissible front axle load Maximum permissible rear axle load 335 kg (739 lb.) 145 kg (320 lb.) 190 kg (419 lb.) Run-in the engine.

– 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 During the first operating hour Maximum engine performance During the first 3 service hours 7,000 rpm ≤ 75 % – Avoid fully opening the throttle!

6.3

Preparing vehicle for arduous riding conditions

– Using a motorcycle in arduous conditions can lead to excessive wear of components such as the power train or brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached.

Arduous riding conditions are:

Riding on dry sand. ( p. 26)

– –

Riding on wet sand. ( p. 27)

Rides on wet and muddy surfaces. ( p. 28)

– –

Rides at high temperature and slow speed. ( Rides at low temperatures or in snow. ( p. 29) p. 29)

6.4

Preparations for riding on dry sand

600872-10 – – Check the radiator cap.

Value on the radiator cap 1.8 bar (26 psi) » If the displayed value does not equal the setpoint value:

Warning Danger of scalding

  During motorcycle operation, the coolant gets very hot and is under pressure.

– Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

– Change the radiator cap.

Seal the air filter box.

x

Tip

Seal the air filter box at the edges to prevent dirt from entering.

– Clean the air filter and air filter box.

x

( p. 54)

Info

Check the air filter approx. every 30 minutes.

26

PUTTING INTO OPERATION

– Mount the dust cover for the air filter.

Dust protection device for air filter (59006019000)

Info

Read the

KTM PowerParts

installation instructions.

600869-01 600871-01 600868-01 6.5

Preparations for riding on wet sand

– Mount the dust cover for the air filter for sand.

Sand protection device for air filter (59006022000)

Info

Read the

KTM PowerParts

installation instructions.

– – – Adjust the carburetor jetting and setting.

Info

Recommendations on the carburetor setting are available from your autho rized KTM workshop.

Clean the chain.

Chain cleaner ( p. 115)

Mount the steel sprocket.

Tip

Do not grease the chain.

– – Clean the radiator fins.

Carefully align bent radiator fins.

600872-10 – – Check the radiator cap.

Value on the radiator cap 1.8 bar (26 psi) » If the displayed value does not equal the setpoint value:

Warning Danger of scalding

  During motorcycle operation, the coolant gets very hot and is under pressure.

– Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

– Change the radiator cap.

Seal the air filter box.

x

Tip

Seal the air filter box at the edges to prevent dirt from entering.

– Clean the air filter and air filter box.

x

( p. 54)

Info

Check the air filter approx. every 30 minutes.

27

PUTTING INTO OPERATION 28

600870-01 – Mount the rain cover for the air filter.

Waterproofing device for air filter (59006021000)

Info

Read the

KTM PowerParts

installation instructions.

– – – Adjust the carburetor jetting and setting.

Info

Recommendations on the carburetor setting are available from your autho rized KTM workshop.

Clean the chain.

Chain cleaner ( p. 115)

Mount the steel sprocket.

Tip

Do not grease the chain.

– – Clean the radiator fins.

Carefully align bent radiator fins.

600868-01 6.6

Preparing for rides on wet and muddy surfaces

– Seal the air filter box.

x

Tip

Seal the air filter box along the edges to prevent the ingress of dirt.

– Clean the air filter and air filter box.

x

( p. 54)

Info

Check the air filter approx. every 30 minutes.

– Fit a waterproofing device on the air filter.

Waterproofing device for air filter (59006021000) 600870-01 – – – –

Info

See the

KTM PowerParts

fitting instructions.

Adjust the carburetor jetting and settings.

Info

Your authorized KTM workshop has the recommended carburetor tuning set tings.

Fit the steel sprocket.

Clean the motorcycle. ( p. 97)

Straighten bent radiator fins carefully.

600868-01

PUTTING INTO OPERATION 29

6.7

Preparing for rides at high temperature and slow speed

– Check the radiator cap.

Value on radiator cap 1.8 bar (26 psi) » If the displayed value does not correspond to the nominal value: 600872-10 –

Warning Danger of scalding

  During motorcycle operation, the coolant gets very hot and is under pressure.

– Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

– Change the radiator cap.

Seal the air filter box.

x

Tip

Seal the air filter box on the edges against dirt.

– Clean the air filter and air filter box.

x

( p. 54)

Info

Check the air filter approx. every 30 minutes.

– 600868-01 – – – – Adjust the secondary drive to the road conditions.

Info

The engine oil quickly gets hot if the clutch has to be operated very often due to an excessively high secondary drive.

Clean the chain.

Chain cleaner ( p. 115)

Clean radiator fins.

Straighten bent radiator fins carefully.

Check the coolant level. ( p. 84)

6.8

Preparing for rides at low temperatures or in snow

– Seal the air filter box.

x

Tip

Seal the air filter box on the edges against dirt.

– Clean the air filter and air filter box.

x

( p. 54)

Info

Check the air filter approx. every 30 minutes.

– Fit a waterproofing device on the air filter.

Waterproofing device for air filter (59006021000) 600870-01 –

Info

See the

KTM PowerParts

fitting instructions.

Adjust the carburetor jetting and settings.

Info

Your authorized KTM workshop has the recommended carburetor tuning set tings.

RIDING INSTRUCTIONS 30

7.1

Checks and maintenance before putting into operation Info

Before every trip, check the condition of the vehicle and ensure that it is safe to operate.

The vehicle must be in perfect technical condition when used.

– – – – – – – – – – – – – – – – – – –

Check the engine oil level. (

Check the electrical system.

p. 91)

Check the brake fluid level of the front brake. (

Check the rear brake fluid level. ( p. 69)

Check the front brake linings. (

Check the rear brake linings. (

p. 66)

p. 70)

Check the brake system function.

Check the coolant level. ( p. 84)

p. 65)

Check for chain dirt accumulation. ( p. 58)

Check the chain, rear sprocket, engine sprocket and chain guide. (

Check the chain tension. (

Check the tire condition. (

p. 58)

p. 75)

Check the tire air pressure. ( p. 76)

Clean the dust boots of the fork legs. ( Bleed fork legs. ( p. 43) p. 43)

p. 59)

Check the air filter.

Check the settings of all controls and ensure that they can be operated smoothly.

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

Check the fuel reserves.

7.2

Starting Danger Danger of poisoning

  Exhaust gases are poisonous and inhaling them may 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 an enclosed space without an effective exhaust extraction system.

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 may 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 before trying again.

Motorcycle has been out of use for more than 1 week

– Empty the carburetor float chamber.

x (

Turn handle  of the fuel tap to the

ON

p. 89)

position. (Figure 500137-10 p. 22)

Fuel can flow from the fuel tank to the carburetor.

– – Raise the motorcycle off of the stand and secure the stand with rubber band Shift transmission to neutral.

(EXC AUS)

– Turn the emergency OFF switch to the position .

 .

The engine is cold (EXC AUS, XC

W SIX DAYS)

– Pull choke lever out as far as possible.

100842-10

RIDING INSTRUCTIONS

(EXC EU, EXC Factory Edition, 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

Do not rev up.

31

400733-01 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 lock up.

Info

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

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

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

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

When you reach maximum speed after fully opening the throttle, turn back the throttle to about ¾ of its range. This barely reduces vehicle speed but lowers fuel consumption 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 stationary for a long time.

Guideline ≥ 2 min Avoid frequent and prolonged slipping of the clutch. This causes heat build-up in the engine oil, the engine and the cooling sys tem.

Ride at lower engine speeds instead of high revs 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 efficiency caused by spongy pressure point of front or rear brake.

– Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

Warning Danger of accidents

  Reduced braking efficiency due to wet or dirty brakes.

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

RIDING INSTRUCTIONS

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

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

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

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

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 become very hot when the vehicle is operated.

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

Note Danger of damage

  The parked vehicle may roll away or fall over.

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

Note Fire hazard

  Some vehicle components become very hot when the vehicle is operated.

– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first.

Note Material damage

  Damage and destruction of components by excessive load.

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

– Brake the motorcycle.

– Shift transmission to neutral.

(XC

W SIX DAYS)

– 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 – Turn handle  of the fuel tap to the

OFF

while the engine is idling until the engine stops.

position. (Figure 500137-10 p. 22)

– Park the motorcycle on firm ground.

7.7

Refueling Danger Fire hazard

  Fuel is highly flammable.

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

Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

Warning Danger of poisoning

  Fuel is poisonous and a health hazard.

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

Warning Environmental hazard

  Improper handling of fuel is a danger to the environment.

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

– – Switch off engine.

Open the filler cap. ( p. 21)

32

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.

(All EXC models) Total fuel tank capacity, approx.

(XC ‑ W SIX DAYS)

Close the filler cap. (

9.5 l (2.51 US gal) 9.2 l (2.43 US gal)

p. 21)

Super unleaded (ROZ 95 / RON 95 /

PON 91) ( p. 114)

Super unleaded (ROZ 95 / RON 95 /

PON 91) ( p. 114)

33

SERVICE SCHEDULE

8.1

Service schedule

Check the functioning of the electrical equipment.

Check and charge the battery.

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

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

x ( p. 94)

Check the front brake linings. ( p. 66)

(

Check the rear brake linings. ( p. 70)

Check the brake discs. ( p. 65)

Check the brake lines for damage and leakage.

Check the rear brake fluid level. ( p. 69)

Check the free travel of the foot brake lever. ( p. 68)

Check the frame and swingarm.

x Check the swingarm bearing.

x Check the heim joints at the top and bottom of the shock absorber.

x

Check the tire condition. ( p. 75)

Check the tire air pressure. ( p. 76)

p. 91)

Check the wheel bearings for play.

x Check the wheel hubs.

x Check rim run-out.

x

Check the spoke tension. ( p. 76)

Check the chain, rear sprocket, engine sprocket and chain guide. (

Check the chain tension. ( p. 58)

p. 59)

Grease all moving parts (e.g. side stand, hand lever, chain, ...) and check for smooth operation.

x

Check the fluid level of the hydraulic clutch. ( p. 62)

Check the brake fluid level of the front brake. ( p. 65)

Check the free travel of the hand brake lever. (

Check the steering head bearing play. ( p. 50)

p. 64)

Check the valve clearance.

x Check the clutch.

x Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks and correct routing.

x

Check the anti-freeze and coolant level. ( p. 84)

Check the cables for damage and routing without sharp bends.

x Check that the cables are undamaged, routed without sharp bends and set correctly.

Clean the air filter and air filter box.

x Change the glass fiber yarn filling of the main silencer.

x

(

Check the screws and nuts for tightness.

Check the headlight adjustment. (

x

p. 82)

p. 55)

Check idle.

x Check that the radiator fan is functioning properly.

x (EXC SIX DAYS, XC ‑ W SIX DAYS) Final check: Check the vehicle for roadworthiness and take a test ride.

Make the service entry in

KTM DEALER.NET

and in the service record.

x

S1N: S15A: S30A:

Once after one operating hour Every 15 operating hours Every 30 operating hours/after every race • • • • • • • • • • • •

S1N

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

S15A

• • • • • • • • • • •

S30A

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

34

SERVICE SCHEDULE

8.2

Service work (as additional order)

Change the front brake fluid.

x Change the rear brake fluid.

x Change the foot brake cylinder seals.

Change the hydraulic clutch fluid.

x

(

x

p. 62)

Grease the steering head bearing.

Clean the spark arrestor.

x

( p. 51)

x (XC ‑ W SIX DAYS) Check/set the carburetor components.

x Perform a fork service.

x Service the shock absorber.

x Change the spark plug and spark plug connector.

x Change the piston.

x Check/measure the cylinder.

x Check the cylinder head.

x Check the valves, valve springs and valve spring seats.

x Check the camshaft and rocker arm.

x Change the connecting rod, conrod bearing and crank pin.

x Check the transmission and shift mechanism.

x Check the oil pressure regulator valve.

x Check the oil pumps and lubrication system.

x Check the timing assembly.

x Change all engine bearings.

x

S15N: S45A:

Once after 15 operating hours Every 45 operating hours

S90A: J1A:

Every 90 operating hours/every 45 operating hours after sporting use Annually

S15N S45A S90A J1A

• • • • • • • • • • • • • • • • • • • • • • • • • •

35

TUNING THE CHASSIS

9.1

Checking the basic suspension setting against the rider's weight Info

When adjusting the basic suspension setting, first adjust the shock absorber and then the fork.

– – – – For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swingarm and frame, the basic settings of the suspension components must match the rider's 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 the rider's weight is above or below the standard range, the basic setting of the suspension components must be adjusted 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.

36

401030-01 9.2

Compression damping of shock absorber

The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.

High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.

The high-speed setting, for example, has an effect on the landing after a jump: the rear wheel suspension compresses more quickly.

The low-speed setting, for example, has an effect when riding over long ground swells: the rear wheel suspension compresses more slowly.

These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, changes in the high-speed range affect the compression damping in the low-speed range and vice versa.

9.3

Adjusting high-speed compression damping of the shock absorber Caution Danger of accidents

  Disassembly of pressurized parts can lead to injury.

– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)

Info

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

100867-10 – Turn adjusting screw  all the way clockwise with a socket wrench.

Info

Do not loosen nut  !

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

Guideline Compression damping, high-speed Comfort Standard Sport 2 turns 1.5 turns 1.25 turns

TUNING THE CHASSIS 37 Info

Turn clockwise to increase damping; turn counterclockwise to reduce damp ing.

9.4

Adjusting the low-speed compression damping of the shock absorber Caution Danger of accidents

  Disassembly of pressurized parts can lead to injury.

– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)

Info

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

400209-10 – – Turn adjusting screw click.

 clockwise with a screwdriver up to the last perceptible

Info

Do not loosen nut  !

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

Guideline Compression damping, low-speed Comfort Standard Sport 22 clicks 20 clicks 15 clicks

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damp ing.

9.5

Adjusting rebound damping of the shock absorber Caution Danger of accidents

  Disassembly of pressurized parts can lead to injury.

– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) 400210-10 – Turn adjusting screw  clockwise up to the last perceptible click.

Info

Do not loosen nut  !

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

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

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damp ing.

TUNING THE CHASSIS

9.6

Measuring rear wheel sag unloaded

– – – –

Raise the motorcycle with the lift stand. (

Measure the distance –

p. 43)

as vertically as possible point, such as a mark on the side cover.

– between the rear axle and a fixed Make note of the value as measurement  .

Remove the motorcycle from the lift stand. ( p. 43)

38

400220-10 9.7

Checking the static sag of the shock absorber

– – – – Measure distance 

of rear wheel unloaded. ( p. 38)

Hold the motorcycle upright with the aid of an assistant.

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

Note down the value as dimension  .

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.

x

( p. 39)

400221-10 9.8

Checking the riding sag of the shock absorber

– – Measure distance 

of rear wheel unloaded. ( p. 38)

With another person holding the motorcycle, the rider, wearing full protective cloth ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.

– – The rear wheel suspension levels out.

Another person now measures the distance between the rear axle and a fixed point.

Note down the value as dimension  .

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.

x

( p. 39)

400222-10

TUNING THE CHASSIS 39

9.9

Adjusting the spring preload of the shock absorber

x

Caution Danger of accidents

  Disassembly of pressurized parts can lead to injury.

– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)

Info

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

2 1 400216-10 – – – – – – Remove shock absorber.

x

( p. 52)

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.

x

( p. 52)

M6 5 Nm (3.7 lbf ft) 9.10

Adjusting the riding sag

x B00292-10 – – – Remove shock absorber.

x

( p. 52)

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.

x

( p. 52)

Check the static sag of the shock absorber. ( Check the riding sag of the shock absorber. ( p. 38) p. 38)

Adjust the rebound damping of the shock absorber. ( p. 37)

TUNING THE CHASSIS

9.11

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 differences in the rider's weight can be com pensated by the spring preload.

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

40

401000-01 9.12

Adjusting the compression damping of the fork Info

The hydraulic compression damping determines the fork suspension behavior.

100020-10 – – – Remove protection caps  .

Turn adjusting screws  clockwise all the way.

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 by the number of clicks corresponding to the fork type.

Guideline Compression damping Comfort 26 clicks Standard Sport 22 clicks 18 clicks –

Info

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

Mount protection covers  .

9.13

Adjusting the rebound damping of the fork Info

The hydraulic rebound damping determines the fork suspension behavior.

800017-10 – – Turn adjusting screws  clockwise until they stop.

Info

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

Make the same adjustment on both fork legs.

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

Guideline Rebound damping Comfort Standard Sport 24 clicks 20 clicks 20 clicks

TUNING THE CHASSIS 41 Info

Turn clockwise to increase damping; turn counterclockwise to reduce damp ing.

9.14

Adjusting spring preload of the fork

800015-10 – Turn the 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 0 turn 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.

9.15

Fork offset (XC

W SIX DAYS)

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

The fork offset the center of the fork leg to the center of the steering head bearing.

The fork offset can optionally be adjusted.

Marking   has an impact on the handling of the vehicle. It is calculated from to the front gives greater stability on fast racetracks.

Fork offset Front marking 18 mm (0.71 in) Marking  to the rear (condition at delivery) gives better handling in bends.

Fork offset Rear marking 20 mm (0.79 in) 800009-10 9.16

Setting the fork offset

x

(XC

W SIX DAYS)

– – – – Remove the lower triple clamp.

Remove screw

x ( p. 46)

 . Remove the steering stem.

Clean the parts and check for damage.

Rotate the steering stem 180° and insert into the triple clamp. Mount and tighten screw  .

Guideline Screw, bottom steering head M20x1.5

60 Nm (44.3 lbf ft)

Loctite ® 243™

– Install the lower triple clamp.

x ( p. 46)

500104-10

TUNING THE CHASSIS

9.17

Handlebar position 42

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.

400223-11 9.18

Adjusting handlebar position

x

Warning Danger of accidents

  Handlebar breakage.

– If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle bar.

400223-10 – – – Remove the four screws and lay it to one side.

 . Remove the handlebar clamps. Remove the handlebar

Info

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

Do not bend the cables and lines.

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™

Info

Position the left and right handlebar supports evenly.

Position the handlebars.

Info

Make sure cables and wiring are positioned correctly.

– Position the handlebar clamps. 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.

SERVICE WORK ON THE CHASSIS 43

10.1

Raising the motorcycle with the lift stand

500074-01 – –

Note Danger of damage

  The parked vehicle may roll away or fall over.

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

Raise the motorcycle at the frame underneath the engine.

Lift stand (54829055000) The wheels should no longer touch the ground.

Secure the motorcycle against falling over.

10.2

Removing the motorcycle from the lift stand Note Danger of damage

  The parked vehicle may roll away or fall over.

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

– – – Remove the motorcycle from the lift stand.

Remove the lift stand.

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

 to the ground with your foot and

Info

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

500140-10 10.3

Bleeding fork legs

– – – –

Raise the motorcycle with the lift stand. (

Remove bleeder screws  briefly.

p. 43)

Any excess pressure escapes from the interior of the fork.

Mount and tighten bleeder screws.

Remove the motorcycle from the lift stand. ( p. 43)

100021-10 10.4

Cleaning the dust boots of the fork legs

– – –

Raise the motorcycle with the lift stand. (

Loosen the fork protector. ( p. 44)

p. 43)

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, there is an ingress of dirt inside the boots. If this dirt is not removed, it may cause the oil seals to leak.

500088-10 –

Warning Danger of accidents

  Reduced braking efficiency 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. 116)

SERVICE WORK ON THE CHASSIS

– – – – Press the dust boots back into their normal position.

Remove excess oil.

Position the fork protector. ( p. 44)

Remove the motorcycle from the lift stand. ( p. 43)

10.5

Loosening the fork protector

– – – Remove screws  and remove the clamp.

Remove screws  on the left fork leg. Push the fork protector downwards.

Remove the screws on the right fork leg. Push the fork protector downwards.

44

10.6

Positioning the fork protector

600875-11 600875-10 – – – Position the fork protector 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 wiring harness. Put the clamp on, and mount and tighten screws  .

Position the fork protector on the right fork leg. Mount and tighten the screws.

Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) 10.7

Removing the fork legs

x – – – – Remove front wheel.

Remove screws 

x ( p. 73)

and remove the clamp.

Remove cable clip  , remove screw  and remove the brake caliper.

Allow the brake caliper and brake line to hang tension-free to the side.

100802-10

(EXC Factory Edition, EXC SIX DAYS, XC

W SIX DAYS)

– Unscrew screws  . Take out the left fork leg.

– Unscrew screws  . Take out the right fork leg.

100803-10

(EXC EU/AUS)

– Unscrew screws – Unscrew screws  . Take out the left fork leg.

 . Take out the right fork leg.

100804-10

SERVICE WORK ON THE CHASSIS

10.8

Installing fork legs

x

45

– Position the fork legs.

Info

The topmost milled groove in the fork leg must be flush to the upper edge of the upper triple clamp.

Position bleeder screws  toward the front.

100021-10 100803-11 100804-11

(EXC Factory Edition, EXC SIX DAYS, XC

W SIX DAYS)

– Fully tighten screw  .

Guideline Screw, top triple clamp M8 17 Nm (12.5 lbf ft) – Tighten screws  .

Guideline Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft) – – – –

(EXC EU/AUS)

– Fully tighten screw  .

Guideline Screw, top triple clamp M8 20 Nm (14.8 lbf ft) – Tighten screws  .

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 wiring harness. Put the clamp on, mount and tighten screws  .

Install the front wheel.

x ( p. 73)

100802-11 10.9

Removing the fork protector

x – – – Remove the fork legs.

Remove screws 

x ( p. 44)

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

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

600878-10

SERVICE WORK ON THE CHASSIS

10.10

Installing the fork protector

x – – – 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.

x

( p. 45)

600878-10 10.11

Removing the lower triple clamp

x

(EXC Factory Edition, EXC SIX DAYS, XC

W SIX DAYS)

– – – –

Remove the headlight mask with the headlight. (

Remove the fork legs.

x

Remove the front fender. (

( p. 44)

p. 52)

p. 80)

Remove screws  and hang the CDI control unit to the side.

Info

Do not unplug the CDI control unit.

– 201470-10 – – – Remove screw  . Remove screw bar, and place it on one side.

 , take off the top triple clamp with the handle-

Info

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

Do not bend the cables and lines.

Remove O-ring  . Remove protective ring  .

Take out the lower triple clamp with the steering stem.

Take out the upper steering head bearing.

46

201477-10 10.12

Installing the lower triple clamp

x

(EXC Factory Edition, EXC SIX DAYS, XC

W SIX DAYS)

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

High viscosity grease ( p. 115)

0 1 – – – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

Check whether the top steering head seal  is correctly positioned.

Slide on protective ring  and O-ring  .

500098-10

SERVICE WORK ON THE CHASSIS

– – – Position the upper triple clamp with the steering.

Mount screw  but do not tighten yet.

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

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

47

201470-11 – Position the fork legs.

Info

The topmost milled groove in the fork leg must be flush with the top edge of the upper triple clamp.

Position bleeder screws  toward the front.

201471-10 – Tighten screws  .

Guideline Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft) 201472-10 – Tighten screw  .

Guideline Screw, top steering head M20x1.5

10 Nm (7.4 lbf ft) 201473-10 – Mount and tighten screw  .

Guideline Screw, top steering stem M8 17 Nm (12.5 lbf ft)

Loctite ® 243™

201474-10 – Tighten screws Guideline  .

Screw, top triple clamp M8 17 Nm (12.5 lbf ft) 201475-10

SERVICE WORK ON THE CHASSIS

100802-13 – – – – – – – – Position the brake caliper. Mount and tighten screws  .

Guideline Screw, front brake caliper M8 25 Nm (18.4 lbf ft)

Loctite ® 243™

Mount cable binder  .

Position the brake line, wiring harness, and clamp. Mount and tighten screws  .

Install the front fender. ( p. 52)

Refit the headlight mask with the headlight. ( p. 81)

Install the front wheel.

x ( p. 73)

Check that the wiring harness, cables, and brake and clutch lines can move freely and are routed correctly.

Check the steering head bearing play. ( p. 50)

10.13

Removing the lower triple clamp

x

(EXC EU/AUS)

– – – –

Remove the headlight mask with the headlight. (

Remove the fork legs.

x

Remove the front fender. (

( p. 44)

p. 52)

p. 80)

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 bar and set it aside.

 . Take off the top triple clamp with the handle-

Info

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

Do not bend the cables and lines.

Remove protector ring  .

Take out the lower triple clamp with the steering stem.

Take out the upper steering head bearing.

48

500150-10

SERVICE WORK ON THE CHASSIS 49

10.14

Installing the lower triple clamp

x

(EXC EU/AUS)

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

High viscosity grease ( p. 115)

0 1 – – – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

Check whether the top steering head seal  is correctly positioned.

Push on protective ring  .

500151-10 – – – Position the upper triple clamp with the steering.

Mount screw  but do not tighten yet.

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

Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) 500149-11 – Position the fork legs.

Info

The topmost milled groove in the fork leg must be flush with the top edge of the upper triple clamp.

Position bleeder screws  toward the front.

100888-11 – Fully tighten screws  .

Guideline Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) 100887-12 – Tighten screw  .

Guideline Screw, top steering head M20x1.5

10 Nm (7.4 lbf ft) 100889-10

SERVICE WORK ON THE CHASSIS

– Tighten screw  .

Guideline Screw, top steering stem M8 20 Nm (14.8 lbf ft) 100890-10 – Fully tighten screws  .

Guideline Screw, top triple clamp M8 20 Nm (14.8 lbf ft) 100887-13 100802-12 – – – – – – – – Position the brake caliper. Mount and tighten screws  .

Guideline Screw, front brake caliper M8 25 Nm (18.4 lbf ft)

Loctite ® 243™

Mount cable binder  .

Position the brake line, wiring harness, and clamp. Mount and tighten screws  .

Install the front fender. ( p. 52)

Refit the headlight mask with the headlight. ( p. 81)

Install the front wheel.

x ( p. 73)

Check that the wiring harness, cables, and brake and clutch lines can move freely and are routed correctly.

Check the steering head bearing play. ( p. 50)

10.15

Checking the steering head bearing play Warning Danger of accidents

  Unstable vehicle handling from incorrect steering head bearing play.

– Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.)

Info

If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam aged over time.

400738-11 – – –

Raise the motorcycle with the lift stand. ( p. 43)

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 Factory Edition, EXC SIX DAYS, XC

W SIX DAYS)

– Adjust play of the steering head bearing.

x ( p. 51)

(EXC EU/AUS)

– Adjust play of the steering head bearing.

x (

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

p. 51)

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

» If click positions are noticeable:

50

SERVICE WORK ON THE CHASSIS

– –

(EXC Factory Edition, EXC SIX DAYS, XC

W SIX DAYS)

– Adjust play of the steering head bearing.

x

(EXC EU/AUS)

– Adjust play of the steering head bearing.

x ( ( p. 51) p. 51)

Check the steering head bearing and replace if required.

Remove the motorcycle from the lift stand. ( p. 43)

10.16

Adjusting play of steering head bearing

– – – x

(EXC Factory Edition, EXC SIX DAYS, XC

W SIX DAYS)

Raise the motorcycle with the lift stand. (

Loosen screw  . Remove screw  .

Loosen and retighten screw  .

p. 43)

Guideline Screw, top steering head M20x1.5

201476-10 – – 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 17 Nm (12.5 lbf ft)

Loctite ® 243™

Check the steering head bearing play. ( p. 50)

10.17

Adjusting play of steering head bearing

– – – x

(EXC EU/AUS)

Raise the motorcycle with the lift stand. (

Loosen screws  and  .

Loosen and retighten screw  .

Guideline Screw, top steering head

p. 43)

M20x1.5

800016-10 – – 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) –

Check the steering head bearing play. ( p. 50)

10.18

Greasing the steering head bearing

x

(EXC Factory Edition, EXC SIX DAYS, XC

W SIX DAYS)

– Remove the lower triple clamp.

x ( p. 46)

– Install the lower triple clamp.

x

( p. 46)

(EXC EU/AUS)

– Remove the lower triple clamp.

x ( p. 48)

– Install the lower triple clamp.

x

( p. 49)

51

800010-10

SERVICE WORK ON THE CHASSIS

10.19

Removing the shock absorber

x – – –

Raise the motorcycle with the lift stand. ( p. 43)

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

Remove screw absorber.

 , push splash protector  to the side, and remove the shock

52

800023-10 10.20

Installing the shock absorber

x 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 ® 2701

Mount and tighten screw  .

Guideline Screw, bottom shock absorber M12 80 Nm (59 lbf ft)

Loctite ® 2701

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 dis solve the Teflon coating, thereby drastically reducing the service life.

Remove the motorcycle from the lift stand. ( p. 43)

10.21

Removing the front fender

– – Remove screws  . Remove the front fender.

Make sure the spacers remain in place.

600692-10 10.22

Installing the front fender

600692-10 – – Ensure that the spacers 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

Make sure the holding lugs engage in the start number plate or headlight mask.

SERVICE WORK ON THE CHASSIS

10.23

Removing the seat

– – Remove screw  .

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

53

500080-10 10.24

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 10.25

Removing the air filter box lid

– Pull off the air filter box lid in area  to the side and remove to the front.

10.26

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 10.27

Removing the air filter

x

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

  Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Remove the air filter box lid. ( p. 53)

SERVICE WORK ON THE CHASSIS

– – Detach air filter holder  at the bottom and swing it to one side. Remove the air filter with the air filter support.

Remove the air filter from the air filter support.

54

10.28

Installing the air filter

x 500107-10 – – Mount the clean air filter onto the air filter support.

Apply grease to the section  of the air filter.

Long-life grease ( p. 115)

301262-10 – – Put in both parts together, position them and fix them with air filter holder  .

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. 53)

500107-10 10.29

Cleaning the air filter and air filter box

x

Warning Environmental hazard

  Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

Do not clean the air filter with fuel or petroleum since these substances attack the foam.

B00325-01 – – Remove the air filter.

x

( p. 53)

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

Air filter cleaner ( p. 115)

– – – –

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. 115)

Clean the air filter box.

Check the carburetor connection boot for damage and firm seating.

Install the air filter.

x

( p. 54)

SERVICE WORK ON THE CHASSIS

10.30

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.

55

10.31

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 10.32

Changing the glass fiber yarn filling of the main silencer

x

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.

Remove the main silencer. ( p. 55)

(All EXC models)

– Remove screws –  of connecting cap  .

Remove the connecting cap, perforated pipe – Remove screws  and take off silencer cap   and glass fiber yarn filling with stuffing yarn  .

– Mount the new stuffing yarn  on silencer cap   .

and fix it with adhesive tape.

– – Position the end cap. Mount and tighten the screws.

Insert the perforated piping and mount the new glass fiber yarn filling using a blunt tool.

Tip

To aid you in mounting the glass fiber yarn filling, you can create a wooden or metal cone piece that is inserted into the perforated piping.

Position the connection cap. Mount and tighten the screws.

100444-10

SERVICE WORK ON THE CHASSIS

0 7

(XC

W SIX DAYS)

– Remove screws –  of connecting cap  .

Remove the connecting cap, perforated pipe – Remove screws  and end cap  .

– Remove screws  and take off spark arrestor   and glass fiber yarn filling with stuffing yarn  .

– Mount the new stuffing yarn on spark arrestor   .

and fix it with adhesive tape.

– – – Position the spark arrestor. Mount and tighten the screws.

Position the end cap. Mount and tighten the screws.

Insert the perforated piping and mount the new glass fiber yarn filling using a blunt tool.

Tip

To aid you in mounting the glass fiber yarn filling, you can create a wooden or metal cone piece that is inserted into the perforated piping.

– Position the connection cap. Mount and tighten the screws.

Install the main silencer. ( p. 55)

56

100874-10 10.33

Removing the fuel tank

x

Danger Fire hazard

  Fuel is highly flammable.

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

Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

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

– – –

Remove the seat. (

Turn handle  of the fuel tap to the

OFF

Pull off the fuel hose.

p. 53)

position. (Figure 500137-10

Info

Remaining fuel may flow out of the fuel hose.

– Remove screws  with the collar sleeve.

(All EXC models)

– Hang the horn and horn bracket to one side.

p. 22)

500157-10 – – Remove screw  with the collar sleeve.

Remove the tube from the fuel tank vent line.

800019-10

SERVICE WORK ON THE CHASSIS

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

 and take the fuel tank away

57

500067-10 10.34

Installing the fuel tank

x

Danger Fire hazard

  Fuel is highly flammable.

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

Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

Warning Danger of poisoning

  Fuel is poisonous and a health hazard.

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

– – –

Check the throttle cable routing. ( p. 61)

Position the fuel tank and fit the two spoilers to the sides of the radiator bracket.

Make sure that no cables are trapped or damaged.

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.

Mount the seat. ( p. 53)

500157-11 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft)

SERVICE WORK ON THE CHASSIS

10.35

Checking for chain dirt accumulation

– Check the chain for coarse dirt accumulation.

» If the chain is very dirty: –

Clean the chain. ( p. 58)

58

400678-01 10.36

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 efficiency 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

  Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable 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. 115) Off-road chain spray ( p. 115)

400725-01 10.37

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, bear ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces sary.

– –

Raise the motorcycle with the lift stand. ( p. 43)

Push the chain up at the rear edge of the chain guide to measure the chain ten sion  .

Info

The upper chain section different chain positions.

 must be taut.

Chain wear is not always even, so you should repeat this measurement at Chain tension 8… 10 mm (0.31… 0.39 in) 400213-10

SERVICE WORK ON THE CHASSIS 59

– » If the chain tension does not meet specifications: –

Adjust the chain tension. ( p. 59)

Remove the motorcycle from the lift stand. ( p. 43)

10.38

Adjusting 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, bear ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces sary.

– – – – – – – –

Raise the motorcycle with the lift stand. (

Check the chain tension. ( p. 58)

Loosen nut  .

Loosen nuts  .

p. 43)

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

Chain tension 8… 10 mm (0.31… 0.39 in) Turn adjusting screws  on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks The rear wheel is then correctly aligned.

 .

Tighten nuts  .

Make sure that the chain adjusters screws  .

 Tighten nut  .

are fitted correctly on the adjusting 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 (1.18 in)) enables different secondary ratios with the same chain length.

Chain adjusters  can be turned by 180°.

Remove the motorcycle from the lift stand. ( p. 43)

10.39

Checking the chain, rear sprocket, engine sprocket and chain guide

– – –

Raise the motorcycle with the lift stand. (

Shift gear to neutral.

p. 43)

Check the rear sprocket and engine sprocket for wear.

» If the rear sprocket or engine sprocket is worn: – Change the rear sprocket or engine sprocket.

x

Info

The engine sprocket, rear sprocket and chain should always be replaced together.

400227-01

SERVICE WORK ON THE CHASSIS 1 2 3 16 17 18

400987-10 – – Pull on the upper part of the chain with the specified weight  .

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

Maximum distance chain section  at the longest 272 mm (10.71 in) » If the distance  – is greater than the specified measurement: Change the chain.

x

Info

When the chain is replaced, the rear sprocket and engine sprocket should also be changed.

New chains wear out faster on old, worn sprockets.

60

– – Check the chain sliding guard for wear.

» If the bottom edge of the chain bolt is in line with or below the chain sliding guard: – Change the chain sliding guard.

x Check that the chain sliding guard is firmly seated.

» If the chain sliding guard is loose: – Tighten the chain sliding guard.

Guideline Screw, chain sliding guard M6 6 Nm (4.4 lbf ft)

Loctite ® 243™

400983-01 – – Check the chain sliding piece for wear.

» If the bottom edge of the chain bolt is in line with or below the chain sliding piece: – Change the chain sliding piece.

x Check that the chain sliding piece is firmly seated.

» If the chain sliding piece is loose: – Tighten the chain sliding piece.

Guideline Screw, chain sliding piece M8 15 Nm (11.1 lbf ft) 400986-01

SERVICE WORK ON THE CHASSIS

– Check the chain guide for wear.

Info

Wear is visible on the front of the chain guide.

» If the light part of the chain guide is worn: – Change the chain guide.

x 400985-01 – Check that the chain guide is firmly seated.

» If the chain guide is loose: – Tighten the chain guide.

Guideline Remaining screws, chassis M6 Remaining nuts, chassis M6 100865-10 –

Remove the motorcycle from the lift stand. ( p. 43)

10.40

Adjusting chain guide

x – – Remove the nut of screw Remove screws Guideline  and  .

 . Take off the chain guide.

Condition

Number of teeth: – Insert nut  ≤ 44 teeth in hole  . Position the chain guide.

– Mount and tighten screws  and  .

Remaining screws, chassis M6 – Mount the nut on screw  and tighten.

Guideline Remaining nuts, chassis M6 100857-10

Condition

Number of teeth: ≥ 45 teeth – – Insert nut  in hole  . Position the chain guide.

Mount and tighten screws  and  .

Guideline Remaining screws, chassis M6 – Mount the nut on screw  and tighten it.

Guideline Remaining nuts, chassis M6 10.41

Checking the throttle cable routing

10 Nm (7.4 lbf ft) 15 Nm (11.1 lbf ft) 10 Nm (7.4 lbf ft) 15 Nm (11.1 lbf ft) 10 Nm (7.4 lbf ft) 15 Nm (11.1 lbf ft) – – – Remove the fuel tank.

x

( p. 56)

Check the throttle cable routing.

Both throttle cables must be routed to the carburetor side by side behind the handlebars and above the tank bearing.

» If the throttle cable is not routed as specified: – Correct the throttle cable routing.

Install the fuel tank.

x ( p. 57)

61

500152-10

SERVICE WORK ON THE CHASSIS 62

10.42

Adjusting the basic position of the 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!

10.43

Checking the fluid level of hydraulic clutch

– – –

Warning Skin irritation

  Brake fluid can cause skin irritation on contact.

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

Wear suitable protective clothing and goggles.

If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.

Info

The fluid level rises with increasing wear of the clutch lining disc.

Avoid contact between brake fluid and painted parts. Brake fluid is corrosive!

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.

Brake fluid DOT 4 / DOT 5.1 ( p. 113)

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

Info

Clean up overflowed or spilt fluid immediately with water.

10.44

Changing the hydraulic clutch fluid

x – – –

Warning Skin irritation

  Brake fluid can cause skin irritation on contact.

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

Wear suitable protective clothing and goggles.

If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.

Warning Environmental hazard

  Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

The fluid level rises with increasing wear of the clutch lining disc.

Avoid contact between brake fluid and painted parts. Brake fluid is corrosive!

Use only clean brake fluid from a sealed container.

SERVICE WORK ON THE CHASSIS

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

Remove screws  .

Remove cover  with membrane  .

63

400339-10 – – Fill bleeding syringe  with the appropriate hydraulic fluid.

Bleed syringe (50329050000)

Brake fluid DOT 4 / DOT 5.1 ( p. 113)

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.

BRAKES

11.1

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 in the front brake circuit. The front brake can fail due to overheating. Adjust free travel on hand brake lever according to specifications.

(XC

W SIX DAYS)

– 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 the hand brake lever. ( p. 64)

64

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 hand brake lever. ( p. 64)

400196-13 11.2

Adjusting the basic position of the hand brake lever (XC

W SIX DAYS)

– –

Check the free travel of the hand brake lever. ( p. 64)

Adjust the basic setting of the hand brake lever to your hand size by turning adjust ing screw  .

400196-12

Info

Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar.

Turn the adjusting screw counterclockwise to decrease the distance between the hand brake 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!

11.3

Adjusting free travel of hand brake lever (All EXC models)

– –

Check the free travel of the hand brake lever. ( p. 64)

Adjust the free travel of the hand brake lever with adjusting 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!

BRAKES

11.4

Checking the brake discs Warning Danger of accidents

  Reduced braking efficiency due to worn brake disc(s).

– Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disk 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 – Brake discs - wear limit 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.

Check the front and rear brake discs for damage, cracking and deformation.

» If the brake disc shows signs of damage, cracking or deformation: – Change the brake disc.

11.5

Checking the brake fluid level of the front brake Warning Danger of accidents

  Failure of the brake system.

– If the brake fluid level falls below the

MIN

mark, this indicates a leakage in the brake system or worn-out brake linings.

Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

Warning Danger of accidents

  Reduced braking effect caused by old brake fluid.

– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

Check the brake fluid level in viewer  .

» If the brake fluid is below the

MIN

– Add front brake fluid.

x (

mark:

p. 65)

65

400231-10 11.6

Adding front brake fluid

x

Warning Danger of accidents

  Failure of the brake system.

– If the brake fluid level falls below the

MIN

mark, this indicates a leakage in the brake system or worn-out brake linings.

Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) – – –

Warning Skin irritation

  Brake fluid can cause skin irritation on contact.

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

Wear suitable protective clothing and goggles.

If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.

BRAKES Warning Danger of accidents

  Reduced braking effect caused by old brake fluid.

– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)

Warning Environmental hazard

  Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

66 Info

Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

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

Use only clean brake fluid from a sealed container.

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

Remove screws  .

Remove cover  with membrane  .

Add brake fluid to level Guideline  .

Dimension  (brake fluid level below top edge of container) 5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 ( p. 113)

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

Info

Clean up overflowed or spilt brake fluid immediately with water.

100820-10 11.7

Checking the front brake linings Warning Danger of accidents

  Reduced braking efficiency caused by worn brake linings.

– Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) – – 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. 67)

Check the brake linings for damage and cracking.

» If damage or cracking is visible: – Change the front brake linings.

x ( p. 67)

100394-10

BRAKES

11.8

Changing the front brake linings

x

Warning Danger of accident

  Brake system failure.

– Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) – – –

Warning Skin irritation

  Brake fluid can cause skin irritation on contact.

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

Wear suitable protective clothing and goggles.

If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.

Warning Danger of accidents

  Reduced braking effect caused by old brake fluid.

– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)

Warning Danger of accidents

  Reduced braking efficiency due to oil or grease on the brake discs.

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

Warning Danger of accidents

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

– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

Warning Environmental hazard

  Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

67 Info

Never use DOT 5 brake fluid! It is silicone-based and purple in color. 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.

100395-10 – – – – – – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

Remove screws  .

Remove cover  with membrane  .

Press the brake caliper by hand on to the brake disc in order to press back the brake pistons. Ensure that brake fluid does not overflow from the brake fluid reser voir, using suction to remove it if it does.

Info

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

Remove locking split pins  , withdraw bolt  , and take out the brake linings.

Clean the brake caliper and brake caliper support.

100396-10

BRAKES

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

 in the brake

68

100397-01 – – Fit the brake linings, insert the bolt, and mount the locking split pins.

Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

100398-10 – – Correct the brake fluid quantity to level  .

Guideline Measurement of  5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 ( p. 113)

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

Info

Clean up overflowed or spilt brake fluid immediately with water.

100399-10 11.9

Checking the free travel of the foot brake lever Warning Danger of accidents

  Brake system failure.

– If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating. Adjust free travel on foot brake lever 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 foot brake lever.

x (

Reconnect spring  .

p. 68)

500139-11 11.10

Adjusting the basic position of the foot brake lever

x

Warning Danger of accidents

  Brake system failure.

– If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating. Adjust free travel on foot brake lever according to specifications.

BRAKES

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 foot brake lever individually, loosen 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 foot brake lever.

 . If necessary, adjust the Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) Hold screw  and tighten nut  .

Guideline Nut, foot brake lever stop M8 20 Nm (14.8 lbf ft) Hold push rod  and tighten nut  .

Guideline Remaining nuts, chassis M6 15 Nm (11.1 lbf ft) Reconnect spring  .

11.11

Checking rear brake fluid level Warning Danger of accidents

  Failure of the brake system.

– If the brake fluid level falls below the

MIN

mark, this indicates a leakage in the brake system or worn-out brake linings.

Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

Warning Danger of accidents

  Reduced braking effect caused by old brake fluid.

– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – – Stand the vehicle upright.

Check the brake fluid level in the sight glass  .

» If there is an air bubble in the sight glass –  Add brake fluid to the rear brake circuit.

visible:

x ( p. 69)

69

400234-10 11.12

Adding brake fluid to the rear brake circuit

x

Warning Danger of accidents

  Failure of the brake system.

– If the brake fluid level falls below the

MIN

mark, this indicates a leakage in the brake system or worn-out brake linings.

Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) – – –

Warning Skin irritation

  Brake fluid can cause skin irritation on contact.

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

Wear suitable protective clothing and goggles.

If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.

BRAKES Warning Danger of accidents

  Reduced braking effect caused by old brake fluid.

– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)

Warning Environmental hazard

  Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

70 Info

Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

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

Use only clean brake fluid from a sealed container.

– – – – Stand the vehicle upright.

Remove screw cap  with membrane  and the O-ring.

Add brake fluid to level  .

Brake fluid DOT 4 / DOT 5.1 ( p. 113)

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

Info

Clean up overflowed or spilt brake fluid immediately with water.

400233-10 11.13

Checking rear brake linings Warning Danger of accidents

  Reduced braking efficiency caused by worn brake linings.

– Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) – – 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. 70)

Check the brake linings for damage and cracking.

» If damage or cracking is visible: – Change the rear brake linings.

x ( p. 70)

400238-10 11.14

Changing the rear brake linings

x

Warning Danger of accident

  Brake system failure.

– Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) – – –

Warning Skin irritation

  Brake fluid can cause skin irritation on contact.

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

Wear suitable protective clothing and goggles.

If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.

Warning Danger of accidents

  Reduced braking effect caused by old brake fluid.

– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)

BRAKES Warning Danger of accidents

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

– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

Warning Environmental hazard

  Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

71 Info

Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

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

Use only clean brake fluid from a sealed container.

– – – Stand the vehicle upright.

Remove screw cap  with membrane  and the O-ring.

Push the brake piston back to its basic position and ensure that brake fluid does not flow out of the brake fluid reservoir, sucking it away if it does.

Info

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

100807-10 – – Remove locking split pins  , withdraw bolt  , and take out the brake linings.

Clean the brake caliper and brake caliper support.

100808-10 – Check that leaf spring  in the brake caliper and sliding plate caliper support are seated correctly.

 in the brake 100407-10 – – Fit the brake linings, insert the bolt, and mount the locking split pins.

Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

100408-01

BRAKES

400233-10 – – Correct the brake fluid reservoir level to the marking  .

Brake fluid DOT 4 / DOT 5.1 ( p. 113)

Mount the screw cap  with the membrane  and the O-ring.

Info

Clean up overflowed or spilt brake fluid immediately with water.

72

WHEELS, TIRES

12.1

Removing front wheel

x – –

Raise the motorcycle with the lift stand. ( p. 43)

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

Info

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

73

100809-01 – – 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 operate the hand brake lever when the front wheel is removed.

Always lay the wheel down in such a way that the brake disc is not dam aged.

500085-10 – Remove spacers  .

500086-10 12.2

Installing the front wheel

x

Warning Danger of accidents

  Reduced braking efficiency due to oil or grease on the brake discs.

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

– – – Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn: – Change the wheel bearing.

Clean and grease shaft seal rings  x and bearing surface  of the spacers.

Long-life grease (

Insert the spacers.

p. 115)

500086-11

WHEELS, TIRES

12.3

Removing the rear wheel

x 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) Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc.

Remove the motorcycle from the lift stand. ( p. 43)

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) – – – – – –

Raise the motorcycle with the lift stand. ( p. 43)

Press the brake caliper by hand on to the brake disc in order to press back the brake 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 wheel spindle wheel to be pushed forward.

 only enough to allow the rear 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 swingarm.

Info

Do not operate the foot brake when the rear wheel is removed.

Always lay the wheel down in such a way that the brake disc is not dam aged.

400258-10

74

– Remove spacers  .

400260-11 12.4

Installing the rear wheel

x

Warning Danger of accidents

  Reduced braking efficiency 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.

WHEELS, TIRES

– – – Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn: – Change the wheel bearing.

Clean and grease shaft seal rings  x and bearing surface  of the spacers.

Long-life grease ( p. 115)

Insert the spacers.

400260-10 – – Lift the rear wheel into the swing arm, position it, and insert the wheel spindle  .

Put the chain on.

75

400259-10 – – – – Position chain adjuster  . Mount nut  but do not tighten it yet.

Make sure that chain adjusters  are fitted correctly on adjusting screws  .

Check the chain tension. (

Tighten nut  .

Guideline

p. 58)

Nut, rear wheel spindle M20x1.5

80 Nm (59 lbf ft) – –

Info

The wide adjustment range of the chain adjusters (32 mm (1.18 in)) enables different secondary ratios with the same chain length.

Chain adjusters  can be turned by 180°.

Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

Remove the motorcycle from the lift stand. ( p. 43)

400225-12 12.5

Checking the tire condition Info

Only mount tires approved and/or recommended by KTM.

Other tires could have a negative effect on riding behavior.

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

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

Worn tires have a negative effect on handling characteristics, especially on wet surfaces.

400602-10 – – Check the front and rear tires for cuts, run-in objects 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 ≥ 2 mm ( ≥ 0.08 in) » If the tread depth is less than the minimum allowable depth:

WHEELS, TIRES 76

– – Change the tire.

Check the tire age.

Info

The tire's date of manufacture is usually part of the tire markings and is indicated by the last four digits of the ture.

regardless of the actual state of wear.

DOT

marking. The first two digits indi cate the week of manufacture and the last two digits the year of manufac KTM recommends that the tires be changed after 5 years at the latest, » If the tire is older than five years: – Change the tire.

12.6

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.

400695-01 – – – Remove the dust cap.

Check tire air pressure when tires are cold.

Tire air pressure off road Front Rear 1.0 bar (15 psi) 1.0 bar (15 psi) Road tire pressure (All EXC models) Front Rear 1.5 bar (22 psi) 2.0 bar (29 psi) » If the tire pressure does not meet specifications: – Correct the tire air pressure.

Fit the dust cap.

12.7

Checking spoke tension Warning Danger of accidents

  Instable handling due to incorrect spoke tension.

– Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.)

Info

A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.

If the spokes are too tight, they can break due to local overload.

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

400694-01 – Tap each spoke with a screwdriver.

Info

The sound frequency depends on the length and thickness of the spoke.

If there are different sound frequencies in spokes with the same length and thickness, this indicates different spoke tensions.

– You should hear a high note.

» If the spoke tension varies: – Correct the spoke tension.

Check the spoke torque.

Guideline x Spoke nipple, front wheel Spoke nipple, rear wheel M4.5

M5 5… 6 Nm (3.7… 4.4 lbf ft) 5… 6 Nm (3.7… 4.4 lbf ft)

WHEELS, TIRES

Torque wrench with various accessories in set (58429094000)

77

ELECTRICAL SYSTEM

13.1

Removing the battery

x – – – – –

Warning Risk of injury

  Battery acid and battery gases cause serious cauterization.

Keep batteries out of the reach of children.

Wear suitable protective clothing and goggles.

Avoid contact with battery acid and battery gases.

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

Flush with copious amounts of water in case of skin contact. If battery acid comes into contact with the eyes, flush the eyes with water for at least 15 minutes and consult a physician.

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

Remove the seat. ( p. 53)

Disconnect the negative (minus) cable  of the battery.

Pull back the positive terminal cover the battery.

 and disconnect the positive (plus) cable of Detach rubber band  at the bottom.

Lift the battery up and out.

78

500069-10 13.2

Installing the battery

x – – – – – Place the battery in the battery holder.

Battery (YTX5L-BS) ( p. 108)

Reconnect the rubber band  .

Attach the plus cable and replace the plus pole cover  .

Attach the minus cable  .

Mount the seat. ( p. 53)

500069-11 13.3

Recharging the battery

x – – – – –

Warning Risk of injury

  Battery acid and battery gases cause serious cauterization.

Keep batteries out of the reach of children.

Wear suitable protective clothing and goggles.

Avoid contact with battery acid and battery gases.

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

Flush with copious amounts of water in case of skin contact. If battery acid comes into contact with the eyes, flush the eyes with water for at least 15 minutes and consult a physician.

Warning Environmental hazard

  Battery parts and acid are harmful to the environment.

– Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner.

Give the battery to your KTM dealer or to a recycling center that accepts used batteries.

Warning Environmental hazard

  Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

ELECTRICAL SYSTEM Info

Even when there is no load on the battery, it still loses power steadily.

The charge state and the type of charge are very important for the service life of the battery.

Rapid recharging with a high charging current shortens the battery's service life.

If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. This reduces the battery capacity.

If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.

If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the battery.

The battery is maintenance-free, which means that the acid level does not need to be checked.

400240-10 – – – – – – Switch off all power consumers and switch off the engine.

Remove the seat. ( p. 53)

Disconnect the negative cable of the battery to avoid damage to the onboard elec tronics.

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

Battery charger (58429074000) You can also use the battery charger to test the open-circuit voltage and starting voltage of the battery, and to test the alternator. With this device, you cannot over charge the battery.

Info

Never remove lid Charge the battery with a maximum of 10% of the capacity specified on battery housing   .

.

Switch off the battery 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. 53)

13.4

Removing the main fuse

– – – Switch off all consumers and the engine.

Remove the air filter box lid. ( p. 53)

Remove protective cover  .

Info

The main fuse  is located in starter relay  under the filter box cover.

– Remove main fuse  .

79

400270-10 13.5

Installing the main 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.

ELECTRICAL SYSTEM

– Insert the main fuse.

Fuse (58011109110) ( p. 108)

– –

Info

A reserve fuse  is located in the starter relay.

Replace a faulty fuse  by an equivalent fuse only.

Replace the protection cover.

Install the air filter box lid. ( p. 53)

400273-10 13.6

Changing the fuse of the radiator fan (EXC SIX DAYS, XC

W SIX DAYS) 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.

– Take off the protection cap.

Info

The radiator fan fuse  is in the area of the right-hand radiator.

– – Remove the faulty fuse.

Insert a new fuse.

Fuse (58011109105) ( p. 108)

100863-10 –

Info

Replace a faulty fuse by an equivalent fuse only.

Mount the protection cap.

13.7

Removing headlight mask with headlight

– – – Switch off all electrical equipment.

Remove screw  and take off clamp.

Loosen the rubber band  . Push up the headlight mask and swing it forwards.

80

600703-10 – Pull out the electric plug connector headlight.

 and remove the headlight mask with the 600702-10

ELECTRICAL SYSTEM

13.8

Refitting the headlight mask with the headlight

– Connect the electric plug connector  .

81

600702-11 – Position the headlight mask and fix it with the rubber band  .

Info

Ensure that the retaining lugs engage in the fender.

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

Check the headlight adjustment. ( p. 82)

600703-11 13.9

Changing the headlight bulb Note Damage to reflector

  Reduced luminance.

– Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.

– – –

Remove the headlight mask with the headlight. ( p. 80)

Turn rubber cap  together with the underlying lamp socket counterclockwise all the way and remove it.

Pull lamp socket  of the parking light out of the reflector.

100861-10 100862-10 – – – Press headlight bulb way and pull it out.

 into the lamp socket lightly, turn it counterclockwise all the Insert a new headlight bulb.

Headlight (S2 / socket BA20d) ( p. 109)

Insert the rubber cap together with the lamp socket into the reflector and turn it clockwise all the way.

Info

Ensure that the O-ring  is seated properly.

– – Insert the lamp socket of the parking light into the reflector.

Refit the headlight mask with the headlight. ( p. 81)

ELECTRICAL SYSTEM 82

13.10

Checking the headlight adjustment

400726-10 – – – – – – Stand the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight.

Make another mark at a distance  under the first mark.

Guideline Distance  5 cm (2 in) Position the vehicle vertically at a distance  in front of the wall.

Guideline Distance  5 m (16 ft) The rider now sits down on the motorcycle.

Switch on the low beam.

Check the headlight adjustment.

The border between light and dark must be exactly at the lower mark when the motorcycle is operational and complete with rider.

» If the boundary between light and dark does not meet specifications: –

Adjust the headlight range. ( p. 82)

13.11

Adjusting the headlight range

301251-10 – – –

Check the headlight adjustment. (

Loosen screw  .

p. 82)

Adjust the headlight range of the headlight by moving it up or down.

Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with a rider (mark is applied under: Checking the headlight setting).

Info

A change in weight on the vehicle may require a correction of the headlight range.

Tighten screw  .

13.12

Changing the speedometer battery

– – –

Remove the headlight mask with the headlight. (

Remove screws  .

Pull the speedometer out of the bracket from above.

p. 80)

100859-10 – – – – Using a coin, turn locking cap  counterclockwise all the way and remove it.

Remove speedometer battery  .

Insert the new battery with the label facing upward.

Check that the O-ring of the locking cap is seated properly.

100860-10

ELECTRICAL SYSTEM

100864-10 – – – – – – – – Position locking cap  and, using a coin, turn it clockwise all the way.

Press any button on the speedometer.

The speedometer is activated.

Position the speedometer in the bracket.

Mount and tighten the screws with washers.

Refit the headlight mask with the headlight. (

Set kilometers or miles. ( p. 15)

Adjust the speedometer functions. ( Set the clock. ( p. 16) p. 16)

p. 81)

83

COOLING SYSTEM 84

14.1

Cooling system

400335-10 Water pump  in the engine circulates the coolant.

The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap  . This ensures that operating the vehicle at the specified coolant tem perature will not result in a risk of malfunctions.

120 °C (248 °F) Cooling is effected by the air stream.

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

(EXC SIX DAYS, XC

W SIX DAYS)

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

14.2

Checking the anti-freeze and coolant level Warning Danger of scalding

  During motorcycle operation, the coolant gets very hot and is under pressure.

– Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

Warning Danger of poisoning

  Coolant is poisonous and a health hazard.

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

400243-10 – –

Condition

Engine is cold.

– Stand the motorcycle upright on a horizontal surface.

Remove radiator cap.

Check the anti-freeze of the coolant.

− 25… − 45 °C ( − 13… − 49 °F) – » If the anti-freeze of the coolant does not meet specifications: – Correct the anti-freeze of the coolant.

Check the coolant level in the radiator.

Coolant level  above radiator fins.

10 mm (0.39 in) – » If the level of the coolant does not meet specifications: – Correct the coolant level.

Alternative 1

Coolant ( p. 113)

Alternative 2

Coolant (mixed ready to use) ( p. 113)

Refit the radiator cap.

14.3

Checking the coolant level Warning Danger of scalding

  During motorcycle operation, the coolant gets very hot and is under pressure.

– Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

Warning Danger of poisoning

  Coolant is poisonous and a health hazard.

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

COOLING SYSTEM

400243-10 – –

Condition

The engine is cold.

– Stand the motorcycle upright on a horizontal surface.

Remove radiator cap.

Check the coolant level in the radiator.

– Coolant level  above the radiator fins. 10 mm (0.39 in) » If the coolant level does not meet specifications: – Correct the coolant level.

Alternative 1

Coolant ( p. 113)

Alternative 2

Coolant (mixed ready to use) ( p. 113)

Mount the radiator cap.

14.4

Draining coolant

x

Warning Danger of scalding

  During motorcycle operation, the coolant gets very hot and is under pressure.

– Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

Warning Danger of poisoning

  Coolant is poisonous and a health hazard.

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

– –

Condition

Engine is cold.

– Stand the motorcycle upright.

– Place a suitable container under the water pump cover.

– Remove screw  . Remove the radiator cap  .

Completely drain the coolant.

Fit screw  with a new seal and tighten it.

Guideline Screw, water pump cover M6x25 10 Nm (7.4 lbf ft) 400335-11 14.5

Refilling coolant

x

Warning Danger of poisoning

  Coolant is poisonous and a health hazard.

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

– – – Make sure that the screw  is tightened.

Stand the vehicle upright.

Pour coolant in up to measurement  Guideline above the radiator fins.

10 mm (0.39 in) Coolant 0.95 l (1 qt.)

Coolant ( p. 113)

Coolant (mixed ready to use)

( p. 113)

400244-10

85

COOLING SYSTEM

– – – Refit the radiator cap.

Make a short test ride.

Check the coolant level. ( p. 84)

86

TUNING THE ENGINE

15.1

Checking the play in the throttle cable

400192-10 – – Move the handlebar to the straight-ahead position. Move the throttle grip back wards and forwards to ascertain the play in the throttle cable.

Play in throttle cable 3… 5 mm (0.12… 0.2 in) » If the throttle cable play does not meet specifications: – Adjust the play in the throttle cable.

x

( p. 87)

Danger Danger of poisoning

  Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.

– When running the engine, always make sure there is sufficient ventila tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

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 play in the throttle cable.

x

( p. 87)

15.2

Adjusting the play in the throttle cable

x – – – – – – 500153-10 – – – – – – Remove the fuel tank.

x

( p. 56)

Check the throttle cable routing. ( p. 61)

Move the handlebar to the straight-ahead position.

Push back sleeves  .

Loosen nut  . Turn adjusting screw  in as far as possible.

Loosen nut  . Turn adjusting screw the throttle grip.

 so that there is play in the throttle cable at Guideline Play in throttle 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 throttle cable  .

 out Tighten nut  .

Push sleeves  on. Check the throttle grip for smooth operation.

Install the fuel tank.

x ( p. 57)

Check the play in the throttle cable. ( p. 87)

15.3

Carburetor - idle

The idle setting of the carburetor has a big influence on the starting behavior, stable idling and the response to throttle opening. That means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly.

Info

The carburetor and its components are subject to increased wear caused by engine vibration. Wear can result in malfunctioning.

400341-10 The idle speed is adjusted with the adjustment screw  .

The idle mixture is adjusted with the idle mixture adjustment screw  .

87

TUNING THE ENGINE 88

15.4

Carburetor - adjusting the idle speed

x – 400341-10 – Screw in idle adjusting screw setting.

 all the way and then turn it to the prescribed basic Guideline Idle mixture adjusting screw (All 400 models) Open 0.75 turn Idle mixture adjusting screw (All 530 EXC models) Open 1.5 turns Idle mixture adjusting screw (All 450 models) Open 1.75 turns Idle mixture adjusting screw (530 XC-W SIX DAYS 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 inhaling them may result in unconsciousness and/or death.

– When running the engine, always make sure there is sufficient ventila tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

Adjust the idle speed with adjusting screw  .

Guideline Choke function deactivated – (EXC AUS, XC ‑

W SIX DAYS) (

The choke lever is pushed in to the stop.

p. 22)

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

(EXC EU, EXC Factory Edition, EXC SIX DAYS) ( p. 12)

Idle speed 1,550… 1,650 rpm Turn idle adjusting screw  slowly clockwise 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 large 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 fit a smaller idling jet.

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

After changing the idling jet, repeat the adjusting steps from the beginning.

Adjust the idle speed with adjusting screw  .

Guideline Choke function deactivated – (EXC AUS, XC ‑

W SIX DAYS) (

The choke lever is pushed in to the stop.

p. 22)

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

(EXC EU, EXC Factory Edition, EXC SIX DAYS) ( p. 12)

Idle speed 1,550… 1,650 rpm

TUNING THE ENGINE 89 Info

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

15.5

Emptying the carburetor float chamber

x

Danger Fire hazard

  Fuel is highly flammable.

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

Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

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

Warning Environmental hazard

  Improper handling of fuel is a danger to the environment.

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

Info

Carry out this work with a cold engine.

– – Turn handle  of the fuel tap to the

OFF

position. (Figure 500137-10

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.

p. 22)

– – Undo the screw  the float chamber.

(turn it counterclockwise) a few turns and drain the fuel from Tighten screw  .

500256-10 15.6

Checking the basic position of the shift lever

– Sit on the vehicle in the riding position and determine the distance upper edge of your boot and the shift lever.

 between the Gap between the shift lever and the top of the boot 10… 20 mm (0.39… 0.79 in) » If the distance does not meet the specifications: – Adjust the basic position of the shift lever.

x

( p. 90)

400692-10

TUNING THE ENGINE

15.7

Adjusting the basic position of the shift lever

– x Remove screw  and take off shift lever  .

B00427-10 B00428-10 – – – Clean gear teeth  of the shift lever and shift shaft.

Mount the shift lever on the shift shaft in the required position and engage the gearing.

Info

The range of adjustment is limited.

The shift lever must not come into contact with any other vehicle compo nents during the shift procedure.

Mount and tighten screw.

Guideline Screw, shift lever M6 14 Nm (10.3 lbf ft)

Loctite ® 243™ 90

SERVICE WORK ON THE ENGINE

16.1

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.

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: –

Add engine oil. ( p. 93)

200119-10 16.2

Changing engine oil and oil filter, cleaning engine oil screen

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

Remove the oil filter.

Install the oil filter.

x

x

(

Fill up with engine oil.

x

(

(

p. 92) p. 92)

p. 93)

x

( p. 91)

91

301489-10 16.3

Draining engine oil, cleaning engine oil screen

x

Warning Danger of scalding

  Engine oil and gear oil get very hot when the motorcycle is ridden.

– Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.

Warning Environmental hazard

  Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable 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 engine oil screen.

Clean the sealing surface on the engine.

Mount and tighten the engine oil screen drain plug  .

Guideline Plug, engine oil screen M17x1.5

20 Nm (14.8 lbf ft)

SERVICE WORK ON THE ENGINE

16.4

Removing the oil filter

x

Warning Danger of scalding

  Engine oil and gear oil get very hot when the motorcycle is ridden.

– Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.

Warning Environmental hazard

  Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

– – Place a suitable container under the engine.

Remove screws  . Remove oil filter cover  with the O-ring.

92

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 surface.

16.5

Installing the oil filter

x 200114-10 – – – Lay the motorcycle on its side and fill the oil filter housing to about ⅓ engine oil.

Fill the oil filter  full with with engine oil and place it in the oil filter container.

Lubricate the O/ring  of the oil filter cover.

200114-11 – – – Refit the oil filter cover  .

Mount and tighten screws Guideline  .

Screw, oil filter cover Stand the motorcycle upright.

200113-11 M6 10 Nm (7.4 lbf ft)

SERVICE WORK ON THE ENGINE

16.6

Filling up with engine oil

x

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 alternator cover and fill up with engine oil.

Engine oil (1st partial quantity approx.) 0.35 l (0.37 qt.)

Engine oil (SAE 10W/50) (

Mount and tighten the screw connection on the alternator cover.

p. 113)

Danger Danger of poisoning

  Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.

– When running the engine, always make sure there is sufficient ventila tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

Start the engine and let it run idle for 30 seconds.

Stop the engine and check that it is oil-tight.

Stand the motorcycle upright on a horizontal surface.

Remove the screw connection on the alternator cover.

Fill in engine oil to the upper half of level viewer  .

Engine oil (total filling capacity approx.) 0.60 l (0.63 qt.)

Engine oil (SAE 10W/50) (

Mount and tighten the screw connection on the alternator cover.

p. 113)

301454-10 16.7

Adding 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 alternator cover and fill up with engine oil.

Engine oil (SAE 10W/50) ( p. 113)

Mount and tighten screw cap  .

Danger Danger of poisoning

  Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.

– When running the engine, always make sure there is sufficient ventila tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

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

Check the engine oil level. ( p. 91)

93

SERVICE WORK ON THE ENGINE

16.8

Checking the gear oil level Info

The gear oil level should only 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 motorcycle upright.

A small amount of gear oil should flow out.

– » If no gear oil flows out: – Add gear oil.

x

( p. 95)

Mount and tighten the gear oil level check screw.

Guideline Screw, gear oil level check M6 8 Nm (5.9 lbf ft) 16.9

Changing gear oil, cleaning gear oil screen

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

Fill up with gear oil.

x ( p. 95)

x ( p. 94)

94

301490-10 16.10

Draining gear oil, cleaning gear oil screen

x

Warning Danger of scalding

  Engine oil and gear oil get very hot when the motorcycle is ridden.

– Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.

Warning Environmental hazard

  Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

Drain the gear oil only when the engine is warm.

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

SERVICE WORK ON THE ENGINE

– – – – – – – – – Place a suitable container under the engine.

Remove the gear oil drain plug  .

Remove the gear oil screen plug  .

Completely drain the gear oil.

Thoroughly clean the gear oil drain plug with a magnet.

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

Clean the sealing surface on the engine.

Refit gear oil drain plug  with seal ring and tighten it.

Guideline Gear oil drain plug with magnet M12x1.5

20 Nm (14.8 lbf ft) Mount and tighten the gear oil screen drain plug  .

Guideline Plug, gear oil screen M16x1.5

20 Nm (14.8 lbf ft)

95

500159-10 16.11

Filling up with gear oil

x

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.) Mount and tighten screw cap  .

Engine oil (SAE 10W/50) ( p. 113)

Danger Danger of poisoning

  Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.

– When running the engine, always make sure there is sufficient ventila tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

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

Check the gear oil level. ( p. 94)

16.12

Adding gear oil

x

Info

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

– Remove gear oil level check screw  .

200116-10

SERVICE WORK ON THE ENGINE

200118-11 – – – – – Remove screw cap  . Stand the motorcycle upright.

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

Engine oil (SAE 10W/50) ( p. 113)

Mount and tighten the gear oil level check screw.

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 inhaling them may result in unconsciousness and/or death.

– When running the engine, always make sure there is sufficient ventila tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

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

96

CLEANING, CARE

17.1

Cleaning the 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 electri cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts.

Warning Environmental hazard

  Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

97 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.

401061-01 – – – Close off the exhaust system to prevent water from entering.

First remove coarse dirt particles with a gentle water spray.

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

Motorcycle cleaner ( p. 115)

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.

x

( p. 89)

Warning Danger of accidents

  Reduced braking efficiency due to wet or dirty brakes.

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

– After cleaning, ride a short distance until the engine reaches operating tempera ture.

Info

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

– – – – – Push back the protection covers of the handlebar grips to allow any water that has penetrated to evaporate.

After the motorcycle has cooled off, lubricate all moving parts and bearings.

Clean the chain. ( p. 58)

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

Cleaning and preserving materials for metal, rubber and plastic ( p. 115)

Treat all plastic parts and powder-coated parts with a mild cleaning and care prod uct.

Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic

surfaces ( p. 116)

(All EXC models)

– Lubricate the steering lock.

Universal oil spray ( p. 116)

CLEANING, CARE

17.2

Protection for winter operation Info

If you use the motorcycle in the winter, you can expect to encounter salt on the roads. Precautions need to be taken against road salt corrosion.

If the vehicle has been used on salted roads, clean it with cold water. Warm water intensifies the effects of salt.

401060-01 – – –

Clean the motorcycle. ( p. 97)

Treat the engine, swingarm and all other bare or galvanized parts (except the brake discs) with a wax-based anticorrosive.

Info

Avoid getting anticorrosive on the brake discs: this would badly affect the braking.

After use on salted roads, clean the motorcycle thoroughly with cold water and dry it properly.

Clean the chain. ( p. 58)

98

STORAGE 99

18.1

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

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.

401058-01 – – – – – – – – – –

Clean the motorcycle. ( p. 97)

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

x (

Change the gear oil and clean the gear oil screen.

Check the anti-freeze and coolant level. ( p. 84)

x ( p. 94)

Drain the fuel from the tanks into a suitable container.

Empty the carburetor float chamber.

Check the tire air pressure. ( p. 76)

x

( p. 89)

Remove the battery.

Recharge the battery.

x x (

Guideline

( p. 78) p. 78)

Storage temperature of battery (not placed in direct sunshine) 0… 35 °C (32… 95 °F)

p. 91)

Place the vehicle on a dry storage place that is not subject to large temperature variations.

Info

KTM recommends raising the motorcycle.

– –

Raise the motorcycle with the lift stand. ( p. 43)

Cover the vehicle with an air-permeable cover or blanket.

Info

Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.

Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes parts of the engine and exhaust system to rust.

18.2

Putting into operation after storage

– – – – –

Remove the motorcycle from the lift stand. (

Install the battery.

Refuel. ( p. 32)

x ( p. 78)

p. 43)

Perform checks and maintenance steps before putting into operation. (

Take a test ride.

p. 30)

401059-01

TROUBLESHOOTING Faults

The engine cannot be cranked (elec tric starter).

Engine turns but does not start Engine has no idle Engine does not speed up Engine has a lack of power Engine stalls or pops back into the carburetor

Possible cause

Operating error Battery discharged Main 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 supply interrupted Spark plug oily or wet Electrode distance (plug gap) of spark plug too wide – Ignition system defective Short-circuit cable in wiring harness frayed, short-circuit button or emer gency OFF switch defective Plug connector of CDI control device, pulse generator or ignition coil oxi dized.

Water in carburetor or jets blocked Idling jet blocked Adjusting screws on carburetor dis torted Spark plug defective Ignition system defective Carburetor running over because float needle dirty or worn Loose carburetor jets Ignition system defective Fuel supply interrupted Air filter heavily contaminated Exhaust system leaky, deformed or too little glass fiber yarn filling in main silencer Valve clearance too little Ignition system defective Lack of fuel – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – –

Action

– Go through the steps of starting the engine.

( p. 30)

Recharge the battery.

x (

Check the charging voltage.

x Check the closed current.

x Alternator - check the light and battery wind ing.

x

Remove the main fuse. (

p. 78)

p. 79) Install the main fuse. (

Check the starter relay.

Check the starter motor.

x x

p. 79)

Go through the steps of starting the engine.

( p. 30)

Empty the carburetor float chamber.

( p. 89)

x – – – Check the fuel tank breather.

Clean the fuel tap.

Check/adjust the carburetor components.

x Clean and dry the spark plug or replace if nec essary.

Adjust the plug gap.

Guideline Spark plug electrode gap 0.9 mm (0.035 in) Check the ignition system.

Check the electrical system.

x Check the wiring harness. (visual check) – Clean the plug connector and treat it with con tact spray.

Check/adjust the carburetor components.

x Check/adjust the carburetor components.

x Carburetor - adjust the idle speed.

( p. 88)

x Change spark plug.

Check the ignition system.

x Check/adjust the carburetor components.

x Check/adjust the carburetor components.

x Check the ignition system.

x Check the fuel tank breather.

Clean the fuel tap.

Check/adjust the carburetor components.

x Clean the air filter and air filter box.

( p. 54)

x Check exhaust system for damage.

Change the glass fiber yarn filling of the main silencer.

x ( p. 55)

Adjust the valve clearance.

x Check the ignition system.

x Turn handle  of the fuel tap to the

tion. (Figure 500137-10 p. 22)

ON

posi-

Refuel. ( p. 32)

100

TROUBLESHOOTING Faults

Engine stalls or pops back into the carburetor Engine overheats

Possible cause

The intake system has an air leak Coolant level low in cooling system Insufficient airflow Radiator fins very dirty Foam formation in cooling system Bent radiator hose Thermostat defective High oil consumption Battery discharged Speedometer values deleted (time, stop watch, lap times) Defect in radiator fan system (EXC SIX DAYS, XC ‑ W SIX DAYS) Engine vent hose bent Engine oil level too high Engine oil too thin (low viscosity) Piston and/or cylinder worn Battery is not charged by alternator Undesired power consumer The battery in the speedometer is discharged

101

– – – – – – – – – – – – – – – – – – –

Action

– Check rubber sleeves and carburetor for tight ness.

Check the cooling system for leaks.

Check the coolant level. ( p. 84)

Switch off engine when stationary.

Clean radiator fins.

Drain the coolant.

Refill the coolant.

x x ( ( p. 85) p. 85)

Change the radiator hose.

x Check the thermostat.

x Guideline Opening temperature: 70 °C (158 °F) Check the radiator fan fuse.

Check the radiator fan.

x Check the thermostat.

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

Check the engine oil level. ( p. 91)

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

x

( p. 91)

Piston/cylinder - determine the mounting clear ance x Check the charging voltage.

x Alternator - check the light and battery wind ing.

x Check the closed current.

x

Change the speedometer battery. ( p. 82)

TECHNICAL DATA - ENGINE

Design Displacement (All 400 models) Displacement (All 450 models) Displacement (All 530 models) Stroke (All 400 models) Stroke (All 450 models) Stroke (All 530 models) Bore Compression ratio (All 400 models) Compression ratio (All 450/530 models) Idle speed Control Valve diameter, intake Valve diameter, exhaust Valve clearance Exhaust at: 20 °C (68 °F) Intake at: 20 °C (68 °F) Crankshaft bearing Conrod bearing Piston pin bearing Pistons Piston rings Engine lubrication Primary transmission Clutch Transmission ratio 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Alternator Ignition Spark plug Spark plug electrode gap Cooling Starter 20.1

Capacity - engine oil

Engine oil 0.60 l (0.63 qt.)

102

1-cylinder 4-stroke engine, water-cooled 393.4 cm³ (24.007 cu in) 449.3 cm³ (27.418 cu in) 510.4 cm³ (31.147 cu in) 55.5 mm (2.185 in) 63.4 mm (2.496 in) 72 mm (2.83 in) 95 mm (3.74 in) 11.1:1 11.9:1 1,550… 1,650 rpm OHC, 4 valves controlled via rocker arm, drive via tooth/wheel chain 39.5 mm (1.555 in) 31.7 mm (1.248 in) 0.12… 0.17 mm (0.0047… 0.0067 in) 0.10… 0.15 mm (0.0039… 0.0059 in) 2 grooved ball bearings Needle bearing No bearing bushes - DLC-plated piston pins Forged light alloy 1 compression ring, 1 oil scraper ring Pressure circulation lubrication with 2 rotor pumps (engine) / 1 rotor pump (transmission) 33:76 Multidisc clutch in oil bath / hydraulically activated 14:36 17:32 19:28 22:26 24:23 26:21 12 V, 150 W Contactless controlled fully electronic ignition with digital igni tion adjustment, type Kokusan NGK LKAR 8AI - 9 0.9 mm (0.035 in) Water, permanent circulation of coolant by water pump Electric starter/kick starter

Engine oil (SAE 10W/50) ( p. 113)

TECHNICAL DATA - ENGINE

20.2

Capacity - transmission oil

Gear oil 0.90 l (0.95 qt.) 20.3

Capacity - coolant

Coolant 0.95 l (1 qt.)

Engine oil (SAE 10W/50) ( p. 113) Coolant ( p. 113) Coolant (mixed ready to use) ( p. 113)

103

TECHNICAL DATA - ENGINE TIGHTENING TORQUES

Screw, cable holder in alternator cover Locking screw for bearing Oil jet, piston cooling Oil jet, rocker arm lubrication Screw, ignition pulse generator Screw, locking lever Screw, oil pump cover Bleeding connection, transmission Nut, water pump impeller Plug, vacuum connection Screw, alternator cover Screw, alternator cover Screw, camshaft bearing support Screw, clutch cover Screw, clutch cover Screw, clutch spring Screw, cylinder head Screw, engine case Screw, engine case Screw, exhaust flange Screw, gear oil level check Screw, idler Screw, kickstarter spring hanger Screw, kickstarter stop Screw, oil filter cover Screw, shift drum locating Screw, shift lever Screw, starter motor Screw, stator bracket Screw, timing chain guide rail Screw, timing chain securing guide Screw, timing chain tensioning rail Screw, torque governor Screw, valve cover Screw, water pump cover Screw, water pump cover Oil jet, conrod lubrication Plug, oil channel Screw, rocker arm bearing Plug, crankshaft location Screw, kickstarter Plug, oil drilling Screw, engine sprocket Balancer shaft nut Screw, unlocking of timing chain ten sioner M4 M5 M5 M5 M5 M5 M5 M6 M6 M6 M6x25 M6x40 M6 M6x25 M6x30 M6 M6 M6x60 M6x75 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6x25 M6x55 M6x0.75

M7 M7x1 M8 M8 M10 M10 M10x1 M10x1 4 Nm (3 lbf ft) 6 Nm (4.4 lbf ft) 2 Nm (1.5 lbf ft) 2 Nm (1.5 lbf ft) 6 Nm (4.4 lbf ft) 6 Nm (4.4 lbf ft) 6 Nm (4.4 lbf ft) 4 Nm (3 lbf ft) 8 Nm (5.9 lbf ft) 5 Nm (3.7 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 8 Nm (5.9 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 14 Nm (10.3 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 8 Nm (5.9 lbf ft) 8 Nm (5.9 lbf ft) 8 Nm (5.9 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 4 Nm (3 lbf ft) 9 Nm (6.6 lbf ft) 15 Nm (11.1 lbf ft) 10 Nm (7.4 lbf ft) 25 Nm (18.4 lbf ft) 15 Nm (11.1 lbf ft) 60 Nm (44.3 lbf ft) 40 Nm (29.5 lbf ft) 10 Nm (7.4 lbf ft)

Loctite ® 243™ Loctite ® 243™ Loctite ® 243™ Loctite ® 243™ Loctite ® 243™ Loctite ® 243™ Loctite ® 222 Loctite ® 243™ Loctite ® 243™

– – – – – – –

Loctite ® 243™

– –

Loctite ®

243™ Loctite ® 243™

Loctite ® 243™

Loctite ® 243™ Loctite ® 243™

Loctite ® 243™ Loctite ® 243™ Loctite ® 243™

– – –

Loctite ® 243™ Loctite ® 243™

Loctite ® 243™

– –

Loctite ® 243™ Loctite ® 243™ Loctite ® 243™

– –

104

TECHNICAL DATA - ENGINE TIGHTENING TORQUES

Screw, cylinder head Nut, rotor Spark plug Gear oil drain plug with magnet Oil pressure control valve plug Plug, SLS Plug, rocker arm Plug, gear oil screen Plug, engine oil screen Nut, inner clutch hub Nut, primary gear Plug, timing chain tensioner M10x1.25

M12x1 M12x1.25

M12x1.5

M12x1.5

M12x1.5

M14x1.25

M16x1.5

M17x1.5

M18x1.5

M20LHx1.5

M24x1.5

Tightening sequence: Tighten diagonally, begin ning with the rear screw on the chain shaft.

Step 1 10 Nm (7.4 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 50 Nm (36.9 lbf ft) 60 Nm (44.3 lbf ft) 15… 20 Nm (11.1… 14.8 lbf ft) 20 Nm (14.8 lbf ft) 20 Nm (14.8 lbf ft) 20 Nm (14.8 lbf ft) 20 Nm (14.8 lbf ft) 20 Nm (14.8 lbf ft) 20 Nm (14.8 lbf ft) 80 Nm (59 lbf ft) 100 Nm (73.8 lbf ft) 30 Nm (22.1 lbf ft) Lubricated with engine oil – – – – – – – – –

Loctite ® 243™

105

TECHNICAL DATA - CARBURETOR

22.1

All 400 models

Carburetor type Carburetor identification number Needle position Idle mixture adjusting screw Open Pump diaphragm stop Main jet Jet needle Idling jet Idle air jet Cold start jet Spill jet Slide stop KEIHIN FCR-MX 39 3900N 5th position from top 0.75 turn 2.15 mm (0.0846 in) 180 OBDYU (OBDTQ) 42 100 65 (85) 40 present 22.2

450 EXC EU/AUS, 450 EXC SIX DAYS, 450 EXC Factory Edition EU

Carburetor type Carburetor identification number Needle position Idle mixture adjusting screw Open Pump diaphragm stop Main jet Jet needle Idling jet Idle air jet Cold start jet Spill jet Slide stop KEIHIN FCR-MX 39 3900I 4th position from top 1.75 turns 2.15 mm (0.0846 in) 180 OBDYU (OBDTQ) 40 100 65 (85) 40 present 22.3

450 XC-W SIX DAYS USA

Carburetor type Carburetor identification number Needle position Idle mixture adjusting screw Open Pump membrane stop Main jet Jet needle Idling jet Idle air jet Cold start jet Spill jet KEIHIN FCR-MX 39 3900L 1st position from top 1.75 turns 2.15 mm (0.0846 in) 180 OBDTQ 40 100 85 40

106

TECHNICAL DATA - CARBURETOR

22.4

All 530 EXC models

Carburetor type Carburetor identification number Needle position Idle mixture adjusting screw Open Pump membrane stop Main jet Jet needle Idling jet Idle air jet Cold start jet Spill jet Slide stop 22.5

530 XC-W SIX DAYS USA

Carburetor type Carburetor identification number Needle position Idle mixture adjusting screw Open Pump membrane stop Main jet Jet needle Idling jet Idle air jet Cold start jet Spill jet KEIHIN FCR-MX 39 3900J 5th position from top 1.5 turns 2.15 mm (0.0846 in) 180 OBDZT (OBDTR) 40 100 65 (85) 40 present KEIHIN FCR-MX 39 3900M 1st position from top 2.0 turns 2.15 mm (0.0846 in) 180 OBDTR 40 100 85 40

107

TECHNICAL DATA - CHASSIS

Frame Fork Suspension travel Front Rear Fork offset (EXC EU/AUS) Fork offset (EXC Factory Edition, EXC SIX DAYS) Fork offset (XC ‑ W SIX DAYS) Front marking Rear marking Shock absorber Brake system Brake discs - diameter Front Rear Brake discs - wear limit Front Rear Tire air pressure off road Front Rear Road tire pressure (All EXC models) Front Rear Final drive (All 400/450 EXC models) Final drive (450 XC-W SIX DAYS USA) Final drive (530 XC-W SIX DAYS USA) Final drive (All 530 EXC models) Chain Rear sprockets available Steering head angle Wheelbase Seat height unloaded Ground clearance unloaded Weight without fuel, approx. (All EXC models) Weight without fuel, approx. (XC ‑ W SIX DAYS) Maximum permissible front axle load Maximum permissible rear axle load Maximum permissible overall weight Battery YTX5L-BS Fuse Fuse 58011109105 58011109110 Central tube frame made of chrome molybdenum steel tubing

WP Suspension

Up Side Down 4860 MXMA PA 300 mm (11.81 in) 335 mm (13.19 in) 20 mm (0.79 in) 19 mm (0.75 in) 18 mm (0.71 in) 20 mm (0.79 in)

WP Suspension

PDS 5018 DCC Disc brakes, brake calipers on floating bearings 260 mm (10.24 in) 220 mm (8.66 in) 2.5 mm (0.098 in) 3.5 mm (0.138 in) 1.0 bar (15 psi) 1.0 bar (15 psi) 1.5 bar (22 psi) 2.0 bar (29 psi) 15:45 (13:52) 13:52 13:50 15:45 (13:50) 5/8 x 1/4" 38, 40, 42, 45, 48, 49, 50, 51, 52 63.5° 1,475±10 mm (58.07±0.39 in) 985 mm (38.78 in) 380 mm (14.96 in) 113.9 kg (251.1 lb.) 112.2 kg (247.4 lb.) 145 kg (320 lb.) 190 kg (419 lb.) 335 kg (739 lb.) Battery voltage: 12 V Nominal capacity: 4 Ah Maintenance-free 5 A 10 A

108

TECHNICAL DATA - CHASSIS

23.1

Lighting equipment

Headlight Parking light Indicator lights (All EXC models) Turn signal (All EXC models) Brake / tail light License plate lamp (All EXC models) S2 / socket BA20d W5W / socket W2.1x9.5d

W2.3W / socket W2x4.6d

R10W / socket BA15s LED W5W / socket W2.1x9.5d

12 V 35/35 W 12 V 5 W 12 V 2.3 W 12 V 10 W 12 V 5 W 23.2

Tires Validity

(All EXC models) (XC ‑ W SIX DAYS)

Front tire 90/90 - 21 M/C 54M M+S TT

Metzeler MCE 6 DAYS EXTREME

80/100 - 21 51M TT

Bridgestone M59 Additional information is available in the Service section under: http://www.ktm.com

23.3

Capacity - fuel

Total fuel tank capacity, approx. (All EXC models) Total fuel tank capacity, approx. (XC ‑ W SIX DAYS) Fuel reserve, approx.

9.5 l (2.51 US gal) 9.2 l (2.43 US gal) 2 l (2 qt.)

Rear tire 140/80 - 18 M/C 70M M+S TT

Metzeler MCE 6 DAYS EXTREME

110/100 - 18 64M TT

Bridgestone M402

Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. 114) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. 114)

109

TECHNICAL DATA - FORK

Fork part number Fork Compression damping Comfort Standard Sport Rebound damping Comfort Standard Sport Spring length with preload spacer(s) 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.) Air chamber length Spring preload -

Preload Adjuster

Comfort Standard Sport Fork length Fork oil per fork leg 626 ml (21.17 fl. oz.) 14.18.7J.06

WP Suspension

Up Side Down 4860 MXMA PA 26 clicks 22 clicks 18 clicks 24 clicks 20 clicks 20 clicks 510 mm (20.08 in) 4.4 N/mm (25.1 lb/in) 4.6 N/mm (26.3 lb/in) 4.8 N/mm (27.4 lb/in) 110 +20 − 30 mm (4.33

+0.79

− 1.18

in) 0 turn 2 turns 4 turns 940 mm (37.01 in)

Fork oil (SAE 5) ( p. 113)

110

TECHNICAL DATA - SHOCK ABSORBER

Shock absorber part number Shock absorber Compression damping, low-speed Comfort Standard Sport Compression damping, high-speed Comfort Standard Sport Rebound damping Comfort Standard Sport Spring preload 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.) Spring length Gas pressure Static sag Riding sag Fitted length Damper oil 12.18.7J.06

WP Suspension

PDS 5018 DCC 22 clicks 20 clicks 15 clicks 2 turns 1.5 turns 1.25 turns 26 clicks 24 clicks 22 clicks 9 mm (0.35 in) 69 N/mm (394 lb/in) 72 N/mm (411 lb/in) 76 N/mm (434 lb/in) 250 mm (9.84 in) 10 bar (145 psi) 35 mm (1.38 in) 105 mm (4.13 in) 411 mm (16.18 in)

Shock absorber oil (SAE 2,5) (50180342S1) ( p. 113)

111

TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS

Spoke nipple, front wheel Screw, spoiler on fuel tank (XC ‑ W SIX DAYS) Spoke nipple, rear wheel Remaining nuts, chassis Remaining screws, chassis Screw, ball joint of push rod on foot brake cylinder Screw, chain sliding guard Screw, front brake disc Screw, rear brake disc Screw, shock absorber adjusting ring Nut, rear sprocket screw Nut, rim lock Remaining nuts, chassis Remaining screws, chassis Screw, bottom triple clamp (EXC Factory Edition, EXC SIX DAYS, XC ‑ W SIX DAYS) Screw, bottom triple clamp (EXC EU/AUS) Screw, chain sliding piece Screw, engine brace Screw, fork stub Screw, front brake caliper Screw, handlebar clamp Screw, side stand fixing Screw, subframe Screw, top steering stem (EXC Factory Edition, EXC SIX DAYS, XC ‑ W SIX DAYS) Screw, top steering stem (EXC EU/AUS) Screw, top triple clamp (EXC Factory Edition, EXC SIX DAYS, XC ‑ W SIX DAYS) Screw, top triple clamp (EXC EU/AUS) Engine attachment bolt Remaining nuts, chassis Remaining screws, chassis Screw, handlebar support Screw, bottom shock absorber Screw, top shock absorber Nut, seat fixing Nut, swingarm pivot Nut, rear wheel spindle Screw, bottom steering head (XC ‑ W SIX DAYS) Screw, top steering head Screw-in nozzles, cooling system Screw, front wheel spindle M4.5

M5x12 M5 M6 M6 M6 M6 M6 M6 M6 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M10 M10 M10 M10 M12 M12 M12x1 M16x1.5

M20x1.5

M20x1.5

M20x1.5

M20x1.5

M24x1.5

5… 6 Nm (3.7… 4.4 lbf ft) 1.5 Nm (1.11 lbf ft) – – 5… 6 Nm (3.7… 4.4 lbf ft) 15 Nm (11.1 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) – – – – 6 Nm (4.4 lbf ft) 14 Nm (10.3 lbf ft) 14 Nm (10.3 lbf ft) 5 Nm (3.7 lbf ft) 35 Nm (25.8 lbf ft) 10 Nm (7.4 lbf ft) 30 Nm (22.1 lbf ft) 25 Nm (18.4 lbf ft) 12 Nm (8.9 lbf ft)

Loctite ® 243™ Loctite ® 243™ Loctite ® 243™

– – –

Loctite ® 2701

– – 15 Nm (11.1 lbf ft) 15 Nm (11.1 lbf ft) 33 Nm (24.3 lbf ft) 15 Nm (11.1 lbf ft) 25 Nm (18.4 lbf ft) 20 Nm (14.8 lbf ft) 40 Nm (29.5 lbf ft) 35 Nm (25.8 lbf ft) 17 Nm (12.5 lbf ft) 20 Nm (14.8 lbf ft) 17 Nm (12.5 lbf ft) 20 Nm (14.8 lbf ft) 60 Nm (44.3 lbf ft) 50 Nm (36.9 lbf ft) 45 Nm (33.2 lbf ft) 40 Nm (29.5 lbf ft) 80 Nm (59 lbf ft) 80 Nm (59 lbf ft) 20 Nm (14.8 lbf ft) 100 Nm (73.8 lbf ft) 80 Nm (59 lbf ft) 60 Nm (44.3 lbf ft) 10 Nm (7.4 lbf ft) 12 Nm (8.9 lbf ft) 45 Nm (33.2 lbf ft) – – – – – –

Loctite ® 243™

Loctite ® 2701 Loctite ® 2701 Loctite ® 243™

– – – –

Loctite ® 243™ Loctite ® 2701 Loctite ® 2701

– – –

Loctite ® 243™

Loctite ® 243™

112

SUBSTANCES 113 Brake fluid DOT 4 / DOT 5.1

According to

– DOT

Guideline

– Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre sponding properties. KTM recommends

Castrol

and

Motorex ®

products.

Supplier Castrol

RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®

Brake Fluid DOT 5.1

Coolant Guideline

– Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foam ing. KTM recommends

Motorex ®

products.

Mixture ratio

Antifreeze protection: − 49 °F) − 25… − 45 °C ( − 13… 50 % corrosion inhibitor/antifreeze 50 % distilled water

Coolant (mixed ready to use)

Antifreeze

Supplier Motorex ®

Anti Freeze

− 40 °C ( − 40 °F)

Engine oil (SAE 10W/50) According to

JASO T903 MA (

SAE ( p. 117) p. 117) (SAE 10W/50)

Guideline

– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre sponding properties. KTM recommends

Motorex ®

products.

Synthetic engine oil

Supplier Motorex ®

Cross Power 4T Fork oil (SAE 5) According to

SAE ( p. 117) (SAE 5)

Guideline

– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends

Motorex ®

products.

Supplier Motorex ®

Racing Fork Oil Shock absorber oil (SAE 2,5) (50180342S1) According to

SAE ( p. 117) (SAE 2,5)

Guideline

– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties.

SUBSTANCES Super unleaded (ROZ 95 / RON 95 / PON 91) According to

– DIN EN 228 (ROZ 95 / RON 95 / PON 91)

114

AUXILIARY SUBSTANCES Air filter cleaner Guideline

– KTM recommends

Motorex ®

products.

Supplier Motorex ®

Twin Air Dirt Bio Remover Chain cleaner Guideline

– KTM recommends

Motorex ®

products.

Supplier Motorex ®

Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline

– KTM recommends

Motorex ®

products.

Supplier Motorex ®

Protect & Shine High viscosity grease Guideline

– KTM recommends

SKF ® Supplier SKF ®

LGHB 2

products.

Long-life grease Guideline

– KTM recommends

Motorex ® Supplier Motorex ®

Bike Grease 2000

products.

Motorcycle cleaner Guideline

– KTM recommends

Motorex ®

products.

Supplier Motorex ®

Moto Clean 900 Off-road chain spray Guideline

– KTM recommends

Motorex ®

products.

Supplier Motorex ®

Chainlube Offroad Oil for foam air filter Guideline

– KTM recommends

Motorex ®

products.

Supplier Motorex ®

Twin Air Liquid Bio Power 115

AUXILIARY SUBSTANCES Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline

– KTM recommends

Motorex ®

products.

Supplier Motorex ®

Clean & Polish Universal oil spray Guideline

– KTM recommends

Motorex ®

products.

Supplier Motorex ®

Joker 440 Synthetic 116

STANDARDS 117 JASO T903 MA

Different technical development directions required a new specification for 4-stroke motorcycles lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi cation. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the fore ground for motorcycle engines. With most motorcycles, the gearbox and the clutch are lubricated with the same oil as the engine. The JASO MA Standard meets these special requirements.

– the JASO T903 MA Standard. Ear-

SAE

The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis cosity. The viscosity describes only one property of oil and says nothing about quality.

INDEX 118

INDEX

A Accessories

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Air filter

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Air filter box

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Air filter box lid

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Anti-freeze

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Arduous riding conditions

. . . . . . . . . . . . . . . . . . . . . . . . . 26

high temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 slow speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

B Basic suspension setting

checking against the rider's weight . . . . . . . . . . . . . . . 36

Battery

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Brake discs

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Brake fluid

front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 65

rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Brake fluid level

front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 65

rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 69

Brake linings

front brake, changing . . . . . . . . . . . . . . . . . . . . . . . . 67

front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 66

rear brake, changing . . . . . . . . . . . . . . . . . . . . . . . . . 70 rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 70

C Carburetor

float chamber, emptying . . . . . . . . . . . . . . . . . . . . . . 89

idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

idle speed, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 88

Chain

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Chain guide

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Chain tension

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Chassis number

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Choke Cleaning

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12, 22

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97-98

Clutch

fluid level, checking . . . . . . . . . . . . . . . . . . . . . . . . . 62 fluid, changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Clutch lever

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 62

Compression damping

fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Compression damping, high-speed

shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 36

Compression damping, low-speed

shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 37

Coolant

draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Coolant level

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Cooling system

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

D Difficult operating conditions

dry sand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

low temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

muddy surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

wet sand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

wet surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

E Electric starter button Emergency OFF switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . 14

. . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Engine

running-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Engine number

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Engine oil

adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

filling up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Engine oil level

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Engine oil screen

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Engine sprocket

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Environment

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

F Filler cap

closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Filling up

fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Foot brake lever

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 68 free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 68

Fork legs

basic setting, checking . . . . . . . . . . . . . . . . . . . . . . . 40

bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 dust boots, cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 43

fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

INDEX 119 Fork offset

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Fork protector

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Front fender

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Front wheel

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Fuel tank

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Fuel tap

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Fuel, oils, etc.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Fuse

main fuse, installing . . . . . . . . . . . . . . . . . . . . . . . . . 79 main fuse, removing . . . . . . . . . . . . . . . . . . . . . . . . . 79

of radiator fan, changing . . . . . . . . . . . . . . . . . . . . . . 80

G Gear oil

adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Gear oil level

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Gear oil screen

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

H Hand brake lever

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 64 free travel, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 64 free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 64

Handlebar position

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Headlight

headlight range, adjusting . . . . . . . . . . . . . . . . . . . . . 82

Headlight adjustment

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Headlight bulb

changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Headlight mask with headlight

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Horn button

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

K Key number Kick starter

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

L Light switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14

Lower triple clamp

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46, 49

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46, 48

M Main fuse

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Main silencer

glass fiber yarn filling, changing . . . . . . . . . . . . . . . . . 55 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Motorcycle

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

raising with lift stand . . . . . . . . . . . . . . . . . . . . . . . . 43 removing from lift stand . . . . . . . . . . . . . . . . . . . . . . 43

O Oil filter

changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Overview of indicator lamps Owner's manual

. . . . . . . . . . . . . . . . . . . . . . . 14

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

P Play in throttle cable

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Protection for winter operation

. . . . . . . . . . . . . . . . . . . . . . 98

Putting into operation

advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . 25

after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

checks and maintenance before putting into operation . . 30

R Rear sprocket

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Rear wheel

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Rebound damping

fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 37

Riding sag

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

S Seat

mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Service

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Service schedule

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-35

Shift lever

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 90

basic position, checking . . . . . . . . . . . . . . . . . . . . . . 89

Shock absorber

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

riding sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 38 static sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 38

Short circuit button Side stand

. . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

INDEX Spare parts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Speedometer

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

battery, changing . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

clock, setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

function description . . . . . . . . . . . . . . . . . . . . . . . . . 14

kilometers or miles, setting . . . . . . . . . . . . . . . . . . . . 15

Spoke tension

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Spring preload

fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 39

Starting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Steering

locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Steering head bearing

greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Steering head bearing play

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Storage

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

T Technical data

carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106-107

chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108-109

chassis tightening torques . . . . . . . . . . . . . . . . . . . . 112

engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102-103

engine tightening torques . . . . . . . . . . . . . . . . . 104-105

fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Throttle cable routing

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Throttle grip

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Tire condition

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Tire pressure

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Transport

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Troubleshooting

. . . . . . . . . . . . . . . . . . . . . . . . . . . 100-101

Turn signal switch Type label

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

U Use definition

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

V View of vehicle

left front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

right rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

W Warranty Work rules

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

120

*3211690en*

3211690en

KTM-Sportmotorcycle AG

5230 Mattighofen/Austria

http://www.ktm.com

09/2010 Photo: Mitterbauer

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