KTM 500 XCF-W US 2020 Cross Country Bike Owner Manual

KTM 500 XCF-W US 2020 Cross Country Bike Owner Manual
OWNER'S MANUAL 2020
450 EXC‑F
450 EXC‑F Six Days
500 EXC‑F
500 EXC‑F Six Days
500 XCF‑W
Art. no. 3214012en
DEAR KTM CUSTOMER
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art
sports vehicle that will continue giving you pleasure for a long time if you maintain it properly.
DEAR KTM CUSTOMER
We wish you good and safe riding at all times!
Please enter the serial number of your vehicle below.
Vehicle identification number (
Engine number (
p. 14)
Stamp of dealer
p. 14)
Key number (All EU models) (
p. 14)
The Owner's Manual contained the latest information for this model series at the time of going to print. Slight
deviations resulting from continuing development and design of the motorcycles can, however, not be completely
excluded.
All specifications contained herein are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right
to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc.,
without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from figures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that
does not belong to the regular scope of supply.
© 2019 KTM Sportmotorcycle GmbH, 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)
KTM applies quality assurance processes that lead to the highest possible product quality as
defined in the ISO 9001 international quality management standard.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
450 EXC‑F EU (F8403T9)
450 EXC‑F Six Days EU (F8403T2)
500 EXC‑F EU (F8503T9)
500 EXC‑F Six Days EU (F8503T2)
500 XCF-W US (F8575T1)
*3214012en*
3214012en
05/2019
TABLE OF CONTENTS
TABLE OF CONTENTS
1
1.1
1.2
2
Manufacturer and implied warranty....
Fuel, auxiliary substances .................
Spare parts, accessories ...................
Service ...........................................
Figures ...........................................
Customer service..............................
11
11
11
11
11
11
7.9
7.10
7.11
7.12
7.13
View of vehicle, front left (example) ... 12
View of vehicle, rear right
(example)........................................ 13
Vehicle identification number............
Type label .......................................
Key number (All EU models) .............
Engine number ................................
Fork part number .............................
Shock absorber article number ..........
7.14
7.15
14
14
14
14
15
15
6.12
6.13
Clutch lever.....................................
Hand brake lever..............................
Throttle grip ....................................
Switch-off button .............................
Horn button (All EU models) .............
Light switch (All EU models) .............
Light switch (XCF‑W)........................
Turn signal switch (All EU models) ....
Emergency OFF switch .....................
Start button.....................................
Combination switch (All EXC-F Six
Days, XCF‑W)...................................
Overview of indicator lamps (All EU
models)...........................................
Overview of indicator lamps
(XCF‑W) ..........................................
16
16
16
16
17
17
17
18
18
18
7.16
7.17
7.18
7.19
19
19
19
7.20
7.21
7.22
7.23
7.24
8
Opening fuel tank filler cap...............
Closing the fuel tank filler cap...........
Cold start button..............................
Idle speed adjusting screw ................
Shift lever .......................................
Foot brake lever ...............................
Side stand.......................................
Steering lock (All EU models)............
Locking the steering (All EU
models)...........................................
Unlocking the steering (All EU
models)...........................................
20
20
21
21
22
22
22
23
23
24
COMBINATION INSTRUMENT ..................... 25
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
CONTROLS................................................. 16
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
2
7
SERIAL NUMBERS ..................................... 14
5.1
5.2
5.3
5.4
5.5
5.6
6
6.23
VIEW OF VEHICLE ...................................... 12
4.1
4.2
5
Use definition – intended use.............. 7
Misuse.............................................. 7
Safety advice..................................... 7
Degrees of risk and symbols ................ 8
Tampering warning............................. 8
Safe operation ................................... 8
Protective clothing ............................. 9
Work rules......................................... 9
Environment...................................... 9
Owner's Manual ............................... 10
IMPORTANT NOTES.................................... 11
3.1
3.2
3.3
3.4
3.5
3.6
4
Symbols used .................................... 6
Formats used..................................... 6
SAFETY ADVICE............................................ 7
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
3
6.14
6.15
6.16
6.17
6.18
6.19
6.20
6.21
6.22
MEANS OF REPRESENTATION ...................... 6
Combination instrument overview ......
Activation and test ...........................
Setting the kilometers or miles ..........
Setting the combination instrument ...
Setting the clock..............................
Viewing the lap time.........................
Display mode SPEED (speed) ............
Display mode SPEED/H (operating
hours) .............................................
Setup menu ....................................
Adjusting the unit of measurement ....
Display mode SPEED/CLK (time) .......
Setting the clock..............................
Display mode SPEED/LAP (lap
time) ..............................................
Viewing the lap time.........................
Display mode SPEED/ODO
(odometer) ......................................
Display mode SPEED/TR1 (trip
master 1) ........................................
Display mode SPEED/TR2 (trip
master 2) ........................................
Setting 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) .........................................
Table of functions ............................
Table of conditions and menu
activation ........................................
25
25
25
26
27
27
28
28
28
29
30
30
30
31
31
32
32
32
33
33
34
34
35
36
PREPARING FOR USE................................. 37
8.1
8.2
8.3
8.4
Advice on preparing for first use ........
Running-in the engine ......................
Starting power of lithium-ion
batteries at low temperatures ............
Preparing the vehicle for difficult
riding conditions ..............................
37
38
39
39
TABLE OF CONTENTS
8.5
8.6
8.7
8.8
8.9
9
Preparing the vehicle for riding on
dry sand..........................................
Preparing the vehicle for riding on
wet sand .........................................
Preparing the vehicle for riding on
wet and muddy circuits ....................
Preparing vehicle for high
temperatures or slow riding ...............
Preparing the vehicle for low
temperatures or snow .......................
40
11.14 Adjusting the spring preload of the
fork (All EXC-F Six Days)................... 60
11.15 Handlebar position........................... 61
11.16 Adjusting the handlebar position .... 61
41
12 SERVICE WORK ON THE CHASSIS............... 64
39
41
42
RIDING INSTRUCTIONS.............................. 43
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
Checks and maintenance measures
when preparing for use .....................
Starting the vehicle ..........................
Activating traction control (All EXC-F
Six Days, XCF‑W) .............................
Starting off......................................
Shifting, riding ................................
Braking ...........................................
Stopping, parking.............................
Transporting ....................................
Refueling ........................................
43
43
44
45
45
45
46
47
47
10 SERVICE SCHEDULE .................................. 49
12.1
12.2
12.3
12.4
12.5
12.6
12.7
12.8
12.9
12.10
12.11
12.12
Additional information ...................... 49
Required work ................................. 49
Recommended work ......................... 50
12.13
11 TUNING THE CHASSIS ............................... 52
12.15
10.1
10.2
10.3
11.1
11.2
11.3
11.4
11.5
11.6
11.7
11.8
11.9
11.10
11.11
11.12
11.13
Checking the basic chassis setting
with rider's weight............................
Compression damping of the shock
absorber..........................................
Adjusting the low-speed
compression damping of the shock
absorber..........................................
Adjusting the high-speed
compression damping of the shock
absorber..........................................
Adjusting the rebound damping of
the shock absorber ...........................
Measuring the dimension of the rear
wheel unloaded................................
Checking the static sag of the shock
absorber..........................................
Checking the riding sag of the shock
absorber..........................................
Adjusting the spring preload of the
shock absorber .............................
Adjusting the riding sag ................
Checking the basic setting of the
fork ................................................
Adjusting the compression damping
of the fork .......................................
Adjusting the rebound damping of
the fork...........................................
12.14
52
12.16
52
12.17
12.18
12.19
12.20
12.21
12.22
12.23
12.24
12.25
12.26
12.27
52
53
54
54
55
55
12.28
56
57
12.29
12.30
12.31
57
12.32
58
12.33
12.34
Raising the motorcycle with the lift
stand ..............................................
Removing the motorcycle from the
lift stand .........................................
Bleeding the fork legs.......................
Cleaning the dust boots of the fork
legs ................................................
Removing the fork protector ..............
Installing the fork protector...............
Removing the fork legs ..................
Installing the fork legs ..................
Removing the lower triple clamp
(EXC‑F EU, XCF‑W) ..........................
Removing the lower triple clamp
(All EXC-F Six Days) .........................
Installing the lower triple clamp
(EXC‑F EU, XCF‑W) ..........................
Installing the lower triple clamp
(All EXC-F Six Days) .........................
Checking steering head bearing
play ................................................
Adjusting steering head bearing
play (EXC‑F EU, XCF‑W)................
Adjusting steering head bearing
play (All EXC-F Six Days)...............
Lubricating the steering head
bearing ........................................
Removing front fender ......................
Installing front fender.......................
Removing the shock absorber ........
Installing the shock absorber .........
Removing the seat ...........................
Mounting the seat ............................
Removing the air filter box cover .......
Installing the air filter box cover ........
Removing the air filter ..................
Installing the air filter ...................
Cleaning the air filter and air filter
box .............................................
Preparing air filter box cover for
securing ......................................
Removing the main silencer ..............
Installing the main silencer...............
Cleaning the spark arrestor
(XCF‑W) ..........................................
Changing the glass fiber yarn filling
of the main silencer ......................
Removing the fuel tank .................
Installing the fuel tank ..................
64
64
64
65
65
66
66
67
68
69
70
72
73
74
75
75
76
77
78
78
78
79
79
80
81
81
82
82
83
83
83
85
86
87
59
3
TABLE OF CONTENTS
12.35 Checking for chain dirt
accumulation...................................
12.36 Cleaning the chain ...........................
12.37 Checking the chain tension ...............
12.38 Adjusting the chain tension...............
12.39 Checking the chain, rear sprocket,
engine sprocket, and chain guide ......
12.40 Checking the frame ......................
12.41 Checking the link fork ...................
12.42 Checking throttle cable routing..........
12.43 Checking the rubber grip ..................
12.44 Adjusting the basic position of the
clutch lever .....................................
12.45 Checking/correcting the fluid level of
the hydraulic clutch .........................
12.46 Changing the hydraulic clutch
fluid ............................................
12.47 Removing the engine guard (All
EXC-F Six Days, XCF‑W) ...................
12.48 Installing the engine guard (All
EXC-F Six Days, XCF‑W) ...................
15 ELECTRICAL SYSTEM ............................... 121
89
89
90
91
92
94
94
94
95
96
96
97
98
99
13 BRAKE SYSTEM ....................................... 100
13.1
13.2
13.3
13.4
13.5
13.6
13.7
13.8
13.9
13.10
13.11
13.12
13.13
13.14
Checking the free travel of the
hand brake lever ............................
Adjusting the free travel of the
handbrake lever (All EU models)......
Adjusting the basic position of the
hand brake lever (XCF‑W)................
Checking the brake discs ................
Checking the front brake fluid
level .............................................
Adding the front brake fluid .........
Checking the front brake linings ......
Changing the brake linings of the
front brake .................................
Checking the free travel of foot
brake lever ....................................
Adjusting the basic position of the
foot brake lever ..........................
Checking the rear brake fluid
level .............................................
Adding rear brake fluid ...............
Checking the rear brake linings .......
Changing the rear brake linings ....
100
100
101
101
102
102
104
4
Removing the front wheel ............
Installing the front wheel ............
Removing the rear wheel .............
Installing the rear wheel ..............
Checking the tire condition .............
Checking tire pressure ....................
Checking spoke tension ..................
15.6
15.7
15.8
15.9
15.10
15.11
15.12
15.13
16.1
16.2
16.3
16.4
16.5
17.1
17.2
17.3
108
17.5
17.6
109
17.7
115
116
116
117
119
119
120
121
122
123
125
126
127
128
129
129
130
130
131
132
Cooling system ..............................
Checking the antifreeze and
coolant level ..................................
Checking the coolant level ..............
Draining the coolant ...................
Refilling coolant .........................
133
133
134
135
136
17 TUNING THE ENGINE............................... 137
104
110
110
111
112
Removing the 12-V battery ..........
Installing the 12-V battery ...........
Charging the 12-V battery ...........
Changing the main fuse ..................
Changing the fuses of individual
power consumers ...........................
Removing the headlight mask with
the headlight .................................
Installing the headlight mask with
the headlight .................................
Changing the headlight bulb ...........
Checking the headlight setting ........
Adjusting the headlight range..........
Changing the turn signal bulb
(All EU models) .............................
Changing the combination
instrument battery..........................
Diagnostics connector ....................
16 COOLING SYSTEM .................................... 133
17.4
14 WHEELS, TIRES ....................................... 115
14.1
14.2
14.3
14.4
14.5
14.6
14.7
15.1
15.2
15.3
15.4
15.5
17.8
Checking the throttle cable play ......
Adjusting the throttle cable
play ..........................................
Adjusting the characteristic map of
the throttle response ...................
Changing the mapping (All EXC-F
Six Days, XCF‑W) ...........................
Adjusting the idle speed ..............
Teaching the throttle valve
position.........................................
Checking the basic position of the
shift lever......................................
Adjusting the basic position of the
shift lever ..................................
137
137
138
139
140
141
141
142
18 SERVICE WORK ON THE ENGINE .............. 143
18.1
18.2
18.3
18.4
Changing the fuel screen .............
Checking the engine oil level...........
Changing the engine oil and oil
filter, cleaning the oil screens ......
Adding engine oil ...........................
143
144
144
147
19 CLEANING, CARE ..................................... 148
19.1
19.2
Cleaning the motorcycle ................. 148
Checks and maintenance steps for
winter operation............................. 149
TABLE OF CONTENTS
20 STORAGE ................................................. 150
20.1
20.2
Storage ......................................... 150
Preparing for use after storage......... 151
21 TROUBLESHOOTING ................................ 152
22 TECHNICAL DATA..................................... 155
22.1
22.2
22.3
22.3.1
22.3.2
22.3.3
22.4
22.5
22.6
22.7
22.7.1
22.7.2
22.8
22.9
Engine ..........................................
Engine tightening torques ...............
Capacities .....................................
Engine oil .................................
Coolant .....................................
Fuel .........................................
Chassis .........................................
Electrical system............................
Tires .............................................
Fork..............................................
EXC‑F EU, XCF‑W ......................
All EXC-F Six Days .....................
Shock absorber ..............................
Chassis tightening torques ..............
155
156
157
157
157
157
158
159
159
159
159
160
160
161
23 SUBSTANCES .......................................... 164
24 AUXILIARY SUBSTANCES ......................... 166
25 STANDARDS ............................................ 168
26 INDEX OF SPECIAL TERMS ....................... 169
27 LIST OF ABBREVIATIONS.......................... 170
28 LIST OF SYMBOLS.................................... 171
28.1
28.2
Yellow and orange symbols.............. 171
Green and blue symbols.................. 171
INDEX ............................................................. 172
5
1 MEANS OF REPRESENTATION
1.1
Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding.
In the interest of your own safety, have these jobs performed by an authorized KTM workshop!
Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary
tools required.
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates the end of an activity, including potential rework.
1.2
Formats used
The typographical formats used in this document are explained below.
Proprietary name
Indicates a proprietary name.
Name®
Indicates a protected name.
Brand™
Indicates a brand available on the open market.
Underlined terms
Refer to technical details of the vehicle or indicate technical terms, which
are explained in the glossary.
6
SAFETY ADVICE 2
Use definition – intended use
2.1
(All EU models)
This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle
complies with the currently valid regulations and categories of the top international motorsports organizations.
Info
This vehicle is only authorized for operation on public roads in the homologated (restricted) version.
The derestricted version of this vehicle must only be operated in closed off areas away from public
highway traffic.
This vehicle is designed for use in offroad endurance competition, and not primarily for use in
motocross.
(XCF‑W)
This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle
complies with the currently valid regulations and categories of the top international motorsport organizations.
Info
This vehicle is designed for use in offroad endurance competition, and not primarily for use in
motocross.
2.2
Misuse
The vehicle must only be used as intended.
Dangers can arise for people, property and the environment through use not as intended.
Any use of the vehicle beyond the intended and defined use constitutes misuse.
Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the
respective use.
2.3
Safety advice
A number of safety instructions need to be followed to operate the product described safely. Therefore read this
instruction and all further instructions included carefully. The safety instructions are highlighted in the text and
are referred to at the relevant passages.
Info
Various information and warning labels are attached in prominent locations on the product described. Do
not remove any information or warning labels. If they are missing, you or others may not recognize dangers
and may therefore be injured.
7
2 SAFETY ADVICE
2.4
Degrees of risk and symbols
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.
Note
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
2.5
Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing
thereof:
1
The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or
2
the use of the vehicle after such device or element of design has been removed or rendered inoperative by any
person.
Among those acts presumed to constitute tampering are the acts listed below:
1
Removal or puncturing of the main silencers, baffles, manifolds or any other components which conduct
exhaust gases.
2
Removal or puncturing of parts of the intake system.
3
Lack of proper maintenance.
4
Replacing moving parts of the vehicle, or parts of the exhaust system or intake system, with parts other than
those specified by the manufacturer.
(XCF‑W)
An add-on or modified part must be compliant with applicable ARB evaporative emission control standards. A
violation of this requirement is punishable by civil and/or criminal punishment.
2.6
Safe operation
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
8
–
Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
–
Do not operate the vehicle if you are physically or mentally impaired.
SAFETY ADVICE 2
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
–
Always make sure there is sufficient ventilation when running the engine.
–
Use effective exhaust extraction when starting or running the engine in an enclosed space.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
–
Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system
before the vehicle parts have cooled down.
–
Let the vehicle parts cool down before you perform any work on the vehicle.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a
safe and environmentally compatible manner.
An appropriate driver's license is needed to ride the vehicle on public roads.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
2.7
Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
–
Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket
with protectors on all rides.
–
Always wear protective clothing that is in good condition and meets the legal regulations.
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective
clothing.
2.8
Work rules
Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered
using the number in parentheses. Example: bearing puller (15112017000)
During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts, seals,
sealing rings, O-rings, pins, and lock washers).
In the case of certain screws, a screw adhesive (e.g. Loctite®) is required. Observe the manufacturer's instructions.
If thread locker (e.g., Precote®) has already been applied to a new part, do not apply any additional thread locker.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged
or worn parts.
After completing a repair or service work, check the operating safety of the vehicle.
2.9
Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the
future of the motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and
regulations of the respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no
legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad
to advise you.
9
2 SAFETY ADVICE
2.10
Owner's Manual
It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains useful information and many tips on how to operate, handle, and service your motorcycle.
Only then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself
from injury.
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed.
If you would like to know more about the vehicle or have questions on the material you read, please contact an
authorized KTM dealer.
The Owner's Manual is an important component of the vehicle and must be handed over to the new owner if the
vehicle is sold.
The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website.
International KTM Website: http://www.ktm.com
10
IMPORTANT NOTES 3
3.1
Manufacturer and implied warranty
The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and confirmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused
by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.
3.2
Fuel, auxiliary substances
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
–
Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use fuels and auxiliary substances in accordance with the Owner's Manual and specification.
3.3
Spare parts, accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM
and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any
resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized KTM
dealer will be glad to advise you.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4
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. An incorrect suspension
setting can lead to damage and breakage of chassis components.
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can result in significantly increased wear of components, such as the drive train, brake system, or suspension components. For this
reason, it may be necessary to inspect or replace parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly,
you will ensure a much longer service life for your motorcycle.
The relevant mileage or time interval is whichever occurs first.
3.5
Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not
always necessary to disassemble the component to perform the activity in question. Please follow the instructions
in the text.
3.6
Customer service
Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.
A list of authorized KTM dealers can be found on the KTM website.
International KTM Website: http://www.ktm.com
11
4 VIEW OF VEHICLE
4.1
View of vehicle, front left (example)
V01746-10
1
2
3
4
5
6
12
Clutch lever (
p. 16)
Fuel tank filler cap
Air filter box cover
Side stand (
p. 22)
Engine number (
Shift lever (
p. 14)
p. 22)
VIEW OF VEHICLE 4
4.2
View of vehicle, rear right (example)
V01747-10
1
1
1
1
2
3
4
5
6
7
8
Switch-off button (
p. 16)
Horn button (
p. 17) (All EU models)
Light switch (
p. 17) (All EU models)
Turn signal switch (
Start button (
p. 18) (All EU models)
p. 18)
Emergency OFF switch (
Throttle grip (
p. 18)
p. 16)
Hand brake lever (
p. 16)
Fork part number (
p. 15)
Foot brake lever (
p. 22)
Level viewer for brake fluid, rear
13
5 SERIAL NUMBERS
5.1
Vehicle identification number
The vehicle identification number
of the steering head.
1 is stamped on the right side
401945-10
5.2
Type label
(All EU models)
The Europe type label
head.
The Canada type label
tube.
1 is fixed to the front of the steering
2 is fixed to the front of the chest
V01808-10
5.3
Key number (All EU models)
The key number
connector.
1 for the steering lock is stamped onto the key
402247-10
5.4
Engine number
1
Engine number
is embossed on the left side of the engine
behind the shift lever.
H00940-10
14
SERIAL NUMBERS 5
5.5
Fork part number
The fork part number
stub.
1 is stamped on the inner side of the fork
401947-10
5.6
Shock absorber article number
1
Shock absorber article number
is stamped on the top of the
shock absorber above the adjusting ring towards the engine side.
H02222-10
15
6 CONTROLS
6.1
Clutch lever
1
The clutch lever
is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
E00817-10
6.2
Hand brake lever
1
The hand brake lever
is fitted on the right side of the handlebar.
The hand brake lever is used to activate the front brake.
E01205-10
6.3
Throttle grip
The throttle grip
1 is fitted on the right side of the handlebar.
E01206-10
6.4
Switch-off button
(All EU models)
Switch-off button
bar.
S01302-10
16
1 is fitted on the left side of the handle-
CONTROLS 6
(XCF‑W)
Switch-off button
bar.
E00821-10
6.5
1 is fitted on the left side of the handle-
Possible states
• The switch-off button is in the basic position – In this
position, the ignition circuit is closed and the engine can be
started.
• The switch-off button is pressed – In this position, the ignition circuit is interrupted, a running engine stops, and a nonrunning engine will not start.
Horn button (All EU models)
Horn button
1 is fitted on the left side of the handlebar.
Possible states
• The horn button
• The horn button
position.
is in the basic position
is pressed – The horn is operated in this
S01303-10
6.6
Light switch (All EU models)
The light switch
1 is fitted on the left side of the handlebar.
Possible states
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 – The light switch is turned counterclockwise. In this position, the high beam and the tail
light are switched on.
S01307-10
6.7
Light switch (XCF‑W)
The light switch
instrument.
1 is located to the left of the combination
Possible states
• Light off – Light switch is pressed in up to the stop. In this
position, the light is switched off.
• Light on – Light switch is pulled out to the stop. In this position, the low beam and the tail light are switched on.
V01748-10
17
6 CONTROLS
6.8
Turn signal switch (All EU models)
The turn signal switch
bar.
1 is fitted on the left side of the handle-
Possible states
Turn signal off – Turn signal switch is in the central
position.
Turn signal, left, on – The turn signal switch is turned
to the left.
S01304-10
6.9
Turn signal, right, on – The turn signal switch is
turned to the right.
Emergency OFF switch
(All EU models)
The emergency OFF switch
handlebar.
1 is fitted on the right side of the
Possible states
Ignition off – In this position, the ignition circuit
is interrupted, a running engine stops, and a
non-running engine will not start.
V01749-10
6.10
Ignition on – In this position, the ignition circuit is
closed and the engine can be started.
Start button
(All EU models)
Start button
1 is fitted on the right side of the handlebar.
(XCF‑W)
Start button
1 is fitted on the right side of the handlebar.
V01749-11
Possible states
• The start button
• The start button
in this position.
V01750-10
18
is in the basic position
is pressed – The starter motor is actuated
CONTROLS 6
6.11
Combination switch (All EXC-F Six Days, XCF‑W)
The combination switch is fitted on the left side of the handlebar.
Possible states
1
STANDARD – STANDARD mapping is activated when
LED 1 lights up.
1TC
STANDARD with TC – STANDARD mapping with traction control is activated when LED 1 and TC light up.
2
ADVANCED – ADVANCED mapping is activated, when
LED 2 lights up.
2TC
ADVANCED with TC – ADVANCED mapping with traction control is activated when LED 2 and TC light up.
Warning
Voiding of the government approval for road use and the
insurance coverage If the combination switch is mounted,
the vehicle’s road permit, if any, expires.
–
H02887-01
Only operate the vehicle in closed-off areas remote
from public road traffic if the combination switch is
installed.
The engine characteristic can be changed using button MAP on the
combination switch.
The traction control can also be activated via the combination
switch.
6.12
Overview of indicator lamps (All EU models)
Possible states
The high beam indicator lamp lights up blue – The
high beam is switched on.
Malfunction indicator lamp lights up/flashes yellow
– The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized KTM workshop.
The fuel level warning lamp lights up yellow – The
fuel level has reached the reserve mark.
V01752-10
Turn signal indicator lamp flashes green – The turn
signal is switched on.
6.13
Overview of indicator lamps (XCF‑W)
Possible states
Malfunction indicator lamp lights up/flashes yellow
– The OBD has detected an error in the vehicle electronics. Stop and contact an authorized KTM workshop.
The fuel level warning lamp lights up yellow – The
fuel level has reached the reserve mark.
V01751-10
19
6 CONTROLS
6.14
Opening fuel tank filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–
Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–
Switch off the engine for refueling.
–
Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–
If any fuel is spilled, wipe it off immediately.
–
Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–
Avoid skin, eye and clothing contact with fuel.
–
Immediately consult a doctor if you swallow fuel.
–
Do not inhale fuel vapors.
–
In case of skin contact, rinse the affected area with plenty of water.
–
Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–
Change your clothing in case of fuel spills on them.
–
Keep fuels correctly in a suitable canister, and out of the reach of children.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
–
Do not allow fuel to enter the groundwater, the soil, or the sewage system.
–
Press release button
, turn the fuel tank filler cap counterclockwise, and lift it off.
–
Mount fuel tank filler cap and turn it clockwise until the
release button
engages.
1
K01334-10
6.15
Closing the fuel tank filler cap
1
Info
Route fuel tank breather hose
K01334-11
20
2 without kinks.
CONTROLS 6
6.16
Cold start button
1
The cold start button
is fitted to the bottom of the throttle
valve body.
The electronic fuel injection system extends the injection time if
the engine is cold and the ambient temperature is low. To help the
engine burn the increased fuel quantity, it must be supplied with
additional oxygen by pushing the cold start button.
After briefly opening up the throttle and then releasing the throttle
grip again, or turning the throttle grip towards the front, the cold
start button returns to its original position.
Info
Check whether the cold start button has returned to its
basic position.
Possible states
• The cold start button is activated – The cold start button is
pushed in all the way.
• The cold start button is deactivated – The cold start button is
in its basic position.
H02253-10
6.17
Idle speed adjusting screw
The idle setting of the throttle valve body substantially influences
the vehicle’s starting behavior, a stable idle speed, and the vehicle’s response when the throttle is opened.
An engine with a correctly set idle speed is easier to start than an
engine with the idle speed set incorrectly.
The idle speed is adjusted using the idle speed adjusting
screw
.
Increase the idle speed by turning the idle speed adjusting screw
clockwise.
Decrease the idle speed by turning the idle speed adjusting screw
counterclockwise.
1
H02254-10
21
6 CONTROLS
6.18
Shift lever
The shift lever
1 is fitted on the left side of the engine.
401950-10
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
401950-11
6.19
Foot brake lever
1
The foot brake lever
is attached in front of the right footrest.
The foot brake lever is used to activate the rear brake.
401956-10
6.20
Side stand
The side stand
401943-10
22
1 is attached to the left side of the vehicle.
CONTROLS 6
The side stand is used for parking the motorcycle.
Info
When you are riding, side stand
secured with rubber strap
.
1 must be folded up and
2
401944-10
6.21
Steering lock (All EU models)
1
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.
S01311-10
6.22
Locking the steering (All EU models)
Note
Danger of damage The parked vehicle can roll away or fall over.
–
Park the vehicle on a firm and level surface.
–
Park the vehicle.
–
Turn handlebar as far as possible to the right.
–
Lubricate the steering lock regularly.
Universal oil spray (
–
400732-01
p. 167)
Insert the key for the steering lock into the steering lock
( p. 23), turn it to the left, push it in, and turn it to the
right. Pull out the key for the steering lock.
Steering is no longer possible.
Info
Never leave the key for the steering lock in the steering
lock.
23
6 CONTROLS
6.23
Unlocking the steering (All EU models)
–
Insert the key for the steering lock into the steering lock
( p. 23), turn it to the left, pull it out, and turn it to the
right. Pull out the key for the steering lock.
The handlebar can now be moved again.
Info
Never leave the key for the steering lock in the steering
lock.
400731-01
24
COMBINATION INSTRUMENT 7
7.1
Combination instrument overview
–
Press the button
to control different functions.
–
Press the button
to control different functions.
Info
When the vehicle is delivered, only the SPEED/H and
SPEED/ODO display modes are activated.
V00799-01
7.2
Activation and test
Activating combination instrument
The combination instrument is activated when one of the buttons
is pressed or an impulse comes from the wheel speed sensor.
Display test
To enable you to check that the display is functioning properly, all
display segments light up briefly.
400313-01
WS (wheel size)
After the display function check, the wheel circumference WS is
displayed briefly.
Info
The number 2205 equals the circumference of the 21"
front wheel with standard tires.
The display then changes to the last selected mode.
400314-01
7.3
Setting the kilometers or miles
Info
If you change the unit, the value ODO is retained and converted accordingly.
The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed.
Condition
The motorcycle is stationary.
–
Repeatedly press the button
bottom right of the display.
–
Press the button
briefly until H appears at the
for 2–3 seconds.
The Setup menu is displayed and the active functions are
shown.
–
400329-01
Repeatedly press the button
Adjusting the Km/h
– Press the button
.
Adjusting the Mph
– Press the button
.
briefly until Km/h/Mph flashes.
25
7 COMBINATION INSTRUMENT
–
Wait 3 - 5 seconds.
The settings are stored.
Info
If no button is pressed for 10–12 seconds, or if an
impulse comes from the wheel speed sensor, the
settings are automatically saved and the setup menu is
closed.
7.4
Setting the combination instrument
Info
When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.
Condition
The motorcycle is stationary.
–
Repeatedly press the button
bottom right of the display.
–
Press the button
briefly until H appears at the
for 2–3 seconds.
The Setup menu is displayed and the active functions are
shown.
Info
If no button is pressed for 10–12 seconds, the settings
are automatically saved.
If no button is pressed for 20 seconds, or if an impulse
comes from the wheel speed sensor, the settings are
automatically saved and the setup menu is closed.
400318-01
–
Repeatedly press the button
tion flashes.
briefly until the desired func-
The selected function flashes.
Activating the function
– Press the button
.
The symbol continues to appear in the display and the
next function appears.
Deactivating a function
– Press the button
.
The symbol disappears in the display and the next
function appears.
26
COMBINATION INSTRUMENT 7
7.5
Setting the clock
Condition
The motorcycle is stationary.
–
Repeatedly press the button
bottom right of the display.
–
Press the button
–
Adjust the hour display with the button
–
Wait 3 - 5 seconds.
briefly until CLK appears at the
for 2–3 seconds.
The hour display flashes.
and/or button
.
The next segment of the display flashes and can be set.
–
400330-01
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.
If no button is pressed for 15–20 seconds, or if an
impulse comes from the wheel speed sensor, the
settings are automatically saved and the setup menu is
closed.
7.6
Viewing the lap time
Info
This function can only be opened if lap times have actually been timed.
Condition
The motorcycle is stationary.
–
Repeatedly press the button
bottom right of the display.
–
Briefly press the button
briefly until LAP appears at the
.
LAP 1 appears on the left side of the display.
–
The laps 1–10 can be viewed with the button
–
Press and hold the button
–
Briefly press the button
.
for 3-5 seconds.
The lap times are deleted.
400321-01
.
Next display mode
Info
When an impulse is received from the wheel speed sensor, the left side of the display changes back to the
SPEED mode.
27
7 COMBINATION INSTRUMENT
7.7
Display mode SPEED (speed)
–
Repeatedly press the button
the left side of the display.
briefly until SPEED appears on
The current speed is displayed in the SPEED display mode.
The current speed can be displayed in Km/h or Mph.
Info
Make the setting according to the country.
When an impulse comes from the front wheel, the left side
of the display changes to the SPEED mode and the current
speed is shown.
400317-02
7.8
Display mode SPEED/H (operating hours)
Condition
• The motorcycle is stationary.
–
Repeatedly press the button
bottom right of the display.
briefly until H appears at the
In display mode H, the operating hours of the engine are
displayed.
The operating hour counter stores the total traveling time.
Info
400316-01
7.9
The operating hour counter is necessary for ensuring that
service work is carried out at the right intervals.
If the combination instrument is in H display mode when
starting off, it automatically changes to the ODO display
mode.
The H display mode is suppressed during the journey.
Press the button for 2–3
seconds.
The display changes to the functions setup
menu.
Briefly press
the button .
Next display mode
Press the button for 2–3
seconds.
No function
Briefly press
the button .
No function
Setup menu
Condition
• The motorcycle is stationary.
–
Repeatedly press the button
bottom right of the display.
–
Press the button
briefly until H appears at the
for 2–3 seconds.
The Setup menu displays the active functions.
400344-01
28
COMBINATION INSTRUMENT 7
Info
Repeatedly press the button briefly until the desired
function is reached.
If no button is pressed for 20 seconds, the settings are
automatically saved.
7.10
Briefly press
the button .
Activates the flashing display and changes to
the next display
Press the button for 2–3
seconds.
No function
Briefly press
the button .
Deactivates the flashing display and changes to
the next display
Press the button for 2–3
seconds.
No function
Wait 3 - 5
seconds.
Changes to the next display without changes
Wait 10 - 12
seconds.
Setup menu starts, stores the settings, and
changes to H or ODO.
Adjusting the unit of measurement
Condition
• The motorcycle is stationary.
–
Repeatedly press the button
bottom right of the display.
–
Press the button
–
Repeatedly press the button
briefly until H appears at the
for 2–3 seconds.
briefly until Km/h/Mph flashes.
In measurement unit mode, you can change the unit of measurement.
400329-01
Info
If no button is pressed for 5 seconds, the settings are automatically saved.
Briefly press
the button .
Starts selection, activates Km/h display
Press the button for 2–3
seconds.
No function
Briefly press
the button .
Activates Mph display
Press the button for 2–3
seconds.
No function
Wait 3 - 5
seconds.
Changes to the next display, changes from
selection to the Setup menu
Wait 10 - 12
seconds.
Stores and closes the Setup menu
29
7 COMBINATION INSTRUMENT
7.11
Display mode SPEED/CLK (time)
–
Repeatedly press the button
bottom right of the display.
briefly until CLK appears at the
The time is shown in display mode CLK.
400319-01
7.12
Press the button for 2–3
seconds.
The display changes to the Setup menu of the
clock.
Briefly press
the button .
Next display mode
Press the button for 2–3
seconds.
No function
Briefly press
the button .
No function
Setting the clock
Condition
• The motorcycle is stationary.
–
Repeatedly press the button
bottom right of the display.
–
Press the button
400319-01
7.13
briefly until CLK appears at the
for 2–3 seconds.
Press the button for 2–3
seconds.
Increases the value
Briefly press
the button .
Increases the value
Press the button for 2–3
seconds.
Reduces the value
Briefly press
the button .
Reduces the value
Wait 3 - 5
seconds.
Changes to the next value
Wait 10 - 12
seconds.
Closes the SETUP menu
Display mode SPEED/LAP (lap time)
–
Repeatedly press the button
bottom right of the display.
briefly until LAP appears at the
In the LAP display mode, up to 10 lap times can be timed with the
stop watch.
Info
400320-01
30
If the lap time continues running after the button
pressed, 9 memory locations are occupied.
Lap 10 must be timed using the button .
is
COMBINATION INSTRUMENT 7
7.14
Press the button for 2–3
seconds.
The stop watch and the lap time are reset.
Briefly press
the button .
Next display mode
Press the button for 2–3
seconds.
Stops the clock.
Briefly press
the button .
Starts the stop watch or stop the current lap
time measurement, stores it and the stop watch
starts the next lap.
Viewing the lap time
Condition
• The motorcycle is stationary.
–
Repeatedly press the button
bottom right of the display.
–
Briefly press the button
400321-01
7.15
briefly until LAP appears at the
.
Press the button for 2–3
seconds.
The stop watch and the lap time are reset.
Briefly press
the button .
Select a lap from 1–10
Press the button for 2–3
seconds.
No function
Briefly press
the button .
View the next lap time.
Display mode SPEED/ODO (odometer)
–
Repeatedly press the button
bottom right of the display.
briefly until ODO appears at the
The total traveled distance is shown in display mode ODO.
400317-01
Press the button for 2–3
seconds.
No function
Briefly press
the button .
Next display mode
Press the button for 2–3
seconds.
No function
Briefly press
the button .
No function
31
7 COMBINATION INSTRUMENT
7.16
Display mode SPEED/TR1 (trip master 1)
–
Repeatedly press the button
top right of the display.
briefly until TR1 appears at the
TR1 (trip master 1) runs constantly and counts up to 999.9.
You can use it to measure trips or the distance between refueling
stops.
TR1 is coupled with A1 (average speed 1) and S1 (stop watch 1).
Info
If 999.9 is exceeded, the values of TR1, A1 and S1 are
automatically reset to 0.0.
400323-01
7.17
Press the button for 2–3
seconds.
Displays of TR1, A1 and S1 are reset to 0,0.
Briefly press
the button .
Next display mode
Press the button for 2–3
seconds.
No function
Briefly press
the button .
No function
Display mode SPEED/TR2 (trip master 2)
–
Repeatedly press the button
top right of the display.
briefly until TR2 appears at the
TR2 (trip master 2) runs constantly and counts up to 999.9.
400324-01
7.18
Press the button for 2–3
seconds.
Clears the values TR2 and A2.
Briefly press
the button .
Next display mode
Press the button for 2–3
seconds.
Reduces value of TR2.
Briefly press
the button .
Reduces value of TR2.
Setting TR2 (trip master 2)
Condition
• The motorcycle is stationary.
–
Repeatedly press the button
top right of the display.
–
Press the button
briefly until TR2 appears at the
for 2–3 seconds until TR2 flashes.
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.
400324-01
32
COMBINATION INSTRUMENT 7
Info
The TR2 value can also be corrected manually during the
journey with the button and the button .
If 999.9 is exceeded, the value of TR2 is automatically
reset to 0.0.
7.19
Press the button for 2–3
seconds.
Increases value of TR2.
Briefly press
the button .
Increases value of TR2.
Press the button for 2–3
seconds.
Reduces value of TR2.
Briefly press
the button .
Reduces value of TR2.
Wait 10 - 12
seconds.
Stores and closes the Setup menu.
Display mode SPEED/A1 (average speed 1)
–
Repeatedly press the button
top right of the display.
briefly until A1 appears at the
A1 (average speed 1) shows the average speed calculated using
TR1 (trip master 1) and S1 (stop watch 1).
The calculation of this value is activated by the first impulse of the
wheel speed sensor and ends 3 seconds after the last impulse.
400325-01
7.20
Press the button for 2–3
seconds.
Displays of TR1, A1 and S1 are reset to 0.0.
Briefly press
the button .
Next display mode
Press the button for 2–3
seconds.
No function
Briefly press
the button .
No function
Display mode SPEED/A2 (average speed 2)
–
Repeatedly press the button
top right of the display.
briefly until A2 appears at 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 S2 was not stopped after the ride.
400326-01
Briefly press
the button .
Next display mode
33
7 COMBINATION INSTRUMENT
7.21
Press the button for 2–3
seconds.
No function
Press the button for 2–3
seconds.
No function
Briefly press
the button .
No function
Display mode SPEED/S1 (stop watch 1)
–
Repeatedly press the button
top right of the display.
briefly until S1 appears at the
S1 (Stop watch 1) shows the riding time based on TR1 and continues running as soon as an impulse arrives from the wheel speed
sensor.
The calculation of this value starts with the first impulse from the
wheel speed sensor and ends 3 seconds after the last impulse.
400327-01
7.22
Press the button for 2–3
seconds.
Displays of TR1, A1 and S1 are reset to 0.0.
Briefly press
the button .
Next display mode
Press the button for 2–3
seconds.
No function
Briefly press
the button .
No function
Display mode SPEED/S2 (stop watch 2)
–
Repeatedly press the button
top right of the display.
briefly until S2 appears at the
S2 (Stop watch 2) is a manual stop watch.
If S2 is running in the background, the display S2 flashes.
400328-01
34
Press the button for 2–3
seconds.
The displays of S2 and A2 are set to 0,0.
Briefly press
the button .
Next display mode
Press the button for 2–3
seconds.
No function
Briefly press
the button .
Starts or stops S2.
COMBINATION INSTRUMENT 7
7.23
Table of functions
Display
Press the button for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
Wait 3 - 5
seconds.
Wait 10 - 12
seconds.
Display mode
SPEED/H (operating hours)
The display
changes to
the functions
setup menu.
Next display
mode
No function
No function
Setup menu
No function
Activates
the flashing
display and
changes to
the next display
No function
Deactivates
the flashing
display and
changes to
the next display
Changes to
the next display without
changes
Setup menu
starts, stores
the settings,
and changes
to H or ODO.
Adjusting the
unit of measurement
No function
Starts selection, activates Km/h
display
No function
Activates
Mph display
Changes to
the next display, changes
from selection to the
Setup menu
Stores and
closes the
Setup menu
Display mode
SPEED/CLK
(time)
The display
changes to
the Setup
menu of the
clock.
Next display
mode
No function
No function
Setting the
clock
Increases the
value
Increases the
value
Reduces the
value
Reduces the
value
Changes
to the next
value
Closes the
SETUP menu
Display mode
SPEED/LAP (lap
time)
The stop
watch and
the lap time
are reset.
Next display
mode
Stops the
clock.
Starts the
stop watch or
stop the current lap time
measurement, stores
it and the
stop watch
starts the
next lap.
Viewing the lap
time
The stop
watch and
the lap time
are reset.
Select a lap
from 1–10
No function
View the next
lap time.
Display mode
SPEED/ODO
(odometer)
No function
Next display
mode
No function
No function
Display mode
SPEED/TR1 (trip
master 1)
Displays of
TR1, A1 and
S1 are reset
to 0,0.
Next display
mode
No function
No function
Display mode
SPEED/TR2 (trip
master 2)
Clears the
values TR2
and A2.
Next display
mode
Reduces
value of TR2.
Reduces
value of TR2.
35
7 COMBINATION INSTRUMENT
Display
Press the button for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
Setting TR2
(trip master 2)
Increases
value of TR2.
Increases
value of TR2.
Reduces
value of TR2.
Reduces
value of TR2.
Display mode
SPEED/A1 (average speed 1)
Displays of
TR1, A1 and
S1 are reset
to 0.0.
Next display
mode
No function
No function
Display mode
SPEED/A2 (average speed 2)
No function
Next display
mode
No function
No function
Display mode
SPEED/S1 (stop
watch 1)
Displays of
TR1, A1 and
S1 are reset
to 0.0.
Next display
mode
No function
No function
Display mode
SPEED/S2 (stop
watch 2)
The displays
of S2 and
A2 are set to
0,0.
Next display
mode
No function
Starts or
stops S2.
7.24
Wait 3 - 5
seconds.
Wait 10 - 12
seconds.
Stores and
closes the
Setup menu.
Table of conditions and menu activation
Display
The motorcycle is
stationary.
Display mode SPEED/H (operating hours)
•
Setup menu
•
Adjusting the unit of measurement
•
Setting the clock
•
Display mode SPEED/LAP (lap time)
Viewing the lap time
Menu can be activated
•
•
Display mode SPEED/TR1 (trip master 1)
•
Display mode SPEED/TR2 (trip master 2)
•
Setting 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)
•
36
PREPARING FOR USE 8
8.1
Advice on preparing for first use
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
–
Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
–
Do not operate the vehicle if you are physically or mentally impaired.
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
–
Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket
with protectors on all rides.
–
Always wear protective clothing that is in good condition and meets the legal regulations.
Warning
Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling characteristic.
Different tire tread patterns can make the vehicle significantly more difficult to control.
–
Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.
Warning
Danger of accidents An unadapted riding style impairs the handling characteristic.
–
Adapt your riding speed to the road conditions and your riding ability.
Warning
Danger of accidents The vehicle is not designed to carry passengers.
–
Do not ride with a passenger.
Warning
Danger of accidents The brake system fails in the event of overheating.
If the foot brake lever is not released, the brake linings drag continuously.
–
Take your foot off the foot brake lever when you are not braking.
Warning
Danger of accidents Total weight and axle loads influence the handling characteristic.
–
Do not exceed the maximum permissible overall weight or the axle loads.
Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
–
Do not leave the vehicle unattended if the engine is running.
–
Protect the vehicle against access by unauthorized persons.
Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.
–
Make sure that the pre-sales inspection work has been carried out by an authorized KTM workshop.
You will receive a delivery certificate when the vehicle is handed over.
–
Before riding for the first time, read the entire Owner's Manual carefully.
–
Get to know the controls.
–
Adjust basic position of the clutch lever. (
p. 96)
37
8 PREPARING FOR USE
(All EU models)
– Adjust the free travel of the handbrake lever. (
p. 100)
(XCF‑W)
– Adjust the basic position of the hand brake lever. (
p. 101)
–
Adjust the basic position of the foot brake lever.
–
Adjust the basic position of the shift lever.
–
Get used to the handling characteristics of the motorcycle on a suitable surface before undertaking more challenging trips.
(
(
p. 109)
p. 142)
Info
When offroad, it is recommended that you are accompanied by another person on another vehicle so
that you can help each other.
–
Try also to ride as slowly as possible and in a standing position to get a better feel for the motorcycle.
–
Do not make any off-road trips that exceed your ability and experience.
–
Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
–
If you carry any luggage, make sure you fix it firmly as close as possible to the center of the vehicle and
ensure even weight distribution between the front and rear wheels.
Info
Motorcycles react sensitively to any changes of weight distribution.
–
Do not exceed the maximum permissible weight and maximum permissible axle loads.
Guideline
Maximum permissible overall weight
–
335 kg (739 lb.)
Maximum permissible front axle load
145 kg (320 lb.)
Maximum permissible rear axle load
190 kg (419 lb.)
Check the spoke tension. (
p. 120)
Info
The spoke tension must be checked after half an hour of operation.
–
Run in the engine. (
8.2
–
p. 38)
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
7,000 rpm
Maximum engine performance
During the first 3 operating hours
–
38
Avoid fully opening the throttle!
≤ 75 %
PREPARING FOR USE 8
8.3
Starting power of lithium-ion batteries at low temperatures
Lithium-ion batteries are far lighter than lead batteries, have a low
self-discharge rate, and have more starting power at temperatures
over 15 °C (60 °F). At low temperatures, however, the starting
power of lithium-ion batteries drops to below that of lead batteries.
Multiple starting attempts may be needed. Press the start button
for 5 seconds, and wait 30 seconds between attempts. The pauses
are necessary so that the heat created can distribute through the
lithium-ion battery and the lithium-ion battery is not damaged.
If the charged lithium-ion battery is unable to actuate the electric
starter when temperatures are below 15 °C (60 °F), the battery is
not faulty, but needs to be warmed up internally to increase its
starting power (current output).
The starting power increases as the battery warms up.
402555-01
8.4
Preparing the vehicle for difficult riding conditions
Info
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can lead to
considerably more rapid wear of components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.
–
Clean the air filter and air filter box.
(
p. 82)
Info
Check the air filter approx. every 30 minutes.
–
Seal the air filter box.
–
Check the connector for humidity and corrosion and to ensure it is firmly seated.
»
If humidity, corrosion, or damage is found:
–
Clean and dry the connector, or change it if necessary.
Difficult riding conditions are:
– Rides on dry sand. (
p. 39)
–
Rides on wet sand. (
–
Rides on wet and muddy circuits. (
–
Rides at high temperatures or slow riding. (
–
Riding at low temperatures and in snow. (
8.5
p. 40)
p. 41)
p. 41)
p. 42)
Preparing the vehicle for riding on dry sand
–
Mount the air filter dust cover.
Air filter dust cover (79006920000)
Info
Observe the fitting instructions for KTM PowerParts.
102136-01
39
8 PREPARING FOR USE
–
Mount the air filter sand cover.
Air filter sand cover (79006922000)
Info
Observe the fitting instructions for KTM PowerParts.
102138-01
–
Clean the chain.
Chain cleaner (
p. 166)
–
Mount the steel sprocket.
–
Grease the chain.
Universal oil spray (
p. 167)
–
Clean the radiator fins.
–
Straighten the bent radiator fins carefully.
600868-01
(All 450 models)
– Change the clutch spring.
Clutch spring, hard (78932005000)
M01459-01
8.6
Preparing the vehicle for riding on wet sand
–
Mount the air filter rain cover.
Air filter rain cover (79006921000)
Info
Observe the fitting instructions for KTM PowerParts.
102137-01
–
Clean the chain.
Chain cleaner (
p. 166)
–
Mount the steel sprocket.
–
Grease the chain.
Universal oil spray (
600868-01
40
p. 167)
–
Clean the radiator fins.
–
Straighten the bent radiator fins carefully.
PREPARING FOR USE 8
(All 450 models)
– Change the clutch spring.
Clutch spring, hard (78932005000)
M01459-01
8.7
Preparing the vehicle for riding on wet and muddy circuits
–
Mount the air filter rain cover.
Air filter rain cover (79006921000)
Info
Observe the fitting instructions for KTM PowerParts.
102137-01
–
Mount the steel sprocket.
–
Clean motorcycle. (
–
Straighten the bent radiator fins carefully.
p. 148)
600868-01
(All 450 models)
– Change the clutch spring.
Clutch spring, hard (78932005000)
M01459-01
8.8
Preparing vehicle for high temperatures or slow riding
–
Adjust the secondary drive to the road conditions.
Info
The engine oil heats up quickly when the clutch is
operated frequently due to an excessively high secondary ratio.
–
600868-01
Clean the chain.
Chain cleaner (
–
p. 166)
Clean the radiator fins.
41
8 PREPARING FOR USE
8.9
–
Straighten the bent radiator fins carefully.
–
Check the coolant level. (
p. 134)
Preparing the vehicle for low temperatures or snow
–
Mount the air filter rain cover.
Air filter rain cover (79006921000)
Info
Observe the fitting instructions for KTM PowerParts.
102137-01
42
RIDING INSTRUCTIONS 9
9.1
Checks and maintenance measures when preparing for use
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 it is being operated.
H02217-01
–
Check the engine oil level. (
–
Check the electrical system.
–
Check front brake fluid level. (
–
Check the rear brake fluid level. (
–
Check the front brake linings. (
–
Check the rear brake linings. (
–
Check that the brake system is functioning properly.
–
Check the coolant level. (
–
Check for chain dirt accumulation. (
–
Check the chain, rear sprocket, engine sprocket, and chain
guide. ( p. 92)
–
Check the chain tension. (
p. 90)
–
Check the tire condition. (
p. 119)
–
Check tire pressure. (
–
Check the spoke tension. (
p. 144)
p. 102)
p. 110)
p. 104)
p. 111)
p. 134)
p. 89)
p. 119)
p. 120)
Info
The spoke tension must be checked regularly as incorrect spoke tension will strongly impair riding safety.
9.2
–
Clean the dust boots of the fork legs. (
–
Bleed the fork legs. (
–
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 level.
p. 65)
p. 64)
Starting the vehicle
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
–
Always make sure there is sufficient ventilation when running the engine.
–
Use effective exhaust extraction when starting or running the engine in an enclosed space.
Note
Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.
–
Always run the engine warm at a low speed.
43
9 RIDING INSTRUCTIONS
–
Take the motorcycle off side stand
stand with rubber strap
.
1 and secure the side
2
–
Shift the transmission into neutral.
–
Turn the emergency OFF switch to the position
.
Condition
Ambient temperature: < 20 °C (< 68 °F)
–
Push the cold start button in all the way.
401944-10
–
Press the start button.
Info
Press the start button for a maximum of 5 seconds.
Wait for 30 seconds before a further attempt at starting.
At temperatures below 15 °C (60 °F), several attempts
at starting may be necessary to warm-up the lithium-ion
battery and thereby increase the starting power.
During the starting process, the malfunction indicator
lamp lights up.
400733-01
9.3
Activating traction control (All EXC-F Six Days, XCF‑W)
Warning
Voiding of the government approval for road use and the insurance coverage If the combination switch is
mounted, the vehicle’s road permit, if any, expires.
–
Only operate the vehicle in closed-off areas remote from public road traffic if the combination switch
is installed.
Info
The traction control reduces excessive slip on the rear wheel in favor of more control and propulsion, particularly in wet conditions.
When traction control is switched off, the rear wheel may spin more during high acceleration and on surfaces with low grip.
Traction control can be switched on or off during the ride.
The setting most recently selected is activated again when restarting.
–
Press button TC to switch the traction control on or off.
Guideline
Engine speed
≤ 4,000 rpm
The TC LED lights up when the traction control is activated.
H02885-01
44
RIDING INSTRUCTIONS 9
9.4
Starting off
Info
When you are riding, the side stand must be folded up and secured with the rubber strap.
–
Pull the clutch lever, shift into first gear, release the clutch lever slowly and at the same time open the throttle carefully.
9.5
Shifting, riding
Warning
Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine
races.
–
Do not change into a low gear at high engine speed.
Info
If unusual noises occur while riding, stop immediately, switch off the engine and contact an authorized
KTM workshop.
First-gear is used for starting off and for steep inclines.
–
Shift into a higher gear when conditions allow (incline, road situation, etc.). To do so, release the throttle
while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever and open the
throttle.
–
After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This
will barely reduce the speed, but fuel consumption will be considerably lower.
–
Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel consumption.
–
To shift down, apply the brakes and close the throttle at the same time.
–
Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and either open the throttle or
shift again.
–
Switch off the engine if running at idle speed or stationary for a long time.
Guideline
≥ 2 min
–
Avoid frequent and lengthy slipping of the clutch. This causes the engine oil, engine and cooling system to
heat up.
–
Ride at a low engine speed instead of at a high engine speed with a slipping clutch.
9.6
Braking
Warning
Danger of accidents Excessively forceful application of the brakes blocks the wheels.
–
Adjust application of the brakes to the respective riding situation and riding surface conditions.
Warning
Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency.
–
Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
45
9 RIDING INSTRUCTIONS
Warning
Danger of accidents Moisture and dirt impair the brake system.
–
Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs.
–
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.
–
Make use of the braking effect of the engine when driving down long downhill stretches. To do so, shift back
one or two gears, but do not overrev the engine. You will need to apply the brakes far less often and the brake
system will not overheat.
9.7
Stopping, parking
Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
–
Do not leave the vehicle unattended if the engine is running.
–
Protect the vehicle against access by unauthorized persons.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
–
Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system
before the vehicle parts have cooled down.
–
Let the vehicle parts cool down before you perform any work on the vehicle.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
–
Do not park the vehicle near to materials which are highly flammable or explosive.
–
Allow the vehicle to cool down before covering it.
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
–
Park the vehicle on a firm and level surface.
–
Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
–
Apply brakes on the motorcycle.
–
Shift the transmission into neutral.
–
Press and hold the switch-off button
–
Park the motorcycle on firm ground.
46
while the engine is idling until the engine stops.
RIDING INSTRUCTIONS 9
9.8
Transporting
Note
Danger of damage The parked vehicle can roll away or fall over.
–
Park the vehicle on a firm and level surface.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
–
Do not park the vehicle near to materials which are highly flammable or explosive.
–
Allow the vehicle to cool down before covering it.
–
Switch off the engine.
–
Use tension belts or other suitable devices to secure the
motorcycle against falling over or rolling away.
401475-01
9.9
Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–
Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–
Switch off the engine for refueling.
–
Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–
If any fuel is spilled, wipe it off immediately.
–
Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–
Avoid skin, eye and clothing contact with fuel.
–
Immediately consult a doctor if you swallow fuel.
–
Do not inhale fuel vapors.
–
In case of skin contact, rinse the affected area with plenty of water.
–
Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–
Change your clothing in case of fuel spills on them.
Note
Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged.
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in
problems with the fuel system.
–
Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to
help.)
47
9 RIDING INSTRUCTIONS
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
–
Do not allow fuel to enter the groundwater, the soil, or the sewage system.
–
Switch off engine.
–
Open fuel tank filler cap. (
–
Fill the fuel tank with fuel up to measurement
p. 20)
A.
Guideline
Measurement of
401226-10
–
48
35 mm (1.38 in)
A
Total fuel tank
capacity, approx.
(All EU models)
9l
(2.4 US gal)
Super unleaded
(ROZ 95/RON
95/PON 91)
( p. 165)
Total fuel tank
capacity, approx.
(XCF‑W)
8.5 l
(2.25 US gal)
Super unleaded
(ROZ 95/RON
95/PON 91)
( p. 165)
Close the fuel tank filler cap. (
p. 20)
SERVICE SCHEDULE 10
10.1
Additional information
Any further work that results from the compulsory work or from the recommended work must be ordered separately and invoiced separately.
Different service intervals may apply in your country, depending on the local operating conditions.
Individual service intervals and scopes may change in the course of technical developments. The most up-to-date
service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise
you.
10.2
Required work
Every 10 operating hours when used for motorsports
Every 45 operating hours
Every 30 operating hours
Every 15 operating hours
After 1 operating hour
Read out the fault memory using the KTM diagnostics tool.
○
●
●
●
●
Check that the electrical system is functioning properly.
○
●
●
●
●
Check and charge the 12-V battery.
●
●
●
●
Check the front brake linings. (
●
●
●
●
●
●
●
●
Check the rear brake linings. (
p. 104)
p. 111)
●
●
●
●
Check the brake lines for damage and leakage.
●
●
●
●
Check the rear brake fluid level. (
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
Check the brake discs. (
p. 101)
p. 110)
Check the free travel of the foot brake lever. (
Check the frame.
(
Check the link fork.
p. 108)
p. 94)
(
p. 94)
●
Check the fork bearing for play.
●
●
●
○
●
●
●
●
○
●
●
●
●
Check the wheel bearing for play.
●
●
●
●
Check the wheel hubs.
●
●
●
●
○
●
●
●
○
●
●
●
●
●
●
●
●
Check the heim joint for play.
Check the tire condition. (
Check tire pressure. (
p. 119)
p. 119)
Check the rim run-out.
Check the spoke tension. (
p. 120)
Check the chain, rear sprocket, engine sprocket, and chain guide. (
p. 92)
●
●
●
●
Grease all moving parts (e.g. side stand, hand lever, chain, etc.) and check for smooth
operation.
●
●
●
●
Check/correct the fluid level of the hydraulic clutch. (
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
Check the chain tension. (
○
p. 90)
Check front brake fluid level. (
p. 96)
p. 102)
Check the free travel of the hand brake lever. (
Check steering head bearing play. (
p. 100)
○
p. 73)
○
Check the valve clearance.
●
●
Check the clutch.
Change the engine oil and oil filter, clean the oil screens.
(
p. 144)
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking,
leaks, and incorrect routing.
●
○
●
●
●
●
○
●
●
●
●
49
10 SERVICE SCHEDULE
Every 10 operating hours when used for motorsports
Every 45 operating hours
Every 30 operating hours
Every 15 operating hours
After 1 operating hour
Check the antifreeze and coolant level. (
p. 133)
○
●
●
●
●
●
●
●
●
○
●
●
●
●
●
●
●
●
Check the cables for damage and for routing without kinks.
Check that the throttle cables are undamaged, routed without sharp bends, and set correctly.
Clean the air filter and air filter box.
(
p. 82)
Change the glass fiber yarn filling of the main silencer.
(
●
p. 85)
●
●
Service the fork.
●
Perform the shock absorber service.
Check the tightness of the easily accessible, safety-relevant screws and nuts.
○
●
●
●
●
Check the headlight setting. (
○
●
●
●
●
○
●
●
●
●
●
●
●
●
●
Change the fuel screen.
(
p. 129)
p. 143)
Check the fuel pressure.
Check the idle speed.
○
●
●
●
Check that the radiator fan is functioning properly.
○
●
●
●
Final check: Check the vehicle is roadworthy and take a test ride.
○
●
●
●
●
Read out the error memory after the test ride using the KTM diagnostics tool.
○
●
●
●
●
Make a service entry in KTM Dealer.net.
○
●
●
●
●
Check the inlet membrane.
○
One-time interval
●
Periodic interval
10.3
●
(XCF‑W)
Recommended work
Every 135 operating hours
Every 70 operating hours when used for motorsports
After 20 operating hours
After 10 operating hours
every 12 months
Change the front brake fluid.
●
Change the rear brake fluid.
●
Change the hydraulic clutch fluid.
(
Lubricate the steering head bearing.
Clean the spark arrestor. (XCF‑W)
Service the fork.
Perform the shock absorber service.
Change the fuel filter.
50
p. 97)
(
(
p. 75)
p. 83)
●
●
●
○
○
●
SERVICE SCHEDULE 10
Every 135 operating hours
Every 70 operating hours when used for motorsports
After 20 operating hours
After 10 operating hours
every 12 months
Perform engine service including removing and installing the engine. (Change the spark
plug and spark plug connector. Change the piston. Check/measure the cylinder. Check
the cylinder head. Change the valves, valve springs, and valve spring seats. Check the
camshaft, rocker arm and rocker arm shafts. Change the connecting rod, conrod bearing
and crank pin. Change the shaft seal ring of the water pump. Check the transmission
and shift mechanism. Check the oil pressure control valve. Change the suction pump.
Check the force pump and lubrication system. Check the timing assembly. Change the
timing chain. Change all engine bearings. Change the freewheel.)
○
One-time interval
●
Periodic interval
●
●
51
11 TUNING THE CHASSIS
11.1
Checking the basic chassis setting with rider's weight
Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
–
For optimal motorcycle riding characteristics and to avoid
damage to forks, shock absorbers, link fork and frame, the
basic settings of the suspension components must match the
rider's weight.
–
As delivered, KTM offroad motorcycles are adjusted for an
average rider's weight (with full protective clothing).
Guideline
Standard rider weight
75 … 85 kg (165 …
187 lb.)
–
If the rider's weight is above or below this 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.
401030-01
11.2
Compression damping of the 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 compression adjuster has an effect, for example, when landing after a jump: the rear wheel suspension compresses quickly.
The low-speed compression adjuster has an effect, for example, when riding over long ground swells: the rear
wheel suspension compresses slowly.
These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, modifications in the high-speed range affect the compression damping in the low-speed range and vice
versa.
11.3
Adjusting the low-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
–
Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
Info
The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock
absorber.
52
TUNING THE CHASSIS 11
–
1
Turn adjusting screw
clockwise with a screwdriver as far as
the last perceptible click.
Info
Do not loosen fitting
–
2!
Turn counterclockwise by the number of clicks corresponding
to the shock absorber type.
Guideline
K01335-10
Low-speed compression damping
Comfort
18 clicks
Standard
15 clicks
Sport
12 clicks
Info
Turn clockwise to increase the damping; turn counterclockwise to reduce the damping.
11.4
Adjusting the high-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
–
Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
Info
The effect of the high-speed compression adjuster can be seen in fast compression of the shock absorber.
–
Using an open end wrench, turn adjusting screw
all the way.
1 clockwise
Info
Do not loosen fitting
–
K01341-10
2!
Turn counterclockwise by the number of turns corresponding
to the shock absorber type.
Guideline
High-speed compression damping
Comfort
2.5 turns
Standard
2 turns
Sport
1 turn
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping during compression.
53
11 TUNING THE CHASSIS
11.5
Adjusting the rebound damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
–
Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
–
Turn adjusting screw
click.
–
Turn counterclockwise by the number of clicks corresponding
to the shock absorber type.
1 clockwise up to the last perceptible
Guideline
Rebound damping
Comfort
V00331-10
18 clicks
Standard
15 clicks
Sport
12 clicks
Info
Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber
rebounds.
11.6
Measuring the dimension of the rear wheel unloaded
Preparatory work
– Raise the motorcycle with the lift stand. (
p. 64)
Main work
– Position the sag gage in the rear axle and measure the
distance to marking SAG on the rear fender.
Sag gauge (00029090100)
Sag gage pin (00029990010)
–
Note the value as dimension
A.
402415-10
Finishing work
– Remove the motorcycle from the lift stand. (
54
p. 64)
TUNING THE CHASSIS 11
11.7
Checking the static sag of the shock absorber
–
Measure dimension
–
Hold the motorcycle upright with aid of an assistant.
–
Measure the distance again between the rear axle and marking SAG on the rear fender using the sag gage.
–
Note the value as dimension
A of rear wheel unloaded. (
p. 54)
B.
Info
The static sag is the difference between
measurements
and
.
A
–
B
Check the static sag.
Static sag
»
37 mm (1.46 in)
If the static sag is less or more than the specified value:
–
Adjust the spring preload of the shock absorber.
( p. 56)
402416-10
11.8
Checking the riding sag of the shock absorber
–
Measure dimension
–
With another person holding the motorcycle, the rider, wearing full protective clothing, sits on the seat in a normal sitting
position (feet on footrests) and bounces up and down a few
times.
–
Another person again measures the distance between the rear
axle and marking SAG on the rear fender using the sag gage.
–
Note the value as dimension
A of rear wheel unloaded. (
p. 54)
The rear wheel suspension levels out.
C.
Info
The riding sag is the difference between
measurements
and
.
A
–
Check riding sag.
Riding sag
»
402417-10
C
110 mm (4.33 in)
If the riding sag differs from the specified measurement:
–
Adjust the riding sag.
(
p. 57)
55
11 TUNING THE CHASSIS
11.9
Adjusting the spring preload of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
–
Please follow 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 spring
length.
Preparatory work
– Raise the motorcycle with the lift stand. (
p. 64)
–
Remove the shock absorber.
–
After removing the shock absorber, clean it thoroughly.
Main work
– Loosen screw
–
(
p. 78)
1.
Turn adjusting ring
sion.
2 until the spring is no longer under ten-
Hook wrench (90129051000)
Info
If the spring cannot be fully released, the spring must
be removed to accurately measure the spring length.
–
Measure the total spring length while the spring is not under
tension.
–
Tension the spring by turning adjusting ring
dimension
.
2 to specified
A
Guideline
Spring preload
8 mm (0.31 in)
Info
402659-10
Depending on the static sag and/or the riding sag, it
may be necessary to increase or decrease the spring
preload.
–
Tighten screw
1.
Guideline
Screw, shock
absorber adjusting
ring
M5
Finishing work
– Install the shock absorber.
–
56
5 Nm (3.7 lbf ft)
(
p. 78)
Remove the motorcycle from the lift stand. (
p. 64)
TUNING THE CHASSIS 11
11.10
Adjusting the riding sag
Preparatory work
– Raise the motorcycle with the lift stand. (
p. 64)
–
Remove the shock absorber.
–
After removing the shock absorber, clean it thoroughly.
(
p. 78)
Main work
– Choose and mount a suitable spring.
Guideline
Spring rate
B00292-10
Weight of rider: 65 …
75 kg (143 … 165 lb.)
60 … 66 N/mm (343 …
377 lb/in)
Weight of rider: 75 …
85 kg (165 … 187 lb.)
63 … 69 N/mm (360 …
394 lb/in)
Weight of rider: 85 …
95 kg (187 … 209 lb.)
66 … 72 N/mm (377 …
411 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.
Finishing work
– Install the shock absorber.
11.11
(
p. 78)
–
Remove the motorcycle from the lift stand. (
p. 64)
–
Check the static sag of the shock absorber. (
p. 55)
–
Check the riding sag of the shock absorber. (
p. 55)
–
Adjust the rebound damping of the shock absorber. (
p. 54)
Checking the basic setting of the fork
Info
For various reasons, no exact riding sag can be determined for the fork.
–
As with the shock absorber, smaller differences in the rider's
weight can be compensated by the spring preload.
–
However, if the fork frequently bottoms out (hard end stop on
compression), harder springs must be fitted to avoid damage
to the fork and frame.
–
If the fork feels unusually hard after extended periods of operation, the fork legs need to be bled.
401000-01
57
11 TUNING THE CHASSIS
11.12
Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
(EXC‑F EU, XCF‑W)
– Turn white adjuster
1 clockwise as far as it will go.
Info
1
Adjuster
is located at the upper end of the left
fork leg.
The compression damping is located in left fork
leg COMP (white adjuster). The rebound damping is
located in right fork leg REB (red adjuster).
S03470-10
–
Turn counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping
Comfort
18 clicks
Standard
15 clicks
Sport
12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping during compression.
(All EXC-F Six Days)
– Turn white adjuster
1 clockwise as far as it will go.
Info
1
Adjuster
is located at the upper end of the left
fork leg.
The compression damping is located in left fork
leg COM (white adjuster). The rebound damping is
located in right fork leg REB (red adjuster).
S03471-10
–
Turn counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping
Comfort
18 clicks
Standard
15 clicks
Sport
12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping during compression.
58
TUNING THE CHASSIS 11
11.13
Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
(EXC‑F EU, XCF‑W)
– Turn red adjuster
1 clockwise as far as it will go.
Info
1
Adjuster
is located at the upper end of the right
fork leg.
The rebound damping is located in right fork
leg REB (red adjuster). The compression damping is
located in left fork leg COMP (white adjuster).
V01754-10
–
Turn counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
Comfort
18 clicks
Standard
15 clicks
Sport
12 clicks
Info
Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock
absorber rebounds.
(All EXC-F Six Days)
– Turn red adjuster
1 clockwise as far as it will go.
Info
1
Adjuster
is located at the upper end of the right
fork leg.
The rebound damping is located in right fork
leg REB (red adjuster). The compression damping is
located in left fork leg COM (white adjuster).
V01753-10
–
Turn counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
Comfort
18 clicks
Standard
15 clicks
Sport
12 clicks
Info
Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock
absorber rebounds.
59
11 TUNING THE CHASSIS
11.14
Adjusting the spring preload of the fork (All EXC-F Six Days)
Preparatory work
– Raise the motorcycle with the lift stand. (
Main work
– Turn T-grips
p. 64)
1 counterclockwise all the way.
The marking +0 aligns with the right wing.
Info
Make the adjustment by hand only. Do not use a tool.
Make the same adjustment on both fork legs.
–
V01755-10
Turn the T-grips clockwise.
Guideline
Spring preload - Preload Adjuster
Comfort
+0
Standard
+0
Sport
+3
The T-grips engage noticeably at the numerical values.
Info
Adjust the spring preload to the numerical values only
as the preload will not engage between the numerical
values.
Turn clockwise to increase the spring preload; turn
counterclockwise to reduce the spring preload.
Adjusting the spring preload has no influence on the
absorption setting of the rebound.
Basically, however, you should set the rebound damping higher with a higher spring preload.
Finishing work
– Remove the motorcycle from the lift stand. (
60
p. 64)
TUNING THE CHASSIS 11
11.15
Handlebar position
(EXC‑F EU, XCF‑W)
On the upper triple clamp, there are 2 holes at a distance
of
to each other.
A
Hole distance
A
15 mm (0.59 in)
The holes on the handlebar supports are placed at a distance
of
from the center.
B
Hole distance
B
3.5 mm (0.138 in)
The handlebar holders can be mounted in four different positions.
M00993-10
(All EXC-F Six Days)
On the upper triple clamp, there are 2 holes at a distance
of
to each other.
A
Hole distance
A
15 mm (0.59 in)
The holes on the handlebar supports are placed at a distance
of
from the center.
B
Hole distance
B
3.5 mm (0.138 in)
The handlebar holders can be mounted in four different positions.
M00987-10
11.16
Adjusting the handlebar position
Warning
Danger of accidents A repaired handlebar poses a safety risk.
If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a
result.
–
Change the handlebar if the handlebar is damaged or bent.
61
11 TUNING THE CHASSIS
(EXC‑F EU, XCF‑W)
– Remove screws
. Take off the handlebar clamps.
Remove the handlebar and lay it to one side.
1
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
–
Remove screws
–
Place the handlebar supports in the required position.
Mount and tighten screws
.
2. Take off the handlebar supports.
2
Guideline
Screw, handlebar holder
M10
40 Nm (29.5 lbf ft)
Loctite®243™
Info
Position the left and right handlebar supports
evenly.
M00993-11
–
Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
–
Position the handlebar clamps. Mount screws
tighten evenly.
1 and
Guideline
Screw, handlebar
clamp
M8
20 Nm
(14.8 lbf ft)
Info
Make sure the gap widths are even.
62
TUNING THE CHASSIS 11
(All EXC-F Six Days)
– Remove screws
. Take off the handlebar clamps.
Remove the handlebar and lay it to one side.
1
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
–
Remove screws
–
Place the handlebar supports in the required position.
Mount and tighten screws
.
2. Take off the handlebar supports.
2
Guideline
Screw, handlebar holder
M10
40 Nm (29.5 lbf ft)
Loctite®243™
Info
Position the left and right handlebar supports
evenly.
M00987-11
–
Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
–
Position the handlebar clamps. Mount screws
tighten evenly.
1 and
Guideline
Screw, handlebar
clamp
M8
20 Nm
(14.8 lbf ft)
Info
Make sure the gap widths are even.
63
12 SERVICE WORK ON THE CHASSIS
12.1
Raising the motorcycle with the lift stand
Note
Danger of damage The parked vehicle can roll away or fall
over.
–
–
Park the vehicle on a firm and level surface.
Raise the motorcycle at the frame underneath the engine.
Lift stand (78129955100)
Neither wheel is in contact with the ground.
401942-01
–
12.2
Secure the motorcycle against falling over.
Removing the motorcycle from the lift stand
Note
Danger of damage The parked vehicle can roll away or fall over.
–
Park the vehicle on a firm and level surface.
–
Remove the motorcycle from the lift stand.
–
Remove the lift stand.
–
To park the motorcycle, press side stand
to the ground
with your foot and lean the motorcycle on it.
1
Info
When you are riding, the side stand must be folded up
and secured with rubber strap.
401943-10
12.3
Bleeding the fork legs
Preparatory work
– Raise the motorcycle with the lift stand. (
Main work
– Release bleeder screws
p. 64)
1.
Any excess pressure escapes from the interior of the fork.
–
Tighten the bleeder screws.
402556-10
Finishing work
– Remove the motorcycle from the lift stand. (
64
p. 64)
SERVICE WORK ON THE CHASSIS 12
12.4
Cleaning the dust boots of the fork legs
Preparatory work
– Raise the motorcycle with the lift stand. (
–
Remove the fork protector. (
Main work
– Push dust boots
p. 64)
p. 65)
1 of both fork legs downward.
Info
The dust boots remove dust and coarse dirt particles
from the inside fork tubes. Over time, dirt can accumulate behind the dust boots. If this dirt is not removed,
the oil seals behind can start to leak.
K00070-10
Warning
Danger of accidents Oil or grease on the brake discs
reduces the braking effect.
–
–
Always keep the brake discs free of oil and grease.
–
Clean the brake discs with brake cleaner when necessary.
Clean and oil the dust boots and inner fork tubes of both fork
legs.
Universal oil spray (
p. 167)
–
Press the dust boots back into their installation position.
–
Remove excess oil.
Finishing work
– Install the fork protector. (
12.5
p. 66)
–
Remove the motorcycle from the lift stand. (
–
Remove screws
p. 64)
Removing the fork protector
–
1 and take off the clamp.
Remove screws 2 on the left fork leg and take off the left
fork protector.
–
Remove screws
fork protector.
3 on the right fork leg and take off the right
V00332-10
65
12 SERVICE WORK ON THE CHASSIS
12.6
Installing the fork protector
–
Position the fork protector on the left fork leg. Mount and
tighten screws
.
1
Guideline
Remaining screws,
chassis
M6
10 Nm (7.4 lbf ft)
–
Position the brake line, wiring harness, and clamp. Mount and
tighten screws
.
–
Position the fork protector on the right fork leg. Mount and
tighten screws
.
2
3
V00332-11
Guideline
Remaining screws,
chassis
12.7
M6
10 Nm (7.4 lbf ft)
Removing the fork legs
Preparatory work
– Press and hold the switch-off button
idling until the engine stops.
while the engine is
–
Remove the headlight mask with the headlight. (
–
Raise the motorcycle with the lift stand. (
–
Remove the front wheel.
Main work
– Remove screws
(
p. 64)
p. 115)
1 and take off the clamp.
–
Remove the cable tie.
–
Remove screws
–
Allow the brake caliper and brake line to hang loosely to the
side.
2 and take off the brake caliper.
K00545-10
(EXC‑F EU, XCF‑W)
– Loosen screws
–
V01756-10
66
p. 127)
3. Remove the left fork leg.
Loosen screws 4. Remove the right fork leg.
SERVICE WORK ON THE CHASSIS 12
(All EXC-F Six Days)
– Loosen screws
–
3. Remove the left fork leg.
Loosen screws 4. Remove the right fork leg.
V01784-10
12.8
Installing the fork legs
Main work
(EXC‑F EU, XCF‑W)
– Position the fork legs.
Bleeder screws
1 are positioned toward the front.
Info
The rebound damping is located in right fork
leg REB (red adjusting screw). The compression
damping is located in left fork leg COMP (white
adjusting screw).
Grooves are milled into the side of the upper end of
the fork legs. The second milled groove (from the
top) must be flush with the upper edge of the upper
triple clamp.
402556-10
–
Tighten screws
2.
Guideline
Screw, top triple
clamp
–
Tighten screws
M8
20 Nm
(14.8 lbf ft)
M8
15 Nm
(11.1 lbf ft)
3.
Guideline
V01756-11
Screw, bottom
triple clamp
(All EXC-F Six Days)
– Position the fork legs.
Bleeder screws
1 are positioned toward the front.
Info
402556-10
The rebound damping is located in right fork
leg REB (red adjusting screw). The compression
damping is located in left fork leg COM (white
adjusting screw).
Grooves are milled into the side of the upper end of
the fork legs. The second milled groove (from the
top) must be flush with the upper edge of the upper
triple clamp.
67
12 SERVICE WORK ON THE CHASSIS
–
Tighten screws
2.
Guideline
Screw, top triple
clamp
–
Tighten screws
M8
17 Nm
(12.5 lbf ft)
M8
15 Nm
(11.1 lbf ft)
3.
Guideline
Screw, bottom
triple clamp
V01784-11
–
Position the brake caliper, and mount and tighten screws
4.
Guideline
Screw, front
brake caliper
M8
25 Nm (18.4 lbf ft)
Loctite®243™
–
Mount the cable tie.
–
Position the brake line, wiring harness, and clamp. Mount and
tighten screws
.
5
K00546-10
Finishing work
– Install the front wheel.
12.9
(
p. 116)
–
Install the headlight mask with the headlight. (
–
Check the headlight setting. (
Removing the lower triple clamp
p. 128)
p. 129)
(EXC‑F EU, XCF‑W)
Preparatory work
– Press and hold the switch-off button
idling until the engine stops.
while the engine is
–
Remove the headlight mask with the headlight. (
–
Raise the motorcycle with the lift stand. (
–
Remove the front wheel.
–
Remove the fork legs.
–
Remove front fender. (
–
Remove the handlebar cushion.
(
(
p. 127)
p. 64)
p. 115)
p. 66)
p. 76)
Main work
– Open the cable holder in front of the left radiator and detach
the wiring harness.
–
–
–
V01785-10
1.
Remove screw 2.
Loosen screw
Take off the upper triple clamp with the handlebar and hang
them to the side.
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
68
SERVICE WORK ON THE CHASSIS 12
–
Remove O-ring
–
Take off the lower triple clamp with the steering stem.
–
Remove the upper steering head bearing.
3 and protective ring 4.
V01757-10
12.10
Removing the lower triple clamp
(All EXC-F Six Days)
Preparatory work
– Press and hold the switch-off button
idling until the engine stops.
while the engine is
–
Remove the headlight mask with the headlight. (
–
Raise the motorcycle with the lift stand. (
–
Remove the front wheel.
–
Remove the fork legs.
–
Remove front fender. (
–
Remove the handlebar cushion.
(
(
p. 127)
p. 64)
p. 115)
p. 66)
p. 76)
Main work
– Open the cable holder in front of the left radiator and detach
the wiring harness.
–
–
–
1.
Remove screw 2.
Remove screw
Take off the upper triple clamp with the handlebar and hang
them to the side.
Info
V01787-10
Cover the components to protect them against damage.
Do not kink the cables and lines.
–
Remove O-ring
–
Take off the lower triple clamp with the steering stem.
–
Remove the upper steering head bearing.
3 and protective ring 4.
V01788-10
69
12 SERVICE WORK ON THE CHASSIS
12.11
Installing the lower triple clamp
(EXC‑F EU, XCF‑W)
Main work
– Clean the bearing and sealing elements, check for damage,
and grease.
High viscosity grease (
p. 166)
–
Insert the lower triple clamp with the steering stem. Mount
upper steering head bearing.
–
Check whether upper steering head seal
tioned.
–
Slide on protective ring
–
Position the upper triple clamp with the handlebar.
–
Mount screw
–
Secure the wiring harness and the clutch line with the cable
holder.
–
Position the fork legs.
1 is correctly posi-
2 and O-ring 3.
B01605-10
4, but do not tighten yet.
V01785-11
Bleeder screws
5 are positioned toward the front.
Info
The rebound damping is located in right fork leg REB
(red adjuster). The compression damping is located in
left fork leg COMP (white adjuster).
Grooves are milled into the side of the upper end of the
fork legs. The second milled groove (from the top) must
be flush with the upper edge of the upper triple clamp.
V01791-10
–
Tighten screws
6.
Guideline
Screw, top triple
clamp
V01790-10
70
M8
20 Nm (14.8 lbf ft)
SERVICE WORK ON THE CHASSIS 12
–
Tighten screw
4.
Guideline
Screw, top steering
head
–
Tighten screw
M20x1.5
12 Nm (8.9 lbf ft)
M8
20 Nm (14.8 lbf ft)
M8
20 Nm (14.8 lbf ft)
7.
Guideline
Screw, top steering
stem
V01789-10
–
Tighten screws
8.
Guideline
Screw, top triple
clamp
V01790-11
–
Position the brake caliper, and mount and tighten screws
9.
Guideline
Screw, front
brake caliper
M8
25 Nm (18.4 lbf ft)
Loctite®243™
–
Mount the cable ties.
–
Position the brake line, the wiring harness, and the clamp.
Mount and tighten screws
.
bk
V01792-10
Finishing work
– Mount the handlebar cushion.
–
Install front fender. (
–
Install the front wheel.
–
Install the headlight mask with the headlight. (
–
Check that the wiring harness, throttle cables, and brake and
clutch lines can move freely and are routed correctly.
–
Check steering head bearing play. (
–
Remove the motorcycle from the lift stand. (
–
Check the headlight setting. (
p. 77)
(
p. 116)
p. 128)
p. 73)
p. 64)
p. 129)
71
12 SERVICE WORK ON THE CHASSIS
12.12
Installing the lower triple clamp
(All EXC-F Six Days)
Main work
– Clean the bearing and sealing elements, check for damage,
and grease.
High viscosity grease (
p. 166)
–
Position the lower triple clamp with the steering stem. Mount
upper steering head bearing.
–
Check whether upper steering head seal
tioned.
–
Mount protective ring
–
Position the upper triple clamp with the handlebar.
–
Mount screw
–
Secure the wiring harness and the clutch line with the cable
holder.
–
Position the fork legs.
1 is correctly posi-
2 and O-ring 3.
B01604-10
4, but do not tighten yet.
V01787-11
Bleeder screws
5 are positioned toward the front.
Info
The rebound damping is located in right fork leg REB
(red adjuster). The compression damping is located in
left fork leg COM (white adjuster).
Grooves are milled into the side of the upper end of the
fork legs. The second milled groove (from the top) must
be flush with the upper edge of the upper triple clamp.
V01791-10
–
Tighten screws
6.
Guideline
Screw, bottom triple
clamp
V01793-10
72
M8
15 Nm (11.1 lbf ft)
SERVICE WORK ON THE CHASSIS 12
–
Tighten screw
4.
Guideline
Screw, top steering
head
–
M20x1.5
Mount and tighten screw
12 Nm (8.9 lbf ft)
7.
Guideline
Screw, top
steering stem
V01794-10
–
Tighten screws
M8
17 Nm (12.5 lbf ft)
Loctite®243™
8.
Guideline
Screw, top triple
clamp
M8
17 Nm (12.5 lbf ft)
V01793-11
–
Position the brake caliper, and mount and tighten screws
9.
Guideline
Screw, front
brake caliper
M8
25 Nm (18.4 lbf ft)
Loctite®243™
–
Mount the cable ties.
–
Position the brake line, the wiring harness, and the clamp.
Mount and tighten screws
.
bk
V01792-10
Finishing work
– Mount the handlebar cushion.
12.13
–
Install front fender. (
–
Install the front wheel.
–
Install the headlight mask with the headlight. (
–
Check that the wiring harness, throttle cables, and brake and
clutch lines can move freely and are routed correctly.
–
Check steering head bearing play. (
–
Remove the motorcycle from the lift stand. (
–
Check the headlight setting. (
p. 77)
(
p. 116)
p. 128)
p. 73)
p. 64)
p. 129)
Checking steering head bearing play
Warning
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components.
–
Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad
to help.)
73
12 SERVICE WORK ON THE CHASSIS
Info
If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the
bearing seats in the frame can become damaged over time.
Preparatory work
– Raise the motorcycle with the lift stand. (
p. 64)
Main work
– Move the handlebar to the straight-ahead position. Move the
fork legs to and fro in the direction of travel.
Play should not be detectable on the steering head bearing.
»
If there is detectable play:
H01167-01
–
(EXC‑F EU, XCF‑W)
– Adjust steering head bearing play.
(
p. 74)
(All EXC-F Six Days)
– Adjust steering head bearing play.
(
p. 75)
Move the handlebar to and fro over the entire steering range.
It must be possible to move the handlebar easily over the
entire steering range. There should be no detectable detent
positions.
»
If detent positions are detected:
(EXC‑F EU, XCF‑W)
– Adjust steering head bearing play.
(
p. 74)
(All EXC-F Six Days)
– Adjust steering head bearing play.
(
p. 75)
–
Check the steering head bearing and replace if necessary.
Finishing work
– Remove the motorcycle from the lift stand. (
12.14
Adjusting steering head bearing play
(EXC‑F EU, XCF‑W)
Preparatory work
– Raise the motorcycle with the lift stand. (
Main work
(EXC‑F EU)
– Loosen screws
–
p. 64)
p. 64)
1 and 2.
Loosen and retighten screw
3.
Guideline
Screw, top steering
head
M20x1.5
12 Nm (8.9 lbf ft)
–
Using a plastic hammer, tap lightly on the upper triple
clamp to avoid stresses.
–
Tighten screws
K01336-10
1.
Guideline
Screw, top triple
clamp
–
74
Tighten screw
2.
M8
20 Nm
(14.8 lbf ft)
SERVICE WORK ON THE CHASSIS 12
Guideline
Screw, top steering
stem
M8
20 Nm
(14.8 lbf ft)
Finishing work
– Check steering head bearing play. (
–
12.15
p. 73)
Remove the motorcycle from the lift stand. (
Adjusting steering head bearing play
p. 64)
(All EXC-F Six Days)
Preparatory work
– Raise the motorcycle with the lift stand. (
p. 64)
Main work
– Loosen screws
–
1.
Remove screw 2.
–
Loosen and retighten screw
3.
Guideline
Screw, top steering
head
V01795-10
M20x1.5
12 Nm (8.9 lbf ft)
–
Using a plastic hammer, tap lightly on the upper triple clamp
to avoid stresses.
–
Tighten screws
1.
Guideline
Screw, top triple
clamp
–
M8
Mount and tighten screw
17 Nm (12.5 lbf ft)
2.
Guideline
Screw, top
steering stem
M8
17 Nm (12.5 lbf ft)
Loctite®243™
Finishing work
– Check steering head bearing play. (
–
12.16
p. 73)
Remove the motorcycle from the lift stand. (
p. 64)
Lubricating the steering head bearing
(EXC‑F EU, XCF‑W)
– Remove the lower triple clamp.
–
Install the lower triple clamp.
(
(
(All EXC-F Six Days)
– Remove the lower triple clamp.
–
Install the lower triple clamp.
(
(
p. 68)
p. 70)
p. 69)
p. 72)
H02387-01
75
12 SERVICE WORK ON THE CHASSIS
12.17
Removing front fender
Preparatory work
– Press and hold the switch-off button
idling until the engine stops.
–
while the engine is
Remove the headlight mask with the headlight. (
Main work
(EXC‑F EU, XCF‑W)
– Remove screws
1.
V00340-10
–
Remove screws
2. Take off front fender.
V00341-10
(All EXC-F Six Days)
– Remove screws
1.
K00576-10
–
S01321-10
76
Remove screws
2. Take off front fender.
p. 127)
SERVICE WORK ON THE CHASSIS 12
12.18
Installing front fender
Main work
(EXC‑F EU, XCF‑W)
– Position front fender. Mount and tighten screws
1.
Guideline
Remaining screws,
chassis
M6
10 Nm (7.4 lbf ft)
V00340-10
–
Mount and tighten screws
2.
Guideline
Remaining screws,
chassis
M6
10 Nm (7.4 lbf ft)
V00341-10
(All EXC-F Six Days)
– Position front fender. Mount and tighten screws
1.
Guideline
Remaining screws,
chassis
M6
10 Nm (7.4 lbf ft)
K00576-10
–
Mount and tighten screws
2.
Guideline
Remaining screws,
chassis
M6
10 Nm (7.4 lbf ft)
S01321-10
Finishing work
– Install the headlight mask with the headlight. (
–
Check the headlight setting. (
p. 128)
p. 129)
77
12 SERVICE WORK ON THE CHASSIS
12.19
Removing the shock absorber
Preparatory work
– Raise the motorcycle with the lift stand. (
p. 64)
Main work
– Remove screw
and lower the rear wheel with the link fork
as far as possible without blocking the rear wheel. Secure the
rear wheel in this position.
1
–
2
Remove screw
, push splash protector
remove the shock absorber.
3 to the side, and
K01337-10
12.20
Installing the shock absorber
Main work
– Push splash protector
to the side and position the shock
absorber. Mount and tighten screw
.
1
2
Guideline
Screw, top
shock absorber
–
M12
Mount and tighten screw
80 Nm (59 lbf ft)
Loctite®2701™
3.
Guideline
K01337-11
Screw, bottom
shock absorber
M12
80 Nm (59 lbf ft)
Loctite®2701™
Info
The heim joint for the shock absorber on the link fork
is Teflon coated. It must not be lubricated with grease,
nor with any other lubricants. Lubricants dissolve the
Teflon coating, thereby drastically reducing the service
life.
Finishing work
– Remove the motorcycle from the lift stand. (
12.21
Removing the seat
–
S03480-10
78
Remove screw
1 on the left side.
p. 64)
SERVICE WORK ON THE CHASSIS 12
–
Raise the rear of the seat, pull the seat back, and lift it off.
–
Mount the front of the seat on the collar bushings of the fuel
tank, lower the seat at the rear, and push the seat forward.
–
Make sure the seat is locked in correctly.
–
Mount and tighten screw
H02218-10
12.22
Mounting the seat
H02218-11
1.
Guideline
Remaining screws,
chassis
M6
10 Nm (7.4 lbf ft)
S03480-10
12.23
Removing the air filter box cover
Condition
The air filter box cover is secured.
–
Remove the seat. (
–
Remove screw
p. 78)
1.
V01759-10
79
12 SERVICE WORK ON THE CHASSIS
–
Pull off the air filter box cover in area
off at the front.
A laterally and take it
V01759-11
Condition
The air filter box cover is not secured.
–
Pull off the air filter box cover in area
it off at the front.
A laterally and take
V01760-10
12.24
Installing the air filter box cover
Condition
The air filter box cover is secured.
–
Insert the air filter box cover in area
area
.
A and clip it into
B
V01759-12
–
Mount and tighten screw
1.
Guideline
Screw, air filter box
cover
–
Mount the seat. (
EJOT PT®
K60x20-Z
3 Nm (2.2 lbf ft)
p. 79)
V01759-10
Condition
The air filter box cover is not secured.
–
Insert the air filter box cover in area
area
.
A and clip it into
B
–
Insert the air filter box cover in area
area
.
B
V01760-11
80
A and clip it into
SERVICE WORK ON THE CHASSIS 12
12.25
Removing the air filter
Note
Engine damage Unfiltered intake air has a negative effect on the service life of the engine.
Dust and dirt will enter the engine without an air filter.
–
Never start to use the vehicle without an air filter.
Note
Environmental hazard Hazardous substances cause environmental damage.
–
Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Preparatory work
– Remove the air filter box cover. (
Main work
– Detach retaining tab
port.
–
p. 79)
1. Remove air filter with air filter sup-
Remove air filter from air filter support.
K01338-10
12.26
Installing the air filter
Main work
– Mount the clean air filter on the air filter support.
–
Grease the air filter in area
Long-life grease (
A.
p. 166)
H02459-01
–
Insert air filter and position retaining pin
1 in bushing B.
The air filter is correctly positioned.
–
Secure the bottom retaining pin with holding tab
2.
Info
If the air filter is not mounted correctly, dust and dirt
may enter the engine and result in damage.
V01761-10
Finishing work
– Install the air filter box cover. (
p. 80)
81
12 SERVICE WORK ON THE CHASSIS
12.27
Cleaning the air filter and air filter box
Note
Environmental hazard Hazardous substances cause environmental damage.
–
Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.
Preparatory work
– Remove the air filter box cover. (
–
Remove the air filter.
(
p. 79)
p. 81)
Main work
– Wash the air filter thoroughly in special cleaning liquid and
allow it to dry properly.
Air filter cleaner (
p. 166)
Info
Only press the air filter to dry it, never wring it out.
F01027-01
–
Oil the dry air filter with a high-grade air filter oil.
Oil for foam air filter (
–
Clean the air filter box.
–
Check the intake flange for damage and looseness.
Finishing work
– Install the air filter.
–
12.28
p. 166)
(
p. 81)
Install the air filter box cover. (
p. 80)
Preparing air filter box cover for securing
Preparatory work
– Remove the air filter box cover. (
Main work
– Drill a hole at marking
p. 79)
A.
Guideline
Diameter
6 mm (0.24 in)
S03499-10
Finishing work
– Install the air filter box cover. (
82
p. 80)
SERVICE WORK ON THE CHASSIS 12
12.29
Removing the main silencer
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
–
Allow the exhaust system to cool down before performing any work on the vehicle.
–
Detach spring
1.
Spring hook (50305017000C1)
–
Remove screws
–
Position the main silencer. Mount screws
tighten yet.
–
Attach spring
2 and take off the main silencer.
K01339-10
12.30
Installing the main silencer
1, but do not
2.
Spring hook (50305017000C1)
–
Tighten screws
1.
Guideline
K01339-11
12.31
Cleaning the spark arrestor
Remaining screws,
chassis
M6
10 Nm (7.4 lbf ft)
(XCF‑W)
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
–
Allow the exhaust system to cool down before performing any work on the vehicle.
Info
Soot particles accumulate on the screen of the spark arrestor over time.
This changes the performance characteristics.
Preparatory work
– Remove main silencer. (
p. 83)
83
12 SERVICE WORK ON THE CHASSIS
V01736-10
Main work
– Remove screws
1 and take off silencer cap 2 with O-ring 3.
Info
Do not remove the glass fiber yarn filling.
Caution
Danger to health Soot particles irritate the eyes and mucuous membranes.
–
–
–
–
Wear suitable breathing and eye protection when cleaning the main silencer and carbon screen.
4 and screen 5 of the spark arrestor with compressed air.
Mount new O-ring 3 on silencer cap 2.
Position silencer cap 2. Mount and tighten screws 1.
Clean main silencer sleeve
Guideline
Screws on main silencer
Finishing work
– Install the main silencer. (
84
M5
p. 83)
7 Nm (5.2 lbf ft)
SERVICE WORK ON THE CHASSIS 12
12.32
Changing the glass fiber yarn filling of the main silencer
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
–
Allow the exhaust system to cool down before performing any work on the vehicle.
Info
Over time, the fibers of the glass fiber yarn escape and the damper “burns” out.
Not only is the noise level higher, but the performance characteristics change.
Preparatory work
– Remove main silencer. (
Main work
(All EU models)
– Remove screws
p. 83)
1.
–
Take off silencer cap
–
Remove the old glass fiber yarn filling.
–
Clean the parts that need to be reinstalled and check for
damage.
–
Mount the new glass fiber yarn filling
silencer.
–
Mount the O-ring on the silencer cap.
–
Position the silencer cap.
–
Mount and tighten all of the screws.
2 with O-ring 3.
4 in the main
Guideline
Screws on main
silencer
M5
7 Nm (5.2 lbf ft)
V01734-10
(XCF‑W)
– Remove screws
1.
–
Take off silencer cap
–
Remove the old glass fiber yarn filling.
–
Clean the parts that need to be reinstalled and check for
damage.
–
Mount the new glass fiber yarn filling
silencer.
–
Mount the O-ring on the silencer cap.
–
Position the silencer cap.
–
Mount and tighten all of the screws.
2 with O-ring 3.
4 in the main
Guideline
Screws on main
silencer
M5
7 Nm (5.2 lbf ft)
V01735-10
85
12 SERVICE WORK ON THE CHASSIS
Finishing work
– Install the main silencer. (
12.33
p. 83)
Removing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–
Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–
Switch off the engine for refueling.
–
Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–
If any fuel is spilled, wipe it off immediately.
–
Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–
Avoid skin, eye and clothing contact with fuel.
–
Immediately consult a doctor if you swallow fuel.
–
Do not inhale fuel vapors.
–
In case of skin contact, rinse the affected area with plenty of water.
–
Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–
Change your clothing in case of fuel spills on them.
–
Keep fuels correctly in a suitable canister, and out of the reach of children.
Preparatory work
– Remove the seat. (
Main work
– Unplug connector
–
p. 78)
1 of the fuel pump.
2 of the fuel line thoroughly with
Clean plug-in connection
compressed air.
Info
Under no circumstances should dirt enter into the fuel
line. Dirt in the fuel line clogs the injection valve!
V01762-10
–
Disconnect the plug-in connection of the fuel line.
Info
Remaining fuel may flow out of the fuel line.
–
Mount wash cap set
3.
Wash cap set (81212016100)
V01763-10
86
SERVICE WORK ON THE CHASSIS 12
(All EU models)
– Remove screws
–
4.
Hang the horn and horn bracket to one side.
V01764-10
(XCF‑W)
– Remove screws
4.
V01765-10
–
Remove screw
–
Remove the hose from the fuel tank breather.
–
Pull both spoilers laterally off the radiator and lift off the fuel
tank.
5 with the rubber bushing.
V01766-10
V01767-10
12.34
Installing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–
Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–
Switch off the engine for refueling.
–
Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–
If any fuel is spilled, wipe it off immediately.
–
Observe the specifications for refueling.
87
12 SERVICE WORK ON THE CHASSIS
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–
Avoid skin, eye and clothing contact with fuel.
–
Immediately consult a doctor if you swallow fuel.
–
Do not inhale fuel vapors.
–
In case of skin contact, rinse the affected area with plenty of water.
–
Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–
Change your clothing in case of fuel spills on them.
Main work
– Check throttle cable routing. (
p. 94)
–
Position the fuel tank and fit the two spoilers to the sides in
front of the radiator bracket.
–
Make sure that no cables or throttle cables are trapped or damaged.
–
Attach the fuel tank breather hose.
–
Mount and tighten screw
V01767-11
1 with the rubber bushing.
Guideline
Remaining screws,
chassis
M6
10 Nm (7.4 lbf ft)
V01766-11
(All EU models)
– Position the horn with the horn bracket.
–
Mount and tighten screws
2.
Guideline
Remaining screws,
chassis
M6
10 Nm (7.4 lbf ft)
V01764-11
(XCF‑W)
– Mount and tighten screws
2.
Guideline
Remaining screws,
chassis
V01765-11
88
M6
10 Nm (7.4 lbf ft)
SERVICE WORK ON THE CHASSIS 12
–
Plug in connector
–
Remove the wash cap set.
–
Thoroughly clean the plug-in connection of the fuel line using
compressed air.
3 for the fuel pump.
Info
Under no circumstances should dirt enter into the fuel
line. Dirt in the fuel line clogs the injection valve!
V01762-11
–
Lubricate the O-ring and connect plug-in connection
the fuel line.
4 for
Info
Route the cable and fuel line at a safe distance from
the exhaust system.
Finishing work
– Mount the seat. (
12.35
p. 79)
Checking for chain dirt accumulation
–
Check the chain for coarse dirt accumulation.
»
If the chain is very dirty:
–
Clean the chain. (
p. 89)
400678-01
12.36
Cleaning the chain
Warning
Danger of accidents Lubricants on the tires reduces the road grip.
–
Remove lubricants from the tires using a suitable cleaning agent.
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
–
Always keep the brake discs free of oil and grease.
–
Clean the brake discs with brake cleaner when necessary.
Note
Environmental hazard Hazardous substances cause environmental damage.
–
Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
The service life of the chain depends largely on its maintenance.
89
12 SERVICE WORK ON THE CHASSIS
Preparatory work
– Raise the motorcycle with the lift stand. (
p. 64)
Main work
– Rinse off loose dirt with a soft jet of water.
–
Remove old grease residue with chain cleaner.
Chain cleaner (
–
p. 166)
After drying, apply chain spray.
Off-road chain spray (
p. 166)
400725-01
Finishing work
– Remove the motorcycle from the lift stand. (
12.37
p. 64)
Checking the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear
wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the
rear wheel locks or the engine will be damaged.
–
Check the chain tension regularly.
–
Set the chain tension in accordance with the specification.
Preparatory work
– Raise the motorcycle with the lift stand. (
p. 64)
Main work
– Pull the chain at the end of the chain sliding piece upward to
measure chain tension
.
A
Info
1
Lower chain section
must be taut.
When the chain guard is mounted, it must be possible
to pull up the chain at least to the point where it makes
contact with chain guard
.
Chain wear is not always even, so you should repeat
this measurement at different chain positions.
B
Chain tension
»
55 … 58 mm (2.17 …
2.28 in)
If the chain tension does not meet the specification:
–
Adjust the chain tension. (
p. 91)
V00354-10
Finishing work
– Remove the motorcycle from the lift stand. (
90
p. 64)
SERVICE WORK ON THE CHASSIS 12
12.38
Adjusting the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear
wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the
rear wheel locks or the engine will be damaged.
–
Check the chain tension regularly.
–
Set the chain tension in accordance with the specification.
Preparatory work
– Raise the motorcycle with the lift stand. (
–
Check the chain tension. (
Main work
– Loosen nut
p. 64)
p. 90)
1.
2.
–
Loosen nuts
–
Adjust the chain tension by turning adjusting screws
and right.
3 left
Guideline
Chain tension
55 … 58 mm (2.17 …
2.28 in)
3
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.
A
–
Tighten nuts
–
Make sure that chain adjusters
adjusting screws
.
2.
4 are fitted correctly on
3
–
E00330-10
Tighten nut
1.
Guideline
Nut, rear wheel spindle
M20x1.5
80 Nm (59 lbf ft)
Info
The wide adjustment range of the chain adjusters
(32 mm (1.26 in)) enables different secondary ratios
with the same chain length.
Chain adjusters
can be turned by 180°.
4
Finishing work
– Remove the motorcycle from the lift stand. (
p. 64)
91
12 SERVICE WORK ON THE CHASSIS
12.39
Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work
– Raise the motorcycle with the lift stand. (
p. 64)
Main work
– Shift the transmission into neutral.
–
Check the rear sprocket and engine sprocket for wear.
»
If the rear sprocket and engine sprocket are worn:
–
Change the drivetrain kit.
Info
The engine sprocket, rear sprocket and chain
should always be replaced together.
400227-01
–
Pull on the top section of the chain with the specified
weight
.
A
Guideline
Weight of chain wear measurement
–
Measure distance
section.
10 … 15 kg (22 … 33 lb.)
B of 18 chain rollers in the lower chain
Info
Chain wear is not always even, so you should repeat
this measurement at different chain positions.
B
Maximum distance
from
18 chain rollers at the
longest chain section
»
If distance
–
400987-10
272 mm (10.71 in)
B is greater than the specified measurement:
Change the drivetrain kit.
Info
When a new chain is mounted, the rear sprocket
and engine sprocket should also be changed.
New chains wear out faster on old, worn sprockets.
92
SERVICE WORK ON THE CHASSIS 12
–
Check the chain sliding guard for wear.
»
If the lower edge of the chain pins is in line with, or below,
the chain sliding guard:
–
–
Change the chain sliding guard.
Check that the chain sliding guard is firmly seated.
»
If the chain sliding guard is loose:
–
Tighten the screws on the chain sliding guard.
Guideline
Screw, chain
sliding guard
M6
6 Nm (4.4 lbf ft)
Loctite®243™
E00805-10
–
Check the chain sliding piece for wear.
»
If the lower edge of the chain pins is in line with or below
the chain sliding piece:
–
–
Change the chain sliding piece.
Check that the chain sliding piece is firmly seated.
»
If the chain sliding piece is loose:
–
Tighten the screw of the chain sliding piece.
Guideline
Screw, chain sliding piece
M8
15 Nm
(11.1 lbf ft)
E00806-10
–
Check the chain guide for wear.
Info
Wear can be seen on the front of the chain guide.
»
If the light part of the chain guide is worn:
–
Change the chain guide.
401760-01
93
12 SERVICE WORK ON THE CHASSIS
–
Check that the chain guide is firmly seated.
»
If the chain guide is loose:
–
Tighten the screws on the chain guide.
Guideline
Remaining screws,
chassis
M6
10 Nm
(7.4 lbf ft)
Remaining nuts,
chassis
M6
10 Nm
(7.4 lbf ft)
E00333-01
Finishing work
– Remove the motorcycle from the lift stand. (
12.40
p. 64)
Checking the frame
–
Check the frame for cracking and deformation.
»
If the frame exhibits cracking or deformation due to a
mechanical impact:
–
Change the frame.
Info
Always replace a frame that has been damaged due to a mechanical impact. Repair of the
frame is not authorized by KTM.
S01316-10
12.41
Checking the link fork
–
Check the link fork for damage, cracking, and deformation.
»
If the link fork exhibits damage, cracking, or deformation:
–
Change the link fork.
Info
Always replace a damaged link fork. Repairing
the link fork is not authorized by KTM.
S01317-10
12.42
Checking throttle cable routing
Preparatory work
– Remove the seat. (
–
94
p. 78)
Remove the fuel tank.
(
p. 86)
SERVICE WORK ON THE CHASSIS 12
Main work
– Check throttle cable routing.
Both throttle cables must be routed, side by side, on the
back of the handlebars and above the fuel tank bracket, to
the throttle valve body. Both throttle cables must be secured
behind the rubber strap of the fuel tank support.
»
If the throttle cable routing is not as specified:
–
Correct throttle cable routing.
H01695-10
Finishing work
– Install the fuel tank.
12.43
(
p. 87)
–
Mount the seat. (
–
Check the rubber grips on the handlebar for damage, wear,
and looseness.
p. 79)
Checking the rubber grip
Info
The rubber grips are vulcanized onto a sleeve on the
left and onto the handle tube of the throttle grip on the
right. The left sleeve is clamped onto the handlebar.
The rubber grip can only be replaced with the sleeve or
the throttle tube.
401197-01
»
If a rubber grip is damaged, worn, or loose:
–
Change the rubber grip.
(All EU models)
– Check that screw
1 is firmly seated.
Guideline
Screw, fixed
grip
Diamond
figure.
M4
5 Nm (3.7 lbf ft)
Loctite®243™
A must be positioned visibly as shown in the
K01340-10
95
12 SERVICE WORK ON THE CHASSIS
(XCF‑W)
– Check that screw
1 is firmly seated.
Guideline
Screw, fixed
grip
Diamond
figure.
M4
5 Nm (3.7 lbf ft)
Loctite®243™
A must be positioned visibly as shown in the
V01768-10
12.44
Adjusting the basic position of the clutch lever
–
Adjust the basic position of the clutch lever to your hand size
by turning adjusting screw
.
1
Info
E00842-10
12.45
Turn the adjusting screw clockwise to increase the
distance between the clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease
the distance between the clutch lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not
apply any force.
Do not make any adjustments while riding.
Checking/correcting the fluid level of the hydraulic clutch
Warning
Skin irritation Brake fluid causes skin irritation.
–
Keep brake fluid out of the reach of children.
–
Wear suitable protective clothing and safety glasses.
–
Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
–
Consult a doctor immediately if brake fluid has been swallowed.
–
Rinse the affected area with plenty of water in the event of contact with the skin.
–
Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
–
If brake fluid spills on to your clothing, change the clothing.
Note
Environmental hazard Hazardous substances cause environmental damage.
–
Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
The fluid level rises with increasing wear of the clutch facing discs.
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
96
SERVICE WORK ON THE CHASSIS 12
–
Move the clutch fluid reservoir mounted on the handlebar to a
horizontal position.
–
Remove screws
–
1.
Remove cover 2 with membrane 3.
–
Check the fluid level.
Fluid level below container
rim
»
V00456-10
4 mm (0.16 in)
If the fluid level does not meet specifications:
–
Correct the fluid level of the hydraulic clutch.
Brake fluid DOT 4 / DOT 5.1 (
–
p. 164)
Position the cover with the membrane. Mount and tighten the
screws.
Info
Clean up overflowed or spilled brake fluid immediately
with water.
12.46
Changing the hydraulic clutch fluid
Warning
Skin irritation Brake fluid causes skin irritation.
–
Keep brake fluid out of the reach of children.
–
Wear suitable protective clothing and safety glasses.
–
Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
–
Consult a doctor immediately if brake fluid has been swallowed.
–
Rinse the affected area with plenty of water in the event of contact with the skin.
–
Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
–
If brake fluid spills on to your clothing, change the clothing.
Note
Environmental hazard Hazardous substances cause environmental damage.
–
Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
97
12 SERVICE WORK ON THE CHASSIS
–
Move the hydraulic clutch fluid reservoir mounted on the handlebar into a horizontal position.
–
Remove screws
–
1.
Take off cover 2 with membrane 3.
–
Fill bleeding syringe
V00456-10
4 with the appropriate hydraulic fluid.
Syringe (50329050000)
Brake fluid DOT 4 / DOT 5.1 (
–
p. 164)
On the clutch slave cylinder, remove the protection cap,
remove bleeder screw
and mount bleeding syringe
.
5
4
K01342-10
–
Now inject fluid into the system until it escapes from the
opening
of the master cylinder without bubbles.
–
Occasionally extract the fluid from the master cylinder reservoir to prevent overflowing.
–
Remove the bleeding syringe. Mount and tighten the bleeder
screw. Mount the protection cap.
–
Correct the fluid level of the hydraulic clutch.
6
Guideline
Fluid level below container
rim
E01224-10
–
4 mm (0.16 in)
Position the cover with the membrane. Mount and tighten the
screws.
Info
Immediately clean up any brake fluid that has overflowed or spilled with water.
12.47
Removing the engine guard (All EXC-F Six Days, XCF‑W)
–
H01638-10
98
Remove screws
1 and engine guard.
SERVICE WORK ON THE CHASSIS 12
12.48
Installing the engine guard (All EXC-F Six Days, XCF‑W)
–
Attach the engine guard on the frame at the rear and swing up
at the front.
–
Mount and tighten screws
1.
Guideline
Remaining screws,
chassis
M6
10 Nm (7.4 lbf ft)
H01638-10
99
13 BRAKE SYSTEM
13.1
Checking the free travel of the hand brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit.
–
Set the free travel on the hand brake lever in accordance with the specification.
(All EU models)
– Push the hand brake lever to the handlebar and check free
travel
.
A
Free travel of hand brake
lever
»
≥ 3 mm (≥ 0.12 in)
If the free travel does not match the specification:
–
Adjust the free travel of the handbrake lever.
( p. 100)
K01343-10
(XCF‑W)
– Push the hand brake lever forward and check free
travel
.
A
Free travel of hand brake
lever
»
≥ 3 mm (≥ 0.12 in)
If the free travel does not match the specification:
–
Adjust the basic position of the hand brake lever.
( p. 101)
K01344-10
13.2
Adjusting the free travel of the handbrake lever (All EU models)
–
Check the free travel of the hand brake lever. (
–
Adjust the free travel of the handbrake lever with adjustment
screw
.
p. 100)
1
Info
K01343-11
100
Turn the adjusting screw clockwise to reduce free
travel. The pressure point moves away from the
handlebar.
Turn the adjusting 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.
BRAKE SYSTEM 13
13.3
Adjusting the basic position of the hand brake lever (XCF‑W)
–
Check the free travel of the hand brake lever. (
–
Adjust the basic position of the hand brake lever to your hand
size by turning adjusting screw
.
p. 100)
1
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.
K01343-11
13.4
Checking the brake discs
Warning
Danger of accidents Worn-out brake discs reduce the braking effect.
–
Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will
be glad to help.)
–
Check the front and rear brake disc thickness at multiple
points for the dimension
.
A
Info
Wear reduces the thickness of the brake disc around
the contact surface of the brake linings.
Brake discs - wear limit (EXC‑F EU, XCF‑W)
400257-10
front
2.5 mm (0.098 in)
rear
3.5 mm (0.138 in)
Brake discs - wear limit (All EXC-F Six Days)
»
–
front
2.5 mm (0.098 in)
rear
3.7 mm (0.146 in)
If the brake disc thickness is less than the specified value:
–
Change the front brake disc.
–
Change the rear brake disc.
Check the front and rear brake discs for damage, cracking, and
deformation.
»
If the brake disc exhibits damage, cracking, or deformation:
–
Change the front brake disc.
–
Change the rear brake disc.
101
13 BRAKE SYSTEM
13.5
Checking the front brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is
leaking or the brake linings are worn down.
–
Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
Warning
Danger of accidents Old brake fluid reduces the braking effect.
–
Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)
(All EU models)
– Move the brake fluid reservoir mounted on the handlebar to
a horizontal position.
–
Check the brake fluid level in level viewer
»
1.
If the brake fluid level has dropped below the marking
:
A
–
Add the front brake fluid.
(
p. 102)
V01775-10
(XCF‑W)
– Move the brake fluid reservoir mounted on the handlebar to
a horizontal position.
–
Check the brake fluid level in level viewer
»
1.
If the brake fluid level has dropped below the marking
:
A
–
Add the front brake fluid.
(
p. 102)
K01345-10
13.6
Adding the front brake fluid
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is
leaking or the brake linings are worn down.
–
102
Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
BRAKE SYSTEM 13
Warning
Skin irritation Brake fluid causes skin irritation.
–
Keep brake fluid out of the reach of children.
–
Wear suitable protective clothing and safety glasses.
–
Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
–
Consult a doctor immediately if brake fluid has been swallowed.
–
Rinse the affected area with plenty of water in the event of contact with the skin.
–
Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
–
If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
–
Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)
Note
Environmental hazard Hazardous substances cause environmental damage.
–
Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
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.
Only use clean brake fluid from a sealed container.
Preparatory work
– Check the front brake linings. (
p. 104)
Main work
(All EU models)
– Move the brake fluid reservoir mounted on the handlebar to
a horizontal position.
–
–
–
1.
Take off cover 2 with membrane 3.
Add brake fluid to level A.
Remove screws
Guideline
A
Level
(brake fluid level
below reservoir rim)
5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 (
–
p. 164)
Position the cover with the membrane. Mount and tighten
the screws.
Info
Immediately clean up any brake fluid that has overflowed or spilled with water.
V01770-10
103
13 BRAKE SYSTEM
(XCF‑W)
– Move the brake fluid reservoir mounted on the handlebar to
a horizontal position.
–
–
–
1.
Take off cover 2 with membrane 3.
Add brake fluid to level A.
Remove screws
Guideline
A
Level
(brake fluid level
below reservoir rim)
5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 (
–
p. 164)
Position the cover with the membrane. Mount and tighten
the screws.
Info
Immediately clean up any brake fluid that has overflowed or spilled with water.
V01771-10
13.7
Checking the front brake linings
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
–
Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be
glad to help.)
–
Check the brake linings for minimum thickness
Minimum thickness
»
13.8
Change the brake linings of the front brake.
( p. 104)
Check the brake linings for damage and cracking.
»
E00342-10
≥ 1 mm (≥ 0.04 in)
If the minimum thickness is less than specified:
–
–
A
A.
If damage or cracking is visible:
–
Change the brake linings of the front brake.
( p. 104)
Changing the brake linings of the front brake
Warning
Danger of accidents Incorrect servicing will cause the brake system to fail.
–
104
Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop
will be glad to help.)
BRAKE SYSTEM 13
Warning
Skin irritation Brake fluid causes skin irritation.
–
Keep brake fluid out of the reach of children.
–
Wear suitable protective clothing and safety glasses.
–
Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
–
Consult a doctor immediately if brake fluid has been swallowed.
–
Rinse the affected area with plenty of water in the event of contact with the skin.
–
Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
–
If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
–
Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
–
Always keep the brake discs free of oil and grease.
–
Clean the brake discs with brake cleaner when necessary.
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient
of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologation is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the
warranty shall be void.
–
Only use brake linings approved and recommended by KTM.
Note
Environmental hazard Hazardous substances cause environmental damage.
–
Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
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.
Only use clean brake fluid from a sealed container.
(All EU models)
– Move the brake fluid reservoir mounted on the handlebar to
a horizontal position.
–
–
–
V01772-10
1.
Take off cover 2 with membrane 3.
Remove screws
Manually press the brake caliper toward the brake disc to
push back the brake pistons. Ensure that brake fluid does
not flow out of the brake fluid reservoir; extract some if
necessary.
105
13 BRAKE SYSTEM
Info
Make sure that you do not press the brake caliper
against the spokes when pushing back the brake
pistons.
–
Remove cotter pin
brake linings.
–
Clean the brake caliper and the brake caliper bracket.
–
Check that spring plate
in the brake caliper and sliding
plate
in the brake caliper bracket are seated properly.
4, pull out pin 5, and remove the
E00344-10
6
7
100397-01
–
Insert the new brake linings, insert the pin, and mount the
cotter pins.
Info
Always change the brake linings in pairs.
–
E00345-10
106
Operate the hand brake lever repeatedly until the brake
linings are in contact with the brake disc and there is a
pressure point.
BRAKE SYSTEM 13
–
Correct the brake fluid quantity to level
A.
Guideline
A
Level
(brake fluid level
below reservoir rim)
5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 (
–
Position cover
screws
.
p. 164)
2 with membrane 3. Mount and tighten
1
Info
Immediately clean up any brake fluid that has overflowed or spilled with water.
V01770-10
(XCF‑W)
– Move the brake fluid reservoir mounted on the handlebar to
a horizontal position.
–
–
–
V01773-10
1.
Take off cover 2 with membrane 3.
Remove screws
Manually press the brake caliper toward the brake disc to
push back the brake pistons. Ensure that brake fluid does
not flow out of the brake fluid reservoir; extract some if
necessary.
Info
Make sure that you do not press the brake caliper
against the spokes when pushing back the brake
pistons.
–
Remove cotter pin
brake linings.
–
Clean the brake caliper and the brake caliper bracket.
4, pull out pin 5, and remove the
E00344-10
107
13 BRAKE SYSTEM
–
6
Check that spring plate
in the brake caliper and sliding
plate
in the brake caliper bracket are seated properly.
7
100397-01
–
Insert the new brake linings, insert the pin, and mount the
cotter pins.
Info
Always change the brake linings in pairs.
–
Operate the hand brake lever repeatedly until the brake
linings are in contact with the brake disc and there is a
pressure point.
–
Correct the brake fluid quantity to level
E00345-10
A.
Guideline
A
Level
(brake fluid level
below reservoir rim)
5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 (
–
Position cover
screws
.
p. 164)
2 with membrane 3. Mount and tighten
1
Info
Immediately clean up any brake fluid that has overflowed or spilled with water.
V01771-10
13.9
Checking the free travel of foot brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear
brake.
–
108
Set the free travel on the foot brake lever in accordance with the specification.
BRAKE SYSTEM 13
–
Disconnect spring
–
Move the foot brake lever back and forth between the end stop
and the contact to the foot brake cylinder piston and check
free travel
.
1.
A
Guideline
Free travel at foot brake lever
»
–
13.10
If the free travel does not meet specifications:
–
402026-10
3 … 5 mm (0.12 … 0.2 in)
Adjust the basic position of the foot brake lever.
( p. 109)
Reconnect spring
1.
Adjusting the basic position of the foot brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear
brake.
–
Set the free travel on the foot brake lever in accordance with the specification.
–
–
1.
Loosen nut 4 and, with push rod 5, turn it back until you
Detach spring
have maximum free travel.
–
To adjust the basic position of the foot brake lever to individual requirements, loosen nut
and turn screw
accordingly.
2
3
Info
The range of adjustment is limited.
–
5
A
Turn push rod
accordingly until you have free travel
. If
necessary, adjust the basic position of the foot brake lever.
Guideline
Free travel at foot brake lever
–
Hold screw
3 … 5 mm (0.12 … 0.2 in)
3 and tighten nut 2.
Guideline
Nut, foot brake lever
stop
K00563-10
–
Hold push rod
M8
20 Nm (14.8 lbf ft)
5 and tighten nut 4.
Guideline
Remaining nuts,
chassis
–
Attach spring
M6
10 Nm (7.4 lbf ft)
1.
109
13 BRAKE SYSTEM
13.11
Checking the rear brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is
leaking or the brake linings are worn down.
–
Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
Warning
Danger of accidents Old brake fluid reduces the braking effect.
–
Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)
–
Stand the vehicle upright.
–
Check the brake fluid level in level viewer
»
1.
If the brake fluid level has dropped below marking
–
Add rear brake fluid.
(
A:
p. 110)
K01346-10
13.12
Adding rear brake fluid
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is
leaking or the brake linings are worn down.
–
Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
–
Keep brake fluid out of the reach of children.
–
Wear suitable protective clothing and safety glasses.
–
Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
–
Consult a doctor immediately if brake fluid has been swallowed.
–
Rinse the affected area with plenty of water in the event of contact with the skin.
–
Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
–
If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
–
110
Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)
BRAKE SYSTEM 13
Note
Environmental hazard Hazardous substances cause environmental damage.
–
Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
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.
Only use clean brake fluid from a sealed container.
Preparatory work
– Check the rear brake linings. (
p. 111)
Main work
– Stand the vehicle upright.
–
–
1 with membrane 2 and the O-ring.
Add brake fluid to level A.
Remove screw cap
Brake fluid DOT 4 / DOT 5.1 (
–
p. 164)
Mount the screw cap with the membrane and the O-ring.
Info
Clean up overflowed or spilled brake fluid immediately
with water.
K01347-10
13.13
Checking the rear brake linings
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
–
Ensure that worn-out brake linings are replaced 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:
–
–
A
A.
Change the rear brake linings.
(
p. 112)
Check the brake linings for damage and cracking.
»
If damage or cracking is visible:
–
Change the rear brake linings.
(
p. 112)
E00349-10
111
13 BRAKE SYSTEM
13.14
Changing the rear brake linings
Warning
Danger of accidents Incorrect servicing will cause the brake system to fail.
–
Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop
will be glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
–
Keep brake fluid out of the reach of children.
–
Wear suitable protective clothing and safety glasses.
–
Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
–
Consult a doctor immediately if brake fluid has been swallowed.
–
Rinse the affected area with plenty of water in the event of contact with the skin.
–
Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
–
If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
–
Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
–
Always keep the brake discs free of oil and grease.
–
Clean the brake discs with brake cleaner when necessary.
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient
of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologation is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the
warranty shall be void.
–
Only use brake linings approved and recommended by KTM.
Note
Environmental hazard Hazardous substances cause environmental damage.
–
Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
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.
Only use clean brake fluid from a sealed container.
112
BRAKE SYSTEM 13
–
Stand the vehicle upright.
–
Remove screw cap
–
Press the brake piston back into the basic position and ensure
that brake fluid does not flow out of the brake fluid reservoir;
extract some if necessary.
1 with membrane 2 and the O-ring.
Info
Make sure that you do not press the brake caliper
against the spokes when pushing back the brake piston.
V01774-10
–
Remove cotter pin
linings.
–
Clean the brake caliper and brake caliper bracket.
–
Check that spring plate
in the brake caliper and sliding
plate
in the brake caliper bracket are seated properly.
3, pull out pin 4, and remove the brake
E00351-10
5
6
E00352-10
–
Insert the new brake linings, insert the pin, and mount the cotter pins.
Info
Always change the brake linings in pairs.
–
Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure
point.
E00353-01
113
13 BRAKE SYSTEM
–
Add brake fluid to level
A.
Brake fluid DOT 4 / DOT 5.1 (
–
Mount screw cap
p. 164)
1 with membrane 2 and O-ring.
Info
Clean up overflowed or spilled brake fluid immediately
with water.
K01347-10
114
WHEELS, TIRES 14
14.1
Removing the front wheel
Preparatory work
– Raise the motorcycle with the lift stand. (
p. 64)
Main work
– Manually press the brake caliper toward the brake disc to push
back the brake pistons.
Info
Make sure that you do not press the brake caliper
against the spokes when pushing back the brake
pistons.
V00363-10
–
–
–
1 by several rotations.
Loosen screws 2.
Press on screw 1 to push the wheel spindle out of the axle
Loosen screw
clamp.
–
Remove screw
1.
V00364-10
Warning
Danger of accidents Damaged brake discs reduce the
braking effect.
–
–
V00365-10
Always lay the wheel down in such a way that the
brake disc is not damaged.
Hold front wheel and remove wheel spindle. Take front wheel
out of the fork.
Info
Do not actuate the hand brake lever when the front
wheel is removed.
–
Remove spacers
3.
H00934-10
115
14 WHEELS, TIRES
14.2
Installing the front wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
–
Always keep the brake discs free of oil and grease.
–
Clean the brake discs with brake cleaner when necessary.
–
Check the wheel bearing for damage and wear.
»
If the wheel bearing is damaged or worn:
–
–
Change front wheel bearing.
Clean and grease shaft seal rings
of the spacers.
Long-life grease (
H00935-10
1 and contact surface A
p. 166)
–
Insert the spacers.
–
Clean and grease the wheel spindle.
Long-life grease (
–
p. 166)
Position the front wheel and insert the wheel spindle.
The brake linings are correctly positioned.
–
Mount and tighten screw
2.
Guideline
Screw, front wheel
spindle
V00364-11
M20x1.5
35 Nm (25.8 lbf ft)
–
Operate the hand brake lever several times until the brake linings are seated correctly against the brake disc.
–
Remove the motorcycle from the lift stand. (
–
Operate the front brake and compress the fork a few times
firmly.
p. 64)
The fork legs straighten.
–
Tighten screws
3.
Guideline
Screw, fork stub
14.3
M8
Removing the rear wheel
Preparatory work
– Raise the motorcycle with the lift stand. (
116
15 Nm (11.1 lbf ft)
p. 64)
WHEELS, TIRES 14
Main work
– Manually press the brake caliper toward the brake disc to push
back the brake piston.
Info
Make sure that you do not press the brake caliper
against the spokes when pushing back the brake piston.
–
Remove nut
–
Take off chain adjuster
. Pull out wheel spindle
enough to allow the rear wheel to be pushed forward.
–
Push the rear wheel forward as far as possible. Remove the
chain from the rear sprocket.
1.
2
3 far
Info
Cover the components to protect them against damage.
Warning
Danger of accidents Damaged brake discs reduce the
braking effect.
V00366-10
–
–
Always lay the wheel down in such a way that the
brake disc is not damaged.
Hold the rear wheel and remove the wheel spindle. Take the
rear wheel out of the link fork.
Info
Do not operate the foot brake lever when the rear wheel
is removed.
–
Remove spacers
4.
H03002-10
14.4
Installing the rear wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
–
Always keep the brake discs free of oil and grease.
–
Clean the brake discs with brake cleaner when necessary.
117
14 WHEELS, TIRES
Main work
– Check the wheel bearing for damage and wear.
»
If the wheel bearing is damaged or worn:
–
–
Change the rear wheel bearing.
Clean and grease shaft seal rings
of the spacers.
Long-life grease (
H03001-10
1 and contact surface A
p. 166)
–
Insert the spacers.
–
Clean and grease the wheel spindle.
Long-life grease (
p. 166)
–
Position the rear wheel and insert wheel spindle
–
Mount the chain.
–
Position chain adjuster
it yet.
–
Make sure that chain adjusters
adjusting screws
.
–
Check the chain tension. (
–
Tighten nut
2.
The brake linings are correctly positioned.
V00367-10
3. Mount nut 4, but do not tighten
3 are fitted correctly on
5
p. 90)
4.
Guideline
Nut, rear wheel spindle
M20x1.5
80 Nm (59 lbf ft)
Info
The wide adjustment range of the chain adjusters
(32 mm (1.26 in)) enables different secondary ratios
with the same chain length.
Chain adjusters
can be turned by 180°.
3
–
V00368-10
Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure
point.
Finishing work
– Remove the motorcycle from the lift stand. (
118
p. 64)
WHEELS, TIRES 14
14.5
Checking the tire condition
Info
Only mount tires approved and/or recommended by KTM.
Other tires could have a negative effect on handling characteristics.
The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the
motorcycle.
The tires mounted on the front and rear wheels must have a similar profile.
Worn tires have a negative effect on handling characteristics, especially on wet surfaces.
–
Check the front and rear tires for cuts, run-in objects, and
other damage.
»
If the tires have cuts, run-in objects, or other damage:
–
–
Change the tires.
Check the tread depth.
Info
Adhere to the legally required minimum tread depth.
400602-10
Minimum tread depth
»
If the tread depth is less than the minimum tread depth:
–
–
≥ 2 mm (≥ 0.08 in)
Change the tires.
Check the tire age.
Info
The tire date of manufacture is usually contained in the
tire label and is indicated by the last four digits of the
DOT number. The first two digits indicate the week of
manufacture and the last two digits the year of manufacture.
KTM recommends that the tires be changed after 5
years at the latest, regardless of the actual state of
wear.
H01144-01
»
If the tires are more than 5 years old:
–
14.6
Change the tires.
Checking tire pressure
Info
Low tire pressure leads to abnormal wear and overheating of the tire.
Correct tire pressure ensures optimal riding comfort and maximum tire service life.
119
14 WHEELS, TIRES
–
Remove the protection cap.
–
Check the tire pressure when the tires are cold.
Offroad tire pressure
front
1.0 bar (15 psi)
rear
1.0 bar (15 psi)
Street tire pressure (All EU models)
400695-01
front
2.0 bar (29 psi)
rear
2.0 bar (29 psi)
Street tire pressure (XCF‑W)
»
14.7
1.8 bar (26 psi)
rear
1.8 bar (26 psi)
If the tire pressure does not meet specifications:
–
–
front
Correct the tire pressure.
Mount the protection cap.
Checking spoke tension
Warning
Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage.
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes
is too low, then lateral and radial run-out will form in the wheel. Other spokes will become looser as a
result.
–
Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will
be glad to help.)
–
Strike each spoke briefly using a screwdriver blade.
Info
The frequency of the sound depends on the spoke
length and spoke diameter.
If you hear different tone frequencies from different
spokes of equal length and diameter, this is an indication of different spoke tensions.
You should hear a high note.
400694-01
»
If the spoke tension differs:
–
–
Correct the spoke tension.
Check the spoke torque.
Guideline
Spoke nipple, front
wheel
M4.5
5 Nm (3.7 lbf ft)
Spoke nipple, rear
wheel
M4.5
5 Nm (3.7 lbf ft)
Torque wrench kit (58429094000)
120
ELECTRICAL SYSTEM 15
15.1
Removing the 12-V battery
Warning
Risk of injury 12 V batteries contain harmful substances.
–
Keep 12 V batteries out of the reach of children.
–
Keep sparks and open flames away from 12 V batteries.
–
Only charge 12 V batteries in well-ventilated rooms.
–
Maintain a minimum clearance from inflammable materials when charging 12 V batteries.
Minimum clearance
–
1 m (3 ft)
Do not charge deeply discharged 12 V batteries if the charge is already below the minimum voltage.
Minimum voltage before the start of the charge
–
9V
Dispose of 12 V batteries with less than the minimum voltage correctly.
Preparatory work
– Press and hold the switch-off button
idling until the engine stops.
–
Remove the seat. (
while the engine is
p. 78)
Main work
– Disconnect negative cable
–
1 from the 12-V battery.
Pull back positive terminal cover 2 and disconnect the positive cable from the 12-V battery.
V01776-10
–
Pull off starter relay
and fuse box
compartment and hang to the side.
–
Detach wiring harness
them to the side.
3
4 from the battery
V01777-10
5, disconnect relays 6 and hang
V01778-10
121
15 ELECTRICAL SYSTEM
–
Remove screw
–
Lift out the 12-V battery.
7 and detach the battery compartment.
V01779-10
15.2
Installing the 12-V battery
Main work
– Insert the 12 V battery into the battery compartment with the
terminals facing forward and secure with holding bracket
.
1
12-V battery (HJTZ5S-FP‑C) (
–
Mount and tighten screw
p. 159)
2.
Guideline
Remaining screws,
chassis
V01779-11
–
Mount relays
–
Mount starter relay
M6
3 and attach wiring harness 4.
V01778-11
V01777-11
122
10 Nm (7.4 lbf ft)
5 and fuse box 6.
ELECTRICAL SYSTEM 15
–
Connect the positive cable to the 12-V battery.
Guideline
Screw, battery terminal
M5
2.5 Nm
(1.84 lbf ft)
Info
A
8
7
Contact disk
must be mounted under screw
and
cable lug
with the claws toward the battery terminal.
–
Slide positive terminal cover
–
Connect negative cable
9 over the positive terminal.
bk to the 12-V battery.
Guideline
Screw, battery terminal
M5
2.5 Nm
(1.84 lbf ft)
Info
A
8
Finishing work
– Mount the seat. (
15.3
7
Contact disk
must be mounted under screw
and
cable lug
with the claws toward the battery terminal.
V01780-10
p. 79)
Charging the 12-V battery
Note
Environmental hazard 12 V batteries contain environmentally hazardous materials.
–
Do not dispose of 12 V batteries as household waste.
–
Dispose of 12 V batteries at a collection point for used batteries.
Note
Environmental hazard Hazardous substances cause environmental damage.
–
Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
Even if there is no load on the 12-V battery, it discharges each day.
The charging level and the method of charging are very important for the service life of the 12-V battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, or charging time is exceeded, the 12 V battery will be destroyed.
If the 12-V battery is depleted by repeated starting, the 12-V battery must be charged immediately.
If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged
and suffer a loss of capacity, destroying the battery.
The 12-V battery is maintenance-free.
Preparatory work
– Press and hold the switch-off button
idling until the engine stops.
–
Remove the seat. (
–
Remove the 12-V battery.
while the engine is
p. 78)
(
p. 121)
123
15 ELECTRICAL SYSTEM
Main work
Warning
Risk of injury 12 V batteries contain harmful substances.
S00863-10
–
Keep 12 V batteries out of the reach of children.
–
Keep sparks and open flames away from 12 V batteries.
–
Only charge 12 V batteries in well-ventilated
rooms.
–
Maintain a minimum clearance from inflammable
materials when charging 12 V batteries.
Minimum clearance
–
1 m (3 ft)
Do not charge deeply discharged 12 V batteries if
the charge is already below the minimum voltage.
Minimum voltage before 9 V
the start of the charge
–
–
Dispose of 12 V batteries with less than the minimum voltage correctly.
Check the battery voltage.
»
»
Battery voltage: < 9 V
–
Do not charge the 12 V battery.
–
Replace the 12 V battery and dispose of the old 12 V
battery properly.
If the specifications have been met:
Battery voltage: ≥ 9 V
–
Connect a battery charger to the 12-V battery. Switch
on the battery charger.
Guideline
Maximum charging voltage
14.4 V
Maximum charging current
3.0 A
Maximum charging time
24 h
Recharge the 12-V battery regularly when the
motorcycle is not being
used
6 months
Ideal charging and storage temperature of the
lithium-ion battery
10 … 20 °C (50 …
68 °F)
Battery charger (79629974000)
124
ELECTRICAL SYSTEM 15
This battery charger tests whether the 12-V battery
retains its voltage. It is also impossible to overcharge
the 12-V battery with this battery charger. The charging
time may be longer at low temperatures.
This battery charger is only suitable for lithium iron
phosphate batteries. Read the accompanying KTM PowerParts instructions.
Info
Never remove cover
–
Switch off the battery charger after charging and disconnect it
from the 12-V battery.
Finishing work
– Install the 12-V battery.
–
15.4
1.
Mount the seat. (
(
p. 122)
p. 79)
Changing the main fuse
Warning
Fire hazard Incorrect fuses overload the electrical system.
–
Only use fuses with the required ampere value.
–
Do not bypass or repair fuses.
Info
The main fuse protects all power consumers of the vehicle.
Preparatory work
– Press and hold the switch-off button
idling until the engine stops.
–
Remove the seat. (
Main work
– Pull starter relay
while the engine is
p. 78)
1 from the holder.
V01776-11
125
15 ELECTRICAL SYSTEM
–
–
2.
Remove faulty main fuse 3.
Take off protection caps
Info
A
A faulty fuse has a burned-out fuse wire
.
A spare fuse
is located in the starter relay.
4
–
Install a new main fuse.
Fuse (58011109120) (
–
p. 159)
Check that the electrical system is functioning properly.
Tip
Insert a spare fuse so that it is available if needed.
–
Mount the starter relay onto the holder and route the cable.
–
Mount the protection caps.
V01781-10
Finishing work
– Mount the seat. (
15.5
p. 79)
Changing the fuses of individual power consumers
Info
The fuse box containing the fuses of individual power consumers is located under the seat.
Preparatory work
– Press and hold the switch-off button
idling until the engine stops.
–
Remove the seat. (
Main work
– Open fuse box cover
–
while the engine is
p. 78)
1.
Remove faulty fuse.
Guideline
(All EU models)
Fuse 1 ‑ 10 A - EFI control unit, lambda sensor, combination instrument, combination switch (optional), electronic fuel injection, diagnostics connector, fuse 4
V01801-10
Fuse 2 - 10 A - high beam, low beam, position light, tail
light, license plate lamp
Fuse 3 - 10 A - radiator fan, horn, brake light, turn signal
Fuse 4 - 5 A - fuel pump
Fuses res - 10 A - spare fuse
126
ELECTRICAL SYSTEM 15
(XCF‑W)
Fuse 1 ‑ 10 A - EFI control unit, combination instrument, combination switch (optional), electronic fuel
injection, diagnostics connector, evaporate emission
control system, fuse 4
Fuse 2 - 10 A - low beam, position light, tail light
Fuse 3 - 10 A - radiator fan
Fuse 4 - 5 A - fuel pump
Fuses res - 10 A - spare fuse
Info
A faulty fuse has a burned-out fuse wire
A.
Warning
Fire hazard Incorrect fuses overload the electrical system.
–
–
Only use fuses with the required ampere value.
–
Do not bypass or repair fuses.
Insert spare fuse with the correct rating.
Fuse (75011088010) (
p. 159)
Fuse (75011088005) (
p. 159)
Tip
Insert a spare fuse in the fuse box so that it is available
if needed.
–
Check that the power consumer is functioning properly.
–
Close the fuse box cover.
Finishing work
– Mount the seat. (
15.6
p. 79)
Removing the headlight mask with the headlight
Preparatory work
– Press and hold the switch-off button
idling until the engine stops.
while the engine is
Main work
– Detach the brake line and wiring harness from the headlight
mask.
–
Loosen rubber straps
swing it forward.
1. Slide the headlight mask up and
V01782-10
127
15 ELECTRICAL SYSTEM
(All EU models)
– Detach plug-in connectors
mask with the headlight.
2 and take off the headlight
S01328-10
(XCF‑W)
– Disconnect plug-in connector
and take off the headlight mask together with the headlight.
2
V01802-10
15.7
Installing the headlight mask with the headlight
Main work
(All EU models)
– Join plug-in connectors
1.
S01328-11
(XCF‑W)
– Join plug-in connector
1.
V01802-11
–
Position the headlight mask and secure it with rubber
straps
.
2
The holding lugs engage in the fender.
–
Position the brake line and wiring harness in the brake line
guide.
V01782-11
Finishing work
– Check the headlight setting. (
128
p. 129)
ELECTRICAL SYSTEM 15
15.8
Changing the headlight bulb
Note
Damage to reflector Grease on the reflector reduces the light intensity.
Grease on the bulb will evaporate due to the heat and be deposited on the reflector.
–
Clean and degrease the bulbs before mounting.
–
Do not touch the bulbs with your bare hands.
Preparatory work
– Press and hold the switch-off button
idling until the engine stops.
–
while the engine is
Remove the headlight mask with the headlight. (
p. 127)
Main work
– Turn protection cap
together with the underlying bulb
socket counterclockwise all the way and remove it.
1
–
Pull bulb socket
–
Pull out headlight bulb
–
Insert the new headlight bulb.
2 of the position light out of the reflector.
V01783-10
3.
Headlight (HS1 / socket PX43t) (
–
p. 159)
Insert the protection cap with the bulb socket into the reflector
and turn it clockwise all the way.
Info
Ensure that O-ring
E00359-10
–
4 is seated properly.
Insert the bulb socket of the position light into the reflector.
Finishing work
– Install the headlight mask with the headlight. (
15.9
p. 128)
–
Check the headlight setting. (
–
Position the vehicle upright on a horizontal surface in front of
a light wall and make a marking at the height of the center of
the low beam headlight.
–
Make another mark at a distance
p. 129)
Checking the headlight setting
B under the first marking.
Guideline
Distance
–
400726-10
B
5 cm (2 in)
Position the vehicle vertically at a distance
wall.
A away from the
Guideline
Distance
A
5 m (16 ft)
129
15 ELECTRICAL SYSTEM
–
The rider now sits down on the motorcycle.
–
Switch on the low beam.
–
Check the headlight setting.
The boundary between light and dark must be exactly on the
lower mark for a motorcycle with rider.
»
If the boundary between light and dark does not meet
specifications:
–
15.10
Adjust the headlight range. (
p. 130)
Adjusting the headlight range
Preparatory work
– Check the headlight setting. (
Main work
– Loosen screw
–
p. 129)
1.
Adjust the headlight range by pivoting the headlight.
Guideline
The boundary between light and dark must be exactly on the
lower mark for a motorcycle with rider (instructions on how
to apply the mark: Checking the headlight setting).
Info
V00369-10
A change in weight on the vehicle may require a correction of the headlight range.
–
15.11
Tighten screw
1.
Changing the turn signal bulb (All EU models)
Note
Damage to reflector Grease on the reflector reduces the light intensity.
Grease on the bulb will evaporate due to the heat and be deposited on the reflector.
–
Clean and degrease the bulbs before mounting.
–
Do not touch the bulbs with your bare hands.
130
ELECTRICAL SYSTEM 15
Main work
– Remove the screw on the rear of the turn signal housing.
–
Carefully remove turn signal glass
–
Lightly squeeze together the orange cap
holding lugs and take it off.
–
Press the turn signal bulb lightly into the socket, turn it counterclockwise by about 30°, and pull it out of the socket.
1.
2 in the area of the
Info
Do not touch the reflector with your fingers and keep it
free from grease.
–
Press the new turn signal bulb carefully into the socket and
turn it clockwise until it stops.
Turn signal (R10W / socket BA15s) (
E00360-10
p. 159)
–
Mount the orange cap.
–
Position the turn signal glass.
–
Insert the screw and first turn counterclockwise until it
engages in the thread with a small jerk. Tighten the screw
lightly.
Finishing work
– Check that the turn signal system is functioning properly.
15.12
Changing the combination instrument battery
Preparatory work
– Press and hold the switch-off button
idling until the engine stops.
–
while the engine is
Remove the headlight mask with the headlight. (
Main work
– Remove screws
p. 127)
1 with the washers.
–
Pull the combination instrument upward out of the holder.
–
Using a coin, turn protection cap
wise and take it off.
–
Remove combination instrument battery
–
Insert the combination instrument with the label facing
upward.
V01807-10
2 all the way counterclock3.
Combination instrument battery (CR 2430) (
–
p. 159)
Check the O-ring of the protection cap for correct seating.
V00371-10
131
15 ELECTRICAL SYSTEM
–
Position protection cap
using a coin.
–
Press any button on the combination instrument.
–
Position the combination instrument in the holder.
–
Mount and tighten the screws with washers.
2 and turn all the way clockwise
The combination instrument is activated.
V00372-10
Finishing work
– Install the headlight mask with the headlight. (
15.13
–
Check the headlight setting. (
p. 129)
–
Set the kilometers or miles. (
p. 25)
–
Set the combination instrument. (
–
Set the clock. (
Diagnostics connector
Diagnostics connector
H00933-12
132
p. 26)
p. 27)
1 is located under the seat.
p. 128)
COOLING SYSTEM 16
16.1
Cooling system
(All EU models)
Water pump
in the engine ensures forced circulation of 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 temperature will
not result in a risk of malfunctions.
1
2
120 °C (248 °F)
V01798-10
(XCF‑W)
Water pump
in the engine ensures forced circulation of 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 temperature will
not result in a risk of malfunctions.
1
2
120 °C (248 °F)
V01799-11
16.2
Cooling is effected by the air stream.
The lower the speed, the less the cooling effect. Dirty cooling fins
also reduce the cooling effect.
Additional cooling is provided by the radiator fan, which is activated on a temperature-dependent basis.
Checking the antifreeze and coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
–
Do not open the radiator, the radiator hoses or other cooling system components if the engine or the
cooling system are at operating temperature.
–
Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses
or other components of the cooling system.
–
In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
–
Keep coolant out of the reach of children.
–
Do not allow coolant to come into contact with the skin, the eyes and clothing.
–
Consult a doctor immediately if coolant is swallowed.
–
Rinse the affected area immediately with plenty of water in the event of contact with the skin.
–
Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
–
Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
133
16 COOLING SYSTEM
–
Stand the motorcycle upright on a horizontal surface.
–
Remove the radiator cap.
–
Check the antifreeze in the coolant.
−25 … −45 °C (−13 … −49 °F)
»
If the antifreeze in the coolant does not match the specified value:
–
400243-10
–
Correct the antifreeze in the coolant.
Check the coolant level in the radiator.
Coolant level
radiator fins
»
A above the
If the coolant level does not match the specified value:
–
Correct the coolant level.
Coolant (
–
16.3
10 mm (0.39 in)
p. 164)
Mount the radiator cap.
Checking the coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
–
Do not open the radiator, the radiator hoses or other cooling system components if the engine or the
cooling system are at operating temperature.
–
Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses
or other components of the cooling system.
–
In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
–
Keep coolant out of the reach of children.
–
Do not allow coolant to come into contact with the skin, the eyes and clothing.
–
Consult a doctor immediately if coolant is swallowed.
–
Rinse the affected area immediately with plenty of water in the event of contact with the skin.
–
Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
–
Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
–
Stand the motorcycle upright on a horizontal surface.
–
Remove the radiator cap.
–
Check the coolant level in the radiator.
Coolant level
radiator fins
»
Correct the coolant level.
Coolant (
400243-10
–
10 mm (0.39 in)
If the coolant level does not match the specified value:
–
134
A above the
p. 164)
Mount the radiator cap.
COOLING SYSTEM 16
16.4
Draining the coolant
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
–
Do not open the radiator, the radiator hoses or other cooling system components if the engine or the
cooling system are at operating temperature.
–
Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses
or other components of the cooling system.
–
In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
–
Keep coolant out of the reach of children.
–
Do not allow coolant to come into contact with the skin, the eyes and clothing.
–
Consult a doctor immediately if coolant is swallowed.
–
Rinse the affected area immediately with plenty of water in the event of contact with the skin.
–
Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
–
Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
Preparatory work
(All EXC-F Six Days, XCF‑W)
– Remove the engine guard. (
p. 98)
Main work
(All EU models)
– Position the motorcycle vertically.
–
Place an appropriate container under the water pump
cover.
–
Remove screw
–
Completely drain the coolant.
–
Mount and tighten screw
1. Take off radiator cap 2.
1 with a new seal ring.
Guideline
V01798-11
Screw, water pump
cover
M6
10 Nm (7.4 lbf ft)
(XCF‑W)
– Position the motorcycle vertically.
–
Place an appropriate container under the water pump
cover.
–
Remove screw
–
Completely drain the coolant.
–
Mount and tighten screw
1. Take off radiator cap 2.
1 with a new seal ring.
Guideline
V01799-10
Screw, water pump
cover
M6
10 Nm (7.4 lbf ft)
135
16 COOLING SYSTEM
16.5
Refilling coolant
Warning
Danger of poisoning Coolant is toxic and a health hazard.
–
Keep coolant out of the reach of children.
–
Do not allow coolant to come into contact with the skin, the eyes and clothing.
–
Consult a doctor immediately if coolant is swallowed.
–
Rinse the affected area immediately with plenty of water in the event of contact with the skin.
–
Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
–
Change clothing if coolant spills onto your clothing.
Main work
– Make sure that the screw
1 is tightened.
–
Stand the vehicle upright.
–
Pour coolant in up to measurement
A above the radiator fins.
Guideline
10 mm (0.39 in)
Coolant
H01698-10
–
1.2 l (1.3 qt.)
Refit the radiator cap.
Finishing work
(All EXC-F Six Days, XCF‑W)
– Install the engine guard. (
136
–
Take a short test ride.
–
Check the coolant level. (
p. 99)
p. 134)
Coolant (
p. 164)
TUNING THE ENGINE 17
17.1
Checking the throttle cable play
–
Check the throttle grip for smooth operation.
–
Move the handlebar to the straight-ahead position. Turn the
throttle grip back and forth slightly and determine the play in
throttle cable
.
A
Throttle cable play
»
If the throttle cable play does not meet specifications:
–
400192-11
–
3 … 5 mm (0.12 … 0.2 in)
Adjust the throttle cable play.
(
p. 137)
Push the cold start button in all the way.
When the throttle grip is turned forward, the cold start button returns to its original position.
»
If the cold start button does not return to its original position:
–
Adjust the throttle cable play.
(
p. 137)
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
–
–
Always make sure there is sufficient ventilation
when running the engine.
–
Use effective exhaust extraction when starting or
running the engine in an enclosed space.
Start the engine and let it run at idle speed. Move the handlebar to and fro over the entire steering range.
The idle speed must not change.
»
If the idle speed changes:
–
17.2
Adjust the throttle cable play.
(
p. 137)
Adjusting the throttle cable play
Info
If the correct routing of the throttle cables has already been secured, the fuel tank does not need to be
removed.
Preparatory work
– Remove the seat. (
p. 78)
–
Remove the fuel tank.
–
Check throttle cable routing. (
(
p. 86)
p. 94)
137
17 TUNING THE ENGINE
Main work
– Move the handlebar to the straight-ahead position.
–
Push back sleeve
–
Loosen nut
–
Turn adjusting screw
–
Loosen nut
–
Push cold start button
–
1.
2.
3 in as far as possible.
4.
6 all the way to the stop.
Turn adjusting screw 5 so that the cold start button moves to
the basic position when the throttle grip is turned to the front.
–
Tighten nut
–
Turn adjusting screw
so that there is play in the throttle
cable at the throttle grip.
4.
3
Guideline
Throttle cable play
–
V01804-10
–
2.
Slide on sleeve 1.
–
Check the throttle grip for smooth operation.
Tighten nut
Finishing work
– Check the throttle cable play. (
17.3
3 … 5 mm (0.12 … 0.2 in)
p. 137)
Adjusting the characteristic map of the throttle response
Info
On the throttle grip, the characteristic map of the throttle response is changed by changing the guide
plate.
A guide plate with a different characteristic map is supplied.
Main work
– Push back sleeve
V01758-10
138
–
1.
Remove screws 2 and half-shells 3.
–
Detach the throttle cables and take off the grip tube.
TUNING THE ENGINE 17
–
Remove guide plate
–
Position the required guide plate on the grip tube.
4 from handle tube 5.
Guideline
The label OUTSIDE must be visible. Marking
positioned at marking
.
A must be
B
Grey guide plate (79002014000)
Alternative 1
Black guide plate (79002014100)
Info
The gray guide plate opens the throttle valve more
slowly.
The black guide plate opens the throttle valve more
quickly.
The gray guide plate is mounted upon delivery.
102246-10
–
Clean the outside of the handlebar and the inside of the grip
tube. Mount the grip tube on the handlebar.
–
Attach the throttle cables to the guide plate and route correctly.
–
Position half-shells
3, mount and tighten screws 2.
Guideline
Screw, throttle grip
V01803-10
–
Slide on sleeve
movement.
M6
1 and check the throttle grip for ease of
Finishing work
– Check the throttle cable play. (
17.4
5 Nm (3.7 lbf ft)
p. 137)
Changing the mapping (All EXC-F Six Days, XCF‑W)
Warning
Voiding of the government approval for road use and the insurance coverage If the combination switch is
mounted, the vehicle’s road permit, if any, expires.
–
Only operate the vehicle in closed-off areas remote from public road traffic if the combination switch
is installed.
Info
The
The
The
The
desired engine characteristic can be activated via the MAP button on the combination switch.
setting most recently selected is activated again when restarting.
traction control can also be activated in each mapping using the TC button.
mapping can also be changed during the ride.
139
17 TUNING THE ENGINE
Activating STANDARD mapping:
– Press button MAP until LED 1 lights up.
Guideline
Engine speed
< 4,000 rpm
STANDARD – balanced response
H02889-01
Activating ADVANCED mapping:
– Press button MAP until LED 2 lights up.
Guideline
Engine speed
< 4,000 rpm
ADVANCED – direct response
H02886-01
17.5
Adjusting the idle speed
Warning
Danger of accidents The engine may go out spontaneously if the idle speed is set too low.
–
Set the idle speed to the specified value. (Your authorized KTM workshop will be glad to help.)
–
Run the engine until warm.
The cold start button is deactivated – The cold start button is in its basic position. ( p. 21)
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
–
–
Always make sure there is sufficient ventilation
when running the engine.
–
Use effective exhaust extraction when starting or
running the engine in an enclosed space.
Set the idle speed by turning idle speed adjusting screw
Guideline
Idle speed
1,800 … 1,900 rpm
Tachometer (45129075000)
H02254-10
Info
Turning counterclockwise lowers the idle speed.
Turning clockwise raises the idle speed.
140
1.
TUNING THE ENGINE 17
17.6
Teaching the throttle valve position
Info
If the control unit detects that the throttle valve position at idle speed needs to be retaught, then the malfunction indicator lamp flashes 2x per second.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
–
–
Always make sure there is sufficient ventilation
when running the engine.
–
Use effective exhaust extraction when starting or
running the engine in an enclosed space.
Allow the vehicle to run at idle speed.
The malfunction indicator lamp stops flashing once teaching is completed.
Info
If the engine becomes too hot, perform a cool-down
ride at medium revs.
Then do not switch off the engine after this, but leave it
running at idle speed until teaching is completed.
H02263-10
17.7
Checking the basic position of the shift lever
Info
When driving, the shift lever must not touch the rider's boot when in the basic position.
When the shift lever keeps touching the boot, the transmission will be subject to an excessive load.
–
Sit on the vehicle in the riding position and determine
distance
between the upper edge of your boot and the shift
lever.
A
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 specifications:
–
Adjust the basic position of the shift lever.
( p. 142)
400692-10
141
17 TUNING THE ENGINE
17.8
Adjusting the basic position of the shift lever
–
Remove screw
lever
.
1 with the washers and take off shift
2
401950-12
–
Clean gear teeth
–
Mount the shift lever on the shift shaft in the required position
and engage gearing.
A of the shift lever and shift shaft.
Info
The range of adjustment is limited.
The shift lever must not come into contact with any
other vehicle components during the shift procedure.
401951-10
–
Mount the screw with the washers and tighten.
Guideline
Screw, shift
lever
142
M6
14 Nm (10.3 lbf ft)
Loctite®243™
SERVICE WORK ON THE ENGINE 18
18.1
Changing the fuel screen
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–
Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–
Switch off the engine for refueling.
–
Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–
If any fuel is spilled, wipe it off immediately.
–
Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–
Avoid skin, eye and clothing contact with fuel.
–
Immediately consult a doctor if you swallow fuel.
–
Do not inhale fuel vapors.
–
In case of skin contact, rinse the affected area with plenty of water.
–
Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–
Change your clothing in case of fuel spills on them.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
–
Do not allow fuel to enter the groundwater, the soil, or the sewage system.
–
Clean plug-in connection
compressed air.
1 of the fuel line thoroughly with
Info
Under no circumstances should dirt enter into the fuel
line. Dirt in the fuel line clogs the injection valve!
–
Disconnect the plug-in connection of the fuel line.
Info
Remaining fuel may flow out of the fuel hose.
–
Pull fuel screen
–
Insert the new fuel screen all the way into the connecting
piece.
–
Lubricate the O-ring and join the plug-in connection of the fuel
line.
2 out of the connecting piece.
Danger
V01800-10
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
–
–
Always make sure there is sufficient ventilation
when running the engine.
–
Use effective exhaust extraction when starting or
running the engine in an enclosed space.
Start the engine and check the response.
143
18 SERVICE WORK ON THE ENGINE
18.2
Checking the engine oil level
Condition
The engine is at operating temperature.
Preparatory work
– Stand the motorcycle upright on a horizontal surface.
Main work
– Check the engine oil level.
Info
After switching off the engine, wait one minute before
checking the level.
The engine oil is at a level between lower edge
middle of level viewer
.
A and the
B
V01805-10
»
If the engine oil is not up to lower edge
viewer:
–
18.3
Add engine oil. (
A of the level
p. 147)
Changing the engine oil and oil filter, cleaning the oil screens
Warning
Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden.
–
Wear suitable protective clothing and safety gloves.
–
In the event of scalding, rinse the area affected immediately with lukewarm water.
Note
Environmental hazard Hazardous substances cause environmental damage.
–
Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
Drain the engine oil with the engine at operating temperature.
Preparatory work
(All EXC-F Six Days, XCF‑W)
– Remove the engine guard. (
–
p. 98)
Park the motorcycle on a level surface.
Main work
– Place an appropriate container under the engine.
–
H01703-10
144
Remove oil drain plug
1 with the magnet and seal ring.
SERVICE WORK ON THE ENGINE 18
–
Remove screw plug
rings.
2 with the short oil screen and the O-
Info
Do not remove screw
A.
H01704-10
–
Remove screw plug
rings.
–
Allow the engine oil to drain completely.
–
Thoroughly clean the parts and the sealing surfaces.
–
Mount and tighten screw plug
the O-rings.
3 with the long oil screen 4 and the O-
H01705-10
2 with the short oil screen and
Guideline
Screw plug, oil
screen
M20x1.5
15 Nm (11.1 lbf ft)
H01706-10
–
Position long oil screen
–
Position the pin wrench through the drill hole of the screw plug
in the opposite section of the engine case.
–
Push the oil screen all the way into the engine case.
–
Mount and tighten screw plug
4 with the O-rings on a pin wrench.
H01707-10
3 with the O-ring.
Guideline
Screw plug, oil
screen
–
M20x1.5
Mount and tighten oil drain plug
new seal ring.
15 Nm (11.1 lbf ft)
1 with the magnet and a
Guideline
H01708-10
Oil drain plug with
magnet
M12x1.5
20 Nm (14.8 lbf ft)
145
18 SERVICE WORK ON THE ENGINE
–
Remove screws
–
Pull oil filter
5. Remove the oil filter cover with the O-ring.
H01709-10
6 out of the oil filter housing.
Lock ring plier (51012011000)
–
Allow the engine oil to drain completely.
–
Thoroughly clean the parts and the sealing surface.
–
Lay the motorcycle on its side and fill the oil filter housing to
about ⅓ full with engine oil.
–
Insert the new oil filter into the oil filter housing.
–
Oil the O-ring of the oil filter cover and mount it together with
oil filter cover
.
–
Mount and tighten the screws.
H01710-10
7
Guideline
Screw, oil filter cover
H01711-10
M6
–
Stand the motorcycle upright.
–
Remove filler plug
oil.
Engine oil
10 Nm (7.4 lbf ft)
8 with the O-ring, and fill up with engine
1.2 l (1.3 qt.)
Engine oil
(SAE 10W/50)
( p. 164)
Info
Too little engine oil or poor-quality engine oil will result
in premature wear of the engine.
H01713-10
–
Mount and tighten the filler plug together with the O-ring.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
–
146
–
Always make sure there is sufficient ventilation
when running the engine.
–
Use effective exhaust extraction when starting or
running the engine in an enclosed space.
Start the engine and check that it is oil-tight.
SERVICE WORK ON THE ENGINE 18
Finishing work
(All EXC-F Six Days, XCF‑W)
– Install the engine guard. (
–
18.4
Check the engine oil level. (
p. 99)
p. 144)
Adding engine oil
Info
Too little engine oil or poor-quality engine oil will result in premature wear of the engine.
Main work
– Remove filler plug
–
1 with the O-ring.
Fill engine oil to the middle A of the level viewer.
Engine oil (SAE 10W/50) (
p. 164)
Info
For optimal performance of the engine oil, do not mix
different types of engine oil.
We recommended changing the engine oil when necessary.
–
Mount and tighten the filler plug together with the O-ring.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
V01806-10
–
–
Always make sure there is sufficient ventilation
when running the engine.
–
Use effective exhaust extraction when starting or
running the engine in an enclosed space.
Start the engine and check for tightness.
Finishing work
– Check the engine oil level. (
p. 144)
147
19 CLEANING, CARE
19.1
Cleaning the motorcycle
Note
Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly.
The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc.
Pressure which is too high causes malfunctions and destroys components.
–
Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
–
Maintain a minimum distance between the nozzle of the pressure cleaner and the component.
Minimum clearance
60 cm (23.6 in)
Note
Environmental hazard Hazardous substances cause environmental damage.
–
Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
To maintain the value and appearance of the motorcycle over a long period, clean it regularly.
Avoid direct sunshine when cleaning the motorcycle.
–
Close off the exhaust system to keep water from entering.
–
Remove the coarse dirt particles with a gentle water jet.
–
Spray heavily soiled parts with a normal commercial motorcycle cleaner and then brush off with a soft brush.
Motorcycle cleaner (
p. 166)
Info
Use warm water containing normal motorcycle cleaner
and a soft sponge.
Never apply motorcycle cleaner to a dry vehicle; always
rinse the vehicle with water first.
401061-01
–
After rinsing the motorcycle with a gentle spray of water, allow
it to dry thoroughly.
–
Remove the closure of the exhaust system.
Warning
Danger of accidents Moisture and dirt impair the
brake system.
–
–
Brake carefully several times to dry out and remove
dirt from the brake linings and the brake discs.
After cleaning, ride the vehicle a short distance until the
engine warms up.
Info
The heat produced causes water at inaccessible locations in the engine and on the brake system to evaporate.
148
–
After the motorcycle has cooled down, lubricate all moving
parts and pivot points.
–
Clean the chain. (
p. 89)
CLEANING, CARE 19
–
Treat bare metal (except for brake discs and the exhaust system) with a corrosion inhibitor.
Preserving materials for paints, metal and rubber
( p. 166)
–
Treat all plastic parts and powder-coated parts with a mild
cleaning and care product.
Special cleaner for glossy and matte paint finishes, metal
and plastic surfaces ( p. 167)
(All EU models)
– Lubricate the steering lock.
Universal oil spray (
19.2
p. 167)
Checks and maintenance steps for winter operation
Info
If you use the vehicle in winter, you must expect salt on the roads. You should therefore take precautions
against aggressive road salt.
If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance
the corrosive effects of salt.
–
Clean motorcycle. (
–
Clean brake system.
p. 148)
Info
After EVERY trip on salted roads, thoroughly clean the
brake calipers and brake linings, after they have cooled
down and without removing them, with cold water and
dry them carefully.
After riding on salted roads, thoroughly clean the vehicle with cold water and dry it well.
401060-01
–
Treat the engine, link fork, and all other bare or zinc-plated
parts (except the brake discs) with a wax-based corrosion
inhibitor.
Info
Corrosion inhibitor must not come in contact with the
brake discs as this would greatly reduce the braking
force.
–
Clean the chain. (
p. 89)
149
20 STORAGE
20.1
Storage
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–
Avoid skin, eye and clothing contact with fuel.
–
Immediately consult a doctor if you swallow fuel.
–
Do not inhale fuel vapors.
–
In case of skin contact, rinse the affected area with plenty of water.
–
Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–
Change your clothing in case of fuel spills on them.
–
Keep fuels correctly in a suitable canister, and out of the reach of children.
Info
If you plan to garage the motorcycle for a longer period, perform the following steps or have them performed.
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.
–
When refueling for the last time before taking the motorcycle
out of service, add fuel additive.
Fuel additive (
401058-01
p. 166)
–
Refuel. (
–
Clean motorcycle. (
–
Change the engine oil and oil filter, clean the oil screens.
( p. 144)
–
Check the antifreeze and coolant level. (
–
Check tire pressure. (
–
Remove the 12-V battery.
–
Charge the 12-V battery.
p. 47)
p. 148)
p. 133)
p. 119)
(
(
p. 121)
p. 123)
Guideline
Ideal charging and storage
temperature of the lithiumion battery
–
10 … 20 °C (50 … 68 °F)
Store the vehicle in a dry location that is not subject to large
fluctuations in temperature.
Info
KTM recommends jacking up the motorcycle.
150
–
Raise the motorcycle with the lift stand. (
–
Preferably cover the motorcycle with a tarp or similar cover
that is permeable to air. Do not use non-porous materials since
they prevent humidity from escaping, thus causing corrosion.
p. 64)
STORAGE 20
Info
Avoid running the engine for a short time only. Since
the engine cannot warm up properly, the water vapor
produced during combustion condenses and causes
valves and the exhaust system to rust.
20.2
Preparing for use after storage
–
Remove the motorcycle from the lift stand. (
–
Install the 12-V battery.
–
Perform checks and maintenance measures when preparing for
use. ( p. 43)
–
Take a test ride.
(
p. 64)
p. 122)
401059-01
151
21 TROUBLESHOOTING
Faults
Possible cause
Action
The engine cannot be cranked
(starter motor)
Operating error
–
Carry out start procedure. (
12-V battery discharged
–
Charge the 12-V battery.
–
Check charging voltage.
–
Check the open-circuit current.
–
Check the stator winding of the alternator.
Main fuse blown
–
Change the main fuse. (
Starter relay defective
–
Check the starter relay.
Starter motor defective
–
Check the starter motor.
Operating error
–
Carry out start procedure. (
The plug-in connection of the
fuel hose connection is not
connected
–
Connect the plug-in connection of the
fuel line.
Fuse 1 blown
–
Change the fuses of individual power
consumers. ( p. 126)
Fuse 4 blown
–
Change the fuses of individual power
consumers. ( p. 126)
Idle speed is not set correctly
–
Adjust the idle speed.
Spark plug oily or wet
–
Clean and dry the spark plug or replace
if necessary.
Plug gap of spark plug too wide
–
Adjust plug gap.
The engine turns but does not
start
p. 43)
(
p. 123)
p. 125)
(
p. 43)
p. 140)
Guideline
Spark plug electrode gap
1.0 mm (0.039 in)
Engine does not speed up
Engine has too little power
152
Ignition system defective
–
Check the ignition system.
Short-circuit cable in wiring
harness frayed, switch-off button or emergency OFF switch
faulty
–
Check the wiring harness. (visual
check)
–
Check the electrical system.
Error in the electronic fuel
injection
–
Read out the fault memory using the
KTM diagnostics tool.
Error in the electronic fuel
injection
–
Read out the fault memory using the
KTM diagnostics tool.
Ignition system defective
–
Ignition coil - check the secondary
winding.
–
Check the spark plug connector.
–
Check the stator winding of the alternator.
Air filter heavily contaminated
–
Clean the air filter and air filter box.
( p. 82)
Fuel filter is very dirty
–
Change the fuel filter.
Fuel screen is very dirty
–
Change the fuel screen.
Error in the electronic fuel
injection
–
Read out the fault memory using the
KTM diagnostics tool.
Exhaust system leaky,
deformed or too little glass
fiber yarn filling in the main
silencer
–
Check exhaust system for damage.
–
Change the glass fiber yarn filling of
the main silencer. ( p. 85)
(
p. 143)
TROUBLESHOOTING 21
Faults
Possible cause
Action
Engine has too little power
Valve clearance too little
–
Adjust the valve clearance.
Ignition system defective
–
Ignition coil - check the secondary
winding.
–
Check the spark plug connector.
–
Check the stator winding of the alternator.
Lack of fuel
–
Refuel. (
Fuse 1 blown
–
Change the fuses of individual power
consumers. ( p. 126)
Fuse 4 blown
–
Change the fuses of individual power
consumers. ( p. 126)
Coolant level low in cooling system
–
Check the cooling system for leaks.
–
Check the coolant level. (
Insufficient airflow
–
Switch off engine when stationary.
Radiator fins very dirty
–
Clean radiator fins.
Foam formation in cooling system
–
Drain the coolant.
(
p. 135)
–
Refill the coolant.
(
p. 136)
Bent radiator hose
–
Change the radiator hose.
Thermostat defective
–
Check the thermostat.
The engine dies during the trip
Engine overheats
p. 47)
p. 134)
Guideline
Opening temperature: 70 °C (158 °F)
–
Check the radiator fan fuse.
–
Check fuse 4.
–
Check the radiator fan.
–
Stop motorcycle and identify faulty
component using the blink code.
–
Check wiring for damage and electrical
plug-in connectors for corrosion and
damage.
–
Read out the fault memory using the
KTM diagnostics tool.
Engine vent hose bent
–
Route the vent hose without bends or
replace it if necessary.
Engine oil level too high
–
Check the engine oil level. (
Engine oil too thin (low viscosity)
–
Change the engine oil and oil filter,
clean the oil screens. ( p. 144)
Piston and cylinder worn
–
Measure the piston/cylinder mounting
clearance.
The 12-V battery is not being
charged by the alternator
–
Check charging voltage.
–
Check the stator winding of the alternator.
Undesired power consumer
–
Check the open-circuit current.
Values in combination
instrument deleted (time, stop
watch, lap times)
The combination instrument
battery is empty
–
Change combination instrument battery. ( p. 131)
The high beam, low beam, tail
light, position light, and license
plate lamp are not working
Fuse 2 blown
–
Change the fuses of individual power
consumers. ( p. 126)
Defect in radiator fan system
Malfunction indicator lamp
lights up or flashes
High oil consumption
12-V battery discharged
Error in the electronic fuel
injection
p. 144)
153
21 TROUBLESHOOTING
Faults
Possible cause
Action
The horn, brake light, turn signal, and radiator fan are not
working
Fuse 3 blown
–
154
Change the fuses of individual power
consumers. ( p. 126)
TECHNICAL DATA 22
22.1
Engine
Design
1-cylinder 4-stroke engine, water-cooled
Displacement (All 450 models)
449.9 cm³ (27.455 cu in)
Displacement (All 500 models)
510.9 cm³ (31.177 cu in)
Stroke (All 450 models)
63.4 mm (2.496 in)
Stroke (All 500 models)
72 mm (2.83 in)
Bore
95 mm (3.74 in)
Compression ratio
12.7:1
Idle speed
1,800 … 1,900 rpm
Control
OHC, 4 valves controlled via rocker arm
Valve diameter, intake
40 mm (1.57 in)
Valve diameter, exhaust
33 mm (1.3 in)
Valve clearance
Intake at: 20 °C (68 °F)
0.10 … 0.15 mm (0.0039 … 0.0059 in)
Exhaust at: 20 °C (68 °F)
0.12 … 0.17 mm (0.0047 … 0.0067 in)
Crankshaft bearing
2 cylinder roller bearing
Conrod bearing
Slide bearing
Piston pin bearing
No bearing bush – DLC coated piston pin
Pistons
Forged light alloy
Piston rings
1 compression ring, 1 oil scraper ring
Engine lubrication
Pressure circulation lubrication with two Eaton pumps
Primary transmission
31:76
Clutch
Multidisc clutch in oil bath, hydraulically activated
Transmission ratio
first-gear
14:36
second-gear
17:32
third-gear
19:28
fourth-gear
22:26
fifth-gear
23:24
sixth-gear
26:21
Alternator
12 V, 70 W
Ignition
Contactless controlled fully electronic ignition with
digital ignition adjustment
Spark plug
NGK LZMAR8BI-19
Spark plug electrode gap
1.0 mm (0.039 in)
Cooling
Water cooling, permanent circulation of coolant by
water pump
Starting aid
Starter motor
155
22 TECHNICAL DATA
22.2
Engine tightening torques
Oil jet, piston cooling
M4
2 Nm (1.5 lbf ft)
Loctite®243™
Crankshaft speed sensor screw and
cable retainer
M5
Oil nozzle for clutch lubrication
M5
6 Nm (4.4 lbf ft)
Loctite®243™
2 Nm (1.5 lbf ft)
Loctite®243™
Oil nozzle for timing chain lubrication
M5
Oil nozzle, piston cooling
M5
2 Nm (1.5 lbf ft)
Loctite®243™
2 Nm (1.5 lbf ft)
Loctite®243™
Oil nozzle, rocker arm lubrication
M5
2 Nm (1.5 lbf ft)
Loctite®243™
Screw, bearing retainer
M5
6 Nm (4.4 lbf ft)
Loctite®243™
Screw, clutch spring retainer
M5
6 Nm (4.4 lbf ft)
Screw, gear position sensor
M5
5 Nm (3.7 lbf ft)
Loctite®243™
Screw, locking lever
M5
6 Nm (4.4 lbf ft)
Loctite®243™
Screw, stator
M5
6 Nm (4.4 lbf ft)
Loctite®243™
Screw, suction pump cover
M5
6 Nm (4.4 lbf ft)
Loctite®243™
Nut, water pump impeller
M6
6 Nm (4.4 lbf ft)
Loctite®243™
Screw, alternator cover
M6
10 Nm (7.4 lbf ft)
Screw, clutch cover
M6
10 Nm (7.4 lbf ft)
Screw, clutch slave cylinder
M6
10 Nm (7.4 lbf ft)
Screw, cylinder head
M6
10 Nm (7.4 lbf ft)
Screw, engine case
M6
10 Nm (7.4 lbf ft)
Screw, EVAP plug (All EU models)
M6
5 Nm (3.7 lbf ft)
Loctite®243™
Screw, exhaust flange
M6
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, oil filter cover
M6
10 Nm (7.4 lbf ft)
Screw, pressure pump cover
M6
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, shift drum locating
M6
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, shift lever
M6
14 Nm (10.3 lbf ft)
Loctite®243™
Screw, starter motor
M6
10 Nm (7.4 lbf ft)
Screw, timing chain clip
M6
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, timing chain tensioner
M6
10 Nm (7.4 lbf ft)
Screw, timing chain tensioning rail
M6
10 Nm (7.4 lbf ft)
Loctite®243™
156
TECHNICAL DATA 22
Screw, torque governor
M6
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, valve cover
M6
10 Nm (7.4 lbf ft)
Screw, water pump cover
M6
10 Nm (7.4 lbf ft)
Oil nozzle for conrod bearing lubrication
M6x0.75
2 Nm (1.5 lbf ft)
Plug, oil channel
M7
9 Nm (6.6 lbf ft)
Loctite®243™
Screw, rocker arm bearing
M7
15 Nm (11.1 lbf ft)
Crankshaft clamp screw plug
M8
10 Nm (7.4 lbf ft)
Plug, timing chain tensioner
M8
8 Nm (5.9 lbf ft)
Plug, oil channel
M10
15 Nm (11.1 lbf ft)
Loctite®243™
Screw, engine sprocket
M10
60 Nm (44.3 lbf ft)
Loctite®2701™
Spark plug
M10x1
10 … 12 Nm (7.4 … 8.9 lbf ft)
Engine coolant temperature sensor
M10x1.25
12 Nm (8.9 lbf ft)
Screw, cylinder head
M10x1.25
1st stage
10 Nm (7.4 lbf ft)
2nd stage
30 Nm (22.1 lbf ft)
3rd stage
50 Nm (36.9 lbf ft)
Collar and thread oiled
Nut, rotor
M12x1
60 Nm (44.3 lbf ft)
Thread, oiled with engine oil/cone
degreased
Oil drain plug with magnet
M12x1.5
20 Nm (14.8 lbf ft)
Plug, SLS
M12x1.5
20 Nm (14.8 lbf ft)
Screw plug, oil pressure control
valve
M12x1.5
20 Nm (14.8 lbf ft)
Nut, inner clutch hub
M18x1.5
80 Nm (59 lbf ft)
Nut, primary gear wheel
M20LHx1.5
100 Nm (73.8 lbf ft)
Loctite®243™
Screw plug, oil screen
22.3
Capacities
22.3.1
Engine oil
Engine oil
22.3.2
15 Nm (11.1 lbf ft)
1.2 l (1.3 qt.)
Engine oil (SAE 10W/50)
( p. 164)
1.2 l (1.3 qt.)
Coolant (
9 l (2.4 US gal)
Super unleaded (ROZ 95/RON
95/PON 91) ( p. 165)
Coolant
Coolant
22.3.3
M20x1.5
p. 164)
Fuel
Total fuel tank capacity, approx.
(All EU models)
157
22 TECHNICAL DATA
Total fuel tank capacity, approx.
(XCF‑W)
8.5 l (2.25 US gal)
Fuel reserve, approx.
22.4
Super unleaded (ROZ 95/RON
95/PON 91) ( p. 165)
1.5 l (1.6 qt.)
Chassis
Frame
Central tube frame made of chrome molybdenum steel
tubing
Fork (EXC‑F EU, XCF‑W)
WP SuspensionXplor 5348
Fork (All EXC-F Six Days)
WP XPLOR 5548
Suspension travel
front
300 mm (11.81 in)
rear
310 mm (12.2 in)
Fork offset
22 mm (0.87 in)
Shock absorber
WP Suspension 5018 PDS DCC
Brake system
Disc brakes, floating brake calipers
Brake discs - diameter
front
260 mm (10.24 in)
rear
220 mm (8.66 in)
Brake discs - wear limit (EXC‑F EU, XCF‑W)
front
2.5 mm (0.098 in)
rear
3.5 mm (0.138 in)
Brake discs - wear limit (All EXC-F Six Days)
front
2.5 mm (0.098 in)
rear
3.7 mm (0.146 in)
Offroad tire pressure
front
1.0 bar (15 psi)
rear
1.0 bar (15 psi)
Street tire pressure (All EU models)
front
2.0 bar (29 psi)
rear
2.0 bar (29 psi)
Final drive (All 450 models)
14:52 (13:52)
Final drive (500 EXC‑F EU, 500 EXC‑F Six Days EU)
14:50 (13:50)
Final drive (XCF‑W)
14:48
Chain
5/8 x 1/4"
Rear sprockets available
48, 50, 52
Steering head angle
63.5°
Wheelbase
1,482 ± 10 mm (58.35 ± 0.39 in)
Seat height unloaded
960 mm (37.8 in)
Ground clearance unloaded
355 mm (13.98 in)
Weight without fuel, approx. (450 EXC‑F EU)
105.5 kg (232.6 lb.)
Weight without fuel, approx. (500 EXC‑F EU)
105.6 kg (232.8 lb.)
Weight without fuel, approx. (450 EXC‑F Six Days EU)
106 kg (234 lb.)
Weight without fuel, approx. (500 EXC‑F Six Days EU)
106 kg (234 lb.)
Weight without fuel, approx. (XCF‑W)
109.5 kg (241.4 lb.)
Maximum permissible front axle load
145 kg (320 lb.)
158
TECHNICAL DATA 22
Maximum permissible rear axle load
190 kg (419 lb.)
Maximum permissible overall weight
335 kg (739 lb.)
22.5
Electrical system
12-V battery
HJTZ5S-FP‑C
Lithium-ion battery
Battery voltage: 12 V
Nominal capacity: 2.0 Ah
Maintenance-free
Combination instrument battery
CR 2430
Battery voltage: 3 V
Fuse
75011088005
5A
Fuse
75011088010
10 A
Fuse
58011109120
20 A
Headlight
HS1 / socket PX43t
12 V
35/35 W
Position light
W5W / socket W2.1x9.5d
12 V
5W
Indicator lamps
W2.3W / socket W2x4.6d
12 V
2.3 W
Turn signal (All EU models)
R10W / socket BA15s
12 V
10 W
Brake/tail light
LED
License plate lamp
LED
22.6
Tires
Validity
Front tire
Rear tire
(EXC‑F EU)
80/100 - 21 M/C 51M TT
Maxxis Maxx EnduPro
140/80 - 18 M/C 70R M+S TT
Maxxis Maxx EnduPro
(XCF‑W)
90/90 - 21 54M TT
Dunlop GEOMAX AT81F
110/100 - 18 64M TT
Dunlop GEOMAX AT81
(All EXC-F Six Days)
90/90 - 21 M/C 54M M+S TT
Metzeler MCE 6 Days Extreme
140/80 - 18 M/C 70M M+S TT
Metzeler MCE 6 Days Extreme
The tires specified represent one of the possible series production tires. Additional information is available in
the Service section under:
http://www.ktm.com
22.7
Fork
22.7.1
EXC‑F EU, XCF‑W
Fork article number
14.18.8T.69
Fork
WP SuspensionXplor 5348
Compression damping
Comfort
18 clicks
Standard
15 clicks
Sport
12 clicks
Rebound damping
Comfort
18 clicks
Standard
15 clicks
159
22 TECHNICAL DATA
Sport
12 clicks
Spring length with preload spacer(s)
477 mm (18.78 in)
Spring rate
Weight of rider: 65 … 75 kg (143 … 165 lb.)
4.0 N/mm (22.8 lb/in)
Weight of rider: 75 … 85 kg (165 … 187 lb.)
4.2 N/mm (24 lb/in)
Weight of rider: 85 … 95 kg (187 … 209 lb.)
4.4 N/mm (25.1 lb/in)
Fork length
Fork oil per fork leg
22.7.2
928 mm (36.54 in)
610 ± 10 ml (20.62
± 0.34 fl. oz.)
Fork oil (SAE 4) (48601166S1)
( p. 165)
All EXC-F Six Days
Fork article number
14.18.8T.68
Fork
WP XPLOR 5548
Compression damping
Comfort
18 clicks
Standard
15 clicks
Sport
12 clicks
Rebound damping
Comfort
18 clicks
Standard
15 clicks
Sport
12 clicks
Spring preload - Preload Adjuster
Comfort
+0
Standard
+0
Sport
+3
Spring length with preload spacer(s)
477 mm (18.78 in)
Spring rate
Weight of rider: 65 … 75 kg (143 … 165 lb.)
4.0 N/mm (22.8 lb/in)
Weight of rider: 75 … 85 kg (165 … 187 lb.)
4.2 N/mm (24 lb/in)
Weight of rider: 85 … 95 kg (187 … 209 lb.)
Fork length
Fork oil per fork leg
22.8
4.4 N/mm (25.1 lb/in)
928 mm (36.54 in)
610 ± 10 ml (20.62
± 0.34 fl. oz.)
Fork oil (SAE 4) (48601166S1)
( p. 165)
Shock absorber
Shock absorber article number
12.18.7T.69
Shock absorber
WP Suspension 5018 PDS DCC
Low-speed compression damping
Comfort
18 clicks
Standard
15 clicks
Sport
12 clicks
High-speed compression damping
160
Comfort
2.5 turns
Standard
2 turns
TECHNICAL DATA 22
Sport
1 turn
Rebound damping
Comfort
18 clicks
Standard
15 clicks
Sport
12 clicks
Spring preload
8 mm (0.31 in)
Spring rate
Weight of rider: 65 … 75 kg (143 … 165 lb.)
60 … 66 N/mm (343 … 377 lb/in)
Weight of rider: 75 … 85 kg (165 … 187 lb.)
63 … 69 N/mm (360 … 394 lb/in)
Weight of rider: 85 … 95 kg (187 … 209 lb.)
66 … 72 N/mm (377 … 411 lb/in)
Spring length
225 mm (8.86 in)
Gas pressure
10 bar (145 psi)
Static sag
37 mm (1.46 in)
Riding sag
110 mm (4.33 in)
Fitted length
415 mm (16.34 in)
Damper oil
22.9
Shock absorber fluid (SAE 2.5)
(50180751S1) ( p. 165)
Chassis tightening torques
Remaining screws, chassis
EJOT PT® K60x25‑Z
2 Nm (1.5 lbf ft)
Screw, combination switch (All
EXC-F Six Days, XCF‑W)
EJOT PT® K50x18
2 Nm (1.5 lbf ft)
Screw, intake air temperature sensor (All EU models)
EJOT DELTA PT® 45x12‑Z
0.7 Nm (0.52 lbf ft)
Screw, pressure regulator
EJOT PT® K60x25‑Z
2 Nm (1.5 lbf ft)
Screw, seat fixing
EJOT EJOFORM
PT®
K60x23/18
2.5 Nm (1.84 lbf ft)
Screw, emergency OFF switch
M4
1 Nm (0.7 lbf ft)
Screw, fixed grip
M4
5 Nm (3.7 lbf ft)
Loctite®243™
Spoke nipple, front wheel
M4.5
5 Nm (3.7 lbf ft)
Spoke nipple, rear wheel
M4.5
5 Nm (3.7 lbf ft)
Remaining nuts, chassis
M5
5 Nm (3.7 lbf ft)
Remaining screws, chassis
M5
5 Nm (3.7 lbf ft)
Screw, battery terminal
M5
2.5 Nm (1.84 lbf ft)
Screw, intake air temperature sensor (XCF‑W)
M5
3 Nm (2.2 lbf ft)
Screw, light switch
M5
1 Nm (0.7 lbf ft)
Screw, turn signal switch
M5
1 Nm (0.7 lbf ft)
Nut, starter motor
M6
4 Nm (3 lbf ft)
Remaining nuts, chassis
M6
10 Nm (7.4 lbf ft)
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
Screw, ball joint of push rod on
foot brake cylinder
M6
10 Nm (7.4 lbf ft)
Screw, chain sliding guard
M6
Loctite®243™
6 Nm (4.4 lbf ft)
Loctite®243™
161
22 TECHNICAL DATA
Screw, front brake disc
M6
14 Nm (10.3 lbf ft)
Loctite®243™
Screw, rear brake disc
M6
14 Nm (10.3 lbf ft)
Loctite®243™
Screw, throttle grip
M6
5 Nm (3.7 lbf ft)
Fuel connection on fuel pump
M8
10 Nm (7.4 lbf ft)
Nut, foot brake lever stop
M8
20 Nm (14.8 lbf ft)
Nut, rear sprocket screw
M8
35 Nm (25.8 lbf ft)
Loctite®2701™
Nut, rim lock
M8
12 Nm (8.9 lbf ft)
Remaining nuts, chassis
M8
25 Nm (18.4 lbf ft)
Remaining screws, chassis
M8
25 Nm (18.4 lbf ft)
Screw, bottom triple clamp (All
EXC-F Six Days)
M8
15 Nm (11.1 lbf ft)
Screw, bottom triple clamp
(EXC‑F EU, XCF‑W)
M8
15 Nm (11.1 lbf ft)
Screw, chain sliding piece
M8
15 Nm (11.1 lbf ft)
Screw, engine brace on engine
M8x20
25 Nm (18.4 lbf ft)
Loctite®243™
Screw, engine brace on frame
M8x15
25 Nm (18.4 lbf ft)
Loctite®2701™
Screw, fork stub
M8
15 Nm (11.1 lbf ft)
Screw, front brake caliper
M8
25 Nm (18.4 lbf ft)
Loctite®243™
Screw, handlebar clamp
M8
20 Nm (14.8 lbf ft)
Screw, manifold
M8
15 Nm (11.1 lbf ft)
Screw, side stand attachment
M8
35 Nm (25.8 lbf ft)
Loctite®2701™
Screw, subframe bottom
M8
30 Nm (22.1 lbf ft)
Loctite®2701™
Screw, subframe top
M8
35 Nm (25.8 lbf ft)
Loctite®2701™
Screw, top steering stem (All EXCF Six Days)
M8
17 Nm (12.5 lbf ft)
Screw, top steering stem
(EXC‑F EU, XCF‑W)
M8
20 Nm (14.8 lbf ft)
Screw, top triple clamp (All EXC-F
Six Days)
M8
17 Nm (12.5 lbf ft)
Screw, top triple clamp (EXC‑F EU, M8
XCF‑W)
20 Nm (14.8 lbf ft)
Engine attachment bolt
M10
60 Nm (44.3 lbf ft)
Remaining nuts, chassis
M10
45 Nm (33.2 lbf ft)
Remaining screws, chassis
M10
45 Nm (33.2 lbf ft)
Screw, handlebar holder
M10
40 Nm (29.5 lbf ft)
Loctite®243™
Loctite®243™
Nut, fuel pump fixation
M12
15 Nm (11.1 lbf ft)
Screw, bottom shock absorber
M12
80 Nm (59 lbf ft)
Loctite®2701™
162
TECHNICAL DATA 22
Screw, top shock absorber
M12
80 Nm (59 lbf ft)
Loctite®2701™
Nut, fork pivot
M16x1.5
100 Nm (73.8 lbf ft)
Nut, rear wheel spindle
M20x1.5
80 Nm (59 lbf ft)
Screw, front wheel spindle
M20x1.5
35 Nm (25.8 lbf ft)
Screw, top steering head
M20x1.5
12 Nm (8.9 lbf ft)
Screw-in fitting, cooling system
M24x1.5
15 Nm (11.1 lbf ft)
Loctite®243™
163
23 SUBSTANCES
Brake fluid DOT 4 / DOT 5.1
Standard/classification
– DOT
Guideline
– Use only brake fluid that complies with the specified standard (see specifications on the container) and that
exhibits the corresponding properties.
Recommended supplier
Castrol
– REACT PERFORMANCE DOT 4
MOTOREX®
– Brake Fluid DOT 5.1
Coolant
Guideline
– Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors. Low grade
and unsuitable antifreeze causes corrosion, deposits and frothing.
–
Do not use pure water as only coolant is able to meet the requirements needed in terms of corrosion protection and lubrication properties.
–
Only use coolant that complies with the requirements stated (see specifications on the container) and that
has the relevant properties.
Antifreeze protection to at least
−25 °C (−13 °F)
The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant needs
to be diluted.
The use of premixed coolant is recommended.
Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility)
with other coolants.
Recommended supplier
MOTOREX®
– COOLANT M3.0
Engine oil (SAE 10W/50)
Standard/classification
– JASO T903 MA2 (
–
SAE (
p. 168)
p. 168) (SAE 10W/50)
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that
possess the corresponding properties.
Fully synthetic engine oil
Recommended supplier
MOTOREX®
– Cross Power 4T
164
SUBSTANCES 23
Fork oil (SAE 4) (48601166S1)
Standard/classification
– SAE ( p. 168) (SAE 4)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit
the corresponding properties.
Shock absorber fluid (SAE 2.5) (50180751S1)
Standard/classification
– SAE ( p. 168) (SAE 2.5)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit
the corresponding properties.
Super unleaded (ROZ 95/RON 95/PON 91)
Standard/classification
– DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
– Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
–
Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15,
E25, E85, E100).
165
24 AUXILIARY SUBSTANCES
Air filter cleaner
Recommended supplier
MOTOREX®
– Racing Bio Dirt Remover
Chain cleaner
Recommended supplier
MOTOREX®
– Chain Clean
Fuel additive
Recommended supplier
MOTOREX®
– Fuel Stabilizer
High viscosity grease
Recommended supplier
SKF®
– LGHB 2
Long-life grease
Recommended supplier
MOTOREX®
– Bike Grease 2000
Motorcycle cleaner
Recommended supplier
MOTOREX®
– Moto Clean
Off-road chain spray
Recommended supplier
MOTOREX®
– Chainlube Offroad
Oil for foam air filter
Recommended supplier
MOTOREX®
– Racing Bio Liquid Power
Preserving materials for paints, metal and rubber
Recommended supplier
MOTOREX®
– Moto Protect
166
AUXILIARY SUBSTANCES 24
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
Recommended supplier
MOTOREX®
– Quick Cleaner
Universal oil spray
Recommended supplier
MOTOREX®
– Joker 440 Synthetic
167
25 STANDARDS
JASO T903 MA2
Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2
standard.
Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle specification.
Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high
performance at high engine speeds.
In most motorcycle engines, the transmission and clutch are lubricated with the same oil.
The JASO T903 MA2 standard meets these special requirements.
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils
according to their viscosity. The viscosity describes only one property of oil and says nothing about quality.
168
INDEX OF SPECIAL TERMS 26
OBD
On-board diagnosis
Vehicle system, which monitors the specified parameters of the vehicle electronics
169
27 LIST OF ABBREVIATIONS
Art. no.
Article number
ca.
circa
cf.
compare
e.g.
for example
etc.
et cetera
i.a.
inter alia
no.
number
poss.
possibly
170
LIST OF SYMBOLS 28
28.1
Yellow and orange symbols
Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are
also represented by yellow or orange symbols.
Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the
vehicle electronics. Come safely to a halt, and contact an authorized KTM workshop.
The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.
28.2
Green and blue symbols
Green and blue symbols reflect information.
The high beam indicator lamp lights up blue – The high beam is switched on.
Turn signal indicator lamp flashes green – The turn signal is switched on.
171
INDEX
Chain guide
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 92
INDEX
1
12-V battery
charging . . .
installing . . .
removing . . .
starting power
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123
122
121
. 39
A
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Air filter
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 82
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 81
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Air filter box
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Air filter box cover
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 80
preparing for securing . . . . . . . . . . . . . . . . . 82
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Antifreeze
checking . . . . . . . . . . . . . . . . . . . . . . . . . 133
Auxiliary substances . . . . . . . . . . . . . . . . . . . . . 11
B
Basic chassis setting
rider's weight, checking with . . . . . . . . . . . . 52
Brake discs
checking . . . . . . . . . . . . . . . . . . . . . . . . . 101
Brake fluid
of front brake, adding . . . . . . . . . . . . . . . . 102
of rear brake, adding . . . . . . . . . . . . . . . . . 110
Brake fluid level
of front brake, checking . . . . . . . . . . . . . . . 102
rear brake, checking . . . . . . . . . . . . . . . . . 110
Chain tension
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 91
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Characteristic map of the throttle response
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 138
Clutch
fluid level, checking/correcting . . . . . . . . . . . 96
fluid, changing . . . . . . . . . . . . . . . . . . . . . . 97
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
basic position, adjusting . . . . . . . . . . . . . . . 96
Cold start button . . . . . . . . . . . . . . . . . . . . . . . . 21
Combination instrument
combination instrument battery, changing
kilometers or miles, setting . . . . . . . . . .
lap time, viewing . . . . . . . . . . . . . . . . .
overview . . . . . . . . . . . . . . . . . . . . . . .
setting . . . . . . . . . . . . . . . . . . . . . . . .
setting the clock . . . . . . . . . . . . . . . . . .
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131
. 25
. 27
. 25
. 26
. 27
Compression damping
fork, adjusting . . . . . . . . . . . . . . . . . . . . . . 58
Coolant
antifreeze and coolant level, checking
draining . . . . . . . . . . . . . . . . . . . .
level, checking . . . . . . . . . . . . . . . .
refilling . . . . . . . . . . . . . . . . . . . . .
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133
135
134
136
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . 133
Customer service . . . . . . . . . . . . . . . . . . . . . . . 11
D
Diagnostics connector . . . . . . . . . . . . . . . . . . . 132
Brake system . . . . . . . . . . . . . . . . . . . . . . 100-114
Difficult operating conditions
dry sand . . . . . . . . . .
high temperatures . . .
low temperature . . . . .
muddy surfaces . . . . .
slow speed . . . . . . . .
snow . . . . . . . . . . . . .
wet sand . . . . . . . . . .
wet surfaces . . . . . . .
C
Difficult riding conditions . . . . . . . . . . . . . . . . . . 39
Capacity
coolant . . . . . . . . . . . . . . . . . . . . . . 136, 157
engine oil . . . . . . . . . . . . . . . . . . . . 146, 157
fuel . . . . . . . . . . . . . . . . . . . . . . 48, 157-158
E
Brake linings
front brake, checking .
of front brake, changing
of rear brake, changing
rear brake, checking . .
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104
104
112
111
Chain
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 92
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 89
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39
41
42
41
41
42
40
41
Emergency OFF switch . . . . . . . . . . . . . . . . . . . . 18
Engine
running-in . . . . . . . . . . . . . . . . . . . . . . . . . 38
Engine guard
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 99
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . 14
172
INDEX
free travel, checking . . . . . . . . . . . . . . . . . 100
Engine oil
adding . . . . . . . . . . . . . . . . . . . . . . . . . . 147
changing . . . . . . . . . . . . . . . . . . . . . . . . . 144
Handlebar position . . . . . . . . . . . . . . . . . . . . . . 61
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Engine oil level
checking . . . . . . . . . . . . . . . . . . . . . . . . . 144
Headlight
range, adjusting . . . . . . . . . . . . . . . . . . . . 130
Engine sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Headlight bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . 129
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Headlight mask with headlight
installing . . . . . . . . . . . . . . . . . . . . . . . . . 128
removing . . . . . . . . . . . . . . . . . . . . . . . . . 127
Filling up
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Headlight setting
checking . . . . . . . . . . . . . . . . . . . . . . . . . 129
Foot brake lever . . . . . . . . . . . . . . . . . . . . . . . . 22
basic position, adjusting . . . . . . . . . . . . . . 109
free travel, checking . . . . . . . . . . . . . . . . . 108
High-speed compression damping
shock absorber, adjusting . . . . . . . . . . . . . . 53
Fork legs
basic setting, checking .
bleeding . . . . . . . . . . .
dust boots, cleaning . . .
installing . . . . . . . . . . .
removing . . . . . . . . . . .
spring preload, adjusting
I
F
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57
64
65
67
66
60
Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Idle speed
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 140
Idle speed adjusting screw . . . . . . . . . . . . . . . . . 21
Implied warranty . . . . . . . . . . . . . . . . . . . . . . . . 11
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
K
Fork protector
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 66
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Frame
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Front fender
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 77
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Front wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . 116
removing . . . . . . . . . . . . . . . . . . . . . . . . . 115
Fuel screen
changing . . . . . . . . . . . . . . . . . . . . . . . . . 143
Fuel tank
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 87
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Fuel tank filler cap
closing . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
opening . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fuse
main fuse, changing . . . . . . . . . . . . . . . . . 125
of the individual power consumers, changing 126
H
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . 16
basic position, adjusting . . . . . . . . . . . . . . 101
free travel, adjusting . . . . . . . . . . . . . . . . . 100
L
Link fork
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Lower triple clamp
installing . . . . . . . . . . . . . . . . . . . . . . . 70, 72
removing . . . . . . . . . . . . . . . . . . . . . . . . 68-69
Low-speed compression damping
shock absorber, adjusting . . . . . . . . . . . . . . 52
M
Main fuse
changing . . . . . . . . . . . . . . . . . . . . . . . . . 125
Main silencer
glass fiber yarn filling, changing
installing . . . . . . . . . . . . . . . .
removing . . . . . . . . . . . . . . . .
spark arrestor, cleaning . . . . . .
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85
83
83
83
Manufacturer warranty . . . . . . . . . . . . . . . . . . . . 11
Mapping
changing . . . . . . . . . . . . . . . . . . . . . . . . . 139
Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Motorcycle
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 148
lift stand, removing from . . . . . . . . . . . . . . . 64
173
INDEX
raising with lift stand
. . . . . . . . . . . . . . . . . 64
O
Oil filter
changing . . . . . . . . . . . . . . . . . . . . . . . . . 144
Start button . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Starting power of lithium-ion batteries at low temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Oil screens
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 144
Steering
locking . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
unlocking . . . . . . . . . . . . . . . . . . . . . . . . . 24
Overview of indicator lamps . . . . . . . . . . . . . . . . 19
Owner's Manual . . . . . . . . . . . . . . . . . . . . . . . . 10
Steering head bearing
lubricating . . . . . . . . . . . . . . . . . . . . . . . . . 75
P
Steering head bearing play
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 73
setting . . . . . . . . . . . . . . . . . . . . . . . . . 74-75
Preparing for use
advice on preparing for first use . . .
after storage . . . . . . . . . . . . . . . .
checks and maintenance measures
preparing for use . . . . . . . . . . . . .
. . . . . . . 37
. . . . . . 151
when
. . . . . . . 43
Protective clothing . . . . . . . . . . . . . . . . . . . . . . . 9
R
Rear sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Rear wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . 117
removing . . . . . . . . . . . . . . . . . . . . . . . . . 116
Rebound damping
fork, adjusting . . . . . . . . . . . . . . . . . . . . . . 59
shock absorber, adjusting . . . . . . . . . . . . . . 54
Storage . . . . . . . . . . . . . . . . . . . . . . . . . 150-151
Switch-off button . . . . . . . . . . . . . . . . . . . . . . . 16
T
Technical data
capacities . . . . . . . . . . .
chassis . . . . . . . . . . . . .
chassis tightening torques
electrical system . . . . . .
engine . . . . . . . . . . . . .
engine tightening torques
fork . . . . . . . . . . . . . . .
shock absorber . . . . . . . .
tires . . . . . . . . . . . . . . .
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157
158
161
159
155
156
159
160
159
Riding sag
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Throttle cable play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 137
checking . . . . . . . . . . . . . . . . . . . . . . . . . 137
Rubber grip
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Throttle cable routing
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 94
S
Throttle grip . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Throttle valve position
teaching . . . . . . . . . . . . . . . . . . . . . . . . . 141
Seat
mounting . . . . . . . . . . . . . . . . . . . . . . . . . 79
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . 119
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Service schedule . . . . . . . . . . . . . . . . . . . . . 49-51
Tire pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . 119
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
basic position, adjusting . . . . . . . . . . . . . . 142
basic position, checking . . . . . . . . . . . . . . 141
Traction control
activating . . . . . . . . . . . . . . . . . . . . . . . . . 44
Shock absorber
installing . . . . . . . . . . .
removing . . . . . . . . . . .
riding sag, checking . . .
spring preload, adjusting
static sag, checking . . .
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78
78
55
56
55
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Spoke tension
checking . . . . . . . . . . . . . . . . . . . . . . . . . 120
174
Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Troubleshooting . . . . . . . . . . . . . . . . . . . . 152-154
Turn signal bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . 130
Turn signal switch . . . . . . . . . . . . . . . . . . . . . . . 18
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
U
Use definition
.......................... 7
INDEX
V
Vehicle identification number . . . . . . . . . . . . . . . 14
View of vehicle
front left . . . . . . . . . . . . . . . . . . . . . . . . . . 12
rear right . . . . . . . . . . . . . . . . . . . . . . . . . . 13
W
Winter operation
checks and maintenance steps . . . . . . . . . . 149
Work rules
............................ 9
175
*3214012en*
3214012en
05/2019
KTM Sportmotorcycle GmbH
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer/KISKA/KTM
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