KTM 400 XC-W, 530 EXC User Manual
OWNER'S MANUAL 2010
400 EXC EU
400 EXC AUS
400 XC-W USA
450 EXC EU
450 EXC AUS
450 EXC SIX DAYS EU
450 XC-W SIX DAYS USA
450 XC-W ZA
530 EXC EU
530 EXC AUS
530 EXC SIX DAYS EU
530 XC-W SIX DAYS USA
530 XC-W ZA
Art. no. 3211467en
DEAR KTM CUSTOMER 1
DEARKTM CUSTOMER
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you enormous pleasure if you service and maintain it accordingly.
We wish you great pleasure riding the vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( p. 9) Dealer's stamp
Engine number ( p. 9)
Key number (all EXC models) ( p. 9)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing
development and design of our motorcycles can however not be completely excluded.
All details contained in it are non-binding. KTM Sportmotorcycle AG 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 illustrations and descriptions, as well as for printing and other errors. The models portrayed partly
contain special equipment that does not belong to the regular scope of delivery.
© 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS 2
TABLEOF CONTENTS
MEANS OF REPRESENTATION ............................................ 4
IMPORTANT INFORMATION ................................................ 5
VIEW OF VEHICLE............................................................... 7
View of the vehicle from the left front (example) ................. 7
View of the vehicle from the right rear (example) ................ 8
LOCATION OF SERIAL NUMBERS ........................................ 9
Chassis number............................................................... 9
Type label....................................................................... 9
Key number (all EXC models) ........................................... 9
Engine number................................................................ 9
Fork part number............................................................. 9
Shock absorber part number ........................................... 10
CONTROLS....................................................................... 11
Clutch lever .................................................................. 11
Hand brake lever ........................................................... 11
Short circuit button (all XC‑W models)............................. 11
Short circuit button (all EXC models)............................... 11
Emergency OFF switch (EXC AUS) .................................. 11
Electric starter button (EXC EU, EXC SIX DAYS, XC-W,
XC‑W SIX DAYS)............................................................ 12
Electric starter button (EXC AUS).................................... 12
Light switch (all EXC models) ......................................... 12
Light switch (all XC‑W models) ....................................... 12
Horn button (all EXC models) ......................................... 12
Flasher switch (all EXC models) ...................................... 13
Overview of indicator lamps (all EXC models) ................... 13
Speedometer................................................................. 13
Speedometer activation and test ..................................... 13
Tripmaster switch .......................................................... 14
Setting kilometers or miles ............................................. 14
Setting the clock ........................................................... 14
Adjusting the speedometer functions............................... 15
Querying the lap time .................................................... 15
SPEED display mode (speed).......................................... 16
Display mode SPEED/H (service hours) ............................ 16
Display mode SPEED/CLK (clock) ................................... 16
Display mode SPEED/LAP (lap time) ............................... 16
Display mode SPEED/ODO (odometer) ............................. 17
Display mode SPEED/TR1 (trip master 1) ........................ 17
Display mode SPEED/TR2 (trip master 2) ........................ 17
Disply mode SPEED/A1 (average speed 1) ....................... 18
Display mode SPEED/A2 (average speed 2)...................... 18
Display mode SPEED/S1 (stop watch 1) .......................... 18
Display mode SPEED/S2 (stop watch 2) .......................... 18
Fuel tap........................................................................ 20
Opening filler cap.......................................................... 20
Closing filler cap ........................................................... 20
Choke (EXC AUS, XC‑W, XC‑W SIX DAYS) ........................ 20
Choke (EXC EU, EXC SIX DAYS) ..................................... 21
Shift lever..................................................................... 21
Foot brake pedal ........................................................... 21
Kick starter................................................................... 21
Side stand .................................................................... 22
Steering lock (all EXC models) ........................................ 22
Locking the steering (all EXC models).............................. 22
Unlocking the steering (all EXC models) .......................... 23
GENERAL TIPS AND HINTS ON PUTTING INTO
OPERATION...................................................................... 24
Advice on first use ......................................................... 24
Running-in the engine ................................................... 25
Preparing vehicle for arduous riding conditions................. 25
Preparing for riding on dry sand ...................................... 25
Preparing for riding on wet sand...................................... 26
Preparing for riding on wet and muddy surfaces................ 27
Preparing for rides at high temperature and slow speed ..... 28
Preparing for rides at low temperatures or in snow ............ 28
RIDING INSTRUCTIONS .................................................... 29
Checks before putting into operation ............................... 29
Starting ........................................................................ 29
Starting up ................................................................... 30
Shifting, riding.............................................................. 30
Braking ........................................................................ 30
Stopping, parking .......................................................... 31
Refueling...................................................................... 31
SERVICE SCHEDULE......................................................... 33
Important maintenance work to be carried out by an
authorized KTM workshop. ............................................. 33
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order)................ 34
Important checks and maintenance work to be carried
out by the rider. ............................................................ 35
MAINTENANCE WORK ON CHASSIS AND ENGINE .............. 36
Jacking up the motorcycle .............................................. 36
Removing the motorcycle from the work stand.................. 36
Checking the basic suspension setting with the rider's
weight .......................................................................... 36
Compression damping of shock absorber.......................... 36
Adjusting high-speed compression damping of the shock
absorber ....................................................................... 36
Adjusting the low-speed compression damping of the
shock absorber .............................................................. 37
Adjusting rebound damping of the shock absorber ............ 37
Measuring rear wheel sag unloaded ................................. 38
Checking static sag of shock absorber.............................. 38
Checking riding sag of shock absorber ............................. 39
Adjusting spring preload of the shock absorber x............ 39
Adjusting riding sag x .................................................. 40
Removing the shock absorber x..................................... 40
Installing the shock absorber x ..................................... 40
Checking basic setting of fork ......................................... 41
Adjusting the compression damping of the fork ................ 41
Adjusting rebound damping of fork.................................. 41
Adjusting spring preload of the fork................................. 42
Bleeding fork legs.......................................................... 42
Cleaning the dust boots of the fork legs ........................... 42
Loosening the fork protector ........................................... 43
Positioning the fork protector.......................................... 43
Checking steering head bearing play................................ 43
Adjusting play of steering head bearing x (EXC EU,
EXC AUS, XC‑W ZA)....................................................... 44
Adjusting play of steering head bearing x
(EXC SIX DAYS, XC‑W SIX DAYS, XC‑W USA)................... 44
Removing the fork legs x.............................................. 44
Installing fork legs x .................................................... 45
Removing the fork protector x....................................... 46
Installing the fork protector x ....................................... 46
Removing the front fender .............................................. 46
Installing the front fender............................................... 46
Removing headlight mask with headlight (all EXC
models, all 450/530 XC-W models) ................................. 46
Refitting the headlight mask with the headlight (all EXC
models, all 450/530 XC-W models) ................................. 47
Removing the start number plate (400 XC-W USA) ........... 47
Installing the start number plate (400 XC-W USA) ............ 47
TABLE OF CONTENTS 3
Handlebar position ........................................................ 48
Adjusting handlebar position x...................................... 48
Checking throttle cable route .......................................... 48
Checking the play in the throttle cable............................. 49
Adjusting the play in the throttle cable x ....................... 49
Checking for chain dirt accumulation .............................. 49
Cleaning the chain......................................................... 50
Checking the chain tension ............................................ 50
Checking chain tension when fitting rear wheel ................ 51
Checking the rear sprocket/engine sprocket for wear ......... 51
Checking chain wear...................................................... 51
Adjusting chain tension.................................................. 52
Adjusting chain tension - after checking .......................... 53
Adjusting chain tension - fitting rear wheel ...................... 53
Adjusting chain guide x ............................................... 54
Checking brake discs ..................................................... 54
Checking free travel of hand brake lever........................... 54
Adjusting basic position of hand brake lever (all XC‑W
models) ........................................................................ 55
Adjusting free travel of hand brake lever (all EXC
models) ........................................................................ 55
Checking the brake fluid level of the front brake ............... 55
Topping up the front brake fluid x................................. 56
Checking the front brake linings...................................... 57
Changing the front brake linings x................................. 57
Checking free play of foot brake lever .............................. 59
Adjusting basic position of foot brake lever x.................. 59
Checking rear brake fluid level ........................................ 59
Adding brake fluid to the rear brake circuit x ................. 60
Checking rear brake linings ............................................ 60
Changing rear brake linings x ....................................... 61
Removing front wheel x................................................ 62
Fitting front wheel x .................................................... 63
Removing the rear wheel x ........................................... 64
Fitting rear wheel x...................................................... 64
Checking the tire condition............................................. 65
Checking tire air pressure ............................................... 66
Checking spoke tension.................................................. 66
Removing the battery x ................................................ 67
Installing the battery x................................................. 67
Recharging the battery x .............................................. 67
Removing a fuse............................................................ 68
Installing the fuse ......................................................... 68
Checking the headlight adjustment (all EXC models, all
450/530 XC-W models) ................................................. 69
Adjusting the beam width of the headlight (all EXC
models, all 450/530 XC-W models) ................................. 69
Removing the seat ......................................................... 69
Mounting the seat ......................................................... 70
Removing the fuel tank x ............................................. 70
Installing the fuel tank x .............................................. 71
Cooling system .............................................................. 71
Checking the anti-freeze and coolant level ....................... 72
Checking the coolant level.............................................. 72
Draining coolant x ....................................................... 73
Refilling coolant x ....................................................... 73
Glass fiber yarn filling of main silencer ............................ 74
Removing main silencer ................................................. 74
Installing the main silencer ............................................ 74
Removing the air filter box lid......................................... 74
Installing the air filter box lid.......................................... 74
Removing the air filter x............................................... 75
Installing the air filter x ............................................... 75
Cleaning air filter x...................................................... 75
Adjusting basic position of clutch lever............................ 76
Checking the fluid level of hydraulic clutch...................... 76
Changing the hydraulic clutch fluid x ............................ 76
Checking the basic position of the shift lever.................... 77
Adjusting the basic position of the shift lever x .............. 77
Carburetor - idle ............................................................ 78
Carburetor - adjusting idle x ......................................... 78
Emptying the carburetor float chamber x ....................... 79
Checking engine oil level................................................ 80
Changing engine oil and oil filter, cleaning engine oil
screen x ..................................................................... 80
Draining engine oil, cleaning engine oil screen x ............ 80
Removing the oil filter x............................................... 81
Installing the oil filter x ............................................... 81
Filling up with engine oil x........................................... 82
Topping up engine oil .................................................... 82
Checking the gear oil level.............................................. 83
Changing gear oil, cleaning gear oil screen x.................. 83
Draining gear oil, cleaning gear oil screen x ................... 83
Filling up with gear oil x .............................................. 84
Adding gear oil x ......................................................... 84
TROUBLESHOOTING......................................................... 86
CLEANING........................................................................ 88
Cleaning the motorcycle ................................................. 88
STORAGE ......................................................................... 89
Storage......................................................................... 89
Putting into operation after storage ................................. 89
TECHNICAL DATA - ENGINE .............................................. 90
Capacity - engine oil ...................................................... 90
Capacity - gear oil.......................................................... 91
Capacity - coolant.......................................................... 91
TECHNICAL DATA - ENGINE TIGHTENING TORQUES .......... 92
TECHNICAL DATA - CARBURETOR..................................... 94
400 EXC EU/AUS .......................................................... 94
400 XC-W USA ............................................................. 94
450 EXC EU/AUS, 450 EXC SIX DAYS ............................ 94
450 XC‑W ZA, 450 XC‑W SIX DAYS ................................ 95
530 EXC EU/AUS, 530 EXC SIX DAYS ............................ 95
530 XC‑W ZA, 530 XC‑W SIX DAYS ................................ 95
TECHNICAL DATA - CHASSIS ............................................ 96
Lighting equipment ....................................................... 96
Tires ............................................................................ 97
Capacity - fuel............................................................... 97
TECHNICAL DATA - FORK.................................................. 98
TECHNICAL DATA - SHOCK ABSORBER ............................. 99
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 100
WIRING DIAGRAM .......................................................... 102
Wiring diagram (all EXC models) ................................... 102
Wiring diagram (all XC‑W models) ................................. 106
SUBSTANCES................................................................. 108
AUXILIARY SUBSTANCES................................................ 110
STANDARDS................................................................... 112
INDEX ............................................................................ 113
MEANS OF REPRESENTATION 4
Symbols used
The symbols used are explained in the following.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of
your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced
optimally by specially trained experts using the specialist tools required.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained in the following.
Specific name Identifies a specific name.
®
Name
Brand™ Identifies a brand in merchandise traffic.
Identifies a protected name.
IMPORTANT INFORMATION 5
Use definition (all EXC models)
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle is authorized for use on public roads in the homologated (reduced) version only.
In the derestricted version, the motorcycle must be used only on closed off properties remote from public road traffic.
The motorcycle is designed for off-road sport endurance competition (Enduro) and not for the predominant motocross use.
Use definition (all XC‑W models)
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle may only be used in closed off areas remote from public road traffic.
The motorcycle is designed for off-road sport endurance competition (Enduro) and not for the predominant motocross use.
Maintenance
A prerequisite for trouble free operation and avoiding premature wear is that the engine and suspension are maintained and adjusted
as described in this manual. Poor adjustment and tuning of the engine and suspension can lead to damage and breakage of components.
Using a motorcycle in difficult conditions such as on sand or very wet and muddy ground can lead to excessive wear of components
such as the power train or brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the
service schedule is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. Observing these rules will vastly
increase the service life of your motorcycle.
Warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
service record; otherwise, all warranty claims will be void. No warranty claim can be honored for damage resulting from manipulation
and/or other changes to the vehicle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
Spare parts, accessories
For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have
them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Some spare parts and accessories are specified in brackets in the respective descriptions. Your KTM dealer will be happy to advise
you.
You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com
Work rules
Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in
parentheses. Ex: valve spring compressor (59029019000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
If thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its
usage.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Following repairs or servicing, the vehicle must be checked for roadworthiness.
IMPORTANT INFORMATION 6
Transport
Note
Danger of damage The parked vehicle can roll away or fall over.
– Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from
being run. Always let the vehicle cool first.
– Switch off engine.
– Turn handle of the fuel tap to the OFF position. (Figure 500137-10 p. 20)
– Use straps or other suitable devices to secure the motorcycle against accidents or falling over.
Environment
Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the
environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
Notes/warnings
Pay close attention to the notes/warnings.
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing, you or others may not recognize potential hazards and may therefore be injured.
Grades of risks
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Owner's manual
– It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful infor-
mation and many tips on how to operate and handle your motorcycle. Only then will you find out how to best customize the motorcycle for your own use and how you can protect yourself from injury. The owner's manual also contains important information on
servicing the motorcycle.
– The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is
sold.
VIEW OF VEHICLE 7
3.1View of the vehicle from the left front (example)
1 Hand brake lever
2 Clutch lever
3 Air filter box lid
4 Fuel tap
5 Chain guide
6 Side stand
7 Shift lever
100799-10
VIEW OF VEHICLE 8
3.2View of the vehicle from the right rear (example)
1 Filler cap
2 Short circuit button
3 Speedometer
4 Electric starter button
5 Fork rebound adjustment
6 Horn
7 Fork compression adjustment
8 Shock absorber rebound adjustment
9 Level viewer for brake fluid, rear
10 Shock absorber compression adjustment
11 Foot brake pedal
12 Kick starter
100800-10
LOCATION OF SERIAL NUMBERS 9
4.1Chassis number
The chassis number is stamped on the steering head on the right.
500127-10
4.2Type label
The type label is fixed to the front of the steering head.
4.3Key number (all EXC models)
4.4Engine number
500128-10
The key number is stamped on the key strap.
500125-10
The engine number is stamped on the left side of the engine under the engine
sprocket.
4.5Fork part number
500072-10
The fork part number is stamped on the inner side of the fork stub.
100801-10
LOCATION OF SERIAL NUMBERS 10
4.6Shock absorber part number
The shock absorber part number is stamped on the top of the shock absorber above
the adjusting ring on the engine side.
500129-10
CONTROLS 11
5.1Clutch lever
The clutch lever is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
500133-10
5.2Hand brake lever
Hand brake lever is located on the right side of the handlebar.
The hand brake lever is used to activate the front brake.
400196-10
5.3Short circuit button (all XC‑W models)
500132-10
5.4Short circuit button (all EXC models)
The short circuit button is fitted on the left side of the handlebar.
Possible states
• Short circuit button in basic position – In this position, the ignition circuit is
closed, and the engine can be started.
• Short circuit button pressed – In this position, the ignition circuit is interrupted,
a running engine stops, and a non-running engine will not start.
The short circuit button is fitted on the left side of the handlebar.
Possible states
• Short circuit button in basic position – In this position, the ignition circuit is
closed, and the engine can be started.
• Short circuit button pressed – In this position, the ignition circuit is interrupted,
a running engine stops, and a non-running engine will not start.
500134-10
5.5Emergency OFF switch (EXC AUS)
500131-10
The emergency OFF switch is fitted on the right side of the handlebar.
Possible states
Ignition off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.
Ignition on – In this position, the ignition circuit is closed, and the
engine can be started.
CONTROLS 12
5.6Electric starter button (EXC EU, EXC SIX DAYS, XC-W, XC‑W SIX DAYS)
The electric starter button is fitted on the right side of the handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button pressed – In this position, the electric starter is actuated.
400198-10
5.7Electric starter button (EXC AUS)
The electric starter button is fitted on the right side of the handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button pressed – In this position, the electric starter is actuated.
500131-11
5.8Light switch (all EXC models)
500134-12
5.9Light switch (all XC‑W models)
500146-10
The light switch is fitted on the left side of the handlebar.
Possible states
Light off – Light switch is turned to the right. In this position, the light
is switched off.
Low beam on – Light switch is in the central position. In this position,
the low beam and tail light are switched on.
High beam on – Light switch is turned to the left. In this position, the
high beam and the tail light are switched on.
The light switch is on the right of the speedometer.
Possible states
(XC‑W ZA, XC‑W SIX DAYS)
• 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 tail light are switched on.
(400 XC-W USA)
• The light switch has no function when delivered – It can be used if lighting is
fitted later.
5.10Horn button (all EXC models)
The horn button is fitted on the left side of the handlebar.
Possible states
• Horn button in neutral position
• Horn button pressed – The horn is operated in this position.
500134-11
CONTROLS 13
5.11Flasher switch (all EXC models)
The flasher switch is fitted on the left side of the handlebar.
Possible states
Flasher light off – Flasher switch is in the central position.
Flasher light, left, on – Flasher switch turned to the left.
Flasher light, right, on – Flasher switch turned to the right.
500145-10
5.12Overview of indicator lamps (all EXC models)
Possible states
High beam indicator lamp lights up blue – High beam is switched on.
Turn signal indicator lamp flashes green – Turn signal light is switched
on.
500147-01
5.13Speedometer
400312-01
5.14Speedometer activation and test
– Press the key to change the display mode or change to one of the setup menus.
– Press the button to control different functions.
– Press the button to control different functions.
Info
In its condition at delivery, the display mode SPEED/H andSPEED/ODO is activated.
Activating the speedometer:
The speedometer is activated when one of the keys is pressed or a signal is received
from the wheel speed sensor.
Display test
For the function test of the display, all display segments light up briefly.
400313-01
400314-01
WS (wheel size)
After the display function test, the wheel size WS is displayed briefly.
Info
2205 mm corresponds to the size of the 21" front wheel with a series production tire.
The display then changes to the last selected mode.
CONTROLS 14
5.15Tripmaster switch
(Option: Tripmaster switch)
You can use the trip master switch to control the functions of the speedometer from the handlebar.
Info
The trip master is an optional accessory.
5.16Setting 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.
– Press the button briefly and repeatedly until H appears at the bottom right of the
display.
– Press the button for 3 - 5 seconds.
The setup menu is displayed and the active functions shown.
– Press the button repeatedly until the Km/h/Mph display flashes.
Km/h adjusting
– Press the button .
Mph adjusting
400329-01
– Press the button .
– Press the button for 3 - 5 seconds.
The settings are stored and the setup menu closed.
5.17Setting the clock
400330-01
Info
If no button is actuated for 20 seconds or there is no signal from the wheel
speed sensor, then the settings are automatically stored and the setup menu
closed.
Condition
The motorcycle is stationary.
– Press the button briefly and repeatedly until CLK appears at the bottom right of
the display.
– Press the button for 3 - 5 seconds.
The hour display flashes.
– Set the hour display with the button and/or button .
– Press the button briefly.
The next segment of the display flashes and can be set.
– You can set the following segments in the same way as the hours by pressing
the button and the button .
Info
The seconds can only be set to zero.
– Press the button for 3 - 5 seconds.
The settings are saved and the Setup menu closed.
Info
If no button is pressed for 20 seconds, or if no impulse comes from the
wheel speed sensor, the settings are automatically saved and the Setup
menu closed.
CONTROLS 15
5.18Adjusting the speedometer functions
Info
Upon delivery, only the SPEED/H and SPEED/ODO display modes are activated.
Condition
The motorcycle is stationary.
– Press the button briefly and repeatedly until H appears at the bottom right of the
display.
– Press the button for 3 - 5 seconds.
The Setup menu opens and the active functions are displayed.
– Switch to the function you require by briefly pressing the button .
The selected function flashes.
Activating a function
– Press the button .
400318-01
Deactivating a function
– Press the button .
– Activate or deactivate all functions accordingly.
– Press the button for 3 - 5 seconds.
The icon remains in the display and the display changes to the next function.
The icon disappears from the display and the display changes to the next
function.
The settings are saved and the Setup menu closed.
5.19Querying the lap time
Info
This function can be called only if lap times are measured.
Condition
The motorcycle is stationary.
– Press the button briefly and repeatedly until LAP appears at the bottom right of
the display.
– Press the button briefly.
– Laps 1-10 can be displayed by pressing the button .
– The button has no function
– Press the button briefly.
400321-01
Info
If no button is pressed for 20 seconds, or if no impulse comes from the
wheel speed sensor, the settings are automatically saved and the Setup
menu is closed.
LAP 1 appears on the left side of the display.
Next display mode
Info
If an impulse is received from the wheel speed sensor, the left side of the
display changes back to the SPEED mode.
CONTROLS 16
5.20SPEED display mode (speed)
– Press the button briefly and repeatedly until SPEED appears on the left side of
the display.
The current speed is displayed in the SPEED display mode.
The current speed can be displayed in Km/h or Mph.
Info
Making the setting according to the country.
When an impulse comes from the front wheel, the left side of the speedometer
400317-02
5.21Display mode SPEED/H (service hours)
400316-01
display changes to the SPEED mode and the current speed is shown.
Condition
• The motorcycle is stationary
– Press the button briefly and repeatedly until H appears at the bottom right of the
display.
In display mode H, the service hours of the engine are displayed.
The service hour counter stores the total traveling time.
Info
The service hour counter is necessary for ensuring that maintenance work is carried out at the right intervals.
If the speedometer is in H display mode at the start of the journey, it automatically changes to the ODO display mode.
The H display mode is suppressed during the journey.
5.22Display mode SPEED/CLK (clock)
400319-01
5.23Display mode SPEED/LAP (lap time)
Press the button . No function
Press the button . No function
Press the button
for 3 - 5 seconds.
Press the button
The display changes to the Setup menu of the speedometer
functions.
Next display mode
briefly.
– Press the button briefly and repeatedly until CLK appears at the bottom right of
the display.
The time is displayed in CLK display mode.
Press the button . No function
Press the button . No function
Press the button
The display changes to the Setup menu of the clock.
for 3 - 5 seconds.
Press the button
Next display mode
briefly.
– Press the button briefly and repeatedly until LAP appears at the bottom right of
the display.
In the LAP display mode, up to 10 lap times can be timed with the stop watch.
400320-01
Info
If the lap time continues after you press the button , 9 memory locations are
already occupied.
Lap 10 must be timed with the button .
Press the button . Starts or stops the clock.
Press the button . Stops the current lap time and saves it, and the stop watch
starts the next lap.
CONTROLS 17
5.24Display mode SPEED/ODO (odometer)
400317-01
5.25Display mode SPEED/TR1 (trip master 1)
Press the button
The stop watch and the lap time are reset.
for 3 - 5 seconds.
Press the button
Next display mode
briefly.
– Press the button briefly and repeatedly until ODO appears at the bottom right of
the display.
In ODO display mode, the total number of kilometers ridden is displayed.
Press the button . No function
Press the button . No function
Press the button
–
for 3 - 5 seconds.
Press the button
Next display mode
briefly.
– Press the button briefly and repeatedly until TR1 appears at the top right of the
display.
TR1 (trip master 1) runs constantly and counts up to 999.9.
You can use it to measure trips or the distance between refuelling stops.
TR1 is coupled with A1 (average speed 1) and S1 (stop watch 1).
400323-01
5.26Display mode SPEED/TR2 (trip master 2)
400324-01
Info
If 999.9 is exceeded, the values of TR1, A1 and S1 are automaticallt reset to
0.0.
Press the button . No function
Press the button . No function
Press the button
Displays of TR1, A1 and S1 are reset to 0,0.
for 3 - 5 seconds.
Press the button
Next display mode
briefly.
– Press the button briefly and repeatedly until TR2 appears at the top right of the
display.
TR2 (trip master 2) runs constantly and counts up to 999.9.
The displayed value can be set manually with the button and the button . A very
practical function when riding using the road book.
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.
Press the button . Increases value of TR2.
Press the button . Reduces value of TR2.
Press the button
Deletes value of TR2.
for 3 - 5 seconds.
Press the button
Next display mode
briefly.
CONTROLS 18
5.27Disply mode SPEED/A1 (average speed 1)
– Press the button briefly and repeatedly until A1 appears at the top right of the
display.
A1 (average speed 1) shows the average speed calculated 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.
Press the button . No function
400325-01
5.28Display mode SPEED/A2 (average speed 2)
Press the button . No function
Press the button
Displays of TR1, A1 and S1 are reset to 0,0.
for 3 - 5 seconds.
Press the button
Next display mode
briefly.
– Press the button briefly and repeatedly until A2 appears at the top right of the
display.
A2 (average speed 2) shows the average speed on the basis of the current speed if the
stop watch S2 (stop watch 2) is running.
400326-01
5.29Display mode SPEED/S1 (stop watch 1)
400327-01
Info
The displayed value can differ from the actual average speed if S2 was not
timed after the ride.
Press the button . No function
Press the button . No function
Press the button
for 3 - 5 seconds.
Press the button
briefly.
– Press the button briefly and repeatedly until S1 appears at the top right of the
display.
S1 (stop watch 1) displays the journey time on the basis of TR1 and continues when an
impulse is received from the wheel speed sensor.
The calculation of this value starts with the first impulse of the wheel speed sensor and
ends 3 seconds after the last impulse.
Press the button . No function
Press the button . No function
Press the button
for 3 - 5 seconds.
Press the button
briefly.
–
Next display mode
Displays of TR1, A1 and S1 are reset to 0,0.
Next display mode
5.30Display mode SPEED/S2 (stop watch 2)
400328-01
– Press the button briefly and repeatedly until S2 appears at the top right of the
display.
S2 (stop watch 2) is a manual stop watch.
If S2 is running in the background, the S2 display flashes in the speedometer display.
Press the button . Starts or stops S2.
Press the button . No function
Press the button
Displays of S2 and A2 are reset to 0.0.
for 3 - 5 seconds.
Press the button
Next display mode
briefly.
CONTROLS 19
Table of functions
Display Press the button . Press the button . Press the button for 3 -
5 seconds.
Display mode SPEED/H
(service hours)
Display mode SPEED/CLK
(clock)
Display mode SPEED/LAP
(lap time)
Display mode
SPEED/ODO (odometer)
Display mode SPEED/TR1
(trip master 1)
Display mode SPEED/TR2
(trip master 2)
Disply 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)
No function No function The display changes to
the Setup menu of the
speedometer functions.
No function No function The display changes to
the Setup menu of the
clock.
Starts or stops the
clock.
No function No function – Next display mode
No function No function Displays of TR1, A1 and
Increases value of TR2. Reduces value of TR2. Deletes value of TR2. Next display mode
No function No function Displays of TR1, A1 and
No function No function – Next display mode
No function No function Displays of TR1, A1 and
Starts or stops S2. No function Displays of S2 and A2
Stops the current lap
time and saves it, and
the stop watch starts
the next lap.
The stop watch and the
lap time are reset.
S1 are reset to 0,0.
S1 are reset to 0,0.
S1 are reset to 0,0.
are reset to 0.0.
Press the button
briefly.
Next display mode
Next display mode
Next display mode
Next display mode
Next display mode
Next display mode
Next display mode
Table of conditions and activability
Display The motorcycle is
stationary
Display mode SPEED/H (service hours) •
Display mode SPEED/CLK (clock) •
Display mode SPEED/LAP (lap time) •
Display mode SPEED/TR1 (trip master 1) •
Display mode SPEED/TR2 (trip master 2) •
Disply 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) •
Menu can be activated
CONTROLS 20
5.31Fuel tap
The fuel tap is on the left of the fuel tank.
With tap handle on the fuel tap, you can open or close the supply of fuel to the carburetor.
Possible states
• Fuel supply closed OFF – No fuel flows from the tank to the carburetor.
• Fuel supply open ON – Fuel flows from the tank to the carburetor. The fuel tank
empties down to the reserve.
• Reserve fuel supply open RES – Fuel flows from the tank to the carburetor. The
fuel tank empties completely.
500137-10
5.32Opening filler cap
5.33Closing filler cap
– Press release button , turn filler cap counterclockwise and lift it upwards and
remove.
400199-10
– Replace the filler cap and turn clockwise until the release button locks in place.
Info
Route the fuel tank breather hose without kinking.
400199-11
5.34Choke (EXC AUS, XC‑W, XC‑W SIX DAYS)
500135-10
Choke is fitted on the left side of the carburetor.
Activating the choke function frees an opening through which the engine can draw
extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.
Info
If the engine is warm, the choke function must be deactivated.
Possible states
• Choke function activated – The choke lever is pulled out to the stop.
• Choke function deactivated – The choke lever is pushed in to the stop.
CONTROLS 21
5.35Choke (EXC EU, EXC SIX DAYS)
The flasher switch is fitted on the left side of the handlebar.
Activating the choke opens a drilling which supplies the engine with extra fuel. This
enriches the fuel-air mixture, which is needed for a cold start.
Info
If the engine is warm, the choke function must be deactivated.
Possible states
500136-10
5.36Shift lever
• Choke function activated – The choke lever is pulled to the stop.
• Choke function deactivated – The choke lever is pushed back to the stop.
Shift lever is mounted on the left side of the engine.
5.37Foot brake pedal
500138-10
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
500138-11
Foot brake pedal is located in front of the right footrest.
The foot brake pedal is used to activate the rear brake.
500139-10
5.38Kick starter
The kick starter is fitted on the right of the engine.
The engine can be started with either the kick starter or the electric starter.
The upper part of the kick starter can be swung out.
Info
Before riding, swing the upper part of the kick starter inwards towards the
engine.
500148-10
CONTROLS 22
5.39Side stand
Note
Danger of damage The parked vehicle can roll away or fall over.
– Always place the vehicle on a firm and even surface.
Note
Material damage Damage and destruction of components by excessive load.
– The side stand is designed for the weight of the motorcycle only. Do not sit on the
500140-10
motorcycle when it is supported by the side stand only. The side stand and/or the
frame could be damaged and the motorcycle could fall over.
To park the motorcycle, press side stand to the ground with your foot and lean the
motorcycle on it.
When you are riding, side stand must be folded up and secured with rubber
band .
500141-10
5.40Steering lock (all EXC models)
Steering lock is fitted on the left side of the steering head.
The steering lock is used to lock the steering. Steering, and therefore riding, is no
longer possible.
500126-10
5.41Locking the steering (all EXC models)
Note
Danger of damage The parked vehicle can roll away or fall over.
– Always place the vehicle on a firm and even surface.
– Park the vehicle.
– Turn the handlebar as far as possible to the right.
– Insert the key in the steering lock, turn it to the left, press it in and turn it to the right. Remove the key.
Steering is no longer possible.
Info
Never leave the key in the steering lock.
CONTROLS 23
5.42Unlocking the steering (all EXC models)
– Insert the key in the steering lock, turn it to the left, pull it out and turn it to the right. Remove the key.
You can now steer the bike again.
Info
Never leave the key in the steering lock.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 24
6.1Advice on first use
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
– Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs.
Warning
Risk of injury Missing or poor protective clothing present an increased safety risk.
– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always
wear protective clothing, which must be undamaged and meet legal requirements.
Warning
Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidents Critical handling characteristic due to inappropriate riding style.
– Adapt your riding speed to the road conditoins and your riding ability.
Warning
Danger of accidents Accident risk caused by presence of a passenger.
– Your vehicle is not designed to carry passengers. Do not ride with a passenger.
Warning
Danger of accidents Failure of brake system.
– If the foot brake lever is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take
your foot off the foot brake lever if you do not want to brake.
Warning
Danger of accidents Unstable riding behavior.
– Do not exceed the maximum permissible weight and axle loads.
Warning
Risk of misappropriation Usage by unauthorized persons.
– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.
Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.
– Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.
You receive a delivery certificate and the service record at vehicle handover.
– Before your first trip, read the entire operating instructions carefully.
– Get to know the controls.
– Adjust the basic position of clutch lever. ( p. 76)
(all XC‑W models)
– adjust the basic position of hand brake lever. ( p. 55)
(all EXC models)
– Adjust the free travel of the hand brake lever. ( p. 55)
–
Adjust the basic position of the foot brake lever. x ( p. 59)
–
Adjust the basic position of the shift lever. x ( p. 77)
– Get used to handling the motorcycle on a suitable piece of land before making a longer trip.
Info
Off-road, you should be accompanied by another person on another machine so that you can help each other.
– Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.
– Do not make any off-road trips that over-stress your ability and experience.
– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 25
– If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis-
tribution between the front and rear wheels.
Info
Motorcycles react sensitively to any changes of weight distribution.
– Do not exceed the overall maximum permitted weight and the axle loads.
Guideline
Maximum permissible overall weight 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. 66)
Info
The spoke tension must be checked after half an hour of operation.
– Run-in the engine.
6.2Running-in the engine
– During the running-in phase, do not exceed the specified engine speed and engine performance.
Guideline
Maximum engine speed
During the first 3 service hours 7,000 rpm
Maximum engine performance
During the first 3 service hours ≤ 50 %
During the next 12 service hours ≤ 75 %
– Avoid fully opening the throttle!
6.3Preparing vehicle for arduous riding conditions
– Using a motorcycle in arduous conditions can lead to excessive wear of components such as the power train or brakes. For this
reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached.
Arduous riding conditions are:
– Riding on dry sand. ( p. 25)
– Riding on wet sand. ( p. 26)
– Riding on wet and muddy surfaces. ( p. 27)
– Rides at high temperature and slow speed. ( p. 28)
– Rides at low temperatures or in snow. ( p. 28)
6.4Preparing for riding on dry sand
– Check the radiator cap.
Value on radiator cap 1.8 bar (26 psi)
» If the displayed value does not correspond to specifications:
Warning
Danger of scalding During motorcycle operation, the coolant gets
very hot and is under pressure.
600872-10
– Do not remove the radiator cap, radiator hoses or other cooling
system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.
– Change the radiator cap.
–
Seal the air filter box. x
Tip
Seal the air filter box on the edges against dirt.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 26
–
Clean the air filter. x ( p. 75)
Info
Check the air filter approx. every 30 minutes.
– Fit a dust protection device on the air filter.
Dust protection device for air filter (59006019000)
Info
See the KTM PowerParts fitting instructions.
600869-01
– Fit a sand screen device on the air filter.
Sand protection device for air filter (59006022000)
Info
See the KTM PowerParts fitting instructions.
– Adjust the carburetor jetting and settings.
600871-01
600868-01
6.5Preparing for riding on wet sand
600872-10
Info
Your authorized KTM workshop has the recommended carburetor tuning settings.
– Clean the chain.
Chain cleaner ( p. 110)
– Fit the steel sprocket.
Tip
Do not grease the chain.
– Clean radiator fins.
– Straighten bent radiator fins carefully.
– Check the radiator cap.
Value on radiator cap 1.8 bar (26 psi)
» If the displayed value does not correspond to specifications:
Warning
Danger of scalding During motorcycle operation, the coolant gets
very hot and is under pressure.
– Do not remove the radiator cap, radiator hoses or other cooling
system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.
– Change the radiator cap.
–
Seal the air filter box. x
Tip
Seal the air filter box on the edges against dirt.
–
Clean the air filter. x ( p. 75)
Info
Check the air filter approx. every 30 minutes.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 27
– Fit a waterproofing device on the air filter.
Waterproofing device for air filter (59006021000)
Info
See the KTM PowerParts fitting instructions.
– Adjust the carburetor jetting and settings.
600870-01
– Clean the chain.
Chain cleaner ( p. 110)
– Fit the steel sprocket.
– Clean radiator fins.
600868-01
6.6Preparing for riding on wet and muddy surfaces
– Straighten bent radiator fins carefully.
–
Seal the air filter box. x
–
Clean the air filter. x ( p. 75)
Info
Your authorized KTM workshop has the recommended carburetor tuning settings.
Tip
Do not grease the chain.
Tip
Seal the air filter box along the edges to prevent the ingress of dirt.
Info
Check the air filter approx. every 30 minutes.
600870-01
600868-01
– Fit a waterproofing device on the air filter.
Waterproofing device for air filter (59006021000)
Info
See the KTM PowerParts fitting instructions.
– Adjust the carburetor jetting and settings.
Info
Your authorized KTM workshop has the recommended carburetor tuning settings.
– Fit the steel sprocket.
– Clean the motorcycle. ( p. 88)
– Straighten bent radiator fins carefully.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 28
6.7Preparing for rides at high temperature and slow speed
– Check the radiator cap.
Value on radiator cap 1.8 bar (26 psi)
» If the displayed value does not correspond to specifications:
Warning
Danger of scalding During motorcycle operation, the coolant gets
very hot and is under pressure.
600872-10
– Change the radiator cap.
–
Seal the air filter box. x
–
Clean the air filter. x ( p. 75)
– Do not remove the radiator cap, radiator hoses or other cooling
system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.
Tip
Seal the air filter box on the edges against dirt.
Info
Check the air filter approx. every 30 minutes.
– Adjust the secondary drive to the road conditions.
– Clean the chain.
Chain cleaner ( p. 110)
600868-01
– Clean radiator fins.
– Straighten bent radiator fins carefully.
– Check the coolant level. ( p. 72)
6.8Preparing for rides at low temperatures or in snow
–
Seal the air filter box. x
–
Clean the air filter. x ( p. 75)
– Fit a waterproofing device on the air filter.
Info
The engine oil quickly gets hot if the clutch has to be operated very often
due to an excessively high secondary drive.
Tip
Seal the air filter box on the edges against dirt.
Info
Check the air filter approx. every 30 minutes.
600870-01
Waterproofing device for air filter (59006021000)
Info
See the KTM PowerParts fitting instructions.
– Adjust the carburetor jetting and settings.
Info
Your authorized KTM workshop has the recommended carburetor tuning settings.
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