KTM 450 EXC 2012 Owner's manual

OWNER'S MANUAL 2012

450 EXC EU

450 EXC AUS

450 EXC SIX DAYS EU

450 XC-W USA

500 EXC EU

500 EXC AUS

500 EXC SIX DAYS EU

500 XC-W USA

Art. no. 3211723en

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 a lot of enjoyment in riding this 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 the motorcycles can, however, not be completely excluded.

All specifications 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 misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery.

© 2011 KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.

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

KTM-Sportmotorcycle AG 5230 Mattighofen, Austria

TABLE OF CONTENTS 2

TABLEOF CONTENTS

MEANS OF REPRESENTATION ............................................ 4

IMPORTANT INFORMATION ................................................ 5

VIEW OF VEHICLE............................................................... 7

View of vehicle, front left (example)................................... 7

View of vehicle, rear right (example) .................................. 8

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

Throttle grip.................................................................. 11

Kill switch (All XC‑W models) ......................................... 11

Kill switch (All EXC models) ........................................... 11

Horn button (All EXC models) ......................................... 12

Light switch (All EXC models) ......................................... 12

Turn signal switch (All EXC models) ................................ 12

Emergency OFF switch (EXC AUS) .................................. 12

Electric starter button (EXC AUS).................................... 12

Electric starter button (EXC EU, EXC SIX DAYS, all XC-F

models) ........................................................................ 13

Map‑Select switch for the basic setting (EXC SIX DAYS).... 13

Map‑Select switch for vehicle operation

(EXC SIX DAYS) ............................................................ 13

Light switch (All XC‑W models) ....................................... 13

Overview of indicator lamps (All XC‑W models) ................. 13

Overview of indicator lamps (All EXC models)................... 14

Speedometer................................................................. 14

Speedometer activation and test ..................................... 14

Tripmaster switch .......................................................... 14

Setting kilometers or miles ............................................. 15

Setting the clock ........................................................... 15

Adjusting the speedometer functions............................... 16

Querying lap time .......................................................... 16

Display mode SPEED (speed) ......................................... 17

Display mode SPEED/H (operating hours) ........................ 17

Display mode SPEED/CLK (clock) ................................... 17

Display mode SPEED/LAP (lap time) ............................... 17

Display mode SPEED/ODO (odometer) ............................. 18

Display mode SPEED/TR1 (trip master 1) ........................ 18

Display mode SPEED/TR2 (trip master 2) ........................ 18

Display mode SPEED/A1 (average speed 1)...................... 19

Display mode SPEED/A2 (average speed 2)...................... 19

Display mode SPEED/S1 (stop watch 1) .......................... 19

Display mode SPEED/S2 (stop watch 2) .......................... 19

Opening filler cap.......................................................... 20

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

Idle speed adjusting screw ............................................. 21

Shift lever..................................................................... 21

Kick starter................................................................... 22

Foot brake lever............................................................. 22

Side stand .................................................................... 22

Steering lock (All EXC models)........................................ 22

Locking the steering (All EXC models) ............................. 23

Unlocking the steering (All EXC models) .......................... 23

PREPARING FOR USE ....................................................... 24

Advice on first use ......................................................... 24

Running-in the engine ................................................... 25

Preparing the vehicle for difficult riding conditions ........... 25

Preparing for rides on dry sand ....................................... 26

Preparing for rides on wet sand....................................... 26

Preparing for rides on wet and muddy surfaces................. 27

Preparing for rides at high temperature and slow speed ..... 27

Preparing for rides at low temperatures or in snow ............ 28

RIDING INSTRUCTIONS .................................................... 29

Checks and maintenance work when preparing for use ...... 29

Starting ........................................................................ 29

Starting off ................................................................... 30

Shifting, riding.............................................................. 30

Braking ........................................................................ 30

Stopping, parking .......................................................... 31

Refueling...................................................................... 31

SERVICE SCHEDULE......................................................... 33

Service schedule ........................................................... 33

Service work (as additional order).................................... 34

TUNING THE CHASSIS...................................................... 35

Checking the basic suspension setting against the rider's

weight .......................................................................... 35

Compression damping of shock absorber.......................... 35

Adjusting the low-speed compression damping of the

shock absorber .............................................................. 35

Adjusting the high-speed compression damping of the

shock absorber .............................................................. 36

Adjusting the rebound damping of the shock absorber....... 36

Measuring rear wheel sag unloaded ................................. 37

Checking the static sag of the shock absorber .................. 37

Checking the riding sag of the shock absorber .................. 37

Adjusting the spring preload of the shock absorber x ...... 38

Adjusting the riding sag x............................................. 38

Checking basic setting of fork ......................................... 39

Adjusting the compression damping of the fork ................ 39

Adjusting the rebound damping of the fork....................... 39

Adjusting the spring preload of the fork ........................... 40

Handlebar position ........................................................ 40

Adjusting handlebar position x...................................... 40

SERVICE WORK ON THE CHASSIS ..................................... 42

Raising the motorcycle with the lift stand ........................ 42

Removing the motorcycle from the lift stand .................... 42

Bleeding fork legs.......................................................... 42

Cleaning the dust boots of the fork legs ........................... 42

Loosening the fork protector ........................................... 43

Positioning the fork protection ........................................ 43

Removing the fork legs................................................... 43

Installing the fork legs x............................................... 44

Removing the fork protector x....................................... 44

Installing the fork protector x ....................................... 45

Removing the lower triple clamp x (EXC EU, EXC AUS,

All XC‑W models)........................................................... 45

Removing the lower triple clamp x (EXC SIX DAYS) ........ 45

Installing the lower triple clamp x (EXC EU, EXC AUS,

All XC‑W models)........................................................... 46

Installing the lower triple clamp x (EXC SIX DAYS) ......... 48

Checking the steering head bearing play .......................... 49

Adjusting the play of the steering head bearing x

(EXC EU, EXC AUS, All XC‑W models) ............................. 50

Adjusting the play of the steering head bearing x

(EXC SIX DAYS) ............................................................ 50

Greasing the steering head bearing x............................. 50

Removing the shock absorber x..................................... 51

Installing the shock absorber x ..................................... 51

TABLE OF CONTENTS 3

Removing the front fender .............................................. 51

Installing the front fender............................................... 51

Removing the seat ......................................................... 52

Mounting the seat ......................................................... 52

Removing the air filter box lid......................................... 52

Installing the air filter box lid.......................................... 52

Removing the air filter x............................................... 52

Installing the air filter x ............................................... 53

Cleaning the air filter and air filter box x........................ 53

Removing main silencer ................................................. 54

Installing the main silencer ............................................ 54

Changing the glass fiber yarn filling of the main

silencer x ................................................................... 54

Removing the fuel tank x ............................................. 55

Installing the fuel tank x .............................................. 56

Checking for chain dirt accumulation .............................. 57

Cleaning the chain......................................................... 57

Checking the chain tension ............................................ 58

Adjusting the chain tension ............................................ 58

Checking the chain, rear sprocket, engine sprocket and

chain guide................................................................... 59

Adjusting the chain guide x.......................................... 61

Checking the frame x................................................... 61

Checking the swingarm x ............................................. 61

Checking the throttle cable routing.................................. 62

Checking the rubber grip ................................................ 62

Additionally securing the rubber grip ............................... 62

Adjusting the basic position of the clutch lever................. 62

Checking the fluid level of the hydraulic clutch ................ 63

Changing the hydraulic clutch fluid x ............................ 63

Removing the engine guard (EXC SIX DAYS, EXC AUS) ..... 64

Installing the engine guard (EXC SIX DAYS, EXC AUS) ...... 64

BRAKES........................................................................... 65

Checking free travel of hand brake lever........................... 65

Adjusting the basic position of the hand brake lever (All

XC‑W models) ............................................................... 65

Adjusting free travel of hand brake lever (All EXC

models) ........................................................................ 65

Checking the brake discs................................................ 66

Checking the front brake fluid level ................................. 66

Adding front brake fluid x ............................................ 66

Checking the front brake linings...................................... 67

Changing the front brake linings x................................. 67

Checking the free travel of foot brake lever....................... 69

Adjusting the basic position of the foot brake lever x ...... 69

Checking the rear brake fluid level .................................. 70

Adding brake fluid to the rear brake circuit x ................. 70

Checking the rear brake linings ....................................... 71

Changing the rear brake linings x.................................. 72

WHEELS, TIRES ............................................................... 74

Removing the front wheel x .......................................... 74

Installing the front wheel x........................................... 74

Removing the rear wheel x ........................................... 75

Installing the rear wheel x ............................................ 75

Checking the tire condition............................................. 76

Checking tire air pressure ............................................... 77

Checking spoke tension.................................................. 77

ELECTRICAL SYSTEM ....................................................... 79

Removing the battery x ................................................ 79

Installing the battery x................................................. 79

Charging the battery x.................................................. 79

Changing the main fuse ................................................. 80

Changing the fuses of individual power consumers............ 81

Changing the fuse of the radiator fan............................... 82

Removing headlight mask with headlight ......................... 83

Refitting the headlight mask with the headlight................ 83

Changing the headlight bulb........................................... 83

Checking the headlight setting........................................ 84

Adjusting the headlight range ......................................... 84

Changing the speedometer battery .................................. 84

COOLING SYSTEM ............................................................ 86

Cooling system .............................................................. 86

Checking the antifreeze and coolant level ........................ 86

Checking the coolant level.............................................. 87

Draining the coolant x.................................................. 87

Refilling coolant x ....................................................... 88

TUNING THE ENGINE ....................................................... 89

Checking the play in the throttle cable............................. 89

Adjusting the play in the throttle cable x ....................... 89

Adjusting the idle speed x............................................ 89

Checking the basic position of the shift lever.................... 90

Adjusting the basic position of the shift lever x .............. 90

Setting the engine characteristics (EXC SIX DAYS) ........... 90

SERVICE WORK ON THE ENGINE ...................................... 92

Checking the engine oil level .......................................... 92

Changing the engine oil and oil filter, cleaning the oil

screens x.................................................................... 92

Adding engine oil .......................................................... 94

CLEANING, CARE ............................................................. 96

Cleaning the motorcycle ................................................. 96

Checks and maintenance steps for winter operation .......... 97

STORAGE ......................................................................... 98

Storage......................................................................... 98

Preparing for use after storage ........................................ 98

TROUBLESHOOTING......................................................... 99

BLINK CODE .................................................................. 101

TECHNICAL DATA - ENGINE ............................................ 103

Capacity - engine oil .................................................... 103

Capacity - coolant........................................................ 104

TECHNICAL DATA - ENGINE TIGHTENING TORQUES ........ 105

TECHNICAL DATA - CHASSIS .......................................... 107

Lighting equipment ..................................................... 108

Tires .......................................................................... 108

Capacity - fuel............................................................. 108

TECHNICAL DATA - FORK................................................ 109

TECHNICAL DATA - SHOCK ABSORBER ........................... 110

TECHNICAL DATA - TIGHTENING TORQUES FOR

CHASSIS ........................................................................ 111

SUBSTANCES................................................................. 112

AUXILIARY SUBSTANCES................................................ 114

STANDARDS................................................................... 116

INDEX ............................................................................ 117

MEANS OF REPRESENTATION 4

Symbols used

The symbols used are explained in the following.

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

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

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

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

Formats used

The typographical and other formats used are explained below.

Proprietary name Denotes a proprietary name.

Name

Brand™ Denotes a brand available on the open market.

Denotes 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 public road traffic in the homologous (reduced) version only. In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. The motorcycle is designed for off-road sport endurance competition (Enduro) and not for the use predominantly in motocross.

Use definition (All XC‑W models)

Info

The motorcycle may only be used in closed off areas remote from public road traffic. This motorcycle is designed for use in offroad endurance competition (enduro) and not primarily for use in Motocross.

Service

A prerequisite for perfect operation and prevention of premature wear is that the service, care and tuning work on the engine and chassis is properly carried out as described in the owner's manual. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of components. Using the vehicle in difficult conditions such as on sand or very muddy or wet terrain can lead to above-average wear of components such as the drive train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached. Pay careful attention to the prescribed running-in period and service intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle.

Warranty

The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claim can be honored for damage resulting from manipulation and/or other changes to the vehicle.

Fuel, oils, etc.

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

Spare parts, accessories

For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss. Some spare parts and accessories are specified in brackets in the respective descriptions. Your KTM dealer will be happy to advise you.

You will find the current KTM PowerParts for your vehicle on the KTM website. International KTM Website: http://www.ktm.com

Work rules

Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in parentheses. Ex: valve spring compressor (59029019000) During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts. If thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its usage. Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or worn parts. Ensure that the vehicle is safe to operate after completing repair and maintenance work.

IMPORTANT INFORMATION 6

Transport

Note

Danger of damage The parked vehicle may roll away or fall over.

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

Note

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

– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from

being run. Always let the vehicle cool first.

– Switch off the engine. – 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.

Caution

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

Note

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

Warning

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

Owner's manual

– It is important that you read this owner's manual carefully and completely before making your first trip. It contains information and

tips to help you operate and handle your motorcycle. Only then will you learn how to best adjust the motorcycle for your own use and how to protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.

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

sold.

VIEW OF VEHICLE 7

3.1View of vehicle, front left (example)

1 Filler cap 2 Air filter box lid 3 Fork compression adjustment 4 Shift lever ( p. 21) 5 Engine number ( p. 9) 6 Side stand ( p. 22)

601610-10

VIEW OF VEHICLE 8

3.2View of vehicle, rear right (example)

1 Kill switch ( p. 11) 1 Horn button ( p. 12) 1 Light switch ( p. 12) 1 Turn signal switch ( p. 12) 2 Emergency OFF switch ( p. 12) 2 Electric starter button ( p. 13) 3 Throttle grip ( p. 11) 4 Fork rebound adjustment and spring preload adjustment 5 Shock absorber rebound adjustment 6 Level viewer for brake fluid, rear 7 Shock absorber compression adjustment 8 Level viewer, engine oil 9 Foot brake lever ( p. 22) 10 Kick starter ( p. 22)

601611-10

SERIAL NUMBERS 9

4.1Chassis number

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

101289-10

4.2Type label

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

4.3Key number (All EXC models)

4.4Engine number

101290-10

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

500125-10

The engine number  is stamped on the left side of the engine under the engine sprocket.

4.5Fork part number

601612-10

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

B00265-01

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.

601613-10

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.

101293-10

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.

5.3Throttle grip

5.4Kill switch (All XC‑W models)

101294-10

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

101295-10

Kill switch  is fitted on the left side of the handlebar.

Possible states

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

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

5.5Kill switch (All EXC models)

101296-10

Kill switch  is fitted on the left side of the handlebar.

Possible states

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

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

101297-10

CONTROLS 12

5.6Horn 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.

101297-11

5.7Light switch (All EXC models)

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

101298-10

high beam and the tail light are switched on.

5.8Turn signal switch (All EXC models)

101299-10

5.9Emergency OFF switch (EXC AUS)

101300-10

Turn signal switch  is fitted on the left side of the handlebar.

Possible states

Turn signal light off – Turn signal switch is in the central position. Turn signal light, left, on – Turn signal switch is turned to the left.

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

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.

5.10Electric starter button (EXC AUS)

101300-11

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.

CONTROLS 13

5.11Electric starter button (EXC EU, EXC SIX DAYS, all XC-F models)

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.

101301-10

5.12Map‑Select switch for the basic setting (EXC SIX DAYS)

The Map‑Select switch for the basic setting  is fitted under the seat. Possible states

1 SOFT – The mapping with reduced peak performance for better ride-

ability is activated.

2 ADVANCED – The mapping for performance with a very direct response

is activated.

3 - 9, 0 STANDARD – The mapping for performance with a balanced response

is activated.

101474-10

The Map‑Select switch for the basic setting is used to make a preselection of the engine characteristics.

5.13Map‑Select switch for vehicle operation (EXC SIX DAYS)

The Map‑Select switch for vehicle operation  is fitted on the right side of the handlebar.

Possible states

STANDARD – STANDARD mapping is always activated in this setting.

SOFT or ADVANCED – The mapping that is set on the Map‑Select switch for the basic setting is activated in this setting.

101431-10

The Map‑Select switch for vehicle operation is used to change the engine characteristics on the handlebar. This change is activated when the engine is idling or after the motorcycle is restarted.

5.14Light switch (All XC‑W models)

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

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 tail light are switched on.

101303-10

5.15Overview of indicator lamps (All XC‑W models)

Possible states

101302-01

FI warning lamp (MIL) lights up/flashes orange – The OBD has detected an emission- or safety-critical fault.

The fuel level warning lamp lights up orange – The fuel level has reached the reserve mark.

CONTROLS 14

5.16Overview of indicator lamps (All EXC models)

Possible states

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

FI warning lamp (MIL) lights up/flashes orange – The OBD has detected an emission- or safety-critical fault.

The fuel level warning lamp lights up orange – The fuel level has reached the reserve mark.

101304-01

5.17Speedometer

400312-01

5.18Speedometer activation and test

Turn signal indicator light flashes green – Turn signal is switched on.

– Press the button 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

When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.

Activating the speedometer

The speedometer is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor.

Display test

For the function test of the display, all display segments light up briefly.

400313-01

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

Info

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

The display then changes to the last selected mode.

400314-01

5.19Tripmaster 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.

CONTROLS 15

5.20Setting kilometers or miles

Info

If you change the unit of measure, the ODO value 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 are shown.

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

– Press the button .

Adjusting Mph

400329-01

– Press the button .

– Press the button for 3 - 5 seconds.

The settings are stored and the Setup menu is closed.

Info

If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu is closed.

5.21Setting the clock

400330-01

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 stored and the Setup menu is closed.

Info

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

CONTROLS 16

5.22Adjusting the speedometer functions

Info

When the vehicle is delivered, 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 is displayed and the activated functions are shown.

– Change to the desired function by pressing the button briefly.

The selected function flashes.

Activating a function

– Press the button .

400318-01

Deactivating the function

– Press the button .

– All desired functions are activated or deactivated accordingly. – Press the button for 3 - 5 seconds.

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

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

The settings are stored and the Setup menu is closed.

5.23Querying lap time

Info

This function can be called up 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 a pulse arrives from the wheel speed sensor, the settings are stored automatically 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 17

5.24Display mode SPEED (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 display changes to the SPEED mode and the current speed is shown.

400317-02

5.25Display mode SPEED/H (operating hours)

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 operating hours of the engine are displayed. The operating hours counter stores the total traveling time.

Info

The operating hours counter is necessary for ensuring that maintenance work is

400316-01

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.

5.26Display mode SPEED/CLK (clock)

400319-01

5.27Display 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.

Press the button for 3 - 5 seconds.

The stop watch and the lap time are reset.

CONTROLS 18

5.28Display mode SPEED/ODO (odometer)

400317-01

5.29Display mode SPEED/TR1 (trip master 1)

400323-01

Press the button

Next display mode

briefly.

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

the display.

The total distance traveled is displayed in the ODO display mode.

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 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.

Press the button . No function Press the button . No function Press the button

for 3 - 5 seconds. Press the button

briefly.

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

Next display mode

5.30Display mode SPEED/TR2 (trip master 2)

400324-01

– 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 . This is a very practical function when riding using the road book.

Info

The TR2 value can also be corrected manually during the journey with the 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

for 3 - 5 seconds. Press the button

briefly.

Deletes value of TR2.

Next display mode

CONTROLS 19

5.31Display 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 on the basis of TR1 (trip master 1) and S1 (stop watch 1). The calculation of this value is activated by the first impulse of the wheel speed sensor and ends 3 seconds after the last impulse.

Press the button . No function Press the button . No function

400325-01

5.32Display mode SPEED/A2 (average speed 2)

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

A2 (average speed 2) shows the average speed on the basis of the current speed if the stop watch S2 (stop watch 2) is running.

Press the button for 3 - 5 seconds.

Press the button briefly.

display.

Info

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

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

Next display mode

400326-01

5.33Display mode SPEED/S1 (stop watch 1)

400327-01

5.34Display mode SPEED/S2 (stop watch 2)

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 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

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 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.

400328-01

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 20

Table of functions Display Press the button . Press the button . Press the button for 3 -

5 seconds.

Display mode SPEED/H (operating 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)

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)

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 The TR1, A1 and S1 dis-

Increases value of TR2. Reduces value of TR2. Deletes value of TR2. Next display mode

No function No function The TR1, A1 and S1 dis-

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.

plays are reset to 0.0.

S1 are reset to 0.0.

are reset to 0.0.

Press the button briefly.

Next display mode

Table of conditions and menu activation Display The motorcycle is

stationary.

Display mode SPEED/H (operating 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) • 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) •

5.35Opening filler cap

Menu can be activated

Danger

Fire hazard Fuel is highly flammable.

– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no

fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

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

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-

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

Warning

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

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

CONTROLS 21

– Press release button , turn filler cap counterclockwise and lift it upwards and

remove.

101305-10

5.36Closing filler cap

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

Info

Route the fuel tank breather hose  without kinking.

101306-10

5.37Idle speed adjusting screw

5.38Shift lever

Idle speed adjusting screw  is located on the throttle valve body at the top left. The idle speed adjusting screw has two functions. Turning it controls the idle speed. Pulling it out all the way raises the idle speed during a cold start.

Possible states

• RPM increase activated – Idle speed adjusting screw is pulled out all the way.

• RPM increase deactivated – Idle speed adjusting screw is pushed in all the way.

401342-10

Shift lever  is mounted on the left side of the engine.

601614-10

The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears.

601615-10

CONTROLS 22

5.39Kick 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.

601616-10

5.40Foot brake lever

Foot brake lever  is located in front of the right footrest. The foot brake lever is used to activate the rear brake.

5.41Side stand

601618-10

The side stand  is on the left side of the vehicle.

C00077-01

The side stand is used to park the motorcycle.

Info

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

C00078-01

5.42Steering lock (All EXC models)

101313-10

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.

CONTROLS 23

5.43Locking the steering (All EXC models)

Note

Danger of damage The parked vehicle may roll away or fall over.

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

– Park the vehicle. – Turn the handlebar as far as possible to the right. – Insert the key in the steering lock, turn it to the left, press it in and turn it to the

right. Remove the key.

Steering is no longer possible.

Info

Never leave the key in the steering lock.

400732-01

5.44Unlocking 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.

400731-01

Info

Never leave the key in the steering lock.

PREPARING FOR USE 24

6.1Advice on first use

Danger

Danger of accidents Danger arising from the rider's judgement being impaired.

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

impaired.

Warning

Risk of injury Missing or poor protective clothing present an increased safety risk.

– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always

wear protective clothing, which must be undamaged and meet legal requirements.

Warning

Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.

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

Warning

Danger of accidents Critical riding behavior due to inappropriate riding.

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

Warning

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

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

Warning

Danger of accidents Failure of brake system.

– If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take

your foot off the foot brake lever when you are not braking.

Warning

Danger of accidents Unstable riding behavior.

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

Warning

Risk of misappropriation Usage by unauthorized persons.

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

Info

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

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

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

– Before your first trip, read the entire operating instructions carefully. – Get to know the controls. – Adjust the basic position of the clutch lever. ( p. 62) (All XC‑W models)

– Adjust the basic position of the hand brake lever. ( p. 65)

(All EXC models)

– Adjust the free travel of the hand brake lever. ( p. 65)

–

Adjust the basic position of the foot brake lever. x ( p. 69)

–

Adjust the basic position of the shift lever. x ( p. 90)

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

Info

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

– Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle. – Do not make any offroad trips that over-stress your ability and experience.

PREPARING FOR USE 25

– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis-

tribution between the front and rear wheels.

Info

Motorcycles react sensitively to any changes of weight distribution.

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

Guideline

Maximum permissible overall weight 335 kg (739 lb.) Maximum permissible front axle load 145 kg (320 lb.) Maximum permissible rear axle load 190 kg (419 lb.)

– Run the engine in.

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 operating hour 7,000 rpm

Maximum engine performance

During the first 3 operating hours ≤ 75 %

– Avoid fully opening the throttle!

6.3Preparing the vehicle for difficult riding conditions

Info

Using a motorcycle in difficult 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.

– KTM recommends that you use the specified engine oil for difficult riding conditions and to increase performance.

Engine oil (SAE 10W/60) (00062010035) ( p. 112)

–

Seal the air filter box. x

Tip

Seal the air filter box at the edges against dirt.

–

Clean the air filter and air filter box. x ( p. 53)

Info

Check the air filter approx. every 30 minutes.

– Additionally secure the rubber grip. ( p. 62) – Check the electrical 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. 26) – Rides on wet sand. ( p. 26) – Rides on wet and muddy surfaces. ( p. 27) – Rides at high temperature and slow speed. ( p. 27) – Rides at low temperatures or in snow. ( p. 28)

PREPARING FOR USE 26

6.4Preparing for rides on dry sand

– Check the radiator cap.

Value on radiator cap 1.8 bar (26 psi)

» If the displayed value does meet 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

600872-10

– Change the radiator cap.

– Fit a dust cover on the air filter.

Dust protection device for air filter (59006019000)

Info

See the KTM PowerParts fitting instructions.

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.

600869-01

600871-01

600868-01

6.5Preparing for rides on wet sand

– Fit a sand cover on the air filter.

Sand protection device for air filter (59006022000)

Info

See the KTM PowerParts fitting instructions.

– Adjust the carburetor jetting and the setting.

Info

The specific carburetor tuning can be recommended by your authorized KTM workshop.

– Clean the chain.

Chain cleaner ( p. 114)

– Fit the steel sprocket.

Tip

Do not grease the chain.

– Clean the radiator fins. – Straighten bent radiator fins carefully.

– Check the radiator cap.

600872-10

Value on radiator cap 1.8 bar (26 psi)

» If the displayed value does meet 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.

PREPARING FOR USE 27

– Change the radiator cap.

– Fit a rain cover on the air filter.

Waterproofing device for air filter (59006021000)

Info

See the KTM PowerParts fitting instructions.

– Adjust the carburetor jetting and the setting.

600870-01

– Clean the chain.

Chain cleaner ( p. 114)

– Fit the steel sprocket.

– Clean the radiator fins.

600868-01

6.6Preparing for rides on wet and muddy surfaces

– Straighten bent radiator fins carefully.

– Fit a waterproofing device on the air filter.

Waterproofing device for air filter (59006021000)

– Adjust the carburetor jetting and setting.

600870-01

Info

The specific carburetor tuning can be recommended by your authorized KTM workshop.

Tip

Do not grease the chain.

Info

See the KTM PowerParts fitting instructions.

Info

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

– Fit the steel sprocket. – Clean the motorcycle. ( p. 96) – Straighten bent radiator fins carefully.

600868-01

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 meet specifications:

600872-10

Warning

Danger of scalding During motorcycle operation, the coolant gets

very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling

system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

PREPARING FOR USE 28

– Change the radiator cap.

– Adjust the secondary drive to the road conditions.

Info

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

– Clean the chain.

Chain cleaner ( p. 114)

600868-01

6.8Preparing for rides at low temperatures or in snow

600870-01

– Clean the radiator fins. – Straighten bent radiator fins carefully. – Check the coolant level. ( p. 87)

– Fit a waterproofing device on the air filter.

Waterproofing device for air filter (59006021000)

– Adjust the carburetor jetting and setting.

Info

See the KTM PowerParts fitting instructions.

Info

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

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