KTM 450 EXC AUS, 530 EXC S, 400 EXC AUS, 530 XC-W ZA, 530 EXC EU Manual

MEANS OF REPRESENTATION

IMPORTANT INFORMATION

VIEW OF VEHICLE

LOCATION OF SERIAL NUMBERS

CONTROLS

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION

Speedometer5.13

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KTM 450 EXC AUS, 530 EXC S, 400 EXC AUS, 530 XC-W ZA, 530 EXC EU 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

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.

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

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

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

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®	Identifies a protected name.
Brand™	Identifies a brand in merchandise traffic.

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)

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

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

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

View3.1 of the vehicle from the left front (example)

100799-10

1Hand brake lever

2Clutch lever

3Air filter box lid

4Fuel tap

5Chain guide

6Side stand

7Shift lever

VIEW OF VEHICLE

View3.2 of the vehicle from the right rear (example)

100800-10

1Filler cap

2Short circuit button

3Speedometer

4Electric starter button

5Fork rebound adjustment

6Horn

7Fork compression adjustment

8Shock absorber rebound adjustment

9Level viewer for brake fluid, rear

10Shock absorber compression adjustment

11Foot brake pedal

12Kick starter

Chassis4.1 number

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

500127-10

Type4.2 label

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

500128-10

Key4.3 number (all EXC models)

The key number is stamped on the key strap.

500125-10

Engine4.4 number

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

500072-10

Fork4.5 part number

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

100801-10

LOCATION OF SERIAL NUMBERS

Shock4.6 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

Clutch5.1 lever

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

The clutch is hydraulically operated and self-adjusting.

500133-10

Hand5.2 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

Short5.3 circuit button (all XC W models)

The short circuit button is fitted on the left side of the handlebar.

Possible states

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

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

500132-10

Short5.4 circuit button (all EXC models)

The short circuit button is fitted on the left side of the handlebar.

Possible states

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

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

500134-10

Emergency5.5 OFF switch (EXC AUS)

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.

500131-10

CONTROLS

Electric5.6 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

Electric5.7 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

Light5.8 switch (all EXC models)

500134-12

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.

Light5.9 switch (all XC W models)

500146-10

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.

Horn5.10 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

Flasher5.11 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

Overview5.12 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

400312-01

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

–Press the button to control different functions.

Info

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

Speedometer5.14 activation and test

400313-01

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.

WS (wheel size)

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

Info

2205 mm corresponds to the size of the 21" front wheel with a series production tire.

The display then changes to the last selected mode.

400314-01

CONTROLS

Tripmaster5.15 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.

Setting5.16 kilometers or miles

Info

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

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

400329-01

Setting5.17 the clock

400330-01

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

– Press the button .

–Press the button for 3 - 5 seconds.

The settings are stored and the setup menu closed.

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

Adjusting5.18 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	The icon remains in the display and the display changes to the next func-

		tion.

Deactivating a function

–Press the button .

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

–Activate or deactivate all functions accordingly.

–Press the button for 3 - 5 seconds.

The settings are saved and the Setup menu closed.

Info

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

Querying5.19 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.

LAP 1 appears on the left side of the display.

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

– The button has no function

– Press the button briefly.

Next display mode

400321-01

Info

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

CONTROLS

SPEED5.20 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

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

400317-02

Display5.21 mode SPEED/H (service hours)

400316-01

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.

Press the button .	No function

Press the button .	No function

Press the button	The display changes to the Setup menu of the speedometer
for 3 - 5 seconds.	functions.

Press the button	Next display mode
briefly.

Display5.22 mode SPEED/CLK (clock)

400319-01

–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.

Display5.23 mode SPEED/LAP (lap time)

–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.

Info

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

Lap 10 must be timed with the button .

400320-01

Press the button .	Starts or stops the clock.

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

CONTROLS		17

	Press the button	The stop watch and the lap time are reset.
	for 3 - 5 seconds.

	Press the button	Next display mode
	briefly.

Display5.24 mode SPEED/ODO (odometer)

400317-01

–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.

Display5.25 mode SPEED/TR1 (trip master 1)

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

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

Info

If 999.9 is exceeded, the values of TR1, A1 and S1 are automaticallt reset to

0.0.

400323-01

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.

Display5.26 mode SPEED/TR2 (trip master 2)

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

TR2 (trip master 2) runs constantly and counts 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 but-
								ton and the button .
		400324-01						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

Disply5.27 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

	Press the button .	No function

400325-01
400325-01	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.

Display5.28 mode SPEED/A2 (average speed 2)

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

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

Info

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

400326-01

Press the button .	No function

Press the button .	No function

Press the button	–
for 3 - 5 seconds.

Press the button	Next display mode
briefly.

Display5.29 mode SPEED/S1 (stop watch 1)

400327-01

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

S1 (stop watch 1) 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.

Display5.30 mode SPEED/S2 (stop watch 2)

–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 .	No function

	Press the button	Displays of S2 and A2 are reset to 0.0.
	for 3 - 5 seconds.
400328-01	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 -		Press the button
			5 seconds.		briefly.

Display mode SPEED/H	No function	No function	The display changes to		Next display mode
(service hours)			the Setup menu of the
			speedometer functions.

Display mode SPEED/CLK	No function	No function	The display changes to		Next display mode
(clock)			the Setup menu of the
			clock.

Display mode SPEED/LAP	Starts or stops the	Stops the current lap	The stop watch and the		Next display mode
(lap time)	clock.	time and saves it, and	lap time are reset.
		the stop watch starts
		the next lap.

Display mode	No function	No function	–		Next display mode
SPEED/ODO (odometer)

Display mode SPEED/TR1	No function	No function	Displays of TR1, A1 and		Next display mode
(trip master 1)			S1 are reset to 0,0.

Display mode SPEED/TR2	Increases value of TR2.	Reduces value of TR2.	Deletes value of TR2.		Next display mode
(trip master 2)

Disply mode SPEED/A1	No function	No function	Displays of TR1, A1 and		Next display mode
(average speed 1)			S1 are reset to 0,0.

Display mode SPEED/A2	No function	No function	–		Next display mode
(average speed 2)

Display mode SPEED/S1	No function	No function	Displays of TR1, A1 and		Next display mode
(stop watch 1)			S1 are reset to 0,0.

Display mode SPEED/S2	Starts or stops S2.	No function	Displays of S2 and A2		Next display mode
(stop watch 2)			are reset to 0.0.


Table of conditions and activability

Display				The motorcycle is		Menu can be acti-
				stationary		vated

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)						•

CONTROLS

Fuel5.31 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

Opening5.32 filler cap

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

400199-10

Closing5.33 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.

400199-11

Choke5.34 (EXC AUS, XC W, XC W SIX DAYS)

Choke is fitted on the left side of the carburetor.

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

		Info
		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.
500135-10
500135-10	• Choke function deactivated – The choke lever is pushed in to the stop.

CONTROLS

Choke5.35 (EXC EU, EXC SIX DAYS)

500136-10

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

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

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

Shift5.36 lever

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

500138-10

The gear positions can be seen in the photograph.

The neutral or idle position is between the first and second gears.

500138-11

Foot5.37 brake pedal

Foot brake pedal is located in front of the right footrest.

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

500139-10

Kick5.38 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

Side5.39 stand

500140-10

500141-10

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 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 .

Steering5.40 lock (all EXC models)

500126-10

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.

Locking5.41 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

Unlocking5.42 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.

Your authorized KTM workshop has the recommended carburetor tuning set-

Advice6.1 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

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

Info

Motorcycles react sensitively to any changes of weight distribution.

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

	Maximum permissible overall weight	335 kg (739 lb.)

	Maximum permissible front axle load	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.

Running6.2 -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!

Preparing6.3 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)

Preparing6.4	for riding on dry sand
			– Check the radiator cap.
			– Check the radiator cap.

				Value on radiator cap		1.8 bar (26 psi)

				» If the displayed value does not correspond to specifications:

					Warning
					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			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

600869-01

600871-01

600868-01

–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.

–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.

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.

Preparing6.5	for riding on wet sand
			– Check the radiator cap.
			– Check the radiator cap.

				Value on radiator cap					1.8 bar (26 psi)

				» If the displayed value does not correspond to specifications:

							Warning
							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					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
						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

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.

–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.

Preparing6.6 for riding on wet and muddy surfaces

–Seal the air filter box. x

Tip

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

–Clean the air filter. x( p. 75)

Info

Check the air filter approx. every 30 minutes.

–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.

–Fit the steel sprocket.

–Clean the motorcycle. ( p. 88)

–Straighten bent radiator fins carefully.

600868-01

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION		28

Preparing6.7	for rides at high temperature and slow speed

600872-10

600868-01

–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.

–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. 110)

–Clean radiator fins.

–Straighten bent radiator fins carefully.

–Check the coolant level. ( p. 72)

Preparing6.8 for rides at low temperatures or in snow

–Seal the air filter box. x

Tip

Seal the air filter box on the edges against dirt.

–Clean the air filter. x( p. 75)

Info

Check the air filter approx. every 30 minutes.

–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.

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