KTM 450 EXC-R USA, 450 XCR-W USA, 450 EXC-R EU, 530 EXC-R USA, 530 XCR-W USA User Manual

OWNER'S MANUAL 2008

450bEXC-RbEU

450bEXC-RbAUS/UK

450bEXC-RbSIXbDAYS

450bEXC-RbUSA

450bXCR-WbUSA

450bXCR-WbZA

530bEXC-RbEU

530bEXC-RbAUS/UK

530bEXC-RbSIXbDAYS

530bEXC-RbUSA

530bXCR-WbUSA

530bXCR-WbZA

ART. NO. 3211254en

DEAR KTM CUSTOMER 1

'($5.70 &86720(5

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. 8) Dealer's stamp

Engine number ( P. 8)

Key number (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA) ( P. 8)

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

All specifications are not binding. KTM Sportmotorcycle AG in particular 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 prudction of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special
equipment that does not belong to the regular scope of delivery.

© 2007 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)
Within the meaning of 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

CONTENTS 2

&217(176

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

IMPORTANT NOTES............................................................ 6

LOCATION OF SERIAL NUMBERS........................................ 8

Chassis number............................................................... 8

Type label....................................................................... 8

Key number (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA) ........ 8

Engine number................................................................ 8

Fork part number............................................................. 8

Shock absorber part number............................................. 9

OPERATING ELEMENTS.................................................... 10

Clutch lever .................................................................. 10

Hand brake lever ........................................................... 10

Short circuit button (EVERY XCR-W MODELS).................. 10

Short circuit button (EXC-RbEU, EXC-RbAUS/UK,

EXC-RbSIXbDAYS) .......................................................... 10

Emergency OFF switch (EXC-RbAUS/UK).......................... 10

Emergency OFF switch (EXC-RbUSA) ............................... 11

Ignition switch (EXC-RbUSA)........................................... 11

Electric starter button (EXC-RbEU, EXC-RbSIXbDAYS,
EXC-RbUSA,

Electric starter button (EXC-RbAUS/UK)........................... 11

Light switch (EXC-RbEU, EXC-RbAUS/UK,

EXC-RbSIXbDAYS) .......................................................... 11

Light switch (EVERY XCR-W MODELS) ............................ 12

Light switch (EXC-RbUSA) .............................................. 12

Headlight flasher switch (EXC-RbUSA) ............................. 12

Horn (EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS) ......... 12

Horn (EXC-RbUSA)......................................................... 12

Flasher switch (EXC-RbEU, EXC-RbAUS/UK) ..................... 13

Flasher switch (EXC-RbUSA) ........................................... 13

Overview of indicator lamps (EXC-RbEU, EXC-RbAUS/UK,

EXC-RbUSA).................................................................. 13

Overview of indicator lamps (EXC-RbSIXbDAYS)................. 13

Speedometer................................................................. 13

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

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

Setting kilometers or miles............................................. 14

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

Adjusting speedometer functions ....................................

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

Display mode SPEED..................................................... 16

Display mode SPEED/H (service hours)............................ 16

Display mode SPEEDb/bCLK (time)................................... 17

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

Display mode SPEED/ODO (odometer)............................. 17

Display mode SPEED/TR1 (trip masterb1) ........................ 17

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

Disply mode SPEED/A1 (average speedb1) ....................... 18

Display mode SPEED/A2 (average speed 2)...................... 18

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

Display mode SPEED/S2 (stop watchb2)........................... 19

Fuel tap........................................................................ 20

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

Closing filler cap ........................................................... 20

Choke (EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA,

XCR-W) ........................................................................ 21

Choke (EXC-RbEU)......................................................... 21

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

Foot brake pedal ........................................................... 21

Kickstarter.................................................................... 22

Side stand ....................................................................

Steering lock (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA)..... 22

XCR-W) ...................................................... 11

15

22

Locking the steering (EXC-RbEU, EXC-RbAUS/UK,

EXC-RbUSA).................................................................. 22

Unlocking the steering (EXC-RbEU, EXC-RbAUS/UK,

EXC-RbUSA).................................................................. 23

GENERAL TIPS AND HINTS ON PUTTING INTO

OPERATION...................................................................... 24

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

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

RIDING INSTRUCTIONS .................................................... 26

Checks before putting into operation ............................... 26

Starting ........................................................................ 26

Starting up ................................................................... 27

Shifting, riding.............................................................. 27

Braking ........................................................................ 27

Stopping, parking .......................................................... 28

Refueling...................................................................... 28

GREASING AND SERVICE TABLE....................................... 29

Important maintenance work to be carried out by an

authorized KTM workshop. .............................................

Important maintenance work to be carried out by an

authorized KTM workshop. (as additional order)................ 30

Important checks and maintenance work to be carried

out by the rider. ............................................................ 30

MAINTENANCE WORK ON CHASSIS AND ENGINE.............. 32

Jacking up the motorcycle.............................................. 32

Removing the motorcycle from the work stand.................. 32

Checking the basic chassis setting with the rider's

weight .......................................................................... 32

Compression damping of shock absorber.......................... 32

Adjusting high-speed compression damping of the shock

absorber ....................................................................... 32

Adjusting the low-speed compression damping of the

shock absorber.............................................................. 33

Adjusting rebound damping of the shock absorber............ 33

Measuring rear wheel sag unloaded................................. 34

Checking static sag of the shock absorber........................ 34

Checking the riding sag of the shock absorber.................. 35

Adjusting spring preload of the shock absorberb
Adjusting riding sagb
Removing the shock absorberb
Installing shock absorberb

Checking basic setting of fork......................................... 37

Adjusting compression damping of fork ........................... 37

Adjusting rebound damping of fork.................................. 37

Adjusting spring preload of the fork................................. 38

Bleeding fork legs.......................................................... 38

Cleaning dust boots of fork legs ...................................... 39

Loosening the fork protection.......................................... 39

Positioning the fork protection ........................................ 39

Checking play of steering head bearing............................ 39

Adjusting play of steering head bearingb

EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA) ......................... 40

Adjusting play of steering head bearingb

(EXC-RbSIXbDAYS, XCR-WbUSA) ...................................... 40

Fork offset (EXC-RbSIXbDAYS, XCR-WbUSA) ...................... 41

Setting the fork offsetb

XCR-WbUSA) ................................................................. 41

Removing the fork legs................................................... 41

Installing the fork legsb
Removing the fork protectorb
Installing the fork protectorb
Removing the lower triple clampb

XCR-WbUSA) ................................................................. 43

x .................................................. 36

x..................................... 36

x ........................................... 36

x (EXC-RbSIXbDAYS,

x............................................... 42

x....................................... 43

x........................................ 43

x (EXC-RbSIXbDAYS,

x ............ 35

x (EXC-RbEU,

x

29

CONTENTS 3

Removing the lower triple clampbx (EXC-RbEU,

EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA) ......................... 44

Installing the lower triple clampb

XCR-WbUSA) ................................................................. 44

Installing the lower triple clampb

EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA) ......................... 45

Greasing the steering head bearingb

Dismounting the front fender.......................................... 46

Installing the front fender............................................... 46

Removing headlight mask with headlight (EXC-RbEU,
EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA,

XCR-WbZA).................................................................... 46

Refitting the headlight mask with the headlight
(EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS,

EXC-RbUSA, XCR-WbZA) ................................................. 47

Dismount the start number plate (XCR-WbUSA) ................ 47

Fitting the start number plate (XCR-WbUSA)..................... 47

Handlebar position ........................................................ 47

Adjusting handlebar positionb

Checking gas Bowden cable route ................................... 49

Checking play in the gas Bowden cable ........................... 50

Adjusting the gas Bowden cable playb

Checking chain dirt ....................................................... 50

Cleaning the chain......................................................... 50

Checking the chain tension ............................................ 51

Checking the chain tension when fitting rear wheel........... 51

Checking the rear sprocket / engine sprocket for wear ....... 52

Checking chain wear...................................................... 52

Adjusting the chain tension ............................................ 52

Adjusting chain tension - after checking .......................... 53

Adjusting chain tension - fitting rear wheel ...................... 54

Adjusting chain guideb

Brake fluid reservoir....................................................... 54

Brake calipers ............................................................... 55

Checking brake discs ..................................................... 55

Checking free play of hand brake lever............................. 55

Adjusting basic position of handbrake lever (Every XCR-W

models) ........................................................................ 56

Adjusting free travel of handbrake lever (Every EXC-R

models) ........................................................................ 56

Checking the front brake fluid level................................. 56

Topping up the front brake fluidb

Checking the front brake linings...................................... 57

Removing front brake liningsb
Installing the front brake liningsb
Changing the front brake liningsb

Checking free play of foot brake lever .............................. 59

Adjusting basic position of footbrake leverb

Checking the rear brake fluid level .................................. 60

Adding rear brake fluidb

Checking rear brake linings ............................................ 61

Removing rear brake liningsb
Installing the rear brake liningsb
Changing the rear brake liningsb
Removing front wheelb
Fitting front wheelb
Removing rear wheelb
Fitting rear wheelb

Tire condition checking.................................................. 66

Checking tire air pressure............................................... 66

Checking spoke tension.................................................. 67

Removing the batteryb

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

x.............................................. 61

x................................................ 63

x .................................................... 64

x ................................................. 65

x...................................................... 65

x ................................................ 67

x (EXC-RbSIXbDAYS,

x (EXC-RbEU,

x ............................. 46

x...................................... 48

x .......................... 50

x................................. 56

x...................................... 58

x................................. 58

x................................. 59

x................... 60

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

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

x .................................. 63

Installing the batteryb
Recharging the batteryb

Removing a fuse............................................................ 69

Replacing the fuse......................................................... 69

Removing the seat......................................................... 69

Mounting the seat ......................................................... 69

Dismounting the fuel tankb
Installing the fuel tankb

Cooling system.............................................................. 71

Checking antifreeze and coolant level.............................. 71

Checking the coolant level.............................................. 72

Draining coolantb
Refilling coolantb

Glass fiber yarn filling of main silencer............................ 73

Removing main silencer ................................................. 73

Fitting the main silencer ................................................ 74

Dismounting the air filter box lid..................................... 74

Installing the air filter box lid.......................................... 74

Removing the air filterb
Installing the air filterb
Cleaning air filterb

Adjusting basic position of clutch lever............................ 75

Checking fluid level of hydraulic clutch ........................... 75

Changing fluid level of hydraulic clutchb

Carburetor - idle ............................................................ 77

Carburetor - adjusting idleb
Emptying the carburetor float chamberb

Checking engine oil level................................................ 79

Changing engine oil and oil filter, cleaning engine oil

x ..................................................................... 79

screenb
Draining engine oil, cleaning engine oil screenb
Removing the oil filterb
Mounting oil filterb
Filling up with engine oilb

Topping up engine oil .................................................... 81

Checking gear oil level ................................................... 81

Changing gear oil, cleaning gear oil screenb
Draining gear oil, cleaning gear oil screenb
Filling up with gear oilb

Topping up with gear oilb

TROUBLESHOOTING......................................................... 84

CLEANING........................................................................ 86

Cleaning motorcycle ...................................................... 86

STORAGE ......................................................................... 87

Storage......................................................................... 87

Putting into operation after storage ................................. 87

TECHNICAL DATA - ENGINE.............................................. 88

Capacity - engine oil ...................................................... 88

Capacity - gear oil.......................................................... 88

Capacity - coolant.......................................................... 89

TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 90

TECHNICAL DATA - CARBURETOR..................................... 92

450bEXC-RbEU, 450bEXC-RbAUS/UK (3900I)................... 92

450bEXC-RbSIXbDAYS, 450bEXC-RbUSA, 450bXCR-W

(3900L) ....................................................................... 92

530bEXC-RbEU, 530bEXC-RbAUS/UK (3900J)................... 93

530bEXC-RbSIXbDAYS,

(3900M) ...................................................................... 93

TECHNICAL DATA - CHASSIS ............................................ 94

Lighting equipment ....................................................... 95

Tires ............................................................................ 95

x ................................................. 67

x .............................................. 68

x ......................................... 70

x .............................................. 70

x ....................................................... 72

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

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

x ............................................... 75

x...................................................... 75

x ...................... 76

x ......................................... 77

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

x ............ 79

x............................................... 80

x ..................................................... 80

x ........................................... 81

x .................. 82

x ................... 82

x............................................... 83

x ............................................ 83

530bEXC-RbUSA, 530bXCR-W

CONTENTS 4

Capacity - fuel............................................................... 95

TECHNICAL DATA - FORK.................................................. 96

TECHNICAL DATA - SHOCK ABSORBER ............................. 97

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ........ 98

WIRING DIAGRAM .......................................................... 100

Wiring diagram (EXC-RbEU) .......................................... 100

Wiring diagram (EXC-RbAUS/UK)................................... 102

Wiring diagram (EXC-RbUSA) ........................................ 104

Wiring diagram (EXC-RbSIXbDAYS)................................. 108

Wiring diagram (XCR-WbUSA) ....................................... 110

Wiring diagram (XCR-WbZA).......................................... 112

SUBSTANCES................................................................. 114

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

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

CONSUMER INFORMATION (EXC-R USA).......................... 118

INDEX ............................................................................ 120

MEANS OF REPRESENTATION 5

0($162)5(35(6(17$7,21

Symbols used

The symbols used are explained in the following.

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

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

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

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

Formats used

The typographical and other formats used are explained in the following.

Specific name Identifies a specific name.

®

Name

Brand™ Identifies a brand in merchandise traffic.

Identifies a protected name.

IMPORTANT NOTES 6

,03257$17127(6

Use definition (Every EXC-R 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 secluded property 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 (Every XCR-W models)

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

Info

The motorcycle must be used only on secluded property 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 perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described
in the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and break­age of components.
Using the motorcycle in extreme conditions such as very muddy or wet terrain can lead to above-average wear of components such as
the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in
the greasing and service table is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will
ensure a much longer service life for your motorcycle.

Warranty

The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed
in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for
damage resulting from manipulations and alterations to the motorcycle.

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, use only spare parts and accessories approved by KTM. KTM accepts no liability for other products and any re­sulting damage or loss.

Transport

Note

Danger of damageಘDanger of damage by the vehicle running away or falling over.

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

Note

Fire hazardಘSome components (engine, radiator and exhaust system) get very hot when the engine is running.

ದ Do not place the vehicle where there are flammable or explosive substances.

ದ switch off engine.
ದ Turn the handleb
ದ Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

 of the fuel tap to the OFF position. (Figureb500137-10b P. 20)

IMPORTANT NOTES 7

Environment

Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. 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.

Warning notes

In your own interest, read the specified warning notes.

Info

Various warning labels are attached to your vehicle. Do not remove any warning labels. If they are missing, you or others may
not recognize dangers and may therefore be injured.

Grades of risks

Danger

Danger that leads immediately and certainly to severe and permanent injury or death.

Warning

Danger that will probably lead to severe and permanent injury or death.

Note

Danger of serious damage to machine or material.

Warning

Risk of environmental damage.

OWNER'S MANUAL

ದ Read this owner's manual carefully and completely before making your first trip. It contains a lot of information and tips to help

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

ದ 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.

LOCATION OF SERIAL NUMBERS 8

/2&$7,212)6(5,$/ 180%(56

Chassis number



The chassis numberb is stamped on the steering head on the right.

500127-10

Type label

The type labelb is fixed to the front of the steering head.

500128-10

Key number (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA)

The key numberb is stamped on the key strap.

500125-10

Engine number

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

Fork part number

500072-10

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

500082-10

LOCATION OF SERIAL NUMBERS 9

Shock absorber part number

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

500129-10

OPERATING ELEMENTS 10

23(5$7,1*(/(0(176

Clutch lever



The clutch leverb is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.

500133-10

Hand brake lever

The hand brake leverb is located on the right side of the handlebar and operates the
front wheel brake.

400196-10

Short circuit button (EVERY XCR-W MODELS)

The short circuit buttonb is mounted on the left side of the handlebar.

Possible states

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

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

500132-10

Short circuit button (EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS)

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

Possible states

• Short circuit buttonb in basic position ದbIn this position, the ignition circuit is
closed, and the engine can be started.

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

500134-10

Emergency OFF switch (EXC-RbAUS/UK)

500131-10

The emergency OFF switchb is fitted on the left side of the handlebar.

Possible states

Ignition off ದbIn this position, the ignition circuit is interrupted, a running
engine stops, and a non-running engine will not start.

Ignition on ದbIn this position, the ignition circuit is closed, and the en­gine can be started.

OPERATING ELEMENTS 11

Emergency OFF switch (EXC-RbUSA)

The emergency OFF switchb is fitted on the left side of the handlebar.

Possible states

Ignition off ದbIn this position, the ignition circuit is interrupted, a running
engine stops, and a non-running engine will not start.

Ignition on ದbIn this position, the ignition circuit is closed, and the en­gine can be started.

500144-10

Ignition switch (EXC-RbUSA)

The ignition switchb is on the right behind the headlight mask.

Possible states

Ignition off ದbIn this position, the ignition circuit is interrupted, a running
engine stops, and a non-running engine will not start.

Ignition on ದbIn this position, the ignition circuit is closed, and the en­gine can be started.

500130-10

Electric starter button (EXC-RbEU, EXC-RbSIXbDAYS, EXC-RbUSA, XCR-W)

The electric starter buttonb is fitted on the right side of the handlebar.

Possible states

• Electric starter buttonb in basic position

• Electric starter buttonb pressed ದbIn this position, the electric starter is actuated.

400198-10

Electric starter button (EXC-RbAUS/UK)

The electric starter buttonb is fitted on the right side of the handlebar.

Possible states

• Electric starter buttonb in basic position

• Electric starter buttonb pressed ದbIn this position, the electric starter is actuated.

500131-11

Light switch (EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS)

The light switchb is fitted on the left side of the handlebar.

Possible states

Light off ದbLight switch is turned to the right. In this position, the light is
switched off.

Low beam on ದbLight switch is in the central position. In this position,
the low beam and tail light are switched on.

High beam on ದbLight switch is turned to the left. In this position, the
high beam and the tail light are switched on.

500134-12

OPERATING ELEMENTS 12

Light switch (EVERY XCR-W MODELS)

The light switchb is on the right of the speedometer.

Possible states

(XCR-WbZA)

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

is switched off.

• Light on ದbLight switch is pulled out to the stop. In this position, the low beam

and tail light are switched on.

(XCR-WbUSA)

500146-10

Light switch (EXC-RbUSA)

• The light switch has no function when delivered. ದbIt can be used if lighting is

fitted later.

The light switchb is fitted on the left side of the handlebar.

Possible states

Low beam on ದbLight switch is turned downwards. In this position, the
low beam and tail light are switched on.

High beam on ದbLight switch is turned upwards. In this position, the high
beam and the tail light are switched on.

500142-10

Headlight flasher switch (EXC-RbUSA)

The headlight flasher switchb is fitted on the left side of the handlebar.

Possible states

• Headlight flasher switch in neutral position

• Headlight flasher switch pressed ದbIn this position, the headlight flasher (high
beam) is actuated.

500143-10

Horn (EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS)

The horn buttonb is fitted on the left side of the handlebar.

Possible states

• Horn buttonb in neutral position

• Horn buttonb pressed ದbThe horn is operated in this position.

Horn (EXC-RbUSA)

500134-11

The horn buttonb is fitted on the left side of the handlebar.

Possible states

• Horn buttonb in neutral position

• Horn buttonb pressed ದbThe horn is operated in this position.

500142-11

OPERATING ELEMENTS 13

Flasher switch (EXC-RbEU, EXC-RbAUS/UK)

The flasher switchb is fitted on the left side of the handlebar.

Possible states

Flasher light off ದbFlasher switch is in the central position.
Flasher light, left, on ದbFlasher switch turned to the left.

Flasher light, right, on ದbFlasher switch turned to the right.

500145-10

Flasher switch (EXC-RbUSA)

The flasher switchb is fitted on the left side of the handlebar.

Possible states

Flasher light off
Flasher light, left, on ದbFlasher switch pressed to the right. The flasher
switch returns automatically to the central position after use.

Flasher light, right, on ದbFlasher switch pressed to the right. The flasher
switch returns automatically to the central position after use.

To switch off the flasher light, press the flasher switch towards the switch case.

500142-12

Overview of indicator lamps (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA)

Possible states

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

Flasher indicator lamp flashes green ದbFlasher light is switched on.

500147-01

Overview of indicator lamps (EXC-RbSIXbDAYS)

Possible states

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

500160-01

Speedometer

ದ Press the key b to change the display mode or change to one of the setup menus.
ದ Press the key b"+" to control different functions.
ದ Press the key b"ತ" to control different functions.

Info

In its condition at delivery, the disply mode SPEED/H and SPEED/ODO is acti­vated.

400312-01

OPERATING ELEMENTS



Speedometer activation and test

400313-01

400314-01

14

Activating the speedometer:
The speedometer is activated when one of the keys is pressed or an impulse comes
from the wheel speed sensor.
Display test
For the function test of the display, all display segments light up briefly.

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

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.



Tripmaster switch

(Option: Tripmaster switch)

You can use the trip master switch to control the functions of the speedometer from the handlebar.

Info

The trip master is an optional accessory.



Setting kilometers or miles

Info

If you change the unit, the ODO value is retained and converted accordingly.
The values TR1, TR2, A1, A2 and S1 are deleted at the changeover.

Condition

The motorcycle is standing.
ದ Press the buttonb briefly and repeatedly until H appears at the bottom right of the

display.

ದ Press the buttonb for 3 - 5 seconds.

The Setup menu opens and the active functions are displayed.

ದ Press the button b repeatedly until the Km/h / Mphdisplay flashes.
Setting Km/h

ದ Press the buttonb"+".

Setting Mph

400329-01

ದ Press the buttonb"ತ".

ದ Press the buttonb 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.

OPERATING ELEMENTS 15



Setting the clock

Condition

The motorcycle is standing.
ದ Press the button b briefly and repeatedly until CLK appears at the bottom right of

the display.

ದ Press the buttonb for 3 - 5 seconds.

The hour display flashes.

ದ Set the hour display with the buttonb"+" and/or buttonb"ತ".
ದ Press the buttonb briefly.

The next segment of the display flashes and can be set.

400330-01

ದ You can set the following segments in the same way as the hours by pressing the

buttonb"+" and the buttonb"ತ".

Info

The seconds can only be set to zero.

ದ Press the buttonb 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.



Adjusting speedometer functions

Info

In the condition at delivery, only the SPEEDb/bH display mode and SPEEDb/bODO are active.

Condition

The motorcycle is standing.
ದ Press the buttonb briefly and repeatedly until H appears at the bottom right of the

display.

ದ Press the buttonb for 3 - 5 seconds.

The Setup menu opens and the active functions are displayed.

ದ Switch to the function you require by briefly pressing the buttonb .

The selected function flashes.

Activating a function

ದ Press the buttonb"+".

400318-01

Deactivating a function

ದ Press the buttonb"ತ".

ದ Activate or deactivate all functions accordingly.
ದ Press the buttonb for 3 - 5 seconds.

The icon remains in the display and the display changes to the next func­tion.

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

The settings are saved and the Setup menu closed.

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.

OPERATING ELEMENTS 16

Querying lap time

Info

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

Condition

The motorcycle is standing.
ದ Press the buttonb briefly and repeatedly until LAP appears at the bottom right of

the display.

ದ Press the buttonb briefly.

The LAPb1 is displayed on the left of the display.

ದ Laps 1-10 can be displayed by pressing the buttonb"+".
ದ buttonb"ತ" no function
ದ Press the buttonb briefly.

400321-01

next display mode

Info

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

Display mode SPEED

400317-02

Display mode SPEED/H (service hours)

400316-01

ದ Press the buttonb briefly and repeatedly until SPEED appears on the left of the

display.

In the SPEED display mode, the current speed is displayed.
The current speed can be displayed in Km/h or in 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.

Condition

The motorcycle is standing
ದ Press the buttonb 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 buttonb"+". No function
Press the buttonb"ತ". No function
Press the buttonb
for 3 - 5 seconds.
Press the buttonb

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

briefly.

OPERATING ELEMENTS 17

Display mode SPEEDb/bCLK (time)

ದ Press the button b briefly and repeatedly until CLK appears at the bottom right of

the display.

The time is displayed in CLK display mode.

Press the buttonb"+". no function
Press the buttonb"ತ". no function

400319-01

Display mode SPEED/LAP (lap time)

Press the buttonb
for 3 - 5 seconds.
Press the buttonb
briefly.

ದ Press the buttonb 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 buttonb"ತ", 9 memory locations are
already occupied.
Lap 10 must be timed with the buttonb"+".

The display changes to the Setup menu of the clock.

next display mode

400320-01

Display mode SPEED/ODO (odometer)

400317-01

Display mode SPEED/TR1 (trip masterb1)

Press the buttonb"+". Starts or stops the clock.
Press the buttonb"ತ". Stops the current lap time and saves it, and the stop watch

starts the next lap.

Press the buttonb

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

Next display mode
briefly.

ದ Press the buttonb 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 buttonb"+". No function
Press the buttonb"ತ". No function
Press the buttonb

ದ

for 3 - 5 seconds.
Press the buttonb

Next display mode
briefly.

ದ Press the buttonb briefly and repeatedly until TR1 appears at the top right of the

display.

TR1 (trip masterb1) runs constantly and counts up to 999.9.
It can be used to measure the distance covered during trips or between two refueling
stops.
TR1 is coupled with A1 (average speed 1) and S1 (stop watch 1).

400323-01

Info

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

0.0.

Press the buttonb"+". No function
Press the buttonb"ತ". No function
Press the buttonb
for 3 - 5 seconds.
Press the buttonb
briefly.

Displays of TR1, A1 and S1 are reset to 0,0.

Next display mode

OPERATING ELEMENTS 18

Display mode SPEED/TR2 (trip master 2)

ದ Press the buttonb briefly and repeatedly until TR2 appears at the top right of the

display.

TR2 (trip masterb2) runs constantly and counts up to 999.9.
The displayed value can be set manually with the button b"+" and the buttonb"ತ". A very
practical function for rides by the road book.

Info

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

400324-01

Disply mode SPEED/A1 (average speedb1)

tonb"+" and the buttonb"ತ".
If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0.

Press the buttonb"+". Increases value of TR2.
Press the buttonb"ತ". Reduces value of TR2.
Press the buttonb

Deletes value of TR2.
for 3 - 5 seconds.
Press the buttonb

Next display mode
briefly.

ದ Press the buttonb 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 sensor and
ends 3 seconds after the last impulse.

Press the buttonb"+". No function
Press the buttonb"ತ". No function

400325-01

Press the buttonb
for 3 - 5 seconds.
Press the buttonb
briefly.

Display mode SPEED/A2 (average speed 2)

ದ Press the buttonb 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 watchb2) is running.

400326-01

Press the buttonb"+". No function
Press the buttonb"ತ". No function
Press the buttonb
for 3 - 5 seconds.
Press the buttonb
briefly.

Displays of TR1, A1 and S1 are reset to 0,0.

Next display mode

display.

Info

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

ದ

Next display mode

OPERATING ELEMENTS 19

Display mode SPEED/S1 (stop watch 1)

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

Press the buttonb"+". No function
Press the buttonb"ತ". No function

400327-01

Display mode SPEED/S2 (stop watchb2)

400328-01

Press the buttonb
for 3 - 5 seconds.
Press the buttonb
briefly.

ದ Press the buttonb 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 buttonb"+". Starts or stops S2.
Press the buttonb"ತ". No function
Press the buttonb
for 3 - 5 seconds.
Press the buttonb
briefly.

Displays of TR1, A1 and S1 are reset to 0,0.

Next display mode

Displays of S2 and A2 are reset to 0.0.

Next display mode

Overview of speedomer functions
Display Press the buttonb"+". Press the buttonb"ತ". Press the buttonb for 3 -

5 seconds.

Display mode SPEED/H
(service hours)

No function No function The display changes to

the Setup menu of the
speedometer functions.

Display mode
SPEEDb/bCLK (time)

no function no function The display changes to

the Setup menu of the
clock.

Display mode SPEED/LAP
(lap time)

Starts or stops the
clock.

Stops the current lap
time and saves it, and

The stop watch and the

lap time are reset.
the stop watch starts
the next lap.

Display mode

No function No function ದ Next display mode

SPEED/ODO (odometer)
Display mode SPEED/TR1

(trip masterb1)
Display mode SPEED/TR2

No function No function Displays of TR1, A1 and

S1 are reset to 0,0.

Increases value of TR2.

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

(trip master 2)
Disply mode SPEED/A1

(average speedb1)
Display mode SPEED/A2

No function No function Displays of TR1, A1 and

S1 are reset to 0,0.

No function No function ದ Next display mode

(average speed 2)
Display mode SPEED/S1

(stop watch 1)
Display mode SPEED/S2

(stop watchb2)

No function No function Displays of TR1, A1 and

S1 are reset to 0,0.

Starts or stops S2. No function Displays of S2 and A2

are reset to 0.0.

Press the buttonb
briefly.

Next display mode

next display mode

Next display mode

Next display mode

Next display mode

Next display mode

Next display mode

Overview of conditions and ability to be enabled
Display The motorcycle is

standing

Menu can be en­abled

Display mode SPEED
Display mode SPEED/H (service hours) •
Display mode SPEEDb/bCLK (time) •

OPERATING ELEMENTS 20

Overview of conditions and ability to be enabled
Display The motorcycle is

standing

Display mode SPEED/LAP (lap time) •
Display mode SPEED/ODO (odometer)
Display mode SPEED/TR1 (trip masterb1) •
Display mode SPEED/TR2 (trip master 2) •
Disply mode SPEED/A1 (average speedb1) •
Display mode SPEED/A2 (average speed 2) •
Display mode SPEED/S1 (stop watch 1) •
Display mode SPEED/S2 (stop watchb2) •

Fuel tap

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

 on the fuel tap, you can open or close the supply of fuel to the

carburetor.

Possible states

• Fuel supply closed OFF ದbNo fuel can flow from the tank to the carburetor.

• Fuel supply open ON ದbFuel can flow from the tank to the carburetor. The fuel tank
empties down to the reserve.

• Reserve fuel supply open RES ದbFuel can flow from the tank to the carburetor. The
fuel tank empties completely.

Menu can be en­abled

Opening filler cap

Closing filler cap

500137-10

ದ Press release buttonb, turn filler cap counterclockwise and lift it free.

400199-10

ದ Replace the filler cap and turn clockwise until the release buttonb locks in place.

Info

Run the fuel tank breather hoseb without kinks.

400199-11

OPERATING ELEMENTS 21

Choke (EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA, XCR-W)

The chokeb is fitted on the left side of the carburetor.
Activating the choke function frees an opening through which the engine can draw ex­tra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.

Info

If the engine is warm, the choke function must be deactivated.

Possible states

500135-10

Choke (EXC-RbEU)

500136-10

• Choke function activated ದbThe choke lever is pulled out to the stop.

• Choke function deactivated ದbThe choke lever is pushed in to the stop.

The flasher switchb is fitted on the left side of the handlebar.
Activating the choke function frees an opening through which the engine can draw ex­tra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.

Info

If the engine is warm, the choke function must be deactivated.

Possible states

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

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

Shift lever

Foot brake pedal

The shift leverb 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

The foot brake pedalb is located in front of the right footrest and operates the rear
wheel brake.

500139-10

OPERATING ELEMENTS 22

Kickstarter

The kickstarterb is fitted on the right of the engine.
The engine can be started with either the kickstarter or the electric starter.
The upper part of the kickstarter can be swung out.

Info

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

500148-10

Side stand

Note

Danger of damageಘDanger of damage by the vehicle running away or falling over.

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

Note

Material damageಘDamage and destruction of components by excessive load.

ದ The side stand is designed for the weight of the motorcycle only. Do not sit on the

500140-10

motorcycle when it is supported by the side stand only. The side stand and/or the
frame could be damaged and the motorcycle could fall over.

To park the motorcycle, press the side standb
the motorcycle on it.

When you are riding, the side standb must be folded up and secured with the rubber
bandb

.

500141-10

Steering lock (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA)

The steering lockb is fitted on the left of the steering head.
The steering lock is used to lock the steering. Steering, and therefore riding, is no
longer possible.

500126-10

 with your foot to the ground and lean

Locking the steering (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA)

Note

Danger of damageಘDanger of damage by the vehicle running away or falling over.

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

ದ Park the motorcycle.
ದ Turn the handlebar as far as possible to the right.

OPERATING ELEMENTS 23

ದ 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.

Unlocking the steering (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA)

ದ Insert the key in the steering lock, turn it to the left, pull it out and turn it to the right. Remove the key.

You can now steer the bike again.

Info

Never leave the key in the steering lock.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 24

*(1(5$/7,36$1' +,17621 3877,1*,172 23(5$7,21

Advice on first use



Danger

Danger of accidentsಘDanger from inadequate traffic experience.

ದ Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs.

Warning

Risk of injuryಘRisk of injury by missing/inadequate protective clothing.

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

Warning

Danger of crashingಘImpairment of riding behavior due to different tire tread patterns on front and rear wheels.

ದ 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 accidentsಘCritical riding behavior due to inappropriate riding.

ದ Adapt your riding speed to the road conditoins and your riding ability.

Warning

Danger of accidentsಘAccident risk caused by presence of a passenger.

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

Warning

Danger of accidentsಘBrake system failure.

ದ If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take

your foot off the foot brake pedal if you do not want to brake.

Warning

Danger of accidentsಘUnstable riding behavior.

ದ Do not exceed the maximum permitted weight and axle loads.

Warning

Risk of misappropriationಘUsage by unauthorized persons.

ದ 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.

ದ 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.

ದ Before your first trip, read the entire operating instructions carefully.
ದ Get to know the operating elements.
ದ adjust the basic position of clutch lever. ( P. 75)

(Every XCR-W models)

ದ adjust the basic position of handbrake lever. ( P. 56)

(Every EXC-R models)

ದ Adjust the free travel of the handbrake lever. ( P. 56)
ದ Adjust the basic position of the footbrake lever. ( P. 60)
ದ 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.

ದ Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.
ದ Do not make any offroad trips that over-stress your ability and experience.
ದ Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
ದ Do not make any changes to the motorcycle, and use only KTM approved parts.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 25

ದ 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.

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

Specification

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

ದ Run the engine in.

Running in the engine

ದ During the running-in phase, do not exceed the specified engine speed and engine performance.

Specification

Maximum engine speed

During the first 3 service hours 7000brpm

Maximum engine performance during the running-in period

During the first 3 service hours ืb50b%
During the next 12 service hours ืb75b%

ದ Avoid fully opening the throttle!

RIDING INSTRUCTIONS 26

5,',1*,16758&7,216

Checks before putting into operation



Info

Make sure that the motorcycle is in a perfect technical condition before use.

Info

In the interests of riding safety, make a habit of making a general check before you ride.

ದ Check the engine oil level. ( P. 79)
ದ Check the chain tension. ( P. 51)
ದ Check the chain dirt accumulation. ( P. 50)
ದ Check the tire condition. ( P. 66)
ದ Checking the tire air pressure. ( P. 66)
ದ Check the front brake fluid level. ( P. 56)
ದ Check the rear brake fluid level. ( P. 60)
ದ Check the front brake linings. ( P. 57)
ದ Check the rear brake linings. ( P. 61)
ದ Check brake system function.
ದ Check the coolant level. ( P. 72)
ದ Check that all operating elements are correctly adjusted and free to move.
ದ Check the functioning of the electrical equipment.

Starting

Danger

Danger of poisoningಘExhaust gases are poisonous and can result in unconsciousness and/or death.

ದ When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed

space.

Note

Engine failureಘHigh engine speeds in cold engines have a negative effect on the service life of the engine.

ದ Always warm up the engine at low engine speeds.

Info

If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel
evaporate after a long time of standing.
If the float chamber is filled with fresh fuel, the engine starts immediately.
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds until trying again.

Conditions

Motorcycle standing still: ุb1bweek

ದ Empty the carburetor float chamber. ( P. 78)
ದ Turn the handleb

Fuel can flow from the tank to the carburetor.

ದ Remove the motorcycle from the stand.
ದ Shift gear to neutral.
(EXC-RbUSA)

ದ Turn the key in the ignition switch to the positionb .

ದ Turn the emergency OFF switch to the positionb .
(EXC-RbAUS/UK)

ದ Turn the emergency OFF switch to the positionb .

Conditions

Engine cold

(EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA, XCR-W)

ದ Pull choke lever out as far as possible.

(EXC-RbEU)

ದ Pull the choke lever to the stop.

 of the fuel tap to the ON position. (Figureb500137-10b P. 20)

RIDING INSTRUCTIONS 27

ದ Press the electric starter button or press the kickstarter robustly through its full range.

Info

Don't open the throttle.

Conditions

Engine hot and running

ದ Push back the hot start lever to the stop with the engine running.

Starting up

Info

If your bike has lights, switch them on before riding. You will then be seen earlier by other motorists.
When you are riding, the side stand must be folded up and secured with the rubber band.

ದ Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.

Shifting, riding

Warning

Danger of accidentsಘIf you change down at high engine speed, the rear wheel can lock up.

ದ Do not change into a low gear at high engine speed. The engine races and the rear wheel can block.

Info

If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.
First gear is used for starting off or for steep inclines.

ದ When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simulta-

neously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.

ದ If the choke function was activated, deactivate it after the engine has warmed up.
ದ When you reach maximum speed after fully opening the throttle, turn back the throttle to about 3/4 of its range; the speed hardly

drops, but the fuel consumption falls considerably.

ದ Always open the throttle only as much as the engine can handle ದ abrupt throttle opening increases fuel consumption.
ದ To shift down, brake if necessary and close the throttle at the same time.
ದ Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again.
ದ Switch off the engine if you expect to be standing for a long time.

Specification

ุb2bmin

ದ Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and the cooling system.
ದ Ride with a lower engine speed instead of with a high engine speed and a slipping clutch.

Braking

Warning

Danger of accidentsಘIf you brake too hard, the wheels can lock.

ದ Adapt your braking to the traffic situation and the road conditions.

Warning

Danger of accidentsಘReduced braking caused by spongy pressure point of front or rear brake.

ದ Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Danger of accidentsಘReduced braking due to wet or dirty brakes.

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

ದ On sandy, wet or slippery surfaces, use the rear brake.
ದ Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
ದ On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine.

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

RIDING INSTRUCTIONS



Stopping, parking

Warning

Danger of burnsಘSome vehicle components get very hot when the machine is driven.

ದ Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these compo-

nents to cool down before starting work on them.

Note

Danger of damageಘDanger of damage by the vehicle running away or falling over.

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

Note

Fire hazardಘSome components (engine, radiator and exhaust system) get very hot when the engine is running.

ದ Do not place the vehicle where there are flammable or explosive substances.

ದ Brake the motorcycle.
ದ Shift gear to neutral.

(Every XCR-W models)

ದ Press the short circuit buttonb at engine idling speed until the engine stops.
(EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS)

ದ Press the short circuit buttonb at engine idling speed until the engine stops.
(EXC-RbUSA)

ದ Push the emergency off switch at engine indling speed to the positionb .
ದ Turn the handleb
ದ Stand the motorcycle on a hard surface.



of the fuel tap to the OFF position. (Figureb500137-10b P. 20)

28



Refueling

Danger

Fire hazardಘFuel can easily catch fire.

ದ Never fill up 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.

ದ Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.

Warning

Danger of poisoningಘFuel is poisonous and a health hazard.

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

diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.

Warning

Environmental hazardಘImproper handling of fuel is a danger to the environment.

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

ದ Open the filler cap. ( P. 20)

AA

400382-10

ದ Fill the fuel tank with fuel up to measurementb

Specification

Measurement ofb

Tank capacity
(EXC-RbEU, EXC­RbAUS/UK, EXC­RbSIXbDAYS, XCR­WbZA)

Tank capacity
(EXC-RbUSA, XCR­WbUSA)



9bl (2.4bUSbgal) Super unleaded (ROZ 95 / RON 95 /

9.2bl
(2.43bUSbgal)



.

35bmm (1.38bin)

PON 91) ( P. 114)

Super unleaded (ROZ 95 / RON 95 /
PON 91) ( P. 114)

ದ Close the filler cap. ( P. 20)

GREASING AND SERVICE TABLE 29

*5($6,1*$1'6(59,&( 7$%/(

Important maintenance work to be carried out by an authorized KTM workshop.



S3N S15A S30A

Engine Change the engine oil and oil filter and clean the engine oil screen. ( P. 79) • • •

Change the gear oil and clean the gear oil screen. ( P. 82) • • •
Replace spark plug. •
Check and adjust valve clearance. • • •
Check engine mounting screws for tightness. • • •
Clean spark plug connectors and check for tightness. • • •
Check that the screws in the shift lever and the kickstarter are tight. • • •

Carburetor Check carburetor connection boots for cracks and leakage. • •

Check vent hoses for damage and routing without sharp bends. • • •
Check idle. •••

Attachments Check the cooling system for leakage. • • •

Check the antifreeze and coolant level. ( P. 71) • • •
Check the exhaust system for leakage and looseness. • •
Check Bowden cables for damage, smooth operation and routing without sharp

bends.
Check the fluid level of the hydraulic clutch. ( P. 75) • • •
Clean the air filter. ( P. 75) • • •
Check cables for damage and routing without sharp bends. • •
Check that the electrical equipment is functioning properly. • • •
Check the headlamp setting. • •

Brakes Check the front brake linings. ( P. 57) • • •

Check the rear brake linings. ( P. 61) • • •
Check the brake discs. ( P. 55) • • •
Check the front brake fluid level. ( P. 56) • • •
Check the rear brake fluid level. ( P. 60) • • •
Check brake lines for damage and leakage. • • •
Check the free play of the hand brake lever. ( P. 55) • • •
Check the free play of the foot brake lever. ( P. 59) • • •
Check brake system function. • • •
Check screws and guide bolts of brake system for tightness. • • •

Chassis Check shock absorber and fork for leakage and functioning. • • •

Clean dust boots of fork legs. ( P. 39) • •
Bleed fork legs. ( P. 38) • •
Check swingarm bearing. ••
Check play of steering head bearing. ( P. 39) • • •
Check all screws to see if they are tight. • • •

Wheels Check the spoke tension. ( P. 67) • • •

Check rim run-out. • • •
Check the tire condition. ( P. 66) • • •
Checking the tire air pressure. ( P. 66) • • •
Check the chain wear. ( P. 52) • • •
Check the chain tension. ( P. 51) • • •
Clean the chain. ( P. 50) • • •
Check wheel bearing for play. • • •
Clean and grease adjusting screws of chain adjuster. • • •

•••

S3N: After 3 service hours
S15A: Every 15 service hours / after every race
S30A: Every 30 service hours

GREASING AND SERVICE TABLE 30

Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)

Competition use Hobby use J1A J2A

S15A S30A S45A S30A S60A S90A

Carry out a complete fork service. ••
Carry out a complete shock absorber service. •
Grease the steering head bearing. ( P. 46) ••
Clean and adjust carburetor. ••
Treat electric contacts with contact spray. ••
Change hydraulic clutch fluid. ( P. 76) ••
Change the front brake fluid. ••
Change the rear brake fluid. ••
Clean spark arrestor. (EXC-RbUSA, XCR-WbUSA) • •
Check wear of clutch discs. • • • • • •
Check the clutch. • •
Check/measure the cylinder. • •
Change the piston. • •
Check the camshaft. • •
Change the camshaft bearing. • •
Check the lower valve spring retainer. • •
Check the cylinder head. • •
Check the valves. • •
Check the valve springs. • •
Check the radial clearance of the rocker arm rollers. • •
Check the timing chain tensioner function. • •
Check the balancer shaft. • •
Check the crankshaft run-out on the bearing pin. • •
Change conrod bearing. • •
Change the crankshaft main bearing. • •
Check the transmission. • •
Check the shift mechanism. • •
Check the spring length of the oil pressure regulator

valve.
Change glass fiber yarn filling of main silencer. • •
Replace foot brake cylinder seals. • •
Check the carburetor components. • •

••

S15A: Every 15 service hours / after every race
S30A: Every 30 service hours
S45A: Every 45 service hours
S60A: Every 60 service hours
S90A: Every 90 service hours
J1A: annually
J2A: every 2 years

Important checks and maintenance work to be carried out by the rider.

Check the engine oil level. ( P. 79) •
Check the front brake fluid level. ( P. 56) •
Check the rear brake fluid level. ( P. 60) •
Check the front brake linings. ( P. 57) •
Check the rear brake linings. ( P. 61) •
Check and adjust Bowden cables. •
Bleed fork legs. ( P. 38) •
Clean dust boots of fork legs. ( P. 39) •

NB1A

GREASING AND SERVICE TABLE 31

NB1A

Clean the chain. ( P. 50) •
Check the chain tension. ( P. 51) •
Check the chain wear. ( P. 52) •
Check the rear sprocket / engine sprocket for wear. ( P. 52) •
Clean the air filter. ( P. 75) •
Checking the tire air pressure. ( P. 66) •
Check the tire condition. ( P. 66) •
Check the coolant level. ( P. 72) •
Empty the carburetor float chamber. ( P. 78) •
Check that all operating elements for smooth operation. •
Check braking. •
Check all screws, nuts and hose clamps regularly for tightness. •

NB1A: Depending on conditions of use according to requirements.

MAINTENANCE WORK ON CHASSIS AND ENGINE 32

0$,17(1$1&(:25. 21&+$66,6 $1'(1*,1(

Jacking up the motorcycle



Note

Danger of damageಘDanger of damage by the vehicle running away or falling over.

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

ದ Jack up the motorcycle underneath the engine. The wheels must no longer touch

the ground.

Work stand (54829055000)

500074-01

Removing the motorcycle from the work stand

ದ Secure the motorcycle against falling over.

Note

Danger of damageಘDanger of damage by the vehicle running away or falling over.

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

ದ Remove the motorcycle from the work stand.
ದ Remove the work stand.

Checking the basic chassis setting with the rider's weight

Info

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

ದ For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swing arm and frame, the basic set-

tings of the suspension components must match your body weight.
ದ As delivered, KTM offroad motorcycles are adjusted for a standard rider weight (with full protective clothing).

Specification

Standard rider weight 75… 85bkg (165… 187blb.)

ದ If your weight is above or below the standard range, you have to adjust the basic setting of the suspension components accord-

ingly.
ದ Small weight differences can be compensated by adjusting the spring preload, but in the case of large weight differences, the

springs must be replaced.

Compression damping of shock absorber

The shock absorber can regulate compression damping in low- and high-speed range separately (Dual Compression Control).
The term low and high speed refers to the movement of the shock absorber during compression and not the riding speed of the motor­cycle.
The low- and high-speed technology works non-specifically.

Adjusting high-speed compression damping of the shock absorber

Danger

Danger of accidentsಘThe shock absorber is under high pressure.

ದ The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-

tenance on it yourself.

Info

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

MAINTENANCE WORK ON CHASSIS AND ENGINE 33

ದ Turn the adjusting screwb clockwise with a ring wrench until it stops.

Info

Do not loosen nutb!

ದ Turn back counterclockwise the number of turns corresponding to the shock ab-

sorber type.
Specification

Compression damping, high-speed

400208-10

Adjusting the low-speed compression damping of the shock absorber

Danger

Danger of accidentsಘThe shock absorber is under high pressure.

ದ The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-

tenance on it yourself.

Comfort 2bturns
Standard 1.5bturns
Sport 1bturn

Info

Turn clockwise to increase damping, turn counterclockwise to reduce sus­pension damping.

Info

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

ದ Turn the adjusting screwb clockwise with a screwdriver until it stops.

Info

Do not loosen nutb!

ದ Turn back counterclockwise the number of clicks corresponding to the shock ab-

sorber type.
Specification

Compression damping, low-speed

400209-10

Comfort 18bclicks
Standard 15bclicks
Sport 12bclicks

Info

Turn clockwise to increase damping, turn counterclockwise to reduce sus­pension damping.

Adjusting rebound damping of the shock absorber

Danger

Danger of accidentsಘThe shock absorber is under high pressure.

ದ The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-

tenance on it yourself.

MAINTENANCE WORK ON CHASSIS AND ENGINE 34

ದ Turn the adjusting screwbclockwise until it stops.

Info

Do not loosen nutb!

ದ Turn back counterclockwise the number of clicks corresponding to the shock ab-

sorber type.
Specification

Rebound damping

400210-10



Measuring rear wheel sag unloaded

00AA

ದ Jack up the motorcycle. ( P. 32)
ದ Measure the distance ದ as vertical as possible ದ between the rear axle and a fixed

ದ Make a note of the value as measurementb
ದ Remove the motorcycle from the work stand. ( P. 32)

Comfort 24bclicks
Standard 22bclicks
Sport 20bclicks

Info

Turn clockwise to increase damping, turn counterclockwise to reduce sus­pension damping.

point, for example, a mark on the side cover.



.

400220-10



Checking static sag of the shock absorber

ದ Measure distancebof rear wheel unloaded. ( P. 34)
ದ Ask someone to help you by holding the motorcycle upright.
ದ Measure the distance between the rear axle and the fixed point again.

00AA

ದ Make a note of the value as measurementb

ದ Check the static sag.

000BB

400221-10



.

Info

The static sag is the difference between measurementsbandb.

Static sag 35bmm (1.38bin)

» If the static sag is less or more than the specified value:

ದ Adjust the spring preload of the shock absorber. ( P. 35)

MAINTENANCE WORK ON CHASSIS AND ENGINE



Checking the riding sag of the shock absorber

ದ Measure distanceb of rear wheel unloaded. ( P. 34)
ದ With another person holding the motorcycle, sit on the saddle with full protective

clothing in a normal sitting position (feet on footrests) and bounce up and down a
few times until the rear suspension levels out.

00AA

ದ The other person now has to measure the distance between the rear axle and a

fixed point.

ದ Make a note of the value as measurementb

Info

The riding sag is the difference between measurementsb andb.

ದ Check the riding sag.

Riding sag 105bmm (4.13bin)

35

.

CC

400222-10



Adjusting spring preload of the shock absorberbx

» If the riding sag differs from the specified measurement:

ದ Adjust the riding sag. ( P. 36)

Danger

Danger of accidentsಘThe shock absorber is under high pressure.

ದ The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-

tenance on it yourself.

Info

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

ದ Remove shock absorber. ( P. 36)
ದ After removing the shock absorber, clean it thoroughly.
ದ Loosen screwb.

22

11

ದ Turn adjusting ringb

Combination wrench (50329080000)
Hook wrench (T106S)

 until the spring is no longer under tension.

AA

ದ Measure the overall spring length when not under tension.
ದ Tighten the spring by turning adjusting ringb

Specification

Spring preload

Standard 9bmm

 to measurementb.

400216-10

Info

Depending on the static sag and/or the riding sag, it may be necessary to
increase or decrease the spring preload.

ದ Tighten screwb

Specification

Screw, shock absorber adjusting ring M6 5bNm (3.7blbfbft)

ದ Installing shock absorber. ( P. 36)

.

MAINTENANCE WORK ON CHASSIS AND ENGINE 36

Adjusting riding sagbx

ದ Remove shock absorber. ( P. 36)
ದ After removing the shock absorber, clean it thoroughly.
ದ Choose and fit a suitable spring.

Specification

Spring rate

Weight of rider: 65… 75bkg (143… 165blb.) 69bN/mm (394blb/in)
Weight of rider: 75… 85bkg (165… 187blb.) 72bN/mm (411blb/in)
Weight of rider: 85… 95bkg (187… 209blb.) 76bN/mm (434blb/in)

Info

The spring rate is shown on the outside of the spring.
Smaller weight differences can be compensated by changing the spring preload.

ದ Installing shock absorber. ( P. 36)
ದ Check the static sag of the shock absorber. ( P. 34)
ದ Check the riding sag of the shock absorber. ( P. 35)
ದ Adjust the rebound damping of the shock absorber. ( P. 33)

Removing the shock absorberbx

ದ Jack up the motorcycle. ( P. 32)
ದ Remove screwb and lower the rear wheel with the swing arm as far as possible

without blocking the rear wheel. Fix the rear wheel in this position.

ದ Remove screwb

sorber.

, push splash protectorb to the side, and remove the shock ab-

Installing shock absorberbx

500075-10

500075-11

ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Push splash protectorb

tighten screwb

.

 to the side and position the shock absorber. Mount and

Specification

Screw, top shock absorber M12 80bNm

Loctite

(59blbfbft)

ದ Mount and tighten screwb

.

Specification

Screw, bottom shock ab­sorber

M12 80bNm

(59blbfbft)

Loctite

Info

The heim joint for the shock absorber at the swing arm is Teflon coated. It
must not be greased with grease or with other lubricants. Lubricants dis­solve the Teflon coating, thereby drastically reducing the service life.

ದ Remove the motorcycle from the work stand. ( P. 32)

®

®

243™

243™

MAINTENANCE WORK ON CHASSIS AND ENGINE



Checking basic setting of fork

Info

For various reasons, no exact riding sag can be determined for the forks.

ದ As with the shock absorber, smaller weight differences can be compensated by the

spring preload.

ದ However, if your fork is often overloaded (hard end stop on compression), you must

fit harder springs to avoid damage to the fork and frame.

400189-01



Adjusting compression damping of fork

Info

The hydraulic compression damping determines the fork suspension behavior.

ದ Remove protection coversb.



ದ Turn adjusting screwsb

clockwise until they stop.

37

Info

The adjusting screwsbare located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.

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

Specification

100020-10

Compression damping (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)

Comfort 24bclicks
Standard 20bclicks
Sport 18bclicks

Compression damping (EXC-RbSIXbDAYS)

Comfort 24bclicks
Standard 22bclicks
Sport 18bclicks

Info

Turn clockwise to increase damping, turn counterclockwise to reduce sus­pension damping.

ದ Mount protection coversb



Adjusting rebound damping of fork

Info

The hydraulic rebound damping determines the fork suspension behavior.



.

100019-10

ದ Turn adjusting screwsbclockwise until they stop.

Info

The adjusting screwsbare located at the top end of the fork legs.
Make the same adjustment on both fork legs.

MAINTENANCE WORK ON CHASSIS AND ENGINE 38

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

Specification

Rebound damping (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)

Comfort 20bclicks
Standard 18bclicks
Sport 18bclicks

Rebound damping (EXC-RbSIXbDAYS)

Comfort 20bclicks
Standard 20bclicks
Sport 18bclicks

Info

Turn clockwise to increase damping, turn counterclockwise to reduce sus­pension damping.

Adjusting spring preload of the fork

ದ Turn adjusting screws counterclockwise until they stop.

Info

Make the same adjustment on both fork legs.

Bleeding fork legs

100025-10

ದ Turn back clockwise the number of turns corresponding to the fork type.

Specification

Spring preload - PreloadbAdjuster (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-
W)

Comfort 2bturns
Standard 4bturns
Sport 7bturns

Spring preload - PreloadbAdjuster (EXC-RbSIXbDAYS)

Comfort 2bturns
Standard 2bturns
Sport 7bturns

Info

Turn clockwise to increase spring preload, turn counterclockwise to reduce
spring preload.
Adjusting the spring preload has no influence on the absorption setting of
the rebound damping.
Basically, however, you should set the rebound damping higher with a
higher spring preload.

ದ Jack up the motorcycle. ( P. 32)
ದ Remove bleeder screwsb briefly.

Any excess pressure escapes from the interior of the fork.

ದ Mount and tighten bleeder screws.
ದ Remove the motorcycle from the work stand. ( P. 32)

100021-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 39

Cleaning dust boots of fork legs

ದ Jack up the motorcycle. ( P. 32)
ದ Loosen the fork protection. ( P. 39)
ದ Push dust bootsb of both fork legs downwards.

Info

The dust boots should remove dust and coarse dirt particles from the fork
tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not
removed, the oil seals behind can start to leak.

Warning

500088-10

ದ Clean and oil the dust boots and inner fork tube of both fork legs.

ದ Press the dust boots back into their normal position.
ದ Remove excess oil.
ದ Position the fork protection. ( P. 39)
ದ Remove the motorcycle from the work stand. ( P. 32)

Danger of accidentsಘReduced braking due to oil or grease on the brake
discs.

ದ Always keep the brake discs free of oil and grease, and clean them with

brake cleaner when necessary.

Universal oil spray ( P. 115)

Loosening the fork protection

500087-11

Positioning the fork protection

500087-10

ದ Remove screwsb and take off clamp.
ದ Remove screwsb

 on left fork leg. Push the fork protection downwards.

ದ Remove the screws on the right fork leg. Push the fork protection downwards.

ದ Position the fork protection on the left fork leg. Mount and tighten screwsb.

Specification

Remaining screws, chassis M6 10bNm (7.4blbfbft)

ದ Position the brake line and cable harness. Put the clamp on, mount and tighten

screwsb

.

ದ Position the fork protection on the right fork leg. Mount and tighten screws.

Specification

Remaining screws, chassis M6 10bNm (7.4blbfbft)

Checking play of steering head bearing

Warning

Danger of accidentsಘUnsafe riding behavior due to incorrect steering head bearing play.

ದ The steering head bearing play should be adjusted immediately in an authorized KTM workshop.

Info

If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can
be damaged after time.

ದ Jack up the motorcycle. ( P. 32)

MAINTENANCE WORK ON CHASSIS AND ENGINE 40

ದ Move the handlebar to the straight-ahead position. Move the fork legs to and fro in

the direction of travel.

No play should be noticeable in the steering head bearing.

» If there is noticeable play present:

(EXC-RbSIXbDAYS, XCR-WbUSA)

ದ Adjust play of the steering head bearing. ( P. 40)

(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)

400189-10

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

ದ Remove the motorcycle from the work stand. ( P. 32)



Adjusting play of steering head bearingbx(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)

ದ Jack up the motorcycle. ( P. 32)
ದ Loosen screwsbandb.
ದ Loosen and retighten screwb

ದ Adjust play of the steering head bearing. ( P. 40)

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

» If click positions are noticeable:

(EXC-RbSIXbDAYS, XCR-WbUSA)

ದ Adjust play of the steering head bearing. ( P. 40)

(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)

ದ Adjust play of the steering head bearing. ( P. 40)

ದ Check the steering head bearing and replace if required.



.

Specification

Screw, top steering head M20x1,5 10bNm (7.4blbfbft)

ದ Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.



ದ Fully tighten screwb

.

Specification

100022-10

Screw, top triple clamp M8 20bNm

ದ Tighten screwb



.

Specification

Screw, top steering stem M8 20bNm

ದ Check play of steering head bearing. ( P. 39)



Adjusting play of steering head bearingbx(EXC-RbSIXbDAYS, XCR-WbUSA)

ದ Jack up the motorcycle. ( P. 32)
ದ Loosen screwb. Remove screwb.
ದ Loosen and retighten screwb



.

Specification

Screw, top steering head M20x1,5 10bNm (7.4blbfbft)

ದ Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
ದ Fully tighten screwb



.

Specification

500103-11

Screw, top triple clamp M8 17bNm

(14.8blbfbft)

(14.8blbfbft)

(12.5blbfbft)

ದ Mount and tighten screwb



.

Specification

Screw, top steering stem M8 17bNm

ದ Check play of steering head bearing. ( P. 39)

(12.5blbfbft)

Loctite

®

243™

MAINTENANCE WORK ON CHASSIS AND ENGINE



Fork offset (EXC-RbSIXbDAYS, XCR-WbUSA)

You can see the currently set offset if you remove screwb.



has an impact on the handling of the vehicle. It is calculated from

to the front gives greater stability on fast racetracks.

00AA

00BB

The fork offsetb
the center of the fork leg to the center of the steering head bearing.
The fork offset can optionally be adjusted.
Markingb



Fork offset

Front marking 18bmm (0.71bin)

41

Markingb

0011

400188-10



Setting the fork offsetbx (EXC-RbSIXbDAYS, XCR-WbUSA)

ದ Remove the lower triple clamp. ( P. 43)
ದ Remove screwb. Remove the steering stem.
ದ Clean the parts and check for damage.
ದ Rotate the steering stem 180° and insert into the triple clamp. Mount and tighten

500104-10

ದ Install the lower triple clamp. ( P. 44)



to the rear (condition at delivery) gives better handling in bends.

Fork offset

Rear marking 20bmm (0.79bin)

screwb



.

Specification

Screw, bottom steering
head

M20x1,5 60bNm

(44.3blbfbft)

Loctite

®

243™



Removing the fork legs

500093-10

500094-10

ದ Remove front wheel. ( P. 63)
ದ Remove screwsband take off clamp.



ದ Remove cable clipb
ದ Hang the brake caliper and the brake line loosely to the side.

(EXC-RbSIXbDAYS, XCR-WbUSA)

ದ Loosen screwb
ದ Loosen screwb

, remove screwband take off the brake caliper.



. Remove the fork leg on the left.



. Remove the fork leg on the right.

MAINTENANCE WORK ON CHASSIS AND ENGINE 42

(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)

ದ Loosen screwb
ದ Loosen screwb

100023-11

Installing the fork legsbx

ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Position the fork legs.

Info

The topmost sunk nut in the fork leg must be flush to the upper edge of the
upper triple clamp.
Position the bleeder screwb

100021-10

(EXC-RbSIXbDAYS, XCR-WbUSA)

ದ Fully tighten screwb

Specification

Screw, top triple clamp M8 17bNm

. Remove the fork leg on the left.
. Remove the fork leg on the right.

 to the front.

.

(12.5blbfbft)

500094-11

100023-10

500093-11

ದ Fully tighten screwb

.

Specification

Screw, bottom triple clamp M8 12bNm

(8.9blbfbft)

(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)

ದ Fully tighten screwb

.

Specification

Screw, top triple clamp M8 20bNm

(14.8blbfbft)

ದ Fully tighten screwb

.

Specification

Screw, bottom triple clamp M8 15bNm

(11.1blbfbft)

ದ Position brake caliper, mount and tighten screwsb.

Specification

Screw, front brake caliper M8 25bNm

Loctite

®

243™

(18.4blbfbft)

ದ Fit cable clipb

.

ದ Position the brake line and cable harness. Put the clamp on, mount and tighten

.

screwsb

ದ Fit front wheel. ( P. 64)

MAINTENANCE WORK ON CHASSIS AND ENGINE 43

Removing the fork protectorbx

ದ Remove the fork legs. ( P. 41)
ದ Remove screwsb on the left fork leg. Remove the fork protector upwards.
ದ Remove the screws on the right fork leg. Remove the fork protector upwards.

500105-10

Installing the fork protectorbx

ದ Check parts for damage and wear. Replace damaged or worn parts.

.

500105-10

ದ Position the fork protection on the left fork leg. Mount and tighten screwsb

Specification

Remaining screws, chassis M6 10bNm (7.4blbfbft)

ದ Position the fork protection on the right fork leg. Mount and tighten screws.

Specification

Remaining screws, chassis M6 10bNm (7.4blbfbft)

ದ Install the fork legs. ( P. 42)

Removing the lower triple clampbx (EXC-RbSIXbDAYS, XCR-WbUSA)

ದ Remove the fork legs. ( P. 41)
(XCR-WbUSA)

ದ Dismount the start number plate. ( P. 47)

(EXC-RbSIXbDAYS)

ದ Remove the headlight mask with the headlight. ( P. 46)
ದ Dismount the front fender. ( P. 46)
ದ Remove screwsb and hang the CDI control unit to the side.

Info

Do not unplug the CDI control unit.

ದ Remove screwb

. Remove screwb, take off top triple clamp with the handlebar

and place it on one side.

Info

500099-10

ದ Remove o-ringb. Remove protector ringb.
ದ Remove the lower triple clamp with the steering stem.
ದ Remove the upper steering head bearing.

Protect the motorcycle and its attachments from damage by covering them.
Do not bend the cables and lines.

500100-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 44

Removing the lower triple clampbx (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)

ದ Remove the fork legs. ( P. 41)
ದ Remove the headlight mask with the headlight. ( P. 46)
ದ Dismount the front fender. ( P. 46)
ದ Remove screwsb and hang the CDI control unit to the side.

Info

Do not unplug the CDI control unit.

ದ Remove screwb

and place it on one side.

. Loosen screwb. Take off top triple clamp with the handlebar

Info

500149-10

ದ Remove protector ringb.
ದ Remove the lower triple clamp with the steering stem.
ದ Remove the upper steering head bearing.

500150-10

Installing the lower triple clampbx (EXC-RbSIXbDAYS, XCR-WbUSA)

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

0033

ದ Insert the lower triple clamp with the steering stem. Mount the upper steering head

0022
0011

Protect the motorcycle and its attachments from damage by covering them.
Do not bend the cables and lines.

Long-life grease ( P. 115)

bearing.

Info

Check whether the top steering head sealb is correctly positioned.

500098-10

500099-11

ದ Push up protective ringb

ದ Position the upper triple clamp with the steering.
ದ Mount and tighten screwb

Specification

Screw, top steering head M20x1,5 10bNm (7.4blbfbft)

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

screwsb

.

Specification

Remaining screws, chassis M6 10bNm (7.4blbfbft)

ದ Install the front fender. ( P. 46)

(XCR-WbUSA)

ದ Fit the start number plate. ( P. 47)

 and o-ringb.

.

MAINTENANCE WORK ON CHASSIS AND ENGINE 45

(EXC-RbSIXbDAYS)

ದ Refit the headlight mask with the headlight. ( P. 47)
ದ Install the fork legs. ( P. 42)
ದ Mount and tighten screwb.

Specification

Screw, top steering stem M8 17bNm

(12.5blbfbft)

ದ Check the cable harness, cable, brake and clutch line for free movement and free

laying.
ದ Check play of steering head bearing. ( P. 39)

500103-10

Installing the lower triple clampbx (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)

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

Long-life grease ( P. 115)

ದ Insert the lower triple clamp with the steering stem. Mount the upper steering head

bearing.

0022
0011

Info

Check whether the top steering head sealb is correctly positioned.

Loctite

®

243™

500151-10

500149-11

ದ Push on protective ringb

ದ Position the upper triple clamp with the steering.
ದ Mount and tighten screwb

Specification

Screw, top steering head M20x1,5 10bNm (7.4blbfbft)

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

screwsb

.

Specification

Remaining screws, chassis M6 10bNm (7.4blbfbft)

ದ Install the front fender. ( P. 46)
ದ Refit the headlight mask with the headlight. ( P. 47)
ದ Install the fork legs. ( P. 42)
ದ Tighten screwb.

Specification

Screw, top steering stem M8 20bNm

.

.

(14.8blbfbft)

100022-11

ದ Check the cable harness, cable, brake and clutch line for free movement and free

laying.
ದ Check play of steering head bearing. ( P. 39)

MAINTENANCE WORK ON CHASSIS AND ENGINE 46

Greasing the steering head bearingbx

(EXC-RbSIXbDAYS, XCR-WbUSA)

Remove the lower triple clamp. ( P. 43)
Install the lower triple clamp. ( P. 44)

(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)

Remove the lower triple clamp. ( P. 44)
Install the lower triple clamp. ( P. 45)

Dismounting the front fender

ದ Remove screwsb. Remove the front fender.
ದ Make sure that the distance bushings remain in place.

500092-10

Installing the front fender

ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Make sure that the distance bushings are mounted in the fender.
ದ Position the front fender. Mount and tighten screwsb

Specification

Remaining screws, chassis M6 10bNm (7.4blbfbft)

.

Info

Ensure that there is contact between the holding lugs and the start number

500092-10

Removing headlight mask with headlight (EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA, XCR-WbZA)

ದ Switch off all electrical equipment.
ದ Remove screwb
ದ Loosen the rubber bandb

500155-10

ದ Pull out the electric plug connectorb and remove the headlight mask with the

plate or headlight mask.

 and take off clamp.

. Push up the headlight mask and swing it forwards.

headlight.

500156-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 47



Refitting the headlight mask with the headlight (EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA,
XCR-WbZA)

ದ Check parts for damage and wear. Replace damaged or worn parts.

.

500156-11

500155-11

ದ Connect the electric plug connectorb

ದ Position the headlight mask and fix it with the rubber bandb.

Info

Take care with the contact of the holding lug at the fender.

ದ Position the brake line and cable harness. Put the clamp on, mount and tighten

screwb

.

ದ Check the headlamp setting.



Dismount the start number plate (XCR-WbUSA)

ದ Remove screwb and take off clamp.
ದ Remove screwb

500101-10



Fitting the start number plate (XCR-WbUSA)

ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Position the start number plate. Fit and tighten screwb

Specification

500101-11

ದ Position the brake line and cable harness. Put the clamp on, mount and tighten

screwb

 with distance bushing. Remove the start number plate.

 with distance bushing.

Remaining screws, chassis M6 10bNm (7.4blbfbft)

Info

Take care with the contact of the holding lug at the fender.

.



Handlebar position

00AA

00BB

00AA

00BB

400223-11

On the upper triple clamp, there are 2 holes at a distance ofb to each other.

Distanceb

The holes on the handlebar support are placed at a distance ofb

Distanceb

The handlebar supports can be mounted in 4 different positions.

(EXC-RbSIXbDAYS)

 between holes 15bmm (0.59bin)

 from the center.

 between holes 3.5bmm (0.138bin)

The handlebar supports can also be mounted at 2 different heights (with and with-

out spacer).

Thick spacer 9bmm (0.35bin)

MAINTENANCE WORK ON CHASSIS AND ENGINE



Adjusting handlebar positionbx

(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)

0011
0022

0011
0022

ದ Remove the four screwsb

bar and lay it to one side.

Info

Protect the motorcycle and its attachments from damage by covering
them.
Do not bend the cables and lines.



. Remove the handlebar clamp. Remove the handle-

48

00

11
22

00
33

00
0044
0055

400223-10

ದ Remove the two screwsb

ದ Check parts for damage and wear. Replace damaged or worn parts.

ದ Place the handlebar support in the required position. Fit and tighten the two

screwsb



.

Specification

Screw, handlebar support M10 40bNm

Info

Position the left and right handlebar supports evenly.

ದ Position the handlebar.

Info

Make sure cables and wiring are positioned correctly.

ದ Position the handlebar clamp. Fit and evenly tighten the four screwsb

Specification

Screw, handlebar clamp M8 20bNm

Info

Make sure the gap width is even.

(EXC-RbSIXbDAYS)

ದ Remove the four screwsb

ersb



and elastomersb.

ದ Remove the handlebar and lay it to one side.

Info

Protect the motorcycle and its attachments from damage by covering
them.
Do not bend the cables and lines.



. Remove the handlebar support.

Loctite

(29.5blbfbft)

(14.8blbfbft)



. Remove the handlebar clampsbwith rubber wash-

®

243™



.

0066
0077

0088
0099

400343-10

ದ Remove the lower shellsb

ದ Remove the clamp barb

ದ Remove the two screwsb

ದ Check parts for damage and wear. Replace damaged or worn parts.



.



with the rubber conesb.



. Remove the handlebar support.

MAINTENANCE WORK ON CHASSIS AND ENGINE 49

ದ Place the handlebar support in the required position. Fit and tighten the two

screwsb

.

Specification

Screw, handlebar support M10 40bNm

(29.5blbfbft)

Condition

 Spacer fitted:

Use a M10x35 screw

Condition

without a spacerb

Use a M10x25 screw

:

Info

Position the left and right handlebar supports evenly.

Loctite

®

243™

ದ Fit the rubber conesb

ದ Fit the lower shellsb

ದ Position the handlebar.

 and clamp barb.

.

Info

Make sure cables and wiring are positioned correctly.

ದ Position the handlebar clampsb

Elastomer kit green - soft qualityb(SXS05125203)
Elastomer kit yellow - medium quality (standard)b(SXS05125204)
Elastomer kit red - hard qualityb(SXS05125205)

 with rubber washersb and elastomersb.

Info

The elastomeres are available in different versions.

ದ Fit and evenly tighten the four screwsb

Specification

Screw, handlebar clamp M8 16bNm

.

Info

Make sure the gap width is even.

(11.8blbfbft)

Checking gas Bowden cable route

500152-10

ದ The two gas Bowden cables must run parallel behind the handlebar down to the

frame. They must be routed directly on the frame above the tank bearing to the car-

buretor.

MAINTENANCE WORK ON CHASSIS AND ENGINE 50



Checking play in the gas Bowden cable

ದ Move the handlebar to the straight-ahead position. Move the throttle grip back and

forth slightly to ascertain the play in the gas Bowden cable.

Play in gas Bowden cable 3… 5bmm (0.12… 0.2bin)

» If the gas Bowden cable play does not meet specifications:

ದ Adjust the gas Bowden cable play. ( P. 50)

Danger

Danger of poisoningಘExhaust gases are poisonous and can result in uncon-

400192-10



Adjusting the gas Bowden cable playbx

ದ Start the engine and let it run idle. Move the handlebar to and fro over the entire

ದ Dismount the fuel tank. ( P. 70)
ದ Check gas Bowden cable route. ( P. 49)
ದ Move the handlebar to the straight-ahead position.
ದ Push back bellowsb
ದ Loosen nutb
ದ Loosen nutb

sciousness and/or death.

ದ When running the engine, always make sure there is sufficient ventila-

tion, and do not start or run the engine in a closed space.

steering range.

The idle speed must not change.

» If the idle speed changes:

ದ Adjust the gas Bowden cable play. ( P. 50)



.



. Turn adjusting screwbin as far as possible.



. Turn adjusting screwbso that there is play in the gas Bowden ca-

ble at the throttle grip.

Specification

Play in gas Bowden cable 3… 5bmm (0.12… 0.2bin)



500153-10

ದ Tighten nutb
ದ Press and hold the throttle grip in the closed setting. Turn adjusting screwb

until there is no play in the Bowden cableb
ದ Tighten nutb
ದ Push bellowsb

.



.



.



on. Check the throttle grip for smooth operation.

ದ Install the fuel tank. ( P. 70)
ದ Check play in the gas Bowden cable. ( P. 50)



Checking chain dirt

ದ Check the chain for coarse dirt accumulation.

» If the chain is very dirty:

ದ Clean the chain. ( P. 50)



Cleaning the chain

Warning

Danger of accidentsಘOil or grease on the tires reduces their grip.

ದ Remove oil and grease with a suitable cleaning material.

Warning

Danger of accidentsಘReduced braking due to oil or grease on the brake discs.

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



out

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

MAINTENANCE WORK ON CHASSIS AND ENGINE 51

Info

The service life of the chain depends largely on its maintenance.

ದ Clean the chain regularly and then treat with chain spray.

Chain cleaner ( P. 115)
Offroad chain spray ( P. 115)

Checking the chain tension

Warning

Danger of accidentsಘDanger caused by incorrect chain tension.

ದ If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-

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

ದ Jack up the motorcycle. ( P. 32)
ದ Push the chain at the end of the chain sliding component upwards to measure the

chain tensionb

.

Info

The upper chain sectionb must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.

Chain tension 8… 10bmm (0.31… 0.39bin)

400213-10

» If the chain tension does not meet specifications:

ದ Adjusting chain tension - after checking. ( P. 53)

ದ Remove the motorcycle from the work stand. ( P. 32)

Checking the chain tension when fitting rear wheel

Warning

Danger of accidentsಘDanger caused by incorrect chain tension.

ದ If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-

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

ದ Make sure that the chain adjusters are fitted correctly on the adjusting screws.
ದ Push the chain at the end of the chain sliding component upwards to measure

chain tensionb

.

400213-10

Info

The upper chain sectionb must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.

Chain tension 8… 10bmm (0.31… 0.39bin)

» If the chain tension does not meet specifications:

ದ Adjust the chain tension when fitting rear wheel. ( P. 54)

0

MAINTENANCE WORK ON CHASSIS AND ENGINE



Checking the rear sprocket / engine sprocket for wear

ದ Check the rear sprocket / engine sprocket for wear.

» If the rear sprocket / engine sprocket are worn:

ದ Replace rear sprocket / engine sprocket.

Info

When fitting the chain joint, always make sure that the closed side
of the joint faces forward (riding direction).
The engine sprocket, rear sprocket and chain should always be re­placed together.



Checking chain wear

00AA

400227-01

ದ Check that the chain guide is firmly seated and not worn.

ದ Jack up the motorcycle. ( P. 32)
ದ Shift to neutral and pull the upper chain length with the specified tensionb.

Specification

Chain tension 10… 15bkg (22… 33blb.)

ದ Measure distanceb



of 18 chain links in the lower chain section.

Info

Chain wear is not always even, so you should repeat this measurement at
different chain positions.

52



BB

00

1 2 3 16 17 18



Adjusting the chain tension

400226-10

Maximum distanceb
chain section

» If distanceb

ದ Replace the chain.



at the longest

is greater than the specified measurement:

Info

When you replace the chain, you should also replace the rear and
engine sprockets.
New chains wear out faster on old, worn sprockets.

ದ Remove the motorcycle from the work stand. ( P. 32)

272bmm (10.71bin)

Warning

Danger of accidentsಘDanger caused by incorrect chain tension.

ದ If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-

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

ದ Jack up the motorcycle. ( P. 32)
ದ Push the chain at the end of the chain sliding component upwards to measure

chain tensionb



.

Info

The upper chain sectionbmust be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.

400213-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 53

ದ Loosen nutb.
ದ Loosen nutsb
ದ Adjust the chain tension by turning the left and right adjusting screwsb

Specification

Chain tension 8… 10bmm (0.31… 0.39bin)
Turn the left and right adjusting screwsb

right chain adjusters are in the same position relative to the reference marksb
The rear wheel is then correctly aligned.

.

.

 so that the markings on the left and

.

400225-10

Adjusting chain tension - after checking

ದ Tighten nutsb
ದ Make sure that chain adjustersb
ದ Tighten nutb

Specification

Nut, rear wheel spindle M20x1,5 80bNm (59blbfbft)

.

 are fitted correctly on the adjusting screwsb.

.

Info

The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
Chain adjustersb

ದ Remove the motorcycle from the work stand. ( P. 32)

ದ Loosen nutb.
ದ Loosen nutsb
ದ Adjust the chain tension by turning the adjusting screwsb

Specification

Chain tension 8… 10bmm (0.31… 0.39bin)
Turn the adjusting screwsb

right chain adjusters are in the same position relative to the reference marksb
The rear wheel is then correctly aligned.

ದ Tighten nutsb
ದ Make sure that the chain adjustersb

screwsb
ದ Tighten nutb

Specification

Nut, rear wheel spindle M20x1,5 80bNm (59blbfbft)

.

.

.

.

 can be turned by 180°.

 left and right.

 left and right so that the markings on the left and

 are fitted correctly on the adjusting

.

400225-13

Info

The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
The chain adjustersb

 can be turned by 180°.

MAINTENANCE WORK ON CHASSIS AND ENGINE 54

Adjusting chain tension - fitting rear wheel

ದ Loosen nutsb.
ದ Adjust the chain tension by turning the adjusting screwsb

Specification

Chain tension 8… 10bmm (0.31… 0.39bin)
Turn the adjusting screwsb

 left and right so that the markings on the left and

right chain adjusters are in the same position relative to the reference marksb
The rear wheel is then correctly aligned.

 left and right.

.

Adjusting chain guidebx

400225-11

ದ Tighten nutsb

.

ದ Remove screwsb andb. Take off the chain guide.

Conditions

Number of teeth: ืb44bteeth

ದ Insert nutb

ದ Mount and tighten screwsb

 in holeb. Position the chain guide.

 andb.

Specification

Remaining screws, chassis M6 10bNm

Conditions

Number of teeth: ุb45bteeth

ದ Insert nutb

ದ Mount and tighten screwsb

 in holeb. Position the chain guide.

 andb.

Specification

Remaining screws, chassis M6 10bNm

(7.4blbfbft)

(7.4blbfbft)

400252-10

Brake fluid reservoir

Warning

Danger of accidentsಘBrake system failure.

ದ If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.

Have the brake system checked in an authorized KTM workshop, and do not ride any further.

The brake fluid reservoirs of the front and rear brakes are dimensioned so that they do not need topping up with brake fluid even if the
brake linings are worn.

A

MAINTENANCE WORK ON CHASSIS AND ENGINE 55

Brake calipers

The brake calipers of this series are "floating", which means that they are not fixed to the brake caliper support.
The lateral compensation ensures an optimal position of the brake pad in relation to the brake disc.

Checking brake discs

Warning

Danger of accidentsಘReduced braking due to worn brake discs.

ದ Worn brake discs should be replaced immediately by an authorized KTM workshop.

ದ Check the thickness of the front and rear brake discs at several places on the disc

to see if it conforms to measurementb

.

A

400257-10

Checking free play of hand brake lever

Wear reduces the thickness of the brake disc around the area used by the
brake linings.

Wear limit of brake discs

front 2.5bmm (0.098bin)
Rear 3.5bmm (0.138bin)

» The brake disc thickness is less than the specified value.

ದ Replace the brake disc.

Warning

Danger of accidentsಘBrake system failure.

ದ If there is no free travel on the hand brake lever, pressure builds up on the front brake in the brake system. The front brake

can fail due to overheating. Adjust free travel on hand brake lever according to specifications.

(Every XCR-W models)

Info

ದ Push the hand brake lever forwards and check free play.b

Free play of hand brake lever ุb3bmm (ุb0.12bin)

» If the free travel does not meet specifications:

ದ adjust the basic position of handbrake lever. ( P. 56)

.

400196-11

400196-13

(Every EXC-R models)

ದ Push the hand brake to the handlebar and check free playb

Free play of hand brake lever ุb3bmm (ุb0.12bin)

» If the free travel does not meet specifications:

ದ Adjust the free travel of the handbrake lever. ( P. 56)

.

MAINTENANCE WORK ON CHASSIS AND ENGINE 56

Adjusting basic position of handbrake lever (Every XCR-W models)

ದ Adjust the basic setting of the handbrake lever to your hand size by turning adjust-

ing screwb

400196-12

ದ Check the free play of the hand brake lever. ( P. 55)

Adjusting free travel of handbrake lever (Every EXC-R models)

ದ Adjust the free travel of the handbrake lever with the adjustment screwb.

400196-12

ದ Check the free play of the hand brake lever. ( P. 55)

.

Info

Turn the adjusting screw clockwise to increase the distance between the
handbrake lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the handbrake lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!

Info

Turn the adjustment screw clockwise to reduce free travel. The pressure
point moves away from the handlebar.
Turn the adjustment screw counterclockwise to increase free travel. The
pressure point moves towards the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!

Checking the front brake fluid level

Warning

Danger of accidentsಘBrake system failure.

ದ If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.

Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Danger of accidentsಘReduced braking due to old brake fluid.

ದ Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

ದ Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
ದ Check the brake fluid level in the viewerb

» If the brake fluid is below the MIN mark:

ದ Top up the brake fluid of the front brake. ( P. 56)

400231-10

Topping up the front brake fluidbx

.

Warning

Danger of accidentsಘBrake system failure.

ದ If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.

Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Skin irritationsಘBrake fluid can cause skin irritation on contact.

ದ Avoid contact with skin and eyes, and keep out of the reach of children.
ದ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

MAINTENANCE WORK ON CHASSIS AND ENGINE 57

Warning

Danger of accidentsಘReduced braking due to old brake fluid.

ದ Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

KTM recommends DOTb5.1 brake fluid from Motorex®. This has a higher wet boiling point than DOTb4 brake fluid and provides
greater safety for high demands.
Never user DOTb5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOTb5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

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



ದ Remove screwsb
ದ Remove the coverb
ದ Top up brake fluid to levelb

Specification

Measurement ofb

.



with membraneb.



.



5bmm (0.2bin)

Brake fluid DOT 5.1 ( P. 114)

ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Position the cover with membrane. Mount and tighten screws.

Info

Clean up overflowed or spilt brake fluid immediately with water.

400230-10



Checking the front brake linings

Warning

Danger of accidentsಘReduced braking due to worn brake linings.

ದ Worn brake linings should be replaced immediately in an authorized KTM workshop.

ದ Check the brake linings for minimum thicknessb.



» Minimum thicknessb

If the minimum thickness is less than specified:
ದ Change the front brake linings. ( P. 59)

: ุb1bmm (ุb0.04bin)

400235-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 58

Removing front brake liningsbx

Warning

Danger of accidentsಘImproper brake maintenance and repair.

ದ Always have your brake system maintained and repaired in an authorized KTM workshop.

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

brake pistons.

Info

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

ದ Remove the locking split pinsb

, withdraw the boltb, and take out the brake

pads.

500089-11

ದ Remove cable clipb

. Remove screwsb and take off brake caliper.

ದ Clean brake caliper and brake caliper support.

Installing the front brake liningsbx

Warning

Danger of accidentsಘReduced braking due to oil or grease on the brake discs.

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

Warning

Danger of accidentsಘReduced braking due to use of non-approved brake linings.

ದ Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-

tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi­nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

ದ Check the brake discs. ( P. 55)
ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Check that leaf springb

 in the brake caliper and sliding plateb in the brake

caliper support are seated correctly.

Info

The arrow on the leaf spring points in the rotation direction of the brake
disc.

500091-10

500089-12

ದ Fit the brake linings, insert boltb, and mount locking split pinsb.
ದ Position brake caliper, mount and tighten screwsb

.

Specification

®

Screw, front brake caliper M8 25bNm

Loctite

243™

(18.4blbfbft)

ದ Fit cable clipb

.

ದ Operate the hand brake lever repeatedly until the brake linings lie on the brake disc

and there is a tight spot.

MAINTENANCE WORK ON CHASSIS AND ENGINE 59



Changing the front brake liningsb

Warning

Skin irritationsಘBrake fluid can cause skin irritation on contact.

ದ Avoid contact with skin and eyes, and keep out of the reach of children.
ದ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidentsಘReduced braking due to old brake fluid.

ದ Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

KTM recommends brake fluid DOTb5.1 from Motorex®. This brake fluid has a higher wet boiling point than brake fluid DOTb4
and offers more protection under high load.
Never user DOTb5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOTb5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

x

ದ Remove the front brake linings. ( P. 58)
ದ Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
ದ Remove screwsb
ದ Remove coverb
ದ Press the brake piston back to its basic position and make sure that no brake fluid

overflows from the brake fluid reservoir.

ದ Install the front brake linings. ( P. 58)
ದ Add brake fluid to levelb

Specification

Measurement ofb

Brake fluid DOT 5.1 ( P. 114)

ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Position the cover with the membrane. Mount and tighten the screws.



.



with membraneb.



.



5bmm (0.2bin)

Info

Clean up overflowed or spilt brake fluid immediately with water.

400230-10



Checking free play of foot brake lever

Warning

Danger of accidentsಘBrake system failure.

ದ If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake

can fail due to overheating. Adjust free travel on foot brake pedal according to specifications.

500139-11

ದ Disconnect springb.
ದ Move the foot brake lever backwards and forwards between the end stop and the

foot brake cylinder piston bracket and check free playb

Specification

Free play at foot brake lever 3… 5bmm (0.12… 0.2bin)

» If the free travel does not meet specifications:

ದ Adjust the basic position of the footbrake lever. ( P. 60)

ದ Reconnect springb



.



.

MAINTENANCE WORK ON CHASSIS AND ENGINE 60

Adjusting basic position of footbrake leverbx

Warning

Danger of accidentsಘBrake system failure.

ದ If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake

can fail due to overheating. Adjust free travel on foot brake pedal according to specifications.

ದ Disconnect springb.
ದ Loosen nutb
ದ To adjust the basic position of the footbrake lever individually, lossen nutb

turn screwb

 and with push rodb, turn it back until you have maximum free play.

 and

 accordingly.

Info

The range of adjustment is limited.

500154-10

Checking the rear brake fluid level

ದ Turn push rodb

basic position of the footbrake lever.

Specification

Free play at foot brake lever 3… 5bmm (0.12… 0.2bin)

ದ Hold screwb

Specification

Remaining nuts, chassis M8 30bNm

ದ Hold push rodb

Specification

Remaining nuts, chassis M6 15bNm

ದ Reconnect springb

 accordingly until you have free playb. If necessary, adjust the

 and tighten nutb.

 and tighten nutb.

.

Warning

Danger of accidentsಘBrake system failure.

ದ If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.

Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Danger of accidentsಘReduced braking due to old brake fluid.

ದ Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

(22.1blbfbft)

(11.1blbfbft)

400234-10

ದ Stand the vehicle upright.
ದ Check the brake fluid level in the viewerb

» When in the viewerb

ದ Add rear brake fluid. ( P. 61)

 an air bubble is visible:

.

MAINTENANCE WORK ON CHASSIS AND ENGINE 61



Adding rear brake fluidb

Warning

Danger of accidentsಘBrake system failure.

ದ If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.

Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Skin irritationsಘBrake fluid can cause skin irritation on contact.

ದ Avoid contact with skin and eyes, and keep out of the reach of children.
ದ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidentsಘReduced braking due to old brake fluid.

ದ Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

KTM recommends brake fluid DOTb5.1 frombMotorex®. This brake fluid has a higher wet boiling point than brake fluid DOTb4
and offers more protection under high load.
Never user DOTb5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOTb5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

x

ದ Stand the vehicle upright.



with membraneband the O-ring.



.



Checking rear brake linings

400233-10

ದ Remove screw capb
ದ Add brake fluid to levelb

Brake fluid DOT 5.1 ( P. 114)

ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Mount the screw cap with the membraneband the O-ring.

Info

Clean up overflowed or spilt brake fluid immediately with water.

Warning

Danger of accidentsಘReduced braking due to worn brake linings.

ದ Worn brake linings should be replaced immediately in an authorized KTM workshop.

ದ Check the brake linings for minimum thicknessb.



» Minimum thicknessb

If the minimum thickness is less than specified:
ದ Change the rear brake linings. ( P. 63)

: ุb1bmm (ุb0.04bin)

400238-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 62

Removing rear brake liningsbx

Warning

Danger of accidentsಘImproper brake maintenance and repair.

ದ Always have your brake system maintained and repaired in an authorized KTM workshop.

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

brake piston.

Info

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

ದ Remove the locking split pinsb

, withdraw the boltb, and take out the brake

pads.

400236-10

Installing the rear brake liningsbx

ದ Clean brake caliper and brake caliper support.

Warning

Danger of accidentsಘReduced braking due to oil or grease on the brake discs.

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

Warning

Danger of accidentsಘReduced braking due to use of non-approved brake linings.

ದ Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-

tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi­nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

ದ Check the brake discs. ( P. 55)
ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Check that leaf springb

 in the brake caliper and sliding plateb in the brake

caliper support are seated correctly.

Info

The arrow on the leaf spring points in the rotation direction of the brake
disc.

500122-10

400237-10

ದ Fit the brake linings, insert boltb, and mount locking split pinsb.

Info

Make sure that the decoupling plateb is mounted on the piston side of the
brake pad.

ದ Operate the foot brake lever repeatedly until the brake linings lie on the brake disc

and there is a tight spot.

MAINTENANCE WORK ON CHASSIS AND ENGINE 63



Changing the rear brake liningsb

Warning

Skin irritationsಘBrake fluid can cause skin irritation on contact.

ದ Avoid contact with skin and eyes, and keep out of the reach of children.
ದ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidentsಘReduced braking due to old brake fluid.

ದ Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

KTM recommends brake fluid DOTb5.1 from Motorex®. This brake fluid has a higher wet boiling point than brake fluid DOTb4
and offers more protection under high load.
Never user DOTb5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOTb5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

x



Removing front wheelb

x

400233-10

ದ Remove the rear brake linings. ( P. 62)
ದ Stand the vehicle upright.
ದ Remove screw capb
ದ Press the brake piston back to its basic position and make sure that no brake fluid

overflows from the brake fluid reservoir.

ದ Install the rear brake linings. ( P. 62)
ದ Add brake fluid to levelb

Brake fluid DOT 5.1 ( P. 114)

ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Mount the screw cap with the membraneband the O-ring.



with membraneband the O-ring.



.

Info

Clean up overflowed or spilt brake fluid immediately with water.

ದ Jack up the motorcycle. ( P. 32)
ದ Press the brake caliper by hand on to the brake disc in order to press back the

brake pistons.

Info

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

500089-10

500084-10

ದ Remove screwb.
ದ Loosen screwb



.

MAINTENANCE WORK ON CHASSIS AND ENGINE 64

ದ Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of

the fork.

Info

Do not pull the hand brake lever when the front wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam­aged.

500085-10

ದ Remove distance bushingb.

500086-10

Fitting front wheelbx

Warning

Danger of accidentsಘReduced braking due to oil or grease on the brake discs.

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

ದ Check parts for damage and wear. Replace damaged or worn parts.

500086-11

500084-11

ದ Clean and grease shaft seal ringsb

ings.

Long-life grease ( P. 115)

ದ Fit the distance bushings.

ದ Lift the front wheel into the fork, position it, and insert the wheel spindle.
ದ Mount and tighten screwb

.

Specification

Screw, front wheel spindle M24x1,5 40bNm

ದ Operate the hand brake lever several times until the brake pads are lying correctly

on the brake disc.

ದ Remove the motorcycle from the work stand. ( P. 32)
ದ Pull the front wheel brake and push down hard on the fork several times to align

the fork legs.
ದ Fully tighten screwb

.

Specification

Screw, fork stub M8 15bNm

 and bearing surfaceb of the distance bush-

(29.5blbfbft)

(11.1blbfbft)

MAINTENANCE WORK ON CHASSIS AND ENGINE 65

Removing rear wheelbx

ದ Jack up the motorcycle. ( P. 32)
ದ Press the brake caliper by hand on to the brake disc in order to press back the

brake piston.

Info

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

400258-10

400260-11

ದ Remove nutb
ದ Remove chain adjusterb

.

. Withdraw the wheel spindleb only enough to allow the

rear wheel to be pushed forward.
ದ Push the rear wheel forward as far as possible. Remove the chain from the rear

sprocket.
ದ Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of the

swing arm.

Info

Do not operate the foot brake when the rear wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam­aged.

ದ Remove the spacing sleevesb.

Fitting rear wheelbx

Warning

Danger of accidentsಘReduced braking due to oil or grease on the brake discs.

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

ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Clean and grease shaft seal ringsb

Long-life grease ( P. 115)

ದ Fit the spacing sleeves.

400260-10

ದ Lift the rear wheel into the swing arm, position it, and insert the wheel spindleb.
ದ Put the chain on.

 and bearing surfaceb of the spacing sleeves.

400259-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 66

ದ Position the chain adjusterb. Fit nutb, but do not tighten it yet.
ದ Check the chain tension when fitting rear wheel. ( P. 51)

Tire condition checking

400225-12

ದ Make sure that the chain adjustersb

screwsb

.

ದ Tighten nutb

.

Specification

Nut, rear wheel spindle M20x1,5 80bNm (59blbfbft)

Info

The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
The chain adjustersb

ದ Operate the foot brake lever repeatedly until the brake linings lie on the brake disc

and there is a tight spot.
ದ Remove the motorcycle from the work stand. ( P. 32)

 can be turned by 180°.

 are fitted correctly on the adjusting

Info

Fit only tires approved by KTM.
Other tires could have a negative effect on riding behavior.
The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.
The front and rear wheels must be fitted with tires with similar profiles.
Worn tires have a negative effect on riding behavior, especially on wet surfaces.

ದ Examine the tires for cuts, foreign bodies and other damage.
ದ Check the depth of the tread.

»

Info

Note local national regulations concerning the minimum tread depth.

Minimum tread depth: ุb2bmm (ุb0.08bin)
If the minimum tread depth is insufficient:

ದ Replace the tire(s).

Checking tire air pressure

Info

Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.

ದ Remove dust cap.
ದ Check tire air pressure when tires are cold.

400241-01

Tire air pressure off road

front 1.0bbar (15bpsi)
Rear 1.0bbar (15bpsi)

Road tire pressure (Every EXC-R models)

front 1.5bbar (22bpsi)
Rear 2.0bbar (29bpsi)

» If the tire pressure does not meet specifications:

ದ Correct tire pressure.

ದ Mount dust cap.

MAINTENANCE WORK ON CHASSIS AND ENGINE 67

Checking spoke tension

Warning

Danger of accidentsಘUnstable riding behavior due to loose spokes.

ದ If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop.

Info

A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.

ದ To check spoke tension, tap each spoke with a screwdriver.

Specification

You should hear a high note.

Spoke nipple, front wheel M4,5 5bNm (3.7blbfbft)
Spoke nipple, rear wheel M5 5bNm (3.7blbfbft)

Info

400228-01

If you hear different tone frequencies from different spokes, this is an indi­cation of different spoke tensions.

Removing the batterybx

Warning

Risk of injuryಘBattery acid and battery gases cause serious cauterization.

ದ Keep batteries out of the reach of children.
ದ Wear suitable protective clothing and goggles.
ದ Avoid contact with battery acid and battery gases.
ದ Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
ದ In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least

15 minutes and contact a doctor.

ದ Switch off all power-consuming components and switch off the engine.
ದ Remove the seat. ( P. 69)
ದ Disconnect the negative (minus) cableb of the battery.
ದ Pull back the plus pole coverb

tery.

ದ Hang the rubber bandb
ದ Lift the battery up.

500069-10

 and disconnect the positive (plus) cable of the bat-

 out to the bottom.

Installing the batterybx

500069-11

ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Place the battery in the battery holder.

4Ah batteryb(YTX5L-BS) ( P. 94)

ದ Reconnect the rubber bandb
ದ Attach the plus cable and replace the plus pole coverb
ದ Attach the minus cableb

.

.

.

ದ Mount the seat. ( P. 69)

MAINTENANCE WORK ON CHASSIS AND ENGINE 68



Recharging the batteryb

Warning

Risk of injuryಘBattery acid and battery gases cause serious cauterization.

ದ Keep batteries out of the reach of children.
ದ Wear suitable protective clothing and goggles.
ದ Avoid contact with battery acid and battery gases.
ದ Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
ದ In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least

15 minutes and contact a doctor.

Warning

Environmental hazardಘComponents and battery acid are a danger to the environment.

ದ Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Even if there is no load on the battery, it loses power every day.
The charge state and the type of charge are very important for the service life of the battery.
Fast recharging with a high charge current shortens the battery's service life.
If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes.
The battery capacity is then reduced.
If the battery is discharged from starting, it must be recharged immediately.
If it stands for a long time in a discharged state, the battery becomes over-discharged and sulfated, and then it is destroyed.
The battery is maintenance-free, i.e., the acid level does not have to be checked.

x

400240-10

ದ Switch off all power-consuming components and switch off the engine.
ದ Remove the seat. ( P. 69)
ದ Disconnect the minus (negative) cable of the battery to avoid damage to the motor-

cycle's electronics.
ದ Connect the battery charger to the battery. Switch on the battery charger.

Battery chargerb(58429074000)

You can also use the battery charger to test rest potential and start potential of the

battery, and to test the generator. With this device, you cannot overcharge the bat-

tery.

Info

Never remove the lidb.
Charge the battery according to the instructionsb

ದ Switch off the charger after charging. Disconnect the battery.

Specification

The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the

motorcycle is not in use.

ದ Mount the seat. ( P. 69)

3bmonths



on the battery casing.

MAINTENANCE WORK ON CHASSIS AND ENGINE 69

Removing a fuse

ದ Switch off all power-consuming components and switch off the engine.
ದ Dismount the air filter box lid. ( P. 74)
ದ Remove the protection coverb.

Info

The fuseb is located in the starter relayb under the filter box cover.

ದ Remove the fuseb

400270-10

Replacing the fuse

.

Warning

Fire hazardಘThe electrical system can be overloaded by the use of incorrect fuses.

ದ Use only fuses with the prescribed amperage. Never by-pass or repair fuses.

ದ Check parts for damage and wear. Replace damaged or worn parts.

Info

A reserve fuseb is located in the starter relay.
Replace a burned-out fuseb

ದ Refit the fuse.

Fuseb(58011109110)

400273-10

Info

If the new fuse burns out, contact an authorized KTM workshop.

 only by an equivalent fuse.

Removing the seat

Mounting the seat

ದ Replace the protection cover.
ದ Install the air filter box lid. ( P. 74)

ದ Remove screwb. Lift up the seat at the rear, pull it back and then remove from

above.

500080-10

ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Hook the front of the seat into the flange adapter of the fuel tank, lower the rear of

the seat and simultaneously push it forwards.

ದ Make sure that the seat is correctly locked in.
ದ Mount and tighten the screw of the seat fixing.

Specification

Remaining screws, chassis M6 10bNm (7.4blbfbft)

500068-01

MAINTENANCE WORK ON CHASSIS AND ENGINE 70

Dismounting the fuel tankbx

Danger

Fire hazardಘFuel can easily catch fire.

ದ Never fill up 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.

ದ Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.

Warning

Danger of poisoningಘFuel is poisonous and a health hazard.

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

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

ದ Remove the seat. ( P. 69)
ದ Turn the handleb of the fuel tap to the OFF position. (Figureb500137-10b P. 20)
ದ Pull off the fuel hose.

Info

Remaining fuel may run out of the fuel hose.

500157-10

500066-10

500067-10

ದ Remove screwsb

 with collar sleeve.

(Every EXC-R models)

ದ Hang the horn and horn bracket to one side.

ದ Remove screwb with collar sleeve.
ದ Remove the tube from the fuel tank vent line.

ದ Pull both spoilers to the side of the radiator bracketb and take the fuel tank away

upwards.

Installing the fuel tankbx

Danger

Fire hazardಘFuel can easily catch fire.

ದ Never fill up 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.

ದ Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.

Warning

Danger of poisoningಘFuel is poisonous and a health hazard.

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

diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.

MAINTENANCE WORK ON CHASSIS AND ENGINE 71

ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Position the fuel tank and fit the two spoilers to the side of the radiator fixing.
ದ Make sure that no cables or Bowden cables are trapped or damaged.

500067-01

ದ Mount the fuel tank vent hose.
ದ Fit and tighten screwb

Specification

Remaining screws, chassis M6 10bNm (7.4blbfbft)

(Every EXC-R models)

ದ Position horn with horn bracket.

500066-11

ದ Fit and tighten screwsb with collar sleeve.

Specification

Remaining screws, chassis M6 10bNm (7.4blbfbft)

 with collar sleeve.

ದ Connect fuel hose.
ದ Mount the seat. ( P. 69)

500157-11

Cooling system

The water pumpb in the engine forces the coolant to flow.
The pressure resulting from the warming of the cooling system is regulated by a valve
in the radiator capb

. The specified coolant temperature is therefore permissible with-

out danger of function problems.

120b°C (248b°F)

Coolant ( P. 114)
Cooling is effected by the air stream.
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cool-

400335-10

ing effect.

(EXC-RbSIXbDAYS, XCR-WbZA)

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

Checking antifreeze and coolant level

Warning

Danger of scaldingಘThe coolant gets very hot when the motorcycle is driven and is under high pressure.

ದ Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and

cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.

Warning

Danger of poisoningಘCoolants are poisonous and a health hazard.

ದ Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and

contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor im­mediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

MAINTENANCE WORK ON CHASSIS AND ENGINE 72

ದ Stand the motorcycle upright on a horizontal surface.
ದ Remove the radiator cap.
ದ Check antifreeze of coolant.

෥25… ෥45b°C (෥13… ෥49b°F)

» If the antifreeze of the cooling liquid does not meet specifications:

ದ Correct antifreeze of coolant.

ದ Check the coolant level in the radiator.

400243-10

Checking the coolant level

Warning

Danger of scaldingಘThe coolant gets very hot when the motorcycle is driven and is under high pressure.

ದ Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and

cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.

Coolant levelb

 above radiator fins. 10bmm (0.39bin)

» If the level of the cooling liquid does not meet specifications:

ದ Correct the coolant level.

Alternative 1

Coolant ( P. 114)

Alternative 2

Coolant (mixed ready to use) ( P. 114)

ದ Refit the radiator cap.

Warning

Danger of poisoningಘCoolants are poisonous and a health hazard.

ದ Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and

contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor im­mediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

ದ Stand the motorcycle upright on a horizontal surface.
ದ Remove the radiator cap.
ದ Check the coolant level in the radiator.

Coolant levelb

 above radiator fins. 10bmm (0.39bin)

» If the level of the cooling liquid does not meet specifications:

ದ Correct the coolant level.

Alternative 1

400243-10

Coolant ( P. 114)

Alternative 2

Coolant (mixed ready to use) ( P. 114)

ದ Refit the radiator cap.

Draining coolantbx

Warning

Danger of scaldingಘThe coolant gets very hot when the motorcycle is driven and is under high pressure.

ದ Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and

cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.

Warning

Danger of poisoningಘCoolants are poisonous and a health hazard.

ದ Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and

contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor im­mediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

MAINTENANCE WORK ON CHASSIS AND ENGINE 73

ದ Stand the vehicle upright.
ದ Place a suitable container under the water pump cover.
ದ Remove screwb
ದ Completely drain the coolant.
ದ Fit screwb

Specification

Screw, water pump cover M6x25 10bNm (7.4blbfbft)

400335-11

Refilling coolantbx

Warning

Danger of poisoningಘCoolants are poisonous and a health hazard.

ದ Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and

contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor im­mediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

ದ Make sure that the screwb is tightened.
ದ Stand the vehicle upright.
ದ Pour coolant in up to measurementb

Specification

10bmm (0.39bin)

. Remove the radiator capb.

 with a new seal and tighten it.

 above the radiator fins.

Coolant 0.95bl(1bqt.) Coolant ( P. 114)

Coolant (mixed ready to use)

400244-10

( P. 114)

ದ Refit the radiator cap.
ದ Make a short test ride.
ದ Check the coolant level. ( P. 72)

Glass fiber yarn filling of main silencer

The main silencer is filled with glass fiber yarn.
Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out".
Not only is the noise level higher, the performance characteristic changes.

Removing main silencer

Warning

Danger of burnsಘThe exhaust system gets very hot when the vehicle is driven.

ದ Allow the exhaust system to cool down. Do not touch hot components.

ದ Disconnect springb.
ದ Remove screwsb

 and take off main silencer.

400337-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 74



Fitting the main silencer

ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Mount the main silencer. Mount and tighten screwsb

Specification

Remaining screws, chassis M6 10bNm (7.4blbfbft)



.

400337-11



Dismounting the air filter box lid

400338-10



Installing the air filter box lid

ದ Reconnect springb



.

ದ Pull off the air filter box lid in areabto the side and remove to the front.

ದ Check parts for damage and wear. Replace damaged or worn parts.



ದ Insert the air filter box lid into the rear areab

and clip it into the front areab.

400338-11



Removing the air filterb

x

Note

Engine failureಘUnfiltered intake air has a negative effect on the service life of the engine.

ದ Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

ದ Dismount the air filter box lid. ( P. 74)
ದ Hang the air filter holderbout to the bottom and swing it to the side. Remove the

air filter with the air filter support.
ದ Remove the air filter from the air filter support.

500107-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 75



Installing the air filterb



Cleaning air filterb

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

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

x

x

500107-10

ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Mount the clean air filter onto the air filter support.
ದ Put in both parts together, position them and fix them with the air filter supportb

Info

If the air filter is not correctly mounted, dust and dirt can penetrate into the
engine and can cause damage.

ದ Install the air filter box lid. ( P. 74)



.

ದ Remove the air filter. ( P. 74)
ದ Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.

Air filter cleaner ( P. 115)

Info

Only press the air filter to dry it, never wring it out.

ದ Oil the dry air filter with a high/quality filter oil.

Oil for foam air filter ( P. 115)

ದ Clean the air filter box.
ದ Check carburetor connection boot for damage and tightness.
ದ Install the air filter. ( P. 75)



Adjusting basic position of clutch lever

ದ Adjust the basic setting of the clutch lever to your hand size by turning adjusting

screwb



.

Info

Turn the adjusting screw clockwise to increase the distance between the
clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the clutch lever and the handlebar.
The range of adjustment is limited.

500133-11

Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!



Checking fluid level of hydraulic clutch

Warning

Skin irritationsಘBrake fluid can cause skin irritation on contact.

ದ Avoid contact with skin and eyes, and keep out of the reach of children.
ದ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Info

The fluid level rises with increasing wear of the clutch lining disc.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

MAINTENANCE WORK ON CHASSIS AND ENGINE 76

ದ Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
ದ Remove screwsb
ದ Take off coverb
ದ Check the fluid level.

Fluid level under top level of container. 4bmm (0.16bin)

» If the level of the cooling liquid does not meet specifications:

ದ Correct the fluid level of the hydraulic clutch.

400339-10

ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Position the cover with the membrane. Mount and tighten screws.

Info

Clean up overflowed or spilt fluid immediately with water.



Changing fluid level of hydraulic clutchb

x

Warning

Skin irritationsಘBrake fluid can cause skin irritation on contact.

ದ Avoid contact with skin and eyes, and keep out of the reach of children.
ದ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.



.



with membraneb.

Brake fluid DOT 5.1 ( P. 114)

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

The fluid level rises with increasing wear of the clutch lining disc.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

ದ Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
ದ Remove screwsb
ದ Take off coverb

400339-10

ದ Fill the bleeding syringebwith the appropriate hydraulic fluid.

Bleed syringe (50329050000)
Brake fluid DOT 5.1 ( P. 114)



.



with membraneb.

500158-10

ದ On the slave cylinder, remove the bleeder screwb



and fit the bleeding syringeb.

MAINTENANCE WORK ON CHASSIS AND ENGINE 77

ದ Inject the liquid into the system until it escapes from the bore holeb of the mas-

ter cylinder without bubbles.

ದ To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
ದ Remove the bleeding syringe. Mount and tighten screws bleeder screw.
ದ Correct the fluid level of the hydraulic clutch.

Specification

Fluid level under top level of container. 4bmm (0.16bin)

Carburetor - idle

Carburetor - adjusting idlebx

400340-10

400341-10

400341-10

ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Position the cover with the membrane. Mount and tighten screws.

Info

Clean up overflowed or spilt fluid immediately with water.

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

Info

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

The idle speed is adjusted with the adjustment screwb
The idle mixture is adjusted with the idle mixture adjustment screwb

ದ Screw in the idle adjusting screwb until it stops and then to the prescribed basic

setting.

Specification

Idle mixture adjusting screw (XCR-WbUSA)

Open 0.5bturn

Idle mixture adjusting screw (EXC-RbSIXbDAYS)

Open 1.0bturn

Idle mixture adjusting screw (XCR-WbZA, 530bEXC-RbEU, 530bEXC-RbAUS/UK)

Open 1.5bturns

Idle mixture adjusting screw (450bEXC-RbEU, 450bEXC-RbAUS/UK, 450bEXC­RbUSA)

Open 1.75bturns

Idle mixture adjusting screw (530bEXC-RbUSA)

Open 2.0bturns

.

.

Adjustment tool for mixture control screw (77329034000)

ದ Run the engine until warm.

Specification

Warm-up time ุb5bmin

MAINTENANCE WORK ON CHASSIS AND ENGINE 78

Danger

Danger of poisoningಘExhaust gases are poisonous and can result in uncon-

sciousness and/or death.

ದ When running the engine, always make sure there is sufficient ventila-

tion, and do not start or run the engine in a closed space.

ದ Adjust the idle speed with the adjusting screwb

Specification

Choke function deactivated ದbThe choke lever is pushed in to the stop.

( P. 21)

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

( P. 21)

Idle speed 1550… 1650brpm

ದ Turn the idle adjusting screwb
ದ Note the position and turn the idle adjusting screw slowly counterclockwise until

the idle speed falls.
ದ Adjust to the point between these two positions with the highest idle speed.

 slowly until the idle speed begins to fall.

.

Info

If there is a big engine speed rise, reduce the idle speed to a normal level
and repeat the above steps.
The extremely sporty rider will set the mixture about 1/4 of a turn back from
this ideal value (leaner, in a clockwise direction) since the engine becomes
hotter in sporting use.
If the procedure described here does not lead to satisfactory results, the
cause may be a wrongly dimensioned idling jet.
If you can turn the idle adjusting screw to the end without any change of
engine speed, you have to fit a smaller idling jet.
The idle adjusting screw must not be opened more than two turns. If more
than two turns are necessary (rich mixture), use a larger idling jet.
After changing the idling jet, start from the beginning with the adjusting
steps.

ದ Adjust the idle speed with the adjusting screwb

Specification

Choke function deactivated ದbThe choke lever is pushed in to the stop.

( P. 21)

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

( P. 21)

Idle speed 1550… 1650brpm

.

Info

Following extreme air temperature or altitude changes, adjust the idle speed
again.

Emptying the carburetor float chamberbx

Danger

Fire hazardಘFuel can easily catch fire.

ದ Never fill up 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.

ದ Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.

Warning

Danger of poisoningಘFuel is poisonous and a health hazard.

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

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

MAINTENANCE WORK ON CHASSIS AND ENGINE 79

Warning

Environmental hazardಘImproper handling of fuel is a danger to the environment.

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

Info

Carry out this work with a cold engine.



ದ Turn the handleb

No more fuel flows from the tank to the carburetor.

ದ Guide the hose coming down behind the engine into a suitable container.

Info

Water in the float chamber results in malfunctioning.

of the fuel tap to the OFF position. (Figureb500137-10b P. 20)



Checking engine oil level

ದ Undo the screwb

the float chamber.
ದ Tighten screwb

400341-11





.

Info

The engine oil level must be checked when the engine is cold.

ದ Stand the motorcycle upright on a horizontal surface.

Condition

Engine is cold.

ದ Check the engine oil level.

The engine oil must be between the halfway mark and the top of the oil level
viewerb



.

» If the engine oil level is below the specified level:

ದ Top up the engine oil. ( P. 81)

200119-10



Changing engine oil and oil filter, cleaning engine oil screenb

ದ Drain the engine oil and clean the engine oil screen. ( P. 79)
ದ Remove the oil filter. ( P. 80)
ದ Mount the oil filter. ( P. 80)
ದ Fill up with engine oil. ( P. 81)

(turn it counterclockwise) a few turns and drain the fuel from

x



Draining engine oil, cleaning engine oil screenb

x

Warning

Danger of scaldingಘEngine oil and gear oil get very hot when the motocycle is driven.

ದ Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Drain the engine oil only when the engine is warm.

ದ Stand the motorcycle on its side stand on a horizontal surface.

MAINTENANCE WORK ON CHASSIS AND ENGINE 80

ದ Place a suitable container under the engine.
ದ Remove engine oil plug screenb
ದ Completely drain the engine oil.
ದ Thoroughly clean the plug and gear oil screen.
ದ Clean the sealing area on the engine.
ದ Check parts for damage and wear. Replace damaged or worn parts.



for the engine oil screen and tighten it.



Removing the oil filterb

x

200112-10

ದ Fit plugb

Specification

Plug, engine oil screen M17x1,5 20bNm

Warning

Danger of scaldingಘEngine oil and gear oil get very hot when the motocycle is driven.

ದ Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.



.

(14.8blbfbft)



Mounting oil filterb

x

200113-10

200114-10

ದ Place a suitable container under the engine.
ದ Remove screwsb. Remove oil filter coverbwith O-ring.

ದ Pull the oil filter insertbout of the oil filter casing.

Circlip pliers reverse (51012011000)

ದ Completely drain the engine oil.
ದ Thoroughly clean parts and sealing area.

ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Lay the motorcycle on its side and fill the oil filter housing to about 1/3 full with

engine oil.

ದ Fill the oil filterb
ದ Lubricate the O/ringb



with engine oil and place it in the oil filter container.



of the oil filter cover.

200114-11

MAINTENANCE WORK ON CHASSIS AND ENGINE 81

ದ Refit the oil filter coverb.
ದ Mount and tighten screwsb

Specification

Screw, oil filter cover M5 6bNm (4.4blbfbft)

ದ Stand the motorcycle up.

200113-11

Filling up with engine oilbx

Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

ದ Remove the screw capb on the generator cover and fill up with engine oil.

Engine oil 0.6bl (0.6bqt.) Engine oil (SAE 10W/50) ( P. 114)

.

ದ Mount and tighten screw capb

Danger

Danger of poisoningಘExhaust gases are poisonous and can result in uncon-

sciousness and/or death.

ದ When running the engine, always make sure there is sufficient ventila-

200115-10

tion, and do not start or run the engine in a closed space.

ದ Start the engine and check that it is oil-tight.
ದ Check the engine oil level. ( P. 79)

Topping up engine oil

Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

ದ Remove the screw capb on the generator cover and fill up with engine oil.

Engine oil (SAE 10W/50) ( P. 114)

ದ Mount and tighten screw capb

Danger

Danger of poisoningಘExhaust gases are poisonous and can result in uncon-

sciousness and/or death.

200115-10

ದ When running the engine, always make sure there is sufficient ventila-

tion, and do not start or run the engine in a closed space.

.

.

ದ Start the engine and check that it is oil-tight.
ದ Check the engine oil level. ( P. 79)

Checking gear oil level

Info

The gear oil level must be checked when the engine is cold.

ದ Stand the motorcycle upright on a horizontal surface.

MAINTENANCE WORK ON CHASSIS AND ENGINE 82

Condition

Engine is cold.

ದ Remove gear oil level check screwb

ದ Check the gear oil level.

A small amount of gear oil should flow out.

» If no gear oil flows out:

ದ Top up with gear oil. ( P. 83)

200116-10



Changing gear oil, cleaning gear oil screenb

ದ Drain the gear oil and clean the gear oil screen. ( P. 82)
ದ Fill up with gear oil. ( P. 83)



Draining gear oil, cleaning gear oil screenb

ದ Mount and tighten the gear oil level check screw.

Specification

Screw, gear oil level check M6 10bNm

x

x

Warning

Danger of scaldingಘEngine oil and gear oil get very hot when the motocycle is driven.

ದ Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.



. Stand the vehicle upright.

(7.4blbfbft)

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Drain the gear oil only when the engine is warm.

ದ Stand the motorcycle on its side stand on a horizontal surface.
ದ Place a suitable container under the engine.
ದ Remove the gear oil drain plugb
ದ Remove the gear oil screen plugb
ದ Completely drain the gear oil.
ದ Thoroughly clean the gear oil drain plug with a magnet.
ದ Thoroughly clean the drain plug and gear oil screen with a magnet.
ದ Clean the sealing surface on the engine.
ದ Check parts for damage and wear. Replace damaged or worn parts.
ದ Refit gear oil drain plugb

Specification

Gear oil drain plug with magnet M12x1,5 20bNm

ದ Fit the plugb

Specification

Plug, gear oil screen M16x1,5 20bNm



for the gear oil screen and tighten it.



.



.



with seal ring and tighten it.

(14.8blbfbft)

(14.8blbfbft)

500159-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 83

Filling up with gear oilbx

Info

Too little gear oil or poor-quality oil results in premature wear to the transmission.

ದ Remove the screw capb and fill up with gear oil.

Gear oil 0.9bl(1bqt.) Engine oil (SAE 10W/50) ( P. 114)

ದ Mount and tighten screw capb

Danger

Danger of poisoningಘExhaust gases are poisonous and can result in uncon-

sciousness and/or death.

ದ When running the engine, always make sure there is sufficient ventila-

200118-10

tion, and do not start or run the engine in a closed space.

ದ Start the engine and check that it is oil-tight.
ದ Check the gear oil level. ( P. 81)

Topping up with gear oilbx

Info

Too little gear oil or poor-quality oil results in premature wear to the transmission.

ದ Remove gear oil level check screwb.

.

200116-10

200118-11

ದ Remove screw capb. Stand the vehicle upright.
ದ Top up with gear oil until it flows out of the bore of the gear oil level screw.

Engine oil (SAE 10W/50) ( P. 114)

ದ Mount and tighten the gear oil level check screw.

Specification

Screw, gear oil level check M6 10bNm (7.4blbfbft)

ದ Mount and tighten screw capb

.

Danger

Danger of poisoningಘExhaust gases are poisonous and can result in uncon-

sciousness and/or death.

ದ When running the engine, always make sure there is sufficient ventila-

tion, and do not start or run the engine in a closed space.

ದ Start the engine and check that it is oil-tight.

TROUBLESHOOTING 84

7528%/(6+227,1*

Faults Possible cause Measure

The engine cannot be cranked (electric
starter).

Engine turns but does not start. Operating error ದ Carry out instructions on starting.

Operating error ದ Carry out instructions on starting.

( P. 26)

Battery discharged ದ Recharge the battery. ( P. 68)

ದ Check the cause of discharging.

Fuse blown ದ Remove the fuse. ( P. 69)

ದ Replace the fuse. ( P. 69)

Low external temperature ದ Start the engine with the kickstarter.

ದ Recharge the battery. Establish the

reason for discharging or have it
checked in a KTM workshop.

( P. 26)

Motorcycle was out of use for a long time
and there is old fuel in the float chamber

Fuel feed interrupted ದ Check tank vent.

Engine flooded ದ Clean and dry spark plug or replace if

Spark plug oily or wet ದ Clean and dry spark plug or replace if

Electrode distance (plug gap) of spark
plug too wide

Spark plug connector or spark plug defec­tive

ದ Empty the carburetor float chamber.

( P. 78)

ದ Clean fuel tap.
ದ Clean carburetor.

necessary.

necessary.

ದ Adjust plug gap.

Specification
Spark plug electrode gap

0.8… 0.9bmm (0.031… 0.035bin)

Warning

Risk of injuryಘThe ignition sys-

tem is under high voltage.

ದ Do not touch parts of the ig-

nition system. Have work on
the ignition system carried
out in an authorized KTM
workshop.

Short-circuit cable in cable harness
frayed, short-circuit button or emergency
OFF switch defective

Socket connector of CDI control device,
pulse generator or ignition coil oxidized.

ದ Remove spark plug, connect ignition

cable, hold spark plug to ground (bare
metal area on engine), and try to start
the engine.

Specification
You should see a strong spark on the
spark plug.

ದ If there is no spark, change the spark

plug.

ದ If there is still no spark, remove the

spark plug cap from the ignition cable,
hold it at the specified distance from
the ground contact, and try to start the
engine.

Specification
5bmm (0.2bin)

ದ If you now have a spark, replace the

spark plug connector.

ದ If there is no spark, have the ignition

system checked.

ದ Check wiring harness. (visual check)
ದ Check electrical system.

ದ Clean socket connector and treat it

with contact spray.

TROUBLESHOOTING 85

Faults Possible cause Measure

Engine turns but does not start. Water in carburetor or jets blocked ದ Clean carburetor.
Engine has no idle. Idling jet blocked ದ Clean carburetor.

Adjusting screws on carburetor distorted ದ Have the carburetor adjusted.
Spark plug defective ದ Change spark plug.
Ignition system defective ದ Have ignition system checked.

Engine does not speed up. Carburetor running over because float

needle dirty or worn
Loose carburetor jets ದ Have carburetor checked.
Electronic ignition adjustment defective ದ Have ignition system checked.

Engine has too little power. Fuel feed interrupted ದ Check tank vent.

Air filter very dirty ದ Clean the air filter. ( P. 75)
Exhaust system leaky, deformed or too lit-

tle glass fiber yarn filling in main silencer

Valve clearance too little ದ Have valve clearance adjusted.
Electronic ignition adjustment defective ದ Have ignition system checked.

Engine stalls or is popping into the carbu­retor

Engine overheats. Too little coolant in cooling system ದ Check the cooling system for leakage.

High oil consumption Engine vent hose bent ದ Route the vent hose without bends or

Battery discharged Battery is not charged by generator ದ Check electrical system.
Speedometer values deleted (time, stop

watch, lap times)

Lack of fuel ದ Clean and check the fuel system and

Engine takes in bad air ದ Check rubber sleeves and carburetor

Too little air stream ದ Switch off engine when standing.
Radiator fins very dirty ದ Clean radiator fins.
Foam formation in cooling system ದ Drain the coolant. ( P. 72)

Bent radiator hose ದ Replace the radiator hose.
Thermostat defective ದ Have thermostat removed and checked.

Defect in radiator fan system
(EXC-RbSIXbDAYS, XCR-WbZA)

Engine
Engine oil too thin (low viscosity) ದ Change the engine oil and oil filter and

The battery in the speedometer ist empty. ದ Change the battery in the speedometer.

oil level too high ದ Check the engine oil level. ( P. 79)

ದ Have carburetor checked.

ದ Clean fuel tap.
ದ Clean carburetor.

ದ Check exhaust system for damage.
ದ Change glass fiber yarn filling of main

silencer.

carburetor.

for tightness.

ದ Check the coolant level. ( P. 72)

ದ Refill the coolant. ( P. 73)

Specification
Opening temperature: 70b°C (158b°F)

ದ Have the radiator fan system checked.

replace it if necessary.

clean the engine oil screen. ( P. 79)

CLEANING 86

&/($1,1*

Cleaning motorcycle



Note

Material damageಘDamage and destruction of components by high-pressure cleaning equipment.

ದ Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri-

cal components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts.

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

If you clean the motorcycle regularly, its value and appearance are maintained over a long period.
Avoid direct sunshine on the motorcycle during cleaning.

ದ Before you clean the motocycle, seal the exhaust system to prevent penetration by water.
ದ First remove coarse dirt particles with a gentle water spray.
ದ Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush.

Motorcycle cleaner ( P. 115)

Info

Use warm water containing normal motorcycle cleaner and a soft sponge.

ದ After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly.
ದ Empty the carburetor float chamber. ( P. 78)

Warning

Danger of accidentsಘReduced braking due to wet or dirty brakes.

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

ದ After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes.

Info

The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.

ದ Push back the protection covers on the handlebar instruments to allow water to evaporate.
ದ After the motorcycle has cooled off, oil or grease all moving parts and bearings.
ದ Clean the chain. ( P. 50)
ದ Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.

Cleaning and polishing materials for metal, rubber and plastic ( P. 115)

ದ Treat all painted parts with a mild paint polish.

High-luster polish for paint ( P. 116)

ದ To prevent electrical problems, treat electric contacts and switches with contact spray.

Contact spray ( P. 116)

(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA)

ದ Lubricate the steering lock.

Universal oil spray ( P. 115)

STORAGE 87

6725$*(

Storage



Warning

Danger of poisoningಘFuel is poisonous and a health hazard.

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

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

Info

If you want to garage the motorcycle for a longer period, take the following actions.
Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you
should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the
start of the new season.

ದ Clean the motorcycle. ( P. 86)
ದ Change the engine oil and oil filter and clean the engine oil screen. ( P. 79)
ದ Change the gear oil and clean the gear oil screen. ( P. 82)
ದ Check the antifreeze and coolant level. ( P. 71)
ದ Drain the fuel from the tanks into a suitable container.
ದ Empty the carburetor float chamber. ( P. 78)
ದ Checking the tire air pressure. ( P. 66)
ದ Remove the battery. ( P. 67)
ದ Recharge the battery. ( P. 68)

Specification

Storage temperature of battery without direct sunshine. 0… 35b°C (32… 95b°F)

ದ The storage place should be dry and not subject to large temperature differences.

Info

KTM recommends propping up the motorcycle.

ದ Jack up the motorcycle. ( P. 32)
ದ Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping,

thus causing corrosion.

Info

Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during
combustion condenses and causes valves and exhaust system to rust.

Putting into operation after storage

ದ Remove the motorcycle from the work stand. ( P. 32)
ದ Install the battery. ( P. 67)
ದ Fill up with fuel. ( P. 28)
ದ Checks before putting into operation ( P. 26)
ದ Make a test ride.

TECHNICAL DATA - ENGINE 88

7(&+1,&$/'$7$ (1*,1(

Design 1-cyliner 4-stroke engine, water-cooled
Displacement (Every 450 models) 449.3bcm³ (27.418bcubin)
Displacement (Every 530 models) 510.4bcm³ (31.147bcubin)
Stroke (Every 450 models) 63.4bmm (2.496bin)
Stroke (Every 530 models) 72bmm (2.83bin)
Bore 95bmm (3.74bin)
Compression ratio 11,9:1
Idle speed 1550… 1650brpm
Control 4 valves controlled via rocker arm, drive via tooth/wheel chain
Valve diameter, intake 39.5bmm (1.555bin)
Valve diameter, exhaust 31.7bmm (1.248bin)
Valve clearance

Outfeed at: 20b°C (68b°F) 0.12… 0.17bmm (0.0047… 0.0067bin)

Infeed at: 20b°C (68b°F) 0.10… 0.15bmm (0.0039… 0.0059bin)
Crankshaft bearing 2 grooved ball bearings
Conrod bearing Needle bearing
Piston pin bearing not a bearing bush - DLC-plated piston pins
Pistons Forged light alloy
Piston rings 1 compression ring, 1 oil scraper ring
Engine lubrication Pressure circulation lubrication with 2 rotor pumps (engine) / 1

rotor pump (transmission)
Primary transmission 33:76
Clutch Multidisc clutch in oil bath / hydraulically activated
Transmission ratio

1st gear 14:36
2nd gear 17:32
3rd gear 19:28
4th gear 22:26
5th gear 24:23

6th gear 26:21
Generator 12bV, 150bW
Ignition Contactless controlled fully electronic ignition with digital igni-

tion adjustment, type Kokusan
Spark plug NGK LK AR 8A - 9
Spark plug electrode gap 0.8… 0.9bmm (0.031… 0.035bin)
Cooling Water cooling, permanent circulation of coolant by water pump
Starting aid Electric starter / kickstarter

Capacity - engine oil

Engine oil 0.6bl (0.6bqt.) Engine oil (SAE 10W/50) ( P. 114)

Capacity - gear oil

Gear oil 0.9bl(1bqt.) Engine oil (SAE 10W/50) ( P. 114)

TECHNICAL DATA - ENGINE 89

Capacity - coolant

Coolant 0.95bl(1bqt.) Coolant ( P. 114)

Coolant (mixed ready to use) ( P. 114)

TECHNICAL DATA - ENGINE TIGHTENING TORQUES 90

7(&+1,&$/'$7$ (1*,1(7,*+7(1,1* 72548(6

Screw, cable holder in generator cover M4 4bNm (3blbfbft) Loctite®243™
Oil jet, rocker arm lubrication M5 2bNm (1.5blbfbft) Loctite
Oil jet, piston cooling M5 2bNm (1.5blbfbft) Loctite
Screw, locking lever M5 6bNm (4.4blbfbft) Loctite
Screw, ignition pulse generator M5 6bNm (4.4blbfbft) Loctite
Screw, clutch spring M6 10bNm (7.4blbfbft) ದ
Locking screw for bearing M5 6bNm (4.4blbfbft) Loctite
Screw, oil filter cover M5 6bNm (4.4blbfbft) ದ
Screw, oil pump cover M5 6bNm (4.4blbfbft) Loctite
Oil jet, conrod lubrication M6x0,75 4bNm (3blbfbft) Loctite
Nut, water-pump wheel M6 6bNm (4.4blbfbft) Loctite
Screw, kickstarter stop M6 10bNm (7.4blbfbft) Loctite
Screw, timing chain securing guide M6 10bNm (7.4blbfbft) Loctite
Screw, exhaust flange M6 10bNm (7.4blbfbft) ದ
Screw, torque governor M6 10bNm (7.4blbfbft) Loctite
Screw, starter motor M6 10bNm (7.4blbfbft) ದ
Screw, kickstarter spring hanger M6 10bNm (7.4blbfbft) ದ
Screw, timing chain guide rail M6 10bNm (7.4blbfbft) Loctite
Screw generator cover M6x25 10bNm (7.4blbfbft) ದ
Screw generator cover M6x40 10bNm (7.4blbfbft) ದ
Screw, gear oil level check M6 10bNm (7.4blbfbft) ದ
Screw, clutch cover M6x25 10bNm (7.4blbfbft) ದ
Screw, clutch cover M6x30 10bNm (7.4blbfbft) ದ
Screw, clutch cover M6x55 10bNm (7.4blbfbft) ದ
Screw, engine housing M6x65 10bNm (7.4blbfbft) ದ
Screw, engine housing M6x80 10bNm (7.4blbfbft) ದ
Screw, camshaft bearing support M6 10bNm (7.4blbfbft) Loctite
Screw, shift drum locating M6 10bNm (7.4blbfbft) Loctite
Screw, shift lever M6 10bNm (7.4blbfbft) Loctite
Screw, timing chain tensioning rail M6 10bNm (7.4blbfbft) Loctite
Screw, stator bracket M6 10bNm (7.4blbfbft) Loctite
Screw, valve cover M6 10bNm (7.4blbfbft) ದ
Screw, water pump cover M6x25 10bNm (7.4blbfbft) ದ
Screw, water pump cover M6x55 10bNm (7.4blbfbft) ದ
Screw, idler M6 10bNm (7.4blbfbft) Loctite
Screw, cylinder head M6 10bNm (7.4blbfbft) ದ
Screw, rocker arm bearing M7x1 15bNm (11.1blbfbft) ದ
Plug, oil channel M7 9bNm (6.6blbfbft) Loctite
Screw, kickstarter M8 25bNm (18.4blbfbft) Loctite
Plug, crankshaft location M8 10bNm (7.4blbfbft) ದ
Balancer shaft nut M10x1 40bNm (29.5blbfbft) ದ
Screw, unlocking of timing chain ten-

M10x1 10bNm (7.4blbfbft) ದ

sioner
Screw, engine sprocket M10 60bNm (44.3blbfbft) Loctite
Plug, oil channel M10 15bNm (11.1blbfbft) Loctite

®

243™

®

243™

®

243™

®

243™

®

243™

®

222

®

243™

®

648™

®

243™

®

243™

®

243™

®

243™

®

243™

®

243™

®

243™

®

243™

®

243™

®

243™

®

243™

®

243™

®

243™

®

243™

TECHNICAL DATA - ENGINE TIGHTENING TORQUES 91

Screw, cylinder head M10x1,25 Tightening sequence:

Tighten diagonally, begin­ning with the rear screw on
the chain shaft.
Step 1
10bNm (7.4blbfbft)
Step 2
30bNm (22.1blbfbft)
Step 3

50bNm (36.9blbfbft)
Gear oil drain plug with magnet M12x1,5 20bNm (14.8blbfbft) ದ
Ignition rotor nut M12x1 60bNm (44.3blbfbft) ದ
Plug, SLS M12x1,5 20bNm (14.8blbfbft) ದ
Oil pressure control valve plug M12x1,5 20bNm (14.8blbfbft) ದ
Spark plug M12x1,25 15… 20bNm (11.1…

14.8blbfbft)
Plug, rocker arm M14x1,25 20bNm (14.8blbfbft) ದ
Plug, gear oil screen M16x1,5 20bNm (14.8blbfbft) ದ
Plug, engine oil screen M17x1,5 20bNm (14.8blbfbft) ದ
Nut, inner clutch hub M18x1,5 80bNm (59blbfbft) ದ
Nut, primary gear M20LHx1,5 150bNm
Plug, timing chain tensioner M24x1,5 25bNm (18.4blbfbft) ದ

(110.6blbfbft) Loctite

Engine oil (any)

ದ

®

648™

TECHNICAL DATA - CARBURETOR 92

7(&+1,&$/'$7$ &$5%85(725

450bEXC-RbEU, 450bEXC-RbAUS/UK (3900I)



Carburetor type KEIHIN FCR-MX 39
Carburetor identification number 3900I
Needle position 4th position from top
Idle mixture adjusting screw

Open 1.75bturns
Pump membrane stop 2.15bmm (0.0846bin)
Main jet 180
Jet needle OBDYU (OBDTQ)
Idling jet 40
Main air jet 200
Idle air jet 100
Cold start jet 65 (85)
Leakage nozzle 40
Throttle slide 15
Slide stop present

450bEXC-RbSIXbDAYS, 450bEXC-RbUSA, 450bXCR-W (3900L)

Carburetor type KEIHIN FCR-MX 39
Carburetor identfication number 3900L
Needle position (450bXCR-WbUSA) 1st position from top
Needle position (450bEXC-RbSIXbDAYS) 3rd position from top
Needle position (450bEXC-RbUSA, 450bXCR-WbZA) 4th position from top
Idle mixture adjusting screw (450bXCR-WbUSA)

Open 0.5bturn
Idle mixture adjusting screw (450bEXC-RbSIXbDAYS)

Open 1.0bturn
Idle mixture adjusting screw (450bXCR-WbZA)

Open 1.5bturns
Idle mixture adjusting screw (450bEXC-RbUSA)

Open 1.75bturns
Pump membrane stop 2.15bmm (0.0846bin)
Main jet (450bEXC-RbSIXbDAYS, 450bEXC-RbUSA, 450bXCR-

180

WbUSA)
Main jet (450bXCR-WbZA) 185
Jet needle (450bXCR-W, 450bEXC-RbSIXbDAYS) OBDTQ
Jet needle (450bEXC-RbUSA) OBDYU
Idling jet (450bXCR-W, 450

bEXC-RbSIXbDAYS)

40
Idling jet (450bEXC-RbUSA) 48
Main air jet 200
Idle air jet 100
Cold start jet 85
Leakage nozzle 40
Throttle slide 15

TECHNICAL DATA - CARBURETOR 93

530bEXC-RbEU, 530bEXC-RbAUS/UK (3900J)

Carburetor type KEIHIN FCR-MX 39
Carburetor identfication number 3900J
Needle position 5th position from top
Idle mixture adjusting screw

Open 1.5bturns
Pump membrane stop 2.15bmm (0.0846bin)
Main jet 180
Jet needle OBDZT (OBDTR)
Idling jet 40
Main air jet 200
Idle air jet 100
Cold start jet 65 (85)
Leakage nozzle 40
Throttle slide 15
Slide stop present

530bEXC-RbSIXbDAYS, 530bEXC-RbUSA, 530bXCR-W (3900M)

Carburetor type KEIHIN FCR-MX 39
Carburetor identfication number 3900M
Needle position (530bXCR-WbUSA) 1st position from top
Needle position (530bEXC-RbSIXbDAYS, 530bEXC-RbUSA) 3rd position from top
Needle position (530bXCR-WbZA) 4th position from top
Idle mixture adjusting screw (530bXCR-WbUSA)

Open 0.5bturn
Idle mixture adjusting screw (530bEXC-RbSIXbDAYS)

Open 1.0bturn
Idle mixture adjusting screw (530bXCR-WbZA)

Open 1.5bturns
Idle mixture adjusting screw (530bEXC-RbUSA)

Open 2.0bturns
Pump membrane stop 2.15bmm (0.0846bin)
Main jet (530bEXC-RbSIXbDAYS, 530bEXC-RbUSA, 530bXCR-

180

WbUSA)
Main jet (530bXCR-WbZA) 185
Jet needle (530bXCR-W, 530bEXC-RbSIXbDAYS) OBDTR
Jet needle (530bEXC-RbUSA) OBDZT
Idling jet (530bXCR-W, 530b

EXC-RbSIXbDAYS)

40
Idling jet (530bEXC-RbUSA) 48
Main air jet 200
Idle air jet 100
Cold start jet 85
Leakage nozzle 40
Throttle slide 15

TECHNICAL DATA - CHASSIS 94

7(&+1,&$/'$7$ &+$66,6

Frame Central tube frame made of chrome molybdenum steel tubing
Fork WP 4860 MXMA PA
Suspension travel

front 300bmm (11.81bin)
Rear 335bmm (13.19bin)

Fork offset (EXC-RbSIXbDAYS, XCR-WbUSA)

Front marking 18bmm (0.71bin)

Rear marking 20bmm (0.79bin)
Fork offset (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA) 20bmm (0.79bin)
Shock absorber WP PDS 5018 DCC
Brake system Disc brakes, brake calipers on floating bearings
Diameter of brake discs

front 260bmm (10.24bin)

Rear 220bmm (8.66bin)
Wear limit of brake discs

front 2.5bmm (0.098bin)

Rear 3.5bmm (0.138bin)
Tire air pressure off road

front 1.0bbar (15bpsi)

Rear 1.0bbar (15bpsi)
Road tire pressure (Every EXC-R models)

front 1.5bbar (22bpsi)

Rear 2.0bbar (29bpsi)
Rear wheel gearing (450bEXC-RbEU, 450bEXC-RbAUS/UK,

450bEXC-Rb
Rear wheel gearing (450bEXC-RbSIXbDAYS, XCR-WbZA) 14:52
Rear wheel gearing (530bEXC-RbSIXbDAYS, XCR-WbUSA) 14:50
Rear wheel gearing (530bEXC-RbEU, 530bEXC-RbAUS/UK) 15:45 (14:50)
Chain 5/8 x 1/4"
Rear sprockets available 38, 40, 42, 45, 48, 49, 50, 51, 52
Steering head angle 63.5°
Wheelbase 1475±10bmm (58.07±0.39bin)
Seat height unloaded 925bmm (36.42bin)
Ground clearance unloaded 380bmm (14.96bin)
Weight without fuel (EXC-RbEU, EXC-RbAUS/UK,

EXC-RbSIXbDAYS)
Weight without fuel (XCR-WbUSA) 112.2bkg (247.4blb.)
Weight without fuel (XCR-WbZA) 113bkg (249blb.)
Weight without fuel (EXC-RbUSA) 114.8bkg (253.1blb.)
Maximum permissible front axle load 145bkg (320blb.)
Maximum permissible rear axle load 190bkg (419blb.)
Maximum permissible overall weight 335bkg (739blb.)

USA)

15:45

(14:52)

113.9bkg (251.1blb.)

4Ah battery YTX5L-BS Battery voltage: 12bV

Nominal capacity: 4bAh
maintenance-free

TECHNICAL DATA - CHASSIS 95

Lighting equipment

Headlight (EXC-RbEU, EXC-RbAUS/UK,
EXC-RbSIXbDAYS, EXC-RbUSA, XCR-WbZA)

Parking light (EXC-RbEU, EXC-RbAUS/UK,
EXC-RbSIXbDAYS, EXC-RbUSA, XCR-WbZA)

BA20d 12bV

35/35bW

W2,1x9,5d 12bV

5bW

Indicator lights (Every EXC-R models) W2x4,6d 12bV

1.2bW

Flasher light (EXC-RbEU, EXC-RbAUS/UK) BA15s 12bV

10bW

Flasher light (EXC-RbUSA) BAU15s 12bV

10bW

Brake / tail light (EXC-RbEU,

LED
EXC-RbAUS/UK, EXC-RbSIXbDAYS,
XCR-WbZA)

Brake / tail light (EXC-RbUSA) BAY15d 12bV

21/5bW

Licence plate lamp (EXC-RbEU, EXC­RbAUS/UK)

Tires

W2,1x9,5d 12bV

5bW

Validity Front tire Rear tire

(Every EXC-R models) 90/90b-b21b48bM+SbMbTT

Metzeler MCEb6bDAYSbEXTREME
(Every XCR-W models) 80/100b-b21b51bMbTT

Bridgestone M59

140/80b-b18b70bM+SbMbTT

Metzeler MCEb6bDAYSbEXTREME

110/100b-b18b64bMbTT

Bridgestone M402

For further information, see:
http://www.ktm.com

Capacity - fuel

Tank capacity (EXC-RbEU,
EXC-RbAUS/UK,
EXC-RbSIXbDAYS, XCR-WbZA)

Tank capacity (EXC-RbUSA,
XCR-WbUSA)

9bl (2.4bUSbgal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( P. 114)

9.2bl (2.43bUSbgal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( P. 114)

TECHNICAL DATA - FORK 96

7(&+1,&$/'$7$ )25.

Fork part number (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)14.18.7D.06

Fork part number (EXC-RbSIXbDAYS) 14.18.7D.35
Fork WP 4860 MXMA PA
Compression damping (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)

Comfort 24bclicks
Standard 20bclicks
Sport 18bclicks

Compression damping (EXC-RbSIXbDAYS)

Comfort 24bclicks
Standard 22bclicks
Sport 18bclicks

Rebound damping (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)

Comfort 20bclicks
Standard 18bclicks
Sport 18bclicks

Rebound damping (EXC-RbSIXbDAYS)

Comfort 20bclicks
Standard 20bclicks

Sport 18bclicks
Spring length with preload spacer(s) 510bmm (20.08bin)
Spring rate (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)

Weight of rider: 65… 75bkg (143… 165blb.) 4.4bN/mm (25.1blb/in)

Weight of rider: 75… 85bkg (165… 187blb.) 4.6

Weight of rider: 85… 95bkg (187… 209blb.) 4.8bN/mm (27.4blb/in)
Spring rate (EXC-RbSIXbDAYS)

Weight of rider: 65… 75bkg (143… 165blb.) 4.6bN/mm (26.3blb/in)

Weight of rider: 75… 85bkg (165… 187blb.) 4.8bN/mm (27.4blb/in)
Air chamber length 100
Spring preload - PreloadbAdjuster (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)

Comfort 2bturns

Standard 4bturns

Sport 7bturns
Spring preload - PreloadbAdjuster (EXC-RbSIXbDAYS)

Comfort 2bturns

Standard 2bturns

Sport 7bturns
Fork length 940bmm (37.01bin)
Fork oil ( P. 114) SAE 5

bN/mm

+30

bmm (3.94

෥20

(26.3blb/in)

+1.18

෥0.79

bin)

TECHNICAL DATA - SHOCK ABSORBER 97

7(&+1,&$/'$7$ 6+2&.$%625%(5

Shock absorber part number (EXC-RbEU, EXC-RbAUS/UK, EXC-
RbUSA, XCR-W)

Shock absorber part number (EXC-RbSIXbDAYS) 12.18.7D.35
Shock absorber WP PDS 5018 DCC
Compression damping, low-speed

Comfort 18bclicks

Standard 15bclicks

Sport 12bclicks
Compression damping, high-speed

Comfort 2bturns

Standard 1.5bturns

Sport 1bturn
Rebound damping

Comfort 24bclicks

Standard 22bclicks

Sport 20bclicks
Spring preload

Standard 9bmm
Spring rate

Weight of rider: 65… 75bkg (143… 165blb.) 69bN/mm (394blb/in)

Weight of rider: 75… 85bkg (165… 187blb.) 72bN/mm (411blb/in)

Weight of rider: 85… 95bkg (187… 209blb.) 76bN/mm (434blb/in)
Spring length 250bmm (9.84bin)
Gas pressure 10bbar (145bpsi)
Static sag 35bmm (1.38bin)
Riding sag 105bmm (4.13bin)
Fitted length 411bmm (16.18b

12.18.7D.06

in)

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 98

7(&+1,&$/'$7$ &+$66,67,*+7(1,1* 72548(6

Spoke nipple, front wheel M4,5 5bNm (3.7blbfbft) ದ
Spoke nipple, rear wheel M5 5bNm (3.7blbfbft) ದ
Remaining nuts, chassis M6 15bNm (11.1blbfbft) ದ
Remaining screws, chassis M6 10bNm (7.4blbfbft) ದ
Screw, rear brake disc M6 14bNm (10.3blbfbft) ದ
Screw, front brake disc M6 14bNm (10.3blbfbft) ದ
Screw, shock absorber adjusting ring M6 5bNm (3.7blbfbft) ದ
Screw, ball joint of push rod on foot-

brake cylinder
Nut, rear sprocket screw M8 35bNm (25.8blbfbft) Loctite
Nut, rim lock M8 10bNm (7.4blbfbft) ದ
Remaining nuts, chassis M8 30bNm (22.1blbfbft) ದ
Remaining screws, chassis M8 25bNm (18.4blbfbft) ದ
Screw, front brake caliper M8 25bNm (18.4blbfbft) Loctite
Screw, top triple clamp

(EXC-RbSIXbDAYS, XCR-WbUSA)
Screw, top triple clamp (EXC-RbEU,

EXC-RbAUS/UK, EXC-RbUSA, XCR­WbZA)

Screw, bottom triple clamp
(EXC-RbSIXbDAYS, XCR-WbUSA)

Screw, bottom triple clamp (EXC-RbEU,
EXC-RbAUS/UK, EXC-RbUSA, XCR­WbZA)

Screw, fork stub M8 15bNm (11.1blbfbft) ದ
Screw, top steering stem

(EXC-RbSIXbDAYS, XCR-WbUSA)
Screw, top steering stem (EXC-RbEU,

EXC-RbAUS/UK, EXC-RbUSA, XCR­WbZA)

Screw, handlebar clamp (EXC-RbEU,
EXC-RbAUS/UK, EXC-RbUSA, XCR-W)

Screw, handlebar clamp
(EXC-RbSIXbDAYS)

Screw, engine brace M8 33bNm (24.3blbfbft) ದ
Screw, subframe M8 35bNm (25.8blbfbft) Loctite
Screw, side stand fixing M8 40bNm (29.5blbfbft) Loctite
Engine carrying screw M10 60bNm (44.3blbfbft) ದ
Remaining nuts, chassis M10 50bNm (36.9blbfbft) ದ
Remaining screws, chassis M10 45bNm (33.2blbfbft) ದ
Screw, handlebar support M10 40bNm (29.5blbfbft) Loctite
Nut, seat fixing M12x1 20bNm (14.8blbfbft) ದ
Screw, top shock absorber M12 80bNm (59blbfbft) Loctite
Screw, bottom shock absorber M12 80bNm (59blbfbft) Loctite
Nut, swingarm pivot M16x1,5 100bNm (73.8blbfbft) ದ
Screw-in nozzles, cooling system M20x1,5 12bNm (8.9blbfbft) Loctite
Nut, rear wheel spindle M20x1,5 80bNm (59blbfbft) ದ
Screw, top steering head M20x1,5 10bNm (7.4blbfbft) ದ
Screw, bottom steering head (EXC-

RbSIXbDAYS, XCR-WbUSA)
Screw, front wheel spindle M24x1,5 40bNm (29.5blbfbft) ದ

M6 10bNm (7.4blbfbft) ದ

M8 17bNm (12.5blbfbft) ದ

M8 20bNm (14.8blbfbft) ದ

M8 12bNm (8.9blbfbft) ದ

M8 15bNm (11.1blbfbft) ದ

M8 17bNm (12.5blbfbft) Loctite

M8 20bNm (14.8blbfbft) ದ

M8 20bNm (14.8blbfbft) ದ

M8 16bNm (11.8blbfbft) ದ

M20x1,5 60bNm (44.3blbfbft) Loctite

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