KTM 450 EXC USA User Manual

OWNER'S MANUAL 2010

450 EXC USA
530 EXC USA

Art. no. 3211468en

DEAR KTM CUSTOMER 1

DEARKTM CUSTOMER

Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you enormous pleasure if you service and maintain it accordingly.

We wish you great pleasure riding the vehicle!

Enter the serial numbers of your vehicle below.

Chassis number ( p. 12) Dealer's stamp

Engine number ( p. 12)

Key number ( p. 12)

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 non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica­tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe­cial equipment that does not belong to the regular scope of delivery.

© 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.

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

KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

TABLE OF CONTENTS 2

TABLEOF CONTENTS

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

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

Overview of labels............................................................ 6

VIEW OF VEHICLE............................................................. 10

View of the vehicle from the left front (example) ............... 10

View of the vehicle from the right rear (example) .............. 11

LOCATION OF SERIAL NUMBERS ...................................... 12

Chassis number............................................................. 12

Type label..................................................................... 12

Key number .................................................................. 12

Engine number.............................................................. 12

Fork part number........................................................... 13

Shock absorber part number ........................................... 13

CONTROLS....................................................................... 14

Clutch lever .................................................................. 14

Hand brake lever ........................................................... 14

Emergency OFF switch................................................... 14

Ignition switch .............................................................. 14

Electric starter button .................................................... 14

Light switch .................................................................. 15

Highlight flasher button ................................................. 15

Horn button .................................................................. 15

Flasher switch............................................................... 15

Overview of indicator lamps ............................................ 15

Speedometer................................................................. 16

Speedometer activation and test ..................................... 16

Tripmaster switch .......................................................... 16

setting kilometers or miles.............................................. 16

Setting the clock ........................................................... 17

Adjusting the speedometer functions............................... 17

Querying the lap time .................................................... 18

Display mode SPEED (speed) ......................................... 18

Display mode SPEED/H (service hours) ............................ 18

Display mode SPEED/CLK (clock) ................................... 19

Display mode SPEED/LAP (lap time) ............................... 19

Display mode SPEED/ODO (odometer) ............................. 19

Display mode SPEED/TR1 (trip master 1) ........................ 19

Display mode SPEED/TR2 (trip master 2) ........................ 20

Display mode SPEED/A1 (average speed 1)...................... 20

Display mode SPEED/A2 (average speed 2)...................... 20

Display mode SPEED/S1 (stop watch 1) .......................... 21

Display mode SPEED/S2 (stop watch 2) .......................... 21

Fuel tap........................................................................ 22

Opening filler cap.......................................................... 22

Closing filler cap ........................................................... 22

Choke........................................................................... 23

Shift lever..................................................................... 23

Foot brake lever............................................................. 23

Kick starter................................................................... 23

Side stand .................................................................... 24

Steering lock................................................................. 24

Locking the steering ...................................................... 24

Unlocking the steering ................................................... 25

GENERAL TIPS AND HINTS ON PUTTING INTO

OPERATION...................................................................... 26

Advice on first use ......................................................... 26

Running-in the engine ................................................... 27

Preparing vehicle for arduous riding conditions................. 27

Preparing for riding on dry sand ...................................... 27

Preparing for riding on wet sand...................................... 28

Preparing for riding on wet and muddy surfaces................ 29

Preparing for rides at high temperature and slow speed ..... 30

Preparing for rides at low temperatures or in snow ............ 30

RIDING INSTRUCTIONS .................................................... 31

Checks before putting into operation ............................... 31

Starting ........................................................................ 31

Starting up ................................................................... 32

Shifting, riding.............................................................. 32

Braking ........................................................................ 32

Stopping, parking .......................................................... 33

Refueling...................................................................... 33

SERVICE SCHEDULE......................................................... 35

Important maintenance work to be carried out by an

authorized KTM workshop. ............................................. 35

Important maintenance work to be carried out by an

authorized KTM workshop. (as additional order)................ 36

Important checks and maintenance work to be carried

out by the rider ............................................................. 37

MAINTENANCE WORK ON CHASSIS AND ENGINE .............. 38

Jacking up the motorcycle .............................................. 38

Removing the motorcycle from the work stand.................. 38

Checking the basic suspension setting with the rider's

weight .......................................................................... 38

Compression damping of shock absorber.......................... 38

Adjusting the high-speed compression damping of the

shock absorber .............................................................. 38

Adjusting the low-speed compression damping of the

shock absorber .............................................................. 39

Adjusting rebound damping of the shock absorber ............ 39

Measuring rear wheel sag unloaded ................................. 40

Checking static sag of shock absorber.............................. 40

Checking riding sag of shock absorber ............................. 41

Adjusting spring preload of the shock absorber x............ 41

Adjusting riding sag x .................................................. 42

Removing the shock absorber x..................................... 42

Installing the shock absorber x ..................................... 42

Checking basic setting of fork ......................................... 43

Adjusting the compression damping of the fork ................ 43

Adjusting rebound damping of fork.................................. 43

Adjusting spring preload of the fork................................. 44

Bleeding fork legs.......................................................... 44

Cleaning the dust boots of the fork legs ........................... 44

Loosening the fork protector ........................................... 45

Positioning the fork protector.......................................... 45

Checking steering head bearing play................................ 45

Adjusting play of steering head bearing x....................... 46

Removing the fork legs x.............................................. 46

Installing fork legs x .................................................... 46

Removing the fork protector x....................................... 47

Installing the fork protector x ....................................... 47

Removing the lower triple clamp x ................................ 47

Installing the lower triple clamp x................................. 48

Greasing the steering head bearing x............................. 49

Removing the front fender .............................................. 49

Installing the front fender............................................... 49

Removing headlight mask with headlight ......................... 49

Refitting the headlight mask with the headlight................ 50

Handlebar position ........................................................ 50

Adjusting the handlebar position x................................ 50

Checking throttle cable route .......................................... 51

Checking the play in the throttle cable............................. 51

Adjusting the play in the throttle cable x ....................... 51

Checking for chain dirt accumulation .............................. 52

TABLE OF CONTENTS 3

Cleaning the chain......................................................... 52

Checking the chain tension ............................................ 52

Checking chain tension when fitting rear wheel ................ 53

Checking the rear sprocket/engine sprocket for wear ......... 53

Checking chain wear...................................................... 53

Adjusting chain tension.................................................. 54

Adjusting chain tension - after checking .......................... 55

Adjusting chain tension - fitting rear wheel ...................... 55

Adjusting chain guide x ............................................... 56

Checking brake discs ..................................................... 56

Checking free travel of hand brake lever........................... 56

Adjusting free travel of hand brake lever .......................... 57

Checking the brake fluid level of the front brake ............... 57

Topping up the front brake fluid x................................. 57

Checking the front brake linings...................................... 58

Changing the front brake linings x................................. 59

Checking the free travel of the foot brake lever ................. 60

Adjusting the basic position of the foot brake lever x ...... 60

Checking rear brake fluid level ........................................ 61

Adding brake fluid to the rear brake circuit x ................. 61

Checking rear brake linings ............................................ 62

Changing rear brake linings x ....................................... 62

Removing front wheel x................................................ 64

Installing the front wheel x........................................... 65

Removing the rear wheel x ........................................... 65

Installing the rear wheel x ............................................ 66

Tire condition checking.................................................. 67

Checking tire air pressure ............................................... 67

Checking spoke tension.................................................. 68

Removing the battery x ................................................ 68

Installing the battery x................................................. 69

Recharging the battery x .............................................. 69

Removing a fuse............................................................ 70

Installing the fuse ......................................................... 70

Checking the headlight adjustment ................................. 70

Adjusting the beam width of the headlight ....................... 71

Removing the seat ......................................................... 71

Mounting the seat ......................................................... 71

Removing the fuel tank x ............................................. 71

Installing the fuel tank x .............................................. 72

Cooling system .............................................................. 73

Checking the anti-freeze and coolant level ....................... 73

Checking the coolant level.............................................. 74

Draining coolant x ....................................................... 74

Refilling coolant x ....................................................... 75

Glass fiber yarn filling of main silencer ............................ 75

Removing main silencer ................................................. 75

Installing the main silencer ............................................ 76

Removing the air filter box lid......................................... 76

Installing the air filter box lid.......................................... 76

Removing the air filter x............................................... 76

Installing the air filter x ............................................... 77

Cleaning air filter x...................................................... 77

Adjusting basic position of clutch lever............................ 77

Checking the fluid level of hydraulic clutch...................... 78

Changing the hydraulic clutch fluid x ............................ 78

Checking the basic position of the shift lever.................... 79

Adjusting the basic position of the shift lever x .............. 79

Carburetor - idle ............................................................ 80

Carburetor - adjusting idle x ......................................... 80

Emptying the carburetor float chamber x ....................... 81

Checking engine oil level................................................ 81

Changing engine oil and oil filter, cleaning engine oil

screen x ..................................................................... 82

Draining engine oil, cleaning engine oil screen x ............ 82

Removing the oil filter x............................................... 82

Installing the oil filter x ............................................... 83

Filling up with engine oil x........................................... 83

Topping up engine oil .................................................... 84

Checking the gear oil level.............................................. 84

Changing gear oil, cleaning gear oil screen x.................. 84

Draining gear oil, cleaning gear oil screen x ................... 85

Filling up with gear oil x .............................................. 85

Adding gear oil x ......................................................... 86

TROUBLESHOOTING......................................................... 87

CLEANING........................................................................ 89

Cleaning the motorcycle ................................................. 89

STORAGE ......................................................................... 90

Storage......................................................................... 90

Putting into operation after storage ................................. 90

TECHNICAL DATA - ENGINE .............................................. 91

Capacity - engine oil ...................................................... 91

Capacity - gear oil.......................................................... 91

Capacity - coolant.......................................................... 92

TECHNICAL DATA - ENGINE TIGHTENING TORQUES .......... 93

TECHNICAL DATA - CARBURETOR..................................... 95

450 EXC USA ............................................................... 95

530 EXC USA ............................................................... 95

TECHNICAL DATA - CHASSIS ............................................ 96

Lighting equipment ....................................................... 96

Tires ............................................................................ 97

Capacity - fuel............................................................... 97

TECHNICAL DATA - FORK.................................................. 98

TECHNICAL DATA - SHOCK ABSORBER ............................. 99

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 100

WIRING DIAGRAM .......................................................... 102

Wiring diagram............................................................ 102

SUBSTANCES................................................................. 105

AUXILIARY SUBSTANCES................................................ 107

STANDARDS................................................................... 109

INDEX ............................................................................ 110

MEANS OF REPRESENTATION 4

Symbols used

The symbols used are explained in the following.

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

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

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

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

Formats used

The typographical and other formats used are explained below.

Proprietary name Denotes a proprietary name.

®

Name

Brand™ Denotes a brand available on the open market.

Denotes a protected name.

IMPORTANT INFORMATION 5

Use definition

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

Info

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

Maintenance

A prerequisite for trouble free operation and avoiding premature wear is that the engine and suspension are maintained and adjusted
as described in this manual. Poor adjustment and tuning of the engine and suspension can lead to damage and breakage of compo­nents.
Using a motorcycle in difficult conditions such as on sand or very wet and muddy ground can lead to excessive wear of components
such as the power train or brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the
service schedule is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. Observing these rules will vastly
increase the service life of your motorcycle.

Warranty

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

Fuel, oils, etc.

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

Spare parts, accessories

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

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

Work rules

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

Transport

Note

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

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

Note

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

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

being run. Always let the vehicle cool first.

– Switch off engine.

IMPORTANT INFORMATION 6

– Turn handle  of the fuel tap to the OFF position. (Figure 500137-10 p. 22)
– Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

Environment

Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the
environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such prob­lems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, dis­play environmental consciousness, and respect the rights of others.

2.1Overview of labels

1 Type label for Canada
2 Type label for the USA
3 Fuel evaporative system information
4 Chain tension information
5 Information on putting into operation
6 Emission control information
7 Noise emission information

Type label for Canada

300401-10

500250-01

IMPORTANT INFORMATION 7

500251-01

Type label for the USA

Fuel evaporative system information

100841-01

Chain tension information

Emission control information

500255-01

Information on putting into operation

700210-01

100840-01

IMPORTANT INFORMATION 8

100839-01

Noise emission information

Notes/warnings

Pay close attention to the notes/warnings.

Info

Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are miss­ing, you or others may not recognize potential hazards and may therefore be injured.

Grades of risks

Danger

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.

Warning

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Note

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

Warning

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

Owner's manual

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

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

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

sold.

Reporting of safety defects

If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform
the National Highway Traffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc.
If NHTSA receives similar complaints, it may open an investigation. If it finds that a safety defect exists in a group of vehicles, it may
order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or
KTM North America, Inc.
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1–888–327–4236; or visit www.nhtsa.dot.gov; or write
to: NHTSA Headquarters, 1200 New Jersey Avenue, SE, West Building, Washington, DC 20590, USA. You can also obtain other infor­mation about motor vehicle safety from the Hotline.

Noise emission warranty

KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise stan­dards.
This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.
Warranty claims should be directed to:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Telefon: [phone]
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7
Phone: [phone] x 4250
www.ktmcanada.com

IMPORTANT INFORMATION 9

Tampering warning

Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:

1 The removal or rendering inoperative by any person, other than for purposes of maintenance, repair, or replacement, of any device

or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate
purchaser or while it is in use; or

2 The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

1 Removal of, or puncturing the muffler, baffles, header pipes or any other components which conducts exhaust gases.
2 Removal or puncturing of any part of the intake system.
3 Lack of proper maintenance.
4 Replacement of any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by

the manufacturer.

Operating noise warning

This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise,
the owner may become subject to penalties under state and local ordinances.

Consumer rights

Warranty claims should be submitted to a KTM workshop. If you are not satisfied, please contact:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Telefon: [phone]
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7
Phone: [phone] x 4250
www.ktmcanada.com
Different rights may apply, according to national or regional legislation.

VIEW OF VEHICLE 10

3.1View of the vehicle from the left front (example)

1 Side stand
2 Shift lever
3 Chain guide
4 Fuel tap
5 Air filter box lid
6 Clutch lever
7 Light switch, headlight flasher button, flasher switch, horn button
8 Hand brake lever

300399-10

VIEW OF VEHICLE 11

3.2View of the vehicle from the right rear (example)

1 Level viewer for brake fluid, rear
2 Fork compression adjustment
3 Foot brake pedal
4 Kickstarter
5 Horn
6 Ignition switch
7 Fork rebound adjustment
8 Filler cap
9 Shock absorber compression adjustment
10 Shock absorber rebound adjustment

300398-10

LOCATION OF SERIAL NUMBERS 12

4.1Chassis number

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

500127-10

4.2Type label

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

4.3Key number

300402-10

The type label Canada  is fixed to the front of the front pipe.

300403-10

The key number  is provided on the KEYCODECARD.

Info

You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.

300397-10

4.4Engine number

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

500072-10

LOCATION OF SERIAL NUMBERS 13

4.5Fork part number

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

100801-10

4.6Shock absorber part number

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

500129-10

CONTROLS 14

5.1Clutch lever

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

500133-10

5.2Hand brake lever

Hand brake lever  is located on the right side of the handlebar.
The hand brake lever is used to activate the front brake.

5.3Emergency OFF switch

5.4Ignition switch

400196-10

The emergency OFF switch  is fitted on the left side of the handlebar.

Possible states

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

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

500144-10

The ignition switch  is on the right behind the headlight mask.

Possible states

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

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

5.5Electric starter button

300396-10

Electric starter button  is fitted on the right side of the handlebar.

Possible states

• Electric starter button is in home position

• Electric starter button is pressed – In this position, the electric starter is actu­ated.

500144-12

CONTROLS 15

5.6Light switch

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

Possible states

Low beam on – Light switch is turned downward. In this position, the
low beam and tail light are switched on.

High beam on – Light switch is turned upward. In this position, the
high beam and tail light are switched on.

500142-10

5.7Highlight flasher button

Headlight flasher button  is fitted on the left side of the handlebar.

Possible states

• Headlight flasher button is in home position

• Headlight flasher button is pressed – The headlight flasher is activated in this
position.

5.8Horn button

5.9Flasher switch

500143-10

Horn button  is fitted on the left side of the handlebar.

Possible states

• Horn button is in home position

• Horn button is pressed – The horn is sounded in this position.

500142-11

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

Possible states

Flasher light off
Flasher light, left, on – Flasher switch is pressed to the left. The flasher

switch returns to the middle position after activation.

Flasher light, right, on – Flasher switch is pressed to the right. The
flasher switch returns to the middle position after activation.

5.10Overview of indicator lamps

500142-12

500147-01

To switch off the flasher, push the flasher switch toward the switch housing.

Possible states

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

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

CONTROLS 16

5.11Speedometer

– Press the key to change the display mode or change to one of the Setup menus.
– Press the key to control different functions.
– Press the key to control different functions.

Info

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

400312-01

5.12Speedometer activation and test

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

400313-01

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

Info

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

The display then changes to the last selected mode.

400314-01

5.13Tripmaster switch

(Option: Tripmaster switch)

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

Info

The trip master is an optional accessory.

5.14setting kilometers or miles

Info

If you change the unit, the value ODO is retained and converted accordingly.
The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed.

400329-01

Condition

The motorcycle is stationary.
– Press the button briefly and repeatedly until H appears at the bottom right of the

display.

– Press the button for 3 - 5 seconds.

The setup menu is displayed and the active functions shown.

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

– Press the button .

Mph adjusting

– Press the button .

CONTROLS 17

– Press the button for 3 - 5 seconds.

The settings are stored and the setup menu is closed.

Info

If no button is actuated for 20 seconds or there is no signal from the wheel
speed sensor, then the settings are automatically stored and the setup menu
closed.

5.15Setting the clock

Condition

The motorcycle is stationary.
– Press the button briefly and repeatedly until CLK appears at the bottom right of

the display.

– Press the button for 3 - 5 seconds.

The hour display flashes.

– Set the hour display with the button and/or button .
– Press the button briefly.

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

400330-01

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

the button and the button .

Info

The seconds can only be set to zero.

– Press the button for 3 - 5 seconds.

The settings are stored and the setup menu is closed.

Info

If no button is actuated for 20 seconds or there is no signal from the wheel
speed sensor, then the settings are automatically stored and the setup menu
closed.

5.16Adjusting the speedometer functions

Info

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

Condition

The motorcycle is stationary.
– Press the button briefly and repeatedly until H appears at the bottom right of the

display.

– Press the button for 3 - 5 seconds.

The Setup menu is displayed and the activated functions are shown.

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

The selected function flashes.

Activating a function

– Press the button .

400318-01

Deactivating the function

– Press the button .

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

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

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

The settings are stored and the Setup menu is closed.

CONTROLS 18

Info

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

5.17Querying the lap time

Info

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

Condition

The motorcycle is stationary.
– Press the button briefly and repeatedly until LAP appears at the bottom right of

the display.

– Press the button briefly.

LAP 1 appears on the left side of the display.

– Laps 1-10 can be displayed by pressing the button .
– The button has no function
– Press the button briefly.

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 the SPEED mode.

5.18Display mode SPEED (speed)

400317-02

5.19Display mode SPEED/H (service hours)

400316-01

– Press the button briefly and repeatedly until SPEED appears on the left side of

the display.

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

Info

Making the setting according to the country.
When an impulse comes from the front wheel, the left side of the speedometer
display changes to the SPEED mode and the current speed is shown.

Condition

• The motorcycle is stationary

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

display.

In display mode H, the service hours of the engine are displayed.
The service hour counter stores the total traveling time.

Info

The service hour counter is necessary for ensuring that maintenance work is car­ried out at the right intervals.
If the speedometer is in H display mode at the start of the journey, it automati­cally changes to the ODO display mode.
The H display mode is suppressed during the journey.

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

for 3 - 5 seconds.
Press the button

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

Next display mode

briefly.

CONTROLS 19

5.20Display mode SPEED/CLK (clock)

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

the display.

The time is displayed in CLK display mode.

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

400319-01

5.21Display mode SPEED/LAP (lap time)

Press the button
for 3 - 5 seconds.

Press the button
briefly.

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

the display.

In the LAP display mode, up to 10 lap times can be timed with the stop watch.

Info

If the lap time continues after you press the button , 9 memory locations are
already occupied.
Lap 10 must be timed with the button .

The display changes to the Setup menu of the clock.

Next display mode

400320-01

5.22Display mode SPEED/ODO (odometer)

400317-01

5.23Display mode SPEED/TR1 (trip master 1)

Press the button . Starts or stops the clock.
Press the button . Stops the current lap time and saves it, and the stop watch

starts the next lap.

Press the button

The stop watch and the lap time are reset.

for 3 - 5 seconds.
Press the button

Next display mode

briefly.

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

the display.

In ODO display mode, the total number of kilometers ridden is displayed.

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

–

for 3 - 5 seconds.
Press the button

Next display mode

briefly.

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

display.

TR1 (trip master 1) runs constantly and counts to 999.9.
You can use it to measure trips or the distance between refueling stops.
TR1 is coupled with A1 (average speed 1) and S1 (stop watch 1).

400323-01

Info

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

0.0.

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

for 3 - 5 seconds.

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

CONTROLS 20

5.24Display mode SPEED/TR2 (trip master 2)

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

TR2 (trip master 2) runs constantly and counts up to 999.9.
The displayed value can be set manually with the button and the button . A very
practical function when riding using the road book.

400324-01

5.25Display mode SPEED/A1 (average speed 1)

– Press the button briefly and repeatedly until A1 appears at the top right of the

A1 (average speed 1) shows the average speed calculated on the basis of TR1 (trip mas­ter 1) and S1 (stop watch 1).
The calculation of this value is activated by the first impulse of the wheel speed sensor
and ends 3 seconds after the last impulse.

Press the button

Next display mode

briefly.

display.

Info

The TR2 value can also be corrected manually during the journey with the but­ton and the button .
If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0.

Press the button . Increases value of TR2.
Press the button . Reduces value of TR2.
Press the button

for 3 - 5 seconds.
Press the button

briefly.

display.

Deletes value of TR2.

Next display mode

400325-01

5.26Display mode SPEED/A2 (average speed 2)

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

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

400326-01

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

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

for 3 - 5 seconds.
Press the button

Next display mode

briefly.

display.

Info

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

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

for 3 - 5 seconds.
Press the button

briefly.

–

Next display mode

CONTROLS 21

5.27Display mode SPEED/S1 (stop watch 1)

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

display.

S1 (stop watch 1) displays the journey time on the basis of TR1 and continues when an
impulse is received from the wheel speed sensor.
The calculation of this value starts with the first impulse of the wheel speed sensor and
ends 3 seconds after the last impulse.

Press the button . No function

400327-01

5.28Display mode SPEED/S2 (stop watch 2)

Press the button . No function
Press the button

Displays of TR1, A1 and S1 are reset to 0.0.

for 3 - 5 seconds.
Press the button

Next display mode

briefly.

– Press the button briefly and repeatedly until S2 appears at the top right of the

display.

S2 (stop watch 2) is a manual stop watch.
If S2 is running in the background, the S2 display flashes in the speedometer display.

Press the button . Starts or stops S2.
Press the button . No function

400328-01

Press the button
for 3 - 5 seconds.

Press the button

Displays of S2 and A2 are reset to 0.0.

Next display mode

briefly.

Table of functions
Display Press the button . Press the button . Press the button 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 SPEED/CLK
(clock)

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 – Next display mode

SPEED/ODO (odometer)
Display mode SPEED/TR1

(trip master 1)
Display mode SPEED/TR2

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

plays are reset to 0.0.

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

(trip master 2)
Display mode SPEED/A1

(average speed 1)
Display mode SPEED/A2

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

plays are reset to 0.0.

No function No function – Next display mode

(average speed 2)
Display mode SPEED/S1

(stop watch 1)
Display mode SPEED/S2

(stop watch 2)

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 button
briefly.

Next display mode

Next display mode

Next display mode

Next display mode

Next display mode

Next display mode

Next display mode

Table of conditions and menu activation
Display The motorcycle is

stationary

Display mode SPEED/H (service hours) •

Menu can be acti­vated

CONTROLS 22

Table of conditions and menu activation
Display The motorcycle is

stationary

Display mode SPEED/CLK (clock) •
Display mode SPEED/LAP (lap time) •
Display mode SPEED/TR1 (trip master 1) •
Display mode SPEED/TR2 (trip master 2) •
Display mode SPEED/A1 (average speed 1) •
Display mode SPEED/A2 (average speed 2) •
Display mode SPEED/S1 (stop watch 1) •
Display mode SPEED/S2 (stop watch 2) •

5.29Fuel tap

The fuel tap is on the left of the fuel tank.
With tap handle  on the fuel tap, you can open or close the supply of fuel to the car­buretor.

Possible states

• Fuel supply closed OFF – No fuel flows from the tank to the carburetor.

• Fuel supply open ON – Fuel flows from the tank to the carburetor. The fuel tank
empties down to the reserve.

• Reserve fuel supply open RES – Fuel flows from the tank to the carburetor. The
fuel tank empties completely.

Menu can be acti­vated

5.30Opening filler cap

5.31Closing filler cap

500137-10

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

remove.

400199-10

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

Info

Route the fuel tank breather hose  without kinking.

400199-11

CONTROLS 23

5.32Choke

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

Info

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

Possible states

500135-10

5.33Shift lever

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

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

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

5.34Foot brake lever

500138-10

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

500138-11

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

500139-10

5.35Kick starter

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

Info

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

500148-10

CONTROLS 24

5.36Side stand

Note

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

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

Note

Material damage Damage and destruction of components by excessive load.

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

500140-10

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

To park the motorcycle, press side stand  to the ground with your foot and lean the
motorcycle on it.

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

500141-10

5.37Steering lock

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

500126-10

5.38Locking the steering

Note

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

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

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

right. Remove the key.

Steering is no longer possible.

400732-01

Info

Never leave the key in the steering lock.

CONTROLS 25

5.39Unlocking the steering

– 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.

400731-01

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 26

6.1Advice on first use

Danger

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

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

Warning

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

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

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

Warning

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

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

Warning

Danger of accidents Critical riding behavior due to inappropriate riding.

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

Warning

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

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

Warning

Danger of accidents Failure of brake system.

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

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

Warning

Danger of accidents Unstable riding behavior.

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

Warning

Risk of misappropriation Usage by unauthorized persons.

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

Info

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

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

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

– Before your first trip, read the entire operating instructions carefully.
– Get to know the controls.
– Adjust the basic position of clutch lever. ( p. 77)
– Adjust the free travel of the hand brake lever. ( p. 57)

–

Adjust the basic position of the foot brake lever. x ( p. 60)

–

Adjust the basic position of the shift lever. x ( p. 79)

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

Info

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

– Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.
– Do not make any off-road trips that over-stress your ability and experience.
– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
– 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.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 27

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

Guideline

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

– Check the spoke tension. ( p. 68)

Info

The spoke tension must be checked after half an hour of operation.

– Run-in the engine.

6.2Running-in the engine

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

Guideline

Maximum engine speed

During the first 3 service hours 7,000 rpm

Maximum engine performance

During the first 3 service hours ≤ 50 %
During the next 12 service hours ≤ 75 %

– Avoid fully opening the throttle!

6.3Preparing vehicle for arduous riding conditions

– Using a motorcycle in arduous conditions can lead to excessive wear of components such as the power train or brakes. For this

reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached.

Arduous riding conditions are:

– Riding on dry sand. ( p. 27)
– Riding on wet sand. ( p. 28)
– Riding on wet and muddy surfaces. ( p. 29)
– Rides at high temperature and slow speed. ( p. 30)
– Rides at low temperatures or in snow. ( p. 30)

6.4Preparing for riding on dry sand

– Check the radiator cap.

Value on radiator cap 1.8 bar (26 psi)

» If the displayed value does not correspond to specifications:

Warning

Danger of scalding During motorcycle operation, the coolant gets

very hot and is under pressure.

600872-10

– Do not remove the radiator cap, radiator hoses or other cooling

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

– Change the radiator cap.

–

Seal the air filter box. x

Tip

Seal the air filter box on the edges against dirt.

–

Clean the air filter. x ( p. 77)

Info

Check the air filter approx. every 30 minutes.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 28

– Fit a dust protection device on the air filter.

Dust protection device for air filter (59006019000)

Info

See the KTM PowerParts fitting instructions.

600869-01

– Fit a sand screen device on the air filter.

Sand protection device for air filter (59006022000)

Info

See the KTM PowerParts fitting instructions.

– Adjust the carburetor jetting and settings.

600871-01

600868-01

6.5Preparing for riding on wet sand

600872-10

Info

Your authorized KTM workshop has the recommended carburetor tuning set­tings.

– Clean the chain.

Chain cleaner ( p. 107)

– Fit the steel sprocket.

Tip

Do not grease the chain.

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

– Check the radiator cap.

Value on radiator cap 1.8 bar (26 psi)

» If the displayed value does not correspond to specifications:

Warning

Danger of scalding During motorcycle operation, the coolant gets

very hot and is under pressure.

– Do not remove the radiator cap, radiator hoses or other cooling

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

– Change the radiator cap.

–

Seal the air filter box. x

Tip

Seal the air filter box on the edges against dirt.

–

Clean the air filter. x ( p. 77)

Info

Check the air filter approx. every 30 minutes.