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

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

OWNER'S MANUAL 2009

400 EXC EU

400 EXC AUS

400 XC-W USA

450 EXC EU

450 EXC AUS

450 EXC SIX DAYS EU

450 XC-W USA

450 XC-W ZA

530 EXC EU

530 EXC AUS

530 EXC SIX DAYS EU

530 XC-W USA

530 XC-W ZA

ART. NO. 3211355en

DEAR KTM CUSTOMER

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

We wish you great pleasure riding the vehicle!

Enter the serial numbers of your vehicle below.

Chassis number ( p. 9)

Dealer's stamp

Engine number ( p. 9)

Key number (all EXC models) ( p. 9)

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

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

Reproduction, even in part, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)

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

MEANS OF REPRESENTATION ............................................	4
IMPORTANT NOTES............................................................	5
VIEW OF VEHICLE...............................................................	7
View of the vehicle from the left front (example).................	7
View of the vehicle from the right rear (example) ................	8
LOCATION OF SERIAL NUMBERS ........................................	9
Chassis number...............................................................	9
Type label.......................................................................	9
Key number (all EXC models) ...........................................	9
Engine number................................................................	9
Fork part number.............................................................	9
Shock absorber part number...........................................	10
OPERATING ELEMENTS....................................................	11
Clutch lever ..................................................................	11
Hand brake lever ...........................................................	11
Short circuit button (all XC W models).............................	11
Short circuit button (all EXC models)...............................	11
Emergency OFF switch (EXC AUS) ..................................	11
Electric starter button (EXC EU, EXC SIX DAYS, XC-W) .....	12
Electric starter button (EXC AUS)....................................	12
Light switch (all EXC models) .........................................	12
Light switch (all XC W models) .......................................	12
Horn button (all EXC models) .........................................	12
Flasher switch (all EXC models) ......................................	13
Overview of indicator lamps (all EXC models) ...................	13
Speedometer.................................................................	13
Speedometer activation and test .....................................	13
Tripmaster switch ..........................................................	14
Setting kilometers or miles .............................................	14
Setting the clock ...........................................................	14
Adjusting the speedometer functions...............................	15
Querying the lap time ....................................................	15
SPEED display mode (speed)..........................................	16
SPEED/H display mode (service hours) ............................	16
SPEED/CLK display mode (time).....................................	16
SPEED/LAP display mode (lap time)................................	16
SPEED/ODO display mode (odometer) .............................	17
SPEED/TR1 display mode (trip master 1).........................	17
SPEED/TR2 display mode (trip master 2).........................	17
SPEED/A1 display mode (average speed 1) ......................	18
SPEED/A2 display mode (average speed 2) ......................	18
SPEED/S1 display mode (stop watch 1)...........................	18
SPEED/S2 display mode (stop watch 2)...........................	18
Fuel tap........................................................................	20
Opening filler cap..........................................................	20
Closing filler cap ...........................................................	20
Choke (EXC AUS, XC W).................................................	20
Choke (EXC EU, EXC SIX DAYS) .....................................	21
Shift lever.....................................................................	21
Foot brake pedal ...........................................................	21
Kickstarter....................................................................	21
Side stand ....................................................................	22
Steering lock (all EXC models) ........................................	22
Locking the steering (all EXC models)..............................	22
Unlocking the steering (all EXC models) ..........................	23
GENERAL TIPS AND HINTS ON PUTTING INTO
OPERATION......................................................................	24
Advice on first use.........................................................	24
Running in the engine....................................................	25
RIDING INSTRUCTIONS ....................................................	26
Checks before putting into operation ...............................	26

Starting ........................................................................	26
Starting up ...................................................................	27
Shifting, riding..............................................................	27
Braking ........................................................................	27
Stopping, parking ..........................................................	28
Refueling......................................................................	28
SERVICE SCHEDULE.........................................................	30
Important maintenance work to be carried out by an
authorized KTM workshop. .............................................	30
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order)................	31
Important checks and maintenance work to be carried
out by the rider. ............................................................	31
MAINTENANCE WORK ON CHASSIS AND ENGINE..............	33
Jacking up the motorcycle ..............................................	33
Removing the motorcycle from the work stand..................	33
Checking the basic chassis setting with the rider's
weight ..........................................................................	33
Compression damping of shock absorber..........................	33
Adjusting high-speed compression damping of the shock
absorber .......................................................................	33
Adjusting the low-speed compression damping of the
shock absorber ..............................................................	34
Adjusting rebound damping of the shock absorber ............	34
Measuring rear wheel sag unloaded .................................	35
Checking static sag of the shock absorber ........................	35
Checking the riding sag of the shock absorber ..................	36
Adjusting spring preload of the shock absorber x............	36
Adjusting riding sag x..................................................	37
Removing the shock absorber x.....................................	37
Installing the shock absorber x.....................................	37
Checking basic setting of fork .........................................	38
Adjusting compression damping of fork ...........................	38
Adjusting rebound damping of fork..................................	38
Adjusting spring preload of the fork.................................	39
Bleeding fork legs..........................................................	39
Cleaning dust boots of fork legs ......................................	39
Loosening the fork protection..........................................	40
Positioning the fork protection ........................................	40
Checking play of steering head bearing............................	40
Adjusting play of steering head bearing x(EXC EU,
EXC AUS, XC W ZA).......................................................	41
Adjusting play of steering head bearing x
(EXC SIX DAYS, XC W USA) ...........................................	41
Removing the fork legs...................................................	42
Installing the fork legs x...............................................	42
Removing the fork protector x.......................................	43
Installing the fork protector x.......................................	43
Removing the lower triple clamp x(EXC SIX DAYS,
XC W USA) ...................................................................	43
Removing the lower triple clamp x(EXC EU, EXC AUS,
XC W ZA)......................................................................	44
Installing the lower triple clamp x(EXC SIX DAYS,
XC W USA) ...................................................................	45
Installing the lower triple clamp x(EXC EU, EXC AUS,
XC W ZA)......................................................................	46
Greasing the steering head bearing x.............................	46
Dismounting the front fender ..........................................	47
Installing the front fender...............................................	47
Removing headlight mask with headlight (EXC,
EXC SIX DAYS, XC W ZA) ...............................................	47
Refitting the headlight mask with the headlight (EXC,
EXC SIX DAYS, XC W ZA) ...............................................	47

CONTENTS

Dismount the start number plate (XC W USA)...................	48
Installing the start number plate (XC W USA)...................	48
Handlebar position ........................................................	48
Adjusting handlebar position x......................................	48
Checking gas Bowden cable route ...................................	50
Checking play in the gas Bowden cable ...........................	50
Adjusting the gas Bowden cable play x..........................	50
Checking for chain dirt accumulation ..............................	51
Cleaning the chain.........................................................	51
Checking the chain tension ............................................	52
Checking the chain tension when fitting rear wheel...........	52
Checking the rear sprocket / engine sprocket for wear .......	52
Checking chain wear......................................................	53
Adjusting the chain tension ............................................	53
Adjusting chain tension - after checking ..........................	54
Adjusting chain tension - fitting rear wheel ......................	55
Adjusting chain guide x...............................................	55
Checking the brake discs................................................	55
Checking free travel of hand brake lever...........................	56
Adjusting basic position of handbrake lever (all XC W
models) ........................................................................	56
Adjusting free travel of handbrake lever (all EXC
models) ........................................................................	57
Checking the front brake fluid level .................................	57
Adding front brake fluid x............................................	57
Checking the front brake linings......................................	58
Removing front brake linings x.....................................	58
Mounting front brake linings x......................................	59
Changing the front brake linings x.................................	59
Checking free travel of foot brake lever ............................	60
Adjusting basic position of footbrake lever x...................	60
Checking the rear brake fluid level ..................................	61
Adding brake fluid for the rear brake x..........................	61
Checking the rear brake linings .......................................	62
Removing rear brake linings x.......................................	62
Installing the rear brake linings x..................................	62
Changing the rear brake linings x..................................	63
Removing the front wheel x..........................................	64
Installing the front wheel x...........................................	64
Removing rear wheel x.................................................	65
Installing the rear wheel x............................................	65
Tire condition checking..................................................	66
Checking tire air pressure...............................................	67
Checking spoke tension..................................................	67
Removing the battery x................................................	67
Installing the battery x.................................................	68
Recharging the battery x..............................................	68
Removing a fuse............................................................	69
Installing the fuse .........................................................	69
Removing the seat .........................................................	69
Mounting the seat .........................................................	70
Dismounting the fuel tank x.........................................	70
Installing the fuel tank x..............................................	71
Cooling system ..............................................................	71
Checking antifreeze and coolant level ..............................	72
Checking the coolant level..............................................	72
Draining coolant x.......................................................	73
Refilling coolant x.......................................................	73
Glass fiber yarn filling of main silencer ............................	73
Removing main silencer .................................................	74
Installing the main silencer ............................................	74

Dismounting the air filter box lid.....................................	74
Installing the air filter box lid..........................................	74
Removing the air filter x...............................................	75
Installing the air filter x...............................................	75
Cleaning air filter x......................................................	75
Adjusting basic position of clutch lever............................	76
Checking the fluid level of hydraulic clutch......................	76
Changing the hydraulic clutch fluid x............................	76
Carburetor - idle ............................................................	77
Carburetor - adjusting idle x.........................................	78
Emptying the carburetor float chamber x.......................	79
Checking engine oil level................................................	79
Changing engine oil and oil filter, cleaning engine oil
screen x.....................................................................	80
Draining engine oil, cleaning engine oil screen x............	80
Removing the oil filter x...............................................	80
Mounting oil filter x.....................................................	81
Filling up with engine oil x...........................................	81
Topping up engine oil ....................................................	82
Checking gear oil level ...................................................	82
Changing gear oil, cleaning gear oil screen x..................	82
Draining gear oil, cleaning gear oil screen x...................	82
Filling up with gear oil x..............................................	83
Adding gear oil x.........................................................	83
TROUBLESHOOTING.........................................................	85
CLEANING........................................................................	87
Cleaning motorcycle ......................................................	87
STORAGE .........................................................................	88
Storage.........................................................................	88
Putting into operation after storage .................................	88
TECHNICAL DATA - ENGINE..............................................	89
Capacityengine oil .......................................................	89
Capacity - gear oil..........................................................	90
Capacity - coolant..........................................................	90
TECHNICAL DATA - ENGINE TIGHTENING TORQUES..........	91
TECHNICAL DATA - CARBURETOR.....................................	93
400 EXC.......................................................................	93
400 XC-W USA .............................................................	93
450 EXC, 450 EXC SIX DAYS.........................................	93
450 XC-W.....................................................................	94
530 EXC, 530 EXC SIX DAYS.........................................	94
530 XC W.....................................................................	94
TECHNICAL DATA - CHASSIS ............................................	95
Lighting equipment .......................................................	95
Tires ............................................................................	96
Capacity - fuel...............................................................	96
TECHNICAL DATA - FORK..................................................	97
TECHNICAL DATA - SHOCK ABSORBER .............................	98
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ........	99
WIRING DIAGRAM ..........................................................	100
Wiring diagram (all EXC models) ...................................	100
Wiring diagram (all XC W models) .................................	104
SUBSTANCES.................................................................	106
AUXILIARY SUBSTANCES................................................	107
STANDARDS...................................................................	109
INDEX ............................................................................	110

MEANS OF REPRESENTATION

Symbols used

The symbols used are explained in the following.

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

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

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

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

Formats used

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

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

IMPORTANT NOTES

Use definition (all EXC models)

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

Info

The motorcycle is authorized for public road traffic in the homologous (reduced) version only.

In the derestricted version, the motorcycle must be used only on 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 (all XC W models)

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 service schedule 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 work prescribed in the service schedule 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/or alterations 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 are 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.

The current KTM PowerParts for your vehicle can be found on the KTM website.

International KTM Website: http://www.ktm.com

Work rules

When the vehicle is assembled, non-reusable parts (e.g., self-locking screws and nuts, gaskets, seal rings, O-rings, splints, lock washers) must be replaced with new parts.

Where thread lockers are used on screw connections (e.g., Loctite®), follow the instructions for use from the manufacturer. After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or worn parts. After you complete the repair or maintenance work, check the roadworthiness of the vehicle.

Transport

Note

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

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

Note

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

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

–switch off engine.

IMPORTANT NOTES

–Turn handle of the fuel tap to the OFF position. (Figure 500137-10 p. 20)

–Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

Environment

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.

Notes/warnings

Be sure to pay attention to the notes and warnings given here.

Info

Various notes and warning stickers are attached to the vehicle. Do not remove any notes and warning stickers. 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

–It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful information and many tips on how to operate and handle your motorcycle. Only then will you find out how to best customize the motorcycle for your own use and how you can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.

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

VIEW OF VEHICLE

3View.1 of the vehicle from the left front (example)

800014-10

1Side stand

2Shift lever

3Chain guide

4Fuel tap

5Air filter box lid

6Clutch lever

7Hand brake lever

VIEW OF VEHICLE

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

800013-10

1Level viewer for brake fluid, rear

2Fork compression adjustment

3Foot brake pedal

4Kickstarter

5Horn

6Filler cap

7Fork rebound adjustment

8Electric starter button

9Speedometer

10Short circuit button

11Shock absorber compression adjustment

12Shock absorber rebound adjustment

LOCATION OF SERIAL NUMBERS

4Chassis.1 number

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

500127-10

Type4.2 label

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

500128-10

Key4.3 number (all EXC models)

The key number is stamped on the key strap.

500125-10

Engine4.4 number

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

500072-10

Fork4.5 part number

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

500082-10

LOCATION OF SERIAL NUMBERS

Shock4.6 absorber part number

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

500129-10

OPERATING ELEMENTS

5Clutch.1 lever

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

The clutch is hydraulically operated and self-adjusting.

500133-10

Hand5.2 brake lever

Hand brake lever is located on the right side of the handlebar.

The hand brake lever is used to activate the front brake.

400196-10

Short5.3 circuit button (all XC W models)

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

Possible states

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

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

500132-10

Short5.4 circuit button (all EXC models)

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

Possible states

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

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

500134-10

Emergency5.5 OFF switch (EXC AUS)

The emergency OFF switch is fitted on the 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.

500131-10

OPERATING ELEMENTS

Electric5.6 starter button (EXC EU, EXC SIX DAYS, XC-W)

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

Possible states

•Electric starter button in basic position

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

400198-10

Electric5.7 starter button (EXC AUS)

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

Possible states

•Electric starter button in basic position

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

500131-11

Light5.8 switch (all EXC models)

The light switch is fitted on the left side of the handlebar.

Possible states

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

Low beam on – Light switch is in the central position. In this position,

the low beam and tail light are switched on.

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

500134-12

Light5.9 switch (all XC W models)

500146-10

The light switch is on the right of the speedometer.

Possible states (XC W ZA)

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

•Light on – Light switch is pulled out to the stop. In this position, the low beam and the tail light are switched on.

(XC W USA)

•The light switch has no function when delivered. – It can be used if lighting is fitted later.

Horn5.10 button (all EXC models)

The horn button is fitted on the left side of the handlebar.

Possible states

•Horn button in neutral position

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

500134-11

OPERATING ELEMENTS

Flasher5.11 switch (all EXC models)

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

Possible states

Flasher light off – Flasher switch is in the central position.

Flasher light, left, on – Flasher switch turned to the left.

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

500145-10

Overview5.12 of indicator lamps (all EXC models)

Possible states

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

Flasher indicator lamp flashes green – Flasher light is switched on.

500147-01

Speedometer5.13

400312-01

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

–Press the button to control different functions.

Info

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

Speedometer5.14 activation and test

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.

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

OPERATING ELEMENTS

Tripmaster5.15 switch

(Option: Tripmaster switch)

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

Info

The trip master is an optional accessory.

Setting5.16 kilometers or miles

Info

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

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

400329-01

Setting5.17 the clock

400330-01

Condition

The motorcycle is standing.

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

–Press the button for 3 - 5 seconds.

The Setup menu opens and the active functions are displayed.

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

Km/hadjusting

–Press the button .

Mphadjusting

– Press the button .

–Press the button for 3 - 5 seconds.

The settings are saved and the Setup menu closed.

Info

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

Condition

The motorcycle is standing.

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

–Press the button for 3 - 5 seconds.

The hour display flashes.

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

–Press the button briefly.

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

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

Info

The seconds can only be set to zero.

–Press the button for 3 - 5 seconds.

The settings are saved and the Setup menu closed.

Info

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

OPERATING ELEMENTS

Adjusting5.18 the speedometer functions

Info

Upon delivery, only the SPEED/H and SPEED/ODO display modes are activated.

Condition

The motorcycle is standing.

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

–Press the button for 3 - 5 seconds.

The Setup menu opens and the active functions are displayed.

– Switch to the function you require by briefly pressing the button .

The selected function flashes.

Activating a function

–Press the button .

400318-01	The icon remains in the display and the display changes to the next func-


	tion.

Deactivating a function

–Press the button .

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

–Activate or deactivate all functions accordingly.

–Press the button for 3 - 5 seconds.

The settings are saved and the Setup menu closed.

Info

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

Querying5.19 the lap time

Info

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

Condition

The motorcycle is standing.

–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.

OPERATING ELEMENTS

SPEED5.20 display mode (speed)

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

The current speed is displayed in the SPEED display mode.

The current speed can be displayed in Km/h or Mph.

Info

Making the setting according to the country.

When an impulse comes from the front wheel, the left side of the speedometer

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

400317-02

SPEED/H5.21 display mode (service hours)

400316-01

Condition

•Vehicle at a standstill

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

The number of service hours of the engine is shown in the H display mode. 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 the H display mode at the start of the trip, it automatically changes to the ODO display mode.

The H display mode is suppressed during travel.

Press the button .	No function
Press the button .	No function
Press the button	The display changes to the Setup menu of the speedometer
for 3 - 5 seconds.	functions.
Press the button	next display mode
briefly.

SPEED/CLK5.22 display mode (time)

400319-01

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

The time is displayed in the CLK display mode.

Press the button .	No function
Press the button .	No function
Press the button	The display changes to the Setup menu of the clock.
for 3 - 5 seconds.
Press the button	next display mode
briefly.

SPEED/LAP5.23 display mode (lap time)

400320-01

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

In the LAP display mode, up to ten laps 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 .

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.

OPERATING ELEMENTS

SPEED/ODO5.24 display mode (odometer)

400317-01

Press the button next display mode briefly.

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

The total number of kilometers ridden is shown in the ODO display mode.

Press the button .	No function
Press the button .	No function
Press the button	–
for 3 - 5 seconds.
Press the button	next display mode
briefly.

SPEED/TR15.25 display mode (trip master 1)

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

TR1 (trip master 1) runs constantly and counts to 999.9.

You can use it to measure trips or the distance between refueling stops.

TR1 is coupled with A1 (average speed 1) and S1 (stop watch 1).

Info

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

0.0.

400323-01

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.

SPEED/TR25.26 display mode (trip master 2)

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

TR2 (trip master 2) runs constantly and counts to 999.9.

The displayed value can be set manually with the button and the button . A very practical function for rides by the road book.

		Info


		The TR2 value can also be corrected manually during the trip using the but-
400324-01		ton and the button .
400324-01		If 999.9 is exceeded, TR2 is automatically reset to 0.0.

	Press the button .		Increases value TR2.
	Press the button .		Decreases value TR2.
	Press the button		Clears value TR2.
	for 3 - 5 seconds.
	Press the button		next display mode
	briefly.

OPERATING ELEMENTS

SPEED/A15.27 display mode (average speed 1)

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

A1 (average speed 1) shows the average speed calculated on the basis of TR1 (trip master 1) and S1 (stop watch 1).

The calculation of this value is activated by the first impulse of the wheel speed sensor and ends 3 seconds after the last impulse.

	Press the button .	No function
	Press the button .	No function
	Press the button .	No function
400325-01	Press the button	The TR1, A1 and S1 displays are reset to 0.0.
400325-01	for 3 - 5 seconds.


	Press the button	next display mode
	briefly.

SPEED/A25.28 display mode (average speed 2)

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

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

Info

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

400326-01	Press the button .	No function
	Press the button .	No function
	Press the button .	No function
	Press the button	–
	for 3 - 5 seconds.
	Press the button	next display mode
	briefly.

SPEED/S15.29 display mode (stop watch 1)

400327-01

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

S1 (stop watch 1) shows the trip time on the basis of TR1 and continues running 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 three seconds after the last impulse.

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.

SPEED/S25.30 display mode (stop watch 2)

400328-01

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

S2 (stop watch 2) is a manual stop watch.

If S2 is running in the background, the S2 display flashes in the speedometer display.

Press the button .	Starts or stops S2.
Press the button .	No function
Press the button	The S2 and A2 displays are reset to 0.0.
for 3 - 5 seconds.
Press the button	next display mode
briefly.

OPERATING ELEMENTS					19

Table of functions

Display	Press the button .	Press the button .	Press the button for 3 -		Press the button
			5 seconds.		briefly.

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

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

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

SPEED/ODO display mode	No function	No function	–		next display mode
(odometer)

SPEED/TR1 display mode	No function	No function	The TR1, A1 and S1 dis-		next display mode
(trip master 1)			plays are reset to 0.0.

SPEED/TR2 display mode	Increases value TR2.	Decreases value TR2.	Clears value TR2.		next display mode
(trip master 2)

SPEED/A1 display mode	No function	No function	The TR1, A1 and S1 dis-		next display mode
(average speed 1)			plays are reset to 0.0.

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

SPEED/S1 display mode	No function	No function	The TR1, A1 and S1 dis-		next display mode
(stop watch 1)			plays are reset to 0.0.

SPEED/S2 display mode	Starts or stops S2.	No function	The S2 and A2 displays		next display mode
(stop watch 2)			are reset to 0.0.


Table of conditions and activability

Display				Vehicle at a stand-		Menu can be acti-
				still		vated

SPEED/H display mode (service hours)				•

SPEED/CLK display mode (time)						•

SPEED/LAP display mode (lap time)						•

SPEED/TR1 display mode (trip master 1)						•

SPEED/TR2 display mode (trip master 2)						•

SPEED/A1 display mode (average speed 1)						•

SPEED/A2 display mode (average speed 2)						•

SPEED/S1 display mode (stop watch 1)						•

SPEED/S2 display mode (stop watch 2)						•

OPERATING ELEMENTS

Fuel5.31 tap

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

With the 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 can flow from the tank to the carburetor.

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

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

500137-10

Opening5.32 filler cap

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

400199-10

Closing5.33 filler cap

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

Info

Run the fuel tank breather hose without kinks.

400199-11

Choke5.34 (EXC AUS, XC W)

500135-10

Choke is fitted on the left side of the carburetor.

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

Info

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

Possible states

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

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

OPERATING ELEMENTS

Choke5.35 (EXC EU, EXC SIX DAYS)

500136-10

The flasher switch 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 – The choke lever is pulled to the stop.

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

Shift5.36 lever

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

500138-10

The gear positions can be seen in the photograph.

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

500138-11

Foot5.37 brake pedal

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

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

500139-10

Kickstarter5.38

Kickstarter 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 inward toward the engine.

500148-10

OPERATING ELEMENTS

Side5.39 stand

500140-10

500141-10

Note

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

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

Note

Material damage Damage and destruction of components by excessive load.

–The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over.

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

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

Steering5.40 lock (all EXC models)

500126-10

Steering lock is fitted on the left side of the steering head.

The steering lock is used to lock the steering. Steering, and therefore riding, is no longer possible.

Locking5.41 the steering (all EXC models)

Note

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

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

–Park the motorcycle.

–Turn the handlebar as far as possible to the right.

–Insert the key in the steering lock, turn it to the left, press it in and turn it to the right. Remove the key.

Steering is no longer possible.

Info

Never leave the key in the steering lock.

OPERATING ELEMENTS

Unlocking5.42 the steering (all EXC models)

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

You can now steer the bike again.

Info

Never leave the key in the steering lock.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION

6Advice.1 on first use

Danger

Danger of accidents Danger from insufficient traffic competence.

–Do not use the vehicle if you are not fit to deal with traffic or if you have consumed alcohol and/or medicaments or drugs.

Warning

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

–Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing, which must be in perfect condition and meet legal requirements.

Warning

Danger of crashing Impairment of riding behavior 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 Brake system failure.

–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 accidents Unstable riding behavior.

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

Warning

Risk of misappropriation Usage by unauthorized persons.

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

Info

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

–Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover.

–Before your first trip, read the entire operating instructions carefully.

–Get to know the controls.

–Adjust the basic position of clutch lever. ( p. 76)

(all XC W models)

–adjust the basic position of handbrake lever. ( p. 56)

(all EXC models)

– Adjust the free travel of the handbrake lever. ( p. 57)

–Adjust the basic position of the footbrake lever. x( p. 60)

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

Info

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

–Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.

–Do not make any offroad trips that over-stress your ability and experience.

–Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION

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

Info

Motorcycles react sensitively to any changes of weight distribution.

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

Maximum permissible overall weight	335 kg (739 lb.)

Maximum permissible front axle load	145 kg (320 lb.)

Maximum permissible rear axle load	190 kg (419 lb.)

– Run the engine in.

Running6.2 in the engine

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

Maximum engine speed

During the first 3 service hours	7,000 rpm

Maximum engine performance during the running-in period

During the first 3 service hours	≤ 50 %

During the next 12 service hours	≤ 75 %

– Avoid fully opening the throttle!

RIDING INSTRUCTIONS

7Checks.1 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.

–Check the engine oil level. ( p. 79)

–Check the chain tension. ( p. 52)

–Check for chain dirt accumulation. ( p. 51)

–Check the tire condition. ( p. 66)

–Check the tire air pressure. ( p. 67)

–Check the front brake fluid level. ( p. 57)

–Check the rear brake fluid level. ( p. 61)

–Check the front brake linings. ( p. 58)

–Check the rear brake linings. ( p. 62)

–Check brake system function.

–Check the coolant level. ( p. 72)

–Check that all operating elements are correctly adjusted and free to move.

–Check the functioning of the electrical equipment.

Starting7.2

Danger

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

–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 failure High engine speeds in cold engines have a negative effect on the service life of the engine.

–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.

Motorcycle has been out of use for more than 1 week

– Empty the carburetor float chamber. x( p. 79)

–Turn handle of the fuel tap to the ON position. (Figure 500137-10 p. 20)

Fuel can flow from the fuel tank to the carburetor.

–Remove the motorcycle from the stand.

–Shift gear to neutral.

(EXC AUS)

–Turn the emergency OFF switch to the position .

Engine cold

(EXC AUS, XC W)

–Pull the choke lever out as far as possible.

(EXC EU, EXC SIX DAYS)

–Pull the choke lever to the stop.

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

Info

Don't open the throttle.

RIDING INSTRUCTIONS

Starting7.3 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.

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

Shifting,7.4 riding

Warning

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

–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.

–When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.

–If the choke function was activated, deactivate it after the engine has warmed up.

–When you reach maximum speed after fully opening the throttle, turn back the throttle to about ¾ of its range; the speed hardly drops, but the fuel consumption falls considerably.

–Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel consumption.

–To shift down, brake and close the throttle at the same time.

–Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again.

–Switch off the engine if you expect to be standing for a long time. Guideline

≥2 min

–Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and the cooling system.

–Ride with a lower engine speed instead of with a high engine speed and a slipping clutch.

Braking7.5

Warning

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

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

Warning

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

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

Warning

Danger of accidents Reduced braking due to wet or dirty brakes.

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

–On sandy, wet or slippery surfaces, use the rear brake.

–Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.

–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,7.6 parking

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.

Warning

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

–Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these components to cool down before starting work on them.

Note

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

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

Note

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

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

Note

Material damage Damage and destruction of components by excessive load.

–Brake the motorcycle.

–Shift gear to neutral.

(all XC W models)

–Press and hold the short circuit button while the engine is idling until the engine stops.

(all EXC models)

– Press and hold the short circuit button while the engine is idling until the engine stops.

–Turn handle of the fuel tap to the OFF position. (Figure 500137-10 p. 20)

–Park the motorcycle on firm ground.

Refueling7.7

Danger

Fire hazard Fuel can easily catch fire.

–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.

–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 poisoning Fuel is poisonous and a health hazard.

–Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately 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 hazard Improper handling of fuel is a danger to the environment.

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

–Switch off the engine.

–Open the filler cap. ( p. 20)

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