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

© 2008 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.

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

KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

CONTENTS 2

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 3

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

Capacity- engine 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 4

1MEANSOFREPRESENTATION

Symbols used

The symbols used are explained in the following.

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

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

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

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

Formats used

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

Specific name Identifies a specific name.

®

Name

Brand™ Identifies a brand in merchandise traffic.

Identifies a protected name.

IMPORTANT NOTES 5

2IMPORTANTNOTES

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)

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

Info

The motorcycle must be used only on secluded property remote from public road traffic.
The motorcycle is designed for off-road sport endurance competition (Enduro) and not for the predominant motocross use.

Maintenance

A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described
in the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and break­age of components.
Using the motorcycle in extreme conditions such as very muddy or wet terrain can lead to above-average wear of components such as
the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in
the 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 6

– 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 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.

VIEW OF VEHICLE 7

3VIEWOFVEHICLE

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 Hand brake lever

800014-10

VIEW OF VEHICLE 8

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 Filler cap
7 Fork rebound adjustment
8 Electric starter button
9 Speedometer
10 Short circuit button
11 Shock absorber compression adjustment
12 Shock absorber rebound adjustment

800013-10

LOCATION OF SERIAL NUMBERS 9

4LOCATIONOFSERIALNUMBERS

4.1Chassis number

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

500127-10

4.2Type label

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

4.3Key number (all EXC models)

4.4Engine number

500128-10

The key number  is stamped on the key strap.

500125-10

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

4.5Fork part number

500072-10

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

500082-10

LOCATION OF SERIAL NUMBERS 10

4.6Shock absorber part number

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

500129-10

OPERATING ELEMENTS 11

5OPERATINGELEMENTS

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.

400196-10

5.3Short circuit button (all XC‑W models)

500132-10

5.4Short 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.

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

5.5Emergency OFF switch (EXC AUS)

500131-10

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.

OPERATING ELEMENTS 12

5.6Electric 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

5.7Electric 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

5.8Light switch (all EXC models)

500134-12

5.9Light switch (all XC‑W models)

500146-10

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.

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.

5.10Horn 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 13

5.11Flasher 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

5.12Overview 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

5.13Speedometer

400312-01

5.14Speedometer activation and test

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

Info

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

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

400314-01

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.

OPERATING ELEMENTS 14

5.15Tripmaster 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.

5.16Setting 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.

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

400329-01

– Press the button .

– Press the button for 3 - 5 seconds.

The settings are saved and the Setup menu closed.

5.17Setting the clock

400330-01

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 15

5.18Adjusting 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

Deactivating a function

– Press the button .

– Activate or deactivate all functions accordingly.
– Press the button for 3 - 5 seconds.

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

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

The settings are saved and the Setup menu closed.

5.19Querying 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.

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

400321-01

Info

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

LAP 1 appears on the left side of the display.

Next display mode

Info

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

OPERATING ELEMENTS 16

5.20SPEED 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

400317-02

5.21SPEED/H display mode (service hours)

400316-01

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

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.

5.22SPEED/CLK display mode (time)

400319-01

5.23SPEED/LAP display mode (lap time)

Press the button . No function
Press the button . No function
Press the button
for 3 - 5 seconds.
Press the button

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

briefly.

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

the display.

The time is displayed in 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.

– 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.

400320-01

Info

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

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

starts the next lap.
Press the button
for 3 - 5 seconds.

The stop watch and the lap time are reset.

OPERATING ELEMENTS 17

5.24SPEED/ODO display mode (odometer)

400317-01

5.25SPEED/TR1 display mode (trip master 1)

400323-01

Press the button

next display mode
briefly.

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

the display.

The total 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.

– 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.

5.26SPEED/TR2 display mode (trip master 2)

400324-01

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.

– 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 but­ton and the button .
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
for 3 - 5 seconds.
Press the button
briefly.

Clears value TR2.

next display mode

OPERATING ELEMENTS 18

5.27SPEED/A1 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

400325-01

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

5.28SPEED/A2 display mode (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.

display.

Info

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

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

next display mode

400326-01

5.29SPEED/S1 display mode (stop watch 1)

400327-01

5.30SPEED/S2 display mode (stop watch 2)

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

–

for 3 - 5 seconds.
Press the button

next display mode
briefly.

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

display.

S1 (stop watch 1) 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.

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

display.

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

400328-01

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

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 -

5 seconds.

SPEED/H display mode

(service hours)

SPEED/CLK display mode
(time)

SPEED/LAP display mode
(lap time)

SPEED/ODO display mode
(odometer)

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)

No function No function The display changes to

the Setup menu of the
speedometer functions.

No function No function The display changes to

the Setup menu of the
clock.

Starts or stops the
clock.

No function No function – next display mode

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

Increases value TR2. Decreases value TR2. Clears value TR2. next display mode

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

No function No function – next display mode

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

Starts or stops S2. No function The S2 and A2 displays

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

The stop watch and the
lap time are reset.

plays are reset to 0.0.

plays are reset to 0.0.

plays are reset to 0.0.

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 activability
Display Vehicle at a stand-

still

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) •

Menu can be acti­vated

OPERATING ELEMENTS 20

5.31Fuel 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

5.32Opening filler cap

5.33Closing filler cap

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

400199-10

– 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

5.34Choke (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 21

5.35Choke (EXC EU, EXC SIX DAYS)

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

500136-10

5.36Shift lever

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

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

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

5.37Foot brake pedal

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

500139-10

5.38Kickstarter

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 22

5.39Side stand

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

500140-10

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

To park the motorcycle, press the side 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 .

500141-10

5.40Steering lock (all EXC models)

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

5.41Locking 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 23

5.42Unlocking 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 24

6GENERALTIPSANDHINTS ONP UTTINGINTO OPERATION

6.1Advice 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 25

– If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis-

tribution between the front and rear wheels.

Info

Motorcycles react sensitively to any changes of weight distribution.

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

Guideline

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

– Run the engine in.

6.2Running in the engine

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

Guideline

Maximum engine speed

During the first 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 26

7RIDINGINSTRUCTIONS

7.1Checks 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.

7.2Starting

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 27

7.3Starting 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.

7.4Shifting, 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 simulta-

neously 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.

7.5Braking

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 28

7.6Stopping, 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 compo-

nents 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.

– 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.

– 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.

7.7Refueling

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 imme-

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

Warning

Environmental 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)

AA

RIDING INSTRUCTIONS 29

– Fill the fuel tank with fuel up to measurement .

Guideline

Measurement of  35 mm (1.38 in)

400382-10

Total fuel tank
capacity,
approx. (EXC,
EXC SIX DAYS,
XC‑W ZA)

Total fuel tank
capacity, approx.
(XC‑W USA)

– Close the filler cap. ( p. 20)

9.0 l
(2.38 US gal)

9.2 l
(2.43 US gal)

Super unleaded (ROZ 95 / RON 95 /
PON 91) ( p. 106)

Super unleaded (ROZ 95 / RON 95 /
PON 91) ( p. 106)

SERVICE SCHEDULE 30

8SERVICESCHEDULE

8.1Important maintenance work to be carried out by an authorized KTM workshop.

S3N S15A S30A

Engine

Change the engine oil and oil filter and clean the engine oil screen. x ( p. 80)
Change the gear oil and clean the gear oil screen. x ( p. 82)

Replace spark plug. •

Check the valve clearance. x

Check engine mounting screws for tightness. • • •
Clean spark plug connectors and check for tightness. • • •
Check that the screws in the shift lever and the kickstarter are tight. • • •

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

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

Attachments Check the cooling system for leakage. • • •

Check the antifreeze and coolant level. ( p. 72) • • •
Check the exhaust system for leakage and looseness. • •
Check Bowden cables for damage, smooth operation and routing without sharp

bends.
Check the fluid level of the hydraulic clutch. ( p. 76) • • •

Clean the air filter. x ( p. 75)

Check cables for damage and routing without sharp bends. • •
Check that the electrical equipment is functioning properly. • • •
Check the headlamp setting. • •

Brakes Check the front brake linings. ( p. 58) • • •

Check the rear brake linings. ( p. 62) • • •
Check the brake discs. ( p. 55) • • •
Check the front brake fluid level. ( p. 57) • • •
Check the rear brake fluid level. ( p. 61) • • •
Check brake lines for damage and leakage. • • •
Check the free travel of the hand brake lever. ( p. 56) • • •
Check the free travel of the foot brake lever. ( p. 60) • • •
Check brake system function. • • •
Check screws and guide bolts of brake system for tightness. • • •

Chassis

Check shock absorber and fork for leakage and functioning. x

Clean dust boots of fork legs. ( p. 39) • •
Bleed fork legs. ( p. 39) • •

Check the swingarm bearing. x

Check play of steering head bearing. ( p. 40) • • •
Check all screws to see if they are tight. • • •

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

Check rim run-out. • • •
Check the tire condition. ( p. 66) • • •
Check the tire air pressure. ( p. 67) • • •
Check the chain wear. ( p. 53) • • •
Check the chain tension. ( p. 52) • • •
Clean the chain. ( p. 51) • • •

Check the wheel bearing for play. x

Clean and grease adjusting screws of chain adjuster. • • •

• • •

• • •

• • •

• • •

• • •

• • •

• •

• • •

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

SERVICE SCHEDULE 31

8.2Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)

Competition use Hobby use J1A J2A

S15A S30A S45A S30A S60A S90A

Carry out a complete fork service. x
Carry out a complete shock absorber service. x
Grease the steering head bearing. x ( p. 46)

Treat electric contacts with contact spray. • •

Change the hydraulic clutch fluid. x ( p. 76)
Change the front brake fluid. x
Change the rear brake fluid. x
Clean the spark arrestor. x (XC‑W USA)
Check wear of clutch discs. x
Check the clutch. x
Check/measure the cylinder. x
Change the piston. x
Check the camshaft. x
Change the camshaft bearing. x
Check the valve spring seat. x
Check the cylinder head. x
Check the valves. x
Check the valve springs. x
Check the radial clearance of the rocker arm rollers. x
Check the timing-chain tensioner function. x
Check the balancer shaft. x
Check the crankshaft run-out at the bearing pin. x
Change the conrod bearing. x
Change the crankshaft main bearing. x
Check the transmission. x
Check the shift mechanism. x

Check the spring length of the oil pressure regulator

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

• • • • • •

• •

• •

• •

• •

• •

• •

• •

• •

• •

• •

• •

• •

• •

• •

• •

• •

• •

• •

• •

• •

• • • •

• •

•

• •

• •

• •

• •

• •

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

8.3Important checks and maintenance work to be carried out by the rider.

Check the engine oil level. ( p. 79) •
Check the front brake fluid level. ( p. 57) •
Check the rear brake fluid level. ( p. 61) •
Check the front brake linings. ( p. 58) •
Check the rear brake linings. ( p. 62) •
Check and adjust Bowden cables. •
Bleed fork legs. ( p. 39) •
Clean dust boots of fork legs. ( p. 39) •

NB1A

SERVICE SCHEDULE 32

NB1A

Clean the chain. ( p. 51) •
Check the chain tension. ( p. 52) •
Check the chain wear. ( p. 53) •
Check the rear sprocket / engine sprocket for wear. ( p. 52) •

Clean the air filter. x ( p. 75)

Check the tire air pressure. ( p. 67) •
Check the tire condition. ( p. 66) •
Check the coolant level. ( p. 72) •

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

Check that all operating elements for smooth operation. •
Check braking. •
Check all screws, nuts and hose clamps regularly for tightness. •

NB1A: Depending on conditions of use according to requirements.

•

•

MAINTENANCE WORK ON CHASSIS AND ENGINE 33

9MAINTENANCEWORKONCHAS SISAND ENGINE

9.1Jacking up the motorcycle

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.

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

the ground.

Work stand (54829055000)

500074-01

9.2Removing the motorcycle from the work stand

– Secure the motorcycle against falling over.

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.

– Remove the motorcycle from the work stand.
– Remove the work stand.

9.3Checking the basic chassis setting with the rider's weight

Info

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

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

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

Guideline

Standard rider weight 75… 85 kg (165… 187 lb.)

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

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

springs must be replaced.

9.4Compression damping of shock absorber

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

9.5Adjusting high-speed compression damping of the shock absorber

Danger

Danger of accidents The shock absorber is under high pressure.

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

tenance on it yourself.

Info

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

MAINTENANCE WORK ON CHASSIS AND ENGINE 34

– Turn the adjusting screw  clockwise with a ring wrench until it stops.

Info

Do not loosen nut !

– Turn back counterclockwise the number of turns corresponding to the shock

absorber type.
Guideline

Compression damping, high-speed

400208-10

9.6Adjusting the low-speed compression damping of the shock absorber

Danger

Danger of accidents The shock absorber is under high pressure.

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

tenance on it yourself.

Comfort 2 turns
Standard 1.5 turns
Sport 1 turn

Info

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

Info

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

– Turn the adjusting screw  clockwise with a screwdriver until it stops.

Info

Do not loosen nut !

– Turn back counterclockwise the number of clicks corresponding to the shock

absorber type.
Guideline

Compression damping, low-speed

400209-10

Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks

Info

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

9.7Adjusting rebound damping of the shock absorber

Danger

Danger of accidents The shock absorber is under high pressure.

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

tenance on it yourself.

00AA

000BB

0

0

AA

MAINTENANCE WORK ON CHASSIS AND ENGINE 35

– Turn the adjusting screw  clockwise until it stops.

Info

Do not loosen nut !

– Turn back counterclockwise the number of clicks corresponding to the shock

absorber type.
Guideline

Rebound damping

400210-10

9.8Measuring rear wheel sag unloaded

– Jack up the motorcycle. ( p. 33)
– Measure the distance – as vertical as possible – between the rear axle and a fixed

– Make a note of the value as measurement .
– Remove the motorcycle from the work stand. ( p. 33)

Comfort 26 clicks
Standard 24 clicks
Sport 22 clicks

Info

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

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

400220-10

9.9Checking static sag of the shock absorber

– Measure distance  of rear wheel unloaded. ( p. 35)
– Ask someone to help you by holding the motorcycle upright.
– Measure the distance between the rear axle and the fixed point again.
– Make a note of the value as measurement .

– Check the static sag.

400221-10

Info

The static sag is the difference between measurements  and .

Static sag 35 mm (1.38 in)

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

–

Adjust the spring preload of the shock absorber. x ( p. 36)

CC

0

0

AA

AA

22
11

MAINTENANCE WORK ON CHASSIS AND ENGINE 36

9.10Checking the riding sag of the shock absorber

– Measure distance  of rear wheel unloaded. ( p. 35)
– With another person holding the motorcycle, sit on the saddle with full protective

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

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

fixed point.

– Make a note of the value as measurement .

Info

The riding sag is the difference between measurements  and .

– Check the riding sag.

Riding sag 105 mm (4.13 in)

» If the riding sag differs from the specified measurement:

–

Adjust the riding sag. x ( p. 37)

400222-10

9.11Adjusting spring preload of the shock absorber x

Danger

Danger of accidents The shock absorber is under high pressure.

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

tenance on it yourself.

Info

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

–

Remove shock absorber. x ( p. 37)

– After removing the shock absorber, clean it thoroughly.
– Loosen screw .
– Turn adjusting ring  until the spring is no longer under tension.

Combination wrench (50329080000)
Hook wrench (T106S)

– Measure the overall spring length when not under tension.
– Tighten the spring by turning adjusting ring  to measurement .

Guideline

Spring preload 9 mm (0.35 in)

Info

– Tighten screw .

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

Guideline

Screw, shock absorber adjusting ring M6 5 Nm (3.7 lbf ft)

400216-10

–

Install the shock absorber. x ( p. 37)

MAINTENANCE WORK ON CHASSIS AND ENGINE 37

9.12Adjusting riding sag x

–

Remove shock absorber. x ( p. 37)

– After removing the shock absorber, clean it thoroughly.
– Choose and mount a suitable spring.

Guideline

Spring rate

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

Info

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

–

Install the shock absorber. x ( p. 37)

– Check the static sag of the shock absorber. ( p. 35)
– Check the riding sag of the shock absorber. ( p. 36)
– Adjust the rebound damping of the shock absorber. ( p. 34)

9.13Removing the shock absorber x

– Jack up the motorcycle. ( p. 33)
– Remove screw  and lower the rear wheel with the swing arm as far as possible

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

– Remove screw , push splash protector  to the side, and remove the shock

absorber.

800023-10

9.14Installing the shock absorber x

800023-11

– Push splash protector  to the side and position the shock absorber. Mount and

tighten screw .
Guideline

Screw, top shock absorber M12 80 Nm

Loctite®243™

(59 lbf ft)

– Mount and tighten screw .

Guideline

Screw, bottom shock
absorber

M12 80 Nm

(59 lbf ft)

Loctite®243™

Info

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

– Remove the motorcycle from the work stand. ( p. 33)

MAINTENANCE WORK ON CHASSIS AND ENGINE 38

9.15Checking basic setting of fork

Info

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

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

spring preload.

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

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

400189-01

9.16Adjusting compression damping of fork

Info

The hydraulic compression damping determines the fork suspension behavior.

– Remove protection covers .
– Turn adjusting screws  clockwise until they stop.

Info

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

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

Guideline

100020-10

Compression damping

Comfort 26 clicks
Standard 22 clicks
Sport 20 clicks

Info

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

– Mount protection covers .

9.17Adjusting rebound damping of fork

Info

The hydraulic rebound damping determines the fork suspension behavior.

– Turn adjusting screws  clockwise until they stop.

800017-10

Info

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

MAINTENANCE WORK ON CHASSIS AND ENGINE 39

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

Guideline

Rebound damping

Comfort 24 clicks
Standard 22 clicks
Sport 22 clicks

Info

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

9.18Adjusting spring preload of the fork

– Turn adjusting screws counterclockwise until they stop.

Info

Make the same adjustment on both fork legs.

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

Guideline

Spring preload - Preload Adjuster

800015-10

Comfort 2 turns
Standard 2 turns
Sport 4 turns

9.19Bleeding fork legs

100021-10

9.20Cleaning dust boots of fork legs

Info

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

– Jack up the motorcycle. ( p. 33)
– Remove bleeder screws  briefly.

Any excess pressure escapes from the interior of the fork.

– Mount and tighten bleeder screws.
– Remove the motorcycle from the work stand. ( p. 33)

– Jack up the motorcycle. ( p. 33)
– Loosen the fork protection. ( p. 40)
– Push dust boots  of both fork legs downwards.

500088-10

Info

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

MAINTENANCE WORK ON CHASSIS AND ENGINE 40

Warning

Danger of accidents Reduced braking due to oil or grease on the brake

discs.

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

brake cleaner when necessary.

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

Universal oil spray ( p. 108)

– Press the dust boots back into their normal position.
– Remove excess oil.
– Position the fork protection. ( p. 40)
– Remove the motorcycle from the work stand. ( p. 33)

9.21Loosening the fork protection

– Remove screws  and take off clamp.
– Remove screws  on left fork leg. Push the fork protection downwards.
– Remove the screws on the right fork leg. Push the fork protection downwards.

500087-11

9.22Positioning the fork protection

– Position the fork protection on the left fork leg. Mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

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

screws .

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

Guideline

500087-10

9.23Checking play of steering head bearing

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

Warning

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

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

Info

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

400387-10

– Jack up the motorcycle. ( p. 33)
– Move the handlebar to the straight-ahead position. Move the fork legs to and fro in

the direction of travel.

No play should be noticeable in the steering head bearing.

» If there is noticeable play present:

(EXC SIX DAYS, XC‑W USA)

–

Adjust play of the steering head bearing. x ( p. 41)

(EXC EU, EXC AUS, XC‑W ZA)

–

Adjust play of the steering head bearing. x ( p. 41)

MAINTENANCE WORK ON CHASSIS AND ENGINE 41

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

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

» If click positions are noticeable:

(EXC SIX DAYS, XC‑W USA)

–

Adjust play of the steering head bearing. x ( p. 41)

(EXC EU, EXC AUS, XC‑W ZA)

–

Adjust play of the steering head bearing. x ( p. 41)

– Check the steering head bearing and replace if required.

– Remove the motorcycle from the work stand. ( p. 33)

9.24Adjusting play of steering head bearing x (EXC EU, EXC AUS, XC‑W ZA)

– Jack up the motorcycle. ( p. 33)
– Loosen screws  and .
– Loosen and retighten screw .

Guideline

Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft)

– Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
– Fully tighten screw .

Guideline

800016-10

Screw, top triple clamp M8 20 Nm

(14.8 lbf ft)

– Tighten screw .

Guideline

Screw, top steering stem M8 20 Nm

– Check play of steering head bearing. ( p. 40)

9.25Adjusting play of steering head bearing x (EXC SIX DAYS, XC‑W USA)

– Jack up the motorcycle. ( p. 33)
– Loosen screw . Remove screw .
– Loosen and retighten screw .

Guideline

Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft)

– Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
– Fully tighten screw .

Guideline

800022-10

Screw, top triple clamp M8 17 Nm

– Mount and tighten screw .

Guideline

Screw, top steering stem M8 17 Nm

(14.8 lbf ft)

(12.5 lbf ft)

Loctite®243™

(12.5 lbf ft)

– Check play of steering head bearing. ( p. 40)

MAINTENANCE WORK ON CHASSIS AND ENGINE 42

9.26Removing the fork legs

–

Remove the front wheel. x ( p. 64)

– Remove screws  and take off clamp.
– Remove cable clip , remove screw  and take off the brake caliper.
– Hang the brake caliper and the brake line loosely to the side.

500093-10

(EXC SIX DAYS, XC‑W USA)

– Loosen screw . Remove the fork leg on the left.
– Loosen screw . Remove the fork leg on the right.

500094-10

(EXC EU, EXC AUS, XC‑W ZA)

– Loosen screw . Remove the fork leg on the left.
– Loosen screw . Remove the fork leg on the right.

9.27Installing the fork legs x

100023-11

100021-10

500094-11

– Position the fork legs.

Info

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

(EXC SIX DAYS, XC‑W USA)

– Fully tighten screw .

Guideline

Screw, top triple clamp M8 17 Nm

(12.5 lbf ft)

– Fully tighten screw .

Guideline

Screw, bottom triple clamp M8 12 Nm

(8.9 lbf ft)

MAINTENANCE WORK ON CHASSIS AND ENGINE 43

(EXC EU, EXC AUS, XC‑W ZA)

– Fully tighten screw .

Guideline

Screw, top triple clamp M8 20 Nm

(14.8 lbf ft)

– Fully tighten screw .

Guideline

100023-10

– Position brake caliper, mount and tighten screws .

– Mount cable clip .
– Position the brake line and cable harness. Put the clamp on, mount and tighten

–

500093-11

9.28Removing the fork protector x

– Remove the fork legs. ( p. 42)
– Remove screws  on the left fork leg. Remove the fork protector upwards.
– Remove the screws on the right fork leg. Remove the fork protector upwards.

Screw, bottom triple clamp M8 15 Nm

Guideline

Screw, front brake caliper M8 25 Nm

(18.4 lbf ft)

screws .

Install the front wheel. x ( p. 64)

(11.1 lbf ft)

Loctite®243™

500105-10

9.29Installing the fork protector x

– Position the fork protection on the left fork leg. Mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

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

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

–

Install the fork legs. x ( p. 42)

500105-10

9.30Removing the lower triple clamp x (EXC SIX DAYS, XC‑W USA)

– Remove the fork legs. ( p. 42)
(XC‑W USA)

– Dismount the start number plate. ( p. 48)

(EXC SIX DAYS)

– Remove the headlight mask with the headlight. ( p. 47)

– Dismount the front fender. ( p. 47)

MAINTENANCE WORK ON CHASSIS AND ENGINE 44

– Remove screws  and hang the CDI control unit to the side.

Info

Do not unplug the CDI control unit.

– Remove screw . Remove screw , take off top triple clamp with the handlebar

and place it on one side.

Info

500099-10

– Remove o-ring . Remove protector ring .
– Remove the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.

500100-10

9.31Removing the lower triple clamp x (EXC EU, EXC AUS, XC‑W ZA)

– Remove the fork legs. ( p. 42)
– Remove the headlight mask with the headlight. ( p. 47)
– Dismount the front fender. ( p. 47)
– Remove screws  and hang the CDI control unit to the side.

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

500149-10

500150-10

Info

Do not unplug the CDI control unit.

– Remove screw . Loosen screw . Take off top triple clamp with the handlebar

and place it on one side.

Info

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

– Remove protector ring .
– Remove the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.

0022
0

0

11

0

0

33

MAINTENANCE WORK ON CHASSIS AND ENGINE 45

9.32Installing the lower triple clamp x (EXC SIX DAYS, XC‑W USA)

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

Long-life grease ( p. 107)

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

bearing.

Info

Check whether the top steering head seal  is correctly positioned.

– Push up protective ring  and o-ring .

500098-10

– Position the upper triple clamp with the steering.
– Mount and tighten screw .

Guideline

Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft)

500099-11

500103-10

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

screws .
Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

– Install the front fender. ( p. 47)

(XC‑W USA)

– Install the start number plate. ( p. 48)

(EXC SIX DAYS)

– Refit the headlight mask with the headlight. ( p. 47)

–

Install the fork legs. x ( p. 42)

– Mount and tighten screw .

Guideline

Screw, top steering stem M8 17 Nm

(12.5 lbf ft)

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

laying.

– Check play of steering head bearing. ( p. 40)

Loctite®243™

0022
0

0

11

MAINTENANCE WORK ON CHASSIS AND ENGINE 46

9.33Installing the lower triple clamp x (EXC EU, EXC AUS, XC‑W ZA)

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

Long-life grease ( p. 107)

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

bearing.

Info

Check whether the top steering head seal  is correctly positioned.

– Push on protective ring .

500151-10

– Position the upper triple clamp with the steering.
– Mount and tighten screw .

Guideline

Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft)

500149-11

100022-11

9.34Greasing the steering head bearing x

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

screws .
Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

– Install the front fender. ( p. 47)
– Refit the headlight mask with the headlight. ( p. 47)

–

Install the fork legs. x ( p. 42)

– Tighten screw .

Guideline

Screw, top steering stem M8 20 Nm

(14.8 lbf ft)

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

laying.

– Check play of steering head bearing. ( p. 40)

(EXC SIX DAYS, XC‑W USA)

–

Remove the lower triple clamp. x ( p. 43)

–

Install the lower triple clamp. x ( p. 45)

(EXC EU, EXC AUS, XC‑W ZA)

–

Remove the lower triple clamp. x ( p. 44)

–

Install the lower triple clamp. x ( p. 46)

800010-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 47

9.35Dismounting the front fender

– Remove screws . Remove the front fender.
– Make sure that the distance bushings remain in place.

500092-10

9.36Installing the front fender

– Ensure that the spacing sleeves are mounted in the fender.
– Position the front fender. Mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

Info

Take care with the contact between the holding lugs and the start number
plate or headlight mask.

500092-10

9.37Removing headlight mask with headlight (EXC, EXC SIX DAYS, XC‑W ZA)

– Switch off all electrical equipment.
– Remove screw  and take off clamp.
– Loosen the rubber band . Push up the headlight mask and swing it forwards.

800018-10

– Pull out the electric plug connector  and remove the headlight mask with the

headlight.

500156-10

9.38Refitting the headlight mask with the headlight (EXC, EXC SIX DAYS, XC‑W ZA)

– Connect the electric plug connector .

500156-11

00BB 00BB

0

0

AA 00AA

0022

0

0

11

0

0

22

0

0

11

MAINTENANCE WORK ON CHASSIS AND ENGINE 48

– Position the headlight mask and fix it with the rubber band .

Info

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

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

screw .

– Check the headlamp setting.

800018-11

9.39Dismount the start number plate (XC‑W USA)

– Remove screw  and take off clamp.
– Remove screw  with distance bushing. Remove the start number plate.

500101-10

9.40Installing the start number plate (XC‑W USA)

– Position the start number plate. Mount and tighten screw  with the distance

500101-11

9.41Handlebar position

400223-11

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

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

Distance  between holes 15 mm (0.59 in)

The holes on the handlebar support are placed at a distance of  from the center.

Distance  between holes 3.5 mm (0.138 in)

The handlebar supports can be mounted in 4 different positions.

(EXC SIX DAYS)

bushing.
Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

Info

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

screw .

The handlebar supports can also be mounted at 2 different heights (with and with­out spacer).

Thick spacer 9 mm (0.35 in)

9.42Adjusting handlebar position x

400223-10

(EXC EU, EXC AUS, XC‑W)

– Remove the four screws . Remove the handlebar clamp. Remove the handle-

bar and lay it to one side.

Info

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

– Remove the two screws . Remove the handlebar support.

0

0

33

0

0

22

0

0

11

0

0

44
0

0

55

0

0

66
0

0

77
0

0

88
0

0

99

MAINTENANCE WORK ON CHASSIS AND ENGINE 49

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

screws .
Guideline

Screw, handlebar support M10 40 Nm

(29.5 lbf ft)

Info

Position the left and right handlebar supports evenly.

– Position the handlebar.

Info

Make sure cables and wiring are positioned correctly.

– Position the handlebar clamp. Fit and evenly tighten the four screws .

Guideline

Screw, handlebar clamp M8 20 Nm

Info

Make sure the gap width is even.

(EXC SIX DAYS)

– Remove the four screws . Remove the handlebar clamps  with rubber wash-

ers  and elastomers .

– Remove the handlebar and lay it to one side.

Loctite®243™

(14.8 lbf ft)

400343-10

Info

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

– Remove the lower shells .
– Remove the clamp bar  with the rubber cones .
– Remove the two screws . Remove the handlebar support.
– Place the handlebar support in the required position. Fit and tighten the two

screws .
Guideline

Screw, handlebar support M10 40 Nm

(29.5 lbf ft)

Condition

 Spacer fitted:

Use a M10x35 screw

Condition

without a spacer :

Use a M10x25 screw

Info

Position the left and right handlebar supports evenly.

– Fit the rubber cones  and clamp bar .
– Fit the lower shells .
– Position the handlebar.

Loctite®243™

Info

Make sure cables and wiring are positioned correctly.

MAINTENANCE WORK ON CHASSIS AND ENGINE 50

– Position the handlebar clamps  with rubber washers  and elastomers .

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

Info

The elastomers are available in different versions.

– Fit and evenly tighten the four screws .

Guideline

Screw, handlebar clamp M8 16 Nm

(11.8 lbf ft)

Info

Make sure the gap width is even.

9.43Checking gas Bowden cable route

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

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

500152-10

9.44Checking play in the gas Bowden cable

400192-10

9.45Adjusting the gas Bowden cable play x

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

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

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

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

–

Adjust the gas Bowden cable play. x ( p. 50)

Danger

Danger of poisoning Exhaust gases are poisonous and can result in uncon-

sciousness and/or death.

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

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

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

steering range.

The idle speed must not change.

» If the idle speed changes:

–

Adjust the gas Bowden cable play. x ( p. 50)

–

Dismount the fuel tank. x ( p. 70)

– Check gas Bowden cable route. ( p. 50)

MAINTENANCE WORK ON CHASSIS AND ENGINE 51

– Move the handlebar to the straight-ahead position.
– Push back bellows .
– Loosen nut . Turn adjusting screw  in as far as possible.
– Loosen nut . Turn adjusting screw  so that there is play in the gas Bowden

cable at the throttle grip.
Guideline

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

500153-10

– Tighten nut .
– Press and hold the throttle grip in the closed setting. Turn adjusting screw  out

until there is no play in the Bowden cable .

– Tighten nut .
– Push bellows  on. Check the throttle grip for smooth operation.

–

Install the fuel tank. x ( p. 71)

– Check play in the gas Bowden cable. ( p. 50)

9.46Checking for chain dirt accumulation

– Check the chain for coarse dirt accumulation.

» If the chain is very dirty:

– Clean the chain. ( p. 51)

800012-10

9.47Cleaning the chain

Warning

Danger of accidents Oil or grease on the tires reduces their grip.

– Remove oil and grease with a suitable cleaning material.

Warning

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

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

Warning

Environmental hazard Problem materials cause environmental damage.

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

Info

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

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

Chain cleaner ( p. 107)
Offroad chain spray ( p. 107)

MAINTENANCE WORK ON CHASSIS AND ENGINE 52

9.48Checking the chain tension

Warning

Danger of accidents Danger caused by incorrect chain tension.

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

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

– Jack up the motorcycle. ( p. 33)
– Push the chain at the end of the chain sliding component upwards to measure the

chain tension .

Info

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

Chain tension 8… 10 mm (0.31… 0.39 in)

400213-10

» If the chain tension does not meet specifications:

– Adjusting chain tension - after checking. ( p. 54)

– Remove the motorcycle from the work stand. ( p. 33)

9.49Checking the chain tension when fitting rear wheel

Warning

Danger of accidents Danger caused by incorrect chain tension.

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

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

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

chain tension .

Info

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

400213-10

9.50Checking the rear sprocket / engine sprocket for wear

Chain tension 8… 10 mm (0.31… 0.39 in)

» If the chain tension does not meet specifications:

– Adjust the chain tension when fitting rear wheel. ( p. 55)

– Check the rear sprocket / engine sprocket for wear.

» If the rear sprocket / engine sprocket are worn:

– Replace rear sprocket / engine sprocket.

400227-01

Info

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

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

00

0

BB

0

0

AA

1 2 3 16 17 18

MAINTENANCE WORK ON CHASSIS AND ENGINE 53

9.51Checking chain wear

– Jack up the motorcycle. ( p. 33)
– Shift gear to neutral.
– Pull the upper chain section with the specified weight .

Guideline

Weight of chain wear measurement 10… 15 kg (22… 33 lb.)

– Measure distance  of 18 chain links in the lower chain section.

Info

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

Maximum distance  at the longest
chain section

» If the distance  is greater than the specified measurement:

– Replace the chain.

Info

When you replace the chain, you should also replace the rear
sprocket and the engine sprocket.

400226-10

– Remove the motorcycle from the work stand. ( p. 33)

9.52Adjusting the chain tension

Warning

Danger of accidents Danger caused by incorrect chain tension.

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

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

– Jack up the motorcycle. ( p. 33)
– Push the chain at the end of the chain sliding component upwards to measure

chain tension .

New chains wear out faster on old, worn sprockets.

272 mm (10.71 in)

Info

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

400213-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 54

– Loosen nut .
– Loosen nuts .
– Adjust the chain tension by turning the left and right adjusting screws .

Guideline

Chain tension 8… 10 mm (0.31… 0.39 in)
Turn the left and right adjusting screws  so that the markings on the left and

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

– Tighten nuts .
– Make sure that chain adjusters  are fitted correctly on the adjusting screws .
– Tighten nut .

Guideline

Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft)

Info

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

400225-10

– Remove the motorcycle from the work stand. ( p. 33)

Chain adjusters  can be turned by 180°.

9.53Adjusting chain tension - after checking

400225-13

– Loosen nut .
– Loosen nuts .
– Adjust the chain tension by turning the adjusting screws  left and right.

Guideline

Chain tension 8… 10 mm (0.31… 0.39 in)
Turn the adjusting screws  left and right so that the markings on the left and

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

– Tighten nuts .
– Make sure that the chain adjusters  are fitted correctly on the adjusting

screws .

– Tighten nut .

Guideline

Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft)

Info

The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
The chain adjusters  can be turned by 180°.

MAINTENANCE WORK ON CHASSIS AND ENGINE 55

9.54Adjusting chain tension - fitting rear wheel

– Loosen nuts .
– Adjust the chain tension by turning the adjusting screws  left and right.

Guideline

Chain tension 8… 10 mm (0.31… 0.39 in)
Turn the adjusting screws  left and right so that the markings on the left and

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

– Tighten nuts .

400225-11

9.55Adjusting chain guide x

9.56Checking the brake discs

– Remove screws  and . Take off the chain guide.

Condition

Number of teeth: ≤ 44 teeth
– Insert nut  in hole . Position the chain guide.
– Mount and tighten screws  and .

Guideline

Remaining screws, chassis M6 10 Nm

(7.4 lbf ft)

Condition

Number of teeth: ≥ 45 teeth
– Insert nut  in hole . Position the chain guide.
– Mount and tighten screws  and .

Guideline

Remaining screws, chassis M6 10 Nm

(7.4 lbf ft)

400252-10

Warning

Danger of accidents Reduced braking due to worn brake discs.

– Worn brake discs should be replaced immediately in an authorized KTM workshop.

A

A

MAINTENANCE WORK ON CHASSIS AND ENGINE 56

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

to see if it conforms to measurement .

Info

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

Wear limit of brake discs

Front 2.5 mm (0.098 in)

400257-10

9.57Checking free travel of hand brake lever

Warning

Danger of accidents Brake system failure.

– If there is no free travel on the hand brake lever, pressure builds up on the front brake in the brake system. The front brake

can fail due to overheating. Adjust free travel on hand brake lever according to specifications.

(all XC‑W models)

Rear 3.5 mm (0.138 in)

» If the brake disc thickness is less than the specified value:

– Change the brake disc.

– Push the hand brake lever forwards and check free travel .

Free travel of hand brake lever ≥ 3 mm (≥ 0.12 in)

» If the free travel does not meet specifications:

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

400196-11

(all EXC models)

– Push the hand brake to the handlebar and check free travel .

Free travel of hand brake lever ≥ 3 mm (≥ 0.12 in)

» If the free travel does not meet specifications:

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

400196-13

9.58Adjusting basic position of handbrake lever (all XC‑W models)

– Adjust the basic setting of the handbrake lever to your hand size by turning adjust-

ing screw .

Info

Turn the adjusting screw clockwise to increase the distance between the
handbrake lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the handbrake lever and the handlebar.
The range of adjustment is limited.

400196-12

Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!

– Check the free travel of the hand brake lever. ( p. 56)

MAINTENANCE WORK ON CHASSIS AND ENGINE 57

9.59Adjusting free travel of handbrake lever (all EXC models)

– Adjust the free travel of the handbrake lever with the adjustment screw .

Info

Turn the adjustment screw clockwise to reduce free travel. The pressure
point moves away from the handlebar.
Turn the adjustment screw counterclockwise to increase free travel. The
pressure point moves towards the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.

400196-12

– Check the free travel of the hand brake lever. ( p. 56)

9.60Checking the front brake fluid level

Warning

Danger of accidents Brake system failure.

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

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

Warning

Danger of accidents Reduced braking due to old brake fluid.

– Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Do not make any adjustments while riding!

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Check the brake fluid level in the viewer .

» If the brake fluid is below the MIN mark:

–

Add front brake fluid. x ( p. 57)

400231-10

9.61Adding front brake fluid x

Warning

Danger of accidents Brake system failure.

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

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

Warning

Skin irritations Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking due to old brake fluid.

– Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Environmental hazard Problem materials cause environmental damage.

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

Info

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

MAINTENANCE WORK ON CHASSIS AND ENGINE 58

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws .
– Remove cover  with membrane .
– Add brake fluid to level .

Guideline

Measurement of  5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 ( p. 106)

– Position the cover with the membrane. Mount and tighten the screws.

Info

Clean up overflowed or spilt brake fluid immediately with water.

600706-10

9.62Checking the front brake linings

Warning

Danger of accidents Reduced braking due to worn brake linings.

– Worn brake linings should be replaced immediately in an authorized KTM workshop.

– Check the brake linings for minimum thickness .

Minimum thickness  ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

–

Change the front brake linings. x ( p. 59)

400235-10

9.63Removing front brake linings x

Warning

Danger of accidents Improper brake maintenance and repair.

– Always have your brake system maintained and repaired in an authorized KTM workshop.

– Press the brake caliper by hand on to the brake disc in order to press back the

brake pistons.

500089-11

Info

Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.

– Remove the locking split pins , withdraw the bolt , and take out the brake

pads.

– Remove cable clip . Remove screws  and take off brake caliper.
– Clean brake caliper and brake caliper support.

MAINTENANCE WORK ON CHASSIS AND ENGINE 59

9.64Mounting front brake linings x

Warning

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

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

Warning

Danger of accidents Reduced braking due to use of non-approved brake linings.

– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-

tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi­nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

– Check the brake discs. ( p. 55)
– Check that leaf spring  in the brake caliper and sliding plate  in the brake

caliper support are seated correctly.

Info

The arrow on the leaf spring points in the rotation direction of the brake
disc.

500091-10

– Insert the brake pads, insert bolt , and mount locking split pins .
– Position brake caliper, mount and tighten screws .

Guideline

Screw, front brake caliper M8 25 Nm

(18.4 lbf ft)

– Mount cable clip .
– Operate the hand brake lever repeatedly until the brake linings lie on the brake disc

and there is a tight spot.

500089-12

9.65Changing the front brake linings x

Warning

Skin irritations Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking due to old brake fluid.

– Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Environmental hazard Problem materials cause environmental damage.

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

Loctite®243™

Info

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

MAINTENANCE WORK ON CHASSIS AND ENGINE 60

–

Remove the front brake linings. x ( p. 58)

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws .
– Remove cover  with membrane .
– Press the brake piston back to its basic position and make sure that no brake fluid

overflows from the brake fluid reservoir.

–

Mount the front brake linings. x ( p. 59)

– Add brake fluid to level .

Guideline

Measurement of  5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 ( p. 106)

– Position the cover with the membrane. Mount and tighten the screws.

Info

Clean up overflowed or spilt brake fluid immediately with water.

600706-10

9.66Checking free travel of foot brake lever

Warning

Danger of accidents Brake system failure.

– If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake

can fail due to overheating. Adjust free travel on foot brake pedal according to specifications.

– Disconnect spring .
– Move the foot brake lever backwards and forwards between the end stop and the

foot brake cylinder piston bracket and check free travel .
Guideline

Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)

» If the free travel does not meet specifications:

–

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

500139-11

9.67Adjusting basic position of footbrake lever x

– Reconnect spring .

Warning

Danger of accidents Brake system failure.

– If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake

can fail due to overheating. Adjust free travel on foot brake pedal according to specifications.

– Disconnect spring .
– Loosen nut  and with push rod , turn it back until you have maximum free

travel.

– To adjust the basic position of the footbrake lever individually, lossen nut  and

turn screw  accordingly.

500154-10

Info

The range of adjustment is limited.

– Turn push rod  accordingly until you have free travel . If necessary, adjust the

basic position of the footbrake lever.
Guideline

Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)

MAINTENANCE WORK ON CHASSIS AND ENGINE 61

– Hold screw  and tighten nut .

Guideline

Remaining nuts, chassis M8 30 Nm

(22.1 lbf ft)

– Hold push rod  and tighten nut .

Guideline

Remaining nuts, chassis M6 15 Nm

(11.1 lbf ft)

– Reconnect spring .

9.68Checking the rear brake fluid level

Warning

Danger of accidents Brake system failure.

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

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

Warning

Danger of accidents Reduced braking due to old brake fluid.

– Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

– Stand the vehicle upright.
– Check the brake fluid level in the viewer .

» When in the viewer  an air bubble is visible:

–

Add brake fluid for the rear brake. x ( p. 61)

400234-10

9.69Adding brake fluid for the rear brake x

Warning

Danger of accidents Brake system failure.

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

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

Warning

Skin irritations Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking due to old brake fluid.

– Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Environmental hazard Problem materials cause environmental damage.

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

Info

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

MAINTENANCE WORK ON CHASSIS AND ENGINE 62

– Stand the vehicle upright.
– Remove screw cap  with membrane  and the O-ring.
– Add brake fluid to level .

Brake fluid DOT 4 / DOT 5.1 ( p. 106)

– Mount the screw cap with the membrane and the O-ring.

Info

400233-10

9.70Checking the rear brake linings

Warning

Danger of accidents Reduced braking due to worn brake linings.

– Worn brake linings should be replaced immediately in an authorized KTM workshop.

– Check the brake linings for minimum thickness .

Clean up overflowed or spilt brake fluid immediately with water.

Minimum thickness  ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

–

Change the rear brake linings. x ( p. 63)

400238-10

9.71Removing rear brake linings x

Warning

Danger of accidents Improper brake maintenance and repair.

– Always have your brake system maintained and repaired in an authorized KTM workshop.

– Press the brake caliper by hand on to the brake disc in order to press back the

brake piston.

Info

Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.

– Remove the locking split pins , withdraw the bolt , and take out the brake

pads.

400236-10

9.72Installing the rear brake linings x

– Clean brake caliper and brake caliper support.

Warning

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

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

Warning

Danger of accidents Reduced braking due to use of non-approved brake linings.

– Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-

tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi­nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

– Check the brake discs. ( p. 55)

MAINTENANCE WORK ON CHASSIS AND ENGINE 63

– Check that leaf spring  in the brake caliper and sliding plate  in the brake

caliper support are seated correctly.

Info

The arrow on the leaf spring points in the rotation direction of the brake
disc.

500122-10

– Fit the brake pads, insert bolt , and mount locking split pins .

Info

Make sure that the decoupling plate  is mounted on the piston side of the
brake pad.

– Operate the foot brake lever repeatedly until the brake linings lie on the brake disc

and there is a tight spot.

400237-10

9.73Changing the rear brake linings x

Warning

Skin irritations Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking due to old brake fluid.

– Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Environmental hazard Problem materials cause environmental damage.

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

Info

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

–

Remove the rear brake linings. x ( p. 62)

– Stand the vehicle upright.
– Remove screw cap  with membrane  and the O-ring.
– Press the brake piston back to its basic position and make sure that no brake fluid

overflows from the brake fluid reservoir.

–

Install the rear brake linings. x ( p. 62)

– Add brake fluid to level .

400233-10

Brake fluid DOT 4 / DOT 5.1 ( p. 106)

– Mount the screw cap with the membrane and the O-ring.

Info

Clean up overflowed or spilt brake fluid immediately with water.

MAINTENANCE WORK ON CHASSIS AND ENGINE 64

9.74Removing the front wheel x

– Jack up the motorcycle. ( p. 33)
– Press the brake caliper by hand on to the brake disc in order to press back the

brake pistons.

Info

Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.

500089-10

– Remove screw .
– Loosen screw .

500084-10

– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of

the fork.

Info

Do not pull the hand brake lever when the front wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam­aged.

500085-10

– Remove spacing sleeves .

500086-10

9.75Installing the front wheel x

Warning

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

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

500086-11

– Clean and grease shaft seal rings  and bearing surface  of the spacing sleeves.

Long-life grease ( p. 107)

– Insert the spacing sleeves.

MAINTENANCE WORK ON CHASSIS AND ENGINE 65

– Lift the front wheel into the fork, position it, and insert the wheel spindle.
– Mount and tighten screw .

Guideline

Screw, front wheel spindle M24x1.5 45 Nm

(33.2 lbf ft)

– Operate the hand brake lever several times until the brake pads are lying correctly

on the brake disc.

500084-11

9.76Removing rear wheel x

– Remove the motorcycle from the work stand. ( p. 33)
– Pull the front wheel brake and push down hard on the fork several times to align

the fork legs.

– Fully tighten screw .

Guideline

Screw, fork stub M8 15 Nm

(11.1 lbf ft)

– Jack up the motorcycle. ( p. 33)
– Press the brake caliper by hand on to the brake disc in order to press back the

brake piston.

400258-10

Info

Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.

– Remove nut .
– Remove chain adjuster . Withdraw the wheel spindle  only enough to allow the

rear wheel to be pushed forward.

– Push the rear wheel forward as far as possible. Remove the chain from the rear

sprocket.

– Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of the

swing arm.

Info

Do not operate the foot brake when the rear wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam­aged.

– Remove the spacing sleeves .

400260-11

9.77Installing the rear wheel x

Warning

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

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

MAINTENANCE WORK ON CHASSIS AND ENGINE 66

– Clean and grease shaft seal rings  and bearing surface  of the spacing sleeves.

Long-life grease ( p. 107)

– Insert the spacing sleeves.

400260-10

– Lift the rear wheel into the swing arm, position it, and insert the wheel spindle .
– Put the chain on.

400259-10

– Position the chain adjuster . Mount nut , but do not tighten it yet.
– Check the chain tension when fitting rear wheel. ( p. 52)
– Make sure that the chain adjusters  are fitted correctly on the adjusting

screws .

– Tighten nut .

Guideline

Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft)

Info

The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
The chain adjusters  can be turned by 180°.

– Operate the foot brake lever repeatedly until the brake linings lie on the brake disc

and there is a tight spot.

– Remove the motorcycle from the work stand. ( p. 33)

400225-12

9.78Tire condition checking

Info

Only mount tires approved or recommended by KTM.
Other tires could have a negative effect on riding behavior.
The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.
The front and rear wheels must be mounted with tires with similar profiles.
Worn tires have a negative effect on riding behavior, especially on wet surfaces.

– Examine the front and rear tires for cuts, foreign bodies and other damage.

» If you find cuts, foreign bodies or other damage on a tire:

– Change the tire.

– Check the depth of the tread.

Info

Note local national regulations concerning the minimum tread depth.

Minimum tread depth ≥ 2 mm (≥ 0.08 in)

» If the tread depth is less than the minimum allowable depth:

– Change the tire.

MAINTENANCE WORK ON CHASSIS AND ENGINE 67

9.79Checking tire air pressure

Info

Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.

– Remove dust cap.
– Check tire air pressure when tires are cold.

Tire air pressure off road

Front 1.0 bar (15 psi)
Rear 1.0 bar (15 psi)

Road tire pressure (all EXC models)

front 1.5 bar (22 psi)

400241-01

– Mount dust cap.

9.80Checking spoke tension

Rear 2.0 bar (29 psi)

» If the tire pressure does not meet specifications:

– Correct tire pressure.

Warning

Danger of accidents Unstable riding behavior due to loose spokes.

– If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop.

Info

A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.

– To check spoke tension, tap each spoke with a screwdriver.

Guideline

You should hear a high note.

Spoke nipple, front wheel M4,5 5 Nm (3.7 lbf ft)
Spoke nipple, rear wheel M5 5 Nm (3.7 lbf ft)

Info

400228-01

9.81Removing the battery x

If you hear different tone frequencies from different spokes, this is an indi­cation of different spoke tensions.

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep the battery away from sparks or open fire. Charge only in well-ventilated rooms.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least

15 minutes and contact a physician.

– Switch off all power-consuming components and switch off the engine.
– Remove the seat. ( p. 69)

MAINTENANCE WORK ON CHASSIS AND ENGINE 68

– Disconnect the negative (minus) cable  of the battery.
– Pull back the plus pole cover  and disconnect the positive (plus) cable of the bat-

tery.

– Hang the rubber band  out to the bottom.
– Lift the battery up.

500069-10

9.82Installing the battery x

– Place the battery in the battery holder.

4Ah battery (YTX5L-BS) ( p. 95)

– Reconnect the rubber band .
– Attach the plus cable and replace the plus pole cover .
– Attach the minus cable .
– Mount the seat. ( p. 70)

500069-11

9.83Recharging the battery x

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep the battery away from sparks or open fire. Charge only in well-ventilated rooms.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least

15 minutes and contact a physician.

Warning

Environmental hazard Components and battery acid are a danger to the environment.

– Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.

Warning

Environmental hazard Problem materials cause environmental damage.

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

Info

Even if there is no load on the battery, it loses power every day.
The charge state and the type of charge are very important for the service life of the battery.
Fast recharging with a high charge current shortens the battery's service life.
If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes.
The battery capacity is then reduced.
If the battery is discharged from starting, it must be recharged immediately.
If it stands for a long time in a discharged state, the battery becomes over-discharged and sulfated, and then it is destroyed.
The battery is maintenance-free, i.e., the acid level does not have to be checked.

– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 69)
– Disconnect the minus (negative) cable of the battery to avoid damage to the motor-

cycle's electronics.

MAINTENANCE WORK ON CHASSIS AND ENGINE 69

– Connect the battery charger to the battery. Switch on the battery charger.

Battery charger (58429074000)

You can also use the battery charger to test rest potential and start potential of the
battery, and to test the generator. With this device, you cannot overcharge the bat­tery.

Info

Never remove the lid .

400240-10

– Switch off the charger after charging. Disconnect the battery.

– Mount the seat. ( p. 70)

9.84Removing a fuse

– Switch off all power-consuming components and switch off the engine.
– Dismount the air filter box lid. ( p. 74)
– Remove the protection cover .

Charge the battery with at most 10% of the capacity specified on the bat­tery .

Guideline

The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the

3 months

motorcycle is not in use.

Info

The fuse  is located in the starter relay  under the filter box cover.

– Remove the fuse .

400270-10

9.85Installing the fuse

Warning

Fire hazard The electrical system can be overloaded by the use of incorrect fuses.

– Use only fuses with the prescribed amperage. Never by-pass or repair fuses.

– Insert the fuse.

Fuse (58011109110)

Info

A reserve fuse  is located in the starter relay.
Replace a burned-out fuse  only by an equivalent fuse.
If the new fuse burns out, contact an authorized KTM workshop.

400273-10

– Replace the protection cover.
– Install the air filter box lid. ( p. 74)

9.86Removing the seat

– Remove screw . Lift up the seat at the rear, pull it back and then remove from

above.

500080-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 70

9.87Mounting the seat

– Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear

and simultaneously push it forward.

– Make sure that the seat is correctly locked in.
– Mount and tighten the screw of the seat fixing.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

500068-01

9.88Dismounting the fuel tank x

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 immedi-

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

500157-10

800019-10

– Remove the seat. ( p. 69)
– Turn handle  of the fuel tap to the OFF position. (Figure 500137-10 p. 20)
– Pull off the fuel hose.

Info

Remaining fuel may run out of the fuel hose.

– Remove screws  with collar sleeve.

(all EXC models)

– Hang the horn and horn bracket to one side.

– Remove screw  with collar sleeve.
– Remove the tube from the fuel tank vent line.

– Pull both spoilers to the side of the radiator bracket  and take the fuel tank away

upwards.

500067-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 71

9.89Installing the fuel tank x

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 imme-

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

– Position the fuel tank and install the two spoilers to the side of the radiator fixing.
– Make sure that no cables or Bowden cables are trapped or damaged.

9.90Cooling system

500067-01

– Mount the fuel tank vent hose.
– Mount and tighten screw  with the collar sleeve.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

(all EXC models)

– Position the horn with the horn bracket.

800019-11

– Mount and tighten screws  with the collar sleeve.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

– Connect the fuel hose.
– Mount the seat. ( p. 70)

500157-11

The water pump  in the engine forces the coolant to flow.
The pressure resulting from the warming of the cooling system is regulated by a valve
in the radiator cap . The specified coolant temperature is therefore permissible with­out danger of function problems.

400335-10

120 °C (248 °F)

Cooling is effected by the air stream.
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cool­ing effect.

(EXC SIX DAYS, XC-W ZA)

The radiator fan provides extra cooling. It is controlled by a thermoswitch.

MAINTENANCE WORK ON CHASSIS AND ENGINE 72

9.91Checking antifreeze and coolant level

Warning

Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure.

– Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and

cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.

Warning

Danger of poisoning Coolants are poisonous and a health hazard.

– Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and

contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor
immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

– Stand the motorcycle upright on a horizontal surface.
– Remove the radiator cap.
– Check antifreeze of coolant.

−25… −45 °C (−13… −49 °F)

» If the antifreeze of the cooling liquid does not meet specifications:

– Correct antifreeze of coolant.

– Check the coolant level in the radiator.

400243-10

Coolant level  above radiator fins. 10 mm (0.39 in)

» If the level of the cooling liquid does not meet specifications:

– Correct the coolant level.

Alternative 1

Coolant ( p. 106)

Alternative 2

Coolant (mixed ready to use) ( p. 106)

– Refit the radiator cap.

9.92Checking the coolant level

Warning

Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure.

– Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and

cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.

Warning

Danger of poisoning Coolants are poisonous and a health hazard.

– Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and

contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor
immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

– Stand the motorcycle upright on a horizontal surface.
– Remove the radiator cap.
– Check the coolant level in the radiator.

400243-10

Coolant level  above radiator fins. 10 mm (0.39 in)

» If the level of the cooling liquid does not meet specifications:

– Correct the coolant level.

Alternative 1

Coolant ( p. 106)

Alternative 2

Coolant (mixed ready to use) ( p. 106)

– Refit the radiator cap.

MAINTENANCE WORK ON CHASSIS AND ENGINE 73

9.93Draining coolant x

Warning

Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure.

– Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and

cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.

Warning

Danger of poisoning Coolants are poisonous and a health hazard.

– Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and

contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor
immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

– Stand the vehicle upright.
– Place a suitable container under the water pump cover.
– Remove screw . Remove the radiator cap .
– Completely drain the coolant.
– Mount and tight screw  with a new seal ring.

Guideline

Screw, water pump cover M6x25 10 Nm (7.4 lbf ft)

400335-11

9.94Refilling coolant x

Warning

Danger of poisoning Coolants are poisonous and a health hazard.

– Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and

contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor
immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

– Make sure that the screw  is tightened.
– Stand the vehicle upright.
– Pour coolant in up to measurement  above the radiator fins.

Guideline

10 mm (0.39 in)

Coolant 0.95 l (1 qt.) Coolant ( p. 106)

Coolant (mixed ready to use)

400244-10

– Refit the radiator cap.
– Make a short test ride.
– Check the coolant level. ( p. 72)

( p. 106)

9.95Glass fiber yarn filling of main silencer

The main silencer is filled with glass fiber yarn.
Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out".
Not only is the noise level higher, the performance characteristic changes.

MAINTENANCE WORK ON CHASSIS AND ENGINE 74

9.96Removing main silencer

Warning

Danger of burns The exhaust system gets very hot when the vehicle is driven.

– Allow the exhaust system to cool down. Do not touch hot components.

– Disconnect spring .
– Remove screws  and take off main silencer.

800020-10

9.97Installing the main silencer

– Mount the main silencer. Mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

800020-11

9.98Dismounting the air filter box lid

800021-10

9.99Installing the air filter box lid

– Reconnect spring .

– Pull off the air filter box lid in area  to the side and remove to the front.

– Insert the air filter box lid into the rear area  and clip it into the front area .

800021-11

MAINTENANCE WORK ON CHASSIS AND ENGINE 75

9.100Removing the air filter x

Note

Engine failure Unfiltered intake air has a negative effect on the service life of the engine.

– Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.

Warning

Environmental hazard Problem materials cause environmental damage.

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

– Dismount the air filter box lid. ( p. 74)
– Hang the air filter holder  out to the bottom and swing it to the side. Remove the

air filter with the air filter support.

– Remove the air filter from the air filter support.

500107-10

9.101Installing the air filter x

– Mount the clean air filter onto the air filter support.
– Put in both parts together, position them and fix them with the air filter support .

Info

If the air filter is not correctly mounted, dust and dirt can penetrate into the
engine and can cause damage.

– Install the air filter box lid. ( p. 74)

500107-10

9.102Cleaning air filter x

Warning

Environmental hazard Problem materials cause environmental damage.

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

Info

Do not clean the air filter with fuel or petroleum since these substances attack the foam.

–

Remove the air filter. x ( p. 75)

– Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.

Air filter cleaner ( p. 107)

Info

Only press the air filter to dry it, never wring it out.

– Oil the dry air filter with a high quality filter oil.

Oil for foam air filter ( p. 108)

– Clean the air filter box.
– Check carburetor connection boot for damage and tightness.

–

Install the air filter. x ( p. 75)

MAINTENANCE WORK ON CHASSIS AND ENGINE 76

9.103Adjusting basic position of clutch lever

– Adjust the basic setting of the clutch lever to your hand size by turning adjusting

screw .

Info

Turn the adjusting screw clockwise to increase the distance between the
clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the clutch lever and the handlebar.
The range of adjustment is limited.

500133-11

9.104Checking the fluid level of hydraulic clutch

Warning

Skin irritations Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Info

The fluid level rises with increasing wear of the clutch lining disc.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws .
– Remove cover  with membrane .
– Check the fluid level.

Fluid level under top level of container. 4 mm (0.16 in)

» If the level of the fluid does not meet specifications:

– Correct the fluid level of the hydraulic clutch.

400339-10

Brake fluid DOT 4 / DOT 5.1 ( p. 106)

– Position the cover with the membrane. Mount and tighten the screws.

Info

Clean up overflowed or spilt fluid immediately with water.

9.105Changing the hydraulic clutch fluid x

Warning

Skin irritations Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Environmental hazard Problem materials cause environmental damage.

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

Info

The fluid level rises with increasing wear of the clutch lining disc.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

MAINTENANCE WORK ON CHASSIS AND ENGINE 77

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws .
– Remove cover  with membrane .

400339-10

– Fill bleeding syringe  with the appropriate hydraulic fluid.

Bleed syringe (50329050000)
Brake fluid DOT 4 / DOT 5.1 ( p. 106)

–

On the slave cylinder, remove bleeder screw  and mount bleeding syringe .

500158-10

– Inject the liquid into the system until it escapes from bore hole  of the master

cylinder without bubbles.

– To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
– Remove the bleeding syringe. Mount and tighten screws bleeder screw.
– Correct the fluid level of the hydraulic clutch.

Guideline

Fluid level under top level of container. 4 mm (0.16 in)

9.106Carburetor - idle

400340-10

400341-10

– Position the cover with the membrane. Mount and tighten the screws.

Info

Clean up overflowed or spilt fluid immediately with water.

The idle setting of the carburetor has a big influence on the starting behavior, stable
idling and the response to throttle opening. That means that an engine with a correctly
set idle speed is easier to start than if the idle is set wrongly.

Info

The carburetor and its components are subject to increased wear caused by
engine vibration. Wear can result in malfunctioning.

The idle speed is adjusted with the adjustment screw .
The idle mixture is adjusted with the idle mixture adjustment screw .

MAINTENANCE WORK ON CHASSIS AND ENGINE 78

9.107Carburetor - adjusting idle x

– Screw in the idle adjusting screw  until it stops and then to the prescribed basic

setting.
Guideline

Idle mixture adjusting screw (400 EXC)

Open 0.75 turn

Idle mixture adjusting screw (530 EXC, 530 EXC SIX DAYS, 450 XC-W ZA,
530 XC-W ZA)

Open 1.5 turns

400341-10

Idle mixture adjusting screw (450 EXC, 450 EXC SIX DAYS, 400 XC-W USA,
450 XC-W USA)

Open 1.75 turns

Idle mixture adjusting screw (530 XC-W USA)

Open 2.0 turns

Adjustment tool for mixture control screw (77329034000)

– Run the engine until warm.

Guideline

Warm-up time ≥ 5 min

Danger

Danger of poisoning Exhaust gases are poisonous and can result in uncon-

sciousness and/or death.

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

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

– Adjust the idle speed with adjusting screw .

Guideline

Choke function deactivated – The choke lever is pushed in to the stop.
(EXC AUS, XC‑W) ( p. 20)

Choke function deactivated – The choke lever is pushed back to the stop.
(EXC EU, EXC SIX DAYS) ( p. 21)

Idle speed 1,550… 1,650 rpm

– Turn the idle adjusting screw  slowly until the idle speed begins to fall.
– Note the position and turn the idle adjusting screw slowly counterclockwise until

the idle speed falls.

– Adjust to the point between these two positions with the highest idle speed.

Info

If there is a big engine speed rise, reduce the idle speed to a normal level
and repeat the above steps.
The extreme sport motorcyclist will set the mixture about ¼ of a turn back
from this ideal value (leaner, in a clockwise direction) since the engine
becomes hotter in sporting use.
If the procedure described here does not lead to satisfactory results, the
cause may be a wrongly dimensioned idling jet.
If you can turn the idle adjusting screw to the end without any change of
engine speed, you have to mount a smaller idling jet.
The idle adjusting screw must not be opened more than two turns. If more
than two turns are necessary (rich mixture), use a larger idling jet.
After changing the idling jet, start from the beginning with the adjusting
steps.

MAINTENANCE WORK ON CHASSIS AND ENGINE 79

– Adjust the idle speed with adjusting screw .

Guideline

Choke function deactivated – The choke lever is pushed in to the stop.
(EXC AUS, XC‑W) ( p. 20)

Choke function deactivated – The choke lever is pushed back to the stop.
(EXC EU, EXC SIX DAYS) ( p. 21)

Idle speed 1,550… 1,650 rpm

Info

Following extreme air temperature or altitude changes, adjust the idle speed
again.

9.108Emptying the carburetor float chamber x

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 immedi-

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

Warning

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

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

Info

Carry out this work with a cold engine.

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

No more fuel flows from the tank to the carburetor.

– Direct the hose of the float chamber into a suitable container.

Info

Water in the float chamber results in malfunctioning.

– Undo the screw  (turn it counterclockwise) a few turns and drain the fuel from

the float chamber.

– Tighten screw .

500256-10

9.109Checking engine oil level

Info

The engine oil level must be checked when the engine is cold.

– Stand the motorcycle upright on a horizontal surface.

MAINTENANCE WORK ON CHASSIS AND ENGINE 80

Condition

Engine is cold.
– Check the engine oil level.

The engine oil must be between the halfway mark and the top of the oil level
viewer .

» If the engine oil level is below the specified level:

– Top up the engine oil. ( p. 82)

200119-10

9.110Changing engine oil and oil filter, cleaning engine oil screen x

–

Drain the engine oil and clean the engine oil screen. x ( p. 80)

–

Remove the oil filter. x ( p. 80)

–

Mount the oil filter. x ( p. 81)

–

Fill up with engine oil. x ( p. 81)

9.111Draining engine oil, cleaning engine oil screen x

Warning

Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven.

– Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning

Environmental hazard Problem materials cause environmental damage.

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

Info

Drain the engine oil only when the engine is warm.

– Stand the motorcycle on its side stand on a horizontal surface.
– Place a suitable container under the engine.
– Remove engine oil plug screen .
– Completely drain the engine oil.
– Thoroughly clean the plug and gear oil screen.
– Clean the sealing area on the engine.
– Mount and tighten the plug of engine oil screen .

Guideline

200112-10

9.112Removing the oil filter x

Plug, engine oil screen M17x1.5 20 Nm

(14.8 lbf ft)

Warning

Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven.

– Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning

Environmental hazard Problem materials cause environmental damage.

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

– Place a suitable container under the engine.

MAINTENANCE WORK ON CHASSIS AND ENGINE 81

– Remove screws . Remove oil filter cover  with O-ring.

200113-10

– Pull the oil filter insert  out of the oil filter casing.

Circlip pliers reverse (51012011000)

– Completely drain the engine oil.
– Thoroughly clean parts and sealing area.

200114-10

9.113Mounting oil filter x

– Lay the motorcycle on its side and fill the oil filter housing to about ⅓ full with

engine oil.

– Fill the oil filter  with engine oil and place it in the oil filter container.
– Lubricate the O-ring  of the oil filter cover.

200114-11

– Refit the oil filter cover .
– Mount and tighten screws .

Guideline

Screw, oil filter cover M6 10 Nm (7.4 lbf ft)

– Stand the motorcycle up.

200113-11

9.114Filling up with engine oil x

Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

– Remove the screw cap  on the generator cover and fill up with engine oil.

Engine oil 0.60 l (0.63 qt.) Engine oil (SAE 10W/50) ( p. 106)

– Mount and tighten screw cap .

Danger

Danger of poisoning Exhaust gases are poisonous and can result in uncon-

sciousness and/or death.

200115-10

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

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

– Start the engine and check that it is oil-tight.
– Check the engine oil level. ( p. 79)

MAINTENANCE WORK ON CHASSIS AND ENGINE 82

9.115Topping up engine oil

Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

– Remove the screw cap  on the generator cover and fill up with engine oil.

Engine oil (SAE 10W/50) ( p. 106)

– Mount and tighten screw cap .

Danger

Danger of poisoning Exhaust gases are poisonous and can result in uncon-

sciousness and/or death.

200115-10

– Start the engine and check that it is oil-tight.
– Check the engine oil level. ( p. 79)

9.116Checking gear oil level

Info

The gear oil level must be checked when the engine is cold.

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

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

– Stand the motorcycle upright on a horizontal surface.

Condition

Engine is cold.

– Remove gear oil level check screw . Stand the vehicle upright.
– Check the gear oil level.

A small amount of gear oil should flow out.

» If no gear oil flows out:

–

Add gear oil. x ( p. 83)

200116-10

– Mount and tighten the gear oil level check screw.

Guideline

Screw, gear oil level check M6 8 Nm (5.9 lbf ft)

9.117Changing gear oil, cleaning gear oil screen x

–

Drain the gear oil and clean the gear oil screen. x ( p. 82)

–

Fill up with gear oil. x ( p. 83)

9.118Draining gear oil, cleaning gear oil screen x

Warning

Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven.

– Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning

Environmental hazard Problem materials cause environmental damage.

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

Info

Drain the gear oil only when the engine is warm.

– Stand the motorcycle on its side stand on a horizontal surface.

MAINTENANCE WORK ON CHASSIS AND ENGINE 83

– Place a suitable container under the engine.
– Remove the gear oil drain plug .
– Plug - remove the gear oil screen .
– Completely drain the gear oil.
– Thoroughly clean the gear oil drain plug with a magnet.
– Thoroughly clean the drain plug and gear oil screen with a magnet.
– Clean the sealing area on the engine.
– Mount and tighten gear oil drain plug  with the seal ring.

Guideline

Gear oil drain plug with magnet M12x1.5 20 Nm

(14.8 lbf ft)

– Mount and tighten the plug of gear oil screen .

Guideline

Plug, gear oil screen M16x1.5 20 Nm

(14.8 lbf ft)

500159-10

9.119Filling up with gear oil x

Info

Too little gear oil or poor-quality oil results in premature wear to the transmission.

– Remove the screw cap  and fill up with gear oil.

Gear oil 0.90 l (0.95 qt.) Engine oil (SAE 10W/50) ( p. 106)

– Mount and tighten screw cap .

Danger

Danger of poisoning Exhaust gases are poisonous and can result in uncon-

sciousness and/or death.

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

200118-10

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

– Start the engine and check that it is oil-tight.
– Check the gear oil level. ( p. 82)

9.120Adding gear oil x

Info

Too little gear oil or poor-quality oil results in premature wear to the transmission.

– Remove gear oil level check screw .

200116-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 84

– Remove screw cap . Stand the vehicle upright.
– Add gear oil until it flows out of the bore of the gear oil level screw.

Engine oil (SAE 10W/50) ( p. 106)

– Mount and tighten the gear oil level check screw.

Guideline

Screw, gear oil level check M6 8 Nm (5.9 lbf ft)

– Mount and tighten screw cap .

200118-11

Danger

Danger of poisoning Exhaust gases are poisonous and can result in uncon-

sciousness and/or death.

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

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

– Start the engine and check that it is oil-tight.

TROUBLESHOOTING 85

10TROUBLESHOOTING

Faults Possible cause Action

The engine cannot be cranked (electric
starter).

Engine turns but does not start. Operating error – Go through the steps of starting the

Engine has no idle. Idling jet blocked – Check/adjust the carburetor compo-

Engine does not speed up. Carburetor running over because float

Operating error – Go through the steps of starting the

engine. ( p. 26)

Battery discharged –

Fuse blown – Remove the fuse. ( p. 69)

Starter relay defective –
Starter motor defective –

Motorcycle was out of use for a long time
and there is old fuel in the float chamber

Fuel feed interrupted – Check the fuel tank breather.

Engine flooded – Clean and dry the spark plug or replace

Spark plug oily or wet – Clean and dry the spark plug or replace

Electrode distance (plug gap) of spark
plug too wide

Defect in ignition system –
Short-circuit cable in cable harness

frayed, short-circuit button or emergency
OFF switch defective

Plug connector of CDI control device,
pulse generator or ignition coil oxidized.

Water in carburetor or jets blocked – Check/adjust the carburetor compo-

Adjusting screws on carburetor distorted –

Spark plug defective – Change spark plug.
Ignition system defective –

needle dirty or worn.
Loose carburetor jets – Check/adjust the carburetor compo-

Ignition system defective –

Recharge the battery. x ( p. 68)

–

Check the charging voltage. x

–

Check the closed current. x

–

Check the generator. x

– Install the fuse. ( p. 69)

Check the starter relay. x
Check the starter motor. x

engine. ( p. 26)

– Empty the carburetor float

chamber. x ( p. 79)

– Clean the fuel tap.
– Check/adjust the carburetor compo-

nents. x

if necessary.

if necessary.

– Adjust plug gap.

Guideline
Spark plug electrode gap

0.9 mm (0.035 in)

Check the ignition system. x

– Check the wiring harness (visual

check).

– Check the electrical system.
– Clean the plug connector and treat it

with contact spray.

nents. x
nents. x

Carburetor - adjust the idle speed. x

( p. 78)

Check the ignition coil. x

–

Check the CDI unit. x

–

Check the spark plug connector. x

–

Check the ignition pulse generator. x

–

Check the generator. x

– Check/adjust the carburetor compo-

nents. x
nents. x

Check the ignition coil. x

–

Check the CDI unit. x

–

Check the spark plug connector. x

–

Check the ignition pulse generator. x

–

Check the generator. x

TROUBLESHOOTING 86

Faults Possible cause Action

Engine has too little power. Fuel feed interrupted – Check the fuel tank breather.

– Clean the fuel tap.
– Check/adjust the carburetor compo-

nents. x

Air filter very dirty –
Exhaust system leaky, deformed or too lit-

tle glass fiber yarn filling in main silencer

Valve clearance too little –
Ignition system defective –

Engine stalls or is popping into the carbu­retor

Engine overheats. Too little coolant in cooling system – Check the cooling system for leakage.

High oil consumption Engine vent hose bent – Route the vent hose without bends or

Battery discharged The battery does not charge –

Speedometer values deleted (time, stop
watch, lap times)

Lack of fuel – Turn handle  of the fuel

Engine takes in bad air – Check rubber sleeves and carburetor

Too little air stream – Switch off engine when standing.
Radiator fins very dirty – Clean radiator fins.
Foam formation in cooling system –

Bent radiator hose –
Thermostat defective –

Defect in radiator fan system
(EXC SIX DAYS, XC-W ZA)

Engine oil level too high – Check the engine oil level. ( p. 79)
Engine oil too thin (low viscosity) – Change the engine oil and oil filter

Piston or cylinder is worn – Piston/cylinder - determine the mount-

Undesired power consumer –
The battery in the speedometer is empty. – Change the battery in the speedometer.

Clean the air filter. x ( p. 75)

– Check exhaust system for damage.
– Change glass fiber yarn filling of main

silencer. x
Adjust the valve clearance. x
Check the ignition coil. x

–

Check the CDI unit. x

–

Check the spark plug connector. x

–

Check the ignition pulse generator. x

–

Check the generator. x

tap to the ON position.

(Figure 500137-10 p. 20)

– Fill up with fuel. ( p. 28)

for tightness.

– Check the coolant level. ( p. 72)

Drain the coolant. x ( p. 73)

–

Refill the coolant. x ( p. 73)
Change the radiator hose. x
Check the thermostat. x

Guideline
Opening temperature: 70 °C (158 °F)

– Check the radiator fan fuse.

–

Check the radiator fan. x

–

Check the thermostat. x

replace it if necessary.

and clean the engine oil screen. x

( p. 80)

ing clearance x
Check the charging voltage. x

–

Check the charging current. x

–

Check the generator. x
Check the closed current. x

CLEANING 87

11CLEANING

11.1Cleaning motorcycle

Note

Material damage Damage and destruction of components by high-pressure cleaning equipment.

– Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri-

cal components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts.

Warning

Environmental hazard Problem materials cause environmental damage.

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

Info

If you clean the motorcycle regularly, its value and appearance are maintained over a long period.
Avoid direct sunshine on the motorcycle during cleaning.

– Before you clean the motocycle, seal the exhaust system to prevent penetration by water.
– First remove coarse dirt particles with a gentle water spray.
– Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush.

Motorcycle cleaner ( p. 107)

Info

Use warm water containing normal motorcycle cleaner and a soft sponge.

– After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly.

–

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

Warning

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

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

– After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes.

Info

The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.

– Push back the protection covers on the handlebar instruments to allow water to evaporate.
– After the motorcycle has cooled off, oil or grease all moving parts and bearings.
– Clean the chain. ( p. 51)
– Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.

Cleaning and polishing materials for metal, rubber and plastic ( p. 107)

– Treat all painted parts with a mild paint polish.

High-luster polish for paint ( p. 107)

– To prevent electrical problems, treat electric contacts and switches with contact spray.

Contact spray ( p. 107)

(all EXC models)

– Lubricate the steering lock.

Universal oil spray ( p. 108)

STORAGE 88

12STORAGE

12.1Storage

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

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

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

Info

If you want to garage the motorcycle for a longer period, take the following actions.
Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you
should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the
start of the new season.

– Clean the motorcycle. ( p. 87)

–

Change the engine oil and oil filter and clean the engine oil screen. x ( p. 80)

–

Change the gear oil and clean the gear oil screen. x ( p. 82)

– Check the antifreeze and coolant level. ( p. 72)
– Drain the fuel from the tanks into a suitable container.

–

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

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

–

Remove the battery. x ( p. 67)

–

Recharge the battery. x ( p. 68)

Guideline

Storage temperature of battery without direct sunshine. 0… 35 °C (32… 95 °F)

– The storage place should be dry and not subject to large temperature differences.

Info

KTM recommends propping up the motorcycle.

– Jack up the motorcycle. ( p. 33)
– Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping,

thus causing corrosion.

Info

Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during
combustion condenses and causes valves and exhaust system to rust.

12.2Putting into operation after storage

– Remove the motorcycle from the work stand. ( p. 33)

–

Install the battery. x ( p. 68)

– Fill up with fuel. ( p. 28)
– Checks before putting into operation ( p. 26)
– Make a test ride.

TECHNICAL DATA - ENGINE 89

13TECHNICAL DATA- ENGINE

Design 1-cylinder 4-stroke engine, water-cooled
Displacement (all 400 models) 393.4 cm³ (24.007 cu in)
Displacement (all 450 models) 449.3 cm³ (27.418 cu in)
Displacement (all 530 models) 510.4 cm³ (31.147 cu in)
Stroke (all 400 models) 55.5 mm (2.185 in)
Stroke (all 450 models) 63.4 mm (2.496 in)
Stroke (all 530 models) 72 mm (2.83 in)
Bore 95 mm (3.74 in)
Compression ratio (all 400 models) 11.1:1
Compression ratio (all 450/530 models) 11.9:1
Idle speed 1,550… 1,650 rpm
Control OHC, 4 valves controlled via rocker arm, drive via tooth/wheel

chain
Valve diameter, intake 39.5 mm (1.555 in)
Valve diameter, exhaust 31.7 mm (1.248 in)
Valve clearance

Outfeed at: 20 °C (68 °F) 0.12… 0.17 mm (0.0047… 0.0067 in)

Infeed at: 20 °C (68 °F) 0.10… 0.15 mm (0.0039… 0.0059 in)
Crankshaft bearing 2 grooved ball bearings
Conrod bearing Needle bearing
Piston pin bearing not a bearing bush - DLC-plated piston pins
Pistons Forged light alloy
Piston rings 1 compression ring, 1 oil scraper ring
Engine lubrication Pressure circulation lubrication with 2 rotor pumps (engine) / 1

rotor pump (transmission)
Primary transmission 33:76
Clutch Multidisc clutch in oil bath / hydraulically activated
Transmission ratio

1st gear 14:36
2nd gear 17:32
3rd gear 19:28
4th gear 22:26
5th gear 24:23

6th gear 26:21
Generator 12 V, 150 W
Ignition Contactless controlled fully electronic ignition with digital igni-

tion adjustment, type Kokusan
Spark plug NGK LKAR 8AI - 9
Spark plug electrode gap 0.9 mm (0.035 in)
Cooling Water cooling, permanent circulation of coolant by water pump
Starting aid Electric starter / kickstarter

13.1Capacity- engine oil

Engine oil 0.60 l (0.63 qt.) Engine oil (SAE 10W/50) ( p. 106)

TECHNICAL DATA - ENGINE 90

13.2Capacity - gear oil

Gear oil 0.90 l (0.95 qt.) Engine oil (SAE 10W/50) ( p. 106)

13.3Capacity - coolant

Coolant 0.95 l (1 qt.) Coolant ( p. 106)

Coolant (mixed ready to use) ( p. 106)

TECHNICAL DATA - ENGINE TIGHTENING TORQUES 91

14TECHNICAL DATA- ENGINETIGHT ENINGTORQUES

Screw, cable holder in generator cover M4 4 Nm (3 lbf ft)
Oil jet, rocker arm lubrication M5 2 Nm (1.5 lbf ft)
Oil jet, piston cooling M5 2 Nm (1.5 lbf ft)
Screw, locking lever M5 6 Nm (4.4 lbf ft)
Screw, ignition pulse generator M5 6 Nm (4.4 lbf ft)
Locking screw for bearing M5 6 Nm (4.4 lbf ft)
Screw, oil pump cover M5 6 Nm (4.4 lbf ft)
Oil jet, conrod lubrication M6x0.75 4 Nm (3 lbf ft) –
Bleeding connection, transmission M6 4 Nm (3 lbf ft)
Nut, water-pump wheel M6 8 Nm (5.9 lbf ft)
Screw, kickstarter stop M6 10 Nm (7.4 lbf ft)
Screw, timing chain securing guide M6 8 Nm (5.9 lbf ft)
Screw, exhaust flange M6 10 Nm (7.4 lbf ft) –
Screw, torque governor M6 10 Nm (7.4 lbf ft)
Screw, starter motor M6 10 Nm (7.4 lbf ft) –
Screw, kickstarter spring hanger M6 10 Nm (7.4 lbf ft) –
Screw, timing chain guide rail M6 8 Nm (5.9 lbf ft)
Screw generator cover M6x25 10 Nm (7.4 lbf ft) –
Screw generator cover M6x40 10 Nm (7.4 lbf ft) –
Screw, gear oil level check M6 8 Nm (5.9 lbf ft) –
Screw, clutch cover M6x25 10 Nm (7.4 lbf ft) –
Screw, clutch cover M6x30 10 Nm (7.4 lbf ft) –
Screw, clutch spring M6 10 Nm (7.4 lbf ft) –
Screw, engine housing M6x60 10 Nm (7.4 lbf ft) –
Screw, engine housing M6x75 10 Nm (7.4 lbf ft) –
Screw, camshaft bearing support M6 10 Nm (7.4 lbf ft)
Screw, oil filter cover M6 10 Nm (7.4 lbf ft) –
Screw, shift drum locating M6 10 Nm (7.4 lbf ft)
Screw, shift lever M6 10 Nm (7.4 lbf ft)
Screw, timing chain tensioning rail M6 8 Nm (5.9 lbf ft)
Screw, stator bracket M6 10 Nm (7.4 lbf ft)
Plug, vacuum connection M6 5 Nm (3.7 lbf ft)
Screw, valve cover M6 10 Nm (7.4 lbf ft) –
Screw, water pump cover M6x25 10 Nm (7.4 lbf ft) –
Screw, water pump cover M6x55 10 Nm (7.4 lbf ft) –
Screw, idler M6 10 Nm (7.4 lbf ft)
Screw, cylinder head M6 10 Nm (7.4 lbf ft) –
Screw, rocker arm bearing M7x1 15 Nm (11.1 lbf ft) –
Plug, oil channel M7 9 Nm (6.6 lbf ft)
Screw, kickstarter M8 25 Nm (18.4 lbf ft)
Plug, crankshaft location M8 10 Nm (7.4 lbf ft) –
Balancer shaft nut M10x1 40 Nm (29.5 lbf ft) –
Screw, unlocking of timing chain ten-

sioner
Screw, engine sprocket M10 60 Nm (44.3 lbf ft)
Plug, oil channel M10 15 Nm (11.1 lbf ft)

M10x1 10 Nm (7.4 lbf ft) –

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®222

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

TECHNICAL DATA - ENGINE TIGHTENING TORQUES 92

Screw, cylinder head M10x1.25 Tightening sequence:

Tighten diagonally, begin­ning with the rear screw on
the chain shaft.
Step 1
10 Nm (7.4 lbf ft)
Step 2
30 Nm (22.1 lbf ft)
Step 3

50 Nm (36.9 lbf ft)
Nut, rotor M12x1 60 Nm (44.3 lbf ft) –
Spark plug M12x1.25 15… 20 Nm (11.1…

14.8 lbf ft)
Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –
Plug, SLS M12x1.5 20 Nm (14.8 lbf ft) –
Oil pressure control valve plug M12x1.5 20 Nm (14.8 lbf ft) –
Plug, rocker arm M14x1.25 20 Nm (14.8 lbf ft) –
Plug, gear oil screen M16x1.5 20 Nm (14.8 lbf ft) –
Plug, engine oil screen M17x1.5 20 Nm (14.8 lbf ft) –
Nut, inner clutch hub M18x1.5 80 Nm (59 lbf ft) –
Nut, primary gear M20LHx1.5 100 Nm (73.8 lbf ft)
Plug, timing chain tensioner M24x1.5 30 Nm (22.1 lbf ft) –

lubricated with engine oil

–

Loctite®243™

TECHNICAL DATA - CARBURETOR 93

15TECHNICAL DATA- CARBURETOR

15.1400 EXC

Carburetor type KEIHIN FCR-MX 39
Carburetor identification number 3900N
Needle position 5th position from top
Idle mixture adjusting screw

Open 0.75 turn
Pump membrane stop 2.15 mm (0.0846 in)
Main jet 180
Jet needle OBDYU (OBDTQ)
Idling jet 42
Idle air jet 100
Cold start jet 65 (85)
Leakage nozzle 40
Slide stop present

15.2400 XC-W USA

Carburetor type KEIHIN FCR-MX 39
Carburetor identification number 3900W
Needle position 1st position from top
Idle mixture adjusting screw

Open 1.75 turns
Pump membrane stop 2.15 mm (0.0846 in)
Main jet 180
Jet needle OBDTQ
Idling jet 42
Idle air jet 100
Cold start jet 85
Leakage nozzle 40

15.3450 EXC, 450 EXC SIX DAYS

Carburetor type KEIHIN FCR-MX 39
Carburetor identification number 3900I
Needle position 4th position from top
Idle mixture adjusting screw

Open 1.75 turns
Pump membrane stop 2.15 mm (0.0846 in)
Main jet 180
Jet needle OBDYU (OBDTQ)
Idling jet 40
Idle air jet 100
Cold start jet 65 (85)
Leakage nozzle 40
Slide stop present

TECHNICAL DATA - CARBURETOR 94

15.4450 XC-W

Carburetor type KEIHIN FCR-MX 39
Carburetor identfication number 3900L
Needle position (450 XC-W USA) 1st position from top
Needle position (450 XC-W ZA) 4th position from top
Idle mixture adjusting screw (450 XC-W ZA)

Open 1.5 turns
Idle mixture adjusting screw (450 XC-W USA)

Open 1.75 turns
Pump membrane stop 2.15 mm (0.0846 in)
Main jet (450 XC-W USA) 180
Main jet (450 XC-W ZA) 185
Jet needle OBDTQ
Idling jet 40
Idle air jet 100
Cold start jet 85
Leakage nozzle 40

15.5530 EXC, 530 EXC SIX DAYS

Carburetor type KEIHIN FCR-MX 39
Carburetor identfication number 3900J
Needle position 5th position from top
Idle mixture adjusting screw

Open 1.5 turns
Pump membrane stop 2.15 mm (0.0846 in)
Main jet 180
Jet needle OBDZT (OBDTR)
Idling jet 40
Idle air jet 100
Cold start jet 65 (85)
Leakage nozzle 40
Slide stop present

15.6530 XC‑W

Carburetor type KEIHIN FCR-MX 39
Carburetor identfication number 3900M
Needle position (530 XC-W USA) 1st position from top
Needle position (530 XC-W ZA) 4th position from top
Idle mixture adjusting screw (530 XC-W ZA)

Open 1.5 turns
Idle mixture adjusting screw (530 XC-W USA)

Open 2.0 turns
Pump membrane stop 2.15 mm (0.0846 in)
Main jet (530 XC-W USA) 180
Main jet (530 XC-W ZA) 185
Jet needle OBDTR
Idling jet 40
Idle air jet 100
Cold start jet 85
Leakage nozzle 40

TECHNICAL DATA - CHASSIS 95

16TECHNICAL DATA- CHASSIS

Frame Central tube frame made of chrome molybdenum steel tubing
Fork WP Suspension 4860 MXMA PA
Suspension travel

Front 300 mm (11.81 in)

Rear 335 mm (13.19 in)
Fork offset (EXC SIX DAYS, XC‑W USA) 19 mm (0.75 in)
Fork offset (EXC EU, EXC AUS, XC‑W ZA) 20 mm (0.79 in)
Shock absorber WP Suspension PDS 5018 DCC
Brake system Disc brakes, brake calipers on floating bearings
Diameter of brake discs

Front 260 mm (10.24 in)

Rear 220 mm (8.66 in)
Wear limit of brake discs

Front 2.5 mm (0.098 in)

Rear 3.5 mm (0.138 in)
Tire air pressure off road

Front 1.0 bar (15 psi)

Rear 1.0 bar (15 psi)
Road tire pressure (all EXC models)

front 1.5 bar (22 psi)

Rear 2.0 bar (29 psi)
Final drive (400 EXC, 450 EXC, 450 EXC SIX DAYS) 15:45 (13:52)
Final drive (400 XC‑W, 450 XC‑W) 13:52
Final drive (530 XC‑W) 14:52
Final drive (530 EXC, 530 EXC SIX DAYS) 15:45 (14:52)
Chain 5/8 x 1/4"
Rear sprockets available 38, 40, 42, 45, 48, 49, 50, 51, 52
Steering head angle 63.5°
Wheelbase 1,475±10 mm (58.07±0.39 in)
Seat height unloaded 985 mm (38.78 in)
Ground clearance unloaded 380 mm (14.96 in)
Weight without fuel, approx. (all EXC models) 113.9 kg (251.1 lb.)
Weight without fuel, approx. (XC‑W USA) 112.2 kg (247.4 lb.)
Weight without fuel, approx. (XC‑W ZA) 113 kg (249 lb.)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
Maximum permissible overall weight 335 kg (739 lb.)

4Ah battery YTX5L-BS Battery voltage: 12 V

Nominal capacity: 4 Ah
maintenance-free

16.1Lighting equipment

Headlight (EXC, EXC SIX DAYS, XC‑W ZA) BA20d 12 V

35/35 W

Parking light (EXC, EXC SIX DAYS,
XC‑W ZA)

W2,1x9,5d 12 V

5 W

Indicator lights (all EXC models) W2x4,6d 12 V

1.2 W

Flasher light (all EXC models) BA15s 12 V

10 W

Brake / tail light (EXC, EXC SIX DAYS,

LED

XC‑W ZA)

TECHNICAL DATA - CHASSIS 96

Licence plate lamp (all EXC models) W2,1x9,5d 12 V

5 W

16.2Tires

Validity Front tire Rear tire

(all EXC models) 90/90 - 21 M/C 54M M+S TT

Metzeler MCE 6 DAYS EXTREME

(all XC‑W models) 80/100 - 21 51M TT

Bridgestone M59

For further information, see the Service section under:
http://www.ktm.com

16.3Capacity - fuel

140/80 - 18 M/C 70M M+S TT

Metzeler MCE 6 DAYS EXTREME

110/100 - 18 64M TT

Bridgestone M402

Total fuel tank capacity,

9.0 l (2.38 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. 106)
approx. (EXC, EXC SIX DAYS,
XC‑W ZA)

Total fuel tank capacity,

9.2 l (2.43 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. 106)
approx. (XC‑W USA)

Fuel reserve, approx. 2 l (2 qt.)

TECHNICAL DATA - FORK 97

17TECHNICAL DATA- FORK

Fork part number 14.18.7E.06
Fork WP Suspension 4860 MXMA PA
Compression damping

Comfort 26 clicks
Standard 22 clicks
Sport 20 clicks

Rebound damping

Comfort 24 clicks
Standard 22 clicks

Sport 22 clicks
Spring length with preload spacer(s) 510 mm (20.08 in)
Spring rate

Weight of rider: 65… 75 kg (143… 165 lb.) 4.4 N/mm (25.1 lb/in)

Weight of rider: 75… 85 kg (165… 187 lb.) 4.6 N/mm (26.3 lb/in)

Weight of rider: 85… 95 kg (187… 209 lb.) 4.8 N/mm (27.4 lb/in)
Air chamber length 110

+20

mm (4.33

−30

Spring preload - Preload Adjuster

Comfort 2 turns

Standard 2 turns

Sport 4 turns
Fork length 940 mm (37.01 in)

+0.79

−1.18

in)

FORK OIL Fork oil (SAE 5) ( p. 106)

TECHNICAL DATA - SHOCK ABSORBER 98

18TECHNICAL DATA- SHOCKABSOR BER

Shock absorber part number 12.18.7E.06
Shock absorber WP Suspension PDS 5018 DCC
Compression damping, low-speed

Comfort 18 clicks

Standard 15 clicks

Sport 12 clicks
Compression damping, high-speed

Comfort 2 turns

Standard 1.5 turns

Sport 1 turn
Rebound damping

Comfort 26 clicks

Standard 24 clicks

Sport 22 clicks
Spring preload 9 mm (0.35 in)
Spring rate

Weight of rider: 65… 75 kg (143… 165 lb.) 69 N/mm (394 lb/in)

Weight of rider: 75… 85 kg (165… 187 lb.) 72 N/mm (411 lb/in)

Weight of rider: 85… 95 kg (187… 209 lb.) 76 N/mm (434 lb/in)
Spring length 250 mm (9.84 in)
Gas pressure 10 bar (145 psi)
Static sag 35 mm (1.38 in)
Riding sag 105 mm (4.13 in)
Fitted length 411 mm (16.18 in)