KTM 450 EXC EU 2013 Operating instructions

REPAIR MANUAL 2013 ''l'MWI:ii~8ijIIM
450 EXC EU
450 EXC AUS
450 EXC SIX DAYS EU
450 XC-W USA
500 EXC EU
500 EXC AUS
500 EXC SIX DAYS EU
500 EXC USA
500 XC-W USA
Art. no. 32D6152en

TABLE OF CONTENTS
1
2
3
4
5
6
MEANS OF REPRESENTATION ..................................... 6
1.1 Symbols
used ................................................... 6
1.2
Formats used .................................................... 6
SAFETY ADViCE ........................................................... 7
2.1 Repair
Manual .................................................. 7
2.2 Safety advice.................................................... 7
2.3
Degrees of risk and symbols............................... 7
2.4
Work rules ........................................................ 7
IMPORTANT NOTES ..................................................... 8
3.1
Guarantee, warranty .......................................... 8
3.2 Operating
and auxiliary substances ..................... 8
3.3
Spare parts, accessories .................................... 8
3.4 Figures ............................................................ 8
SERIAL NUMBERS ...................................................... 9
4.1
Chassis number ................................................ 9
4.2
Type label ........................................................ 9
4.3
Key number (All EXC moeelsl........................... 10
4.4 Engine number ............................................... 10
4.5 Fork part number ............................................ 10
4.6 Shock absorber part number ............................ 10
MOTORCYCLE ........................................................... 12
5.1 Raising the motorcycle with the
lift stand.......... 12
5.2
Removing the motorcycle from the lift stand ...... 12
5.3 Starting.......................................................... 12
5.4 Starting the motorcycle for acheck................... 13
FORK, TRIPLE CLAMP ............................................... 14
6.1
EXC EU/AUS/USA, XC-W ................................. 14
6.1.1 Adjusting the
compression damping of the
6.1.2
6.1.3
6.1.4
6.1.5
6.1.6
6.1.7
6.1.8
6.1.9
6.1.10
6.1.11
6.1.12
6.1.13
6.1.14
6.1.15
6.1.16
6.1.17
6.1.18
6.1.19
6.1.20
6.1.21
6.1.22
6.1.23
6.1.24
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
fork ........................................................... 14
Adjusting the
rebound damping of the fork.... 14
Adjusting the spring
preload of the fork......... 14
Bleeding fork
legs ....................................... 15
Cleaning the dust
boots of the fork legs ......... 15
Loosening the fork protector......................... 16
Positioning the fork protection ..................... 16
Removing the fork legs ................................ 16
Installi
ng the fork legs ................................. 17
Removing the fork protector......................... 17
Installing the fork protector.......................... 18
Performing a fork service ............................. 18
Disassembling the fork
legs ......................... 18
Cartridge disassembly ................................. 21
Disassembling the compression damping
fitting........................................................ 23
Checking the fork
legs ................................. 23
Assembling the compression damping
fitting........................................................
25
Assembling the cartridge ............................. 25
Assembling the fork legs .............................. 27
Greasing the steering head bearing ............... 31
Removing the lower triple clamp .................. 31
Installing the
lower triple clamp ................... 32
Checking the steering head bearing play ....... 34
Adjusting the play of the steering head
bearing ...................................................... 34
EXC SIX DAYS ................................................ 35
Adjusting the compression damping of the
fork ........................................................... 35
Adjusting the rebound damping of the fork.... 35
Bleeding fork legs ....................................... 35
Cleaning the dust boots of the fork legs ......... 36
Loosening the fork protector......................... 36
7
8
9
6.2.6
6.2.7
6.2.8
6.2.9
6.2.10
6.2.11
6.2.12
6.2.13
6.2.14
6.2.15
6.2.16
6.2.17
6.2.18
6.2.19
6.2.20
6.2.21
6.2.22
6.2.23
2
Positioning the fork protection ..................... 37
Removing the fork legs ................................ 37
Installing the fork legs ................................. 37
Removing the fork protector......................... 38
Installing the fork protector.......................... 38
Performing a fork service ............................. 38
Disessembling the fork legs ......................... 39
Removing the spring ................................... 41
Disassembling the cartridge......................... 42
Disassembling the piston
rod ....................... 43
Disassembling the hydrostop unit................. 44
Disassembling the seal ring retainer .............. 44
Checki ng the fork legs................................. 45
Assembling the
seal ring retainer.................. 46
Assembling the hydrostop unit ..................... 46
Assembling the piston
rod ........................... 47
Assembling the cartridge ............................. 48
Assembling the fork
legs .............................. 49
6.2.24
Greasing the steering head bearing............... 53
6.2.25
6.2.26
6.2.27
Removing the lower triple clamp .................. 53
Installing the lower triple clamp ................... 54
Checking the steering head bearing play ....... 55
6.2.28 Adjusting the play of the steering head
bearing ...................................................... 56
HANDLEBAR, CONTROLS ........................................... 57
7.1 Handlebar position ..........................................
57
7.2 Adjusting handlebar position ............................ 57
7.3 Adjusting the basic position of the clutch
lever ..............................................................
57
7.4 Checking the throttle cable routing ................... 58
7.5 Checking the play in the throttle cable .............. 58
7.6 Adjusting the play in the throttle cable.............. 59
FRAME ..................................................................... 61
8.1
Removing the engine guard (EXC SIX DAYS,
EXC AUSl....................................................... 61
8.2 Installing the engine
guard (EXC SIX DAYS,
EXC AUSl....................................................... 61
SHOCK ABSORBER, SWINGARM ................................ 62
9.1 Adjusting the high-speed compression
damping of the shock absorber.........................
62
9.2 Adjusting the low-speed compression damping
of the shock absorber ...................................... 62
9.3 Adjusting the rebound damping of the shock
absorber.........................................................
63
9.4 Measuring rear wheel sag unloaded ................... 63
9.5 Checking the static sag of the shock absorber.... 63
9.6 Checking the riding sag of the shock absorber.... 64
9.7 Adjusting the spring preload of the shock
absorber.........................................................
64
9.8 Adjusting the riding sag ................................... 65
9.9 Removing the shock absorber........................... 65
9.10 Installing the shock absorber ............................ 65
9.11 Servicing the shock absorber............................ 66
9.12 Removing the spring........................................ 66
9.13 Disassembling the damper............................... 67
9.14 Disassembling the piston rod ........................... 68
9.15 Disassembling the seal ring retainer.................. 69
9.16 Replacing the pilot bushing ............................. 70
9.17 Checking the damper ...................................... 71
9.18 Disassembling the rebound adjuster.................. 71
9.19
Removing the heim join!.................................. 72
9.20 Installing the heim join!................................... 73

TABLE OF CONTENTS
9.21 Assembling the rebound adjuster...................... 74
9.22
Assembling the seal ring retainer...................... 74
9.23
Assembling the piston rod ................................ 75
9.24
Assembling the damper ................................... 76
9.25
Bleeding and filling the damper ....................... 79
9.26 Filling the
damper with nitrogen ....................... 81
9.27 Installing the spring ........................................ 82
9.28
Changing the heim jOint ................................... 83
10
EXHAUST .................................................................. 85
10.1
Removing the manifold.................................... 85
10.2 Installing the manifold .................................... 85
10.3 Removing main silencer ................................... 86
10.4 Installing the main silencer.............................. 86
10.5 Changing the glass fiber yarn filling of the
main silencer.................................................. 86
11 AIR FILTER ............................................................... 88
11.1
Removing the air filter box lid .......................... 88
11.2 Installing the air filter box lid ........................... 88
11.3 Removing the air filter..................................... 88
11.4 Installing the air filter...................................... 88
11.5 Cleaning the air filter and air filter box .............. 89
12 FUEL TANK, SEAT, TRIM ........................................... 90
12.1
Opening filler cap ........................................... 90
12.2
Closing filler cap ............................................. 90
12.3
Removing the seat .......................................... 90
12.4 Mounting
the sea!........................................... 91
12.5 Removing the fuel tank.................................... 91
12.6 Installing the fuel tank .................................... 92
12.7
Changing the fuel screen ................................. 93
12.8
Changing the fuel filter.................................... 94
12.9
Changing the fuel pump .................................. 96
12.10
Checking the fuel pressure ............................... 97
13 MASK, FENDER ......................................................... 99
13.1 Removing the front fender ............................... 99
13.2 Installing the front
fender ................................ 99
13.3
Removing headlight mask with headligh!........... 99
13.4 Refitting
the headlight mask with the
headlight........................................................ 99
14
WHEELS ................................................................. 101
14.1
Checking the tire air pressure ......................... 101
14.2 Checking the tire condition ............................ 101
14.3
Checking the brake discs ............................... 102
14.4
Checking spoke tension ................................. 102
14.5
Front wheel .................................................. 103
14.5.1
Removing the front wheel .......................... 103
14.5.2 Installing
the front wheel ........................... 103
14.5.3
Removing the front brake disc.................... 104
14.5.4 Installing
the front brake disc .................... 104
14.6
Rear wheel ................................................... 104
14.6.1
Removing the rear wheel ........................... 104
14.6.2 Installing
the rear wheel ............................ 105
14.6.3
Removing the rear brake disc ..................... 106
14.6.4 Installing
the rear brake disc ...................... 106
14.6.5
Checking the chain tension ........................ 107
14.6.6 Adjusting the
chain tension ....................... 107
14.6.7 Adjusting the
chain guide.......................... 108
14.6.8
Checking the chain, rear sprocket, engine
sprocket and chain guide........................... 108
14.6.9
Checking for chain dirt accumulation.......... 110
14.6.10
Cleaning the chain .................................... 110
15
WIRING HARNESS, BATTERy ................................... 112
15.1 Changing the main fuse ................................. 112
15.2
Changing the fuses of individual power
consumers ....................................................
15.3 Changing the fuse of the radiator fan ............ ..
15.4 Removi ng the battery .................................. ..
15.5 Installing the battery .....................................
15.6
Charging the battery.................................... ..
16 BRAKE SYSTEM .................................................... ..
3
113
113
114
115
115
117
16.1
16.2
Checking the front brake linings ..................... 117
Changing the front brake linings..................... 117
16.3
Checking free travel of hand brake lever .......... 119
16.4 Adjusting
the basic position of the hand
brake lever (all XC-W models) ......................... 119
16.5 Adjusting
free travel of hand brake lever (All
EXC models)................................................. 119
16.6
16.7
Checking the front brake fluid level ................ 120
Adding front brake fluid................................. 120
16.8
Changing the front brake fluid ........................ 121
16.9
Checking the rear brake linings ...................... 122
16.10
Changing the rear brake linings ...................... 122
16.11
Checking the free travel of foot brake lever ...... 124
16.12 Adjusting
the basic position of the foot brake
lever ............................................................ 124
16.13
Checking the rear brake fluid level .................. 125
16.14
Adding brake fluid to the rear brake circui!...... 125
16.15
Changing the rear brake fluid ......................... 126
17
LIGHTING SYSTEM, INSTRUMENTS ......................... 128
17.1 Adjusting
the speedometer functions .............. 128
17.2 Setting kilometers or miles............................. 128
17.3 Activating the additional functions.................. 129
17.4 Setting
the wheel circumference .................... 129
17.5 Setting
the clock........................................... 130
17.6
Checking the headlight setting ....................... 130
17.7 Adjusting
the headlight range ......................... 131
18
ENGINE .................................................................. 132
18.1 Removing the engine ..................................... 132
18.2 Installing
the engine ...................................... 136
18.3
Engine disassembly ....................................... 140
18.3.1
Preparations ............................................. 140
18.3.2
Draining the engine oil .............................. 140
18.3.3
Removing the clutch push rod .................... 141
18.3.4 Removing the oil filter............................... 141
18.3.5
Removing the starter motor ........................ 141
18.3.6
Removing the spark plug ........................... 141
18.3.7
Removing the valve cover........................... 142
18.3.8
Removing the alternator cover .................... 142
18.3.9 Positioning
the engine at ignition top dead
18.3.10
18.3.11
18.3.12
center ...................................................... 142
Removing the timing chain tensioner .......... 143
Removing the camshaft............................. 143
Removing the cylinder head ....................... 144
18.3.13
Removing the piston ................................. 144
18.3.14
Removing the rotor .................................... 144
18.3.15
Removing the timing chain guide rail .......... 145
18.3.16
Removing the timing chain tensioning
rail .......................................................... 145
18.3.17
Removing the timing chain securing
guide....................................................... 145
18.3.18
Removing the timing chain ........................ 145
18.3.19
Removing the ignition pulse generator ........ 145
18.3.20
Removing the suction pump ....................... 146
18.3.21 Removing the water pump cover ................. 146
18.3.22
Removing the clutch cover ......................... 146

TABLE OF CONTENTS
18.3.23 Removing the clutch discs......................... 147
18.3.24
Removing the primary gear nut................... 148
18.3.25
Removing the outer clutch hub .................. 148
18.3.26
Removing the torque limiter....................... 149
18.3.27
Removing the starter idler gear ................... 149
18.3.28
Removing the kickstarter idler gear ............. 149
18.3.29
Removing the kickstarter idler gear ............. 149
18.3.30
Removing the shift shaft............................ 149
18.3.31
Removing the shift drum locating unit ........ 150
18.3.32
Removing the locking lever ........................ 150
18.3.33
Removing the oil pump gear wheels ............ 150
18.3.34
Removing the force pump .......................... 151
18.3.35
Removing the primary gear ........................ 151
18.3.36
Removing the free wheel gear .................... 151
18.3.37
Removing the left engine case section ........ 151
18.3.38
Removing the shift rails............................. 152
18.3.39
Removing the shift drum ........................... 152
18.3.40
Removing the shift lorks............................ 153
18.3.41
Removing the transmission shafts............... 153
18.3.42
Removing the crankshaft ........................... 153
18.4
Work on individual parts ................................ 154
18.4.1
Work on the right section of the engine
18.4.2
18.4.3
18.4.4
18.4.5
18.4.6
18.4.7
18.4.8
18.4.9
18.4.10
18.4.11
18.4.12
18.4.13
18.4.14
18.4.15
18.4.16
18.4.17
18.4.18
18.4.19
18.4.20
18.4.21
18.4.22
18.4.23
18.4.24
18.4.25
18.4.26
18.4.27
18.4.28
18.4.29
18.4.30
18.4.31
18.4.32
18.4.33
case ........................................................ 154
Work on the left section of the engine
case ........................................................ 155
Removing the oil pressure regulator valve .... 156
Checking spring length of oil pressure
regulator valve .......................................... 156
Installing the oil
pressure regulator valve ..... 157
Removing the crankshaft seal ring in the
clutch
cover ............................................. 157
Installing the crankshaft
seal ring in the
clutch
cover ............................................. 157
Removing the water pump ......................... 157
Installing the water pump.......................... 158
Removing the timing chain sprocket ........... 159
Installing the timing chain sprocket............ 159
Changing the connecting rod, conrod
bearing. and crank pin .............................. 159
Checking crankshaft run-out at bearing
pin .......................................................... 161
Cylinder -Nikasil" coating ......................... 161
Checking/measuring the cylinder ................ 161
Checking/measuring the piston................... 162
Checking the piston ring
end gap ............... 162
Measuring the piston/cylinder mounting
clearance ................................................. 163
Checking the oil pumps ............................. 163
Disassembling the autodecompressor.......... 163
Assembling the autodecompressor.............. 164
Checking camshaft ................................... 165
Checking the timing
assembly .................... 165
Removing the rocker arm ........................... 166
Removing the valves .................................. 166
Changing camshaft bearing........................ 167
Checking the
valves .................................. 167
Checking
valve springs .............................. 168
Checking
valve spring seal......................... 168
Checking the cylinder
head ........................ 168
Checking the
rocker arm shafts .................. 169
Installing the
valves .................................. 169
Installi
ng the rocker arm............................ 170
4
18.4.34 Checking the clutch .................................. 170
18.4.35
Checking the shift mechanism ................... 172
18.4.36
Preassembling the shift shaft..................... 173
18.4.37 Disassembling the
main shaft .................... 173
18.4.38 Assembling the
main shaft......................... 174
18.4.39 Disassembling the countershaft.................. 175
18.4.40 Assembling the countershaft...................... 175
18.4.41
Checking the transmission ......................... 176
18.4.42 Premountingthe kickstarter shaft............... 178
18.4.43
Checking the starter drive .......................... 179
18.4.44
Removing the Ireewheel ............................ 179
18.4.45
Checking the freewheel ............................. 180
18.4.46 Installing the free
wheel ............................ 180
18.5
Engine assembly ........................................... 181
18.5.1 Installing the crankshaft............................ 181
18.5.2 Installing the transmission shafts ............... 181
18.5.3 Installing the shift lorks............................. 181
18.5.4 Installing the shift drum ............................ 182
18.5.5 Installing the shift rails ............................. 182
18.5.6 Installing the left engine
case .................... 182
18.5.7 Installing the free
wheel gear ..................... 183
18.5.8 Installing the primary
gear ......................... 183
18.5.9 Installing the lorce
pump ........................... 183
18.5.10 Installing the oil
pump gear wheels ............. 184
18.5.11 Installing the locking
lever ......................... 184
18.5.12 Installing the shift drum locating unit......... 184
18.5.13 Installing the shift shaft ............................ 185
18.5.14 Installing the kickstarter idler
gear .............. 185
18.5.15 Installing the kickstarter shaft.................... 185
18.5.16 Installing the starter idler
gear ................... 185
18.5.17 Installing the torque limiter ....................... 186
18.5.18 Installing the outer clutch
hub ................... 186
18.5.19 Installing the primary
gear nut ................... 187
18.5.20 Installing the clutch discs.......................... 187
18.5.21 Installing the clutch
cover ......................... 188
18.5.22 Installing the water
pump cover .................. 189
18.5.23 Installing the suction pump ....................... 189
18.5.24 Installing the ignition pulse generator ......... 190
18.5.25 Installing the timing chain ......................... 190
18.5.26 Installing the timing chain securing guide ... 190
18.5.27 Installing the timing chain tensioning rail.... 191
18.5.28 Installing the timing chain guide rail........... 191
18.5.29 Installing the rotor .................................... 191
18.5.30 Installing the piston .................................. 191
18.5.31 Installing the cylinder
head ........................ 193
18.5.32 Installing the camshaft.............................. 194
18.5.33 Installing the timing chain tensioner........... 194
18.5.34
Checking the valve clearance ..................... 194
18.5.35 Adjusting the
valve clearance..................... 195
18.5.36 Installing the alternator
cover ..................... 195
18.5.37 Installing the
valve cover ........................... 196
18.5.38 Installing the spark plug............................ 196
18.5.39 Installing the starter motor......................... 196
18.5.40 Installing the oil filter................................ 196
18.5.41 Installing the clutch
push rod .................... 197
18.5.42 Installing the oil
screen ............................. 197
18.5.43
Removing the engine lrom the engine
assembly stand......................................... 198
19
CLUTCH .................................................................. 199
19.1 Checking/correcting the fluid
level of the
hydraulic clutch............................................ 199
19.2
Changing the hydraulic clutch fluid ................ 199

TABLE OF CONTENTS 5
20 WATER PUMP, COOLING SYSTEM ............................ 201 29.8 Page 8 of 8 (EXC EU, EXC SIX DAYS) ............. 242
20.1 Cooling
system ............................................. 201 29.9 Page 1 of 8 (EXC AUS) .................................. 244
20.2 Checking the antifreeze
and coolant level ........ 201 29.10 Page 2 of 8 (EXC AUS) .................................. 246
20.3 Checking the coolant
level ............................. 202 29.11 Page 3 of 8 (EXC AUS) .................................. 248
20.4 Draining the coolanl...................................... 202 29.12
Page 4 of 8 (EXC AUS) .................................. 250
20.5 Refilling coolant ........................................... 203 29.13
Page 5 of 8 (EXC AUS) .................................. 252
21
LUBRICATION SySTEM ............................................ 204 29.14 Page 6 of 8 (EXC AUS) .................................. 254
21.1
Oil circui!..................................................... 204 29.15
Page 7 of 8 (EXC AUS) .................................. 256
21.2 Checking the engine oil
level .......................... 204 29.16 Page 8 of 8 (EXC AUS) .................................. 258
21.3
Changing the engine oil and oil filter, 29.17 Page 1 of 8 (EXC USA) .................................. 260
cleaning the oil
screens ................................. 204 29.18
Page 2 of 8 (EXC USA) .................................. 262
21.4 Adding engine oil .......................................... 207 29.19
page 3 of 8 (EXC USA) .................................. 264
21.5 Checking the engine oil
pressure .................... 208 29.20
Page 4 of 8 (EXC USA) .................................. 266
22
IGNITION SySTEM ................................................... 209 29.21
Page 5 of 8 (EXC USA) .................................. 268
22.1 Ignition coil -checking the secondary 29.22
Page 6 of 8 (EXC USA) .................................. 270
winding........................................................ 209 29.23
Page 7 of 8 (EXC USA) .................................. 272
22.2 Checking the spark plug connector ................. 209 29.24
Page 8 of 8 (EXC USA) .................................. 274
22.3 Alternator -checking the stator winding .......... 209 29.25
Page 1 of 7 (all XC-W models) ........................ 276
22.4
Removing the stator ...................................... 210 29.26
Page 2 of 7 (all XC-W models) ........................ 278
22.5 Installing the stator ....................................... 210 29.27
page 3 of 7 (all XC-W models)........................ 280
23
ELECTRIC STARTER ................................................ 211 29.28
Page 4 of 7 (all XC-W models) ........................ 282
23.1 Checking the starter motor............................. 211 29.29
Page 5 of 7 (all XC-W models) ........................ 284
24 THROTILE VALVE BODy .......................................... 212 29.30
Page 6 of 7 (all XC-W models)........................ 286
24.1 Adjusting the idle
speed ................................ 212 29.31
Page 7 of 7 (all XC-W models)........................ 288
24.2 Throttle position sensor circuit A- checking
30 SUBSTANCES ......................................................... 290
the basic settings.......................................... 212 31
AUXILIARY SUBSTANCES ........................................ 292
24.3 Throttle position
sensor -adjusting the basic
settings........................................................ 212
25 TECHNICAL DATA .................................................... 214
25.1
Engine ......................................................... 214
32 SPECIAL TOOLS ...................................................... 294
33 STANDARDS ........................................................... 308
INDEX ............................................................................ 309
25.2 Engine tolerance, wear limits ......................... 214
25.3
Engine tightening torques .............................. 215
25.4 Capacities .................................................... 217
25.4.1
Engine oil ................................................ 217
25.4.2 Coolant .................................................... 217
25.4.3
Fuel ........................................................ 217
25.5
Chassis ........................................................ 217
25.6 Electrical
system ........................................... 218
25.7 Tires............................................................ 218
25.8
Fork ............................................................. 219
25.8.1
EXC EUiAUS/USA, XC-W ........................... 219
25.8.2
EXC SIX DAyS .......................................... 219
25.9 Shock absorber............................................. 220
25.10
Chassis tightening torques ............................. 220
26 CLEANING, CARE .................................................... 222
26.1 Cleaning the motorcycle ................................ 222
26.2
Checks and maintenance steps for winter
operation...................................................... 223
27
STORAGE ................................................................ 224
27.1
Storage ........................................................ 224
27.2 Preparing for
use after storage ........................ 224
28 SERVICE SCHEDULE ............................................... 225
28.1
Service schedule........................................... 225
28.2
Service work (as additional order) ................... 226
29 WIRING DIAGRAM ................................................... 228
29.1
Page 1 of 8 (EXC EU, EXC SIX DAyS) ............. 228
29.2
Page 2 of 8 (EXC EU, EXC SIX DAYS) ............. 230
29.3
page 3 of 8 (EXC EU, EXC SIX DAYS) ............. 232
29.4
Page 4 of 8 (EXC EU, EXC SIX DAYS) ............. 234
29.5
Page 5 of 8 (EXC EU, EXC SIX DAYS) ............. 236
29.6
Page 6 of 8 (EXC EU, EXC SIX DAYS) ............. 238
29.7
Page 7 of 8 (EXC EU, EXC SIX DAYS) ............. 240

1 MEANS OF REPRESENTATION 6
1.1 S J!!! bols used
The meaning of specific symbols is described below.
Indicates
an expected reaction (e.g. of a work step or a function).
x Indicates
an unexpected reaction (e.g. of a work step or a function).
Indicates a page reference (more information is provided on the specified page).
•
I Indicates information with more details or tips.
» Indicates the result of a testing step.
v Denotes a voltage measurement.
A
Denotes a current measurement.
Denotes a resistance measurement.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Identifies a protected name.
Identifies a trademark.

2 SAFETY ADVICE
2.1 Rlp! ir Manual
Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you
repair and maintain your vehicle.
This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available.
advice
A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety
instructions are highlighted in the text and are referred to at the relevant passages.
• Inlo
I The vehicle has various information and warning labels at prominent locations. Do not remove informationiwarning labels. If
they are missing, you or others may not recognize dangers and may therefore be injured.
2.3 ~ u of rilll and !lJl!! bols
n Danler
t..!.J Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
2.4 Wortll1llu
7
Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren-
theses. E.g.: bearing puller (15112017000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
In some instances, a thread locker (e.g. Lactiree) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.

3 IMPORTANT NOTES 8
3.1 Guarantee, wam!!lJ
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
service record and in the KTM dlaler.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage
resulting from manipulations and/or alterations to the vehicle.
Additional information on the guarantee or warranty and the procedures involved can be found in the service record.
o aratinl and alillililry substances
Warninl
Enviranmental 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.
Use the operating and auxiliary substances (such as fuel and lubricants) as specified in the manual.
3.3 Sp!18 parts, Ic_rias
Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any
resulting damage or loss.
The current KTM PawerParts for your vehicle can be found on the KTM website.
International KTM Website, httpdlwww.ktm.com
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to dis·
assemble the component to perform the activity in question. Please follow the instructions in the text.

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4 SERIAL NUMBERS 9
(EXC ELVAUS, EXC SIX DAYS, XC-W)
The chassis number is stamped on the steering head on the right.
(EXC USA)
The chassis number is stamped on the steering head on the right.
(EXC ELVAUS, EXC SIX DAYS, XC-W)
The type label is fixed to the front of the steering head.
(EXC USA)
The type label USA is fixed to the front of the steering head.
(EXC USA)
The type label Canada is fixed to the front of the front pipe.

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4 SERIAL NUMBERS
4.3 Key number All EXC models)
500125-10
101543·10
10
(EXC ELVAUS, EXC SIX DAYS)
The key number for the steering lock is stamped onto the key connector.
(EXC USA)
Key number for the ignition and steering lock is indicated on the KEYCODECARD.
• Info
I You need the key number to order a replacement key. Keep the KEYCODE·
CARD in a safe place.
The engine number is stamped
on the left side of the engine under the engine
sprocket.
The fork part number is stamped
on the inner side of the fork stub.
(EXC EU, EXC SIX DAYS)
The shock absorber part number is stamped on the top of the shock absorber
above the adjusting ring on the engine side.

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4 SERIAL NUMBERS 11
(EXC AUS, EXC USA, XC-W)
The shock absorber part number is stamped on the top of the shock absorber
above the adjusting ring on the engine side.

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5 MOTORCYCLE
Note
Danger of damage The parked vehicle may roll away or fall over.
-Always place the vehicle
on a firm and even surface.
-Raise the motorcycle at the frame underneath the engine.
I Lift stand (54829055000) ( .- p. 296)
~ The wheels should no longer touch the ground.
-Secure the motorcycle against falling over.
5.2 Ramovi!ll the motorcycle from the lift stand
Note
Danger of damage The parked vehicle may roll away or fall over.
-Always place the vehicle on a firm and even surface.
-Remove the motorcycle from the
lift stand.
-Remove the
lift stand.
-
To park the motorcycle, press the side stand to the ground with your foot and
lean the motorcycle
on it.
• Info
12
I When you are riding, the side stand must be folded up and secured with the
rubber band.
5.3
Note
COoo77-01
Danger
Danller of poisoninll Exhaust gases are toxic and inhaling them may result in unconsciousness andlor death.
-
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
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.
400733-01
-Raise the motorcycle off of the stand and secure the stand with the rubber band
-
Shift transmission to neutral.
(EXC USA)
-Turn the key in the ignition lock to the position O.
-Turn the emergency
OFF switch to the position O.
(EXC AUS)
-Turn the emergency OFF switch to the position O.
Condition
Ambient temperature, < 20 'C « 68 'F)
-Pull the idle speed adjusting screw all the way out.
-
Press the electric starter button or press the kick starter robustly through its full
range.
• Info
I Press the electric starter button for at most 5 seconds. Wait for a least 5
seconds before trying again.
Warning lamp
FI lights up briefly as a functional control when starting.

5 MOTORCYCLE 13
5.4 Startinlllli mato !!=J!; 11 for a chick
Danger
Danger 0' poisoning Exhaust gases are toxic and inhaling them may 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 an enclosed
space without an effective exhaust extraction system.
• Inlo
I Press the starter for a maximum of 5 seconds. Wait for at least 5 seconds before trying again.
-Shift transmission to neutral.
(EXC USA)
- Turn the key in the ignition lock to the position O.
-
Turn the emergency OFF switch to the position O.
(EXC AUS)
- Turn the emergency OFF switch to the position O.
-
Press the electric starter button or press the kickstarter robustly through its full range.
• Info
I Do not open the throttle.

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6 FORK, TRIPLE CLAMP 15
6.1 A Bilidini fork IllS
Guideline
Spring preload -Preload Adjuster
Comfort 1 turn
Standard 2 turns
Sport 2 turns
• Info
I 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.
PreparatolY work
-Raise the motorcycle with the
lift stand. ( .. p. 12)
Main work
-Release bleeder screws
./ Any excess pressure escapes from the interior of the fork.
-
Mou nt and tighten bleeder screws.
Finishinl work
-Remove the motorcycle from the
lift stand. ( .. p. 12)
6.1.5 Cleanlnl the dust boots of the fork IllS
PreparatolY work
-Raise the motorcycle with the
lift stand. ( .. p. 12)
-Loosen the fork protector. ( .. p. 16)
Main work
-Push dust boot down on both fork leg.
• Info
I The dust boots remove dust and coarse dirt particles from the inside 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.
Warninll
Danler 01 accidents Reduced braking efficiency 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 lubricate the dust boot and inside fork tube
on both fork legs.
IUniversal oil spray ( .. p. 293)
- Press the dust boots back into the installation position.
-Remove excess
oi I.
Finishing work
-Position the fork protection. (
.. p. 16)
-Remove the motorcycle from the
lift stand. ( .. p. 12)

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6 FORK, TRIPLE CLAMP 16
6.1.6 Loosening the lark protector
6.1.7 Positioninl the lark protection
6.1.8 Relloving the lark IBIS
- Remove screws and remove the clamp.
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Remove screws on the left fork leg. Push the fork protector downwards.
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Remove the screws on the right fork leg. Push the fork protector downwards.
-Position the fork protection
on the left fork leg. Mount and tighten screws
Guideline
1 Remaining screws, chassis
110 Nm (7.4 Ibf fl) 1
-Position the wiring harness.
-Position the brake line. Put the clamp
on, mount and tighten screws
-Position the fork protection
on the right fork leg. Mount and tighten the screws.
Guideline
IRemaining screws, chassis
110 Nm (7.4 Ibf It) 1
Preparatory work
- Remove the headlight mask with the headlight. (' r p. 99)
- Raise the motorcycle with the lift stand. (r p. 12)
- Remove the front wheel. (r p. 103)
Main work
- Remove screws and take off the clamp.
-
Remove cable binder
-
Remove screws and take off the brake caliper.
-Allow the brake caliper and brake line
to hang tension-free to the side.
(EXC EUJAUS, XC-W)
-Release screws . Take out the left fork leg.
-Release screws . Take out the right fork leg.
(EXC USA)
-Release screws . Take out the left fork leg.
-Release screws . Take out the right fork leg.

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6 FORK, TRIPLE CLAMP 17
6.1.9 Installing the fork legs
6.1.10 Relloviq the fork protector
Main work
(EXC EUIAUS, XC-W)
-Position the fork legs.
• Info
I Grooves are milled into the side of the upper end of the fork legs. The
second milled
groove (from the top) must be flush with the top edge of
the upper triple clamp.
Position bleeder screws toward the front.
-Tighten screws
Guideline
Screw, top triple clamp
-Tighten screws
Guideline
Screw, bottom triple clamp
(EXC USA)
-Position the fork legs.
• Info
M8
M8
20 Nm
(14.8 Ibf It)
15 Nm
(11.1 Ibf It)
I Grooves are milled into the side of the upper end of the fork legs. The
second milled
groove (from the top) must be flush with the top edge of
the upper triple clamp.
Position bleeder screws toward the front.
-Tighten screws
Guideline
Screw, top triple clamp
-Tighten screws
Guideline
Screw, bottom triple clamp
M8
M8
-Position brake caliper, and mount and tighten screws
Guideline
Screw, front brake caliper M8
-Mount cable binder
25 Nm
(18.4 Ibf ft)
20 Nm
(14.8 Ibf It)
15 Nm
(11.1 Ibf It)
Loctile- 243'"
-Position the brake line, wiring harness, and clamp. Mount and tighten screws
Finishing work
-Install the front wheel. ( .. p. 103)
-Refit the headlight mask with the headlight. (
.. p. 99)
-Check the headlight setting. ( .. p. 130)
PreparalolY work
- Remove the headlight mask with the headlight. ( .. p. 99)
- Raise the motorcycle with the lift stand. ( .. p. 12)
-
Remove the front wheel. ( .. p. 103)

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6 FORK, TRIPLE CLAMP
6.1.11 InSlalilna: the fork protector
- Remove the fork legs. ( .. p. 16)
Main work
- 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.
Main work
-Position the fork protection on the left fork leg. Mount and tighten screws
Guideline
18
I Remaining screws, chassis
110 Nm (7.4 Ibf It) 1
-Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
I Remaining screws, chassis
110 Nm (7.4 Ibf It) 1
Finishinl work
-Install the fork legs. ( .. p. 17)
-Install the front wheel. (
.. p. 103)
-Refit the headlight mask with the headlight. ( .. p. 99)
-Check the headlight setting. ( .. p. 130)
6.1.12 Performina: a fork service
• Info
I These operations are the same on both fork legs.
Condition
The fork legs have been removed.
-Disassemble the fork legs. (
.. p. 18)
-Disassemble the cartridge. (
.. p. 21)
-Check the fork legs. ( .. p. 23)
-Assemble the cartridge. ( .. p. 25)
-Assemble the fork legs. ( .. p. 27)
I.
I §
<0
0 !
0 e
e 200979-01
6.1.13 Dlsassembllna: the fork lea;s
• Info
I The steps are identical for both fork legs.

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6 FORK, TRIPLE CLAMP
Condition
The fork legs are disassembled.
- Remove protective cover
-Note down the present state of rebound damping and compression damping
-Note down of the present state of the spring preload.
19
-Completely open the adjusters of the rebound damping and compression damping.
200736-10
-Clamp the fork leg in the area of lower triple clamp.
IClamping stand (Tl403S) ( eo p. 306)
- Loosen Preload Adjuster
IPin wrench (Tl03) (eo p. 302)
• Info
I The Preload Adjuster cannot be taken off yet.
200737-10
-Take out the fork leg and clamp with the axle clamp.
• Info
I Use soft jaws.
200690-10
- Push the outer tube downward.
-Pull the spring downward. Place the special tool
on the hexagonal part.
IOpen-end wrench (Tl4032) ( eo p. 306)
• Info
I The preload spacers should be above the special tool.
-Clamp the special tool in the bench vise.
Loosen Preload Adjuster

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