KTM 450 EXC EU 2014 Manual

SETUP INSTRUCTIONS 2014
450 EXC EU
450 EXC SIX DAYS EU
450 EXC AUS
450 XC-W USA
500 EXC EU
500 EXC AUS
500 EXC SIX DAYS EU
500 EXC USA
500 XC-W USA
Art. no. 3213135en

INTRODUCTION 1
INTRODUCTION
The work described in these setup instructions must be performed before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
Print out the current PDI form found on the KTM DEALER.NET.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter-
est of technical advancement without at the same time updating these setup instructions.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that the work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not belong to the regular scope of supply.
© 2013 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

1 MEANS OF REPRESENTATION 2
1.1 Symbols used
The meaning of specific symbols is described below.
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).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Denotes a voltage measurement.
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.
Name®Identifies a protected name.
Brand™ Identifies a trademark.

2 SETUP 3
2.1 Unpacking and setting up the vehicle
C00103-01
Packaging 2
–Remove the box and the plastic packaging.
Info
To avoid damaging the motorcycle during the setup, leave the protective
film on the vehicle until you have finished.
–Remove the separate enclosure and unpack it. Check that the scope of supply
is complete on the basis of the enclosed packing list.
–Have a lift stand available.
Lift stand (54829055000)
–Carefully loosen and remove the tension belt of the footrest mount.
Info
An assistant prevents the motorcycle from falling over.
601706-01
–Together with an assistant, take the vehicle off the palette.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
–Remove the headlight mask with the headlight. ( p. 8)
C00104-01
Package 12
–Remove the box and the plastic packaging.
Info
An assistant prevents the motorcycle from falling over.
To avoid damaging the motorcycle during the setup, leave the protective
film on the vehicle until you have finished.
–Remove the separate enclosure and unpack it. Check that the scope of supply
is complete on the basis of the enclosed packing list.
C00105-01
–Have a lift stand available.
Lift stand (54829055000)
–Together with an assistant, take the vehicle off the palette.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
–Install the shock absorber. ( p. 10)
600814-01
–Route the clutch line with the clutch master cylinder toward the front between
the upper and lower triple clamps.
(EXC EU, EXC AUS, all XC‑W models, 500 EXC USA)
–Position the fork legs and tighten the screws of the triple clamp.
Guideline
Screw, top triple clamp M8 20 Nm
(14.8 lbf ft)
Screw, bottom triple clamp M8 15 Nm
(11.1 lbf ft)
Info
Grooves are milled into the side of the top end of the fork legs. The
second milled groove (from the top) in the fork leg must be flush
with the top edge of the upper triple clamp.
Position the bleeder screws toward the front.

2 SETUP 4
(EXC SIX DAYS)
–Position the fork legs and tighten the screws of the triple clamp.
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
Screw, bottom triple clamp M8 15 Nm
(11.1 lbf ft)
Info
The rebound damping is located in the right fork leg REB (red
adjusting screw). The compression damping is located in the left
fork leg COMP (white adjusting screw).
Grooves are milled into the side of the top end of the fork legs. The
topmost milled groove must be flush with the top edge of the upper
triple clamp.
Position the bleeder screws toward the front.
101488-10
–Remove screws 1. Take off the handlebar clamps.
–Remove screws 2. Take off the handlebar supports.
–Place the handlebar supports in the required position. Mount and tighten
screws 2.
Guideline
Screw, handlebar holder M10 40 Nm
(29.5 lbf ft)
Loctite®243™
Info
Position the left and right handlebar supports evenly.
C00108-10
–Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
–Position the handlebar clamps. Mount and tighten the screws evenly.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
Info
The markings on the handlebar should be at the center of the handlebar
clamps.
Keep the gap widths equal when tightening.
C00521-01
(EXC EU, EXC AUS, 500 EXC USA)
–Insert the indicator lamp with the black and black cable colors into
socket 3.
–Insert the indicator lamp with the black and violet cable colors into
socket 4.
–Insert the indicator lamp with the orange and brown cable colors into
socket 5.
–Insert indicator lamp LED with the black and black cable colors into
socket 6.

2 SETUP 5
C00522-10
(all XC‑W models)
–Insert the indicator lamp with the orange and brown cable colors into
socket 7.
–Insert indicator lamp LED with the black and black cable colors into
socket 8.
–Connect pull switch 9with the yellow and white cables.
C00539-10
(EXC SIX DAYS)
–Insert the indicator lamp with the black and violet cable colors into
socket bk.
–Position the speedometer and connector board. Mount and tighten screws.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
C00523-10
–Position the controls on the right half of the handlebar.
Info
The routing of the cables can be seen in the figure.
C00524-10
–Position the controls on the left half of the handlebar.
Info
The figure shows how to route the clutch line and wiring harness.
B01749-01
(all EXC models)
–Remove the fuel tank.
–Position the turn signal wiring harness against the main wiring harness and
secure with cable binders.
B01750-01
–Disconnect the plug-in connection from the main wiring harness and con-
nect the turn signal wiring harness.
–Install the fuel tank.

2 SETUP 6
B01753-01
–Position the turn signal on each side and mount and tighten nuts.
–Connect plug-in connection of the right turn signal using the black and
brown cable colors.
–Connect plug-in connection of the left turn signal using the violet and
brown cable colors.
401382-01
(all EXC models)
–Mount the turn signal switch.
–Install the front fender. ( p. 11)
–Refit the headlight mask with the headlight. ( p. 9)
–Install the front wheel. ( p. 10)
–Correctly mount the fuel tank breather.
601710-01
–Secure the handlebar cushion with two cable binders.
101019-01
–Mount the footrests with the springs and pins. Secure the pins using the washers
and cotter pins.
Pliers for footrest spring (58429083000)
601711-01
(all 450 EXC models, all 500 EXC models, EXC EU, EXC SIX DAYS)
–Mount the license plate holder with the license plate lamp, turn signals, and
reflector.
–Connect the electrical components.
–Connect the connector of the left turn signal with connector that is marked red.
–Connect the connector of the right turn signal with the connector that is marked
green.

2 SETUP 7
C00117-01
(500 EXC USA)
–Mount the license plate holder with the license plate lamp, turn signals, and
reflector.
–Connect the electrical components.
–Connect the connector of the left turn signal with connector that is marked red.
–Connect the connector of the right turn signal with the connector that is marked
green.
101393-12
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 sparks and open flames away from the battery. Only charge 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 con-
tact a physician.
–Fill the battery.
Info
Read the notes in the battery package.
–Charge the battery. ( p. 12)
–Install the battery. ( p. 12)
–Unpack and mount the KTM PowerParts included in the delivery (optional).
Info
Read the accompanying KTM PowerParts fitting instructions.
–Apply the label included in the delivery (optional).
(EXC EU, EXC AUS, all XC‑W models, 500 EXC USA)
–Set kilometers or miles. ( p. 15)
–Adjust the speedometer functions. ( p. 15)
–Set the clock. ( p. 15)
(EXC SIX DAYS)
–Set kilometers or miles. ( p. 16)
–Set the speedometer functions. ( p. 16)
–Set the clock. ( p. 17)
–Refuel. ( p. 14)
–Position all controls in their exact positions on the handlebar. Tighten all screws.
–Print out the current PDI form found on KTM DEALER.NET and perform the
pre-delivery inspection.

3 WORK 8
3.1 Raising the motorcycle with the lift stand
L00710-01
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.
Lift stand (54829055000)
The wheels should no longer touch the ground.
–Secure the motorcycle against falling over.
3.2 Removing 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.
L00706-10
–Remove the motorcycle from the lift stand.
–Remove the lift stand.
–To park the motorcycle, press the side stand 1to the ground with your foot and
lean the motorcycle on it.
Info
When you are riding, the side stand must be folded up and secured with the
rubber band.
3.3 Removing headlight mask with headlight
B01560-10
–Switch off all electrical equipment.
–Remove screw 1and take off clamp.
–Loosen the rubber band 2. Push up the headlight mask and swing it forwards.
B01561-10
–Pull out the electric plug connector 3and remove the headlight mask with the
headlight.