KTM 450 EXC EU 2016 User manual

OWNER'S MANUAL 2016
450 EXC EU
450 EXC AU
450 EXC Six Days EU
450 XC-W US
500 EXC EU
500 EXC AU
500 EXC Six Days EU
500 XC-W US
Art. no. 3213338en

DEAR KTM CUSTOMER 1
DEAR KTM CUSTOMER
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you enormous pleasure if you service and maintain it accordingly.
We hope you enjoy your new vehicle!
Please enter the serial number of your vehicle below.
Chassis number ( p. 12) Stamp of dealer
Engine number ( p. 12)
Key number (All EXC models) ( p. 12)
The Owner's Manual contained the latest information for this model series at the time of going to print. Slight deviations resulting
from continuing development and design of the motorcycles can, however, not be completely excluded.
All specifications are non-binding. KTM Sportmotorcycle GmbH 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, misprints, and other errors. The models portrayed partly contain special equip-
ment that does not belong to the regular scope of supply.
© 2015 KTM Sportmotorcycle GmbH, 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 GmbH
5230 Mattighofen, Austria

TABLE OF CONTENTS 2
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ..................................... 5
1.1 Symbols used ................................................... 5
1.2 Formats used.................................................... 5
2 SAFETY ADVICE........................................................... 6
2.1 Use definition - intended use ............................. 6
2.2 Safety advice.................................................... 6
2.3 Degrees of risk and symbols ............................... 6
2.4 Tampering warning............................................ 6
2.5 Safe operation .................................................. 7
2.6 Protective clothing ............................................ 7
2.7 Work rules........................................................ 7
2.8 Environment..................................................... 7
2.9 Owner's Manual ................................................ 8
3 IMPORTANT NOTES..................................................... 9
3.1 Guarantee, warranty .......................................... 9
3.2 Operating and auxiliary substances ..................... 9
3.3 Spare parts, accessories .................................... 9
3.4 Service ............................................................ 9
3.5 Figures ............................................................ 9
3.6 Customer service............................................... 9
4 VIEW OF VEHICLE ..................................................... 10
4.1 View of vehicle, front left (example) .................. 10
4.2 View of vehicle, rear right (example) ................. 11
5 SERIAL NUMBERS .................................................... 12
5.1 Chassis number .............................................. 12
5.2 Type label ...................................................... 12
5.3 Key number (All EXC models)........................... 12
5.4 Engine number ............................................... 12
5.5 Fork part number ............................................ 12
5.6 Shock absorber part number ............................ 13
6 CONTROLS................................................................ 14
6.1 Clutch lever.................................................... 14
6.2 Hand brake lever............................................. 14
6.3 Throttle grip ................................................... 14
6.4 Kill switch (All EXC models)............................. 14
6.5 Kill switch (XC‑W) ........................................... 14
6.6 Horn button (All EXC models)........................... 15
6.7 Light switch (All EXC models) .......................... 15
6.8 Light switch (XC‑W)......................................... 15
6.9 Turn signal switch (All EXC models).................. 15
6.10 Emergency OFF switch (EXC AU)...................... 15
6.11 Electric starter button (EXC EU,
EXC SIX DAYS, XC-W) ..................................... 16
6.12 Electric starter button (EXC AU) ....................... 16
6.13 Overview of indicator lamps (All EXC models) .... 16
6.14 Overview of indicator lamps (XC‑W)................... 16
6.15 Opening filler cap ........................................... 16
6.16 Closing filler cap............................................. 17
6.17 Idle speed adjusting screw............................... 17
6.18 Shift lever ...................................................... 18
6.19 Kick starter .................................................... 18
6.20 Foot brake lever .............................................. 18
6.21 Side stand...................................................... 18
6.22 Steering lock (All EXC models) ......................... 19
6.23 Locking the steering (All EXC models)............... 19
6.24 Unlocking the steering (All EXC models)............ 19
7 SPEEDOMETER ......................................................... 20
7.1 Speedometer overview ..................................... 20
7.2 Activation and test .......................................... 20
7.3 Setting kilometers or miles............................... 20
7.4 Setting the speedometer functions.................... 21
7.5 Setting the clock............................................. 21
7.6 Viewing the lap time........................................ 21
7.7 Display mode SPEED (speed)........................... 22
7.8 Display mode SPEED/H (service hours) ............. 22
7.9 Setup menu ................................................... 23
7.10 Setting the unit of measurement ...................... 23
7.11 Display mode SPEED/CLK (time)...................... 24
7.12 Setting the clock............................................. 24
7.13 Display mode SPEED/LAP (lap time)................. 24
7.14 Viewing the lap time........................................ 25
7.15 Display mode SPEED/ODO (odometer) .............. 25
7.16 Display mode SPEED/TR1 (trip master 1).......... 25
7.17 Display mode SPEED/TR2 (trip master 2).......... 26
7.18 Setting TR2 (trip master 2).............................. 26
7.19 Display mode SPEED/A1 (average speed 1) ....... 26
7.20 Display mode SPEED/A2 (average speed 2) ....... 27
7.21 Display mode SPEED/S1 (stop watch 1)............ 27
7.22 Display mode SPEED/S2 (stop watch 2)............ 27
7.23 Table of functions ........................................... 28
7.24 Table of conditions and menu activation ........... 29
8 PREPARING FOR USE................................................ 30
8.1 Advice on first use .......................................... 30
8.2 Running-in the engine..................................... 31
8.3 Preparing the vehicle for difficult riding
conditions ...................................................... 31
8.4 Preparing for rides on dry sand......................... 32
8.5 Preparing for rides on wet sand ........................ 32
8.6 Preparing for rides on wet and muddy
surfaces ......................................................... 33
8.7 Preparing for rides at high temperature and
slow speed ..................................................... 33
8.8 Preparing for rides at low temperature or in
snow.............................................................. 33
9 RIDING INSTRUCTIONS............................................. 34
9.1 Checks and maintenance work when preparing
for use ........................................................... 34
9.2 Starting.......................................................... 34
9.3 Starting off..................................................... 35
9.4 Shifting, riding ............................................... 35
9.5 Braking.......................................................... 35
9.6 Stopping, parking............................................ 36
9.7 Transport ....................................................... 36
9.8 Refueling ....................................................... 37
10 SERVICE SCHEDULE ................................................. 38
10.1 Service schedule............................................. 38
10.2 Service work (as additional order) ..................... 39
11 TUNING THE CHASSIS .............................................. 40
11.1 Checking the basic suspension setting against
the rider's weight ............................................ 40
11.2 Compression damping of shock absorber ........... 40
11.3 Adjusting the low-speed compression damping
of the shock absorber ...................................... 40
11.4 Adjusting the high-speed compression
damping of the shock absorber......................... 41
11.5 Adjusting the rebound damping of the shock
absorber......................................................... 41
11.6 Measuring rear wheel sag unloaded................... 42
11.7 Checking the static sag of the shock absorber.... 42
11.8 Checking the riding sag of the shock absorber.... 42
11.9 Adjusting the spring preload of the shock
absorber ..................................................... 43
11.10 Adjusting the riding sag ............................... 43
11.11 Checking basic setting of fork .......................... 44

TABLE OF CONTENTS 3
11.12 Adjusting the compression damping of the
fork ............................................................... 44
11.13 Adjusting the rebound damping of the fork ........ 45
11.14 Adjusting the spring preload of the fork
(EXC EU/AU, XC‑W)......................................... 46
11.15 Handlebar position.......................................... 47
11.16 Adjusting handlebar position ........................ 48
12 SERVICE WORK ON THE CHASSIS.............................. 50
12.1 Raising the motorcycle with the lift stand.......... 50
12.2 Removing the motorcycle from the lift stand...... 50
12.3 Bleeding the fork legs...................................... 50
12.4 Cleaning the dust boots of the fork legs............. 51
12.5 Removing the fork legs ................................. 51
12.6 Installing the fork legs ................................. 52
12.7 Removing the fork protector ............................. 54
12.8 Installing the fork protector.............................. 54
12.9 Removing the lower triple clamp (All EXC
models).......................................................... 54
12.10 Removing the lower triple clamp (XC‑W) ........ 55
12.11 Installing the lower triple clamp (All EXC
models).......................................................... 56
12.12 Installing the lower triple clamp (XC‑W)......... 59
12.13 Checking the steering head bearing play............ 60
12.14 Adjusting the play of the steering head
bearing (All EXC models).............................. 61
12.15 Adjusting the play of the steering head
bearing (XC‑W)............................................ 62
12.16 Greasing the steering head bearing ................ 62
12.17 Removing the front fender ............................... 62
12.18 Installing the front fender ................................ 63
12.19 Removing the shock absorber ....................... 63
12.20 Installing the shock absorber ........................ 63
12.21 Removing the seat .......................................... 64
12.22 Mounting the seat........................................... 64
12.23 Removing the air filter box cover ...................... 64
12.24 Installing the air filter box cover ....................... 64
12.25 Removing the air filter ................................. 65
12.26 Installing the air filter .................................. 65
12.27 Cleaning the air filter and air filter box .......... 65
12.28 Sealing the air filter box ............................... 66
12.29 Removing main silencer................................... 66
12.30 Installing the main silencer.............................. 66
12.31 Cleaning spark arrestor (XC‑W)...................... 67
12.32 Changing glass fiber yarn filling in the main
silencer ...................................................... 68
12.33 Removing the fuel tank ................................ 69
12.34 Installing the fuel tank ................................. 70
12.35 Checking for chain dirt accumulation................ 72
12.36 Cleaning the chain .......................................... 72
12.37 Checking the chain tension .............................. 73
12.38 Adjusting the chain tension.............................. 73
12.39 Checking the chain, rear sprocket, engine
sprocket and chain guide................................. 74
12.40 Checking the frame ..................................... 76
12.41 Checking the swingarm ................................ 76
12.42 Checking throttle cable routing......................... 76
12.43 Checking the rubber grip ................................. 77
12.44 Additionally securing the rubber grip................. 77
12.45 Adjusting the basic position of the clutch
lever .............................................................. 77
12.46 Checking/correcting the fluid level of the
hydraulic clutch.............................................. 77
12.47 Changing the hydraulic clutch fluid ............... 78
12.48 Removing the engine guard (All EXC models)..... 78
12.49 Installing the engine guard (All EXC models) ..... 78
13 BRAKE SYSTEM ........................................................ 79
13.1 Checking free travel of hand brake lever ............ 79
13.2 Adjusting free travel of hand brake lever (All
EXC models)................................................... 79
13.3 Adjusting the basic position of the hand brake
lever (XC‑W) ................................................... 79
13.4 Checking the brake discs ................................. 80
13.5 Checking the brake fluid level of the front
brake ............................................................. 80
13.6 Adding front brake fluid ............................... 80
13.7 Checking the front brake linings ....................... 81
13.8 Changing the front brake linings ................... 82
13.9 Checking the free travel of foot brake lever ........ 83
13.10 Adjusting the basic position of the foot brake
lever ........................................................... 83
13.11 Checking the rear brake fluid level.................... 84
13.12 Adding rear brake fluid ................................ 84
13.13 Checking the rear brake linings ........................ 85
13.14 Changing the rear brake linings ..................... 86
14 WHEELS, TIRES ........................................................ 88
14.1 Removing the front wheel ............................. 88
14.2 Installing the front wheel ............................. 88
14.3 Removing the rear wheel .............................. 89
14.4 Installing the rear wheel ............................... 90
14.5 Checking the tire condition .............................. 90
14.6 Checking the tire air pressure........................... 91
14.7 Checking spoke tension ................................... 91
15 ELECTRICAL SYSTEM ................................................ 93
15.1 Removing the battery ................................... 93
15.2 Installing the battery .................................... 93
15.3 Charging the battery .................................... 94
15.4 Changing the main fuse................................... 95
15.5 Changing the fuses of individual power
consumers...................................................... 96
15.6 Removing headlight mask with headlight........... 96
15.7 Refitting the headlight mask with the
headlight........................................................ 97
15.8 Changing the headlight bulb ............................ 98
15.9 Changing the turn signal bulb (All EXC
models).......................................................... 98
15.10 Checking the headlight setting ......................... 99
15.11 Adjusting the headlight range........................... 99
15.12 Changing the speedometer battery.................. 100
16 COOLING SYSTEM ................................................... 101
16.1 Cooling system ............................................. 101
16.2 Checking the antifreeze and coolant level........ 101
16.3 Checking the coolant level ............................. 101
16.4 Draining the coolant .................................. 102
16.5 Refilling coolant ........................................ 102
17 TUNING THE ENGINE.............................................. 104
17.1 Checking the play in the throttle cable ............ 104
17.2 Adjusting the play in the throttle cable ........ 104
17.3 Adjusting the idle speed ............................. 105
17.4 Checking the basic position of the shift lever... 105
17.5 Adjusting the basic position of the shift
lever ......................................................... 105
18 SERVICE WORK ON THE ENGINE ............................. 107
18.1 Changing the fuel screen ............................ 107
18.2 Checking the engine oil level.......................... 107
18.3 Changing the engine oil and oil filter,
cleaning the oil screens ............................. 108

TABLE OF CONTENTS 4
18.4 Adding engine oil.......................................... 110
19 CLEANING, CARE .................................................... 111
19.1 Cleaning the motorcycle ................................ 111
19.2 Checks and maintenance steps for winter
operation...................................................... 112
20 STORAGE................................................................ 113
20.1 Storage ........................................................ 113
20.2 Preparing for use after storage........................ 113
21 TROUBLESHOOTING ............................................... 114
22 BLINK CODE ........................................................... 116
23 TECHNICAL DATA.................................................... 118
23.1 Engine ......................................................... 118
23.2 Engine tightening torques .............................. 118
23.3 Capacities .................................................... 120
23.3.1 Engine oil ................................................ 120
23.3.2 Coolant .................................................... 120
23.3.3 Fuel ........................................................ 120
23.4 Chassis ........................................................ 120
23.5 Electrical system........................................... 121
23.6 Tires............................................................ 121
23.7 Fork............................................................. 121
23.7.1 EXC EU/AU, XC‑W..................................... 121
23.7.2 EXC Six Days............................................ 122
23.8 Shock absorber............................................. 122
23.9 Chassis tightening torques ............................. 123
24 SUBSTANCES ......................................................... 125
25 AUXILIARY SUBSTANCES ........................................ 126
26 STANDARDS ........................................................... 128
27 LIST OF ABBREVIATIONS......................................... 129
28 LISY OF SYMBOLS................................................... 130
28.1 Yellow and orange symbols............................. 130
28.2 Green and blue symbols................................. 130
INDEX ............................................................................ 131

1 MEANS OF REPRESENTATION 5
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).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of
your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be opti-
mally cared for by specially trained experts using the specialist tools required.
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.
1.2 Formats used
The typographical formats used in this document are explained below.
Specific name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms that are explained in
the glossary.

2 SAFETY ADVICE 6
2.1 Use definition - intended use
(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
Only trained personnel are allowed to drive the vehicle. The vehicle is only authorized for operation on public roads in the
homologated (restricted) version.
The derestricted version of the vehicle must only be operated in closed off areas away from public highway traffic.
This motorcycle is designed for use in offroad endurance competition and not primarily for use in motocross.
(XC‑W)
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
This motorcycle is designed for use in offroad endurance competition and not primarily for use in motocross.
2.2 Safety 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.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If
they are missing, you or others may not recognize dangers and may therefore be injured.
2.3 Degrees of risk and symbols
Danger
Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are
not taken.
Warning
Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
2.4 Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device
or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate
purchaser or while it is in use, or
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:

2 SAFETY ADVICE 7
1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases.
2 Removal or puncturing of parts of the intake system.
3 Lack of proper maintenance.
4 Replacing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manu-
facturer.
2.5 Safe operation
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
–Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally
impaired.
Danger
Danger of 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.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
–Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these
components to cool down before starting work on them.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmen-
tally compatible manner.
An appropriate driver's license is needed to ride the vehicle on public roads.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
2.6 Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
–Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always
wear protective clothing that is in good condition and meets the legal requirements.
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.
2.7 Work rules
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. Loctite®) 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.
2.8 Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcy-
cle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the
respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that
pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.

2 SAFETY ADVICE 8
2.9 Owner's Manual
It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains
useful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to cus-
tomize the vehicle ideally for your own use and how you can protect yourself from injury.
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed.
If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.
The Owner's Manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold.