KTM 450 EXC-F 2017 Operating instructions

REPAIR MANUAL 2017 I
•J t1•fli•l:t:lij4
I
450 EXC-F
450 EXC-F Six Days
500 EXC-F
500 EXC-F Six Days
Art.no.3206275en

INTRODUCTION
Read this repair manual carefully and thoroughly before beginning work.
The vehicle will only be able
to meet the demands placed on it if the specified service work is performed regularly and properly.
This repair manual was written to correspo nd to the latest state of thi s model series. We re serve the right to make changes in the interest
of technical advancement without updating this repair manual at the sa me time .
We shall not provide a de scrip tion of general workshop methods. Likewise, safety rules that apply in a workshop are not spec ified here. It
is assumed that the repair work will be performed by a fully trained mechanic .
All specifications are non- binding . KTM Sportmotorcycle GmbH specif ically reserves the right to modify or delete technical sp ecifi cations,
prices, colors, forms, materials, services, designs,
equipment, etc., without prior notice and wit h out specifying reasons, to adapt these to
local con dition s, as well as to stop production of a particu lar model without prior noti ce. KTM accepts no l iability for delivery options, devi-
ations from i
llu s tration s and descriptions, misprints, and other errors. The models portrayed partly con tain special equipment that does not
belong to the regular scope of sup ply.
© 2016 KTM Sportmotorcycle GmbH, Mattighofen Austria
All right s reserved
Reproduction, even in part, as
we ll as copying of all kinds, is permitted only with the express written permission of the copyrig ht owner.
ISO 9001(12 100 606 1)
KTM Sportmotorcycle GmbH
5230 Mattighofen, Austria
This
document is va lid for the fo ll owing model s:
450 EXC-F EU (F8403Q9)
450 E XC -F AU (F8460Q9)
450 EXC-F Six Days EU (F8403Q2)
450 E XC -F Six Da ys US (F8475Q2)
500 EXC-F EU (F8503Q9)
500 E XC -F AU (F8560Q9)
500 EXC-F US (F8575Q9)
500 E XC -F Six Days EU (F8503Q2)
1111111111111111111111111111111111111111111111111111111
3206275en
07 /2 016

TABLE OF CONTENTS 2
1 MEANS OF REPRESENTATION ..................................... 6 6.16 Ins
talling the lower triple clamp
1.1 Sy mb ols used ................................................... 6 (All EXC-F Six Day
s) ........................................ 50
1.2 Formats used .................................................... 6 6.
17 Changing the steer ing head bearing
2 SAFETY ADVICE
........................................................... 7 (EXC-F
EU /AU/US) ................................ .......... 52
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 ..................................................... 83
6.18 Changing the steer
ing head bearing
(All EXC-F Six Day
s) ........................................ 53
6.19 Checking the pla y of the steering head
b ea ring .......................................................... 54
6.20 Adjus ting the steering head bearing play
(E XC- F EU /AU/US) .......................................... 55
3.1 Manufac turer and implied warranty ..................... 8
3.2 Operating and auxiliary s ub stances ..................... 8
6.21 Adjus ting the steering head bearing play
(All E XC- F Six Da ys) ........................................ 55
3.3 Spare parts, accessories .................................... 8 7 HANDLEBAR, CONTROLS
........................................... 57
3.4 Fig ur es ............................................................ 8
7.1 Handlebar pos ition .......................................... 57
4 SERIAL NUMBERS ............ . ......................................... 9
7.2 Adju st ing th e ha ndl ebar p os ition ...................... 57
4.1 Chassis number ....... ......................................... 9
7.3 Adju st ing th e b as ic p os ition of the c lut ch
4.2 Ty pe label ........................................................ 9 lever
.............................................................. 59
4.3 Key number ...................................................... 9
7.4 Checking thr o ttle cable routing ......................... 59
4.4 Engine number ............................................... 10
7.5 Checking th e play in th e throttl e cable .............. 60
4.5 Fork part number ............................................ 10
7.6 Adjus ting th e play in th e throttle cable .............. 60
4.6 Shock absorber article number ......................... 10
8 FRAME ..................................................................... 62
5 MOTORCYCLE ........................................................... 11
8.1 Checking the frame ......................................... 62
5.1 Rais ing the motorcycle wi th the lift stand .......... 11
8.2 Removing the engine guard
5.2 Removing th e motorcycle from the lift s tand ...... 11 (All E
XC- F Six Days, E XC -F AU) ........................ 62
5.3 S tartin g .......................................................... 11
8.3 Ins talling the engine guard
5.4 S tartin g th e motorcycle for a check ................... 12 (All E
XC- F Six Days, E XC -F AU) ........................ 62
6 FORK, TRIPLE CLAMP ............................................... 13
8.4 Changing the footrests ..................................... 62
6.1 Adjusting the compression damping of th e 9 SHOCK ABSORBER,
SW INGARM .... .................. .......... 65
fork ............................................................... 13 9.1 Adju
st ing th e high-speed compre ss ion
6.2 Adjusting the rebound damping of the fork ........ 13
damping of the shock absorber ......................... 65
6.3 Adjus ting the spring preload of the fork
(A ll EXC-F Six Da ys) ........................................ 14
9.2 Adju st ing th e low-speed compression damping
of th e shock absorber ........ .................... .......... 65
6.4 Bleeding th e fork legs ...................................... 15
6.5 Cleaning the dust boots of the fork legs ............. 15
6.6 Removing the fork le gs .................................... 15
6.7 Installing the fork legs ..................................... 16
6.8 Removing the fork protector ............................. 17
6.9 Ins talling the fork protector...... .................. ...... 17
6.10 EX C-F EU /AU/ US ................ .... .................. ...... 17
9.3 Adju st ing th e rebound dampin g of th e shock
absorber
......................................................... 66
9.4 Measuring the rear wheel dimension
unloaded
........................................................ 66
9.5 Checking the static sag of the sho ck absorber.... 67
9 .6 Checking the ridin g sag of the shock absorber.... 67
9 .7 Adjus ting the spring preload of the shock
absorber
......................................................... 67
6.10.1 Servicingthefork .................................. ...... 17
6.10.2 Disassem bling the fork legs .................... .. ... 18
6.10.3 Disassem bling the cartridge .................... .. ... 20
6.10.4 Disassem bling the tap co mpre ss ion .............. 23
6.10.5 Checking the for k legs ................................. 23
6.10.6 Assembling the tap compression .................. 25
6.10. 7 Assembling the cartridge ............................. 25
6.10.8 Assembling the fork legs .............................. 28
6.11 All E XC -F Six Da ys .......................................... 32
6.11.1 Servicing the for k ........................................ 32
6.11.2 Disas se mblin g the fork legs ......................... 32
6.11.3 Disassem bling the cartridge ......................... 34
6.11.4 Disassem bling the tap compre ss ion .............. 37
6.11.5 Check ing the fork legs ................................. 38
6.11.6 Assembling th e tap compre ss ion .................. 39
6.11. 7 cartridge, assembling .................................. 40
6.11.8 Assembling th e fork legs .............................. 43
6.12 Lubrica ting the steering head bearing ............... 47
6.13 Removing the lo we r triple clamp
(EXC-F
EU /AU/US) .......................................... 47
6.14 Installing the lower triple clamp
(EXC -F EU /AU/US) .......................................... 48
9.8 Adjus ting the ridin g sag ................................... 68
9.9 Remov ing the shock absorber ........................... 69
9. 10 Ins talling the shock absorber ............................ 69
9.11 Servicing th e shock absorber ............................ 69
9.12 Remov ing the spring ........................................ 70
9. 13 Di sasse mbling the damper ............................... 71
9. 14 Di sasse mbling the piston rod ........................... 72
9. 15 Di sasse mbling the seal ring retainer .................. 73
9.16 Replacing the pilot bus hin g ............................. 74
9.17 Checking the damper ...................................... 75
9.18 Removing the heim joint.. ................................ 75
9.19 Ins tallin g the heim joint ................................... 76
9.20 As s emblin g seal ring retainer ........................... 77
9.21 As s emblin g the piston rod ................................ 77
9.22 As s emblin g the damper ................................... 79
9.23 Bleeding and filling th e damper ................ ....... 80
9.2 4 Filling damper with nitrogen .................. .......... 83
9.25 Ins talling the spring .............................. .......... 84
9.26 Checking th e he im joint for play................ ....... 85
9.27 Changing the shock absorber heim joint ............ 85
9.28 Changing the swingarm heim joint .................... 86
6.15 Removing the lo we r triple clamp
(A ll EXC-F Six Da ys) ........................................ 49
9 .29 Checking the swingarm bearing for play ............ 88
9 .3 0 Re mo ving the swingarm ................................... 88

TABLE OF CONTENTS 3
9.31 Ins tallin g the swingarm .......... .. ........................ 89 15 WIRING HARNESS, BATTERY........ .................... .. ..... 134
9. 32 Changing the swingarm bearing ........................ 91 15.1 Changingthema infu se .......................... .. ..... 134
10 EX HAUST .................. ... ................... ... .................. ..... 93 1 5.2 Changing the fu ses of individual power
10.1 Removing th e manif old .......... .. ........................ 93
consumers .................................................... 134
10.2 Ins tallin g the manifold .......... .. ........................ 93
1 5.3 Remov ing the battery .................................... 136
10.3 Removing main silencer ................................... 94
15.4 Ins tallin g the battery ..................................... 136
10.4 Installing the main silencer .............................. 95
15.5 Re charg ing the battery .................................. 137
10.5 Changing the gla ss fib er yarn fillin g in the
15.6 Checking the charging voltage ........................ 138
main silencer .................................................. 95 15.7 Checking the quiescent current ...................... 138
10.6 Cleaning the spark arrestor (All US models) ....... 96 15.8 Checking the starter relay .............................. 138
11 A IR FILTER ............................................................... 98 16 BRAKE SYS TEM ...................................................... 139
11.1 Removing the air filter box cover ...................... 98 16.1 Checking the front brake lini ngs ..................... 139
11.2 Ins talling the air filter box cover ....................... 98 1 6.2 Changing the fr ont brake linings ..................... 139
11.3 Sea lin g th e air fi lter box .................................. 98 1 6.3 Checking free travel of hand brake lever .......... 141
11.4 Removing th e air filt er ..................................... 99 1 6.4 Adjus ting free tra ve l of ha nd brake lever .......... 141
11.5 Ins talling the air filter ...................................... 99 1 6.5 Checking th e brake fluid le ve l of the front
11.6 Clea ning the air filter and air fi lter box .............. 99
brake ........................................................... 141
11.7 C he cking th e inlet membrane (All US 1
6.6 Adding front brake fl uid ................................. 14 2
models) ........................................................ 100
1 6.7 Changing the front brake fluid ........................ 14 3
12 FUEL TANK, SEAT, TRIM ......................................... 101 16.8 Checking the rear brake lini ngs ...................... 144
12.1 Opening the filler cap .................................... 101 16.9 Changing the rear brake linings ...................... 144
12.2 Closing the filler cap ..................................... 101 16.10 Checking the free travel of foot brake le ve r ...... 146
12.3 Removing the seat ............ .. .......................... 101 16.11 Adjusting the basic position of the foot brake
12.4 Mounting the seat ......................................... 102
lever ............................................................ 147
12.5 Removing the fue l tank ........ .......................... 102
16.12 Checking the rear brake fluid level .................. 14 7
12.6 Ins talling the fuel tank .................................. 104
16.13 Adding rear brake fl uid .................................. 148
12.7 Changing the fuel screen ............................... 10 5 16.
14 Changing the rear brake fluid .................. .. ..... 149
12.8 Changing the fuel filt er .................................. 10 6
17 LIGHTING SYSTEM, INSTRUMENTS .................. .. ..... 151
12.9 Changing the fuel pump ................................ 109
1 7. 1 Checking th e headI ight se tt ing ................ .. ..... 151
12.10 Checkingthefue l pressure ............................. 111
17 .2 Adju st ing th e headIight range .................. .. ..... 151
13 MASK, FENDER ....................................................... 113
17 .3 Speedomete ro verview...... .. .................... .. ..... 151
13.1 Removing th e front fender ............................. 113
17.4 A ct ivation and test ................................ ........ 151
13.2 Installing the front fender .............................. 113
17.5 Settingki l ometersormi les ............................. 15 2
13.3 Removing the headlig ht mask with the
17.6 Setting the speedometer fun c tions .................. 15 2
headligh t.. .................................................... 114 17.7 Settingtheclock ........................................... 153
13.4 Installing the headlig ht mask with the 17.8 Activating additional functions ....................... 153
headlig ht ...................................................... 115
17.9 Setting the wheel c ir cumference .................... 154
14 WHEELS ................................................................. 117
17.10 Viewingt h elaptime ...................................... 154
14.1 Checking the tire air pressure ......................... 117
18 ENGINE .................................................................. 155
14.2 C he cking th e tire cond iti on ............................ 117
18 .1 Remov ing the engine ..................................... 155
14.3 C he cking th e wh ee l bearing for play ................ 118
18 .2 Instal ling the engine ...................................... 160
14.4 C he cking th e brake discs ............................... 118
18 .3 Engine disassembly ....................................... 165
14.5 C he cking spoke te nsion ................................. 119
18 .3. 1 Preparations ............................................. 165
14.6 C he cking th e rim run-out ............................... 119
18 .3.2 Draining the engine oil .............................. 166
14.7 Fro nt wheel .................................................. 120
18 .3.3 Removing the c lut ch push rod .................... 166
14.7 .1 Removing the front wheel .......................... 1 20
18 .3.4 Removing the oil filter ............................... 16 7
14.7.2 Installing the front wheel ........................... 120
18.3.5 Removing the starter motor ........................ 167
14.7 .3 Changing the front brake discs ................... 121
18.3.6 Removing the spark plug ........................... 168
14.7 .4 Changing the front wheel bearing ............... 121
18.3.7 Removing the va lve cover ........................... 168
14.8 Rear wheel ................................................... 123
18.3.8 Removing the alternator cover .................... 168
14.8.1 Removing the rear wheel ........................... 123
18.3.9 Pos itioning the engine at ignition top dead
14.8.2 Installing the rear wheel ............................ 123 ce nter ...................................................... 169
14.8.3 Chang ing th e rear brake disc ...................... 124 18 .3.10 Removing the timin g chain tensioner .......... 169
14.8.4 Chang ing th e rear wheel bearing .............. .. . 1 25 18 .3. 11 Removing the camsha ft ...................... .. ..... 170
14.8.5 Check ing the chain tension .. ...................... 1 26 18 .3. 12 Removing the cylinder head ................ .. ..... 171
14.8.6 Adjusting the chain tension .................... .. . 1 27
18 .3. 13 Removing the piston .......................... .. ..... 171
14.8.7 Check ing the chain, rear sprocket, motor 18 .3. 14 Removing the rotor ........ .. .................. ........ 17 3
sprocket, and chain guide
.......................... 1 28
18 .3. 15 Removing the timin g chain ................ ........ 17 3
14.8.8 Check ing for chain dirt accumulation .......... 1 29
18 .3. 16 Removing su ct ion pump .................... ........ 174
14.8.9 Cleaning the chain .................................... 129
18.3.17 Removing the gear position sensor .............. 17 4
14.8.10 Changing the drivetrain kit ......................... 130
18.3.18 Removing the water pump cover ................. 17 4
18.3.19 Removing the c lut ch cover ......................... 175

TABLE OF CONTENTS
1 8.3.2 0 Removing th e c lut ch discs.. .................... .. . 1 75
1 8.3.2 1 Removing th e c lut ch b as ket .................... .. . 1 76
1 8.3.22 Removing th e torque limit er .................... .. . 1 77
1 8.3.23 Removing th e starter idl er gear ................ .. . 1 77
1 8.3.2 4 Removing th e force pump .... .................. .... 1 77
18. 3.2 5 Removing the s hift sha ft .......... .. .............. .. 178
18. 3.26 Removing the s hift drum loca tin g unit ........ 178
18. 3.2 7 Removing the locking lever ........ .............. .. 179
18. 3.28 Removing the primary gear ........ .............. .. 179
18. 3.2 9 Removing the freewh ee l gear .................... . 179
18. 3.3 0 Removing the le ft engine case sec tion ........ 179
18. 3.3 1 Removing the s hift rails........ .................... . 180
1 8.3.32 Removing th e s hift drum ........................... 18 1
1
8.3.33 Removing th e s hift fo rks ............................ 18 1
1
8.3.3 4 Removing th e tr ans mi ss ion sh aft s............... 18 1
1
8.3.35 Removing th e cr an ksha ft ........................... 18 2
18
.4 Wo rking on individual pa rt s ............................ 18 2
18
.4 .1 Wo rking on the right sec ti on of th e engine
ca
se ........................................................ 18 2
18 .4.2 Wo rking on the left sec ti on of the engine
case ........
..................... . ................... ....... 18 3
18 .4.3 Removing the oil pr ess ur e regulator valve .... 184
18 .4 .4 Ch ecking spring len gt h of o il pr ess ur e
regulator va lve ........ .. .............. .. .............. .. 184
18 .4 .5 Insta llin g th e o il press ur e regulator valve..... 185
18 .4 .6 Changing th e cranksha ft seal ring in th e
18
.4.7
18 .4 .8
18 .4 .9
c lut ch cover ............................................. 18 5
Removing
th e water pump ......................... 18 5
Insta lli ng th e water pump .......................... 1 86
Removing th e cra nk sha ft b ea ring inner
race..............
........................................ ... 1 87
18 .4 . 10 Insta lli ng th e cran ks ha ft bear ing inner
race ......................................................... 1 87
18.4. 11 Changing th e connec tin g rod, co nr od
bearing, and crank
pin ............ .. ................ 188
1 8.4. 12 Checking cra nk sha ft run-o ut at bearing
pin .......................................................... 18 9
18.4. 13 Me as urin g th e cranksha ft end pl ay ............. 189
18.4. 14 Cy lind er - Nik as il ®co atin g ......................... 190
18.4. 15 Checkin g/ measuring the cy linder ................ 190
18 .4 .16 Checking/meas urin g th e piston ................... 191
18
.4 .17 Checking piston rin g end gap ..................... 1 93
18 .4 .18 Meas ur ing the piston/cylinder mo untin g
cl ea rance .... .. ........ .. ......... .. ......... .. ......... .. 194
18
.4 .19 Checking the oil pumps ............................. 194
18
.4.2 0 Disassembling th e a ut odeco mpr essor .......... 1 95
18 .4.2 1 Asse mbling th e a ut odeco mpr essor .............. 1 95
18.4.22 Ch ecking cams haft ............................ ....... 19 6
18.4.23 Ch ecking the timin g assembly .................... 197
18.4.2 4 Removing the rock er arm .................... ....... 197
18.4.2 5 Removing the va lves .................................. 198
18.4.26 Changing th e camsha ft be aring .................. 198
18.4.2 7 Ch ecking the valves .................................. 199
18.4.28 Ch ecking va lve springs .............................. 20 0
18
.4 .29 Checking va lve spring seat.. ....................... 20 0
18
.4.3 0 Checking the cy lind er head ........................ 20 0
18
.4.3 1 Checking the rocker arm sha ft s .................. 20 1
18
.4 .32 Insta lli ng th e va l ves .................................. 20 1
18
.4 .33 Insta lli ng th e r oc ker arm ............................ 202
18 .4 .3 4 Checking the c lut ch .................................. 203
18.4.35 Checking the shi ft mechanism ................... 2 04
18.4.36 Preasse mblin g th e shift sha ft.. ................... 2 05
18.4.3 7 Disass emblin g the main s haft .................... 206
4
18.4 .38 Disasse mbli ng th e countersha ft.. ................ 206
18.4 .39 Checking th e trans mi ss ion ................ .... ..... 207
18.4.4 0 A sse mblin g th e main s ha ft.. .............. ......... 208
18.4.41 A sse mblin g th e co unt ershaft .............. ........ 208
18.4.4 2 Checking th e starter drive .................. ........ 2 10
18.4 .43 Ch ecking the freewh ee l ............................. 21 0
18.4 .44 Rem ov ing the fre ewheel ........ .................... 2 11
18.4 . 45 Insta llin g the f re ewheel ............................. 2 11
18 .5 En gine ass embly ........................................... 212
18 .5.1 Insta llin g the cra nk s haft ........ .................... 212
18 .5.2 Insta llin g the tr ans mi ss ion sha ft s ............... 212
18 .5 .3 Insta llin g the sh ift for ks ............................. 213
18 .5.4 Insta llin g th e s hift drum ............................ 213
18 .5.5 Insta llin g th e s hift rails ............................. 213
18 .5.6 Insta llin g th e l ef t engine case .................... 2 14
18 .5.7 Insta llin g th e freewh ee l gear ...................... 2 14
18 .5.8 Insta llin g th e prim ary gear ......................... 215
18 .5.9 Insta llin g th e locking lever ......................... 215
18 .5. 10 Insta lling the sh ift drum loca tin g unit ......... 2 15
18 .5. 11 Insta lling the sh ift shaft ............................ 2 15
18 .5.12 Insta lling the force pump ........................... 2 15
18 .5.13 Insta lling the s tart er idler gear ................... 21 6
18 .5.14 Insta lling the torque limite r ....................... 2 17
18
.5. 15 Insta lling the c lut ch b as ket.. .......... .. .......... 2 17
18
.5.16 Insta lling the c lut ch discs.. ............ .. .......... 218
1 8.5. 17 Insta llin g th e c lut ch cover ......................... 22 0
1
8.5. 18 Insta llin g th e wa ter pum p cover .................. 22 0
1
8.5. 19 Insta llin g th e gear posi ti on se nsor .............. 22 1
1
8.5.20 Insta llin g th e suction pump ....................... 22 1
1
8.5.2 1 Insta llin g th e tim ing chain ......................... 22 1
1
8.5.22 Insta llin g th e rotor .................................... 222
1 8.5.23 Insta llin g th e piston .................................. 222
18 .5.24 Insta llin g cy lind er he ad ............................. 22 6
18 .5.2 5 Insta llin g the cams haft .............................. 227
18 .5.26 Insta llin g the timin g chain tension er ........... 228
18 .5.2 7 Ch ecking the valve cleara nc e ..................... 22 9
18 .5.2 8 A dju s ti ng the valve clearance ..................... 22 9
18 .5.29 Insta llin g the a lt erna tor cover ..................... 23 0
1
8.5.30 Insta llin g th e va lve cover ........................... 23 0
1
8.5.3 1 Insta llin g th e spark plu g ............................ 23 0
1
8.5.32 Insta llin g th e starter motor ......................... 23 1
1
8.5.33 Insta llin g th e oil filt er ................................ 23 1
1
8.5.34 Insta llin g th e c lut ch push rod .................... 232
1 8.5.35 Insta llin g th e oil screens ............................ 232
1 8.5.36 Re m ov ing the engine fr om th e engine
assembly stand ......................................... 233
19 CLUTCH ............ .. .................................................... 23 4
19.1 Chec
kin g/correcting the fluid level of th e
hy dr a uli c cl utc h ...................... .. .............. ...... 23 4
1
9.2 Changing the hydraulic c lut ch fluid ................ 23 4
1
9.3 Chec kin g the clu tc h .. .............. .. .............. ...... 23 5
19
.4 Changing the c lut ch spring ........ .............. ...... 242
20 WATER PUMP, COO LING SYS TEM .................... ........ 2 44
20. 1 Cooling system .................................... ......... 2 44
20.2 Chec kin g th e a ntif reeze and coolant level .. ...... 244
20.3 Chec kin g th e coola nt level .. .................. .... ..... 245
20 .4 Dra inin g the coolan t.. ............................ ........ 245
20.5 Refi llin g cool an t .................................. ......... 246
21 LUB
RI CATION SYS TEM .............. .... .................. ........ 247
21.1 Oil circ
uit.. ........................ .. ......................... 247
21.2 Chec kin g the engine oil level .......................... 247

TABLE OF CONTENTS 5
21.3 Changing the engine oil and oil filt er,
30. 11 Pag e 3 of 8 (EXC-F AU).... .. .................... .. ..... 296
cleaning the oil screens ................................. 248
30. 12 Pag e 4 of 8 (EXC-F AU).... .. .................... .. ..... 298
2 1.4 Adding engine o il .......................................... 250
30. 13 Pag e 5 of 8 (EXC-F AU).... .. .................... .. ..... 300
2 1.5 Check ing th e engine o il press ur e .................... 250
30. 14 Pag e 6 of 8 (EXC-F AU).... .. .................... .. ..... 302
22 IGNITION SYS TEM ................................................... 252
30. 15 Pag e 7 of 8 (EXC-F AU).... .. .................... .. ..... 30 4
22. 1 Igni tion coil -check ing the secondary
30. 16 Page 8 of 8 (EXC-F AU) ................................. 306
winding ........................................................ 252
30. 17 Page 1 of 8 (EXC-F US) ................................. 308
22.2 Checking th e spark plug connector ................. 252
30. 18 Page 2 of 8 (EXC-F US) ................................. 310
22.3 Alternator- checking the s tat or w inding .......... 252
30. 19 Page 3 of 8 (EXC-F US) ................................. 312
22.4 Removing the stator ...................................... 253
30.2 0 Page 4 of 8 (EXC-F US) ................................. 314
22.5 Installing the stator ....................................... 253
30.21 Page 5 of 8 (EXC-F US) ................................. 316
22.6 Changing the spark plug ................................ 253
30.22 Page 6 of 8 (EXC-F US) ................................. 318
23 CYLINDER HEAD ..................................................... 255
30.23 Page 7 of 8 (EXC-F US) ................................. 320
23. 1 Check ing th e va l ve clearance ......................... 255
30.24 Page 8 of 8 (EXC-F US) ................................. 322
23.2 Adjus tin g the va lve clearance ......................... 256
30.25 Page 1 of 8 (EXC-F Six Days EU) .................... 324
24 ELECTRIC STARTER ................................................ 258
30.26 Page 2 of 8 (EXC-F Six Days EU) .................... 326
24.1 Check ing th e sta rt er motor ............................. 258
30.27 Page 3 of 8 (EXC-F Six Days EU) .................... 328
25 TH RO TTLE VALVE BOD Y .......................................... 259
30.28 Page 4 of 8 (EXC-F Six Days EU) .................... 330
25. 1 Adjus tin g the idl e speed ................................ 259
30.29 Page 5 of 8 (EXC-F Six Days EU) .................... 332
25.2 Throttle position sensor circuit A- checking
the basic settings .......................................... 260
25.3 Adjusting the basic throttl e position sen so r
se ttin g ......................................................... 260
25.4 Exec utin g the in it iali za ti on run ....................... 26 1
26 TECHNICAL DATA .................................................... 262
26.1 Engine ......................................................... 262
26.2 Tolerance, engine wear l imits ......................... 262
26.3 Engine ti ghtening torqu es .............................. 263
26.4 Ca pac iti es.................................................... 26 4
26.4. 1 Engine oil ........... ..................................... 264
26.4.2 Coola nt ............. ... .................................... 264
26.4.3 Fuel ................. ... .................................... 264
26.5 Chassis ........................................................ 26 4
26.6 Elec tri cal system ........................................... 265
26.7 Tir es ............................................................ 266
26.8 Fork ............................................................. 266
26.8. 1 E XC- F EU /AU/US ...................................... 266
26.8.2 All E XC -F Six Days .................................... 266
30.3 0 Page 6 of 8 (EXC-F Six Days EU) .................... 334
30.31 Page 7 of 8 (EXC-F Six Days EU) .................... 336
30.32 Page 8 of 8 (EXC-F Six Days EU) .................... 338
30.33 Page 1 of 8 (EXC-F Six Days US) .................... 340
30.34 Page 2 of 8 (EXC-F Six Days US) .................... 342
30.35 Page 3 of 8 (EXC-F Six Days US) .................... 344
30.36 Page 4 of 8 (EXC-F Six Days US) .................... 346
30.37 Page 5 of 8 (EXC-F Six Days US) .................... 348
30.38 Page 6 of 8 (EXC-F Six Days US) .................... 350
30.39 Page 7 of 8 (EXC-F Six Days US) .................... 352
30 .40 Page 8 of 8 (EXC-F Six Days US) .................... 354
31 SUBSTANCES ......................................................... 356
32 AUXI LIARY SUBSTANCES ........................................ 358
33 SPECIAL TO OLS ...................................................... 360
34 STANDARDS ........................................................... 375
35 INDEX OF S PE CIAL TER MS ...................................... 376
36 LIST OF ABBREVIATIONS ......................................... 377
INDEX ............................................................................ 378
26.9 Shock absorber ............................................. 267
26. 10 C ha ss is tightening torqu es ............................. 268
27 CLEANING, CARE .................................................... 270
27. 1 Clea ning the motorcycle ................................ 270
27.2 Checks and maint enance steps for winter
opera
tion ...................................................... 27 1
28 STORAGE ................................................................ 272
28. 1 Storage ........................................................ 272
28.2 Preparing for u se after sto ra ge ........................ 272
29 SERVICE SC HEDULE ............................................... 273
29.1 Additional information ................................... 273
29.2 Required work .............................................. 273
29.3 Recommended work ...................................... 27 4
30 WIRING DIAGRAM ................................................... 276
30.1 Pa ge 1 of 8 (EXC-F EU) ................................. 276
30.2 Pa ge 2 of 8 (EXC-F EU) ................................. 278
30.3 Pa ge 3 of 8 (EXC-F EU) ................................. 280
30.4 Pa ge 4 of 8 (EXC-F EU) ................................. 282
30.5 Pa ge 5 of 8 (EXC-F EU) ................................. 28 4
30.6 Pa ge 6 of 8 (EXC-F EU) ................................. 286
30.7 Pa ge 7 of 8 (EXC-F EU) ................................. 288
30 .8 Pa ge 8 of 8 (EXC-F EU) ................................. 290
30 .9 Pa ge 1 of 8 (EXC-F AU) ................................. 292
30. 10 Pa ge 2 of 8 (EXC-F AU) ................................. 29 4

1 MEANS OF REPRESENTATION
1.1 Symbols used
The meaning of specific symbols is described below.
Indi ca te s an expected reaction (e.g. of a work s tep or a fun c ti on).
X Indicates
an unexpected reac tion (e.g. of a work s tep or a function).
Indi ca tes a page reference (more inf ormation is provided on the sp ecif ied page).
•
I
Indi cates inf ormation with mo re details or tips.
»
Indi ca te s the res ult of a te s tin g s tep .
v Denotes a vo
lt age measurement.
A Denotes a curre
nt meas ur eme nt .
Denotes a
re sistance measurement.
Formats used
The typographical formats used in thi s doc ument are explained below.
Proprietary name
Brand™
Underlined terms
I dentif i es a proprie tar y name.
Identifi es a protected name.
I dentif i es a trademark.
Refer to
techni cal details of the ve hicle or indicate technical terms, which are explained
in th e glossary.
6

2 SAFETY ADVICE
2. 1 Repair Manual
Read thi s Repair Manual care full y and th oroughly before beginning work. It contains u se ful inf ormation and tips that wi ll help you
repair and maintain your vehicl
e.
This manual assumes that the ne cessary special KTM to ols and KTM workplace and workshop equipment are available.
2.2 Safe advice
A number of sa fet y instruc ti ons need to be followed to operate the ve hicle safel y. Therefore, read this manual carefully. The safety
instruc
tion s are hig hli ghted in the text and are referred to at the rele va nt pa ssages.
2.3
Info
The ve hicle has va rious inf ormation and warn ing labels at prominent locations. Do not remove inf ormation/ wa rning labels. If
th ey are mi ss in g, you or ot hers may not recogni ze dangers and may th erefore be injur ed.
De rees of risk and s mbols
Danger
7
Indi cates a danger that w ill immediately and invariably lead to fatal or serious perma ne nt injury if th e appropriate measures are
not taken.
Warning
Indicates a danger that is lik ely to lead to fatal or serious injury if th e appropriate measur es are not taken.
Caution
Indi cates a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Indicat es a danger that w ill lead to considerable machine and mat erial damage if th e appropriate measures are not ta ke n.
Warning
Indicates a danger that w ill lead to environmental damage if th e appropriate measu re s are not taken.
2.4 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-
th es es. E.g.: bearing puller (15112017000)
During assembly, non-reusable parts (e.g. se lf -locking screws and nuts, se als and seal rings, 0-r ings, pin s, l oc k washers) mu st be
replaced by new part s.
In so me instances, a thread locker (e.g. Loctite®) is required. The manufacturer instruc tion s for use must be followed.
After disassembly, clean the parts that are to be reu se d and check th em for damage and wear. Chan ge damaged or worn part s.
After you complete the repair or se rvice work, check the operating sa fety of the ve hicle.

3 IMPORTANT NOTES
3.1 Manufacturer and implied warranty
The work specified in the service schedule may only be performed in an authorized KTM workshop and mu st be recorded in both the
Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage
caused by
tampering with and/or conversions on the vehicle are not covered by the warranty.
Additional information on the manufacturer or implied warranty and the procedures involved can be found in the Service & Warranty
Booklet.
Warning
Environmental hazard Improper handling of fuel is a danger to th e environment.
Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use
the operating and auxiliary s ub stances (such as fuel and lubricants) as specified in the manual.
3.3 Spare parts, accessories
Only u se spare parts and accessories approved and/or recommended by KTM. KTM accepts no l iability 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
The figures contained in the manual may
depict special equipment.
In the intere st of clarity, so me components may be shown disa sse mbled or may not be shown at all. It is not always necessary to dis-
assemble the component to perform the activity in ques tion . Please follow the ins tru c tion s in the text.
8

4 SERIAL NUMBERS 9
The chassis number 0 is s tamped on the steering head on the right.
401945-10
4.2 Ty~e label
(EXC-F EU/AU , EXC-F Six Days EU)
The type label 0 is fixed to the front of th e steering head.
401946-10
(All US models)
The type label 0 is fixed to the front of th e steering head.
~ ~ · ~
_/ 0)
The add it ional type label for Canada 8 is fi xed to th e front of the front pipe.
/\\~
""==-..
I
f- , l ~ ~
(@)/
M00994-10
4.3
Key number
(EXC-F EU/AU, EXC-F Six Days EU)
The key number 0 for the steer ing lock is s tamp ed onto the key connector.
402247-10

4 SERIAL NUMBERS
''
0
KEYCOOECARO J
1234
l lll lll ll lll llll ll l ll llll
0 ll6iN
402246-10
En ine number
~
\
H00940-l0
4.5 Fork art number
10
(All US models)
Key number 0 for the ignition and steer ing l ock is indicated on the KEYCODECARD .
• Info
I You need the key number to order a repl acement key. Keep
the KEYCODECARD in a safe place.
Engine number 0 is embossed on the l eft side of the engine behind the shift le ve r.
The fork part number 0 is stamped on the inner side of the fork s tub .
4.6 Shock absorber article number
Shock absorber article number 0 is stamped on the top of the shock absorber above
the adjus
ting ring towards the engine side.

5 MOTORCYCLE 11
5.1 Raising the motorcycle with the lift stand
401942-01
Note
Danger of damage The parked vehicle can ro ll away or fall over.
Park the ve hicle on a firm and level surface.
Raise
the motorcycle at the frame underneath the engine.
I Lift stand (78129955100) ( I!!! p. 368)
./ Neither wheel is in contact w ith the ground.
Secure
the motorcycle against fal ling over.
5.2 Removing the motorc~cle from the lift stand
Note
Danger of damage The parked ve hicle can roll away or fall over.
Park the veh icle on a firm and level su rface.
401943-10
Remove the motorcycle from th e lift s tand .
Remove the I
itt stand.
To
pa rk th e motorcycle, pr ess side stand 0 to the ground with your foot and lean
the motorcycle on it.
• Info
I While riding , th e s id e s tand mu st be folded up and sec ur ed w ith th e rubber
band.
5.3 Startin
Danger
Danger of poisoning Exhaust gases are to xic and inhaling them may result in unconsciousness and death.
Always make sure there is s uffi cie nt ve n ti lation when r unni ng the engine.
Use
an effective exhaust extrac ti on system when s tart ing or running the engi ne in an enclosed space.
Note
Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.
Always run the engine warm at a low speed.
401944-10
400733-01
Take the motorcycle off side stand 0 and secure th e side stand with rubber
band @ .
Shi ft transmission to ne utr al.
(All US models)
Turn the key in the i gni tion lock to the position 0 .
Turn th e emergency OF F sw it ch to th e position 0 .
Condition
Ambient temperature: < 20 oc (< 68 °F)
Push
the cold s tart butt on in all the way.
Press the el ectric starter button.
• Info
I Press the elec tri c starter button for a maximum of 5 second s. Wa it for 30
seconds before a further attempt at sta rting .
At temp eratures below 15 oc (60 °F), several attempts at s tartin g may be
necessary to wa rm -up the lithium -ion battery and thereby increase the s tart -
ing power.
During
the starting process, th e malfunct i on indicator lamp lights up.

5 MOTORCYCLE
5.4 Starting the motorcycle for a check
Danger
Danger of poisoning Exhaust gases are to xic and inhaling them may result in unconsciousness and death.
Always make sure ther e is s uffi c ient ventilation when running the en gine.
U
se an effective exhaust extrac ti on system when s tartin g or running the engine in an en closed space.
Info
Pre ss the sta rt er for a max imum of 5 seconds. Wait for at least 5 seconds before trying aga in.
S hift transmission to neutral.
(All US models)
Turn th e key in the ig nition lock to th e position 0 .
Turn th e emergency OFF sw it ch to th e position 0 .
(EXC-F AU)
Turn the emer ge ncy OF F sw it ch to the position 0 .
Pr
ess th e el ectric starter butt on or pre ss the kickstarter robus tl y through its full ran ge.
Info
Do not open the thr o ttl e.
12

6 FORK, TRIPLE CLAMP 13
Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
Info
(EXC-F EU/AU/US)
-Turn white adjusting screw 0 clockwise as far as it will go.
• Info
I Adjusting screw 0 is located at the upper end of the l eft fork leg.
The compression damping is located in left fork leg COMP (white adjust-
ing screw). The rebound damping is located in right fork leg REB (red
adjusting screw).
-Turn counterclockwise by
the number of clicks corresponding to the fork type.
Guideline
Compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
• Info
I Turn clockwise to increase damping ; turn counterclockwise to reduce
damping.
(All EXC-F Six Days)
-Turn white adjusting screw 0 clockwise as far as it will go.
• Info
I Adjusting screw 0 is located at the upper end of the l eft fork leg.
The compression damping is located in left fork leg COM (white adjust-
ing screw). The rebound damping is located in right fork leg REB (red
adjusting screw).
-Turn counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
• Info
I Turn clockwise to increase damping ; turn counterclockwise to reduce
damping.
Ad"usting the rebound dam ing of the fork
The hydraulic rebound damping determines the fork suspension behavior.
(EXC-F EU/AU/US)
-Turn red adjusting screw 0 clockwise as far as it will go.
• Info
I Adjusting screw 0 is located at the upper end of the right fork leg.
The rebound damping is located in right fork leg REB (red adjusting
screw). The compression damping is located in left fork leg COMP (white
adjusting screw).

6 FORK, TRIPLE CLAMP
Turn counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
• Info
I Turn cl ockwise to increa se damping; turn co unter clockwise to reduce
damping .
14
(All EXC-F Six Days)
Turn red adjusting screw 0 clockwise as far as it will go.
• Info
I Adjusting screw 0 is located at th e upper end of the right fork leg.
The rebound damping is located in right fork leg REB (red adjusting
screw). The comp re ssion damping is located in l eft fork leg COM (white
adjusting
sc rew).
Turn counterclockwise by
the number of clicks corresponding to the fork type.
Guideline
Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
• Info
I Turn clockwise to increa se damping ; turn co unter clockwise to reduce
damping .
6.3 Adjusting the spring preload of the fork (All EXC-F Six Days)
Preparatory work
Rai se the motorcycle wi th the lift stand. ( 1!:!1 p. 11)
Main work
Turn th e adjusting wings 0 counterclockwise all the way.
./ The marking +0 aligns with the right wing.
• Info
I Make the adjustment by hand only. Do not u se a tool.
Make the sa me adjustment on both fork legs.
Turn the adjusting w ing s clockwise.
Guideline
Spring preload - Preload Adjuster
Comfort
Standard
Sport
+0
+0
+3
./ The adjusting wings engage no ti ceably at the numerical values.
• Info
I Adjust the spring preload to the numerical values only as the preload will
not engage between th e num erical values.
Turn clockwise to increa se the spring preload; turn counterclockwise to
reduce the spring preload.
Adjusting the s pring prel oa d ha s no influen ce on the absorption se tting of
the rebound damping.
Basi ca ll y, however, you sho uld se t the rebo und damping higher with a
higher spring prel oa d.

6 FORK, TRIPLE CLAMP
6.4 Bleeding the fork le s
402556-10
Finishing work
Remove the motorcycle from th e lift s tand . (0 p. 11)
Preparatory work
Rai se th e motorcycle wi th the lift stand. (0 p. 11)
Main work
Release bleeder screws 0 .
./ Any excess pressure escapes from the int erior of the fork.
Tighten the bleeder screws.
Finishing work
Remove the motorcycle from the lift stand. (i!ll p. 11)
6.5 Cleaning the dust boots of the fork legs
6.6 Removing the fork legs
Preparatory work
Raise the motorcycle wi th the lift stand. (0 p. 11)
Remove the fork protector. (0 p. 17)
Main work
Push dust boots 0 of both fork legs downward.
• Info
I The dust boots remove dust and coarse dirt particles from the inside fork
tub es. Over tim e, dirt can accumulate behind the dust boots. If thi s dirt is
not removed, the oil seals behind can s tart to leak.
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking
effect.
Always keep the brake discs free of oil and grease.
Clean the brake discs wit h brake cleaner when necessary.
Clean and oil th e dust boots and inner fork tub es of both fork legs.
IUni ve r sa l oil sp ra y (0 p. 359)
Press the dust boots back into their installation position.
Remove excess oil.
Finishing work
Install the fork protector. (0 p. 17)
Remove the motorcycle fr om th e lift stand. (0 p. 11)
Preparatory work
Remove the headlig ht mask wi th the headlight. (!!;! p. 11 4)
Raise th e motorcycle wi th the lift stand. (0 p. 11)
Remove the front wheel. (0 p. 1 20)
Main work
Remove screws 0 and take off the cla mp .
Remove the cable ti e(s).
Remove screws 8 and take
off th e brake ca lip er.
Allow the brake ca
lip er and brake line to hang loosely to the side.
15

6 FORK, TRIPLE CLAMP 16
40 2 556-10
40 25 56 -10
(EXC-F EU/AU/US)
Loosen screws 8 .Take o ut the left fo rk leg.
Loosen screws 8 .Take o ut the right fork le g.
(All EXC-F Six Days)
Lo ose n screws 8 .Take o ut th e left fork leg.
Loosen screws 8 .Take out the right fork le g.
Main work
(EXC-F EU/AU/US)
Position the fo rk legs.
./ Bleeder screws 0 are positioned toward th e front .
• Info
I The rebound damping is located in rig ht fork leg REB (red adjusting
screw). The compression
damping is located in l eft fork leg COMP (white
adjusting
sc rew).
Grooves are
milled int o the side of the upper end of th e fork legs. The
second
milled groove (from the top) must be flu sh w ith the top edge of
the upper triple clamp.
- Tighten sc re ws 8 .
G uid eline
Screw, top
tripl e cla mp M8
-Tig
ht en screws 8 .
Guideline
Sc
re w, bottom tripl e clamp M8
(All EXC-F Six Days)
Po sition the fork legs.
./ Bleeder screws 0 are positioned toward th e fro nt .
• Info
20 Nm
(14.8 lbf ft)
15 Nm
(11.1 lbf ft)
I The rebound damping is located in rig ht fork le g REB (red adjusting
screw). The comp
re ssion damping is loca ted in l eft fork leg COM (white
adjusting
sc rew).
Grooves are
mill ed int o the side of the upper end of th e fork legs. The
second
mill ed groove (from th e top) must be flu sh w ith the top edge of
th e upper triple clamp.

6
6.10
6.10.1
FORK, TRIPLE CLAMP 17
EXC-F EU/AUJUS
Servicing the fork
-Tighten screws 8 .
Guideline
Sc
re w, top triple cla mp M8
- Tighten sc re ws CD .
G uid eline
Screw, bottom
tripl e clamp M8
Position th e brake caliper, and mount and tighten sc re ws 8 .
Guideline
Screw,
fr o nt brake ca lip er M8
Mount th e cable ti e(s).
25 Nm
(18 .4 lbf ft)
17 Nm
(12.5 lbf ft)
15 Nm
(11.1 lbf ft)
Loctite «> 243™
P os ition the brake lin e, w irin g harness, and clamp. Mount and ti ghten screws @) .
Finishing work
Install the front wheel. (e p. 120)
Insta ll the headlight mask w ith the headlig ht . ( e) p. 115 )
-Check the headlight
se ttin g. ( 1!;!1 p. 151)
Remo ve screws 0 and take off the cla mp .
Remove screws 8 on the le
ft fork leg and take off the l eft fork protector.
Remove screws
CD on the right fork leg and take off the rig ht fork protector.
P
os iti on the fork protector on the le ft fork leg. Mount and tighten screws 0 .
Guideline
IRema inin g screws, chassis I M6 11 0 Nm (7.4 lbf ft) I
Position th e brake lin e, w iring harness, and clamp. Mount and tight en screws 8 .
Position th e fork protector on the right fork l eg. Mount and tight en screws CD .
Guideline
IRemaining screws, chassis 10 Nm (7.4 lbf ft)
Condition
The fork legs have been removed.

6 FORK, TRIPLE CLAMP
e
•
g
I
•
•
®
I
e
..
•
0
803062-0 1
Disassemble the fork legs. ( 10 p. 18)
Disassemble the ca rtrid ge. (a p. 20)
-Check the fork legs. ( 19 p. 23)
-Assemble th e ca rtrid ge. ( 19 p. 25)
Assemble the fork legs. (0 p. 28)
18
6.1 0.2 Disassembling the fork legs
Info
The procedures are th e same on both fo rk le gs.
80 4 512- 10
Condition
The fork legs have been removed.
Note down
the current s tate of compression dampin g 0 COMP (white adjuster of
left fork leg).
Note down the current s tate of rebound damping 8 REB (red adjuster of right fork
le g).
Open the adjusters of the rebound and compression damping completely.
- Cl amp th e fork leg in the area of the lower tripl e clamp.
IClamping stand (T1403S) (0 p. 373)
Remove screw 8 .Remove adjuster.
Loosen the screw cover 8 .
IRing wrench (T14017) ( 10 p. 372)
• Info
I Th e sc re w cover ca nnot be removed ye t.