KTM 450 EXC SIX DAYS EU Manual

SETUP INSTRUCTIONS 2010
450 EXC SIX DAYS EU
450 XC-W SIX DAYS USA
530 EXC SIX DAYS EU
530 XC-W SIX DAYS USA
450 EXC Champions Edition EU
450 EXC Champions Edition USA
450 XC‑W Champions Edition USA
530 EXC Champions Edition EU
530 EXC Champions Edition USA
400 EXC EU
400 EXC AUS
400 XC-W USA
450 EXC EU
450 EXC AUS
450 EXC USA
450 XC-W ZA
530 EXC EU
530 EXC AUS
530 EXC USA
530 XC-W ZA
Art. no. 3211585en

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 this manual.
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 delivery.
© 2010 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

MEANS OF REPRESENTATION 2
Symbols used
The symbols used are explained in the following.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained in the following.
Specific name Indicates a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a brand in merchandise traffic.

SET‑UP 3
2.1Unpacking and setting up the vehicle
800030-10
Packaging 2
–Remove the box and the plastic packaging.
Info
To avoid damaging the motorcycle during assembly, leave the protective
film on the vehicle until you have finished.
–Take out the separate enclosure and unpack it. Check its contents on the basis
of the enclosure list.
–Set up the work stand.
Work stand (54829055000)
–Carefully loosen and remove the tensioning belt over the link fork.
Info
An assistant prevents the motorcycle from falling over.
–Carefully loosen and remove the tensioning belts around the lower triple clamp.
The vehicle is released at the front.
–Together with an assistant, take the vehicle off the palette.
–Position the vehicle on a work stand.
–Check the vehicle for transport damage.
600811-10
Packaging 12
–Remove the box and the plastic packaging.
Info
An assistant prevents the motorcycle from falling over.
To avoid damaging the motorcycle during assembly, leave the protective
film on the vehicle until you have finished.
–Take out the separate enclosure and unpack it. Check its contents on the basis
of the enclosure list.
–Set up the work stand.
Work stand (54829055000)
–Together with an assistant, take the vehicle off the palette.
–Position the vehicle on a work stand.
–Check the vehicle for transport damage.
B00148-01
–Install the shock absorber. ( p. 9)
600814-10
–Route the clutch line with the clutch master cylinder toward the front between
the upper and lower triple clamps.
–Position the fork legs and tighten the screws of the triple clamp.

SET‑UP 4
Guideline
Screw, top triple clamp
(EXC SIX DAYS, XC‑W SIX DAYS,
XC‑W USA, XC‑W Champions
Edition USA, EXC Champions
Edition USA, EXC USA)
M8 17 Nm
(12.5 lbf ft)
Screw, bottom triple clamp
(EXC SIX DAYS, XC‑W SIX DAYS,
XC‑W USA, XC‑W Champions
Edition USA, EXC Champions
Edition USA, EXC USA)
M8 12 Nm
(8.9 lbf ft)
Screw, top triple clamp (EXC EU,
EXC AUS, XC‑W ZA, EXC Champions
Edition EU)
M8 20 Nm
(14.8 lbf ft)
Screw, bottom triple clamp (EXC EU,
EXC AUS, XC‑W ZA, EXC Champions
Edition EU)
M8 15 Nm
(11.1 lbf ft)
Info
The upper milled groove in the fork leg must be flush with the top edge
of the upper triple clamp.
Position bleeder screws toward the front.
600820-10
–Mount the handlebar.
The scale on the handlebar should be centered on the handlebar clamp.
–Position the handlebar clamps. Mount the screws and tighten evenly.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
600816-10
–Position the controls on the right half of the handlebar.
Info
The routing of the cables can be seen in the figure.
600817-10
–Position the controls on the left half of the handlebar.
Info
The routing of the clutch line and wiring harness can be seen in the figure.
600818-10
(all EXC models)
–Attach the retaining bracket for the connector and turn signal bracket with the
turn signal and speedometer to the upper triple clamp.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
–Connect the connector.

SET‑UP 5
600819-10
(All XC‑W models)
–Attach the speedometer to the upper triple clamp.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
–Connect the connector.
800042-10
–Mount the footrests with the springs and bolts. Secure the bolts using the washers
and pins.
Plier for footrest spring (58429083000)
–Remove the protective plastic.
–Install the front fender. ( p. 8)
–Install the front wheel. ( p. 6)
800035-10
Warning
Risk of injury Battery acid and battery gases cause serious cauterization.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep the battery away from sparks or open fire. Charge only in well ven-
tilated 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 doctor.
–Fill the battery.
Info
Read the notes in the battery package.
–Recharge the battery. ( p. 7)
–Install the battery. ( p. 8)
–Unpack the KTM PowerParts (optional) contained in the delivery and install them.
Info
Read the accompanying KTM PowerParts installation instructions.
–Attach the stickers contained in the delivery (optional).
(all EXC models)
–Mount and tighten the rear mirror adapter and rear mirror on both sides.
–Exactly position all controls on the handlebar. Tighten all screws.
–Mount the reflector.
–Refuel. ( p. 8)
–Print out the current PDI form found on KTM DEALER.NET and perform the delivery
inspection.

WORK 6
3.1Removing the seat
500080-10
–Remove screw . Lift up the seat at the rear, pull it back and then remove from
above.
3.2Mounting the seat
500068-01
–Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear
and simultaneously push it forward.
–Make sure that the seat is correctly locked in.
–Mount and tighten the screw of the seat fixing.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
3.3Installing the front wheel
Warning
Danger of 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.
500086-11
–Clean and grease shaft seal rings and bearing surface of the spacers.
Long-life grease ( p. 13)
–Insert the spacers.
500084-11
–Lift the front wheel into the fork, position it, and insert the wheel spindle.
–Mount and tighten screw .
Guideline
Screw, front wheel spindle M24x1.5 45 Nm
(33.2 lbf ft)
–Operate the hand brake lever several times until the brake linings are lying correctly
on the brake disc.
–Remove the motorcycle from the work stand.
–Pull the front wheel brake and push down hard on the fork several times to align
the fork legs.
–Fully tighten screw .
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)

WORK 7
3.4Recharging the battery
Warning
Risk of injury Battery acid and battery gases cause serious cauterization.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
–In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a doctor.
Warning
Environmental hazard Battery parts and acid are harmful to the environment.
–Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner.
Give the battery to your KTM dealer or to a recycling center that accepts used batteries.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Even if there is no load on the battery, it loses power every day.
The charge state and the type of charge are very important for the service life of the battery.
Fast recharging with a high charge current shortens the battery's service life.
If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes.
The battery capacity is then reduced.
If the battery is discharged from starting, it must be recharged immediately.
If it stands for a long time in a discharged state, the battery becomes over-discharged and sulfated, and then it is destroyed.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
–Switch off all consumers and the engine.
–Remove the seat. ( p. 6)
–Disconnect the minus (negative) cable of the battery to avoid damage to the motor-
cycle's electronics.
400240-10
–Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test the open-circuit voltage and cranking
power of the battery, and to test the generator. With this device, you cannot over-
charge the battery.
Info
Never remove the lid .
Charge the battery with at most 10% of the capacity specified on the bat-
tery .
–Switch off the charger after charging. Disconnect the battery.
Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use
3 months
–Mount the seat. ( p. 6)

WORK 8
3.5Installing the battery
500069-11
–Place the battery in the battery holder.
Battery (YTX5L-BS)
–Reconnect the rubber band .
–Attach the plus cable and replace the plus pole cover .
–Attach the minus cable .
–Mount the seat. ( p. 6)
3.6Installing the front fender
600692-10
–Ensure that the spacers are mounted in the fender.
–Position the front fender. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Info
Make sure the holding lugs engage in the start number plate or headlight
mask.
3.7Opening filler cap
400199-10
–Press release button , turn filler cap counterclockwise and lift it upwards and
remove.
3.8Closing filler cap
400199-11
–Replace the filler cap and turn clockwise until the release button locks in place.
Info
Route the fuel tank breather hose without kinking.
3.9Refueling
Danger
Fire hazard Fuel is highly flammable.
–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.

WORK 9
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.
–Switch off engine.
–Open the filler cap. ( p. 8)
A
A
400382-10
–Fill the fuel tank with fuel up to measurement .
Guideline
Measurement of 35 mm (1.38 in)
Total fuel tank
capacity,
approx. (EXC,
EXC SIX DAYS,
XC‑W ZA,
EXC Champions
Edition EU)
9.5 l
(2.51 US gal)
Super unleaded (ROZ 95 / RON 95 /
PON 91) ( p. 12)
Total fuel tank
capacity, approx.
(XC‑W USA,
XC‑W SIX DAYS,
XC‑W Champions
Edition USA,
EXC Champions
Edition USA,
EXC USA)
9.2 l
(2.43 US gal)
Super unleaded (ROZ 95 / RON 95 /
PON 91) ( p. 12)
–Close the filler cap. ( p. 8)
3.10Installing the shock absorber
800023-11
–Push splash protector to the side and position the shock absorber. Mount and
tighten screw .
Guideline
Screw, top shock absorber M12 80 Nm
(59 lbf ft)
Loctite®243™
–Mount and tighten screw .
Guideline
Screw, bottom shock
absorber
M12 80 Nm
(59 lbf ft)
Loctite®243™
Info
The heim joint for the shock absorber at the swing arm is Teflon coated. It
must not be greased with grease or with other lubricants. Lubricants dis-
solve the Teflon coating, thereby drastically reducing the service life.
–Remove the motorcycle from the work stand.

TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS 10
Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) –
Screw, spoiler on fuel tank (XC‑W USA,
XC‑W SIX DAYS, XC‑W Champions
Edition USA, EXC Champions Edi-
tion USA, EXC USA)
M5x12 1.5 Nm (1.11 lbf ft) –
Spoke nipple, rear wheel M5 5… 6 Nm (3.7… 4.4 lbf ft) –
Remaining nuts, chassis M6 15 Nm (11.1 lbf ft) –
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –
Screw, ball joint of push rod on foot
brake cylinder
M6 10 Nm (7.4 lbf ft) –
Screw, front brake disc M6 14 Nm (10.3 lbf ft) –
Screw, rear brake disc M6 14 Nm (10.3 lbf ft) –
Screw, shock absorber adjusting ring M6 5 Nm (3.7 lbf ft) –
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite®243™
Nut, rim lock M8 10 Nm (7.4 lbf ft) –
Remaining nuts, chassis M8 30 Nm (22.1 lbf ft) –
Remaining screws, chassis M8 25 Nm (18.4 lbf ft) –
Screw, bottom triple clamp
(EXC SIX DAYS, XC‑W SIX DAYS,
XC‑W USA, XC‑W Champions
Edition USA, EXC Champions
Edition USA, EXC USA)
M8 12 Nm (8.9 lbf ft) –
Screw, bottom triple clamp (EXC EU,
EXC AUS, XC‑W ZA, EXC Champions
Edition EU)
M8 15 Nm (11.1 lbf ft) –
Screw, engine brace M8 33 Nm (24.3 lbf ft) –
Screw, fork stub M8 15 Nm (11.1 lbf ft) –
Screw, front brake caliper M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –
Screw, side stand fixing M8 40 Nm (29.5 lbf ft) Loctite®243™
Screw, subframe M8 35 Nm (25.8 lbf ft) Loctite®243™
Screw, top steering stem
(EXC SIX DAYS, XC‑W SIX DAYS,
XC‑W USA, XC‑W Champions
Edition USA, EXC Champions
Edition USA, EXC USA)
M8 17 Nm (12.5 lbf ft) Loctite®243™
Screw, top steering stem (EXC EU,
EXC AUS, XC‑W ZA, EXC Champions
Edition EU)
M8 20 Nm (14.8 lbf ft) –
Screw, top triple clamp
(EXC SIX DAYS, XC‑W SIX DAYS,
XC‑W USA, XC‑W Champions
Edition USA, EXC Champions
Edition USA, EXC USA)
M8 17 Nm (12.5 lbf ft) –
Screw, top triple clamp (EXC EU,
EXC AUS, XC‑W ZA, EXC Champions
Edition EU)
M8 20 Nm (14.8 lbf ft) –
Engine attachment bolt M10 60 Nm (44.3 lbf ft) –
Remaining nuts, chassis M10 50 Nm (36.9 lbf ft) –
Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –
Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite®243™
Screw, bottom shock absorber M12 80 Nm (59 lbf ft) Loctite®243™
Screw, top shock absorber M12 80 Nm (59 lbf ft) Loctite®243™
Nut, seat fixing M12x1 20 Nm (14.8 lbf ft) –
Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) –
Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft) –
Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft) –

TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS 11
Screw-in nozzles, cooling system M20x1.5 12 Nm (8.9 lbf ft) Loctite®243™
Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) –

SUBSTANCES 12
Super unleaded (ROZ 95 / RON 95 / PON 91)
According to
–DIN EN 228 (ROZ 95 / RON 95 / PON 91)

AUXILIARY SUBSTANCES 13
Long-life grease
Guideline
–KTM recommends Motorex®products.
Supplier
Motorex®
–Fett 2000

*3211585en*
3211585en
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
01/2010
Photo: Mitterbauer