KTM 450 EXC SIX DAYS Manual

SETUP INSTRUCTIONS 2016
450 EXC
450 EXC Six Days
450 XC‑W
500 EXC
500 EXC Six Days
500 XC‑W
Art. no. 3213434en

INTRODUCTION 1
*3213434en*
3213434en
11/2015
INTRODUCTION
Perform the work described in these setup instructions before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the interest
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 GmbH specifically reserves the right to modify or delete technical specifications,
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, devi-
ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment 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
This document is valid for the following models:
450 EXC EU (F8403P9)
450 EXC AU (F8460P9)
450 EXC Six Days EU (F8403P2)
450 XC-W US (F8475P3)
500 EXC EU (F8503P9)
500 EXC AU (F8560P9)
500 EXC US (F8575P9)
500 EXC Six Days EU (F8503P2)
500 XC-W US (F8575P3)

1 MEANS OF REPRESENTATION 2
1.1 Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained
in the glossary.

2 SETUP 3
2.1 Unpacking and setting up the vehicle
M00075-10
Package 2
–Remove the box and the plastic packaging.
Info
To avoid damaging the motorcycle during the setup, leave the protective
film on the vehicle until you have finished.
–Remove the separate enclosure and unpack it. Check that the scope of supply
is complete on the basis of the enclosed packing list.
–Have a lift stand available.
Lift stand (78129955100)
–Carefully loosen and remove the tension belt of the footrest mount.
Info
An assistant prevents the motorcycle from falling over.
402050-01
–Together with an assistant, take the vehicle off the palette.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
–Remove the headlight mask with the headlight. ( p. 8)
M00075-11
Package 12
–Remove the box and the plastic packaging.
Info
An assistant prevents the motorcycle from falling over.
To avoid damaging the motorcycle during the setup, leave the protective
film on the vehicle until you have finished.
–Remove the separate enclosure and unpack it. Check that the scope of supply
is complete on the basis of the enclosed packing list.
402051-01
–Have a lift stand available.
Lift stand (78129955100)
–Together with an assistant, take the vehicle off the palette.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
–Install the shock absorber. ( p. 11)
600814-01
–Route the clutch line with the clutch master cylinder toward the front between
the upper and lower triple clamps.
(XC‑W, 500 EXC US)
–Position the fork legs and tighten the screws of the triple clamp.
Guideline
Screw, top triple clamp M8 20 Nm
(14.8 lbf ft)
Screw, bottom triple clamp M8 15 Nm
(11.1 lbf ft)
Info
Grooves are milled into the side of the upper end of the fork legs.
The second milled groove (from the top) must be flush with the top
edge of the upper triple clamp.
Position the bleeder screws toward the front.

2 SETUP 4
(EXC EU, EXC Six Days EU, EXC AU)
–Position the fork legs and tighten the screws of the triple clamp.
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
Screw, bottom triple clamp M8 15 Nm
(11.1 lbf ft)
Info
The rebound damping is located in right fork leg REB (red adjusting
screw). The compression damping is located in left fork leg COMP
(white adjusting screw).
Grooves are milled into the side of the upper end of the fork legs.
The topmost milled groove must be flush with the top edge of the
upper triple clamp.
Position the bleeder screws toward the front.
M00987-11
–Remove screws . Take off the handlebar clamps.
–Remove screws . Take off the handlebar supports.
–Place the handlebar supports in the required position. Mount and tighten
screws .
Guideline
Screw, handlebar holder M10 40 Nm
(29.5 lbf ft)
Loctite®243™
Info
Position the left and right handlebar supports evenly.
V00032-01
–Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
–Position the handlebar clamps. Mount and tighten the screws evenly.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
Info
The markings on the handlebar should be at the center of the handlebar
clamps.
Keep the gap widths equal when tightening.

2 SETUP 5
102049-11
(EXC EU, EXC Six Days EU, EXC AU, 500 EXC US)
–Insert the indicator lamp with the black and violet cable colors into
socket .
102048-11
(XC‑W)
–Connect pull switch with the yellow and white cables.
–Position the speedometer and connector board. Mount and tighten the screws.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
V00033-10
–Position the controls on the right half of the handlebar.
Info
The routing of the throttle cables can be seen in the figure.
V00034-10
–Position the controls on the left half of the handlebar.
Info
The figure shows how to route the clutch line and wiring harness.
B01749-01
(EXC EU, EXC Six Days EU, EXC AU, 500 EXC US)
–Remove the fuel tank. ( p. 17)
–Position the turn signal wiring harness against the main wiring harness and
secure with cable ties.
B01750-01
–Disconnect the plug-in connection from the main wiring harness and con-
nect the turn signal wiring harness.
–Install the fuel tank. ( p. 19)

2 SETUP 6
M00149-01
–Position the turn signal on each side and mount and tighten nuts.
–Connect the plug-in connection of the right turn signal using the black and
brown cable colors.
–Connect the plug-in connection of the left turn signal using the violet and
brown cable colors.
402148-01
(EXC EU, EXC Six Days EU, EXC AU)
–Mount the turn signal switch.
–Install the front fender. ( p. 14)
–Refit the headlight mask with the headlight. ( p. 9)
–Install the front wheel. ( p. 13)
–Correctly mount the fuel tank breather.
601710-01
–Secure the handlebar cushion with two cable ties.
101019-01
–Mount the footrests with the springs and pins. Secure the pins using the washers
and cotter pins.
Pliers for footrest spring (58429083000)
601711-01
(EXC EU, EXC Six Days EU, EXC AU)
–Mount the license plate holder with the license plate lamp, turn signals, and
reflector.
–Connect the electrical components.
–Connect the connector of the left turn signal with the connector that is marked
red.
–Connect the connector of the right turn signal with the connector that is marked
green.

2 SETUP 7
C00117-01
(500 EXC US)
–Mount the license plate holder with the license plate lamp, turn signals, and
reflector.
–Connect the electrical components.
–Connect the connector of the left turn signal with the connector that is marked
red.
–Connect the connector of the right turn signal with the connector that is marked
green.
101393-12
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep sparks and open flames away from the battery. Only charge in
well-ventilated rooms.
–In the event of skin contact, rinse with large amounts of water. If battery
acid gets in the eyes, rinse with water for at least 15 minutes and con-
tact a physician.
–Fill the battery.
Info
Read the notes in the battery package.
–Charge the battery. ( p. 16)
–Install the battery. ( p. 15)
–Unpack and mount the KTM PowerParts included in the delivery (optional).
Info
Read the accompanying KTM PowerParts fitting instructions.
–Apply the label included in the delivery (optional).
–Set kilometers or miles. ( p. 23)
–Set the speedometer functions. ( p. 24)
–Set the clock. ( p. 24)
–Refuel. ( p. 22)
–Position all controls in their exact positions on the handlebar. Tighten all screws.
–Prepare the vehicle according to the specifications in the KTM Dealer.net for han-
dover to the customer.

3 WORK 8
3.1 Raising the motorcycle with the lift stand
401942-01
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
–Raise the motorcycle at the frame underneath the engine.
Lift stand (78129955100)
Neither wheel is in contact with the ground.
–Secure the motorcycle against falling over.
3.2 Removing the motorcycle from the lift stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
401943-10
–Remove the motorcycle from the lift stand.
–Remove the lift stand.
–To park the motorcycle, press side stand to the ground with your foot and lean
the motorcycle on it.
Info
While riding, the side stand must be folded up and secured with the rubber
band.
3.3 Removing headlight mask with headlight
K00117-10
(EXC EU, EXC Six Days EU, EXC AU)
–Switch off all power consumers and switch off the engine.
–Remove screw and take off the clamp.
–Release rubber straps . Slide the headlight mask up and swing it forward.
K00118-10
–Detach plug-in connectors and take off the headlight mask with the head-
light.
V00035-10
(500 EXC US)
–Switch off all power consumers and switch off the engine.
–Remove screw and take off the clamp.
–Release rubber straps . Slide the headlight mask up and swing it forward.