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KTM 450 EXC-R EU, 450 EXC-R AUS/UK, 450 EXC-R SIX DAYS, 450 EXC-R USA, 450 XCR-W UsA, 450 XCR-W ZA, 530 EXC-R EU, 530 EXC-R AUS/UK, 530 EXC-R SIX DAYS manual

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Table of contents for the manual

  • Page 1

    OWNER'S MANUAL 2008 450 b EXC-R b EU 450 b EXC-R b AUS/UK 450 b EXC-R b SIX b DAYS 450 b EXC-R b USA 450 b XCR-W b USA 450 b XCR-W b ZA 530 b EXC-R b EU 530 b EXC-R b AUS/UK 530 b EXC-R b SIX b DAYS 530 b EXC-R b USA 530 b XCR-W b USA 530 b XCR-W b ZA ART. NO. 3211254en[...]

  • Page 2

    [...]

  • Page 3

    DEAR KTM CUSTOMER 1 '($5 .70 &86720(5 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 wish you great pleasure riding the vehicle! Enter the serial numbers of your vehicle below. Ch[...]

  • Page 4

    CONTENTS 2 &217(176 MEANS OF REPRESENTATION ............................................ 5 IMPORTANT NOTES ..................................................... ....... 6 LOCATION OF SERIAL NUMBERS ........................................ 8 Chassis number ............................................. .................. 8 Type label ............[...]

  • Page 5

    CONTENTS 3 Removing the lower triple clamp b x (EXC-R b EU, EXC-R b AUS/UK, EXC-R b USA, XCR-W b ZA) . ............ .......... .. 44 Installing the lower triple clamp b x (EXC-R b SIX b DAYS, XCR-W b USA) ... .......... ......... .......... ......... ............ .......... .. 44 Installing the lower triple clamp b x (EXC-R b EU, EXC-R b AUS/UK, EX[...]

  • Page 6

    CONTENTS 4 Capacity - fuel ............................................... ................ 95 TECHNICAL DATA - FORK.................................................. 96 TECHNICAL DATA - SHOCK ABSORBER ............................. 97 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ........ 98 WIRING DIAGRAM ............................................[...]

  • Page 7

    MEANS OF REPRESENTATION 5  0($16 2) 5(35(6(17$7,21 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). All work marked with this symbol requires specialist knowledge and technical understanding. In t[...]

  • Page 8

    IMPORTANT NOTES 6  ,03257$17 127(6 Use definition (Every EXC-R models) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply with currently valid regulations and categories of the top international motorsport organizations. Info The motorcycle is authorized for publ[...]

  • Page 9

    IMPORTANT NOTES 7 Environment Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a poten- tial problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can en- sure that such problems and conflicts do not ha[...]

  • Page 10

    LOCATION OF SERIAL NUMBERS 8  /2&$7,21 2) 6(5,$/ 180%(56  Chassis number 500127-10 The chassis number b  is stamped on the steering head on the right.  Type label 500128-10 The type label b  is fixed to the front of the steering head.  Key number (EXC-R b EU, EXC-R b AUS/UK, EXC-R b USA) 500125-10 The key num[...]

  • Page 11

    LOCATION OF SERIAL NUMBERS 9  Shock absorber part number 500129-10 The shock absorber part number b  is stamped on the top of the shock absorber above the adjusting ring on the engine side.[...]

  • Page 12

    OPERATING ELEMENTS 10  23(5$7,1* (/(0(176  Clutch lever 500133-10 The clutch lever b  is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting.  Hand brake lever 400196-10 The hand brake lever b  is located on the right side of the handlebar and operates the front wheel brake. ?[...]

  • Page 13

    OPERATING ELEMENTS 11  Emergency OFF switch (EXC-R b USA) 500144-10 The emergency OFF switch b  is fitted on the left side of the handlebar. Possible states Ignition off ದb In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. Ignition on ದb In this position, the igni[...]

  • Page 14

    OPERATING ELEMENTS 12  Light switch (EVERY XCR-W MODELS) 500146-10 The light switch b  is on the right of the speedometer. Possible states (XCR-W b ZA) • Light off ದb Light switch is pressed in up to the stop. In this position, the light is switched off. • Light on ದb Light switch is pulled out to the stop. In this position, [...]

  • Page 15

    OPERATING ELEMENTS 13  Flasher switch (EXC-R b EU, EXC-R b AUS/UK) 500145-10 The flasher switch b  is fitted on the left side of the handlebar. Possible states Flasher light off ದb Flasher switch is in the central position. Flasher light, left, on ದb Flasher switch turned to the left. Flasher light, right, on ದb Flasher switch [...]

  • Page 16

    OPERATING ELEMENTS 14  Speedometer activation and test 400313-01 Activating the speedometer: The speedometer is activated when one of the keys is pressed or an impulse comes from the wheel speed sensor. Display test For the function test of the display, all display segments light up briefly. 400314-01 WS (wheel size) After the function [...]

  • Page 17

    OPERATING ELEMENTS 15  Setting the clock Condition The motorcycle is standing. 400330-01 ದ Press the button b briefly and repeatedly until CLK appears at the bottom right of the display. ದ Press the button b for 3 - 5 seconds. The hour display flashes. ದ Set the hour display with the button b "+" and/or button b " ?[...]

  • Page 18

    OPERATING ELEMENTS 16  Querying lap time Info This function can be called only if lap times are measured. Condition The motorcycle is standing. 400321-01 ದ Press the button b briefly and repeatedly until LAP appears at the bottom right of the display. ದ Press the button b briefly. The LAP b 1 is displayed on the left of the display.[...]

  • Page 19

    OPERATING ELEMENTS 17  Display mode SPEED b / b CLK (time) 400319-01 ದ Press the button b briefly and repeatedly until CLK appears at the bottom right of the display. The time is displayed in CLK display mode. Press the button b "+". no function Press the button b " ತ ". no function Press the button b for 3 - 5 s[...]

  • Page 20

    OPERATING ELEMENTS 18  Display mode SPEED/TR2 (trip master 2) 400324-01 ದ Press the button b briefly and repeatedly until TR2 appears at the top right of the display. TR2 (trip master b 2) runs constantly and counts up to 999.9. The displayed value can be set manually with the button b "+" and the button b " ತ ".[...]

  • Page 21

    OPERATING ELEMENTS 19  Display mode SPEED/S1 (stop watch 1) 400327-01 ದ Press the button b briefly and repeatedly until S1 appears at the top right of the display. S1 (stop watch 1) displays the journey time on the basis of TR1 and continues when an impulse is received from the wheel sensor. The calculation of this value starts with t[...]

  • Page 22

    OPERATING ELEMENTS 20 Overview of conditions and ability to be enabled Display The motorcycle is standing Menu can be en- abled Display mode SPEED/LAP (lap time) • Display mode SPEED/ODO (odometer) Display mode SPEED/TR1 (trip master b 1) • Display mode SPEED/TR2 (trip master 2) • Disply mode SPEED/A1 (average speed b 1) • Display mode SPEE[...]

  • Page 23

    OPERATING ELEMENTS 21  Choke (EXC-R b AUS/UK, EXC-R b SIX b DAYS, EXC-R b USA, XCR-W) 500135-10 The choke b  is fitted on the left side of the carburetor. Activating the choke function frees an opening through which the engine can draw ex- tra fuel. This gives a richer fuel-air mixture, which is needed for a cold start. Info If the e[...]

  • Page 24

    OPERATING ELEMENTS 22  Kickstarter 500148-10 The kickstarter b  is fitted on the right of the engine. The engine can be started with either the kickstarter or the electric starter. The upper part of the kickstarter can be swung out. Info Before riding, swing the upper part of the kickstarter inwards towards the en- gine. [...]

  • Page 25

    OPERATING ELEMENTS 23 ದ Insert the key in the steering lock, turn it to the left, press it in and turn it to the right. Remove the key. Steering is no longer possible. Info Never leave the key in the steering lock.  Unlocking the steering (EXC-R b EU, EXC-R b AUS/UK, EXC-R b USA) ದ Insert the key in the steering lock, turn it to the[...]

  • Page 26

    GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 24  *(1(5$/ 7,36 $1' +,176 21 3877,1* ,172 23(5$7,21  Advice on first use Danger Danger of accidents ಘ Danger from inadequate traffic experience. ದ Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs. Warning Risk of injury ಘ Risk of injury [...]

  • Page 27

    GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 25 ದ If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis- tribution between the front and rear wheels. Info Motorcycles react sensitively to any changes of weight distribution. ದ Do not exceed the overall maximum perm[...]

  • Page 28

    RIDING INSTRUCTIONS 26  5,',1* ,16758&7,216  Checks before putting into operation Info Make sure that the motorcycle is in a perfect technical condition before use. Info In the interests of riding safety, make a habit of making a general check before you ride. ದ Check the engine oil level. ( P. 79) ದ Check the chain tension[...]

  • Page 29

    RIDING INSTRUCTIONS 27 ದ Press the electric starter button or press the kickstarter robustly through its full range. Info Don't open the throttle. Conditions Engine hot and running ದ Push back the hot start lever to the stop with the engine running.  Starting up Info If your bike has lights, switch them on before riding. You will [...]

  • Page 30

    A A RIDING INSTRUCTIONS 28  Stopping, parking Warning Danger of burns ಘ Some vehicle components get very hot when the machine is driven. ದ Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these compo- nents to cool down before starting work on them. Note Danger of damage ಘ Danger [...]

  • Page 31

    GREASING AND SERVICE TABLE 29  *5($6,1* $1' 6(59,&( 7$%/(  Important maintenance work to be carried out by an authorized KTM workshop. S3N S15A S30A Engine Change the engine oil and oil filter and clean the engine oil screen. ( P. 79) • • • Change the gear oil and clean the gear oil screen. ( P. 82) • • • Replace sp[...]

  • Page 32

    GREASING AND SERVICE TABLE 30  Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) Competition use Hobby use J1A J2A S15A S30A S45A S30A S60A S90A Carry out a complete fork service. •• Carry out a complete shock absorber service. • Grease the steering head bearing. ( P. 46) •• Clean a[...]

  • Page 33

    GREASING AND SERVICE TABLE 31 NB1A Clean the chain. ( P. 50) • Check the chain tension. ( P. 51) • Check the chain wear. ( P. 52) • Check the rear sprocket / engine sprocket for wear. ( P. 52) • Clean the air filter. ( P. 75) • Checking the tire air pressure. ( P. 66) • Check the tire condition. ( P. 66) • Check the coolant level. ( P[...]

  • Page 34

    MAINTENANCE WORK ON CHASSIS AND ENGINE 32  0$,17(1$1&( :25. 21 &+$66,6 $1' (1*,1(  Jacking up the motorcycle 500074-01 Note Danger of damage ಘ Danger of damage by the vehicle running away or falling over. ದ Always place the vehicle on a firm and even surface. ದ Jack up the motorcycle underneath the engine. The wheels [...]

  • Page 35

    MAINTENANCE WORK ON CHASSIS AND ENGINE 33 400208-10 ದ Turn the adjusting screw b  clockwise with a ring wrench until it stops. Info Do not loosen nut b  ! ದ Turn back counterclockwise the number of turns corresponding to the shock ab- sorber type. Specification Compression damping, high-speed Comfort 2 b turns Standard 1.5 b turns Sport 1[...]

  • Page 36

    0 0 A A 0 0 0 B B 0 0 A A MAINTENANCE WORK ON CHASSIS AND ENGINE 34 400210-10 ದ Turn the adjusting screw b  clockwise until it stops. Info Do not loosen nut b  ! ದ Turn back counterclockwise the number of clicks corresponding to the shock ab- sorber type. Specification Rebound damping Comfort 24 b clicks Standard 22 b clicks Sport 20 b cl[...]

  • Page 37

    C C 0 0 A A A A 2 2 1 1 MAINTENANCE WORK ON CHASSIS AND ENGINE 35  Checking the riding sag of the shock absorber 400222-10 ದ Measure distance b  of rear wheel unloaded. ( P. 34) ದ With another person holding the motorcycle, sit on the saddle with full protective clothing in a normal sitting position (feet on footrests) and bounce[...]

  • Page 38

    MAINTENANCE WORK ON CHASSIS AND ENGINE 36  Adjusting riding sag b x ದ Remove shock absorber. ( P. 36) ದ After removing the shock absorber, clean it thoroughly. ದ Choose and fit a suitable spring. Specification Spring rate Weight of rider: 65… 75 b kg (143… 165 b lb.) 69 b N/mm (394 b lb/in) Weight of rider: 75… 85 b kg (165?[...]

  • Page 39

    MAINTENANCE WORK ON CHASSIS AND ENGINE 37  Checking basic setting of fork Info For various reasons, no exact riding sag can be determined for the forks. 400189-01 ದ As with the shock absorber, smaller weight differences can be compensated by the spring preload. ದ However, if your fork is often overloaded (hard end stop on compressio[...]

  • Page 40

    MAINTENANCE WORK ON CHASSIS AND ENGINE 38 ದ Turn back counterclockwise the number of clicks corresponding to the fork type. Specification Rebound damping (EXC-R b EU, EXC-R b AUS/UK, EXC-R b USA, XCR-W) Comfort 20 b clicks Standard 18 b clicks Sport 18 b clicks Rebound damping (EXC-R b SIX b DAYS) Comfort 20 b clicks Standard 20 b clicks Sport 18[...]

  • Page 41

    MAINTENANCE WORK ON CHASSIS AND ENGINE 39  Cleaning dust boots of fork legs ದ Jack up the motorcycle. ( P. 32) ದ Loosen the fork protection. ( P. 39) 500088-10 ದ Push dust boots b  of both fork legs downwards. Info The dust boots should remove dust and coarse dirt particles from the fork tubes. Over time, dirt can penetrate beh[...]

  • Page 42

    MAINTENANCE WORK ON CHASSIS AND ENGINE 40 400189-10 ದ Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: (EXC-R b SIX b DAYS, XCR-W b USA) ದ Adjust play of the steering head bearing. ( P. 4[...]

  • Page 43

    0 0 1 1 0 0 B B 0 0 A A MAINTENANCE WORK ON CHASSIS AND ENGINE 41  Fork offset (EXC-R b SIX b DAYS, XCR-W b USA) 400188-10 You can see the currently set offset if you remove screw b  . The fork offset b  has an impact on the handling of the vehicle. It is calculated from the center of the fork leg to the center of the steering hea[...]

  • Page 44

    MAINTENANCE WORK ON CHASSIS AND ENGINE 42 100023-11 (EXC-R b EU, EXC-R b AUS/UK, EXC-R b USA, XCR-W b ZA) ದ Loosen screw b  . Remove the fork leg on the left. ದ Loosen screw b  . Remove the fork leg on the right.  Installing the fork legs b x 100021-10 ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Pos[...]

  • Page 45

    MAINTENANCE WORK ON CHASSIS AND ENGINE 43  Removing the fork protector b x ದ Remove the fork legs. ( P. 41) 500105-10 ದ Remove screws b  on the left fork leg. Remove the fork protector upwards. ದ Remove the screws on the right fork leg. Remove the fork protector upwards.  Installing the fork protector b x 500105-10 [...]

  • Page 46

    0 0 2 2 0 0 1 1 0 0 3 3 MAINTENANCE WORK ON CHASSIS AND ENGINE 44  Removing the lower triple clamp b x (EXC-R b EU, EXC-R b AUS/UK, EXC-R b USA, XCR-W b ZA) ದ Remove the fork legs. ( P. 41) ದ Remove the headlight mask with the headlight. ( P. 46) ದ Dismount the front fender. ( P. 46) 500149-10 ದ Remove screws b  and hang the [...]

  • Page 47

    0 0 2 2 0 0 1 1 MAINTENANCE WORK ON CHASSIS AND ENGINE 45 (EXC-R b SIX b DAYS) ದ Refit the headlight mask with the headlight. ( P. 47) ದ Install the fork legs. ( P. 42) 500103-10 ದ Mount and tighten screw b  . Specification Screw, top steering stem M8 17 b Nm (12.5 b lbf b ft) Loctite ® 243™ ದ Check the cable harness, cable, brake and[...]

  • Page 48

    MAINTENANCE WORK ON CHASSIS AND ENGINE 46  Greasing the steering head bearing b x (EXC-R b SIX b DAYS, XCR-W b USA) Remove the lower triple clamp. ( P. 43) Install the lower triple clamp. ( P. 44) (EXC-R b EU, EXC-R b AUS/UK, EXC-R b USA, XCR-W b ZA) Remove the lower triple clamp. ( P. 44) Install the lower triple clamp. ( P. 45) [...]

  • Page 49

    0 0 B B 0 0 B B 0 0 A A 0 0 A A MAINTENANCE WORK ON CHASSIS AND ENGINE 47  Refitting the headlight mask with the headlight (EXC-R b EU, EXC-R b AUS/UK, EXC-R b SIX b DAYS, EXC-R b USA, XCR-W b ZA) 500156-11 ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Connect the electric plug connector b  . 500155-11 ದ P[...]

  • Page 50

    0 0 2 2 0 0 1 1 0 0 2 2 0 0 1 1 0 0 3 3 0 0 2 2 0 0 1 1 0 0 4 4 0 0 5 5 0 0 6 6 0 0 7 7 0 0 8 8 0 0 9 9 MAINTENANCE WORK ON CHASSIS AND ENGINE 48  Adjusting handlebar position b x 400223-10 (EXC-R b EU, EXC-R b AUS/UK, EXC-R b USA, XCR-W) ದ Remove the four screws b  . Remove the handlebar clamp. Remove the handle- bar and lay it to[...]

  • Page 51

    MAINTENANCE WORK ON CHASSIS AND ENGINE 49 ದ Place the handlebar support in the required position. Fit and tighten the two screws b  . Specification Screw, handlebar support M10 40 b Nm (29.5 b lbf b ft) Loctite ® 243™ Condition  Spacer fitted: Use a M10x35 screw Condition without a spacer b  : Use a M10x25 screw Info Position the left[...]

  • Page 52

    MAINTENANCE WORK ON CHASSIS AND ENGINE 50  Checking play in the gas Bowden cable 400192-10 ದ Move the handlebar to the straight-ahead position. Move the throttle grip back and forth slightly to ascertain the play in the gas Bowden cable. Play in gas Bowden cable 3… 5 b mm (0.12… 0.2 b in) » If the gas Bowden cable play does not m[...]

  • Page 53

    MAINTENANCE WORK ON CHASSIS AND ENGINE 51 Info The service life of the chain depends largely on its maintenance. ದ Clean the chain regularly and then treat with chain spray. Chain cleaner ( P. 115) Offroad chain spray ( P. 115)  Checking the chain tension Warning Danger of accidents ಘ Danger caused by incorrect chain tension. ದ If[...]

  • Page 54

    0 0 0 B B 0 0 A A 1 2 3 1 6 1 7 1 8 MAINTENANCE WORK ON CHASSIS AND ENGINE 52  Checking the rear sprocket / engine sprocket for wear 400227-01 ದ Check the rear sprocket / engine sprocket for wear. » If the rear sprocket / engine sprocket are worn: ದ Replace rear sprocket / engine sprocket. Info When fitting the chain joint, always [...]

  • Page 55

    MAINTENANCE WORK ON CHASSIS AND ENGINE 53 400225-10 ದ Loosen nut b  . ದ Loosen nuts b  . ದ Adjust the chain tension by turning the left and right adjusting screws b  . Specification Chain tension 8… 10 b mm (0.31… 0.39 b in) Turn the left and right adjusting screws b  so that the markings on the left and right chain adjusters [...]

  • Page 56

    MAINTENANCE WORK ON CHASSIS AND ENGINE 54  Adjusting chain tension - fitting rear wheel 400225-11 ದ Loosen nuts b  . ದ Adjust the chain tension by turning the adjusting screws b  left and right. Specification Chain tension 8… 10 b mm (0.31… 0.39 b in) Turn the adjusting screws b  left and right so that the markings on t[...]

  • Page 57

    A A MAINTENANCE WORK ON CHASSIS AND ENGINE 55  Brake calipers The brake calipers of this series are "floating", which means that they are not fixed to the brake caliper support. The lateral compensation ensures an optimal position of the brake pad in relation to the brake disc.  Checking brake discs Warning Danger [...]

  • Page 58

    MAINTENANCE WORK ON CHASSIS AND ENGINE 56  Adjusting basic position of handbrake lever (Every XCR-W models) 400196-12 ದ Adjust the basic setting of the handbrake lever to your hand size by turning adjust- ing screw b  . Info Turn the adjusting screw clockwise to increase the distance between the handbrake lever and the handlebar. T[...]

  • Page 59

    MAINTENANCE WORK ON CHASSIS AND ENGINE 57 Warning Danger of accidents ಘ Reduced braking due to old brake fluid. ದ Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard ಘ Problem materials cause environmental damage. ದ Dispose of oil, grease, filters, fuel, clea[...]

  • Page 60

    MAINTENANCE WORK ON CHASSIS AND ENGINE 58  Removing front brake linings b x Warning Danger of accidents ಘ Improper brake maintenance and repair. ದ Always have your brake system maintained and repaired in an authorized KTM workshop. 500089-11 ದ Press the brake caliper by hand on to the brake disc in order to press back the brake pi[...]

  • Page 61

    MAINTENANCE WORK ON CHASSIS AND ENGINE 59  Changing the front brake linings b x Warning Skin irritations ಘ Brake fluid can cause skin irritation on contact. ದ Avoid contact with skin and eyes, and keep out of the reach of children. ದ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. [...]

  • Page 62

    MAINTENANCE WORK ON CHASSIS AND ENGINE 60  Adjusting basic position of footbrake lever b x Warning Danger of accidents ಘ Brake system failure. ದ If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can fail due to overheating. Adjust free travel on foot brake pe[...]

  • Page 63

    MAINTENANCE WORK ON CHASSIS AND ENGINE 61  Adding rear brake fluid b x Warning Danger of accidents ಘ Brake system failure. ದ If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any furth[...]

  • Page 64

    MAINTENANCE WORK ON CHASSIS AND ENGINE 62  Removing rear brake linings b x Warning Danger of accidents ಘ Improper brake maintenance and repair. ದ Always have your brake system maintained and repaired in an authorized KTM workshop. 400236-10 ದ Press the brake caliper by hand on to the brake disc in order to press back the brake pis[...]

  • Page 65

    MAINTENANCE WORK ON CHASSIS AND ENGINE 63  Changing the rear brake linings b x Warning Skin irritations ಘ Brake fluid can cause skin irritation on contact. ದ Avoid contact with skin and eyes, and keep out of the reach of children. ದ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. W[...]

  • Page 66

    MAINTENANCE WORK ON CHASSIS AND ENGINE 64 500085-10 ದ Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. Info Do not pull the hand brake lever when the front wheel is removed. Always lay the wheel down in such a way that the brake disc is not dam- aged. 500086-10 ದ Remove distance bushing b  . ?[...]

  • Page 67

    MAINTENANCE WORK ON CHASSIS AND ENGINE 65  Removing rear wheel b x ದ Jack up the motorcycle. ( P. 32) 400258-10 ದ Press the brake caliper by hand on to the brake disc in order to press back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes. ದ Remove nut b[...]

  • Page 68

    MAINTENANCE WORK ON CHASSIS AND ENGINE 66 400225-12 ದ Position the chain adjuster b  . Fit nut b  , but do not tighten it yet. ದ Check the chain tension when fitting rear wheel. ( P. 51) ದ Make sure that the chain adjusters b  are fitted correctly on the adjusting screws b  . ದ Tighten nut b  . Specification Nut, rear wheel s[...]

  • Page 69

    MAINTENANCE WORK ON CHASSIS AND ENGINE 67  Checking spoke tension Warning Danger of accidents ಘ Unstable riding behavior due to loose spokes. ದ If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop. Info A loose spoke can cause wheel imbalance, which leads to more loose s[...]

  • Page 70

    MAINTENANCE WORK ON CHASSIS AND ENGINE 68  Recharging the battery b x Warning Risk of injury ಘ Battery acid and battery gases cause serious cauterization. ದ Keep batteries out of the reach of children. ದ Wear suitable protective clothing and goggles. ದ Avoid contact with battery acid and battery gases. ದ Keep the battery away [...]

  • Page 71

    MAINTENANCE WORK ON CHASSIS AND ENGINE 69  Removing a fuse ದ Switch off all power-consuming components and switch off the engine. ದ Dismount the air filter box lid. ( P. 74) 400270-10 ದ Remove the protection cover b  . Info The fuse b  is located in the starter relay b  under the filter box cover. ದ Remove the fuse b ?[...]

  • Page 72

    MAINTENANCE WORK ON CHASSIS AND ENGINE 70  Dismounting the fuel tank b x Danger Fire hazard ಘ Fuel can easily catch fire. ದ Never fill up 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.[...]

  • Page 73

    MAINTENANCE WORK ON CHASSIS AND ENGINE 71 500067-01 ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Position the fuel tank and fit the two spoilers to the side of the radiator fixing. ದ Make sure that no cables or Bowden cables are trapped or damaged. 500066-11 ದ Mount the fuel tank vent hose. ದ Fit and tighten screw b[...]

  • Page 74

    MAINTENANCE WORK ON CHASSIS AND ENGINE 72 400243-10 ದ Stand the motorcycle upright on a horizontal surface. ದ Remove the radiator cap. ದ Check antifreeze of coolant. ෥ 25… ෥ 45 b °C ( ෥ 13… ෥ 49 b °F) » If the antifreeze of the cooling liquid does not meet specifications: ದ Correct antifreeze of coolant. ದ Check the coolant[...]

  • Page 75

    MAINTENANCE WORK ON CHASSIS AND ENGINE 73 400335-11 ದ Stand the vehicle upright. ದ Place a suitable container under the water pump cover. ದ Remove screw b  . Remove the radiator cap b  . ದ Completely drain the coolant. ದ Fit screw b  with a new seal and tighten it. Specification Screw, water pump cover M6x25 10 b Nm (7.4 b lbf b [...]

  • Page 76

    MAINTENANCE WORK ON CHASSIS AND ENGINE 74  Fitting the main silencer 400337-11 ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Mount the main silencer. Mount and tighten screws b  . Specification Remaining screws, chassis M6 10 b Nm (7.4 b lbf b ft) ದ Reconnect spring b  .  Dismounting t[...]

  • Page 77

    MAINTENANCE WORK ON CHASSIS AND ENGINE 75  Installing the air filter b x 500107-10 ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Mount the clean air filter onto the air filter support. ದ Put in both parts together, position them and fix them with the air filter support b  . Info If the air filter is not[...]

  • Page 78

    MAINTENANCE WORK ON CHASSIS AND ENGINE 76 400339-10 ದ Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. ದ Remove screws b  . ದ Take off cover b  with membrane b  . ದ Check the fluid level. Fluid level under top level of container. 4 b mm (0.16 b in) » If the level of the cooling liquid does not mee[...]

  • Page 79

    MAINTENANCE WORK ON CHASSIS AND ENGINE 77 400340-10 ದ Inject the liquid into the system until it escapes from the bore hole b  of the mas- ter cylinder without bubbles. ದ To prevent overflow, drain fluid occasionally from the master cylinder reservoir. ದ Remove the bleeding syringe. Mount and tighten screws bleeder screw. ದ Correct the f[...]

  • Page 80

    MAINTENANCE WORK ON CHASSIS AND ENGINE 78 Danger Danger of poisoning ಘ Exhaust gases are poisonous and can result in uncon- sciousness and/or death. ದ When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in a closed space. ದ Adjust the idle speed with the adjusting screw b  . Speci[...]

  • Page 81

    MAINTENANCE WORK ON CHASSIS AND ENGINE 79 Warning Environmental hazard ಘ Improper handling of fuel is a danger to the environment. ದ Do not allow fuel to get into the ground water, the ground, or the sewage system. Info Carry out this work with a cold engine. ದ Turn the handle b  of the fuel tap to the OFF position. (Figure b 500137-10 b P[...]

  • Page 82

    MAINTENANCE WORK ON CHASSIS AND ENGINE 80 200112-10 ದ Place a suitable container under the engine. ದ Remove engine oil plug screen b  . ದ Completely drain the engine oil. ದ Thoroughly clean the plug and gear oil screen. ದ Clean the sealing area on the engine. ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Fit p[...]

  • Page 83

    MAINTENANCE WORK ON CHASSIS AND ENGINE 81 200113-11 ದ Refit the oil filter cover b  . ದ Mount and tighten screws b  . Specification Screw, oil filter cover M5 6 b Nm (4.4 b lbf b ft) ದ Stand the motorcycle up.  Filling up with engine oil b x Info Too little engine oil or poor-quality engine oil results in premature wear t[...]

  • Page 84

    MAINTENANCE WORK ON CHASSIS AND ENGINE 82 200116-10 Condition Engine is cold. ದ Remove gear oil level check screw b  . Stand the vehicle upright. ದ Check the gear oil level. A small amount of gear oil should flow out. » If no gear oil flows out: ದ Top up with gear oil. ( P. 83) ದ Mount and tighten the gear oil level check screw. Specifi[...]

  • Page 85

    MAINTENANCE WORK ON CHASSIS AND ENGINE 83  Filling up with gear oil b x Info Too little gear oil or poor-quality oil results in premature wear to the transmission. 200118-10 ದ Remove the screw cap b  and fill up with gear oil. Gear oil 0.9 b l( 1 b qt.) Engine oil (SAE 10W/50) ( P. 114) ದ Mount and tighten screw cap b  . Da[...]

  • Page 86

    TROUBLESHOOTING 84  7528%/(6+227,1* Faults Possible cause Measure The engine cannot be cranked (electric starter). Operating error ದ Carry out instructions on starting. ( P. 26) Battery discharged ದ Recharge the battery. ( P. 68) ದ Check the cause of discharging. Fuse blown ದ Remove the fuse. ( P. 69) ದ Replace the fuse. ( P. 69) Low e[...]

  • Page 87

    TROUBLESHOOTING 85 Faults Possible cause Measure Engine turns but does not start. Water in carburetor or jets blocked ದ Clean carburetor. Engine has no idle. Idling jet blocked ದ Clean carburetor. Adjusting screws on carburetor distorted ದ Have the carburetor adjusted. Spark plug defective ದ Change spark plug. Ignition system defective ದ [...]

  • Page 88

    CLEANING 86  &/($1,1*  Cleaning motorcycle Note Material damage ಘ Damage and destruction of components by high-pressure cleaning equipment. ದ Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, connects, Bowden cables, and bearin[...]

  • Page 89

    STORAGE 87  6725$*(  Storage Warning Danger of poisoning ಘ Fuel is poisonous and a health hazard. ದ Avoid contact between fuel and 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 fu[...]

  • Page 90

    TECHNICAL DATA - ENGINE 88  7(&+1,&$/ '$7$  (1*,1( Design 1-cyliner 4-stroke engine, water-cooled Displacement (Every 450 models) 449.3 b cm³ (27.418 b cu b in) Displacement (Every 530 models) 510.4 b cm³ (31.147 b cu b in) Stroke (Every 450 models) 63.4 b mm (2.496 b in) Stroke (Every 530 models) 72 b mm (2.83 b in) Bore 95[...]

  • Page 91

    TECHNICAL DATA - ENGINE 89  Capacity - coolant Coolant 0.95 b l( 1 b qt.) Coolant ( P. 114) Coolant (mixed ready to use) ( P. 114)[...]

  • Page 92

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES 90  7(&+1,&$/ '$7$ (1*,1( 7,*+7(1,1* 72548(6 Screw, cable holder in generator cover M4 4 b Nm (3 b lbf b ft) Loctite ® 243™ Oil jet, rocker arm lubrication M5 2 b Nm (1.5 b lbf b ft) Loctite ® 243™ Oil jet, piston cooling M5 2 b Nm (1.5 b lbf b ft) Loctite ® 243 ™ Screw, lock[...]

  • Page 93

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES 91 Screw, cylinder head M10x1,25 Tightening sequence : Tighten diagonally, begin- ning with the rear screw on the chain shaft. Step 1 10 b Nm (7.4 b lbf b ft) Step 2 30 b Nm (22.1 b lbf b ft) Step 3 50 b Nm (36.9 b lbf b ft) Engine oil (any) Gear oil drain plug with magnet M12x1,5 20 b Nm (14.8 b lbf b ft)[...]

  • Page 94

    TECHNICAL DATA - CARBURETOR 92  7(&+1,&$/ '$7$  &$5%85(725  450 b EXC-R b EU, 450 b EXC-R b AUS/UK (3900I) Carburetor type KEIHIN FCR-MX 39 Carburetor identification number 3900I Needle position 4th position from top Idle mixture adjusting screw Open 1.75 b turns Pump membrane stop 2.15 b mm (0.0846 b in) Main [...]

  • Page 95

    TECHNICAL DATA - CARBURETOR 93  530 b EXC-R b EU, 530 b EXC-R b AUS/UK (3900J) Carburetor type KEIHIN FCR-MX 39 Carburetor identfication number 3900J Needle position 5th position from top Idle mixture adjusting screw Open 1.5 b turns Pump membrane stop 2.15 b mm (0.0846 b in) Main jet 180 Jet needle OBDZT (OBDTR) Idling jet 40 Main air [...]

  • Page 96

    TECHNICAL DATA - CHASSIS 94  7(&+1,&$/ '$7$  &+$66,6 Frame Central tube frame made of chrome molybdenum steel tubing Fork WP 4860 MXMA PA Suspension travel front 300 b mm (11.81 b in) Rear 335 b mm (13.19 b in) Fork offset (EXC-R b SIX b DAYS, XCR-W b USA) Front marking 18 b mm (0.71 b in) Rear marking 20 b mm (0.79 b in) [...]

  • Page 97

    TECHNICAL DATA - CHASSIS 95  Lighting equipment Headlight (EXC-R b EU, EXC-R b AUS/UK, EXC-R b SIX b DAYS, EXC-R b USA, XCR-W b ZA) BA20d 12 b V 35/35 b W Parking light (EXC-R b EU, EXC-R b AUS/UK, EXC-R b SIX b DAYS, EXC-R b USA, XCR-W b ZA) W2,1x9,5d 12 b V 5 b W Indicator lights (Every EXC-R models) W2x4,6d 12 b V 1.2 b W Flasher lig[...]

  • Page 98

    TECHNICAL DATA - FORK 96  7(&+1,&$/ '$7$  )25. Fork part number (EXC-R b EU, EXC-R b AUS/UK, EXC-R b USA, XCR- W) 14.18.7D.06 Fork part number (EXC-R b SIX b DAYS) 14.18.7D.35 Fork WP 4860 MXMA PA Compression damping (EXC-R b EU, EXC-R b AUS/UK, EXC-R b USA, XCR-W) Comfort 24 b clicks Standard 20 b clicks Sport 18 b clicks Com[...]

  • Page 99

    TECHNICAL DATA - SHOCK ABSORBER 97  7(&+1,&$/ '$7$  6+2&. $%625%(5 Shock absorber part number (EXC-R b EU, EXC-R b AUS/UK, EXC- R b USA, XCR-W) 12.18.7D.06 Shock absorber part number (EXC-R b SIX b DAYS) 12.18.7D.35 Shock absorber WP PDS 5018 DCC Compression damping, low-speed Comfort 18 b clicks Standard 15 b clicks Sport[...]

  • Page 100

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 98  7(&+1,&$/ '$7$  &+$66,6 7,*+7(1,1* 72548(6 Spoke nipple, front wheel M4,5 5 b Nm (3.7 b lbf b ft) ದ Spoke nipple, rear wheel M5 5 b Nm (3.7 b lbf b ft) ದ Remaining nuts, chassis M6 15 b Nm (11.1 b lbf b ft) ದ Remaining screws, chassis M6 10 b Nm (7.4 b lbf b ft) ದ Scr[...]

  • Page 101

    99[...]

  • Page 102

    m a r g a i d g n i r i w s s e n r a h n i a m 3 / T B _ C 3 / G B _ C 2 / H A _ C 2 / K A _ C 2 / V B _ C 2 / O B _ C C_AH1/2 C_AK1/2 C_BF/1 C_BA/1 6 / C A _ C 6 / C B _ C 1 / 1 A B _ C 1 / 1 F B _ C G 2 / 2 H A _ C C_AJ1/3 C_BG1/3 v 2 / S B _ C 4 / R B _ C 4 / K B _ C C_BA2/1 U C_CE/4 C_CA/4 8 1 / U B _ C C_CW/2 C_CX/2 C_CW1/2 C_CX1/2 C_CW2/2 C_[...]

  • Page 103

    WIRING DIAGRAM 101 Components 1 Battery 2 Generator 3 Ignition coil 4 Pulse generator 5 Voltage regulator/rectifier 6 Electric starter button 7 Starter relay with fuse 8 Starter motor 9 Light switch, horn button, short circuit button 10 Throttle valve sensor TPS 11 Ignition curve plug connection 12 CDI controller 13 Headlight 14 Parking light 15 Br[...]

  • Page 104

    m a r g a i d g n i r i w s s e n r a h n i a m 3 / T B _ C 3 / G B _ C 2 / H A _ C 2 / K A _ C 2 / V B _ C 2 / O B _ C C_AH1/2 C_AK1/2 C_BF/1 C_BA/1 6 / C A _ C 6 / C B _ C 1 / 1 A B _ C 1 / 1 F B _ C G 2 / 2 H A _ C C_AJ1/3 C_BG1/3 v 2 / S B _ C C_BA2/1 U C_CE/4 C_CA/4 8 1 / U B _ C C_CW/2 C_CX/2 C_CW1/2 C_CX1/2 C_CW2/2 C_CX2/2 C_CW3/2 C_CX3/2 C_[...]

  • Page 105

    WIRING DIAGRAM 103 Components 1 Battery 2 Generator 3 Ignition coil 4 Pulse generator 5 Voltage regulator/rectifier 6 Flasher switch 7 Starter relay with fuse 8 Starter motor 9 Light switch, horn button, short circuit button 10 Throttle valve sensor TPS 11 Ignition curve plug connection 12 CDI controller 13 Headlight 14 Parking light 15 Brake / tai[...]

  • Page 106

    m a r g a i d g n i r i w s s e n r a h n i a m 2 / H A _ C 2 / K A _ C 2 / V B _ C 2 / O B _ C C_AH1/2 C_AK1/2 G 2 / 2 H A _ C C_AJ1/3 C_BG1/3 v 2 / S B _ C 4 / R B _ C 4 / K B _ C black U C_CE/4 C_CA/4 8 1 / U B _ C C_CW/2 C_CX/2 C_CW1/2 C_CX1/2 C_CW2/2 C_CX2/2 C_CW3/2 C_CX3/2 C_BF/1 C_BA/1 OFF ON 4 / Y B _ C 4 / V C _ C 6 / C A _ C 6 / C B _ C 3[...]

  • Page 107

    WIRING DIAGRAM 105 Components 1 Battery 2 Generator 3 Ignition coil 4 Pulse generator 5 Voltage regulator/rectifier 6 Electric starter button 7 Starter relay with fuse 8 Starter motor 9 Emergency OFF switch 10 Throttle valve sensor TPS 11 Ignition curve plug connection 12 CDI controller 13 Headlight 14 Parking light 15 Brake / tail light 16 Light s[...]

  • Page 108

    WIRING DIAGRAM 106 ye yellow ye-bl yellow-black ye-re yellow-red[...]

  • Page 109

    WIRING DIAGRAM 107[...]

  • Page 110

    m a r g a i d g n i r i w s s e n r a h n i a m 2 / H A _ C 2 / K A _ C 2 / O B _ C C_AH1/2 C_AK1/2 C_BF/1 C_BA/1 6 / C A _ C 6 / C B _ C 1 / 1 A B _ C 1 / 1 F B _ C v 4 / R B _ C 4 / K B _ C C_BA2/1 U C_CE/4 C_CA/4 8 1 / U B _ C C_AJ/3 C_BG/3 2 / S B _ C 1 2 3 C_CY/3 C_CZ/3 C_DA/4 C_DB/4 C_CW/2 C_CX/2 C_BP/4 C_DG/4 M A 0 1 4 / F A _ C 3 / M A _ C [...]

  • Page 111

    WIRING DIAGRAM 109 Components 1 Battery 2 Generator 3 Ignition coil 4 Pulse generator 5 Voltage regulator/rectifier 6 Electric starter button 7 Starter relay with fuse 8 Starter motor 9 Light switch, horn button, short circuit button 10 Throttle valve sensor TPS 11 Ignition curve plug connection 12 CDI controller 13 Headlight 14 Parking light 15 Br[...]

  • Page 112

    m m a r g a i d g n i r i w s s e n r a h n i a m 0 0 1 . 5 7 0 . 1 1 . 4 9 5 G 3 v M A 0 1 U 0 0 0 . 2 3 0 . 9 3 . 0 8 7 s s e n r a h I D C e r - e y e y h w r b h w r b wh ye re-wh re-bl gn re re gn re-bl re-wh bu-wh br ye-bl bu-wh br br r b e r - e y r b l b - e y l b l b e r u b h w r b bu ye bl bl ye bu ye-re wh-re wh-re ye-re br ye-re br wh [...]

  • Page 113

    WIRING DIAGRAM 111 Components 1 Battery 2 Generator 3 Ignition coil 4 Pulse generator 5 Voltage regulator/rectifier 6 Electric starter button 7 Starter relay with fuse 8 Starter motor 9 Short circuit button 10 Throttle valve sensor TPS 11 Ignition curve plug connection 12 CDI controller 13 Light switch 14 Speedometer 15 Wheel speed sensor 16 Tripma[...]

  • Page 114

    m m a r g a i d g n i r i w s s e n r a h n i a m 0 0 1 . 5 7 0 . 1 1 . 4 9 5 G 3 v M A 0 1 U 2 / S B _ C A 5 t M 0 0 0 . 2 3 0 . 9 3 . 0 8 7 s s e n r a h I D C e r - e y e y h w r b h w r b wh ye re-wh re-bl gn re re gn re-bl re-wh bu-wh br ye-bl bu-wh br br ye r b e r - e y r b l b - e y l b l b e r u b h w r b bu ye bl bl ye bu ye-re wh-re wh-r[...]

  • Page 115

    WIRING DIAGRAM 113 Components 1 Battery 2 Generator 3 Ignition coil 4 Pulse generator 5 Voltage regulator/rectifier 6 Electric starter button 7 Starter relay with fuse 8 Starter motor 9 Short circuit button 10 Throttle valve sensor TPS 11 Ignition curve plug connection 12 CDI controller 13 Headlight 14 Parking light 15 Brake / tail light 16 Light s[...]

  • Page 116

    SUBSTANCES 114  68%67$1&(6 Super unleaded (ROZ 95 / RON 95 / PON 91) according to ದ DIN b EN b 228 (ROZ 95 / RON 95 / PON 91) Brake fluid DOT 5.1 according to ದ DOT Specification ದ Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- sponding properties. [...]

  • Page 117

    AUXILIARY SUBSTANCES 115  $8;,/,$5< 68%67$1&(6 Universal oil spray Specification ದ KTM recommends Motorex ® products. Supplier Motorex ದ Motorex ® b Joker b 440 b Universal Long-life grease Specification ದ KTM recommends Motorex ® products. Supplier Motorex ದ Motorex ® b Long b Therm b 2000 Chain cleaner Specification ದ K[...]

  • Page 118

    AUXILIARY SUBSTANCES 116 High-luster polish for paint Specification ದ KTM recommends Motorex ® products. Supplier Motorex ದ Motorex ® b Moto b Polish Contact spray Specification ದ KTM recommends Motorex ® products. Supplier Motorex ದ Motorex ® b Accu b Contact[...]

  • Page 119

    STANDARDS 117  67$1'$5'6 JASO b T903 b MA Different technical development directions required a new specification for 4-stroke motorcycles ದ the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation. Whereas long servic[...]

  • Page 120

    on steering head tube on front frame tube on upper frame tube  T ype label USA  Before you go for the first ride  Chain tension  EA VP on rear fender on swing arm LH inside filter cover LH on frame tube RH  Green sticker  T ype label CAN  Noise emission       CONSUMER INFORMATION (EXC-R USA) 118[...]

  • Page 121

    CONSUMER INFORMATION (EXC-R USA) 119 REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect which could cause an accident resulting in injury or death, you should immediately inform the National Highway T raffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc. If NHTSA receives similar complaints, it ma[...]

  • Page 122

    INDEX 120 ,1'(; A Accessories ........ ............ ............. .. 6 Air filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Air filter box lid fitting[...]

  • Page 123

    INDEX 121 Fork protector fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Front fender installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 124

    INDEX 122 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Starting ........ ............ ............. ... 2 6 steering locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Steering head bearing greasing . . . . . . .[...]

  • Page 125

    *3211254 en* 3211254en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com 10/2007 Photo Mitterbauer[...]