KTM 450 EXC USA manual

OWN ER'S MAN UAL 20 10 450 EXC USA 530 EXC USA Art. no. 3211468e n[...]

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DEAR KTM CUS TOMER 1 DEAR KTM CUSTOMER Congratulations on yo ur decision to purchase a K TM motorcycle. You are no w the owner of a state-of-the -art sports motorcycle th at will give you enormous ple asure if you service and ma intain it accordingly. We wish you great pleasu re riding the vehicle! Enter the serial numb ers of your vehicle belo w. [...]

TABLE OF CON TENTS 2 TABLE OF CONTENTS MEANS OF REPRESEN TATION ............................ ................ 4 IMPORTANT INFORMATION ............... .............................. ... 5 Overview of labels ............................ .............................. .. 6 VIEW OF VEHICLE ............................................ ................. [...]

TABLE OF CON TENTS 3 Cleaning the chain.......................... .............................. . 52 Checking the chain ten sion ............. .............................. . 52 Checking chain tensi on when fitting rear wheel .......... ...... 53 Checking the rear sproc ket/engine sprocket fo r wear ......... 53 Checking chain wear ..............[...]

MEANS OF RE PRESENTA TION 4 Symbols used The symbols used are ex plained in the following. Indicates an expecte d reaction (e.g. of a work step or a fu nction). Indicates an unexpec ted reaction (e.g. of a work ste p or a function). All work marked with this sy mbol requires special ist knowledge and techn ical understanding. In th e interest of yo[...]

IMPORTA NT INFORMA TION 5 Use definition KTM sport motorcycle s are designed and built to wi thstand the normal stres ses and strains of compet itive use. The motorcycl es com- ply with currently valid re gulations and categori es of the top international m otorsport organizatio ns. Info The motorcycle is auth orized for use on public road s in the[...]

IMPORTA NT INFORMA TION 6 – Turn handle  of the fuel tap to the OFF position. (Figure 50 0137-10 p. 22) – Use straps or other suita ble devices to secure the m otorcycle against acci dents or falling over. Environment Motorcycling is a wond erful sport and we naturally h ope that you can enjoy it to the fu ll. However, it is a potential p ro[...]

IMPORTA NT INFORMA TION 7 500251-01 Type label for the USA 100841-01 Fuel evaporative syste m information 500255-01 Chain tension informa tion 700210-01 Information on putting i nto operation 100840-01 Emission control info rmation[...]

IMPORTA NT INFORMA TION 8 100839-01 Noise emission infor mation Notes/warnings Pay close attention to the n otes/warnings. Info Various information a nd warning labels are affix ed to the vehicle. Do not remo ve information/warnin g labels. If they are miss- ing, you or others may not re cognize potential haza rds and may therefore be in jured. Gra[...]

IMPORTA NT INFORMA TION 9 Tampering warnin g Tampering with the nois e control system is prohib ited. Federal law prohib its the following acts or the ca using thereof: 1 The removal or rende ring inoperative by any person, other than for purp oses of maintenance , repair, or replacemen t, of any device or element of design inco rporated into any n[...]

VIEW OF VEHICL E 10 3.1 View of the vehicle from t he left front (example) 300399-10 1 Side stand 2 Shift lever 3 Chain guide 4 Fuel tap 5 Air filter box lid 6 Clutch lever 7 Light switch, headlig ht flasher button, flash er switch, horn button 8 Hand brake lever[...]

VIEW OF VEHICL E 11 3.2 View of the vehicle from t he right rear (example ) 300398-10 1 Level viewer for brake fluid, rear 2 Fork compression ad justment 3 Foot brake pedal 4 Kickstarter 5 Horn 6 Ignition switch 7 Fork rebound adjustm ent 8 Filler cap 9 Shock absorber comp ression adjustment 10 Shock absorber rebou nd adjustment[...]

LOCATION O F SERIAL NUM BERS 12 4.1 Chassis number 500127-10 The chassis number  is st amped on the steering hea d on the right. 4.2 Type label 300402-10 The type label USA  is fixe d to the front of the steering hea d. 300403-10 The type label Canada  is f ixed to the front of the front pipe . 4.3 Key number 300397-10 The key number  i[...]

LOCATION O F SERIAL NUM BERS 13 4.5 Fork part number 100801-10 The fork part number  is st amped on the inner side of the f ork stub. 4.6 Shock absorber par t number 500129-10 The shock absorber pa rt number  is stamped on the t op of the shock absorber ab ove the adjusting ring on the en gine side.[...]

CONTROL S 14 5.1 Clutch lever 500133-10 The clutch lever  is fitted on t he left side of the handlebar . The clutch is hydraulic ally operated and self-ad justing. 5.2 Hand brake lever 400196-10 Hand brake lever  is locat ed on the right side of the handl ebar. The hand brake lever is us ed to activate the front brake . 5.3 Emergency OFF swi [...]

CONTROL S 15 5.6 Light switch 500142-10 Light switch  is fitted on the le ft side of the handlebar. Possible states Low beam on – Light switch is tu rned downward. In this pos ition, the low beam and tail light are s witched on. High beam on – Light switch i s turned upward. In this posi tion, the high beam and tail light are s witched on. 5[...]

CONTROL S 16 5.11 Speedometer 400312-01 – Press the key to change the display mode or change t o one of the Setup menus. – Press the key to control different functions. – Press the key to control different functions. Info When the vehicle is deliv ered, only the SPEED/H and S PEED/ODO display mod es are activated. 5.12 Speedometer acti vation[...]

CONTROL S 17 – Press the button for 3 - 5 seconds. The settings are stored a nd the setup menu is closed . Info If no button is actuated for 20 s econds or there is no signa l from the wheel speed sensor, then the s ettings are automatica lly stored and the setup men u closed. 5.15 Setting the clock Condition The motorcycle is stati onary. 400330[...]

CONTROL S 18 Info If no button is pressed for 20 s econds, or if a pulse arrives fr om the wheel speed sensor, the setti ngs are stored automatic ally and the Setup menu is closed. 5.17 Querying the lap time Info This function can be call ed only if lap times are measu red. Condition The motorcycle is stati onary. 400321-01 – Press the button bri[...]

CONTROL S 19 5.20 Display mode SPEE D/CLK (clock) 400319-01 – Press the button briefly and repeatedly until CLK a ppears at the bottom right o f the display. The time is displayed in CL K display mode. Press the button . No function Press the button . No function Press the button for 3 - 5 seconds. The display changes to t he Setup menu of the cl[...]

CONTROL S 20 Press the button briefly. Next display mode 5.24 Display mode SPEE D/TR2 (trip master 2) 400324-01 – Press the button briefly and repeatedly until TR2 a ppears at the top right of the display. TR2 (trip master 2) runs con stantly and counts up to 999 .9. The displayed value ca n be set manually with the bu tton and the button . A ver[...]

CONTROL S 21 5.27 Display mode SPEE D/S1 (stop watch 1) 400327-01 – Press the button briefly and repeatedly until S1 ap pears at the top right of the display. S1 (stop watch 1) displays t he journey time on the basis o f TR1 and continues when a n impulse is received fro m the wheel speed sensor . The calculation of this va lue starts with the fi[...]

CONTROL S 22 Table of conditions a nd menu activation Display The motorcycle is stationary Menu can be acti- vated Display mode SPEED/C LK (clock) • Display mode SPEED/L AP (lap time) • Display mode SPEED/T R1 (trip master 1) • Display mode SPEED/T R2 (trip master 2) • Display mode SPEED/A 1 (average speed 1) • Display mode SPEED/A 2 (ave[...]

CONTROL S 23 5.32 Choke 500135-10 Choke  is fitted on the left sid e of the carburetor. Activating the choke fu nction frees an opening th rough which the engine ca n draw extra fuel. This gives a rich er fuel-air mixture, which i s needed for a cold start. Info If the engine is warm, the cho ke function must be deac tivated. Possible states •[...]

CONTROL S 24 5.36 Side stand 500140-10 Note Danger of damage   T he parked vehicle may ro ll away or fall over. – Always place the vehic le on a firm and even surface. Note Material damage   Damage and destructio n of components by exce ssive load. – The side stand is design ed for the weight of the motorc ycle only. Do not sit on the motor[...]

CONTROL S 25 5.39 Unlocking the steerin g 400731-01 – Insert the key in the steerin g lock, turn it to the left, pull it out an d turn it to the right. Remove the key. You can now steer the bike a gain. Info Never leave the key in the s teering lock.[...]

GENERAL TI PS AND HINTS O N PUTTING INT O OPERATIO N 26 6.1 Advice on first use Danger Danger of accident s   Danger arising from the ri der's judgement being im paired. – Do not use the vehicle if you a re inexperienced or if you ha ve consumed alcohol o r drugs. Warning Risk of injury   Missi ng or poor protective cloth ing present an [...]

GENERAL TI PS AND HINTS O N PUTTING INT O OPERATIO N 27 – Do not exceed the overal l maximum permitted we ight and the axle loads. Guideline Maximum permissi ble overall weight 335 kg (739 lb.) Maximum permissi ble front axle load 145 kg (320 lb.) Maximum permissi ble rear axle load 190 kg (419 lb.) – Check the spoke tensio n. ( p. 68) Info The[...]

GENERAL TI PS AND HINTS O N PUTTING INT O OPERATIO N 28 600869-01 – Fit a dust protection devi ce on the air filter. Dust protection devi ce for air filter (5900601 9000) Info See the KTM PowerParts fitting instructions. 600871-01 – Fit a sand screen device o n the air filter. Sand protection devic e for air filter (5900602200 0) Info See the K[...]

GENERAL TI PS AND HINTS O N PUTTING INT O OPERATIO N 29 600870-01 – Fit a waterproofing devi ce on the air filter. Waterproofing devi ce for air filter (5900602 1000) Info See the KTM PowerParts fitting instructions. – Adjust the carburetor je tting and settings. Info Your authorized KTM wo rkshop has the recomm ended carburetor tunin g set- ti[...]

GENERAL TI PS AND HINTS O N PUTTING INT O OPERATIO N 30 6.7 Preparing for rides at h igh temperature and sl ow speed 600872-10 – Check the radiator cap. Value on radiator cap 1.8 bar (26 psi) » If the displayed value do es not correspond to spec ifications: Warning Danger of scalding   During motorcycle ope ration, the coolant gets very hot an[...]

RIDING INST RUCTIONS 31 7.1 Checks before putti ng into operation Info Make sure that the motor cycle is in a perfect technic al condition before use. Info In the interests of riding sa fety, make a habit of making a g eneral check before you r ide. – Check the engine oil leve l. ( p. 81) – Check the chain tensio n. ( p. 52) – Check for chain[...]

RIDING INST RUCTIONS 32 400733-01 – Press the electric starte r button or press the kicksta rter robustly through its fu ll range. Info Do not rev up. 7.3 Starting up Info If your bike has lights, swit ch them on before riding. Yo u will then be seen earlier by oth er motorists. When you are riding, the si de stand must be folded up an d secured [...]

RIDING INST RUCTIONS 33 – On sandy, wet or slippe ry surfaces, use the rea r brake. – Braking should alway s be completed before you g o into a bend. Change down to a l ower gear appropriate to yo ur road speed. – On long downhill stretch es, use the braking effect o f the engine. Change down o ne or two gears, but do not overs tress the engi[...]

RIDING INST RUCTIONS 34 A A 400382-10 – Fill the fuel tank with fuel up to m easurement  . Guideline Measurement of  35 mm (1.38 in) Total fuel tank capacity, approx. 9.2 l (2.43 US gal) Super unleaded (ROZ 95 / R ON 95 / PON 91) ( p. 106) – Close the filler cap. ( p. 22)[...]

SERVICE SC HEDULE 35 8.1 Important mainten ance work to be carried o ut by an authorized KTM workshop. S3N S15A S30A Engine Change the eng ine oil and oil filter and clean th e engine oil screen. x ( p. 82) • • • Change the gear oil and cle an the gear oil screen. x ( p. 84) • • • Replace spark plug. • Check the valve cleara nce. x ?[...]

SERVICE SC HEDULE 36 8.2 Important mainten ance work to be carried o ut by an authorized KTM workshop. (as additional o rder) Competition use Hobby use S15N S45A J1A S15A S30A S45A S30A S60A S90 A Perform a fork service. x • • Perform a shock absorb er service. x • • Grease the steering hea d bearing. x ( p. 49) • Treat electric contact s[...]

SERVICE SC HEDULE 37 8.3 Important checks a nd maintenance wor k to be carried out by the ride r NB1A Check the engine oil leve l. ( p. 81) • Check the brake fluid lev el of the front brake. ( p. 57) • Check the rear brake fluid l evel. ( p. 61) • Check the front brake lini ngs. ( p. 58) • Check the rear brake linin gs. ( p. 62) • Check a[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 38 9.1 Jacking up the motorc ycle 500074-01 Note Danger of damage   T he parked vehicle may ro ll away or fall over. – Always place the vehic le on a firm and even surface. – Jack up the motorcycle u nderneath the engine. T he wheels should no longe r touch the ground. Work stand (5482905 5000) – Se[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 39 400208-10 – Turn adjusting screw  c lockwise with a socket wre nch until it stops. Info Do not loosen nut  ! – Turn back counterclo ckwise by the number of turn s corresponding to the sh ock absorber type. Guideline Compression damp ing, high-speed Comfort 2 turns Standard 1.5 turns Sport 1.25 [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 40 400210-10 – Turn adjusting screw  c lockwise up to the last perce ptible click. Info Do not loosen nut  ! – Turn back counterclo ckwise by the number of clic ks corresponding to the s hock absorber type. Guideline Rebound damping Comfort 26 clicks Standard 24 clicks Sport 22 clicks Info Turn cl[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 41 9.10 Checking riding sag o f shock absorber C C 0 0 A A 400222-10 – Measure distance  of re ar wheel unloaded. ( p. 40) – With the help of another pe rson holding the motorcy cle, the rider, wearing com - plete clothing, sits on the m otorcycle in a normal pos ition (feet on footrests) an d rocks [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 42 9.12 Adjusting riding sag x – Remove shock absor ber. x ( p. 42) – After removing the shoc k absorber, clean it thorou ghly. – Choose and fit a suitable s pring. Guideline Spring rate Weight of rider: 65… 75 kg (1 43… 165 lb.) 69 N/mm (394 lb/in) Weight of rider: 75… 85 kg (1 65… 187 lb.) 7[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 43 9.15 Checking basic setti ng of fork Info For various reasons, no e xact riding sag can be dete rmined for the forks. 400189-01 – As with the shock absorb er, smaller weight differe nces can be compensat ed by the spring preload. – However, if your fork is ofte n overloaded (hits the bum p stops on c[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 44 Info Turn clockwise to incre ase damping, turn count erclockwise to reduce su s- pension damping. 9.18 Adjusting spring pre load of the fork 800015-10 – Turn adjusting screws c ounterclockwise unt il they stop. Info Make sure the setting is id entical on both fork legs. – Turn back clockwise by t he [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 45 – Remove excess oil. – Position the fork protec tor. ( p. 45) – Remove the motorcyc le from the work stand. ( p. 38) 9.21 Loosening the fork pro tector 600875-11 – Remove screws  and rem ove the clamp. – Remove screws  on the lef t fork leg. Push the fork protec tor downwards. – Remove [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 46 9.24 Adjusting play of stee ring head bearing x – Jack up the motorcycle . ( p. 38) 800022-10 – Loosen screw  . Remov e screw  . – Loosen and retighten s crew  . Guideline Screw, top steering hea d M20x1.5 10 Nm (7.4 lbf ft) – Using a plastic hamme r, tap lightly on the upper tripl e cla[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 47 100803-11 – Fully tighten screw  . Guideline Screw, top triple clamp M8 17 Nm (12.5 lbf ft) – Tighten screws  . Guideline Screw, bottom triple cla mp M8 12 Nm (8.9 lbf ft) 100802-11 – Position brake calipe r, mount and tighten screw s  . Guideline Screw, front brake calip er M8 25 Nm (18.4[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 48 500100-10 – Remove o-ring  . Rem ove protector ring  . – Remove the lower triple c lamp with the steering stem . – Remove the upper stee ring head bearing. 9.30 Installing the lower trip le clamp x 0 0 2 2 0 0 1 1 0 0 3 3 500098-10 – Clean the bearing and se aling elements, check fo r damag[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 49 9.31 Greasing the steerin g head bearing x 800010-10 – Remove the lower triple c lamp. x ( p. 47) – Install the lower triple cla mp. x ( p. 48) 9.32 Removing the front fe nder 600692-10 – Remove screws  . Rem ove the front fender. – Make sure the spacers re main in place. 9.33 Installing the f[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 50 9.35 Refitting the headligh t mask with the headlig ht 600702-11 – Connect the electric plu g connector  . 600703-11 – Position the headligh t mask and fix it with the rubber ba nd  . Info Ensure that the retainin g lugs engage in the fender. – Position the brake line an d wiring harness. Put[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 51 – Position the handleba r clamp. Mount and evenl y tighten the four screws  . Guideline Screw, handlebar cla mp M8 20 Nm (14.8 lbf ft) Info Make sure the gap width is e ven. 9.38 Checking throttle ca ble route 500152-10 – The two throttle cables m ust run parallel behind the h andlebar down to the[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 52 9.41 Checking for chain di rt accumulation 400678-01 – Check the chain for coars e dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 52) 9.42 Cleaning the chain Warning Danger of accident s   Oil or grease on the tires redu ces their grip. – Remove oil and grease w ith a s[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 53 » If the chain tension does n ot meet specifications : – Adjusting chain tens ion - after checking. ( p. 55) – Remove the motorcyc le from the work stand. ( p. 38) 9.44 Checking chain tens ion when fitting rear whe el Warning Danger of accident s   Danger caused by inco rrect chain tension. – If[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 54 – Remove the motorcyc le from the work stand. ( p. 38) 9.47 Adjusting chain tens ion Warning Danger of accident s   Danger caused by inco rrect chain tension. – If the chain tension is too hig h, the components of the se condary power train (cha in, engine sprocket, rea r sprocket, bear- ings in tr[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 55 9.48 Adjusting chain tens ion - after checking 400225-13 – Loosen nut  . – Loosen nuts  . – Adjust the chain tensio n by turning the adjusting sc rews  left and right. Guideline Chain tension 8… 10 mm (0.31… 0.39 in ) Turn the adjusting scre ws  left and right so that the mar kings [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 56 9.50 Adjusting chain guid e x 400252-10 – Remove screws  and  . T ake off the chain guide. Condition Number of teeth: ≤ 44 te eth – Insert nut  in hole  . Positio n the chain guide. – Mount and tighten scre ws  and  . Guideline Remaining screws, ch assis M6 10 Nm (7.4 lbf ft) Co[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 57 400196-13 – Push the hand brake to the h andlebar and check free tr avel  . Free travel of hand brake le ver ≥ 3 mm ( ≥ 0.12 in) » If the free travel does no t meet specifications : – Adjust the free travel of the h and brake lever. ( p. 57) 9.53 Adjusting free travel o f hand brake lever 400[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 58 Warning Danger of accident s   Reduced braking effe ct caused by old brake fluid . – Change the brake fluid of th e front and rear brakes acco rding to the service sched ule. (Your authorized KT M workshop will be glad to help.) Warning Environmental ha zard   Hazardous subs tances cause environ me[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 59 9.57 Changing the front br ake linings x Warning Danger of accident   Brake system failure. – Maintenance work an d repairs must be carried ou t professionally. (Your au thorized KTM worksho p will be glad to help.) Warning Skin irritation   Brak e fluid can cause skin irrita tion on contact. – A[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 60 0 0 7 7 0 0 6 6 100397-01 – Check that anti-sque al shim  in the brake calip er and anti-rattle shim  in th e brake caliper support a re seated correctly. 100398-10 – Fit the brake pads, insert th e bolt, and mount the lockin g split pins. – Operate the hand brake le ver repeatedly until the [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 61 500154-10 – Disconnect spring  . – Loosen nut  , and with pu sh rod  , turn it back until you h ave maximum free travel. – To adjust the basic posit ion of the foot brake lever indi vidually, loosen nut  and turn screw  accordingly . Info The range of adjustmen t is limited. – Turn[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 62 Warning Danger of accident s   Reduced braking effe ct caused by old brake fluid . – Change the brake fluid of th e front and rear brakes acco rding to the service sched ule. (Your authorized KT M workshop will be glad to help.) Warning Environmental ha zard   Hazardous subs tances cause environ me[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 63 Warning Danger of accident s   Reduced braking effic iency due to oil or grease on th e brake discs. – Always keep the brake di scs free of oil and grease, and c lean them with brake clea ner when necessary. Warning Danger of accident s   Reduced braking effic iency due to use of non-app roved brak[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 64 400233-10 – Correct the brake fluid res ervoir level to the marking  . Brake fluid DOT 4 / DOT 5.1 ( p. 105) – Mount the screw cap  with the m embrane  and the O-ring . Info Clean up overflowed or sp ilt brake fluid immediate ly with water. 9.64 Removing front whee l x – Jack up the motorc[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 65 9.65 Installing the front whe el x Warning Danger of accident s   Reduced braking effic iency due to oil or grease on th e brake discs. – Always keep the brake di scs free of oil and grease, and c lean them with brake clea ner when necessary. 500086-11 – Clean and grease shaft s eal rings  and b[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 66 400260-11 – Remove spacers  . 9.67 Installing the rear whe el x Warning Danger of accident s   Reduced braking effic iency due to oil or grease on th e brake discs. – Always keep the brake di scs free of oil and grease, and c lean them with brake clea ner when necessary. 400260-10 – Clean and [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 67 9.68 Tire condition check ing Info Only mount tires approv ed or recommended by KT M. Other tires could have a ne gative effect on riding beh avior. The type, condition and a ir pressure of the tires all hav e an important impact on the r iding behavior of the moto rcycle. The front and rear wheels m ust[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 68 9.70 Checking spoke ten sion Warning Danger of accident s   Instable handling due t o incorrect spoke tensio n. – Ensure that the spoke ten sion is correct. (Your auth orized KTM workshop wil l be glad to help.) Info A loose spoke can cause w heel imbalance, which l eads to more loose spoke s in a sh[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 69 9.72 Installing the battery x 500069-11 – Place the battery in the bat tery holder. Battery (YTX5L-BS) ( p. 96) – Reconnect the rubbe r band  . – Attach the plus cable and r eplace the plus pole cove r  . – Attach the minus cable  . – Mount the seat. ( p. 71) 9.73 Recharging the batt e[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 70 Guideline The charge current, cha rge voltage and charge tim e must not be exceeded. Charge the battery regu larly when the motorcycle is not in use 3 months – Mount the seat. ( p. 71) 9.74 Removing a fuse – Switch off all consumer s and the engine. – Remove the air filter bo x lid. ( p. 76) 400270[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 71 9.77 Adjusting the beam w idth of the headlight – Check the headlight a djustment. ( p. 70) 301251-10 – Loosen screw  . – Adjust the light range by sw iveling the headlight. Guideline The boundary betwee n light and dark must be exac tly on the lower mark for a motorcycle with a rider (m ark is [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 72 500157-10 – Turn handle  of the fuel tap to th e OFF position. (Figure 5 00137-10 p. 22) – Pull off the fuel hose. Info Remaining fuel may f low out of the fuel hose. – Remove screws  with the c ollar sleeve. – Hang the horn and horn bra cket to one side. 800019-10 – Remove screw  with[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 73 800019-11 – Mount the fuel tank ve nt hose. – Mount and tighten scre w  with the collar sleeve. Guideline Remaining screws, ch assis M6 10 Nm (7.4 lbf ft) – Position the horn with the h orn bracket. 500157-11 – Mount and tighten scre ws  with the collar sleeve. Guideline Remaining screws, c[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 74 – Correct the coolant le vel. Alternative 1 Coolant ( p. 105) Alternative 2 Coolant (mixed ready to u se) ( p. 105) – Refit the radiator cap. 9.84 Checking the coolan t level Warning Danger of scalding   D uring motorcycle oper ation, the coolant gets ver y hot and is under pressure. – Do not rem[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 75 400335-11 – Stand the motorcycle u pright. – Place a suitable contai ner under the water pump co ver. – Remove screw  . Remo ve the radiator cap  . – Completely drain the co olant. – Fit screw  with a new seal and ti ghten it. Guideline Screw, water pump cove r M6x25 10 Nm (7.4 lbf ft)[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 76 9.89 Installing the main sile ncer 800020-11 – Mount the main silence r. Mount and tighten screw s  . Guideline Remaining screws, ch assis M6 10 Nm (7.4 lbf ft) – Reconnect spring  . 9.90 Removing the air filter b ox lid 800021-10 – Pull off the air filter box lid in are a  to the side and[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 77 9.93 Installing the air filter x 301262-10 – Mount the clean air filt er onto the air filter suppo rt. – Apply grease to the secti on  of the air filter. Long-life grease ( p. 107) 500107-10 – Put in both parts together , position them and fix them w ith air filter holder  . Info If the air f[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 78 9.96 Checking the fluid leve l of hydraulic clutch Warning Skin irritation   Brak e fluid can cause skin irrita tion on contact. – Avoid contact with skin a nd eyes, and keep out of the rea ch of children. – Wear suitable protect ive clothing and goggles . – If brake fluid gets into your e yes, r[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 79 500158-10 – Fill bleeding syringe  wi th the appropriate hydrau lic fluid. Bleed syringe (50329 050000) Brake fluid DOT 4 / DOT 5.1 ( p. 105) – On the slave cylinder, rem ove bleeder screw  and m ount bleeding syringe  . 400340-10 – Inject the liquid into the sy stem until it escapes from [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 80 9.100 Carburetor - idle 400341-10 The idle setting of the carb uretor has a big influence on t he starting behavior, sta ble idling and the response t o throttle opening. That me ans that an engine with a corr ectly set idle speed is easier to st art than if the idle is set wrongly . Info The carburetor [...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 81 Guideline Choke function deact ivated – The choke lever is p ushed in to the stop. ( p. 23) Idle speed 1,550… 1,650 rpm Info Following extreme air te mperature or altitude ch anges, adjust the idle spe ed again. 9.102 Emptying the carbur etor float chamber x Danger Fire hazard   Fuel is hig hly fla[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 82 9.104 Changing engine oil a nd oil filter, cleaning en gine oil screen x 301489-10 – Drain the engine oil and cle an the engine oil screen. x ( p. 82) – Remove the oil filter. x ( p. 82) – Install the oil filter. x ( p. 83) – Fill up with engine oil. x ( p. 83) 9.105 Draining engine oil, c leanin[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 83 200114-10 – Pull the oil filter insert  out of the oil filter casing. Circlip pliers reverse (5 1012011000) – Completely drain the en gine oil. – Thoroughly clean par ts and sealing surface. 9.107 Installing the oil filter x 200114-11 – Lay the motorcycle on its s ide and fill the oil filter h[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 84 301454-10 – Stand the motorcycle u pright on a horizontal surfa ce. – Remove the screw con nection on the generator c over. – Fill in engine oil to the up per half of level viewer  . Engine oil (total filling capacity approx.) 0.60 l (0.63 qt.) En gine oil (SAE 10W/50) ( p. 105) – Mount and ti[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 85 9.112 Draining gear oil, clea ning gear oil screen x Warning Danger of scalding   E ngine oil and gear oil get very h ot when the motorcycle is ri dden. – Wear appropriate prot ective clothing and safe ty gloves. In case of burns, rin se immediately with luk ewarm water. Warning Environmental ha zard[...]

MAINTENA NCE WORK O N CHASSIS AN D ENGINE 86 9.114 Adding gear oil x Info Too little gear oil or poor-qu ality oil results in prematu re wear to the transmissio n. 200116-10 – Remove gear oil leve l check screw  . 200118-11 – Remove screw cap  . Stan d the vehicle upright. – Top up with gear oil unti l it flows out of the bore of the ge[...]

TROUBLES HOOTING 87 Faults Possible cause Action The engine cannot be cra nked (elec- tric starter). Operating error – Go through the steps of sta rting the engine. ( p. 31) Battery discharged – Recharge the battery. x ( p. 69) – Check the charging vol tage. x – Check the stall current. x – Check the generator. x Fuse blown – Remove the[...]

TROUBLES HOOTING 88 Faults Possible cause Action Engine has a lack of power Air filter heavily contam inated – Clean the air filter. x ( p. 77) Exhaust system lea ky, deformed or too little glass fiber yarn fil ling in main silencer – Check exhaust syst em for damage. – Change glass fiber yarn f illing of main silencer. x Valve clearance too [...]

CLEANING 89 11.1 Cleaning the motorc ycle Note Material damage   Damage and destructi on of components by high -pressure cleaning equ ipment. – Never clean the vehicl e with high-pressure clea ning equipment or a stron g water-jet. The excessiv e pressure can penetrat e electri- cal components, so cket connects, throttl e cables, and bearings ,[...]

STORAGE 90 12.1 Storage Warning Danger of poisoning   Fuel is poisonous and a he alth hazard. – Avoid contact betwe en fuel and skin, eyes an d clothing. Do not inhal e fuel vapors. If fuel gets i nto your eyes, rinse imm edi- ately with water and conta ct a doctor. Wash affected s kin areas immediately w ith soap and water. If fuel is swa llow[...]

TECHNICA L DATA - ENGINE 91 Design 1-cylinder 4-stroke e ngine, water-cooled Displacement (450 EX C USA) 449.3 cm³ (27.418 cu in) Displacement (530 EX C USA) 510.4 cm³ (31.147 cu in) Stroke (450 EXC USA) 63.4 mm (2.496 in) Stroke (530 EXC USA) 72 mm (2.83 in) Bore 95 mm (3.74 in) Compression ratio 11.9:1 Idle speed 1,550… 1,650 rpm Control OHC,[...]

TECHNICA L DATA - ENGINE 92 13.3 Capacity - coolant Coolant 0.95 l (1 qt.) Coolant ( p. 105) Coolant (mixed ready to u se) ( p. 105)[...]

TECHNICA L DATA - ENGINE T IGHTENING T ORQUES 93 Screw, cable holder in ge nerator cover M4 4 Nm (3 lbf ft) Loctite ® 243™ Locking screw for bear ing M5 6 Nm (4.4 lbf ft) Loctite ® 243™ Oil jet, piston cooling M5 2 Nm (1.5 lbf ft) Loctite ® 243™ Oil jet, rocker arm lubri cation M5 2 Nm (1.5 lbf ft) Loctite ® 243™ Screw, ignition pulse g[...]

TECHNICA L DATA - ENGINE T IGHTENING T ORQUES 94 Screw, cylinder head M10x1.25 Tightening sequence: Tighten diagonally, b egin- ning with the rear screw on the chain shaft. Step 1 10 Nm (7.4 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 50 Nm (36.9 lbf ft) lubricated with engine o il Nut, rotor M12x1 60 Nm (44.3 lbf ft) – Spark plug M12x1.25 15… 20[...]

TECHNICA L DATA - CARBU RETOR 95 15.1 450 EXC USA Carburetor type KEIHIN FCR-MX 39 Carburetor identifica tion number 3900Z Needle position 4th position from top Idle mixture adjusting s crew Open 1.75 turns Pump membrane stop 2.15 mm (0.0846 in) Main jet 180 Jet needle OBDYU Idling jet 48 Idle air jet 100 Cold start jet 85 Leakage nozzle 40 15.2 53[...]

TECHNICA L DATA - CHASS IS 96 Frame Central tube frame mad e of chrome molybdenum steel tubing Fork WP Suspension Up Side Down 4860 MXMA PA Suspension travel Front 300 mm (11.81 in) Rear 335 mm (13.19 in) Fork offset 19 mm (0 .75 in) Shock absorber WP Suspension PDS 5018 DCC Brake system Disc brakes, brake cali pers on floating bearings Brake discs[...]

TECHNICA L DATA - CHASS IS 97 16.2 Tires Front tire Rear tire 90/90 - 21 M/C 54M M+S TT Metzeler MCE 6 DAYS EXT REME 140/80 - 18 M/C 70M M+S TT Metzeler MCE 6 DAYS EXT REME Additional informati on is available in the Servic e section under: http://www.ktm.com 16.3 Capacity - fuel Total fuel tank capac ity, approx. 9.2 l (2.43 US gal) Super unleaded[...]

TECHNICA L DATA - FORK 98 Fork part number 14.18.7J.06 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damp ing Comfort 26 clicks Standard 22 clicks Sport 18 clicks Rebound damping Comfort 24 clicks Standard 20 clicks Sport 20 clicks Spring length with prelo ad spacer(s) 510 mm (20.08 in) Spring rate Weight of rider: 65… 75 kg (1 43… 1[...]

TECHNICA L DATA - SHOCK A BSORBER 99 Shock absorber part n umber 12.18.7J.06 Shock absorber WP Suspension PDS 5018 DCC Compression damp ing, low-speed Comfort 22 clicks Standard 20 clicks Sport 15 clicks Compression damp ing, high-speed Comfort 2 turns Standard 1.5 turns Sport 1.25 turns Rebound damping Comfort 26 clicks Standard 24 clicks Sport 22[...]

TECHNICA L DATA - CHASS IS TIGHTENIN G TORQUES 100 Spoke nipple, front whe el M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Screw, spoiler on fuel t ank M5x12 1.5 Nm (1.11 lbf ft) – Spoke nipple, rear whee l M5 5… 6 Nm (3.7… 4.4 lbf ft) – Remaining nuts, chas sis M6 15 Nm (11.1 lbf ft) – Remaining screws, ch assis M6 10 Nm (7.4 lbf ft) – Screw[...]

101[...]

WIRING DIAG RAM 102 20.1 Wiring diagram 2 / H A 2 / K A 2 / V B 2 / O B AH1/2 AK1/2 G 2 / 2 H A AJ1/3 BG1/3 1 3 2 v 2 / S B 4 / R B 4 / K B black U CE/4 CA/4 8 1 / U B CW/2 CX/2 2 1 CW1/2 CX1/2 1 2 CW2/2 CX2/2 CW3/2 CX3/2 BF/1 BA/1 OFF ON 4 / Y B 4 / V C 4 / K B 1 2 4 3 4 / K B 6 / C A 6 / C B 3 / T B 3 / G B 6 5 2 1 4 3 1 2 3 1 / I E 1 / H E _ 1 1[...]

WIRING DIAG RAM 103 Components A6 CDI controller B1 Throttle position sens or B3 Wheel speed sensor G1 Battery G2 Generator H1 Right rear flas her H2 Left front flas her H3 Left rear flash er H4 Right front fla sher H5 Brake/tail lig ht H7 Parking light H11 Low/high beam H13 Horn H15 Flasher indicator light H18 High beam indicator light K1 Starter [...]

WIRING DIAG RAM 104 ye Yellow ye-bl Yellow-black ye-re Yellow-red[...]

SUBSTAN CES 105 Brake fluid DOT 4 / DOT 5 .1 According to – DOT Guideline – Use only brake fluid that c omplies with the specifie d standards (see specif ications on the containe r) and that possesses the co rre- sponding properties . KTM recommends Castro l and Motorex ® products . Supplier Castrol – RESPONSE BRAKE FLUID SU PER DOT 4 Motore[...]

SUBSTAN CES 106 Super unleaded (ROZ 9 5 / RON 95 / PON 91) According to – DIN EN 228 (ROZ 95 / RON 95 / PON 91)[...]

AUXILIARY S UBSTANC ES 107 Air filter cleaner Guideline – KTM recommends Mot orex ® products. Supplier Motorex ® – Twin Air Dirt Bio Remover Chain cleaner Guideline – KTM recommends Mot orex ® products. Supplier Motorex ® – Chain Clean 611 Cleaning and preser ving materials for meta l, rubber and plastic Guideline – KTM recommends Mot[...]

AUXILIARY S UBSTANC ES 108 Paint cleaner and po lish for high-gloss and m atte finishes, bare meta l and plastic surfaces Guideline – KTM recommends Mot orex ® products. Supplier Motorex ® – Clean & Polish Universal oil spray Guideline – KTM recommends Mot orex ® products. Supplier Motorex ® – Joker 440 Universal[...]

STANDAR DS 109 JASO T903 MA Different technical de velopment directions r equired a new specifica tion for 4-stroke motorcy cles – the JASO T903 MA St andard. Ear- lier, engine oils from the au tomobile industry were u sed for 4-stroke motorcy cles because there was n o separate motorcycle s pecifi- cation. Whereas long s ervice intervals are dem[...]

INDEX 110 INDEX A Accessories ................................... 5 Air filter c l e a n i n g ................................. 7 7 i n s t a l l i n g ................................. 7 7 r e m o v i n g ................................. 7 6 Air filter box lid i n s t a l l i n g ................................. 7 6 r e m o v i n g ............[...]

INDEX 111 Front fender i n s t a l l i n g ................................. 4 9 r e m o v i n g ................................. 4 9 Front wheel i n s t a l l i n g ................................. 6 5 r e m o v i n g ................................. 6 4 Fuel tank i n s t a l l i n g ................................. 7 2 r e m o v i n g .......[...]

INDEX 112 Steering l o c k i n g .................................. 2 4 u n l o c k i n g ................................ 2 5 Steering head bearin g g r e a s i n g ................................. 4 9 Steering head bearin g play a d j u s t i n g ................................. 4 6 c h e c k i n g ................................. 4 5 Storage [...]

*321 1468 en* 3211468en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com 09/2009 Photo: Mitterbauer[...]