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Cadillac 2011 Escalade ESV Automobile User Manual

1. 0007260 6 lt 084 12 00L S40 LL 765 sseujeu 400310 10 WIRING DIAGRAM 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 Tripmaster switch optional 17 Plug connector for radiator fan optional 18 Plug connector headlight optional 19 Plug connector brake tail light optional 21 Thermoswitch Cable colors bl black bl wh black white br brown bu blue bu wh blue white gn green gr gray re red re bl red black re wh red white wh white wh re white red ye yellow ye bl yellow black ye re yellow red Wiring diagram XCR W ZA a 2 S 3 3 on 0007260 6 lt 08 12 00L S40 LL 765 sseujeu 400311 10 WIRING DIAGRAM 8 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 S
2. 16 Display mode SPEED de tetur 16 Display mode SPEED H service hours 16 Display mode SPEED CLK 17 Display mode SPEED LAP lap time 17 Display mode SPEED ODO odometer 17 Display mode SPEED TR1 trip master 1 17 Display mode SPEED TR2 trip master 2 18 Disply mode SPEED A1 average speed 1 18 Display mode SPEED A2 average speed 2 18 Display mode SPEED S1 stop watch 1 19 Display mode SPEED S2 stop watch 2 19 eine det 20 Opening filler 20 Closing filler Gap ceo tert Rc ces 20 Choke EXC R AUS UK EXC R SIX DAYS EXC R USA XCR W cive eee see so deprecantes 21 Choke EXC R EU rue aer kg ke 21 Nondum 21 Foot brake pedal 21 KlICkstarteE roe dee tede rig ded cuoi te 22 oIde starid oi rna eue Ru era Une deo nope 22 Steering lock EXC R EU EXC R AUS UK EXC R USA 22 ___CONTENTS gt 1 1 0 Locking the steering EXC R EU EXC R AUS UK EXC R USA aiu de uerus eS 22 Unlocking the steering EXC R EU EXC R AUS UK EXC R USA iioi e dt e i e et e ues 23 GENERAL TIPS AND HINTS ON
3. 67 ___CONTENTS tg Installing the battery 67 Recharging the battery 68 Removing 69 Replacing the 69 Removing the 69 MOUNTING The Seat Deere tco eo CR be Red 69 Dismounting the fuel tank 70 Installing the fuel tank 70 COOLING SySEGm s aco t ci 71 Checking antifreeze and coolant 71 Checking the coolant 72 Draining coolant 72 Refilling Coolant Wet het eee etm 73 Glass fiber yarn filling of main silencer 73 Removing main 73 Fitting the main silencer 74 Dismounting the air filter box 222 74 Installing the air filter box 110 2 2 2 2 74 Removing the air filter 74 Installing the air filter 75 Cleaning air filter VM 75 Adjusting basic position of clutch 75 Checking fluid level of hydraulic clutch
4. 56 Checking the front brake 2 2 2 57 Removing front brake linings 58 Installing the front brake linings 58 Changing the front brake linings 59 Checking free play of foot brake lever 59 Adjusting basic position of footbrake lever 60 Checking the rear brake fluid 60 Adding rear brake fluid 61 Checking rear brake linings 2 2 61 Removing rear brake linings 62 Installing the rear brake linings 62 Changing the rear brake linings 63 Removing front wheel 63 Fitting front wheel 64 Removing rear wheel 5 65 Fitting rear wheel 65 Tire condition 66 Checking tire air 22 22 66 Checking spoke 67 Removing the battery
5. 47 EDIDENIDT P 48 Headlight flasher switch 12 HO s net EIS Y metis 12 Ignition switch 11 Key n mbher Gsen et EI RES wey TA 8 Kickstatter m ER 22 Light switch 11 12 Lower triple clamp ip ae TT 44 45 FEMOVING vege oaks add sete ete de dde 43 44 Main silencer fitting INDEX removing uuu 73 Maintenance 6 Motorcycle cleaning uses AE das ed 86 Oil filter CHANGING red edu eer ok asl Ye 79 PIECING scs sese ven dr axe VALERE EO A 80 IemovlHB Se cea desuper e E He RUNS 80 Overview of indicator lamps 13 OWNER S MANUAL 7 Play in gas Bowden cable adjusting xc EI EE 50 cheking sum rel ean S De dd 50 Putting into operation Advice on first USE xx tng tk ELLAS Sa PRA A 24 after Storage RR LAUR a a 87 Checks before putting into operation 26 Rear sprocket engine sprocket checking for wear 52 Rear wheel PITTING i Set oe dea a dae dc edu Sd 65 removing xe eee ME LR ed 65 Rebound damping Tork adjustillg Sx dato e ha SEE RES 37 of shock absorber adjusting
6. 117 CONSUMER INFORMATION EXC R 118 The symbols used explained 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 the interest of your own safety have these jobs done in an authorized KTM workshop There your motorcycle will be serviced optimally by specially trained experts using the specialist tools required lt Identifies a page reference more information is provided on the specified page The typographical and other formats used are explained in the following Specific name Identifies a specific name Name Identifies a protected name Brand Identifies a brand in merchandise traffic 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 public road traffic in the homologous reduced version only In the derestricted version the motorcycle must be used only on secluded property remote from public road traffic The motorcycle is designed for off road sport endurance competition Enduro and not for the predominant motocross use KTM s
7. 75 Changing fluid level of hydraulic clutch 76 Carburetor idle wicca Sl ie eee del 77 Carburetor adjusting idle 77 Emptying the carburetor float chamber 78 Checking engine Oil 0 79 Changing engine oil and oil filter cleaning engine oil SCHOEN M 79 Draining engine oil cleaning engine oil screen 79 Removing the oil filter 80 Mounting oil filter VM 80 Filling up with engine oil 81 TOPPING up engine 0 81 Checking gear oil level eese 81 Changing gear oil cleaning gear oil screen 82 Draining gear oil cleaning gear oil screen 82 Filling up with gear oil 83 Topping up with gear oil 83 84 CLEAN 86 Cleaning motorcycle c a ete e nius 86 STORAGE Storage Putting into operation after storage 87 TECHNICAL DATA ENGINE oreet ete teque 88 Capacity engine nn 88 Capacity gear 88 Capacity Coola
8. DES fade baw ceed 73 Coolant level CHECKING d wer we bU OR ed 71 72 Cooling system 71 D Dust boots Cleaning eue ouo n ete eee bea 39 E Electric starter button 11 Emergency OFF switch 10 11 Engine r rining A uec uro RE ON ond 25 Engine number 8 Engine oil CHANGING seco want m edem ta ie E rU SER 79 GIANG i douce ea BM A OS SOS 79 Baw mese A EYE 81 topplng Uuprz ss us uu eas ddd owe Seles od 81 Engine oil level CHECKING i 5 EAE Ed DE LEVEL sd 79 engine oil screen cleanings ses bars veis astare oe Sa NOR 79 Engine oil screen Gleaniflg cuenta E aUe E BSEC PS 79 Environment 7 F Filler cap ClOSIDng ux pese d uus Y YES 20 opening e daa Se Aan eae he eae gan 20 Filling up iden S ubt ina t Saag qi 28 Flasher switch 13 Foot brake 21 adjusting basic position 60 checking free play 59 Fork checking basic setting 37 Fork legs bleeding 45 aa ws oP IAS dns 38 eek ofi tacere Qo a Tae 42 FOMOVING as
9. 33 Riding sag 36 D c MOURNE uro ENIM UAR INS 69 TemoVvlHng a Pose eR RAT UR Bown ae 69 Shift levei c core voee suns SUR TS eS LS 21 Shock absorber checking riding sag 35 checking static Sag llle 34 ud ap PP Ba ee eas A ee 36 FEMOVING b roi Re WE RE ANS 36 Short circuit button 10 Side stand 5 sd RE wh eh 22 Spare parts eur Ye esu re ey s 6 Speedometer adjusting ENDS BE 15 Function description 13 Setting kilometers or miles 14 Setting the clock eee 15 Spoke tension CHECKING eddie eee a tte MER wu 67 Spring preload 5 uos teu RS ERE 38 of shock absorber adjusting 35 Start number plate TITLING ud Exe ex neuer i De 47 INDEX FEMOVING iussu D RW 47 Starting nosse 26 steering Ded nA Omm 22 UNLOCKING hr READ Dg 23 Steering head bearing greasing aues NSW s 46 Steering head bearing play dos REPE AS ey 40 checking assess E LEV Ewa RES 39 Storage 222222222222 2292510 S Sai owe b 87 T Technical data G
10. Mit DOTHAN pedum 5 eanan eT zumal Pas 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 Traffic Safety Administration NHTSA in addition to notifying KTM North America Inc If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remady campaign However NHTSA cannot become involved in individual problems between you your dealer or KTM North America Inc To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 888 327 4236 or visit the website www nhtsa dot gov or write to NHTSA Headquarters 1200 New Jersey Avenue SE West Buildding Washington DC 20590 You can also obtain other information about motor vehicle safety from the Hotline NOISE EMISSION WARRANTY KTM Sportmotorcycle AG warrants that this exhaust system at the time of sale meets all applicable U S EPA Federal noise stan dards This warranty extends to the first person who buys this exhaust system for purposes other than resale and to all subsequent buyers Warranty claims should be directed to KTM North America Inc Customer Support 1119 Milan Ave Amherst OH 44001 Phone 440 985 3553 www ktmus
11. front 260 mm 10 24 in Rear 220 mm 8 66 in Wear limit of brake discs front 2 5 mm 0 098 in Rear 3 5 mm 0 138 in Tire air pressure off road front 1 0 bar 15 psi Rear 1 0 bar 15 psi Road tire pressure Every EXC R models Rear wheel gearing 450 EXC R EU 450 EXC R AUS UK 450 EXC R USA Rear wheel gearing 450 EXC R SIX DAYS XCR W ZA Rear wheel gearing 530 EXC R SIX DAYS XCR W USA Rear wheel gearing 530 EXC R EU 530 EXC R AUS UK 15 45 14 50 Chain 5 8 x 1 4 Rear sprockets available 38 40 42 45 48 49 50 51 52 Steering head angle 63 5 Wheelbase 1475 10 mm 58 07 0 39 in Seat height unloaded 925 mm 36 42 in Ground clearance unloaded 380 mm 14 96 in Weight without fuel EXC R EU EXC R AUS UK 113 9 kg 251 1 Ib EXC R SIX DAYS Weight without fuel XCR W USA 112 2 kg 247 4 Ib Weight without fuel XCR W ZA 113 kg 249 Ib Weight without fuel EXC R USA 114 8 kg 253 1 Ib Maximum permissible front axle load 145 kg 320 Ib Maximum permissible rear axle load 190 kg 419 Ib Maximum permissible overall weight 335 kg 739 Ib 4Ah battery YTX5L BS Battery voltage 12 V Nominal capacity 4 Ah maintenance free TECHNICAL DATA CHASSIS 8 Lighting equipment Headlight EXC R EU EXC R AUS UK BA20d 12V EXC R SIX DAYS EXC R USA XCR W ZA 35 35 W Parking light EXC R EU EXC R AUS UK W2 1x9 5d EXC R SIX DAYS EXC R USA XCR W ZA In
12. Querying lap time e Info This function can be called only if lap times are measured riri gn 19 LILILILI LAP 400321 01 Display mode SPEED SPEED 400317 02 Display mode SPEED H service hours 400316 01 Condition The Int The Con motorcycle is standing Press the button O briefly and repeatedly until LAP appears at the bottom right of the display Press the button O briefly The LAP 1 is displayed the left of the display Laps 1 10 can be displayed by pressing the button button no function Press the button O briefly next display mode e Info If an impulse is received from the wheel speed sensor the left side of the display changes back to SPEED mode Press the button O briefly and repeatedly until SPEED appears on the left of the display he SPEED display mode the current speed is displayed current speed can be displayed in Km h or in Mph Info Making the setting according to the country When an impulse comes from the front wheel the left side of the speedometer display changes to the SPEED mode and the current speed is shown dition The motorcycle is standing Press the button O briefly and repeatedly until H appears at the bottom right of the display In display mode H the service hours of the engine are displayed The service hour counter stores the total traveling time
13. Cold start jet 65 85 Leakage nozzle 40 Throttle slide Slide stop 15 present 530 EXC R SIX DAYS 530 EXC R USA 530 XCR W 3900M Carburetor type Carburetor identfication number Needle position 530 XCR W USA KEIHIN FCR MX 39 3900M Ist position from top Needle position 530 EXC R SIX DAYS 530 EXC R USA 3rd position from top Needle position 530 XCR W ZA 4th position from top Idle mixture adjusting screw 530 XCR W USA Open Idle mixture adjusting screw 530 EXC R SIX DAYS Open 0 5 turn 1 0 turn Idle mixture adjusting screw 530 XCR W ZA Open Idle mixture adjusting screw 530 EXC R USA Open Pump membrane stop 2 0 turns 2 15 mm 0 0846 in ren O1 A 2 o Main jet 530 EXC R SIX DAYS 530 EXC R USA 530 XCR 180 W USA Main jet 530 XCR W ZA 185 Jet needle 530 XCR W 530 EXC R SIX DAYS Idling jet 530 XCR W 530 EXC R SIX DAYS Idling jet 530 EXC R USA 48 Main air jet 200 Idle air jet 100 Cold start jet 85 Leakage nozzle Throttle slide B rA TECHNICAL DATA CHASSIS 1 Suspension travel front 300 mm 11 81 in Rear 335 mm 13 19 in Fork offset EXC R SIX DAYS XCR W USA Front marking 18 mm 0 71 in Fork offset EXC R EU EXC R AUS UK EXC R USA XCR W ZA Brake system Disc brakes brake calipers on floating bearings Diameter of brake discs
14. e Info Check whether the top steering head seal is correctly positioned Push on protective ring Position the upper triple clamp with the steering Mount and tighten screw Specification Screw top steering head M20x1 5 10 Nm 7 4 Ibf ft Position the clutch line wiring harness and CDI control unit Mount and tighten screws Specification Remaining screws chassis 6 10 Nm 7 4 Ibf ft Install the front fender P 46 Refit the headlight mask with the headlight P 47 Install the fork legs P 42 Tighten screw Specification Screw top steering stem M8 20 Nm 14 8 Ibf ft Check the cable harness cable brake and clutch line for free movement and free laying Check play of steering head bearing P 39 MAINTENANCE WORK ON CHASSIS AND ENGINE 4 Greasing the steering head bearing EXC R SIX DAYS XCR W USA Remove the lower triple clamp P 43 Install the lower triple clamp P 44 EXC R EU EXC R AUS UK EXC R USA XCR W ZA Remove the lower triple clamp P 44 Install the lower triple clamp P 45 Dismounting the front fender Remove screws Remove the front fender Make sure that the distance bushings remain in place Check parts for damage and wear Replace damaged or worn parts Make sure that the distance bushings are mounted in the fender Position the front fender Mount and tighten screws
15. E S 41 FotK offset ugue xem x aue ERR 41 ez echa RR Sn GRIP RU NE 41 Fork protector TITLING iuc e ru DEOS WEE e ue 43 FOMOVING ese te X eder REPE 43 Front fender INStANING sug xad ede UE d dnte ds 46 removing aude e te i XR RR 46 Front wheel TITLING cte ea eS 64 removing usce y RR RR ede 63 Fuel tank installing Eug uos 70 removing cue RAW CD RR 70 sas hate vie nsu BAS terne Views sus 20 File oils os ses ba RESET RUNI NS 6 Fuse ea and 69 FEMOVING aue aS aleve e e os e ee EN aes 69 Gas Bowden cable route checking ie dd aed HE eios 49 gear oil changing ite ar ads 82 Gear oil draining apro 82 refillings 9 1 ues gd cer 83 TODDIng Up Lose C Gave 83 gear oil level checking RR Rae e ee EROS Y 81 gear oil screen leaning TES eed us 82 Gear oil screen CLEANING ui ste deesset eb xm oy de ge e aub bacs 82 Hand brake lever 10 adjusting basic position 56 adjusting free travel 56 checking free play 55 Handlebar position
16. main harness 594 11 075 244 CDI harness 780 39 032 000 400309 10 WIRING DIAGRAM Components Battery Generator Ignition coil Pulse generator Voltage regulator rectifier Electric starter button Starter relay with fuse Starter motor o ol NI AJAJ BY W M 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 switch 17 Flasher switch 18 Flasher relay 19 Left front flasher 20 Left rear flasher 21 Right front flasher 22 Right rear flasher 23 Speedometer 24 Wheel speed sensor 25 Tripmaster switch optional 26 Horn button 27 Horn 28 Ignition switch 29 Front brake light switch 30 Rear brake light switch 31 High beam indicator light 32 Flasher indicator light 33 Plug connector for radiator fan optional Cable colors bl black bl wh black white br brown br bl brown black bu blue bu wh blue white gn green gn wh green white gr gray or orange pu violet re red re bl red black re wh red white wh white wh gn white green wh re white red WIRING DIAGRAM gt ye yellow ye bl yellow black ye re yellow red Wiring diagram EXC R SIX DAYS C 4 C_BP 4 yere affe 1140
17. Change the engine oil and oil filter and clean the engine oil screen P 79 Check electrical system Speedometer values deleted time stop watch lap times The battery in the speedometer ist empty Change the battery in the speedometer CLEANING Cleaning motorcycle Note Material damage Damage and destruction of components by high pressure cleaning equipment 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 bearings etc and can damage or destroy these parts Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations e Info If you clean the motorcycle regularly its value and appearance are maintained over a long period Avoid direct sunshine on the motorcycle during cleaning Before you clean the motocycle seal the exhaust system to prevent penetration by water First remove coarse dirt particles with a gentle water spray Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush Motorcycle cleaner P 115 e Info Use warm water containing normal motorcycle cleaner and a soft sponge After rinsing the motorcycle with a gentle water spray allow it to dry thor
18. OWNER S MANUAL 2008 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 930 EXC R EU 930 EXC R AUS UK 930 EXC R SIX DAYS 930 EXC R USA 930 XCR W USA 930 XCR W ZA ART NO 3211254en DEAR CUSTOMER 14 Congratulations on your decision to purchase 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 Chassis number P 8 Dealer s stamp Engine number 7 P 8 Key number EXC R EU EXC R AUS UK EXC R USA P 8 The owner s manual corresponded to the latest state of this series at the time of printing Slight deviations resulting from continuing development and design of our motorcycles can however not be completely excluded All specifications are not binding KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifica tions prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop prudction of a particular model without prior notice KTM accepts no liability for delivery options deviations from illustrations and descriptions as well as printing and other errors The models portrayed partly con
19. Starts or stops the clock Press the button Stops the current lap time and saves it and the stop watch starts the next lap Press the button O The stop watch and the lap time are reset for 3 5 seconds Press the button O Next display mode briefly Press the button O briefly and repeatedly until 000 appears at the bottom right of the display 000 display mode the total number of kilometers ridden is displayed Press the button No function Press the button No function Press the button O for 3 5 seconds Press the button O Next display mode briefly Display mode SPEED TR1 trip master 1 TRI 2202 FL 400323 01 Press the button O briefly and repeatedly until TR1 appears at the top right of the display TR1 trip master 1 runs constantly and counts up to 999 9 It can be used to measure the distance covered during trips or between two refueling stops TR1 is coupled with A1 average speed 1 and S1 stop watch 1 e Info If 999 9 is exceeded the values of TR1 A1 and S1 are automaticallt reset to 0 0 Press the button No function Press the button No function Press the button O Displays of TR1 A1 and S1 are reset to 0 0 for 3 5 seconds Press the button O Next display mode briefly ____ OPERATING ELEMENTS Display mode SPEED TR2 trip master 2 1 M 36 4 400324 01 Press the button O bri
20. br N u Ca EX 2 o E bl br a gt br e yere br C CRA wh 9 e P La C CR1A 000 Z 0 6 087 12 000820 LL v6S 400307 10 WIRING DIAGRAM gt Components Battery Generator Ignition coil Pulse generator Voltage regulator rectifier Electric starter button Starter relay with fuse Starter motor WO CO NI AJAJ BR W M 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 tail light 16 Thermoswitch 17 Speedometer 18 Wheel speed sensor 19 Tripmaster switch optional 20 Horn 21 Front brake light switch 22 Rear brake light switch 23 High beam indicator light 24 Radiator fan 25 Plug connector for flasher cable harness optional 26 Fuse radiator fan Cable colors bl black bl wh black white br brown br bl brown black bu blue bu wh blue white gn green gr gray re red re bl red black re wh red white wh white wh gn white green wh re white red ye yellow ye bl yellow black ye re yellow red Wiring diagram XCR W USA a 2 S 3 3
21. 11500129 10 OPERATING ELEMENTS 8 Clutch lever The clutch lever is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 500133 10 Hand brake lever The hand brake lever is located on the right side of the handlebar and operates the front wheel brake Short circuit button EVERY XCR W MODELS The short circuit button is mounted on the left side of the handlebar Possible states e Short circuit button basic position In this position the ignition circuit is closed and the engine can be started e Short circuit button amp pressed In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start Short circuit button EXC R EU EXC R AUS UK EXC R SIX DAYS ie The short circuit button is fitted on the left side of the handlebar Possible states e Short circuit button amp in basic position In this position the ignition circuit is closed and the engine can be started e Short circuit button amp pressed In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start 500134 10 Emergency OFF switch EXC R AUS UK The emergency OFF switch is fitted on the left side of the handlebar Possible states Ignition off In this position the ignition circuit is interrupted a running engine stops and a n
22. Operating error Carry out instructions on starting P 26 Battery discharged Fuse blown Low external temperature Recharge the battery P 68 Check the cause of discharging Remove the fuse P 69 Replace the fuse P 69 Start the engine with the kickstarter Recharge the battery Establish the reason for discharging or have it checked in a KTM workshop Engine turns but does not start Operating error Motorcycle was out of use for a long time and there is old fuel in the float chamber Fuel feed interrupted Engine flooded Carry out instructions on starting 26 Empty the carburetor float chamber 78 Check tank vent Clean fuel tap Clean carburetor Clean and dry spark plug or replace if necessary Spark plug oily or wet Electrode distance plug gap of spark plug too wide Clean and dry spark plug or replace if necessary Adjust plug gap Specification Spark plug electrode gap 0 8 0 9 mm 0 031 0 035 in Spark plug connector or spark plug defec tive Warning Risk of injury The ignition sys tem is under high voltage Do not touch parts of the ig nition system Have work on the ignition system carried out in an authorized KTM workshop Remove spark plug connect ignition cable hold spark plug to ground bare metal area on engine and try to start the engine Specification You should see a strong spark
23. Specification IW CAR e Info Ensure that there is contact between the holding lugs and the start number plate or headlight mask Removing headlight mask with headlight EXC R EU EXC R AUS UK EXC R SIX DAYS EXC R USA XCR W ZA Switch off all electrical equipment Remove screw and take off clamp Loosen the rubber band Push up the headlight mask and swing it forwards 500155 10 Pull out the electric plug connector and remove the headlight mask with the headlight Refitting the headlight mask with the headlight EXC R EU EXC R AUS UK EXC R SIX DAYS EXC R USA XCR W ZA Check parts for damage and wear Replace damaged or worn parts Connect the electric plug connector Position the headlight mask and fix it with the rubber band e Info Take care with the contact of the holding lug at the fender Position the brake line and cable harness Put the clamp on mount and tighten screw Check the headlamp setting Dismount the start number plate XCR W USA Remove screw and take off clamp Remove screw with distance bushing Remove the start number plate Check parts for damage and wear Replace damaged or worn parts Position the start number plate Fit and tighten screw with distance bushing Specification Remaining screws chassis M6 10 Nm 7 4 Ibf ft Info Take care with the contact of the holding lug at the f
24. Brake linings available from accessory suppliers are often not tested and approved for use KTM vehicles The construc tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings If brake linings are used that differ from the originals there is no guarantee that they comply with the origi nal license The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid Check the brake discs P 55 Check parts for damage and wear Replace damaged or worn parts Check that leaf spring 6 in the brake caliper and sliding plate in the brake caliper support are seated correctly e Info The arrow on the leaf spring points in the rotation direction of the brake disc Fit the brake linings insert bolt and mount locking split pins e Info Make sure that the decoupling plate is mounted on the piston side of the brake pad Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot MAINTENANCE WORK ON CHASSIS AND ENGINE 40 Changing the rear brake linings 36 Warning Skin irritations Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children f brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediately Warni
25. Fork offset EXC R SIX DAYS XCR W 41 Setting the fork offset amp EXC R SIX DAYS XCR W USA ortae p verti outre ete pa D chad da aee ele Removing the fork legs Installing the fork legs 74 Removing the fork protector 43 Installing the fork protector 43 Removing the lower triple clamp amp EXC R SIX DAYS PGUMBRY y 43 Removing the lower triple clamp EXC R EU EXC R AUS UK EXC R USA XCR W ZA 44 Installing the lower triple clamp EXC R SIX DAYS De nea weal 44 Installing the lower triple clamp EXC R EU EXC R AUS UK EXC R USA XCR W ZA 45 Greasing the steering head bearing 46 Dismounting the front 46 Installing the front 46 Removing headlight mask with headlight EXC R EU EXC R AUS UK EXC R SIX DAYS EXC R USA KGREW ZA esee deo e TR 46 Refitting the headlight mask with the headlight EXC R EU EXC R AUS UK EXC R SIX DAYS EXC R USA XCR W 7 0 47 Dismount the start number plate XCR W USA 47 Fitting the start number plate XCR W 47 Handleba
26. Info The dust boots should remove dust and coarse dirt particles from the fork tubes Over time dirt can penetrate behind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray P 115 Press the dust boots back into their normal position Remove excess oil Position the fork protection P 39 Remove the motorcycle from the work stand P 32 Remove screws and take off clamp Remove screws on left fork leg Push the fork protection downwards Remove the screws on the right fork leg Push the fork protection downwards Position the fork protection on the left fork leg Mount and tighten screws Specification Remaining screws chassis M6 10 Nm 7 4 Ibf ft Position the brake line and cable harness Put the clamp on mount and tighten screws Position the fork protection on the right fork leg Mount and tighten screws Specification Remaining screws chassis M6 10 Nm 7 4 Ibf ft Danger of accidents Unsafe riding behavior due to incorrect steering head bearing play The steering head bearing play should be adjusted immediately in an authorized KTM workshop
27. and that possess the corre sponding properties KTM recommends Motorex products Synthetic engine oil Supplier Motorex Motorex Cross Power 4T according to SAE P 117 SAE 5 Specification Use only oils that comply with the specified standards see specifications on the container and that possesses the corresponding properties KTM recommends Motorex products Supplier Motorex Motorex Racing Fork Oil Specification KTM recommends Motorex products Supplier Motorex Motorex Joker 440 Universal Specification recommends Motorex products Supplier Motorex Motorex Long Therm 2000 Specification KTM recommends Motorex products Supplier Motorex Motorex Chain Clean 611 Specification KTM recommends Motorex products Supplier Motorex Motorex Chain Lube 622 Specification KTM recommends Motorex products Supplier Motorex Motorex Twin Air Dirt Bio Remover Specification recommends Motorex products Supplier Motorex Motorex Twin Air Liquid Power Specification KTM recommends Motorex products Supplier Motorex Motorex Moto Clean 900 Specification KTM recommends Motorex products Supplier Motorex Motorex Protect amp Shine 645 Specification recommends Motorex products Supplier Motorex Motorex Moto Polish Specification KTM recommends Motorex products Supplier Motorex Motorex Accu Contact
28. medium quality standard 5 505125204 Elastomer kit red hard quality SXS05125205 e info The elastomeres are available in different versions Fit and evenly tighten the four screws Specification Screw handlebar clamp M8 16 Nm 11 8 Ibf ft e Info Make sure the gap width is even two gas Bowden cables must run parallel behind the handlebar down to the frame They must be routed directly on the frame above the tank bearing to the car buretor MAINTENANCE WORK ON CHASSIS AND ENGINE 4 Checking play in the gas Bowden cable 00000000000 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 mm 0 12 0 2 in Ifthe gas Bowden cable play does not meet specifications Adjust the gas Bowden cable play P 50 Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon 400192 10 sciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in a closed space Start the engine and let it run idle Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the gas Bowden cable play P 50 Dismount the fuel tank 7 P 70 Check gas Bowden cable
29. 0 0 for 3 5 seconds Press the button O Next display mode briefly Display Display mode SPEED H service hours No function Display mode no function SPEED CLK time Display mode SPEED LAP lap time Starts or stops the clock Press the button Press the button O for 3 5 seconds Press the button O briefly Press the button No function The display changes to the Setup menu of the speedometer functions Next display mode no function The display changes to the Setup menu of the clock next display mode Stops the current lap time and saves it and the stop watch starts the next lap The stop watch and the lap time are reset Next display mode Display mode No function SPEED ODO odometer Display mode SPEED TR1 trip master 1 No function No function Next display mode No function Displays of TR1 A1 and 81 are reset to 0 0 Next display mode Display mode SPEED TR2 trip master 2 Disply mode SPEED A1 average speed 1 Display mode SPEED A2 average speed 2 No function No function Increases value of TR2 Reduces value of TR2 Deletes value of TR2 Next display mode No functi Displays of TR1 A1 and 81 are reset to 0 0 Next display mode Next display mode Display mode SPEED S1 stop watch 1 Display mode SPEED S2 stop watch 2 No function Starts or stops S2 Displays of TR1 A1 and 81 are reset
30. 114 400244 10 Refit the radiator cap a short test ride Check the coolant level P 72 The main silencer is filled with glass fiber yarn Over a period the fibers of the insulating material vanish into the air and the silencer burns out Not only is the noise level higher the performance characteristic changes Warning Danger of burns exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down Do not touch hot components Disconnect spring Remove screws and take off main silencer 400337 10 MAINTENANCE WORK ON CHASSIS AND ENGINE Fitting the main silencer Removing the air filter Note Check parts for damage and wear Replace damaged or worn parts Mount the main silencer Mount and tighten screws Specification Remaining screws chassis M6 10 Nm 7 4 Ibf ft Reconnect spring Pull off the air filter box lid in area to the side and remove to the front Check parts for damage and wear Replace damaged or worn parts Insert the air filter box lid into the rear area and clip it into the front area Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear Warning Environmental hazard Problem materials cause
31. AND ENGINE 0 4 400340 10 Carburetor idle Inject the liquid into the system until it escapes from the bore hole of the mas ter cylinder without bubbles To prevent overflow drain fluid occasionally from the master cylinder reservoir Remove the bleeding syringe Mount and tighten screws bleeder screw Correct the fluid level of the hydraulic clutch Specification Fluid level under top level of container 4 mm 0 16 in Check parts for damage and wear Replace damaged or worn parts Position the cover with the membrane Mount and tighten screws e Info Clean up overflowed or spilt fluid immediately with water The idle setting of the carburetor has a big influence on the starting behavior stable idling and the response to throttle opening That means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly e Info The carburetor and its components are subject to increased wear caused by en gine vibration Wear can result in malfunctioning The idle speed is adjusted with the adjustment screw The idle mixture is adjusted with the idle mixture adjustment screw Screw in the idle adjusting screw until it stops and then to the prescribed basic setting Specification Idle mixture adjusting screw XCR W USA Open 0 5 turn Idle mixture adjusting screw EXC R SIX DAYS Idle mixture adjusting screw XCR W ZA 530 EXC R EU 530
32. Danger of poisoning Coolants are poisonous and a health hazard Avoid contact between coolants and skin eyes and clothing If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor im mediately Change clothes that have come into contact with coolants Keep coolants out of the reach of children MAINTENANCE WORK ON CHASSIS AND ENGINE 8 Stand the vehicle upright Place a suitable container under the water pump cover Remove screw Remove the radiator cap Completely drain the coolant Fit screw with a new seal and tighten it Specification Screw water pump cover M6x25 10 Nm 7 4 Ibf ft Warning E Danger of poisoning Coolants are poisonous and a health hazard Avoid contact between coolants and skin eyes and clothing If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor im mediately Change clothes that have come into contact with coolants Keep coolants out of the reach of children sure that the screw is tightened Stand the vehicle upright Pour coolant up to measurement above the radiator fins Specification 10 mm 0 39 in Coolant 0 95 1 qt Coolant P 114 Coolant mixed ready to use P
33. Different technical development directions required a new specification for 4 stroke motorcycles the JASO T903 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 service intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with the oil as the engine The JASO MA Standard meets these special requirements The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis cosity The viscosity describes only one property of oil and says nothing about quality CONSUMER INFORMATION EXC R USA 118 e 6 on swing arm LH on rear fender steering head tube e on front frame tube on upper frame tube on frame tube RH inside filter cover LH D i Chain tension WO BF SOT i MDOTDECYCLE DATE d ig PETH Re TEE label CAN Q Noise emission Q Green sticker Saree WT z E fit aad tar a SS a ee MC EE rq Ro Lat a ee ee aas E ae SS pupa Pere a et E Lg i riis Rp LBL PADIT
34. EXC R AUS UK Open 1 5 turns Idle mixture adjusting screw 450 EXC R EU 450 EXC R AUS UK 450 EXC R USA Idle mixture adjusting screw 530 EXC R USA Open 2 0 turns Adjustment tool for mixture control screw 77329034000 Runthe engine until warm Specification Warm up time 2 5 MAINTENANCE WORK ON CHASSIS AND ENGINE 1 zs Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon sciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in a closed space Adjust the idle speed with the adjusting screw Specification Choke function deactivated The choke lever is pushed in to the stop P 21 Choke function deactivated The choke lever is pushed back to the stop P 21 Idle speed 1550 1650 rpm Turn the idle adjusting screw slowly until the idle speed begins to fall Note the position and turn the idle adjusting screw slowly counterclockwise until the idle speed falls Adjust to the point between these two positions with the highest idle speed e Info If there is a big engine speed rise reduce the idle speed to a normal level and repeat the above steps The extremely sporty rider will set the mixture about 1 4 of a turn back from this ideal value leaner in a clockwise direction since the engine become
35. Info be damaged after time If the bike is driven for a longer time with play in the steering head bearing the bearing and the bearing seats in the frame can Jack up the motorcycle P 32 MAINTENANCE WORK ON CHASSIS AND ENGINE 4 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 SIX DAYS XCR W USA Adjust play of the steering head bearing P 40 EXC R EU EXC R AUS UK EXC R USA XCR W ZA Adjust play of the steering head bearing P 40 Move the handlebar to and fro over the entire steering range The handlebar must be able to move easily over the entire steering range No resting locations should be noticeable If click positions are noticeable EXC R SIX DAYS XCR W USA Adjust play of the steering head bearing P 40 EXC R EU EXC R AUS UK EXC R USA XCR W ZA Adjust play of the steering head bearing P 40 Check the steering head bearing and replace if required Remove the motorcycle from the work stand P 32 Adjusting play of steering head bearing EXC R EU EXC R AUS UK EXC R USA XCR W ZA Jack up the motorcycle P 32 Loosen screws and Loosen and retighten screw Specification Screw top steering head M20x1 5 10 Nm 7 4 Ibf f
36. M8 17 Nm 12 5 Ibf ft Fully tighten screw Specification Screw bottom triple clamp M8 12 Nm 8 9 Ibf ft EXC R EU EXC R AUS UK EXC R USA XCR W ZA Fully tighten screw Specification Screw top triple clamp M8 20 Nm 14 8 Ibf ft Fully tighten screw Specification Screw bottom triple clamp M8 15 Nm 11 1 Ibf ft Position brake caliper mount and tighten screws Specification Screw front brake caliper M8 25 Nm Loctite 2437 18 4 Ibf ft Fitcable clip Position the brake line and cable harness Put the clamp on mount and tighten screws Fit front wheel P 64 MAINTENANCE WORK ON CHASSIS AND ENGINE 4 Removing the fork protector 500105 10 Remove the fork legs P 41 Remove screws on the left fork leg Remove the fork protector upwards Remove the screws on the right fork leg Remove the fork protector upwards Check parts for damage and wear Replace damaged or worn parts Position the fork protection on the left fork leg Mount and tighten screws Specification Remaining screws chassis 6 10 Nm 7 4 Ibf ft Position the fork protection the right fork leg Mount and tighten screws Specification Install the fork legs P 42 Removing the lower triple clamp EXC R SIX DAYS XCR W USA 500099 10 Remove the fork legs P 41 XCR W USA Dismount th
37. PUTTING INTO OPERATION eder ea nee ne ere e o na aea s 24 Advice ori first E ede Pasce o eina 24 Running in the 2 22 25 RIDING 65 26 Checks before putting into operation 26 Starting eec con ete etre Tae Oa YR 26 ie Nev edle ein 27 Td iara oT 27 Braking c meet ERU tet dud 27 STOPPING parkih p ico erectione era ee gane 28 Refu eling eicere e e o ge dae ia rax 28 GREASING AND SERVICE 29 Important maintenance work to be carried out by an authorized KTM workshop 20 0 0 29 Important maintenance work to be carried out by authorized KTM workshop as additional order 30 Important checks and maintenance work to be carried OUT DY the rider ec 30 MAINTENANCE WORK ON CHASSIS AND 32 Jacking up the 2 22 32 Removing the motorcycle from the work stand 32 Checking the basic chassis setting with the rider s c ELE 32 Compression damping of shock absorber 32 Adjusting high speed compression damping of the shock absorber ca oo REOR An vie ale 32 Adjusting the low speed co
38. air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life Remove dust cap Check tire air pressure when tires are cold Tire air pressure off road LO bar 15 s Rear 1 0 bar 15 psi Road tire pressure Every EXC R models front 1 5 bar 22 psi Rear 2 0 bar 29 psi Ifthe tire pressure does not meet specifications Correct tire pressure Mount dust cap MAINTENANCE WORK ON CHASSIS AND ENGINE 4 Checking spoke tension Warning Danger of accidents Unstable riding behavior due to loose spokes f you ride with loose spokes the spokes can break Have the spoke tension corrected in an authorized KTM workshop e Info loose spoke cause wheel imbalance which leads to more loose spokes in a short time If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle check spoke tension tap each spoke with a screwdriver Specification You should hear a high note Spoke nipple front wheel 5 Nm 3 7 Ibf ft Spoke nipple rear wheel M5 5 Nm 3 7 Ibf ft e Info 0022501 If you hear different tone frequencies from different spokes this is indi 400228 01 4 cation of different spoke tensions Removing the battery Warning Risk of injury Battery acid and battery gases
39. changing the spring preload Installing shock absorber P 36 Check the static sag of the shock absorber P 34 Check the riding sag of the shock absorber P 35 Adjust the rebound damping of the shock absorber P 33 Removing the shock absorber Jack up the motorcycle P 32 Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel Fix the rear wheel in this position Remove screw push splash protector to the side and remove the shock ab sorber Check parts for damage and wear Replace damaged or worn parts Push splash protector 6 to the side and position the shock absorber Mount and tighten screw Specification Screw top shock absorber M12 80 Nm Loctite 2437 59 Ibf ft Mount and tighten screw Specification Screw bottom shock ab M12 80 Nm Loctite 243 sorber 59 Ibf ft Info The heim joint for the shock absorber at the swing arm is Teflon coated It must not be greased with grease or with other lubricants Lubricants dis solve the Teflon coating thereby drastically reducing the service life Remove the motorcycle from the work stand P 32 MAINTENANCE WORK ON CHASSIS AND ENGINE 4 Checking basic setting of fork e Info For various reasons no exact riding sag can be determined for the forks with the shock absorber smaller weight differences can be co
40. cycle The low and high speed technology works non specifically Adjusting high speed compression damping of the shock absorber Danger Danger of accidents shock absorber is under high pressure shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any main tenance on it yourself e Info The high speed setting be seen during the fast compression of the shock absorber MAINTENANCE WORK ON CHASSIS AND ENGINE 8 Turn the adjusting screw clockwise with a ring wrench until it stops e Info Do not loosen nut Turn back counterclockwise the number of turns corresponding to the shock ab sorber type Specification Compression damping high speed 400208 10 e Info Turn clockwise to increase damping turn counterclockwise to reduce sus pension damping Adjusting the low speed compression damping of the shock absorber Danger Danger of accidents shock absorber is under high pressure shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any main tenance on it yourself e Info The low speed setting can be seen during the slow normal compression of the shock absorber Turn the adjusting screw clockwise with a screwdriver until it stops e info Do not loosen nut Turn back counterclockwise the number of clicks correspondi
41. do not ride any further Warning Skin irritations Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children f brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediately MAINTENANCE WORK ON CHASSIS AND ENGINE 0 4 Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan an authorized KTM workshop Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info KTM recommends DOT 5 1 brake fluid from Motorex9 This has a higher wet boiling point than DOT 4 brake fluid and provides greater safety for high demands Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove the cover with membrane Top up brake fluid to level Specification Measurement of Q 5 mm 0 2 in Brake fluid DOT 5 1 P 114 Check parts for damage and wear Replace da
42. e 1 2 s e e a i 9 400334 10 WIRING DIAGRAM gt Components Battery Generator Ignition coil Pulse generator Voltage regulator rectifier Flasher switch Starter relay with fuse Starter motor o ol NI AJAJ BY W M 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 tail light 16 Licence plate lamp 17 Electric starter button emergency OFF switch 18 Flasher relay 19 Left front flasher 20 Left rear flasher 21 Right front flasher 22 Right rear flasher 23 Speedometer 24 Wheel speed sensor 25 Tripmaster switch optional 26 Horn 27 Front brake light switch 28 Rear brake light switch 29 High beam indicator light 30 Flasher indicator light 31 Plug connector for radiator fan optional Cable colors bl black bl wh black white br brown br bl brown black bu blue bu wh blue white gn green gr gray or orange pu violet re red re bl red black re wh red white wh white wh gn white green wh re white red ye yellow ye bl yellow black ye re yellow red 104 WIRING DIAGRAM Wiring diagram EXC R USA wiring diagram
43. filter box Check carburetor connection boot for damage and tightness Install the air filter P 75 Adjusting basic position of clutch lever Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw e Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 500133 11 Checking fluid level of hydraulic clutch Warning Skin irritations Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children f brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediately Info The fluid level rises with increasing wear of the clutch lining disc Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container MAINTENANCE WORK ON CHASSIS AND ENGINE 5 Move the clutch fluid reservoir mounted the handlebar to a horizontal position Remove screws Take off cover with membrane Check the fluid level Fluid level under top level of container 4 mm 0 16 in Ifthe level
44. get very hot when the engine is running Do not place the vehicle where there are flammable or explosive substances Brake the motorcycle Shift gear to neutral Every XCR W models Press the short circuit button amp at engine idling speed until the engine stops EXC R EU EXC R AUS UK EXC R SIX DAYS Press the short circuit button amp at engine idling speed until the engine stops EXC R USA Push the emergency off switch at engine indling speed to the position i Turn the handle of the fuel tap to the OFF position Figure 500137 10 P 20 Stand the motorcycle on a hard surface Refueling Danger Fire hazard Fuel can easily catch fire 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 Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See specifications on filling up with fuel Warning Danger of poisoning Fuel is poisonous a health hazard 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 fuel is swallowed contact a doctor immediately Change clothing that has come into contact with fuel Warning 3 En
45. of the cooling liquid does not meet specifications Correct the fluid level of the hydraulic clutch Brake fluid DOT 5 1 P 114 Check parts for damage and wear Replace damaged or worn parts Position the cover with the membrane Mount and tighten screws e Info Clean up overflowed or spilt fluid immediately with water Changing fluid level of hydraulic clutch 36 Warning Skin irritations Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children If brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediately Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info The fluid level rises with increasing wear of the clutch lining disc Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws Take off cover with membrane Fill the bleeding syringe with the appropriate hydraulic fluid Bleed syringe 50329050000 Brake fluid DOT 5 1 114 On the slave cylinder remove the bleeder screw and fit the bleeding syringe Z MAINTENANCE WORK ON CHASSIS
46. protective clothing and gloves If you scald yourself hold the affected area under cold water immediately Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Place a suitable container under the engine Remove screws Remove oil filter cover with O ring Pull the oil filter insert out of the oil filter casing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean parts and sealing area Check parts for damage and wear Replace damaged or worn parts Lay the motorcycle on its side and fill the oil filter housing to about 1 3 full with engine oil Fill the oil filter with engine oil and place it in the oil filter container Lubricate the O ring of the oil filter cover MAINTENANCE WORK ON CHASSIS AND ENGINE 04 Refit the oil filter cover Mount and tighten screws Specification Screw oil filter cover M5 6 Nm 4 4 Ibf ft Stand the motorcycle up e Info Too little engine oil or poor quality engine oil results in premature wear to the engine Remove the screw cap on the generator cover and fill up with engine oil Engine oil 0 61 0 6 qt Engine oil SAE 10W 50 P 114 Mount and tighten screw cap Danger Danger of poisoning Exhaust gase
47. route P 49 Move the handlebar to the straight ahead position Push back bellows Loosen nut Turn adjusting screw in as far as possible Loosen nut Turn adjusting screw so that there is play in the gas Bowden ca ble at the throttle grip Specification Play in gas Bowden cable 3 5 mm 0 12 0 2 in Tighten nut Press and hold the throttle grip in the closed setting Turn adjusting screw out until there is no play in the Bowden cable Tighten nut Push bellows on Check the throttle grip for smooth operation Install the fuel tank P 70 Check play in the gas Bowden cable P 50 Check the chain for coarse dirt accumulation Ifthe chain is very dirty Clean the chain P 50 Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations MAINTENANCE WORK ON CHASSIS AND ENGINE 0 4 e Info The service life of the chain depends largely on
48. the adjustment screw clockwise to reduce free travel The pressure point moves away from the handlebar Turn the adjustment screw counterclockwise to increase free travel The pressure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force I 400196 12 Do not make any adjustments while riding Check the free play of the hand brake lever P 55 Checking the front brake fluid level Warning Danger of accidents Brake system failure lf 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 further Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop Move the brake fluid reservoir mounted on the handlebar to a horizontal position Check the brake fluid level in the viewer Ifthe brake fluid is below the MIN mark up the brake fluid of the front brake P 56 Topping up the front brake fluid Warning Danger of accidents Brake system failure Ifthe 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
49. to 0 0 Displays of S2 and A2 are reset to 0 0 Next display mode No function Next display mode Overview of conditions and ability to be enabled Display Display mode SPEED Menu can be en abled The motorcycle is standing Display mode SPEED H service hours Display mode SPEED CLK time ____ OPERATING ELEMENTS Overview of conditions and ability to be enabled Display The motorcycle is Menu en standing abled Display mode SPEED LAP lap time Display mode SPEED ODO odometer Display mode SPEED TR1 trip master 1 Display mode SPEED TR2 trip master 2 Disply mode SPEED A1 average speed 1 NENNEN EC cee a e Display mode SPEED A2 average speed 2 Display mode SPEED S1 stop watch 1 Display mode SPEED S2 stop watch 2 Fuel tap The fuel tap is on the left of the fuel tank With the tap handle on the fuel tap you can open or close the supply of fuel to the carburetor Possible states Fuel supply closed OFF No fuel can flow from the tank to the carburetor e Fuel supply open ON Fuel can flow from the tank to the carburetor The fuel tank empties down to the reserve e Reserve fuel supply open RES Fuel can flow from the tank to the carburetor The fuel tank empties completely 500137 10 Press release button turn filler cap counterclockwise and lift it free Replace the filler c
50. worn parts Mount the screw cap with the membrane and the O ring e Info Clean up overflowed or spilt brake fluid immediately with water Warning Danger of accidents Reduced braking due to worn brake linings 400233 10 Worn brake linings should be replaced immediately in an authorized KTM workshop Check the brake linings for minimum thickness Minimum thickness gt 1 mm gt 0 04 in If the minimum thickness is less than specified Change the rear brake linings P 63 MAINTENANCE WORK ON CHASSIS AND ENGINE 40 Removing rear brake linings f Warning Danger of accidents Improper brake maintenance and repair Always have your brake system maintained and repaired in an authorized KTM workshop Press the brake caliper by hand on to the brake disc in order to press back the brake piston e Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove the locking split pins withdraw the bolt and take out the brake pads Clean brake caliper and brake caliper support Installing the rear brake linings T Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents Reduced braking due to use of non approved brake linings
51. 0 Main air jet 200 Idle air jet 100 Cold start jet 65 85 Leakage nozzle Throttle slide Slide stop 40 present 450 EXC R SIX DAYS 450 EXC R USA 450 XCR W 3900L Carburetor type Carburetor identfication number Needle position 450 XCR W USA KEIHIN FCR MX 39 3900L 154 position from top Needle position 450 EXC R SIX DAYS 3rd position from top Needle position 450 EXC R USA 450 XCR W ZA 4th position from top Idle mixture adjusting screw 450 XCR W USA Pump membrane stop Idle mixture adjusting screw 450 EXC R SIX DAYS Open 1 0 turn Idle mixture adjusting screw 450 XCR W ZA Open 1 5 turns Idle mixture adjusting screw 450 EXC R USA 2 15 mm 0 0846 in Main jet 450 EXC R SIX DAYS 450 EXC R USA 450 XCR W USA 180 Main jet 450 XCR W ZA 185 Leakage nozzle Throttle slide Jet needle 450 XCR W 450 EXC R SIX DAYS Idling jet 450 XCR W 450 EXC R SIX DAYS Idling jet 450 EXC R USA 48 Main air jet 200 Idle air jet 100 Cold start jet 85 40 m 530 EXC R EU 530 EXC R AUS UK 3900 J TECHNICAL DATA CARBURETOR 1 8 Carburetor type KEIHIN FCR MX 39 Carburetor identfication number Needle position Idle mixture adjusting screw 3900J bth position from top Open 1 5 turns Pump membrane stop 2 15 mm 0 0846 in Main jet 180 Jet needle OBDZT OBDTR Main air jet Idle air jet 100
52. 00 500074 01 secure the motorcycle against falling over Removing the motorcycle from the work stand Note Danger of damage Danger of damage by the vehicle running away or falling over Always place the vehicle on a firm and even surface Remove the motorcycle from the work stand Remove the work stand Checking the basic chassis setting with the rider s weight e Info When adjusting the basic chassis setting first adjust the shock absorber and then the fork For optimal motorcycle riding characteristics and to avoid damage to forks shock absorbers swing arm and frame the basic set tings of the suspension components must match your body weight delivered KTM offroad motorcycles are adjusted for a standard rider weight with full protective clothing Specification Standard rider weight 75 85 kg 165 187 Ib If your weight is above or below the standard range you have to adjust the basic setting of the suspension components accord ingly Small weight differences can be compensated by adjusting the spring preload but in the case of large weight differences the springs must be replaced Compression damping of shock absorber The shock absorber can regulate compression damping in low and high speed range separately Dual Compression Control The term low and high speed refers to the movement of the shock absorber during compression and not the riding speed of the motor
53. 18 4 Ibf ft Loctite 243 Balancer shaft nut 10 1 40 Nm 29 5 Ibf ft Screw unlocking of timing chain ten M10x1 10 Nm 7 4 Ibf ft sioner Screw engine sprocket M10 60 Nm 44 3 Ibf ft Loctite 243 Plug oil channel M10 15 Nm 11 1 Ibf ft Loctite 243 Screw cylinder head M10x1 25 Tightening sequence Engine oil any Tighten diagonally begin ning with the rear screw on the chain shaft Step 1 10 Nm 7 4 Ibf ft Step 2 30 Nm 22 1 Ibf ft Step 3 50 Nm 36 9 Ibf ft Gear oil drain plug with magnet 12 1 5 20 Nm 14 8 Ibf ft Ignition rotor nut 12 1 60 Nm 44 3 Ibf ft 515 M12x1 5 20 Nm 14 8 Ibf ft Oil pressure control valve plug M12x1 5 20 Nm 14 8 Ibf ft Spark plug M12x1 25 15 20 Nm 11 1 14 8 Ibf ft Plug rocker arm M14x1 25 20 Nm 14 8 Ibf ft Plug gear oil screen M16x1 5 20 Nm 14 8 Ibf ft Plug engine oil screen M17x1 5 20 Nm 14 8 Ibf ft Nut inner clutch hub M18x1 5 80 Nm 59 Ibf ft Nut primary gear M20LHx1 5 150 Nm 110 6 Ibf ft Loctite 6487 Plug timing chain tensioner M24x1 5 25 Nm 18 4 Ibf ft TECHNICAL DATA CARBURETOR 450 EXC R EU 450 EXC R AUS UK 39001 Carburetor type Carburetor identification number Needle position Idle mixture adjusting screw KEIHIN FCR MX 39 39001 4th position from top Open 1 75 turns Pump membrane stop 2 15 mm 0 0846 in Main jet 18
54. ENTS 43 Insert the key in the steering lock turn it to the left press it in and turn it to the right Remove the key v Steering is no longer possible e Info Never leave the key in the steering lock Unlocking the steering EXC R EU EXC R AUS UK EXC R USA Insert the key in the steering lock turn it to the left pull it out and turn it to the right Remove the key v You can now steer the bike again e Info Never leave the key in the steering lock GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION Advice on first use Danger Danger of accidents Danger from inadequate traffic experience Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs Warning Risk of injury Risk of injury by missing inadequate protective clothing Wear protective clothing helmet boots gloves pants and jacket with protectors every time you ride the vehicle Warning Danger of crashing Impairment of riding behavior due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Critical riding behavior due to inappropriate riding Adapt your riding speed to the road conditoins and your riding ability Warning Danger of accidents Accident risk caused by presence of a passenger Your vehicle is not desig
55. Info The service hour counter is necessary for ensuring that maintenance work is car ried out at the right intervals If the speedometer is in H display mode at the start of the journey it automati cally changes to the ODO display mode The H display mode is suppressed during the journey Press the button No function Press the button No function Press the button O The display changes to the Setup menu of the speedometer for 3 5 seconds functions Press the button O Next display mode briefly OPERATING ELEMENTS 4 Display mode SPEED CLK time 400319 01 Display mode SPEED LAP lap time 60 08 39 Lip 400320 01 Display mode SPEED ODO odometer 400317 01 Press the button O briefly and repeatedly until CLK appears at the bottom right of the display The time is displayed in CLK display mode Press the button no function Press the button no function Press the button O The display changes to the Setup menu of the clock for 3 5 seconds Press the button O next display mode briefly Press the button O briefly and repeatedly until LAP appears at the bottom right of the display In the LAP display mode up to 10 lap times can be timed with the stop watch e Info If the lap time continues after you press the button memory locations are already occupied Lap 10 must be timed with the button Press the button
56. Specification Measurement of Q 5 0 2 Brake fluid DOT 5 1 114 Check parts for damage and wear Replace damaged or worn parts Position the cover with the membrane Mount and tighten the screws e Info Clean up overflowed or spilt brake fluid immediately with water 400230 10 Checking free play of foot brake lever Warning Danger of accidents Brake system failure 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 pedal according to specifications Disconnect spring Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free play Q Specification Free play at foot brake lever 3 5 mm 0 12 0 2 in Ifthe free travel does not meet specifications Adjust the basic position of the footbrake lever P 60 Reconnect spring ____ MAINTENANCE WORK ON CHASSIS AND ENGINE 4 Adjusting basic position of footbrake lever Warning Danger of accidents Brake system failure 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 pedal according to specifications Disconnect spring Loosen nut and
57. a com KTM Canada Inc Customer Support 1375 1 Marie Victorin Saint Bruno QC J3V 6B7 Phone 450 441 4451 x 39 www ktmcanada com TAMPERING WARNING TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED FEDERAL LAW PROHIBITS THE FOLLOWING ACTS OR CAUSING THEREOF 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW 1 Removal of or puncturing the muffler baffles header pipes or any other components which conducts exhaust gases 2 Removal or puncturing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving part of the vehicle or parts of the exhaust or intake system with parts other than those specified by the manufacturer WARNING STATEMENT This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use Otherwise the owner may become subject to penalties under state and local ordinances CONSUMER RIGHTS Limited Warranty claims should be directed to an authorized KTM dealer If you are not satisfied ple
58. and water If fuel is swallowed contact a doctor immediately Change clothing that has come into contact with fuel MAINTENANCE WORK ON CHASSIS AND ENGINE 1 Check parts for damage and wear Replace damaged or worn parts Position the fuel tank and fit the two spoilers to the side of the radiator fixing Make sure that no cables or Bowden cables are trapped or damaged Mount the fuel tank vent hose Fit and tighten screw with collar sleeve Specification Remaining screws chassis M6 10 Nm 7 4 Ibf ft Every EXC R models Position horn with horn bracket Fit and tighten screws with collar sleeve Specification INR AR Connect fuel hose Mount the seat P 69 The water pump in the engine forces the coolant to flow The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap The specified coolant temperature is therefore permissible with out danger of function problems 120 C 248 F Coolant 7 P 114 Cooling is effected by the air stream The lower the speed the less the cooling effect Dirty cooling fins also reduce the cool ing effect EXC R SIX DAYS XCR W ZA The radiator fan provides extra cooling It is controlled by a thermoswitch Checking antifreeze and coolant level Warning Danger of scalding coolant gets very hot when the motorcycle is driven and is under high pressure Do not o
59. ap and turn clockwise until the release button locks in place e info Run the fuel tank breather hose without kinks choke 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 e Info If the engine is warm the choke function must be deactivated Possible states e Choke function activated The choke lever is pulled out to the stop e Choke function deactivated The choke lever is pushed in to the stop The flasher switch is fitted on the left side of the handlebar 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 e Info If the engine is warm the choke function must be deactivated Possible states e Choke function activated The choke lever is pulled to the stop e Choke function deactivated The choke lever is pushed back to the stop The shift lever is mounted on the left side of the engine The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears The foot brake pedal is located in front of the right footrest and operates the rear wheel brake OPERATING ELEMENTS 5 Kickstarter The kickstarter is fitted on the r
60. ar oil or poor quality oil results in premature wear to the transmission Remove the screw cap and fill up with gear oil 0 9 I 1 qt Engine oil SAE 10W 5O P 114 Mount and tighten screw Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon sciousness and or death When running the engine always make sure there is sufficient ventila EO tion do not start run the engine a closed space Start the engine and check that it is oil tight Check the gear oil level P 81 Topping up with gear oil e Info Too little gear oil or poor quality oil results in premature wear to the transmission Remove gear oil level check screw Remove screw Stand the vehicle upright Top up with gear oil until it flows out of the bore of the gear oil level screw Engine oil SAE 10W 50 114 Mount and tighten the gear oil level check screw Specification Screw gear oil level check 6 10 Nm 7 4 Ibf ft Mount and tighten screw cap p Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon sciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in a closed space Start the engine and check that it is oil tight Faults The engine cannot be cranked electric starter Possible cause Measure
61. arbUutretot us y e ED EVER 92 93 CHASSIS x cfs trent by dr tette datos 94 95 ar We P PR 88 89 ed N 96 Shock absorber 97 Tightening torque chassis 98 Tightening torque engine 90 91 Tire air pressure uuo meinst sei ra eae RSS 66 Tire condition Checking ceva t ae AS TESI qe 66 Transport i wee eS eRe ee ae 6 TROUBLESHOOTING 84 85 Type label ser 2 aec ae a ER Oe etd wx 8 Warranty ERE RS 6 Wiring diagram 100 113 3211254en 2 6 JaneqieniW oy ud 002 0L KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com
62. ase contact KTM North America Inc Customer Support 1119 Milan Ave Amherst OH 44001 Phone 440 985 3553 www ktmusa com KTM Canada Inc Customer Support 1375 1 Marie Victorin Saint Bruno QC J3V 6B7 Phone 450 441 4451 x 39 www ktmcanada com Your rights may vary please refer to the applicable state laws 550 5 5 255 ed seta oa 6 Air filter cleaning RU EG Ed Gesund 75 fitting ince X DAS 75 FEMOVING a ortho ve ONE EH eter 74 Air filter box lid TIEEITIBE cee et ora a eee e Et e od 74 FEMOVING d huile SOR d RU tm est 74 Antifreeze Checking irse acne eee A E TA ee ed 71 B Basic chassis setting checking with rider s weight 32 Battery MINEA cele de oh ine BSE ODS 67 recharging 5 io dowd ten eod 68 ew ieee V REY Nu GANE S Y TAS 67 Brake calipers 55 Brake discs checking i ev eee RS peter hate hee 55 Brake fluid of rear brake adding 61 Topping up brake fluid of front brake 56 Brake fluid level of front brake checking 56 of rear brake 60 Brake linings of front brake changing 59 of front brake checking 57 of
63. at you can help each other Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle Do not make any offroad trips that over stress your ability and experience Hold the handlebar firmly with both hands and keep your feet on the footrests when riding Do not make any changes to the motorcycle and use only KTM approved parts GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 1x 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 e Info Motorcycles react sensitively to any changes of weight distribution Do not exceed the overall maximum permitted weight and the axle loads Specification Maximum permissible overall weight 335 kg 739 Ib Maximum permissible front axle load 145 kg 320 Ib Maximum permissible rear axle load 190 kg 419 Ib Runthe engine in Running in the engine During the running in phase do not exceed the specified engine speed and engine performance Specification Maximum engine speed During the first 3 service hours 7000 rpm Maximum engine performance during the running in period During the first 3 service hours lt 50 During the next 12 service hours Avoid fully opening the throttle RIDING INSTRUCTIONS 1 9 Checks before putting into operati
64. ative cable of the battery to avoid damage to the motor cycle s electronics Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 You can also use the battery charger to test rest potential and start potential of the battery and to test the generator With this device you cannot overcharge the bat tery e Info Never remove the lid Charge the battery according to the instructions on the battery casing 400240 10 Switch off the charger after charging Disconnect the battery Specification The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the 3 months motorcycle is not in use Mount the seat P 69 MAINTENANCE WORK ON CHASSIS AND ENGINE Removing a fuse Switch off all power consuming components and switch off the engine Dismount the air filter box lid P 74 Remove the protection cover e Info The fuse is located in the starter relay under the filter box cover Remove the fuse 400270 10 Replacing the fuse Warning Fire hazard electrical system can be overloaded by the use of incorrect fuses Use only fuses with the prescribed amperage Never by pass or repair fuses Check parts for damage and wear Replace damaged or worn parts e Info A reserve fuse is located in the starter relay Replace a burned
65. cause serious cauterization Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep the battery away from sparks or open fire Charge only in well ventilated rooms Inthe event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Switch off all power consuming components and switch off the engine Remove the seat P 69 Disconnect the negative minus cable of the battery Pull back the plus pole cover and disconnect the positive plus cable of the bat tery Hang the rubber band out to the bottom Lift the battery up 500069 10 Check parts for damage and wear Replace damaged or worn parts Place the battery in the battery holder 4Ah battery YTX5L BS P 94 Reconnect the rubber band Attach the plus cable and replace the plus pole cover Attach the minus cable Mount the seat P 69 500069 11 MAINTENANCE WORK ON CHASSIS AND ENGINE 68 Recharging the battery T Warning Risk of injury Battery acid and battery gases cause serious cauterization Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep the battery away from spark
66. damping EXC R EU EXC R AUS UK EXC R USA XCR W Comfort Standard Rebound damping EXC R SIX DAYS Standard 20 clicks Sport 18 clicks e info Turn clockwise to increase damping turn counterclockwise to reduce sus pension damping Turn adjusting screws counterclockwise until they stop e Info Make the same adjustment on both fork legs Turn back clockwise the number of turns corresponding to the fork type Specification Spring preload Preload Adjuster EXC R EU EXC R AUS UK EXC R USA XCR W Standard 4 turns Sport 7 turns Spring preload Preload Adjuster EXC R SIX DAYS Comfort 2 turns Standard 2 turns Info Turn clockwise to increase spring preload turn counterclockwise to reduce spring preload Adjusting the spring preload has no influence on the absorption setting of the rebound damping Basically however you should set the rebound damping higher with a higher spring preload Jack up the motorcycle P 32 Remove bleeder screws briefly Any excess pressure escapes from the interior of the fork Mount and tighten bleeder screws Remove the motorcycle from the work stand P 32 Cleaning dust boots of fork legs 500088 10 Loosening the fork protection Checking play of steering head bearing Warning Jack up the motorcycle P 32 Loosen the fork protection P 39 Push dust boots of both fork legs downwards
67. dered for damage resulting from manipulations and alterations to the motorcycle You should use the fuels oils and greases according to specifications as listed in the owner s manual For your own safety use only spare parts and accessories approved by KTM KTM accepts no liability for other products and any re sulting damage or loss Note Danger of damage Danger of damage by the vehicle running away or falling over Always place the vehicle on a firm and even surface Note Fire hazard Some components engine radiator and exhaust system get very hot when the engine is running Do not place the vehicle where there are flammable or explosive substances switch off engine Turn the handle Q of the fuel tap to the OFF position Figure 500137 10 P 20 Use straps or other suitable devices to secure the motorcycle against accidents or falling over Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest However it is 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 have to occur To protect the future of motorcycle sport make sure that you use your mo torcycle legally display environmental consciousness and respect the rights of others In your own interest read the specified warning notes e Info Various warning labels are attac
68. dicator lights Every EXC R models W2x4 6d Flasher light EXC R EU EXC R AUS UK BA15s Flasher light EXC R USA BAU15s Brake tail light EXC R EU LED EXC R AUS UK EXC R SIX DAYS XCR W ZA Brake tail light EXC R USA BAY15d Licence plate lamp EXC R EU EXC W2 1x9 5d R AUS UK Tires Every EXC R models 90 90 21 48 M S M TT 140 80 18 70 M S M TT Metzeler MCE 6 DAYS EXTREME Metzeler MCE 6 DAYS EXTREME Every XCR W models 80 100 2151 MTT 110 100 18 64 MTT Bridgestone M59 Bridgestone M402 For further information see http www ktm com Capacity fuel Tank capacity EXC R EU 9 2 4 US gal Super unleaded ROZ 95 RON 95 PON 91 P 114 EXC R AUS UK EXC R SIX DAYS XCR W ZA Tank capacity EXC R USA 9 2 2 43 US gal Super unleaded ROZ 95 RON 95 PON 91 P 114 XCR W USA ___ TECHNICAL DATA 8 Fork part number EXC R EU EXC R AUS UK EXC R USA XCR Spring length with preload spacer s Weight of rider 65 75 kg 143 Spring rate EXC R EU EXC R AUS UK W Fork part number EXC R SIX DAYS Fork WP 4860 MXMA PA Compression damping EXC R EU EXC R AUS UK EXC R USA XCR W Comfort 24 clicks Standard 20 clicks Sport 18 clicks Compression damping EXC R SIX DAYS Standard 22 clicks Sport 18 clicks Rebound damping EXC R EU EXC R AUS UK EXC R USA XCR W Comfort 20 click
69. e Do not open the radiator radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down If you scald yourself hold the affected area under cold water immediately Warning Danger of poisoning Coolants are poisonous and a health hazard Avoid contact between coolants and skin eyes and clothing If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor im mediately Change clothes that have come into contact with coolants Keep coolants out of the reach of children Stand the motorcycle upright on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level Q above radiator fins 10 mm 0 39 in If the level of the cooling liquid does not meet specifications Correct the coolant level Alternative 1 400243 10 Coolant P 114 Alternative 2 Coolant mixed ready to use P 114 Refit the radiator cap Draining coolant Warning Danger of scalding coolant gets very hot when the motorcycle is driven and is under high pressure Do not open the radiator radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down If you scald yourself hold the affected area under cold water immediately Warning
70. e Check for correct chain tension and adjust if necessary F 18 400213 10 Jack up the motorcycle 7 P 32 Push the chain at the end of the chain sliding component upwards to measure chain tension e Info The upper chain section must be taut Chain wear is not always even so you should repeat this measurement at different chain positions MAINTENANCE WORK ON CHASSIS AND ENGINE 04 Loosen nut Loosen nuts Adjust the chain tension by turning the left and right adjusting screws O Specification Chain tension 8 10 mm 0 31 0 39 in Turn the left and right adjusting screws so that the markings on the left and right chain adjusters are in the same position relative to the reference marks The rear wheel is then correctly aligned Tighten nuts Make sure that chain adjusters G are fitted correctly on the adjusting screws O Tighten nut Specification Nut rear wheel spindle M20x1 5 80 Nm 59 Ibf ft e Info The wide adjustment range of the chain adjusters 32 mm enables different secondary transmissions with the same chain length Chain adjusters can be turned by 180 Remove the motorcycle from the work stand P 32 Loosen nut Loosen nuts Adjust the chain tension by turning the adjusting screws left and right Specification Chain tension 8 10 mm 0 31 0 39 in Turn the adjusting screws left and right so that the markings on th
71. e 000 value is retained and converted accordingly The values TR1 TR2 A1 A2 and S1 are deleted at the changeover TRO Al A2 8182 3 Mh 00 LAP CLK H ANAS 400329 01 Condition The motorcycle is standing Press the button O briefly and repeatedly until H appears at the bottom right of the display Press the button O for 3 5 seconds v The Setup menu opens and the active functions are displayed Press the button O repeatedly until the Km h Mphdisplay flashes Setting Km h Press the button Setting Mph Press the button Press the button O for 3 5 seconds v settings are saved and the Setup menu closed e Info If no button is pressed for 20 seconds or if no impulse comes from the wheel speed sensor the settings are automatically saved and the Setup menu closed OPERATING ELEMENTS Setting the clock Condition The motorcycle is standing Press the button O briefly and repeatedly until CLK appears at the bottom right of the display Press the button O for 3 5 seconds The hour display flashes Set the hour display with the button and or button Press the button O briefly The next segment of the display flashes and can be set You can set the following segments in the same way as the hours by pressing the 200930 0 button and the button e Info The seconds can only be set t
72. e down at high engine speed the rear wheel can lock up not change into a low gear at high engine speed The engine races and the rear wheel can block e Info If you hear unusual noises while riding stop immediately switch off the engine and contact an authorized workshop First gear is used for starting off or for steep inclines When conditions allow incline road situation etc you can shift into a higher gear To do so release the throttle while simulta neously pulling the clutch lever shift into the next gear release the clutch and open the throttle Ifthe choke function was activated deactivate it after the engine has warmed up When you reach maximum speed after fully opening the throttle turn back the throttle to about 3 4 of its range the speed hardly drops but the fuel consumption falls considerably Always open the throttle only as much as the engine can handle abrupt throttle opening increases fuel consumption shift down brake if necessary and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Switch off the engine if you expect to be standing for a long time Specification 22min Avoid frequent and longer slipping of the clutch This heats the engine oil the engine and the cooling system Ride with a lower engine speed instead of with a hi
73. e left and right chain adjusters in the same position relative to the reference marks The rear wheel is then correctly aligned Tighten nuts Make sure that the chain adjusters are fitted correctly on the adjusting screws Tighten nut 9 Specification Nut rear wheel spindle M20x1 5 80 Nm 59 Ibf ft e Info The wide adjustment range of the chain adjusters 32 mm enables different secondary transmissions with the same chain length The chain adjusters O can be turned by 180 Loosen nuts Adjust the chain tension by turning the adjusting screws left and right Specification 8 10 nm 0 31 0397 Turn the adjusting screws left and right so that the markings on the left and right chain adjusters in the same position relative to the reference marks The rear wheel is then correctly aligned Tighten nuts Remove screws and Take off the chain guide Conditions Number of teeth lt 44 teeth Insert nut in hole Position the chain guide Mount and tighten screws and Specification 7 4 Ibf ft Remaining screws chassis M6 10 Nm Conditions Number of teeth gt 45 teeth Insert nut in hole Position the chain guide Mount and tighten screws and Specification Remaining screws chassis 10 Nm 7 4 Ibf ft Warning ZJ Danger of accidents Brake system failure Ifthe brake flu
74. e start number plate P 47 EXC R SIX DAYS Remove the headlight mask with the headlight P 46 Dismount the front fender P 46 Remove screws and hang the CDI control unit to the side e Info Do not unplug the CDI control unit Remove screw Remove screw take off top triple clamp with the handlebar and place it on one side e Info Protect the motorcycle and its attachments from damage by covering them Do not bend the cables and lines Remove o ring Remove protector ring Remove the lower triple clamp with the steering stem Remove the upper steering head bearing MAINTENANCE WORK ON CHASSIS AND ENGINE 4 Removing the lower triple clamp EXC R EU EXC R AUS UK EXC R USA XCR W ZA 500150 10 Remove the fork legs P 41 Remove the headlight mask with the headlight P 46 Dismount the front fender 7 P 46 Remove screws and hang the CDI control unit to the side e Info Do not unplug the CDI control unit Remove screw Loosen screw Take off top triple clamp with the handlebar and place it on one side e Info Protect the motorcycle and its attachments from damage by covering them Do not bend the cables and lines Remove protector ring O Remove the lower triple clamp with the steering stem Remove the upper steering head bearing Installing the lower triple clamp EXC R SIX DAYS XCR W USA 500098 10 500099 11 Clean the b
75. earing and sealing elements check for damage and grease Long life grease P 115 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing e Info Check whether the top steering head seal is correctly positioned Push up protective ring and o ring Position the upper triple clamp with the steering Mount and tighten screw Specification Screw top steering head M20x1 5 10 Nm 7 4 Ibf ft Position the clutch line wiring harness and CDI control unit Mount and tighten screws Specification Remaining screws chassis 6 10 Nm 7 4 Ibf ft Install the front fender P 46 XCR W USA Fitthe start number plate P 47 MAINTENANCE WORK ON CHASSIS AND ENGINE 4 5 EXC R SIX DAYS Refit the headlight mask with the headlight P 47 Install the fork legs P 42 Mount and tighten screw Specification Screw top steering stem M8 17 Nm Loctite 243 12 5 Ibf ft Check the cable harness cable brake and clutch line for free movement and free laying Check play of steering head bearing 39 Installing the lower triple clamp EXC R EU EXC R AUS UK EXC R USA XCR W ZA 500151 10 500149 11 Clean the bearing and sealing elements check for damage and grease Long life grease P 115 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing
76. ebar clamp EXC R EU M8 20 Nm 14 8 Ibf ft EXC R AUS UK EXC R USA XCR W Screw handlebar clamp M8 16 Nm 11 8 Ibf ft EXC R SIX DAYS Screw engine brace M8 33 Nm 24 3 Ibf ft Screw subframe M8 35 Nm 25 8 Ibf ft Loctite 243 Engine carrying screw 60 Nm 44 3 Ibf ft Remaining nuts chassis 50 Nm 36 9 Ibf ft Remaining screws chassis 45 Nm 33 2 Ibf ft Screw handlebar support 40 Nm 29 5 Ibf ft Loctite 243 Nut seat fixing M12x1 20 Nm 14 8 Ibf ft Screw top shock absorber M12 80 Nm 59 Ibf ft Loctite 243 Screw bottom shock absorber M12 80 Nm 59 Ibf ft Loctite 243 Nut swingarm pivot M16x1 5 100 Nm 73 8 Ibf ft Screw in nozzles cooling system M20x1 5 12 Nm 8 9 Ibf ft Loctite 243 Nut rear wheel spindle M20x1 5 80 Nm 59 Ibf ft Screw bottom steering head EXC M20x1 5 60 Nm 44 3 Ibf ft Loctite 243 R SIX DAYS XCR W USA Screw front wheel spindle M24x1 5 40 Nm 29 5 Ibf ft Wiring diagram EXC R EU e 400308 10 o gt z z E es Dh Or i o EE 6 evz E main harness 594 11 075 150 CDI harness 780 39 032 000 WIRING DIAGRAM gt Components Battery Generator Ignition coil Pulse generator Voltage regulator rectifier E
77. ed on the basis of the current speed if the stop watch S2 stop watch 2 is running e Info The displayed value can differ from the actual average speed if S2 was not timed after the ride Press the button No function Press the button No function Press the button O for 3 5 seconds Press the button O Next display mode briefly Display mode SPEED S1 stop watch 1 400327 01 Display mode SPEED S2 stop watch 2 400328 01 Overview of speedomer functions ____ OPERATING ELEMENTS 8 Press the button O 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 the first impulse of the wheel sensor and ends 3 seconds after the last impulse Press the button No function Press the button No function Press the button O Displays of TR1 A1 and S1 are reset to 0 0 for 3 5 seconds Press the button O Next display mode briefly Press the button O briefly and repeatedly until S2 appears at the top right of the display S2 stop watch 2 is a manual stop watch If S2 is running in the background the S2 display flashes in the speedometer display Press the button Starts or stops S2 Press the button No function Press the button O Displays of S2 and A2 are reset to
78. efly and repeatedly until TR2 appears at the top right of the display TR2 trip master 2 runs constantly and counts up to 999 9 The displayed value can be set manually with the button and the button A very practical function for rides by the road book Info The TR2 value can also be corrected manually during the journey with the but ton and the button If 999 9 is exceeded the value of TR2 is automatically reset to 0 0 Press the button Increases value of TR2 Press the button Reduces value of TR2 Press the buttonO Deletes value of TR2 for 3 5 seconds Press the button Next display mode briefly Disply mode SPEED A1 average speed 1 400325 01 Press the button O briefly and repeatedly until A1 appears at the top right of the display A1 average speed 1 shows the average speed calculated using TR1 trip master 1 and S1 stop watch 1 The calculation of this value is activated by the first impulse of the wheel sensor and ends 3 seconds after the last impulse Press the button No function Press the button No function Press the button O Displays of TR1 A1 and S1 are reset to 0 0 for 3 5 seconds Press the button O Next display mode briefly Display mode SPEED A2 average speed 2 400326 01 Press the button O briefly and repeatedly until A2 appears at the top right of the display A2 average speed 2 shows the average spe
79. ender Position the brake line and cable harness Put the clamp on mount and tighten screw On the upper triple clamp there 2 holes at a distance of to each other Distance between holes 15 mm 0 59 in The holes on the handlebar support are placed at a distance of from the center Distance between holes 3 5 mm 0 138 in The handlebar supports can be mounted in 4 different positions EXC R SIX DAYS The handlebar supports can also be mounted at 2 different heights with and with LD 400223 11 out spacer Thick spacer 9 mm 0 35 in MAINTENANCE WORK ON CHASSIS AND ENGINE 4 Adjusting handlebar position EXC R EU EXC R AUS UK EXC R USA XCR W Remove the four screws Remove the handlebar clamp Remove the handle bar and lay it to one side Info e Protect the motorcycle and its attachments from damage by covering them Do not bend the cables and lines Remove the two screws Remove the handlebar support Check parts for damage and wear Replace damaged or worn parts Place the handlebar support in the required position Fit and tighten the two screws Specification Screw handlebar support M10 40 Nm Loctite 243 29 5 Ibf ft e Info Position the left and right handlebar supports evenly Position the handlebar e Info Make sure cables and wiring are positioned correctly Position the ha
80. engine 1 rotor pump transmission 33 76 Multidisc clutch in oil bath hydraulically activated Transmission ratio lst gear 14 36 5th gear 24 23 6th gear 26 21 Generator 12V 150 W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment type Kokusan Spark plug NGK LK AR 8A 9 Spark plug electrode gap Cooling 0 8 0 9 mm 0 031 0 035 in Water cooling permanent circulation of coolant by water pump Starting aid Electric starter kickstarter Capacity engine oil Engine oil 0 6 0 6 qt Engine oil SAE 10W 50 P 114 Capacity gear oil Gear oil Engine oil SAE 10W 50 P 114 ___ TECHNICAL DATA ENGINE TECHNICALDATA ENGINE 2 Capacity coolant 000000000000 Coolant 0 95 I 1 qt Coolant P 114 Coolant mixed ready to use P 114 TECHNICAL DATA ENGINE TIGHTENING TORQUES 1 Screw cable holder in generator cover 4 Nm 3 Ibf ft Loctite 243 Oil jet rocker arm lubrication 2 Nm 1 5 Ibf ft Loctite 243 Oil jet piston cooling 2 Nm 1 5 Ibf ft Loctite 243 Screw locking lever 6 Nm 4 4 Ibf ft Loctite 243 Screw ignition pulse generator 6 Nm 4 4 Ibf ft Loctite 243 Screw clutch spring 10 Nm 7 4 Ibf ft Locking screw for bearing 6 Nm 4 Ibf ft Loctite 243 Screw
81. environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Dismount the air filter box lid P 74 Hang the air filter holder out to the bottom and swing it to the side Remove the air filter with the air filter support Remove the air filter from the air filter support Installing the air filter Check parts for damage and wear Replace damaged or worn parts Mount the clean air filter onto the air filter support Put in both parts together position them and fix them with the air filter support e Info If the air filter is not correctly mounted dust and dirt can penetrate into the engine and can cause damage Install the air filter box lid 7 P 74 Cleaning air filter Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations e Info Do not clean the air filter with fuel or petroleum since these substances attack the foam Remove the air filter P 74 Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner P 115 e Info Only press the air filter to dry it never wring it out Oil the dry air filter with a high quality filter oil Oil for foam air filter P 115 Clean the air
82. er every race S30A Every service hours Important maintenance work to be carried out by an authorized workshop as additional order Carry out a complete fork service Carry out a complete shock absorber service Grease the steering head bearing P 46 Clean and adjust carburetor Competition use Hobby use S60A 590 5 gt Treat electric contacts with contact spray Change hydraulic clutch fluid P 76 Change the front brake fluid Change the rear brake fluid Clean spark arrestor EXC R USA XCR W USA Check wear of clutch discs Check the clutch Check measure the cylinder Change the piston Check the camshaft Change the camshaft bearing Check the lower valve spring retainer Check the cylinder head Check the valves Check the valve springs Check the radial clearance of the rocker arm rollers Check the timing chain tensioner function Check the balancer shaft Check the crankshaft run out on the bearing pin Change conrod bearing Change the crankshaft main bearing Check the transmission Check the shift mechanism Check the spring length of the oil pressure regulator valve Change glass fiber yarn filling of main silencer Replace foot brake cylinder seals Check the carburetor components 15A Every 15 service hours after every race S30A Every 30 service hours 545 E
83. es green Flasher light is switched on A 500147 01 Overview of indicator lamps EXC R SIX DAYS Possible states High beam indicator lamp lights up blue High beam is switched Press the key O to change the display mode or change to one of the setup menus Press the key to control different functions Press the key to control different functions e Info In its condition at delivery the disply mode SPEED H and SPEED ODO is acti vated 400312 01 OPERATING ELEMENTS Speedometer activation and test LAP p00 MM JE v FILI 50 00 08 SPEED WS Km h Mph Mies 000 LAP CLK H 400313 01 400314 01 Tripmaster switch Option Tripmaster switch 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 WS wheel size After the function test of the display the wheel size WS is displayed e Info 2205 mm corresponds to the size of the 21 front wheel with a series produc tion tire The display then changes to the last selected mode You can use the trip master switch to control the functions of the speedometer from the handlebar e Info The trip master is an optional accessory Setting kilometers or miles e Info If you change the unit th
84. ets into your eyes rinse imme diately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doctor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister ac cording to regulations and keep it out of the reach of children MAINTENANCE WORK ON CHASSIS AND ENGINE 79 Warning 3 Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system e Info Carry out this work with a cold engine Turn the handle Q of the fuel tap to the OFF position Figure 500137 10 P 20 No more fuel flows from the tank to the carburetor Guide the hose coming down behind the engine into a suitable container e Info Water in the float chamber results in malfunctioning Undo the screw turn it counterclockwise a few turns and drain the fuel from the float chamber Tighten screw Checking engine oil level e Info The engine oil level must be checked when the engine is cold Stand the motorcycle upright on a horizontal surface Condition Engine is cold Check the engine oil level The engine oil must be between the halfway mark and the top of the oil level viewer Ifthe engine oil level is below the specified level up the engine oil 7 P 81 Changing engine oil and oil f
85. f ft Changing gear oil cleaning gear oil screen Drain the gear oil and clean the gear oil screen P 82 Fill up with gear oil P 83 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under cold water immediately Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations e Info Drain the gear oil only when the engine is warm Stand the motorcycle on its side stand on a horizontal surface Place a suitable container under the engine Remove the gear oil drain plug Remove the gear oil screen plug Completely drain the gear oil Thoroughly clean the gear oil drain plug with a magnet Thoroughly clean the drain plug and gear oil screen with a magnet Clean the sealing surface on the engine Check parts for damage and wear Replace damaged or worn parts Refit gear oil drain plug 6 with seal ring and tighten it Specification Gear oil drain plug with magnet M12x1 5 20 Nm 14 8 Ibf ft Fit the plug for the gear oil screen and tighten it Specification Plug gear oil screen M16x1 5 20 Nm 14 8 Ibf ft 500159 10 Filling up with gear oil e Info Too little ge
86. front brake installing 58 of front brake removing 58 of rear brake changing 63 of rear brake 61 of rear brake installing 62 of rear brake removing 62 C Carburetor adjusting Idle reika ceased RR ed 77 emptying the float chamber 78 rr 77 Chain gt served RS peter ee e Rer s 50 Chain guide AC JUSTINE c oem ga sre RR eR eU s 54 Chain tension AC USEING c os eta d merae ehe aeneae WE ue Ah tke daa 52 Checking ai simam eae n EBORE Bau Rave 51 Chain wear Checking siue bue eles 52 Chassis number 8 Choke i nne Bataan delice ten EE WE 21 CLEANING x RES erate x 86 Clutch changing fluid 2222 22 52 76 checking fluid level 75 INDEX 1 40 Clutch levei i incu RUE xn 10 adjusting basic position 75 Compression damping fork adjusting osa wae Sa A 37 Compression damping high speed of shock absorber adjusting 32 Compression damping low speed of shock absorber adjusting 33 Coolant duxisset marmo B EH S 72 uus
87. gh engine speed and a slipping clutch Braking Warning Danger of accidents f you brake too hard the wheels can lock Adapt your braking to the traffic situation and the road conditions Warning Danger of accidents Reduced braking caused by spongy pressure point of front or rear brake Have the brake system checked in an authorized KTM workshop and do not ride any further Warning Danger of accidents Reduced braking due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently sandy wet or slippery surfaces use the rear brake Braking should always be completed before you go into a bend Change down to a lower gear appropriate to your road speed Onlong downhill stretches use the braking effect of the engine Change down one or two gears but do not overstress the engine In this way you have to brake far less and the brakes do not overheat ___ RIDING INSTRUCTIONS 648 Stopping parking f Warning Danger of burns Some vehicle components get very hot when the machine is driven 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 Danger of damage by the vehicle running away or falling over Always place the vehicle on a firm and even surface Note Fire hazard Some components engine radiator and exhaust system
88. hed to your vehicle Do not remove any warning labels If they are missing you or others may not recognize dangers and may therefore be injured Danger Danger that leads immediately and certainly to severe and permanent injury or death A Warning Danger that will probably lead to severe and permanent injury or death Note Danger of serious damage to machine or material Warning 3 Risk of environmental damage Read this owner s manual carefully and completely before making your first trip It contains a lot of information and tips to help you operate and handle your motorcycle Only then will you find out how to customize the motorcycle ideally for your own use and how you can protect yourself from injury The owner s manual also contains important information on servicing the motorcycle The owner s manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold The chassis number is stamped the steering head on the right The type label is fixed to the front of the steering head 1500128 10 The key number is stamped on the key strap 500125 10 The engine number is stamped on the left side of the engine under the engine sprocket 500072 10 The fork part number is stamped on the inner side of the fork stub 1 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side
89. hort 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 switch 17 Speedometer 18 Wheel speed sensor 19 Tripmaster switch optional 20 Radiator fan 21 Thermoswitch 22 Fuse radiator fan Cable colors bl black bl wh black white br brown bu blue bu wh blue white gn green gr gray re red re bl red black re wh red white wh white wh re white red ye yellow ye bl yellow black ye re yellow red according to DIN EN 228 ROZ 95 RON 95 PON 91 according to DOT Specification Use only brake fluid that complies with the specified standards see specifications on the container and that possesses the corre sponding properties KTM recommends Motorex products Supplier Motorex Motorex Brake Fluid DOT 5 1 Specification Use only suitable coolant even in countries with high temperatures Using inferior antifreeze can result in corrosion and foaming recommends Motorex products Mixture ratio Antifreeze 725 45 C 713 49 F 50 Anti corrosion antifreeze 50 distilled water Antifreeze 40 C 40 F Supplier Motorex Motorex Anti Freeze according to JASO T903 MA P 117 SAE P 117 SAE 10W 50 Specification Use only engine oils that comply with the specified standards see specifications on the container
90. id 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 further The brake fluid reservoirs of the front and rear brakes are dimensioned so that they do not need topping up with brake fluid even if the brake linings are worn MAINTENANCE WORK ON CHASSIS AND ENGINE 05 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 of accidents Reduced braking due to worn brake discs Worn brake discs should be replaced immediately by an authorized KTM workshop Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement e Info Wear reduces the thickness of the brake disc around the area used by the brake linings Wear limit of brake discs 2 5 mm 0 098 in 400257 10 3 5 mm 0 138 in The brake disc thickness is less than the specified value Replace the brake disc Checking free play of hand brake lever Warning Danger of accidents Brake system failure lf there is no free travel on the hand brake lever pressure builds up on the front brake in the brake system The front brake can fail due
91. ight 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 e Info Before riding swing the upper part of the kickstarter inwards towards the en gine Side stand Danger of damage Danger of damage by the vehicle running away or falling over Always place the vehicle on a firm and even surface Note Material damage Damage and destruction of components by excessive load side stand is designed for the weight of the motorcycle only Do not sit on the motorcycle when it is supported by the side stand only The side stand and or the frame could be damaged and the motorcycle could fall over 500140 10 To park the motorcycle press the side stand 6 with your foot to the ground and lean the motorcycle on it When you are riding the side stand must be folded up and secured with the rubber band Steering lock EXC R EU EXC R AUS UK EXC R USA The steering lock is fitted on the left of the steering head The steering lock is used to lock the steering Steering and therefore riding is no longer possible Locking the steering EXC R EU EXC R AUS UK EXC R USA Note Danger of damage Danger of damage by the vehicle running away or falling over Always place the vehicle on a firm and even surface Park the motorcycle Turn the handlebar as far as possible to the right OPERATING ELEM
92. ilter cleaning engine oil screen Drain the engine oil and clean the engine oil screen P 79 Remove the oil filter P 80 Mount the oil filter P 80 Fill up with engine P 81 Draining engine oil cleaning engine oil screen Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under cold water immediately Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations e Info Drain the engine oil only when the engine is warm Stand the motorcycle on its side stand on a horizontal surface MAINTENANCE WORK ON CHASSIS AND ENGINE 8 Place a suitable container under the engine Remove engine oil plug screen Completely drain the engine oil Thoroughly clean the plug and gear oil screen Clean the sealing area on the engine Check parts for damage and wear Replace damaged or worn parts Fit plug for the engine oil screen and tighten it Specification 200112 10 Plug engine oil screen M17x1 5 20 Nm 14 8 Ibf ft Removing the oil filter A Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable
93. in Make a note of the value as measurement e Info The static sag is the difference between measurements and Check the static sag 525555555555 555 Static sag 35 mm 1 38 in Ifthe static sag is less or more than the specified value Adjust the spring preload of the shock absorber P 35 400221 10 MAINTENANCE WORK ON CHASSIS AND ENGINE 5 Checking the riding sag of the shock absorber Measure distance of rear wheel unloaded P 34 With another person holding the motorcycle sit on the saddle with full protective clothing in a normal sitting position feet on footrests and bounce up and down a few times until the rear suspension levels out The other person now has to measure the distance between the rear axle and a fixed point Make a note of the value as measurement NY Info The riding sag is the difference between measurements and Check the riding sag Riding sag 105 mm 4 13 in Ifthe riding sag differs from the specified measurement Adjust the riding sag P 36 5 RR RRR 400222 10 Adjusting spring preload of the shock absorber Danger Danger of accidents The shock absorber is under high pressure shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any
94. in areas immediately with soap and water If fuel is swallowed contact a doctor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister ac cording to regulations and keep it out of the reach of children Remove the seat P 69 Turn the handle of the fuel tap to the OFF position Figure 500137 10 P 20 Pull off the fuel hose e Info Remaining fuel may run out of the fuel hose Remove screws with collar sleeve Every EXC R models Hang the horn and horn bracket to one side Remove screw with collar sleeve Remove the tube from the fuel tank vent line Pull both spoilers to the side of the radiator bracket and take the fuel tank away upwards j FU NU 0 Installing the fuel tank Danger Fire hazard Fuel can easily catch fire 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 Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See specifications on filling up with fuel A Warning Danger of poisoning Fuel is poisonous and a health hazard 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
95. its maintenance 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 Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bear ings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check for correct chain tension and adjust if necessary Jack up the motorcycle P 32 Push the chain at the end of the chain sliding component upwards to measure the chain tension Info e The upper chain section must be taut Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 8 10 mm 0 31 0 39 in Ifthe chain tension does not meet specifications Adjusting chain tension after checking P 53 Remove the motorcycle from the work stand P 32 Checking the chain tension when fitting rear wheel Warning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components of the sec
96. lectric starter button Starter relay with fuse Starter motor o ol NI AJAJ BY W M 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 tail light 16 Licence plate lamp 17 Speedometer 18 Wheel speed sensor 19 Tripmaster switch optional 20 Flasher switch 21 Flasher relay 22 Left front flasher 23 Left rear flasher 24 Right front flasher 25 Right rear flasher 26 Horn 27 Front brake light switch 28 Rear brake light switch 29 High beam indicator light 30 Flasher indicator light 31 Plug connector for radiator fan optional Cable colors bl black bl wh black white br brown br bl brown black bu blue bu wh blue white gn green gr gray or orange pu violet re red re bl red black re wh red white wh white wh gn white green wh re white red ye yellow ye bl yellow black ye re yellow red Wiring diagram EXC R AUS UK cwa 2 C 4 c CX3 2 C BP A Pm 5 EX 2 o E CL e P 4 lt CR1A 00026066087 02 061 5207141 66 vo UD Us 17 zl C CXi2
97. luid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children f brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediately Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan an authorized KTM workshop Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info recommends brake fluid DOT 5 1 from Motorex This brake fluid has a higher wet boiling point than brake fluid DOT 4 and offers more protection under high load Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Remove the front brake linings P 58 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir Install the front brake linings P 58 brake fluid to level
98. m 1 38 in TECHNICAL DATA CHASSIS TIGHTENING TORQUES 4 Spoke nipple front wheel 4 5 5 Nm 3 7 Ibf ft Spoke nipple rear wheel M5 5 Nm 3 7 Ibf ft Remaining nuts chassis M6 15 Nm 11 1 Ibf ft 6 m Remaining screws chassis M 10 Nm 7 4 Ibf ft Screw rear brake disc M6 14 Nm 10 3 Ibf ft Screw front brake disc M6 14 Nm 10 3 Ibf ft Screw shock absorber adjusting ring M 5 Nm 3 7 Ibf ft z Screw ball joint of push rod on foot M 10 Nm 7 4 Ibf ft brake cylinder M i 6 6 Nut rear sprocket screw 8 35 Nm 25 8 Ibf ft Loctite 243 8 Nut rim lock M 10 Nm 7 4 Ibf ft Remaining nuts chassis M8 30 Nm 22 1 Ibf ft Remaining screws chassis M8 25 Nm 18 4 Ibf ft Screw front brake caliper M8 25 Nm 18 4 Ibf ft Loctite 243 Screw top triple clamp 17 Nm 12 5 Ibf ft EXC R SIX DAYS XCR W USA Screw top triple clamp EXC R EU 20 Nm 14 8 Ibf ft EXC R AUS UK EXC R USA XCR W ZA Screw bottom triple clamp M8 12 Nm 8 9 Ibf ft EXC R SIX DAYS XCR W USA Screw bottom triple clamp EXC R EU M8 15 Nm 11 1 Ibf ft EXC R AUS UK EXC R USA XCR W ZA Screw fork stub M8 15 Nm 11 1 Ibf ft Screw top steering stem M8 17 Nm 12 5 Ibf ft Loctite 243 EXC R SIX DAYS XCR W USA Screw top steering stem EXC R EU 20 Nm 14 8 Ibf ft EXC R AUS UK EXC R USA XCR W ZA Screw handl
99. m The light switch is fitted on the left side of the handlebar Possible states Light off Light switch is turned to the right In this position the light is e switched off ZO Low beam on Light switch is in the central position In this position z the low beam and tail light are switched on High beam on Light switch is turned to the left In this position the high beam and the tail light are switched on 500134 12 ____ OPERATING ELEMENTS The light switch is on the right of the speedometer Possible states XCR W ZA e Light off Light switch is pressed in up to the stop In this position the light is switched off e Light on Light switch is pulled out to the stop In this position the low beam and tail light are switched on XCR W USA The light switch has no function when delivered It can be used if lighting is fitted later The light switch is fitted on the left side of the handlebar Possible states ZO Low beam on Light switch is turned downwards In this position the 2 low beam and tail light are switched High beam on Light switch is turned upwards this position the high D beam and the tail light are switched on The headlight flasher switch is fitted on the left side of the handlebar Possible states e Headlight flasher switch in neutral position e Headlight flasher switch pressed In this position the headlight flasher high beam is ac
100. m position it and insert the wheel spindle Put the chain on Position the chain adjuster Fit nut but do not tighten it yet Check the chain tension when fitting rear wheel 7 P 51 sure that the chain adjusters are fitted correctly on the adjusting screws Tighten nut Specification Nut rear wheel spindle M20x1 5 80 Nm 59 Ibf ft Info e The wide adjustment range of the chain adjusters 32 mm enables different secondary transmissions with the same chain length The chain adjusters can be turned by 180 Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot Remove the motorcycle from the work stand 7 P 32 i Info Fit only tires approved by KTM Other tires could have a negative effect on riding behavior The type condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle The front and rear wheels must be fitted with tires with similar profiles Worn tires have a negative effect on riding behavior especially on wet surfaces Examine the tires for cuts foreign bodies and other damage Check the depth of the tread Info Note local national regulations concerning the minimum tread depth Minimum tread depth gt 2 mm gt 0 08 in If the minimum tread depth is insufficient Replace the tire s e Info Low tire
101. maged or worn parts b Position the cover with membrane Mount and tighten screws e Info Clean up overflowed or spilt brake fluid immediately with water 400230 10 Checking the front brake linings T Warning Danger of accidents Reduced braking due to worn brake linings Worn brake linings should be replaced immediately in an authorized KTM workshop Check the brake linings for minimum thickness Minimum thickness gt 1 mm gt 0 04 in If the minimum thickness is less than specified Change the front brake linings P 59 MAINTENANCE WORK ON CHASSIS AND ENGINE 080 Removing front brake linings f Warning Danger of accidents Improper brake maintenance and repair Always have your brake system maintained and repaired in an authorized KTM workshop Press the brake caliper by hand on to the brake disc in order to press back the brake pistons e Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes Remove the locking split pins withdraw the bolt and take out the brake pads Remove cable clip Remove screws and take off brake caliper Clean brake caliper and brake caliper support Installing the front brake linings Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean
102. main tenance on it yourself e Info Before changing the spring preload make a note of the present setting e g by measuring the length of the spring Remove shock absorber P 36 After removing the shock absorber clean it thoroughly Loosen screw Turn adjusting ring until the spring is no longer under tension Combination wrench 50329080000 Hook wrench T106S Measure the overall spring length when not under tension Tighten the spring by turning adjusting ring to measurement Specification Spring preload Standard 9 mm e Info Depending on the static sag and or the riding sag it may be necessary to increase or decrease the spring preload Tighten screw Specification Screw shock absorber adjusting ring 5 Nm 3 7 Ibf ft 400216 10 _ Installing shock absorber P 36 MAINTENANCE WORK ON CHASSIS AND ENGINE s Adjusting riding sag Remove shock absorber P 36 After removing the shock absorber clean it thoroughly Choose and fit a suitable spring Specification Spring rate Weight of rider 65 75 kg 143 165 Ib 69 N mm 394 Ib in Weight of rider 75 85 kg 165 187 Ib 72 N mm 411 Ib in Weight of rider 85 95 kg 187 209 Ib 76 N mm 434 Ib in e Info The spring rate is shown on the outside of the spring Smaller weight differences can be compensated by
103. make sure that the closed side of the joint faces forward riding direction The engine sprocket rear sprocket and chain should always be re placed together Check that the chain guide is firmly seated and not worn Jack up the motorcycle P 32 Shift to neutral and pull the upper chain length with the specified tension Q Specification Chain tension 10 15 kg 22 33 Ib Measure distance of 18 chain links in the lower chain section e Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance at the longest 272 mm 10 71 in chain section If distance is greater than the specified measurement Replace the chain Info e When you replace the chain you should also replace the rear and engine sprockets New chains wear out faster on old worn sprockets Remove the motorcycle from the work stand P 32 Warning Danger of accidents Danger caused by incorrect chain tension Ifthe chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bear ings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engin
104. mpensated by the spring preload However if your fork is often overloaded hard end stop on compression you must fit harder springs to avoid damage to the fork and frame Adjusting compression damping of fork e Info The hydraulic compression damping determines the fork suspension behavior Remove protection covers Turn adjusting screws clockwise until they stop e Info The adjusting screws are located at the bottom end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise the number of clicks corresponding to the fork type Specification Compression damping EXC R EU EXC R AUS UK EXC R USA XCR W Comfort 24 clicks Standard 20 clicks Compression damping EXC R SIX DAYS Comfort 24 clicks Standard 22 clicks Sport 18 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce sus pension damping Mount protection covers Adjusting rebound damping of fork e Info The hydraulic rebound damping determines the fork suspension behavior Turn adjusting screws clockwise until they stop e Info The adjusting screws are located at the top end of the fork legs Make the same adjustment on both fork legs MAINTENANCE WORK ON CHASSIS AND ENGINE 1 3s Bleeding fork legs 100025 10 Turn back counterclockwise the number of clicks corresponding to the fork type Specification Rebound
105. mpression damping of the Shock absorber ceram rd esee une 33 Adjusting rebound damping of the shock absorber 33 Measuring rear wheel sag unloaded 34 Checking static sag of the shock absorber 34 Checking the riding sag of the shock absorber 35 Adjusting spring preload of the shock absorber 35 Adjusting riding sag V 36 Removing the shock absorber 36 Installing shock absorber 36 Checking basic setting of 37 Adjusting compression damping of fork 37 Adjusting rebound damping of 37 Adjusting spring preload of the 38 Bleeding fork 1 mnn 38 Cleaning dust boots of fork legs 39 Loosening the fork protection esses 39 Positioning the fork protection 39 Checking play of steering head 39 Adjusting play of steering head bearing EXC R EU EXC R AUS UK EXC R USA XCR W ZA 40 Adjusting play of steering head bearing EXC R SIX DAYS XCR W USA 40
106. ndlebar clamp Fit and evenly tighten the four screws Specification Screw handlebar clamp M8 20 Nm 14 8 Ibf ft e Info Make sure the gap width is even EXC R SIX DAYS Remove the four screws Remove the handlebar clamps with rubber wash ers and elastomers Remove the handlebar and lay it to one side e Info Protect the motorcycle and its attachments from damage by covering them Do not bend the cables and lines Remove the lower shells Remove the clamp bar with the rubber cones Remove the two screws Remove the handlebar support Check parts for damage and wear Replace damaged or worn parts 400343 10 MAINTENANCE WORK ON CHASSIS AND ENGINE 1 1s Checking gas Bowden cable route Mn Place the handlebar support in the required position Fit and tighten the two screws Specification Screw handlebar support M10 40 Nm Loctite 243 29 5 Ibf ft Condition Spacer fitted Use a M10x35 screw Condition without a spacer Use a M10x25 screw e Info Position the left and right handlebar supports evenly Fit the rubber cones and clamp bar Fit the lower shells Position the handlebar e Info Make sure cables and wiring are positioned correctly Position the handlebar clamps with rubber washers and elastomers Elastomer kit green soft quality SXS05125203 Elastomer kit yellow
107. ned to carry passengers Do not ride with a passenger Warning Danger of accidents Brake system failure Ifthe foot brake pedal is not released the brake linings drag permanently The rear brake can fail due to overheating Take your foot off the foot brake pedal if you do not want to brake Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permitted weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons Info When using your motorcycle remember that others may feel disturbed by excessive noise sure that the pre delivery inspection work has been carried out by an authorized KTM workshop You receive a delivery certificate and the service record at vehicle handover Before your first trip read the entire operating instructions carefully Get to know the operating elements adjust the basic position of clutch lever P 75 Every XCR W models adjust the basic position of handbrake lever P 56 Every EXC R models Adjust the free travel of the handbrake lever P 56 Adjust the basic position of the footbrake lever 7 P 60 Get used to handling the motorcycle on a suitable piece of land before making a longer trip e Info Offroad you should be accompanied by another person on another machine so th
108. ng Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info KTM recommends brake fluid DOT 5 1 from Motorex This brake fluid has a higher wet boiling point than brake fluid DOT 4 and offers more protection under high load Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Remove the rear brake linings P 62 Stand the vehicle upright Remove screw cap with membrane the O ring Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir Install the rear brake linings P 62 Add brake fluid to level Brake fluid DOT 5 1 114 400233 10 Check parts for damage and wear Replace damaged or worn parts Mount the screw cap with the membrane and the O ring e Info Clean up overflowed or spilt brake fluid immediately with water Removing front wheel Jack up the moto
109. ng to the shock ab sorber type Specification Compression damping low speed 400209 10 Comfort 18 clicks Standard 15 clicks Sport 12 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce sus pension damping Adjusting rebound damping of the shock absorber Danger Danger of accidents shock absorber is under high pressure shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any main tenance on it yourself MAINTENANCE WORK ON CHASSIS AND ENGINE Turn the adjusting screw clockwise until it stops e Info Do not loosen nut back counterclockwise the number of clicks corresponding to the shock ab sorber type Specification Rebound damping Standard 22 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce sus pension damping Measuring rear wheel sag unloaded Jack up the motorcycle P 32 Measure the distance as vertical as possible between the rear axle and a fixed point for example a mark on the side cover Make a note of the value as measurement Remove the motorcycle from the work stand P 32 Measure distance of rear wheel unloaded P 34 Ask someone to help you by holding the motorcycle upright Measure the distance between the rear axle and the fixed point aga
110. nt t o ea roe ro DEREN RI ROS 89 TECHNICAL DATA ENGINE TIGHTENING TORQUES 90 TECHNICAL DATA 92 450 EXC R EU 450 EXC R AUS UK 39001 92 450 EXC R SIX DAYS 450 EXC R USA 450 XCR W 3900 wannabes sie e SR 92 530 EXC R EU 530 EXC R AUS UK 3900 J 93 530 EXC R SIX DAYS 530 EXC R USA 530 XCR W 3900M 93 TECHNICAL DATA CHASSIS tent rat 94 Lighting equipment nen 95 Jc 95 ___CONTENTS 4 95 TEGHNIGAEDATA 96 TECHNICAL DATA SHOCK ABSORBER 97 TECHNICAL DATA CHASSIS TIGHTENING TORQUES 98 WIRING DIAGRAM 2 20 5 eto re eee ec a ed 100 Wiring diagram EXC R 100 Wiring diagram EXC R 102 Wiring diagram EXC R 05 104 Wiring diagram EXC R SIX 5 108 Wiring diagram XCR W 05 110 Wiring diagram XCR W 27 112 SUBSTANCES beh be Esse ed 114 AUXILIARY 5 5 5 2 022020 2000 0 115 STANDARD
111. o zero Press the button O for 3 5 seconds settings are saved and the Setup menu closed Info If no button is pressed for 20 seconds or if no impulse comes from the wheel speed sensor the settings are automatically saved and the Setup menu closed Adjusting speedometer functions e Info In the condition at delivery only the SPEED H display mode and SPEED 000 are active Condition The motorcycle is standing Press the button O briefly and repeatedly until H appears at the bottom right of the display Press the button O for 3 5 seconds Wem M A2 St 2 v Setup menu opens and the active functions are displayed 7 Switch to the function you require by briefly pressing the button Km h Mph 000 UP CLK H selected function flashes Activating a function Press the button 400318 01 The icon remains in the display and the display changes to the next func tion Deactivating a function Press the button v The icon disappears from the display and the display changes to the next function Activate or deactivate all functions accordingly Press the button O for 3 5 seconds The settings are saved and the Setup menu closed e Info If no button is pressed for 20 seconds if no impulse comes from the wheel speed sensor the settings are automatically saved and the Setup menu closed OPERATING ELEMENTS 58
112. oil pump cover 6 Nm a 4 Ibf ft Loctite 222 Oil jet conrod lubrication M6x0 75 4 Nm 3 Ibf ft Loctite 243 Nut water pump wheel 6 Nm 4 4 Ibf ft Loctite 6487 Screw kickstarter stop 10 Nm 7 4 Ibf ft Loctite 243 Screw timing chain securing guide 10 Nm 7 4 Ibf ft Loctite 243 Screw exhaust flange 10 Nm 7 4 Ibf ft Screw starter motor 10 Nm 4 Ibf ft Screw timing chain guide rail 10 Nm gt 4 Ibf ft Loctite 243 Screw generator cover 10 Nm 7 4 Ibf ft Screw generator cover 10 Nm 7 4 Ibf ft Screw gear oil level check M6 10 Nm 7 4 Ibf ft Screw clutch cover M6x25 10 Nm 7 4 Ibf ft Screw clutch cover 10 Nm 7 4 Ibf ft Screw engine housing 10 Nm 7 4 Ibf ft Screw engine housing 10 Nm 7 4 Ibf ft Screw camshaft bearing support 10 Nm 7 4 Ibf ft Loctite 243 Screw shift drum locating 10 Nm 7 4 Ibf ft Loctite 243 Screw shift lever 10 Nm 7 4 Ibf ft Loctite 243 Screw timing chain tensioning rail 10 Nm 7 4 Ibf ft Loctite 243 Screw stator bracket 10 Nm 7 4 Ibf ft Loctite 243 Screw valve cover 10 Nm 7 4 Ibf ft Screw water pump cover M6x25 10 Nm 7 4 Ibf ft Screw water pump cover M6x55 10 Nm 7 4 Ibf ft Screw idler 10 Nm 7 4 Ibf ft Loctite 243 Screw cylinder head 10 Nm 7 4 Ibf ft Screw rocker arm bearing 15 Nm 11 1 Ibf ft Plug channel 9 Nm 6 6 Ibf ft Loctite 243 Screw kickstarter 25 Nm
113. on e 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 Check the engine oil level 79 Check the chain tension P 51 Check the chain dirt accumulation 7 P 50 Check the tire condition 7 P 66 Checking the tire air pressure P 66 Check the front brake fluid level P 56 Check the rear brake fluid level 7 60 Check the front brake linings P 57 Check the rear brake linings P 61 Check brake system function Check the coolant level P 72 Check that all operating elements are correctly adjusted and free to move Check the functioning of the electrical equipment Starting Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in a closed space Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always warm up the engine at low engine speeds Info If the motorcycle is unwilling to start the cause can be old fuel in the float chamber The flammable elements of the fuel evaporate after a long time of standing If the float chamber is filled with fresh fuel the engine sta
114. on running engine will not start Ignition on In this position the ignition circuit is closed and the en gine can be started ____ OPERATING ELEMENTS 4 Emergency OFF switch EXC R USA The emergency OFF switch is fitted on the left side of the handlebar Possible states Ignition off In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start Ignition on In this position the ignition circuit is closed and the en gine can be started 500144 10 The ignition switch is on the right behind the headlight mask Possible states Ignition off In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start Ignition on In this position the ignition circuit is closed and the en gine can be started Electric starter button EXC R EU EXC R SIX DAYS EXC R USA XCR W The electric starter button is fitted on the right side of the handlebar Possible states e Electric starter button in basic position e Electric starter button pressed In this position the electric starter is actuated The electric starter button is fitted on the right side of the handlebar Possible states e Electric starter button in basic position e Electric starter button pressed In this position the electric starter is actuated Light switch EXC R EU EXC R AUS UK EXC R SIX DAYS EC M
115. on the spark plug If there is no spark change the spark plug If there is still no spark remove the spark plug cap from the ignition cable hold it at the specified distance from the ground contact and try to start the engine Specification 5 mm 0 2 in If you now have a spark replace the spark plug connector If there is no spark have the ignition system checked Short circuit cable in cable harness frayed short circuit button or emergency OFF switch defective Check wiring harness visual check Check electrical system Socket connector of CDI control device pulse generator or ignition coil oxidized Clean socket connector and treat it with contact spray Faults Engine turns but does not start Possible cause Water in carburetor or jets blocked Measure Clean carburetor Engine has no idle Engine does not speed up Idling jet blocked Clean carburetor Adjusting screws on carburetor distorted Have the carburetor adjusted Spark plug defective Change spark plug Ignition system defective Have ignition system checked Carburetor running over because float needle dirty or worn Have carburetor checked Loose carburetor jets Have carburetor checked Electronic ignition adjustment defective Have ignition system checked Engine has too little power Fuel feed interrupted Air filter very dirty Exhaust system leaky defo
116. ondary power train chain engine sprocket rear sprocket bear ings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check for correct chain tension and adjust if necessary sure that the chain adjusters are fitted correctly on the adjusting screws Push the chain at the end of the chain sliding component upwards to measure chain tension Info e The upper chain section must be taut Chain wear is not always even so you should repeat this measurement at different chain positions 11002134 Chain tension 8 10 mm 0 31 0 39 in Ifthe chain tension does not meet specifications Adjust the chain tension when fitting rear wheel P 54 Checking the rear sprocket engine sprocket for wear G9 9C 56969 v 400227 01 Checking chain wear B Ei OO OX X O ma O 123 16 17 18 400226310 Adjusting the chain tension Check the rear sprocket engine sprocket for wear Ifthe rear sprocket engine sprocket are worn Replace rear sprocket engine sprocket e Info When fitting the chain joint always
117. operation and routing without sharp bends Check the fluid level of the hydraulic clutch P 75 Clean the air filter P 75 Check cables for damage and routing without sharp bends Check that the electrical equipment is functioning properly Check the headlamp setting Brakes Chassis Wheels Check the front brake linings P 57 Check the rear brake linings P 61 Check the brake discs P 55 Check the front brake fluid level P 56 Check the rear brake fluid level P 60 Check brake lines for damage and leakage Check the free play of the hand brake lever P 55 Check the free play of the foot brake lever P 59 Check brake system function Check screws and guide bolts of brake system for tightness Check shock absorber and fork for leakage and functioning Clean dust boots of fork legs P 39 Bleed fork legs P 38 Check swingarm bearing Check play of steering head bearing P 39 Check all screws to see if they are tight Check the spoke tension 67 Check rim run out Check the tire condition P 66 Checking the tire air pressure P 66 Check the chain wear P 52 Check the chain tension P 51 Clean the chain P 50 Check wheel bearing for play Clean and grease adjusting screws of chain adjuster S3N After 3 service hours 15A Every 15 service hours aft
118. orcycle from the work stand 7 P 32 500084 11 Pull the front wheel brake and push down hard on the fork several times to align the fork legs Fully tighten screw Specification Screw fork stub M8 15 Nm 11 1 Ibf ft Jack up the motorcycle P 32 Press the brake caliper by hand on to the brake disc in order to press back the brake piston e info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut Remove chain adjuster Withdraw the wheel spindle only enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket Holding the rear wheel withdraw the wheel spindle Take the rear wheel out of the swing arm e Info Do not operate the foot brake when the rear wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged Remove the spacing sleeves f Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Check parts for damage and wear Replace damaged or worn parts Clean and grease shaft seal rings and bearing surface of the spacing sleeves Long life grease P 115 Fit the spacing sleeves Lift the rear wheel into the swing ar
119. oughly Empty the carburetor float chamber P 78 Warning Danger of accidents Reduced braking due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently After cleaning ride the vehicle a short distance until the engine warms up and then apply the brakes e Info The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate Push back the protection covers on the handlebar instruments to allow water to evaporate After the motorcycle has cooled off oil or grease all moving parts and bearings Clean the chain P 50 Treat bare metal parts except for brake discs and exhaust system with anti corrosion materials Cleaning and polishing materials for metal rubber and plastic P 115 Treat all painted parts with a mild paint polish High luster polish for paint P 116 To prevent electrical problems treat electric contacts and switches with contact spray Contact spray P 116 EXC R EU EXC R AUS UK EXC R USA Lubricate the steering lock Universal oil spray P 115 STORAGE Storage T Warning Danger of poisoning Fuel is poisonous and a health hazard 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 immediatel
120. out fuse only by an equivalent fuse Refit the fuse Fuse 58011109110 400273 10 Info If the new fuse burns out contact an authorized KTM workshop Replace the protection cover Install the air filter box lid 9 P 74 Removing the seat Remove screw Lift up the seat at the rear pull it back and then remove from above Check parts for damage and wear Replace damaged or worn parts Hook the front of the seat into the flange adapter of the fuel tank lower the rear of the seat and simultaneously push it forwards sure that the seat is correctly locked in Mount and tighten the screw of the seat fixing Specification IW CAR 500068 01 MAINTENANCE WORK ON CHASSIS AND ENGINE Dismounting the fuel tank Danger Fire hazard Fuel can easily catch fire 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 Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See specifications on filling up with fuel Warning Danger of poisoning Fuel is poisonous and a health hazard 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 sk
121. pen the radiator radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down If you scald yourself hold the affected area under cold water immediately Warning Danger of poisoning Coolants are poisonous and a health hazard Avoid contact between coolants and skin eyes and clothing If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor im mediately Change clothes that have come into contact with coolants Keep coolants out of the reach of children ____ MAINTENANCE WORK ON CHASSIS AND ENGINE Stand the motorcycle upright on a horizontal surface Remove the radiator cap Check antifreeze of coolant 7 25 45 C 713 49 F If the antifreeze of the cooling liquid does not meet specifications Correct antifreeze of coolant Check the coolant level in the radiator 400243 10 Coolant level above radiator fins 10 mm 0 39 in Ifthe level of the cooling liquid does not meet specifications Correct the coolant level Alternative 1 Coolant P 114 Alternative 2 Coolant mixed ready to use 7 P 114 Refit the radiator cap Checking the coolant level Warning Danger of scalding coolant gets very hot when the motorcycle is driven and is under high pressur
122. port 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 e Info The motorcycle must be used only on secluded property remote from public road traffic The motorcycle is designed for off road sport endurance competition Enduro and not for the predominant motocross use A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in the owner s manual are properly carried out Poor adjustment and tuning of the engine and chassis can lead to damage and break age of components Using the motorcycle in extreme conditions such as very muddy or wet terrain can lead to above average wear of components such as the transmission train or the brakes For this reason it may be necessary to service or replace worn parts before the limit specified in the greasing and service table is reached Pay careful attention to the prescribed running in period inspection and maintenance intervals If you observe these exactly you will ensure a much longer service life for your motorcycle The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed in the customer s service record since otherwise no warranty claims will be recognized No warranty claims can be consi
123. r position 3i enc tcm enr DER ERE 47 Adjusting handlebar position 48 Checking gas Bowden cable route 49 Checking play in the gas Bowden cable 50 Adjusting the gas Bowden cable play 50 Checking chain uideatur atte ute reds 50 Cleanihg the chalh c ce 50 Checking the chain tension 22222 51 Checking the chain tension when fitting rear wheel 51 Checking the rear sprocket engine sprocket for wear 52 Checking chain 2 52 Adjusting the chain tension esee 52 Adjusting chain tension after 53 Adjusting chain tension fitting rear wheel 54 Adjusting chain guide 54 Brake fluid 0 54 a 55 Checking brake 15 5 55 Checking free play of hand brake lever 55 Adjusting basic position of handbrake lever Every XCR W nct 56 Adjusting free travel of handbrake lever Every EXC R 56 Checking the front brake fluid 56 Topping up the front brake fluid
124. rcycle P 32 Press the brake caliper by hand on to the brake disc in order to press back the brake pistons e Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes 500089 10 Remove screw Loosen screw 500084 10 MAINTENANCE WORK ON CHASSIS AND ENGINE 1 amp Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork e 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 500085 10 Y Remove distance bushing J T Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Check parts for damage and wear Replace damaged or worn parts Clean and grease shaft seal rings 9 and bearing surface of the distance bush ings Long life grease P 115 Ta Fit the distance bushings ug N Lift the front wheel into the fork position it and insert the wheel spindle Mount and tighten screw Specification Screw front wheel spindle M24x1 5 40 Nm 29 5 Ibf ft Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc Remove the mot
125. rmed or too lit tle glass fiber yarn filling in main silencer Valve clearance too little Check tank vent Clean fuel tap Clean carburetor Check exhaust system for damage Change glass fiber yarn filling of main silencer Have valve clearance adjusted Electronic ignition adjustment defective Have ignition system checked Engine stalls or is popping into the carbu retor Lack of fuel Engine takes in bad air Clean and check the fuel system and carburetor Check rubber sleeves and carburetor for tightness Engine overheats High oil consumption Battery discharged Too little coolant in cooling system Check the cooling system for leakage Check the coolant level P 72 Too little air stream Switch off engine when standing Radiator fins very dirty Foam formation in cooling system Clean radiator fins Drain the coolant P 72 Refill the coolant P 73 Bent radiator hose Thermostat defective Replace the radiator hose Have thermostat removed and checked Specification Opening temperature 70 C 158 F Defect in radiator fan system EXC R SIX DAYS XCR W ZA Engine vent hose bent Have the radiator fan system checked Route the vent hose without bends or replace it if necessary Engine oil level too high Engine oil too thin low viscosity Battery is not charged by generator Check the engine oil level 7 P 79
126. rrosion e Info Avoid running the engine for a short time only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust Putting into operation after storage Remove the motorcycle from the work stand P 32 Install the battery P 67 Fill up with fuel P 28 Checks before putting into operation P 26 Make a test ride Design Displacement Every 450 models Displacement Every 530 models Stroke Every 450 models l cyliner 4 stroke engine water cooled 449 3 cm 27 418 cu in 510 4 cm 31 147 cu in 63 4 mm 2 496 in Stroke Every 530 models 72 mm 2 83 in Bore 95 mm 3 74 in Compression ratio Idle speed Control Valve diameter intake Valve diameter exhaust 11 9 1 1550 1650 rpm 4 valves controlled via rocker arm drive via tooth wheel chain 39 5 mm 1 555 in 31 7 mm 1 248 in Valve clearance Outfeed at 20 C 68 F 0 12 0 17 mm 0 0047 0 0067 in Infeed at 20 C 68 F Crankshaft bearing Conrod bearing Piston pin bearing Pistons 0 10 0 15 mm 0 0039 0 0059 in 2 grooved ball bearings Needle bearing not a bearing bush DLC plated piston pins Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Primary transmission Clutch Pressure circulation lubrication with 2 rotor pumps
127. rts immediately Press the starter for a maximum of 5 seconds Wait for a least 5 seconds until trying again Conditions Motorcycle standing still 2 1 week Empty the carburetor float chamber P 78 Turn the handle of the fuel tap to the ON position Figure 500137 10 P 20 Fuel can flow from the tank to the carburetor Remove the motorcycle from the stand Shift gear to neutral EXC R USA Turn the key in the ignition switch to the position O Turn the emergency OFF switch to the position O EXC R AUS UK Turn the emergency OFF switch to the position Conditions Engine cold EXC R AUS UK EXC R SIX DAYS EXC R USA XCR W Pull choke lever out as far as possible EXC R EU Pull the choke lever to the stop RIDING INSTRUCTIONS 040 Press the electric starter button or press the kickstarter robustly through its full range e Info Don t open the throttle Conditions Engine hot and running Push back the hot start lever to the stop with the engine running Starting up e Info If your bike has lights switch them on before riding You will then be seen earlier by other motorists When you are riding the side stand must be folded up and secured with the rubber band Pull the clutch lever engage lst gear release the clutch lever slowly and simultaneously open the throttle carefully Shifting riding Warning Danger of accidents f you chang
128. s Rebound damping EXC R SIX DAYS Comfort 20 clicks Standard 20 clicks Sport 18 clicks 510 mm 20 08 in EXC R USA XCR W 165 Ib 4 4 N mm 25 1 Ib in Air chamber length Weight of rider 75 85 kg 165 187 Ib 4 6 N mm 26 3 Ib in Weight of rider 85 95 kg 187 209 Ib 4 8 N mm 27 4 Ib in Spring rate EXC R SIX DAYS Weight of rider 65 75 kg 143 165 Ib Weight of rider 75 85 kg 165 187 Ib 10049 mm 3 943118 in 0 79 Spring preload Preload Adjuster EXC R EU EXC R AUS UK EXC R USA XCR W Fork oil P 114 Standard 4 turns Sport 7 turns Spring preload Preload Adjuster EXC R SIX DAYS Comfort 2 turns Standard 2 turns SAE 5 TECHNICAL DATA SHOCK ABSORBER 4 Shock absorber part number EXC R EU EXC R AUS UK EXC R USA XCR W Shock absorber part number EXC R SIX DAYS Shock absorber WP PDS 5018 DCC Compression damping low speed Comfort 18 clicks Standard 15 clicks Sport 12 clicks Compression damping high speed Standard 1 5 turns Sport 1 turn Rebound damping Comfort 24 clicks Spring preload Standard 9 Spring rate Weight of rider 65 75 kg 143 165 Ib 69 N mm 394 Ib in Weight of rider 75 85 kg 165 187 Ib Weight of rider 85 95 kg 187 209 Ib 76 N mm 434 Ib in Spring length 250 mm 9 84 in Gas pressure 10 bar 145 psi Static sag 35 m
129. s hotter in sporting use If the procedure described here does not lead to satisfactory results the cause may be a wrongly dimensioned idling jet If you can turn the idle adjusting screw to the end without any change of engine speed you have to fit a smaller idling jet The idle adjusting screw must not be opened more than two turns If more than two turns are necessary rich mixture use a larger idling jet After changing the idling jet start from the beginning with the adjusting steps Adjust the idle speed with the adjusting screw Specification Choke function deactivated The choke lever is pushed in to the stop P 21 Choke function deactivated The choke lever is pushed back to the stop P 21 Idle speed 1550 1650 rpm e Info Following extreme air temperature or altitude changes adjust the idle speed again Emptying the carburetor float chamber Danger Fire hazard Fuel can easily catch fire 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 Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See specifications on filling up with fuel A Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel g
130. s are poisonous and can result in uncon sciousness and or death When running the engine always make sure there is sufficient ventila 200115 10 tion and do not start or run the engine in a closed space Start the engine and check that it is oil tight Check the engine oil level P 79 e Info Too little engine oil or poor quality engine oil results in premature wear to the engine Remove the screw cap on the generator cover and fill up with engine oil Engine oil SAE 10W 50 P 114 Mount and tighten screw cap Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon sciousness and or death When running the engine always make sure there is sufficient ventila 200115 10 tion and do not start or run the engine in a closed space Start the engine and check that it is oil tight Check the engine oil level P 79 e Info The gear oil level must be checked when the engine is cold Stand the motorcycle upright on a horizontal surface MAINTENANCE WORK ON CHASSIS AND ENGINE Condition Engine is cold Remove gear oil level check screw Stand the vehicle upright Check the gear oil level A small amount of gear oil should flow out If no gear oil flows out up with gear oil 7 P 83 200116 10 Mount and tighten the gear oil level check screw Specification Screw gear oil level check M6 10Nm 7 4 Ib
131. s 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 further Warning Skin irritations Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children If brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediately Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan an authorized KTM workshop Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations e Info KTM recommends brake fluid DOT 5 1 from Motorex9 This brake fluid has a higher wet boiling point than brake fluid DOT 4 and offers more protection under high load Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Stand the vehicle upright Remove screw cap with membrane and the O ring Add brake fluid to level Brake fluid DOT 5 1 114 Check parts for damage and wear Replace damaged or
132. s or open fire Charge only in well ventilated rooms Inthe event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Warning ae Environmental hazard Components and battery acid are a danger to the environment Do not dispose of batteries in normal household waste Take defective or used batteries to a battery recycling operator Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Even if there is no load on the battery it loses power every day The charge state and the type of charge are very important for the service life of the battery Fast recharging with a high charge current shortens the battery s service life If the charge current the charge voltage and the charge time are exceeded electrolyte escapes through the breathing holes The battery capacity is then reduced If the battery is discharged from starting it must be recharged immediately If it stands for a long time in a discharged state the battery becomes over discharged and sulfated and then it is destroyed The battery is maintenance free i e the acid level does not have to be checked Switch off all power consuming components and switch off the engine Remove the seat P 69 Disconnect the minus neg
133. sis Chee repas 10 Emergency OFF switch EXC R 10 Emergency OFF switch EXC R USA 11 Ignition switch EXC R 05 2 4 1 2 11 Electric starter button EXC R EU EXC R SIX DAYS EXC R USA XCR W i een eee netten eara re e ees 11 Electric starter button EXC R AUS UK 11 Light switch EXC R EU EXC R AUS UK EXCsR SIX DAYS 11 Light switch EVERY XCR W MODELS 12 Light switch EXC R 05 2 12 Headlight flasher switch EXC R USA 12 Horn EXC R EU EXC R AUS UK EXC R SIX DAYS 12 Horn EXC R USA sent eus Norte weeny 12 Flasher switch EXC R EU EXC R AUS UK 13 Flasher switch EXC R 05 1 13 Overview of indicator lamps EXC R EU EXC R AUS UK EXC R USA iste n erbe c p Due Pu ded ln ht esl 13 Overview of indicator lamps EXC R SIX DAYS 13 Speedometet iiis cine eek rose vede 13 Speedometer activation and 14 Tripmaaster SwITCh 14 Setting kilometers or 2 2 14 Setting the clock uti e receta 15 Adjusting speedometer functions 15 Querying lap
134. t Using a plastic hammer tap lightly on the upper triple clamp to avoid strains Fully tighten screw Specification 100022 10 Screw top triple clamp M8 20 Nm 14 8 Ibf ft Tighten screw Specification Screw top steering stem M8 20 Nm 14 8 Ibf ft Check play of steering head bearing P 39 Adjusting play of steering head bearing EXC R SIX DAYS XCR W USA Jack up the motorcycle P 32 Loosen screw Remove screw Loosen and retighten screw Specification Screw top steering head M20x1 5 10 Nm 7 4 Ibf ft Using plastic hammer tap lightly on the upper triple clamp to avoid strains Fully tighten screw Specification Screw top triple clamp M8 17 Nm 12 5 Ibf ft Mount and tighten screw Specification Screw top steering stem M8 17 Nm 12 5 Ibf ft Loctite 243 Check play of steering head bearing 39 Fork offset EXC R SIX DAYS XCR W USA 400188 10 You see the currently set offset if you remove screw The fork offset 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 head bearing The fork offset can optionally be adjusted Marking to the front gives greater stability on fast racetracks Fork offset Front marking 18 mm 0 71 in Marking to the rear condition at deli
135. tain special equipment that does not belong to the regular scope of delivery 2007 by KTM Sportmotorcycle AG Mattighofen Austria All rights reserved Reproduction even in part is permitted only with the express written permission of the copyright owner 150 9001 12 100 6061 Within the meaning of the international quality management standard ISO 9001 KTM uses quality assurance processes m LM mw that lead to the maximum possible quality of the products 7 Issued by T V Management Service 1 KTM Sportmotorcycle AG 5230 Mattighofen Austria MEANS OF REPRESENTATION 5 IMPORTANT NOTES 42 eras etait is adh debi E Raga ds 6 LOCATION OF SERIAL 2 1 1 8 Ghassis n mb6r E RE ete ec teres 8 8 Key number EXC R EU EXC R AUS UK EXC R USA 8 Engine number D OE Mee fe t eee 8 Fork part number 45 ere cet can od ree 8 Shock absorber part 9 OPERATING 10 Clutch lever s use e nue c A t uem eva ce dec 10 Hand brake lIeVer iieo irent edP coL de Rue ites 10 Short circuit button EVERY XCR W MODELS 10 Short circuit button EXC R EU EXC R AUS UK EXC R SIX DAYS ries Deme pier te
136. them with brake cleaner when necessary Warning Danger of accidents Reduced braking due to use of non approved brake linings Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construc tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings If brake linings are used that differ from the originals there is no guarantee that they comply with the origi nal license The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid Check the brake discs P 55 Check parts for damage and wear Replace damaged or worn parts Check that leaf spring in the brake caliper and sliding plate the brake caliper support are seated correctly e Info The arrow on the leaf spring points in the rotation direction of the brake disc Fit the brake linings insert bolt and mount locking split pins Position brake caliper mount and tighten screws Specification Screw front brake caliper M8 25 Nm Loctite 243 18 4 Ibf ft Fit cable clip Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot 500089 12 MAINTENANCE WORK ON CHASSIS AND ENGINE 9 Changing the front brake linings 36 Warning Skin irritations Brake f
137. to overheating Adjust free travel on hand brake lever according to specifications Every XCR W models Push the hand brake lever forwards and check free play Free play of hand brake lever gt 20 12 in Ifthe free travel does not meet specifications adjust the basic position of handbrake lever P 56 Every EXC R models Push the hand brake to the handlebar and check free play Free play of hand brake lever 23mm gt 0 12 Ifthe free travel does not meet specifications Adjust the free travel of the handbrake lever P 56 400196 13 MAINTENANCE WORK ON CHASSIS AND ENGINE 5 Adjusting basic position of handbrake lever Every XCR W models Adjust the basic setting of the handbrake lever to your hand size by turning adjust ing screw e Info Turn the adjusting screw clockwise to increase the distance between the handbrake lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the handbrake lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force 400196 12 Ner Do not make any adjustments while riding Check the free play of the hand brake lever P 55 Adjusting free travel of handbrake lever Every EXC R models Adjust the free travel of the handbrake lever with the adjustment screw e Info Turn
138. tuated 500143 10 Horn EXC R EU EXC R AUS UK EXC R SIX DAYS The horn button is fitted the left side of the handlebar i Possible states e Horn button in neutral position e Horn button pressed The horn is operated in this position Horn EXC R USA The horn button is fitted on the left side of the handlebar Possible states e Horn button in neutral position e Horn button pressed The horn is operated in this position 500142 11 OPERATING ELEMENTS gt 3 3 Flasher switch EXC R EU EXC R AUS UK The flasher switch is fitted on the left side of the handlebar Possible states Flasher light off Flasher switch is in the central position a Flasher light left on Flasher switch turned to the left gt Flasher light right on Flasher switch turned to the right 500145 10 The flasher switch is fitted on the left side of the handlebar Possible states Flasher light off Flasher light left on Flasher switch pressed to the right The flasher Ex switch returns automatically to the central position after use Flasher light right on Flasher switch pressed to the right The flasher switch returns automatically to the central position after use To switch off the flasher light press the flasher switch towards the switch case High beam indicator lamp lights up blue High beam is switched Flasher indicator lamp flash
139. very gives better handling in bends Fork offset Rear marking 20 mm 0 79 in Setting the fork offset EXC R SIX DAYS XCR W USA 500104 10 Remove the lower triple clamp P 43 Remove screw Remove the steering stem Clean the parts and check for damage Rotate the steering stem 180 and insert into the triple clamp Mount and tighten screw Specification Screw bottom steering M20x1 5 60 Nm Loctite 243 head 44 3 Ibf ft Install the lower triple clamp P 44 Remove front wheel P 63 Remove screws and take off clamp Remove cable clip remove screw and take off the brake caliper Hang the brake caliper and the brake line loosely to the side EXC R SIX DAYS XCR W USA Loosen screw Remove the fork leg on the left Loosen screw Remove the fork leg on the right MAINTENANCE WORK ON CHASSIS AND ENGINE 042 EXC R EU EXC R AUS UK EXC R USA XCR W ZA Loosen screw Remove the fork leg on the left Loosen screw Remove the fork leg on the right Check parts for damage and wear Replace damaged or worn parts Position the fork legs Info e topmost sunk nut in the fork leg must be flush to the upper edge of the upper triple clamp Position the bleeder screw to the front EXC R SIX DAYS XCR W USA Fully tighten screw Specification Screw top triple clamp
140. very 45 service hours S60A Every 60 service hours S90A Every 90 service hours J1A annually J2A every 2 years Important checks and maintenance work to be carried out by the rider Check the engine oil level 7 P 79 Check the front brake fluid level 7 P 56 Check the rear brake fluid level P 60 Check the front brake linings P 57 Check the rear brake linings P 61 Check and adjust Bowden cables Bleed fork legs P 38 Clean dust boots of fork legs P 39 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 7 75 Checking the tire air pressure 7 P 66 Check the tire condition 7 P 66 Check the coolant level 7 P 72 Empty the carburetor float chamber P 78 Check that all operating elements for smooth operation Check braking Check all screws nuts and hose clamps regularly for tightness NB1A Depending on conditions of use according to requirements MAINTENANCE WORK ON CHASSIS AND ENGINE 1o Note Danger of damage Danger of damage by the vehicle running away or falling over Always place the vehicle on a firm and even surface Jack up the motorcycle underneath the engine The wheels must no longer touch the ground Work stand 548290550
141. vironmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Open the filler cap P 20 Fill the fuel tank with fuel up to measurement Specification Measurement of Q 35 mm 1 38 in Tank capacity 91 2 4 US gal Super unleaded ROZ 95 RON 95 EXC R EU EXC PON 91 114 R AUS UK EXC R SIX DAYS XCR gt 400382 lo W ZA Tank capacity 9 21 Super unleaded ROZ 95 RON 95 EXC R USA XCR 2 43 US gal PON 91 P 114 W USA Close the filler cap P 20 Important maintenance work to be carried out by an authorized workshop Engine Carburetor 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 spark plug Check and adjust valve clearance Check engine mounting screws for tightness Clean spark plug connectors and check for tightness Check that the screws in the shift lever and the kickstarter are tight Check carburetor connection boots for cracks and leakage Check vent hoses for damage and routing without sharp bends Check idle Attachments Check the cooling system for leakage Check the antifreeze and coolant level P 71 Check the exhaust system for leakage and looseness Check Bowden cables for damage smooth
142. with push rod turn it back until you have maximum free play adjust the basic position of the footbrake lever individually lossen nut and turn screw accordingly e Info The range of adjustment is limited Turn push rod accordingly until you have free play If necessary adjust the basic position of the footbrake lever Specification Free play at foot brake lever 3 5 0 12 0 2 Hold screw and tighten nut Specification Remaining nuts chassis M8 30 Nm 22 1 Ibf ft Hold push rod and tighten nut Specification Remaining nuts chassis M6 15 Nm 11 1 Ibf ft Reconnect spring Checking the rear brake fluid level T Warning Danger of accidents Brake system failure Ifthe 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 further Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop Stand the vehicle upright Check the brake fluid level in the viewer When in the viewer air bubble is visible rear brake fluid P 61 A Warning Danger of accidents Brake system failure Ifthe brake fluid level falls below the MIN mark thi
143. y with soap and water If fuel is swallowed contact a doctor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister ac cording to regulations and keep it out of the reach of children Info If you want to garage the motorcycle for a longer period take the following actions Before storing the motorcycle check all parts for function and wear If service repairs or replacements are necessary you should do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season Clean the motorcycle P 86 Change the engine oil and oil filter and clean the engine oil screen 79 Change the gear oil and clean the gear oil screen P 82 Check the antifreeze and coolant level P 71 Drain the fuel from the tanks into a suitable container Empty the carburetor float chamber P 78 Checking the tire air pressure P 66 Remove the battery P 67 Recharge the battery P 68 Specification Storage temperature of battery without direct sunshine 0 35 C 32 95 F The storage place should be dry and not subject to large temperature differences e Info KTM recommends propping up the motorcycle Jack up the motorcycle P 32 Cover the motorcycle with a porous sheet or blanket Do not use non porous materials since they prevent humidity from escaping thus causing co

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