XC R EU, 450 EXC R AUS UK, 450 EXC R SIX DAYS, 450 EXC R USA, 450 XCR W UsA, 450 XCR W ZA, 530 EXC R EU, 530 EXC R AUS UK, 530 EXC R SIX DAYS, 530 EXC R USA, 530 XCR W USA, 530 XCR W ZA User Manual
OWNER'S MANUAL 2008  
450bEXC-RbEU  
450bEXC-RbAUS/UK  
450bEXC-RbSIXbDAYS  
450bEXC-RbUSA  
450bXCR-WbUSA  
450bXCR-WbZA  
530bEXC-RbEU  
530bEXC-RbAUS/UK  
530bEXC-RbSIXbDAYS  
530bEXC-RbUSA  
530bXCR-WbUSA  
530bXCR-WbZA  
ART. NO. 3211254en  
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DEAR KTM CUSTOMER  
1
'($5 .70 &86720(5  
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will  
give you enormous pleasure if you service and maintain it accordingly.  
We wish you great pleasure riding the vehicle!  
Enter the serial numbers of your vehicle below.  
Chassis number ( P. 8)  
Dealer's stamp  
Engine number ( P. 8)  
Key number (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA) ( 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 contain 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.  
ISO 9001(12 100 6061)  
Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes  
that lead to the maximum possible quality of the products.  
Issued by: TÜV Management Service  
KTM-Sportmotorcycle AG  
5230 Mattighofen, Austria  
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CONTENTS  
2
&217(176  
Locking the steering (EXC-RbEU, EXC-RbAUS/UK,  
MEANS OF REPRESENTATION ............................................ 5  
EXC-RbUSA).................................................................. 22  
IMPORTANT NOTES............................................................ 6  
LOCATION OF SERIAL NUMBERS........................................ 8  
Chassis number............................................................... 8  
Type label....................................................................... 8  
Key number (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA) ........ 8  
Engine number................................................................ 8  
Fork part number............................................................. 8  
Shock absorber part number............................................. 9  
OPERATING ELEMENTS.................................................... 10  
Clutch lever .................................................................. 10  
Hand brake lever ........................................................... 10  
Short circuit button (EVERY XCR-W MODELS).................. 10  
Unlocking the steering (EXC-RbEU, EXC-RbAUS/UK,  
EXC-RbUSA).................................................................. 23  
GENERAL TIPS AND HINTS ON PUTTING INTO  
OPERATION...................................................................... 24  
Advice on first use......................................................... 24  
Running in the engine.................................................... 25  
RIDING INSTRUCTIONS.................................................... 26  
Checks before putting into operation ............................... 26  
Starting........................................................................ 26  
Starting up ................................................................... 27  
Shifting, riding.............................................................. 27  
Braking ........................................................................ 27  
Stopping, parking.......................................................... 28  
Refueling...................................................................... 28  
GREASING AND SERVICE TABLE....................................... 29  
Short circuit button (EXC-RbEU, EXC-RbAUS/UK,  
EXC-RbSIXbDAYS) .......................................................... 10  
Emergency OFF switch (EXC-RbAUS/UK).......................... 10  
Emergency OFF switch (EXC-RbUSA) ............................... 11  
Ignition switch (EXC-RbUSA)........................................... 11  
Electric starter button (EXC-RbEU, EXC-RbSIXbDAYS,  
EXC-RbUSA, XCR-W)...................................................... 11  
Electric starter button (EXC-RbAUS/UK)........................... 11  
Important maintenance work to be carried out by an  
authorized KTM workshop. ............................................. 29  
Important maintenance work to be carried out by an  
authorized KTM workshop. (as additional order)................ 30  
Important checks and maintenance work to be carried  
out by the rider. ............................................................ 30  
Light switch (EXC-RbEU, EXC-RbAUS/UK,  
EXC-RbSIXbDAYS) .......................................................... 11  
MAINTENANCE WORK ON CHASSIS AND ENGINE.............. 32  
Jacking up the motorcycle.............................................. 32  
Removing the motorcycle from the work stand.................. 32  
Light switch (EVERY XCR-W MODELS) ............................ 12  
Light switch (EXC-RbUSA) .............................................. 12  
Headlight flasher switch (EXC-RbUSA) ............................. 12  
Horn (EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS) ......... 12  
Horn (EXC-RbUSA)......................................................... 12  
Flasher switch (EXC-RbEU, EXC-RbAUS/UK) ..................... 13  
Flasher switch (EXC-RbUSA) ........................................... 13  
Checking the basic chassis setting with the rider's  
weight.......................................................................... 32  
Compression damping of shock absorber.......................... 32  
Adjusting high-speed compression damping of the shock  
absorber ....................................................................... 32  
Adjusting the low-speed compression damping of the  
shock absorber.............................................................. 33  
Overview of indicator lamps (EXC-RbEU, EXC-RbAUS/UK,  
EXC-RbUSA).................................................................. 13  
Overview of indicator lamps (EXC-RbSIXbDAYS)................. 13  
Speedometer................................................................. 13  
Speedometer activation and test ..................................... 14  
Tripmaster switch.......................................................... 14  
Setting kilometers or miles............................................. 14  
Setting the clock........................................................... 15  
Adjusting speedometer functions .................................... 15  
Querying lap time.......................................................... 16  
Display mode SPEED..................................................... 16  
Display mode SPEED/H (service hours)............................ 16  
Display mode SPEEDb/bCLK (time)................................... 17  
Display mode SPEED/LAP (lap time) ............................... 17  
Display mode SPEED/ODO (odometer)............................. 17  
Display mode SPEED/TR1 (trip masterb1) ........................ 17  
Display mode SPEED/TR2 (trip master 2) ........................ 18  
Disply mode SPEED/A1 (average speedb1) ....................... 18  
Display mode SPEED/A2 (average speed 2)...................... 18  
Display mode SPEED/S1 (stop watch 1) .......................... 19  
Display mode SPEED/S2 (stop watchb2)........................... 19  
Fuel tap........................................................................ 20  
Opening filler cap.......................................................... 20  
Closing filler cap ........................................................... 20  
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 absorberbx............ 35  
Adjusting riding sagbx.................................................. 36  
Removing the shock absorberbx..................................... 36  
Installing shock absorberbx........................................... 36  
Checking basic setting of fork......................................... 37  
Adjusting compression damping of fork ........................... 37  
Adjusting rebound damping of fork.................................. 37  
Adjusting spring preload of the fork................................. 38  
Bleeding fork legs.......................................................... 38  
Cleaning dust boots of fork legs ...................................... 39  
Loosening the fork protection.......................................... 39  
Positioning the fork protection........................................ 39  
Adjusting play of steering head bearingb  
Checking play of steering head bearing.x........................... 39  
(EXC-RbEU,  
Adjusting play of steering head bearingb  
(EXC-RbSIXbDAYS, XCR-WbUSA) ...................................... 40  
EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZAx) ......................... 40  
Setting the fork offsetb  
Fork offset (EXC-RbSIXxbDAYS, XCR-WbUSA)...................... 41  
(EXC-RbSIXbDAYS,  
Choke (EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA,  
XCR-W) ........................................................................ 21  
XCR-WbUSA) ................................................................. 41  
Removing the fork legs................................................... 41  
Installing the fork legsbx  
Choke (EXC-RbEU)......................................................... 21  
Shift lever..................................................................... 21  
Foot brake pedal ........................................................... 21  
Kickstarter.................................................................... 22  
Side stand .................................................................... 22  
Steering lock (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA)..... 22  
Removing the fork protectorb  
....x........................................... 42  
........................................ 43  
Installing the fork protectorb  
x....................................... 43  
Removing the lower triple clampbx(EXC-RbSIXbDAYS,  
XCR-WbUSA) ................................................................. 43  
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CONTENTS  
3
Removing the lower triple clampbx(EXC-RbEU,  
Installing the batterybx................................................. 67  
Recharging the batterybx.............................................. 68  
Removing a fuse............................................................ 69  
Replacing the fuse......................................................... 69  
Removing the seat......................................................... 69  
Mounting the seat ......................................................... 69  
EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA) ......................... 44  
Installing the lower triple clampbx(EXC-RbSIXbDAYS,  
XCR-WbUSA) ................................................................. 44  
Installing the lower triple clampbx(EXC-RbEU,  
EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA) ......................... 45  
Greasing the steering head bearingbx............................. 46  
Dismounting the front fender.......................................... 46  
Installing the front fender............................................... 46  
Removing headlight mask with headlight (EXC-RbEU,  
EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA,  
XCR-WbZA).................................................................... 46  
Refitting the headlight mask with the headlight  
(EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS,  
EXC-RbUSA, XCR-WbZA) ................................................. 47  
Dismount the start number plate (XCR-WbUSA) ................ 47  
Fitting the start number plate (XCR-WbUSA)..................... 47  
Handlebar position ........................................................ 47  
Adjusting handlebar positionbx...................................... 48  
Checking gas Bowden cable route ................................... 49  
Checking play in the gas Bowden cable ........................... 50  
Adjusting the gas Bowden cable playbx.......................... 50  
Checking chain dirt ....................................................... 50  
Cleaning the chain......................................................... 50  
Checking the chain tension ............................................ 51  
Checking the chain tension when fitting rear wheel........... 51  
Checking the rear sprocket / engine sprocket for wear ....... 52  
Checking chain wear...................................................... 52  
Adjusting the chain tension............................................ 52  
Adjusting chain tension - after checking .......................... 53  
Adjusting chain tension - fitting rear wheel ...................... 54  
Adjusting chain guidebx............................................... 54  
Brake fluid reservoir....................................................... 54  
Brake calipers............................................................... 55  
Checking brake discs ..................................................... 55  
Checking free play of hand brake lever............................. 55  
x
......................................... 70  
.............................................. 70  
Installing the fuel tankb  
Dismounting the fuel taxnkb  
Cooling system.............................................................. 71  
Checking antifreeze and coolant level.............................. 71  
Checking the cooxlant level.............................................. 72  
Refilling coolantb  
Draining coolantbx....................................................... 72  
....................................................... 73  
Glass fiber yarn filling of main silencer............................ 73  
Removing main silencer................................................. 73  
Fitting the main silencer ................................................ 74  
Dismounting the air filter box lid..................................... 74  
Installing the air filter box lid.......................................... 74  
Removing the air filterbx  
Installing the air filterb  
x............................................... 74  
............................................... 75  
Cleaning air filterbx...................................................... 75  
Adjusting basic position of clutch lever............................ 75  
Checking fluid level of hydraulic clutch ........................... 75  
Changing fluid level of hydraulic clutchbx...................... 76  
Carburetor - idle............................................................ 77  
Carburetor - adjusting idlebx......................................... 77  
Emptying the carburetor float chamberbx....................... 78  
Checking engine oil level................................................ 79  
Changing engine oil and oil filter, cleaning engine oil  
screenbx..................................................................... 79  
x
............ 79  
............................................... 80  
Removing the oil filterb  
Draining engine oil, clexaning engine oil screenb  
Mounting oil filterbx..................................................... 80  
Filling up with engine oilbx........................................... 81  
Topping up engine oil .................................................... 81  
Checking gear oil level ................................................... 81  
x
Adjusting basic position of handbrake lever (Every XCR-W  
models)........................................................................ 56  
Adjusting free travel of handbrake lever (Every EXC-R  
Changing gear oil, cleaning gear oil screenxb .................. 82  
................... 82  
Filling up with gear oilb  
Draining gear oil, cleanxing gear oil screenb  
............................................... 83  
models)........................................................................ 56  
Checking the front brake fluid level................................. 56  
Topping up the front brake fluidbx................................. 56  
Checking the front brake linings...................................... 57  
Removing front brake liningsbx  
Topping up with gear oilbx............................................ 83  
TROUBLESHOOTING......................................................... 84  
CLEANING........................................................................ 86  
Cleaning motorcycle ...................................................... 86  
STORAGE......................................................................... 87  
Storage......................................................................... 87  
Putting into operation after storage ................................. 87  
TECHNICAL DATA - ENGINE.............................................. 88  
Capacity - engine oil ...................................................... 88  
Capacity - gear oil.......................................................... 88  
Capacity - coolant.......................................................... 89  
TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 90  
TECHNICAL DATA - CARBURETOR..................................... 92  
450bEXC-RbEU, 450bEXC-RbAUS/UK (3900I)................... 92  
.x..................................... 58  
................................. 59  
Changing the front brake liningsb  
Installing the front brake liningsbx................................. 58  
Checking free play of foot brake lever .............................. 59  
Adjusting basic position of footbrake leverbx................... 60  
Adding rear brake fluidb  
Checking the rear brakexfluid level .................................. 60  
.............................................. 61  
Removing rear brake liningsb  
Checking rear brake linings .x........................................... 61  
....................................... 62  
x
Changing the rear brake liningsb  
Installing the rear brake liningsbx.................................. 62  
Removing front wheelbx................................................ 63  
Fitting front wheelbx.................................................... 64  
Removing rear wheelbx................................................. 65  
Fitting rear wheelbx...................................................... 65  
Tire condition checking.................................................. 66  
Checking tire air pressure............................................... 66  
Checking spoke tension.................................................. 67  
Removing the batterybx................................................ 67  
.................................. 63  
450bEXC-RbSIXbDAYS, 450bEXC-RbUSA, 450bXCR-W  
(3900L) ....................................................................... 92  
530bEXC-RbEU, 530bEXC-RbAUS/UK (3900J)................... 93  
530bEXC-RbSIXbDAYS, 530bEXC-RbUSA, 530bXCR-W  
(3900M) ...................................................................... 93  
TECHNICAL DATA - CHASSIS ............................................ 94  
Lighting equipment ....................................................... 95  
Tires ............................................................................ 95  
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CONTENTS  
4
Capacity - fuel............................................................... 95  
TECHNICAL DATA - FORK.................................................. 96  
TECHNICAL DATA - SHOCK ABSORBER ............................. 97  
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ........ 98  
WIRING DIAGRAM .......................................................... 100  
Wiring diagram (EXC-RbEU) .......................................... 100  
Wiring diagram (EXC-RbAUS/UK)................................... 102  
Wiring diagram (EXC-RbUSA) ........................................ 104  
Wiring diagram (EXC-RbSIXbDAYS)................................. 108  
Wiring diagram (XCR-WbUSA) ....................................... 110  
Wiring diagram (XCR-WbZA).......................................... 112  
SUBSTANCES................................................................. 114  
AUXILIARY SUBSTANCES................................................ 115  
STANDARDS................................................................... 117  
CONSUMER INFORMATION (EXC-R USA).......................... 118  
INDEX............................................................................ 120  
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MEANS OF REPRESENTATION  
5
ꢀ0($16 2) 5(35(6(17$7,21  
Symbols used  
The symbols used are explained in the following.  
Indicates an expected reaction (e.g. of a work step or a function).  
Indicates an unexpected reaction (e.g. of a work step or a function).  
All work marked with this symbol requires specialist knowledge and technical understanding. In 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.  
Identifies a page reference (more information is provided on the specified page).  
Formats used  
The typographical and other formats used are explained in the following.  
Specific name  
Identifies a specific name.  
Name®  
Identifies a protected name.  
Brand™  
Identifies a brand in merchandise traffic.  
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IMPORTANT NOTES  
6
ꢁ,03257$17 127(6  
Use definition (Every EXC-R models)  
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com-  
ply with currently valid regulations and categories of the top international motorsport organizations.  
Info  
The motorcycle is authorized for 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.  
Use definition (Every XCR-W models)  
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com-  
ply with currently valid regulations and categories of the top international motorsport organizations.  
Info  
The motorcycle 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.  
Maintenance  
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.  
Warranty  
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 considered for  
damage resulting from manipulations and alterations to the motorcycle.  
Fuel, oils, etc.  
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.  
Spare parts, accessories  
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.  
Transport  
Note  
Danger of damageಘDanger of damage by the vehicle running away or falling over.  
ದ
Always place the vehicle on a firm and even surface.  
Note  
Fire hazardಘSome components (engine, radiator and exhaust system) get very hot when the engine is running.  
ದ
Do not place the vehicle where there are flammable or explosive substances.  
ದ
ದ
ದ
switch off engine.  
Turn the handlebꢀ of the fuel tap to the OFF position. (Figureb500137-10b P. 20)  
Use straps or other suitable devices to secure the motorcycle against accidents or falling over.  
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IMPORTANT NOTES  
7
Environment  
Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a poten-  
tial problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can en-  
sure that such problems and conflicts do not 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.  
Warning notes  
In your own interest, read the specified warning notes.  
Info  
Various warning labels are attached 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.  
Grades of risks  
Danger  
Danger that leads immediately and certainly to severe and permanent injury or death.  
Warning  
Danger that will probably lead to severe and permanent injury or death.  
Note  
Danger of serious damage to machine or material.  
Warning  
Risk of environmental damage.  
OWNER'S MANUAL  
ದ
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.  
ದ
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.  
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LOCATION OF SERIAL NUMBERS  
8
ꢂ/2&$7,21 2) 6(5,$/ 180%(56  
Cꢂꢃꢀ hassis number  
The chassis numberbꢀ is stamped on the steering head on the right.  
500127-10  
ꢂ
ꢃꢁ  
The type labelbꢀ is fixed to the front of the steering head.  
500128-10  
ꢂ
ꢃꢂ  
ey number (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA)  
The key numberbꢀ is stamped on the key strap.  
500125-10  
500072-10  
500082-10  
ꢂ
ꢃꢄ  
ngine number  
The engine numberbꢀ is stamped on the left side of the engine under the engine  
sprocket.  
ꢂ
The fork part numberbꢀ is stamped on the inner side of the fork stub.  
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LOCATION OF SERIAL NUMBERS  
9
ꢂ
ꢃꢆ  
The shock absorber part numberbꢀ is stamped on the top of the shock absorber above  
the adjusting ring on the engine side.  
500129-10  
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OPERATING ELEMENTS  
10  
ꢄ23(5$7,1* (/(0(176  
Cꢄꢃꢀ lutch lever  
The clutch leverbꢀ is fitted on the left side of the handlebar.  
The clutch is hydraulically operated and self-adjusting.  
500133-10  
ꢄ
ꢃꢁ  
The hand brake leverbꢀ is located on the right side of the handlebar and operates the  
front wheel brake.  
400196-10  
ꢄ
ꢃꢂ  
The short circuit buttonbꢀ is mounted on the left side of the handlebar.  
Possible states  
•
Short circuit button b in basic position ದbIn this position, the ignition circuit is  
closed, and the engine can be started.  
•
Short circuit buttonb pressed ದbIn this position, the ignition circuit is interrupted,  
a running engine stops, and a non-running engine will not start.  
500132-10  
ꢄ
ꢃꢄ  
hort circuit button (EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS)  
The short circuit buttonbꢀ is fitted on the left side of the handlebar.  
Possible states  
•
•
Short circuit buttonb in basic position ದbIn this position, the ignition circuit is  
closed, and the engine can be started.  
Short circuit button b pressed ದbIn this position, the ignition circuit is  
interrupted, a running engine stops, and a non-running engine will not start.  
500134-10  
ꢄ
ꢃꢅ  
mergency OFF switch (EXC-RbAUS/UK)  
The emergency OFF switchbꢀ is fitted on the left side of the handlebar.  
Possible states  
Ignition off ದbIn this position, the ignition circuit is interrupted, a running  
engine stops, and a non-running engine will not start.  
Ignition on ದbIn this position, the ignition circuit is closed, and the en-  
gine can be started.  
500131-10  
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OPERATING ELEMENTS  
11  
ꢄ
ꢃꢆ  
mergency OFF switch (EXC-RbUSA)  
The emergency OFF switchbꢀ is fitted on the left side of the handlebar.  
Possible states  
Ignition off ದbIn this position, the ignition circuit is interrupted, a running  
engine stops, and a non-running engine will not start.  
Ignition on ದbIn this position, the ignition circuit is closed, and the en-  
gine can be started.  
500144-10  
ꢄ
ꢃꢇ  
gnition switch (EXC-RbUSA)  
The ignition switchbꢀ is on the right behind the headlight mask.  
Possible states  
Ignition off ದbIn this position, the ignition circuit is interrupted, a running  
engine stops, and a non-running engine will not start.  
Ignition on ದbIn this position, the ignition circuit is closed, and the en-  
gine can be started.  
500130-10  
ꢄ
ꢃꢈ  
lectric starter button (EXC-RbEU, EXC-RbSIXbDAYS, EXC-RbUSA, XCR-W)  
The electric starter buttonbꢀ is fitted on the right side of the handlebar.  
Possible states  
•
•
Electric starter buttonb in basic position  
Electric starter buttonb pressed ದbIn this position, the electric starter is actuated.  
400198-10  
ꢄ
ꢃꢉ  
lectric starter button (EXC-RbAUS/UK)  
The electric starter buttonbꢀ is fitted on the right side of the handlebar.  
Possible states  
•
•
Electric starter buttonb in basic position  
Electric starter buttonb pressed ದbIn this position, the electric starter is actuated.  
500131-11  
ꢄ
ꢃꢀꢊ  
ight switch (EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS)  
The light switchbꢀ is fitted on the left side of the handlebar.  
Possible states  
Light off ದbLight switch is turned to the right. In this position, the light is  
switched off.  
Low beam on ದbLight switch is in the central position. In this position,  
the low beam and tail light are switched on.  
High beam on ದbLight switch is turned to the left. In this position, the  
high beam and the tail light are switched on.  
500134-12  
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OPERATING ELEMENTS  
12  
ꢄ
ꢃꢀꢀ  
ight switch (EVERY XCR-W MODELS)  
The light switchbꢀ is on the right of the speedometer.  
Possible states  
(XCR-WbZA)  
•
Light off ದbLight switch is pressed in up to the stop. In this position, the light  
is switched off.  
•
Light on ದbLight switch is pulled out to the stop. In this position, the low beam  
and tail light are switched on.  
(XCR-WbUSA)  
The light switch has no function when delivered. ದbIt can be used if lighting is  
fitted later.  
•
500146-10  
ꢄ
ꢃꢀꢁ  
ight switch (EXC-RbUSA)  
The light switchbꢀ is fitted on the left side of the handlebar.  
Possible states  
Low beam on ದbLight switch is turned downwards. In this position, the  
low beam and tail light are switched on.  
High beam on ದbLight switch is turned upwards. In this position, the high  
beam and the tail light are switched on.  
500142-10  
ꢄ
ꢃꢀꢂ  
eadlight flasher switch (EXC-RbUSA)  
The headlight flasher switchbꢀ is fitted on the left side of the handlebar.  
Possible states  
•
•
Headlight flasher switch in neutral position  
Headlight flasher switch pressed ದbIn this position, the headlight flasher (high  
beam) is actuated.  
500143-10  
ꢄ
ꢃꢀꢄ  
orn (EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS)  
The horn buttonbꢀ is fitted on the left side of the handlebar.  
Possible states  
•
•
Horn buttonb in neutral position  
Horn buttonb pressed ದbThe horn is operated in this position.  
500134-11  
ꢄ
ꢃꢀꢅ  
orn (EXC-RbUSA)  
The horn buttonbꢀ is fitted on the left side of the handlebar.  
Possible states  
•
•
Horn buttonb in neutral position  
Horn buttonb pressed ದbThe horn is operated in this position.  
500142-11  
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OPERATING ELEMENTS  
13  
ꢄ
ꢃꢀꢆ  
lasher switch (EXC-RbEU, EXC-RbAUS/UK)  
The flasher switchbꢀ is fitted on the left side of the handlebar.  
Possible states  
Flasher light off ದbFlasher switch is in the central position.  
Flasher light, left, on ದbFlasher switch turned to the left.  
Flasher light, right, on ದbFlasher switch turned to the right.  
500145-10  
ꢄ
ꢃꢀꢇ  
lasher switch (EXC-RbUSA)  
The flasher switchbꢀ is fitted on the left side of the handlebar.  
Possible states  
Flasher light off  
Flasher light, left, on ದbFlasher switch pressed to the right. The flasher  
switch returns automatically to the central position after use.  
Flasher light, right, on ದbFlasher 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.  
500142-12  
ꢄ
ꢃꢀꢈ  
verview of indicator lamps (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA)  
Possible states  
High beam indicator lamp lights up blue ದbHigh beam is switched on.  
Flasher indicator lamp flashes green ದbFlasher light is switched on.  
500147-01  
ꢄ
ꢃꢀꢉ  
verview of indicator lamps (EXC-RbSIXbDAYS)  
Possible states  
High beam indicator lamp lights up blue ದbHigh beam is switched on.  
500160-01  
ꢄ
ꢃꢁꢊ  
peedometer  
ದ
ದ
ದ
Press the key b to change the display mode or change to one of the setup menus.  
Press the key b"+" to control different functions.  
Press the key b"ತ" to control different functions.  
Info  
In its condition at delivery, the disply mode SPEED/H and SPEED/ODO is acti-  
vated.  
400312-01  
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OPERATING ELEMENTS  
14  
ꢄ
ꢃꢁꢀ  
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.  
400313-01  
WS (wheel size)  
After the function test of the display, the wheel size WS is displayed.  
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.  
400314-01  
ꢄ
ꢃꢁꢁ  
(Option: Tripmaster switch)  
You can use the trip master switch to control the functions of the speedometer from the handlebar.  
Info  
The trip master is an optional accessory.  
ꢄ
ꢃꢁꢂ  
etting kilometers or miles  
Info  
If you change the unit, the ODO value is retained and converted accordingly.  
The values TR1, TR2, A1, A2 and S1 are deleted at the changeover.  
Condition  
The motorcycle is standing.  
ದ
Press the buttonb briefly and repeatedly until H appears at the bottom right of the  
display.  
ದ
Press the buttonb for 3 - 5 seconds.  
The Setup menu opens and the active functions are displayed.  
ದ Press the button b repeatedly until the Km/h / Mphdisplay flashes.  
Setting Km/h  
ದ Press the buttonb"+".  
Setting Mph  
ದ
Press the buttonb"ತ".  
400329-01  
ದ
Press the buttonb for 3 - 5 seconds.  
The 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.  
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OPERATING ELEMENTS  
15  
ꢄ
ꢃꢁꢄ  
Condition  
The motorcycle is standing.  
ದ
Press the button b briefly and repeatedly until CLK appears at the bottom right of  
the display.  
ದ
Press the buttonb for 3 - 5 seconds.  
The hour display flashes.  
ದ
ದ
Set the hour display with the buttonb"+" and/or buttonb"ತ".  
Press the buttonb briefly.  
The next segment of the display flashes and can be set.  
ದ
You can set the following segments in the same way as the hours by pressing the  
buttonb"+" and the buttonb"ತ".  
400330-01  
Info  
The seconds can only be set to zero.  
ದ
Press the buttonb for 3 - 5 seconds.  
The 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.  
ꢄ
ꢃꢁꢅ  
djusting speedometer functions  
Info  
In the condition at delivery, only the SPEEDb/bH display mode and SPEEDb/bODO are active.  
Condition  
The motorcycle is standing.  
ದ
Press the buttonb briefly and repeatedly until H appears at the bottom right of the  
display.  
ದ
Press the buttonb for 3 - 5 seconds.  
The Setup menu opens and the active functions are displayed.  
ದ
Switch to the function you require by briefly pressing the buttonb .  
The selected function flashes.  
Activating a function  
Press the buttonb"+".  
ದ
400318-01  
The icon remains in the display and the display changes to the next func-  
tion.  
Deactivating a function  
Press the buttonb"ತ".  
ದ
The icon disappears from the display and the display changes to the next  
function.  
ದ
ದ
Activate or deactivate all functions accordingly.  
Press the buttonb for 3 - 5 seconds.  
The 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.  
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OPERATING ELEMENTS  
16  
ꢄ
ꢃꢁꢆ  
uerying lap time  
Info  
This function can be called only if lap times are measured.  
Condition  
The motorcycle is standing.  
ದ
Press the buttonb briefly and repeatedly until LAP appears at the bottom right of  
the display.  
ದ
Press the buttonb briefly.  
The LAPb1 is displayed on the left of the display.  
Laps 1-10 can be displayed by pressing the buttonb"+".  
buttonb"ತ" no function  
ದ
ದ
ದ
Press the buttonb briefly.  
next display mode  
400321-01  
Info  
If an impulse is received from the wheel speed sensor, the left side of the  
display changes back to SPEED mode.  
ꢄ
ꢃꢁꢇ  
ದ
Press the buttonb briefly and repeatedly until SPEED appears on the left of the  
display.  
In the SPEED display mode, the current speed is displayed.  
The 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.  
400317-02  
ꢄ
ꢃꢁꢈ  
isplay mode SPEED/H (service hours)  
Condition  
The motorcycle is standing  
ದ
Press the buttonb 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.  
Info  
The service hour counter is necessary for ensuring that maintenance work is car-  
ried out at the right intervals.  
400316-01  
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 buttonb"+". No function  
Press the buttonb"ತ". No function  
Press the buttonb  
for 3 - 5 seconds.  
Press the buttonb  
briefly.  
The display changes to the Setup menu of the speedometer  
functions.  
Next display mode  
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OPERATING ELEMENTS  
17  
ꢄ
ꢃꢁꢉ  
isplay mode SPEEDb/bCLK (time)  
ದ
Press the button b briefly and repeatedly until CLK appears at the bottom right of  
the display.  
The time is displayed in CLK display mode.  
Press the buttonb"+". no function  
Press the buttonb"ತ". no function  
Press the buttonb  
for 3 - 5 seconds.  
Press the buttonb  
briefly.  
The display changes to the Setup menu of the clock.  
next display mode  
400319-01  
ꢄ
ꢃꢂꢊ  
isplay mode SPEED/LAP (lap time)  
ದ
Press the buttonb 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.  
Info  
If the lap time continues after you press the buttonb"ತ", 9 memory locations are  
already occupied.  
Lap 10 must be timed with the buttonb"+".  
400320-01  
Press the buttonb"+". Starts or stops the clock.  
Press the buttonb"ತ". Stops the current lap time and saves it, and the stop watch  
starts the next lap.  
Press the buttonb  
for 3 - 5 seconds.  
Press the buttonb  
briefly.  
The stop watch and the lap time are reset.  
Next display mode  
ꢄ
ꢃꢂꢀ  
isplay mode SPEED/ODO (odometer)  
ದ
Press the buttonb briefly and repeatedly until ODO appears at the bottom right of  
the display.  
In ODO display mode, the total number of kilometers ridden is displayed.  
Press the buttonb"+". No function  
Press the buttonb"ತ". No function  
Press the buttonb  
for 3 - 5 seconds.  
Press the buttonb  
briefly.  
ದ
Next display mode  
400317-01  
ꢄ
ꢃꢂꢁ  
isplay mode SPEED/TR1 (trip masterb1)  
ದ
Press the buttonb briefly and repeatedly until TR1 appears at the top right of the  
display.  
TR1 (trip masterb1) 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).  
Info  
If 999.9 is exceeded, the values of TR1, A1 and S1 are automaticallt reset to  
0.0.  
400323-01  
Press the buttonb"+". No function  
Press the buttonb"ತ". No function  
Press the buttonb  
for 3 - 5 seconds.  
Press the buttonb  
briefly.  
Displays of TR1, A1 and S1 are reset to 0,0.  
Next display mode  
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OPERATING ELEMENTS  
18  
ꢄ
ꢃꢂꢂ  
isplay mode SPEED/TR2 (trip master 2)  
ದ
Press the buttonb briefly and repeatedly until TR2 appears at the top right of the  
display.  
TR2 (trip masterb2) runs constantly and counts up to 999.9.  
The displayed value can be set manually with the button b"+" and the buttonb"ತ". 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-  
tonb"+" and the buttonb"ತ".  
If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0.  
400324-01  
Press the buttonb"+". Increases value of TR2.  
Press the buttonb"ತ". Reduces value of TR2.  
Press the buttonb  
for 3 - 5 seconds.  
Press the buttonb  
briefly.  
Deletes value of TR2.  
Next display mode  
ꢄ
ꢃꢂꢄ  
isply mode SPEED/A1 (average speedb1)  
ದ
Press the buttonb 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 buttonb"+". No function  
Press the buttonb"ತ". No function  
Press the buttonb  
Displays of TR1, A1 and S1 are reset to 0,0.  
400325-01  
for 3 - 5 seconds.  
Press the buttonb  
briefly.  
Next display mode  
ꢄ
ꢃꢂꢅ  
isplay mode SPEED/A2 (average speed 2)  
ದ
Press the buttonb briefly and repeatedly until A2 appears at the top right of the  
display.  
A2 (average speed 2) shows the average speed on the basis of the current speed if the  
stop watch S2 (stop watchb2) is running.  
Info  
The displayed value can differ from the actual average speed if S2 was not  
timed after the ride.  
400326-01  
Press the buttonb"+". No function  
Press the buttonb"ತ". No function  
Press the buttonb  
for 3 - 5 seconds.  
Press the buttonb  
briefly.  
ದ
Next display mode  
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OPERATING ELEMENTS  
19  
ꢄ
ꢃꢂꢆ  
isplay mode SPEED/S1 (stop watch 1)  
ದ
Press the buttonb 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 buttonb"+". No function  
Press the buttonb"ತ". No function  
Press the buttonb  
for 3 - 5 seconds.  
Press the buttonb  
briefly.  
Displays of TR1, A1 and S1 are reset to 0,0.  
400327-01  
Next display mode  
ꢄ
ꢃꢂꢇ  
isplay mode SPEED/S2 (stop watchb2)  
ದ
Press the buttonb 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 buttonb"+". Starts or stops S2.  
Press the buttonb"ತ". No function  
Press the buttonb  
for 3 - 5 seconds.  
Press the buttonb  
briefly.  
Displays of S2 and A2 are reset to 0.0.  
Next display mode  
400328-01  
Overview of speedomer functions  
Display  
Press the buttonb"+".  
Press the buttonb"ತ".  
Press the buttonb for 3 - Press the buttonb  
5 seconds.  
briefly.  
Display mode SPEED/H  
(service hours)  
No function  
no function  
No function  
no function  
The display changes to  
the Setup menu of the  
speedometer functions.  
Next display mode  
Display mode  
SPEEDb/bCLK (time)  
The display changes to  
the Setup menu of the  
clock.  
next display mode  
Next display mode  
Display mode SPEED/LAP Starts or stops the  
(lap time)  
Stops the current lap  
The stop watch and the  
lap time are reset.  
clock.  
time and saves it, and  
the stop watch starts  
the next lap.  
Display mode  
SPEED/ODO (odometer)  
No function  
No function  
ದ
Next display mode  
Display mode SPEED/TR1 No function  
(trip masterb1)  
No function  
Displays of TR1, A1 and Next display mode  
S1 are reset to 0,0.  
Display mode SPEED/TR2 Increases value of TR2.  
(trip master 2)  
Reduces value of TR2.  
No function  
Deletes value of TR2.  
Next display mode  
Disply mode SPEED/A1  
(average speedb1)  
No function  
Displays of TR1, A1 and Next display mode  
S1 are reset to 0,0.  
Display mode SPEED/A2  
(average speed 2)  
No function  
No function  
ದ
Next display mode  
Display mode SPEED/S1  
(stop watch 1)  
No function  
No function  
Displays of TR1, A1 and Next display mode  
S1 are reset to 0,0.  
Display mode SPEED/S2  
(stop watchb2)  
Starts or stops S2.  
No function  
Displays of S2 and A2  
are reset to 0.0.  
Next display mode  
Overview of conditions and ability to be enabled  
Display  
The motorcycle is  
standing  
Menu can be en-  
abled  
Display mode SPEED  
Display mode SPEED/H (service hours)  
Display mode SPEEDb/bCLK (time)  
•
•
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OPERATING ELEMENTS  
20  
Overview of conditions and ability to be enabled  
Display  
The motorcycle is  
standing  
Menu can be en-  
abled  
Display mode SPEED/LAP (lap time)  
•
Display mode SPEED/ODO (odometer)  
Display mode SPEED/TR1 (trip masterb1)  
Display mode SPEED/TR2 (trip master 2)  
Disply mode SPEED/A1 (average speedb1)  
Display mode SPEED/A2 (average speed 2)  
Display mode SPEED/S1 (stop watch 1)  
Display mode SPEED/S2 (stop watchb2)  
•
•
•
•
•
•
ꢄ
ꢃꢂꢈ  
The fuel tap is on the left of the fuel tank.  
With the tap handlebꢀ on the fuel tap, you can open or close the supply of fuel to the  
carburetor.  
Possible states  
•
•
Fuel supply closed OFF ದbNo fuel can flow from the tank to the carburetor.  
Fuel supply open ON ದbFuel can flow from the tank to the carburetor. The fuel tank  
empties down to the reserve.  
•
Reserve fuel supply open RES ದbFuel can flow from the tank to the carburetor. The  
fuel tank empties completely.  
500137-10  
400199-10  
400199-11  
ꢄ
ꢃꢂꢉ  
ದ
Press release buttonbꢀ, turn filler cap counterclockwise and lift it free.  
ꢄ
ꢃꢄꢊ  
ದ
Replace the filler cap and turn clockwise until the release buttonbꢀ locks in place.  
Info  
Run the fuel tank breather hosebꢁ without kinks.  
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OPERATING ELEMENTS  
21  
ꢄ
ꢃꢄꢀ  
hoke (EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA, XCR-W)  
The chokebꢀ is fitted on the left side of the carburetor.  
Activating the choke function frees an opening through which the engine can draw ex-  
tra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.  
Info  
If the engine is warm, the choke function must be deactivated.  
Possible states  
•
•
Choke function activated ದbThe choke lever is pulled out to the stop.  
Choke function deactivated ದbThe choke lever is pushed in to the stop.  
500135-10  
ꢄ
ꢃꢄꢁ  
hoke (EXC-RbEU)  
The flasher switchbꢀ 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.  
Info  
If the engine is warm, the choke function must be deactivated.  
Possible states  
•
•
Choke function activated ದbThe choke lever is pulled to the stop.  
Choke function deactivated ದbThe choke lever is pushed back to the stop.  
500136-10  
ꢄ
ꢃꢄꢂ  
hift lever  
The shift leverbꢀ is mounted on the left side of the engine.  
500138-10  
The gear positions can be seen in the photograph.  
The neutral or idle position is between the first and second gears.  
500138-11  
ꢄ
ꢃꢄꢄ  
The foot brake pedalbꢀ is located in front of the right footrest and operates the rear  
wheel brake.  
500139-10  
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OPERATING ELEMENTS  
22  
ꢄ
ꢃꢄꢅ  
The kickstarterbꢀ is fitted on the right of the engine.  
The engine can be started with either the kickstarter or the electric starter.  
The upper part of the kickstarter can be swung out.  
Info  
Before riding, swing the upper part of the kickstarter inwards towards the en-  
gine.  
500148-10  
ꢄ
ꢃꢄꢆ  
Note  
Danger of damageಘDanger of damage by the vehicle running away or falling over.  
ದ
Always place the vehicle on a firm and even surface.  
Note  
Material damageಘDamage and destruction of components by excessive load.  
ದ
The 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 standbꢀ with your foot to the ground and lean  
the motorcycle on it.  
When you are riding, the side standbꢀ must be folded up and secured with the rubber  
bandbꢁ.  
500141-10  
ꢄ
ꢃꢄꢇ  
teering lock (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA)  
The steering lockbꢀ 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.  
500126-10  
ꢄ
ꢃꢄꢈ  
ocking the steering (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA)  
Note  
Danger of damageಘDanger of damage by the vehicle running away or falling over.  
ದ
Always place the vehicle on a firm and even surface.  
ದ
ದ
Park the motorcycle.  
Turn the handlebar as far as possible to the right.  
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OPERATING ELEMENTS  
23  
ದ
Insert the key in the steering lock, turn it to the left, press it in and turn it to the right. Remove the key.  
Steering is no longer possible.  
Info  
Never leave the key in the steering lock.  
ꢄ
ꢃꢄꢉ  
nlocking the steering (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA)  
Insert the key in the steering lock, turn it to the left, pull it out and turn it to the right. Remove the key.  
You can now steer the bike again.  
ದ
Info  
Never leave the key in the steering lock.  
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GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION  
24  
ꢅ*(1(5$/ 7,36 $1' +,176 21 3877,1* ,172 23(5$7,21  
A
dvice on first use  
Danger  
Danger of accidentsಘDanger from inadequate traffic experience.  
ದ
Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs.  
Warning  
Risk of injuryಘRisk of injury by missing/inadequate protective clothing.  
ದ
Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle.  
Warning  
Danger of crashingಘImpairment of riding behavior due to different tire tread patterns on front and rear wheels.  
ದ
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 accidentsಘCritical riding behavior due to inappropriate riding.  
ದ
Adapt your riding speed to the road conditoins and your riding ability.  
Warning  
Danger of accidentsಘAccident risk caused by presence of a passenger.  
ದ
Your vehicle is not designed to carry passengers. Do not ride with a passenger.  
Warning  
Danger of accidentsಘBrake system failure.  
ದ
If the 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 accidentsಘUnstable riding behavior.  
ದ
Do not exceed the maximum permitted weight and axle loads.  
Warning  
Risk of misappropriationಘUsage by unauthorized persons.  
ದ
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.  
ದ
Make 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.  
ದ
ದ
ದ
adjust the basic position of clutch lever. ( P. 75)  
(Every XCR-W models)  
ದ adjust the basic position of handbrake lever. ( P. 56)  
(Every EXC-R models)  
ದ
Adjust the free travel of the handbrake lever. ( P. 56)  
ದ
ದ
Adjust the basic position of the footbrake lever. ( P. 60)  
Get used to handling the motorcycle on a suitable piece of land before making a longer trip.  
Info  
Offroad, you should be accompanied by another person on another machine so that you can help each other.  
ದ
ದ
ದ
ದ
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.  
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GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION  
25  
ದ
If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis-  
tribution between the front and rear wheels.  
Info  
Motorcycles react sensitively to any changes of weight distribution.  
ದ
Do not exceed the overall maximum permitted weight and the axle loads.  
Specification  
Maximum permissible overall weight  
Maximum permissible front axle load  
Maximum permissible rear axle load  
335bkg (739blb.)  
145bkg (320blb.)  
190bkg (419blb.)  
ದ
Run the engine in.  
ꢅ
ꢃꢁ  
unning in the engine  
ದ
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  
7000brpm  
Maximum engine performance during the running-in period  
During the first 3 service hours  
ืb50b%  
ืb75b%  
During the next 12 service hours  
ದ
Avoid fully opening the throttle!  
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RIDING INSTRUCTIONS  
26  
ꢆ5,',1* ,16758&7,216  
C
hecks before putting into operation  
Info  
Make sure that the motorcycle is in a perfect technical condition before use.  
Info  
In the interests of riding safety, make a habit of making a general check before you ride.  
ದ
Check the engine oil level. ( P. 79)  
ದ
ದ
ದ
ದ
ದ
ದ
ದ
ದ
ದ
ದ
ದ
ದ
Check the chain tension. ( P. 51)  
Check the chain dirt accumulation. ( P. 50)  
Check the tire condition. ( P. 66)  
Checking the tire air pressure. ( P. 66)  
Check the front brake fluid level. ( 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 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.  
ꢆ
ꢃꢁ  
tarting  
Danger  
Danger of poisoningಘExhaust gases are poisonous and can result in unconsciousness and/or death.  
ದ
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 failureಘHigh engine speeds in cold engines have a negative effect on the service life of the engine.  
ದ
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 starts immediately.  
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds until trying again.  
Conditions  
Motorcycle standing still: ุb1bweek  
Empty the carburetor float chamber. ( P. 78)  
ದ
ದ
Turn the handlebꢀ of the fuel tap to the ON position. (Figureb500137-10b P. 20)  
Fuel can flow from the tank to the carburetor.  
Remove the motorcycle from the stand.  
Shift gear to neutral.  
ದ
ದ
(EXC-RbUSA)  
ದ
ದ
Turn the key in the ignition switch to the positionb .  
Turn the emergency OFF switch to the positionb .  
(EXC-RbAUS/UK)  
ದ Turn the emergency OFF switch to the positionb .  
Conditions  
Engine cold  
(EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA, XCR-W)  
Pull choke lever out as far as possible.  
(EXC-RbEU)  
Pull the choke lever to the stop.  
ದ
ದ
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RIDING INSTRUCTIONS  
27  
ದ
Press the electric starter button or press the kickstarter robustly through its full range.  
Info  
Don't open the throttle.  
Conditions  
Engine hot and running  
Push back the hot start lever to the stop with the engine running.  
ದ
ꢆ
ꢃꢂ  
tarting up  
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.  
ದ
Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.  
ꢆ
ꢃꢄ  
hifting, riding  
Warning  
Danger of accidentsಘIf you change down at high engine speed, the rear wheel can lock up.  
ದ
Do not change into a low gear at high engine speed. The engine races and the rear wheel can block.  
Info  
If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.  
First gear is used for starting off or for steep inclines.  
ದ
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.  
ದ
ದ
If the 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.  
ದ
ದ
ದ
ದ
Always open the throttle only as much as the engine can handle ದ abrupt throttle opening increases fuel consumption.  
To 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  
ุb2bmin  
ದ
ದ
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 high engine speed and a slipping clutch.  
ꢆ
ꢃꢅ  
raking  
Warning  
Danger of accidentsಘIf you brake too hard, the wheels can lock.  
ದ
Adapt your braking to the traffic situation and the road conditions.  
Warning  
Danger of accidentsಘReduced braking caused by spongy pressure point of front or rear brake.  
ದ
Have the brake system checked in an authorized KTM workshop, and do not ride any further.  
Warning  
Danger of accidentsಘReduced braking due to wet or dirty brakes.  
ದ
Clean or dry dirty or wet brakes by riding and braking gently.  
ದ
ದ
ದ
On 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.  
On long 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.  
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RIDING INSTRUCTIONS  
28  
ꢆ
ꢃꢆ  
topping, parking  
Warning  
Danger of burnsಘSome vehicle components get very hot when the machine is driven.  
ದ
Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these compo-  
nents to cool down before starting work on them.  
Note  
Danger of damageಘDanger of damage by the vehicle running away or falling over.  
Always place the vehicle on a firm and even surface.  
ದ
Note  
Fire hazardಘSome components (engine, radiator and exhaust system) get very hot when the engine is running.  
ದ
Do not place the vehicle where there are flammable or explosive substances.  
ದ
ದ
Brake the motorcycle.  
Shift gear to neutral.  
(Every XCR-W models)  
ದ
Press the short circuit buttonb at engine idling speed until the engine stops.  
(EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS)  
ದ
Press the short circuit buttonb at engine idling speed until the engine stops.  
(EXC-RbUSA)  
ದ
Push the emergency off switch at engine indling speed to the positionb .  
ದ
ದ
Turn the handleb  
Stand the motorcycle on a hard surface.  
ꢀ
of the fuel tap to the OFF position. (Figureb500137-10b P. 20)  
ꢆ
ꢃꢇ  
efueling  
Danger  
Fire hazardಘFuel can easily catch fire.  
ದ
Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no  
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.  
ದ
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 poisoningಘFuel is poisonous and a health hazard.  
ದ
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-  
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,  
contact a doctor immediately. Change clothing that has come into contact with fuel.  
Warning  
Environmental hazardಘImproper handling of fuel is a danger to the environment.  
ದ
Do not allow fuel to get into the ground water, the ground, or the sewage system.  
ದ
ದ
Open the filler cap. ( P. 20)  
Fill the fuel tank with fuel up to measurementb  
Specification  
ꢂ.  
Measurement ofb  
ꢂ
35bmm (1.38bin)  
A
Tank capacity  
9bl (2.4bUSbgal)  
Super unleaded (ROZ 95 / RON 95 /  
PON 91) ( P. 114)  
(EXC-RbEU, EXC-  
RbAUS/UK, EXC-  
RbSIXbDAYS, XCR-  
WbZA)  
400382-10  
Tank capacity  
(EXC-RbUSA, XCR- (2.43bUSbgal)  
WbUSA)  
9.2bl  
Super unleaded (ROZ 95 / RON 95 /  
PON 91) ( P. 114)  
ದ
Close the filler cap. ( P. 20)  
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GREASING AND SERVICE TABLE  
29  
ꢇ*5($6,1* $1' 6(59,&( 7$%/(  
Iꢇꢃꢀ mportant maintenance work to be carried out by an authorized KTM workshop.  
S3N  
•
S15A  
S30A  
Engine  
Change the engine oil and oil filter and clean the engine oil screen. ( P. 79)  
Change the gear oil and clean the gear oil screen. ( P. 82)  
Replace 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.  
Carburetor  
•
•
•
•
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 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  
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)  
Chassis  
Wheels  
Check swingarm bearing.  
Check play of steering head bearing. ( P. 39)  
Check all screws to see if they are tight.  
Check the spoke tension. ( P. 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  
S15A: Every 15 service hours / after every race  
S30A: Every 30 service hours  
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GREASING AND SERVICE TABLE  
30  
ꢇ
ꢃꢁ  
Competition use  
Hobby use  
S60A  
J1A  
J2A  
S15A  
S30A  
S45A  
S30A  
S90A  
Carry out a complete fork service.  
•
•
•
•
•
•
•
•
•
•
Carry out a complete shock absorber service.  
Grease the steering head bearing. ( P. 46)  
Clean and adjust carburetor.  
•
•
•
•
•
•
•
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-RbUSA, XCR-WbUSA)  
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.  
S15A: Every 15 service hours / after every race  
S30A: Every 30 service hours  
S45A: Every 45 service hours  
S60A: Every 60 service hours  
S90A: Every 90 service hours  
J1A: annually  
J2A: every 2 years  
ꢇ
ꢃꢂ  
NB1A  
Check the engine oil level. ( P. 79)  
Check the front brake fluid level. ( 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)  
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GREASING AND SERVICE TABLE  
31  
NB1A  
Clean the chain. ( P. 50)  
•
•
•
•
•
•
•
•
•
•
•
•
Check the chain tension. ( P. 51)  
Check the chain wear. ( P. 52)  
Check the rear sprocket / engine sprocket for wear. ( P. 52)  
Clean the air filter. ( P. 75)  
Checking the tire air pressure. ( P. 66)  
Check the tire condition. ( P. 66)  
Check the coolant level. ( P. 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.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
32  
ꢈ0$,17(1$1&( :25. 21 &+$66,6 $1' (1*,1(  
Jꢈꢃꢀ acking up the motorcycle  
Note  
Danger of damageಘDanger of damage by the vehicle running away or falling over.  
ದ
Always place the vehicle on a firm and even surface.  
ದ
ದ
Jack up the motorcycle underneath the engine. The wheels must no longer touch  
the ground.  
Work stand (54829055000)  
Secure the motorcycle against falling over.  
500074-01  
ꢈ
ꢃꢁ  
Note  
Danger of damageಘDanger of damage by the vehicle running away or falling over.  
ದ
Always place the vehicle on a firm and even surface.  
ದ
ದ
Remove the motorcycle from the work stand.  
Remove the work stand.  
ꢈ
ꢃꢂ  
hecking the basic chassis setting with the rider's weight  
Info  
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.  
ದ
ದ
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.  
As delivered, KTM offroad motorcycles are adjusted for a standard rider weight (with full protective clothing).  
Specification  
Standard rider weight  
75… 85bkg (165… 187blb.)  
ದ
ದ
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.  
ꢈ
ꢃꢄ  
ompression 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-  
cycle.  
The low- and high-speed technology works non-specifically.  
ꢈ
ꢃꢅ  
djusting high-speed compression damping of the shock absorber  
Danger  
Danger of accidentsಘThe shock absorber is under high pressure.  
ದ
The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-  
tenance on it yourself.  
Info  
The high-speed setting can be seen during the fast compression of the shock absorber.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
33  
ದ
Turn the adjusting screwbꢀ clockwise with a ring wrench until it stops.  
Info  
Do not loosen nutbꢁ!  
ದ
Turn back counterclockwise the number of turns corresponding to the shock ab-  
sorber type.  
Specification  
Compression damping, high-speed  
400208-10  
Comfort  
Standard  
Sport  
2bturns  
1.5bturns  
1bturn  
Info  
Turn clockwise to increase damping, turn counterclockwise to reduce sus-  
pension damping.  
ꢈ
ꢃꢆ  
djusting the low-speed compression damping of the shock absorber  
Danger  
Danger of accidentsಘThe shock absorber is under high pressure.  
ದ
The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-  
tenance on it yourself.  
Info  
The low-speed setting can be seen during the slow to normal compression of the shock absorber.  
ದ
Turn the adjusting screwbꢀ clockwise with a screwdriver until it stops.  
Info  
Do not loosen nutbꢁ!  
ದ
Turn back counterclockwise the number of clicks corresponding to the shock ab-  
sorber type.  
Specification  
Compression damping, low-speed  
400209-10  
Comfort  
Standard  
Sport  
18bclicks  
15bclicks  
12bclicks  
Info  
Turn clockwise to increase damping, turn counterclockwise to reduce sus-  
pension damping.  
ꢈ
ꢃꢇ  
djusting rebound damping of the shock absorber  
Danger  
Danger of accidentsಘThe shock absorber is under high pressure.  
ದ
The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-  
tenance on it yourself.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
34  
ದ
Turn the adjusting screwb  
ꢀ
clockwise until it stops.  
Info  
Do not loosen nutb  
ꢁ!  
ದ
Turn back counterclockwise the number of clicks corresponding to the shock ab-  
sorber type.  
Specification  
Rebound damping  
400210-10  
Comfort  
Standard  
Sport  
24bclicks  
22bclicks  
20bclicks  
Info  
Turn clockwise to increase damping, turn counterclockwise to reduce sus-  
pension damping.  
ꢈ
ꢃꢈ  
easuring rear wheel sag unloaded  
ದ
ದ
Jack up the motorcycle. ( P. 32)  
Measure the distance ದ as vertical as possible ದ between the rear axle and a fixed  
point, for example, a mark on the side cover.  
ದ
ದ
Make a note of the value as measurementb  
Remove the motorcycle from the work stand. ( P. 32)  
ꢂ
.
0A  
400220-10  
ꢈ
ꢃꢉ  
hecking static sag of the shock absorber  
ದ
ದ
ದ
Measure distanceb  
Ask someone to help you by holding the motorcycle upright.  
ꢂ
of rear wheel unloaded. ( P. 34)  
Measure the distance between the rear axle and the fixed point again.  
ದ
Make a note of the value as measurementb  
ꢃ.  
0A  
Info  
The static sag is the difference between measurementsb  
Check the static sag.  
Static sag  
If the static sag is less or more than the specified value:  
ꢂ
andbꢃ  
.
ದ
35bmm (1.38bin)  
»
ದ
Adjust the spring preload of the shock absorber. ( P. 35)  
0B  
400221-10  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
35  
ꢈ
ꢃꢀꢊ  
ದ
ದ
Measure distancebꢂ 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.  
0A  
ದ
ದ
The other person now has to measure the distance between the rear axle and a  
fixed point.  
Make a note of the value as measurementbꢄ.  
Info  
The riding sag is the difference between measurementsbꢂ andbꢄ.  
ದ
Check the riding sag.  
Riding sag  
If the riding sag differs from the specified measurement:  
Adjust the riding sag. ( P. 36)  
105bmm (4.13bin)  
»
C
ದ
400222-10  
ꢈ
ꢃꢀꢀ  
djusting spring preload of the shock absorberbx  
Danger  
Danger of accidentsಘThe shock absorber is under high pressure.  
ದ
The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-  
tenance on it yourself.  
Info  
Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.  
ದ
ದ
ದ
ದ
Remove shock absorber. ( P. 36)  
After removing the shock absorber, clean it thoroughly.  
Loosen screwbꢀ.  
Turn adjusting ringbꢁ until the spring is no longer under tension.  
2
Combination wrench (50329080000)  
Hook wrench (T106S)  
1
A
ದ
ದ
Measure the overall spring length when not under tension.  
Tighten the spring by turning adjusting ringbꢁ to measurementbꢂ.  
Specification  
Spring preload  
Standard  
9bmm  
Info  
Depending on the static sag and/or the riding sag, it may be necessary to  
increase or decrease the spring preload.  
ದ
ದ
Tighten screwbꢀ.  
Specification  
Screw, shock absorber adjusting ring  
M6  
5bNm (3.7blbfbft)  
400216-10  
Installing shock absorber. ( P. 36)  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
36  
ꢈ
ꢃꢀꢁ  
djusting riding sagbx  
ದ
ದ
ದ
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… 75bkg (143… 165blb.)  
Weight of rider: 75… 85bkg (165… 187blb.)  
Weight of rider: 85… 95bkg (187… 209blb.)  
69bN/mm (394blb/in)  
72bN/mm (411blb/in)  
76bN/mm (434blb/in)  
Info  
The spring rate is shown on the outside of the spring.  
Smaller weight differences can be compensated by changing the spring preload.  
ದ
ದ
ದ
ದ
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)  
ꢈ
ꢃꢀꢂ  
emoving the shock absorberbx  
ದ
ದ
Jack up the motorcycle. ( P. 32)  
Remove screwbꢀ 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.  
ದ
Remove screwbꢁ, push splash protectorbꢅ to the side, and remove the shock ab-  
sorber.  
500075-10  
ꢈ
ꢃꢀꢄ  
nstalling shock absorberbx  
ದ
ದ
Check parts for damage and wear. Replace damaged or worn parts.  
Push splash protectorbꢀ to the side and position the shock absorber. Mount and  
tighten screwbꢁ.  
Specification  
Screw, top shock absorber M12  
80bNm  
Loctite® 243™  
Loctite® 243™  
(59blbfbft)  
ದ
Mount and tighten screwbꢅ.  
Specification  
500075-11  
Screw, bottom shock ab-  
sorber  
M12  
80bNm  
(59blbfbft)  
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.  
ದ
Remove the motorcycle from the work stand. ( P. 32)  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
37  
ꢈ
ꢃꢀꢅ  
hecking basic setting of fork  
Info  
For various reasons, no exact riding sag can be determined for the forks.  
ದ
ದ
As with the shock absorber, smaller weight differences can be compensated 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.  
400189-01  
ꢈ
ꢃꢀꢆ  
djusting compression damping of fork  
Info  
The hydraulic compression damping determines the fork suspension behavior.  
ದ
ದ
Remove protection coversb  
ꢀ
.
Turn adjusting screwsb  
ꢁ
clockwise until they stop.  
Info  
The adjusting screwsb  
ꢁ
are located at the bottom end of the fork legs.  
Make the same adjustment on both fork legs.  
ದ
Turn back counterclockwise the number of clicks corresponding to the fork type.  
Specification  
100020-10  
Compression damping (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)  
Comfort  
24bclicks  
20bclicks  
18bclicks  
Standard  
Sport  
Compression damping (EXC-RbSIXbDAYS)  
Comfort  
Standard  
Sport  
24bclicks  
22bclicks  
18bclicks  
Info  
Turn clockwise to increase damping, turn counterclockwise to reduce sus-  
pension damping.  
ದ
Mount protection coversb  
ꢀ.  
ꢈ
ꢃꢀꢇ  
Info  
The hydraulic rebound damping determines the fork suspension behavior.  
ದ
Turn adjusting screwsb  
ꢀ
clockwise until they stop.  
Info  
The adjusting screwsb  
ꢀ
are located at the top end of the fork legs.  
Make the same adjustment on both fork legs.  
100019-10  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
38  
ದ
Turn back counterclockwise the number of clicks corresponding to the fork type.  
Specification  
Rebound damping (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)  
Comfort  
20bclicks  
18bclicks  
18bclicks  
Standard  
Sport  
Rebound damping (EXC-RbSIXbDAYS)  
Comfort  
Standard  
Sport  
20bclicks  
20bclicks  
18bclicks  
Info  
Turn clockwise to increase damping, turn counterclockwise to reduce sus-  
pension damping.  
ꢈ
ꢃꢀꢈ  
djusting spring preload of the fork  
ದ
ದ
Turn adjusting screws counterclockwise until they stop.  
Info  
Make the same adjustment on both fork legs.  
Turn back clockwise the number of turns corresponding to the fork type.  
Specification  
Spring preload - PreloadbAdjuster (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-  
W)  
100025-10  
Comfort  
Standard  
Sport  
2bturns  
4bturns  
7bturns  
Spring preload - PreloadbAdjuster (EXC-RbSIXbDAYS)  
Comfort  
Standard  
Sport  
2bturns  
2bturns  
7bturns  
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.  
ꢈ
ꢃꢀꢉ  
leeding fork legs  
ದ
ದ
Jack up the motorcycle. ( P. 32)  
Remove bleeder screwsbꢀ briefly.  
Any excess pressure escapes from the interior of the fork.  
Mount and tighten bleeder screws.  
ದ
ದ
Remove the motorcycle from the work stand. ( P. 32)  
100021-10  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
39  
ꢈ
ꢃꢁꢊ  
ದ
ದ
ದ
Jack up the motorcycle. ( P. 32)  
Loosen the fork protection. ( P. 39)  
Push dust bootsbꢀ of both fork legs downwards.  
Info  
The dust boots should remove dust and coarse dirt particles from the fork  
tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not  
removed, the oil seals behind can start to leak.  
Warning  
Danger of accidentsಘReduced braking due to oil or grease on the brake  
discs.  
500088-10  
ದ
Always keep the brake discs free of oil and grease, and clean them with  
brake cleaner when necessary.  
ದ
Clean and oil the dust boots and inner fork tube of both fork legs.  
Universal oil spray ( P. 115)  
ದ
ದ
ದ
ದ
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)  
ꢈ
ꢃꢁꢀ  
ದ
ದ
ದ
Remove screwsbꢀ and take off clamp.  
Remove screwsbꢁ on left fork leg. Push the fork protection downwards.  
Remove the screws on the right fork leg. Push the fork protection downwards.  
500087-11  
ꢈ
ꢃꢁꢁ  
ದ
Position the fork protection on the left fork leg. Mount and tighten screwsbꢀ.  
Specification  
Remaining screws, chassis  
M6  
10bNm (7.4blbfbft)  
ದ
ದ
Position the brake line and cable harness. Put the clamp on, mount and tighten  
screwsbꢁ.  
Position the fork protection on the right fork leg. Mount and tighten screws.  
Specification  
Remaining screws, chassis  
M6  
10bNm (7.4blbfbft)  
500087-10  
ꢈ
ꢃꢁꢂ  
hecking play of steering head bearing  
Warning  
Danger of accidentsಘUnsafe riding behavior due to incorrect steering head bearing play.  
ದ
The steering head bearing play should be adjusted immediately in an authorized KTM workshop.  
Info  
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  
be damaged after time.  
ದ
Jack up the motorcycle. ( P. 32)  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
40  
ದ
Move the handlebar to the straight-ahead position. Move the fork legs to and fro in  
the direction of travel.  
No play should be noticeable in the steering head bearing.  
»
If there is noticeable play present:  
(EXC-RbSIXbDAYS, XCR-WbUSA)  
ದ
Adjust play of the steering head bearing. ( P. 40)  
(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)  
Adjust play of the steering head bearing. ( P. 40)  
ದ
400189-10  
ದ
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-RbSIXbDAYS, XCR-WbUSA)  
ದ
Adjust play of the steering head bearing. ( P. 40)  
(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)  
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)  
ದ
ದ
ದ
ꢈ
ꢃꢁꢄ  
djusting play of steering head bearingbx(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)  
ದ
ದ
ದ
Jack up the motorcycle. ( P. 32)  
Loosen screwsb andb  
ꢀ
ꢁ.  
Loosen and retighten screwb  
ꢅ
.
Specification  
Screw, top steering head  
M20x1,5  
10bNm (7.4blbfbft)  
ದ
ದ
Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.  
Fully tighten screwb  
ꢀ
.
Specification  
Screw, top triple clamp  
M8  
20bNm  
(14.8blbfbft)  
100022-10  
ದ
ದ
Tighten screwb  
Specification  
ꢁ
.
Screw, top steering stem  
M8  
20bNm  
(14.8blbfbft)  
Check play of steering head bearing. ( P. 39)  
ꢈ
ꢃꢁꢅ  
djusting play of steering head bearingbx(EXC-RbSIXbDAYS, XCR-WbUSA)  
ದ
ದ
ದ
Jack up the motorcycle. ( P. 32)  
Loosen screwb . Remove screwb  
ꢀ
ꢁ.  
Loosen and retighten screwb  
ꢅ
.
Specification  
Screw, top steering head  
M20x1,5  
10bNm (7.4blbfbft)  
ದ
ದ
Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.  
Fully tighten screwb  
ꢀ
.
Specification  
Screw, top triple clamp  
M8  
17bNm  
(12.5blbfbft)  
500103-11  
ದ
ದ
Mount and tighten screwb  
Specification  
ꢁ
.
Screw, top steering stem  
M8  
17bNm  
(12.5blbfbft)  
Loctite® 243™  
Check play of steering head bearing. ( P. 39)  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
41  
ꢈ
ꢃꢁꢆ  
ork offset (EXC-RbSIXbDAYS, XCR-WbUSA)  
You can see the currently set offset if you remove screwb  
ꢀ
.
The fork offsetb  
ꢂ
has an impact on the handling of the vehicle. It is calculated from  
0B  
the center of the fork leg to the center of the steering head bearing.  
The fork offset can optionally be adjusted.  
Markingb  
Fork offset  
Front marking  
ꢃ
to the front gives greater stability on fast racetracks.  
0AA  
18bmm (0.71bin)  
Markingb  
Fork offset  
Rear marking  
ꢃ
to the rear (condition at delivery) gives better handling in bends.  
20bmm (0.79bin)  
01  
400188-10  
ꢈ
ꢃꢁꢇ  
etting the fork offsetbx(EXC-RbSIXbDAYS, XCR-WbUSA)  
ದ
ದ
ದ
ದ
Remove the lower triple clamp. ( P. 43)  
Remove screwb . 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  
screwb  
ꢀ
ꢀ.  
Specification  
Screw, bottom steering  
head  
M20x1,5  
60bNm  
(44.3blbfbft)  
Loctite® 243™  
ದ
Install the lower triple clamp. ( P. 44)  
500104-10  
ꢈ
ꢃꢁꢈ  
ದ
ದ
ದ
ದ
Remove front wheel. ( P. 63)  
Remove screwsb  
Remove cable clipb  
Hang the brake caliper and the brake line loosely to the side.  
ꢀ
and take off clamp.  
ꢁ
, remove screwb and take off the brake caliper.  
ꢅ
500093-10  
(EXC-RbSIXbDAYS, XCR-WbUSA)  
ದ
ದ
Loosen screwb  
ꢆ
. Remove the fork leg on the left.  
Loosen screwb  
ꢇ
. Remove the fork leg on the right.  
500094-10  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
42  
(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)  
ದ
ದ
Loosen screwbꢆ. Remove the fork leg on the left.  
Loosen screwbꢇ. Remove the fork leg on the right.  
100023-11  
ꢈ
ꢃꢁꢉ  
nstalling the fork legsbx  
ದ
ದ
Check parts for damage and wear. Replace damaged or worn parts.  
Position the fork legs.  
Info  
The topmost sunk nut in the fork leg must be flush to the upper edge of the  
upper triple clamp.  
Position the bleeder screwbꢀ to the front.  
100021-10  
(EXC-RbSIXbDAYS, XCR-WbUSA)  
ದ
Fully tighten screwbꢁ.  
Specification  
Screw, top triple clamp  
M8  
M8  
17bNm  
(12.5blbfbft)  
ದ
Fully tighten screwbꢅ.  
Specification  
Screw, bottom triple clamp  
12bNm  
(8.9blbfbft)  
500094-11  
(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)  
ದ
Fully tighten screwbꢁ.  
Specification  
Screw, top triple clamp  
M8  
M8  
20bNm  
(14.8blbfbft)  
ದ
Fully tighten screwbꢅ.  
Specification  
Screw, bottom triple clamp  
15bNm  
(11.1blbfbft)  
100023-10  
ದ
Position brake caliper, mount and tighten screwsbꢅ.  
Specification  
Screw, front brake caliper  
M8  
25bNm  
(18.4blbfbft)  
Loctite® 243™  
ದ
ದ
Fit cable clipbꢆ.  
Position the brake line and cable harness. Put the clamp on, mount and tighten  
screwsbꢇ.  
ದ
Fit front wheel. ( P. 64)  
500093-11  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
43  
ꢈ
ꢃꢂꢊ  
emoving the fork protectorbx  
ದ
ದ
ದ
Remove the fork legs. ( P. 41)  
Remove screwsbꢀ on the left fork leg. Remove the fork protector upwards.  
Remove the screws on the right fork leg. Remove the fork protector upwards.  
500105-10  
ꢈ
ꢃꢂꢀ  
nstalling the fork protectorbx  
ದ
ದ
Check parts for damage and wear. Replace damaged or worn parts.  
Position the fork protection on the left fork leg. Mount and tighten screwsbꢀ.  
Specification  
Remaining screws, chassis  
M6  
10bNm (7.4blbfbft)  
ದ
ದ
Position the fork protection on the right fork leg. Mount and tighten screws.  
Specification  
Remaining screws, chassis  
M6  
10bNm (7.4blbfbft)  
500105-10  
Install the fork legs. ( P. 42)  
ꢈ
ꢃꢂꢁ  
emoving the lower triple clampbx(EXC-RbSIXbDAYS, XCR-WbUSA)  
ದ
Remove the fork legs. ( P. 41)  
(XCR-WbUSA)  
Dismount the start number plate. ( P. 47)  
ದ
(EXC-RbSIXbDAYS)  
ದ
Remove the headlight mask with the headlight. ( P. 46)  
ದ
ದ
Dismount the front fender. ( P. 46)  
Remove screwsbꢀ and hang the CDI control unit to the side.  
Info  
Do not unplug the CDI control unit.  
ದ
Remove screwbꢁ. Remove screwbꢅ, take off top triple clamp with the handlebar  
and place it on one side.  
Info  
Protect the motorcycle and its attachments from damage by covering them.  
Do not bend the cables and lines.  
500099-10  
ದ
ದ
ದ
Remove o-ringbꢆ. Remove protector ringbꢇ.  
Remove the lower triple clamp with the steering stem.  
Remove the upper steering head bearing.  
500100-10  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
44  
ꢈ
ꢃꢂꢂ  
emoving the lower triple clampbx(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)  
ದ
ದ
ದ
ದ
Remove the fork legs. ( P. 41)  
Remove the headlight mask with the headlight. ( P. 46)  
Dismount the front fender. ( P. 46)  
Remove screwsbꢀ and hang the CDI control unit to the side.  
Info  
Do not unplug the CDI control unit.  
ದ
Remove screwbꢁ. Loosen screwbꢅ. Take off top triple clamp with the handlebar  
and place it on one side.  
Info  
Protect the motorcycle and its attachments from damage by covering them.  
Do not bend the cables and lines.  
500149-10  
ದ
ದ
ದ
Remove protector ringbꢆ.  
Remove the lower triple clamp with the steering stem.  
Remove the upper steering head bearing.  
500150-10  
ꢈ
ꢃꢂꢄ  
nstalling the lower triple clampbx(EXC-RbSIXbDAYS, XCR-WbUSA)  
ದ
Clean the bearing and sealing elements, check for damage, and grease.  
Long-life grease ( P. 115)  
ದ
Insert the lower triple clamp with the steering stem. Mount the upper steering head  
bearing.  
03  
02  
01  
Info  
Check whether the top steering head sealbꢀ is correctly positioned.  
ದ
Push up protective ringbꢁ and o-ringbꢅ.  
500098-10  
ದ
ದ
Position the upper triple clamp with the steering.  
Mount and tighten screwbꢆ.  
Specification  
Screw, top steering head  
M20x1,5  
10bNm (7.4blbfbft)  
ದ
Position the clutch line, wiring harness and CDI control unit. Mount and tighten  
screwsbꢇ.  
Specification  
Remaining screws, chassis  
M6  
10bNm (7.4blbfbft)  
500099-11  
ದ
Install the front fender. ( P. 46)  
(XCR-WbUSA)  
Fit the start number plate. ( P. 47)  
ದ
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
45  
(EXC-RbSIXbDAYS)  
ದ
Refit the headlight mask with the headlight. ( P. 47)  
ದ
ದ
Install the fork legs. ( P. 42)  
Mount and tighten screwb  
Specification  
.
Screw, top steering stem  
M8  
17bNm  
(12.5blbfbft)  
Loctite® 243™  
ದ
ದ
Check the cable harness, cable, brake and clutch line for free movement and free  
laying.  
Check play of steering head bearing. ( P. 39)  
500103-10  
ꢈ
ꢃꢂꢅ  
nstalling the lower triple clampbx(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)  
ದ
Clean the bearing and sealing elements, check for damage, and grease.  
Long-life grease ( P. 115)  
ದ
Insert the lower triple clamp with the steering stem. Mount the upper steering head  
bearing.  
02  
01  
Info  
Check whether the top steering head sealbꢀ is correctly positioned.  
ದ
Push on protective ringbꢁ.  
500151-10  
ದ
ದ
Position the upper triple clamp with the steering.  
Mount and tighten screwbꢅ.  
Specification  
Screw, top steering head  
M20x1,5  
10bNm (7.4blbfbft)  
ದ
Position the clutch line, wiring harness and CDI control unit. Mount and tighten  
screwsbꢆ.  
Specification  
Remaining screws, chassis  
M6  
10bNm (7.4blbfbft)  
500149-11  
ದ
ದ
ದ
ದ
Install the front fender. ( P. 46)  
Refit the headlight mask with the headlight. ( P. 47)  
Install the fork legs. ( P. 42)  
Tighten screwbꢇ.  
Specification  
Screw, top steering stem  
M8  
20bNm  
(14.8blbfbft)  
ದ
ದ
Check the cable harness, cable, brake and clutch line for free movement and free  
laying.  
Check play of steering head bearing. ( P. 39)  
100022-11  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
46  
ꢈ
ꢃꢂꢆ  
reasing the steering head bearingbx  
(EXC-RbSIXbDAYS, XCR-WbUSA)  
Remove the lower triple clamp. ( P. 43)  
Install the lower triple clamp. ( P. 44)  
(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA)  
Remove the lower triple clamp. ( P. 44)  
Install the lower triple clamp. ( P. 45)  
ꢈ
ꢃꢂꢇ  
ದ
ದ
Remove screwsbꢀ. Remove the front fender.  
Make sure that the distance bushings remain in place.  
500092-10  
ꢈ
ꢃꢂꢈ  
ದ
ದ
ದ
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 screwsbꢀ.  
Specification  
Remaining screws, chassis  
M6  
10bNm (7.4blbfbft)  
Info  
Ensure that there is contact between the holding lugs and the start number  
plate or headlight mask.  
500092-10  
ꢈ
ꢃꢂꢉ  
emoving headlight mask with headlight (EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA, XCR-WbZA)  
ದ
ದ
ದ
Switch off all electrical equipment.  
Remove screwbꢀ and take off clamp.  
Loosen the rubber bandbꢁ. Push up the headlight mask and swing it forwards.  
500155-10  
ದ
Pull out the electric plug connectorbꢅ and remove the headlight mask with the  
headlight.  
500156-10  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
47  
ꢈ
ꢃꢄꢊ  
efitting the headlight mask with the headlight (EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA,  
XCR-WbZA)  
ದ
ದ
Check parts for damage and wear. Replace damaged or worn parts.  
Connect the electric plug connectorb  
ꢀ
.
500156-11  
ದ
Position the headlight mask and fix it with the rubber bandb  
ꢁ.  
Info  
Take care with the contact of the holding lug at the fender.  
ದ
ದ
Position the brake line and cable harness. Put the clamp on, mount and tighten  
screwbꢅ.  
Check the headlamp setting.  
500155-11  
ꢈ
ꢃꢄꢀ  
ismount the start number plate (XCR-WbUSA)  
ದ
ದ
Remove screwb  
Remove screwb  
ꢀ
ꢁ
and take off clamp.  
with distance bushing. Remove the start number plate.  
500101-10  
ꢈ
ꢃꢄꢁ  
itting the start number plate (XCR-WbUSA)  
ದ
Check parts for damage and wear. Replace damaged or worn parts.  
ದ
Position the start number plate. Fit and tighten screwb  
ꢀ
with distance bushing.  
Specification  
Remaining screws, chassis  
M6  
10bNm (7.4blbfbft)  
Info  
Take care with the contact of the holding lug at the fender.  
ದ
Position the brake line and cable harness. Put the clamp on, mount and tighten  
500101-11  
screwbꢁ.  
ꢈ
ꢃꢄꢂ  
andlebar position  
On the upper triple clamp, there are 2 holes at a distance ofb  
Distanceb between holes 15bmm (0.59bin)  
The holes on the handlebar support are placed at a distance ofb  
Distanceb between holes 3.5bmm (0.138bin)  
ꢂ
to each other.  
ꢂ
ꢃ
from the center.  
ꢃ
0AA  
0BB  
0A  
0B  
The handlebar supports can be mounted in 4 different positions.  
(EXC-RbSIXbDAYS)  
The handlebar supports can also be mounted at 2 different heights (with and with-  
out spacer).  
400223-11  
Thick spacer  
9bmm (0.35bin)  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
48  
ꢈ
ꢃꢄꢄ  
djusting handlebar positionbx  
(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)  
ದ
Remove the four screwsb . Remove the handlebar clamp. Remove the handle-  
ꢀ
011  
022  
01  
bar and lay it to one side.  
02  
Info  
Protect the motorcycle and its attachments from damage by covering  
them.  
Do not bend the cables and lines.  
ದ
ದ
ದ
Remove the two screwsbꢁ. Remove the handlebar support.  
Check parts for damage and wear. Replace damaged or worn parts.  
400223-10  
Place the handlebar support in the required position. Fit and tighten the two  
screwsbꢁ  
.
Specification  
Screw, handlebar support M10  
40bNm  
(29.5blbfbft)  
Loctite® 243™  
Info  
Position the left and right handlebar supports evenly.  
ದ
ದ
Position the handlebar.  
Info  
Make sure cables and wiring are positioned correctly.  
Position the handlebar clamp. Fit and evenly tighten the four screwsb  
ꢀ
.
Specification  
Screw, handlebar clamp  
M8  
20bNm  
(14.8blbfbft)  
Info  
Make sure the gap width is even.  
(EXC-RbSIXbDAYS)  
ದ
Remove the four screwsb  
ersb and elastomersb  
ꢀ
. Remove the handlebar clampsb  
ꢁ
with rubber wash-  
ꢅ
ꢆ
.
0
1
2
0
ದ
Remove the handlebar and lay it to one side.  
Info  
3
0
Protect the motorcycle and its attachments from damage by covering  
them.  
Do not bend the cables and lines.  
04  
05  
ದ
ದ
ದ
ದ
Remove the lower shellsb  
ꢇ
.
Remove the clamp barb  
ꢈ
with the rubber conesb  
. Remove the handlebar support.  
.
06  
07  
08  
09  
Remove the two screwsb  
ꢉ
Check parts for damage and wear. Replace damaged or worn parts.  
400343-10  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
49  
ದ
Place the handlebar support in the required position. Fit and tighten the two  
screwsbꢉ.  
Specification  
Screw, handlebar support M10  
40bNm  
(29.5blbfbft)  
Loctite® 243™  
Condition  
ꢊ Spacer fitted:  
Use a M10x35 screw  
Condition  
without a spacerbꢊ:  
Use a M10x25 screw  
Info  
Position the left and right handlebar supports evenly.  
ದ
ದ
ದ
Fit the rubber conesb and clamp barbꢈ.  
Fit the lower shellsbꢇ.  
Position the handlebar.  
Info  
Make sure cables and wiring are positioned correctly.  
ದ
Position the handlebar clampsbꢁ with rubber washersbꢅ and elastomersbꢆ.  
Elastomer kit green - soft qualityb(SXS05125203)  
Elastomer kit yellow - medium quality (standard)b(SXS05125204)  
Elastomer kit red - hard qualityb(SXS05125205)  
Info  
The elastomeres are available in different versions.  
ದ
Fit and evenly tighten the four screwsbꢀ.  
Specification  
Screw, handlebar clamp  
M8  
16bNm  
(11.8blbfbft)  
Info  
Make sure the gap width is even.  
ꢈ
ꢃꢄꢅ  
ದ
The 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.  
500152-10  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
50  
ꢈ
ꢃꢄꢆ  
hecking play in the gas Bowden cable  
ದ
Move the handlebar to the straight-ahead position. Move the throttle grip back and  
forth slightly to ascertain the play in the gas Bowden cable.  
Play in gas Bowden cable  
3… 5bmm (0.12… 0.2bin)  
»
If the gas Bowden cable play does not meet specifications:  
ದ
Adjust the gas Bowden cable play. ( P. 50)  
Danger  
Danger of poisoningಘExhaust gases are poisonous and can result in uncon-  
sciousness and/or death.  
400192-10  
ದ
When running the engine, always make sure there is sufficient ventila-  
tion, and do not start or run the engine in a closed space.  
ದ
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)  
ದ
ꢈ
ꢃꢄꢇ  
djusting the gas Bowden cable playbx  
ದ
ದ
ದ
ದ
ದ
ದ
Dismount the fuel tank. ( P. 70)  
Check gas Bowden cable route. ( P. 49)  
Move the handlebar to the straight-ahead position.  
Push back bellowsb  
ꢀ.  
Loosen nutbꢁ. Turn adjusting screwb  
ꢅ
ꢇ
in as far as possible.  
Loosen nutb  
ꢆ
. Turn adjusting screwb  
so that there is play in the gas Bowden ca-  
ble at the throttle grip.  
Specification  
Play in gas Bowden cable  
3… 5bmm (0.12… 0.2bin)  
ದ
ದ
Tighten nutb  
ꢆ
.
500153-10  
Press and hold the throttle grip in the closed setting. Turn adjusting screwb  
until there is no play in the Bowden cableb  
ꢅ
out  
.
ದ
ದ
ದ
ದ
Tighten nutb  
Push bellowsb  
ꢁ
.
ꢀ
on. Check the throttle grip for smooth operation.  
Install the fuel tank. ( P. 70)  
Check play in the gas Bowden cable. ( P. 50)  
ꢈ
ꢃꢄꢈ  
hecking chain dirt  
ದ
Check the chain for coarse dirt accumulation.  
If the chain is very dirty:  
Clean the chain. ( P. 50)  
»
ದ
ꢈ
ꢃꢄꢉ  
leaning the chain  
Warning  
Danger of accidentsಘOil or grease on the tires reduces their grip.  
Remove oil and grease with a suitable cleaning material.  
ದ
Warning  
Danger of accidentsಘReduced braking due to oil or grease on the brake discs.  
ದ
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.  
Warning  
Environmental hazardಘProblem materials cause environmental damage.  
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
51  
Info  
The service life of the chain depends largely on its maintenance.  
ದ
Clean the chain regularly and then treat with chain spray.  
Chain cleaner ( P. 115)  
Offroad chain spray ( P. 115)  
ꢈ
ꢃꢅꢊ  
hecking the chain tension  
Warning  
Danger of accidentsಘDanger caused by incorrect chain tension.  
ದ
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.  
ದ
ದ
Jack up the motorcycle. ( P. 32)  
Push the chain at the end of the chain sliding component upwards to measure the  
chain tensionbꢂ.  
Info  
The upper chain sectionbꢀ must be taut.  
Chain wear is not always even, so you should repeat this measurement at  
different chain positions.  
Chain tension  
If the chain tension does not meet specifications:  
Adjusting chain tension - after checking. ( P. 53)  
Remove the motorcycle from the work stand. ( P. 32)  
8… 10bmm (0.31… 0.39bin)  
400213-10  
»
ದ
ದ
ꢈ
ꢃꢅꢀ  
hecking the chain tension when fitting rear wheel  
Warning  
Danger of accidentsಘDanger caused by incorrect chain tension.  
ದ
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.  
ದ
ದ
Make 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 tensionbꢂ.  
Info  
The upper chain sectionbꢀ must be taut.  
Chain wear is not always even, so you should repeat this measurement at  
different chain positions.  
Chain tension  
If the chain tension does not meet specifications:  
Adjust the chain tension when fitting rear wheel. ( P. 54)  
8… 10bmm (0.31… 0.39bin)  
400213-10  
»
ದ
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
52  
ꢈ
ꢃꢅꢁ  
ದ
Check the rear sprocket / engine sprocket for wear.  
If the rear sprocket / engine sprocket are worn:  
»
ದ
Replace rear sprocket / engine sprocket.  
Info  
When fitting the chain joint, always 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.  
400227-01  
ದ
Check that the chain guide is firmly seated and not worn.  
ꢈ
ꢃꢅꢂ  
hecking chain wear  
ದ
ದ
Jack up the motorcycle. ( P. 32)  
Shift to neutral and pull the upper chain length with the specified tensionb  
ꢂ
.
Specification  
Chain tension  
10… 15bkg (22… 33blb.)  
0A  
ದ
Measure distanceb  
ꢃ
of 18 chain links in the lower chain section.  
Info  
Chain wear is not always even, so you should repeat this measurement at  
different chain positions.  
Maximum distanceb  
ꢃ
at the longest  
272bmm (10.71bin)  
chain section  
»
If distanceb  
ꢃ
is greater than the specified measurement:  
ದ
Replace the chain.  
Info  
B
0
When you replace the chain, you should also replace the rear and  
engine sprockets.  
New chains wear out faster on old, worn sprockets.  
1 2 3  
16 17 18  
400226-10  
ದ
Remove the motorcycle from the work stand. ( P. 32)  
ꢈ
ꢃꢅꢄ  
djusting the chain tension  
Warning  
Danger of accidentsಘDanger caused by incorrect chain tension.  
ದ
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.  
ದ
ದ
Jack up the motorcycle. ( P. 32)  
Push the chain at the end of the chain sliding component upwards to measure  
chain tensionb  
ꢂ.  
Info  
The upper chain sectionb  
ꢀ
must be taut.  
Chain wear is not always even, so you should repeat this measurement at  
different chain positions.  
400213-10  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
53  
ದ
ದ
ದ
Loosen nutbꢁ.  
Loosen nutsbꢅ.  
Adjust the chain tension by turning the left and right adjusting screwsbꢆ.  
Specification  
Chain tension  
8… 10bmm (0.31… 0.39bin)  
Turn the left and right adjusting screwsbꢆ so that the markings on the left and  
right chain adjusters are in the same position relative to the reference marksbꢃ.  
The rear wheel is then correctly aligned.  
ದ
ದ
ದ
Tighten nutsbꢅ.  
Make sure that chain adjustersbꢇ are fitted correctly on the adjusting screwsbꢆ.  
Tighten nutbꢁ.  
Specification  
Nut, rear wheel spindle  
M20x1,5  
80bNm (59blbfbft)  
Info  
The wide adjustment range of the chain adjusters (32 mm) enables different  
secondary transmissions with the same chain length.  
Chain adjustersbꢇ can be turned by 180°.  
400225-10  
ದ
Remove the motorcycle from the work stand. ( P. 32)  
ꢈ
ꢃꢅꢅ  
djusting chain tension - after checking  
ದ
ದ
ದ
Loosen nutbꢀ.  
Loosen nutsbꢁ.  
Adjust the chain tension by turning the adjusting screwsbꢅ left and right.  
Specification  
Chain tension  
8… 10bmm (0.31… 0.39bin)  
Turn the adjusting screwsbꢅ left and right so that the markings on the left and  
right chain adjusters are in the same position relative to the reference marksbꢂ.  
The rear wheel is then correctly aligned.  
ದ
ದ
Tighten nutsbꢁ.  
Make sure that the chain adjustersbꢆ are fitted correctly on the adjusting  
screwsbꢅ.  
ದ
Tighten nutbꢀ.  
Specification  
Nut, rear wheel spindle  
M20x1,5  
80bNm (59blbfbft)  
Info  
The wide adjustment range of the chain adjusters (32 mm) enables different  
secondary transmissions with the same chain length.  
The chain adjustersbꢆ can be turned by 180°.  
400225-13  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
54  
ꢈ
ꢃꢅꢆ  
djusting chain tension - fitting rear wheel  
ದ
ದ
Loosen nutsbꢀ.  
Adjust the chain tension by turning the adjusting screwsbꢁ left and right.  
Specification  
Chain tension  
8… 10bmm (0.31… 0.39bin)  
Turn the adjusting screwsbꢁ left and right so that the markings on the left and  
right chain adjusters are in the same position relative to the reference marksbꢂ.  
The rear wheel is then correctly aligned.  
ದ
Tighten nutsbꢀ.  
400225-11  
ꢈ
ꢃꢅꢇ  
djusting chain guidebx  
ದ Remove screwsbꢀ andbꢁ. Take off the chain guide.  
Conditions  
Number of teeth: ืb44bteeth  
ದ
ದ
Insert nutbꢅ in holebꢂ. Position the chain guide.  
Mount and tighten screwsbꢀ andbꢁ.  
Specification  
Remaining screws, chassis  
M6  
10bNm  
(7.4blbfbft)  
Conditions  
Number of teeth: ุb45bteeth  
ದ
ದ
Insert nutbꢅ in holebꢃ. Position the chain guide.  
Mount and tighten screwsbꢀ andbꢁ.  
Specification  
Remaining screws, chassis  
M6  
10bNm  
(7.4blbfbft)  
400252-10  
ꢈ
ꢃꢅꢈ  
rake fluid reservoir  
Warning  
Danger of accidentsಘBrake system failure.  
ದ
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.  
Have the brake system checked in an authorized KTM workshop, and do not ride any 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.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
55  
ꢈ
ꢃꢅꢉ  
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.  
ꢈ
ꢃꢆꢊ  
hecking brake discs  
Warning  
Danger of accidentsಘReduced braking due to worn brake discs.  
ದ
Worn brake discs should be replaced immediately by an authorized KTM workshop.  
ದ
Check the thickness of the front and rear brake discs at several places on the disc  
to see if it conforms to measurementbꢂ.  
Info  
A
Wear reduces the thickness of the brake disc around the area used by the  
brake linings.  
Wear limit of brake discs  
front  
Rear  
2.5bmm (0.098bin)  
3.5bmm (0.138bin)  
400257-10  
»
The brake disc thickness is less than the specified value.  
Replace the brake disc.  
ದ
ꢈ
ꢃꢆꢀ  
hecking free play of hand brake lever  
Warning  
Danger of accidentsಘBrake system failure.  
ದ
If 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 to overheating. Adjust free travel on hand brake lever according to specifications.  
(Every XCR-W models)  
ದ
Push the hand brake lever forwards and check free play.bꢂ.  
Free play of hand brake lever ุb3bmm (ุb0.12bin)  
If the free travel does not meet specifications:  
adjust the basic position of handbrake lever. ( P. 56)  
»
ದ
400196-11  
(Every EXC-R models)  
Push the hand brake to the handlebar and check free playbꢂ.  
ದ
Free play of hand brake lever ุb3bmm (ุb0.12bin)  
If the free travel does not meet specifications:  
Adjust the free travel of the handbrake lever. ( P. 56)  
»
ದ
400196-13  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
56  
ꢈ
ꢃꢆꢁ  
ದ
Adjust the basic setting of the handbrake lever to your hand size by turning adjust-  
ing screwbꢀ.  
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.  
Do not make any adjustments while riding!  
400196-12  
ದ
Check the free play of the hand brake lever. ( P. 55)  
ꢈ
ꢃꢆꢂ  
ದ
Adjust the free travel of the handbrake lever with the adjustment screwbꢀ.  
Info  
Turn 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.  
Do not make any adjustments while riding!  
400196-12  
ದ
Check the free play of the hand brake lever. ( P. 55)  
ꢈ
ꢃꢆꢄ  
hecking the front brake fluid level  
Warning  
Danger of accidentsಘBrake system failure.  
ದ
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.  
Have the brake system checked in an authorized KTM workshop, and do not ride any further.  
Warning  
Danger of accidentsಘReduced braking due to old brake fluid.  
ದ
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.  
ದ
ದ
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.  
Check the brake fluid level in the viewerbꢀ.  
»
If the brake fluid is below the MIN mark:  
ದ
Top up the brake fluid of the front brake. ( P. 56)  
400231-10  
ꢈ
ꢃꢆꢅ  
opping up the front brake fluidbx  
Warning  
Danger of accidentsಘBrake system failure.  
ದ
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.  
Have the brake system checked in an authorized KTM workshop, and do not ride any further.  
Warning  
Skin irritationsಘBrake fluid can cause skin irritation on contact.  
ದ
ದ
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.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
57  
Warning  
Danger of accidentsಘReduced braking due to old brake fluid.  
ದ
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.  
Warning  
Environmental hazardಘProblem materials cause environmental damage.  
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.  
Info  
KTM recommends DOTb5.1 brake fluid from Motorex®. This has a higher wet boiling point than DOTb4 brake fluid and provides  
greater safety for high demands.  
Never user DOTb5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for  
DOTb5 brake fluid.  
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!  
Use only clean brake fluid from a sealed container!  
ದ
ದ
ದ
ದ
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.  
Remove screwsb  
Remove the coverb  
ꢀ
.
ꢁ
with membraneb  
ꢅ
.
Top up brake fluid to levelb  
ꢂ.  
Specification  
Measurement ofb  
ꢂ
5bmm (0.2bin)  
Brake fluid DOT 5.1 ( P. 114)  
ದ
ದ
Check parts for damage and wear. Replace damaged or worn parts.  
Position the cover with membrane. Mount and tighten screws.  
Info  
Clean up overflowed or spilt brake fluid immediately with water.  
400230-10  
ꢈ
ꢃꢆꢆ  
Warning  
Danger of accidentsಘReduced braking due to worn brake linings.  
Worn brake linings should be replaced immediately in an authorized KTM workshop.  
ದ
ದ
Check the brake linings for minimum thicknessb  
Minimum thicknessb : ุb1bmm (ุb0.04bin)  
If the minimum thickness is less than specified:  
Change the front brake linings. ( P. 59)  
ꢂ
.
»
ꢂ
ದ
400235-10  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
58  
ꢈ
ꢃꢆꢇ  
emoving front brake liningsbx  
Warning  
Danger of accidentsಘImproper brake maintenance and repair.  
ದ
Always have your brake system maintained and repaired in an authorized KTM workshop.  
ದ
Press the brake caliper by hand on to the brake disc in order to press back the  
brake pistons.  
Info  
Make sure when pushing back the brake pistons that you do not press the  
brake caliper against the spokes.  
ದ
Remove the locking split pinsbꢀ, withdraw the boltbꢁ, and take out the brake  
pads.  
ದ
ದ
Remove cable clipbꢅ. Remove screwsbꢆ and take off brake caliper.  
Clean brake caliper and brake caliper support.  
500089-11  
ꢈ
ꢃꢆꢈ  
nstalling the front brake liningsbx  
Warning  
Danger of accidentsಘReduced 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.  
ದ
Warning  
Danger of accidentsಘReduced braking due to use of non-approved brake linings.  
ದ
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.  
ದ
ದ
ದ
Check the brake discs. ( P. 55)  
Check parts for damage and wear. Replace damaged or worn parts.  
Check that leaf springbꢀ in the brake caliper and sliding platebꢁ in the brake  
caliper support are seated correctly.  
Info  
The arrow on the leaf spring points in the rotation direction of the brake  
disc.  
500091-10  
ದ
ದ
Fit the brake linings, insert boltbꢅ, and mount locking split pinsbꢆ.  
Position brake caliper, mount and tighten screwsbꢇ.  
Specification  
Screw, front brake caliper  
M8  
25bNm  
(18.4blbfbft)  
Loctite® 243™  
ದ
ದ
Fit cable clipb  
.
Operate the hand brake lever repeatedly until the brake linings lie on the brake disc  
and there is a tight spot.  
500089-12  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
59  
ꢈ
ꢃꢆꢉ  
hanging the front brake liningsbx  
Warning  
Skin irritationsಘBrake fluid can cause skin irritation on contact.  
ದ
ದ
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 accidentsಘReduced braking due to old brake fluid.  
ದ
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.  
Warning  
Environmental hazardಘProblem materials cause environmental damage.  
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.  
Info  
KTM recommends brake fluid DOTb5.1 from Motorex®. This brake fluid has a higher wet boiling point than brake fluid DOTb4  
and offers more protection under high load.  
Never user DOTb5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for  
DOTb5 brake fluid.  
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!  
Use only clean brake fluid from a sealed container!  
ದ
ದ
ದ
ದ
ದ
Remove the front brake linings. ( P. 58)  
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.  
Remove screwsb  
Remove coverb  
ꢀ
.
ꢁ
with membraneb  
ꢅ
.
Press the brake piston back to its basic position and make sure that no brake fluid  
overflows from the brake fluid reservoir.  
ದ
ದ
Install the front brake linings. ( P. 58)  
Add brake fluid to levelb  
ꢂ.  
Specification  
Measurement ofb  
ꢂ
5bmm (0.2bin)  
Brake fluid DOT 5.1 ( P. 114)  
ದ
ದ
Check parts for damage and wear. Replace damaged or worn parts.  
Position the cover with the membrane. Mount and tighten the screws.  
Info  
Clean up overflowed or spilt brake fluid immediately with water.  
400230-10  
ꢈ
ꢃꢇꢊ  
hecking free play of foot brake lever  
Warning  
Danger of accidentsಘBrake system failure.  
ದ
If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake  
can fail due to overheating. Adjust free travel on foot brake pedal according to specifications.  
ದ
ದ
Disconnect springb  
ꢀ
.
Move the foot brake lever backwards and forwards between the end stop and the  
foot brake cylinder piston bracket and check free playb  
ꢂ.  
Specification  
Free play at foot brake lever  
If the free travel does not meet specifications:  
Adjust the basic position of the footbrake lever. ( P. 60)  
Reconnect springb  
3… 5bmm (0.12… 0.2bin)  
»
ದ
ದ
ꢀ.  
500139-11  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
60  
ꢈ
ꢃꢇꢀ  
djusting basic position of footbrake leverbx  
Warning  
Danger of accidentsಘBrake system failure.  
ದ
If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake  
can fail due to overheating. Adjust free travel on foot brake pedal according to specifications.  
ದ
ದ
ದ
Disconnect springbꢀ.  
Loosen nutbꢆ and with push rodbꢇ, turn it back until you have maximum free play.  
To adjust the basic position of the footbrake lever individually, lossen nutbꢁ and  
turn screwbꢅ accordingly.  
Info  
The range of adjustment is limited.  
ದ
ದ
ದ
ದ
Turn push rodbꢇ accordingly until you have free playbꢂ. If necessary, adjust the  
basic position of the footbrake lever.  
500154-10  
Specification  
Free play at foot brake lever  
3… 5bmm (0.12… 0.2bin)  
Hold screwbꢅ and tighten nutbꢁ.  
Specification  
Remaining nuts, chassis  
M8  
M6  
30bNm  
(22.1blbfbft)  
Hold push rodbꢇ and tighten nutbꢆ.  
Specification  
Remaining nuts, chassis  
15bNm  
(11.1blbfbft)  
Reconnect springbꢀ.  
ꢈ
ꢃꢇꢁ  
hecking the rear brake fluid level  
Warning  
Danger of accidentsಘBrake system failure.  
ದ
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.  
Have the brake system checked in an authorized KTM workshop, and do not ride any further.  
Warning  
Danger of accidentsಘReduced braking due to old brake fluid.  
ದ
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.  
ದ
ದ
Stand the vehicle upright.  
Check the brake fluid level in the viewerbꢀ.  
»
When in the viewerbꢀ an air bubble is visible:  
Add rear brake fluid. ( P. 61)  
ದ
400234-10  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
61  
ꢈ
ꢃꢇꢂ  
dding rear brake fluidbx  
Warning  
Danger of accidentsಘBrake system failure.  
ದ
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.  
Have the brake system checked in an authorized KTM workshop, and do not ride any further.  
Warning  
Skin irritationsಘBrake fluid can cause skin irritation on contact.  
ದ
ದ
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 accidentsಘReduced braking due to old brake fluid.  
ದ
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.  
Warning  
Environmental hazardಘProblem materials cause environmental damage.  
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.  
Info  
KTM recommends brake fluid DOTb5.1 frombMotorex®. This brake fluid has a higher wet boiling point than brake fluid DOTb4  
and offers more protection under high load.  
Never user DOTb5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for  
DOTb5 brake fluid.  
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!  
Use only clean brake fluid from a sealed container!  
ದ
ದ
ದ
Stand the vehicle upright.  
Remove screw capb with membraneb  
Add brake fluid to levelb  
Brake fluid DOT 5.1 ( P. 114)  
ꢀ
ꢁ
and the O-ring.  
ꢂ.  
ದ
ದ
Check parts for damage and wear. Replace damaged or worn parts.  
Mount the screw cap with the membraneband the O-ring.  
Info  
400233-10  
Clean up overflowed or spilt brake fluid immediately with water.  
ꢈ
ꢃꢇꢄ  
hecking rear brake linings  
Warning  
Danger of accidentsಘReduced braking due to worn brake linings.  
Worn brake linings should be replaced immediately in an authorized KTM workshop.  
ದ
ದ
Check the brake linings for minimum thicknessb  
Minimum thicknessb : ุb1bmm (ุb0.04bin)  
If the minimum thickness is less than specified:  
Change the rear brake linings. ( P. 63)  
ꢂ
.
»
ꢂ
ದ
400238-10  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
62  
ꢈ
ꢃꢇꢅ  
emoving rear brake liningsbx  
Warning  
Danger of accidentsಘImproper brake maintenance and repair.  
ದ
Always have your brake system maintained and repaired in an authorized KTM workshop.  
ದ
Press the brake caliper by hand on to the brake disc in order to press back the  
brake piston.  
Info  
Make sure when pushing back the brake piston that you do not press the  
brake caliper against the spokes.  
ದ
ದ
Remove the locking split pinsbꢀ, withdraw the boltbꢁ, and take out the brake  
pads.  
Clean brake caliper and brake caliper support.  
400236-10  
ꢈ
ꢃꢇꢆ  
nstalling the rear brake liningsbx  
Warning  
Danger of accidentsಘReduced 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.  
ದ
Warning  
Danger of accidentsಘReduced braking due to use of non-approved brake linings.  
ದ
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.  
ದ
ದ
ದ
Check the brake discs. ( P. 55)  
Check parts for damage and wear. Replace damaged or worn parts.  
Check that leaf springbꢀ in the brake caliper and sliding platebꢁ in the brake  
caliper support are seated correctly.  
Info  
The arrow on the leaf spring points in the rotation direction of the brake  
disc.  
500122-10  
ದ
ದ
Fit the brake linings, insert boltbꢅ, and mount locking split pinsbꢆ.  
Info  
Make sure that the decoupling platebꢇ 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.  
400237-10  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
63  
ꢈ
ꢃꢇꢇ  
hanging the rear brake liningsbx  
Warning  
Skin irritationsಘBrake fluid can cause skin irritation on contact.  
ದ
ದ
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 accidentsಘReduced braking due to old brake fluid.  
ದ
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.  
Warning  
Environmental hazardಘProblem materials cause environmental damage.  
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.  
Info  
KTM recommends brake fluid DOTb5.1 from Motorex®. This brake fluid has a higher wet boiling point than brake fluid DOTb4  
and offers more protection under high load.  
Never user DOTb5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for  
DOTb5 brake fluid.  
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!  
Use only clean brake fluid from a sealed container!  
ದ
ದ
ದ
ದ
Remove the rear brake linings. ( P. 62)  
Stand the vehicle upright.  
Remove screw capb  
ꢀ
with membraneb  
ꢁ
and 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.  
ದ
ದ
Install the rear brake linings. ( P. 62)  
Add brake fluid to levelb  
ꢂ.  
Brake fluid DOT 5.1 ( P. 114)  
400233-10  
ದ
ದ
Check parts for damage and wear. Replace damaged or worn parts.  
Mount the screw cap with the membraneband the O-ring.  
Info  
Clean up overflowed or spilt brake fluid immediately with water.  
ꢈ
ꢃꢇꢈ  
emoving front wheelbx  
ದ
ದ
Jack up the motorcycle. ( P. 32)  
Press the brake caliper by hand on to the brake disc in order to press back the  
brake pistons.  
Info  
Make sure when pushing back the brake pistons that you do not press the  
brake caliper against the spokes.  
500089-10  
ದ
ದ
Remove screwb  
ꢀ
.
Loosen screwb  
ꢁ
.
500084-10  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
64  
ದ
Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of  
the fork.  
Info  
Do not pull the hand brake lever when the front wheel is removed.  
Always lay the wheel down in such a way that the brake disc is not dam-  
aged.  
500085-10  
ದ
Remove distance bushingbꢅ.  
500086-10  
ꢈ
ꢃꢇꢉ  
itting front wheelbx  
Warning  
Danger of accidentsಘReduced 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.  
ದ
ದ
ದ
Check parts for damage and wear. Replace damaged or worn parts.  
Clean and grease shaft seal ringsbꢀ and bearing surfacebꢂ of the distance bush-  
ings.  
Long-life grease ( P. 115)  
Fit the distance bushings.  
ದ
500086-11  
ದ
ದ
Lift the front wheel into the fork, position it, and insert the wheel spindle.  
Mount and tighten screwbꢁ.  
Specification  
Screw, front wheel spindle  
M24x1,5  
40bNm  
(29.5blbfbft)  
ದ
Operate the hand brake lever several times until the brake pads are lying correctly  
on the brake disc.  
ದ
ದ
Remove the motorcycle from the work stand. ( P. 32)  
500084-11  
Pull the front wheel brake and push down hard on the fork several times to align  
the fork legs.  
ದ
Fully tighten screwbꢅ.  
Specification  
Screw, fork stub  
M8  
15bNm  
(11.1blbfbft)  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
65  
ꢈ
ꢃꢈꢊ  
emoving rear wheelbx  
ದ
ದ
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.  
Info  
Make sure when pushing back the brake piston that you do not press the  
brake caliper against the spokes.  
ದ
ದ
Remove nutbꢀ.  
Remove chain adjusterbꢁ. Withdraw the wheel spindlebꢅ only enough to allow the  
rear wheel to be pushed forward.  
ದ
ದ
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.  
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.  
400258-10  
ದ
Remove the spacing sleevesbꢆ.  
400260-11  
ꢈ
ꢃꢈꢀ  
itting rear wheelbx  
Warning  
Danger of accidentsಘReduced 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.  
ದ
ದ
ದ
Check parts for damage and wear. Replace damaged or worn parts.  
Clean and grease shaft seal ringsbꢀ and bearing surfacebꢂ of the spacing sleeves.  
Long-life grease ( P. 115)  
Fit the spacing sleeves.  
ದ
400260-10  
ದ
ದ
Lift the rear wheel into the swing arm, position it, and insert the wheel spindlebꢁ.  
Put the chain on.  
400259-10  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
66  
ದ
ದ
ದ
Position the chain adjusterbꢅ. Fit nutbꢆ, but do not tighten it yet.  
Check the chain tension when fitting rear wheel. ( P. 51)  
Make sure that the chain adjustersbꢅ are fitted correctly on the adjusting  
screwsbꢇ.  
ದ
Tighten nutbꢆ.  
Specification  
Nut, rear wheel spindle  
M20x1,5  
80bNm (59blbfbft)  
Info  
The wide adjustment range of the chain adjusters (32 mm) enables different  
secondary transmissions with the same chain length.  
The chain adjustersbꢅ can be turned by 180°.  
ದ
ದ
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. ( P. 32)  
400225-12  
ꢈ
ꢃꢈꢁ  
ire condition checking  
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.  
ದ
ದ
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: ุb2bmm (ุb0.08bin)  
If the minimum tread depth is insufficient:  
ದ
Replace the tire(s).  
ꢈ
ꢃꢈꢂ  
hecking tire air pressure  
Info  
Low tire air pressure leads to abnormal wear and overheating of the tire.  
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.  
ದ
ದ
Remove dust cap.  
Check tire air pressure when tires are cold.  
Tire air pressure off road  
front  
1.0bbar (15bpsi)  
1.0bbar (15bpsi)  
Rear  
Road tire pressure (Every EXC-R models)  
front  
Rear  
1.5bbar (22bpsi)  
2.0bbar (29bpsi)  
400241-01  
»
If the tire pressure does not meet specifications:  
Correct tire pressure.  
Mount dust cap.  
ದ
ದ
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
67  
ꢈ
ꢃꢈꢄ  
hecking spoke tension  
Warning  
Danger of accidentsಘUnstable riding behavior due to loose spokes.  
ದ
If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop.  
Info  
A loose spoke can cause wheel imbalance, which leads to more loose 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.  
ದ
To check spoke tension, tap each spoke with a screwdriver.  
Specification  
You should hear a high note.  
Spoke nipple, front wheel  
Spoke nipple, rear wheel  
M4,5  
M5  
5bNm (3.7blbfbft)  
5bNm (3.7blbfbft)  
Info  
If you hear different tone frequencies from different spokes, this is an indi-  
cation of different spoke tensions.  
400228-01  
ꢈ
ꢃꢈꢅ  
emoving the batterybx  
Warning  
Risk of injuryಘBattery acid and battery gases cause serious cauterization.  
ದ
ದ
ದ
ದ
ದ
Keep batteries out of the reach of children.  
Wear suitable protective clothing and goggles.  
Avoid contact with battery acid and battery gases.  
Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.  
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least  
15 minutes and contact a doctor.  
ದ
ದ
ದ
ದ
Switch off all power-consuming components and switch off the engine.  
Remove the seat. ( P. 69)  
Disconnect the negative (minus) cablebꢀ of the battery.  
Pull back the plus pole coverbꢁ and disconnect the positive (plus) cable of the bat-  
tery.  
ದ
ದ
Hang the rubber bandbꢅ out to the bottom.  
Lift the battery up.  
500069-10  
ꢈ
ꢃꢈꢆ  
nstalling the batterybx  
ದ
ದ
Check parts for damage and wear. Replace damaged or worn parts.  
Place the battery in the battery holder.  
4Ah batteryb(YTX5L-BS) ( P. 94)  
ದ
ದ
ದ
ದ
Reconnect the rubber bandbꢀ.  
Attach the plus cable and replace the plus pole coverbꢁ.  
Attach the minus cablebꢅ.  
Mount the seat. ( P. 69)  
500069-11  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
68  
ꢈ
ꢃꢈꢇ  
echarging the batterybx  
Warning  
Risk of injuryಘBattery acid and battery gases cause serious cauterization.  
ದ
ದ
ದ
ದ
ದ
Keep batteries out of the reach of children.  
Wear suitable protective clothing and goggles.  
Avoid contact with battery acid and battery gases.  
Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.  
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least  
15 minutes and contact a doctor.  
Warning  
Environmental hazardಘComponents and battery acid are a danger to the environment.  
ದ
Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.  
Warning  
Environmental hazardಘProblem materials cause environmental damage.  
ದ
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.  
ದ
ದ
ದ
Switch off all power-consuming components and switch off the engine.  
Remove the seat. ( P. 69)  
Disconnect the minus (negative) cable of the battery to avoid damage to the motor-  
cycle's electronics.  
ದ
Connect the battery charger to the battery. Switch on the battery charger.  
Battery chargerb(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.  
Info  
Never remove the lidb  
ꢀ
.
Charge the battery according to the instructionsb  
ꢁ
on the battery casing.  
400240-10  
ದ
ದ
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  
motorcycle is not in use.  
3bmonths  
Mount the seat. ( P. 69)  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
69  
ꢈ
ꢃꢈꢈ  
emoving a fuse  
ದ
ದ
ದ
Switch off all power-consuming components and switch off the engine.  
Dismount the air filter box lid. ( P. 74)  
Remove the protection coverbꢀ.  
Info  
The fusebꢁ is located in the starter relaybꢅ under the filter box cover.  
ದ
Remove the fusebꢁ.  
400270-10  
ꢈ
ꢃꢈꢉ  
eplacing the fuse  
Warning  
Fire hazardಘThe electrical system can be overloaded by the use of incorrect fuses.  
ದ
Use only fuses with the prescribed amperage. Never by-pass or repair fuses.  
ದ
Check parts for damage and wear. Replace damaged or worn parts.  
Info  
A reserve fusebꢀ is located in the starter relay.  
Replace a burned-out fusebꢁ only by an equivalent fuse.  
ದ
Refit the fuse.  
Fuseb(58011109110)  
400273-10  
Info  
If the new fuse burns out, contact an authorized KTM workshop.  
ದ
ದ
Replace the protection cover.  
Install the air filter box lid. ( P. 74)  
ꢈ
ꢃꢉꢊ  
emoving the seat  
ದ
Remove screwbꢀ. Lift up the seat at the rear, pull it back and then remove from  
above.  
500080-10  
ꢈ
ꢃꢉꢀ  
ದ
ದ
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.  
ದ
ದ
Make sure that the seat is correctly locked in.  
Mount and tighten the screw of the seat fixing.  
Specification  
Remaining screws, chassis  
M6  
10bNm (7.4blbfbft)  
500068-01  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
70  
ꢈ
ꢃꢉꢁ  
ismounting the fuel tankbx  
Danger  
Fire hazardಘFuel can easily catch fire.  
ದ
Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no  
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.  
ದ
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 poisoningಘFuel is poisonous and a health hazard.  
ದ
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-  
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If 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.  
ದ
ದ
ದ
Remove the seat. ( P. 69)  
Turn the handlebꢀ of the fuel tap to the OFF position. (Figureb500137-10b P. 20)  
Pull off the fuel hose.  
Info  
Remaining fuel may run out of the fuel hose.  
ದ Remove screwsbꢀ with collar sleeve.  
(Every EXC-R models)  
ದ
Hang the horn and horn bracket to one side.  
500157-10  
500066-10  
500067-10  
ದ
ದ
Remove screwbꢁ with collar sleeve.  
Remove the tube from the fuel tank vent line.  
ದ
Pull both spoilers to the side of the radiator bracketbꢅ and take the fuel tank away  
upwards.  
ꢈ
ꢃꢉꢂ  
nstalling the fuel tankbx  
Danger  
Fire hazardಘFuel can easily catch fire.  
ದ
Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no  
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.  
ದ
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 poisoningಘFuel is poisonous and a health hazard.  
ದ
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-  
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,  
contact a doctor immediately. Change clothing that has come into contact with fuel.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
71  
ದ
ದ
ದ
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.  
500067-01  
500066-11  
500157-11  
ದ
ದ
Mount the fuel tank vent hose.  
Fit and tighten screwbꢀ with collar sleeve.  
Specification  
Remaining screws, chassis  
M6  
10bNm (7.4blbfbft)  
(Every EXC-R models)  
ದ
Position horn with horn bracket.  
ದ
Fit and tighten screwsbꢁ with collar sleeve.  
Specification  
Remaining screws, chassis  
M6  
10bNm (7.4blbfbft)  
ದ
ದ
Connect fuel hose.  
Mount the seat. ( P. 69)  
ꢈ
ꢃꢉꢄ  
The water pumpbꢀ 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 capbꢁ. The specified coolant temperature is therefore permissible with-  
out danger of function problems.  
120b°C (248b°F)  
Coolant ( 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.  
400335-10  
(EXC-RbSIXbDAYS, XCR-WbZA)  
The radiator fan provides extra cooling. It is controlled by a thermoswitch.  
ꢈ
ꢃꢉꢅ  
hecking antifreeze and coolant level  
Warning  
Danger of scaldingಘThe coolant gets very hot when the motorcycle is driven and is under high pressure.  
ದ
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 poisoningಘCoolants are poisonous and a health hazard.  
ದ
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.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
72  
ದ
ದ
ದ
Stand the motorcycle upright on a horizontal surface.  
Remove the radiator cap.  
Check antifreeze of coolant.  
෥25… ෥45b°C (෥13… ෥49b°F)  
»
If the antifreeze of the cooling liquid does not meet specifications:  
Correct antifreeze of coolant.  
ದ
ದ
ದ
Check the coolant level in the radiator.  
400243-10  
Coolant levelbꢂ above radiator fins.  
10bmm (0.39bin)  
»
If the level of the cooling liquid does not meet specifications:  
ದ
Correct the coolant level.  
Alternative 1  
Coolant ( P. 114)  
Alternative 2  
Coolant (mixed ready to use) ( P. 114)  
Refit the radiator cap.  
ꢈ
ꢃꢉꢆ  
hecking the coolant level  
Warning  
Danger of scaldingಘThe coolant gets very hot when the motorcycle is driven and is under high pressure.  
ದ
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 poisoningಘCoolants are poisonous and a health hazard.  
ದ
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.  
ದ
ದ
ದ
Stand the motorcycle upright on a horizontal surface.  
Remove the radiator cap.  
Check the coolant level in the radiator.  
Coolant levelbꢂ above radiator fins.  
10bmm (0.39bin)  
»
If the level of the cooling liquid does not meet specifications:  
ದ
Correct the coolant level.  
Alternative 1  
Coolant ( P. 114)  
400243-10  
Alternative 2  
Coolant (mixed ready to use) ( P. 114)  
ದ
Refit the radiator cap.  
ꢈ
ꢃꢉꢇ  
raining coolantbx  
Warning  
Danger of scaldingಘThe coolant gets very hot when the motorcycle is driven and is under high pressure.  
ದ
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 poisoningಘCoolants are poisonous and a health hazard.  
ದ
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.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
73  
ದ
ದ
ದ
ದ
ದ
Stand the vehicle upright.  
Place a suitable container under the water pump cover.  
Remove screwbꢀ. Remove the radiator capbꢁ.  
Completely drain the coolant.  
Fit screwbꢀ with a new seal and tighten it.  
Specification  
Screw, water pump cover  
M6x25  
10bNm (7.4blbfbft)  
400335-11  
ꢈ
ꢃꢉꢈ  
efilling coolantbx  
Warning  
Danger of poisoningಘCoolants are poisonous and a health hazard.  
ದ
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.  
ದ
ದ
ದ
Make sure that the screwbꢀ is tightened.  
Stand the vehicle upright.  
Pour coolant in up to measurementbꢂ above the radiator fins.  
Specification  
10bmm (0.39bin)  
Coolant  
0.95bl (1bqt.)  
Coolant ( P. 114)  
Coolant (mixed ready to use)  
(
P. 114)  
400244-10  
ದ
ದ
ದ
Refit the radiator cap.  
Make a short test ride.  
Check the coolant level. ( P. 72)  
ꢈ
ꢃꢉꢉ  
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.  
ꢈ
ꢃꢀꢊꢊ  
emoving main silencer  
Warning  
Danger of burnsಘThe exhaust system gets very hot when the vehicle is driven.  
ದ
Allow the exhaust system to cool down. Do not touch hot components.  
ದ
ದ
Disconnect springbꢀ.  
Remove screwsbꢁ and take off main silencer.  
400337-10  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
74  
ꢈ
ꢃꢀꢊꢀ  
ದ
ದ
Check parts for damage and wear. Replace damaged or worn parts.  
Mount the main silencer. Mount and tighten screwsb  
ꢀ.  
Specification  
Remaining screws, chassis  
Reconnect springb  
M6  
10bNm (7.4blbfbft)  
ದ
ದ
ꢁ.  
400337-11  
ꢈ
ꢃꢀꢊꢁ  
Pull off the air filter box lid in areab  
ꢂ
to the side and remove to the front.  
400338-10  
ꢈ
ꢃꢀꢊꢂ  
ದ
ದ
Check parts for damage and wear. Replace damaged or worn parts.  
Insert the air filter box lid into the rear areab and clip it into the front areab  
ꢂ
ꢃ.  
400338-11  
ꢈ
ꢃꢀꢊꢄ  
emoving the air filterbx  
Note  
Engine failureಘUnfiltered intake air has a negative effect on the service life of the engine.  
ದ
Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.  
Warning  
Environmental hazardಘProblem materials cause environmental damage.  
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.  
ದ
ದ
Dismount the air filter box lid. ( P. 74)  
out to the bottom and swing it to the side. Remove the  
air filter with the air filter support.  
Hang the air filter holderb  
ꢀ
ದ
Remove the air filter from the air filter support.  
500107-10  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
75  
ꢈ
ꢃꢀꢊꢅ  
nstalling the air filterbx  
ದ
ದ
ದ
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 supportb  
ꢀ.  
Info  
If the air filter is not correctly mounted, dust and dirt can penetrate into the  
engine and can cause damage.  
ದ
Install the air filter box lid. ( P. 74)  
500107-10  
ꢈ
ꢃꢀꢊꢆ  
leaning air filterbx  
Warning  
Environmental hazardಘProblem materials cause environmental damage.  
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.  
Info  
Do not clean the air filter with fuel or petroleum since these substances attack the foam.  
ದ
ದ
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)  
Info  
Only press the air filter to dry it, never wring it out.  
ದ
Oil the dry air filter with a high/quality filter oil.  
Oil for foam air filter ( P. 115)  
ದ
ದ
ದ
Clean the air filter box.  
Check carburetor connection boot for damage and tightness.  
Install the air filter. ( P. 75)  
ꢈ
ꢃꢀꢊꢇ  
djusting basic position of clutch lever  
ದ
Adjust the basic setting of the clutch lever to your hand size by turning adjusting  
screwb  
ꢀ.  
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  
ꢈ
ꢃꢀꢊꢈ  
hecking fluid level of hydraulic clutch  
Warning  
Skin irritationsಘBrake fluid can cause skin irritation on contact.  
ದ
ದ
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.  
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!  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
76  
ದ
ದ
ದ
ದ
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.  
Remove screwsb  
Take off coverb  
Check the fluid level.  
ꢀ
.
ꢁ
with membraneb  
ꢅ.  
Fluid level under top level of container. 4bmm (0.16bin)  
»
If the level of the cooling liquid does not meet specifications:  
ದ
Correct the fluid level of the hydraulic clutch.  
400339-10  
Brake fluid DOT 5.1 ( P. 114)  
ದ
ದ
Check parts for damage and wear. Replace damaged or worn parts.  
Position the cover with the membrane. Mount and tighten screws.  
Info  
Clean up overflowed or spilt fluid immediately with water.  
ꢈ
ꢃꢀꢊꢉ  
hanging fluid level of hydraulic clutchbx  
Warning  
Skin irritationsಘBrake fluid can cause skin irritation on contact.  
ದ
ದ
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 hazardಘProblem materials cause environmental damage.  
ದ
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!  
ದ
ದ
ದ
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.  
Remove screwsb  
Take off coverb  
ꢀ
.
ꢁ
with membraneb  
ꢅ.  
400339-10  
ದ
ದ
Fill the bleeding syringeb  
ꢆ
with the appropriate hydraulic fluid.  
Bleed syringe (50329050000)  
Brake fluid DOT 5.1 ( P. 114)  
On the slave cylinder, remove the bleeder screwb  
ꢇ
and fit the bleeding syringeb  
ꢆ.  
500158-10  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
77  
ದ
Inject the liquid into the system until it escapes from the bore holeb of the mas-  
ter cylinder without bubbles.  
ದ
ದ
ದ
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. 4bmm (0.16bin)  
ದ
ದ
Check parts for damage and wear. Replace damaged or worn parts.  
Position the cover with the membrane. Mount and tighten screws.  
400340-10  
Info  
Clean up overflowed or spilt fluid immediately with water.  
ꢈ
ꢃꢀꢀꢊ  
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.  
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 screwbꢀ.  
The idle mixture is adjusted with the idle mixture adjustment screwbꢁ.  
400341-10  
ꢈ
ꢃꢀꢀꢀ  
arburetor - adjusting idlebx  
ದ
Screw in the idle adjusting screwbꢁ until it stops and then to the prescribed basic  
setting.  
Specification  
Idle mixture adjusting screw (XCR-WbUSA)  
Open  
0.5bturn  
Idle mixture adjusting screw (EXC-RbSIXbDAYS)  
Open  
1.0bturn  
Idle mixture adjusting screw (XCR-WbZA, 530bEXC-RbEU, 530bEXC-RbAUS/UK)  
400341-10  
Open  
1.5bturns  
Idle mixture adjusting screw (450bEXC-RbEU, 450bEXC-RbAUS/UK, 450bEXC-  
RbUSA)  
Open  
1.75bturns  
Idle mixture adjusting screw (530bEXC-RbUSA)  
Open  
2.0bturns  
Adjustment tool for mixture control screw (77329034000)  
ದ
Run the engine until warm.  
Specification  
Warm-up time  
ุb5bmin  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
78  
Danger  
Danger of poisoningಘExhaust gases are poisonous and can result in uncon-  
sciousness and/or death.  
ದ
When running the engine, always make sure there is sufficient ventila-  
tion, and do not start or run the engine in a closed space.  
ದ
Adjust the idle speed with the adjusting screwbꢀ.  
Specification  
Choke function deactivated ದbThe choke lever is pushed in to the stop.  
(
P. 21)  
Choke function deactivated ದbThe choke lever is pushed back to the stop.  
P. 21)  
(
Idle speed  
1550… 1650brpm  
ದ
ದ
Turn the idle adjusting screwbꢁ slowly until the idle speed begins to fall.  
Note the position and turn the idle adjusting screw slowly counterclockwise until  
the idle speed falls.  
ದ
Adjust to the point between these two positions with the highest idle speed.  
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 becomes  
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.  
ದ
Adjust the idle speed with the adjusting screwbꢀ.  
Specification  
Choke function deactivated ದbThe choke lever is pushed in to the stop.  
(
P. 21)  
Choke function deactivated ದbThe choke lever is pushed back to the stop.  
P. 21)  
(
Idle speed  
1550… 1650brpm  
Info  
Following extreme air temperature or altitude changes, adjust the idle speed  
again.  
ꢈ
ꢃꢀꢀꢁ  
mptying the carburetor float chamberbx  
Danger  
Fire hazardಘFuel can easily catch fire.  
ದ
Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no  
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.  
ದ
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 poisoningಘFuel is poisonous and a health hazard.  
ದ
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-  
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If 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.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
79  
Warning  
Environmental hazardಘImproper handling of fuel is a danger to the environment.  
ದ
Do not allow fuel to get into the ground water, the ground, or the sewage system.  
Info  
Carry out this work with a cold engine.  
ದ
ದ
Turn the handleb  
ꢀ
of the fuel tap to the OFF position. (Figureb500137-10b P. 20)  
No more fuel flows from the tank to the carburetor.  
Guide the hose coming down behind the engine into a suitable container.  
Info  
Water in the float chamber results in malfunctioning.  
ದ
ದ
Undo the screwb  
the float chamber.  
Tighten screwb  
ꢀ
(turn it counterclockwise) a few turns and drain the fuel from  
ꢀ.  
400341-11  
ꢈ
ꢃꢀꢀꢂ  
hecking engine oil level  
Info  
The engine oil level must be checked when the engine is cold.  
ದ 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  
viewerb  
If the engine oil level is below the specified level:  
Top up the engine oil. ( P. 81)  
ದ
ꢀ
.
»
ದ
200119-10  
ꢈ
ꢃꢀꢀꢄ  
hanging engine oil and oil filter, cleaning engine oil screenbx  
ದ
ದ
ದ
ದ
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 oil. ( P. 81)  
ꢈ
ꢃꢀꢀꢅ  
raining engine oil, cleaning engine oil screenbx  
Warning  
Danger of scaldingಘEngine oil and gear oil get very hot when the motocycle is driven.  
ದ
Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.  
Warning  
Environmental hazardಘProblem materials cause environmental damage.  
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.  
Info  
Drain the engine oil only when the engine is warm.  
ದ
Stand the motorcycle on its side stand on a horizontal surface.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
80  
ದ
ದ
ದ
ದ
ದ
ದ
ದ
Place a suitable container under the engine.  
Remove engine oil plug screenb  
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 plugbꢀ  
for the engine oil screen and tighten it.  
Specification  
200112-10  
Plug, engine oil screen  
M17x1,5  
20bNm  
(14.8blbfbft)  
ꢈ
ꢃꢀꢀꢆ  
emoving the oil filterbx  
Warning  
Danger of scaldingಘEngine 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.  
ದ
Warning  
Environmental hazardಘProblem materials cause environmental damage.  
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.  
ದ
ದ
Place a suitable container under the engine.  
Remove screwsb . Remove oil filter coverb with O-ring.  
ꢀ
ꢁ
200113-10  
ದ
Pull the oil filter insertb  
ꢅ
out of the oil filter casing.  
Circlip pliers reverse (51012011000)  
ದ
ದ
Completely drain the engine oil.  
Thoroughly clean parts and sealing area.  
200114-10  
ꢈ
ꢃꢀꢀꢇ  
ounting oil filterbx  
ದ
ದ
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.  
ದ
ದ
Fill the oil filterb  
Lubricate the O/ringb  
ꢀ
with engine oil and place it in the oil filter container.  
of the oil filter cover.  
ꢁ
200114-11  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
81  
ದ
ದ
Refit the oil filter coverbꢅ.  
Mount and tighten screwsbꢆ.  
Specification  
Screw, oil filter cover  
M5  
6bNm (4.4blbfbft)  
ದ
Stand the motorcycle up.  
200113-11  
ꢈ
ꢃꢀꢀꢈ  
illing up with engine oilbx  
Info  
Too little engine oil or poor-quality engine oil results in premature wear to the engine.  
ದ
ದ
Remove the screw capbꢀ on the generator cover and fill up with engine oil.  
Engine oil 0.6bl (0.6bqt.) Engine oil (SAE 10W/50) ( P. 114)  
Mount and tighten screw capbꢀ.  
Danger  
Danger of poisoningಘExhaust gases are poisonous and can result in uncon-  
sciousness and/or death.  
ದ
When running the engine, always make sure there is sufficient ventila-  
tion, and do not start or run the engine in a closed space.  
200115-10  
ದ
ದ
Start the engine and check that it is oil-tight.  
Check the engine oil level. ( P. 79)  
ꢈ
ꢃꢀꢀꢉ  
opping up engine oil  
Info  
Too little engine oil or poor-quality engine oil results in premature wear to the engine.  
ದ
ದ
Remove the screw capbꢀ on the generator cover and fill up with engine oil.  
Engine oil (SAE 10W/50) ( P. 114)  
Mount and tighten screw capbꢀ.  
Danger  
Danger of poisoningಘExhaust gases are poisonous and can result in uncon-  
sciousness and/or death.  
ದ
When running the engine, always make sure there is sufficient ventila-  
tion, and do not start or run the engine in a closed space.  
200115-10  
ದ
ದ
Start the engine and check that it is oil-tight.  
Check the engine oil level. ( P. 79)  
ꢈ
ꢃꢀꢁꢊ  
hecking gear oil level  
Info  
The gear oil level must be checked when the engine is cold.  
ದ
Stand the motorcycle upright on a horizontal surface.  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
82  
Condition  
Engine is cold.  
ದ
ದ
Remove gear oil level check screwbꢀ. Stand the vehicle upright.  
Check the gear oil level.  
A small amount of gear oil should flow out.  
If no gear oil flows out:  
»
ದ
Top up with gear oil. ( P. 83)  
ದ
Mount and tighten the gear oil level check screw.  
Specification  
200116-10  
Screw, gear oil level check  
M6  
10bNm  
(7.4blbfbft)  
ꢈ
ꢃꢀꢁꢀ  
hanging gear oil, cleaning gear oil screenbx  
ದ
ದ
Drain the gear oil and clean the gear oil screen. ( P. 82)  
Fill up with gear oil. ( P. 83)  
ꢈ
ꢃꢀꢁꢁ  
raining gear oil, cleaning gear oil screenbx  
Warning  
Danger of scaldingಘEngine oil and gear oil get very hot when the motocycle is driven.  
ದ
Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.  
Warning  
Environmental hazardಘProblem materials cause environmental damage.  
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.  
Info  
Drain the gear oil only when the engine is warm.  
ದ
ದ
ದ
ದ
ದ
ದ
ದ
ದ
ದ
ದ
Stand the motorcycle on its side stand on a horizontal surface.  
Place a suitable container under the engine.  
Remove the gear oil drain plugb  
ꢀ
.
Remove the gear oil screen plugb  
ꢁ
.
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 plugb  
Specification  
ꢀ
with seal ring and tighten it.  
M12x1,5  
Gear oil drain plug with magnet  
20bNm  
(14.8blbfbft)  
ದ
Fit the plugb  
Specification  
Plug, gear oil screen  
ꢁ
for the gear oil screen and tighten it.  
M16x1,5  
20bNm  
(14.8blbfbft)  
500159-10  
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MAINTENANCE WORK ON CHASSIS AND ENGINE  
83  
ꢈ
ꢃꢀꢁꢂ  
illing up with gear oilbx  
Info  
Too little gear oil or poor-quality oil results in premature wear to the transmission.  
ದ
ದ
Remove the screw capbꢀ and fill up with gear oil.  
Gear oil 0.9bl (1bqt.) Engine oil (SAE 10W/50) ( P. 114)  
Mount and tighten screw capbꢀ.  
Danger  
Danger of poisoningಘExhaust gases are poisonous and can result in uncon-  
sciousness and/or death.  
ದ
When running the engine, always make sure there is sufficient ventila-  
tion, and do not start or run the engine in a closed space.  
200118-10  
ದ
ದ
Start the engine and check that it is oil-tight.  
Check the gear oil level. ( P. 81)  
ꢈ
ꢃꢀꢁꢄ  
opping up with gear oilbx  
Info  
Too little gear oil or poor-quality oil results in premature wear to the transmission.  
ದ
Remove gear oil level check screwbꢀ.  
200116-10  
ದ
ದ
Remove screw capbꢁ. 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) ( P. 114)  
ದ
ದ
Mount and tighten the gear oil level check screw.  
Specification  
Screw, gear oil level check  
M6  
10bNm (7.4blbfbft)  
Mount and tighten screw capbꢁ.  
200118-11  
Danger  
Danger of poisoningಘExhaust gases are poisonous and can result in uncon-  
sciousness and/or death.  
ದ
When running the engine, always make sure there is sufficient ventila-  
tion, and do not start or run the engine in a closed space.  
ದ
Start the engine and check that it is oil-tight.  
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TROUBLESHOOTING  
84  
ꢉ7528%/(6+227,1*  
Faults  
Possible cause  
Measure  
The engine cannot be cranked (electric  
starter).  
Operating error  
ದ
Carry out instructions on starting.  
P. 26)  
(
Battery discharged  
Fuse blown  
ದ
ದ
ದ
ದ
ದ
ದ
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.  
Low external temperature  
Recharge the battery. Establish the  
reason for discharging or have it  
checked in a KTM workshop.  
Engine turns but does not start.  
Operating error  
ದ
ದ
Carry out instructions on starting.  
(
P. 26)  
Empty the carburetor float chamber.  
P. 78)  
Motorcycle was out of use for a long time  
and there is old fuel in the float chamber  
(
Fuel feed interrupted  
ದ
ದ
ದ
ದ
Check tank vent.  
Clean fuel tap.  
Clean carburetor.  
Engine flooded  
Clean and dry spark plug or replace if  
necessary.  
Spark plug oily or wet  
ದ
ದ
Clean and dry spark plug or replace if  
necessary.  
Electrode distance (plug gap) of spark  
plug too wide  
Adjust plug gap.  
Specification  
Spark plug electrode gap  
0.8… 0.9bmm (0.031… 0.035bin)  
Spark plug connector or spark plug defec-  
tive  
Warning  
Risk of injuryಘThe ignition sys-  
tem is under high voltage.  
ದ
Do not touch parts of the ig-  
nition system. Have work on  
the ignition system carried  
out in an authorized KTM  
workshop.  
ದ
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 on the  
spark plug.  
ದ
ದ
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  
5bmm (0.2bin)  
ದ
ದ
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  
ದ
ದ
Check wiring harness. (visual check)  
Check electrical system.  
Socket connector of CDI control device,  
pulse generator or ignition coil oxidized.  
ದ
Clean socket connector and treat it  
with contact spray.  
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TROUBLESHOOTING  
85  
Faults  
Possible cause  
Measure  
Engine turns but does not start.  
Engine has no idle.  
Water in carburetor or jets blocked  
Idling jet blocked  
ದ
ದ
ದ
ದ
ದ
ದ
Clean carburetor.  
Clean carburetor.  
Adjusting screws on carburetor distorted  
Spark plug defective  
Have the carburetor adjusted.  
Change spark plug.  
Ignition system defective  
Have ignition system checked.  
Have carburetor checked.  
Engine does not speed up.  
Engine has too little power.  
Carburetor running over because float  
needle dirty or worn  
Loose carburetor jets  
ದ
ದ
ದ
ದ
ದ
ದ
ದ
ದ
Have carburetor checked.  
Have ignition system checked.  
Check tank vent.  
Electronic ignition adjustment defective  
Fuel feed interrupted  
Clean fuel tap.  
Clean carburetor.  
Air filter very dirty  
Clean the air filter. ( P. 75)  
Check exhaust system for damage.  
Exhaust system leaky, deformed or too lit-  
tle glass fiber yarn filling in main silencer  
Change glass fiber yarn filling of main  
silencer.  
Valve clearance too little  
ದ
ದ
ದ
Have valve clearance adjusted.  
Have ignition system checked.  
Electronic ignition adjustment defective  
Engine stalls or is popping into the carbu- Lack of fuel  
retor  
Clean and check the fuel system and  
carburetor.  
Engine takes in bad air  
ದ
Check rubber sleeves and carburetor  
for tightness.  
Engine overheats.  
Too little coolant in cooling system  
ದ
ದ
ದ
ದ
ದ
ದ
ದ
ದ
Check the cooling system for leakage.  
Check the coolant level. ( P. 72)  
Switch off engine when standing.  
Clean radiator fins.  
Too little air stream  
Radiator fins very dirty  
Foam formation in cooling system  
Drain the coolant. ( P. 72)  
Refill the coolant. ( P. 73)  
Replace the radiator hose.  
Bent radiator hose  
Thermostat defective  
Have thermostat removed and checked.  
Specification  
Opening temperature: 70b°C (158b°F)  
Defect in radiator fan system  
(EXC-RbSIXbDAYS, XCR-WbZA)  
Engine vent hose bent  
ದ
ದ
Have the radiator fan system checked.  
High oil consumption  
Battery discharged  
Route the vent hose without bends or  
replace it if necessary.  
Engine oil level too high  
ದ
ದ
Check the engine oil level. ( P. 79)  
Engine oil too thin (low viscosity)  
Change the engine oil and oil filter and  
clean the engine oil screen. ( P. 79)  
Battery is not charged by generator  
ದ
ದ
Check electrical system.  
Speedometer values deleted (time, stop  
watch, lap times)  
The battery in the speedometer ist empty.  
Change the battery in the speedometer.  
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CLEANING  
86  
ꢀ&ꢊ/($1,1*  
Cꢀꢊꢃꢀ leaning motorcycle  
Note  
Material damageಘDamage and destruction of components by high-pressure cleaning equipment.  
ದ
Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri-  
cal components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts.  
Warning  
Environmental hazardಘProblem materials cause environmental damage.  
ದ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.  
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.  
ದ
ದ
ದ
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)  
Info  
Use warm water containing normal motorcycle cleaner and a soft sponge.  
ದ
ದ
After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly.  
Empty the carburetor float chamber. ( P. 78)  
Warning  
Danger of accidentsಘReduced braking due to wet or dirty brakes.  
ದ
Clean or dry dirty or wet brakes by riding and braking gently.  
ದ
After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes.  
Info  
The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.  
ದ
ದ
ದ
ದ
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.  
ದ
ದ
High-luster polish for paint ( P. 116)  
To prevent electrical problems, treat electric contacts and switches with contact spray.  
Contact spray ( P. 116)  
(EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA)  
ದ
Lubricate the steering lock.  
Universal oil spray ( P. 115)  
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STORAGE  
87  
ꢀ6ꢀ725$*(  
Sꢀꢀꢃꢀ torage  
Warning  
Danger of poisoningಘFuel is poisonous and a health hazard.  
ದ
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-  
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If 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.  
ದ
ದ
ದ
ದ
ದ
ದ
ದ
ದ
ದ
Clean the motorcycle. ( P. 86)  
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)  
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… 35b°C (32… 95b°F)  
ದ
The storage place should be dry and not subject to large temperature differences.  
Info  
KTM recommends propping up the motorcycle.  
ದ
ದ
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 corrosion.  
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.  
ꢀ
ꢀꢃꢁ  
utting into operation after storage  
ದ
ದ
ದ
ದ
ದ
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.  
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TECHNICAL DATA - ENGINE  
88  
ꢀ7ꢁ(&+1,&$/ '$7$  
ꢋ
(1*,1(  
Design  
1-cyliner 4-stroke engine, water-cooled  
449.3bcm³ (27.418bcubin)  
510.4bcm³ (31.147bcubin)  
63.4bmm (2.496bin)  
72bmm (2.83bin)  
95bmm (3.74bin)  
Displacement (Every 450 models)  
Displacement (Every 530 models)  
Stroke (Every 450 models)  
Stroke (Every 530 models)  
Bore  
Compression ratio  
Idle speed  
11,9:1  
1550… 1650brpm  
Control  
4 valves controlled via rocker arm, drive via tooth/wheel chain  
Valve diameter, intake  
Valve diameter, exhaust  
Valve clearance  
39.5bmm (1.555bin)  
31.7bmm (1.248bin)  
Outfeed at: 20b°C (68b°F)  
Infeed at: 20b°C (68b°F)  
Crankshaft bearing  
Conrod bearing  
0.12… 0.17bmm (0.0047… 0.0067bin)  
0.10… 0.15bmm (0.0039… 0.0059bin)  
2 grooved ball bearings  
Needle bearing  
Piston pin bearing  
Pistons  
not a bearing bush - DLC-plated piston pins  
Forged light alloy  
Piston rings  
1 compression ring, 1 oil scraper ring  
Engine lubrication  
Pressure circulation lubrication with 2 rotor pumps (engine) / 1  
rotor pump (transmission)  
Primary transmission  
Clutch  
33:76  
Multidisc clutch in oil bath / hydraulically activated  
Transmission ratio  
1st gear  
14:36  
2nd gear  
17:32  
3rd gear  
19:28  
4th gear  
22:26  
5th gear  
24:23  
6th gear  
26:21  
Generator  
Ignition  
12bV, 150bW  
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… 0.9bmm (0.031… 0.035bin)  
Water cooling, permanent circulation of coolant by water pump  
Electric starter / kickstarter  
Starting aid  
ꢀ
ꢁꢃꢀ  
apacity - engine oil  
Engine oil  
0.6bl (0.6bqt.)  
0.9bl (1bqt.)  
Engine oil (SAE 10W/50) ( P. 114)  
Engine oil (SAE 10W/50) ( P. 114)  
C
ꢁꢃꢁ  
apacity - gear oil  
Gear oil  
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TECHNICAL DATA - ENGINE  
89  
ꢀ
ꢁꢃꢂ  
Coolant  
0.95bl (1bqt.)  
Coolant ( P. 114)  
Coolant (mixed ready to use) ( P. 114)  
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TECHNICAL DATA - ENGINE TIGHTENING TORQUES  
90  
ꢀ7ꢂ(&+1,&$/ '$7$  
ꢋ
(1*,1( 7,*+7(1,1* 72548(6  
Screw, cable holder in generator cover  
Oil jet, rocker arm lubrication  
Oil jet, piston cooling  
M4  
4bNm (3blbfbft)  
Loctite® 243™  
M5  
2bNm (1.5blbfbft)  
2bNm (1.5blbfbft)  
6bNm (4.4blbfbft)  
6bNm (4.4blbfbft)  
10bNm (7.4blbfbft)  
6bNm (4.4blbfbft)  
6bNm (4.4blbfbft)  
6bNm (4.4blbfbft)  
4bNm (3blbfbft)  
Loctite® 243™  
M5  
Loctite® 243™  
Screw, locking lever  
M5  
Loctite® 243™  
Screw, ignition pulse generator  
Screw, clutch spring  
M5  
Loctite® 243™  
M6  
ದ
Locking screw for bearing  
Screw, oil filter cover  
M5  
Loctite® 243™  
M5  
ದ
Screw, oil pump cover  
Oil jet, conrod lubrication  
Nut, water-pump wheel  
Screw, kickstarter stop  
Screw, timing chain securing guide  
Screw, exhaust flange  
Screw, torque governor  
Screw, starter motor  
M5  
Loctite® 222  
M6x0,75  
M6  
Loctite® 243™  
6bNm (4.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
10bNm (7.4blbfbft)  
15bNm (11.1blbfbft)  
9bNm (6.6blbfbft)  
25bNm (18.4blbfbft)  
10bNm (7.4blbfbft)  
40bNm (29.5blbfbft)  
10bNm (7.4blbfbft)  
Loctite® 648™  
M6  
Loctite® 243™  
M6  
Loctite® 243™  
M6  
ದ
M6  
Loctite® 243™  
M6  
ದ
ದ
Screw, kickstarter spring hanger  
Screw, timing chain guide rail  
Screw generator cover  
Screw generator cover  
Screw, gear oil level check  
Screw, clutch cover  
M6  
M6  
Loctite® 243™  
M6x25  
M6x40  
M6  
ದ
ದ
ದ
ದ
ದ
ದ
ದ
ದ
M6x25  
M6x30  
M6x55  
M6x65  
M6x80  
M6  
Screw, clutch cover  
Screw, clutch cover  
Screw, engine housing  
Screw, engine housing  
Screw, camshaft bearing support  
Screw, shift drum locating  
Screw, shift lever  
Loctite® 243™  
M6  
Loctite® 243™  
M6  
Loctite® 243™  
Screw, timing chain tensioning rail  
Screw, stator bracket  
M6  
Loctite® 243™  
M6  
Loctite® 243™  
Screw, valve cover  
M6  
ದ
ದ
ದ
Screw, water pump cover  
Screw, water pump cover  
Screw, idler  
M6x25  
M6x55  
M6  
Loctite® 243™  
Screw, cylinder head  
M6  
ದ
ದ
Screw, rocker arm bearing  
Plug, oil channel  
M7x1  
M7  
Loctite® 243™  
Screw, kickstarter  
M8  
Loctite® 243™  
Plug, crankshaft location  
Balancer shaft nut  
M8  
ದ
ದ
ದ
M10x1  
M10x1  
Screw, unlocking of timing chain ten-  
sioner  
Screw, engine sprocket  
Plug, oil channel  
M10  
M10  
60bNm (44.3blbfbft)  
15bNm (11.1blbfbft)  
Loctite® 243™  
Loctite® 243™  
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TECHNICAL DATA - ENGINE TIGHTENING TORQUES  
91  
Screw, cylinder head  
M10x1,25  
Tightening sequence:  
Tighten diagonally, begin-  
ning with the rear screw on  
the chain shaft.  
Step 1  
Engine oil (any)  
10bNm (7.4blbfbft)  
Step 2  
30bNm (22.1blbfbft)  
Step 3  
50bNm (36.9blbfbft)  
Gear oil drain plug with magnet  
Ignition rotor nut  
M12x1,5  
M12x1  
20bNm (14.8blbfbft)  
60bNm (44.3blbfbft)  
20bNm (14.8blbfbft)  
20bNm (14.8blbfbft)  
15… 20bNm (11.1…  
14.8blbfbft)  
ದ
ದ
ದ
ದ
ದ
Plug, SLS  
M12x1,5  
M12x1,5  
M12x1,25  
Oil pressure control valve plug  
Spark plug  
Plug, rocker arm  
M14x1,25  
M16x1,5  
M17x1,5  
M18x1,5  
M20LHx1,5  
M24x1,5  
20bNm (14.8blbfbft)  
20bNm (14.8blbfbft)  
20bNm (14.8blbfbft)  
80bNm (59blbfbft)  
150bNm (110.6blbfbft)  
25bNm (18.4blbfbft)  
ದ
ದ
ದ
ದ
Plug, gear oil screen  
Plug, engine oil screen  
Nut, inner clutch hub  
Nut, primary gear  
Loctite® 648™  
Plug, timing chain tensioner  
ದ
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TECHNICAL DATA - CARBURETOR  
92  
ꢀ7ꢄ(&+1,&$/ '$7$  
ꢋ
&$5%85(725  
4
50bEXC-RbEU, 450bEXC-RbAUS/UK (3900I)  
Carburetor type  
Carburetor identification number  
Needle position  
Idle mixture adjusting screw  
Open  
KEIHIN FCR-MX 39  
3900I  
4th position from top  
1.75bturns  
Pump membrane stop  
Main jet  
2.15bmm (0.0846bin)  
180  
Jet needle  
OBDYU (OBDTQ)  
Idling jet  
40  
Main air jet  
200  
100  
65 (85)  
40  
Idle air jet  
Cold start jet  
Leakage nozzle  
Throttle slide  
15  
Slide stop  
present  
ꢀ
ꢄꢃꢁ  
50bEXC-RbSIXbDAYS, 450bEXC-RbUSA, 450bXCR-W (3900L)  
Carburetor type  
KEIHIN FCR-MX 39  
3900L  
Carburetor identfication number  
Needle position (450bXCR-WbUSA)  
Needle position (450bEXC-RbSIXbDAYS)  
Needle position (450bEXC-RbUSA, 450bXCR-WbZA)  
Idle mixture adjusting screw (450bXCR-WbUSA)  
Open  
1st position from top  
3rd position from top  
4th position from top  
0.5bturn  
1.0bturn  
1.5bturns  
Idle mixture adjusting screw (450bEXC-RbSIXbDAYS)  
Open  
Idle mixture adjusting screw (450bXCR-WbZA)  
Open  
Idle mixture adjusting screw (450bEXC-RbUSA)  
Open  
1.75bturns  
Pump membrane stop  
2.15bmm (0.0846bin)  
180  
Main jet (450bEXC-RbSIXbDAYS, 450bEXC-RbUSA, 450bXCR-  
WbUSA)  
Main jet (450bXCR-WbZA)  
Jet needle (450bXCR-W, 450bEXC-RbSIXbDAYS)  
Jet needle (450bEXC-RbUSA)  
Idling jet (450bXCR-W, 450bEXC-RbSIXbDAYS)  
Idling jet (450bEXC-RbUSA)  
Main air jet  
185  
OBDTQ  
OBDYU  
40  
48  
200  
100  
85  
Idle air jet  
Cold start jet  
Leakage nozzle  
40  
Throttle slide  
15  
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TECHNICAL DATA - CARBURETOR  
93  
ꢀ
ꢄꢃꢂ  
30bEXC-RbEU, 530bEXC-RbAUS/UK (3900J)  
Carburetor type  
Carburetor identfication number  
Needle position  
Idle mixture adjusting screw  
Open  
KEIHIN FCR-MX 39  
3900J  
5th position from top  
1.5bturns  
Pump membrane stop  
Main jet  
2.15bmm (0.0846bin)  
180  
Jet needle  
OBDZT (OBDTR)  
Idling jet  
40  
Main air jet  
200  
100  
65 (85)  
40  
Idle air jet  
Cold start jet  
Leakage nozzle  
Throttle slide  
15  
Slide stop  
present  
ꢀ
ꢄꢃꢄ  
30bEXC-RbSIXbDAYS, 530bEXC-RbUSA, 530bXCR-W (3900M)  
Carburetor type  
KEIHIN FCR-MX 39  
3900M  
Carburetor identfication number  
Needle position (530bXCR-WbUSA)  
Needle position (530bEXC-RbSIXbDAYS, 530bEXC-RbUSA)  
Needle position (530bXCR-WbZA)  
Idle mixture adjusting screw (530bXCR-WbUSA)  
Open  
1st position from top  
3rd position from top  
4th position from top  
0.5bturn  
1.0bturn  
1.5bturns  
Idle mixture adjusting screw (530bEXC-RbSIXbDAYS)  
Open  
Idle mixture adjusting screw (530bXCR-WbZA)  
Open  
Idle mixture adjusting screw (530bEXC-RbUSA)  
Open  
2.0bturns  
Pump membrane stop  
2.15bmm (0.0846bin)  
180  
Main jet (530bEXC-RbSIXbDAYS, 530bEXC-RbUSA, 530bXCR-  
WbUSA)  
Main jet (530bXCR-WbZA)  
Jet needle (530bXCR-W, 530bEXC-RbSIXbDAYS)  
Jet needle (530bEXC-RbUSA)  
Idling jet (530bXCR-W, 530bEXC-RbSIXbDAYS)  
Idling jet (530bEXC-RbUSA)  
Main air jet  
185  
OBDTR  
OBDZT  
40  
48  
200  
100  
85  
Idle air jet  
Cold start jet  
Leakage nozzle  
40  
Throttle slide  
15  
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TECHNICAL DATA - CHASSIS  
94  
ꢀ7ꢅ(&+1,&$/ '$7$  
ꢋ
&+$66,6  
Frame  
Central tube frame made of chrome molybdenum steel tubing  
WP 4860 MXMA PA  
Fork  
Suspension travel  
front  
300bmm (11.81bin)  
335bmm (13.19bin)  
Rear  
Fork offset (EXC-RbSIXbDAYS, XCR-WbUSA)  
Front marking  
18bmm (0.71bin)  
20bmm (0.79bin)  
Rear marking  
Fork offset (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA) 20bmm (0.79bin)  
Shock absorber  
WP PDS 5018 DCC  
Brake system  
Disc brakes, brake calipers on floating bearings  
Diameter of brake discs  
front  
260bmm (10.24bin)  
220bmm (8.66bin)  
Rear  
Wear limit of brake discs  
front  
2.5bmm (0.098bin)  
3.5bmm (0.138bin)  
Rear  
Tire air pressure off road  
front  
1.0bbar (15bpsi)  
1.0bbar (15bpsi)  
Rear  
Road tire pressure (Every EXC-R models)  
front  
Rear  
1.5bbar (22bpsi)  
2.0bbar (29bpsi)  
15:45 (14:52)  
Rear wheel gearing (450bEXC-RbEU, 450bEXC-RbAUS/UK,  
450bEXC-RbUSA)  
Rear wheel gearing (450bEXC-RbSIXbDAYS, XCR-WbZA)  
Rear wheel gearing (530bEXC-RbSIXbDAYS, XCR-WbUSA)  
Rear wheel gearing (530bEXC-RbEU, 530bEXC-RbAUS/UK)  
Chain  
14:52  
14:50  
15:45 (14:50)  
5/8 x 1/4"  
Rear sprockets available  
38, 40, 42, 45, 48, 49, 50, 51, 52  
63.5°  
Steering head angle  
Wheelbase  
1475 10bmm (58.07 0.39bin)  
925bmm (36.42bin)  
380bmm (14.96bin)  
113.9bkg (251.1blb.)  
Seat height unloaded  
Ground clearance unloaded  
Weight without fuel (EXC-RbEU, EXC-RbAUS/UK,  
EXC-RbSIXbDAYS)  
Weight without fuel (XCR-WbUSA)  
Weight without fuel (XCR-WbZA)  
Weight without fuel (EXC-RbUSA)  
Maximum permissible front axle load  
Maximum permissible rear axle load  
Maximum permissible overall weight  
112.2bkg (247.4blb.)  
113bkg (249blb.)  
114.8bkg (253.1blb.)  
145bkg (320blb.)  
190bkg (419blb.)  
335bkg (739blb.)  
4Ah battery  
YTX5L-BS  
Battery voltage: 12bV  
Nominal capacity: 4bAh  
maintenance-free  
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TECHNICAL DATA - CHASSIS  
95  
ꢀ
ꢅꢃꢀ  
Headlight (EXC-RbEU, EXC-RbAUS/UK,  
EXC-RbSIXbDAYS, EXC-RbUSA, XCR-WbZA)  
BA20d  
12bV  
35/35bW  
Parking light (EXC-RbEU, EXC-RbAUS/UK, W2,1x9,5d  
EXC-RbSIXbDAYS, EXC-RbUSA, XCR-WbZA)  
12bV  
5bW  
Indicator lights (Every EXC-R models)  
W2x4,6d  
12bV  
1.2bW  
Flasher light (EXC-RbEU, EXC-RbAUS/UK) BA15s  
12bV  
10bW  
Flasher light (EXC-RbUSA)  
BAU15s  
LED  
12bV  
10bW  
Brake / tail light (EXC-RbEU,  
EXC-RbAUS/UK, EXC-RbSIXbDAYS,  
XCR-WbZA)  
Brake / tail light (EXC-RbUSA)  
BAY15d  
12bV  
21/5bW  
Licence plate lamp (EXC-RbEU, EXC-  
RbAUS/UK)  
W2,1x9,5d  
12bV  
5bW  
ꢀ
ꢅꢃꢁ  
ires  
Validity  
Front tire  
Rear tire  
(Every EXC-R models)  
90/90b-b21b48bM+SbMbTT  
Metzeler MCEb6bDAYSbEXTREME  
140/80b-b18b70bM+SbMbTT  
Metzeler MCEb6bDAYSbEXTREME  
(Every XCR-W models)  
80/100b-b21b51bMbTT  
Bridgestone M59  
110/100b-b18b64bMbTT  
Bridgestone M402  
For further information, see:  
http://www.ktm.com  
ꢀ
ꢅꢃꢂ  
apacity - fuel  
Tank capacity (EXC-RbEU,  
EXC-RbAUS/UK,  
9bl (2.4bUSbgal)  
Super unleaded (ROZ 95 / RON 95 / PON 91) ( P. 114)  
Super unleaded (ROZ 95 / RON 95 / PON 91) ( P. 114)  
EXC-RbSIXbDAYS, XCR-WbZA)  
Tank capacity (EXC-RbUSA,  
XCR-WbUSA)  
9.2bl (2.43bUSbgal)  
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TECHNICAL DATA - FORK  
96  
ꢀ7ꢆ(&+1,&$/ '$7$  
ꢋ
)25.  
Fork part number (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR- 14.18.7D.06  
W)  
Fork part number (EXC-RbSIXbDAYS)  
14.18.7D.35  
Fork  
WP 4860 MXMA PA  
Compression damping (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)  
Comfort  
24bclicks  
Standard  
20bclicks  
18bclicks  
Sport  
Compression damping (EXC-RbSIXbDAYS)  
Comfort  
Standard  
Sport  
24bclicks  
22bclicks  
18bclicks  
Rebound damping (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)  
Comfort  
20bclicks  
Standard  
18bclicks  
18bclicks  
Sport  
Rebound damping (EXC-RbSIXbDAYS)  
Comfort  
20bclicks  
Standard  
20bclicks  
Sport  
18bclicks  
Spring length with preload spacer(s)  
Spring rate (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)  
Weight of rider: 65… 75bkg (143… 165blb.)  
Weight of rider: 75… 85bkg (165… 187blb.)  
Weight of rider: 85… 95bkg (187… 209blb.)  
Spring rate (EXC-RbSIXbDAYS)  
Weight of rider: 65… 75bkg (143… 165blb.)  
Weight of rider: 75… 85bkg (165… 187blb.)  
Air chamber length  
510bmm (20.08bin)  
4.4bN/mm (25.1blb/in)  
4.6bN/mm (26.3blb/in)  
4.8bN/mm (27.4blb/in)  
4.6bN/mm (26.3blb/in)  
4.8bN/mm (27.4blb/in)  
100+෥2300bmm (3.94෥+01..7198bin)  
Spring preload - PreloadbAdjuster (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W)  
Comfort  
2bturns  
4bturns  
7bturns  
Standard  
Sport  
Spring preload - PreloadbAdjuster (EXC-RbSIXbDAYS)  
Comfort  
2bturns  
Standard  
2bturns  
Sport  
7bturns  
Fork length  
Fork oil ( P. 114)  
940bmm (37.01bin)  
SAE 5  
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TECHNICAL DATA - SHOCK ABSORBER  
97  
ꢀ7ꢇ(&+1,&$/ '$7$  
ꢋ
6+2&. $%625%(5  
Shock absorber part number (EXC-RbEU, EXC-RbAUS/UK, EXC-  
RbUSA, XCR-W)  
12.18.7D.06  
Shock absorber part number (EXC-RbSIXbDAYS)  
12.18.7D.35  
Shock absorber  
WP PDS 5018 DCC  
Compression damping, low-speed  
Comfort  
18bclicks  
15bclicks  
12bclicks  
Standard  
Sport  
Compression damping, high-speed  
Comfort  
2bturns  
1.5bturns  
1bturn  
Standard  
Sport  
Rebound damping  
Comfort  
24bclicks  
22bclicks  
20bclicks  
Standard  
Sport  
Spring preload  
Standard  
9bmm  
Spring rate  
Weight of rider: 65… 75bkg (143… 165blb.)  
Weight of rider: 75… 85bkg (165… 187blb.)  
Weight of rider: 85… 95bkg (187… 209blb.)  
69bN/mm (394blb/in)  
72bN/mm (411blb/in)  
76bN/mm (434blb/in)  
250bmm (9.84bin)  
10bbar (145bpsi)  
Spring length  
Gas pressure  
Static sag  
35bmm (1.38bin)  
Riding sag  
105bmm (4.13bin)  
411bmm (16.18bin)  
Fitted length  
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TECHNICAL DATA - CHASSIS TIGHTENING TORQUES  
98  
ꢀ7ꢈ(&+1,&$/ '$7$  
ꢋ
&+$66,6 7,*+7(1,1* 72548(6  
Spoke nipple, front wheel  
Spoke nipple, rear wheel  
Remaining nuts, chassis  
Remaining screws, chassis  
Screw, rear brake disc  
M4,5  
M5  
M6  
M6  
M6  
M6  
M6  
M6  
5bNm (3.7blbfbft)  
5bNm (3.7blbfbft)  
15bNm (11.1blbfbft)  
10bNm (7.4blbfbft)  
14bNm (10.3blbfbft)  
14bNm (10.3blbfbft)  
5bNm (3.7blbfbft)  
10bNm (7.4blbfbft)  
ದ
ದ
ದ
ದ
ದ
ದ
ದ
ದ
Screw, front brake disc  
Screw, shock absorber adjusting ring  
Screw, ball joint of push rod on foot-  
brake cylinder  
Nut, rear sprocket screw  
Nut, rim lock  
M8  
M8  
M8  
M8  
M8  
M8  
35bNm (25.8blbfbft)  
10bNm (7.4blbfbft)  
30bNm (22.1blbfbft)  
25bNm (18.4blbfbft)  
25bNm (18.4blbfbft)  
17bNm (12.5blbfbft)  
Loctite® 243™  
ದ
ದ
ದ
Remaining nuts, chassis  
Remaining screws, chassis  
Screw, front brake caliper  
Loctite® 243™  
Screw, top triple clamp  
(EXC-RbSIXbDAYS, XCR-WbUSA)  
ದ
Screw, top triple clamp (EXC-RbEU,  
EXC-RbAUS/UK, EXC-RbUSA, XCR-  
WbZA)  
Screw, bottom triple clamp  
(EXC-RbSIXbDAYS, XCR-WbUSA)  
Screw, bottom triple clamp (EXC-RbEU, M8  
EXC-RbAUS/UK, EXC-RbUSA, XCR-  
WbZA)  
M8  
M8  
20bNm (14.8blbfbft)  
ದ
12bNm (8.9blbfbft)  
15bNm (11.1blbfbft)  
ದ
ದ
Screw, fork stub  
M8  
15bNm (11.1blbfbft)  
17bNm (12.5blbfbft)  
ದ
Screw, top steering stem  
(EXC-RbSIXbDAYS, XCR-WbUSA)  
M8  
Loctite® 243™  
Screw, top steering stem (EXC-RbEU,  
EXC-RbAUS/UK, EXC-RbUSA, XCR-  
WbZA)  
M8  
20bNm (14.8blbfbft)  
ದ
Screw, handlebar clamp (EXC-RbEU,  
EXC-RbAUS/UK, EXC-RbUSA, XCR-W)  
Screw, handlebar clamp  
M8  
M8  
20bNm (14.8blbfbft)  
16bNm (11.8blbfbft)  
ದ
ದ
(EXC-RbSIXbDAYS)  
Screw, engine brace  
M8  
33bNm (24.3blbfbft)  
35bNm (25.8blbfbft)  
40bNm (29.5blbfbft)  
60bNm (44.3blbfbft)  
50bNm (36.9blbfbft)  
45bNm (33.2blbfbft)  
40bNm (29.5blbfbft)  
20bNm (14.8blbfbft)  
80bNm (59blbfbft)  
80bNm (59blbfbft)  
100bNm (73.8blbfbft)  
12bNm (8.9blbfbft)  
80bNm (59blbfbft)  
10bNm (7.4blbfbft)  
60bNm (44.3blbfbft)  
ದ
Screw, subframe  
M8  
Loctite® 243™  
Screw, side stand fixing  
Engine carrying screw  
Remaining nuts, chassis  
Remaining screws, chassis  
Screw, handlebar support  
Nut, seat fixing  
M8  
Loctite® 243™  
M10  
ದ
ದ
ದ
M10  
M10  
M10  
Loctite® 243™  
M12x1  
M12  
ದ
Screw, top shock absorber  
Screw, bottom shock absorber  
Nut, swingarm pivot  
Loctite® 243™  
M12  
Loctite® 243™  
M16x1,5  
M20x1,5  
M20x1,5  
M20x1,5  
M20x1,5  
ದ
Screw-in nozzles, cooling system  
Nut, rear wheel spindle  
Screw, top steering head  
Loctite® 243™  
ದ
ದ
Screw, bottom steering head (EXC-  
RbSIXbDAYS, XCR-WbUSA)  
Loctite® 243™  
Screw, front wheel spindle  
M24x1,5  
40bNm (29.5blbfbft)  
ದ
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99  
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WIRING DIAGRAM  
100  
ꢀ:ꢉ,5,1* ',$*5$0  
W
iring diagram (EXC-RbEU)  
C_CX/2  
C_CW/2  
C_CZ/3  
C_CY/3  
C_DB/4  
C_DA/4  
C_AK1/2  
C_AH1/2  
C_CW2/2  
C_CX2/2  
C_DG/4  
C_BP/4  
C_CW3/2  
C_CX3/2  
wh  
bu  
gn  
ye  
re  
br  
ye-bl  
bl-wh  
gr  
br  
C_BA/1  
bu-wh  
C_BF/1  
bu-wh  
ye-re  
br  
ye-re  
br  
ye-re  
or  
br  
gr  
ye-bl  
re-wh  
re-bl  
gn  
or  
pu  
bl  
re  
bu  
ye  
C_BA2/1  
bl  
ye-bl  
ye-re  
wh-re  
br  
bl  
bl  
bl  
ye  
bu  
br  
re  
ye-re  
br  
gn  
bl  
wh-re  
re-bl  
re-wh  
ye-re  
C_CR/1  
ye  
wh  
C_CR1/1  
ye  
wh-gn  
C_BG1/3  
C_AJ1/3  
C_CA/4  
C_CE/4  
C_CX/2  
C_CW/2  
C_CX1/2  
C_CW1/2  
3
2
1
C_AJ/3  
C_BG/3  
wh  
br  
2
1
C_DI/2  
400308-10  
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WIRING DIAGRAM  
101  
Components  
1
Battery  
2
Generator  
3
Ignition coil  
4
Pulse generator  
5
Voltage regulator/rectifier  
Electric starter button  
Starter relay with fuse  
Starter motor  
6
7
8
9
Light switch, horn button, short circuit button  
Throttle valve sensor TPS  
Ignition curve plug connection  
CDI controller  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
Headlight  
Parking light  
Brake / tail light  
Licence plate lamp  
Speedometer  
Wheel speed sensor  
Tripmaster switch (optional)  
Flasher switch  
Flasher relay  
Left front flasher  
Left rear flasher  
Right front flasher  
Right rear flasher  
Horn  
Front brake light switch  
Rear brake light switch  
High beam indicator light  
Flasher indicator light  
Plug connector for radiator fan (optional)  
Cable colors  
bl  
black  
bl-wh  
br  
black-white  
brown  
br-bl  
bu  
brown-black  
blue  
bu-wh  
gn  
blue-white  
green  
gr  
gray  
or  
orange  
pu  
violet  
re  
red  
re-bl  
re-wh  
wh  
red-black  
red-white  
white  
wh-gn  
wh-re  
ye  
white-green  
white-red  
yellow  
ye-bl  
ye-re  
yellow-black  
yellow-red  
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WIRING DIAGRAM  
102  
ꢀ
ꢉꢃꢁ  
iring diagram (EXC-RbAUS/UK)  
C_CX/2  
C_CW/2  
C_CZ/3  
C_CY/3  
C_DB/4  
C_DA/4  
C_AK1/2  
C_AH1/2  
C_CW2/2  
C_CX2/2  
C_DG/4  
C_BP/4  
C_CW3/2  
C_CX3/2  
wh  
bu  
gn  
ye  
re  
br  
ye-bl  
bl-wh  
br  
gr  
C_BA/1  
bu-wh  
C_BF/1  
bu-wh  
br  
ye-re  
br  
ye-re  
br  
ye-re  
or  
gr  
ye-bl  
re-wh  
re-bl  
gn  
or  
pu  
bl  
re  
bu  
ye  
bl  
C_BA2/1  
ye-bl  
ye-re  
wh-re  
bl  
br  
bl  
ye  
bu  
br  
re  
ye-re  
br  
gn  
bl  
wh-re  
re-bl  
re-wh  
ye-re  
C_CR/1  
ye  
wh  
C_CR1/1  
ye  
wh-gn  
C_BG1/3  
C_AJ1/3  
C_CA/4  
C_CE/4  
C_CX/2  
C_CW/2  
C_CX1/2  
C_CW1/2  
3
2
1
C_AJ/3  
C_BG/3  
wh  
br  
2
1
C_DI/2  
400334-10  
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WIRING DIAGRAM  
103  
Components  
1
Battery  
2
Generator  
3
Ignition coil  
4
Pulse generator  
5
Voltage regulator/rectifier  
Flasher switch  
6
7
Starter relay with fuse  
Starter motor  
8
9
Light switch, horn button, short circuit button  
Throttle valve sensor TPS  
Ignition curve plug connection  
CDI controller  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
Headlight  
Parking light  
Brake / tail light  
Licence plate lamp  
Electric starter button, emergency OFF switch  
Flasher relay  
Left front flasher  
Left rear flasher  
Right front flasher  
Right rear flasher  
Speedometer  
Wheel speed sensor  
Tripmaster switch (optional)  
Horn  
Front brake light switch  
Rear brake light switch  
High beam indicator light  
Flasher indicator light  
Plug connector for radiator fan (optional)  
Cable colors  
bl  
black  
bl-wh  
br  
black-white  
brown  
br-bl  
bu  
brown-black  
blue  
bu-wh  
gn  
blue-white  
green  
gr  
gray  
or  
orange  
pu  
violet  
re  
red  
re-bl  
re-wh  
wh  
red-black  
red-white  
white  
wh-gn  
wh-re  
ye  
white-green  
white-red  
yellow  
ye-bl  
ye-re  
yellow-black  
yellow-red  
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WIRING DIAGRAM  
104  
ꢀ
ꢉꢃꢂ  
iring diagram (EXC-RbUSA)  
C_CX/2  
C_CW/2  
C_CZ/3  
C_CY/3  
C_DB/4  
C_DA/4  
C_AK1/2  
C_AH1/2  
C_CW2/2  
C_CX2/2  
C_DG/4  
C_BP/4  
C_CW3/2  
C_CX3/2  
gn bu  
wh  
bu  
gn  
ye  
re  
br  
bl-wh  
br  
gr  
or  
pu  
bl  
bu-wh  
bu-wh  
ye-re  
br  
ye-re  
br  
ye-re  
or  
br  
gr  
ye-bl  
re-wh  
re-bl  
gn  
ye-re  
or  
re  
bu  
br  
bl  
ye  
black  
bl  
OFF  
ON  
C_BF/1  
C_BA/1  
bl  
ye-re  
ye-re  
ye-bl  
br  
ye  
bu  
br  
ye-bl  
re  
gn  
bl  
re-bl  
wh-re  
re-wh  
ye-re  
C_CR/1  
ye  
wh  
C_CR1/1  
ye  
wh-gn  
C_BG1/3  
C_AJ1/3  
C_CA/4  
C_CE/4  
C_CX/2  
C_CW/2  
C_CX1/2  
C_CW1/2  
C_AJ/3  
C_BG/3  
400309-10  
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WIRING DIAGRAM  
105  
Components  
1
Battery  
2
Generator  
3
Ignition coil  
4
Pulse generator  
5
Voltage regulator/rectifier  
Electric starter button  
Starter relay with fuse  
Starter motor  
6
7
8
9
Emergency OFF switch  
Throttle valve sensor TPS  
Ignition curve plug connection  
CDI controller  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
Headlight  
Parking light  
Brake / tail light  
Light switch  
Flasher switch  
Flasher relay  
Left front flasher  
Left rear flasher  
Right front flasher  
Right rear flasher  
Speedometer  
Wheel speed sensor  
Tripmaster switch (optional)  
Horn button  
Horn  
Ignition switch  
Front brake light switch  
Rear brake light switch  
High beam indicator light  
Flasher indicator light  
Plug connector for radiator fan (optional)  
Cable colors  
bl  
black  
bl-wh  
br  
black-white  
brown  
br-bl  
bu  
brown-black  
blue  
bu-wh  
gn  
blue-white  
green  
gn-wh  
gr  
green-white  
gray  
or  
orange  
pu  
violet  
re  
red  
re-bl  
re-wh  
wh  
red-black  
red-white  
white  
wh-gn  
wh-re  
white-green  
white-red  
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WIRING DIAGRAM  
106  
ye  
yellow  
ye-bl  
ye-re  
yellow-black  
yellow-red  
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WIRING DIAGRAM  
107  
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WIRING DIAGRAM  
108  
ꢀ
ꢉꢃꢄ  
iring diagram (EXC-RbSIXbDAYS)  
C_CX/2  
C_CW/2  
C_CZ/3  
C_CY/3  
C_DB/4  
C_DA/4  
C_AK1/2  
C_AH1/2  
C_DG/4  
C_BP/4  
wh  
bu  
gn  
ye  
re  
br  
ye-bl  
bl-wh  
br  
gr  
C_BA/1  
C_BF/1  
bu-wh  
bu-wh  
br  
ye-re  
br  
C_BA2/1  
ye-bl  
gr  
ye-bl  
re-wh  
re-bl  
gn  
ye-re  
wh-re  
br  
bl  
bl  
re  
bu  
ye  
bl  
br  
br  
bl  
bl  
br  
ye  
bu  
ye-re  
br  
bl  
br  
bl  
br  
re  
gn  
bl  
wh-re  
re-bl  
re-wh  
ye-re  
C_CR/1  
ye  
wh  
C_CR1/1  
ye  
wh-gn  
C_CA/4  
C_CE/4  
3
2
1
C_AJ/3  
C_BG/3  
400307-10  
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WIRING DIAGRAM  
109  
Components  
1
Battery  
2
Generator  
3
Ignition coil  
4
Pulse generator  
5
Voltage regulator/rectifier  
Electric starter button  
Starter relay with fuse  
Starter motor  
6
7
8
9
Light switch, horn button, short circuit button  
Throttle valve sensor TPS  
Ignition curve plug connection  
CDI controller  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
Headlight  
Parking light  
Brake / tail light  
Thermoswitch  
Speedometer  
Wheel speed sensor  
Tripmaster switch (optional)  
Horn  
Front brake light switch  
Rear brake light switch  
High beam indicator light  
Radiator fan  
Plug connector for flasher cable harness (optional)  
Fuse, radiator fan  
Cable colors  
bl  
black  
bl-wh  
br  
black-white  
brown  
br-bl  
bu  
brown-black  
blue  
bu-wh  
gn  
blue-white  
green  
gr  
gray  
re  
red  
re-bl  
re-wh  
wh  
red-black  
red-white  
white  
wh-gn  
wh-re  
ye  
white-green  
white-red  
yellow  
ye-bl  
ye-re  
yellow-black  
yellow-red  
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WIRING DIAGRAM  
110  
ꢀ
ꢉꢃꢅ  
iring diagram (XCR-WbUSA)  
bl-wh  
br  
gr  
ye-bl  
bu-wh  
bu-wh  
br  
gr  
ye-bl  
re-wh  
re-bl  
gn  
wh  
ye  
re  
bu  
ye  
bl  
ye-re  
wh-re  
bl  
bl  
ye  
bu  
br  
re  
ye-re  
br  
gn  
br  
wh-re  
re-bl  
re-wh  
ye-re  
ye  
wh  
400310-10  
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WIRING DIAGRAM  
111  
Components  
1
Battery  
2
Generator  
3
Ignition coil  
4
Pulse generator  
5
Voltage regulator/rectifier  
Electric starter button  
Starter relay with fuse  
Starter motor  
6
7
8
9
Short circuit button  
Throttle valve sensor TPS  
Ignition curve plug connection  
CDI controller  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
21  
Light switch  
Speedometer  
Wheel speed sensor  
Tripmaster switch (optional)  
Plug connector for radiator fan (optional)  
Plug connector, headlight (optional)  
Plug connector, brake / tail light (optional)  
Thermoswitch  
Cable colors  
bl  
black  
bl-wh  
br  
black-white  
brown  
bu  
blue  
bu-wh  
gn  
blue-white  
green  
gr  
gray  
re  
red  
re-bl  
re-wh  
wh  
red-black  
red-white  
white  
wh-re  
ye  
white-red  
yellow  
ye-bl  
ye-re  
yellow-black  
yellow-red  
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WIRING DIAGRAM  
112  
ꢀ
ꢉꢃꢆ  
iring diagram (XCR-WbZA)  
bl-wh  
br  
gr  
ye-bl  
bu-wh  
bu-wh  
br  
gr  
ye-bl  
re-wh  
re-bl  
gn  
wh  
ye  
re  
bu  
ye  
bl  
ye-re  
wh-re  
bl  
br  
bl  
br  
bl  
ye  
bu  
br  
br  
ye-re  
br  
bl  
br  
bl  
re  
gn  
br  
wh-re  
re-bl  
re-wh  
ye-re  
ye  
wh  
400311-10  
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WIRING DIAGRAM  
113  
Components  
1
Battery  
2
Generator  
3
Ignition coil  
4
Pulse generator  
Voltage regulator/rectifier  
Electric starter button  
Starter relay with fuse  
Starter motor  
5
6
7
8
9
Short circuit button  
Throttle valve sensor TPS  
Ignition curve plug connection  
CDI controller  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
Headlight  
Parking light  
Brake / tail light  
Light switch  
Speedometer  
Wheel speed sensor  
Tripmaster switch (optional)  
Radiator fan  
Thermoswitch  
Fuse, radiator fan  
Cable colors  
bl  
black  
bl-wh  
br  
black-white  
brown  
bu  
blue  
bu-wh  
gn  
blue-white  
green  
gr  
gray  
re  
red  
re-bl  
re-wh  
wh  
red-black  
red-white  
white  
wh-re  
ye  
white-red  
yellow  
ye-bl  
ye-re  
yellow-black  
yellow-red  
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SUBSTANCES  
114  
ꢁ6ꢊ8%67$1&(6  
Super unleaded (ROZ 95 / RON 95 / PON 91)  
according to  
DINbENb228 (ROZ 95 / RON 95 / PON 91)  
ದ
Brake fluid DOT 5.1  
according to  
DOT  
Specification  
ದ
ದ
Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre-  
sponding properties. KTM recommends Motorex® products.  
Supplier  
Motorex  
ದ
Motorex®bBrakebFluidbDOTb5.1  
Coolant  
Specification  
Use only suitable coolant (even in countries with high temperatures). Using inferior antifreeze can result in corrosion and foaming.  
KTM recommends Motorex® products.  
ದ
Mixture ratio  
Antifreeze: ෥25… ෥45b°C (෥13… ෥49b°F)  
50b% Anti-corrosion/antifreeze  
50b% distilled water  
Coolant (mixed ready to use)  
Antifreeze  
෥40b°C (෥40b°F)  
Supplier  
Motorex  
ದ
Motorex®bAntibFreeze  
Engine oil (SAE 10W/50)  
according to  
ದ
ದ
JASObT903bMA ( P. 117)  
SAE ( P. 117) (SAE 10W/50)  
Specification  
ದ
Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre-  
sponding properties. KTM recommends Motorex® products.  
Synthetic engine oil  
Supplier  
Motorex  
ದ
Motorex®bCrossbPowerb4T  
Fork oil (SAE 5)  
according to  
ದ SAE ( P. 117) (SAE 5)  
Specification  
ದ
Use only oils that comply with the specified standards (see specifications on the container) and that possesses the corresponding  
properties. KTM recommends Motorex® products.  
Supplier  
Motorex  
ದ
Motorex®bRacingbForkbOil  
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AUXILIARY SUBSTANCES  
115  
ꢁ$ꢀ8;,/,$5< 68%67$1&(6  
Universal oil spray  
Specification  
ದ
Supplier  
KTM recommends Motorex® products.  
Motorex  
ದ
Motorex®bJokerb440bUniversal  
Long-life grease  
Specification  
ದ
Supplier  
KTM recommends Motorex® products.  
Motorex  
ದ
Motorex®bLongbThermb2000  
Chain cleaner  
Specification  
ದ
Supplier  
KTM recommends Motorex® products.  
Motorex  
ದ
Motorex®bChainbCleanb611  
Offroad chain spray  
Specification  
ದ
Supplier  
KTM recommends Motorex® products.  
Motorex  
ದ
Motorex®bChainbLubeb622  
Air filter cleaner  
Specification  
ದ
Supplier  
KTM recommends Motorex® products.  
Motorex  
ದ
Motorex®bTwinbAirbDirtbBiobRemover  
Oil for foam air filter  
Specification  
ದ
Supplier  
KTM recommends Motorex® products.  
Motorex  
ದ
Motorex®bTwinbAirbLiquidbPower  
Motorcycle cleaner  
Specification  
ದ
Supplier  
KTM recommends Motorex® products.  
Motorex  
ದ
Motorex®bMotobCleanb900  
Cleaning and polishing materials for metal, rubber and plastic  
Specification  
ದ
Supplier  
KTM recommends Motorex® products.  
Motorex  
ದ
Motorex®bProtectb&bShineb645  
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AUXILIARY SUBSTANCES  
116  
High-luster polish for paint  
Specification  
ದ
Supplier  
KTM recommends Motorex® products.  
Motorex  
ದ
Motorex®bMotobPolish  
Contact spray  
Specification  
ದ
Supplier  
KTM recommends Motorex® products.  
Motorex  
ದ
Motorex®bAccubContact  
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STANDARDS  
117  
ꢁ6ꢁ7$1'$5'6  
JASObT903bMA  
Different technical development directions required a new specification for 4-stroke motorcycles ದ the JASO T903 MA Standard. Ear-  
lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi-  
cation. Whereas long 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.  
SAE  
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.  
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CONSUMER INFORMATION (EXC-R USA)  
118  
ꢀ ꢇ  
ꢈ
ꢅ
ꢁ
ꢆ
Type label USA  
Chain tension  
EAVP  
ꢀ
ꢁ
ꢅ
Before you go for the first ride  
Type label CAN  
ꢇ
ꢆ
Noise emission  
Green sticker  
ꢈ
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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.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  
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, please 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.  
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INDEX  
120  
,1'(;  
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10  
A
adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 75  
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
Compression damping  
Air filter  
fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37  
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75  
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75  
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74  
Compression damping, high-speed  
of shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . 32  
Compression damping, low-speed  
Air filter box lid  
of shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . 33  
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74  
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74  
Coolant  
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72  
refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73  
Antifreeze  
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71  
Coolant level  
B
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71-72  
Basic chassis setting  
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71  
checking with rider's weight . . . . . . . . . . . . . . . . . . . . 32  
D
Battery  
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67  
recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68  
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67  
Dust boots  
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39  
E
Brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55  
Electric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . 11  
Emergency OFF switch . . . . . . . . . . . . . . . . . . . . . . . . .10-11  
Brake discs  
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55  
Engine  
Brake fluid  
running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25  
of rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . 61  
Topping up brake fluid of front brake . . . . . . . . . . . . . . 56  
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
Engine oil  
Brake fluid level  
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79  
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79  
refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81  
topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81  
of front brake, checking . . . . . . . . . . . . . . . . . . . . . . . 56  
of rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . 60  
Brake linings  
of front brake, changing . . . . . . . . . . . . . . . . . . . . . . 59  
of front brake, checking . . . . . . . . . . . . . . . . . . . . . . . 57  
of front brake, installing . . . . . . . . . . . . . . . . . . . . . . 58  
of front brake, removing . . . . . . . . . . . . . . . . . . . . . . 58  
of rear brake, changing . . . . . . . . . . . . . . . . . . . . . . . 63  
of rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . 61  
of rear brake, installing . . . . . . . . . . . . . . . . . . . . . . . 62  
of rear brake, removing . . . . . . . . . . . . . . . . . . . . . . . 62  
Engine oil level  
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79  
engine oil screen  
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79  
Engine oil screen  
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79  
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
C
F
Carburetor  
Filler cap  
adjusting idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77  
emptying the float chamber . . . . . . . . . . . . . . . . . . . . 78  
idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77  
closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20  
opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20  
Filling up  
Chain  
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28  
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50  
Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
Chain guide  
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21  
adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 60  
checking free play . . . . . . . . . . . . . . . . . . . . . . . . . . 59  
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54  
Chain tension  
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52  
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51  
Fork  
checking basic setting . . . . . . . . . . . . . . . . . . . . . . . . 37  
Chain wear  
Fork legs  
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52  
bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38  
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42  
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41  
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21  
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86  
Fork offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41  
Clutch  
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41  
changing fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76  
checking fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . 75  
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INDEX  
121  
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73  
Fork protector  
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43  
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43  
Front fender  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
Motorcycle  
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86  
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46  
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46  
O
Oil filter  
Front wheel  
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79  
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80  
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80  
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64  
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63  
Fuel tank  
Overview of indicator lamps . . . . . . . . . . . . . . . . . . . . . . . 13  
OWNER'S MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70  
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70  
P
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20  
Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
Play in gas Bowden cable  
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50  
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50  
Fuse  
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69  
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69  
Putting into operation  
Advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . 24  
after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87  
Checks before putting into operation . . . . . . . . . . . . . . 26  
G
Gas Bowden cable route  
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49  
R
gear oil  
Rear sprocket / engine sprocket  
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82  
checking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 52  
Gear oil  
Rear wheel  
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82  
refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83  
topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83  
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65  
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65  
Rebound damping  
gear oil level  
fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37  
of shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . 33  
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81  
gear oil screen  
Riding sag  
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82  
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36  
Gear oil screen  
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82  
S
H
Seat  
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69  
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69  
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10  
adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 56  
adjusting free travel . . . . . . . . . . . . . . . . . . . . . . . . . 56  
checking free play . . . . . . . . . . . . . . . . . . . . . . . . . . 55  
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21  
Shock absorber  
checking riding sag . . . . . . . . . . . . . . . . . . . . . . . . . . 35  
checking static sag . . . . . . . . . . . . . . . . . . . . . . . . . . 34  
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36  
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36  
Handlebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47  
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48  
Headlight flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . 12  
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12  
Short circuit button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10  
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22  
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
I
Ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11  
K
Speedometer  
Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22  
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
Function description . . . . . . . . . . . . . . . . . . . . . . . . . 13  
Setting kilometers or miles . . . . . . . . . . . . . . . . . . . . . 14  
Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
L
Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-12  
Spoke tension  
Lower triple clamp  
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67  
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44-45  
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43-44  
preload  
Spring  
fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38  
of shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . 35  
M
Main silencer  
Start number plate  
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74  
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47  
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INDEX  
122  
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47  
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26  
steering  
locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22  
unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23  
Steering head bearing  
greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46  
Steering head bearing play  
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40  
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39  
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87  
T
Technical data  
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92-93  
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94-95  
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88-89  
Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96  
Shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97  
Tightening torque - chassis . . . . . . . . . . . . . . . . . . . . 98  
Tightening torque - engine . . . . . . . . . . . . . . . . . . .90-91  
Tire air pressure  
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66  
Tire condition  
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66  
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . .84-85  
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-113  
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*3211254en*  
3211254en  
KTM-Sportmotorcycle AG  
5230 Mattighofen/Austria  
http://www.ktm.com  
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