User manual KTM 450 EXC

[. . . ] OWNER'S MANUAL 2010 400 EXC EU 400 EXC AUS 400 XC-W USA 450 EXC EU 450 EXC AUS 450 EXC SIX DAYS EU 450 XC-W SIX DAYS USA 450 XC-W ZA 530 EXC EU 530 EXC AUS 530 EXC SIX DAYS EU 530 XC-W SIX DAYS USA 530 XC-W ZA Art. 3211467en DEAR KTM CUSTOMER DEAR KTM CUSTOMER 1 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. [. . . ] Take out the right fork leg. 45 100804-10 Installing fork legs 9. 27 x ­ Position the fork legs. Info The topmost milled groove in the fork leg must be flush to the upper edge of the upper triple clamp. Position bleeder screws toward the front. 100021-10 (EXC SIX DAYS, XCW SIX DAYS, XCW USA) ­ Fully tighten screw . Guideline Screw, bottom triple clamp 100803-11 M8 17 Nm (12. 5 lbf ft) M8 12 Nm (8. 9 lbf ft) (EXC EU, EXC AUS, XCW ZA) ­ Fully tighten screw . Guideline Screw, bottom triple clamp 100804-11 M8 20 Nm (14. 8 lbf ft) M8 15 Nm (11. 1 lbf ft) ­ Position brake caliper, mount and tighten screws . Guideline Screw, front brake caliper M8 25 Nm (18. 4 lbf ft) Loctite® 243TM ­ ­ ­ 100802-11 Mount cable clip . 63) MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the fork protector 9. 28 46 x ­ ­ ­ Remove the fork legs. x( p. Remove the fork protector upwards. 600878-10 Installing the fork protector 9. 29 x ­ Position the fork protection on the left fork leg. Guideline Remaining screws, chassis ­ Guideline Remaining screws, chassis ­ 600878-10 M6 10 Nm (7. 4 lbf ft) Position the fork protection on the right fork leg. 45) 10 Nm (7. 4 lbf ft) Install the fork legs. x( Removing the front fender 9. 30 ­ ­ Remove screws . Pay attention to the location of the distance bushings. 600692-10 Installing the front fender 9. 31 ­ ­ Ensure that the spacing sleeves are mounted in the fender. Guideline Remaining screws, chassis M6 10 Nm (7. 4 lbf ft) Info Take care with the contact between the holding lugs and the start number plate or headlight mask. 600692-10 Removing headlight mask with headlight (all EXC models, all 450/530 XC-W models) 9. 32 ­ ­ ­ Switch off all electrical equipment. Push up the headlight mask and swing it forwards. 600703-10 MAINTENANCE WORK ON CHASSIS AND ENGINE ­ Pull out the electric plug connector and remove the headlight mask with the headlight. 47 600702-10 Refitting the headlight mask with the headlight (all EXC models, all 450/530 XC-W models) 9. 33 ­ Connect the electric plug connector . 600702-11 ­ Position the headlight mask and fix it with the rubber band . Info Ensure that the retaining lugs engage in the fender. 69) Removing the start number plate (400 XC-W USA) 9. 34 ­ ­ Remove screw and remove the clamp. Remove the start number plate. 500101-10 Installing the start number plate (400 XC-W USA) 9. 35 ­ Position the start number plate. Guideline Remaining screws, chassis M6 10 Nm (7. 4 lbf ft) Info Take care with the contact of the holding lug at the fender. 500101-11 ­ Position the brake line and cable harness. Put the clamp on, mount and tighten screw . MAINTENANCE WORK ON CHASSIS AND ENGINE Handlebar position 9. 36 48 On the upper triple clamp, there are 2 holes at a distance of to each other. Distance between holes 15 mm (0. 59 in) The holes on the handlebar support are placed at a distance of from the center. 0 A B 0 A 0 B 0 400223-11 Distance between holes 3. 5 mm (0. 138 in) The handlebar supports can be mounted in 4 different positions. Adjusting handlebar position 9. 37 x Warning Danger of accidentsHandlebar breakage. ­ If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handlebar. 1 0 2 0 1 0 2 0 ­ Remove the four screws . Remove the handlebar and lay it to one side. Info Protect the motorcycle and its attachments against damage by covering them. Fit and tighten the two screws 400223-10 ­ . Guideline Screw, handlebar support M10 40 Nm (29. 5 lbf ft) Loctite® 243TM Info Position the left and right handlebar supports evenly. ­ Position the handlebars. Info Make sure cables and wiring are positioned correctly. [. . . ] 108) 26 clicks 24 clicks 22 clicks 9 mm (0. 35 in) 2 turns 1. 5 turns 1. 25 turns 22 clicks 20 clicks 15 clicks 12. 18. 7J. 06 WP Suspension PDS 5018 DCC 99 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES Spoke nipple, front wheel Screw, spoiler on fuel tank (XCW USA, XCW SIX DAYS) Spoke nipple, rear wheel Remaining nuts, chassis Remaining screws, chassis Screw, ball joint of push rod on footbrake cylinder Screw, front brake disc Screw, rear brake disc Screw, shock absorber adjusting ring Nut, rear sprocket screw Nut, rim lock Remaining nuts, chassis Remaining screws, chassis Screw, bottom triple clamp (EXC SIX DAYS, XCW SIX DAYS, XCW USA) Screw, bottom triple clamp (EXC EU, EXC AUS, XCW ZA) Screw, engine brace Screw, fork stub Screw, front brake caliper Screw, handlebar clamp Screw, side stand fixing Screw, subframe Screw, top steering stem (EXC SIX DAYS, XCW SIX DAYS, XCW USA) Screw, top steering stem (EXC EU, EXC AUS, XCW ZA) Screw, top triple clamp (EXC SIX DAYS, XCW SIX DAYS, XCW USA) Screw, top triple clamp (EXC EU, EXC AUS, XCW ZA) Engine attachment bolt Remaining nuts, chassis Remaining screws, chassis Screw, handlebar support Screw, bottom shock absorber Screw, top shock absorber Nut, seat fixing Nut, swingarm pivot Nut, rear wheel spindle Screw, top steering head Screw-in nozzles, cooling system Screw, front wheel spindle M4. 5 M5x12 M5 M6 M6 M6 M6 M6 M6 M8 M8 M8 M8 M8 5. . . 4. 4 lbf ft) 15 Nm (11. 1 lbf ft) 10 Nm (7. 4 lbf ft) 10 Nm (7. 4 lbf ft) 14 Nm (10. 3 lbf ft) 14 Nm (10. 3 lbf ft) 5 Nm (3. 7 lbf ft) 35 Nm (25. 8 lbf ft) 10 Nm (7. 4 lbf ft) 30 Nm (22. 1 lbf ft) 25 Nm (18. 4 lbf ft) 12 Nm (8. 9 lbf ft) ­ ­ ­ ­ ­ ­ ­ ­ ­ Loctite® 243TM ­ ­ ­ ­ 100 M8 M8 M8 M8 M8 M8 M8 M8 15 Nm (11. 1 lbf ft) 33 Nm (24. 3 lbf ft) 15 Nm (11. 1 lbf ft) 25 Nm (18. 4 lbf ft) 20 Nm (14. 8 lbf ft) 40 Nm (29. 5 lbf ft) 35 Nm (25. 8 lbf ft) 17 Nm (12. 5 lbf ft) ­ ­ ­ Loctite® 243TM ­ Loctite® 243TM Loctite® 243TM Loctite® 243TM M8 M8 20 Nm (14. 8 lbf ft) 17 Nm (12. 5 lbf ft) ­ ­ M8 M10 M10 M10 M10 M12 M12 M12x1 M16x1. 5 M20x1. 5 M20x1. 5 M20x1. 5 M24x1. 5 20 Nm (14. 8 lbf ft) 60 Nm (44. 3 lbf ft) 50 Nm (36. 9 lbf ft) 45 Nm (33. 2 lbf ft) 40 Nm (29. 5 lbf ft) 80 Nm (59 lbf ft) 80 Nm (59 lbf ft) 20 Nm (14. 8 lbf ft) 100 Nm (73. 8 lbf ft) 80 Nm (59 lbf ft) 10 Nm (7. 4 lbf ft) 12 Nm (8. 9 lbf ft) 45 Nm (33. 2 lbf ft) ­ ­ ­ ­ Loctite® 243TM Loctite® 243TM Loctite® 243TM ­ ­ ­ ­ Loctite® 243TM ­ 101 102 M 10 A K1 G1 M1 S6 S5 BC/6 BF1/1 AF/4 S7 wh-re G S8 E6 BG/3 AH2/2 BT/3 BK/4 BR/4 t S10 S11 BF/1 BA/1 BK/4 BR/4 S10 43 2 K2 3 br br AC/6 P1 3 2 ye-re ye-bl wh 64 5 1 or pu 12 2 1 H13 BA1/1 1 ye-re wh-re 2 3 4 ye-bl 1 1 2 3 4 br bu gn ye re br or 4 bu re ye-re wh br ye-re br bl DB/4 DA/4 1 1 3 br-bl br CV/2 br ye-re bl 1 ye 4 3 U 5A BL/2 CY/3 CZ/3 CA/4 2 1 bl bl ye-re br B3 wh 2 CW/2 CX/2 2 M H14 BV/2 BS/2 H15 ye-re v 2 pu bl H18 BV/2 BO/2 bl br S1 1 br AK/2 AH/2 ye-re ye wh-gn br bl br S2 1 AK1/2 AH1/2 2 wh-gn br CW2/2 CX2/2 1 2 bl br br BA/1 BF/1 1 BG1/3 H11 ye-bl ye-bl 2 AJ1/3 bl pu 3 3 AJ/3 BG/3 wh wh-gn H4 2 1 BS/2 BV/2 2. 2 2. 1 gr H5 ye br bu CX/2 br CW/2 1 2 2 bu 1 4 DG/4 BP/4 br gn br 3 wh EH/1 EI/1 Wiring diagram (all EXC models) re-wh re-bl re gn 2. 1 bu-wh bu-wh re-wh ye-bl re-bl gn bl-wh br bu ye br gr re bl bu bl ye 2 1 2 BU/18 1 4 5 7 6 11 10 12 13 14 3 AM/3 AR/3 WIRING DIAGRAM AL1/2 AL/2 AT/2 CR/1 2 1 CR1/1 2 1 1 A6 B1 2 CW3/2 CX3/2 3 br 1 pu L1 L2 G G2 20. 1 H2 CW1/2 CX1/2 br pu 2 H3 AT1/2 ye wh DI/2 1 2 1 H9 wh H1 12 CE/4 N2 3 bl bl 2 re bl ye-re 600879-01 WIRING DIAGRAM Components A6 B1 B3 E6 G1 G2 H1 H2 H3 H4 H5 H7 H9 H11 H13 H14 H15 H18 K1 K2 L1 L2 M1 N2 P1 S1 S2 S5 S6 S7 S8 S10 S11 X1 Cable colors bl bl-wh br br-bl bu bu-wh gn gr or pu re re-bl re-wh wh wh-gn wh-re Black Black-white Brown Brown-black Blue Blue-white Green Gray Orange Violet Red Red-black Red-white White White-green White-red CDI controller Throttle position sensor Wheel speed sensor Thermoswitch (EXC SIX DAYS) Battery Generator Right rear flasher Left front flasher Left rear flasher Right front flasher Brake/tail light Parking light License plate lamp Low/high beam Horn Radiator fan (EXC SIX DAYS) Flasher indicator light High beam indicator light Starter relay with main fuse Flasher relay Pulse generator Ignition coil Starter motor Voltage regulator/rectifier Speedometer Rear brake light switch Front brake light switch Tripmaster switch (optional) Light switch Horn button, short circuit button Flasher switch Electric starter button Emergency OFF switch (EXC-R AUS) Ignition curve plug connection 103 WIRING DIAGRAM ye ye-bl ye-re Yellow Yellow-black Yellow-red 104 WIRING DIAGRAM 105 WIRING DIAGRAM Wiring diagram (all XCW models) 20. 2 106 P1 H11 H7 v S5 re bu wh br bl bl br ye-re B3 wh br wh X1 bl-wh br gr ye-bl bu-wh L2 S9 bu-wh br gr ye-bl re-wh re-bl gn re bu ye bl ye-bl wh ye S6 ye-re wh-re S10 bl br bl ye bu br bl H14 A6 B1 L1 M br t br bl E6 5A ye-re br bl br M1 re M gn K1 re-bl re-wh ye wh br wh-re 3 G G2 10 A ye-re G1 br ye-re ye wh br wh C_BV/2 U N2 H5 500248-10 WIRING DIAGRAM Components A6 B1 B3 E6 G1 G2 H5 H7 H11 H14 K1 L1 L2 M1 N2 P1 S5 S6 S9 S10 X1 Cable colors bl bl-wh br bu bu-wh gn gr re re-bl re-wh wh wh-re ye ye-bl ye-re Black Black-white Brown Blue Blue-white Green Gray Red Red-black Red-white White White-red Yellow Yellow-black Yellow-red CDI controller Throttle position sensor Wheel speed sensor Thermoswitch (XC-W ZA, XC-W SIX DAYS) Battery Generator Brake/tail light (XC-W ZA) Parking light (XC-W ZA, XC-W SIX DAYS) Low beam/high beam (XC-W ZA, XC-W SIX DAYS) Radiator fan (XC-W ZA, XC-W SIX DAYS) Starter relay with main fuse Pulse generator Ignition coil Starter motor Voltage regulator/rectifier Speedometer Tripmaster switch (optional) Light switch Short circuit button Electric starter button Ignition curve plug connection 107 SUBSTANCES Brake fluid DOT 4 / DOT 5. 1 according to ­ DOT 108 Guideline ­ Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. Supplier Castrol ­ RESPONSE BRAKE FLUID SUPER DOT 4 Motorex® ­ Brake Fluid DOT 5. 1 Coolant Guideline ­ Use only suitable coolant (also in countries with high temperatures). -49 °F) 50 % corrosion inhibitor/antifreeze 50 % distilled water Coolant (mixed ready to use) Antifreeze Supplier Motorex® ­ Anti Freeze -40 °C (-40 °F) Engine oil (SAE 10W/50) according to ­ JASO T903 MA ( ­ SAE ( p. [. . . ]