KTM 450 XC-W USA Setup Instructions Download | Manualshive

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SETUP INSTRUCTIONS

2016

450 EXC

450 EXC Six Days

450 XC

‑

W

500 EXC

500 EXC Six Days

500 XC

‑

W

Art. no. 3213434en

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Summary of Contents for 450 XC-W USA

Page 1: ...SETUP INSTRUCTIONS 2016 450 EXC 450 EXC Six Days 450 XC W 500 EXC 500 EXC Six Days 500 XC W Art no 3213434en...

Page 2: ......

Page 3: ...thout specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for delivery options devi ations from illu...

Page 4: ...age Indicates information with more details or tips Indicates the result of a testing step Denotes a voltage measurement Denotes a current measurement Denotes a resistance measurement 1 2 Formats used...

Page 5: ...he motorcycle from falling over To avoid damaging the motorcycle during the setup leave the protective film on the vehicle until you have finished Remove the separate enclosure and unpack it Check tha...

Page 6: ...triple clamp Position the bleeder screws toward the front M00987 11 Remove screws Take off the handlebar clamps Remove screws Take off the handlebar supports Place the handlebar supports in the requir...

Page 7: ...rols on the right half of the handlebar Info The routing of the throttle cables can be seen in the figure V00034 10 Position the controls on the left half of the handlebar Info The figure shows how to...

Page 8: ...light p 9 Install the front wheel p 13 Correctly mount the fuel tank breather 601710 01 Secure the handlebar cushion with two cable ties 101019 01 Mount the footrests with the springs and pins Secure...

Page 9: ...rom the battery Only charge 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 con ta...

Page 10: ...cle from the lift stand Remove the lift stand To park the motorcycle press side stand to the ground with your foot and lean the motorcycle on it Info While riding the side stand must be folded up and...

Page 11: ...rd K00143 10 Detach plug in connector and take off the headlight mask with the head light 3 4 Refitting the headlight mask with the headlight K00118 11 Main work EXC EU EXC Six Days EU EXC AU Connect...

Page 12: ...Check the headlight setting p 10 3 5 Checking the headlight setting 400726 10 Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center...

Page 13: ...motorcycle with rider instructions on how to apply the marking Check ing the headlight setting Info A change in weight on the vehicle may require a correction of the head light range Tighten screw V0...

Page 14: ...Press the brake caliper onto the brake disc by hand in order to push back the brake pistons Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spok...

Page 15: ...spindle The brake linings are correctly positioned M01022 10 EXC Six Days Align the brake disc guard so that gaps and are the same size K00082 11 Mount and tighten screw Guideline Screw front wheel s...

Page 16: ...aged when it is pressed in B03417 10 Position spacing tube Press in the new bearing all the way using a suitable tool Info Only press the bearing in via the outer ring otherwise the bearing will be da...

Page 17: ...in Mount and tighten the screw of the seat fixing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 3 14 Installing the battery H00383 10 Main work Insert the battery into the battery compartment...

Page 18: ...h charging current shortens the battery s service life If the charging current charging voltage and charging time are exceeded electrolyte escapes through the safety valves This reduces the battery ca...

Page 19: ...of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water im...

Page 20: ...uel line Mount the wash cap set Wash cap set 81212016100 K00103 10 EXC EU EXC AU Disconnect the connector of the horn Remove screws with the collar bushings and horn M01023 10 EXC Six Days Disconnect...

Page 21: ...ly and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Main...

Page 22: ...s should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Lubricate the O ring and connect plug in connection of the fuel line Info Route the cable and fuel line at a safe...

Page 23: ...filler cap Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especiall...

Page 24: ...e button locks in place Info Run the fuel tank breather hose without kinks 3 22 Refueling Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes an...

Page 25: ...p 27 Total fuel tank capacity approx XC W 500 EXC US 8 5 l 2 25 US gal Super unleaded ROZ 95 RON 95 PON 91 p 27 Close the filler cap p 22 3 23 Setting kilometers or miles Info If you change the unit t...

Page 26: ...lected function flashes Activating the function Press the button The symbol continues to appear in the display and the next function appears Deactivating a function Press the button The symbol disappe...

Page 27: ...lbf ft Remaining nuts chassis M8 25 Nm 18 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft Screw bottom triple clamp EXC EU EXC Six Days EU EXC AU M8 15 Nm 11 1 lbf ft Screw bottom triple clamp...

Page 28: ...6 Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Screw in nozzles cooling system M20x1 5 12 Nm 8 9...

Page 29: ...ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use...

Page 30: ...6 AUXILIARY SUBSTANCES 28 Long life grease Recommended supplier Motorex Bike Grease 2000...

Page 31: ...3213434en 3213434en 11 2015 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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