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450 EXC-R EU
KTM 450 EXC-R EU User Manual
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WIRING
DIAGRAM
112
îîîî
Wiring
diagram
(XCR-W
b
ZA)
400311-10
113
115
Table of Contents
Table of Contents
4
Means of Representation
7
Important Notes
8
Location of Serial Numbers
10
Chassis Number
10
Type Label
10
Key Number (EXC-R EU, EXC-R AUS/UK, EXC-R USA)
10
Engine Number
10
Fork Part Number
10
Shock Absorber Part Number
11
Operating Elements
12
Clutch Lever
12
Hand Brake Lever
12
Short Circuit Button (EVERY XCR-W MODELS)
12
Short Circuit Button (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS)
12
Emergency off Switch (EXC-R AUS/UK)
12
Emergency off Switch (EXC-R USA)
13
Ignition Switch (EXC-R USA)
13
Electric Starter Button (EXC-R EU, EXC-R SIX DAYS, EXC-R USA, XCR-W)
13
Electric Starter Button (EXC-R AUS/UK)
13
Light Switch (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS)
13
Light Switch (EVERY XCR-W MODELS)
14
Light Switch (EXC-R USA)
14
Headlight Flasher Switch (EXC-R USA)
14
Horn (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS)
14
Horn (EXC-R USA)
14
Flasher Switch (EXC-R EU, EXC-R AUS/UK)
15
Flasher Switch (EXC-R USA)
15
Overview of Indicator Lamps (EXC-R EU, EXC-R AUS/UK, EXC-R USA)
15
Overview of Indicator Lamps (EXC-R SIX DAYS)
15
Speedometer
15
Speedometer Activation and Test
16
Tripmaster Switch
16
Setting Kilometers or Miles
16
Setting the Clock
17
Adjusting Speedometer Functions
17
Querying Lap Time
18
Display Mode SPEED
18
Display Mode SPEED/H (Service Hours)
18
Display Mode SPEED / CLK (Time)
19
Display Mode SPEED/LAP (Lap Time)
19
Display Mode SPEED/ODO (Odometer)
19
Display Mode SPEED/TR1 (Trip Master 1)
19
Display Mode SPEED/TR2 (Trip Master 2)
20
Disply Mode SPEED/A1 (Average Speed 1)
20
Display Mode SPEED/A2 (Average Speed 2)
20
Display Mode SPEED/S1 (Stop Watch 1)
21
Display Mode SPEED/S2 (Stop Watch 2)
21
Fuel Tap
22
Opening Filler Cap
22
Closing Filler Cap
22
Choke (EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W)
23
Choke (EXC-R EU)
23
Shift Lever
23
Foot Brake Pedal
23
Kickstarter
24
Side Stand
24
Steering Lock (EXC-R EU, EXC-R AUS/UK, EXC-R USA)
24
Locking the Steering (EXC-R EU, EXC-R AUS/UK, EXC-R USA)
24
Unlocking the Steering (EXC-R EU, EXC-R AUS/UK, EXC-R USA)
25
General Tips and Hints on Putting into Operation
26
Advice on First Use
26
Running in the Engine
27
Riding Instructions
28
Checks before Putting into Operation
28
Starting
28
Starting up
29
Shifting, Riding
29
Braking
29
Stopping, Parking
30
Refueling
30
Greasing and Service Table
31
Important Maintenance Work to be Carried out by an Authorized KTM Workshop
31
Important Maintenance Work to be Carried out by an Authorized KTM Workshop. (as Additional Order)
32
Important Checks and Maintenance Work to be Carried out by the Rider
32
Maintenance Work on Chassis and Engine
34
Jacking up the Motorcycle
34
Removing the Motorcycle from the Work Stand
34
Checking the Basic Chassis Setting with the Rider's Weight
34
Compression Damping of Shock Absorber
34
Adjusting High-Speed Compression Damping of the Shock Absorber
34
Adjusting the Low-Speed Compression Damping of the Shock Absorber
35
Adjusting Rebound Damping of the Shock Absorber
35
Measuring Rear Wheel Sag Unloaded
36
Checking Static Sag of the Shock Absorber
36
Checking the Riding Sag of the Shock Absorber
37
Adjusting Spring Preload of the Shock Absorber
37
Adjusting Riding Sag
38
Removing the Shock Absorber
38
Installing Shock Absorber
38
Checking Basic Setting of Fork
39
Adjusting Compression Damping of Fork
39
Adjusting Rebound Damping of Fork
39
Adjusting Spring Preload of the Fork
40
Bleeding Fork Legs
40
Cleaning Dust Boots of Fork Legs
41
Loosening the Fork Protection
41
Positioning the Fork Protection
41
Checking Play of Steering Head Bearing
41
Adjusting Play of Steering Head Bearing (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA)
42
Adjusting Play of Steering Head Bearing (EXC-R SIX DAYS, XCR-W USA)
42
Fork Offset (EXC-R SIX DAYS, XCR-W USA)
43
Setting the Fork Offset (EXC-R SIX DAYS, XCR-W USA)
43
Removing the Fork Legs
43
Installing the Fork Legs
44
Removing the Fork Protector
45
Installing the Fork Protector
45
Removing the Lower Triple Clamp (EXC-R SIX DAYS, XCR-W USA)
45
Removing the Lower Triple Clamp (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA)
46
Installing the Lower Triple Clamp (EXC-R SIX DAYS, XCR-W USA)
46
Installing the Lower Triple Clamp (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA)
47
Greasing the Steering Head Bearing
48
Dismounting the Front Fender
48
Installing the Front Fender
48
Removing Headlight Mask with Headlight (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W ZA)
48
Refitting the Headlight Mask with the Headlight (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W ZA)
49
Dismount the Start Number Plate (XCR-W USA)
49
Fitting the Start Number Plate (XCR-W USA)
49
Handlebar Position
49
Adjusting Handlebar Position
50
Checking Gas Bowden Cable Route
51
Checking Play in the Gas Bowden Cable
52
Adjusting the Gas Bowden Cable Play
52
Checking Chain Dirt
52
Cleaning the Chain
52
Checking the Chain Tension
53
Checking the Chain Tension When Fitting Rear Wheel
53
Checking the Rear Sprocket / Engine Sprocket for Wear
54
Checking Chain Wear
54
Adjusting the Chain Tension
54
Adjusting Chain Tension - after Checking
55
Adjusting Chain Tension - Fitting Rear Wheel
56
Adjusting Chain Guide
56
Brake Fluid Reservoir
56
Brake Calipers
57
Checking Brake Discs
57
Checking Free Play of Hand Brake Lever
57
Adjusting Basic Position of Handbrake Lever (Every XCR-W Models)
58
Adjusting Free Travel of Handbrake Lever (Every EXC-R Models)
58
Checking the Front Brake Fluid Level
58
Topping up the Front Brake Fluid
58
Checking the Front Brake Linings
59
Removing Front Brake Linings
60
Installing the Front Brake Linings
60
Changing the Front Brake Linings
61
Checking Free Play of Foot Brake Lever
61
Adjusting Basic Position of Footbrake Lever
62
Checking the Rear Brake Fluid Level
62
Adding Rear Brake Fluid
63
Checking Rear Brake Linings
63
Removing Rear Brake Linings
64
Installing the Rear Brake Linings
64
Changing the Rear Brake Linings
65
Removing Front Wheel
65
Fitting Front Wheel
66
Removing Rear Wheel
67
Fitting Rear Wheel
67
Tire Condition Checking
68
Checking Tire Air Pressure
68
Checking Spoke Tension
69
Removing the Battery
69
Installing the Battery
69
Recharging the Battery
70
Removing a Fuse
71
Replacing the Fuse
71
Removing the Seat
71
Mounting the Seat
71
Dismounting the Fuel Tank
72
Installing the Fuel Tank
72
Cooling System
73
Checking Antifreeze and Coolant Level
73
Checking the Coolant Level
74
Draining Coolant
74
Refilling Coolant
75
Glass Fiber Yarn Filling of Main Silencer
75
Removing Main Silencer
75
Fitting the Main Silencer
76
Dismounting the Air Filter Box Lid
76
Installing the Air Filter Box Lid
76
Removing the Air Filter
76
Installing the Air Filter
77
Cleaning Air Filter
77
Adjusting Basic Position of Clutch Lever
77
Checking Fluid Level of Hydraulic Clutch
77
Changing Fluid Level of Hydraulic Clutch
78
Carburetor - Idle
79
Carburetor - Adjusting Idle
79
Emptying the Carburetor Float Chamber
80
Checking Engine Oil Level
81
Changing Engine Oil and Oil Filter, Cleaning Engine Oil Screen
81
Draining Engine Oil, Cleaning Engine Oil Screen
81
Removing the Oil Filter
82
Mounting Oil Filter
82
Filling up with Engine Oil
83
Topping up Engine Oil
83
Checking Gear Oil Level
83
Changing Gear Oil, Cleaning Gear Oil Screen
84
Draining Gear Oil, Cleaning Gear Oil Screen
84
Filling up with Gear Oil
85
Topping up with Gear Oil
85
Troubleshooting
86
Cleaning
88
Cleaning Motorcycle
88
Storage
89
Putting into Operation after Storage
89
Technical Data - Engine
90
Capacity - Engine Oil
90
Capacity - Gear Oil
90
Capacity - Coolant
91
Technical Data - Engine Tightening Torques
92
Technical Data - Carburetor
94
Exc-R Eu, 450 Exc-R Aus/Uk (3900I)
94
Exc-R Six Days, 450 Exc-R Usa, 450 Xcr-W (3900L)
94
Exc-R Eu, 530 Exc-R Aus/Uk (3900J)
95
Exc-R Six Days, 530 Exc-R Usa, 530 Xcr-W (3900M)
95
Technical Data - Chassis
96
Lighting Equipment
97
Tires
97
Capacity - Fuel
97
Technical Data - Fork
98
Technical Data - Shock Absorber
99
Technical Data - Chassis Tightening Torques
100
Wiring Diagram
102
Wiring Diagram (EXC-R EU)
102
Wiring Diagram (EXC-R AUS/UK)
104
Wiring Diagram (EXC-R USA)
106
Wiring Diagram (EXC-R SIX DAYS)
110
Wiring Diagram (XCR-W USA)
112
Wiring Diagram (XCR-W ZA)
114
Substances
116
Auxiliary Substances
117
Standards
119
Consumer Information (Exc-R Usa)
120
Index
122
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KTM 450 EXC-R EU Specifications
General
Brand
KTM
Model
450 EXC-R EU
Category
Motorcycle
Language
English
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