KTM 450 EXC User Manual

136 pages

To Next Page

To Next Page

Page #1 background image

Loading...

Page #1 background image

OWNER'S MANUAL 2016

450 EXC EU

450 EXC AU

450 EXC Six Days EU

450 XC-W US

500 EXC EU

500 EXC AU

500 EXC Six Days EU

500 XC-W US

Art. no. 3213338en

Table of Contents

Default Chapter4
- Table of Contents4
1 Means of Representation7
- Symbols Used7
- Formats Used7
2 Safety Advice8
- Use Definition - Intended Use8
- Degrees of Risk and Symbols8
- Tampering Warning8
- Safe Operation9
- Protective Clothing9
- Work Rules9
- Environment9
- Owner's Manual10
3 Important Notes11
- Guarantee, Warranty11
- Operating and Auxiliary Substances11
- Spare Parts, Accessories11
- Service11
- Figures11
- Customer Service11
4 View of Vehicle12
- View of Vehicle, Front Left (Example)12
- View of Vehicle, Rear Right (Example)13
5 Serial Numbers14
- Chassis Number14
- Type Label14
- Key Number (All EXC Models)14
- Engine Number14
- Fork Part Number14
- Shock Absorber Part Number15
6 Controls16
- Clutch Lever16
- Hand Brake Lever16
- Throttle Grip16
- Kill Switch (All EXC Models)16
- Kill Switch (XC-W)16
- Horn Button (All EXC Models)17
- Light Switch (All EXC Models)17
- Light Switch (XC-W)17
- Turn Signal Switch (All EXC Models)17
- Emergency off Switch (EXC AU)17
- Electric Starter Button (EXC EU, EXC SIX DAYS, XC-W)18
- Electric Starter Button (EXC AU)18
- Overview of Indicator Lamps (All EXC Models)18
- Overview of Indicator Lamps (XC-W)18
- Opening Filler Cap18
- Closing Filler Cap19
- Idle Speed Adjusting Screw19
- Shift Lever20
- Kick Starter20
- Foot Brake Lever20
- Side Stand20
- Steering Lock (All EXC Models)21
- Locking the Steering (All EXC Models)21
- Unlocking the Steering (All EXC Models)21
7 Speedometer22
- Speedometer Overview22
- Activation and Test22
- Setting Kilometers or Miles22
- Setting the Speedometer Functions23
- Setting the Clock23
- Viewing the Lap Time23
- Display Mode SPEED (Speed)24
- Display Mode SPEED/H (Service Hours)24
- Setup Menu25
- Setting the Unit of Measurement25
- Display Mode SPEED/CLK (Time)26
- Setting the Clock26
- Display Mode SPEED/LAP (Lap Time)26
- Viewing the Lap Time27
- Display Mode SPEED/ODO (Odometer)27
- Display Mode SPEED/TR1 (Trip Master 1)27
- Display Mode SPEED/TR2 (Trip Master 2)28
- Setting TR2 (Trip Master 2)28
- Display Mode SPEED/A1 (Average Speed 1)28
- Display Mode SPEED/A2 (Average Speed 2)29
- Display Mode SPEED/S1 (Stop Watch 1)29
- Display Mode SPEED/S2 (Stop Watch 2)29
- Table of Functions30
- Table of Conditions and Menu Activation31
8 Preparing for Use32
- Advice on First Use32
- Running-In the Engine33
- Preparing the Vehicle for Difficult Riding Conditions33
- Preparing for Rides on Dry Sand34
- Preparing for Rides on Wet Sand34
- Preparing for Rides on Wet and Muddy Surfaces35
- Preparing for Rides at High Temperature and Slow Speed35
- Preparing for Rides at Low Temperature or in Snow35
9 Riding Instructions36
- Checks and Maintenance Work When Preparing for Use36
- Starting36
- Starting off37
- Shifting, Riding37
- Braking37
- Stopping, Parking38
- Transport38
- Refueling39
10 Service Schedule40
- Service Work (as Additional Order)41
11 Tuning the Chassis42
- Checking the Basic Suspension Setting against the Rider's Weight42
- Compression Damping of Shock Absorber42
- Adjusting the Low-Speed Compression Damping of the Shock Absorber42
- Adjusting the High-Speed Compression Damping of the Shock Absorber43
- Adjusting the Rebound Damping of the Shock Absorber43
- Measuring Rear Wheel Sag Unloaded44
- Checking the Static Sag of the Shock Absorber44
- Checking the Riding Sag of the Shock Absorber44
- Adjusting the Spring Preload of the Shock Absorber45
- Adjusting the Riding Sag45
- Checking Basic Setting of Fork46
- Adjusting the Compression Damping of the Fork46
- Adjusting the Rebound Damping of the Fork47
- Adjusting the Spring Preload of the Fork (EXC EU/AU, XC-W)48
- Handlebar Position49
- Adjusting Handlebar Position50
12 Service Work on the Chassis52
- Raising the Motorcycle with the Lift Stand52
- Removing the Motorcycle from the Lift Stand52
- Bleeding the Fork Legs52
- Cleaning the Dust Boots of the Fork Legs53
- Removing the Fork Legs53
- Installing the Fork Legs54
- Removing the Fork Protector56
- Installing the Fork Protector56
- Removing the Lower Triple Clamp (All EXC Models)56
- Removing the Lower Triple Clamp (XC-W)57
- Installing the Lower Triple Clamp (All EXC Models)58
- Installing the Lower Triple Clamp (XC-W)61
- Checking the Steering Head Bearing Play62
- Adjusting the Play of the Steering Head Bearing (All EXC Models)63
- Adjusting the Play of the Steering Head Bearing (XC-W)64
- Greasing the Steering Head Bearing64
- Removing the Front Fender64
- Installing the Front Fender65
- Removing the Shock Absorber65
- Installing the Shock Absorber65
- Removing the Seat66
- Mounting the Seat66
- Removing the Air Filter Box Cover66
- Installing the Air Filter Box Cover66
- Removing the Air Filter67
- Installing the Air Filter67
- Cleaning the Air Filter and Air Filter Box67
- Sealing the Air Filter Box68
- Removing Main Silencer68
- Installing the Main Silencer68
- Cleaning Spark Arrestor (XC-W)69
- Changing Glass Fiber Yarn Filling in the Main Silencer70
- Removing the Fuel Tank71
- Installing the Fuel Tank72
- Checking for Chain Dirt Accumulation74
- Cleaning the Chain74
- Checking the Chain Tension75
- Adjusting the Chain Tension75
- Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide76
- Checking the Frame78
- Checking the Swingarm78
- Checking Throttle Cable Routing78
- Checking the Rubber Grip79
- Additionally Securing the Rubber Grip79
- Adjusting the Basic Position of the Clutch Lever79
- Checking/Correcting the Fluid Level of the Hydraulic Clutch79
- Changing the Hydraulic Clutch Fluid80
- Removing the Engine Guard (All EXC Models)80
- Installing the Engine Guard (All EXC Models)80
13 Brake System81
- Checking Free Travel of Hand Brake Lever81
- Adjusting Free Travel of Hand Brake Lever (All EXC Models)81
- Adjusting the Basic Position of the Hand Brake Lever (XC-W)81
- Checking the Brake Discs82
- Checking the Brake Fluid Level of the Front Brake82
- Adding Front Brake Fluid82
- Checking the Front Brake Linings83
- Changing the Front Brake Linings84
- Checking the Free Travel of Foot Brake Lever85
- Adjusting the Basic Position of the Foot Brake Lever85
- Checking the Rear Brake Fluid Level86
- Adding Rear Brake Fluid86
- Checking the Rear Brake Linings87
- Changing the Rear Brake Linings88
14 Wheels, Tires90
- Removing the Front Wheel90
- Installing the Front Wheel90
- Removing the Rear Wheel91
- Installing the Rear Wheel92
- Checking the Tire Condition92
- Checking the Tire Air Pressure93
- Checking Spoke Tension93
15 Electrical System95
- Removing the Battery95
- Installing the Battery95
- Charging the Battery96
- Changing the Main Fuse97
- Changing the Fuses of Individual Power Consumers98
- Removing Headlight Mask with Headlight98
- Refitting the Headlight Mask with the Headlight99
- Changing the Headlight Bulb100
- Changing the Turn Signal Bulb (All EXC Models)100
- Checking the Headlight Setting101
- Adjusting the Headlight Range101
- Changing the Speedometer Battery102
16 Cooling System103
- Checking the Antifreeze and Coolant Level103
- Checking the Coolant Level103
- Draining the Coolant104
- Refilling Coolant104
17 Tuning the Engine106
- Checking the Play in the Throttle Cable106
- Adjusting the Play in the Throttle Cable106
- Adjusting the Idle Speed107
- Checking the Basic Position of the Shift Lever107
- Adjusting the Basic Position of the Shift Lever107
18 Service Work on the Engine109
- Changing the Fuel Screen109
- Checking the Engine Oil Level109
- Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens110
- Adding Engine Oil112
19 Cleaning, Care113
- Cleaning the Motorcycle113
- Checks and Maintenance Steps for Winter Operation114
20 Storage115
- Preparing for Use after Storage115
21 Troubleshooting116
22 Blink Code118
23 Technical Data120
- Engine120
- Engine Tightening Torques120
- Capacities122
- Engine Oil122
- Coolant122
- Fuel122
- Chassis122
- Electrical System123
- Tires123
- Fork123
- Exc Eu/Au, XC-W123
- EXC Six Days124
- Shock Absorber124
- Chassis Tightening Torques125
24 Substances127
25 Auxiliary Substances128
26 Standards130
27 List of Abbreviations131
28 Lisy of Symbols132
- Yellow and Orange Symbols132
- Green and Blue Symbols132
- Index133

Questions and Answers:

Need help?

Do you have a question about the KTM 450 EXC and is the answer not in the manual?

KTM 450 EXC Specifications

General

Displacement	449.9 cc
Bore x Stroke	95 mm x 63.4 mm
Compression Ratio	12.75:1
Starter	Electric Starter
Transmission	6-speed
Seat Height	960 mm
Ground Clearance	370 mm
Engine Type	Single Cylinder, 4-Stroke
Cooling	Liquid Cooled
Front Suspension	WP XPLOR USD Forks
Rear Suspension	WP XPLOR Shock with PDS
Front Brake	Single Disc Brake
Rear Brake	220 mm disc
Dry Weight	107 kg
ABS	No

Related product manuals

Preview: KTM 450 EXC EU

Preview: KTM 450 EXC-R EU

KTM 450 EXC-R EU

Preview: KTM 450 EXC-F 2022

KTM 450 EXC-F 2022

Preview: KTM 450 EXC-F 2021

KTM 450 EXC-F 2021

KTM 450 EXC-F 2017

KTM 450 EXC-F 2024

Preview: KTM 450 EXC EU 2013

KTM 450 EXC EU 2013

Preview: KTM 450 EXC SIX DAYS

KTM 450 EXC SIX DAYS

KTM 450 EXC USA 2009

Preview: KTM 450 EXC SIX DAYS EU

KTM 450 EXC SIX DAYS EU

KTM 450 EXC SIX DAYS EU 2011

Preview: KTM 2013 450 EXC SIX DAYS EU

KTM 2013 450 EXC SIX DAYS EU