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.
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) Engine number ( P. 8) Key number (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA) ( Dealer's stamp P.
CONTENTS 2 &217(176 MEANS OF REPRESENTATION ............................................ 5 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..................................
CONTENTS 3 x x x x Removing the lower triple clampb (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA) ......................... Installing the lower triple clampb (EXC-RbSIXbDAYS, XCR-WbUSA) ................................................................. Installing the lower triple clampb (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA) ......................... Greasing the steering head bearingb ............................. Dismounting the front fender ..........................................
CONTENTS 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)...................................
MEANS OF REPRESENTATION 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.
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 comply 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.
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 potential problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such problems and conflicts do not have to occur.
LOCATION OF SERIAL NUMBERS /2&$7,21 2) 6(5,$/ 180%(56 Chassis number The chassis numberb is stamped on the steering head on the right. 500127-10 Type label The type labelb is fixed to the front of the steering head. 500128-10 Key number (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA) The key numberb is stamped on the key strap. 500125-10 Engine number The engine numberb is stamped on the left side of the engine under the engine sprocket.
LOCATION OF SERIAL NUMBERS Shock absorber part number The shock absorber part numberb is stamped on the top of the shock absorber above the adjusting ring on the engine side.
OPERATING ELEMENTS 10 23(5$7,1* (/(0(176 Clutch lever The clutch leverb is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 500133-10 Hand brake lever The hand brake leverb is located on the right side of the handlebar and operates the front wheel brake. 400196-10 Short circuit button (EVERY XCR-W MODELS) The short circuit buttonb is mounted on the left side of the handlebar.
OPERATING ELEMENTS 11 Emergency OFF switch (EXC-RbUSA) The emergency OFF switchb 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 engine can be started. 500144-10 Ignition switch (EXC-RbUSA) The ignition switchb is on the right behind the headlight mask.
OPERATING ELEMENTS 12 Light switch (EVERY XCR-W MODELS) The light switchb 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. 500146-10 (XCR-WbUSA) • The light switch has no function when delivered. ದbIt can be used if lighting is fitted later.
OPERATING ELEMENTS 13 Flasher switch (EXC-RbEU, EXC-RbAUS/UK) The flasher switchb 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 Flasher switch (EXC-RbUSA) The flasher switchb is fitted on the left side of the handlebar.
OPERATING ELEMENTS 14 Speedometer activation and test 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 production tire.
OPERATING ELEMENTS 15 Setting the clock Condition The motorcycle is standing. ದ Press the button b the display. ದ Press the buttonb ದ Set the hour display with the buttonb"+" and/or buttonb"ತ". ದ Press the buttonb briefly and repeatedly until CLK appears at the bottom right of for 3 - 5 seconds. The hour display flashes. briefly. The next segment of the display flashes and can be set.
OPERATING ELEMENTS 16 Querying lap time Info This function can be called only if lap times are measured. Condition The motorcycle is standing. ದ Press the buttonb the display. briefly and repeatedly until LAP appears at the bottom right of ದ Press the buttonb briefly. The LAPb1 is displayed on the left of the display. ದ Laps 1-10 can be displayed by pressing the buttonb"+". ದ buttonb"ತ" no function ದ Press the buttonb briefly.
OPERATING ELEMENTS 17 Display mode SPEEDb/bCLK (time) ದ Press the button b the display. briefly and repeatedly until CLK appears at the bottom right of The time is displayed in CLK display mode. 400319-01 Press the buttonb"+". Press the buttonb"ತ". Press the buttonb for 3 - 5 seconds. Press the buttonb briefly. no function no function The display changes to the Setup menu of the clock. next display mode Display mode SPEED/LAP (lap time) ದ Press the buttonb the display.
OPERATING ELEMENTS 18 Display mode SPEED/TR2 (trip master 2) ದ Press the buttonb display. briefly and repeatedly until TR2 appears at the top right of the 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 buttonb"+" and the buttonb"ತ". If 999.
OPERATING ELEMENTS 19 Display mode SPEED/S1 (stop watch 1) ದ Press the buttonb display. briefly and repeatedly until S1 appears at the top right of the 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. 400327-01 Press the buttonb"+". Press the buttonb"ತ". Press the buttonb for 3 - 5 seconds.
OPERATING ELEMENTS 20 Overview of conditions and ability to be enabled Display The motorcycle is standing Menu can be enabled 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) • Fuel tap The fuel tap is on the left of the fuel
OPERATING ELEMENTS 21 Choke (EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA, XCR-W) The chokeb is fitted on the left side of the carburetor. Activating the choke function frees an opening through which the engine can draw extra 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. 500135-10 Possible states • Choke function activated ದbThe choke lever is pulled out to the stop.
OPERATING ELEMENTS 22 Kickstarter The kickstarterb 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 engine. 500148-10 Side stand 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.
OPERATING ELEMENTS 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. Unlocking the steering (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA) ದ 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. Info Never leave the key in the steering lock.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 24 *(1(5$/ 7,36 $1' +,176 21 3877,1* ,172 23(5$7,21 Advice 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.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 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 distribution 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 ದ Maximum permissible overall weight 335bkg (739blb.) Maximum permissible front axle load 145bkg (320blb.
RIDING INSTRUCTIONS 26 5,',1* ,16758&7,216 Checks 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. ( ದ Check the chain tension. ( ದ Check the chain dirt accumulation. ( ದ Check the tire condition. ( ದ Checking the tire air pressure. ( ದ Check the front brake fluid level.
RIDING INSTRUCTIONS ದ 27 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 ದ Push back the hot start lever to the stop with the engine running. Starting 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.
RIDING INSTRUCTIONS 28 Stopping, 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 components to cool down before starting work on them. 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.
GREASING AND SERVICE TABLE 29 *5($6,1* $1' 6(59,&( 7$%/( Important maintenance work to be carried out by an authorized KTM workshop. Engine Change the engine oil and oil filter and clean the engine oil screen. ( Change the gear oil and clean the gear oil screen. ( P. 79) P. 82) S3N S15A S30A • • • • • • Replace spark plug. Carburetor Attachments • Check and adjust valve clearance. • • • Check engine mounting screws for tightness.
GREASING AND SERVICE TABLE 30 Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) Competition use S15A S30A Hobby use S45A S30A S60A J1A J2A • • S90A Carry out a complete fork service. Carry out a complete shock absorber service. Grease the steering head bearing. ( • P. 46) • • • • Treat electric contacts with contact spray. • • Change hydraulic clutch fluid. ( • • Change the front brake fluid. • • Change the rear brake fluid.
GREASING AND SERVICE TABLE 31 NB1A Clean the chain. ( P. 50) Check the chain tension. ( Check the chain wear. ( • P. 51) • P. 52) • Check the rear sprocket / engine sprocket for wear. ( Clean the air filter. ( P. 52) P. 75) Checking the tire air pressure. ( Check the tire condition. ( Check the coolant level. ( • • P. 66) P. 66) • P. 72) Empty the carburetor float chamber. ( • • P. 78) • Check that all operating elements for smooth operation. • Check braking.
MAINTENANCE WORK ON CHASSIS AND ENGINE 32 0$,17(1$1&( :25. 21 &+$66,6 $1' (1*,1( Jacking up the motorcycle Note Danger of damageಘDanger of damage by the vehicle running away or falling over. ದ ದ Always place the vehicle on a firm and even surface. Jack up the motorcycle underneath the engine. The wheels must no longer touch the ground. Work stand (54829055000) 500074-01 ದ Secure the motorcycle against falling over.
MAINTENANCE WORK ON CHASSIS AND ENGINE ದ 33 Turn the adjusting screwb clockwise with a ring wrench until it stops. Info Do not loosen nutb ! ದ Turn back counterclockwise the number of turns corresponding to the shock absorber type. Specification Compression damping, high-speed 400208-10 Comfort 2bturns Standard 1.5bturns Sport 1bturn Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
MAINTENANCE WORK ON CHASSIS AND ENGINE ದ 34 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 absorber type. Specification Rebound damping 400210-10 Comfort 24bclicks Standard 22bclicks Sport 20bclicks Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping. Measuring rear wheel sag unloaded A 0 ದ Jack up the motorcycle.
MAINTENANCE WORK ON CHASSIS AND ENGINE 35 Checking the riding sag of the shock absorber A 0 ದ Measure distanceb ದ 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. ದ The other person now has to measure the distance between the rear axle and a fixed point. ದ Make a note of the value as measurementb . of rear wheel unloaded. ( P.
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting riding sagb 36 x ದ Remove shock absorber. ( ದ After removing the shock absorber, clean it thoroughly. ದ Choose and fit a suitable spring. P. 36) Specification Spring rate Weight of rider: 65… 75bkg (143… 165blb.) 69bN/mm (394blb/in) Weight of rider: 75… 85bkg (165… 187blb.) 72bN/mm (411blb/in) Weight of rider: 85… 95bkg (187… 209blb.) 76bN/mm (434blb/in) Info The spring rate is shown on the outside of the spring.
MAINTENANCE WORK ON CHASSIS AND ENGINE 37 Checking basic setting of fork Info For various reasons, no exact riding sag can be determined for the forks. ದ As with the shock absorber, smaller weight differences can be compensated by the spring preload. ದ 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE ದ 38 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 Standard 18bclicks Sport 18bclicks Rebound damping (EXC-RbSIXbDAYS) Comfort 20bclicks Standard 20bclicks Sport 18bclicks Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
MAINTENANCE WORK ON CHASSIS AND ENGINE 39 Cleaning dust boots of fork legs ದ Jack up the motorcycle. ( ದ Loosen the fork protection. ( ದ Push dust bootsb of both fork legs downwards. P. 32) P. 39) 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE ದ 40 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. » 400189-10 ದ 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) ದ Adjust play of the steering head bearing. ( P.
MAINTENANCE WORK ON CHASSIS AND ENGINE 41 Fork offset (EXC-RbSIXbDAYS, XCR-WbUSA) You can see the currently set offset if you remove screwb . The fork offsetb has an impact on the handling of the vehicle. It is calculated from the center of the fork leg to the center of the steering head bearing. The fork offset can optionally be adjusted. Markingb to the front gives greater stability on fast racetracks. B 0 A 0 Fork offset Front marking 18bmm (0.
MAINTENANCE WORK ON CHASSIS AND ENGINE 42 (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA) ದ Loosen screwb . Remove the fork leg on the left. ದ Loosen screwb . Remove the fork leg on the right. 100023-11 Installing the fork legsb x ದ Check parts for damage and wear. Replace damaged or worn parts. ದ 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 screwb to the front.
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the fork protectorb 43 x ದ Remove the fork legs. ( ದ Remove screwsb on the left fork leg. Remove the fork protector upwards. ದ Remove the screws on the right fork leg. Remove the fork protector upwards. ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Position the fork protection on the left fork leg. Mount and tighten screwsb . P.
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the lower triple clampb 44 x (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA) ದ Remove the fork legs. ( ದ Remove the headlight mask with the headlight. ( ದ Dismount the front fender. ( ದ Remove screwsb and hang the CDI control unit to the side. P. 41) P. 46) P. 46) Info Do not unplug the CDI control unit. ದ Remove screwb . Loosen screwb . Take off top triple clamp with the handlebar and place it on one side.
MAINTENANCE WORK ON CHASSIS AND ENGINE 45 (EXC-RbSIXbDAYS) ದ Refit the headlight mask with the headlight. ( ದ Install the fork legs. ( ದ Mount and tighten screwb . P. 47) P. 42) Specification Screw, top steering stem M8 17bNm (12.5blbfbft) Loctite® 243™ ದ Check the cable harness, cable, brake and clutch line for free movement and free laying. ದ Check play of steering head bearing. ( P.
MAINTENANCE WORK ON CHASSIS AND ENGINE Greasing the steering head bearingb 46 x (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) Dismounting the front fender ದ Remove screwsb . Remove the front fender. ದ Make sure that the distance bushings remain in place. ದ Check parts for damage and wear.
MAINTENANCE WORK ON CHASSIS AND ENGINE 47 Refitting the headlight mask with the headlight (EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA, XCR-WbZA) ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Connect the electric plug connectorb . ದ Position the headlight mask and fix it with the rubber bandb . 500156-11 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 screwb .
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting handlebar positionb 1 0 2 0 48 x 1 0 2 0 (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-W) ದ Remove the four screwsb . Remove the handlebar clamp. Remove the handlebar and lay it to one side. Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines. 400223-10 ದ Remove the two screwsb . Remove the handlebar support. ದ Check parts for damage and wear. Replace damaged or worn parts.
MAINTENANCE WORK ON CHASSIS AND ENGINE ದ 49 Place the handlebar support in the required position. Fit and tighten the two screwsb . Specification Screw, handlebar support M10 40bNm (29.5blbfbft) Loctite® 243™ Condition Spacer fitted: Use a M10x35 screw Condition without a spacerb : Use a M10x25 screw Info Position the left and right handlebar supports evenly. ದ Fit the rubber conesb ದ Fit the lower shellsb . ದ Position the handlebar. and clamp barb .
MAINTENANCE WORK ON CHASSIS AND ENGINE 50 Checking 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 unconsciousness and/or death.
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) Checking the chain tension Warning Danger of accidentsಘDanger caused by incorrect chain tension.
MAINTENANCE WORK ON CHASSIS AND ENGINE 52 Checking the rear sprocket / engine sprocket for wear 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 replaced together.
MAINTENANCE WORK ON CHASSIS AND ENGINE 53 ದ Loosen nutb . ದ Loosen nutsb . ದ Adjust the chain tension by turning the left and right adjusting screwsb . Specification Chain tension 8… 10bmm (0.31… 0.39bin) Turn the left and right adjusting screwsb so that the markings on the left and right chain adjusters are in the same position relative to the reference marksb . The rear wheel is then correctly aligned. ದ Tighten nutsb .
MAINTENANCE WORK ON CHASSIS AND ENGINE 54 Adjusting chain tension - fitting rear wheel ದ Loosen nutsb . ದ Adjust the chain tension by turning the adjusting screwsb left and right. Specification Chain tension 8… 10bmm (0.31… 0.39bin) Turn the adjusting screwsb left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marksb . The rear wheel is then correctly aligned. ದ Tighten nutsb . ದ Remove screwsb andb .
MAINTENANCE WORK ON CHASSIS AND ENGINE 55 Brake calipers 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. Checking 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE 56 Adjusting basic position of handbrake lever (Every XCR-W models) ದ Adjust the basic setting of the handbrake lever to your hand size by turning adjusting screwb . 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.
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®.
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing front brake liningsb 58 x 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the front brake liningsb 59 x Warning Skin irritationsಘBrake fluid can cause skin irritation on contact. ದ Avoid contact with skin and eyes, and keep out of the reach of children. ದ 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting basic position of footbrake leverb 60 x 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 Disconnect springb . ದ Loosen nutb and with push rodb , turn it back until you have maximum free play.
MAINTENANCE WORK ON CHASSIS AND ENGINE Adding rear brake fluidb 61 x 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 Avoid contact with skin and eyes, and keep out of the reach of children.
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing rear brake liningsb 62 x 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the rear brake liningsb 63 x Warning Skin irritationsಘBrake fluid can cause skin irritation on contact. ದ Avoid contact with skin and eyes, and keep out of the reach of children. ದ 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE ದ 64 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 damaged. 500085-10 ದ Remove distance bushingb . 500086-10 Fitting front wheelb x Warning Danger of accidentsಘReduced braking due to oil or grease on the brake discs.
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing rear wheelb 65 x ದ Jack up the motorcycle. ( ದ Press the brake caliper by hand on to the brake disc in order to press back the brake piston. P. 32) Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes. ದ Remove nutb . ದ Remove chain adjusterb . Withdraw the wheel spindleb only enough to allow the rear wheel to be pushed forward. ದ Push the rear wheel forward as far as possible.
MAINTENANCE WORK ON CHASSIS AND ENGINE 66 ದ Position the chain adjusterb . Fit nutb , but do not tighten it yet. ದ Check the chain tension when fitting rear wheel. ( ದ Make sure that the chain adjustersb are fitted correctly on the adjusting screwsb . ದ Tighten nutb . P. 51) 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE 67 Checking 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE Recharging the batteryb 68 x Warning Risk of injuryಘBattery acid and battery gases cause serious cauterization. ದ Keep batteries out of the reach of children. ದ Wear suitable protective clothing and goggles. ದ Avoid contact with battery acid and battery gases. ದ Keep the battery away from sparks or open fire. Charge only in well ventilated rooms. ದ In the event of skin contact, rinse with large amounts of water.
MAINTENANCE WORK ON CHASSIS AND ENGINE 69 Removing a fuse ದ Switch off all power-consuming components and switch off the engine. ದ Dismount the air filter box lid. ( ದ Remove the protection coverb . P. 74) Info The fuseb is located in the starter relayb under the filter box cover. ದ Remove the fuseb . 400270-10 Replacing the fuse Warning Fire hazardಘThe electrical system can be overloaded by the use of incorrect fuses. ದ Use only fuses with the prescribed amperage.
MAINTENANCE WORK ON CHASSIS AND ENGINE Dismounting the fuel tankb 70 x 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE 71 ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Position the fuel tank and fit the two spoilers to the side of the radiator fixing. ದ Make sure that no cables or Bowden cables are trapped or damaged. ದ Mount the fuel tank vent hose. ದ Fit and tighten screwb with collar sleeve. 500067-01 Specification Remaining screws, chassis M6 10bNm (7.4blbfbft) (Every EXC-R models) ದ Position horn with horn bracket.
MAINTENANCE WORK ON CHASSIS AND ENGINE 72 ದ Stand the motorcycle upright on a horizontal surface. ದ Remove the radiator cap. ದ Check antifreeze of coolant. 25… 45b°C (13… 49b°F) » If the antifreeze of the cooling liquid does not meet specifications: ದ ದ Correct antifreeze of coolant. Check the coolant level in the radiator. 400243-10 Coolant levelb » above radiator fins. If the level of the cooling liquid does not meet specifications: ದ Correct the coolant level.
MAINTENANCE WORK ON CHASSIS AND ENGINE 73 ದ Stand the vehicle upright. ದ Place a suitable container under the water pump cover. ದ Remove screwb . Remove the radiator capb . ದ Completely drain the coolant. ದ Fit screwb with a new seal and tighten it. Specification Screw, water pump cover M6x25 10bNm (7.4blbfbft) 400335-11 Refilling coolantb x Warning Danger of poisoningಘCoolants are poisonous and a health hazard. ದ Avoid contact between coolants and skin, eyes and clothing.
MAINTENANCE WORK ON CHASSIS AND ENGINE 74 Fitting the main silencer ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Mount the main silencer. Mount and tighten screwsb . Specification Remaining screws, chassis M6 10bNm (7.4blbfbft) ದ Reconnect springb . ದ Pull off the air filter box lid in areab ದ Check parts for damage and wear. Replace damaged or worn parts.
MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the air filterb 75 x ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Mount the clean air filter onto the air filter support. ದ 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE 76 ದ Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. ದ Remove screwsb . ದ Take off coverb with membraneb . ದ Check the fluid level. Fluid level under top level of container. » If the level of the cooling liquid does not meet specifications: ದ 400339-10 4bmm (0.16bin) Correct the fluid level of the hydraulic clutch. Brake fluid DOT 5.1 ( P. 114) ದ Check parts for damage and wear. Replace damaged or worn parts.
MAINTENANCE WORK ON CHASSIS AND ENGINE 77 ದ Inject the liquid into the system until it escapes from the bore holeb ter cylinder without bubbles. ದ To prevent overflow, drain fluid occasionally from the master cylinder reservoir. ದ Remove the bleeding syringe. Mount and tighten screws bleeder screw. ದ Correct the fluid level of the hydraulic clutch. of the mas- Specification Fluid level under top level of container. 400340-10 4bmm (0.16bin) ದ Check parts for damage and wear.
MAINTENANCE WORK ON CHASSIS AND ENGINE 78 Danger Danger of poisoningಘExhaust gases are poisonous and can result in unconsciousness and/or death. ದ ದ When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space. Adjust the idle speed with the adjusting screwb . 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.
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 Turn the handleb of the fuel tap to the OFF position. (Figureb500137-10b ದ Guide the hose coming down behind the engine into a suitable container. P. 20) No more fuel flows from the tank to the carburetor.
MAINTENANCE WORK ON CHASSIS AND ENGINE 80 ದ Place a suitable container under the engine. ದ Remove engine oil plug screenb . ದ Completely drain the engine oil. ದ Thoroughly clean the plug and gear oil screen. ದ Clean the sealing area on the engine. ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Fit plugb for the engine oil screen and tighten it. Specification 200112-10 Removing the oil filterb Plug, engine oil screen M17x1,5 20bNm (14.
MAINTENANCE WORK ON CHASSIS AND ENGINE ದ Refit the oil filter coverb . ದ Mount and tighten screwsb . 81 Specification Screw, oil filter cover ದ M5 6bNm (4.4blbfbft) Stand the motorcycle up. 200113-11 Filling up with engine oilb x Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. ದ Remove the screw capb on the generator cover and fill up with engine oil. Engine oil ದ 0.6bl (0.6bqt.) Engine oil (SAE 10W/50) ( P.
MAINTENANCE WORK ON CHASSIS AND ENGINE 82 Condition Engine is cold. ದ Remove gear oil level check screwb . Stand the vehicle upright. ದ Check the gear oil level. A small amount of gear oil should flow out. » If no gear oil flows out: ದ ದ 200116-10 Top up with gear oil. ( P. 83) Mount and tighten the gear oil level check screw. Specification Screw, gear oil level check Changing gear oil, cleaning gear oil screenb M6 10bNm (7.
MAINTENANCE WORK ON CHASSIS AND ENGINE Filling up with gear oilb 83 x Info Too little gear oil or poor-quality oil results in premature wear to the transmission. ದ Remove the screw capb and fill up with gear oil. Gear oil ದ 0.9bl (1bqt.) Engine oil (SAE 10W/50) ( P. 114) Mount and tighten screw capb . Danger Danger of poisoningಘExhaust gases are poisonous and can result in unconsciousness and/or death.
TROUBLESHOOTING 84 7528%/(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 ದ Recharge the battery. ( ದ Check the cause of discharging. ದ Remove the fuse. ( P. 69) ದ Replace the fuse. ( P. 69) ದ Start the engine with the kickstarter. ದ Recharge the battery. Establish the reason for discharging or have it checked in a KTM workshop.
TROUBLESHOOTING 85 Faults Possible cause Measure Engine turns but does not start. Water in carburetor or jets blocked ದ Clean carburetor. Engine has no idle. Idling jet blocked ದ Clean carburetor. Adjusting screws on carburetor distorted ದ Have the carburetor adjusted. Spark plug defective ದ Change spark plug. Ignition system defective ದ Have ignition system checked. Carburetor running over because float needle dirty or worn ದ Have carburetor checked.
CLEANING 86 &/($1,1* Cleaning motorcycle Note Material damageಘDamage and destruction of components by high-pressure cleaning equipment. ದ Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazardಘProblem materials cause environmental damage.
STORAGE 87 6725$*( Storage 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 immediately 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.
TECHNICAL DATA - ENGINE 88 7(&+1,&$/ '$7$ (1*,1( Design 1-cyliner 4-stroke engine, water-cooled Displacement (Every 450 models) 449.3bcm³ (27.418bcubin) Displacement (Every 530 models) 510.4bcm³ (31.147bcubin) Stroke (Every 450 models) 63.4bmm (2.496bin) Stroke (Every 530 models) 72bmm (2.83bin) Bore 95bmm (3.74bin) Compression ratio 11,9:1 Idle speed 1550… 1650brpm Control 4 valves controlled via rocker arm, drive via tooth/wheel chain Valve diameter, intake 39.5bmm (1.
TECHNICAL DATA - ENGINE 89 Capacity - coolant Coolant 0.95bl (1bqt.) Coolant ( P. 114) Coolant (mixed ready to use) ( P.
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 90 7(&+1,&$/ '$7$ (1*,1( 7,*+7(1,1* 72548(6 Screw, cable holder in generator cover M4 4bNm (3blbfbft) Loctite® 243™ Oil jet, rocker arm lubrication M5 2bNm (1.5blbfbft) Loctite® 243™ Oil jet, piston cooling M5 2bNm (1.5blbfbft) Loctite® 243™ Screw, locking lever M5 6bNm (4.4blbfbft) Loctite® 243™ Screw, ignition pulse generator M5 6bNm (4.4blbfbft) Loctite® 243™ Screw, clutch spring M6 10bNm (7.
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 91 Screw, cylinder head M10x1,25 Tightening sequence: Tighten diagonally, beginning with the rear screw on the chain shaft. Step 1 10bNm (7.4blbfbft) Step 2 30bNm (22.1blbfbft) Step 3 50bNm (36.9blbfbft) Engine oil (any) Gear oil drain plug with magnet M12x1,5 20bNm (14.8blbfbft) ದ Ignition rotor nut M12x1 60bNm (44.3blbfbft) ದ Plug, SLS M12x1,5 20bNm (14.8blbfbft) ದ Oil pressure control valve plug M12x1,5 20bNm (14.
TECHNICAL DATA - CARBURETOR 92 7(&+1,&$/ '$7$ &$5%85(725 450bEXC-RbEU, 450bEXC-RbAUS/UK (3900I) Carburetor type KEIHIN FCR-MX 39 Carburetor identification number 3900I Needle position 4th position from top Idle mixture adjusting screw Open Pump membrane stop 1.75bturns 2.15bmm (0.
TECHNICAL DATA - CARBURETOR 93 530bEXC-RbEU, 530bEXC-RbAUS/UK (3900J) Carburetor type KEIHIN FCR-MX 39 Carburetor identfication number 3900J Needle position 5th position from top Idle mixture adjusting screw Open Pump membrane stop 1.5bturns 2.15bmm (0.
TECHNICAL DATA - CHASSIS 94 7(&+1,&$/ '$7$ &+$66,6 Frame Central tube frame made of chrome molybdenum steel tubing Fork WP 4860 MXMA PA Suspension travel front 300bmm (11.81bin) Rear 335bmm (13.19bin) Fork offset (EXC-RbSIXbDAYS, XCR-WbUSA) Front marking 18bmm (0.71bin) Rear marking 20bmm (0.79bin) Fork offset (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCR-WbZA) 20bmm (0.
TECHNICAL DATA - CHASSIS 95 Lighting equipment Headlight (EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA, XCR-WbZA) BA20d 12bV 35/35bW Parking light (EXC-RbEU, EXC-RbAUS/UK, EXC-RbSIXbDAYS, EXC-RbUSA, XCR-WbZA) W2,1x9,5d 12bV 5bW Indicator lights (Every EXC-R models) W2x4,6d 12bV 1.
TECHNICAL DATA - FORK 96 7(&+1,&$/ '$7$ )25. Fork part number (EXC-RbEU, EXC-RbAUS/UK, EXC-RbUSA, XCRW) 14.18.7D.06 Fork part number (EXC-RbSIXbDAYS) 14.18.7D.
TECHNICAL DATA - SHOCK ABSORBER 7(&+1,&$/ '$7$ 6+2&. $%625%(5 Shock absorber part number (EXC-RbEU, EXC-RbAUS/UK, EXCRbUSA, XCR-W) 12.18.7D.06 Shock absorber part number (EXC-RbSIXbDAYS) 12.18.7D.35 Shock absorber WP PDS 5018 DCC Compression damping, low-speed Comfort 18bclicks Standard 15bclicks Sport 12bclicks Compression damping, high-speed Comfort 2bturns Standard 1.
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 98 7(&+1,&$/ '$7$ &+$66,6 7,*+7(1,1* 72548(6 Spoke nipple, front wheel M4,5 5bNm (3.7blbfbft) ದ Spoke nipple, rear wheel M5 5bNm (3.7blbfbft) ದ Remaining nuts, chassis M6 15bNm (11.1blbfbft) ದ Remaining screws, chassis M6 10bNm (7.4blbfbft) ದ Screw, rear brake disc M6 14bNm (10.3blbfbft) ದ Screw, front brake disc M6 14bNm (10.3blbfbft) ದ Screw, shock absorber adjusting ring M6 5bNm (3.
99
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WIRING DIAGRAM Components 1 Battery 2 Generator 3 Ignition coil 4 Pulse generator 5 Voltage regulator/rectifier 6 Electric starter button 7 Starter relay with fuse 8 Starter motor 9 Light switch, horn button, short circuit button 10 Throttle valve sensor TPS 11 Ignition curve plug connection 12 CDI controller 13 Headlight 14 Parking light 15 Brake / tail light 16 Licence plate lamp 17 Speedometer 18 Wheel speed sensor 19 Tripmaster switch (optional) 20 Flasher switch
cn 1 2 1 3 2 2 4 3 1 bl bl ye-re b r -b l br re bu wh br cp ye wh-gn bu gn br wh C_BC /6 9 C_BF1/1 C _B A1 /1 cq ye-bl bs G 6 C_BG/3 C _B T/ 3 3 2 1 C_AH2/2 2 1 or pu bl C_AC/6 ye-re re ye-bl C_BV/2 C_BO/2 2 1 C_BA2/1 ye-bl 1 2 4 5 7 6 11 10 12 13 14 C_BU/18 br C_BK/4 2 1 C_BR/4 4 3 2 1 C_AM/3 3 C_AR/ 3 8 M C_BS/2 dl 2 1 1 C _A L /2 2 C _ A T /2 4 7 30 A 2 C_ A F /4 4 3 C_A T 1 / 2 2 1 C _A L 1 / 2 3 ye wh G 2 1 br ye-re ye wh cs C_AH/2 C _ A K/ 2 1 2
WIRING DIAGRAM Components 1 Battery 2 Generator 3 Ignition coil 4 Pulse generator 5 Voltage regulator/rectifier 6 Flasher switch 7 Starter relay with fuse 8 Starter motor 9 Light switch, horn button, short circuit button 10 Throttle valve sensor TPS 11 Ignition curve plug connection 12 CDI controller 13 Headlight 14 Parking light 15 Brake / tail light 16 Licence plate lamp 17 Electric starter button, emergency OFF switch 18 Flasher relay 19 Left front flasher 20 Left r
cn dm 4 2 br wh bu re ye-re bl cp bq cq br 2 3 2 1 bs 6 4 3 C_BR/4 G 1 C_AH2/2 C_BK/4 2 2 1 cs C_BY/4 C_CV/4 8 3 9 4 M C _BK/4 2 1 C_BR/4 2 10 A 7 C _A F / 4 4 3 1 C_A T 1 / 2 2 C _A L 1 / 2 wh br 2 4 3 1 2 3 ye-re dk C_AH/2 C _ A K/ 2 1 2 br bl pu 1 ye 1 C_CR1/1 C_BG/3 1 br C_BC/6 5 cr ye-re C _B T /3 6 4 br C_AC/6 3 ye-re re C _ B S/ 2 2 1 dn 1 C_A T /2 C _A L /2 2 br bl 1 2 2 2 1 1 wh gn-wh 3 br br pu 5 C_CW/
WIRING DIAGRAM Components 1 Battery 2 Generator 3 Ignition coil 4 Pulse generator 5 Voltage regulator/rectifier 6 Electric starter button 7 Starter relay with fuse 8 Starter motor 9 Emergency OFF switch 10 Throttle valve sensor TPS 11 Ignition curve plug connection 12 CDI controller 13 Headlight 14 Parking light 15 Brake / tail light 16 Light switch 17 Flasher switch 18 Flasher relay 19 Left front flasher 20 Left rear flasher 21 Right front flasher 22 Right rear fl
WIRING DIAGRAM ye yellow ye-bl yellow-black ye-re yellow-red 106
WIRING DIAGRAM 107
cn 1 3 2 2 4 3 1 bl bl ye-re b r -b l br re bu wh br bt ye wh-gn 9 6 C_BK/4 4 3 2 1 C_BR/4 5 7 br C_BU/18 6 11 10 12 13 14 M bq 5A cq t C _ B L /2 C _ C V/ 2 br co C_BV/2 C_BS/2 2 1 2 1 C_AR/3 C_AM/3 3 8 M 1 C_A T /2 C _A L /2 2 7 10 A 2 C _A F / 4 4 3 C_A T 1 / 2 2 1 C _A L 1 / 2 3 ye wh G 2 1 br ye-re ye wh cm C_AH/2 C _ A K/ 2 1 2 1 4 3 2 br wh wh-gn 5 C_BG/3 C_BF1/1 4 4 C_AJ/3 C_BC /6 C _ BA 1 / 1 ck C_BO/2 cp 2 1 2 bk 3 2 1 C_AC/6 ye-re
WIRING DIAGRAM Components 1 Battery 2 Generator 3 Ignition coil 4 Pulse generator 5 Voltage regulator/rectifier 6 Electric starter button 7 Starter relay with fuse 8 Starter motor 9 Light switch, horn button, short circuit button 10 Throttle valve sensor TPS 11 Ignition curve plug connection 12 CDI controller 13 Headlight 14 Parking light 15 Brake / tail light 16 Thermoswitch 17 Speedometer 18 Wheel speed sensor 19 Tripmaster switch (optional) 20 Horn 21 Front brake
WIRING DIAGRAM 110 Wiring diagram (XCR-WbUSA) bo v bl bl re bu wh br bp bs bq br ye-re wh br wh bl gr bl-wh br 9 3 ye-bl bu-wh ye-bl wh bn bm ye ye-re wh-re 6 wiring diagramm bu-wh br gr ye-bl re-wh re-bl gn re bu ye bl bl bl bk ye bu br 8 M 4 gn br ye-re br re 10 A G ye-re 7 3 2 ye wh 1 br ye-re ye wh main harness 594.11.075.100 CDI harness 780.39.032.
WIRING DIAGRAM Components 1 Battery 2 Generator 3 Ignition coil 4 Pulse generator 5 Voltage regulator/rectifier 6 Electric starter button 7 Starter relay with fuse 8 Starter motor 9 Short circuit button 10 Throttle valve sensor TPS 11 Ignition curve plug connection 12 CDI controller 13 Light switch 14 Speedometer 15 Wheel speed sensor 16 Tripmaster switch (optional) 17 Plug connector for radiator fan (optional) 18 Plug connector, headlight (optional) 19 Plug connector, b
WIRING DIAGRAM 112 Wiring diagram (XCR-WbZA) br bn bo v bl bl re bu wh br bs bt br ye-re wh br wh bl gr bl-wh br 9 3 ye-bl bu-wh ye-bl wh bq bm ye 6 wiring diagramm bu-wh br gr ye-bl re-wh re-bl gn re bu ye bl ye-re wh-re bl br bl br bl M br t cl ck bk ye bu cm bl br 5A ye-re br br bl 8 re M 4 gn 10 A G ye-re 7 3 2 ye wh 1 br ye-re ye wh main harness 594.11.075.100 CDI harness 780.39.032.
WIRING DIAGRAM Components 1 Battery 2 Generator 3 Ignition coil 4 Pulse generator 5 Voltage regulator/rectifier 6 Electric starter button 7 Starter relay with fuse 8 Starter motor 9 Short circuit button 10 Throttle valve sensor TPS 11 Ignition curve plug connection 12 CDI controller 13 Headlight 14 Parking light 15 Brake / tail light 16 Light switch 17 Speedometer 18 Wheel speed sensor 19 Tripmaster switch (optional) 20 Radiator fan 21 Thermoswitch 22 Fuse, radiato
SUBSTANCES 114 68%67$1&(6 Super unleaded (ROZ 95 / RON 95 / PON 91) according to ದ DINbENb228 (ROZ 95 / RON 95 / PON 91) Brake fluid DOT 5.1 according to ದ DOT Specification ದ Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex® products. Supplier Motorex ದ Motorex®bBrakebFluidbDOTb5.1 Coolant Specification ದ Use only suitable coolant (even in countries with high temperatures).
AUXILIARY SUBSTANCES $8;,/,$5< 68%67$1&(6 Universal oil spray Specification ದ KTM recommends Motorex® products. Supplier Motorex ದ Motorex®bJokerb440bUniversal Long-life grease Specification ದ KTM recommends Motorex® products. Supplier Motorex ದ Motorex®bLongbThermb2000 Chain cleaner Specification ದ KTM recommends Motorex® products. Supplier Motorex ದ Motorex®bChainbCleanb611 Offroad chain spray Specification ದ KTM recommends Motorex® products.
AUXILIARY SUBSTANCES High-luster polish for paint Specification ದ KTM recommends Motorex® products. Supplier Motorex ದ Motorex®bMotobPolish Contact spray Specification ದ KTM recommends Motorex® products.
STANDARDS 117 67$1'$5'6 JASObT903bMA Different technical development directions required a new specification for 4-stroke motorcycles ದ the JASO T903 MA Standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.
Chain tension Before you go for the first ride Type label CAN Green sticker on rear fender on swing arm LH inside filter cover LH on front frame tube Type label USA Noise emission 118 on frame tube RH on upper frame tube on steering head tube CONSUMER INFORMATION (EXC-R USA) EAVP
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.
INDEX 120 ,1'(; A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 75 Air filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX 121 Fork protector fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Front fender installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Front wheel fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 removing . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX 122 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 steering locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Steering head bearing greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Steering head bearing play adjusting . . . . . . . . . . . . . . . . .
*3211254en* 3211254en 10/2007 Photo Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.
