KTM 450 EXC EU 2013 Manual

SETUP INSTRUCTIONS 2013

450 EXC EU

450 EXC AUS

450 EXC SIX DAYS EU

450 XC-W USA

500 EXC EU

500 EXC AUS

500 EXC SIX DAYS EU

500 EXC USA

500 XC-W USA

Art. no. 3211919en

INTRODUCTION 1

INTRODUCTION

The work described in these setup instructions must be performed before the vehicle is delivered to the customer.

Read the setup instructions in their entirety before beginning work.

Print out the current PDI form found on the KTM DEALER.NET.

These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter-

est of technical advancement without at the same time updating this manual.

We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.

It is assumed that the work will be performed by a fully trained mechanic.

All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-

tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without 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, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-

cial equipment that does not belong to the regular scope of delivery.

Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright

owner.

ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead

to the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM-Sportmotorcycle AG

5230 Mattighofen, Austria

1 MEANS OF REPRESENTATION 2

1.1 Symbols used

The meaning of specific symbols is described below.

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).

Indicates a page reference (more information is provided on the specified page).

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

The typographical formats used in this document are explained below.

Proprietary name Identifies a proprietary name.

Name®Identifies a protected name.

Brand™ Identifies a trademark.

2 SETUP 3

2.1 Unpacking and setting up the vehicle

C00116-01

Packaging 2

–Remove the box and the plastic packaging.

Info

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 that the scope of delivery

is complete on the basis of the enclosed packing list.

–Have a lift stand available.

Lift stand (54829055000)

–Carefully loosen and remove the footrest mount.

Info

An assistant prevents the motorcycle from falling over.

C00112-01

–Together with an assistant, take the vehicle off the palette.

–Position the vehicle on a lift stand.

–Check the vehicle for transport damage.

–Remove the headlight mask with the headlight. ( p. 8)

C00114-01

Package 12

–Remove the box and the plastic packaging.

Info

An assistant prevents the 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 that the scope of delivery

is complete on the basis of the enclosed packing list.

C00113-01

–Have a lift stand available.

Lift stand (54829055000)

–Together with an assistant, take the vehicle off the palette.

–Position the vehicle on a lift stand.

–Check the vehicle for transport damage.

–Install the shock absorber. ( p. 10)

601704-10

(All EXC models)

–Insert the indicator lamp with the blue and brown cable colors into

socket 1.

–Insert the indicator lamp with the blue and violet cable colors into

socket 2.

–Insert the indicator lamp with the brown/red and yellow/blue cable colors

into socket 3.

–Insert indicator lamp LED with the white and orange cable colors into

socket 4.

2 SETUP 4

C00115-10

(all XC‑W models)

–Insert the indicator lamp with the brown/red and yellow/blue cable colors

into socket 3.

–Insert indicator lamp LED with the white and orange cable colors into

socket 4.

–Connect pull switch 5with the yellow and white cables.

401380-01

(All EXC models)

–Attach the retaining bracket for the connector, the turn signal bracket with

the turn signal, and the speedometer to the upper triple clamp.

Guideline

Remaining screws, chassis M6 10 Nm

(7.4 lbf ft)

401381-01

(all XC‑W models)

–Attach the speedometer to the upper triple clamp.

Guideline

Remaining screws, chassis M6 10 Nm

(7.4 lbf ft)

601705-10

(All EXC models)

–Mount and tighten nuts 6of the turn signals on both sides.

–Connect connector 7of the right turn signal with connector 8, which is

marked green.

–Connect connector 9of the left turn signal with connector bk, which is

marked red.

–Route the clutch line with the clutch master cylinder toward the front between

the upper and lower triple clamps.

601707-10

(EXC EU/AUS/USA, XC-W)

–Position the fork legs and tighten the screws of the triple clamp.

Guideline

Screw, top triple clamp M8 20 Nm

(14.8 lbf ft)

Screw, bottom triple clamp M8 15 Nm

(11.1 lbf ft)

Info

The topmost milled groove in the fork leg must be flush with the top

edge of the upper triple clamp.

Position bleeder screws bl toward the front.

(EXC SIX DAYS)

–Position the fork legs and tighten the screws of the triple clamp.

Guideline

Screw, top triple clamp M8 17 Nm

(12.5 lbf ft)

Screw, bottom triple clamp M8 12 Nm

(8.9 lbf ft)

2 SETUP 5

Info

The rebound damping is located in the right fork leg (red adjust-

ing screw). The compression damping is located in the left fork leg

(white adjusting screw).

The topmost milled groove in the fork leg must be flush with the top

edge of the upper triple clamp.

Position the bleeder screws toward the front.

C00108-10

–Position the handlebar.

Info

Make sure cables and wiring are positioned correctly.

–Position the handlebar clamps. Mount and tighten the screws.

Guideline

Screw, handlebar clamp M8 20 Nm

(14.8 lbf ft)

Info

The markings on the handlebar should be at the center of the handlebar

clamps.

Keep the gap widths equal when tightening.

C00110-10

–Position the controls on the right half of the handlebar.

Info

The routing of the cables can be seen in the figure.

401382-01

(All EXC models)

–Mount the turn signal switch.

2 SETUP 6

C00111-10

–Position the controls on the left half of the handlebar.

Info

The figure shows how to route the clutch line and wiring harness.

–Install the front fender. ( p. 11)

–Refit the headlight mask with the headlight. ( p. 9)

–Install the front wheel. ( p. 10)

–Correctly mount the fuel tank breather.

601710-01

–Secure the handlebar cushion with two cable binders.

101019-01

–Mount the footrests with the springs and bolts. Secure the bolts using the washers

and pins.

Pliers for footrest spring (58429083000)

601711-01

(EXC EU/AUS, EXC SIX DAYS)

–Mount the license plate holder with the license plate lamp, turn signals, and

reflector.

–Connect the electrical components.

–Connect the connector of the left turn signal with connector that is marked red.

–Connect the connector of the right turn signal with the connector that is marked

green.

C00117-01

(500 EXC USA)

–Mount the license plate holder with the license plate lamp, turn signals, and

reflector.

–Connect the electrical components.

–Connect the connector of the left turn signal with connector that is marked red.

–Connect the connector of the right turn signal with the connector that is marked

green.

101393-12

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

–Keep batteries out of the reach of children.

–Wear suitable protective clothing and goggles.

–Avoid contact with battery acid and battery gases.

–Keep the battery away from sparks or open flames. Charge only in well-

ventilated areas.

–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-

tact a physician.

2 SETUP 7

–Fill the battery.

Info

Read the notes in the battery package.

–Charge the battery. ( p. 12)

–Install the battery. ( p. 11)

–Unpack and mount the KTM PowerParts included in the delivery (optional).

Info

Read the accompanying KTM PowerParts installation instructions.

–Apply the label included in the delivery (optional).

–Refuel. ( p. 13)

–Position all controls in their exact positions on the handlebar. Tighten all screws.

–Print out the current PDI form found on KTM DEALER.NET and perform the delivery

inspection.

3 WORK 8

3.1 Raising the motorcycle with the lift stand

601620-01

Note

Danger of damage The parked vehicle may roll away or fall over.

–Always place the vehicle on a firm and even surface.

–Raise the motorcycle at the frame underneath the engine.

Lift stand (54829055000)

The wheels should no longer touch the ground.

–Secure the motorcycle against falling over.

3.2 Removing the motorcycle from the lift stand

Note

Danger of damage The parked vehicle may roll away or fall over.

–Always place the vehicle on a firm and even surface.

C00077-01

–Remove the motorcycle from the lift stand.

–Remove the lift stand.

–To park the motorcycle, press the side stand 1to the ground with your foot and

lean the motorcycle on it.

Info

When you are riding, the side stand must be folded up and secured with the

rubber band.

3.3 Removing headlight mask with headlight

101401-10

–Switch off all electrical equipment.

–Remove screw 1and take off clamp.

–Loosen the rubber band 2. Push up the headlight mask and swing it forwards.

C00124-11

–Pull out the electric plug connector 3and remove the headlight mask with the

headlight.

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