KTM 450 EXC EU 2015 Manual

SETUP INSTRUCTIONS 2015

450 EXC EU

450 EXC SIX DAYS EU

450 EXC AU

450 XC-W US

500 EXC EU

500 EXC AU

500 EXC SIX DAYS EU

500 EXC US

500 XC-W US

Art. no. 3213199en

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, misprints, and other errors. The models portrayed partly contain special equip-

ment that does not belong to the regular scope of supply.

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

M00075-10

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.

402050-01

–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)

M00075-11

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.

402051-01

–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. 11)

600814-01

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

the upper and lower triple clamps.

(EXC EU, EXC AU, XC‑W, 500 EXC US)

–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

Grooves are milled into the side of the top end of the fork legs. The

second milled groove (from the top) in the fork leg must be flush

with the top edge of the upper triple clamp.

Position the bleeder screws toward the front.

2 SETUP 4

(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 15 Nm

(11.1 lbf ft)

Info

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

adjusting screw). The compression damping is located in the left

fork leg COMP (white adjusting screw).

Grooves are milled into the side of the top end of the fork legs. The

topmost milled groove must be flush with the top edge of the upper

triple clamp.

Position the bleeder screws toward the front.

101488-10

–Remove screws . Take off the handlebar clamps.

–Remove screws . Take off the handlebar supports.

–Place the handlebar supports in the required position. Mount and tighten

screws .

Guideline

Screw, handlebar holder M10 40 Nm

(29.5 lbf ft)

Loctite®243™

Info

Position the left and right handlebar supports evenly.

M00148-10

–Position the handlebar.

Info

Make sure the cables and wiring are positioned correctly.

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

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.

102049-10

(all 450 EXC models, alle 500 EXC Modelle, EXC EU, EXC SIX DAYS)

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

socket .

2 SETUP 5

102048-10

(XC‑W)

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

–Position the speedometer and connector board. Mount and tighten screws.

Guideline

Remaining screws, chassis M6 10 Nm

(7.4 lbf ft)

C00523-10

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

Info

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

C00524-10

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

Info

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

B01749-01

(all 450 EXC models, alle 500 EXC Modelle, EXC EU, EXC SIX DAYS)

–Remove the fuel tank.

–Position the turn signal wiring harness against the main wiring harness and

secure with cable binders.

B01750-01

–Disconnect the plug-in connection from the main wiring harness and con-

nect the turn signal wiring harness.

–Install the fuel tank.

M00149-01

–Position the turn signal on each side and mount and tighten nuts.

–Connect plug-in connection of the right turn signal using the black and

brown cable colors.

–Connect plug-in connection of the left turn signal using the violet and

brown cable colors.

2 SETUP 6

401382-01

(EXC EU, EXC AU)

–Mount the turn signal switch.

402148-01

(EXC SIX DAYS)

–Mount the turn signal switch.

–Install the front fender. ( p. 12)

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

–Install the front wheel. ( p. 11)

–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)

2 SETUP 7

601711-01

(all 450 EXC models, EXC EU, EXC SIX DAYS, EXC AU)

–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 US)

–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 sparks and open flames away from 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-

tact a physician.

–Fill the battery.

Info

Read the notes in the battery package.

–Charge the battery. ( p. 13)

–Install the battery. ( p. 13)

–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).

–Set kilometers or miles. ( p. 16)

–Set the speedometer functions. ( p. 16)

–Set the clock. ( p. 17)

–Refuel. ( p. 15)

–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

401942-01

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.

401943-10

–Remove the motorcycle 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 secured with the rubber

band.

3.3 Removing headlight mask with headlight

M00143-10

(all 450 models, EXC AU, EXC EU, EXC SIX DAYS, XC-W)

–Switch off all electrical equipment.

–Remove screw and take off the clamp.

–Release rubber straps . Slide the headlight mask up and swing it forward.

M00127-10

–Detach electrical plug-in connector and take off the headlight mask with

the headlight.

M00188-10

(500 EXC US)

–Switch off all electrical equipment.

–Remove screw and take off the clamp.

–Release rubber straps . Slide the headlight mask up and swing it forward.

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