OWNER'S MANUAL 2010 400 EXC EU 400 EXC AUS 400 XC-W USA 450 EXC EU 450 EXC AUS 450 EXC SIX DAYS EU 450 XC-W SIX DAYS USA 450 XC-W ZA 530 EXC EU 530 EXC AUS 530 EXC SIX DAYS EU 530 XC-W SIX DAYS USA 530 XC-W ZA Art. no. 3211467en DEAR KTM CUSTOMER DEAR KTM CUSTOMER 1 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 ( Engine number ( p. 9) p. 9) p. 9) Dealer's stamp Key number (all EXC models) ( The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing development and design of our motorcycles can however not be completely excluded. All details contained in it are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications, 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 for printing and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery. © 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, 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 TABLE OF CONTENTS TABLE OF CONTENTS 2 Preparing for riding on wet sand...................................... Preparing for riding on wet and muddy surfaces................ Preparing for rides at high temperature and slow speed ..... Preparing for rides at low temperatures or in snow ............ RIDING INSTRUCTIONS .................................................... Checks before putting into operation ............................... Starting ........................................................................ Starting up ................................................................... Shifting, riding .............................................................. Braking ........................................................................ Stopping, parking .......................................................... Refueling...................................................................... SERVICE SCHEDULE......................................................... Important maintenance work to be carried out by an authorized KTM workshop. ............................................. Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)................ Important checks and maintenance work to be carried out by the rider. ............................................................ MAINTENANCE WORK ON CHASSIS AND ENGINE.............. Jacking up the motorcycle .............................................. Removing the motorcycle from the work stand.................. Checking the basic suspension setting with the rider's weight .......................................................................... Compression damping of shock absorber.......................... Adjusting high-speed compression damping of the shock absorber ....................................................................... Adjusting the low-speed compression damping of the shock absorber .............................................................. Adjusting rebound damping of the shock absorber ............ Measuring rear wheel sag unloaded ................................. Checking static sag of shock absorber.............................. Checking riding sag of shock absorber ............................. Adjusting spring preload of the shock absorber Adjusting riding sag Removing the shock absorber Installing the shock absorber Checking basic setting of fork ......................................... Adjusting the compression damping of the fork ................ Adjusting rebound damping of fork.................................. Adjusting spring preload of the fork................................. Bleeding fork legs.......................................................... Cleaning the dust boots of the fork legs ........................... Loosening the fork protector ........................................... Positioning the fork protector.......................................... Checking steering head bearing play................................ Adjusting play of steering head bearing (EXC EU, EXC AUS, XCW ZA)....................................................... Adjusting play of steering head bearing (EXC SIX DAYS, XCW SIX DAYS, XCW USA)................... Removing the fork legs Installing fork legs Removing the fork protector Installing the fork protector ....................................... Removing the front fender .............................................. Installing the front fender............................................... Removing headlight mask with headlight (all EXC models, all 450/530 XC-W models)................................. Refitting the headlight mask with the headlight (all EXC models, all 450/530 XC-W models)................................. Removing the start number plate (400 XC-W USA) ........... Installing the start number plate (400 XC-W USA) ............ 26 27 28 28 29 29 29 30 30 30 31 31 33 33 34 35 36 36 36 36 36 36 37 37 38 38 39 39 40 40 40 41 41 41 42 42 42 43 43 43 MEANS OF REPRESENTATION ............................................ 4 IMPORTANT INFORMATION ................................................ 5 VIEW OF VEHICLE............................................................... 7 View of the vehicle from the left front (example) ................. 7 View of the vehicle from the right rear (example) ................ 8 LOCATION OF SERIAL NUMBERS ........................................ 9 Chassis number............................................................... 9 Type label....................................................................... 9 Key number (all EXC models) ........................................... 9 Engine number................................................................ 9 Fork part number............................................................. 9 Shock absorber part number........................................... 10 CONTROLS ....................................................................... 11 Clutch lever .................................................................. 11 Hand brake lever ........................................................... 11 Short circuit button (all XCW models)............................. 11 Short circuit button (all EXC models)............................... 11 Emergency OFF switch (EXC AUS) .................................. 11 Electric starter button (EXC EU, EXC SIX DAYS, XC-W, XCW SIX DAYS)............................................................ 12 Electric starter button (EXC AUS).................................... 12 Light switch (all EXC models) ......................................... 12 Light switch (all XCW models) ....................................... 12 Horn button (all EXC models) ......................................... 12 Flasher switch (all EXC models) ...................................... 13 Overview of indicator lamps (all EXC models) ................... 13 Speedometer................................................................. 13 Speedometer activation and test ..................................... 13 Tripmaster switch .......................................................... 14 Setting kilometers or miles ............................................. 14 Setting the clock ........................................................... 14 Adjusting the speedometer functions............................... 15 Querying the lap time .................................................... 15 SPEED display mode (speed).......................................... 16 Display mode SPEED/H (service hours)............................ 16 Display mode SPEED/CLK (clock) ................................... 16 Display mode SPEED/LAP (lap time) ............................... 16 Display mode SPEED/ODO (odometer) ............................. 17 Display mode SPEED/TR1 (trip master 1) ........................ 17 Display mode SPEED/TR2 (trip master 2) ........................ 17 Disply mode SPEED/A1 (average speed 1) ....................... 18 Display mode SPEED/A2 (average speed 2)...................... 18 Display mode SPEED/S1 (stop watch 1) .......................... 18 Display mode SPEED/S2 (stop watch 2) .......................... 18 Fuel tap........................................................................ 20 Opening filler cap .......................................................... 20 Closing filler cap ........................................................... 20 Choke (EXC AUS, XCW, XCW SIX DAYS) ........................ 20 Choke (EXC EU, EXC SIX DAYS) ..................................... 21 Shift lever..................................................................... 21 Foot brake pedal ........................................................... 21 Kick starter ................................................................... 21 Side stand .................................................................... 22 Steering lock (all EXC models) ........................................ 22 Locking the steering (all EXC models).............................. 22 Unlocking the steering (all EXC models) .......................... 23 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION...................................................................... 24 Advice on first use ......................................................... 24 Running-in the engine ................................................... 25 Preparing vehicle for arduous riding conditions................. 25 Preparing for riding on dry sand ...................................... 25 x............ x.................................................. x..................................... x..................................... x 44 x 44 x.............................................. 44 x.................................................... 45 x....................................... 46 x 46 46 46 46 47 47 47 TABLE OF CONTENTS Handlebar position ........................................................ Adjusting handlebar position Checking throttle cable route .......................................... Checking the play in the throttle cable............................. Adjusting the play in the throttle cable ....................... Checking for chain dirt accumulation .............................. Cleaning the chain......................................................... Checking the chain tension ............................................ Checking chain tension when fitting rear wheel ................ Checking the rear sprocket/engine sprocket for wear ......... Checking chain wear ...................................................... Adjusting chain tension.................................................. Adjusting chain tension - after checking .......................... Adjusting chain tension - fitting rear wheel ...................... Adjusting chain guide ............................................... Checking brake discs ..................................................... Checking free travel of hand brake lever........................... Adjusting basic position of hand brake lever (all XCW models) ........................................................................ Adjusting free travel of hand brake lever (all EXC models) ........................................................................ Checking the brake fluid level of the front brake ............... Topping up the front brake fluid Checking the front brake linings...................................... Changing the front brake linings Checking free play of foot brake lever .............................. Adjusting basic position of foot brake lever Checking rear brake fluid level........................................ Adding brake fluid to the rear brake circuit ................. Checking rear brake linings ............................................ Changing rear brake linings ....................................... Removing front wheel Fitting front wheel ...................................... ...