KTM 450 EXC EU 2010 User Manual

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

KTM 450 EXC EU 2010 Specifications

General

Engine Type	Single cylinder, 4-stroke
Displacement	449.3 cc
Bore x Stroke	95 mm x 63.4 mm
Compression Ratio	11.8:1
Transmission	6-speed
Front Suspension	WP USD 48 mm
Rear Suspension	WP PDS shock absorber
Rear Brake	Single disc, Brembo caliper
Seat Height	970 mm
Fuel Tank Capacity	8.5 liters
Ignition	Kokusan
Starter	Electric starter
Front Tire	90/90-21
Rear Tire	140/80-18
Fuel System	Keihin EFI, throttle body 42 mm
Front Brake	260 mm disc
Frame	Central tube frame made of chrome molybdenum steel tubing

Summary

Dear KTM Customer

Means of Representation

Important Information

Use Definition for EXC Models

Defines the intended use of KTM EXC sport motorcycles.

Use Definition for XC-W Models

Defines the intended use of KTM XC-W sport motorcycles.

General Operation and Maintenance Guidelines

Covers maintenance, warranty, fuel, spare parts, and work rules.

View of Vehicle

Vehicle View: Left Front

Diagram showing the left front view with numbered components.

Vehicle View: Right Rear

Diagram showing the right rear view with numbered components.

Location of Serial Numbers

Chassis Number and Type Label

Locates the chassis number and type label on the motorcycle.

Key, Engine, and Fork Numbers

Locates key, engine, and fork part numbers.

Shock Absorber Part Number

Locates the shock absorber part number on the motorcycle.

Controls Overview

Clutch and Hand Brake Levers

Details operation and adjustment of clutch and hand brake levers.

Engine Kill Switches and Emergency OFF

Explains function and states of short circuit and emergency OFF switches.

Electric Starter and Light Switches

Operation of electric starter and light switches for different models.

Horn Button Operation

Details the position and states of the horn button.

Flasher Switch and Indicator Lamps

Operation of flasher switch and overview of indicator lamps.

Speedometer Functions

Instructions for using speedometer, activation, and display tests.

Tripmaster and Unit Settings

Using tripmaster and setting units (km/miles).

Clock Setting Procedure

Instructions for setting the time on the motorcycle's display.

Adjusting Speedometer Modes

How to activate and deactivate different display modes on the speedometer.

Lap Time Query Function

Procedure for displaying recorded lap times from the stopwatch function.

Speedometer Modes: Speed and Service Hours

Displays current speed and total engine service hours.

Speedometer Modes: Clock and Lap Time

Displays current time and lap times from the stopwatch.

Speedometer Modes: Odometer and Trip Master 1

Displays total distance and trip meter 1.

Speedometer Mode: Trip Master 2

Manual trip meter for road book navigation, adjustable.

Speedometer Modes: Average Speed 1 & 2

Displays average speeds calculated by the system.

Speedometer Modes: Stop Watch 1 & 2

Displays journey time and manual stopwatch functions.

Fuel Tap and Filler Cap Operations

Operation of fuel tap and procedures for opening/closing filler cap.

Choke Operation (AUS/XC-W Models)

Details the choke lever position for cold starts on specific models.

Choke Operation (EU/EXC SIX DAYS)

Describes the choke lever operation for cold starts on specific models.

Shift Lever and Foot Brake Pedal

Details operation of shift lever and foot brake pedal.

Kick Starter Operation

Details the position and use of the kick starter.

Side Stand and Steering Lock

Operation and function of the side stand and steering lock.

Locking the Steering (EXC Models)

Step-by-step guide on how to lock the motorcycle's steering.

Unlocking the Steering (EXC Models)

Step-by-step guide on how to unlock the motorcycle's steering.

General Tips for Operation

Advice on First Use

Essential safety precautions and initial checks before riding.

Engine Running-In Procedure

Guidelines for the engine break-in period to ensure longevity.

Preparing for Arduous Riding Conditions Overview

Introduction to preparing for challenging riding conditions.

Preparing for Dry Sand Riding

Specific steps for preparing the motorcycle for riding on dry sand.

Preparing for Wet Sand Riding

Specific steps for preparing the motorcycle for riding on wet sand.

Preparing for Wet/Muddy Surfaces

Steps to prepare the motorcycle for riding on wet or muddy terrain.

Preparing for Extreme Temperature Conditions

Adjustments for hot, cold, or snowy riding conditions.

Riding Instructions

Pre-Ride Checks

Mandatory safety and operational checks before riding.

Starting the Engine

Detailed steps for starting the motorcycle in various conditions.

Shifting and Riding Techniques

Guidance on gear shifting, riding, and throttle control.

Braking Techniques

Proper braking methods and safety warnings for various conditions.

Stopping and Parking

Instructions for safely stopping and parking the motorcycle.

Refueling Procedures

Safe practices and warnings related to refueling the motorcycle.

Service Schedule

Workshop Maintenance Schedule

Tasks and intervals for servicing by an authorized KTM workshop.

Rider Maintenance Schedule

Regular checks and maintenance tasks for the rider to perform.

Chassis and Engine Maintenance

Jacking Up the Motorcycle

Safe procedure for lifting the motorcycle for maintenance.

Removing from Work Stand

Steps to safely remove the motorcycle from a work stand.

Basic Suspension Setting

Adjusting suspension based on rider's weight for optimal performance.

Adjusting Shock Absorber High-Speed Damping

Procedure for adjusting the high-speed compression damping.

Adjusting Shock Absorber Low-Speed Damping

Procedure for adjusting the low-speed compression damping.

Adjusting Shock Absorber Rebound Damping

Procedure for adjusting the rebound damping of the shock absorber.

Measuring Unloaded Rear Wheel Sag

Steps to measure the rear wheel sag without rider load.

Checking Static Shock Absorber Sag

Procedure to check the static sag of the rear shock absorber.

Checking Riding Shock Absorber Sag

Procedure to check the riding sag with rider load.

Adjusting Shock Absorber Spring Preload

Steps to adjust the spring preload on the rear shock absorber.

Adjusting Riding Shock Absorber Sag

Procedure to adjust the riding sag of the rear shock absorber.

Removing the Shock Absorber

Step-by-step guide for removing the rear shock absorber.

Installing the Shock Absorber

Step-by-step guide for installing the rear shock absorber.

Checking Basic Fork Setting

Guidance on checking fork settings and potential issues.

Adjusting Fork Compression Damping

Procedure for adjusting the compression damping on the fork legs.

Adjusting Fork Rebound Damping

Procedure for adjusting the rebound damping on the fork legs.

Adjusting Fork Spring Preload

Steps to adjust the spring preload on the front fork legs.

Bleeding Fork Legs

Procedure for bleeding air from the fork legs.

Cleaning Fork Leg Dust Boots

Instructions for cleaning dust boots to prevent seal leaks.

Loosening Fork Protector

Steps to loosen and remove the fork protector.

Positioning Fork Protector

Steps to correctly position and mount the fork protector.

Checking Steering Head Bearing Play

Procedure to check for play in the steering head bearing.

Adjusting Steering Head Bearing (EU/AUS/ZA)

Procedure to adjust steering head bearing play for specific models.

Adjusting Steering Head Bearing (SIX DAYS/USA)

Procedure to adjust steering head bearing play for specific models.

Removing Fork Legs

Step-by-step guide for removing the front fork legs.

Installing Fork Legs

Step-by-step guide for installing the front fork legs.

Removing Start Number Plate (400 XC-W USA)

Procedure for removing the start number plate on this model.

Installing Start Number Plate (400 XC-W USA)

Procedure for installing the start number plate on this model.

Removing Fork Protector

Steps to remove the fork protector from the fork legs.

Installing Fork Protector

Steps to install the fork protector onto the fork legs.

Removing Front Fender

Procedure for removing the front fender.

Installing Front Fender

Procedure for installing the front fender.

Removing Headlight Mask and Headlight

Steps to remove the headlight mask and headlight assembly.

Refitting Headlight Mask and Headlight

Steps to refit the headlight mask and headlight assembly.

Handlebar Position Options

Details on handlebar mounting positions on the triple clamp.

Adjusting Handlebar Position

Procedure for adjusting the handlebar position for comfort.

Checking Throttle Cable Routing

Ensuring correct routing of throttle cables to the carburetor.

Checking Throttle Cable Play

Procedure to check and measure the play in the throttle cable.

Adjusting Throttle Cable Play

Steps to adjust the throttle cable play for smooth operation.

Checking Chain for Dirt Accumulation

Visual inspection to check the chain for excessive dirt build-up.

Cleaning the Motorcycle Chain

Procedure and recommendations for cleaning the drive chain.

Checking Chain Tension

Method for measuring and verifying correct chain tension.

Checking Chain Tension (Rear Wheel Fit)

Verifying chain tension when the rear wheel is installed.

Checking Sprocket Wear

Procedure to inspect front and rear sprockets for wear.

Checking Chain Wear

Method to measure chain wear and determine replacement.

Adjusting Chain Tension

Steps to adjust chain tension and align the rear wheel.

Adjusting Chain Guide

Procedure for adjusting the chain guide based on tooth count.

Checking Brake Disc Thickness

Procedure to check brake disc wear limits for front and rear.

Checking Hand Brake Lever Free Travel

Procedure to check the free travel of the front brake lever.

Adjusting Hand Brake Lever Position (XC-W)

Adjusting lever position for hand size on XC-W models.

Adjusting Hand Brake Lever Free Travel (EXC)

Adjusting free travel on the front brake lever for EXC models.

Checking Front Brake Fluid Level

Procedure to check the brake fluid level in the front reservoir.

Topping Up Front Brake Fluid

Steps and warnings for adding brake fluid to the front system.

Checking Front Brake Linings

Procedure to check the minimum thickness of front brake linings.

Changing Front Brake Linings

Instructions for replacing worn front brake linings.

Checking Foot Brake Lever Free Play

Procedure to check the free play of the rear brake pedal.

Adjusting Foot Brake Lever Position

Steps to adjust the basic position of the rear brake pedal.

Checking Rear Brake Fluid Level

Procedure to check the brake fluid level in the rear reservoir.

Adding Rear Brake Fluid

Steps and warnings for adding brake fluid to the rear system.

Checking Rear Brake Linings

Procedure to check the minimum thickness of rear brake linings.

Changing Rear Brake Linings

Instructions for replacing worn rear brake linings.

Removing Front Wheel

Step-by-step guide for removing the front wheel.

Fitting Front Wheel

Step-by-step guide for installing the front wheel.

Removing Rear Wheel

Step-by-step guide for removing the rear wheel.

Fitting Rear Wheel

Step-by-step guide for installing the rear wheel.

Checking Tire Condition

Procedure to check tire condition, damage, and tread depth.

Checking Tire Air Pressure

Procedure to check and correct tire air pressure.

Checking Spoke Tension

Procedure to check and correct spoke tension.

Removing the Battery

Step-by-step guide for safely removing the motorcycle battery.

Installing the Battery

Step-by-step guide for safely installing the motorcycle battery.

Recharging the Battery

Procedure for recharging the battery and safety precautions.

Removing a Fuse

Procedure for locating and removing a fuse.

Installing a Fuse

Procedure for installing a fuse and safety warnings.

Checking Headlight Adjustment

Procedure to check headlight alignment against a wall.

Adjusting Headlight Beam Width

Procedure to adjust the headlight beam width for proper illumination.

Removing the Seat

Procedure for removing the motorcycle seat.

Mounting the Seat

Procedure for correctly mounting the motorcycle seat.

Removing the Fuel Tank

Step-by-step guide for removing the fuel tank.

Installing the Fuel Tank

Step-by-step guide for installing the fuel tank.

Cooling System Overview

Description of the cooling system's function and components.

Checking Anti-Freeze and Coolant Level

Procedure to check coolant anti-freeze and level.

Checking the Coolant Level

Procedure to check the coolant level in the radiator.

Draining Coolant

Steps for safely draining the motorcycle's coolant.

Refilling Coolant

Procedure for refilling the cooling system with coolant.

Glass Fiber Yarn Filling of Main Silencer

Explanation of silencer insulation and its degradation.

Removing Main Silencer

Steps for removing the main silencer.

Installing Main Silencer

Steps for installing the main silencer.

Removing Air Filter Box Lid

Procedure for removing the air filter box lid.

Installing Air Filter Box Lid

Procedure for installing the air filter box lid.

Removing the Air Filter

Steps for removing the air filter from the air filter support.

Installing the Air Filter

Steps for installing a clean air filter correctly.

Cleaning the Air Filter

Procedure for cleaning the air filter using special cleaning liquid.

Adjusting Basic Position of Clutch Lever

Adjusting clutch lever position for hand size and comfort.

Checking the Fluid Level of Hydraulic Clutch

Procedure to check the hydraulic clutch fluid level.

Changing the Hydraulic Clutch Fluid

Procedure for changing the hydraulic clutch fluid.

Checking the Basic Position of the Shift Lever

Procedure to measure the gap between boot and shift lever.

Adjusting the Basic Position of the Shift Lever

Steps to adjust the shift lever position for optimal shifting.

Carburetor - Idle Setting

Explains the influence of idle setting on engine behavior.

Carburetor - Adjusting Idle

Procedure for adjusting idle speed and mixture.

Emptying the Carburetor Float Chamber

Steps for emptying the carburetor float chamber.

Checking the Gear Oil Level

Procedure to check the gear oil level when the engine is cold.

Changing Gear Oil, Cleaning Gear Oil Screen

Procedure for changing gear oil and cleaning the screen.

Draining Gear Oil, Cleaning Gear Oil Screen

Steps for draining gear oil and cleaning the oil screen.

Filling Up With Gear Oil

Procedure for filling the transmission with gear oil.

Adding Gear Oil

Procedure to add gear oil to the transmission.

Checking Engine Oil Level

Procedure to check the engine oil level when the engine is cold.

Changing Engine Oil and Oil Filter, Cleaning Engine Oil Screen

Procedure for changing engine oil, filter, and cleaning screen.

Draining Engine Oil, Cleaning Engine Oil Screen

Steps for draining engine oil and cleaning the oil screen.

Removing the Oil Filter

Steps for removing the engine oil filter.

Installing the Oil Filter

Steps for installing the engine oil filter.

Filling Up With Engine Oil

Procedure for filling the engine with oil.

Topping Up Engine Oil

Procedure to top up the engine oil level.

Troubleshooting

Engine Cannot Be Cranked

Troubleshooting steps for when the electric starter fails.

Engine Turns But Does Not Start

Diagnosing why the engine cranks but fails to start.

Engine Has No Idle

Troubleshooting steps for engines with no idle speed.

Engine Does Not Speed Up

Diagnosing issues preventing the engine from reaching higher speeds.

Engine Has Lack of Power

Troubleshooting steps for a motorcycle with reduced engine power.

Engine Stalls or Pops Back

Diagnosing and fixing engine stalling or backfiring issues.

Engine Overheating Issues

Troubleshooting steps for an overheating engine.

Cleaning the Motorcycle

Motorcycle Storage

Putting into Operation After Storage

Steps to recommission the motorcycle after a storage period.

Technical Data: Engine

Engine Oil Capacity

Specifies the required engine oil capacity and type.

Gear Oil Capacity

Specifies the required gear oil capacity.

Coolant Capacity

Specifies the required coolant capacity and type.

Engine Tightening Torques

Technical Data: Carburetor

Carburetor Specs: 400 EXC EU/AUS

Carburetor settings for the 400 EXC EU/AUS model.

Carburetor Specs: 400 XC-W USA

Carburetor settings for the 400 XC-W USA model.

Carburetor Specs: 450 EXC EU/AUS/SIX DAYS

Carburetor settings for 450 EXC EU/AUS and SIX DAYS models.

Carburetor Specs: 450 XC-W ZA/SIX DAYS

Carburetor settings for 450 XC-W ZA and SIX DAYS models.

Carburetor Specs: 530 EXC EU/AUS/SIX DAYS

Carburetor settings for 530 EXC EU/AUS and SIX DAYS models.

Carburetor Specs: 530 XC-W ZA/SIX DAYS

Carburetor settings for 530 XC-W ZA and SIX DAYS models.

Technical Data: Chassis

Suspension Travel Specifications

Details front and rear suspension travel distances.

Brake Disc Diameter

Specifies the diameter of the front and rear brake discs.

Brake Disc Wear Limits

Specifies the minimum wear limit for brake discs.

Tire Air Pressure (Off-Road)

Recommended tire air pressure for off-road riding.

Tire Air Pressure (Road)

Recommended tire air pressure for road riding.

Tire Specifications

Details tire validity and sizes for front and rear.

Fuel Tank Capacity

Specifies the total fuel tank capacity and reserve.

Technical Data: Fork

Fork Compression Damping Settings

Details the click settings for fork compression damping.

Fork Rebound Damping Settings

Details the click settings for fork rebound damping.

Fork Spring Preload Adjustment

Instructions for adjusting the fork spring preload.

Technical Data: Shock Absorber

Shock Absorber Low-Speed Compression Damping

Details the click settings for low-speed shock compression damping.

Shock Absorber High-Speed Compression Damping

Details the turn settings for high-speed shock compression damping.

Shock Absorber Rebound Damping

Details the click settings for shock absorber rebound damping.

Shock Absorber Spring Preload

Specifies the spring preload adjustment for the shock absorber.

Shock Absorber Static Sag

Specifies the static sag measurement for the shock absorber.

Shock Absorber Riding Sag

Specifies the riding sag measurement for the shock absorber.

Chassis Tightening Torques

Wiring Diagram (EXC Models)

EXC Models: Components

List of electrical components and their designations in the wiring diagram.

EXC Models: Cable Colors

Key for understanding wire colors used in the wiring diagram.

Wiring Diagram (XC-W Models)

XC-W Models: Components

List of electrical components and their designations for XC-W models.

XC-W Models: Cable Colors

Key for understanding wire colors used in the XC-W wiring diagram.

Recommended Substances

Brake Fluid Specifications

Details on approved brake fluid types and recommended brands.

Coolant Specifications

Guidance on suitable coolant types and mixture ratios.

Engine Oil Specifications

Details on recommended engine oil viscosity and standards.

Fork Oil Specifications

Details on recommended fork oil viscosity and brands.

Shock Absorber Oil Specifications

Details on recommended shock absorber oil viscosity and part number.

Auxiliary Substances

Air Filter Cleaner Recommendation

Recommends specific cleaner for the air filter.

Chain Cleaner Recommendation

Recommends specific cleaner for the drive chain.

Metal, Rubber, Plastic Care Products

Recommends cleaning and polishing products for various materials.

Contact Spray Recommendation

Recommends contact spray for electrical components.

Long-Life Grease Recommendation

Recommends specific grease for lubrication.

Motorcycle Cleaner Recommendation

Recommends a specific cleaner for the overall motorcycle.

Off-Road Chain Spray Recommendation

Recommends specific chain spray for off-road use.

Foam Air Filter Oil Recommendation

Recommends specific oil for the foam air filter.

Universal Oil Spray Recommendation

Recommends a specific universal oil spray.

Standards and Classifications

JASO T903 MA Standard Explanation

Details the JASO T903 MA standard for 4-stroke motorcycle engines.

SAE Viscosity Classification

Explanation of SAE viscosity classes for engine oils.