This document is the Owner's Manual for the 2016 KTM 450 EXC EU, 450 EXC AU, 450 EXC Six Days EU, 450 XC-W US, 500 EXC EU, 500 EXC AU, 500 EXC Six Days EU, and 500 XC-W US models. It provides comprehensive information on the operation, handling, and maintenance of these sport motorcycles.
Function Description:
The KTM motorcycles covered by this manual are state-of-the-art sport motorcycles designed and built to withstand the normal stresses and strains of competitive use. They comply with valid regulations and categories of top international motorsport organizations. The XC-W models are specifically designed for offroad endurance competition, not primarily motocross. The manual emphasizes safe operation, proper maintenance, and adherence to environmental regulations.
Important Technical Specifications (General):
The manual details various technical specifications across different sections, including:
- Engine: Specifications for the engine, including tightening torques and capacities (engine oil, coolant, fuel).
- Chassis: Chassis specifications, including tightening torques.
- Electrical System: Details on the electrical system, including battery, fuses, and lighting components.
- Tires: Information on tire condition and air pressure.
- Fork: Specific fork models for EXC EU/AU, XC-W, and EXC Six Days, along with their part numbers and adjustment procedures.
- Shock Absorber: Shock absorber part numbers and adjustment procedures.
- Brake System: Information on hand brake and foot brake levers, brake fluid, brake discs, and brake linings.
- Cooling System: Details on the cooling system, including antifreeze, coolant levels, and draining/refilling procedures.
Usage Features:
The manual outlines various usage features, including:
- Speedometer Functions: Detailed instructions on speedometer overview, activation, setting kilometers or miles, setting clock, viewing lap time, display modes (speed, service hours, time, lap time, odometer, trip masters, average speed, stop watches), and a table of functions and menu activation.
- Controls: Descriptions and operation of all controls, such as clutch lever, hand brake lever, throttle grip, kill switches (for EXC and XC-W models), horn button, light switches (for EXC and XC-W models), turn signal switch, emergency OFF switch (EXC AU), electric starter buttons (for various models), filler cap (opening and closing), idle speed adjusting screw, shift lever, kick starter, foot brake lever, side stand, and steering lock (locking and unlocking).
- Preparing for Use: Advice on first use, engine running-in, and preparing the vehicle for specific riding conditions (difficult riding, dry sand, wet sand, wet/muddy surfaces, high temperature/slow speed, low temperature/snow).
- Riding Instructions: Checks and maintenance work before use, starting procedures, starting off, shifting, riding, braking, stopping, parking, transport, and refueling.
- Tuning the Chassis: Comprehensive instructions for adjusting the chassis, including checking basic suspension settings, adjusting compression and rebound damping of the shock absorber and fork, adjusting spring preload of the shock absorber and fork, handlebar position adjustments, and measuring rear wheel sag.
- Tuning the Engine: Procedures for checking and adjusting throttle cable play, adjusting idle speed, and adjusting the basic position of the shift lever.
Maintenance Features:
The manual provides extensive maintenance features, including:
- Service Schedule: A detailed service schedule and information on additional service work.
- Service Work on the Chassis: Instructions for raising/removing the motorcycle from a lift stand, bleeding fork legs, cleaning dust boots, removing/installing fork legs, removing/installing fork protectors, removing/installing lower triple clamp, checking/adjusting steering head bearing play, greasing steering head bearing, removing/installing front fender, removing/installing shock absorber, removing/mounting seat, removing/installing air filter box cover, removing/installing air filter, cleaning air filter and air filter box, sealing air filter box, removing/installing main silencer, cleaning spark arrestor (XC-W), changing glass fiber yarn filling in the main silencer, removing/installing fuel tank, checking for chain dirt accumulation, cleaning chain, checking/adjusting chain tension, checking chain, rear sprocket, engine sprocket and chain guide, checking frame, checking swingarm, checking throttle cable routing, checking/additionally securing rubber grip, adjusting basic position of clutch lever, checking/correcting fluid level of hydraulic clutch, changing hydraulic clutch fluid, and removing/installing engine guard.
- Service Work on the Engine: Instructions for changing fuel screen, checking engine oil level, changing engine oil and oil filter, and cleaning oil screens.
- Electrical System Maintenance: Removing/installing battery, charging battery, changing main fuse, changing fuses of individual power consumers, removing/refitting headlight mask with headlight, changing headlight bulb, changing turn signal bulb, checking/adjusting headlight setting, and changing speedometer battery.
- Cooling System Maintenance: Checking antifreeze and coolant level, draining/refilling coolant.
- Cleaning, Care, and Storage: Instructions for cleaning the motorcycle, checks and maintenance steps for winter operation, storage procedures, and preparing for use after storage.
- Troubleshooting: A troubleshooting guide and blink code explanations to help diagnose and resolve common issues.
The manual also includes important notes on guarantee and warranty, operating and auxiliary substances, spare parts and accessories, customer service, and environmental considerations for responsible motorcycle use and disposal. It emphasizes the importance of having specialized tasks performed by an authorized KTM workshop.
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