2013 Ktm Motorcycle 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 Xc-W

REPAIR MANUAL 2013 ''l'MWI:ii~8ijIIM 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. 32D6152en

TABLE OF CONTENTS 1 2 3 4 5 6 MEANS OF REPRESENTATION ..................................... 6 1.1 Symbols used ................................................... 6 1.2 Formats used .................................................... 6 SAFETY ADViCE ........................................................... 7 2.1 Repair Manual .................................................. 7 2.2 Safety advice .................................................... 7 2.3 Degrees of risk and symbols ............................... 7 2.4 Work rules ........................................................ 7 IMPORTANT NOTES ..................................................... 8 3.1 Guarantee, warranty .......................................... 8 3.2 Operating and auxiliary substances ..................... 8 3.3 Spare parts, accessories .................................... 8 3.4 Figures ............................................................ 8 SERIAL NUMBERS ...................................................... 9 4.1 Chassis number ................................................ 9 4.2 Type label ........................................................ 9 4.3 Key number (All EXC moeelsl ........................... 10 4.4 Engine number ............................................... 10 4.5 Fork part number ............................................ 10 4.6 Shock absorber part number ............................ 10 MOTORCYCLE ........................................................... 12 5.1 Raising the motorcycle with the lift stand .......... 12 5.2 Removing the motorcycle from the lift stand ...... 12 5.3 Starting.......................................................... 12 5.4 Starting the motorcycle for a check ................... 13 FORK, TRIPLE CLAMP ............................................... 14 6.1 EXC EU/AUS/USA, XC-W ................................. 14 6.1.1 Adjusting the compression damping of the 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6 6.1.7 6.1.8 6.1.9 6.1.10 6.1.11 6.1.12 6.1.13 6.1.14 6.1.15 6.1.16 6.1.17 6.1.18 6.1.19 6.1.20 6.1.21 6.1.22 6.1.23 6.1.24 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 fork ........................................................... 14 Adjusting the rebound damping of the fork .... 14 Adjusting the spring preload of the fork ......... 14 Bleeding fork legs ....................................... 15 Cleaning the dust boots of the fork legs ......... 15 Loosening the fork protector ......................... 16 Positioning the fork protection ..................... 16 Removing the fork legs ................................ 16 Install i ng the fork legs ........ ...... .............. ..... 17 Removing the fork protector ......................... 17 Installing the fork protector .......................... 18 Performing a fork service ............................. 18 Disassembling the fork legs ......................... 18 Cartridge disassembly ................................. 21 Disassembling the compression damping fitting ........................................................ 23 Checking the fork legs ................................. 23 Assembling the compression damping fitting ........................................................ 25 Assembling the cartridge ............................. 25 Assembling the fork legs .............................. 27 Greasing the steering head bearing ............... 31 Removing the lower triple clamp .................. 31 Installing the lower triple clamp ................... 32 Checking the steering head bearing play ....... 34 Adjusting the play of the steering head bearing ...................................................... 34 EXC SIX DAYS ................................................ 35 Adjusting the compression damping of the fork ........................................................... 35 Adjusting the rebound damping of the fork .... 35 Bleeding fork legs ....................................... 35 Cleaning the dust boots of the fork legs ......... 36 Loosening the fork protector ......................... 36 7 8 9 6.2.6 6.2.7 6.2.8 6.2.9 6.2.10 6.2.11 6.2.12 6.2.13 6.2.14 6.2.15 6.2.16 6.2.17 6.2.18 6.2.19 6.2.20 6.2.21 6.2.22 6.2.23 2 Positioning the fork protection ..................... 37 Removing the fork legs ................................ 37 Installing the fork legs ................................. 37 Removing the fork protector ......................... 38 Installing the fork protector .......................... 38 Performing a fork service ............................. 38 Disessembling the fork legs ......................... 39 Removing the spring ................................... 41 Disassembling the cartridge ......................... 42 Disassembling the piston rod ....................... 43 Disassembling the hydrostop unit ................. 44 Disassembling the seal ring retainer .............. 44 Checki ng the fork legs...... ...... ...... ........ ....... 45 Assembling the seal ring retainer .................. 46 Assembling the hydrostop unit ..................... 46 Assembling the piston rod ........................... 47 Assembling the cartridge ............................. 48 Assembling the fork legs .............................. 49 6.2.24 Greasing the steering head bearing ............... 53 6.2.25 6.2.26 6.2.27 Removing the lower triple clamp .................. 53 Installing the lower triple clamp ................... 54 Checking the steering head bearing play ....... 55 6.2.28 Adjusting the play of the steering head bearing ...................................................... 56 HANDLEBAR, CONTROLS ........................................... 57 7.1 Handlebar position .......................................... 57 7.2 Adjusting handlebar position ............................ 57 7.3 Adjusting the basic position of the clutch lever .............................................................. 57 7.4 Checking the throttle cable routing ................... 58 7.5 Checking the play in the throttle cable .............. 58 7.6 Adjusting the play in the throttle cable .............. 59 FRAME ..................................................................... 61 8.1 Removing the engine guard (EXC SIX DAYS, EXC AUSl ....................................................... 61 8.2 Installing the engine guard (EXC SIX DAYS, EXC AUSl ....................................................... 61 SHOCK ABSORBER, SWINGARM ................................ 62 9.1 Adjusting the high-speed compression damping of the shock absorber ......................... 62 9.2 Adjusting the low-speed compression damping of the shock absorber .... ...... ........ ...... .............. 62 9.3 Adjusting the rebound damping of the shock absorber ......................................................... 63 9.4 Measuring rear wheel sag unloaded ................... 63 9.5 Checking the static sag of the shock absorber .... 63 9.6 Checking the riding sag of the shock absorber .... 64 9.7 Adjusting the spring preload of the shock absorber ......................................................... 64 9.8 Adjusting the riding sag ................................... 65 9.9 Removing the shock absorber ........................... 65 9.10 Installing the shock absorber ............................ 65 9.11 Servicing the shock absorber ............................ 66 9.12 Removing the spring ........................................ 66 9.13 Disassembling the damper ............................... 67 9.14 Disassembling the piston rod ........................... 68 9.15 Disassembling the seal ring retainer .................. 69 9.16 Replacing the pilot bushing ............................. 70 9.17 Checking the damper ...................................... 71 9.18 Disassembling the rebound adjuster .................. 71 9.19 Removing the heim join!.. ................................ 72 9.20 Installing the heim join!.. ................................. 73

TABLE OF CONTENTS 9.21 Assembling the rebound adjuster ...................... 74 9.22 Assembling the seal ring retainer ...................... 74 9.23 Assembling the piston rod ................................ 75 9.24 Assembling the damper ................................... 76 9.25 Bleeding and filling the damper ....................... 79 9.26 Filling the damper with nitrogen ....................... 81 9.27 Installing the spring ........................................ 82 9.28 Changing the heim jOint ................................... 83 10 EXHAUST .................................................................. 85 10.1 Removing the manifold .................................... 85 10.2 Installing the manifold .................................... 85 10.3 Removing main silencer ................................... 86 10.4 Installing the main silencer .............................. 86 10.5 Changing the glass fiber yarn filling of the main silencer .................................................. 86 11 AIR FILTER ............................................................... 88 11.1 Removing the air filter box lid .......................... 88 11.2 Installing the air filter box lid ........................... 88 11.3 Removing the air filter ..................................... 88 11.4 Installing the air filter ...................................... 88 11.5 Cleaning the air filter and air filter box .............. 89 12 FUEL TANK, SEAT, TRIM ........................................... 90 12.1 Opening filler cap ........................................... 90 12.2 Closing filler cap ............................................. 90 12.3 Removing the seat .......................................... 90 12.4 Mounting the sea!.. ......................................... 91 12.5 Removing the fuel tank .................................... 91 12.6 Installing the fuel tank .................................... 92 12.7 Changing the fuel screen ................................. 93 12.8 Changing the fuel filter .................................... 94 12.9 Changing the fuel pump .................................. 96 12.10 Checking the fuel pressure ............................... 97 13 MASK, FENDER ......................................................... 99 13.1 Removing the front fender ............................... 99 13.2 Installing the front fender ................................ 99 13.3 Removing headlight mask with headligh!.. ......... 99 13.4 Refitting the headlight mask with the headlight.. ...................................................... 99 14 WHEELS ................................................................. 101 14.1 Checking the tire air pressure ......................... 101 14.2 Checking the tire condition ............................ 101 14.3 Checking the brake discs ............................... 102 14.4 Checking spoke tension ................................. 102 14.5 Front wheel .................................................. 103 14.5.1 Removing the front wheel .......................... 103 14.5.2 Installing the front wheel ........................... 103 14.5.3 Removing the front brake disc .................... 104 14.5.4 Installing the front brake disc .................... 104 14.6 Rear wheel ................................................... 104 14.6.1 Removing the rear wheel ........................... 104 14.6.2 Installing the rear wheel ............................ 105 14.6.3 Removing the rear brake disc ..................... 106 14.6.4 Installing the rear brake disc ...................... 106 14.6.5 Checking the chain tension ........................ 107 14.6.6 Adjusting the chain tension ....................... 107 14.6.7 Adjusting the chain guide .......................... 108 14.6.8 Checking the chain, rear sprocket, engine sprocket and chain guide ........................... 108 14.6.9 Checking for chain dirt accumulation .......... 110 14.6.10 Cleaning the chain .................................... 110 15 WIRING HARNESS, BATTERy ................................... 112 15.1 Changing the main fuse ................................. 112 15.2 Changing the fuses of individual power consumers .................................................... 15.3 Changing the fuse of the radiator fan ............ .. 15.4 Removi ng the battery .................................. .. 15.5 Installing the battery ..................................... 15.6 Charging the battery .................................... .. 16 BRAKE SYSTEM .................................................... .. 3 113 113 114 115 115 117 16.1 16.2 Checking the front brake linings ..................... 117 Changing the front brake linings ..................... 117 16.3 Checking free travel of hand brake lever .......... 119 16.4 Adjusting the basic position of the hand brake lever (all XC-W models) ......................... 119 16.5 Adjusting free travel of hand brake lever (All EXC models).......... ...... ........ ...... ...... ........ ..... 119 16.6 16.7 Checking the front brake fluid level ................ 120 Adding front brake fluid ................................. 120 16.8 Changing the front brake fluid ........................ 121 16.9 Checking the rear brake linings ...................... 122 16.10 Changing the rear brake linings ...................... 122 16.11 Checking the free travel of foot brake lever ...... 124 16.12 Adjusting the basic position of the foot brake lever ............................................................ 124 16.13 Checking the rear brake fluid level .................. 125 16.14 Adding brake fluid to the rear brake circui!.. .... 125 16.15 Changing the rear brake fluid ......................... 126 17 LIGHTING SYSTEM, INSTRUMENTS ......................... 128 17.1 Adjusting the speedometer functions .............. 128 17.2 Setting kilometers or miles............................. 128 17.3 Activating the additional functions .................. 129 17.4 Setting the wheel circumference .................... 129 17.5 Setting the clock ........................................... 130 17.6 Checking the headlight setting ....................... 130 17.7 Adjusting the headlight range ......................... 131 18 ENGINE .................................................................. 132 18.1 Removing the engine ..................................... 132 18.2 Installing the engine ...................................... 136 18.3 Engine disassembly ....................................... 140 18.3.1 Preparations ............................................. 140 18.3.2 Draining the engine oil .............................. 140 18.3.3 Removing the clutch push rod .................... 141 18.3.4 Removing the oil filter ............................... 141 18.3.5 Removing the starter motor ........................ 141 18.3.6 Removing the spark plug ........................... 141 18.3.7 Removing the valve cover........................... 142 18.3.8 Removing the alternator cover .................... 142 18.3.9 Positioning the engine at ignition top dead 18.3.10 18.3.11 18.3.12 center ...................................................... 142 Removing the timing chain tensioner .......... 143 Removing the camshaft ............................. 143 Removing the cylinder head ....................... 144 18.3.13 Removing the piston ................................. 144 18.3.14 Removing the rotor .................................... 144 18.3.15 Removing the timing chain guide rail .......... 145 18.3.16 Removing the timing chain tensioning rail .......................................................... 145 18.3.17 Removing the timing chain securing guide ....................................................... 145 18.3.18 Removing the timing chain ........................ 145 18.3.19 Removing the ignition pulse generator ........ 145 18.3.20 Removing the suction pump ....................... 146 18.3.21 Removing the water pump cover ................. 146 18.3.22 Removing the clutch cover ......................... 146

TABLE OF CONTENTS 18.3.23 Removing the clutch discs ......................... 147 18.3.24 Removing the primary gear nut. .................. 148 18.3.25 Removing the outer clutch hub .................. 148 18.3.26 Removing the torque limiter ....................... 149 18.3.27 Removing the starter idler gear ................... 149 18.3.28 Removing the kickstarter idler gear ............. 149 18.3.29 Removing the kickstarter idler gear ............. 149 18.3.30 Removing the shift shaft... ......................... 149 18.3.31 Removing the shift drum locating unit ........ 150 18.3.32 Removing the locking lever ........................ 150 18.3.33 Removing the oil pump gear wheels ............ 150 18.3.34 Removing the force pump .......................... 151 18.3.35 Removing the primary gear ........................ 151 18.3.36 Removing the free wheel gear .................... 151 18.3.37 Removing the left engine case section ........ 151 18.3.38 Removing the shift rails ............................. 152 18.3.39 Removing the shift drum ........................... 152 18.3.40 Removing the shift lorks ............................ 153 18.3.41 Removing the transmission shafts ............... 153 18.3.42 Removing the crankshaft ........................... 153 18.4 Work on individual parts ................................ 154 18.4.1 Work on the right section of the engine 18.4.2 18.4.3 18.4.4 18.4.5 18.4.6 18.4.7 18.4.8 18.4.9 18.4.10 18.4.11 18.4.12 18.4.13 18.4.14 18.4.15 18.4.16 18.4.17 18.4.18 18.4.19 18.4.20 18.4.21 18.4.22 18.4.23 18.4.24 18.4.25 18.4.26 18.4.27 18.4.28 18.4.29 18.4.30 18.4.31 18.4.32 18.4.33 case ........................................................ 154 Work on the left section of the engine case ........................................................ 155 Removing the oil pressure regulator valve .... 156 Checking spring length of oil pressure regulator valve .......................................... 156 Installing the oil pressure regulator valve ..... 157 Removing the crankshaft seal ring in the clutch cover ............................................. 157 Installing the crankshaft seal ring in the clutch cover ............................................. 157 Removing the water pump ......................... 157 Installing the water pump .......................... 158 Removing the timing chain sprocket ........... 159 Installing the timing chain sprocket ............ 159 Changing the connecting rod, conrod bearing. and crank pin .............................. 159 Checking crankshaft run-out at bearing pin .......................................................... 161 Cylinder - Nikasil" coating ......................... 161 Checking/measuring the cylinder ................ 161 Checking/measuring the piston ................... 162 Checking the piston ring end gap ............... 162 Measuring the piston/cylinder mounting clearance ................................................. 163 Checking the oil pumps ............................. 163 Disassembling the autodecompressor .......... 163 Assembling the autodecompressor .............. 164 Checking camshaft ................................... 165 Checking the timing assembly .................... 165 Removing the rocker arm ........................... 166 Removing the valves .................................. 166 Changing camshaft bearing ........................ 167 Checking the valves .................................. 167 Checking valve springs .............................. 168 Checking valve spring seal.. ....................... 168 Checking the cylinder head ........................ 168 Checking the rocker arm shafts .................. 169 Installing the valves .................................. 169 Install i ng the rocker arm.... .............. .......... 170 4 18.4.34 Checking the clutch .................................. 170 18.4.35 Checking the shift mechanism ................... 172 18.4.36 Preassembling the shift shaft ..................... 173 18.4.37 Disassembling the main shaft .................... 173 18.4.38 Assembling the main shaft ......................... 174 18.4.39 Disassembling the countershaft .................. 175 18.4.40 Assembling the countershaft ...................... 175 18.4.41 Checking the transmission ......................... 176 18.4.42 Premountingthe kickstarter shaft ............... 178 18.4.43 Checking the starter drive .......................... 179 18.4.44 Removing the Ireewheel ............................ 179 18.4.45 Checking the freewheel ............................. 180 18.4.46 Installing the free wheel ............................ 180 18.5 Engine assembly ........................................... 181 18.5.1 Installing the crankshaft ............................ 181 18.5.2 Installing the transmission shafts ............... 181 18.5.3 Installing the shift lorks............................. 181 18.5.4 Installing the shift drum ............................ 182 18.5.5 Installing the shift rails ............................. 182 18.5.6 Installing the left engine case .................... 182 18.5.7 Installing the free wheel gear ..................... 183 18.5.8 Installing the primary gear ......................... 183 18.5.9 Installing the lorce pump ........................... 183 18.5.10 Installing the oil pump gear wheels ............. 184 18.5.11 Installing the locking lever ......................... 184 18.5.12 Installing the shift drum locating unit ......... 184 18.5.13 Installing the shift shaft ............................ 185 18.5.14 Installing the kickstarter idler gear .............. 185 18.5.15 Installing the kickstarter shaft .................... 185 18.5.16 Installing the starter idler gear ................... 185 18.5.17 Installing the torque limiter ....................... 186 18.5.18 Installing the outer clutch hub ................... 186 18.5.19 Installing the primary gear nut ................... 187 18.5.20 Installing the clutch discs .......................... 187 18.5.21 Installing the clutch cover ......................... 188 18.5.22 Installing the water pump cover .................. 189 18.5.23 Installing the suction pump ....................... 189 18.5.24 Installing the ignition pulse generator ......... 190 18.5.25 Installing the timing chain ......................... 190 18.5.26 Installing the timing chain securing guide ... 190 18.5.27 Installing the timing chain tensioning rail .... 191 18.5.28 Installing the timing chain guide rail ........... 191 18.5.29 Installing the rotor .................................... 191 18.5.30 Installing the piston .................................. 191 18.5.31 Installing the cylinder head ........................ 193 18.5.32 Installing the camshaft .............................. 194 18.5.33 Installing the timing chain tensioner ........... 194 18.5.34 Checking the valve clearance ..................... 194 18.5.35 Adjusting the valve clearance ..................... 195 18.5.36 Installing the alternator cover ..................... 195 18.5.37 Installing the valve cover ........................... 196 18.5.38 Installing the spark plug ............................ 196 18.5.39 Installing the starter motor......................... 196 18.5.40 Installing the oil filter ................................ 196 18.5.41 Installing the clutch push rod .................... 197 18.5.42 Installing the oil screen ............................. 197 18.5.43 Removing the engine lrom the engine assembly stand ......................................... 198 19 CLUTCH .................................................................. 199 19.1 Checking/correcting the fluid level of the hydraulic clutch ............................................ 199 19.2 Changing the hydraulic clutch fluid ................ 199

TABLE OF CONTENTS 5 20 WATER PUMP, COOLING SYSTEM ............................ 201 29.8 Page 8 of 8 (EXC EU, EXC SIX DAYS) ............. 242 20.1 Cooling system ............................................. 201 29.9 Page 1 of 8 (EXC AUS) .................................. 244 20.2 Checking the antifreeze and coolant level ........ 201 29.10 Page 2 of 8 (EXC AUS) .................................. 246 20.3 Checking the coolant level ............................. 202 29.11 Page 3 of 8 (EXC AUS) .................................. 248 20.4 Draining the coolanl.. .................................... 202 29.12 Page 4 of 8 (EXC AUS) .................................. 250 20.5 Refilling coolant ........................................... 203 29.13 Page 5 of 8 (EXC AUS) .................................. 252 21 LUBRICATION SySTEM ............................................ 204 29.14 Page 6 of 8 (EXC AUS) .................................. 254 21.1 Oil circui!.. ................................................... 204 29.15 Page 7 of 8 (EXC AUS) .................................. 256 21.2 Checking the engine oil level .......................... 204 29.16 Page 8 of 8 (EXC AUS) .................................. 258 21.3 Changing the engine oil and oil filter, 29.17 Page 1 of 8 (EXC USA) .................................. 260 cleaning the oil screens ................................. 204 29.18 Page 2 of 8 (EXC USA) .................................. 262 21.4 Adding engine oil .......................................... 207 29.19 page 3 of 8 (EXC USA) .................................. 264 21.5 Checking the engine oil pressure .................... 208 29.20 Page 4 of 8 (EXC USA) .................................. 266 22 IGNITION SySTEM ................................................... 209 29.21 Page 5 of 8 (EXC USA) .................................. 268 22.1 Ignition coil - checking the secondary 29.22 Page 6 of 8 (EXC USA) .................................. 270 winding ........................................................ 209 29.23 Page 7 of 8 (EXC USA) .................................. 272 22.2 Checking the spark plug connector ................. 209 29.24 Page 8 of 8 (EXC USA) .................................. 274 22.3 Alternator - checking the stator winding .......... 209 29.25 Page 1 of 7 (all XC-W models) ........................ 276 22.4 Removing the stator ...................................... 210 29.26 Page 2 of 7 (all XC-W models) ........................ 278 22.5 Installing the stator ....................................... 210 29.27 page 3 of 7 (all XC-W models) ........................ 280 23 ELECTRIC STARTER ................................................ 211 29.28 Page 4 of 7 (all XC-W models) ........................ 282 23.1 Checking the starter motor ............................. 211 29.29 Page 5 of 7 (all XC-W models) ........................ 284 24 THROTILE VALVE BODy .......................................... 212 29.30 Page 6 of 7 (all XC-W models)...... ...... ............ 286 24.1 Adjusting the idle speed ................................ 212 29.31 Page 7 of 7 (all XC-W models)...... ...... ............ 288 24.2 Throttle position sensor circuit A - checking 30 SUBSTANCES ......................................................... 290 the basic settings .......................................... 212 31 AUXILIARY SUBSTANCES ........................................ 292 24.3 Throttle position sensor - adjusting the basic settings ........................................................ 212 25 TECHNICAL DATA .................................................... 214 25.1 Engine ......................................................... 214 32 SPECIAL TOOLS ...................................................... 294 33 STANDARDS ........................................................... 308 INDEX ............................................................................ 309 25.2 Engine tolerance, wear limits ......................... 214 25.3 Engine tightening torques .............................. 215 25.4 Capacities .................................................... 217 25.4.1 Engine oil ................................................ 217 25.4.2 Coolant .................................................... 217 25.4.3 Fuel ........................................................ 217 25.5 Chassis ........................................................ 217 25.6 Electrical system ........................................... 218 25.7 Tires ............................................................ 218 25.8 Fork ............................................................. 219 25.8.1 EXC EUiAUS/USA, XC-W ........................... 219 25.8.2 EXC SIX DAyS .......................................... 219 25.9 Shock absorber ............................................. 220 25.10 Chassis tightening torques ............................. 220 26 CLEANING, CARE .................................................... 222 26.1 Cleaning the motorcycle ................................ 222 26.2 Checks and maintenance steps for winter operation ...................................................... 223 27 STORAGE ................................................................ 224 27.1 Storage ............ ...... .............. ...... ........ .......... 224 27.2 Preparing for use after storage ........................ 224 28 SERVICE SCHEDULE ............................................... 225 28.1 Service schedule ........................................... 225 28.2 Service work (as additional order) ................... 226 29 WIRING DIAGRAM ................................................... 228 29.1 Page 1 of 8 (EXC EU, EXC SIX DAyS) ............. 228 29.2 Page 2 of 8 (EXC EU, EXC SIX DAYS) ............. 230 29.3 page 3 of 8 (EXC EU, EXC SIX DAYS) ............. 232 29.4 Page 4 of 8 (EXC EU, EXC SIX DAYS) ............. 234 29.5 Page 5 of 8 (EXC EU, EXC SIX DAYS) ............. 236 29.6 Page 6 of 8 (EXC EU, EXC SIX DAYS) ............. 238 29.7 Page 7 of 8 (EXC EU, EXC SIX DAYS) ............. 240

1 MEANS OF REPRESENTATION 6 1.1 S J!!! bols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). x 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). • I Indicates information with more details or tips . » Indicates the result of a testing step. v Denotes a voltage measurement. A 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. Identifies a protected name. Identifies a trademark.

2 SAFETY ADVICE 2.1 Rlp! ir Manual Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle. This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available. advice A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages. • Inlo I The vehicle has various information and warning labels at prominent locations. Do not remove informationiwarning labels. If they are missing, you or others may not recognize dangers and may therefore be injured. 2.3 ~u of rilll and !lJl!! bols n Danler t..!.J Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken. Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken. Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken. 2.4 Wortll1llu 7 Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren- theses. E.g.: bearing puller (15112017000) During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts. In some instances, a thread locker (e.g. Lactiree) is required. The manufacturer instructions for use must be followed. After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts. After you complete the repair or service work, check the operating safety of the vehicle.

3 IMPORTANT NOTES 8 3.1 Guarantee, wam!!lJ The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dlaler.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle. Additional information on the guarantee or warranty and the procedures involved can be found in the service record. o aratinl and alillililry substances Warninl Enviranmental hazard Improper handling of fuel is a danger to the environment. - Do not allow fuel to get into the ground water, the ground, or the sewage system. Use the operating and auxiliary substances (such as fuel and lubricants) as specified in the manual. 3.3 Sp!18 parts, Ic_rias Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any resulting damage or loss. The current KTM PawerParts for your vehicle can be found on the KTM website. International KTM Website, httpdlwww.ktm.com The figures contained in the manual may depict special equipment. In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to dis· assemble the component to perform the activity in question. Please follow the instructions in the text.

     4 SERIAL NUMBERS 9 (EXC ELVAUS, EXC SIX DAYS, XC-W) The chassis number is stamped on the steering head on the right. (EXC USA) The chassis number is stamped on the steering head on the right. (EXC ELVAUS, EXC SIX DAYS, XC-W) The type label is fixed to the front of the steering head. (EXC USA) The type label USA is fixed to the front of the steering head. (EXC USA) The type label Canada is fixed to the front of the front pipe.

     4 SERIAL NUMBERS 4.3 Key number All EXC models) 500125-10 101543·10 10 (EXC ELVAUS, EXC SIX DAYS) The key number for the steering lock is stamped onto the key connector. (EXC USA) Key number for the ignition and steering lock is indicated on the KEYCODECARD. • Info I You need the key number to order a replacement key. Keep the KEYCODE· CARD in a safe place. The engine number is stamped on the left side of the engine under the engine sprocket. The fork part number is stamped on the inner side of the fork stub. (EXC EU, EXC SIX DAYS) The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side.

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2013 Ktm Motorcycle 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 Xc-W

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