2012 KTM 450 EXC XC-W 500 EXC XC-W Motorcycle Owners Manual

Description

This 2012 KTM 450 EXC XC-W 500 EXC XC-W Motorcycle Owners Manual is an authorized reproduction of the original, out of print manual. It provides the information you need to operate and maintain your KTM motorcycle. Covers basic maintenance and proper operation. Be sure to get a service manual for in-depth engine repairs.

Table of Contents

MEANS OF REPRESENTATION
IMPORTANT INFORMATION
VIEW OF VEHICLE
View of vehicle, front left (example)
View of vehicle, rear right (example)
SERIAL NUMBERS
Chassis number
Type label
Key number (All EXC models)
Engine number
Fork part number
Shock absorber part number
CONTROLS
Clutch lever
Hand brake lever
Throttle grip
Kill switch (All XC-W models)
Kill switch (All EXC models)
Horn button (All EXC models)
Light switch (All EXC models)
Turn signal switch (All EXC models)
Emergency OFF switch (EXC AUS)
Electric starter button (EXC AUS)
Electric starter button (EXC EU, EXC SIX DAYS, all XC-F
models)
Map-Select switch for the basic setting (EXC SIX DAYS)
Map-Select switch for vehicle operation
(EXC SIX DAYS)
Light switch (All XC-W models)
Overview of indicator lamps (All XC-W models)
Overview of indicator lamps (All EXC models)
Speedometer
Speedometer activation and test
Tripmaster switch
Setting kilometers or miles
Setting the clock
Adjusting the speedometer functions
Querying lap time
Display mode SPEED (speed)
Display mode SPEED/H (operating hours)
Display mode SPEED/CLK (clock)
Display mode SPEED/LAP (lap time)
Display mode SPEED/ODO (odometer)
Display mode SPEED/TRI (trip master 1)
Display mode SPEED/TR2 (trip master 2)
Display mode SPEED/A1 (average speed 1)
Display mode SPEED/A2 (average speed 2)
Display mode SPEED/S 1 (stop watch 1)
Display mode SPEED/S2 (stop watch 2)
Opening filler cap
Closing filler cap
Idle speed adjusting screw
Shift lever
Kick starter
Foot brake lever
Side stand
Steering lock (All EXC models)
Locking the steering (All EXC models)
Unlocking the steering (All EXC models)
PREPARING FOR USE
Advice on first use
Running-in the engine
Preparing the vehicle for difficult riding conditions
Preparing for rides on dry sand
Preparing for rides on wet sand
Preparing for rides 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 and maintenance work when preparing for use
Starting
Starting off
Shifting, riding
Braking
Stopping, parking
Refueling
SERVICE SCHEDULE
Service schedule
Service work (as additional order)
TUNING THE CHASSIS
Checking the basic suspension setting against the rider’s
weight
Compression damping of shock absorber
Adjusting the low-speed compression damping of the
shock absorber
Adjusting the high-speed compression damping of the
shock absorber
Adjusting the rebound damping of the shock absorber
Measuring rear wheel sag unloaded
Checking the static sag of the shock absorber
Checking the riding sag of the shock absorber
Adjusting the spring preload of the shock absorber
Adjusting the riding sag A
Checking basic setting of fork
Adjusting the compression damping of the fork
Adjusting the rebound damping of the fork
Adjusting the spring preload of the fork
Handlebar position
Adjusting handlebar position A
SERVICE WORK ON THE CHASSIS
Raising the motorcycle with the lift stand
Removing the motorcycle from the lift stand
Bleeding fork legs
Cleaning the dust boots of the fork legs
Loosening the fork protector
Positioning the fork protection
Removing the fork legs
Installing the fork legs A
Removing the fork protector A
Installing the fork protector A
Removing the lower triple clamp A (EXC EU, EXC AUS,
All XC-W models)
Removing the lower triple clamp A (EXC SIX DAYS)
Installing the lower triple clamp A (EXC EU, EXC AUS,
All XC-W models)
Installing the lower triple clamp A (EXC SIX DAYS)
Checking the steering head bearing play
Adjusting the play of the steering head bearing A
(EXC EU, EXC AUS, All XC-W models)
Adjusting the play of the steering head bearing A
(EXC SIX DAYS)
Greasing the steering head bearing A
Removing the shock absorber A
Installing the shock absorber A
Removing the front fender
Installing the front fender
Removing the seat
Mounting the seat
Removing the air filter box lid
Installing the air filter box lid
Removing the air filter A
Installing the air filter A
Cleaning the air filter and air filter box A
Removing main silencer
Installing the main silencer
Changing the glass fiber yarn filling of the main
silencer A
Removing the fuel tank A
Installing the fuel tank A
Checking for chain dirt accumulation
Cleaning the chain
Checking the chain tension
Adjusting the chain tension
Checking the chain, rear sprocket, engine sprocket and
chain guide
Adjusting the chain guide A
Checking the frame A
Checking the swingarm A
Checking the throttle cable routing
Checking the rubber grip
Additionally securing the rubber grip
Adjusting the basic position of the clutch lever
Checking the fluid level of the hydraulic clutch
Changing the hydraulic clutch fluid A
Removing the engine guard (EXC SIX DAYS, EXC AUS)
Installing the engine guard (EXC SIX DAYS, EXC AUS)
BRAKES
Checking free travel of hand brake lever
Adjusting the basic position of the hand brake lever (All
XC-W models)
Adjusting free travel of hand brake lever (All EXC
models)
Checking the brake discs
Checking the front brake fluid level
Adding front brake fluid A
Checking the front brake linings
Changing the front brake linings A
Checking the free travel of foot brake lever
Adjusting the basic position of the foot brake lever A
Checking the rear brake fluid level
Adding brake fluid to the rear brake circuit A
Checking the rear brake linings
Changing the rear brake linings A
WHEELS, TIRES
Removing the front wheel A
Installing the front wheel A
Removing the rear wheel A
Installing the rear wheel A
Checking the tire condition
Checking tire air pressure
Checking spoke tension
ELECTRICAL SYSTEM
Removing the battery A
Installing the battery A
Charging the battery
Changing the main fuse
Changing the fuses of individual power consumers
Changing the fuse of the radiator fan
Removing headlight mask with headlight
Refitting the headlight mask with the headlight
Changing the headlight bulb
Checking the headlight setting
Adjusting the headlight range
Changing the speedometer battery
COOLING SYSTEM
Cooling system
Checking the antifreeze and coolant level
Checking the coolant level
Draining the coolant A
Refilling coolant A
TUNING THE ENGINE
Checking the play in the throttle cable
Adjusting the play in the throttle cable A
Adjusting the idle speed A
Checking the basic position of the shift lever
Adjusting the basic position of the shift lever
Setting the engine characteristics (EXC SIX DAYS)
SERVICE WORK ON THE ENGINE
Checking the engine oil level
Changing the engine oil and oil filter, cleaning the oil
screens
Adding engine oil
CLEANING, CARE
Cleaning the motorcycle
Checks and maintenance steps for winter operation
STORAGE
Storage
Preparing for use after storage
TROUBLESHOOTING
BLINK CODE
TECHNICAL DATA-ENGINE
Capacity – engine oil
Capacity – coolant
TECHNICAL DATA – ENGINE TIGHTENING TORQUES
TECHNICAL DATA – CHASSIS
Lighting equipment
Tires
Capacity – fuel
TECHNICAL DATA – FORK
TECHNICAL DATA – SHOCK ABSORBER
TECHNICAL DATA – TIGHTENING TORQUES FOR
CHASSIS
SUBSTANCES
AUXILIARY SUBSTANCES
STANDARDS
INDEX