KTM 450 500 EXC \ EXC Six Days \ XC-W Workshop Service Repair Manual 2012-2013
KTM 450 500 EXC \ EXC Six Days \ XC-W Workshop Service Repair Manual 2012-2013
IMPROVED PDF manuals have: Bookmarks + Searchable Text + Index --BEST ORGANIZATION!
This Workshop Service repair manual offers detailed servicing instructions and will give you complete step by step information on repair, servicing, preventative maintenance & troubleshooting procedures for your Ktm.
This comprehensive service manual features photos and illustrations along with step-by-step instructions that will guide you through the entire repair process. This manual contains all you need to know to keep your Motorcycle working correctly.
Models covered :
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
Table Of Contents:
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
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
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
And Much More ....
Product Details :
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
KTM 450 500 EXC \ EXC Six Days \ XC-W Workshop Service Repair Manual 2012-2013
KTM 450 500 EXC \ EXC Six Days \ XC-W Workshop Service Repair Manual 2012-2013
IMPROVED PDF manuals have: Bookmarks + Searchable Text + Index --BEST ORGANIZATION!
This Workshop Service repair manual offers detailed servicing instructions and will give you complete step by step information on repair, servicing, preventative maintenance & troubleshooting procedures for your Ktm.
This comprehensive service manual features photos and illustrations along with step-by-step instructions that will guide you through the entire repair process. This manual contains all you need to know to keep your Motorcycle working correctly.
Models covered :
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
Table Of Contents:
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
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
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
And Much More ....
Product Details :
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader