2013 KTM 450 500 EXC XC-W Service Repair Manual

Online PDF 2013 KTM 450 500 EXC XC-W Service Repair Manual

Read this repair manual carefully and thoroughly before beginning work, The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly and properly. This repair manual was written to correspond to the latest state of this series. We reserve the right to make changes in the interest of technical advancement without at the same time updating this repair manual.

We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that the repair work will be performed by a fully trained mechanic.

Ail specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical speciticetions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain speccial equipment that does not belong to the regular scope of supply.

10  2013 KTM 450 500 EXC XC-W manual EXHAUST. ...  83
10.1  2013 KTM 450 500 EXC XC-W manual Removing the manifold. .    83
10.2  2013 KTM 450 500 EXC XC-W manual Installing the manifold. ....   83
10.3  2013 KTM 450 500 EXC XC-W manual Removing main silencer. .... 84
10.4  2013 KTM 450 500 EXC XC-W manual Installing the main silencer. .....  84
10.5  2013 KTM 450 500 EXC XC-W manual Changing the glass fiber yarn filling of the main silencer. .  84

11  2013 KTM 450 500 EXC XC-W manual
2013 KTM 450 500 EXC XC-W manual AIR FILTER. . 86
11.1  2013 KTM 450 500 EXC XC-W manual Removing the air filter box lid. .. 86
11.2  2013 KTM 450 500 EXC XC-W manual Installing the air filter box lid. ... 86
11.3  2013 KTM 450 500 EXC XC-W manual Sealing the air filter box. ..  86
11.4  2013 KTM 450 500 EXC XC-W manual Removing the air filter. ....  86
11.5  2013 KTM 450 500 EXC XC-W manual Installing the air filter. .  87
11.6  2013 KTM 450 500 EXC XC-W manual Cleaning the air filter and air filter box. .  87 

12  2013 KTM 450 500 EXC XC-W manual FUEL TANK, SEAT, TRIM. . 89
12.1  2013 KTM 450 500 EXC XC-W manual Opening filler cap. ...   89
12.2  2013 KTM 450 500 EXC XC-W manual Closing filler cap. ..  89
12.3  Removing the seat.  89
12.4  2013 KTM 450 500 EXC XC-W manual Mounting the seat. .  90
12.5  2013 KTM 450 500 EXC XC-W manual Removing the fuel tank. ..... 90
12.6  2013 KTM 450 500 EXC XC-W manual Installing the fuel tank. ....  91
12.7  2013 KTM 450 500 EXC XC-W manual Changing the fuel screen. .  92
12.8  2013 KTM 450 500 EXC XC-W manual Changing the fuel filter. ..... 93
12.9  2013 KTM 450 500 EXC XC-W manual Changing the fuel pump. ..  95
12.10  2013 KTM 450 500 EXC XC-W manual Checking the fuel pressure.    96 

13  2013 KTM 450 500 EXC XC-W manual MASK, FENDER.. . .. 98
13.1  2013 KTM 450 500 EXC XC-W manual Removing the front fender. .. 98
13.2  2013 KTM 450 500 EXC XC-W manual Installing the front fender.  98
13.3  2013 KTM 450 500 EXC XC-W manual Removing headlight mask with headlight. .... 98
13.4  2013 KTM 450 500 EXC XC-W manual Refitting the headlight mask with the headlight.  99

14  2013 KTM 450 500 EXC XC-W manual WHEELS. ..  100
14.1 2013 KTM 450 500 EXC XC-W manual Checking the tire air pressure. . 100
14.2 2013 KTM 450 500 EXC XC-W manual Checking the tire condition. ....  100
14.3 2013 KTM 450 500 EXC XC-W manual Checking the brake discs. .. 101
14.4 2013 KTM 450 500 EXC XC-W manual Checking spoke tension. .  101
14.5  2013 KTM 450 500 EXC XC-W manual Front wheel. .  102
14.5.1  2013 KTM 450 500 EXC XC-W manual Removing the front wheel. .. 102
14.5.2  2013 KTM 450 500 EXC XC-W manual Installing the front wheel. ...  102
14.5.3  2013 KTM 450 500 EXC XC-W manual Removing the front brake disc. .... 103
14.5.4  2013 KTM 450 500 EXC XC-W manual Installing the front brake disc. .... 103
14.6  2013 KTM 450 500 EXC XC-W manual Rear wheel. .... 103
14.6.1  2013 KTM 450 500 EXC XC-W manual Removing the rear wheel. ...  103
14.6.2  2013 KTM 450 500 EXC XC-W manual Installing the rear wheel. ....  104
14.6.3  2013 KTM 450 500 EXC XC-W manual Removing the rear brake disc. ..... 105
14.6.4  2013 KTM 450 500 EXC XC-W manual Installing the rear brake disc.  105
14.6.5  2013 KTM 450 500 EXC XC-W manual Checking the chain tension. ..  106
14.6.6  2013 KTM 450 500 EXC XC-W manual Adjusting the chain tension. .  106
14.6.7  2013 KTM 450 500 EXC XC-W manual Checking the chain, rear sprocket, engine sprocket and chain guide. ...  107
14.6.8  2013 KTM 450 500 EXC XC-W manual Checking for chain dirt accumulation. ....  109
14.6.9  2013 KTM 450 500 EXC XC-W manual Cleaning the chain. ..... 109 

15  2013 KTM 450 500 EXC XC-W manual WIRING HARNESS, BATTERY. .... 110
15.1  2013 KTM 450 500 EXC XC-W manual Changing the main fuse. .  110
15.2  2013 KTM 450 500 EXC XC-W manual Changing the fuses of individual power consumers.  . Ill
15.3  2013 KTM 450 500 EXC XC-W manual 2013 KTM 450 500 EXC XC-W manual Removing the battery. ..... 112
15.4  2013 KTM 450 500 EXC XC-W manual Installing the battery.  112
15.5  2013 KTM 450 500 EXC XC-W manual Checking the charging voltage. ..  113
15.6  2013 KTM 450 500 EXC XC-W manual Checking the quiescent current.  113 

16  2013 KTM 450 500 EXC XC-W manual BRAKE SYSTEM.   114
16.1  2013 KTM 450 500 EXC XC-W manual Checking the front brake linings. ..... 114
16.2  2013 KTM 450 500 EXC XC-W manual Changing the front brake linings. ..... 114
16.3  2013 KTM 450 500 EXC XC-W manual Checking free travel of hand brake lever. ... 116
16.4  2013 KTM 450 500 EXC XC-W manual Adjusting the basic position of the hand brake lever (XC-W). ..  116
16.5  2013 KTM 450 500 EXC XC-W manual Adjusting free travel of hand brake lever (all EXC models). .  116
16.6  2013 KTM 450 500 EXC XC-W manual Checking the brake fluid level of the front brake.    117
16.7 2013 KTM 450 500 EXC XC-W manual Adding front brake fluid. .  117
16.8 2013 KTM 450 500 EXC XC-W manual Changing the front brake fluid. ..  118
16.9 2013 KTM 450 500 EXC XC-W manual Checking the rear brake linings.  119
16.10 2013 KTM 450 500 EXC XC-W manual Changing the rear brake linings.  119
16.11 2013 KTM 450 500 EXC XC-W manual Checking the free travel of foot brake lever. ..... 121
16.12  2013 KTM 450 500 EXC XC-W manual Adjusting the basic position of the foot brake lever.    121
16.13  2013 KTM 450 500 EXC XC-W manual Checking the rear brake fluid level. .  122
16.14  2013 KTM 450 500 EXC XC-W manual Adding rear brake fluid. ..  122
16.15  2013 KTM 450 500 EXC XC-W manual Changing the rear brake fluid. . 123 

17  2013 KTM 450 500 EXC XC-W manual LIGHTING SYSTEM, INSTRUMENTS. ..  125
17.1  2013 KTM 450 500 EXC XC-W manual Checking the headlight setting. .  125
17.2  2013 KTM 450 500 EXC XC-W manual Adjusting the headlight range. . 125
17.3  2013 KTM 450 500 EXC XC-W manual EXC EU/AUS/USA, XC-W. .. 125
17.3.1  2013 KTM 450 500 EXC XC-W manual Speedometer overview. .. 125
17.3.2  2013 KTM 450 500 EXC XC-W manual Activation and test. ..... 126
17.3.3  2013 KTM 450 500 EXC XC-W manual Setting kilometers or miles. ..  126
17.3.4  2013 KTM 450 500 EXC XC-W manual Adjusting the speedometer functions. ... 126
17.3.5 2013 KTM 450 500 EXC XC-W manual Setting the clock. . 127
17.3.6 2013 KTM 450 500 EXC XC-W manual Setting the wheel circumference. .... 127
17.3.7 2013 KTM 450 500 EXC XC-W manual Querying lap time . .....  128
17.4  2013 KTM 450 500 EXC XC-W manual EXC SIX DAYS. ...  128
17.4.1  2013 KTM 450 500 EXC XC-W manual Speedometer overview. .. 128
17.4.2  2013 KTM 450 500 EXC XC-W manual Activation and test. ..... 129
17.4.3 2013 KTM 450 500 EXC XC-W Setting kilometers or miles. ..  129
17.4.4 2013 KTM 450 500 EXC XC-W Setting the speedometer functions.   129
17.4.5 2013 KTM 450 500 EXC XC-W Setting the clock. .  130
17.4.6  2013 KTM 450 500 EXC XC-W Activating the additional functions.   130
17.4.7  2013 KTM 450 500 EXC XC-W Setting the wheel circumference. .... 131
17.4.8  2013 KTM 450 500 EXC XC-W Viewing the lap time. .   131 

18 2013 KTM 450 500 EXC XC-W ENGINE. ...  133
18.1  2013 KTM 450 500 EXC XC-W Removing the engine.  133
18.2  2013 KTM 450 500 EXC XC-W Installing the engine. .  137
18.3  2013 KTM 450 500 EXC XC-W Engine disassembly. ..  142
18.3.1  2013 KTM 450 500 EXC XC-W Preparations. ..  142
18.3.2  2013 KTM 450 500 EXC XC-W Draining the engine oil. . 142
18.3.3  2013 KTM 450 500 EXC XC-W Removing the clutch push rod. ...  143
18.3.4  2013 KTM 450 500 EXC XC-W Removing the oil filter. .. 143
18.3.5  2013 KTM 450 500 EXC XC-W Removing the starter motor. ..  144
18.3.6  2013 KTM 450 500 EXC XC-W Removing the kickstarter. ... 144
18.3.7  2013 KTM 450 500 EXC XC-W Removing the spark plug. ... 144
18.3.8  2013 KTM 450 500 EXC XC-W Removing the valve cover. ... 144
18.3.9  2013 KTM 450 500 EXC XC-W Removing the alternator cover. .... 145
18.3.10  2013 KTM 450 500 EXC XC-W Positioning the engine at ignition top dead center. . 145
18.3.11  2013 KTM 450 500 EXC XC-W Removing the timing chain tensioner. ... 146

2013 KTM 450 500 EXC XC-W Service Repair Manual For Free

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