KTM 500 EXC US Owner's Manual
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KTM 500 EXC US Owner's Manual

2016
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OWNER'S MANUAL
2016
500 EXC US
500 EXC Six Days US
Art. no. 3213339en

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Summary of Contents for KTM 500 EXC US

  • Page 1 OWNER'S MANUAL 2016 500 EXC US 500 EXC Six Days US Art. no. 3213339en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, misprints, and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Setting the clock..........23 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 Viewing the lap time........23 Symbols used ........... 5 Display mode SPEED (speed) ......24 Formats used............ 5 Display mode SPEED/H (service hours) ..... 24 SAFETY ADVICE............
  • Page 5 TABLE OF CONTENTS 11.12 Adjusting the compression damping of the 12.48 Removing the engine guard fork ............... 46 (EXC Six Days US) .......... 76 11.13 Adjusting the rebound damping of the fork ..47 12.49 Installing the engine guard (EXC Six Days US) ... 76 11.14 Adjusting the spring preload of the fork 13 BRAKE SYSTEM ............
  • Page 6 TABLE OF CONTENTS 19 CLEANING, CARE ............ 108 19.1 Cleaning the motorcycle ........ 108 19.2 Checks and maintenance steps for winter operation............109 20 STORAGE ..............110 20.1 Storage ............110 20.2 Preparing for use after storage......110 21 TROUBLESHOOTING ..........111 22 BLINK CODE ............

  • Page 7: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required.

  • Page 8: Safety Advice

    SAFETY ADVICE Use definition - intended use KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply with currently valid regulations and categories of the top international motorsport organizations.

  • Page 9: Overview Of Labels

    SAFETY ADVICE Overview of labels K00165-10 Canada type label USA type label Brake fluid information Information on chain tension Information on starting up Information on emissions control Information on noise emission K00161-01 Canada type label K00162-01 USA type label...
  • Page 10 SAFETY ADVICE Brake fluid information S00026-10 Information on chain tension 101516-01 Information on starting up 700210-01 Information on emissions control K00163-01 K00164-01 Information on noise emission...

  • Page 11: Reporting Safety Defects

    Hotline. Noise emission warranty KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise stan- dards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.

  • Page 12: Safe Operation

    Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.

  • Page 13: Important Notes

    Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM Dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 14: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) K00159-10 Hand brake lever ( p. 16) Clutch lever ( p. 16) Filler cap Side stand ( p. 20) Engine number ( p. 14) Shift lever ( p. 19)

  • Page 15: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) K00160-10 Light switch ( p. 16) Turn signal switch ( p. 17) Emergency OFF switch ( p. 17) Electric starter button ( p. 17) Throttle grip ( p. 16) Chassis number ( p.

  • Page 16: Serial Numbers

    SERIAL NUMBERS Chassis number  The chassis number is stamped on the steering head on the right. 401945-10 Type label The type label  is fixed to the front of the steering head.  The additional type label for Canada is fixed to the front of the front pipe.

  • Page 17: Fork Part Number

    SERIAL NUMBERS Fork part number  The fork part number is stamped on the inner side of the fork stub. 401947-10 Shock absorber part number The shock absorber part number  is stamped on the top of the shock absorber above the adjusting ring on the engine side.

  • Page 18: Controls

    CONTROLS Clutch lever  The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. M00083-10 Hand brake lever The hand brake lever  is fitted on the right side of the handlebar. The hand brake lever is used to activate the front brake.

  • Page 19: Turn Signal Switch

    CONTROLS Turn signal switch  Turn signal switch is fitted on the left side of the handlebar. Possible states Turn signal light off Turn signal light, left, on – The turn signal switch is pressed to the left. The turn signal switch returns to the middle position after activation. Turn signal light, right, on –...

  • Page 20: Opening The Filler Cap

    CONTROLS 6.11 Opening the filler cap Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 21: Idle Speed Adjusting Screw

    CONTROLS 6.13 Idle speed adjusting screw  Idle speed adjusting screw is located at the top left of the throttle valve body. The idle speed adjusting screw has two functions. Turning it controls the idle speed. Pulling it out all the way raises the idle speed during a cold start. Possible states RPM increase activated –...

  • Page 22: Foot Brake Lever

    CONTROLS 6.16 Foot brake lever  The foot brake lever is attached in front of the right footrest. The foot brake lever is used to activate the rear brake. 401956-10 6.17 Side stand The side stand  is attached to the left side of the vehicle. 401943-10 The side stand is used to park the motorcycle.

  • Page 23: Unlocking The Steering

    CONTROLS – Park the vehicle. – Turn the handlebar as far as possible to the right. – Grease steering lock regularly. Universal oil spray ( p. 123) – Insert the key in the steering lock ( p. 20), turn it to the left, press it in, and turn it to the right.

  • Page 24: Speedometer

    SPEEDOMETER Speedometer overview – Press the button to control different functions. – Press the button to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. 401761-01 Activation and test Activating the speedometer The speedometer is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor.

  • Page 25: Setting The Speedometer Functions

    SPEEDOMETER Setting the speedometer functions Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is stationary. – Repeatedly press the button briefly until H appears at the bottom right of the display.

  • Page 26: Display Mode Speed (Speed)

    SPEEDOMETER – Repeatedly press the button briefly until LAP appears at the bottom right of the display. – Briefly press the button LAP 1 appears on the left side of the display. – The laps 1–10 can be viewed with the button –...

  • Page 27: Setup Menu

    SPEEDOMETER Setup menu Condition • The motorcycle is stationary. – Repeatedly press the button briefly until H appears at the bottom right of the display. – Press the button for 2–3 seconds. The Setup menu displays the active functions. Info Repeatedly press the button briefly until the desired function is reached.

  • Page 28: Display Mode Speed/Clk (Time)

    SPEEDOMETER 7.11 Display mode SPEED/CLK (time) – Repeatedly press the button briefly until CLK appears at the bottom right of the display. The time is shown in display mode CLK. Press the button The display changes to the Setup menu of the clock. for 2–3 seconds.

  • Page 29: Viewing The Lap Time

    SPEEDOMETER 7.14 Viewing the lap time Condition • The motorcycle is stationary. – Repeatedly press the button briefly until LAP appears at the bottom right of the display. – Briefly press the button Press the button The stop watch and the lap time are reset. for 2–3 seconds.

  • Page 30: Display Mode Speed/Tr2 (Trip Master 2)

    SPEEDOMETER 7.17 Display mode SPEED/TR2 (trip master 2) – Repeatedly press the button briefly until TR2 appears at the top right of the dis- play. TR2 (trip master 2) runs constantly and counts up to 999.9. Press the button Clears the values TR2 and A2. for 2–3 seconds.

  • Page 31: Display Mode Speed/A2 (Average Speed 2)

    SPEEDOMETER 7.20 Display mode SPEED/A2 (average speed 2) – Repeatedly press the button briefly until A2 appears at the top right of the dis- play. A2 (average speed 2) shows the average speed on the basis of the current speed if the stop watch S2 (stop watch 2) is running.

  • Page 32: Table Of Functions

    SPEEDOMETER 7.23 Table of functions Display Press the but- Briefly press the Press the but- Briefly press the Wait 3–5 sec- Wait 10–12 sec- for 2–3 button for 2–3 button onds onds seconds. seconds. Display mode The display Next display No function No function SPEED/H (service...

  • Page 33: Table Of Conditions And Menu Activation

    SPEEDOMETER 7.24 Table of conditions and menu activation Display The motorcycle is Menu can be acti- stationary. vated Display mode SPEED/H (service hours) • Setup menu • Setting the unit of measurement • Setting the clock • Display mode SPEED/LAP (lap time) •...

  • Page 34: Preparing For Use

    When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.

  • Page 35: Running-In The Engine

    PREPARING FOR USE Info Motorcycles react sensitively to any changes of weight distribution. – Do not exceed maximum permissible weight and maximum permissible axle loads. Guideline Maximum permissible overall weight 335 kg (739 lb.) Maximum permissible front axle load 145 kg (320 lb.) Maximum permissible rear axle load 190 kg (419 lb.) –...

  • Page 36: Preparing For Rides On Dry Sand

    – Fit a dust cover on the air filter. Dust protection device for air filter (77206920100) Info See the KTM PowerParts fitting instructions. M00999-01 – Fit a sand cover on the air filter. Sand protection device for air filter (59006922000) Info See the KTM PowerParts fitting instructions.

  • Page 37: Preparing For Rides On Wet And Muddy Surfaces

    Preparing for rides on wet and muddy surfaces – Fit a waterproofing device on the air filter. Waterproofing device for air filter (77206921100) Info See the KTM PowerParts fitting instructions. M01001-01 – Fit the steel sprocket. – Clean the motorcycle. ( p.

  • Page 38: Riding Instructions

    RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p. 104) –...

  • Page 39: Starting Off

    Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If unusual noises occur while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines.

  • Page 40: Stopping, Parking

    RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. –...

  • Page 41: Refueling

    – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards.

  • Page 42: Service Schedule

    ● ● Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval...

  • Page 43: Service Work (As Additional Order)

    SERVICE SCHEDULE 10.2 Service work (as additional order) Annually Every 135 operating hours/every 70 operating hours when used for motorsports Every 45 operating hours Once after 15 operating hours ● Change the front brake fluid. ● Change the rear brake fluid. ●...

  • Page 44: Tuning The Chassis

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber.

  • Page 45: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber.

  • Page 46: Measuring Rear Wheel Sag Unloaded

    TUNING THE CHASSIS 11.6 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with the lift stand. ( p. 51) Main work – Measure the distance – as vertically as possible – between the rear axle and a fixed point such as a mark on the side cover.

  • Page 47: Adjusting The Spring Preload Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.

  • Page 48: Checking Basic Setting Of Fork

    TUNING THE CHASSIS Info The spring rate is shown on the outside of the spring. Smaller weight differences can be compensated by changing the spring preload. Finishing work – Install the shock absorber. p. 61) – Remove the motorcycle from the lift stand. ( p.

  • Page 49: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS (EXC Six Days US) –  Turn the white adjusting screw all the way clockwise. Info  Adjusting screw is located at the upper end of the left fork leg. The compression damping is located in the left fork leg COMP (white adjusting screw).

  • Page 50: Adjusting The Spring Preload Of The Fork (Exc Us)

    TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 11.14 Adjusting the spring preload of the fork (EXC US) – Turn the adjusting screws counterclockwise all the way. Info Make the same adjustment on both fork legs. –...

  • Page 51: Adjusting Handlebar Position

    TUNING THE CHASSIS (EXC US)  On the upper triple clamp, there are two holes at a distance of to each other. 15 mm (0.59 in)  Hole distance  The holes on the handlebar holders are placed at a distance of from the center.
  • Page 52 TUNING THE CHASSIS (EXC US) –  Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against damage. Do not bend the cables and lines. –...

  • Page 53: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (78129955100) Neither wheel is in contact with the ground.

  • Page 54: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 51) – Remove the fork protector. ( p. 54) Main work –  Push dust boot downward on both fork legs.

  • Page 55: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS (EXC Six Days US) –  Release screws . Take out the left fork leg. –  Release screws . Take out the right fork leg. M00138-10 12.6 Installing the fork legs Main work (EXC US) –...

  • Page 56: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS –  Position brake caliper, and mount and tighten screws Guideline Screw, front brake 25 Nm Loctite ® 243™ caliper (18.4 lbf ft) – Mount cable binder. – Position the brake line, wiring harness, and clamp. Mount and tighten ...

  • Page 57: Removing The Lower Triple Clamp (Exc Six Days Us)

    SERVICE WORK ON THE CHASSIS –   Remove O-ring . Remove protective ring – Take off the lower triple clamp with the steering stem. – Remove the upper steering head bearing. M00990-10 12.10 Removing the lower triple clamp (EXC Six Days US) Preparatory work –...
  • Page 58 SERVICE WORK ON THE CHASSIS – Position the upper triple clamp with the handlebar. –  Mount screw but do not tighten yet. – Position the clutch line, wiring harness, and voltage regulator. Mount and tighten  screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) K00140-10 –...

  • Page 59: Installing The Lower Triple Clamp (Exc Six Days Us)

    SERVICE WORK ON THE CHASSIS –  Position the brake caliper. Mount and tighten screws Guideline Screw, front brake caliper 25 Nm Loctite ® 243™ (18.4 lbf ft) – Mount cable binder. –  Position the brake line, wiring harness, and clamp. Mount and tighten screws K00088-11 Finishing work –...
  • Page 60 SERVICE WORK ON THE CHASSIS – Position the fork legs.  Bleeder screws are positioned toward the front. Info The rebound damping is located in the right fork leg REB (red adjusting screw). The compression damping is located in the left fork leg COMP (white adjusting screw).

  • Page 61: Checking The Steering Head Bearing Play

    Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam- aged over time.

  • Page 62: Adjusting The Play Of The Steering Head Bearing (Exc Six Days Us)

    SERVICE WORK ON THE CHASSIS Guideline Screw, top triple clamp 20 Nm (14.8 lbf ft) –  Tighten screw Guideline Screw, top steering stem 20 Nm (14.8 lbf ft) Finishing work – Check the steering head bearing play. ( p. 59) –...

  • Page 63: Installing The Front Fender

    SERVICE WORK ON THE CHASSIS –  Remove screws . Remove the front fender. K00073-10 12.18 Installing the front fender Main work –  Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) K00072-10 –...

  • Page 64: Removing The Seat

    SERVICE WORK ON THE CHASSIS Guideline Screw, bottom shock 80 Nm Loctite ® 2701™ absorber (59 lbf ft) Info The heim joint for the shock absorber at the swingarm is Teflon-coated. It must not be greased with grease or with other lubricants. Lubricants dis- solve the Teflon coating, thereby drastically reducing the service life.

  • Page 65: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 12.25 Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to increased wear. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 66: Sealing The Air Filter Box

    SERVICE WORK ON THE CHASSIS Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 122) Info Only press the air filter to dry it, never wring it out. –...

  • Page 67: Cleaning Spark Arrestor

    SERVICE WORK ON THE CHASSIS 12.31 Cleaning spark arrestor Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. Info Soot particles accumulate on the screen of the spark arrestor over time. This changes the performance characteristics.

  • Page 68: Changing Glass Fiber Yarn Filling In The Main Silencer

    SERVICE WORK ON THE CHASSIS 12.32 Changing glass fiber yarn filling in the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. Info Over time, the fibers of the glass fiber yarn escape and the damper "burns"...
  • Page 69 SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water.

  • Page 70: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS (EXC US) – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. K00105-10 (EXC Six Days US) – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank.

  • Page 71: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS (EXC US) –  Position the collar bushings, and mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) K00146-11 (EXC Six Days US) – Position collar bushings between the spoiler and radiator shield. –...

  • Page 72: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS Info The service life of the chain depends largely on its maintenance. Preparatory work – Raise the motorcycle with the lift stand. ( p. 51) Main work – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p.

  • Page 73: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 12.38 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear- ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases.
  • Page 74 SERVICE WORK ON THE CHASSIS –  Pull at the top part of the chain with the specified weight Guideline Weight of chain wear measurement 10… 15 kg (22… 33 lb.) –  Measure the distance of 18 chain links in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 75: Checking The Frame

    If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by KTM. 401340-01 12.41 Checking the swingarm –...

  • Page 76: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS Main work – Check throttle cable routing. Both throttle cables must be routed to the throttle valve body side by side behind the handlebars and above the fuel tank bearing. » If the throttle cable routing is not as specified: –...

  • Page 77: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS 12.46 Checking/correcting the fluid level of the hydraulic clutch Info The fluid level rises with increased wear of the clutch lining discs. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...

  • Page 78: Removing The Engine Guard (Exc Six Days Us)

    SERVICE WORK ON THE CHASSIS 12.48 Removing the engine guard (EXC Six Days US) –  Turn quick release counterclockwise until it disengages. Remove the engine guard. S00818-10 12.49 Installing the engine guard (EXC Six Days US) – Attach the engine guard on the frame at the rear and swing up at the front. –...

  • Page 79: Brake System

    Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disk ...

  • Page 80: Checking The Brake Fluid Level Of The Front Brake

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 81: Checking The Front Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
  • Page 82 BRAKE SYSTEM Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

  • Page 83: Checking The Free Travel Of Foot Brake Lever

    If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system is leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

  • Page 84: Adding Rear Brake Fluid

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.

  • Page 85: Checking The Rear Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
  • Page 86 Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
  • Page 87 BRAKE SYSTEM –  Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 121) –   Mount screw cap with membrane and O-ring. Info Clean up overflowed or spilt brake fluid immediately with water. 101380-10...

  • Page 88: Wheels, Tires

    WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 51) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

  • Page 89: Removing The Rear Wheel

    WHEELS, TIRES (EXC Six Days US) –   Align the brake disc guard so that gaps are the same size. M01022-10 –  Mount and tighten screw Guideline Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) – Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc.

  • Page 90: Installing The Rear Wheel

    Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have a significant impact on the handling characteristics of the motorcycle.

  • Page 91: Checking The Tire Air Pressure

    Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.
  • Page 92 WHEELS, TIRES – Tap each spoke with a screwdriver. Info The sound frequency depends on the length and thickness of the spoke. If there are different sound frequencies in spokes with the same length and thickness, this indicates different spoke tensions. You should hear a high note.

  • Page 93: Electrical System

    ELECTRICAL SYSTEM 15.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...

  • Page 94: Charging The Battery

    – Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 95: Changing The Main Fuse

    ELECTRICAL SYSTEM 15.4 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box cover.

  • Page 96: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM 15.5 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat.

  • Page 97: Refitting The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM –  Detach plug-in connectors and take off the headlight mask with the headlight. M00189-10 15.7 Refitting the headlight mask with the headlight Main work –  Connect plug-in connectors M00189-11 –  Position the headlight mask and fix it with rubber straps Info Ensure the holding lugs engage in the fender.

  • Page 98: Changing The Turn Signal Bulb

    ELECTRICAL SYSTEM –  Pull out headlight bulb – Insert the new headlight bulb. Headlight (HS1 / socket PX43t) ( p. 117) – Insert the protection cap with the bulb socket into the reflector and turn it clock- wise all the way. Info ...

  • Page 99: Adjusting The Headlight Range

    ELECTRICAL SYSTEM » If the light-dark border does not meet specifications: – Adjust the headlight range. ( p. 97) 15.11 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 96) Main work –  Loosen screw –...

  • Page 100: Cooling System

    COOLING SYSTEM 16.1 Cooling system  The water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve  in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 101: Checking The Coolant Level

    COOLING SYSTEM 16.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 102: Refilling Coolant

    COOLING SYSTEM 16.5 Refilling coolant Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water imme- diately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swal- lowed, contact a physician immediately.

  • Page 103: Tuning The Engine

    TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back and  forth slightly to ascertain play in the throttle cable. Play in throttle cable 3…...

  • Page 104: Adjusting The Idle Speed

    TUNING THE ENGINE –  Position activated charcoal filter –  Reconnect rubber band S00456-10 Finishing work – Install the fuel tank. p. 68) – Mount the seat. ( p. 62) – Check the play in the throttle cable. ( p.

  • Page 105: Adjusting The Basic Position Of The Shift Lever

    TUNING THE ENGINE 17.5 Adjusting the basic position of the shift lever –   Remove screw with the washers and remove the shift lever 401950-12 –  Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing.

  • Page 106: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 18.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 107: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens

    SERVICE WORK ON THE ENGINE 18.3 Changing the engine oil and oil filter, cleaning the oil screens Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 108 SERVICE WORK ON THE ENGINE –  Position oil screen with the O-rings on a pin wrench. – Position the pin wrench through the drill hole of the screw plug in the opposite sec- tion of the engine case. – Push the oil screen all the way into the engine case.

  • Page 109: Adding Engine Oil

    SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 110: Cleaning, Care

    CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts.

  • Page 111: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE 19.2 Checks and maintenance steps for winter operation Info If you use the vehicle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

  • Page 112: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 51) – Preferably cover the vehicle with a tarp or similar cover that is permeable to air.

  • Page 113: Troubleshooting

    – Check the electrical system. switch defective – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool.
  • Page 114 – Check the cabling for damage and the electri- cal plug-in connectors for corrosion and dam- age. – Read out the fault memory using the KTM diag- nostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary.

  • Page 115: Blink Code

    BLINK CODE Blink code FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Crankshaft position sensor - circuit fault Blink code FI warning lamp (MIL) 06 FI warning lamp (MIL) flashes 6x short Error level condition Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high Blink code FI warning lamp (MIL)

  • Page 116: Technical Data

    TECHNICAL DATA 23.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 510.4 cm³ (31.147 cu in) Stroke 72 mm (2.83 in) Bore 95 mm (3.74 in) Compression ratio 11,8:1 Idle speed 1,950… 2,050 rpm Control OHC, 4 valves controlled via rocker arm, drive via tooth/wheel chain Valve diameter, intake 40 mm (1.57 in)
  • Page 117 TECHNICAL DATA Loctite ® 243™ Screw plug EVAP 5 Nm (3.7 lbf ft) – Screw, alternator cover M6x25 10 Nm (7.4 lbf ft) Screw, camshaft bearing support 10 Nm (7.4 lbf ft) Loctite ® 243™ – Screw, clutch cover M6x25 10 Nm (7.4 lbf ft) –...

  • Page 118: Capacities

    TECHNICAL DATA – Nut, inner clutch hub M18x1.5 80 Nm (59 lbf ft) Nut, primary gear M20LHx1.5 100 Nm (73.8 lbf ft) Loctite ® 648™ – Screw plug, engine oil screen M20x1.5 15 Nm (11.1 lbf ft) – Screw plug, gear oil screen M20x1.5 15 Nm (11.1 lbf ft) 23.3...

  • Page 119: Electrical System

    90/90 - 21 M/C 54M M+S TT 140/80 - 18 M/C 70M M+S TT Metzeler MCE 6 Days Extreme Metzeler MCE 6 Days Extreme Additional information is available in the Service section under: http://www.ktm.com 23.7 Fork 23.7.1 EXC US Fork part number 14.18.7L.69...

  • Page 120: Exc Six Days Us

    TECHNICAL DATA Weight of rider: 85… 95 kg (187… 209 lb.) 4.8 N/mm (27.4 lb/in) Fork length 932 mm (36.69 in) Air chamber length mm (4.33 +0.39 −20 −0.79 Fork oil per fork leg 610 ml (20.62 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p.

  • Page 121: Chassis Tightening Torques

    TECHNICAL DATA Fitted length 417 mm (16.42 in) Damper oil Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 121) 23.9 Chassis tightening torques – Screw, pressure regulator EJOT PT ® K60x25‑Z 3 Nm (2.2 lbf ft) – Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft) –...
  • Page 122 TECHNICAL DATA – Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft) – Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) – Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) Screw-in nozzles, cooling system M20x1.5 12 Nm (8.9 lbf ft) Loctite ®...

  • Page 123: Substances

    SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corre- sponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®...

  • Page 124: Auxiliary Substances

    Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Grip adhesive (00062030051) Recommended supplier KTM Motorrad AG – GRIP GLUE High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier Motorex ®...
  • Page 125 AUXILIARY SUBSTANCES Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic...

  • Page 126: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation.

  • Page 127: List Of Abbreviations

    LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 128: Lisy Of Symbols

    LISY OF SYMBOLS 28.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols. EFI warning lamp (MIL) lights up/flashes orange – The OBD has detected an emission- or safety-critical fault. The low fuel warning lamp lights up orange –...

  • Page 129: Index

    INDEX fluid, changing ......75 INDEX Clutch lever ........16 Accessories .
  • Page 130 INDEX installing ....... . . 53 removing ....... . . 52 Main fuse spring preload, adjusting .
  • Page 131 INDEX Shock absorber installing ....... . . 61 View of vehicle removing .
  • Page 132 *3213339en* 3213339en 04/2015 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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