KTM 500 EXC Owner's Manual page 5

TABLE OF CONTENTS
10.15 Handlebar position.......................................... 43
10.16 Adjusting handlebar position
11 SERVICE WORK ON THE CHASSIS.............................. 45
11.1 Raising the motorcycle with the lift stand .......... 45
11.2 Removing the motorcycle from the lift stand...... 45
11.3 Bleeding fork legs ........................................... 45
11.4 Cleaning the dust boots of the fork legs............. 45
11.5 Loosening the fork protector............................. 46
11.6 Positioning the fork protection.......................... 46
11.7 Removing the fork legs .................................... 46
11.8 Installing the fork legs
11.9 Removing the fork protector
11.10 Installing the fork protector
11.11 Removing the lower triple clamp
11.12 Installing the lower triple clamp
11.13 Checking the steering head bearing play............ 50
11.14 Adjusting the play of the steering head
bearing ..................................................... 51
x
11.15 Greasing the steering head bearing
11.16 Removing the front fender ............................... 52
11.17 Installing the front fender ................................ 52
11.18 Removing the shock absorber
11.19 Installing the shock absorber
11.20 Removing the seat .......................................... 53
11.21 Mounting the seat ........................................... 53
11.22 Removing the air filter box lid .......................... 53
11.23 Installing the air filter box lid ........................... 53
11.24 Removing the air filter
11.25 Installing the air filter
11.26 Cleaning the air filter and air filter box
11.27 Sealing the air filter box
11.28 Removing main silencer................................... 55
11.29 Installing the main silencer.............................. 55
11.30 Changing the glass fiber yarn filling of the
main silencer
11.31 Removing the fuel tank
11.32 Installing the fuel tank
11.33 Checking for chain dirt accumulation ................ 58
11.34 Cleaning the chain .......................................... 58
11.35 Checking the chain tension .............................. 59
11.36 Adjusting the chain tension.............................. 59
11.37 Checking the chain, rear sprocket, engine
sprocket and chain guide ................................. 60
11.38 Adjusting the chain guide
11.39 Checking the frame
11.40 Checking the swingarm
11.41 Checking the throttle cable routing ................... 63
11.42 Checking the rubber grip ................................. 63
11.43 Additionally securing the rubber grip................. 63
11.44 Adjusting the basic position of the clutch
lever .............................................................. 64
11.45 Checking/correcting the fluid level of the
hydraulic clutch.............................................. 64
11.46 Changing the hydraulic clutch fluid
12 BRAKE SYSTEM ........................................................ 66
12.1 Checking free travel of hand brake lever ............ 66
12.2 Adjusting free travel of hand brake lever............ 66
12.3 Checking the brake discs ................................. 66
12.4 Checking the front brake fluid level .................. 67
12.5 Adding front brake fluid
12.6 Checking the front brake linings ....................... 68
x ....................... 44
................................ 47
x
........................ 47
x
......................... 48
x
.................. 48
x
.................. 49
x
.............. 51
x
...................... 52
x
x ....................... 52
................................ 53
x
................................. 54
x
x
.............................. 55
x
............................................. 55
x
............................... 56
x
................................ 57
x
........................... 62
x
.................................... 62
x
............................... 62
x
.............. 64
x
.............................. 67
x
12.7
12.8
12.9
12.10 Checking the rear brake fluid level.................... 70
12.11 Adding brake fluid to the rear brake
12.12 Checking the rear brake linings ........................ 72
12.13 Changing the rear brake linings
13 WHEELS, TIRES ........................................................ 74
13.1
13.2
13.3
13.4
13.5
13.6
13.7
14 ELECTRICAL SYSTEM ................................................ 79
14.1
14.2
14.3
14.4
14.5
14.6
14.7
14.8
14.9
14.10 Changing the turn signal bulb .......................... 84
......... 54
14.11 Checking the headlight setting ......................... 85
14.12 Adjusting the headlight range........................... 85
14.13 Changing the speedometer battery .................... 86
15 COOLING SYSTEM ..................................................... 87
15.1
15.2
15.3
15.4
15.5
16 TUNING THE ENGINE................................................ 90
16.1
16.2
16.3
16.4
16.5
17 SERVICE WORK ON THE ENGINE ............................... 93
17.1
17.2
17.3
17.4
18 CLEANING, CARE ...................................................... 97
18.1
18.2
19 STORAGE .................................................................. 99
19.1
19.2
20 TROUBLESHOOTING ............................................... 100
21 BLINK CODE ........................................................... 102
Changing the front brake linings
Checking the free travel of foot brake lever ........ 70
Adjusting the basic position of the foot brake
lever ......................................................... 70
x
circuit ....................................................... 71
x
Removing the front wheel x
Installing the front wheel
x
Removing the rear wheel x
Installing the rear wheel
x
Checking the tire condition .............................. 76
Checking tire air pressure ................................ 77
Checking spoke tension ................................... 77
Removing the battery .................................. 79
x
Installing the battery .................................. 79
x
Charging the battery ................................... 80
x
Changing the main fuse ................................... 81
Changing the fuses of individual power
consumers...................................................... 82
Changing the fuse of the radiator fan ................ 82
Removing headlight mask with headlight........... 83
Refitting the headlight mask with the
headlight........................................................ 83
Changing the headlight bulb ............................ 84
Cooling system ............................................... 87
Checking the antifreeze and coolant level .......... 87
Checking the coolant level ............................... 88
Draining the coolant ................................... 88
x
Refilling coolant ......................................... 89
x
Checking the play in the throttle cable .............. 90
Adjusting the play in the throttle cable
Adjusting the idle speed
x
Checking the basic position of the shift lever ..... 91
Adjusting the basic position of the shift
lever ......................................................... 91
x
Changing the fuel screen
x
Checking the engine oil level............................ 93
Changing the engine oil and oil filter, cleaning
the oil screens x ........................................... 94
Adding engine oil ............................................ 96
Cleaning the motorcycle .................................. 97
Checks and maintenance steps for winter
operation........................................................ 98
Storage .......................................................... 99
Preparing for use after storage.......................... 99
3
.................. 68
x
................... 72
x
........................... 74
............................ 74
............................. 75
.............................. 75
x ......... 90
............................. 91
............................ 93