KTM 500 EXC EU 2013 Manuals

Manuals and User Guides for KTM 500 EXC EU 2013. We have 1 KTM 500 EXC EU 2013 manual available for free PDF download: Repair Manual

KTM 500 EXC EU 2013 Repair Manual

KTM 500 EXC EU 2013 Repair Manual (313 pages)

Brand: KTM | Category: Motorcycle | Size: 84.12 MB

Table of Contents

Table of Contents
2
1 Means of Representation

6
- Symbols Used
  6
- Formats Used
  6
2 SAFETY Advice

7
- Repair Manual
  7
- Degrees of Risk and Symbols
  7
- Work Rules
  7
3 Important Notes

8
4 Serial Numbers

9
- Chassis Number
  9
- Type Label
  9
- Key Number
  10
- Engine Number
  10
- Fork Part Number
  10
- Shock Absorber Part Number
  10
5 Motorcycle

12
6 Fork, Triple Clamp

15
7 Handlebar, Controls

57
8 Frame

61
- Removing the Engine Guard
  61
  - EXC Ausl
    61
- Installing the Engine Guard
  61
9 Shock Absorber, Swingarm

62
10 Exhaust

85
11 Air Filter

88
- Removing the Air Filter Box Lid
  88
- Installing the Air Filter Box Lid
  88
- Removing the Air Filter
  88
- Installing the Air Filter
  88
- Cleaning the Air Filter and Air Filter Box
  89
- Opening Filler Cap
  90
- Closing Filler Cap
  90
- Removing the Seat
  90
12 Fuel Tank, Seat, Trim

91
- Mounting the Sea
  91
- Removing the Fuel Tank
  91
- Installing the Fuel Tank
  92
- Changing the Fuel Screen
  93
- Changing the Fuel Filter
  94
- Changing the Fuel Pump
  96
- Checking the Fuel Pressure
  97
13 Mask, Fender

99
- Removing the Front Fender
  99
- Installing the Front Fender
  99
- Removing Headlight Mask with Headligh
  99
- Headlight
  99
14 Wheels

101
- Checking the Tire Air Pressure
  101
- Checking the Tire Condition
  101
- Checking the Brake Discs
  102
- Checking Spoke Tension
  102
- Front Wheel
  103
- Removing the Front Wheel
  103
- Installing the Front Wheel
  103
- Removing the Front Brake Disc
  104
- Installing the Front Brake Disc
  104
- Rear Wheel
  104
- Removing the Rear Wheel
  104
- Installing the Rear Wheel
  105
- Removing the Rear Brake Disc
  106
- Installing the Rear Brake Disc
  106
- Checking the Chain Tension
  107
- Adjusting the Chain Tension
  107
- Adjusting the Chain Guide
  108
- Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide
  108
- Checking for Chain Dirt Accumulation
  110
- 14.6.10 Cleaning the Chain
  110
15 WIRING HARNESS, Battery

112
- Changing the Main Fuse
  112
- Changing the Fuses of Individual Power Consumers
  113
- Changing the Fuse of the Radiator Fan
  113
- Removi Ng the Battery
  114
- Installing the Battery
  115
- Charging the Battery
  115
16 Brake System

117
17 Lighting System, Instruments

128
- Adjusting the Speedometer Functions
  128
- Setting Kilometers or Miles
  128
- Activating the Additional Functions
  129
- Setting the Wheel Circumference
  129
- Setting the Clock
  130
- Checking the Headlight Setting
  131
- Adjusting the Headlight Range
  131
18 Engine

132
- Removing the Engine
  132
- Installing the Engine
  136
- Engine Disassembly
  140
- Preparations
  140
- Draining the Engine Oil
  140
- Removing the Clutch Push Rod
  141
- Removing the Oil Filter
  141
- Removing the Starter Motor
  141
- Removing the Spark Plug
  141
- Removing the Valve Cover
  142
- Removing the Alternator Cover
  142
- Positioning the Engine at Ignition Top Dead Center
  142
  - Removing the Timing Chain Tensioner
    143
- Removing the Camshaft
  143
- Removing the Cylinder Head
  144
- Removing the Piston
  144
- Removing the Rotor
  144
- Removing the Timing Chain Guide Rail
  145
- Removing the Timing Chain Tensioning Rail
  145
- Removing the Timing Chain Securing Guide
  145
- Removing the Timing Chain
  145
- Removing the Ignition Pulse Generator
  145
- Removing the Suction Pump
  146
- Removing the Water Pump Cover
  146
- Removing the Clutch Cover
  146
- Removing the Clutch Discs
  147
- Removing the Primary Gear Nut
  148
- Removing the Outer Clutch Hub
  148
- Removing the Torque Limiter
  149
- Removing the Starter Idler Gear
  149
- Removing the Kickstarter Idler Gear
  149
- Removing the Shift Shaft
  149
- Removing the Shift Drum Locating Unit
  150
- Removing the Locking Lever
  150
- Removing the Oil Pump Gear Wheels
  150
- Removing the Force Pump
  151
- Removing the Primary Gear
  151
- Removing the Free Wheel Gear
  151
- Removing the Left Engine Case Section
  151
- Removing the Shift Rails
  152
- Removing the Shift Drum
  152
- Removing the Shift Lorks
  153
- Removing the Transmission Shafts
  153
- Removing the Crankshaft
  153
- Work on Individual Parts
  154
- Work on the Right Section of the Engine Case
  154
- Work on the Left Section of the Engine Case
  155
- Removing the Oil Pressure Regulator Valve
  156
- Checking Spring Length of Oil Pressure Regulator Valve
  156
  - Installing the Oil Pressure Regulator Valve
    157
  - Removing the Crankshaft Seal Ring in the Clutch Cover
    157
- Installing the Crankshaft Seal Ring in the Clutch Cover
  157
- Removing the Water Pump
  157
- Installing the Water Pump
  158
- 18.4.13 Checking Crankshaft Run-Out at Bearing Pin
  161
- Cylinder - Nikasil" Coating
  161
- Checking/Measuring the Cylinder
  161
- Checking/Measuring the Piston
  162
- Checking the Piston Ring End Gap
  162
- 18.4.18 Measuring the Piston/Cylinder Mounting Clearance
  163
- Checking the Oil Pumps
  163
- 18.4.20 Disassembling the Autodecompressor
  163
- Assembling the Autodecompressor
  164
- Checking Camshaft
  165
- Checking the Timing Assembly
  165
- Removing the Rocker Arm
  166
- Removing the Valves
  166
- Changing Camshaft Bearing
  167
- Checking the Valves
  167
- Checking Valve Springs
  168
- Checking Valve Spring Seal
  168
- Checking the Cylinder Head
  168
- Checking the Rocker Arm Shafts
  169
- Installing the Valves
  169
- Install I Ng the Rocker Arm
  170
  - Checking the Clutch
    170
  - 18.4.35 Checking the Shift Mechanism
    172
  - Preassembling the Shift Shaft
    173
  - Disassembling the Main Shaft
    173
  - Assembling the Main Shaft
    174
  - Disassembling the Countershaft
    175
  - Assembling the Countershaft
    175
  - Checking the Transmission
    176
  - Premountingthe Kickstarter Shaft
    178
  - 18.4.43 Checking the Starter Drive
    179
  - Removing the Ireewheel
    179
  - Checking the Freewheel
    180
  - Installing the Free Wheel
    180
  - Engine Assembly
    181
  - Installing the Crankshaft
    181
  - Installing the Transmission Shafts
    181
  - Installing the Shift Lorks
    181
  - Installing the Shift Drum
    182
  - Installing the Shift Rails
    182
  - Installing the Left Engine Case
    182
  - Installing the Free Wheel Gear
    183
  - Installing the Primary Gear
    183
  - Installing the Lorce Pump
    183
  - 18.5.10 Installing the Oil Pump Gear Wheels
    184
  - Installing the Locking Lever
    184
  - Installing the Shift Drum Locating Unit
    184
  - 18.5.13 Installing the Shift Shaft
    185
  - Installing the Kickstarter Idler Gear
    185
  - Installing the Kickstarter Shaft
    185
  - Installing the Starter Idler Gear
    185
  - 18.5.17 Installing the Torque Limiter
    186
  - Installing the Outer Clutch Hub
    186
  - 18.5.19 Installing the Primary Gear Nut
    187
  - Installing the Clutch Discs
    187
  - Installing the Clutch Cover
    188
  - 18.5.22 Installing the Water Pump Cover
    189
  - 18.5.23 Installing the Suction Pump
    189
  - 18.5.24 Installing the Ignition Pulse Generator
    190
  - 18.5.25 Installing the Timing Chain
    190
  - 18.5.28 Installing the Timing Chain Securing Guide
    190
  - Installing the Timing Chain Tensioning Rail
    191
  - Installing the Timing Chain Guide Rail
    191
  - 18.5.29 Installing the Rotor
    191
  - Installing the Piston
    191
  - Installing the Cylinder Head
    193
  - 18.5.32 Installing the Camshaft
    194
  - Installing the Timing Chain Tensioner
    194
  - Checking the Valve Clearance
    194
  - Adjusting the Valve Clearance
    195
  - Installing the Alternator Cover
    195
  - Installing the Valve Cover
    196
  - Installing the Spark Plug
    196
  - Installing the Starter Motor
    196
  - Installing the Oil Filter
    196
  - 18.5.41 Installing the Clutch Push Rod
    197
  - Installing the Oil Screen
    197
  - Removing the Engine Lrom the Engine Assembly Stand
    198
19 Clutch

199
- Checking/Correcting the Fluid Level of the Hydraulic Clutch
  199
- Changing the Hydraulic Clutch Fluid
  199
20 Water Pump, Cooling System

201
- Cooling System
  201
- Checking the Antifreeze and Coolant Level
  201
- Checking the Coolant Level
  202
- Draining the Coolanl
  202
- Refilling Coolant
  203
21 LUBRICATION System

204
- Oil Circui
  204
- Checking the Engine Oil Level
  204
- Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens
  204
- Adding Engine Oil
  207
- Checking the Engine Oil Pressure
  208
22 IGNITION System

209
23 Electric Starter

211
- Checking the Starter Motor
  211
24 THROTILE VALVE Body

212
25 Technical Data

214
- Engine
  214
- Engine Tolerance, Wear Limits
  214
- Engine Tightening Torques
  215
- Capacities
  217
- Engine Oil
  217
- Coolant
  217
- Fuel
  217
- Chassis
  217
- Electrical System
  218
- Tires
  218
- Fork
  219
- EXC Euiaus/Usa, XC-W
  219
- EXC SIX Days
  219
- Shock Absorber
  220
- Chassis Tightening Torques
  220
26 Cleaning, Care

222
- Cleaning the Motorcycle
  222
- Checks and Maintenance Steps for Winter Operation
  223
27 Storage

224
- Preparing for Use after Storage
  224
28 Service Schedule

225
- Service Work (as Additional Order)
  226
29 Wiring Diagram

228
- EXC EU, EXC SIX Days)
  228
- Exc Eu, Exc Six Days)
  230
- Exc Eu, Exc Six Days)
  232
- Exc Eu, Exc Six Days)
  234
- Exc Eu, Exc Six Days)
  236
- Exc Eu, Exc Six Days)
  238
- Exc Eu, Exc Six Days)
  240
  - Exc Eu, Exc Six Days)
    242
- Exc Aus)
  244
  - Exc Aus)
    246
- Exc Aus)
  248
  - Exc Aus)
    250
  - Exc Aus)
    252
- Exc Aus)
  254
  - Exc Aus)
    256
- Exc Aus)
  258
  - Exc Usa)
    260
  - Exc Usa)
    262
  - Exc Usa)
    264
  - Exc Usa)
    266
  - Exc Usa)
    268
  - Exc Usa)
    270
  - Exc Usa)
    272
  - Exc Usa)
    274
  - All XC-W Models)
    276
  - All XC-W Models)
    278
  - All XC-W Models)
    280
  - All XC-W Models)
    282
  - All XC-W Models)
    284
  - All XC-W Models)
    286
  - All XC-W Models)
    288
30 Substances

290
31 Auxiliary Substances

292
32 Special Tools

294
33 Standards

308
- Index
  309

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