Changing Glass Fiber Yarn Filling In The Main Silencer; Removing The Fuel Tank - KTM 500 EXC US Owner's Manual

12 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" out.
Not only is the noise level higher, the performance characteristic changes.
12.33

Removing the fuel tank

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.
–
The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Preparatory work
–
Remove the main silencer. (
Main work
–
Remove screws
–
Remove connecting cap
yarn filling
–
Remove screws
–
Remove screws
–
Clean the parts that need to be reinstalled and check for damage.
–
Mount the new insulating pad on the insert and fasten with adhesive tape.
–
Position the insert with the insulating pad in outer tube.
–
Mount and tighten screws
Guideline
Screws on the main silencer
–
Mount O-ring
–
Fit the new glass fiber yarn filling onto the perforated pipe.
–
Fit the connecting cap with the glass fiber yarn filling in the outer tube.
Info
101426-10
Press the glass fiber yarn filling into the outer tube using a blunt tool.
–
Mount and tighten screws
Guideline
Screws on the main silencer
–
Mount O-ring
–
Position the silencer cap with O-ring
–
Mount and tighten screws
Guideline
Screws on the main silencer
Finishing work
–
Install the main silencer. (
p. 64)

of connecting cap

with the perforated pipe, O-ring

.
 
and silencer cap
 
and insert together with insulating pad
 .

on the silencer cap.

.

on the silencer cap.


.
p. 64)

.

, and glass fiber

with O-ring .

M5 7 Nm (5.2 lbf ft)
M5 7 Nm (5.2 lbf ft)
in the outer tube.
M5 7 Nm (5.2 lbf ft)
66
.