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

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OWNER'S MANUAL
2014
500 EXC USA
Art. no. 3213041en

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Summary of Contents for KTM 500 EXC

  • Page 1 OWNER'S MANUAL 2014 500 EXC USA Art. no. 3213041en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Setting the clock..........23 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 Querying lap time..........24 Symbols used ........... 5 Display mode SPEED (speed) ......24 Formats used............ 5 Display mode SPEED/H (service hours) ..... 24 SAFETY ADVICE............6 Display mode SPEED/CLK (time) ......
  • Page 5 TABLE OF CONTENTS 13.9 Adjusting the basic position of the foot brake 11.16 Adjusting handlebar position ....... 45 lever ............71 12 SERVICE WORK ON THE CHASSIS......46 13.10 Checking the rear brake fluid level....71 12.1 Raising the motorcycle with the lift stand ..46 13.11 Adding rear brake fluid .......
  • Page 6 TABLE OF CONTENTS 23.3 Capacities ............ 105 23.3.1 Engine oil ..........105 23.3.2 Coolant ............ 105 23.3.3 Fuel ............105 23.4 Chassis ............105 23.5 Electrical system........... 106 23.6 Tires ............106 23.7 Fork............. 106 23.8 Shock absorber ..........107 23.9 Chassis tightening torques ......

  • 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 B01609-10 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 602780-01 Canada type label 602781-01 USA type label...
  • Page 10 SAFETY ADVICE Brake fluid information S00026-10 Information on chain tension 101516-01 Information on starting up 700210-01 602782-01 Information on emissions control 602783-01 Information on noise emission...

  • Page 11: Reporting Safety Defects

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

  • Page 12: Protective Clothing

    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) 602784-01 Filler cap Fork compression adjustment Shift lever ( p. 19) Engine number ( p. 14) Side stand ( p. 20)

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

    VIEW OF VEHICLE View of vehicle, rear right (example) 602785-10 Fork rebound adjustment and spring preload adjustment Clutch lever ( p. 16) Light switch ( p. 16) Turn signal switch ( p. 17) Horn button ( p. 16) Emergency OFF switch ( p.

  • Page 16: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. B01612-10 Type label The type label USA is fixed to the front of the steering head. B01612-11 The type label Canada is fixed to the front of the front pipe. B01613-10 Key number Key number...

  • Page 17: Fork Part Number

    SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub. B01494-10 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. B01495-10...

  • 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. B01614-10 Hand brake lever Hand brake lever is located on the right side of the handlebar. The hand brake lever is used to activate the front brake. B01497-10 Throttle grip The throttle grip...

  • 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 Filler Cap

    CONTROLS 6.11 Opening 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 The idle speed adjusting screw is located on the throttle valve body at the top left. 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 Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. L00708-10 6.17 Side stand The side stand is on the left side of the vehicle. L00706-10 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. – Insert the key in the steering lock, turn it to the left, press it in and turn it to the right. Remove the key. Steering is no longer possible.

  • Page 24: Speedometer

    SPEEDOMETER Speedometer overview – Press the button to change the display mode or change to one of the Setup menus. – 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.

  • Page 25: Adjusting The Speedometer Functions

    SPEEDOMETER Adjusting 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. – Press the button briefly and repeatedly until H appears at the bottom right of the display.

  • Page 26: Querying Lap Time

    SPEEDOMETER Querying lap time Info This function can be called up only if lap times are measured. Condition The motorcycle is stationary. – Press the button briefly and repeatedly until LAP appears at the bottom right of the display. – Press the button briefly.

  • Page 27: Display Mode Speed/Clk (Time)

    SPEEDOMETER Display mode SPEED/CLK (time) – Press the button briefly and repeatedly until CLK appears at the bottom right of the display. The time is shown in display mode CLK. Press the button . No function Press the button . No function Press the button The display changes to the Setup menu of the clock.

  • Page 28: Display Mode Speed/Tr2 (Trip Master 2)

    SPEEDOMETER 7.13 Display mode SPEED/TR2 (trip master 2) – Press the button briefly and repeatedly until TR2 appears at the top right of the display. TR2 (trip master 2) runs constantly and counts up to 999.9. The displayed value can be set manually with the button and the button .

  • Page 29: Display Mode Speed/S1 (Stop Watch 1)

    SPEEDOMETER 7.16 Display mode SPEED/S1 (stop watch 1) – Press the button briefly and repeatedly until S1 appears at the top right of the display. S1 (stop watch 1) displays the journey time on the basis of TR1 and continues when an impulse is received from the wheel speed sensor.

  • Page 30: Table Of Conditions And Menu Activation

    SPEEDOMETER 7.19 Table of conditions and menu activation Display The motorcycle is Menu can be acti- stationary. vated Display mode SPEED/H (service hours) • Display mode SPEED/LAP (lap time) • Display mode SPEED/TR1 (trip master 1) • Display mode SPEED/TR2 (trip master 2) •...

  • Page 31: 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 record at vehicle handover.

  • Page 32: Running-In The Engine

    For this reason, it may be neces- sary to inspect or replace parts before the next scheduled service. – KTM recommends that you use the specified engine oil for difficult riding conditions and to increase performance. Engine oil (SAE 10W/60) (00062010035) ( p. 109) –...

  • Page 33: Preparing For Rides On Wet Sand

    PREPARING FOR USE – Fit a sand cover on the air filter. Sand protection device for air filter (59006022000) Info See the KTM PowerParts fitting instructions. 600871-01 – Clean the chain. Chain cleaner ( p. 111) – Fit the steel sprocket.

  • Page 34: Preparing For Rides At High Temperature And Slow Speed

    – Check the coolant level. ( p. 88) Preparing for rides at low temperature or in snow – Fit a waterproofing device on the air filter. Waterproofing device for air filter (77206921000) Info See the KTM PowerParts fitting instructions. 600870-01...

  • Page 35: 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. 93) –...

  • Page 36: 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 you hear unusual noises 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 37: 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 38: 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 39: Service Schedule

    Final check: Check the vehicle for roadworthiness and take a test ride. ○ ● ● Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● ● Make the service entry in KTM DEALER.NET and in the service record.

  • Page 40: Service Work (As Additional Order)

    SERVICE SCHEDULE ● Periodic interval 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 41: 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 42: 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 43: 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. 46) 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 44: 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 45: 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. 54) – Remove the motorcycle from the lift stand. ( p.

  • Page 46: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS 11.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. – Turn adjusting screws clockwise all the way. Info Adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs.

  • Page 47: Adjusting Handlebar Position

    TUNING THE CHASSIS 11.16 Adjusting handlebar position Warning Danger of accidents Handlebar breakage. – If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle- bar. – Remove the four screws . Remove the handlebar clamps. Remove the handlebar and lay it to one side.

  • Page 48: 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 (54829055000) The wheels should no longer touch the ground.

  • Page 49: Loosening The Fork Protector

    SERVICE WORK ON THE CHASSIS Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. – Clean and lubricate the dust boot and inside fork tube on both fork legs.

  • Page 50: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS – Release screws . Take out the left fork leg. – Release screws . Take out the right fork leg. B01516-10 12.8 Installing the fork legs Main work – Position the fork legs. Position bleeder screws toward the front.

  • Page 51: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS Main work – Remove screws on the left fork leg. Remove the fork protector upwards. – Remove the screws on the right fork leg. Remove the fork protector upwards. 101327-10 12.10 Installing the fork protector Main work –...

  • Page 52: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 12.12 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 111) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

  • Page 53: 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 54: Adjusting The Play Of The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: –...

  • Page 55: Removing The Front Fender

    SERVICE WORK ON THE CHASSIS 12.16 Removing the front fender Preparatory work – Remove the headlight mask with the headlight. Main work – Remove screws B01602-10 – Remove screws . Remove the front fender. B01603-11 12.17 Installing the front fender Main work –...

  • Page 56: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS Main work – Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel. Fix the rear wheel in this position. – Remove screw , push splash protector to the side, and remove the shock absorber.

  • Page 57: Removing The Air Filter Box Lid

    SERVICE WORK ON THE CHASSIS 12.22 Removing the air filter box lid – Pull off the air filter box lid in area to the side and remove to the front. L00713-11 12.23 Installing the air filter box lid – Insert the air filter box lid into the rear area and clip it into the front area L00713-10 12.24...

  • Page 58: Cleaning The Air Filter And Air Filter Box

    SERVICE WORK ON THE CHASSIS – Insert both parts together, position them and fasten them using air filter holder The arrow of marking UP faces up. Info If the air filter is not correctly mounted, dust and dirt can enter the engine and cause damage.

  • Page 59: Removing Main Silencer

    SERVICE WORK ON THE CHASSIS 12.28 Removing 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. – Disconnect spring – Remove screws and take off main silencer.

  • Page 60: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS Main work – Remove screws of connecting cap – Take off the connecting cap with the perforated pipe, O-ring , and glass fiber yarn filling – Remove screw and take off silencer cap with O-ring –...

  • Page 61: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS – Remove screws with the collar bushings and horn. B01530-10 – Remove screw with the rubber bushing. B01531-10 – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. B01532-01 12.32 Installing the fuel tank...

  • Page 62: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS – Position the horn, and fit and tighten screws with collar bushings. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) B01530-11 – Connect the electrical plug-in connection – Remove the wash cap set. – Thoroughly clean the plug-in connection of the fuel line using compressed air.

  • Page 63: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 111) Off-road chain spray ( p. 111) 400725-01 12.35 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. –...

  • Page 64: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

    SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55… 58 mm (2.17… 2.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks .
  • Page 65 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the bottom edge of the chain bolt is in line with or below the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated. »...

  • Page 66: Checking The Frame

    If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by KTM. 401340-01 12.39 Checking the swingarm –...

  • Page 67: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS 12.41 Checking the rubber grip – Check the rubber grips on the handlebar for damage and wear and to ensure they are firmly seated. » If a rubber grip is damaged, worn or loose: – Change and secure the rubber grip.

  • Page 68: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 12.45 Changing the hydraulic clutch fluid 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. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...

  • Page 69: 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 70: 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 71: 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 72 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! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid.

  • Page 73: Checking The Free Travel Of Foot Brake Lever

    KTM workshop will be glad to help.) 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.)

  • Page 74: 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.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 75: 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 76 BRAKE SYSTEM – Stand the vehicle upright. – Remove screw cap with membrane and the O-ring. – Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.

  • Page 77: Wheels, Tires

    WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 46) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

  • Page 78: Removing The Rear Wheel

    WHEELS, TIRES – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc.

  • Page 79: 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 80: 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 81 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 82: 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 83: Charging The Battery

    – Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible 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 84: 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 by-pass 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 85: 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 86: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM Main work – Remove protection. Info The radiator fan fuse is in the area of the right-hand radiator. – Remove the defective fuse. – Insert a new fuse. Fuse (58011109105) ( p. 106) 101400-10 Info Replace a faulty fuse by an equivalent fuse only. –...

  • Page 87: Changing The Headlight Bulb

    ELECTRICAL SYSTEM Finishing work – Check the headlight setting. ( p. 85) 15.9 Changing the headlight bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.

  • Page 88: Adjusting The Headlight Range

    ELECTRICAL SYSTEM 15.11 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 85) Main work – Loosen screw – Adjust the headlight range of the headlight by moving it up or down. Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with driver (instructions on how to apply the mark: Checking the headlight setting).
  • Page 89 ELECTRICAL SYSTEM – Using a coin, turn protection cap all the way counterclockwise and remove it. – Remove speedometer battery – Insert the new battery with the label facing upward. Speedometer battery (CR 2430) ( p. 106) – Check the O-ring of the protection cap for correct seating. 101406-10 –...

  • Page 90: Cooling System

    COOLING SYSTEM 16.1 Cooling system 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 tem- perature will not result in a risk of malfunctions.

  • Page 91: Draining The Coolant

    COOLING SYSTEM Condition The engine is cold. – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the coolant level in the radiator. Coolant level above radiator fins. 10 mm (0.39 in) » If the coolant level does not meet specifications: –...
  • Page 92 COOLING SYSTEM Coolant 1.2 l (1.3 qt.) Coolant (mixed ready to use) p. 109) – Refit the radiator cap. Finishing work – Take a short test ride. – Check the coolant level. ( p. 88)

  • Page 93: 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- wards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3…...

  • Page 94: Adjusting The Idle Speed

    TUNING THE ENGINE 17.3 Adjusting the idle speed – Run the engine warm and push the idle speed adjusting screw all the way in. – Set the desired idle speed by turning the idle speed adjusting screw. Guideline Idle speed 1,950…...

  • Page 95: 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 96: 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 97 SERVICE WORK ON THE ENGINE – Push the engine oil screen with the O-rings onto a pin wrench. – Push the pin wrench through the opening into the drill hole of the opposite engine case wall and push the oil screen as far as possible into the engine case. L00735-10 –...

  • Page 98: Adding Engine Oil

    SERVICE WORK ON THE ENGINE – Install and tighten the oil filler plug with O-ring. 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 99: 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 100: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE 19.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. 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 101: 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. 46) – Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materi- als since they prevent humidity from escaping, thus causing corrosion.

  • Page 102: 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 103 – Check the cabling for damage and the electri- cal plug-in connections 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 104: 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 105: 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 106 TECHNICAL DATA ® Screw plug EVAP 5 Nm (3.7 lbf ft) Loctite 243™ – 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 107: Capacities

    TECHNICAL DATA ® 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 Capacities 23.3.1 Engine oil Engine oil...

  • Page 108: Electrical System

    Rear tires 80/100 - 21 M/C 51M TT 140/80 - 18 M/C 70R TT MAXXIS MAXX CROSS SI MAXXIS MAXX ENDURO Additional information is available in the Service section under: http://www.ktm.com 23.7 Fork Fork part number 14.18.7L.69 Fork WP Suspension Up Side Down 4860 MXMA PA...

  • Page 109: Shock Absorber

    TECHNICAL DATA Fork length 940 mm (37.01 in) Air chamber length mm (4.33 +0.39 −20 −0.79 Fork oil per fork leg 618 ml (20.89 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 110) 23.8 Shock absorber Shock absorber part number 12.18.7L.69 WP Suspension PDS 5018 DCC Shock absorber...
  • Page 110 TECHNICAL DATA – Fuel connection on fuel pump 10 Nm (7.4 lbf ft) – Nut, foot brake lever stop 20 Nm (14.8 lbf ft) Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite ® 2701™ – Nut, rim lock 12 Nm (8.9 lbf ft) –...

  • Page 111: Substances

    Brake fluid DOT 4 / DOT 5.1 According to – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Castrol and Motorex ® products. Supplier Castrol –...
  • Page 112 SUBSTANCES Fork oil (SAE 4) (48601166S1) According to – SAE ( p. 113) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Shock absorber oil (SAE 2.5) (50180342S1) According to –...

  • Page 113: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Dirt Bio Remover Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline –...
  • Page 114 AUXILIARY SUBSTANCES Oil for foam air filter Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Liquid Bio Power Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline – KTM recommends Motorex ®...

  • Page 115: 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 116: Index

    INDEX Clutch lever ........16 INDEX basic position, adjusting ..... . 65 Accessories .
  • Page 117 INDEX spring preload, adjusting ..... . 44 Main silencer glass fiber yarn filling, changing ....57 Fork protector installing .
  • Page 118 INDEX Spare parts ........11 Winter operation checks and maintenance steps .
  • Page 119 *3213041en* 3213041en 06/2013 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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