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

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OWNER'S MANUAL
2012
500 EXC USA
Art. no. 3211724en

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Summary of Contents for KTM 500 EXC

  • Page 1 OWNER'S MANUAL 2012 500 EXC USA Art. no. 3211724en...
  • 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 RIDING INSTRUCTIONS ............ 30 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........4 Checks and maintenance work when preparing for use ..30 IMPORTANT INFORMATION ..........5 Starting ................ 30 Overview of labels............6 Starting off ..............31 VIEW OF VEHICLE.............
  • Page 5 TABLE OF CONTENTS Changing the glass fiber yarn filling of the main TUNING THE ENGINE ............85 silencer ..............52 Checking the play in the throttle cable......85 Removing the fuel tank ..........53 Adjusting the play in the throttle cable .......

  • Page 6: 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 in an authorized KTM workshop. There, your motorcycle will be ser- viced optimally by specially trained experts using the specialist tools required.

  • Page 7: Important Information

    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 record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claim can be honored for damage resulting from manipulation and/or other changes to the vehicle.

  • Page 8: Overview Of Labels

    IMPORTANT INFORMATION – Use straps or other suitable devices to secure the motorcycle against accidents or falling over. Environment Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the environment and can lead to conflicts with other persons.
  • Page 9 IMPORTANT INFORMATION 101518-01 USA type label 101519-01 Information on the evaporate emission control system Information on chain tension 101516-01 Information on starting up 700210-01 101520-01 Information on emissions control...
  • Page 10 If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc. If NHTSA receives similar complaints, it may open an investigation. If it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
  • Page 11 IMPORTANT INFORMATION 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: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) 101475-10 Filler cap Fork compression adjustment Shift lever ( p. 23) Engine number ( p. 12) Side stand ( p. 24)

  • Page 13: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) 101476-10 Fork rebound adjustment and spring preload adjustment Clutch lever ( p. 14) Light switch ( p. 14) Turn signal switch ( p. 14) Horn button ( p. 15) Emergency OFF switch ( p.

  • Page 14: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. C00125-10 Type label The type label USA is fixed to the front of the steering head. 101477-10 The type label Canada is fixed to the front of the front pipe. 101478-10 Key number Key number...

  • Page 15: Fork Part Number

    SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub. B00265-01 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. 601613-10...

  • Page 16: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. C00119-10 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. C00120-10 Throttle grip The throttle grip...

  • Page 17: Horn Button

    CONTROLS Horn button The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position Horn button pressed – The horn is operated in this position. • 101483-12 Emergency OFF switch The emergency OFF switch is fitted on the right side of the handlebar.

  • Page 18: Speedometer

    CONTROLS Speedometer 5.11 – 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 19: Setting The Clock

    CONTROLS – Press the button for 3 - 5 seconds. The settings are stored and the Setup menu is closed. Info If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu is closed.

  • Page 20: Querying Lap Time

    CONTROLS Info If no button is pressed for 20 seconds, or if a pulse arrives from the wheel speed sensor, the settings are stored automatically and the Setup menu is closed. Querying lap time 5.17 Info This function can be called up only if lap times are measured. Condition The motorcycle is stationary.

  • Page 21: Display Mode Speed/Clk (Clock)

    CONTROLS Display mode SPEED/CLK (clock) 5.20 – Press the button briefly and repeatedly until CLK appears at the bottom right of the display. The time is displayed in CLK display mode. Press the button . No function Press the button .

  • Page 22: Display Mode Speed/Tr2 (Trip Master 2)

    CONTROLS Display mode SPEED/TR2 (trip master 2) 5.24 – 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 23: Display Mode Speed/S1 (Stop Watch 1)

    CONTROLS Display mode SPEED/S1 (stop watch 1) 5.27 – 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 24: Opening Filler Cap

    CONTROLS Table of conditions and menu activation Display The motorcycle is Menu can be acti- stationary. vated Display mode SPEED/LAP (lap time) • Display mode SPEED/TR1 (trip master 1) • Display mode SPEED/TR2 (trip master 2) • Display mode SPEED/A1 (average speed 1) •...

  • Page 25: Idle Speed Adjusting Screw

    CONTROLS Idle speed adjusting screw 5.31 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 26: Side Stand

    CONTROLS Side stand 5.35 The side stand is on the left side of the vehicle. C00077-01 The side stand is used to park the motorcycle. Info When you are riding, the side stand must be folded up and secured with the rubber band C00078-01 Steering lock...

  • Page 27: Unlocking The Steering

    CONTROLS Unlocking the steering 5.38 – Insert the key in the steering lock, turn it to the left, pull it out and turn it to the right. Remove the key. You can now steer the bike again. Info Never leave the key in the steering lock. 400731-01...

  • Page 28: 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 29: Running-In The Engine

    – KTM recommends that you use the specified engine oil for difficult riding condi- tions and to increase performance.

  • Page 30: 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. 107) – Fit the steel sprocket.

  • Page 31: Preparing For Rides At High Temperature And Slow Speed

    – Check the coolant level. ( p. 83) Preparing for rides at low temperatures 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 32: 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. 87) –...

  • Page 33: 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 34: Stopping, Parking

    – 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 35 RIDING INSTRUCTIONS – Fill the fuel tank with fuel up to measurement Guideline Measurement of 35 mm (1.38 in) Total fuel tank 8.5 l Super unleaded (ROZ 95/RON 95/PON capacity, approx. (2.25 US gal) 91) ( p. 106) – Close the filler cap. ( p.

  • Page 36: Service Schedule

    • • • • • 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. • • • S1N: Once after 1 operating hour...

  • Page 37: Service Work (As Additional Order)

    SERVICE SCHEDULE Service work (as additional order) S15N S45A S105A • Change the front brake fluid. Change the rear brake fluid. • Change the foot brake cylinder seals. • Change the hydraulic clutch fluid. p. 61) • Grease the steering head bearing. p.

  • Page 38: 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 39: 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 40: Measuring Rear Wheel Sag Unloaded

    TUNING THE CHASSIS Measuring rear wheel sag unloaded – Raise the motorcycle with the lift stand. ( p. 43) – Measure the distance – as vertically as possible – between the rear axle and a fixed point, such as a mark on the side cover. –...

  • Page 41: 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 42: Checking Basic Setting Of Fork

    TUNING THE CHASSIS Checking basic setting of fork 9.11 Info For various reasons, no exact riding sag can be determined for the forks. – As with the shock absorber, smaller differences in the rider's weight can be com- pensated by the spring preload. –...

  • Page 43: Adjusting The Spring Preload Of The Fork

    TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. Adjusting the spring preload of the fork 9.14 – Turn the adjusting screws counterclockwise all the way. Info Make the same adjustment on both fork legs. –...
  • Page 44 TUNING THE CHASSIS Info Position the left and right handlebar supports evenly. – Position the handlebar. Info Make sure cables and wiring are positioned correctly. – Position the handlebar clamps. Fit and evenly tighten the four screws Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) Info...

  • Page 45: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS Raising the motorcycle with the lift stand 10.1 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 46: Loosening The Fork Protector

    SERVICE WORK ON THE CHASSIS – Press the dust boots back into their normal position. – Remove excess oil. – Position the fork protection. ( p. 44) – Remove the motorcycle from the lift stand. ( p. 43) Loosening the fork protector 10.5 –...

  • Page 47: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS Installing the fork legs 10.8 – Position the fork legs. Info The topmost milled groove in the fork leg must be flush with the top edge of the upper triple clamp. Position bleeder screws toward the front. 101325-10 –...

  • Page 48: Removing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS Removing the lower triple clamp 10.11 – Remove the fork legs. ( p. 44) – Remove the front fender. ( p. 49) – Remove the handlebar cushion. – Open the cable holder in front of the right radiator and detach the wiring harness. –...
  • Page 49 SERVICE WORK ON THE CHASSIS – Position the fork legs. Info The topmost milled groove in the fork leg must be flush with the top edge of the upper triple clamp. Position bleeder screws toward the front. 101332-10 – Tighten screw Guideline Screw, bottom triple clamp 15 Nm...

  • Page 50: 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 51: Greasing The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS Greasing the steering head bearing 10.15 – Remove the lower triple clamp. p. 46) – Install the lower triple clamp. p. 46) 800010-10 Removing the shock absorber 10.16 – Raise the motorcycle with the lift stand. ( p.

  • Page 52: Installing The Front Fender

    SERVICE WORK ON THE CHASSIS Installing the front fender 10.19 – Ensure that the spacers are mounted in the fender. – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) Info Make sure the holding lugs engage in the start number plate or headlight mask.

  • Page 53: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS Removing the air filter 10.24 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 54: Removing Main Silencer

    SERVICE WORK ON THE CHASSIS – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 107) Info Only press the air filter to dry it, never wring it out. –...

  • Page 55: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS – Remove screws of connecting cap 0 0 6 – Take off the connecting cap with the perforated pipe, O-ring and glass fiber yarn filling 0 0 9 – Remove screws and silencer cap with O-ring –...

  • Page 56: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS – Remove screws with the collar bushings and horn. 101356-10 – Remove screw with the rubber bushing. 101357-10 – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. 101358-01 Installing the fuel tank 10.31...

  • Page 57: 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) 101356-11 – Connect the electrical plug-in connection – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Never let dirt enter the fuel line.

  • Page 58: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 107) Off-road chain spray ( p. 107) 400725-01 Checking the chain tension 10.34 Warning Danger of accidents Danger caused by incorrect chain tension. –...

  • Page 59: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

    SERVICE WORK ON THE CHASSIS – 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 60 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 61: Adjusting The Chain Guide

    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 Checking the swingarm 10.39 –...

  • Page 62: Checking The Throttle Cable Routing

    SERVICE WORK ON THE CHASSIS Checking the throttle cable routing 10.40 – Remove the fuel tank. p. 53) – Check the throttle cable routing. Both throttle cables must be routed to the throttle valve body side by side behind the handlebars and above the tank bearing. »...

  • Page 63: Checking The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS Checking the fluid level of the hydraulic clutch 10.44 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 64: Brakes

    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 65: Checking The Front Brake Fluid Level

    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 66: 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 67 BRAKES – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

  • Page 68: Checking The Free Travel Of Foot Brake Lever

    Check the brake system and do not continue riding. (Your authorized 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 69: Adding Brake Fluid To The Rear Brake Circuit

    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 70: 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 71 BRAKES – 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 72: Wheels, Tires

    WHEELS, TIRES Removing the front wheel 12.1 – Raise the motorcycle with the lift stand. ( p. 43) – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.

  • Page 73: Removing The Rear Wheel

    WHEELS, TIRES – Lift the front wheel into the fork, position it, and insert the wheel spindle. – 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 74: Checking The Tire Condition

    12.5 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 75: Checking 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 76 WHEELS, TIRES Torque wrench with various accessories in set (58429094000)

  • Page 77: Electrical System

    ELECTRICAL SYSTEM Removing the battery 13.1 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 78: Changing The Main Fuse

    – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 79: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM – Remove screw 101395-10 – Lift rear fairing slightly and pull starter relay out of the bracket. 101396-10 – Remove protection caps – Remove the faulty main fuse Info A defective fuse can be identified by the burned-out fuse wire A reserve fuse is located in the starter relay.

  • Page 80: Changing The Fuse Of The Radiator Fan

    ELECTRICAL SYSTEM – Remove the defective fuse. Guideline Fuse 1 - 10 A - EFI control unit Fuse 2 - 10 A - fuel pump Fuse 3 - 10 A - high beam, low beam, parking light, tail light, license plate lamp Fuse 4 - 10 A - horn, brake light, turn signal, radiator fan (optional) Fuse 5 - 10 A - ignition Fuses res - 10 A - spare fuses...

  • Page 81: Removing Headlight Mask With Headlight

    ELECTRICAL SYSTEM Removing headlight mask with headlight 13.7 – Switch off all electrical equipment. – Remove screw and take off clamp. – Loosen the rubber band . Push up the headlight mask and swing it forwards. 101401-10 – Pull out the electric plug connector and remove the headlight mask with the headlight.

  • Page 82: Checking The Headlight Setting

    ELECTRICAL SYSTEM – Press headlight bulb into the lamp socket lightly, turn it counterclockwise all the way and pull it out. – Insert a new headlight bulb. Headlight (S2 / socket BA20d) ( p. 100) – Insert the rubber cap together with the lamp socket into the reflector and turn it clockwise all the way.
  • Page 83 ELECTRICAL SYSTEM – Using a coin, turn locking cap counterclockwise all the way and remove it. – Remove speedometer battery – Insert the new battery with the label facing upward. Speedometer battery (CR 2430) ( p. 100) – Check that the O-ring of the locking cap is seated properly. 101406-10 –...

  • Page 84: Cooling System

    COOLING SYSTEM Cooling system 14.1 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 85: Checking The Coolant Level

    COOLING SYSTEM Checking the coolant level 14.3 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 86: Refilling Coolant

    COOLING SYSTEM Refilling coolant 14.5 Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con- tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi- ately.

  • Page 87: Tuning The Engine

    TUNING THE ENGINE Checking the play in the throttle cable 15.1 – 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 88: Adjusting The Idle Speed

    TUNING THE ENGINE Adjusting the idle speed 15.3 – 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 1,800…...

  • Page 89: Service Work On The Engine

    SERVICE WORK ON THE ENGINE Changing the fuel screen 16.1 – Remove the fuel tank. p. 53) – Thoroughly clean the vehicle in the vicinity of the throttle valve body. – Release screw clamp and pull off the fuel hose. –...
  • Page 90 SERVICE WORK ON THE ENGINE – Place a suitable container under the engine. – Remove oil drain plug with the magnet and seal ring. C00065-10 – Remove screw plug with the gear oil screen and the O-rings. Info Do not remove screw C00067-10 –...
  • Page 91 SERVICE WORK ON THE ENGINE – Remove screws . Remove the oil filter cover with the O-ring. C00070-10 – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) – Completely drain the engine oil. – Thoroughly clean the parts and sealing area. C00071-10 –...

  • Page 92: Adding Engine Oil

    SERVICE WORK ON THE ENGINE Adding engine oil 16.4 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – Remove the oil filler plug with the O-ring from the clutch cover. – Add the same engine oil that was used when the motor was changed. Engine oil (SAE 10W/50) ( p.

  • Page 93: Cleaning, Care

    CLEANING, CARE Cleaning the motorcycle 17.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 94: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE Checks and maintenance steps for winter operation 17.2 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 95: 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. 43) – 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 96: Troubleshooting

    – 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 97 – 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 98: 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 99: Technical Data - Engine

    TECHNICAL DATA - 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 1,800… 1,900 rpm Control OHC, 4 valves controlled via rocker arm, drive via tooth/wheel chain Valve diameter, intake 40 mm (1.57 in)

  • Page 100: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Oil jet, piston cooling 2 Nm (1.5 lbf ft) Loctite 243™ ® Screw, cable holder in alternator cover 4 Nm (3 lbf ft) Loctite 243™ ® Oil jet, piston cooling 2 Nm (1.5 lbf ft) Loctite 243™...
  • Page 101 TECHNICAL DATA - ENGINE TIGHTENING TORQUES Screw, cylinder head M10x1.25 Tightening sequence: Lubricated with engine oil Tighten diagonally, begin- ning with the rear screw on the chain shaft. Step 1 10 Nm (7.4 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 50 Nm (36.9 lbf ft) –...

  • Page 102: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Suspension Up Side Down 4860 MXMA PA Suspension travel Front 300 mm (11.81 in) Rear 335 mm (13.19 in) Fork offset 20 mm (0.79 in) Shock absorber WP Suspension PDS 5018 DCC Brake system...

  • Page 103: Tires

    140/80 - 18 M/C 70M M+S TT Metzeler MEC 6 DAYS EXTREME Metzeler MEC 6 DAYS EXTREME Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 23.3 Total fuel tank capacity, 8.5 l (2.25 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p.

  • Page 104: Technical Data - Fork

    TECHNICAL DATA - FORK Fork part number 14.18.7L.69 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 24 clicks Standard 22 clicks Sport 20 clicks Rebound damping Comfort 22 clicks Standard 20 clicks Sport 18 clicks Spring preload - Preload Adjuster Comfort 1 turn Standard...

  • Page 105: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 12.18.7L.69 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1.25 turns Rebound damping Comfort 28 clicks...

  • Page 106: Technical Data - Tightening Torques For Chassis

    TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS – Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Screw, battery terminal 2.5 Nm (1.84 lbf ft) – Screw, intake air temperature sensor 2 Nm (1.5 lbf ft) –...

  • Page 107: Substances

    – 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 – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 108 SAE ( p. 109) (SAE 5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding ® properties. KTM recommends Motorex products. Supplier ® Motorex – Racing Fork Oil Shock absorber oil (SAE 2.5) (50180342S1)

  • Page 109: 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 110 AUXILIARY SUBSTANCES Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Clean & Polish Rubber grip adhesive (00062030051) Supplier KTM-Sportmotorcycle AG – GRIP GLUE...

  • Page 111: 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 112: Index

    INDEX Compression damping, low-speed INDEX shock absorber, adjusting ..... 36 Accessories ........5 Coolant Air filter draining .
  • Page 113 INDEX removing ....... . . 49 Front wheel Oil filter installing .
  • Page 114 INDEX Steering locking ........24 unlocking ....... . 25 Steering head bearing greasing .
  • Page 115 *3211724en* 3211724en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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