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

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OWNER'S MANUAL
2015
500 EXC US
Art. no. 3213183en

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Summary of Contents for KTM 500 EXC

  • Page 1 OWNER'S MANUAL 2015 500 EXC US Art. no. 3213183en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, misprints, and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Setting the clock..........23 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 Viewing the lap time........23 Symbols used ........... 5 Display mode SPEED (speed) ......24 Formats used............ 5 Display mode SPEED/H (service hours) ..... 24 SAFETY ADVICE............
  • Page 5 TABLE OF CONTENTS 11.12 Adjusting the compression damping of the 13.4 Checking the brake fluid level of the front fork ............... 45 brake ............. 70 11.13 Adjusting the rebound damping of the fork ..46 13.5 Adding front brake fluid .......
  • Page 6 TABLE OF CONTENTS 22 BLINK CODE ............106 23 TECHNICAL DATA............ 107 23.1 Engine ............107 23.2 Engine tightening torques ......107 23.3 Capacities ............ 109 23.3.1 Engine oil ..........109 23.3.2 Coolant ............ 109 23.3.3 Fuel ............109 23.4 Chassis ............

  • 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 M00165-10 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 M00166-01 Canada type label M00167-01 USA type label...
  • Page 10 SAFETY ADVICE Brake fluid information S00026-10 Information on chain tension 101516-01 Information on starting up 700210-01 Information on emissions control S00454-01 S00455-01 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) S00458-10 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) M00211-10 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. 401945-10 Type label The type label  is fixed to the front of the steering head.  The additional type label for Canada is fixed to the front of the front pipe.

  • Page 17: Fork Part Number

    SERIAL NUMBERS Fork part number  The fork part number is stamped on the inner side of the fork stub. 401947-10 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.

  • 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. M00083-10 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.

  • 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  Idle speed adjusting screw is located at the top left of the throttle valve body. 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. 401956-10 6.17 Side stand The side stand  is on the left side of the vehicle. 401943-10 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 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. 401761-01 Activation and test Activating the speedometer The speedometer is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor.

  • Page 25: Setting The Speedometer Functions

    SPEEDOMETER Setting 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. – Repeatedly press the button briefly until H appears at the bottom right of the display.

  • Page 26: Display Mode Speed (Speed)

    SPEEDOMETER – Repeatedly press the button briefly until LAP appears at the bottom right of the display. – Briefly press the button LAP 1 appears on the left side of the display. – The laps 1–10 can be viewed with the button –...

  • Page 27: Setting The Unit Of Measurement

    SPEEDOMETER Briefly press the Activates the flashing display and changes to the next display button Press the button No function for 2–3 seconds. Briefly press the Deactivates the flashing display and changes to the next dis- button play Press the button No function for 2–3 seconds.

  • Page 28: Setting The Clock

    SPEEDOMETER 7.12 Setting the clock Condition • The motorcycle is stationary. – Repeatedly press the button briefly until CLK appears at the bottom right of the display. – Press the button for 2–3 seconds. Press the button Increases the value for 2–3 seconds.

  • Page 29: Display Mode Speed/Odo (Odometer)

    SPEEDOMETER 7.15 Display mode SPEED/ODO (odometer) – Repeatedly press the button briefly until ODO appears at the bottom right of the display. The total traveled distance is shown in display mode ODO. Press the button No function for 2–3 seconds. Briefly press the Next display mode button...

  • Page 30: Display Mode Speed/A1 (Average Speed 1)

    SPEEDOMETER Info The TR2 value can also be corrected manually during the journey with the but- and the button If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0. Press the button Increases value of TR2. for 2–3 seconds. Briefly press the Increases value of TR2.

  • Page 31: Display Mode Speed/S1 (Stop Watch 1)

    SPEEDOMETER 7.21 Display mode SPEED/S1 (stop watch 1) – Repeatedly press the button briefly until S1 appears at the top right of the dis- play. S1 (Stop watch 1) shows the riding time based on TR1 and continues running as soon as an impulse arrives from the wheel speed sensor.

  • Page 32: Table Of Conditions And Menu Activation

    SPEEDOMETER Display Press the but- Briefly press the Press the but- Briefly press the Wait 3–5 sec- Wait 10–12 sec- for 2–3 button for 2–3 button onds onds seconds. seconds. Display mode The stop watch Next display Stops the clock. Starts the stop SPEED/LAP (lap and the lap time...

  • Page 33: 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 34: Running-In The Engine

    Rides at low temperature or in snow. ( p. 34) Preparing for rides on dry sand – Fit a dust cover on the air filter. Dust protection device for air filter (77206920000) Info See the KTM PowerParts fitting instructions. 600869-01...

  • Page 35: 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. 115) – Fit the steel sprocket.

  • Page 36: Preparing For Rides At High Temperature And Slow Speed

    – Check the coolant level. ( p. 92) 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 37: 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. 97) –...

  • Page 38: 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 39: 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 40: 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 41: 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 42: Service Work (As Additional Order)

    SERVICE SCHEDULE 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 43: 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 44: 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 45: 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. 48) 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 46: 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 47: 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. 56) – Remove the motorcycle from the lift stand. ( p.

  • Page 48: 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 49: 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 screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side.

  • Page 50: 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 51: 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 oil the dust boots and inner fork tube of both fork legs.

  • Page 52: 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. M00163-10 12.8 Installing the fork legs Main work – Position the fork legs. ...

  • Page 53: 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 54: 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. 115) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

  • Page 55: 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 56: 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 57: Removing The Front Fender

    SERVICE WORK ON THE CHASSIS 12.16 Removing the front fender Preparatory work – Remove the headlight mask with the headlight. ( p. 86) Main work –  Remove screws L02485-10 –  Remove screws . Remove the front fender. B01603-11 12.17 Installing the front fender Main work...

  • Page 58: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS Main work –  Remove screw and lower the rear wheel with the swingarm 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 59: 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 sideways and remove it toward the front. S00467-10 12.23 Installing the air filter box lid – Insert the air filter box lid into rear area ...

  • Page 60: 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 61: 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 –...

  • Page 62: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS Main work –   Remove screws of connecting cap –   Take off connecting cap with perforated pipe, O-ring and glass fiber yarn filling  –    Remove screws and silencer cap with O-ring –...

  • Page 63: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS –  Mount the wash cap set Wash cap set (81212016100) – Disconnect the connector of the horn. –  Remove screws with the collar bushings and horn. M00181-10 –  Remove screw with the rubber bushing. M00182-10 –...

  • Page 64: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS –  Position the collar bushings and horn, and mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Connect the connector of the horn. M00181-11 –  Plug in connector of the fuel pump.

  • Page 65: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS Main work – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 115) Off-road chain spray ( p. 115) 400725-01 Finishing work – Remove the motorcycle from the lift stand. ( p.

  • Page 66: 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 ...
  • Page 67 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 68: 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 69: 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 70: 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 71: 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 72: 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 73: 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 74 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. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

  • Page 75: Checking The Free Travel Of Foot Brake Lever

    If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system is leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

  • Page 76: 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.) – Stand the vehicle upright.

  • Page 77: 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 78 Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
  • Page 79 BRAKE SYSTEM –  Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 113) –   Mount screw cap with membrane and O-ring. Info Clean up overflowed or spilt brake fluid immediately with water. 101380-10...

  • Page 80: Wheels, Tires

    WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 48) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

  • Page 81: 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 82: 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 83: 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 84 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 85: 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 86: 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 87: 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 88: 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 89: Refitting The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM –  Detach electrical plug-in connector and take off the headlight mask with the headlight. M00189-10 15.7 Refitting the headlight mask with the headlight Main work –  Connect the electrical plug-in connector M00189-11 –  Position the headlight mask and fix it with rubber straps Info Ensure the holding lugs engage in the fender.

  • Page 90: Checking The Headlight Setting

    ELECTRICAL SYSTEM –  Pull out headlight bulb – Insert the new headlight bulb. Headlight (HS1 / socket PX43t) ( p. 110) – Insert the protection cap with the bulb socket into the reflector and turn it clock- wise all the way. Info ...

  • Page 91: Changing The Turn Signal Bulb

    ELECTRICAL SYSTEM 15.11 Changing the turn signal 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. Main work –...
  • Page 92 ELECTRICAL SYSTEM –  Position protection cap and turn all the way clockwise using a coin. – Press any button on the speedometer. The speedometer is activated. – Position the speedometer in the holder. – Mount and tighten the screws with washers. M00193-10 Finishing work –...

  • Page 93: Cooling System

    COOLING SYSTEM 16.1 Cooling system  The 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 temperature will not result in a risk of malfunctions.

  • Page 94: Checking The Coolant Level

    COOLING SYSTEM 16.3 Checking the coolant level 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 95: Refilling Coolant

    COOLING SYSTEM 16.5 Refilling coolant Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water imme- diately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swal- lowed, contact a physician immediately.

  • Page 96: 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 and  forth slightly to ascertain play in the throttle cable. Play in throttle cable 3…...

  • Page 97: Adjusting The Idle Speed

    TUNING THE ENGINE –  Position activated charcoal filter –  Reconnect rubber band S00456-10 Finishing work – Install the fuel tank. p. 61) – Mount the seat. ( p. 56) – Check the play in the throttle cable. ( p.
  • Page 98 TUNING THE ENGINE –  Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle compo- nents during the shift procedure.

  • Page 99: 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 100: 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 101 SERVICE WORK ON THE ENGINE –  Position oil screen with the O-rings on a pin wrench. – Position the pin wrench through the drill hole of the screw plug in the opposite sec- tion of the engine case. – Push the oil screen all the way into the engine case.

  • Page 102: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 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 103: 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 104: 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 105: 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. 48) – 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 106: 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 107 – 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 108: 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 109: 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 110 TECHNICAL DATA Loctite ® 243™ Screw plug EVAP 5 Nm (3.7 lbf ft) – 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 111: Capacities

    TECHNICAL DATA – Nut, inner clutch hub M18x1.5 80 Nm (59 lbf ft) 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...

  • Page 112: Electrical System

    90/90 - 21 M/C 54M M+S TT 140/80 - 18 M/C 70M M+S TT Metzeler MCE 6 Days Extreme Metzeler MCE 6 Days Extreme Additional information is available in the Service section under: http://www.ktm.com 23.7 Fork Fork part number 14.18.7L.69...

  • Page 113: Shock Absorber

    TECHNICAL DATA Fork oil per fork leg 618 ml (20.89 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 113) 23.8 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...
  • Page 114 TECHNICAL DATA Loctite ® 2701™ Nut, rear sprocket screw 35 Nm (25.8 lbf ft) – Nut, rim lock 12 Nm (8.9 lbf ft) – Remaining nuts, chassis 25 Nm (18.4 lbf ft) – Remaining screws, chassis 25 Nm (18.4 lbf ft) –...

  • Page 115: Substances

    SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®...
  • Page 116 SUBSTANCES Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification – DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e.

  • Page 117: Auxiliary Substances

    Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Rubber grip adhesive (00062030051) Recommended supplier KTM-Sportmotorcycle AG – GRIP GLUE Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ® –...
  • Page 118 AUXILIARY SUBSTANCES Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic...

  • Page 119: 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 120: Index

    INDEX Clutch lever ........16 INDEX basic position, adjusting ..... . 67 Accessories .
  • Page 121 INDEX spring preload, adjusting ..... . 46 Fork protector Main fuse installing ....... . . 51 changing .
  • Page 122 INDEX riding sag, checking ......43 spring preload, adjusting ..... . 44 View of vehicle static sag, checking .
  • Page 123 *3213183en* 3213183en 05/2014 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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