Removing The Fuel Tank - KTM 500 EXC Owner's Manual

12 SERVICE WORK ON THE CHASSIS
12.31

Removing the fuel tank

Danger
Fire hazard Fuel is highly flammable.
–
Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–
The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–
Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Store fuel properly in a suitable canister and keep away from children.
Main work
–
Remove screws
–
Take off connecting cap
filling 
–
Remove screws
–
Remove screws
–
Clean the parts that need to be reinstalled and check for damage.
–
Mount the new insulating pad
–
Slide insert
screws 
–
Mount O-ring
–
Slide the new glass fiber yarn filling
–
Mount connecting cap
Info
Slide the glass fiber yarn filling into the main silencer with a blunt tool.
–
Mount and tighten screws
101426-10
–
Mount O-ring
–
Position silencer cap
Finishing work
–
Install the main silencer. (
Preparatory work
–
Remove the seat. (
Main work
–
Detach connector
–
Remove the tube from the fuel tank breather.
M00179-10
–
Thoroughly clean the plug-in connection of the fuel line using compressed air.
Info
Under no circumstances should dirt enter into the fuel line. Dirt in the fuel
line clogs the injection valve.
–
Disconnect the plug-in connection of the fuel line.
S00459-10

of connecting cap

with perforated pipe, O-ring
.

and silencer cap
 
and insert together with the insulating pad

on insert
 
with insulating pad
.

onto connecting cap


and glass fiber yarn filling

.
 
on silencer cap

. Mount and tighten screws
p. 59)
p. 56)

of the fuel pump.

.

and glass fiber yarn
 
with O-ring .

and secure it with adhesive tape.
into the main silencer and secure with

.
over the perforated pipe.

in the main silencer.
.

.
60

.