KTM 500 EXC SIX DAYS US Page 83 Owner'S Manual Download | Manualshive

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13

BRAKE SYSTEM

81

13.8

Checking the free travel of foot brake lever

Warning

Danger of accidents

Brake system failure.

–

If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust the free travel on foot brake lever according to specifications.

402026-10

–

Disconnect spring



.

–

Move the foot brake lever back and forth between the end stop and the contact to
the foot brake cylinder piston and check free travel



.

Guideline

Free travel at foot brake lever

3… 5 mm (0.12… 0.2 in)

» If the free travel does not meet specifications:

–

Adjust the basic position of the foot brake lever.

–

Reconnect spring



.

13.9

Adjusting the basic position of the foot brake lever

Warning

Danger of accidents

Brake system failure.

–

If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust the free travel on foot brake lever according to specifications.

K00112-10

–

Disconnect spring



.

–

Loosen nut



and, with push rod



, turn it back until you have maximum free

travel.

–

To adjust the basic position of the foot brake lever individually, loosen nut



and

turn screw



accordingly.

Info

The range of adjustment is limited.

–

Turn push rod



accordingly until you have free travel



. If necessary, adjust

the basic position of the foot brake lever.
Guideline

Free travel at foot brake lever

3… 5 mm (0.12… 0.2 in)

–

Hold screw



and tighten nut



.

Guideline

Nut, foot brake lever stop

M8

20 Nm
(14.8 lbf ft)

–

Hold push rod



and tighten nut



.

Guideline

Remaining nuts, chassis

M6

10 Nm (7.4 lbf ft)

–

Reconnect spring



.

13.10

Checking the rear brake fluid level

Warning

Danger of accidents

Brake system failure.

–

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.)

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Summary of Contents for 500 EXC SIX DAYS US

Page 1: ...OWNER S MANUAL 2016 500 EXC US 500 EXC Six Days US Art no 3213339en...

Page 2: ......

Page 3: ...chnical specifica tions prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop productio...

Page 4: ...menu 25 7 10 Setting the unit of measurement 25 7 11 Display mode SPEED CLK time 26 7 12 Setting the clock 26 7 13 Display mode SPEED LAP lap time 26 7 14 Viewing the lap time 27 7 15 Display mode SPE...

Page 5: ...rubber grip 74 12 45 Adjusting the basic position of the clutch lever 74 12 46 Checking correcting the fluid level of the hydraulic clutch 75 12 47 Changing the hydraulic clutch fluid 75 12 48 Removi...

Page 6: ...4 23 2 Engine tightening torques 114 23 3 Capacities 116 23 3 1 Engine oil 116 23 3 2 Coolant 116 23 3 3 Fuel 116 23 4 Chassis 116 23 5 Electrical system 117 23 6 Tires 117 23 7 Fork 117 23 7 1 EXC US...

Page 7: ...your motorcycle will be opti mally cared for by specially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page Indicates i...

Page 8: ...re read this manual carefully The safety instructions are highlighted in the text and are referred to at the relevant passages Info The vehicle has various information and warning labels at prominent...

Page 9: ...10 1 Canada type label 2 USA type label 3 Brake fluid information 4 Information on chain tension 5 Information on starting up 6 Information on emissions control 7 Information on noise emission K00161...

Page 10: ...ETY ADVICE 8 S00026 10 Brake fluid information 101516 01 Information on chain tension 700210 01 Information on starting up K00163 01 Information on emissions control K00164 01 Information on noise emi...

Page 11: ...2 7 Operating noise warning This product should be checked for necessary repair or replacement parts if the motorcycle noise has increased significantly through use Otherwise the owner may become subj...

Page 12: ...but can be ordered under the number in paren theses E g bearing puller 15112017000 During assembly non reusable parts e g self locking screws and nuts seals and seal rings O rings pins lock washers mu...

Page 13: ...PowerParts for your vehicle can be found on the KTM website International KTM Website http www ktm com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the se...

Page 14: ...4 VIEW OF VEHICLE 12 4 1 View of vehicle front left example K00159 10 1 Hand brake lever p 16 2 Clutch lever p 16 3 Filler cap 4 Side stand p 20 5 Engine number p 14 6 Shift lever p 19...

Page 15: ...1 Light switch p 16 1 Turn signal switch p 17 2 Emergency OFF switch p 17 2 Electric starter button p 17 3 Throttle grip p 16 4 Chassis number p 14 4 Type label p 14 5 Fork part number p 15 6 Kick st...

Page 16: ...head The additional type label for Canada is fixed to the front of the front pipe 5 3 Key number 402246 10 Key number for the ignition and steering lock is indicated on the KEYCODECARD Info You need t...

Page 17: ...1947 10 The fork part number is stamped on the inner side of the fork stub 5 6 Shock absorber part number 0 0 1 1 401948 10 The shock absorber part number is stamped on the top of the shock absorber a...

Page 18: ...fitted on the right side of the handlebar 6 4 Horn button M00154 10 The horn button is fitted on the left side of the handlebar Possible states Horn button in neutral position Horn button pressed The...

Page 19: ...circuit is closed and the engine can be started 6 8 Electric starter button K00166 11 Electric starter button is fitted on the right side of the handlebar Possible states Electric starter button in ba...

Page 20: ...l 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 physic...

Page 21: ...ncrease deactivated Idle speed adjusting screw is pushed in all the way 6 14 Shift lever 401950 10 The shift lever is fitted on the left side of the engine 401950 11 The gear positions can be seen in...

Page 22: ...de 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 6 18 Steering lock K00064 10 Steering lock is fitted on the left side...

Page 23: ...p 20 turn it to the left press it in and turn it to the right Remove the key Steering is no longer possible Info Never leave the key in the steering lock 6 20 Unlocking the steering 400731 01 Insert...

Page 24: ...rcumference of the 21 front wheel with stan dard tires The display then changes to the last selected mode 7 3 Setting kilometers or miles Info If you change the unit the value ODO is retained and conv...

Page 25: ...e symbol continues to appear in the display and the next function appears Deactivating a function Press the button The symbol disappears in the display and the next function appears 7 5 Setting the cl...

Page 26: ...When an impulse comes from the front wheel the left side of the speedometer display changes to the SPEED mode and the current speed is shown 7 8 Display mode SPEED H service hours 400316 01 Condition...

Page 27: ...conds Changes to the next display without changes Wait 10 12 sec onds Setup menu starts stores the settings and changes to H or ODO 7 10 Setting the unit of measurement 400329 01 Condition The motorcy...

Page 28: ...button Increases the value Press the button for 2 3 seconds Reduces the value Briefly press the button Reduces the value Wait 3 5 seconds Changes to the next value Wait 10 12 sec onds Closes the SETUP...

Page 29: ...isplay mode ODO Press the button for 2 3 seconds No function Briefly press the button Next display mode Press the button for 2 3 seconds No function Briefly press the button No function 7 16 Display m...

Page 30: ...2 value can also be corrected manually during the journey with the but ton and the button If 999 9 is exceeded the value of TR2 is automatically reset to 0 0 Press the button for 2 3 seconds Increases...

Page 31: ...shows the riding time based on TR1 and continues running as soon as an impulse arrives from the wheel speed sensor The calculation of this value starts with the first impulse from the wheel speed sens...

Page 32: ...TUP menu Display mode SPEED LAP lap time The stop watch and the lap time are reset Next display mode Stops the clock Starts the stop watch or stop the current lap time measure ment stores it and the s...

Page 33: ...etup menu Setting the unit of measurement Setting the clock Display mode SPEED LAP lap time Viewing the lap time Display mode SPEED TR1 trip master 1 Display mode SPEED TR2 trip master 2 Setting TR2 t...

Page 34: ...g Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permissible weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicl...

Page 35: ...throttle 8 3 Preparing the vehicle for difficult riding conditions Info Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces can lead to considerably more rapid w...

Page 36: ...ts fitting instructions 600868 01 Clean the chain Chain cleaner p 122 Fit the steel sprocket Tip Do not grease the chain Clean the radiator fins Straighten bent radiator fins carefully 8 5 Preparing f...

Page 37: ...at high temperature and slow speed 600868 01 Adjust the secondary drive to the road conditions Info The engine oil heats up quickly when the clutch is operated frequently due to an excessively high se...

Page 38: ...screws nuts and hose clamps regularly for tightness Check the fuel supply 9 2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death...

Page 39: ...ng increases fuel consumption To shift down apply the brakes and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the thro...

Page 40: ...n Always let the vehicle cool first Note Material damage Damage to or destruction of components due to excessive load The side stand is only designed for the weight of the motorcycle Do no sit on the...

Page 41: ...areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Note Material damage Premature clogging of the fuel filter In...

Page 42: ...ration Check correct the fluid level of the hydraulic clutch p 75 Check the brake fluid level of the front brake p 78 Check the free travel of the hand brake lever p 77 Check the steering head bearing...

Page 43: ...erform a fork service EXC US Perform a fork service EXC Six Days US Service the shock absorber Change the spark plug and spark plug connector Change the piston Check measure the cylinder Check the cyl...

Page 44: ...peed of the rear wheel suspension and not to the vehicle speed The high speed setting for example has an effect on the landing after a jump the rear wheel suspension compresses more quickly The low sp...

Page 45: ...responding to the shock absorber type Guideline Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 25 turns Info Turn clockwise to increase damping turn counterclockwise to redu...

Page 46: ...s the difference between measurements and Check the static sag Static sag 33 35 mm 1 3 1 38 in If the static sag is less or more than the specified value Adjust the spring preload of the shock absorbe...

Page 47: ...ing length while the spring is not under tension Tighten the spring by turning adjusting ring to measurement Guideline Spring preload Comfort 9 mm 0 35 in Standard 9 mm 0 35 in Sport 9 mm 0 35 in Info...

Page 48: ...ider s weight can be com pensated by the spring preload However if the fork is often overloaded hard end stop on compression harder springs must be fit to avoid damage to the fork and frame 11 12 Adju...

Page 49: ...n behavior M01002 10 EXC US 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 Turn back countercl...

Page 50: ...1 turn Info Turn clockwise to increase the spring preload turn counterclockwise to reduce the spring preload Adjusting the spring preload has no influence on the absorption setting of the rebound damp...

Page 51: ...replace handle bar M00987 11 EXC Six Days US Remove screws Take off the handlebar clamps Remove the handlebar and lay it to one side Info Cover the components to protect them against damage Do not ben...

Page 52: ...ar supports Place the handlebar supports in the required position Mount and tighten screws Guideline Screw handlebar holder M10 40 Nm 29 5 lbf ft Loctite 243 Info Position the left and right handlebar...

Page 53: ...ehicle on a firm and even surface 401943 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand to the ground with your foot and lean the motorcycle...

Page 54: ...rease and clean them with brake cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray p 123 Press the dust boots back into their normal position...

Page 55: ...88 10 Position brake caliper and mount and tighten screws Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount cable binder Position the brake line wiring harness and clamp Mount...

Page 56: ...Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line wiring harness and clamp Mount and tighten screws Position the fork protector on the right fork...

Page 57: ...g harness Remove screws and hang the voltage regulator to the side Remove screw Remove screw Take off the upper triple clamp with the handlebar and set it aside Info Cover the components to protect th...

Page 58: ...e front Info Grooves are milled into the side of the upper end of the fork legs The sec ond milled groove from the top must be flush with the top edge of the upper triple clamp K00141 10 Tighten screw...

Page 59: ...heck the steering head bearing play p 59 Remove the motorcycle from the lift stand p 51 Check the headlight setting p 96 12 12 Installing the lower triple clamp EXC Six Days US B01604 10 Main work Cle...

Page 60: ...triple clamp M00139 10 Tighten screws Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft B01232 10 Tighten screw Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft B01233 10 Mount and ti...

Page 61: ...dlebar 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 EXC Six Day...

Page 62: ...5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid strains Tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Mount and tighten screw Guideline...

Page 63: ...the headlight setting p 96 12 19 Removing the shock absorber Preparatory work Raise the motorcycle with the lift stand p 51 K00074 10 Main work Remove screw and lower the rear wheel with the swingarm...

Page 64: ...Lift up the seat at the rear pull it back and then remove it from above 12 22 Mounting the seat K00075 01 Mount the front the seat on to the collar bushing of the fuel tank lower it at the rear and si...

Page 65: ...m the air filter support 12 26 Installing the air filter L00943 10 Main work Mount the clean air filter on the air filter support Grease the air filter in area Long life grease p 122 K00080 10 Insert...

Page 66: ...the air filter box Preparatory work Remove the air filter box cover p 62 401527 10 Main work Seal the air filter box in the marked area Finishing work Install the air filter box cover p 62 12 29 Remov...

Page 67: ...ork Remove the main silencer p 64 402269 10 Main work Remove screws and take off silencer cap with O ring Warning Danger to health Soot particles irritate the eyes and mucuous membranes Wear suitable...

Page 68: ...insulating pad in outer tube Mount and tighten screws Guideline Screws on the main silencer M5 7 Nm 5 2 lbf ft Mount O ring on the silencer cap Fit the new glass fiber yarn filling onto the perforated...

Page 69: ...l properly in a suitable canister and keep away from children Preparatory work Remove the seat p 62 K00100 10 Main work Detach connector of the fuel pump Remove the tube from the fuel tank breather S0...

Page 70: ...lth 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 Immedia...

Page 71: ...ect plug in connection of the fuel line Info Route the cable and fuel line at a safe distance from the exhaust system Finishing work Mount the seat p 62 12 35 Checking for chain dirt accumulation 4006...

Page 72: ...chain or the countershaft of the transmission to break in extreme cases If the chain is too loose however it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the e...

Page 73: ...eft 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...

Page 74: ...w chains wear out faster on old worn sprockets L02465 01 Check the chain sliding guard for wear If the lower edge of the chain pin is at the level of or below the chain sliding guard Change the chain...

Page 75: ...stand p 51 12 40 Checking the frame 401340 01 Check the frame for cracking and deformation If the frame exhibits cracking or deformation due to a mechanical impact Change the frame Info Always replace...

Page 76: ...tionally securing the rubber grip Preparatory work Check the rubber grip p 74 401198 01 Main work Secure the rubber grip at two points using the securing wire Securing wire 54812016000 Wire twister fo...

Page 77: ...substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations M00208 10 Move the clutch fluid reservoir mounted...

Page 78: ...Days US S00818 10 Turn quick release counterclockwise until it disengages Remove the engine guard 12 49 Installing the engine guard EXC Six Days US S00819 10 Attach the engine guard on the frame at th...

Page 79: ...om the handlebar Turn the adjusting screw counterclockwise to increase free travel The pres sure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by hand o...

Page 80: ...n 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 Warning Skin i...

Page 81: ...glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggl...

Page 82: ...ake fluid reservoir extracting it by suction if it does Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes K00108 10 Remove cotter pins pull...

Page 83: ...can fail due to overheating Adjust the free travel on foot brake lever according to specifications K00112 10 Disconnect spring Loosen nut and with push rod turn it back until you have maximum free tr...

Page 84: ...an cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes...

Page 85: ...hange the rear brake linings p 83 13 13 Changing the rear brake linings Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Your authorized...

Page 86: ...in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed contai...

Page 87: ...13 BRAKE SYSTEM 85 101380 10 Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 121 Mount screw cap with membrane and O ring Info Clean up overflowed or spilt brake fluid immediately with water...

Page 88: ...out of the fork Info Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged K00084 11 Remove spacers 14 2 Installi...

Page 89: ...motorcycle with the lift stand p 51 K00113 10 Main work Press the brake caliper by hand on to the brake disc in order to press back the brake piston Info Make sure when pushing back the brake piston t...

Page 90: ...y on adjusting screws Check the chain tension p 70 Tighten nut Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables diff...

Page 91: ...han five years Change the tire 14 6 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfor...

Page 92: ...nd frequencies in spokes with the same length and thickness this indicates different spoke tensions You should hear a high note If the spoke tension varies Correct the spoke tension Check the spoke to...

Page 93: ...ative cable from the battery Pull back positive terminal cover and disconnect the positive cable from the battery Detach rubber band at the bottom Lift the battery up and out 15 2 Installing the batte...

Page 94: ...hortens the battery s service life If the charging current charging voltage and charging time are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the batter...

Page 95: ...e screw K00098 10 Lift rear fairing slightly and pull starter relay out of the holder K00099 10 Remove protection caps Remove the faulty main fuse Info A defective fuse can be identified by the burned...

Page 96: ...nse plate lamp horn brake light turn signal radiator fan Fuses res 10 A spare fuses Info A defective fuse is indicated by a burned out fuse wire Warning Fire hazard The electrical system can be overlo...

Page 97: ...ness Put the clamp on and mount and tighten screw Finishing work Check the headlight setting p 96 15 8 Changing the headlight bulb Note Damage to reflector Reduced brightness Grease on the lamp will e...

Page 98: ...nd take it out of the socket Info Do not touch the reflector with your fingers and keep it free from grease Press the new turn signal bulb carefully into the socket and turn it clockwise until it stop...

Page 99: ...aratory work Remove the headlight mask with the headlight p 94 K00122 10 Main work Remove screws Pull the speedometer upward out of the holder K00123 10 Using a coin turn protection cap all the way co...

Page 100: ...Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come i...

Page 101: ...oes not meet specifications Correct the coolant level Coolant p 121 Mount the radiator cap 16 4 Draining the coolant Warning Danger of scalding During motorcycle operation the coolant gets very hot an...

Page 102: ...he skin with soap and water If fuel is swal lowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children M00220 10 Main work Make sure...

Page 103: ...engine and let it run idle Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable p 101 17 2 Adjust...

Page 104: ...rclockwise to increase the idle speed Turn clockwise to decrease the idle speed 17 4 Checking the basic position of the shift lever Info When driving the shift lever must not touch the driver s boot w...

Page 105: ...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...

Page 106: ...Clean the plug in connection of the fuel line thoroughly with compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Disconnec...

Page 107: ...licable regulations Info Drain the engine oil only when the engine is warm Preparatory work EXC Six Days US Remove the engine guard p 76 Park the motorcycle on a level surface K00126 10 Main work Plac...

Page 108: ...oil filter out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing surface K00133 10 Lay the motorcycle on its side and...

Page 109: ...14 10 Main work Remove the oil filler plug with the O ring from the clutch cover Fill engine oil to the middle of the level viewer Add the same engine oil that was used when the motor was changed Engi...

Page 110: ...ean with a paintbrush Motorcycle cleaner p 122 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry vehicle always rinse with water firs...

Page 111: ...orcycle p 108 Clean the brake system Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings in the cooled down and installed state with cold water and dry carefully...

Page 112: ...otorcycle out of service add fuel additive Fuel additive p 122 Refuel p 39 Clean the motorcycle p 108 Change the engine oil and oil filter and clean the oil screens p 105 Check the antifreeze and cool...

Page 113: ...kill switch or emergency OFF switch defective Check the wiring harness visual check Check the electrical system Defect in fuel injection system Read out the fault memory using the KTM diag nostics to...

Page 114: ...KTM diag nostics tool High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary Engine oil level too high Check the engine oil level p 104 Engine oil too...

Page 115: ...too low Engine coolant temperature sensor input signal too high Blink code FI warning lamp MIL 13 FI warning lamp MIL flashes 1x long 3x short Error level condition Intake air temperature sensor input...

Page 116: ...th gear 22 26 5th gear 24 23 6th gear 26 21 Alternator 12 V 200 W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Spark plug NGK LKAR 8AI 9 Spark plug elect...

Page 117: ...ail M6 10 Nm 7 4 lbf ft Loctite 243 Screw torque governor M6 10 Nm 7 4 lbf ft Loctite 243 Screw valve cover M6 10 Nm 7 4 lbf ft Screw water pump cover M6x25 10 Nm 7 4 lbf ft Screw water pump cover M6x...

Page 118: ...rformance Systems Up Side Down 4860 MXMA 4CS Suspension travel EXC US Front 300 mm 11 81 in Suspension travel EXC Six Days US Front 300 mm 11 81 in Suspension travel Rear 335 mm 13 19 in Fork offset 2...

Page 119: ...ires 90 90 21 M C 54M M S TT Metzeler MCE 6 Days Extreme 140 80 18 M C 70M M S TT Metzeler MCE 6 Days Extreme Additional information is available in the Service section under http www ktm com 23 7 For...

Page 120: ...er 85 95 kg 187 209 lb 4 8 N mm 27 4 lb in Fork length 932 mm 36 69 in Oil capacity per fork leg 630 ml 21 3 fl oz Fork oil SAE 4 48601166S1 p 121 23 8 Shock absorber Shock absorber part number 12 18...

Page 121: ...lbf ft Loctite 2701 Nut rim lock M8 12 Nm 8 9 lbf ft Remaining nuts chassis M8 25 Nm 18 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft Screw bottom triple clamp EXC Six Days US M8 15 Nm 11 1...

Page 122: ...20 Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Screw in nozzles cooling system M20x1 5 12 Nm 8 9...

Page 123: ...ly with the specified standards see specifications on the container and that possess the corre sponding properties Synthetic engine oil Recommended supplier Motorex Cross Power 4T Fork oil SAE 4 48601...

Page 124: ...ecommended supplier SKF LGHB 2 Long life grease Recommended supplier Motorex Bike Grease 2000 Motorcycle cleaner Recommended supplier Motorex Moto Clean Off road chain spray Recommended supplier Motor...

Page 125: ...25 AUXILIARY SUBSTANCES 123 Universal oil spray Recommended supplier Motorex Joker 440 Synthetic...

Page 126: ...vice intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated wi...

Page 127: ...27 LIST OF ABBREVIATIONS 125 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 128: ...EFI warning lamp MIL lights up flashes orange The OBD has detected an emission or safety critical fault The low fuel warning lamp lights up orange The fuel level has reached the reserve mark 28 2 Gre...

Page 129: ...g 71 checking 70 Chassis number 14 Clutch fluid level checking correcting 75 fluid changing 75 Clutch lever 16 basic position adjusting 74 Compression damping fork adjusting 46 Compression damping hig...

Page 130: ...tch 16 Lower triple clamp installing 55 57 removing 54 55 M Main fuse changing 93 Main silencer changing glass fiber yarn filling 66 installing 64 removing 64 spark arrestor cleaning 65 Motor sprocket...

Page 131: ...0 checking 59 Storage 110 Swingarm checking 73 T Technical data capacities 116 chassis 116 chassis tightening torques 119 electrical system 117 engine 114 engine tightening torques 114 fork 117 shock...

Page 132: ...3213339en 3213339en 04 2015 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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