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AUXILIARY SUBSTANCES

112

Oil for foam air filter

Guideline

–

KTM recommends

Motorex

products.

Supplier
Motorex

–

Twin Air Liquid Bio Power

Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces

Guideline

–

KTM recommends

Motorex

products.

Supplier
Motorex

–

Clean & Polish

Rubber grip adhesive (00062030051)

Supplier

KTM-Sportmotorcycle AG

–

GRIP GLUE

Universal oil spray

Guideline

–

KTM recommends

Motorex

products.

Supplier
Motorex

–

Joker 440 Synthetic

Содержание 500 EXC AUS

Страница 1: ...OWNER S MANUAL 2013 500 EXC USA Art no 3211868en...

Страница 2: ......

Страница 3: ...echnical 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 producti...

Страница 4: ...22 6 11 16 Display mode SPEED A2 average speed 2 22 6 11 17 Display mode SPEED S1 stop watch 1 23 6 11 18 Display mode SPEED S2 stop watch 2 23 6 11 19 Table of functions 23 6 11 20 Table of condition...

Страница 5: ...free travel of hand brake lever 66 12 2 Adjusting free travel of hand brake lever 66 12 3 Checking the brake discs 66 12 4 Checking the front brake fluid level 67 12 5 Adding front brake fluid x 67 12...

Страница 6: ...103 22 3 Capacities 105 22 3 1 Engine oil 105 22 3 2 Coolant 105 22 3 3 Fuel 105 22 4 Chassis 105 22 5 Electrical system 106 22 6 Tires 106 22 7 Fork 106 22 8 Shock absorber 107 22 9 Chassis tighteni...

Страница 7: ...tanding 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...

Страница 8: ...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 location...

Страница 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 S00024...

Страница 10: ...ETY ADVICE 8 S00026 10 Brake fluid information 101516 01 Information on chain tension 700210 01 Information on starting up S00025 10 Information on emissions control S00028 10 Information on noise emi...

Страница 11: ...Warranty claims should be submitted to a KTM workshop If you are not satisfied please contact KTM North America Inc Customer Support 1119 Milan Ave Amherst OH 44001 USA Phone 440 985 3553 www ktmusa...

Страница 12: ...r e g Loctite is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them for damage and wear Change damaged or worn parts...

Страница 13: ...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 service care and t...

Страница 14: ...4 VIEW OF VEHICLE 12 4 1 View of vehicle front left example S00015 10 1 Filler cap 2 Fork compression adjustment 3 Shift lever p 25 4 Engine number p 14 5 Side stand p 26...

Страница 15: ...lutch lever p 16 3 Light switch p 16 3 Turn signal switch p 17 3 Horn button p 16 4 Emergency OFF switch p 17 4 Electric starter button p 17 5 Throttle grip p 16 6 Hand brake lever p 16 7 Ignition loc...

Страница 16: ...ng head S00029 10 The type label Canada 2 is fixed to the front of the front pipe 5 3 Key number 101543 10 Key number 1 for the ignition and steering lock is indicated on the KEYCODECARD Info You need...

Страница 17: ...101654 10 The fork part number 1 is stamped on the inner side of the fork stub 5 6 Shock absorber part number S00017 10 The shock absorber part number 1 is stamped on the top of the shock absorber abo...

Страница 18: ...fitted on the right side of the handlebar 6 4 Horn button S00019 10 The horn button 1 is fitted on the left side of the handlebar Possible states Horn button in neutral position Horn button pressed Th...

Страница 19: ...tion circuit is closed and the engine can be started 6 8 Electric starter button S00020 11 Electric starter button 1 is fitted on the right side of the handlebar Possible states Electric starter butto...

Страница 20: ...WS is displayed briefly Info The number 2205 equals the circumference of the 21 front wheel with stan dard tires The display then changes to the last selected mode 6 11 3 Tripmaster switch Option Trip...

Страница 21: ...changes to the next function Deactivating the function Press the button The symbol on the screen goes out and the display changes to the next function All desired functions are activated or deactivat...

Страница 22: ...s displayed in the SPEED display mode The current speed can be displayed in Km h or Mph Info Making the setting according to the country When an impulse comes from the front wheel the left side of the...

Страница 23: ...e next lap Press the button for 3 5 seconds The stop watch and the lap time are reset Press the button briefly Next display mode 6 11 12 Display mode SPEED ODO odometer 400317 01 Press the button brie...

Страница 24: ...repeatedly until A1 appears at the top right of the display A1 average speed 1 shows the average speed calculated on the basis of TR1 trip mas ter 1 and S1 stop watch 1 The calculation of this value i...

Страница 25: ...he button Press the button for 3 5 seconds Press the button briefly Display mode SPEED H operating hours No function No function The display changes to the Setup menu of the speedometer functions Next...

Страница 26: ...he tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fu...

Страница 27: ...e way RPM increase deactivated Idle speed adjusting screw is pushed in all the way 6 15 Shift lever 601614 10 Shift lever 1 is mounted on the left side of the engine 601615 10 The gear positions can b...

Страница 28: ...is used to park the motorcycle Info When you are riding the side stand 1 must be folded up and secured with the rubber band 2 6 19 Steering lock 101313 10 Steering lock 1 is fitted on the left side o...

Страница 29: ...ss 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 21 Unlocking the steering 400731 01 Insert the key in the steering lock...

Страница 30: ...not braking 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...

Страница 31: ...as the drive train brake system or suspension components For this reason it may be neces sary to inspect or replace parts before the next scheduled service KTM recommends that you use the specified en...

Страница 32: ...eparing for rides on wet sand 600870 01 Fit a rain cover on the air filter Waterproofing device for air filter 77206921000 Info See the KTM PowerParts fitting instructions 600868 01 Clean the chain Ch...

Страница 33: ...he engine oil heats up quickly when the clutch is operated frequently due to an excessively high secondary drive Clean the chain Chain cleaner p 111 Clean the radiator fins Straighten bent radiator fi...

Страница 34: ...uts and hose clamps regularly for tightness Check the fuel supply 8 2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When runn...

Страница 35: ...e opening increases fuel consumption To shift down brake 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 throttle...

Страница 36: ...lways let the vehicle cool first Note Material damage Damage and destruction of components by excessive load The side stand is designed for the weight of the motorcycle only Do not sit on the motorcyc...

Страница 37: ...soap and water If fuel is swallowed contact a doctor immediately Change clothing that has come into contact with fuel Note Material damage Premature clogging of the fuel filter In some countries and...

Страница 38: ...eck the front brake fluid level p 67 Check the free travel of the hand brake lever p 66 Check the steering head bearing play p 50 Check the valve clearance x Check the clutch x Change the engine oil a...

Страница 39: ...piston x Check measure the cylinder x Check the cylinder head x Check the valves valve springs and valve spring seats x Check the camshaft and cam lever x Change the connecting rod conrod bearing and...

Страница 40: ...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 speed...

Страница 41: ...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...

Страница 42: ...difference between measurements A and B 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 absorber...

Страница 43: ...g length while the spring is not under tension Tighten the spring by turning adjusting ring 2 to measurement A Guideline Spring preload Comfort 9 mm 0 35 in Standard 9 mm 0 35 in Sport 9 mm 0 35 in In...

Страница 44: ...der 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 10 12 Adjus...

Страница 45: ...counterclockwise all the way Info Make the same adjustment on both fork legs Turn back clockwise by the number of turns corresponding to the fork type Guideline Spring preload Preload Adjuster Comfort...

Страница 46: ...achments from damage by covering them Do not bend the cables and lines Remove the two screws 2 Remove the handlebar supports Place the handlebar supports in the required position Fit and tighten the t...

Страница 47: ...ide stand 1 to the ground with your foot and lean the motorcycle on it Info When you are riding the side stand must be folded up and secured with the rubber band 11 3 Bleeding fork legs Preparatory wo...

Страница 48: ...move the screws on the right fork leg Push the fork protector downwards 11 6 Positioning the fork protection 101321 11 Position the fork protection on the left fork leg Mount and tighten screws 1 Guid...

Страница 49: ...riple clamp M8 20 Nm 14 8 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft 101326 10 Position brake caliper and mount and tighten screws 4 Guideline Screw front brake c...

Страница 50: ...dlight p 83 Check the headlight setting p 85 11 11 Removing the lower triple clamp x Preparatory work Remove the headlight mask with the headlight p 83 Raise the motorcycle with the lift stand p 45 Re...

Страница 51: ...ple clamp with the steering Mount screw 4 but do not tighten yet Position the clutch line wiring harness and voltage regulator Mount and tighten screws 5 Guideline Remaining screws chassis M6 10 Nm 7...

Страница 52: ...all the front wheel x p 74 Refit the headlight mask with the headlight p 83 Check that the wiring harness cables and brake and clutch lines can move freely and are routed correctly Check the steering...

Страница 53: ...earing and replace if required Finishing work Remove the motorcycle from the lift stand p 45 11 14 Adjusting the play of the steering head bearing x Preparatory work Raise the motorcycle with the lift...

Страница 54: ...heel with the swing arm as far as possible without blocking the rear wheel Fix the rear wheel in this position Remove screw 2 push splash protector 3 to the side and remove the shock absorber 11 19 In...

Страница 55: ...1 10 Pull off the air filter box lid in area A to the side and remove to the front 11 23 Installing the air filter box lid S00031 11 Insert the air filter box lid into the rear area A and clip it into...

Страница 56: ...ine and cause damage Finishing work Install the air filter box lid p 53 11 26 Cleaning the air filter and air filter box x Warning Environmental hazard Hazardous substances cause environmental damage...

Страница 57: ...connect spring 1 Remove screws 2 and take off main silencer 11 29 Installing the main silencer S00032 11 Mount the main silencer Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm...

Страница 58: ...ever 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 immediat...

Страница 59: ...escape if the tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact of the fuel with skin eyes and clothing Do not inhale fuel v...

Страница 60: ...Mount the seat p 53 11 33 Checking for chain dirt accumulation 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 58 11 34 Cleaning the chain Warning...

Страница 61: ...ower chain section 1 must be taut When the chain guard is mounted it must be possible to pull up the chain at least to the point where it makes contact with chain guard B Chain wear is not always even...

Страница 62: ...45 11 37 Checking the chain rear sprocket engine sprocket and chain guide Preparatory work Raise the motorcycle with the lift stand p 45 400227 01 Main work Shift gear to neutral Check the rear sprock...

Страница 63: ...ine with or below the chain sliding piece Change the chain sliding piece x Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the chain sliding piece Guide...

Страница 64: ...2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount the nut on screw 1 and tighten Guideline Remaining nuts chassis M6 10 Nm 7 4 lbf ft 11 39 Checking the frame x 401340 01 Check the frame...

Страница 65: ...g work Install the fuel tank x p 57 Mount the seat p 53 11 42 Checking the rubber grip 401197 01 Check the rubber grips on the handlebar for damage and wear and to ensure they are firmly seated If a r...

Страница 66: ...mbrane 3 Check the fluid level Fluid level below container rim 4 mm 0 16 in If the fluid level does not meet specifications Correct the fluid level of the hydraulic clutch Brake fluid DOT 4 DOT 5 1 p...

Страница 67: ...ly with water Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 101367 10 Inject the liquid into the system until it esca...

Страница 68: ...from the handlebar Turn the adjustment screw counterclockwise to increase free travel The pressure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by hand...

Страница 69: ...d 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 goggles...

Страница 70: ...aking 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 acciden...

Страница 71: ...nd remove the brake linings Clean the brake caliper and brake caliper support 100397 01 Check that leaf spring 6 in the brake caliper and sliding plate 7 in the brake caliper support are seated correc...

Страница 72: ...specifications S00039 10 Disconnect spring 1 Loosen nut 4 and with push rod 5 turn it back until you have maximum free travel To adjust the basic position of the foot brake lever individually loosen...

Страница 73: ...ly with water and consult a physician immediately 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 serv...

Страница 74: ...e 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 disc...

Страница 75: ...move the brake linings Clean the brake caliper and brake caliper support 100407 10 Check that leaf spring 5 in the brake caliper and sliding plate 6 in the brake caliper support are seated correctly 1...

Страница 76: ...el 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 101388 10 Remove spacers 3 13 2 Ins...

Страница 77: ...o the brake disc in order to press back the brake piston Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut 1 Remove chain adjuster...

Страница 78: ...ters 3 can be turned by 180 Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Finishing work Remove the motorcycle from t...

Страница 79: ...air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi Road tire pressure Front 1 5 bar 22 psi Rear 1 5 bar 22 psi If the tire pressure does not meet specifications Correct the tire air pressu...

Страница 80: ...13 WHEELS TIRES 78 Guideline Spoke nipple front wheel M4 5 5 6 Nm 3 7 4 4 lbf ft Spoke nipple rear wheel M5 5 6 Nm 3 7 4 4 lbf ft Torque wrench with various accessories in set 58429094000...

Страница 81: ...rk Disconnect negative cable 1 of the battery Pull back the positive terminal cover 2 and disconnect the positive plus cable of the battery Detach rubber band 3 at the bottom Lift the battery up and o...

Страница 82: ...with a high charging current shortens 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...

Страница 83: ...w 1 S00046 10 Lift rear fairing 2 slightly and pull starter relay 3 out of the holder 101397 10 Remove protection caps 4 Remove the faulty main fuse 5 Info A defective fuse can be identified by the bu...

Страница 84: ...10 A spare fuses Info A defective fuse can be identified by the burned out fuse wire A Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the...

Страница 85: ...ask with headlight 101401 10 Switch off all electrical equipment Remove screw 1 and take off clamp Loosen the rubber band 2 Push up the headlight mask and swing it forwards C00124 11 Pull out the elec...

Страница 86: ...the reflector 100862 10 Press headlight bulb 3 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 106 Insert the...

Страница 87: ...he height of the center of the low beam headlight Make another mark a distance B under the first mark Guideline Distance B 5 cm 2 in Position the vehicle vertically a distance A away from the wall Gui...

Страница 88: ...ew battery with the label facing upward Speedometer battery CR 2430 p 106 Check the O ring of the protection cap for correct seating 101407 10 Position protection cap 2 and turn all the way clockwise...

Страница 89: ...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 Avoid contact between coolant and skin eyes...

Страница 90: ...l does not meet specifications Correct the coolant level Alternative 1 Coolant p 109 Alternative 2 Coolant mixed ready to use p 109 Mount the radiator cap 15 4 Draining the coolant x Warning Danger of...

Страница 91: ...ap and water If coolant is swallowed contact a doctor immedi ately Change clothes that have come into contact with coolants Keep coolant out of the reach of children 601630 10 Main work Make sure that...

Страница 92: ...lebar 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 x p 90 16 2 Adjusting the play in the throttle cable x Pr...

Страница 93: ...10 Sit on the vehicle in the riding position and determine the distance A between the upper edge of your boot and the shift lever Gap between the shift lever and the top of the boot 10 20 mm 0 39 0 79...

Страница 94: ...16 TUNING THE ENGINE 92 Mount and tighten the screw Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243...

Страница 95: ...10 Clean the plug in connection 1 of the fuel line thoroughly with compressed air Info Under no circumstances should dirt enter into the fuel line Dirt clogs the injection valve Disconnect the plug i...

Страница 96: ...stipulated in applicable regulations Info Drain the engine oil only when the engine is warm Preparatory work Park the motorcycle on a level surface C00065 10 Main work Place a suitable container under...

Страница 97: ...lter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing area C00072 10 Lay the motorcycle on its side and fill the oil filter housing to...

Страница 98: ...ture wear to the engine S00042 10 Remove the oil filler plug 1 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 109 Altern...

Страница 99: ...and then clean with a paintbrush Motorcycle cleaner p 111 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry vehicle always rinse with...

Страница 100: ...rake system Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts are cooled down and while t...

Страница 101: ...il and oil filter and clean the oil screens x p 94 Check the antifreeze and coolant level p 87 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel addit...

Страница 102: ...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 tool x Engine does not spee...

Страница 103: ...age Read out the fault memory using the KTM diag nostics tool x High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary Engine oil level too high Check...

Страница 104: ...al 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 in...

Страница 105: ...32 3rd gear 19 28 4th 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 type Kokusan Spark plug...

Страница 106: ...t 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 M6x55 10 Nm 7 4 lbf ft Oi...

Страница 107: ...t 22 4 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 Suspension travel Rear 335 mm 13 19...

Страница 108: ...V 5 W 22 6 Tires Front tires Rear tires 80 100 21 M C 51M TT MAXXIS MAXX CROSS SI 140 80 18 M C 70R TT MAXXIS MAXX ENDURO Additional information is available in the Service section under http www ktm...

Страница 109: ...N mm 434 lb in Spring length 250 mm 9 84 in Gas pressure 10 bar 145 psi Static sag 33 35 mm 1 3 1 38 in Riding sag 105 115 mm 4 13 4 53 in Fitted length 417 mm 16 42 in Damper oil Shock absorber oil...

Страница 110: ...f ft Loctite 2701 Screw top steering stem M8 20 Nm 14 8 lbf ft Screw top triple clamp M8 20 Nm 14 8 lbf ft Engine attachment bolt M10 60 Nm 44 3 lbf ft Remaining nuts chassis M10 45 Nm 33 2 lbf ft Rem...

Страница 111: ...rrosion inhibitor antifreeze 50 distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Supplier Motorex COOLANT G48 Engine oil SAE 10W 60 00062010035 According to JASO T903 MA p 113 SAE p 113...

Страница 112: ...ideline Use only oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN...

Страница 113: ...s Motorex products Supplier Motorex Protect Shine Fuel additive Guideline KTM recommends Motorex products Supplier Motorex Fuel Stabilizer High viscosity grease Guideline KTM recommends SKF products S...

Страница 114: ...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 Supp...

Страница 115: ...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...

Страница 116: ...checking 59 Chassis number 14 Clutch fluid level checking correcting 64 fluid changing 64 Clutch lever 16 basic position adjusting 64 Compression damping fork adjusting 42 Compression damping high sp...

Страница 117: ...ter 25 L Light switch 16 Lower triple clamp installing 49 removing 48 M Main fuse changing 81 Main silencer glass fiber yarn filling changing 55 installing 55 removing 55 Motorcycle cleaning 97 raisin...

Страница 118: ...wingarm checking 62 T Technical data capacities 105 chassis 105 chassis tightening torques 107 electrical system 106 engine 103 engine tightening torques 103 fork 106 shock absorber 107 tires 106 Thro...

Страница 119: ...3211868en 3211868en 07 2012 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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