KTM 500 EXC AUS User Manual

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OWNER'S MANUAL 2014

450 EXC EU

450 EXC AUS

450 EXC SIX DAYS EU

450 XC-W USA

500 EXC EU

500 EXC AUS

500 EXC SIX DAYS EU

500 XC-W USA

Art. no. 3213037en

Table of Contents

Default Chapter4
- Table of Contents4
1 Means of Representation7
- Symbols Used7
- Formats Used7
2 Safety Advice8
- Use Definition - Intended Use8
- Degrees of Risk and Symbols8
- Tampering Warning8
- Safe Operation9
- Protective Clothing9
- Work Rules9
- Environment9
- Owner's Manual10
3 Important Notes11
- Guarantee, Warranty11
- Operating and Auxiliary Substances11
- Spare Parts, Accessories11
- Service11
- Figures11
- Customer Service11
4 View of Vehicle12
- View of Vehicle, Front Left (Example)12
- View of Vehicle, Rear Right (Example)13
5 Serial Numbers14
- Chassis Number14
- Type Label14
- Key Number (All EXC Models)14
- Engine Number14
- Fork Part Number14
- Shock Absorber Part Number15
6 Controls16
- Clutch Lever16
- Hand Brake Lever16
- Throttle Grip16
- Kill Switch (All EXC Models)16
- Kill Switch (All XC-W Models)16
- Horn Button (All EXC Models)17
- Light Switch (All EXC Models)17
- Light Switch (All XC-W Models)17
- Turn Signal Switch (All EXC Models)17
- Emergency off Switch (EXC AUS)17
- Electric Starter Button (EXC AUS)18
- Electric Starter Button (EXC EU, EXC SIX DAYS, XC-W)18
- Overview of Indicator Lamps (EXC EU, EXC AUS)18
- Overview of Indicator Lamps (EXC SIX DAYS)18
- Overview of Indicator Lamps (All XC-W Models)18
- Opening Filler Cap19
- Closing Filler Cap19
- Idle Speed Adjusting Screw20
- Shift Lever20
- Kick Starter20
- Foot Brake Lever21
- Side Stand21
- Steering Lock (All EXC Models)21
- Locking the Steering (All EXC Models)21
- Unlocking the Steering (All EXC Models)22
7 Speedometer23
- EXC EU, EXC AUS, All XC-W Models23
- Speedometer Overview23
- Activation and Test23
- Setting Kilometers or Miles23
- Adjusting the Speedometer Functions24
- Setting the Clock24
- Querying Lap Time24
- Display Mode SPEED (Speed)25
- Display Mode SPEED/H (Service Hours)25
- Setup Menu25
- Unit of Measurement Menu26
- Display Mode SPEED/CLK (Time)26
- Setting the Clock26
- Display Mode SPEED/LAP (Lap Time)27
- Viewing the Lap Time27
- Display Mode SPEED/ODO (Odometer)27
- Display Mode SPEED/TR1 (Trip Master 1)27
- Display Mode SPEED/TR2 (Trip Master 2)28
- Setting TR2 (Trip Master 2)28
- Display Mode SPEED/A1 (Average Speed 1)28
- Display Mode SPEED/A2 (Average Speed 2)29
- Display Mode SPEED/S1 (Stop Watch 1)29
- Display Mode SPEED/S2 (Stop Watch 2)29
- Table of Functions29
- Table of Conditions and Menu Activation30
- Exc Six Days30
- Speedometer Overview30
- Activation and Test31
- Setting Kilometers or Miles31
- Setting the Speedometer Functions31
- Setting the Clock32
- Viewing the Lap Time32
- Display Mode SPEED (Speed)33
- Display Mode SPEED/H (Service Hours)33
- Setup Menu33
- Setting the Unit of Measurement34
- Display Mode SPEED/CLK (Time)34
- Setting the Clock34
- Display Mode SPEED/LAP (Lap Time)35
- Viewing the Lap Time35
- Display Mode SPEED/ODO (Odometer)35
- Display Mode SPEED/TR1 (Trip Master 1)35
- Display Mode SPEED/TR2 (Trip Master 2)36
- Setting TR2 (Trip Master 2)36
- Display Mode SPEED/A1 (Average Speed 1)36
- Display Mode SPEED/A2 (Average Speed 2)37
- Display Mode SPEED/S1 (Stop Watch 1)37
- Display Mode SPEED/S2 (Stop Watch 2)37
- Table of Functions38
- Table of Conditions and Menu Activation39
8 Preparing for Use40
- Advice on First Use40
- Running-In the Engine41
- Preparing the Vehicle for Difficult Riding Conditions41
- Preparing for Rides on Dry Sand42
- Preparing for Rides on Wet Sand42
- Preparing for Rides on Wet and Muddy Surfaces43
- Preparing for Rides at High Temperature and Slow Speed43
- Preparing for Rides at Low Temperature or in Snow43
9 Riding Instructions44
- Checks and Maintenance Work When Preparing for Use44
- Starting44
- Starting off45
- Shifting, Riding45
- Braking45
- Stopping, Parking46
- Transport46
- Refueling47
10 Service Schedule48
- Service Work (as Additional Order)49
11 Tuning the Chassis50
- Checking the Basic Suspension Setting against the Rider's Weight50
- Compression Damping of Shock Absorber50
- Adjusting the Low-Speed Compression Damping of the Shock Absorber50
- Adjusting the High-Speed Compression Damping of the Shock Absorber51
- Adjusting the Rebound Damping of the Shock Absorber51
- Measuring Rear Wheel Sag Unloaded52
- Checking the Static Sag of the Shock Absorber52
- Checking the Riding Sag of the Shock Absorber52
- Adjusting the Spring Preload of the Shock Absorber53
- Adjusting the Riding Sag53
- Checking Basic Setting of Fork54
- Adjusting the Compression Damping of the Fork54
- Adjusting the Rebound Damping of the Fork55
- Adjusting the Spring Preload of the Fork (EXC EU, EXC AUS, All XC-W Models)56
- Handlebar Position56
- Adjusting Handlebar Position56
12 Service Work on the Chassis58
- Raising the Motorcycle with the Lift Stand58
- Removing the Motorcycle from the Lift Stand58
- Bleeding Fork Legs58
- Cleaning the Dust Boots of the Fork Legs58
- Loosening the Fork Protector59
- Positioning the Fork Protector59
- Removing the Fork Legs59
- Installing the Fork Legs60
- Removing the Fork Protector61
- Installing the Fork Protector61
- Removing the Lower Triple Clamp (EXC EU, EXC AUS, All XC-W Models)61
- Removing the Lower Triple Clamp (EXC SIX DAYS)62
- Installing the Lower Triple Clamp (EXC EU, EXC AUS, All XC-W Models)63
- Installing the Lower Triple Clamp (EXC SIX DAYS)65
- Checking the Steering Head Bearing Play66
- Adjusting the Play of the Steering Head Bearing (EXC EU, EXC AUS, All XC-W Models)67
- Adjusting the Play of the Steering Head Bearing (EXC SIX DAYS)67
- Greasing the Steering Head Bearing68
- Removing the Front Fender68
- Installing the Front Fender68
- Removing the Shock Absorber69
- Installing the Shock Absorber69
- Removing the Seat69
- Mounting the Seat70
- Removing the Air Filter Box Lid70
- Installing the Air Filter Box Lid70
- Removing the Air Filter70
- Installing the Air Filter71
- Cleaning the Air Filter and Air Filter Box71
- Sealing the Air Filter Box72
- Removing Main Silencer72
- Installing the Main Silencer72
- Changing the Glass Fiber Yarn Filling of the Main Silencer72
- Removing the Fuel Tank73
- Installing the Fuel Tank74
- Checking for Chain Dirt Accumulation75
- Cleaning the Chain76
- Checking the Chain Tension76
- Adjusting the Chain Tension77
- Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide77
- Checking the Frame79
- Checking the Swingarm79
- Checking the Throttle Cable Routing79
- Checking the Rubber Grip80
- Additionally Securing the Rubber Grip80
- Adjusting the Basic Position of the Clutch Lever80
- Checking/Correcting the Fluid Level of the Hydraulic Clutch81
- Changing the Hydraulic Clutch Fluid81
- Removing the Engine Guard (EXC SIX DAYS, EXC AUS)82
- Installing the Engine Guard (EXC SIX DAYS, EXC AUS)82
13 Brake System83
- Checking Free Travel of Hand Brake Lever83
- Adjusting Free Travel of Hand Brake Lever (All EXC Models)83
- Adjusting the Basic Position of the Hand Brake Lever (All XC-W Models)83
- Checking the Brake Discs84
- Checking the Brake Fluid Level of the Front Brake84
- Adding Front Brake Fluid84
- Checking the Front Brake Linings85
- Changing the Front Brake Linings86
- Checking the Free Travel of Foot Brake Lever87
- Adjusting the Basic Position of the Foot Brake Lever87
- Checking the Rear Brake Fluid Level88
- Adding Rear Brake Fluid88
- Checking the Rear Brake Linings89
- Changing the Rear Brake Linings90
14 Wheels, Tires92
- Removing the Front Wheel92
- Installing the Front Wheel92
- Removing the Rear Wheel93
- Installing the Rear Wheel94
- Checking the Tire Condition94
- Checking the Tire Air Pressure95
- Checking Spoke Tension95
15 Electrical System97
- Removing the Battery97
- Installing the Battery97
- Charging the Battery98
- Changing the Main Fuse99
- Changing the Fuses of Individual Power Consumers100
- Removing Headlight Mask with Headlight100
- Refitting the Headlight Mask with the Headlight101
- Changing the Headlight Bulb101
- Changing the Turn Signal Bulb102
- Checking the Headlight Setting102
- Adjusting the Headlight Range103
- Changing the Speedometer Battery103
16 Cooling System105
- Checking the Antifreeze and Coolant Level105
- Checking the Coolant Level105
- Draining the Coolant106
- Refilling Coolant106
17 Tuning the Engine108
- Checking the Play in the Throttle Cable108
- Adjusting the Play in the Throttle Cable108
- Adjusting the Idle Speed109
- Checking the Basic Position of the Shift Lever109
- Adjusting the Basic Position of the Shift Lever109
18 Service Work on the Engine110
- Changing the Fuel Screen110
- Checking the Engine Oil Level110
- Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens111
- Adding Engine Oil113
19 Cleaning, Care114
- Cleaning the Motorcycle114
- Checks and Maintenance Steps for Winter Operation115
20 Storage116
- Preparing for Use after Storage116
21 Troubleshooting117
22 Blink Code119
23 Technical Data121
- Engine121
- Engine Tightening Torques121
- Capacities123
- Capacity - Engine Oil123
- Capacity - Coolant123
- Capacity - Fuel123
- Chassis123
- Electrical System124
- Tires124
- Fork124
- EXC EU, EXC AUS, All XC-W Models124
- Exc Six Days125
- Shock Absorber125
- Chassis Tightening Torques126
24 Substances128

Questions and Answers:

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KTM 500 EXC AUS Specifications

General

Bore x Stroke	95 mm x 72 mm
Transmission	6-speed
Seat Height	960 mm
Starter	Electric starter
Ground Clearance	355 mm
Cooling System	Liquid cooled
Rear Suspension	WP Xplor PDS shock absorber
Rear Brake	Disc brake
Engine Type	1-cylinder, 4-stroke engine
Power	Not available
Torque	Not available
Fuel System	Electronic fuel injection (Keihin EMS)
Front Suspension	WP Xplor 48 upside-down fork
Frame	Central double-cradle type 25CrMo4 steel
ABS	No

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