KTM 500 EXC EU 2013 User Manual

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REPAIR

MANUAL

2013

''l'MWI:ii~8ijIIM

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

EXC

USA

500

XC-W

USA

Art.

no.

32D6152en

Table of Contents

Default Chapter2
- Table of Contents2
1 Means of Representation6
- Symbols Used6
- Formats Used6
2 SAFETY Advice7
- Repair Manual7
- Degrees of Risk and Symbols7
- Work Rules7
3 Important Notes8
- Guarantee, Warranty8
- Operating and Auxiliary Substances8
- Spare Parts, Accessories8
- Figures8
4 Serial Numbers9
- Chassis Number9
- Type Label9
- Key Number10
- Engine Number10
- Fork Part Number10
- Shock Absorber Part Number10
5 Motorcycle12
- Raising the Motorcycle with the Lift Stand12
- Removing the Motorcycle from the Lift Stand12
- Starting12
- Starting the Motorcycle for a Check13
- Adjusting the Compression Damping of the Fork14
- Adjusting the Rebound Damping of the Fork14
- Adjusting the Spring Preload of the Fork14
6 Fork, Triple Clamp15
- Bleeding Fork Legs15
- Cleaning the Dust Boots of the Fork Legs15
- Exc Eu/Aus/Usa, XC-W16
- Loosening the Fork Protector16
- Positioning the Fork Protection16
- Removing the Fork Legs16
- Installing the Fork Legs17
- Removing the Fork Protector17
- Installing the Fork Protector18
- Performing a Fork Service18
- Disassembling the Fork Legs18
- Cartridge Disassembly21
- Disassembling the Compression Damping Fitting23
- Checking the Fork Legs23
- Assembling the Compression Damping Fitting25
- Assembling the Cartridge25
- Assembling the Fork Legs27
- Greasing the Steering Head Bearing31
- Removing the Lower Triple Clamp31
- Installing the Lower Triple Clamp32
- Checking the Steering Head Bearing Play34
  - Adjusting the Play of the Steering Head Bearing34
- Exc Six Days35
- Adjusting the Compression Damping of the Fork35
- Adjusting the Rebound Damping of the Fork35
- Bleeding Fork Legs35
- Cleaning the Dust Boots of the Fork Legs36
- Loosening the Fork Protector36
- Positioning the Fork Protection37
- Removing the Fork Legs37
- Installing the Fork Legs37
- Removing the Fork Protector38
- Installing the Fork Protector38
- Performing a Fork Service38
- Disessembling the Fork Legs39
- Removing the Spring41
- Disassembling the Cartridge42
- Disassembling the Piston Rod43
- Disassembling the Hydrostop Unit44
- Disassembling the Seal Ring Retainer44
- Checki Ng the Fork Legs45
  - Assembling the Seal Ring Retainer46
- Assembling the Hydrostop Unit46
- Assembling the Piston Rod47
- Assembling the Cartridge48
  - Assembling the Fork Legs49
- Greasing the Steering Head Bearing53
  - Removing the Lower Triple Clamp53
  - Installing the Lower Triple Clamp54
  - Bearing54
- Checking the Steering Head Bearing Play55
7 Handlebar, Controls57
- Handlebar Position57
- Adjusting Handlebar Position57
- Adjusting the Basic Position of the Clutch Lever57
- Checking the Throttle Cable Routing58
- Checking the Play in the Throttle Cable58
- Adjusting the Play in the Throttle Cable59
8 Frame61
- Removing the Engine Guard61
  - EXC Ausl61
- Installing the Engine Guard61
9 Shock Absorber, Swingarm62
- Adjusting the High-Speed Compression Damping of the Shock Absorber62
- Adjusting the Low-Speed Compression Damping of the Shock Absorber62
- Adjusting the Rebound Damping of the Shock Absorber63
- Measuring Rear Wheel Sag Unloaded63
- Checking the Static Sag of the Shock Absorber63
- Checking the Riding Sag of the Shock Absorber64
  - Absorber65
- Adjusting the Riding Sag65
- Removing the Shock Absorber65
- Installing the Shock Absorber65
- Servicing the Shock Absorber66
- Removing the Spring66
- Disassembling the Damper67
- Disassembling the Piston Rod68
- Disassembling the Seal Ring Retainer69
- Replacing the Pilot Bushing70
- Checking the Damper71
- Disassembling the Rebound Adjuster71
- Removing the Heim Join72
- Installing the Heim Join73
- Assembling the Rebound Adjuster74
- Assembling the Seal Ring Retainer74
- Assembling the Piston Rod75
- Assembling the Damper76
- Bleeding and Filling the Damper79
- Filling the Damper with Nitrogen81
- Installing the Spring82
- Changing the Heim Joint83
10 Exhaust85
- Removing the Manifold85
- Installing the Manifold85
- Removing Main Silencer86
- Installing the Main Silencer86
- Changing the Glass Fiber Yarn Filling of the Main Silencer86
11 Air Filter88
- Removing the Air Filter Box Lid88
- Installing the Air Filter Box Lid88
- Removing the Air Filter88
- Installing the Air Filter88
- Cleaning the Air Filter and Air Filter Box89
- Opening Filler Cap90
- Closing Filler Cap90
- Removing the Seat90
12 Fuel Tank, Seat, Trim91
- Mounting the Sea91
- Removing the Fuel Tank91
- Installing the Fuel Tank92
- Changing the Fuel Screen93
- Changing the Fuel Filter94
- Changing the Fuel Pump96
- Checking the Fuel Pressure97
13 Mask, Fender99
- Removing the Front Fender99
- Installing the Front Fender99
- Removing Headlight Mask with Headligh99
- Headlight99
14 Wheels101
- Checking the Tire Air Pressure101
- Checking the Tire Condition101
- Checking the Brake Discs102
- Checking Spoke Tension102
- Front Wheel103
- Removing the Front Wheel103
- Installing the Front Wheel103
- Removing the Front Brake Disc104
- Installing the Front Brake Disc104
- Rear Wheel104
- Removing the Rear Wheel104
- Installing the Rear Wheel105
- Removing the Rear Brake Disc106
- Installing the Rear Brake Disc106
- Checking the Chain Tension107
- Adjusting the Chain Tension107
- Adjusting the Chain Guide108
- Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide108
- Checking for Chain Dirt Accumulation110
- 14.6.10 Cleaning the Chain110
15 WIRING HARNESS, Battery112
- Changing the Main Fuse112
- Changing the Fuses of Individual Power Consumers113
- Changing the Fuse of the Radiator Fan113
- Removi Ng the Battery114
- Installing the Battery115
- Charging the Battery115
16 Brake System117
- Checking the Front Brake Linings117
- Changing the Front Brake Linings117
- Checking Free Travel of Hand Brake Lever119
  - Brake Lever (All XC-W Models)119
- Adjusting Free Travel of Hand Brake Lever (All EXC Models)119
- Checking the Front Brake Fluid Level120
- Adding Front Brake Fluid120
- Changing the Front Brake Fluid121
- Checking the Rear Brake Linings122
- Changing the Rear Brake Linings122
- Checking the Free Travel of Foot Brake Lever124
- Adjusting the Basic Position of the Foot Brake Lever124
- Checking the Rear Brake Fluid Level125
- Adding Brake Fluid to the Rear Brake Circui125
- Changing the Rear Brake Fluid126
17 Lighting System, Instruments128
- Adjusting the Speedometer Functions128
- Setting Kilometers or Miles128
- Activating the Additional Functions129
- Setting the Wheel Circumference129
- Setting the Clock130
- Checking the Headlight Setting131
- Adjusting the Headlight Range131
18 Engine132
- Removing the Engine132
- Installing the Engine136
- Engine Disassembly140
- Preparations140
- Draining the Engine Oil140
- Removing the Clutch Push Rod141
- Removing the Oil Filter141
- Removing the Starter Motor141
- Removing the Spark Plug141
- Removing the Valve Cover142
- Removing the Alternator Cover142
- Positioning the Engine at Ignition Top Dead Center142
  - Removing the Timing Chain Tensioner143
- Removing the Camshaft143
- Removing the Cylinder Head144
- Removing the Piston144
- Removing the Rotor144
- Removing the Timing Chain Guide Rail145
- Removing the Timing Chain Tensioning Rail145
- Removing the Timing Chain Securing Guide145
- Removing the Timing Chain145
- Removing the Ignition Pulse Generator145
- Removing the Suction Pump146
- Removing the Water Pump Cover146
- Removing the Clutch Cover146
- Removing the Clutch Discs147
- Removing the Primary Gear Nut148
- Removing the Outer Clutch Hub148
- Removing the Torque Limiter149
- Removing the Starter Idler Gear149
- Removing the Kickstarter Idler Gear149
- Removing the Shift Shaft149
- Removing the Shift Drum Locating Unit150
- Removing the Locking Lever150
- Removing the Oil Pump Gear Wheels150
- Removing the Force Pump151
- Removing the Primary Gear151
- Removing the Free Wheel Gear151
- Removing the Left Engine Case Section151
- Removing the Shift Rails152
- Removing the Shift Drum152
- Removing the Shift Lorks153
- Removing the Transmission Shafts153
- Removing the Crankshaft153
- Work on Individual Parts154
- Work on the Right Section of the Engine Case154
- Work on the Left Section of the Engine Case155
- Removing the Oil Pressure Regulator Valve156
- Checking Spring Length of Oil Pressure Regulator Valve156
  - Installing the Oil Pressure Regulator Valve157
  - Removing the Crankshaft Seal Ring in the Clutch Cover157
- Installing the Crankshaft Seal Ring in the Clutch Cover157
- Removing the Water Pump157
- Installing the Water Pump158
  - Removing the Timing Chain Sprocket159
  - Installing the Timing Chain Sprocket159
  - Changing the Connecting Rod, Conrod Bearing. and Crank Pin159
- 18.4.13 Checking Crankshaft Run-Out at Bearing Pin161
- Cylinder - Nikasil" Coating161
- Checking/Measuring the Cylinder161
- Checking/Measuring the Piston162
- Checking the Piston Ring End Gap162
- 18.4.18 Measuring the Piston/Cylinder Mounting Clearance163
- Checking the Oil Pumps163
- 18.4.20 Disassembling the Autodecompressor163
- Assembling the Autodecompressor164
- Checking Camshaft165
- Checking the Timing Assembly165
- Removing the Rocker Arm166
- Removing the Valves166
- Changing Camshaft Bearing167
- Checking the Valves167
- Checking Valve Springs168
- Checking Valve Spring Seal168
- Checking the Cylinder Head168
- Checking the Rocker Arm Shafts169
- Installing the Valves169
- Install I Ng the Rocker Arm170
  - Checking the Clutch170
  - 18.4.35 Checking the Shift Mechanism172
  - Preassembling the Shift Shaft173
  - Disassembling the Main Shaft173
  - Assembling the Main Shaft174
  - Disassembling the Countershaft175
  - Assembling the Countershaft175
  - Checking the Transmission176
  - Premountingthe Kickstarter Shaft178
  - 18.4.43 Checking the Starter Drive179
  - Removing the Ireewheel179
  - Checking the Freewheel180
  - Installing the Free Wheel180
  - Engine Assembly181
  - Installing the Crankshaft181
  - Installing the Transmission Shafts181
  - Installing the Shift Lorks181
  - Installing the Shift Drum182
  - Installing the Shift Rails182
  - Installing the Left Engine Case182
  - Installing the Free Wheel Gear183
  - Installing the Primary Gear183
  - Installing the Lorce Pump183
  - 18.5.10 Installing the Oil Pump Gear Wheels184
  - Installing the Locking Lever184
  - Installing the Shift Drum Locating Unit184
  - 18.5.13 Installing the Shift Shaft185
  - Installing the Kickstarter Idler Gear185
  - Installing the Kickstarter Shaft185
  - Installing the Starter Idler Gear185
  - 18.5.17 Installing the Torque Limiter186
  - Installing the Outer Clutch Hub186
  - 18.5.19 Installing the Primary Gear Nut187
  - Installing the Clutch Discs187
  - Installing the Clutch Cover188
  - 18.5.22 Installing the Water Pump Cover189
  - 18.5.23 Installing the Suction Pump189
  - 18.5.24 Installing the Ignition Pulse Generator190
  - 18.5.25 Installing the Timing Chain190
  - 18.5.28 Installing the Timing Chain Securing Guide190
  - Installing the Timing Chain Tensioning Rail191
  - Installing the Timing Chain Guide Rail191
  - 18.5.29 Installing the Rotor191
  - Installing the Piston191
  - Installing the Cylinder Head193
  - 18.5.32 Installing the Camshaft194
  - Installing the Timing Chain Tensioner194
  - Checking the Valve Clearance194
  - Adjusting the Valve Clearance195
  - Installing the Alternator Cover195
  - Installing the Valve Cover196
  - Installing the Spark Plug196
  - Installing the Starter Motor196
  - Installing the Oil Filter196
  - 18.5.41 Installing the Clutch Push Rod197
  - Installing the Oil Screen197
  - Removing the Engine Lrom the Engine Assembly Stand198
19 Clutch199
- Checking/Correcting the Fluid Level of the Hydraulic Clutch199
- Changing the Hydraulic Clutch Fluid199
20 Water Pump, Cooling System201
- Cooling System201
- Checking the Antifreeze and Coolant Level201
- Checking the Coolant Level202
- Draining the Coolanl202
- Refilling Coolant203
21 LUBRICATION System204
- Oil Circui204
- Checking the Engine Oil Level204
- Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens204
- Adding Engine Oil207
- Checking the Engine Oil Pressure208
22 IGNITION System209
- Ignition Coil - Checking the Secondary Winding209
- Checking the Spark Plug Connector209
- Alternator - Checking the Stator Winding209
- Removing the Stator210
- Installing the Stator210
23 Electric Starter211
- Checking the Starter Motor211
24 THROTILE VALVE Body212
- Adjusting the Idle Speed212
- Throttle Position Sensor Circuit a - Checking212
- Throttle Position Sensor - Adjusting the Basic Settings212
25 Technical Data214
- Engine214
- Engine Tolerance, Wear Limits214
- Engine Tightening Torques215
- Capacities217
- Engine Oil217
- Coolant217
- Fuel217
- Chassis217
- Electrical System218
- Tires218
- Fork219
- EXC Euiaus/Usa, XC-W219
- EXC SIX Days219
- Shock Absorber220
- Chassis Tightening Torques220
26 Cleaning, Care222
- Cleaning the Motorcycle222
- Checks and Maintenance Steps for Winter Operation223
27 Storage224
- Preparing for Use after Storage224
28 Service Schedule225
- Service Work (as Additional Order)226
29 Wiring Diagram228
- EXC EU, EXC SIX Days)228
- Exc Eu, Exc Six Days)230
- Exc Eu, Exc Six Days)232
- Exc Eu, Exc Six Days)234
- Exc Eu, Exc Six Days)236
- Exc Eu, Exc Six Days)238
- Exc Eu, Exc Six Days)240
  - Exc Eu, Exc Six Days)242
- Exc Aus)244
  - Exc Aus)246
- Exc Aus)248
  - Exc Aus)250
  - Exc Aus)252
- Exc Aus)254
  - Exc Aus)256
- Exc Aus)258
30 Substances290
31 Auxiliary Substances292
32 Special Tools294
33 Standards308
- Index309

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KTM 500 EXC EU 2013 Specifications

General

Engine Type	Single-cylinder, 4-stroke
Displacement	510.4 cc
Bore x Stroke	95 mm x 72 mm
Transmission	6-speed
Fuel System	Electronic Fuel Injection (EFI)
Starter	Electric starter
Fuel Tank Capacity	9.5 liters
Front Suspension	WP USD 48 mm
Rear Suspension	WP monoshock
Front Brake	Disc brake
Rear Brake	240 mm disc

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