KTM 500 EXC SIX DAYS EU User Manual (English)

Questions and Answers:

I
Isabella WellsAug 23, 2025
What to do if my KTM 500 EXC SIX DAYS EU engine turns but does not start?
- R
  Randy FloresAug 23, 2025
  If your KTM Motorcycle engine turns but does not start, ensure you are following the correct start procedure. Check that the fuel hose connection is properly joined. Also, blown fuses 1 or 2 can cause this issue, so replace the fuses of individual power consumers. A spark plug that is oily or wet can also prevent starting, so clean and dry the spark plug, or replace it if necessary. Finally, verify that the electrode distance (plug gap) of the spark plug is correctly adjusted to 0.9 mm (0.035 in).
R
Robert BurgessAug 25, 2025
What to do if my KTM 500 EXC SIX DAYS EU Motorcycle engine dies during the trip?
- C
  claudia03Aug 26, 2025
  If your KTM Motorcycle engine dies during the trip, first check if you are lacking fuel and refuel if necessary. Also, inspect the coolant level in the cooling system and check for leaks.
K
Kelly WalkerAug 27, 2025
Why does my KTM 500 EXC SIX DAYS EU engine not speed up?
- J
  jessicaclayAug 27, 2025
  If your KTM Motorcycle engine does not speed up, the fuel injection system may be defective. Read out the fault memory using the KTM diagnostics tool. Alternatively, the ignition system may be defective, requiring you to check the secondary winding of the ignition coil, the spark plug connector, and the stator winding of the alternator.
A
Amber NguyenAug 28, 2025
How to fix a KTM 500 EXC SIX DAYS EU Motorcycle when the engine cannot be cranked?
- J
  jennifer27Aug 28, 2025
  If the engine of your KTM Motorcycle cannot be cranked using the electric starter, ensure that you are following the correct start procedure. If the battery is discharged, charge it. Also, check if the main fuse is blown and replace it if necessary.
J
Jennifer TorresAug 29, 2025
How to fix KTM 500 EXC SIX DAYS EU engine overheating?
- S
  scottfloresAug 29, 2025
  If your KTM Motorcycle engine is overheating, start by checking the coolant level in the cooling system for leaks. Ensure there's sufficient airflow, and switch off the engine when stationary. Clean any dirt from the radiator fins. If you notice foam formation in the cooling system, drain and refill the coolant. Inspect the radiator hose for bends and replace if needed. A defective thermostat can also cause overheating, so check it, noting that the opening temperature should be 70 °C (158 °F). Lastly, verify the radiator fan system, including the radiator fan fuse (Fuse 4) and the fan itself.
M
melody60Aug 31, 2025
What to do if the FI warning lamp (MIL) lights up on my KTM Motorcycle?
- R
  Rose CostaAug 31, 2025
  If the FI warning lamp (MIL) lights up or flashes on your KTM Motorcycle, stop the motorcycle and use the blink code to identify the faulty part. Also, inspect the cabling for any damage and check the electrical plug-in connections for corrosion and damage. It may be necessary to read out the fault memory using the KTM diagnostics tool.
J
john16Sep 1, 2025
Why does my KTM Motorcycle have high oil consumption?
- S
  Sharon CollinsSep 1, 2025
  If your KTM Motorcycle engine consumes oil at a high rate, check the engine vent hose for bends and correct its routing or replace it if needed. Also, verify that the engine oil level is not too high. If it is, adjust to the correct level. If the engine oil is too thin (low viscosity), replace the engine oil and oil filter, and clean the oil screens.
A
Amber YatesSep 3, 2025
What causes my KTM 500 EXC SIX DAYS EU Motorcycle engine to overheat?
- A
  Alexander WallsSep 3, 2025
  If your KTM Motorcycle engine overheats, it could be due to foam formation in the cooling system. In this case, drain and refill the coolant. A bent radiator hose could also be the cause, requiring replacement of the hose. Another potential issue is a defect in the radiator fan system, so check the radiator fan fuse (fuse 4) and the radiator fan itself.
R
rjonesSep 4, 2025
Why does my KTM 500 EXC SIX DAYS EU engine have too little power?
- A
  achangSep 4, 2025
  If your KTM Motorcycle engine has too little power, the air filter might be heavily contaminated. Clean the air filter and air filter box. Also, a very dirty fuel filter or fuel screen can cause this issue, so replace them. Furthermore, check the exhaust system for leaks or deformation, and replace the glass fiber yarn filling in the main silencer if it's insufficient. Finally, ensure that the valve clearance is properly adjusted.
L
Leslie JonesSep 6, 2025
Why are the speedometer values deleted on my KTM Motorcycle?
- B
  Brian GarciaSep 6, 2025
  If the speedometer values (time, stop watch, lap times) are deleted on your KTM Motorcycle, the battery in the speedometer is likely discharged. Replace the speedometer battery.

KTM 500 EXC SIX DAYS EU Specifications

General

Displacement	510.4 cc
Bore x Stroke	95 mm x 72 mm
Starter	Electric starter
Transmission	6-speed
Front Suspension	WP XPLOR-USD, Ø 48 mm
Seat Height	960 mm
Subframe	Aluminum
Suspension Travel Front	300 mm
Suspension Travel Rear	310 mm
Tires Front	90/90-21
Tires Rear	140/80-18
Engine Type	Single cylinder, 4-stroke
Fuel System	Electronic fuel injection
Cooling	Liquid cooling
Rear Suspension	WP Xplor PDS shock absorber
Front Brake	Disc brake, 260 mm
Rear Brake	Disc brake, 220 mm
Lubrication	Pressure lubrication with 2 oil pumps
Clutch	Wet multi-disc
Ignition	Keihin EMS
Wheels Front	21 inch
Wheels Rear	18 inch
Chain	520
Steering Head Angle	63.5 °
Frame	Central tube frame made of chrome molybdenum steel
Tank Capacity	9 liters
Final Drive	Chain

Summary

1 MEANS OF REPRESENTATION

1.1 Symbols Used

Explains the meaning of symbols used throughout the manual for clarity and safety.

1.2 Formats Used

Describes typographical formats used in the manual for consistent information presentation.

2 SAFETY ADVICE

2.1 Use Definition - Intended Use

Defines the intended use of the motorcycle and compliance with regulations.

2.2 Safety Advice

General safety instructions and warnings to ensure safe operation.

2.3 Degrees of Risk and Symbols

Explains risk levels (Danger, Warning, Caution) and associated symbols.

2.4 Tampering Warning

Warning against tampering with noise control systems and related federal laws.

2.5 Safe Operation

Guidelines for safe operation, including rider impairment and burns precautions.

2.6 Protective Clothing

Emphasizes the importance of wearing appropriate protective clothing for safety.

2.7 Work Rules

Provides rules for performing service work, including tool usage and part replacement.

2.8 Environment

Advice on responsible use and disposal of fluids and components to protect the environment.

2.9 Owner's Manual

Importance of reading the manual and where to get further information.

3 IMPORTANT NOTES

3.1 Guarantee, Warranty

Conditions and procedures for warranty claims and authorized service.

3.2 Operating and Auxiliary Substances

Warnings and guidelines for handling fuel and other operating fluids.

3.3 Spare Parts, Accessories

Recommendations for using approved spare parts and accessories for safety.

3.4 Service

Importance of proper service and maintenance for longevity and performance.

3.5 Figures

Note that manual figures may show special equipment and not always full disassembly.

3.6 Customer Service

Information on contacting authorized KTM dealers for support and information.

4 VIEW OF VEHICLE

4.1 View of Vehicle, Front Left (example)

Illustrates the front-left view of the motorcycle with key components labeled.

4.2 View of Vehicle, Rear Right (example)

Shows the rear-right view of the motorcycle with labeled components and controls.

5 SERIAL NUMBERS

5.1 Chassis Number

Location of the chassis number stamped on the steering head.

5.2 Type Label

Location of the type label affixed to the front of the steering head.

5.3 Key Number (all EXC models)

Location of the key number stamped on the steering lock connector.

5.4 Engine Number

Location of the engine number stamped on the engine casing.

5.5 Fork Part Number

Location of the fork part number stamped on the inner side of the fork stub.

5.6 Shock Absorber Part Number

Location of the shock absorber part number stamped on the absorber body.

6 CONTROLS

6.1 Clutch Lever

Description and function of the clutch lever on the left handlebar.

6.2 Hand Brake Lever

Location and function of the hand brake lever on the right handlebar.

6.3 Throttle Grip

Description and location of the throttle grip on the right handlebar.

6.4 Kill Switch (all EXC models)

Function and states of the kill switch for EXC models.

6.5 Kill Switch (all XC-W models)

Function and states of the kill switch for XC-W models.

6.6 Horn Button (all EXC models)

Location and operation of the horn button for EXC models.

6.7 Light Switch (all EXC models)

Operation of the light switch for different light modes on EXC models.

6.8 Light Switch (all XC-W models)

Operation of the light switch for different light modes on XC-W models.

6.9 Turn Signal Switch (all EXC models)

Operation of the turn signal switch for EXC models.

6.10 Emergency OFF Switch (EXC AUS)

Function and states of the emergency OFF switch for EXC AUS models.

6.11 Electric Starter Button (EXC AUS)

Location and operation of the electric starter button for EXC AUS.

6.12 Electric Starter Button (EXC EU, EXC SIX DAYS, XC-W)

Location and operation of the electric starter button for other EXC/XC-W models.

6.13 Overview of Indicator Lamps (EXC EU, EXC AUS)

Explanation of indicator lamps on the dashboard for EXC EU/AUS models.

6.14 Overview of Indicator Lamps (EXC SIX DAYS)

Explanation of indicator lamps on the dashboard for EXC SIX DAYS models.

6.15 Overview of Indicator Lamps (all XC-W models)

Explanation of indicator lamps on the dashboard for all XC-W models.

6.16 Opening Filler Cap

Safety precautions and procedure for opening the fuel filler cap.

6.17 Closing Filler Cap

Procedure for correctly closing the fuel filler cap.

6.18 Idle Speed Adjusting Screw

Location and function of the idle speed adjusting screw.

6.19 Shift Lever

Location of the shift lever and gear position illustration.

6.20 Kick Starter

Location and operation of the kick starter.

6.21 Foot Brake Lever

Location and function of the foot brake lever for the rear brake.

6.22 Side Stand

Location and use of the side stand for parking the motorcycle.

6.23 Steering Lock (all EXC models)

Location and purpose of the steering lock mechanism.

6.24 Locking the Steering (all EXC models)

Steps for locking the steering using the ignition key.

6.25 Unlocking the Steering (all EXC models)

Steps for unlocking the steering using the ignition key.

7 SPEEDOMETER

7.1 EXC EU, EXC AUS, all XC-W Models Speedometer Functions

Explains overview, activation, testing, and settings for various display modes.

7.2 EXC SIX DAYS Speedometer Functions

Covers overview, activation, testing, and settings for EXC SIX DAYS speedometer.

8 PREPARING FOR USE

8.1 Advice on First Use

Provides essential safety advice and checks before operating the motorcycle for the first time.

8.2 Running-In the Engine

Details guidelines for proper engine break-in to ensure longevity and performance.

8.3 Preparing for Difficult Riding Conditions

Offers advice on preparing the motorcycle for various challenging riding environments.

8.4 Preparing for Rides on Dry Sand

Specific instructions for preparing the motorcycle for riding on dry sandy terrain.

8.5 Preparing for Rides on Wet Sand

Guidelines for preparing the motorcycle for riding on wet sandy terrain.

8.6 Preparing for Rides on Wet and Muddy Surfaces

Advice on preparing the motorcycle for wet and muddy riding conditions.

8.7 Preparing for Rides at High Temperature and Slow Speed

Instructions for preparing the motorcycle for hot weather and slow speed riding.

8.8 Preparing for Rides at Low Temperature or in Snow

Guidance on preparing the motorcycle for cold weather and snowy conditions.

9 RIDING INSTRUCTIONS

9.1 Checks and Maintenance Work When Preparing for Use

Essential checks and maintenance before riding the motorcycle to ensure safety.

9.2 Starting

Step-by-step guide on how to safely start the motorcycle engine.

9.3 Starting Off

Instructions for smoothly engaging first gear and moving off.

9.4 Shifting, Riding

Guidance on gear shifting, throttle control, and general riding techniques.

9.5 Braking

Explains proper braking techniques and potential hazards.

9.6 Stopping, Parking

Procedures for safely stopping and parking the motorcycle.

9.7 Transport

Guidelines for transporting the motorcycle safely.

9.8 Refueling

Instructions and safety precautions for refueling the motorcycle.

10 SERVICE SCHEDULE

10.1 Service Schedule

Outlines regular maintenance intervals and tasks for optimal vehicle upkeep.

10.2 Service Work (as Additional Order)

Lists service tasks that can be performed as additional maintenance.

11 TUNING THE CHASSIS

11.1 Checking Basic Suspension Setting Against Rider's Weight

How to adjust suspension settings based on rider weight for optimal performance.

11.2 Compression Damping of Shock Absorber

Explains the two ranges of shock absorber compression damping.

11.3 Adjusting the Low-Speed Compression Damping of the Shock Absorber

Step-by-step guide to adjust low-speed compression damping on the rear shock absorber.

11.4 Adjusting the High-Speed Compression Damping of the Shock Absorber

How to adjust the high-speed compression damping on the rear shock absorber.

11.5 Adjusting the Rebound Damping of the Shock Absorber

Instructions for adjusting the rebound damping on the rear shock absorber.

11.6 Measuring Rear Wheel Sag Unloaded

Procedure to measure the rear wheel sag when the motorcycle is unloaded.

11.7 Checking the Static Sag of the Shock Absorber

Steps to check the static sag of the rear shock absorber.

11.8 Checking the Riding Sag of the Shock Absorber

How to check the riding sag of the rear shock absorber with rider input.

11.9 Adjusting the Spring Preload of the Shock Absorber

Guide to adjust the spring preload on the rear shock absorber for rider weight.

11.10 Adjusting the Riding Sag

How to adjust the riding sag by selecting or changing the rear spring.

11.11 Checking Basic Setting of Fork

Guidance on checking the basic suspension settings for the front forks.

11.12 Adjusting the Compression Damping of the Fork

Instructions for adjusting the compression damping on the front fork legs.

11.13 Adjusting the Rebound Damping of the Fork

Steps to adjust the rebound damping on the front fork legs for different models.

11.14 Adjusting the Spring Preload of the Fork (EXC EU, EXC AUS, all XC-W models)

Guide to adjust fork spring preload for specific EXC and XC-W models.

11.15 Handlebar Position

Information on handlebar mounting positions and hole distances.

11.16 Adjusting Handlebar Position

Step-by-step process for adjusting the handlebar position.

12 SERVICE WORK ON THE CHASSIS

12.1 Raising the Motorcycle with the Lift Stand

Instructions on how to safely lift the motorcycle using a lift stand.

12.2 Removing the Motorcycle from the Lift Stand

Procedure for safely removing the motorcycle from the lift stand.

12.3 Bleeding Fork Legs

Steps for bleeding the air from the front fork legs.

12.4 Cleaning the Dust Boots of the Fork Legs

Guidance on cleaning the fork dust boots to maintain seal integrity.

12.5 Loosening the Fork Protector

How to loosen and remove the fork protector on the front forks.

12.6 Positioning the Fork Protector

Instructions for correctly positioning and mounting the fork protector.

12.7 Removing the Fork Legs x

Detailed steps for removing the front fork legs from the motorcycle.

12.8 Installing the Fork Legs x

Step-by-step guide for installing the front fork legs on different models.

12.9 Removing the Fork Protector x

How to remove the fork protector from the front fork legs.

12.10 Installing the Fork Protector x

Instructions for installing the fork protector onto the front forks.

12.11 Removing the Lower Triple Clamp x (EXC EU, EXC AUS, all XC-W models)

Steps to remove the lower triple clamp for specific EXC and XC-W models.

12.12 Removing the Lower Triple Clamp x (EXC SIX DAYS)

Procedure to remove the lower triple clamp for EXC SIX DAYS models.

12.13 Installing the Lower Triple Clamp x (EXC EU, EXC AUS, all XC-W models)

Guide to installing the lower triple clamp on specific EXC and XC-W models.

12.14 Installing the Lower Triple Clamp x (EXC SIX DAYS)

Steps to install the lower triple clamp on EXC SIX DAYS models.

12.15 Checking the Steering Head Bearing Play

How to check for play in the steering head bearing for safe handling.

12.16 Adjusting the Play of the Steering Head Bearing x (EXC EU, EXC AUS, all XC-W models)

Procedure to adjust steering head bearing play on specific EXC and XC-W models.

12.17 Adjusting the Play of the Steering Head Bearing x (EXC SIX DAYS)

How to adjust steering head bearing play on EXC SIX DAYS models.

12.18 Greasing the Steering Head Bearing x

Instructions for greasing the steering head bearing for different models.

12.19 Removing the Front Fender

Steps to remove the front fender from the motorcycle.

12.20 Installing the Front Fender

How to install the front fender onto the motorcycle.

12.21 Removing the Shock Absorber x

Detailed steps for removing the rear shock absorber.

12.22 Installing the Shock Absorber x

Guide to installing the rear shock absorber onto the motorcycle.

12.23 Removing the Seat

How to remove the motorcycle seat.

12.24 Mounting the Seat

Instructions for correctly mounting the motorcycle seat.

12.25 Removing the Air Filter Box Lid

Steps to remove the lid of the air filter box.

12.26 Installing the Air Filter Box Lid

How to install the air filter box lid correctly.

12.27 Removing the Air Filter x

Detailed procedure for removing the air filter from the air filter support.

12.28 Installing the Air Filter x

Instructions for installing a clean air filter and securing the air filter box.

12.29 Cleaning the Air Filter and Air Filter Box x

Guide to cleaning the air filter and air filter box properly.

12.30 Sealing the Air Filter Box x

How to seal the air filter box in the marked area.

12.31 Removing Main Silencer

Steps to remove the main silencer from the exhaust system.

12.32 Installing the Main Silencer

How to install the main silencer onto the exhaust system.

12.33 Changing the Glass Fiber Yarn Filling of the Main Silencer x

Procedure to change the glass fiber yarn filling in the main silencer.

12.34 Removing the Fuel Tank x

Detailed steps for safely removing the fuel tank.

12.35 Installing the Fuel Tank x

Instructions for safely installing the fuel tank onto the motorcycle.

12.36 Checking for Chain Dirt Accumulation

How to check the drive chain for dirt accumulation.

12.37 Cleaning the Chain

Steps for properly cleaning the drive chain.

12.38 Checking the Chain Tension

How to check the drive chain tension for correct operation.

12.39 Adjusting the Chain Tension

Procedure to adjust the drive chain tension to specifications.

12.40 Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide

How to check wear on the chain, sprockets, and chain guide.

12.41 Checking the Frame x

How to inspect the motorcycle frame for cracks or deformation.

12.42 Checking the Swingarm x

Procedure to check the swingarm for damage, cracking, or deformation.

12.43 Checking the Throttle Cable Routing

How to check and correct the routing of the throttle cables.

12.44 Checking the Rubber Grip

How to check the rubber grips on the handlebar for wear and security.

12.45 Additionally Securing the Rubber Grip

Steps to further secure the rubber grips using securing wire.

12.46 Adjusting the Basic Position of the Clutch Lever

How to adjust the clutch lever position for hand size.

12.47 Checking/Correcting the Fluid Level of the Hydraulic Clutch

How to check and correct the hydraulic clutch fluid level.

12.48 Changing the Hydraulic Clutch Fluid x

Detailed procedure for changing the hydraulic clutch fluid.

12.49 Removing the Engine Guard (EXC SIX DAYS, EXC AUS)

How to remove the engine guard on specific EXC models.

12.50 Installing the Engine Guard (EXC SIX DAYS, EXC AUS)

Steps to install the engine guard on specific EXC models.

13 BRAKE SYSTEM

13.1 Checking Free Travel of Hand Brake Lever

How to check the free travel of the hand brake lever.

13.2 Adjusting Free Travel of Hand Brake Lever (all EXC models)

Guide to adjust the free travel of the hand brake lever on EXC models.

13.3 Adjusting the Basic Position of the Hand Brake Lever (all XC-W models)

How to adjust the hand brake lever position for hand size on XC-W models.

13.4 Checking the Brake Discs

How to check the thickness and condition of the brake discs.

13.5 Checking the Brake Fluid Level of the Front Brake

Steps to check the brake fluid level in the front brake reservoir.

13.6 Adding Front Brake Fluid x

How to add front brake fluid, including safety precautions.

13.7 Checking the Front Brake Linings

How to check the front brake linings for minimum thickness and wear.

13.8 Changing the Front Brake Linings x

Detailed procedure for changing the front brake linings.

13.9 Checking the Free Travel of Foot Brake Lever

How to check the free travel of the foot brake lever.

13.10 Adjusting the Basic Position of the Foot Brake Lever x

How to adjust the basic position of the foot brake lever.

13.11 Checking the Rear Brake Fluid Level

How to check the brake fluid level in the rear brake reservoir.

13.12 Adding Rear Brake Fluid x

Steps to add rear brake fluid, including safety precautions.

13.13 Checking the Rear Brake Linings

How to check the rear brake linings for minimum thickness and wear.

13.14 Changing the Rear Brake Linings x

Detailed procedure for changing the rear brake linings.

14 WHEELS, TIRES

14.1 Removing the Front Wheel x

Step-by-step guide for removing the front wheel.

14.2 Installing the Front Wheel x

How to install the front wheel, including checks and precautions.

14.3 Removing the Rear Wheel x

Detailed procedure for removing the rear wheel from the swingarm.

14.4 Installing the Rear Wheel x

How to install the rear wheel, including chain and tension checks.

14.5 Checking the Tire Condition

How to check the front and rear tires for cuts, wear, and age.

14.6 Checking the Tire Air Pressure

How to check and adjust tire air pressure for off-road and road use.

14.7 Checking Spoke Tension

How to check and adjust spoke tension for wheel balance and integrity.

15 ELECTRICAL SYSTEM

15.1 Removing the Battery x

Step-by-step guide for safely removing the motorcycle battery.

15.2 Installing the Battery x

How to correctly install the motorcycle battery.

15.3 Charging the Battery x

Instructions for charging the motorcycle battery and maintenance.

15.4 Changing the Main Fuse

How to locate and change the main fuse for the electrical system.

15.5 Changing the Fuses of Individual Power Consumers

How to change fuses for specific electrical components.

15.6 Removing Headlight Mask with Headlight

Steps to remove the headlight mask and headlight assembly.

15.7 Refitting the Headlight Mask with the Headlight

How to reassemble the headlight mask and headlight.

15.8 Changing the Headlight Bulb

Instructions for changing the headlight bulb.

15.9 Changing the Turn Signal Bulb

How to change the turn signal bulbs on the motorcycle.

15.10 Checking the Headlight Setting

Procedure to check and verify the headlight beam alignment.

15.11 Adjusting the Headlight Range

How to adjust the headlight beam range up or down.

15.12 Changing the Speedometer Battery

Steps to replace the battery in the motorcycle speedometer.

16 COOLING SYSTEM

16.1 Cooling System

Overview of how the engine cooling system functions.

16.2 Checking the Antifreeze and Coolant Level

How to check coolant level and antifreeze protection.

16.3 Checking the Coolant Level

Steps to check the coolant level in the radiator.

16.4 Draining the Coolant x

Procedure to drain the coolant from the cooling system.

16.5 Refilling Coolant x

How to refill the cooling system with coolant.

17 TUNING THE ENGINE

17.1 Checking the Play in the Throttle Cable

How to check and adjust the free play in the throttle cable.

17.2 Adjusting the Play in the Throttle Cable x

Step-by-step guide to adjust the throttle cable play.

17.3 Adjusting the Idle Speed x

How to adjust the engine's idle speed.

17.4 Checking the Basic Position of the Shift Lever

How to check the correct position of the shift lever relative to the boot.

17.5 Adjusting the Basic Position of the Shift Lever x

Steps to adjust the basic position of the shift lever.

18 SERVICE WORK ON THE ENGINE

18.1 Changing the Fuel Screen x

How to change the fuel screen for proper fuel delivery.

18.2 Checking the Engine Oil Level

Procedure to check the engine oil level when the engine is at operating temperature.

18.3 Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens x

Detailed guide for changing engine oil, filter, and cleaning oil screens.

18.4 Adding Engine Oil

How to add engine oil, including oil type recommendations.

19 CLEANING, CARE

19.1 Cleaning the Motorcycle

Instructions for cleaning the motorcycle safely and effectively.

19.2 Checks and Maintenance Steps for Winter Operation

Essential checks and maintenance for protecting the motorcycle during winter.

20 STORAGE

20.1 Storage

Guidelines for preparing and storing the motorcycle for longer periods.

20.2 Preparing for Use After Storage

Steps required to get the motorcycle ready after a storage period.

21 TROUBLESHOOTING

Engine Cannot Be Cranked (Electric Starter)

Diagnosing and resolving issues when the engine won't crank via the electric starter.

Engine Cranks But Does Not Start

Troubleshooting steps for when the engine cranks but does not start.

Engine Does Not Accelerate

Diagnosing why the engine fails to accelerate properly.

Low Engine Power

Identifying causes for reduced engine power output.

Engine Stalls During Trip

Troubleshooting steps for when the engine stops running during a trip.

Engine Overheating

Identifying and resolving issues related to engine overheating.

FI Warning Lamp (MIL) Issues

Understanding and addressing the FI warning lamp indicators.

High Engine Oil Consumption

Diagnosing and resolving issues with high engine oil consumption.

Battery Not Charging

Troubleshooting for a discharged battery or charging system issues.

Speedometer Data Loss

Resolving issues with deleted speedometer data.

Lighting System Failures

Troubleshooting for lighting system failures.

Instrument/Control Failures

Diagnosing failures in the speedometer, horn, brake light, turn signal, and fan.

22 BLINK CODE

Blink Code FI Warning Lamp (MIL)

Explains FI warning lamp blink codes for various fault conditions.

23 TECHNICAL DATA

23.1 Engine

Provides detailed technical specifications for the engine.

23.2 Engine Tightening Torques

Lists critical torque specifications for engine components.

23.3 Capacities

Specifies capacities for engine oil, coolant, and fuel.

23.4 Chassis

Technical data related to the motorcycle's chassis, frame, and suspension.

23.5 Electrical System

Details on battery, fuses, lights, and other electrical components.

23.6 Tires

Specifications for front and rear tires, including validity.

23.7 Fork

Technical data for the front fork, including settings and oil type.

23.8 Shock Absorber

Technical specifications for the rear shock absorber, including settings.

23.9 Chassis Tightening Torques

A comprehensive list of torque specifications for chassis components.

24 SUBSTANCES

Brake Fluid DOT 4 / DOT 5.1

Recommended brake fluid types and specifications.

Coolant

Details on recommended coolant types and mixture ratios.

Engine Oil (SAE 10W/60)

Specifications for engine oil suitable for harsh conditions.

Engine Oil (SAE 10W/50)

Recommended engine oil type and specifications.

Fork Oil (SAE 4) (48601166S1)

Recommended fork oil type and specifications.

Shock Absorber Oil (SAE 2.5) (50180342S1)

Recommended shock absorber oil type and specifications.

Super Unleaded (ROZ 95/RON 95/PON 91)

Fuel grade recommendations and ethanol content guidelines.

25 AUXILIARY SUBSTANCES

Air Filter Cleaner

Recommended cleaner for the air filter.

Chain Cleaner

Recommended cleaner for the drive chain.

Cleaning and Preserving Materials for Metal, Rubber and Plastic

Recommended cleaning and preserving products.

Fuel Additive

Recommended fuel additive.

High Viscosity Grease

Recommended high viscosity grease.

Long-Life Grease

Recommended long-life grease.

Motorcycle Cleaner

Recommended motorcycle cleaner.

Off-Road Chain Spray

Recommended chain spray for off-road use.

Oil for Foam Air Filter

Recommended oil for foam air filters.

Paint Cleaner and Polish for High-Gloss and Matte Finishes, Bare Metal and Plastic Surfaces

Recommended cleaner and polish for surfaces.

Rubber Grip Adhesive (00062030051)

Recommended adhesive for rubber grips.

Universal Oil Spray

Recommended universal oil spray.

26 STANDARDS

JASO T903 MA

Explanation of the JASO T903 MA standard for 4-stroke motorcycles.

SAE

Explanation of SAE viscosity classification for oils.

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