Why are the lights not working on my KTM 500 EXC SIX DAYS EU?
If the high beam, low beam, parking light, tail light, and license plate lamp are not working on your KTM Motorcycle, check if fuse 3 is blown and replace it.
Why is the speedometer not working on my KTM Motorcycle?
If the speedometer, horn, brake light, turn signal, and radiator fan are not working on your KTM Motorcycle, check if fuse 4 is blown and replace it.
Why is my KTM Motorcycle battery discharged?
If the battery of your KTM Motorcycle is discharged, the alternator may not be charging it. Check the charging voltage and the stator winding of the alternator. Also, check for any undesired power consumers.
Why KTM 500 EXC SIX DAYS EU engine won't crank with electric starter?
If the electric starter on your KTM Motorcycle isn't cranking the engine, there could be a few reasons. You might be making an operating error, so double-check the start procedure. A discharged battery is a common cause, so try charging it. Also, a blown main fuse can prevent the starter from working, so replace it if needed. Finally, the starter relay or the starter motor itself could be defective, requiring a check of these components.
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 |
Explains the meaning of symbols used throughout the manual for clarity and safety.
Describes typographical formats used in the manual for consistent information presentation.
Defines the intended use of the motorcycle and compliance with regulations.
General safety instructions and warnings to ensure safe operation.
Explains risk levels (Danger, Warning, Caution) and associated symbols.
Warning against tampering with noise control systems and related federal laws.
Guidelines for safe operation, including rider impairment and burns precautions.
Emphasizes the importance of wearing appropriate protective clothing for safety.
Provides rules for performing service work, including tool usage and part replacement.
Advice on responsible use and disposal of fluids and components to protect the environment.
Importance of reading the manual and where to get further information.
Conditions and procedures for warranty claims and authorized service.
Warnings and guidelines for handling fuel and other operating fluids.
Recommendations for using approved spare parts and accessories for safety.
Importance of proper service and maintenance for longevity and performance.
Note that manual figures may show special equipment and not always full disassembly.
Information on contacting authorized KTM dealers for support and information.
Illustrates the front-left view of the motorcycle with key components labeled.
Shows the rear-right view of the motorcycle with labeled components and controls.
Location of the chassis number stamped on the steering head.
Location of the type label affixed to the front of the steering head.
Location of the key number stamped on the steering lock connector.
Location of the engine number stamped on the engine casing.
Location of the fork part number stamped on the inner side of the fork stub.
Location of the shock absorber part number stamped on the absorber body.
Description and function of the clutch lever on the left handlebar.
Location and function of the hand brake lever on the right handlebar.
Description and location of the throttle grip on the right handlebar.
Function and states of the kill switch for EXC models.
Function and states of the kill switch for XC-W models.
Location and operation of the horn button for EXC models.
Operation of the light switch for different light modes on EXC models.
Operation of the light switch for different light modes on XC-W models.
Operation of the turn signal switch for EXC models.
Function and states of the emergency OFF switch for EXC AUS models.
Location and operation of the electric starter button for EXC AUS.
Location and operation of the electric starter button for other EXC/XC-W models.
Explanation of indicator lamps on the dashboard for EXC EU/AUS models.
Explanation of indicator lamps on the dashboard for EXC SIX DAYS models.
Explanation of indicator lamps on the dashboard for all XC-W models.
Safety precautions and procedure for opening the fuel filler cap.
Procedure for correctly closing the fuel filler cap.
Location and function of the idle speed adjusting screw.
Location of the shift lever and gear position illustration.
Location and operation of the kick starter.
Location and function of the foot brake lever for the rear brake.
Location and use of the side stand for parking the motorcycle.
Location and purpose of the steering lock mechanism.
Steps for locking the steering using the ignition key.
Steps for unlocking the steering using the ignition key.
Explains overview, activation, testing, and settings for various display modes.
Covers overview, activation, testing, and settings for EXC SIX DAYS speedometer.
Provides essential safety advice and checks before operating the motorcycle for the first time.
Details guidelines for proper engine break-in to ensure longevity and performance.
Offers advice on preparing the motorcycle for various challenging riding environments.
Specific instructions for preparing the motorcycle for riding on dry sandy terrain.
Guidelines for preparing the motorcycle for riding on wet sandy terrain.
Advice on preparing the motorcycle for wet and muddy riding conditions.
Instructions for preparing the motorcycle for hot weather and slow speed riding.
Guidance on preparing the motorcycle for cold weather and snowy conditions.
Essential checks and maintenance before riding the motorcycle to ensure safety.
Step-by-step guide on how to safely start the motorcycle engine.
Instructions for smoothly engaging first gear and moving off.
Guidance on gear shifting, throttle control, and general riding techniques.
Explains proper braking techniques and potential hazards.
Procedures for safely stopping and parking the motorcycle.
Guidelines for transporting the motorcycle safely.
Instructions and safety precautions for refueling the motorcycle.
Outlines regular maintenance intervals and tasks for optimal vehicle upkeep.
Lists service tasks that can be performed as additional maintenance.
How to adjust suspension settings based on rider weight for optimal performance.
Explains the two ranges of shock absorber compression damping.
Step-by-step guide to adjust low-speed compression damping on the rear shock absorber.
How to adjust the high-speed compression damping on the rear shock absorber.
Instructions for adjusting the rebound damping on the rear shock absorber.
Procedure to measure the rear wheel sag when the motorcycle is unloaded.
Steps to check the static sag of the rear shock absorber.
How to check the riding sag of the rear shock absorber with rider input.
Guide to adjust the spring preload on the rear shock absorber for rider weight.
How to adjust the riding sag by selecting or changing the rear spring.
Guidance on checking the basic suspension settings for the front forks.
Instructions for adjusting the compression damping on the front fork legs.
Steps to adjust the rebound damping on the front fork legs for different models.
Guide to adjust fork spring preload for specific EXC and XC-W models.
Information on handlebar mounting positions and hole distances.
Step-by-step process for adjusting the handlebar position.
Instructions on how to safely lift the motorcycle using a lift stand.
Procedure for safely removing the motorcycle from the lift stand.
Steps for bleeding the air from the front fork legs.
Guidance on cleaning the fork dust boots to maintain seal integrity.
How to loosen and remove the fork protector on the front forks.
Instructions for correctly positioning and mounting the fork protector.
Detailed steps for removing the front fork legs from the motorcycle.
Step-by-step guide for installing the front fork legs on different models.
How to remove the fork protector from the front fork legs.
Instructions for installing the fork protector onto the front forks.
Steps to remove the lower triple clamp for specific EXC and XC-W models.
Procedure to remove the lower triple clamp for EXC SIX DAYS models.
Guide to installing the lower triple clamp on specific EXC and XC-W models.
Steps to install the lower triple clamp on EXC SIX DAYS models.
How to check for play in the steering head bearing for safe handling.
Procedure to adjust steering head bearing play on specific EXC and XC-W models.
How to adjust steering head bearing play on EXC SIX DAYS models.
Instructions for greasing the steering head bearing for different models.
Steps to remove the front fender from the motorcycle.
How to install the front fender onto the motorcycle.
Detailed steps for removing the rear shock absorber.
Guide to installing the rear shock absorber onto the motorcycle.
How to remove the motorcycle seat.
Instructions for correctly mounting the motorcycle seat.
Steps to remove the lid of the air filter box.
How to install the air filter box lid correctly.
Detailed procedure for removing the air filter from the air filter support.
Instructions for installing a clean air filter and securing the air filter box.
Guide to cleaning the air filter and air filter box properly.
How to seal the air filter box in the marked area.
Steps to remove the main silencer from the exhaust system.
How to install the main silencer onto the exhaust system.
Procedure to change the glass fiber yarn filling in the main silencer.
Detailed steps for safely removing the fuel tank.
Instructions for safely installing the fuel tank onto the motorcycle.
How to check the drive chain for dirt accumulation.
Steps for properly cleaning the drive chain.
How to check the drive chain tension for correct operation.
Procedure to adjust the drive chain tension to specifications.
How to check wear on the chain, sprockets, and chain guide.
How to inspect the motorcycle frame for cracks or deformation.
Procedure to check the swingarm for damage, cracking, or deformation.
How to check and correct the routing of the throttle cables.
How to check the rubber grips on the handlebar for wear and security.
Steps to further secure the rubber grips using securing wire.
How to adjust the clutch lever position for hand size.
How to check and correct the hydraulic clutch fluid level.
Detailed procedure for changing the hydraulic clutch fluid.
How to remove the engine guard on specific EXC models.
Steps to install the engine guard on specific EXC models.
How to check the free travel of the hand brake lever.
Guide to adjust the free travel of the hand brake lever on EXC models.
How to adjust the hand brake lever position for hand size on XC-W models.
How to check the thickness and condition of the brake discs.
Steps to check the brake fluid level in the front brake reservoir.
How to add front brake fluid, including safety precautions.
How to check the front brake linings for minimum thickness and wear.
Detailed procedure for changing the front brake linings.
How to check the free travel of the foot brake lever.
How to adjust the basic position of the foot brake lever.
How to check the brake fluid level in the rear brake reservoir.
Steps to add rear brake fluid, including safety precautions.
How to check the rear brake linings for minimum thickness and wear.
Detailed procedure for changing the rear brake linings.
Step-by-step guide for removing the front wheel.
How to install the front wheel, including checks and precautions.
Detailed procedure for removing the rear wheel from the swingarm.
How to install the rear wheel, including chain and tension checks.
How to check the front and rear tires for cuts, wear, and age.
How to check and adjust tire air pressure for off-road and road use.
How to check and adjust spoke tension for wheel balance and integrity.
Step-by-step guide for safely removing the motorcycle battery.
How to correctly install the motorcycle battery.
Instructions for charging the motorcycle battery and maintenance.
How to locate and change the main fuse for the electrical system.
How to change fuses for specific electrical components.
Steps to remove the headlight mask and headlight assembly.
How to reassemble the headlight mask and headlight.
Instructions for changing the headlight bulb.
How to change the turn signal bulbs on the motorcycle.
Procedure to check and verify the headlight beam alignment.
How to adjust the headlight beam range up or down.
Steps to replace the battery in the motorcycle speedometer.
Overview of how the engine cooling system functions.
How to check coolant level and antifreeze protection.
Steps to check the coolant level in the radiator.
Procedure to drain the coolant from the cooling system.
How to refill the cooling system with coolant.
How to check and adjust the free play in the throttle cable.
Step-by-step guide to adjust the throttle cable play.
How to adjust the engine's idle speed.
How to check the correct position of the shift lever relative to the boot.
Steps to adjust the basic position of the shift lever.
How to change the fuel screen for proper fuel delivery.
Procedure to check the engine oil level when the engine is at operating temperature.
Detailed guide for changing engine oil, filter, and cleaning oil screens.
How to add engine oil, including oil type recommendations.
Instructions for cleaning the motorcycle safely and effectively.
Essential checks and maintenance for protecting the motorcycle during winter.
Guidelines for preparing and storing the motorcycle for longer periods.
Steps required to get the motorcycle ready after a storage period.
Diagnosing and resolving issues when the engine won't crank via the electric starter.
Troubleshooting steps for when the engine cranks but does not start.
Diagnosing why the engine fails to accelerate properly.
Identifying causes for reduced engine power output.
Troubleshooting steps for when the engine stops running during a trip.
Identifying and resolving issues related to engine overheating.
Understanding and addressing the FI warning lamp indicators.
Diagnosing and resolving issues with high engine oil consumption.
Troubleshooting for a discharged battery or charging system issues.
Resolving issues with deleted speedometer data.
Troubleshooting for lighting system failures.
Diagnosing failures in the speedometer, horn, brake light, turn signal, and fan.
Explains FI warning lamp blink codes for various fault conditions.
Provides detailed technical specifications for the engine.
Lists critical torque specifications for engine components.
Specifies capacities for engine oil, coolant, and fuel.
Technical data related to the motorcycle's chassis, frame, and suspension.
Details on battery, fuses, lights, and other electrical components.
Specifications for front and rear tires, including validity.
Technical data for the front fork, including settings and oil type.
Technical specifications for the rear shock absorber, including settings.
A comprehensive list of torque specifications for chassis components.
Recommended brake fluid types and specifications.
Details on recommended coolant types and mixture ratios.
Specifications for engine oil suitable for harsh conditions.
Recommended engine oil type and specifications.
Recommended fork oil type and specifications.
Recommended shock absorber oil type and specifications.
Fuel grade recommendations and ethanol content guidelines.
Recommended cleaner for the air filter.
Recommended cleaner for the drive chain.
Recommended cleaning and preserving products.
Recommended fuel additive.
Recommended high viscosity grease.
Recommended long-life grease.
Recommended motorcycle cleaner.
Recommended chain spray for off-road use.
Recommended oil for foam air filters.
Recommended cleaner and polish for surfaces.
Recommended adhesive for rubber grips.
Recommended universal oil spray.
Explanation of the JASO T903 MA standard for 4-stroke motorcycles.
Explanation of SAE viscosity classification for oils.
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