KTM 500 EXC - Page 119

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*3211868en*

3211868en

07/2012

KTM-Sportmotorcycle AG

5230 Mattighofen/Austria

http://www.ktm.com

Photo: Mitterbauer/KTM

Main Page

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
- Overview of Labels9
- Reporting Safety Defects11
- Noise Emission Warranty11
- Operating Noise Warning11
- Consumer Rights11
- Tampering Warning11
- Safe Operation11
- Protective Clothing12
- Work Rules12
- Environment12
- Owner's Manual12
3 Important Notes13
- Guarantee, Warranty13
- Operating and Auxiliary Substances13
- Spare Parts, Accessories13
- Service13
- Figures13
- Customer Service13
4 View of Vehicle14
- View of Vehicle, Front Left (Example)14
- View of Vehicle, Rear Right (Example)15
5 Serial Numbers16
- Chassis Number16
- Type Label16
- Key Number16
- Engine Number16
- Fork Part Number17
- Shock Absorber Part Number17
6 Controls18
- Clutch Lever18
- Hand Brake Lever18
- Throttle Grip18
- Horn Button18
- Light Switch18
- Turn Signal Switch19
- Emergency off Switch19
- Electric Starter Button19
- Overview of Indicator Lamps19
- Ignition Lock19
- Speedometer20
- Overview20
- Activation and Test20
- Tripmaster Switch20
- Setting Kilometers or Miles20
- Adjusting the Speedometer Functions21
- Setting the Clock21
- Querying Lap Time22
- Display Mode SPEED (Speed)22
- Display Mode SPEED/H (Operating Hours)22
- Display Mode SPEED/CLK (Clock)23
- Display Mode SPEED/LAP (Lap Time)23
- Display Mode SPEED/ODO (Odometer)23
- Display Mode SPEED/TR1 (Trip Master 1)23
- Display Mode SPEED/TR2 (Trip Master 2)24
- Display Mode SPEED/A1 (Average Speed 1)24
- Display Mode SPEED/A2 (Average Speed 2)24
- Display Mode SPEED/S1 (Stop Watch 1)25
- Display Mode SPEED/S2 (Stop Watch 2)25
- 6.11.19 Table of Functions25
- 6.11.20 Table of Conditions and Menu Activation26
- Opening Filler Cap26
- Closing Filler Cap26
- Idle Speed Adjusting Screw27
- Shift Lever27
- Kick Starter27
- Foot Brake Lever28
- Side Stand28
- Steering Lock28
- Locking the Steering28
- Unlocking the Steering29
7 Preparing for Use30
- Advice on First Use30
- Running-In the Engine31
- Preparing the Vehicle for Difficult Riding Conditions31
- Preparing for Rides on Dry Sand31
- Preparing for Rides on Wet Sand32
- Preparing for Rides on Wet and Muddy Surfaces32
- Preparing for Rides at High Temperature and Slow Speed33
- Preparing for Rides at Low Temperature or in Snow33
8 Riding Instructions34
- Checks and Maintenance Work When Preparing for Use34
- Starting34
- Starting off35
- Shifting, Riding35
- Braking35
- Stopping, Parking36
- Transport36
- Refueling37
9 Service Schedule38
- Service Work (as Additional Order)39
10 Tuning the Chassis40
- Checking the Basic Suspension Setting against the Rider's Weight40
- Compression Damping of Shock Absorber40
- Adjusting the Low-Speed Compression Damping of the Shock Absorber40
- Adjusting the High-Speed Compression Damping of the Shock Absorber41
- Adjusting the Rebound Damping of the Shock Absorber41
- Measuring Rear Wheel Sag Unloaded42
- Checking the Static Sag of the Shock Absorber42
- Checking the Riding Sag of the Shock Absorber42
- Adjusting the Spring Preload of the Shock Absorber43
- Adjusting the Riding Sag43
- Checking Basic Setting of Fork44
- Adjusting the Compression Damping of the Fork44
- Adjusting the Rebound Damping of the Fork45
- Adjusting the Spring Preload of the Fork45
- Handlebar Position45
- Adjusting Handlebar Position46
11 Service Work on the Chassis47
- Raising the Motorcycle with the Lift Stand47
- Removing the Motorcycle from the Lift Stand47
- Bleeding Fork Legs47
- Cleaning the Dust Boots of the Fork Legs47
- Loosening the Fork Protector48
- Positioning the Fork Protection48
- Removing the Fork Legs48
- Installing the Fork Legs49
- Removing the Fork Protector49
- Installing the Fork Protector50
- Removing the Lower Triple Clamp50
- Installing the Lower Triple Clamp51
- Checking the Steering Head Bearing Play52
- Adjusting the Play of the Steering Head Bearing53
- Greasing the Steering Head Bearing53
- Removing the Front Fender54
- Installing the Front Fender54
- Removing the Shock Absorber54
- Installing the Shock Absorber54
- Removing the Seat55
- Mounting the Seat55
- Removing the Air Filter Box Lid55
- Installing the Air Filter Box Lid55
- Removing the Air Filter55
- Installing the Air Filter56
- Cleaning the Air Filter and Air Filter Box56
- Sealing the Air Filter Box57
- Removing Main Silencer57
- Installing the Main Silencer57
- Changing the Glass Fiber Yarn Filling of the Main Silencer57
- Removing the Fuel Tank58
- Installing the Fuel Tank59
- Checking for Chain Dirt Accumulation60
- Cleaning the Chain60
- Checking the Chain Tension61
- Adjusting the Chain Tension61
- Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide62
- Adjusting the Chain Guide64
- Checking the Frame64
- Checking the Swingarm64
- Checking the Throttle Cable Routing65
- Checking the Rubber Grip65
- Additionally Securing the Rubber Grip65
- Adjusting the Basic Position of the Clutch Lever66
- Checking/Correcting the Fluid Level of the Hydraulic Clutch66
- Changing the Hydraulic Clutch Fluid66
12 Brake System68
- Checking Free Travel of Hand Brake Lever68
- Adjusting Free Travel of Hand Brake Lever68
- Checking the Brake Discs68
- Checking the Front Brake Fluid Level69
- Adding Front Brake Fluid69
- Checking the Front Brake Linings70
- Changing the Front Brake Linings70
- Checking the Free Travel of Foot Brake Lever72
- Adjusting the Basic Position of the Foot Brake Lever72
- Checking the Rear Brake Fluid Level72
- Adding Brake Fluid to the Rear Brake Circuit73
- Checking the Rear Brake Linings74
- Changing the Rear Brake Linings74
13 Wheels, Tires76
- Removing the Front Wheel76
- Installing the Front Wheel76
- Removing the Rear Wheel77
- Installing the Rear Wheel77
- Checking the Tire Condition78
- Checking Tire Air Pressure79
- Checking Spoke Tension79
14 Electrical System81
- Removing the Battery81
- Installing the Battery81
- Charging the Battery82
- Changing the Main Fuse83
- Changing the Fuses of Individual Power Consumers84
- Changing the Fuse of the Radiator Fan84
- Removing Headlight Mask with Headlight85
- Refitting the Headlight Mask with the Headlight85
- Changing the Headlight Bulb86
- Changing the Turn Signal Bulb86
- Checking the Headlight Setting87
- Adjusting the Headlight Range87
- Changing the Speedometer Battery88
15 Cooling System89
- Checking the Antifreeze and Coolant Level89
- Checking the Coolant Level90
- Draining the Coolant90
- Refilling Coolant91
16 Tuning the Engine92
- Checking the Play in the Throttle Cable92
- Adjusting the Play in the Throttle Cable92
- Adjusting the Idle Speed93
- Checking the Basic Position of the Shift Lever93
- Adjusting the Basic Position of the Shift Lever93
17 Service Work on the Engine95
- Changing the Fuel Screen95
- Checking the Engine Oil Level95
- Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens96
- Adding Engine Oil98
18 Cleaning, Care99
- Cleaning the Motorcycle99
- Checks and Maintenance Steps for Winter Operation100
19 Storage101
- Preparing for Use after Storage101
20 Troubleshooting102
21 Blink Code104
22 Technical Data105
- Engine105
- Engine Tightening Torques105
- Specifications105
- Capacities107
- Engine Oil107
- Coolant107
- Fuel107
- Chassis107
- Electrical System108
- Tires108
- Fork108
- Shock Absorber109
- Chassis Tightening Torques109
23 Substances111
24 Auxiliary Substances113
25 Standards115
- Index116

KTM 500 EXC - Page 119

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