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KTM 500 EXC User Manual

KTM 500 EXC
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11 SERVICE WORK ON THE CHASSIS 50
101334-11
Tighten screw 8.
Guideline
Screw, top steering stem M8 20 Nm
(14.8 lbf ft)
101490-11
Tighten screws 9.
Guideline
Screw, top triple clamp M8 20 Nm
(14.8 lbf ft)
Secure the wiring harness with cable holder bk.
101326-11
Position the brake caliper. Mount and tighten screws bl.
Guideline
Screw, front brake caliper M8 25 Nm
(18.4 lbf ft)
Loctite
®
243™
Mount cable binder bm.
Position the brake line, wiring harness, and clamp. Mount and tighten screws bn.
Finishing work
Mount the handlebar cushion.
Install the front fender. ( p. 52)
Install the front wheel. x ( p. 74)
Refit the headlight mask with the headlight. ( p. 83)
Check that the wiring harness, cables, and brake and clutch lines can move freely
and are routed correctly.
Check the steering head bearing play. ( p. 50)
Remove the motorcycle from the lift stand. ( p. 45)
Check the headlight setting. ( p. 85)
11.13 Checking the steering head bearing play
Warning
Danger of accidentsUnstable vehicle handling from incorrect steering head bearing play.
Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.)
Info
If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam-
aged over time.
Preparatory work
Raise the motorcycle with the lift stand. ( p. 45)

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KTM 500 EXC Specifications

General IconGeneral
Engine TypeSingle cylinder, 4-stroke
Bore x Stroke95 mm x 72 mm
StarterElectric starter
Transmission6-speed
CoolingLiquid cooled
Rear SuspensionWP XPLOR PDS shock absorber
Ground Clearance355 mm
Seat Height960 mm
ABSNo
Displacement510.9 cm³
Fuel SystemKeihin EFI, throttle body 42 mm
FrameCentral double-cradle type 25CrMo4 steel
Front SuspensionWP Xplor 48, USD fork
Front Brake260 mm disc
Rear Brake220 mm disc
Fuel Tank Capacity8.5 liters

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