KTM 500 XC-W USA 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 XC-W USA 2013 Specifications

General

Engine Type	Single-cylinder, 4-stroke
Displacement	510.4 cc
Bore x Stroke	95 x 72 mm
Throttle Body	42 mm
Cooling	Liquid cooled
Transmission	6-speed
Starter	Electric starter
Front Brake	260 mm disc
Rear Brake	220 mm disc
Tires (Front)	90/90-21
Tires (Rear)	140/80-18
Fuel System	Electronic Fuel Injection
Frame	Chromoly steel
Front Suspension	WP 48 mm USD
Rear Suspension	WP monoshock

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