KTM 500 EXC US User Manual

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OWNER'S MANUAL 2016

500 EXC US

500 EXC Six Days US

Art. no. 3213339en

Table of Contents

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 Operation12
- 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
- Opening the Filler Cap20
- Closing Filler Cap20
- Idle Speed Adjusting Screw21
- Shift Lever21
- Kick Starter21
- Foot Brake Lever22
- Side Stand22
- Steering Lock22
- Locking the Steering22
- Unlocking the Steering23
7 Speedometer24
- Speedometer Overview24
- Activation and Test24
- Setting Kilometers or Miles24
- Setting the Speedometer Functions25
- Setting the Clock25
- Viewing the Lap Time25
- Display Mode SPEED (Speed)26
- Display Mode SPEED/H (Service Hours)26
- Setup Menu27
- Setting the Unit of Measurement27
- Display Mode SPEED/CLK (Time)28
- Setting the Clock28
- Display Mode SPEED/LAP (Lap Time)28
- Viewing the Lap Time29
- Display Mode SPEED/ODO (Odometer)29
- Display Mode SPEED/TR1 (Trip Master 1)29
- Display Mode SPEED/TR2 (Trip Master 2)30
- Setting TR2 (Trip Master 2)30
- Display Mode SPEED/A1 (Average Speed 1)30
- Display Mode SPEED/A2 (Average Speed 2)31
- Display Mode SPEED/S1 (Stop Watch 1)31
- Display Mode SPEED/S2 (Stop Watch 2)31
- Table of Functions32
- Table of Conditions and Menu Activation33
8 Preparing for Use34
- Advice on First Use34
- Running-In the Engine35
- Preparing the Vehicle for Difficult Riding Conditions35
- Preparing for Rides on Dry Sand36
- Preparing for Rides on Wet Sand36
- Preparing for Rides on Wet and Muddy Surfaces37
- Preparing for Rides at High Temperature and Slow Speed37
- Preparing for Rides at Low Temperature or in Snow37
9 Riding Instructions38
- Checks and Maintenance Work When Preparing for Use38
- Starting38
- Starting off39
- Shifting, Riding39
- Braking39
- Stopping, Parking40
- Transport40
- Refueling41
10 Service Schedule42
- Service Work (as Additional Order)43
11 Tuning the Chassis44
- Checking the Basic Suspension Setting against the Rider's Weight44
- Compression Damping of Shock Absorber44
- Adjusting the Low-Speed Compression Damping of the Shock Absorber44
- Adjusting the High-Speed Compression Damping of the Shock Absorber45
- Adjusting the Rebound Damping of the Shock Absorber45
- Measuring Rear Wheel Sag Unloaded46
- Checking the Static Sag of the Shock Absorber46
- Checking the Riding Sag of the Shock Absorber46
- Adjusting the Spring Preload of the Shock Absorber47
- Adjusting the Riding Sag47
- Checking Basic Setting of Fork48
- Adjusting the Compression Damping of the Fork48
- Adjusting the Rebound Damping of the Fork49
- Adjusting the Spring Preload of the Fork (EXC US)50
- Handlebar Position50
- Adjusting Handlebar Position51
12 Service Work on the Chassis53
- Raising the Motorcycle with the Lift Stand53
- Removing the Motorcycle from the Lift Stand53
- Bleeding the Fork Legs53
- Cleaning the Dust Boots of the Fork Legs54
- Removing the Fork Legs54
- Installing the Fork Legs55
- Removing the Fork Protector56
- Installing the Fork Protector56
- Removing the Lower Triple Clamp (EXC US)56
- Removing the Lower Triple Clamp (EXC Six Days US)57
- Installing the Lower Triple Clamp (EXC US)57
- Installing the Lower Triple Clamp (EXC Six Days US)59
- Checking the Steering Head Bearing Play61
- Adjusting the Play of the Steering Head Bearing (EXC US)61
- Adjusting the Play of the Steering Head Bearing (EXC Six Days US)62
- Greasing the Steering Head Bearing62
- Removing the Front Fender62
- Installing the Front Fender63
- Removing the Shock Absorber63
- Installing the Shock Absorber63
- Removing the Seat64
- Mounting the Seat64
- Removing the Air Filter Box Cover64
- Installing the Air Filter Box Cover64
- Removing the Air Filter65
- Installing the Air Filter65
- Cleaning the Air Filter and Air Filter Box65
- Sealing the Air Filter Box66
- Removing Main Silencer66
- Installing the Main Silencer66
- Cleaning Spark Arrestor67
- Changing Glass Fiber Yarn Filling in the Main Silencer68
- Removing the Fuel Tank68
- Installing the Fuel Tank70
- Checking for Chain Dirt Accumulation71
- Cleaning the Chain71
- Checking the Chain Tension72
- Adjusting the Chain Tension73
- Checking the Chain, Rear Sprocket, Motor Sprocket, and Chain Guide73
- Checking the Frame75
- Checking the Swingarm75
- Checking Throttle Cable Routing75
- Checking the Rubber Grip76
- Additionally Securing the Rubber Grip76
- Adjusting the Basic Position of the Clutch Lever76
- Checking/Correcting the Fluid Level of the Hydraulic Clutch77
- Changing the Hydraulic Clutch Fluid77
- Removing the Engine Guard (EXC Six Days US)78
- Installing the Engine Guard (EXC Six Days US)78
13 Brake System79
- Checking Free Travel of Hand Brake Lever79
- Adjusting Free Travel of Hand Brake Lever79
- Checking the Brake Discs79
- Checking the Brake Fluid Level of the Front Brake80
- Adding Front Brake Fluid80
- Checking the Front Brake Linings81
- Changing the Front Brake Linings81
- Checking the Free Travel of Foot Brake Lever83
- Adjusting the Basic Position of the Foot Brake Lever83
- Checking the Rear Brake Fluid Level83
- Adding Rear Brake Fluid84
- Checking the Rear Brake Linings85
- Changing the Rear Brake Linings85
14 Wheels, Tires88
- Removing the Front Wheel88
- Installing the Front Wheel88
- Removing the Rear Wheel89
- Installing the Rear Wheel90
- Checking the Tire Condition90
- Checking the Tire Air Pressure91
- Checking Spoke Tension91
15 Electrical System93
- Removing the Battery93
- Installing the Battery93
- Charging the Battery94
- Changing the Main Fuse95
- Changing the Fuses of Individual Power Consumers96
- Removing Headlight Mask with Headlight96
- Refitting the Headlight Mask with the Headlight97
- Changing the Headlight Bulb97
- Changing the Turn Signal Bulb98
- Checking the Headlight Setting98
- Adjusting the Headlight Range99
- Changing the Speedometer Battery99
16 Cooling System100
- Checking the Antifreeze and Coolant Level100
- Checking the Coolant Level101
- Draining the Coolant101
- Refilling Coolant102
17 Tuning the Engine103
- Checking the Play in the Throttle Cable103
- Adjusting the Play in the Throttle Cable103
- Adjusting the Idle Speed104
- Checking the Basic Position of the Shift Lever104
- Adjusting the Basic Position of the Shift Lever105
18 Service Work on the Engine106
- Changing the Fuel Screen106
- Checking the Engine Oil Level106
- Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens107
- Adding Engine Oil109
19 Cleaning, Care110
- Cleaning the Motorcycle110
- Checks and Maintenance Steps for Winter Operation111
20 Storage112
- Preparing for Use after Storage112
21 Troubleshooting113
22 Blink Code115
23 Technical Data116
- Engine116
- Engine Tightening Torques116
- Capacities118
- Engine Oil118
- Coolant118
- Fuel118
- Chassis118
- Electrical System119
- Tires119
- Fork119
- Exc Us119
- EXC Six Days US120
- Shock Absorber120
- Chassis Tightening Torques121
24 Substances123
25 Auxiliary Substances124
26 Standards126
27 List of Abbreviations127
28 Lisy of Symbols128
- Yellow and Orange Symbols128
- Green and Blue Symbols128
- Index129

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KTM 500 EXC US Specifications

General

Brand	KTM
Model	500 EXC US
Category	Motorcycle
Language	English

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