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500 XCF-W 2020
KTM 500 XCF-W 2020 User Manual
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12
SERVICE
WORK
ON
THE
CHASSIS
76
12.17
Removing
front
fender
Preparatory
work
–
Press
and
hold
the
switch-off
button
while
the
engine
is
idling
until
the
engine
stops.
–
Remove
the
headlight
mask
with
the
headlight.
(
p.
127)
V00340-10
Main
work
(EXC
‑
F
EU,
XCF
‑
W)
–
Remove
screws
1
.
V00341-10
–
Remove
screws
2
.
Take
off
front
fender.
K00576-10
(All
EXC-F
Six
Days)
–
Remove
screws
1
.
S01321-10
–
Remove
screws
2
.
Take
off
front
fender.
77
79
Table of Contents
Default Chapter
4
Table of Contents
4
1 Means of Representation
8
Symbols Used
8
Formats Used
8
2 Safety Advice 2
9
Use Definition - Intended Use
9
Misuse
9
Degrees of Risk and Symbols
10
Tampering Warning
10
Safe Operation
10
Protective Clothing
11
Work Rules
11
Environment
11
Owner's Manual
12
3 Important Notes 3
13
Manufacturer and Implied Warranty
13
Fuel, Auxiliary Substances
13
Spare Parts, Accessories
13
Service
13
Figures
13
Customer Service
13
4 View of Vehicle
14
View of Vehicle, Front Left (Example)
14
View of Vehicle, Rear Right (Example)
15
5 Serial Numbers
16
Vehicle Identification Number
16
Type Label
16
Key Number (All EU Models)
16
Engine Number
16
Fork Part Number
17
Shock Absorber Article Number
17
6 Controls
18
Clutch Lever
18
Hand Brake Lever
18
Throttle Grip
18
Switch-Off Button
18
Horn Button (All EU Models)
19
Light Switch (All EU Models)
19
Light Switch (XCF-W)
19
Turn Signal Switch (All EU Models)
20
Emergency off Switch
20
Start Button
20
Combination Switch (All EXC-F Six Days, XCF-W)
21
Overview of Indicator Lamps (All EU Models)
21
Overview of Indicator Lamps (XCF-W)
21
Opening Fuel Tank Filler Cap
22
Closing the Fuel Tank Filler Cap
22
Cold Start Button
23
Idle Speed Adjusting Screw
23
Shift Lever
24
Foot Brake Lever
24
Side Stand
24
Steering Lock (All EU Models)
25
Locking the Steering (All EU Models)
25
Unlocking the Steering (All EU Models)
26
7 Combination Instrument 7
27
Combination Instrument Overview
27
Activation and Test
27
Setting the Kilometers or Miles
27
Setting the Combination Instrument
28
Setting the Clock
29
Viewing the Lap Time
29
Display Mode SPEED (Speed)
30
Display Mode SPEED/H (Operating Hours)
30
Setup Menu
30
Adjusting the Unit of Measurement
31
Display Mode SPEED/CLK (Time)
32
Setting the Clock
32
Display Mode SPEED/LAP (Lap Time)
32
Viewing the Lap Time
33
Display Mode SPEED/ODO (Odometer)
33
Display Mode SPEED/TR1 (Trip Master 1)
34
Display Mode SPEED/TR2 (Trip Master 2)
34
Setting TR2 (Trip Master 2)
34
Display Mode SPEED/A1 (Average Speed 1)
35
Display Mode SPEED/A2 (Average Speed 2)
35
Display Mode SPEED/S1 (Stop Watch 1)
36
Display Mode SPEED/S2 (Stop Watch 2)
36
Table of Functions
37
Table of Conditions and Menu Activation
38
8 Preparing for Use 8
39
Advice on Preparing for First Use
39
Running-In the Engine
40
Starting Power of Lithium-Ion Batteries at Low Temperatures
41
Preparing the Vehicle for Difficult Riding Conditions
41
Preparing the Vehicle for Riding on Dry Sand
41
Preparing the Vehicle for Riding on Wet Sand
42
Preparing the Vehicle for Riding on Wet and Muddy Circuits
43
Preparing Vehicle for High Temperatures or Slow Riding
43
Preparing the Vehicle for Low Temperatures or Snow
44
9 Riding Instructions 9
45
Checks and Maintenance Measures When Preparing for Use
45
Starting the Vehicle
45
Activating Traction Control (All EXC-F Six Days, XCF-W)
46
Starting off
47
Shifting, Riding
47
Braking
47
Stopping, Parking
48
Transporting
49
Refueling
49
10 Service Schedule 10
51
Additional Information
51
Required Work
51
Recommended Work
52
11 Tuning the Chassis
54
Checking the Basic Chassis Setting with Rider's Weight
54
Compression Damping of the Shock Absorber
54
Adjusting the Low-Speed Compression Damping of the Shock Absorber
54
Adjusting the High-Speed Compression Damping of the Shock Absorber
55
Adjusting the Rebound Damping of the Shock Absorber
56
Measuring the Dimension of the Rear Wheel Unloaded
56
Checking the Static Sag of the Shock Absorber
57
Checking the Riding Sag of the Shock Absorber
57
Adjusting the Spring Preload of the Shock Absorber
58
Adjusting the Riding Sag
59
Checking the Basic Setting of the Fork
59
Adjusting the Compression Damping of the Fork
60
Adjusting the Rebound Damping of the Fork
61
Adjusting the Spring Preload of the Fork (All EXC-F Six Days)
62
Handlebar Position
63
Adjusting the Handlebar Position
63
12 Service Work on the Chassis
66
Raising the Motorcycle with the Lift Stand
66
Removing the Motorcycle from the Lift Stand
66
Bleeding the Fork Legs
66
Cleaning the Dust Boots of the Fork Legs
67
Removing the Fork Protector
67
Installing the Fork Protector
68
Removing the Fork Legs
68
Installing the Fork Legs
69
Removing the Lower Triple Clamp (EXC-F EU, XCF-W)
70
(All EXC-F Six Days)
71
Installing the Lower Triple Clamp (EXC-F EU, XCF-W)
72
Installing the Lower Triple Clamp (All EXC-F Six Days)
74
Checking Steering Head Bearing Play
75
Adjusting Steering Head Bearing Play (EXC-F EU, XCF-W)
76
Adjusting Steering Head Bearing Play (All EXC-F Six Days)
77
Lubricating the Steering Head Bearing
77
Removing Front Fender
78
Installing Front Fender
79
Removing the Shock Absorber
80
Installing the Shock Absorber
80
Removing the Seat
80
Mounting the Seat
81
Removing the Air Filter Box Cover
81
Installing the Air Filter Box Cover
82
Removing the Air Filter
83
Installing the Air Filter
83
Cleaning the Air Filter and Air Filter Box
84
Preparing Air Filter Box Cover for Securing
84
Removing the Main Silencer
85
Installing the Main Silencer
85
Cleaning the Spark Arrestor (XCF-W)
85
Changing the Glass Fiber Yarn Filling of the Main Silencer
87
Removing the Fuel Tank
88
Installing the Fuel Tank
89
Checking for Chain Dirt Accumulation
91
Cleaning the Chain
91
Checking the Chain Tension
92
Adjusting the Chain Tension
93
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide
94
Checking the Frame
96
Checking the Link Fork
96
Checking Throttle Cable Routing
96
Checking the Rubber Grip
97
Adjusting the Basic Position of the Clutch Lever
98
Checking/Correcting the Fluid Level of the Hydraulic Clutch
98
Changing the Hydraulic Clutch Fluid
99
Removing the Engine Guard (All EXC-F Six Days, XCF-W)
100
Installing the Engine Guard (All EXC-F Six Days, XCF-W)
101
13 Brake System
102
Checking the Free Travel of the Hand Brake Lever
102
Adjusting the Free Travel of the Handbrake Lever (All EU Models)
102
Adjusting the Basic Position of the Hand Brake Lever (XCF-W)
103
Checking the Brake Discs
103
Checking the Front Brake Fluid Level
104
Adding the Front Brake Fluid
104
Checking the Front Brake Linings
106
Changing the Brake Linings of the Front Brake
106
Checking the Free Travel of Foot Brake Lever
110
Adjusting the Basic Position of the Foot Brake Lever
111
Checking the Rear Brake Fluid Level
112
Adding Rear Brake Fluid
112
Checking the Rear Brake Linings
113
Changing the Rear Brake Linings
114
14 Wheels, Tires 14
117
Removing the Front Wheel
117
Installing the Front Wheel
118
Removing the Rear Wheel
118
Installing the Rear Wheel
119
Checking the Tire Condition
121
Checking Tire Pressure
121
Checking Spoke Tension
122
15 Electrical System
123
Electrical System 15
123
Removing the 12-V Battery
123
Installing the 12-V Battery
124
Charging the 12-V Battery
125
Changing the Main Fuse
127
Changing the Fuses of Individual Power Consumers
128
Removing the Headlight Mask with the Headlight
129
Installing the Headlight Mask with the Headlight
130
Changing the Headlight Bulb
131
Checking the Headlight Setting
131
Adjusting the Headlight Range
132
Changing the Turn Signal Bulb (All EU Models)
132
Changing the Combination Instrument Battery
133
Diagnostics Connector
134
16 Cooling System 16
135
Checking the Antifreeze and Coolant Level
135
Checking the Coolant Level
136
Draining the Coolant
137
Refilling Coolant
138
17 Tuning the Engine 17
139
Checking the Throttle Cable Play
139
Adjusting the Throttle Cable Play
139
Adjusting the Characteristic Map of the Throttle Response
140
Changing the Mapping (All EXC-F Six Days, XCF-W)
141
Adjusting the Idle Speed
142
Teaching the Throttle Valve Position
143
Checking the Basic Position of the Shift Lever
143
Adjusting the Basic Position of the Shift Lever
144
18 Service Work on the Engine 18
145
Changing the Fuel Screen
145
Checking the Engine Oil Level
146
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens
146
Adding Engine Oil
149
19 Cleaning, Care
150
Cleaning the Motorcycle
150
Checks and Maintenance Steps for Winter Operation
151
20 Storage
152
Preparing for Use after Storage
153
21 Troubleshooting
154
22 Technical Data 22
157
Engine
157
Engine Tightening Torques
158
Capacities
159
Engine Oil
159
Coolant
159
Fuel
159
Chassis
160
Electrical System
161
Tires
161
Fork
161
Exc-F Eu, Xcf-W
161
All EXC-F Six Days
162
Shock Absorber
162
Chassis Tightening Torques
163
23 Substances
166
24 Auxiliary Substances
168
25 Standards
170
26 Index of Special Terms 26
171
27 List of Abbreviations
172
28 List of Symbols 28
173
Yellow and Orange Symbols
173
Green and Blue Symbols
173
Index
174
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Setup Instructions
44 pages
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KTM 500 XCF-W 2020 Specifications
General
Brand
KTM
Model
500 XCF-W 2020
Category
Motorcycle
Language
English
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