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SERVICE WORK ON THE CHASSIS 12

H02218-10

– Raise the rear of the seat, pull the seat back, and lift it off.

12.22 Mounting the seat

H02218-11

– Mount the front of the seat on the collar bushings of the fuel

tank, lower the seat at the rear, and push the seat forward.

– Make sure the seat is locked in correctly.

S03480-10

–

Mount and tighten screw

Guideline

Remaining screws,

chassis

M6 10 Nm (7.4 lbf ft)

12.23 Removing the air filter box cover

Condition

The air filter box cover is secured.

– Remove the seat. ( p. 78)

V01759-10

–

Remove screw

Default Chapter4
- Table of Contents4
1 Means of Representation8
- Symbols Used8
- Formats Used8
2 Safety Advice 29
- Use Definition - Intended Use9
- Misuse9
- Degrees of Risk and Symbols10
- Tampering Warning10
- Safe Operation10
- Protective Clothing11
- Work Rules11
- Environment11
- Owner's Manual12
3 Important Notes 313
- Manufacturer and Implied Warranty13
- Fuel, 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
- Vehicle Identification Number16
- Type Label16
- Key Number (All EU Models)16
- Engine Number16
- Fork Part Number17
- Shock Absorber Article Number17
6 Controls18
- Clutch Lever18
- Hand Brake Lever18
- Throttle Grip18
- Switch-Off Button18
- 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 Switch20
- Start Button20
- 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 Cap22
- Closing the Fuel Tank Filler Cap22
- Cold Start Button23
- Idle Speed Adjusting Screw23
- Shift Lever24
- Foot Brake Lever24
- Side Stand24
- Steering Lock (All EU Models)25
- Locking the Steering (All EU Models)25
- Unlocking the Steering (All EU Models)26
7 Combination Instrument 727
- Combination Instrument Overview27
- Activation and Test27
- Setting the Kilometers or Miles27
- Setting the Combination Instrument28
- Setting the Clock29
- Viewing the Lap Time29
- Display Mode SPEED (Speed)30
- Display Mode SPEED/H (Operating Hours)30
- Setup Menu30
- Adjusting the Unit of Measurement31
- Display Mode SPEED/CLK (Time)32
- Setting the Clock32
- Display Mode SPEED/LAP (Lap Time)32
- Viewing the Lap Time33
- 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 Functions37
- Table of Conditions and Menu Activation38
8 Preparing for Use 839
- Advice on Preparing for First Use39
- Running-In the Engine40
- Starting Power of Lithium-Ion Batteries at Low Temperatures41
- Preparing the Vehicle for Difficult Riding Conditions41
- Preparing the Vehicle for Riding on Dry Sand41
- Preparing the Vehicle for Riding on Wet Sand42
- Preparing the Vehicle for Riding on Wet and Muddy Circuits43
- Preparing Vehicle for High Temperatures or Slow Riding43
- Preparing the Vehicle for Low Temperatures or Snow44
9 Riding Instructions 945
- Checks and Maintenance Measures When Preparing for Use45
- Starting the Vehicle45
- Activating Traction Control (All EXC-F Six Days, XCF-W)46
- Starting off47
- Shifting, Riding47
- Braking47
- Stopping, Parking48
- Transporting49
- Refueling49
10 Service Schedule 1051
- Additional Information51
- Required Work51
- Recommended Work52
11 Tuning the Chassis54
- Checking the Basic Chassis Setting with Rider's Weight54
- Compression Damping of the Shock Absorber54
- Adjusting the Low-Speed Compression Damping of the Shock Absorber54
- Adjusting the High-Speed Compression Damping of the Shock Absorber55
- Adjusting the Rebound Damping of the Shock Absorber56
- Measuring the Dimension of the Rear Wheel Unloaded56
- Checking the Static Sag of the Shock Absorber57
- Checking the Riding Sag of the Shock Absorber57
- Adjusting the Spring Preload of the Shock Absorber58
- Adjusting the Riding Sag59
- Checking the Basic Setting of the Fork59
- Adjusting the Compression Damping of the Fork60
- Adjusting the Rebound Damping of the Fork61
- Adjusting the Spring Preload of the Fork (All EXC-F Six Days)62
- Handlebar Position63
- Adjusting the Handlebar Position63
12 Service Work on the Chassis66
- Raising the Motorcycle with the Lift Stand66
- Removing the Motorcycle from the Lift Stand66
- Bleeding the Fork Legs66
- Cleaning the Dust Boots of the Fork Legs67
- Removing the Fork Protector67
- Installing the Fork Protector68
- Removing the Fork Legs68
- Installing the Fork Legs69
  - 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 Play75
- 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 Bearing77
- Removing Front Fender78
- Installing Front Fender79
- Removing the Shock Absorber80
- Installing the Shock Absorber80
- Removing the Seat80
- Mounting the Seat81
- Removing the Air Filter Box Cover81
- Installing the Air Filter Box Cover82
- Removing the Air Filter83
- Installing the Air Filter83
- Cleaning the Air Filter and Air Filter Box84
- Preparing Air Filter Box Cover for Securing84
- Removing the Main Silencer85
- Installing the Main Silencer85
- Cleaning the Spark Arrestor (XCF-W)85
- Changing the Glass Fiber Yarn Filling of the Main Silencer87
- Removing the Fuel Tank88
- Installing the Fuel Tank89
  - Checking for Chain Dirt Accumulation91
  - Cleaning the Chain91
  - Checking the Chain Tension92
  - Adjusting the Chain Tension93
  - Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide94
  - Checking the Frame96
  - Checking the Link Fork96
  - Checking Throttle Cable Routing96
  - Checking the Rubber Grip97
  - Adjusting the Basic Position of the Clutch Lever98
  - Checking/Correcting the Fluid Level of the Hydraulic Clutch98
  - Changing the Hydraulic Clutch Fluid99
  - 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 System102
- Checking the Free Travel of the Hand Brake Lever102
- 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 Discs103
- Checking the Front Brake Fluid Level104
- Adding the Front Brake Fluid104
- Checking the Front Brake Linings106
- Changing the Brake Linings of the Front Brake106
- Checking the Free Travel of Foot Brake Lever110
- Adjusting the Basic Position of the Foot Brake Lever111
- Checking the Rear Brake Fluid Level112
- Adding Rear Brake Fluid112
- Checking the Rear Brake Linings113
- Changing the Rear Brake Linings114
14 Wheels, Tires 14117
- Removing the Front Wheel117
- Installing the Front Wheel118
- Removing the Rear Wheel118
- Installing the Rear Wheel119
- Checking the Tire Condition121
- Checking Tire Pressure121
- Checking Spoke Tension122
15 Electrical System123
- Electrical System 15123
- Removing the 12-V Battery123
- Installing the 12-V Battery124
- Charging the 12-V Battery125
- Changing the Main Fuse127
- Changing the Fuses of Individual Power Consumers128
- Removing the Headlight Mask with the Headlight129
- Installing the Headlight Mask with the Headlight130
- Changing the Headlight Bulb131
- Checking the Headlight Setting131
- Adjusting the Headlight Range132
- Changing the Turn Signal Bulb (All EU Models)132
- Changing the Combination Instrument Battery133
- Diagnostics Connector134
16 Cooling System 16135
- Checking the Antifreeze and Coolant Level135
- Checking the Coolant Level136
- Draining the Coolant137
- Refilling Coolant138
17 Tuning the Engine 17139
- Checking the Throttle Cable Play139
- Adjusting the Throttle Cable Play139
- Adjusting the Characteristic Map of the Throttle Response140
- Changing the Mapping (All EXC-F Six Days, XCF-W)141
- Adjusting the Idle Speed142
- Teaching the Throttle Valve Position143
- Checking the Basic Position of the Shift Lever143
- Adjusting the Basic Position of the Shift Lever144
18 Service Work on the Engine 18145
- Changing the Fuel Screen145
- Checking the Engine Oil Level146
- Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens146
- Adding Engine Oil149
19 Cleaning, Care150
- Cleaning the Motorcycle150
- Checks and Maintenance Steps for Winter Operation151
20 Storage152
- Preparing for Use after Storage153
21 Troubleshooting154
22 Technical Data 22157
- Engine157
- Engine Tightening Torques158
- Capacities159
- Engine Oil159
- Coolant159
- Fuel159
- Chassis160
- Electrical System161
- Tires161
- Fork161
- Exc-F Eu, Xcf-W161
- All EXC-F Six Days162
- Shock Absorber162
- Chassis Tightening Torques163
23 Substances166
24 Auxiliary Substances168
25 Standards170
26 Index of Special Terms 26171
27 List of Abbreviations172
28 List of Symbols 28173
- Yellow and Orange Symbols173
- Green and Blue Symbols173
- Index174

Brand	KTM
Model	500 XCF-W 2020
Category	Motorcycle
Language	English

KTM 500 XCF-W 2020 User Manual

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