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SERVICE WORK ON THE CHASSIS 12

V01764-10

(All EU models)

–

Remove screws

– Hang the horn and horn bracket to one side.

V01765-10

(XCF‑W)

–

Remove screws

V01766-10

–

Remove screw

with the rubber bushing.

– Remove the hose from the fuel tank breather.

V01767-10

– Pull both spoilers laterally off the radiator and lift off the fuel

tank.

12.34 Installing the fuel tank

Danger

Fire hazard Fuel is highly flammable.

The fuel in the fuel tank expands when warm and can escape if overfilled.

– Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.

– Switch off the engine for refueling.

– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.

– If any fuel is spilled, wipe it off immediately.

– Observe the specifications for refueling.

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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