| Service work | After 1 operating hour | Every 15 operating hours | Every 45 operating hours | Every 90 operating hours | Every 24 months |
|---|---|---|---|---|---|
| Check the chain, rear sprocket, engine sprocket, and chain guide. (📖 p. 132) | ○ | ● | ● | ● | |
| Check the chain tension. (📖 p. 131) | ○ | ● | ● | ● | ● |
| Grease all moving parts (e.g. side stand, hand lever, chain, etc.) and check for smooth operation. | ○ | ● | ● | ● | ● |
| Check the valve clearance. (📖 p. 278) | ○ | ● | ● | ||
| Change the fuel filter. (📖 p. 109) | ● | ● | |||
| Check the clutch. (📖 p. 248) | ● | ● | |||
| Clean the air filter and air filter box. (📖 p. 101) | ● | ● | ● | ● | |
| Check the funnel in the inlet sleeve in the air filter box. (all EU models, XCF-W, All EXC except US) | ● | ● | ● | ● | |
| Check the intake membrane in the airbox rubber. (XW-F) | ● | ● | |||
| Change the glass fiber yarn filling of the main silencer. (📖 p. 96) | ● | ● | |||
| Service the fork. (📖 p. 20) | ● | ● | |||
| Perform the shock absorber service. (📖 p. 67) | ● | ● | |||
| Check all screws, nuts, and hose clips for a tight fit. | ○ | ● | ● | ● | ● |
| Change the fuel screen. (📖 p. 108) | ○ | ● | ● | ● | ● |
| Check the fuel pressure. (📖 p. 113) | ○ | ● | ● | ● | |
| Check the antifreeze and coolant level. (📖 p. 260) | ● | ● | |||
| Check the coolant level. (📖 p. 261) | ○ | ● | |||
| Change the coolant. (📖 p. 263) | ● | ||||
| Check that the radiator fan is functioning properly. | ○ | ● | ● | ● | |
| Check the steering head bearing for play. (📖 p. 45) | ○ | ● | |||
| Lubricate the steering head bearing. (📖 p. 41) | ● | ● | ● | ||
| Check the headlight setting. (📖 p. 165) | ● | ● | ● | ||
| Clean the spark arrestor. (XW-F) (📖 p. 97) | ● | ● | |||
| Read out the fault memory using the KTM diagnostics tool. | ○ | ● | ● | ● | ● |
| Program the gear position sensor. (📖 p. 288) | ● | ● | ● | ||
| Check that the electrical system is functioning properly. | ○ | ● | ● | ● | |
| Check and charge the 12-V battery. | ● | ● | ● | ● | |
| Check that the brake linings of the front brake are secured. (📖 p. 152) | ● | ● | ● | ● | |
| Check that the brake linings of the rear brake are secured. (📖 p. 160) | ● | ● | ● | ● | |
| Check the brake discs. (📖 p. 150) | ● | ● | ● | ● | |
| Check the brake lines for damage and tightness. | ● | ● | ● | ● | |
| Check the front brake fluid level. (📖 p. 151) | ● | ● | |||
| Change the front brake fluid. (📖 p. 155) | ● | ● | |||
| Check the rear brake fluid level. (📖 p. 158) | ● | ● | |||
| Change the rear brake fluid. (📖 p. 162) | ● | ● | |||
| Check/correct the fluid level of hydraulic clutch. (📖 p. 246) | ● | ||||
| Change the hydraulic clutch fluid. (📖 p. 247) | ● | ● | |||
| Check the free travel of the hand brake lever. | ○ | ● | ● | ● | ● |
| Check the free travel of the foot brake lever. (📖 p. 157) | ● | ● | ● | ● | |
| Check the idle speed. | ○ | ● | ● | ● | ● |
| Change the engine oil and the oil filter, clean the oil screens. (📖 p. 270) | ○ | ● | ● | ● | ● |
| Check all hoses (e.g. fuel, cooling, bleeder, drainage hoses, etc.) and sleeves for cracking, tightness, and correct routing. | ○ | ● | ● | ● | ● |
| Check the cables for damage and that there are no kinks in the routing. | ● | ● | ● | ● | |
| Check that the throttle cables are undamaged, routed without kinks, and set correctly. | ● | ● | ● | ||
| Check the frame. (📖 p. 56) | ● | ● | ● | ||
| Check the link fork. (📖 p. 86) | ● | ● | ● | ||
| Check the fork bearing for play. (📖 p. 86) | ● | ● | |||
| Check the shock absorber heim joint for play. (📖 p. 85) | ● | ● | |||
| Check the tire condition. (📖 p. 119) | ● | ● | ● | ● | |
| Check tire pressure. (📖 p. 119) | ● | ● | ● | ● | |
| Check the wheel bearing for play. (📖 p. 120) | ● | ● | ● | ||
| Check the wheel hubs. | ● | ● | ● | ||
| Check the rim run-out. (📖 p. 122) | ○ | ● | ● | ● | |
| Check the spoke tension. (📖 p. 121) | ○ | ● | ● | ● | |
| ○ One-time interval ● Periodic interval | |||||
KTM 500 EXC-F Six Days 500 XW-F Service manual 2024 Pdf Download