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Old 02-25-2012, 05:41 AM   #541
ABYSS
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Tank capacity

Why yes I do, I own one I got mine in December and they were very hard to get a hold of at the time. I took mine to the gas station after I mounted the pump and fuel spigot off the bike and was able to put 3.52 gallons in it from a new bone dry state.

Acerbis is econsidering making a 4 gallon tank and some of us have called them to reaffirm interest.







Quote:
Originally Posted by 2on2off View Post
Do you know for certain the KTM tank holds 3.5 gallons? I emptied my 500EXC stock tank and filled it at the gas station and it maxed out at 2.25 gallons.

The Safari 4 gallon tank for the 525EXC holds 4.4 gallons. I verified this by emptying it and filling it at the gas station.

My DRZ400S Clark 4.0 gallon Fuel tank holds a max of 4.0 gallons.

The DRZ400S IMS 4 gallon fuel tank holds a max of 4.4 gallons.

Has anyone bought and installed the KTM 13L fuel tank or the Clockworks 3.2 gallon fuel tank, emptied it and refueled it at the gas station to verify how many gallons it truely holds?

IMS is currently working on a 3.1 gallon fuel tank for the 500EXC but have to modify their 350EXC FI fuel tank to allow for the radiator fan on the 500 which the 350 does not have. They might loose capacity to make room for the radiator fan.

I have found the true capacity is often different than the stated capacity.

500EXC owners with larger fuel tanks installed please check in with your own results. Every ounce of fuel matters to me because I often ride close to 200 miles between fuel stops and would prefer not to carry extra fuel if I don't have to.
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Old 02-25-2012, 07:15 AM   #542
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Quote:
Originally Posted by child View Post

Yes that's Munster/Bulcher/Red River, whatever you wanna call it We're up there most weekends.

We've been talking about camping up there all weekend sometime and inviting any and all ADVers that wanna ride. Are you in DFW or are we that famous?
If this is still an open invitation, I would love to have some people to start riding with. Have not been on the dirt in about 20 years. Brought the 500EXC home yesterday and still need to upgrade my street gear to offroad gear, but that shouldn't take too long. Please let me know when you guys head out again, no matter where.

Brad
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Old 02-25-2012, 09:48 AM   #543
EVELKNIEVEL
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Cool2 efi map plug

[QUOTE=Zuber;18066099]Just got back from KTM School on the 450/500 XCW/EXC. Here's a few notes:

1. The power modifying resistors do nothing for the XCW/EXC. The alternative FI and Ign maps are not in these bikes. So, save your money, they don't have the soft/normal/aggressive options like the SX/XCF, only normal.

2. The FI and Ign is locked. You can load new maps as they become available from KTM, but the User Setting Tool will not re-program the XCW/EXC. The UST will only program the SX/XCF. The map types must match the bike type (green sticker/EPA or not green sticker), so don't expect to load the SX/XCF maps and get them to stick. It may load it, but when the UST is removed, you're back to the old map.

3. The bike does a near instant Initialization, also known as the 15 min or 5 min idle. If you move this bike to a new altitude, it may run like crap for a few minutes, it only needs to warm up and get run through the full rpm and full throttle range to learn the new environment. Don't idle it, just ride it and run it through the full range. This is the same for all Kehin FI bikes.

5. If you want a richer across the board setting, you may try a resistor in line with the air temp sensor, mounted on the air box. Nuf said about that.

nice write up zuber much respect
i have a jd tuner tuner onthe way should be here today have you herd positive things about this ?
i talked to sicass racing they said amazing results with map plug
KTM / HUSABERG EFI Map Plugs

$24.95

SICASS racing's exclusive EFI map plugs for the EFI equipped KTM's. Set includes both the Mild and Wild plugs, simply remove your seat and plug into the EFI map socket and you've adjusted the power curve.

NOTE: SICASS EFI plugs change only the ignition mapping, they DO NOT affect the fuel mapping.
  • Fits:
  • 2011-12 KTM 250SX
  • 2011-12 KTM 350SX
  • 2001-12 KTM 250XCF
  • 2011-12 KTM 350XCF
  • 2009-11 Husaberg FE 390/450/570
    • Fits ONLY AFTER ECU is Unlocked By KTM Dealer:
    • 2012 KTM 250XCF-W
    • 2012 KTM 350XCF-W
    • 2012 KTM 450XCW
    • 2012 KTM 500XCW
    • 2012 KTM 350EXC-F
    • 2012 KTM 500EXC
Read a rider review of the SICASS racing EFI map switch here.
If you would prefer on-the-fly adjustment of your EFI mapping for your:
KTM check out our 2011-12 KTM 250/350SXF EFI Mapping Switch here.
Have a Husaberg? Check out our 2009-11 Husaberg EFI mapping switch here NOTE: The 2012 XC-W and EXC models MUST have the ECU unlocked by your KTM dealer before the mapping switch will work.



is unlocking easy for ktm dealers? of course the plug is for off road use only
you can stwitch them out mild and wild
happy landings

EVEL KNIEVEL
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Old 02-25-2012, 04:04 PM   #544
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Quote:
Originally Posted by 2on2off View Post
Disadvantages of the DRZ:
- had to do many mods to: carb, air box, side covers, aluminum handlebars All Done
- needed to add stiffer springs to the fork and shock Done
- weighs 45 lbs. more than the 500EXC can't fix this
- power delivery is soft (this is an advantage and a disadvantage)
-stock gas tank is too small Clarke 4.0 done
Thanks for taking the time to write all that up. I guess I will just have to wait till the DRZ burns out and make a decision. It may be a while, it only has 27,000 miles on it.
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Old 02-25-2012, 07:50 PM   #545
RichardU
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2on2off,

Thanks for the insight. I have about 25,000 miles on my DRZ. Given the schedule for the 500, at an average of 40 mph that would have been 4 new pistons. Ouch.

I guess what I want is the power/weight of the 500 with the low maintenance and reliability of the DRZ. I suppose I also want politicians who tell the truth, and the ability to lose weight while ignoring diet and exercise.
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Old 02-25-2012, 10:36 PM   #546
spagthorpe
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I would think a con of the DRZ would be the five speed gearbox. It's hard to get the gearing right for all around dual sport use, at least if you need to ride the freeway to get anywhere.


Thanks for the comparison though. Good info. I had no idea the piston interval for the 500 was 150 hours. Ouch. Is that the racing spec interval, or for general use?
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Old 02-26-2012, 02:02 PM   #547
AussieClay
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JD Tuning Module

Overhauled the Scotts steering damper I had from my last bike and installed a new mounting kit for the 500 EXC.
I received the JD tuning module in the mail a couple of days ago. Just need to find the time to install and take it for a test ride.... will let you know the results.

I spent a lot of time talking with James from JD and he was very helpful and knowledgable. Great customer service.
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Old 02-26-2012, 07:17 PM   #548
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Quote:
NOTE:
The 2012 XC-W and EXC models MUST have the ECU unlocked by your KTM dealer before the mapping switch will work
is unlocking easy for ktm dealers? of course the plug is for off road use only
you can stwitch them out mild and wild


According to KTM, it is impossible to unlock an XCW or an EXC. The lock is a simple switch in the SX and XCF to prevent accidental mods to the map. The option is not even available on the XCW/EXC. It would be difficult to get around this, currently. I expect the aftermarket to come up with an open source tuner (like TuneECU) and just do an end-run. Currently, the other option is to some how get an SX/XCF ECU on your bike, for off-road use only of course.
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Old 02-26-2012, 09:09 PM   #549
ABYSS
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FYI- Manuals

The 2012 manuals are out and available. I got mine. Saturday..

KTM. Is no longer putting them in plain PDF format. It is now in a propriety PDF reader. The pdf is encapsulated within an .exe file making it hard get on your IPAD type device.. But not impossible
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Old 02-26-2012, 10:34 PM   #550
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Quote:
Originally Posted by RichardU View Post
2on2off,

Thanks for the insight. I have about 25,000 miles on my DRZ. Given the schedule for the 500, at an average of 40 mph that would have been 4 new pistons. Ouch.

I guess what I want is the power/weight of the 500 with the low maintenance and reliability of the DRZ. I suppose I also want politicians who tell the truth, and the ability to lose weight while ignoring diet and exercise.
It isnt that simple. The maintenance schedule is designed for casual trail riders who while aren't racers, arent exactly plodding along with the motor either. It includes alot of movement through the power range and works the oil and components hard.
Now, ride the 500exc like a DRZ400 and it would last just as long IMO. 25,000 miles on the original piston, just casually riding the highways and trails? Easily. People have done it on the RFS motor many times.
The thing is these KTMs make you want to ride them hard, and with that comes more wear on the motor from higher revs.

My opinion, and it makes sense with lots of vehicles that last a very long time when they rarely get revved out. The more horsepower released to the wheel over the life of the engine, the earlier it will require replacement piston/valves etc. Simple as that IMO!
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Old 02-27-2012, 06:48 AM   #551
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Quote:
Originally Posted by ADVJake View Post
. The more horsepower released to the wheel over the life of the engine, the earlier it will require replacement piston/valves etc. Simple as that IMO!
This, to me, seems to be the sister thought to using liters/gallons as a measuring stick for doing maintenance instead of the hours or miles that could be less accurate. It just makes sense.
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Old 02-27-2012, 08:04 AM   #552
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Quote:
Originally Posted by ABYSS View Post
The 2012 manuals are out and available. I got mine. Saturday..

KTM. Is no longer putting them in plain PDF format. It is now in a propriety PDF reader. The pdf is encapsulated within an .exe file making it hard get on your IPAD type device.. But not impossible

Where can we get these, beside the lame local dealership...
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Old 02-27-2012, 01:14 PM   #553
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Wicked latest Mods

So, I've been working on my 500 EXC for some time now, getting it ready for a ride with my brother in Yuma. The Ride was successful in that we didn't have any mechanical failures. However, we did run out of time and had to cut out 137 miles....bummer. Next time we are going to run the route in reverse to see some of the other parts of the Yuma area. If you are interested in downloading the GPS files, you can get the route from DualSportMaps.com, link -> http://dualsportmaps.com/?link=102719

I have put together a Ride report here on ADV, if you care to see some of the sites.....:
http://www.advrider.com/forums/showthread.php?t=767594



Now, on to the Modifications that I have put on the 2012 500 EXC for this trip and any upcoming trips.....




GPS

After a stint with the KOTW, I decided that my Garmin Oregon GPS was not going to cut it for fast motorcycle riding. So, after looking around I came across at Garmin 276C. These are pretty much bomb-proof units that are waterproof, and they have a screen that unlike the newer touch-screen models. I appreciate this because when you are zipping along the trail, the sand and dust will inevitably cover the screen. When I had the Oregon, the dust would quickly cover the screen, which made viewing the tracks difficult. When I cleaned the screen with my glove, the touch-screen would respond with an attempt to either unlock the screen or change the screen setting. This is an unwelcome action when you are moving along a trail trying to follow your GPS tracks. Being that the 276C does not have a touch-screen, cleaning the screen of dust is not a problem at all.
















Mounting the GPS was somewhat of an issue for the 500 EXC, due to the bike being so new. After-market manufactures appear to have not had an opportunity to build anything for the 2012 500 EXC bike. So, I had to build my own GPS mount. I'm using the Tourtech mounting bracket for the 276c, and then I've built my own mount for this unit......I visited Lowes and picked up some 1/2" OD steel tubing. Using a table mounted vise, I was able to bend the tubing to my specs, and pound the ends flat for a secure mounting points. I used some old windshield mounts to hold the end of the primary tube, and then created a couple of small mounts for the lower section to hold the primary tube in place.









In the event that I would have to remove the steering head, or any disconnect the wiring harness from the battery, I put in a waterproof 3 pin plug. This makes the disconnect much easier....














Fuse Block

To power accessories in a safe maner, it's a good idea to have a fuse block for your accessories. I have a PowerLet FuseBlock that is Zip-tied to the top-side of the Air-Filter clamp. So far, this has been working very well. My current powered accessories are:

Hardwired GPS power
PowerLet plug in the HDB Top Clamp for my Cell Phone
SAE Plug, sitting in the AIR Filter compartment, for either charging the battery or heated gear
and coming soon, a 12V standard cigarette lighter plug for standard accessories such as Ipod charging.









TrailTech Headlight

We all know the stock headlights on the KTM bikes are little more than a joke. The one time I relied on the stock headlight I was sorely disappointed by the light, rather lack of light, put out by this joke of a headlight. I had to follow my brother in the dark and use his headlight to see in the dark as we worked our way out of the desert. Since then, I have upgraded to a Trail Tech Torch Halogen Off-Road headlight. While not the brightest on the market, this headlight is significantly better than the stock. On this latest trip of Yuma to Parker, we ended up getting to our camp spot after dark, and I must say, the Trail Tech headlight was a welcome sight.

When I was mounting the headlight, I ran into some issues in that the back of the headlight was quite a bit deeper than the stock headlight, and thus prevented the headlight from securing to the front forks. I created a couple of head-light extensions that allowed the headlight mount to be moved out nearly two inches. Of course, this means the bottom bracket for the headlight needs to be adjusted so that the headlight will throw a beam down the road, and not into the air. So, I used the Trail Tech headlight mount to mount to the fender. Through the up-and downs of the trail I have not had any issues with the headlight moving around or coming off the bottom mounts.







I believe that Paul is working on some really nice headlight extensions. He may have these available in the future. My extensions are cheap plastic..... but, they work very well.





Here you can see how the Trail Tech headlight is deeper than the stock headlight, and will interfere wit the wiring harness behind the headlight



It should be noted that I had to run the cable in front of the headlight due to the HDB Vapor w/dash. This allows the cable to move freely up and down with out restrictions. In this current position, the front fork is fully extended, thus pulling the cable all the way down. Under normal conditions, the cable is not in front of the headlight.






TrailTech Striker Computer

The KTM 500 EXC has a new computer that does a pretty good job of keeping track of the vitals, including a FI light that will light up if there is a problem with the engine or Fuel Injection. I wanted to have a little more info on my dash, so I ordered a Trail Tech Striker computer, model# 712-102. I've found that the bare aluminum can cast quite a reflection in the hot sun, so the stealth (black) is a better option for me. I requested that the mileage and hours be set by Trail Tech before it was sent out to me. I then received an email stating that I would be able to perform this action, using their provided instructions. When I got around to installing the computer I was surprised to find that they in fact did set the mileage and hours per my previous request.....very nice of them. After setting up the computer for the correct tire size, and checked the mileage distance against my GPS, and then against my car; it's spot on. Trail Tech also provides a "dash" For the lights, which I was able to pick up via MotorCycle Superstore for a decent price.

Something to note: The FI light has a very small computer chip that is part of the light. Fortunately, this entire chip and be fitted into the existing Trail Tech light housing with no issues.

Due to the stock A/C voltage system, you will need to use the Trail Tech provided "bulbs", instead of LEDs for the dash indicator lights. Unless you have a converted D/C system, the LED lights will not work. Regardless, everything is working quite nice.












Highway Dirt Bike (HDB) parts

Paul at HighwayDirtBike has been producing high-quality products for dirt bikes for some time now. I picked up the following parts from Paul:

Top Clamp, Anodized
Billet Handguards
Mirrors
Bottom Clamp setup for Scott Steering Damper
Vapor w/Dash Billet protector, Anodized
Key Switch mount w/iPod remote pad

I must say, Paul's parts are Bomb-Proof! Plus, he is a great guy to work with. These parts speak for themselves: high-quality, bomb-proof and plenty of options.....

When getting the HDB setup, I would highly recommend you also get the slimmer combination switch. This makes it possible to have room for the HDB setup. Here you can see how the aftermarket combination switch is slimmer than the stock setup


















To eliminate any rattling of the mirrors some sticky sided foam works really well:














Exhaust Head Shield

Before I acquired a Tail-rack from Globetrottin, I made a heat-shield from an old license plate and a bracket. I have a Giant-Loop Mojavi bag that is ideal for the quick jaunts; smaller than the Coyote bag, but allows for 1.5L bottles of fuel or water. To keep this bag from melting on the extremely hot exhaust, I made up a heat shield to protect the bag. So far, its been working very well....






Flatland Racing Skidplate

This Skid plate has more than paid for itself. just take a look at the beating this thing has been taking......think you might need one?





I found out after I installed the FlatLand Racing skid plate that when one is checking valves, the skid plate interferes with the ability to lock the valves into place, using the Lock-Bolt and the Fly-wheel notch. If you look closely at the skid plate, you can see how I drilled out a hole to allow Lock-Bolt to come all the way out, thus allowing the copper spacer to be removed from the bolt, and then the Lock-Bolt can be put back into place, thus locking the Fly wheel into the Top-Dead-Center position.





GlobeTrottin Top Rack

GlobeTrottin makes an excellent Top (Tail) Rack for the 500 EXC. I recently loaded up this rack with LOTS of gear, in an attempt to really test it out. This rack did, VERY well under the load, and repeated crashes.......
My brother followed me for several miles and commented that the gear that was tied to the rack didn't move an inch, despite the bouncing around and crashes.....











Fuel Filter
I recently took my bike in to have the 10-micron Fuel Filter replaced with the 20-micron Fuel Filter. Here is a close up picture of the 10-micron Fuel Filter. The dealer replaced the Fuel Filter and installed a removable clamp on the hose. They also provided me with a couple of spare 20-micron Fuel Filters....great guys.










I believe somebody asked about the part number for the 20micron fuel filter.
Here is where the fuel filter is found, right next to the throttle body
The actual Fuel Filter Kit is part# 78141013044, but it appears you can not get this part from CheapCycleParts......It's listed as "not-available". I assume because all of these parts are going to the dealers......I do know that if you take you bike to a dealer, they can look up the VIN number and determine if your bike has been serviced. If not, its all of 10 minutes to replace this Filter....




Handlebar Control switch

If there is one upgrade that gives you a better handle on your bike, this is it. Their appears to be several different companies that offer the same type of Handlebar switch. I got this installed with no drama, and besides the expectation of it working great, the thin switch allows me to get a better grip on the clutch lever.....





Scoche RF iPod controller

This thing is GREAT. I enjoy listening to some great tunes when on the trail, and having the ability to stop/start my tunes WITHOUT digging into my gear is awesome:




Future mods:

Larger gas tank from Acerbis
Low-profile "comfortable" seat
Scott steering damper

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Old 02-27-2012, 04:07 PM   #554
dieselcruiserhead
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Interesting as the 500 really could go both ways, dirtbike or ADV it appears. I have a pretty smooth/fully built old '02 520 (510cc, as comfortable as possible) but I hardly consider it a "motorcycle" as its not comfortable for longer trips. Would you say the 500 is different than that? Key with loading the 520 is as minimum stuff as possible. I have a Baja Designs light on mine (came with it, hard to discard it) but I almost consider it to be too much weight up front...
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Old 02-27-2012, 04:49 PM   #555
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Quote:
Originally Posted by dieselcruiserhead View Post
Interesting as the 500 really could go both ways, dirtbike or ADV it appears. I have a pretty smooth/fully built old '02 520 (510cc, as comfortable as possible) but I hardly consider it a "motorcycle" as its not comfortable for longer trips. Would you say the 500 is different than that? Key with loading the 520 is as minimum stuff as possible. I have a Baja Designs light on mine (came with it, hard to discard it) but I almost consider it to be too much weight up front...
I don't know if this 500EXC is that much different than a '02 520.......this is my first KTM bike, and my last KTM bike. I did a whole lot of research on Dual-sport bikes before purchasing this one. My last Dual-sport bike was a 2010 Yamaha WR250R. While this bike was nice, it just didn't have the power. This KTM has the power and is lighter.....I like. As for highway droning, no, it's just not there....Well, at least without some kind of windshield it's not there. Maybe with some kind of windshield it would be acceptable. It certainly has the legs for it.....

The seat is definitely a motocross type seat, not comfortable. I purchased a SheepSkin cover from AlaskaLeather, in hopes that my rear would be a little more comfortable. Yes.....it was "a little" more comfortable, but definitely not all day comfort. A better seat is needed.

The switch I have mounted in the HDB Top Clamp is a DPDT (Dual Pole Dual Throw) ON-OFF-ON switch. Currently I have the switched integrated into the starting system so that if the switch is not in the correct position, the bike will not start......sorta of a little insurance so the bike can't be hot-wired in the parking lot at 1AM. This same switch will be used for auxiliary LED lighting when some funds become available. Of course, I will also have to change the system to DC, but that is a given soon enough.....
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