2012 ktm 500 exc?

Discussion in 'Thumpers' started by Visigothic, Apr 27, 2011.

  1. helotaxi

    helotaxi Been here awhile

    Joined:
    Aug 13, 2011
    Oddometer:
    380
    It won't fit under the fitting and I can't rotate the lever perch far enough down to clear without the fitting hitting the bar. The clutch perch is as far toward the end of the bar as I can get it without the adjuster nut hitting the switch assembly (0.5mm of clearance).

    [​IMG]
  2. avconnect

    avconnect Been here awhile

    Joined:
    Apr 22, 2012
    Oddometer:
    125
    Location:
    Salt Lake City
    I have the same issue and am looking for a solution...tried a EE clutch cable and it was a bit longer but did not solve the problem.
  3. helotaxi

    helotaxi Been here awhile

    Joined:
    Aug 13, 2011
    Oddometer:
    380
    Cable length isn't the issue. The issue is that the fitting that comes out of the clutch master cylinder is straight and too long as opposed to a brake style banjo fitting. I've got a feeling that I'm going to have to switch over to and aftermarket narrow switch set that will let me slide the clutch lever perch farther out.
  4. Thumperconvert

    Thumperconvert n00b

    Joined:
    Jun 24, 2012
    Oddometer:
    1
    Location:
    SoCal
    ...and allows you to tun off the headlight. I put one on my 530 after a fall destroyed the stock unit as dirt got in it. I tried for hours to clean it but it was never the same. When these bikes go down, they go down hard. I destroyed the stock throttle tube (replaced with KTM Powerparts throttle cam system) and just bent a Cycra center reach mount brush guard. That same spill broke the throttle cable plastic where it enters the throttle assembly. Expensive tumble not to mention a bruised rib. Ouch. :eek1

    http://sicassracing.com/store/produ...witches/2007-12_exc_multi-function_bar_switch
  5. LukasM

    LukasM Long timer

    Joined:
    Nov 15, 2006
    Oddometer:
    5,430
    Location:
    On a RTW ride - currently SE Asia on the way to OZ
    What switch do you have now?

    The stock Euro KTM CEV one is super compact and also very durable. I've got an extra if you need one.

    [​IMG]
  6. Vico1

    Vico1 The Maestro

    Joined:
    Oct 31, 2008
    Oddometer:
    6,575
    Location:
    Ft Walton Beach FL
    That looks cool. Can I run over and pick up your extra!!! Oh wait you are in Austria!

    Do you have info on how I can order one? Cost?

    Thanks
  7. helotaxi

    helotaxi Been here awhile

    Joined:
    Aug 13, 2011
    Oddometer:
    380
    It's the stock US market switch setup. The real problem with it is that the housing is too thick on the back side of the bar. As a result the thumbscrew adjuster on the clutch lever hits the housing if the perch is moved any further toward the end of the bar.

    [​IMG]

    I might take you up on that offer. I just wonder if the wiring harnesses are the same between the US and Euro spec models.
  8. Lulu7404

    Lulu7404 Been here awhile

    Joined:
    May 16, 2009
    Oddometer:
    276
    Location:
    Just north of Big D
    I am in the same boat. I am about to give in and buy the new switch that is plug and play. I fiddled with it just enough to ease pressure on HDB spacer, but now my clutch won't engage all the way. When I go from neutral to first it grabs pretty good. I almost have to put it in neutral at stops to keep it from pulling... Could we get some pictures from those not having problems. That have EXC's not XCW's. We know why those who were smart enough to get the XCW have yet another reason they made the better choice...:lol3 I have a feeling that a smaller switch is in order, since Paul himself used his XCW for fitment I am sure.

    [​IMG]
    [​IMG]
  9. SteveO

    SteveO ouch....

    Joined:
    Jul 15, 2010
    Oddometer:
    1,237
    Location:
    Land of ambivalence
    ya gotta get rid of the stock switch housing, and get a smaller switch housing.

    Paul at HDB sells these types of switch housings for a good price:


    [​IMG]



    With a better switch housing, you can get the clutch in much closer. In my case, I moved to a better clutch lever as well

    [​IMG]
  10. LukasM

    LukasM Long timer

    Joined:
    Nov 15, 2006
    Oddometer:
    5,430
    Location:
    On a RTW ride - currently SE Asia on the way to OZ
    Ok I know that switch from my buddies US spec Husaberg, it is indeed quite bulky especially at the back and if I remember correctly it does not even allow you to switch off the headlight due to DOT regulation? I'm pretty sure that is the only difference with the Euro light - which does allow switching off - and the rest of the wiring is plug & play. KTM is pretty good that way, I have had that same switch on all my KTMs, from my first 1998 620 SC all the way to the 2012 fuel injected FE570.

    I can take some detailed pics of the wiring colors tomorrow so you can compare it to yours. Here is what the plugs look like, I assume they are the same?

    [​IMG]

    [​IMG]


    I'll try to find out the part numbers, but I know you can order it from US dealers. Unfortunately it's very expensive, you need a couple of parts and all together retail is almost $150... :eek1
  11. avconnect

    avconnect Been here awhile

    Joined:
    Apr 22, 2012
    Oddometer:
    125
    Location:
    Salt Lake City
    Get the switch from Sicass Racing. I am installing one tonight and am confident it will solve the problem. Here is a link for the part. http://sicassracing.com/store/produ...switch?zenid=0135266039b4713069dded36ba0b8681
  12. helotaxi

    helotaxi Been here awhile

    Joined:
    Aug 13, 2011
    Oddometer:
    380
    Except they are currently out of stock. First place I looked.

    It looks like the HDB switch housing might be the answer, but I assume that there will be some cutting and splicing required? How deep is it behind the bar?
  13. JTucker

    JTucker Long timer

    Joined:
    Sep 27, 2008
    Oddometer:
    2,270
    Location:
    West By God Virginia
  14. LukasM

    LukasM Long timer

    Joined:
    Nov 15, 2006
    Oddometer:
    5,430
    Location:
    On a RTW ride - currently SE Asia on the way to OZ
  15. JTucker

    JTucker Long timer

    Joined:
    Sep 27, 2008
    Oddometer:
    2,270
    Location:
    West By God Virginia
    Adapter: 13011070060
    Screw x2: 0985040163
    Screw X2: 0084040223
    Nut X2: 0934040003

    I think that's it.
  16. ABYSS

    ABYSS KTM

    Joined:
    Oct 16, 2006
    Oddometer:
    1,198
    That sucks I wont bust you EXC guys balls over this one.

    Have any of you looked into making a different Clutch line instead of having to mess with the wiring? It would be alot cheaper and faster.
  17. Geek

    Geek oot & aboot

    Joined:
    Jun 8, 2003
    Oddometer:
    32,160
    Location:
    8000ft.
    We spent the day at the track :ricky

    [​IMG]


    This evening I pulled the bike apart and put new springs in and installed a scotts.
    Also went with a different height riser... its perfect now :thumb

    [​IMG]
    [​IMG]

    I love how changing the spring in the rear is a 2 minute job :thumb

    [​IMG]


    pardon the crappy tapatalk hosted compressed pics from my phone
    [​IMG]
  18. avconnect

    avconnect Been here awhile

    Joined:
    Apr 22, 2012
    Oddometer:
    125
    Location:
    Salt Lake City
  19. Vico1

    Vico1 The Maestro

    Joined:
    Oct 31, 2008
    Oddometer:
    6,575
    Location:
    Ft Walton Beach FL
    Is the problem with the EXC or with the HDB top clamp mount.

    I have no issues but I run normal bark busters and standard levers. All seem to work fine for me.

    I do have a question on EXC wiring. If I use the Sicass switch will it allow me to run the bike without turning on the lights etc. I am constantly forgetting to turn off the bike when stopped. Just not use to it. I have no use or desire for a key switch.

    Any suggestions?
  20. avconnect

    avconnect Been here awhile

    Joined:
    Apr 22, 2012
    Oddometer:
    125
    Location:
    Salt Lake City
    The stock EXC obviously did not have the problem. The HDB top clamp created the problem where the clutch line runs straight into the HDB pivot. The line needs to plunge down sooner to clear. Right now, mine goes above the pivot but it is tight enough to raise concern about wear. The stock KTM switch has turn signal, high low and horn. It was too wide and deep for an aftermarket clutch lever to clear. I discovered the problem with the switch when I installed the KTM hard parts orange bling folding lever. I will try to upload pictures tonight of where I stand. I have talked with Paul at HDB about the issue and sent photos. He has not offered a solution. There is a company back in Ohio or something like that that can make a custom clutch line with cool colors (yes orange) that will solve the clearance issue. I just cannot bear to pay $100+for the thing so I am going to wait to see how the slightly longer EE clutch line wears.