2012 ktm 500 exc?

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

  1. avconnect

    avconnect Been here awhile

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    The lever clearance Robles can be temporarily resolved by rotating the switch. However, that is not a long term solution IMHO. A different switch will solve it. I agree that the clutch lever issue is not Paul's responsibility to fix and he is a class act.

    However, the clutch cable clearance issue is a different issue. Depending on which HDB top clamp you use you will have problems. Paul does not necessarily need to find a solution but should probably disclose the issue to potential purchasers and if we find a different clutch cable that fixes the issue (longer and a different connection at the master cylinder) he should tell folks about that cable or sell it through his website. My earlier representation about Paul was true but not necessarily critical. I spoke with him about the cable issue and sent several pictures at his request in the hope he would lend his expertise to the problem. I never heard back from him but I was probably the first and only person to point it out at the time and I know Paul is very busy. Paul was very accommodating and helpful on other custom requirements and my earlier statement in this forum that Paul is the Bomb remains the case despite my concerns about the cable clearance issue which arises when you use the HDB guards and certain top clamps. I will post more photos when I can get to my computer. The photos will show the cable clearance problem with both the stock cable and the EE cable which is longer and helps lessen but does not eliminate the problem.
  2. avconnect

    avconnect Been here awhile

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    Here are some photos of the stock cable clearance issue. It is really tight and I am convinced it would wear over time. I have since replaced this cable with an EE cable which is longer. The problem largely remains but the extra length of the EE cable helps take some tension off. The second photo shows the wire loom under the cable. That is not how I left it and the wire loom now drops below the pivot and bar but the stock cable was just too tight. You can see the tension in the cable as it turns down. I will post a photo of the current setup tonight with the EE cable installed.

    [​IMG][/IMG][​IMG]
  3. ABYSS

    ABYSS KTM

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    I have a question for you. If you were able to replace the cable do you think you could have got one with a banjo fitting and put inline 90 digree fitting the on it so it would lower the cable down below the top triple clamp? Or how about two 45s or 2 90's to lower the fitting below the top triple clamp.

    Again this is not a criticism just a question?
  4. Lulu7404

    Lulu7404 Been here awhile

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    Unfortunately the DR lady at work will be out of town that week, so I have to see all of her patients. I wanted to, even booked an RV spot, but had to cancel.
  5. ABYSS

    ABYSS KTM

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    sorry man I feel your pain. I wanted to go as well but work was not permitting. Heading up to CO at the end of August
  6. helotaxi

    helotaxi Been here awhile

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    It looks like that Woods high bend bar has helped him out a good bit compared to where I am.

    I'm pretty sure that if the master cylinder is threaded correctly, a banjo style brake line will solve all the problems of cable clearance.
  7. rtadlock

    rtadlock Long timer

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    Just picked one of these bad boys up. Obviously it needs a skid plate. What skid plates are people running? Any thoughts on one that people prefer?
  8. helotaxi

    helotaxi Been here awhile

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    It seems that the KTM Hard Parts models (both aluminum and polymer QD), Flatland Racing and Enduro Engineering are all pretty popular. I have the Flatland and it works well but is a real PITA to install by yourself. A second set of hands is a real plus.
  9. Stifdickerson2006

    Stifdickerson2006 Been here awhile

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    I just received and installed my skid plate from globetrottin.com and am very happy with the biuld of it and the design, I have not truly tested it out yet, but I do not think there is going to be any issues, it is very stout! Here is the link for it
    http://shop.globetrottin.com/product.sc?productId=40&categoryId=33
  10. helotaxi

    helotaxi Been here awhile

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    I'd forgotten that harcus had done one up as well.
  11. Geek

    Geek oot & aboot

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    Good to see you last night Rob.. thanks for the bivy :freaky

    I have the Hyde racing plate on mine.

    Tip: put double sided tape on the "u" mounts when you bolt it up and cinch it down the first time to "stick" the mounting plates to the frame and keep them from sliding around. Now removing and fixing the skid plate is an easy one hand 30 second operation :thumb

    You can see it in this photo from a couple of minutes ago (just loading up to go camping/riding for the weekend :ricky )

    [​IMG]
  12. Lulu7404

    Lulu7404 Been here awhile

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    Wife is driving now and the Tx panhandle is boring as hell. Just found this vid on YouTube. May be euro speck exc, but that means xcw. And if ecu is same then adjustments can be made. Not just a different map. Unless euros get completely different ecu.
    http://m.youtube.com/watch?v=4MkvYBaHlZE
  13. Stifdickerson2006

    Stifdickerson2006 Been here awhile

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    They do not get a different ECU, Just differnt maps. I had the Euro exc map installed on my bike Which is basically the same as the xcw here and is suppose to allow me to use the map switch form sicass/trailtech. For some reason the ECU is locked for the XCW map but the Euro EXC map installs. It did take a little pushing for me to get it done by the dealer.
  14. Vico1

    Vico1 The Maestro

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    I am still wondering about mild v wild mapping on the EXC 500. Is this like the 530 where you buy a switch? I see two open wires dangling loose under my head light. The look like the same wires on the 530. can I plug them together as see if I can tell the difference?

    Just wondering.

    BTW - I do not have an owners manual (very long story). Can anyone lead me to a source. Thanks
  15. avconnect

    avconnect Been here awhile

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    I think a custom cable will solve it if the right fitting at a 45 degree angle is available. 45 is too much. A gentle slope downward will do it. Spiegler makes a nice cable I am told.
  16. harcus

    harcus Long timer

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    And how does the bike run with the Euro map? Better?

    Looking at the electrical schematics indicates that the EU EXC & the EXC Six Days have a Lambda (oxygen) sensor that the USA EXC / all XCW units do not have. Doesn't seem that the EU software should work properly without the sensor. Confusing.

    The optional MAP switch shows up on the EXC & XCW schematics. Sicass says that the dealer MUST unlock the ECU to be effective. Did your dealer do that?

    Just curious... :D
  17. Colemanfu

    Colemanfu King of all manfu

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    I did some single track in TN this past week and realized how wide my bars are :D. I've never cut down bar. Anyone done it to their 500 yet? Curious to hear the proper technique and how much ya can nip off?
  18. helotaxi

    helotaxi Been here awhile

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    I'm thinking that a 90 deg fitting would be perfect. A straight banjo fitting comes 90 degrees off the surface that it's bolted to. That would be straight down in the case in question. If the fitting had a 90 deg bend it would end up back parallel to the bar but offset about an inch up or down (depending on how you install the line) which would provide compete clearance on the pivot.

    Doing some basic research online, it looks like the Brembo master cylinders use a standard diameter metric fitting with a 1.0M thread pitch. If I just had a local source for anything, I'd take it all down and figure it out.
  19. Stifdickerson2006

    Stifdickerson2006 Been here awhile

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    Yes, Its a switch you can buy from Trail Tech or Sicass Racing. But you plug it in under the seat. There is a plug with a dead end cap on it and it plugs in there. I am actually wondering what the additioanl plugs are behind the headlamp myself.

    I live in California and bought the bike out of West Virginia had it shipped here and paid the taxes(was still cheaper than buying it in California out the door). I just received the bike 2 days ago after a 3 week wait to get it here and am in the middle of some major farkling. I did not get to ride the bike before the reprogram but actually gave the mechanic the code number from the Sicass Racing (its noted on the page for the switch) and he got back to me saying that is the euro exc map and that is the only one they can put in and it is the unlock map they use. It was the first time he had done it and took the bike for a test ride after words and said it made a huge difference. I have been riding it around town lately no offroad duty yet and it runs great just the popping on decel, I am doing the desmog kit on it this morning, I will post pics of before and after when I am done.

    I am installing the HDB kit with frt and rear led blinkers looks clean and is well built but but I have to figure out how to wire in some resistors to the" blinker on light", The blinkers will only work correctly with the light out of the socket. No ground to the socket so with the light in, and signals on, all four blink like hazard lights(yes I have the led relay) but am not sure how to wire in a resistor to the lamp to stop the flow from going to the other side of the bike. BTW I am not good with electricity and can usually make it work so dont get to technical on me.
  20. Stifdickerson2006

    Stifdickerson2006 Been here awhile

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    I would not go with the 90 degree fitting I have ran two of those on my old KTM and both times hit a branch or something and broke the line, All I can say is riding back to camp 10-15 miles with no clutch in the middle of a black diamond trail is no fun.But that is just my two cents.