The KTM 500 XC-W Thread.

Discussion in 'Thumpers' started by Geek, Mar 16, 2012.

  1. CamelBill

    CamelBill Ride It!

    Joined:
    Nov 17, 2007
    Oddometer:
    613
    Location:
    St. Chuck, Mizery
    '13 XC-W, the small running light burns, but not the stock headlight bulb. The bulb is good, glows fine when wired direct to a spare battery. I have seen mentionof this as a recurring problem, but have not come upon the fix. Where do I start looking, or is the stock headlight just worthless crap that needs to be replaced.? I really use it as a dirt bike, but it is licensed for occasional trail connector use, so would like some kind of working headlight.

    If I do go aftermarket, looking for suggestions for a rugged headlight the stock electrics can handle - since it is a dirt bike mainly, I don't really need any deer burners. Thanks. :freaky
  2. woodzrider

    woodzrider Been here awhile

    Joined:
    Jan 30, 2008
    Oddometer:
    860
    Location:
    Choctaw, Okla., anywhere I happen to be
    I sprung for the SAR light kit for my '13 XC-W 500 and love the kit. However the stock headlight bulb is absolutely worthless! I ordered a halogen replacement bulb and it works a lot better, although it could be worlds better yet. The stock bulb is also prone to early retirement (measured in minutes depending on trail conditions). Make sure the rubber o-ring that is on the bulb socket is still there-it serves as a vibration damper otherwise the bulbs just vibrate into oblivion. Hope that helps.
  3. RSinBC

    RSinBC Been here awhile

    Joined:
    Feb 19, 2008
    Oddometer:
    236
    Location:
    Vancouver, B.C.
    I got off on a tangent from the KTMforums link above and somewhere it was mentioned that Blaise Racing de smog kit recommends setting the idle speed by unscrewing the idle speed knob, CCW, all the way till it stops. Then screw back in 17 CLICKS CW. the person that posted said they found 15 CLICKS in to work better for them.

    So i tried it at 16. The bike started instantly and idled much smoother and seemed stronger. I did not need to pull the choke knob out either, the bike would never start and stay running without the knob pulled. No chance to ride it yet, but i will tomorrow. I am pretty sure this will help the stalling at traffic lights and flame outs. I am off to the dealer in the AM to re-map to XC-W spec and will have them check the TPS and actual idle speed while it is hooked to the diagnostic computer.

    Richard
  4. The Wolf

    The Wolf Among The Living

    Joined:
    Nov 29, 2012
    Oddometer:
    445
    well done GS:1drink
  5. roadracer

    roadracer Been here awhile

    Joined:
    Sep 20, 2004
    Oddometer:
    345
    Location:
    San Francisco
    If anyone is looking for an ohlins 2.1 I took one off my 350exc when I sold it and it won't mount on my 450xc-f. pm me.

  6. The Wolf

    The Wolf Among The Living

    Joined:
    Nov 29, 2012
    Oddometer:
    445
    Pm sent. also send me some pics plz.
  7. RSinBC

    RSinBC Been here awhile

    Joined:
    Feb 19, 2008
    Oddometer:
    236
    Location:
    Vancouver, B.C.
    i know this is the XC-W thread but they all seem to have similar issues, so here is how it went today.

    I took the bike to my dealer and had them re-map to the XC-W map, check the TPS and idle speed.

    My TPS was at 0.610V so we left it there.

    The idle speed as i had adjusted it was 2300, so it was dropped to 1900 RPM

    And the Map for the XC-W with ending with 601was installed. Looking at it now i need to call them and ask if it was the US map or the EU map.

    I also asked about the 701 Map, and they had not heard of it before so they called KTM Canada and were told no dice! you cannot have this map! and you really should not put the 601 map on an EXC!

    Bottom line, the bike does not seem to stall anymore and will lift the wheel in 4th without really trying. If the flame outs are really gone i will be extremely happy.

    So if you adjust the idle screw as outlined above, 17 clicks may be too fast an idle.
  8. The Wolf

    The Wolf Among The Living

    Joined:
    Nov 29, 2012
    Oddometer:
    445
    anybody have a broken kickstand they want to sell me?
  9. SteveO

    SteveO Long timer

    Joined:
    Jul 15, 2010
    Oddometer:
    1,322
    Location:
    Land of ambivalence
    I have a stock kickstand that is not broken that ill sell ya.
  10. Jason Abbott

    Jason Abbott Long time Idaho rider

    Joined:
    Jun 11, 2008
    Oddometer:
    675
    Location:
    Boise, Idaho, USA
    Been in the garage all day adding Sicass light kit, heated grips and Lynx fairing with USB and dual HID. Nearly killed my brain but it's all working now. This is on a 2013.

    Question: is it really just the thin brown and white wires bringing power up front? The Lynx ran it's own dedicated power from the battery but I'm far from clear about which wires will carry the load for heated grips, GPS, phone. I'm no electrician but I'm handy with a multimeter if anyone has pointers ...
    :ear
  11. RSinBC

    RSinBC Been here awhile

    Joined:
    Feb 19, 2008
    Oddometer:
    236
    Location:
    Vancouver, B.C.
    I ran a dedicated set of wires up forward. 30a fuse at the battery, then into a fuse block.
    From there you have separate fused circuits to each of your accessories, and can run smaller gauge wire to each.

    The fuse block I used has a built in relay, so when the bike is off so is the power to the accessories. I used the stock fan circuit to switch the relay. No dead battery because you forgot to turn something off.

    [​IMG]
  12. Gimme 2

    Gimme 2 wheels , with nobs

    Joined:
    Mar 29, 2009
    Oddometer:
    2,566
    Location:
    still looking
    anybody using extra inline filters . And is there a alternative filter to replace the one used in the tank?
  13. justlookin

    justlookin Been here awhile

    Joined:
    Dec 16, 2007
    Oddometer:
    458
    Location:
    Ohio
    Jason,

    The yellow wire connected to the push - pull switch is the main power wire coming forward. I am assuming the small Brown and White wires you are looking at are to the headlight and the White wire is connected to the other side of the switch making it the hot and Brown is ground.
  14. Jason Abbott

    Jason Abbott Long time Idaho rider

    Joined:
    Jun 11, 2008
    Oddometer:
    675
    Location:
    Boise, Idaho, USA
    Thanks, I think I have it sorted now. The Lynx fairing has a dedicated run to the battery and extra pigtails for switched and unswitched power. I tied into those for the accessories and hardwired the push/pull switch shut since I'm using the Sicass light kit. I'll do a write-up later for others thinking of combining those kits on the XC-W.

  15. Jason Abbott

    Jason Abbott Long time Idaho rider

    Joined:
    Jun 11, 2008
    Oddometer:
    675
    Location:
    Boise, Idaho, USA
    I guess everyone is out riding. :p3rry

    I idled my bike about a minute with too much oil expecting things to settle in the sight glass. Shouldn't have been a lot too much since I still can't see where I deviated at all from the manual. But anyway, after draining to the right level and about 15 more minutes of riding, still some oil smell from the exhaust and a curl of white smoke when I shut off.

    Worry or don't worry?
  16. KrustyKustom

    KrustyKustom Lets Go....

    Joined:
    Dec 9, 2005
    Oddometer:
    674
    Location:
    Desert-away from people...
    How much too much....1/2 a liter or 100ml?

    Should not be a big deal if you did not rev the hell out of it. Get a measuring cup for changes, easy 1.5liters.
  17. Jason Abbott

    Jason Abbott Long time Idaho rider

    Joined:
    Jun 11, 2008
    Oddometer:
    675
    Location:
    Boise, Idaho, USA
    Cool. Had to be closer to the 100ml. Rode about an hour last night (pictures!) and the symptoms seemed to go away so I guess it's all good. Thanks for the answer.
  18. Gimme 2

    Gimme 2 wheels , with nobs

    Joined:
    Mar 29, 2009
    Oddometer:
    2,566
    Location:
    still looking
    Check your airbox, pretty sure the over flow comes in just below the intake throat there will be oil sitting in the btm of the airbox and spatter.

    Oil is'nt bad but it can foul plugs and carbon build up becomes a problem i suppose if its a constant.
  19. MAXVERT

    MAXVERT OG on da OC

    Joined:
    Jan 19, 2004
    Oddometer:
    1,674
    Location:
    Sun Valley Idaho, Baja Arizona
    The dealer here in Tucson gave me a deal I couldn't turn down.
    Thanks to the info here I went with the XCW.
    This scoot will be replacing my 300 and my 690, so it will be doing dual sport as well as
    single track rides.
    A couple of the wrenches at the dealer who ride 530's have had to replace their counter shafts.
    They suggest a cush drive at the rear.
    This just confirms my experience with a 525 and a Honda xr 650 r, both of which ate sprockets
    and chains when dual sported ( ridden on the street )

    Anyone had a cush drive wheel built for your 500 ?
    I'm thinking a Rad hub.

    Twist it, Max
  20. Gimme 2

    Gimme 2 wheels , with nobs

    Joined:
    Mar 29, 2009
    Oddometer:
    2,566
    Location:
    still looking
    I'm building one ATM . Ktm hub, as its rubbers last.