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Geek 03-16-2012 03:41 PM

The KTM 500 XC-W Thread.

Does anyone know the real story on the XCWs compatibility with the fuel map switch?
I've had two dealers tell me two different things.
I've seen articles online that say different things. :scratch

Does anyone have the switch installed? Does it work on your XCW? :lurk

I'm in the process of making my XCW street legal and I'll offer up some detailed photos in case it helps anyone else in the same boat.

So who's bought one so far? :lurk


Geek 03-16-2012 07:37 PM

Some detail shots... XCW fresh off the showroom floor:

Geek 03-16-2012 07:49 PM

I have an appointment with a Colorado State Trooper on Tuesday to get my bike verified "street legal".

This means I'm going to have to add:

1) a mirror
2) a horn
3) a brake light
4) DOT tires

while I'm at it I'm also going to add:

1) fan override circuit
2) electric grips
3) high beam toggle
4) powerlet
5) something to tame the throttle to make the bike more "technical riding friendly".. either a cam or some flywheel weight?

...and then start with the armor:

1) better handguards
2) some sort of skid plate
3) some sort of pipe guard
4) some sort of case guards
5) swingarm guard & chain guard

...and then "long ride" comforts

1) better seat
2) a rear rack
3) better lighting

...and I will call it done.

Would love to hear feedback on what other owners are doing in the above categories?

Geek 03-16-2012 07:57 PM

So this weekend I have to get it street legal.

Dis assembly photos (lots of details for those curious about how the new 500s are put together):

The seat is removed with a single bolt from below (in the rear fender well) revealing:

The stock cockpit

Dis assembly begins:

Stock... under the headlight is a mess (in fact a bunch of the wiring on the bike is a bit of a disaster.. I am guessing it is because the use the same primary loom as the EXC so there are lots of wires unneeded)

To remove the tank: one bolt in the center of the tank (on the bike's backbone), two screws on the shrowds (one on the outside of each radiator) then quick-disconnect the fuel pump and the wiring plug

Left side:

Right side:

The stock wiring to the thermostat: :rolleyes

The stock wiring in the nose (all the grounds coming together) :eek1

Another example of fun wiring.. I'm assuming because the EXC had more stuff connected here..
Nothing like taking the ground wire and giving it 3 potential failure points in a 4 point connector. :rofl

Lots of wiring improvements to be made for sure. be continued.

Geek 03-18-2012 02:32 PM

I decided to go with the HighwayDirtbikes (HDB) handguards/mirrors/switchgear on my XCW. This is my 5th bike that I've put HighwayDirtbikes hand guards on because they work so well.

Paul is making a really nice billet computer guard that integrates well with the risers/topclamp/damper mount.. along with the handguards & mirrors.

First you need to disassemble the computer from its stock plastic mount

Here's the billet computer guard.. mine is anodized black. Everything is a very precise fit

You use the stock hardware to mount the computer into the new guard

To remove the fuel indicator and FI lenses from the stock guard, I warmed the outside black edges a bit with a heat gun first.. then they popped right out with little effort

The billet guard has the key pre-cut into it for alignment (the yellow lense has a key)

It is an interference fit. I put the plate face down and then used a socket that was larger diameter to hit on the billet frame and seat the lense fully in flushly

perfect :thumb

...both lenses seated

Geek 03-18-2012 02:37 PM

HDB has a variety of top clamp layouts available.

I selected one that has space for two powerlets and four switches.

I'm going to use the four switches for:
fan override, headlights off/on, headlight high/low and heated grips off/on

The pushbutton switches simply fit in the holes (which are designed for the fit)

and then the rubber waterproof caps screw on to hold the switch in place.. be continued.

Bora20 03-18-2012 02:59 PM

I'm just curious why you wouldn't have bought the EXC instead?

heetseeker 03-18-2012 03:14 PM

Subscribed! :lurk

Geek 03-18-2012 04:29 PM


Originally Posted by Bora20 (Post 18246305)
I'm just curious why you wouldn't have bought the EXC instead?

A very good question and I'll touch on my thoughts on various bits it as I post my personal build out; I'd love to hear others express why they chose an XCW as well.

Personally my biggest reason: The EXC has all the emissions stuff on it.. the XCW doesn't. It is easier for me (in Colorado) to add the few items I need to be street legal than it is for me to remove all the crap I don't want on the bike.

Another Colorado reason:

Here in Colorado it is very easy to get a dirtbike plated. You do NOT need turn signals to plate a bike (and I'm trying to apply some KISS to this bike)... UNLESS the bike originally came with turn signals in which case they have to be maintained AND in good working order.

In other words.. if I bought an EXC and busted a turn signal (very likely with how I ride :D ) a local Ranger or trooper could pull me over and give me a ticket for my broken signal.

OTOH... riding my XC-W with no turn signals at all, they won't bat an eye and I'm not breaking any laws.

I agree.. it is stupid.

theantipaul 03-18-2012 07:45 PM


ABYSS 03-18-2012 10:10 PM

I have a XCW and GEEK hit the nail on e head with his reasons to get a XCW over a EXC.

Doing the math it's cheaper to get a XCW and get it street legal rather than than to buy a EXC. Plus everyone the starts stripping stuff off the EXC's

Next I see here in the assylum the EXC guys start getting into mapping questions.

While I can't speak for anyone else but my XCW runs like a top. No messing with mapping here.

The only performance thing I did was the FULL AKRA TITANIUM exhaust front to back. It's the A&P in me that made me do it, plus it makes mechanical sense on several levels.

I just about have my own version of headlights done mechanically speaking anyway. I am still in the air about the "nose cone" weather do aluminum, fiberglass or none at all. Right now it kinda looks MAD MAX'ish.

They are definitely different from baja design's and Harcus. They have great stuff I just , I don't know what I am trying to say.


Geek 03-19-2012 05:59 AM

David: do you have any pics of the Akro? I haven't seen it yet.
Is it much louder than stock? I was surprised at just how much bark the stock exhaust has...

heetseeker 03-19-2012 06:14 AM

At around 250 lbs, this bike should be nimble as hell. You are adding some lb's to it with the bar clamps , but losing weight on the exaust....Any thoughts on going to one of the lithium batteries to keep it on a diet? I picked one up at the ktm dealer and thought it was impossible to be that light. I'll be doing a similar build as you....great thread...

Geek 03-19-2012 07:04 AM

I have the Shorai battery in my 950. The only concern I have with it is on those Colorado mornings we are sub-freezing.

I'd be interested to here how well the little one works in the XCW :lurk

Garthe 03-19-2012 08:06 AM

I thought these things came, "ready to race/ride"...:dunno

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