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Old 03-23-2013, 10:28 AM   #3586
FZcruzer
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Never mind found it. Will post up solution later.
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Old 03-23-2013, 01:29 PM   #3587
SoilSampleDave
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Quote:
Originally Posted by fasteddie23 View Post
I am just guessing. But the hi/low is most often used for heated grips


So what have folks done for heated grips? What kit did you buy and how did you wire it in?
I used the heat troller from Warm-n-safe because I like the idea of the solid state control instead of either the crappy ballast resistor style or the two heat traces. I used the connector under the tank that is for the cooling fan, since it is already wired in nicely. I have a 350, so it was just lying there unused. If I had a 500, I would still tie in there, as the odds of needing heated grips and having the cooling fan come on at the same time is pretty slim. There was a post which listed the correct OEM connectors so the connection looks factory. Let me know if you need me to find it for you.
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Old 03-23-2013, 03:41 PM   #3588
buls4evr
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Location: Michissippi & Nuevo Mexico
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Just bought a 2013 500EXC 2 days ago. It is clear that it needs a 3 gallon gas tank. All brands indicate that the charcoal cannister has to be removed first. Is there any problems with the fuel injection operation if the cannister is removed as well as all the hardware hooked to it? Does it need any tubing re-routed or plugged afterward?What should be left intact It seems to run fine with a 1 way vent check tube that I put on the tank.Thanks...... All links also appreciated.
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Old 03-23-2013, 06:59 PM   #3589
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Quote:
Originally Posted by buls4evr View Post
Just bought a 2013 500EXC 2 days ago. It is clear that it needs a 3 gallon gas tank. All brands indicate that the charcoal cannister has to be removed first. Is there any problems with the fuel injection operation if the cannister is removed as well as all the hardware hooked to it? Does it need any tubing re-routed or plugged afterward?What should be left intact It seems to run fine with a 1 way vent check tube that I put on the tank.Thanks...... All links also appreciated.
I have a couple tanks for sale.

http://advrider.com/forums/showthread.php?t=872909
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Old 03-23-2013, 09:09 PM   #3590
Bengt Phorks
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Quote:
Originally Posted by buls4evr View Post
Just bought a 2013 500EXC 2 days ago. It is clear that it needs a 3 gallon gas tank. All brands indicate that the charcoal cannister has to be removed first. Is there any problems with the fuel injection operation if the cannister is removed as well as all the hardware hooked to it? Does it need any tubing re-routed or plugged afterward?What should be left intact It seems to run fine with a 1 way vent check tube that I put on the tank.Thanks...... All links also appreciated.
Desmogulation of the 500EXC post #252 page 17 This thread.
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Old 03-23-2013, 10:19 PM   #3591
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Thinking about a set of street wheels for my 12 500 what should I be looking for? 17 front and rear?
Also looking for the bottom fitting on the front light to move it forward where it meets the front fender?
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Old 03-24-2013, 07:07 AM   #3592
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Quote:
Originally Posted by Bengt Phorks View Post
Desmogulation of the 500EXC post #252 page 17 This thread.

Thank you Bengt......................
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Old 03-24-2013, 07:08 AM   #3593
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Quote:
Originally Posted by YAHBO View Post

A good price but I want to go with the 3 gal tank.
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Old 03-24-2013, 07:58 AM   #3594
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In Case Somone's Looking

Not a 500 EXC, but close...selling my plated 450 XC-W.
Hey guys, I know this is the 500 thread, but thought I'd post up my flea market link in here.
Here you go...http://www.advrider.com/forums/showthread.php?t=871473
Thanks, TW
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Old 03-24-2013, 06:44 PM   #3595
buls4evr
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The proper bolt to use for the air pump replacement spigot is 12mmX 1.50 pitch X 25mm long. Thanks for the info. I did mine today as well as the canister and it took me about an hour and a half to do. Runs like a champ and really does away with clutter and gives you room around the injector now.
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Old 03-25-2013, 11:21 AM   #3596
E-Ticket2
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Quote:
Originally Posted by MJG2 View Post
I have no FI light on or running problems with it disconnected
I understand their thinking -many sensors or components cant be unplugged or you will turn on the FI light- or have driveability issues
Not so with this part
I am glad to have found a cap to plug the electrical connector from the weather. I actually thought about doing as your dealer and leaving the solenoid in place. Its cleaner with it off though. If you do leave it on you might want to at least put caps on the vacuum ports to keep water and mud out of that solenoid since the hoses are now removed
Following are the pics of how I took care of covering/storing the plug for the solenoid valve.
(Note: this is on a '12 350 EXC-F ... but the hardware, etc., is pretty similiar for the 500 EXC-F.)

If you want to see my whole "de-smogify" procedure -- please go here:
http://ktmtalk.com/index.php?showtopic=440785&st=195

Yes, yes, I know it's on another website.
But my "2012 350 EXC-F: Building the Perfect "Wee Beasty" thread is now up to 60 pages ...

It's just too much work right now to re-load it onto Adventure Rider.
I might do it one of these days when I get caught up (... ...) but until then ...

BTW, there is an Index Page on the last page of the thread if you get lost and need help navigating.

http://ktmtalk.com/index.php?showtopic=440785&st=885

Cheers! E-Ticket
====================================

Now the only thing left do is to find a home for the cable/connector that went to the solenoid valve
on the bottom of the throttle body. I thought about just doing the quick and dirty and zip-tying it out of
the way somewhere. But canned that idea as I hate having to keep moving crap around when doing
basic maintenance, etc.

After playing around ... a LOT .... with moving and rerouting wires and cables, I discovered that
the connector would reach clear up to where the ECU resides. Which would be perfect as I wanted
to be sure that it would be up high and protected from water splash, etc.




I played around with a lot of possible locations to mount/stuff it.
But it was hard due to it's unique shape and having *just* enough cable slack to reach that far.
Why go to this much trouble?
Well, if I want or need to restore full EPA compliance I want to have all connectors and parts in usable form.





And then bingo! The clouds parted ... and a little ray of sunshine illuminated the perfect spot.




So I stuffed a bunch of di-electric grease in the connector, bagged and taped it, and zip-tied it in place. El-Done-o!






Here's how the stock emission hoses, cabling, valves, etc., looked before "de-smogifying." Just a total rat's-nest.

Yah ... there *is* an FI throttle body in there ... somewhere! lol.





Man ... after de-smogifying, everything is so much cleaner and accessible now!!
{.... insert big, happy sigh here....}






Heck, I might even be able to reach the idle knob! LOL.




Here's the final pilo 'o emissions stuff. Hoo-boy!
Total weight savings: 1.42 lbs !!


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Mine: '12 KTM 350 EXC-F; '99 Honda VFR 800i Interceptor
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E-Ticket2 screwed with this post 03-25-2013 at 12:38 PM
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Old 03-25-2013, 02:14 PM   #3597
germanairsucker
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Just bought an Acerbis 5.3 gallons for my 2013 500 exc and I find that I have a problem with it! Looks like the 2012 have a 9 liters original fuel tank and the 2013 have an 8.5 liters. So the problem is the bolt that hold the fuel pump is to long for about .180 of an inch! Like the plastic when they made the 2013 was more thick. So I order both bolt and tube from an 2012 and wait to see if it will work!!!

Number 4 and 5



The fuel tank from KTM didn't have the same part number 2012 and 2013 and number 4 and 5 either!

Maybe someone can help me with that!

Sorry for my poor english!!!
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Old 03-25-2013, 04:20 PM   #3598
bill1960
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Quote:
Originally Posted by germanairsucker View Post
Just bought an Acerbis 5.3 gallons for my 2013 500 exc and I find that I have a problem with it! Looks like the 2012 have a 9 liters original fuel tank and the 2013 have an 8.5 liters. So the problem is the bolt that hold the fuel pump is to long for about .180 of an inch! Like the plastic when they made the 2013 was more thick. So I order both bolt and tube from an 2012 and wait to see if it will work!!!

Number 4 and 5



The fuel tank from KTM didn't have the same part number 2012 and 2013 and number 4 and 5 either!

Maybe someone can help me with that!

Sorry for my poor english!!!
I have the Acerbis 3 gallon tank on my 500 xcw.

It came with shorter versions of items 4 and 5 to allow for the thinner plastic of the acerbis vs oem.

You might want to check with the vendor to see if your 5 gal is supposed to come with shorter items 4 and 5.
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Old 03-25-2013, 05:34 PM   #3599
SoilSampleDave
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Quote:
Originally Posted by E-Ticket2 View Post
Following are the pics of how I took care of covering/storing the plug for the solenoid valve.
(Note: this is on a '12 350 EXC-F ... but the hardware, etc., is pretty similiar for the 500 EXC-F.)

If you want to see my whole "de-smogify" procedure -- please go here:
http://ktmtalk.com/index.php?showtopic=440785&st=195

Yes, yes, I know it's on another website.
But my "2012 350 EXC-F: Building the Perfect "Wee Beasty" thread is now up to 60 pages ...

It's just too much work right now to re-load it onto Adventure Rider.
I might do it one of these days when I get caught up (... ...) but until then ...

BTW, there is an Index Page on the last page of the thread if you get lost and need help navigating.

http://ktmtalk.com/index.php?showtopic=440785&st=885

Cheers! E-Ticket
====================================


The two threads that I have been using to sort out my bike are your "Wee Beasty" thread and the 500 thread here on advrider. Thank you, thank you, thank you for doing an index page. It is so hard to go back and find the topic you need, when you need it. I wish there was some way to distill down the knowledge in this thread into a condensed form and sticky it. It's been a lifesaver.
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Old 03-25-2013, 06:41 PM   #3600
E-Ticket2
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Quote:
Originally Posted by SoilSampleDave View Post
The two threads that I have been using to sort out my bike are your "Wee Beasty" thread and the 500 thread here on advrider. Thank you, thank you, thank you for doing an index page. It is so hard to go back and find the topic you need, when you need it. I wish there was some way to distill down the knowledge in this thread into a condensed form and sticky it. It's been a lifesaver.
You're very welcome .... and thank you, sir!
It's always nice to know that it's helping peeps with their scoots.

I finally gave in an created the Index Page around page 40.
Because I was starting to go nuts as well trying to find things!
And I was supposed to know where they were!

I hope no one thinks I am trying to spam this thread -- but here is the Index Page if you want to use it.
A fair portion of it will also apply to the 500 EXC as they share the same emissions equimpent, bodywork, most of the chassis, etc..

Cheers! E-Ticket
===========================================

Wee Beasty Page Index: Updated 2/14/2013


Here are the page-links to the "starting points" for the listed topics.
The topics may run for several pages or be a single entry.

NOTE: It is not an exhaustive list of everything covered.
The page index is simply to make it easier to find the starting point for a given topic. Which may then run on for several pages.

I'll continue to update the index as more material, posts, and tips get posted.

Cheers! E-Ticket
===========================

Page 1
• Prepping/greasing new wheels, axles, and wheel spacers
• Installing KTM Organic brake pads on the rear brake
• Using heat gun to move the end of a graphic "a little"
• Turning KTM "self-retracting" kickstand into a normal kickstand
• Installing footpeg springs
• Removing gas tank and initial internal inspection
• Pics of engine area (w/ gas tank removed), emissions equipment, and below seat
• Pics of air box, filter, and internal view of intake manifold
• Installing Shorai battery
Page 2
• Routing and zip-tying various wires above air filter
• Anti-seize on seat bolt; using duct tape to keep bolt clean
• Installing KTM, quick-release, plastic skid plate
Page 6
• Initial start-up of engine and engine break-in procedure
• First engine oil change; cleaning filter screens and drain plug
Page 7
• Pulling and draining fuel tank; remove fuel pump and wiring assembly; cleaning fuel tank,
pics of fuel pump; reassembly of fuel tank
Page 11
• Installing the 10 micron Golan "Super Mini" filter
• Removing the KTM, black, 10 micron, in-line fuel filter
• Final Golan filter setup tips
Page 12
• Installing the KTM "sock filter" in the neck of the gas tank
Page 13
• Installing the Akropovic slip-on exhaust and 92db spark-arrestor insert
Page 14
• Removing the ECU; remapping the ECU
• Testing de-smogify steps; actual de-smogify procedure
Page 15
• Relocating horn to location near swingarm
Page 17
• The "beginning" of the starting capacitor discussion (it runs for several pages)
Page 20
• Starting discussion point on adjusting valves
• Actual step-by-step procedure for checking and adjusting the valves

>>>> 2012 KTM 350 EXC-F: Check/Adj valve clearances, "Building the Perfect Wee Beasty"

• Preparing cooling system for change-over to Engine Ice coolant
Page 21
• Installing KTM radiator fan and Engine Ice coolant
• Installing lower-temperature rated sensor in radiator
• Installing Bulletprood Design (BPD) radiator guards
• Installing heat shield on gas tank (behind radiator fan)
Page 31
• Initial comments on suspension spring selection
• Discussion on installing the DJH Manual Cam Chain Tensioner (CCT)
• Step-by-step procedure for installing the DJH Manual Cam Chain Tensioner (CCT)

>>>> '12 KTM 350 EXC-F: Installing a DJH Manual CCT
Page 32

• More Akropovc pics
• Installing the P3 Exhaust Shield on header pipe
Page 33
• Changing gearing to 13-52T
• Upgrading to Dirt Tricks' "Ironman" sprockets
• Installing TM Design Chain Guide
• Installing the Bulletproof Design Guard for chain guide
Page 36
• Excellent pictures of 2013 quick-disconnect w/ 20 micron filter (thanks blackwidow!)
Page 39
• Using 9v battery to allow kick-starting a 350 that has a dead battery (thanks, daju!)
Page 41
• Modifying the brake pedal (to reduce clutch cover damage)
• Installing KTM HardParts Carbon Fiber (CF) clutch Cover Guard
• Installing the KTM HardParts Billet Oil-Fill Plug
Page 42
• Swingarm clean up and greasing / Heim joint protection
• Mounting the Bulletproof Designs guard for the rear brake rotor
• Installing the KTM HardPart Clutch Slave-Cylinder Guard and Dirt Tricks 13T Countershaft Sprocket
Page 43
• Installing the Side Frame-Guard Protectors
• Installing DID "X-Ring" 520 VT2 Chain (for 13-52T gearing)
Page 44
• Tightening the Countershaft Sprocket Bolt
• Aligning the Chain (align rear axle to parallel w/ swingarm pivot bolt)
• Setting the Chain Slack (with swingarm "level"/full tight)
• Marking the chain adjuster bolts for easy adjusting (<<< BIG TIP!!)
• Replacing Spring on Shock (from stock to PDS-4) and setting initial preload
Page 45
• Installing the SAR Flush-Mount LED Turn Signals on the "Stock" Rear Fender
Page 46
• Installing the 2012 350 XCF-W Rear Sub-Fender on the 2012 350 EXC-F
• Mounting the SAR Flush-Mount, LED Turn Signals on the 2012 350 XCF-W Sub-Fender. (More on Page 47 as well.)
• Mounting the License Plate on the 2012 350 XCF-W Sub-Fender
• Installing the "Troy" Rear Tugger Strap
Page 47
• Installing the Front, Sicass Racing (SAR) LED Turn Signals
• Installing the SAR LED-Compatible Flasher Unit. (Needed if you run LED turn signals at both front and rear.)
Page 48
• Why Mount a Scott's Steering Stabilizer and Sub-Mount?
• What Comes in Scott's Steering Stabilizer and Sub-Mount Kit
• Removing the Forks and Triple Clamp
• Installing the Clamp-on Tower for the Scott's Steering Stabilizer
• Reassembling and Torquing the Triple Clamps
• Setting the Height of the SSS Tower Pin
• Check for Clearance Issues on the Scott's Steering Stabilizer
"Low-Profile" Bolt for the Triple Clamp Pinch Bolt

Page 49
• Fastway / Pro-Moto Billet Handguards ... and big foam rubber, flappy, handguard shields
• CEV Replacement Headlight / Turn Signal /Horn Switch
• Removing the Forks and Triple Clamp
• Malcom Smith Racing (MSR) Folding Mirror
• KTM HardParts Fork Bleeders
• Considering Moving the Ignition Switch ......
• Backup Ignition Key
"AYHIN" Front Tugger Strap
Page 51
CORRECTION on type of Honda brand/Loc-Tite type used on Wee Beasty
Page 54
• Dunlop D803 trials tire rubbing on mud flap


Cheers! E-Ticket
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Mine: '12 KTM 350 EXC-F; '99 Honda VFR 800i Interceptor
Wife: '08 KTM 250 XCF-W; '04 Honda CBR600 F4i
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