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KTM 350 EXC-F 2015, Owner'S Manual, Page: 68 / 122

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KTM 350 EXC-F 2015 Owner'S Manual Download Page 68

12

SERVICE WORK ON THE CHASSIS

66

12.38

Checking the frame

x

401340-01

–

Check the frame for cracking and deformation.
» If the frame exhibits cracking or deformation due to a mechanical impact:

–

Change the frame.

x

Info

A frame that has been damaged due to a mechanical impact must
always be changed. Repair of the frame is not authorized by KTM.

12.39

Checking the swingarm

x

401341-01

–

Check the swingarm for damage, cracking, and deformation.
» If the swingarm shows signs of damage, cracking, or deformation:

–

Change the swingarm.

x

Info

A damaged swingarm must always be changed. Repair of the
swingarm is not authorized by KTM.

12.40

Checking the throttle cable routing

Preparatory work

–

Remove the seat. (

p. 56)

–

Remove the fuel tank.

x

(

p. 60)

M00184-10

Main work

–

Check the throttle cable routing.

Both throttle cables must be routed to the throttle valve body side by side behind
the handlebars and above the fuel tank bearing.

» If the throttle cable is not routed as specified:

–

Correct the throttle cable routing.

Finishing work

–

Install the fuel tank.

x

(

p. 61)

–

Mount the seat. (

p. 56)

Summary of Contents for 350 EXC-F 2015

Page 1: ...OWNER S MANUAL 2015 350 EXC F US Art no 3213182en ...

Page 2: ......

Page 3: ...or delete technical specifica tions prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for delivery options deviations from illustrations and descriptions misprints and other errors The models portrayed pa...

Page 4: ...u 24 7 10 Setting the unit of measurement 25 7 11 Display mode SPEED CLK time 25 7 12 Setting the clock 26 7 13 Display mode SPEED LAP lap time 26 7 14 Viewing the lap time 26 7 15 Display mode SPEED ODO odometer 27 7 16 Display mode SPEED TR1 trip master 1 27 7 17 Display mode SPEED TR2 trip master 2 27 7 18 Setting TR2 trip master 2 27 7 19 Display mode SPEED A1 average speed 1 28 7 20 Display m...

Page 5: ...hydraulic clutch 67 12 45 Changing the hydraulic clutch fluid x 68 13 BRAKE SYSTEM 69 13 1 Checking free travel of hand brake lever 69 13 2 Adjusting free travel of hand brake lever 69 13 3 Checking the brake discs 69 13 4 Checking the brake fluid level of the front brake 70 13 5 Adding front brake fluid x 70 13 6 Checking the front brake linings 71 13 7 Changing the front brake linings x 71 13 8 ...

Page 6: ...ine tightening torques 106 23 3 Capacities 108 23 3 1 Engine oil 108 23 3 2 Coolant 108 23 3 3 Fuel 108 23 4 Chassis 108 23 5 Electrical system 109 23 6 Tires 109 23 7 Fork 109 23 8 Shock absorber 110 23 9 Chassis tightening torques 110 24 SUBSTANCES 112 25 AUXILIARY SUBSTANCES 114 26 STANDARDS 116 INDEX 117 ...

Page 7: ...standing In the interest of your own safety have these jobs performed by an authorized KTM workshop There your motorcycle will be opti mally cared for by specially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page 1 2 Formats used The typographical formats used in this document are explained below Specific name Identif...

Page 8: ... this manual carefully The safety instructions are highlighted in the text and are referred to at the relevant passages Info The vehicle has various information and warning labels at prominent locations Do not remove information warning labels If they are missing you or others may not recognize dangers and may therefore be injured 2 3 Degrees of risk and symbols Danger Identifies a danger that wil...

Page 9: ...5 10 1 Canada type label 2 USA type label 3 Brake fluid information 4 Information on chain tension 5 Information on starting up 6 Information on emissions control 7 Information on noise emission M00166 01 Canada type label M00167 01 USA type label ...

Page 10: ...FETY ADVICE 8 S00026 10 Brake fluid information 101516 01 Information on chain tension 700210 01 Information on starting up M00169 01 Information on emissions control M00170 01 Information on noise emission ...

Page 11: ...ghts Warranty claims should be submitted to a KTM workshop If you are not satisfied please contact KTM North America Inc Customer Support 1119 Milan Ave Amherst OH 44001 USA Phone 440 985 3553 www ktmusa com KTM Canada Inc Customer Support 1375 1 Marie Victorin Saint Bruno QC J3V 6B7 Phone 450 441 4451 x 4250 www ktmcanada com Different rights may apply according to national or regional legislatio...

Page 12: ...er e g Loctite is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them for damage and wear Change damaged or worn parts After you complete the repair or service work check the operating safety of the vehicle 2 13 Environment If you use your motorcycle responsibly you can ensure that problems and conflicts do not occu...

Page 13: ...M PowerParts for your vehicle can be found on the KTM website International KTM Website http www ktm com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly carried out as described in the Owner s Manual Incorrect adjustment and tuning of the engine and chassis can lead to damage and breaka...

Page 14: ...4 VIEW OF VEHICLE 12 4 1 View of vehicle front left example M00151 10 1 Filler cap 2 Fork compression adjustment 3 Shift lever p 19 4 Engine number p 14 5 Side stand p 20 ...

Page 15: ...Clutch lever p 16 3 Light switch p 16 3 Turn signal switch p 17 3 Horn button p 16 4 Emergency OFF switch p 17 4 Electric starter button p 17 5 Throttle grip p 16 6 Hand brake lever p 16 7 Ignition lock p 17 8 Shock absorber rebound adjustment 9 Shock absorber compression adjustment 10 Foot brake lever p 20 11 Kick starter p 19 ...

Page 16: ... head The additional type label for Canada is fixed to the front of the front pipe 5 3 Key number 101543 10 Key number for the ignition and steering lock is indicated on the KEYCODECARD Info You need the key number to order a replacement key Keep the KEYCODECARD in a safe place 5 4 Engine number 401949 10 The engine number is stamped on the left side of the engine under the engine sprocket ...

Page 17: ...01947 10 The fork part number is stamped on the inner side of the fork stub 5 6 Shock absorber part number 0 0 1 1 401948 10 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side ...

Page 18: ...fitted on the right side of the handlebar 6 4 Horn button M00154 10 The horn button is fitted on the left side of the handlebar Possible states Horn button in neutral position Horn button pressed The horn is operated in this position 6 5 Light switch M00154 11 The light switch is fitted on the left side of the handlebar Possible states Low beam on The light switch is turned downward In this positi...

Page 19: ... circuit is closed and the engine can be started 6 8 Electric starter button S00020 11 Electric starter button is fitted on the right side of the handlebar Possible states Electric starter button in basic position Electric starter button pressed In this position the electric starter is actuated 6 9 Overview of indicator lamps M00088 01 Possible states The high beam indicator lamp lights up blue Th...

Page 20: ...rs If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to th...

Page 21: ...increase deactivated Idle speed adjusting screw is pushed in all the way 6 14 Shift lever 401950 10 Shift lever is mounted on the left side of the engine 401950 11 The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears 6 15 Kick starter 0 0 1 1 401954 10 The kick starter is fitted on the right of the engine The engine can be started with...

Page 22: ...nd is used to park the motorcycle Info When you are riding the side stand must be folded up and secured with the rubber band 6 18 Steering lock S00462 10 Steering lock is fitted on the left side of the steering head The steering lock is used to lock the steering Steering and therefore riding is no longer possible 6 19 Locking the steering Note Danger of damage The parked vehicle may roll away or f...

Page 23: ...ess it in and turn it to the right Remove the key Steering is no longer possible Info Never leave the key in the steering lock 6 20 Unlocking the steering 400731 01 Insert the key in the steering lock turn it to the left pull it out and turn it to the right Remove the key You can now steer the bike again Info Never leave the key in the steering lock ...

Page 24: ...umference of the 21 front wheel with stan dard tires The display then changes to the last selected mode 7 3 Setting kilometers or miles Info If you change the unit the value ODO is retained and converted accordingly The values TR1 TR2 A1 A2 and S1 are cleared when the unit of measure is changed Condition The motorcycle is stationary 400329 01 Repeatedly press the button briefly until H appears at ...

Page 25: ...The symbol continues to appear in the display and the next function appears Deactivating a function Press the button The symbol disappears in the display and the next function appears 7 5 Setting the clock Condition The motorcycle is stationary 400330 01 Repeatedly press the button briefly until CLK appears at the bottom right of the display Press the button for 2 3 seconds The hour display flashe...

Page 26: ...ition The motorcycle is stationary Repeatedly press the button briefly until H appears at the bottom right of the display In display mode H the service hours of the engine are displayed The service hour counter stores the total traveling time Info The service hour counter is necessary for ensuring that service work is carried out at the right intervals If the speedometer is in H display mode at th...

Page 27: ...m h Mph flashes In measurement unit mode you can change the unit of measurement Info If no button is pressed for 5 seconds the settings are automatically stored Briefly press the button Starts selection activates Km h display Press the button for 2 3 seconds No function Briefly press the button Activates Mph display Press the button for 2 3 seconds No function Wait 3 5 seconds Changes to the next ...

Page 28: ... timed with the stop watch Info If the lap time continues running after the button is pressed 9 memory loca tions are occupied Lap 10 must be timed using the button Press the button for 2 3 seconds The stop watch and the lap time are reset Briefly press the button Next display mode Press the button for 2 3 seconds Stops the clock Briefly press the button Starts the stop watch or stop the current l...

Page 29: ...cally reset to 0 0 Press the button for 2 3 seconds Displays of TR1 A1 and S1 are reset to 0 0 Briefly press the button Next display mode Press the button for 2 3 seconds No function Briefly press the button No function 7 17 Display mode SPEED TR2 trip master 2 400324 01 Repeatedly press the button briefly until TR2 appears at the top right of the dis play TR2 trip master 2 runs constantly and cou...

Page 30: ...atch 1 The calculation of this value is activated by the first impulse of the wheel speed sensor and ends 3 seconds after the last impulse Press the button for 2 3 seconds Displays of TR1 A1 and S1 are reset to 0 0 Briefly press the button Next display mode Press the button for 2 3 seconds No function Briefly press the button No function 7 20 Display mode SPEED A2 average speed 2 400326 01 Repeate...

Page 31: ...y mode Press the button for 2 3 seconds No function Briefly press the button Starts or stops S2 7 23 Table of functions Display Press the but ton for 2 3 seconds Briefly press the button Press the but ton for 2 3 seconds Briefly press the button Wait 3 5 sec onds Wait 10 12 sec onds Display mode SPEED H service hours The display changes to the Setup menu of the speedome ter functions Next display ...

Page 32: ... 2 Increases value of TR2 Increases value of TR2 Reduces value of TR2 Reduces value of TR2 Saves and closes the Setup menu Display mode SPEED A1 average speed 1 Displays of TR1 A1 and S1 are reset to 0 0 Next display mode No function No function Display mode SPEED A2 average speed 2 No function Next display mode No function No function Display mode SPEED S1 stop watch 1 Displays of TR1 A1 and S1 a...

Page 33: ...e not braking Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permissible weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons Info When using your motorcycle remember that others may feel disturbed by excessive noise Make sure th...

Page 34: ...ch as the drive train brake system or suspension components For this reason it may be neces sary to inspect or replace parts before the next scheduled service KTM recommends that you use the specified engine oil for difficult riding conditions and to increase performance Engine oil SAE 10W 60 00062010035 p 112 Clean the air filter and air filter box x p 58 Info Check the air filter approx every 30...

Page 35: ...reparing for rides on wet sand 600870 01 Fit a rain cover on the air filter Waterproofing device for air filter 77206921000 Info See the KTM PowerParts fitting instructions 600868 01 Clean the chain Chain cleaner p 114 Fit the steel sprocket Tip Do not grease the chain Clean the radiator fins Straighten bent radiator fins carefully 8 6 Preparing for rides on wet and muddy surfaces 600870 01 Fit a ...

Page 36: ...The engine oil heats up quickly when the clutch is operated frequently due to an excessively high secondary drive Clean the chain Chain cleaner p 114 Clean the radiator fins Straighten bent radiator fins carefully Check the coolant level p 92 8 8 Preparing for rides at low temperature or in snow 600870 01 Fit a waterproofing device on the air filter Waterproofing device for air filter 77206921000 ...

Page 37: ...screws nuts and hose clamps regularly for tightness Check the fuel supply 9 2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Note Engine failure High ...

Page 38: ...ening increases fuel consumption To shift down apply the brakes and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Switch off the engine if you expect to be standing for a long time Guideline 2 min Avoid frequent and longer slipping of the clutch This heats the engine oil the engine and the ...

Page 39: ...un Always let the vehicle cool first Note Material damage Damage to or destruction of components due to excessive load The side stand is only designed for the weight of the motorcycle Do no sit on the motorcycle when it is resting on the side stand The side stand or the frame may become damaged and the motorcycle may fall over Brake the motorcycle Shift transmission to neutral While the engine is ...

Page 40: ... areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Note Material damage Premature clogging of the fuel filter In some countries and regions the available fuel quality and cleanliness may not be sufficient This will result in problems with the fuel system Your authorized KTM workshop will be glad to help Only re...

Page 41: ...heck correct the fluid level of the hydraulic clutch p 67 Check the brake fluid level of the front brake p 70 Check the free travel of the hand brake lever p 69 Check the steering head bearing play p 53 Check the valve clearance x Check the clutch x Change the shaft seal rings of the water pump x Change the engine oil and oil filter clean the oil screen x p 97 Check all hoses e g fuel cooling blee...

Page 42: ...a fork service x Service the shock absorber x Change the spark plug and spark plug connector x Change the piston x Check measure the cylinder x Check the cylinder head x Change the valves valve springs and valve spring seats x Check the camshaft and cam lever x Change the connecting rod conrod bearing and crank pin x Check the transmission and shift mechanism x Check the oil pressure regulator val...

Page 43: ...speed of the rear wheel suspension and not to the vehicle speed The high speed setting for example has an effect on the landing after a jump the rear wheel suspension compresses more quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses more slowly These two ranges can be adjusted separately although the transition between ...

Page 44: ...rresponding to the shock absorber type Guideline Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 25 turns Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 11 5 Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nit...

Page 45: ... the difference between measurements and Check the static sag Static sag 33 35 mm 1 3 1 38 in If the static sag is less or more than the specified value Adjust the spring preload of the shock absorber x p 44 11 8 Checking the riding sag of the shock absorber 400990 10 Measure distance of rear wheel unloaded p 43 With another person holding the motorcycle the rider wearing full protective cloth ing...

Page 46: ...nsion Tighten the spring by turning adjusting ring to measurement Guideline Spring preload 8 mm 0 31 in Info Depending on the static sag and or the riding sag it may be necessary to increase or decrease the spring preload Tighten screw Guideline Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft Finishing work Install the shock absorber x p 56 Remove the motorcycle from the lift stand p 48 11 ...

Page 47: ... harder springs must be fit to avoid damage to the fork and frame 11 12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior M00090 10 Remove protection caps Turn adjusting screws clockwise all the way Info Adjusting screws are located at the bottom end of the fork legs Make the same adjustment on both fork legs Turn back coun...

Page 48: ...nt on both fork legs Turn clockwise by the number of turns corresponding to the fork type Guideline Spring preload Preload Adjuster Comfort 1 turn Standard 2 turns Sport 2 turns Info Turn clockwise to increase spring preload turn counterclockwise to reduce spring preload Adjusting the spring preload has no influence on the absorption setting of the rebound damping Basically however you should set ...

Page 49: ... its attachments from damage by covering them Do not bend the cables and lines Remove screws Take off the handlebar supports Place the handlebar supports in the required position Mount and tighten screws Guideline Screw handlebar holder M10 40 Nm 29 5 lbf ft Loctite 243 Info Position the left and right handlebar supports evenly Position the handlebar Info Make sure the cables and wiring are positi...

Page 50: ...e press side stand to the ground with your foot and lean the motorcycle on it Info While riding the side stand must be folded up and secured with the rubber band 12 3 Bleeding fork legs Preparatory work Raise the motorcycle with the lift stand p 48 M00160 10 Main work Release bleeder screws Any excess pressure escapes from the interior of the fork Tighten the bleeder screws Finishing work Remove t...

Page 51: ...ve the screws on the right fork leg Push the fork protection downwards 12 6 Positioning the fork protector M00213 11 Position the fork protector on the left fork leg Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the wiring harness Position the brake line Put the clamp on and mount and tighten screws Position the fork protector on the right fork leg Mount ...

Page 52: ... top triple clamp M8 20 Nm 14 8 lbf ft Tighten screws Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft M00234 10 Position the brake caliper and mount and tighten screws Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount cable binder Position the brake line wiring harness and clamp Mount and tighten screws Finishing work Install the front wheel x p 78 Refit the headl...

Page 53: ... mask with the headlight Check the headlight setting p 88 12 11 Removing the lower triple clamp x Preparatory work Remove the headlight mask with the headlight Raise the motorcycle with the lift stand p 48 Remove the front wheel x p 78 Remove the fork legs x p 49 Remove the front fender p 55 Remove the handlebar cushion M00096 10 Main work Open the cable holder in front of the right radiator and d...

Page 54: ...upper triple clamp with the handlebar Mount screw but do not tighten yet Position the clutch line wiring harness and voltage regulator Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft M00172 10 Position the fork legs Bleeder screws face forward Info Grooves are milled into the side of the upper end of the fork legs The sec ond milled groove from the top must be flush...

Page 55: ...ront wheel x p 78 Refit the headlight mask with the headlight Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check the steering head bearing play p 53 Remove the motorcycle from the lift stand p 48 Check the headlight setting p 88 12 13 Checking the steering head bearing play Warning Danger of accidents Unstable vehicle handling fr...

Page 56: ...head bearing and replace if required Finishing work Remove the motorcycle from the lift stand p 48 12 14 Adjusting the play of the steering head bearing x Preparatory work Raise the motorcycle with the lift stand p 48 M00174 10 Main work Loosen screws and Loosen and retighten screw Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on the upper triple cla...

Page 57: ...ng the front fender L02485 10 Main work Position the front fender Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft B01603 11 Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Refit the headlight mask with the headlight Check the headlight setting p 88 12 18 Removing the shock absorber x Preparatory work Raise the motorcycl...

Page 58: ...orber M12 80 Nm 59 lbf ft Loctite 2701 Info The heim joint for the shock absorber at the swing arm is Teflon coated It must not be greased with grease or with other lubricants Lubricants dis solve the Teflon coating thereby drastically reducing the service life Finishing work Remove the motorcycle from the lift stand p 48 12 20 Removing the seat 101346 10 Remove screw Lift up the seat at the rear ...

Page 59: ... filter as dust and dirt will enter the engine and lead to increased wear Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Preparatory work Remove the air filter box lid p 57 L02468 10 Main work Detach air filter holder at the bottom and swing it to one side Re...

Page 60: ...er with fuel or petroleum since these substances attack the foam Preparatory work Remove the air filter box lid p 57 Remove the air filter x p 57 S00044 10 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 114 Info Only press the air filter to dry it never wring it out Oil the dry air filter with a high quality filter oil Oil for ...

Page 61: ...ncer Mount screws but do not tighten yet Reconnect spring Tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 12 30 Changing the glass fiber yarn filling of the main silencer x Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down Do not touch hot components Info Over time the fibers of the glass fiber yarn escap...

Page 62: ...vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with...

Page 63: ...ank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and w...

Page 64: ...the seat p 56 12 33 Checking for chain dirt accumulation 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 62 12 34 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grease on the br...

Page 65: ... to measure chain tension Info The lower chain section must be taut When the chain guard is mounted it must be possible to pull up the chain at least to the point where it makes contact with chain guard Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 55 58 mm 2 17 2 28 in If the chain tension does not meet specifications Adjust the cha...

Page 66: ...nd p 48 12 37 Checking the chain rear sprocket engine sprocket and chain guide Preparatory work Raise the motorcycle with the lift stand p 48 400227 01 Main work Shift gear to neutral Check the rear sprocket and engine sprocket for wear If the rear sprocket or engine sprocket is worn Change the power set x Info The engine sprocket rear sprocket and chain should always be replaced together 400987 1...

Page 67: ...line with or below the chain sliding piece Change the chain sliding piece x Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 lbf ft 401760 01 Check the chain guide for wear Info Wear is visible on the front of the chain guide If the light part of the chain guide is worn Change t...

Page 68: ...ormation If the swingarm shows signs of damage cracking or deformation Change the swingarm x Info A damaged swingarm must always be changed Repair of the swingarm is not authorized by KTM 12 40 Checking the throttle cable routing Preparatory work Remove the seat p 56 Remove the fuel tank x p 60 M00184 10 Main work Check the throttle cable routing Both throttle cables must be routed to the throttle...

Page 69: ... Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 12 44 Checking correcting the fluid level of ...

Page 70: ...leeding syringe with the appropriate hydraulic fluid Bleed syringe 50329050000 Brake fluid DOT 4 DOT 5 1 p 112 On the clutch slave cylinder remove bleeder screw and mount bleeding syringe M00209 10 Inject the liquid into the system until it escapes from openings of the master cylinder without bubbles To prevent overflow drain fluid occasionally from the master cylinder reservoir Remove the bleedin...

Page 71: ...rom the handlebar Turn the adjusting screw counterclockwise to increase free travel The pres sure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 13 3 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc s Change the worn b...

Page 72: ...tion that the brake system is leaking or that the brake linings are completely worn down Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes ...

Page 73: ... be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake ...

Page 74: ...rake fluid reservoir extracting it by suction if it does Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes M00111 10 Remove cotter pins pull out pin and remove the brake linings Clean the brake caliper and brake caliper support 100397 01 Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated ...

Page 75: ...ake can fail due to overheating Adjust the free travel on foot brake lever according to specifications L02451 10 Disconnect spring Loosen nut and with push rod turn it back until you have maximum free travel To adjust the basic position of the foot brake lever individually loosen nut and turn screw accordingly Info The range of adjustment is limited Turn push rod accordingly until you have free tr...

Page 76: ...d can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear ...

Page 77: ...hange the rear brake linings x p 75 13 13 Changing the rear brake linings x Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable prot...

Page 78: ...e in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 101382 10 Stand the vehicle upright Remove screw cap with membrane and the O ring Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake flui...

Page 79: ...13 BRAKE SYSTEM 77 101380 10 Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 112 Mount screw cap with membrane and O ring Info Clean up overflowed or spilt brake fluid immediately with water ...

Page 80: ...eel withdraw the wheel spindle Take the front wheel out of the fork Info Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged M00119 10 Remove spacers 14 2 Installing the front wheel x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free...

Page 81: ...cycle with the lift stand p 48 M00123 10 Main work Press the brake caliper by hand on to the brake disc in order to press back the brake piston Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut Remove chain adjuster Withdraw wheel spindle only enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far...

Page 82: ...y on adjusting screws Check the chain tension p 63 Tighten nut Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Chain adjusters can be turned by 180 Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a...

Page 83: ...than five years Change the tire 14 6 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life 400695 01 Remove the protection cap Check the tire air pressure when the tires are cold Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi Road tire p...

Page 84: ...nd frequencies in spokes with the same length and thickness this indicates different spoke tensions You should hear a high note If the spoke tension varies Correct the spoke tension x Check the spoke torque Guideline Spoke nipple front wheel M4 5 6 Nm 4 4 lbf ft Spoke nipple rear wheel M4 5 6 Nm 4 4 lbf ft Torque wrench with various accessories in set 58429094000 ...

Page 85: ...gative cable from the battery Pull back positive terminal cover and disconnect the positive cable from the battery Detach rubber band at the bottom Lift the battery up and out 15 2 Installing the battery x M00233 10 Main work Insert the battery into the battery compartment with the terminals facing forward Battery YTX4L BS p 109 Reconnect rubber band Position the positive cable and mount and tight...

Page 86: ...g current shortens the battery s service life If the charging current charging voltage and charging time are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged...

Page 87: ...ove screw M00120 10 Lift rear fairing slightly and pull starter relay out of the holder 101397 10 Remove protection caps Remove the faulty main fuse Info A defective fuse can be identified by the burned out fuse wire A reserve fuse is located in the starter relay Install a new main fuse Fuse 58011109120 p 109 Check that the electrical equipment is functioning properly Tip Insert the spare fuse so ...

Page 88: ...iator fan optional Fuses res 10 A spare fuses Info A defective fuse can be identified by the burned out fuse wire Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Use spare fuses with the correct rating only Fuse 75011088010 p 109 Tip Replace the spare fuse in the fuse box so that it is...

Page 89: ...ine and wiring harness Put the clamp on and mount and tighten screw Finishing work Check the headlight setting p 88 15 8 Changing the headlight bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Remove the headlight mask with the headlight B01...

Page 90: ...rst mark Guideline Distance 5 cm 2 in Position the vehicle vertically a distance away from the wall Guideline Distance 5 m 16 ft The rider now sits down on the motorcycle Switch on the low beam Check the headlight setting The boundary between light and dark must be exactly on the lower mark for a motorcycle with driver If the light dark border does not meet specifications Adjust the headlight rang...

Page 91: ...carefully into the socket and turn it clockwise until it stops Turn signal RY10W socket BAU15s p 109 Position the diffuser Insert the screw and first turn it counterclockwise until it engages in the thread Tighten the screw slightly Finishing work Check that the turn signal system is functioning properly 15 12 Changing the speedometer battery Preparatory work Remove the headlight mask with the hea...

Page 92: ...ess any button on the speedometer The speedometer is activated Position the speedometer in the holder Mount and tighten the screws with washers Finishing work Refit the headlight mask with the headlight Check the headlight setting p 88 Set kilometers or miles Adjust the speedometer functions Set the clock ...

Page 93: ...ystem to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swal lowed contact ...

Page 94: ...level does not meet specifications Correct the coolant level Alternative 1 Coolant p 112 Alternative 2 Coolant mixed ready to use p 112 Mount the radiator cap 16 4 Draining the coolant x Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow ...

Page 95: ...as on the skin with soap and water If coolant is swal lowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children M00196 10 Main work Make sure that the screw is tightened Stand the vehicle upright Pour coolant in up to measurement above the radiator fins Guideline 10 mm 0 39 in Coolant 1 2 l 1 3 qt Coolant p 112 Coolant mixed ready...

Page 96: ...n idle Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable x p 94 17 2 Adjusting the play in the throttle cable x Preparatory work Remove the seat p 56 Remove the fuel tank x p 60 Check the throttle cable routing p 66 M00197 10 Main work Move the handlebar to the straight ahead position Push bac...

Page 97: ...e of your boot and the shift lever Gap between the shift lever and the top of the boot 10 20 mm 0 39 0 79 in If the distance does not meet the specifications Adjust the basic position of the shift lever x p 95 17 5 Adjusting the basic position of the shift lever x 401950 12 Remove screw and take off shift lever 401951 10 Clean gear teeth of the shift lever and shift shaft Mount the shift lever on ...

Page 98: ...ughly with compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Disconnect the plug in connection of the fuel line Pull fuel screen out of the connecting piece Insert the new fuel screen all the way into the connecting piece Lubricate the O ring and connect plug in connection of the fuel line Danger Danger of poisoning Exha...

Page 99: ... Drain the engine oil only when the engine is warm Preparatory work Park the motorcycle on a level surface M00199 10 Main work Place a suitable container under the engine Remove oil drain plug with the magnet and seal ring Info Do not remove screws on both sides M00200 10 Remove screw plug with oil screen and the O rings Completely drain the engine oil Thoroughly clean the parts and sealing surfac...

Page 100: ...ight M00206 10 Remove the oil filler plug with the O ring from the clutch cover and fill up with engine oil Engine oil 1 2 l 1 3 qt Engine oil SAE 10W 50 p 112 Alternative engine oil for harsh oper ating conditions and increased per formance Engine oil SAE 10W 60 00062010035 p 112 Info Too little engine oil or poor quality engine oil results in premature wear to the engine Install and tighten the ...

Page 101: ...112 Info For optimal performance of the engine oil do not mix different types of engine oil If appropriate change the engine oil Install and tighten the oil filler plug with O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engin...

Page 102: ...rcycle cleaner and then clean with a paintbrush Motorcycle cleaner p 114 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry vehicle always rinse with water first After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the plug from the exhaust system Warning Danger of accidents Reduced braking eff...

Page 103: ... brake system Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts are cooled down and while they are installed After riding on salted roads thoroughly wash the motorcycle with cold water and dry it well Treat the engine swingarm and all other bright and zinc plated parts except for the brak...

Page 104: ...taking the motorcycle out of service add fuel additive Fuel additive p 114 Refuel p 38 Clean the motorcycle p 100 Change the engine oil and oil filter clean the oil screen x p 97 Check the antifreeze and coolant level p 91 Check the tire air pressure p 81 Remove the battery x p 83 Charge the battery x p 84 Guideline Storage temperature of battery without direct sunlight 0 35 C 32 95 F Store the ve...

Page 105: ...y OFF switch defective Check the wiring harness visual check Check the electrical system Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x Ignition system defective Ignition coil check the secondary winding x Check the spark plug connector x...

Page 106: ...i cal plug in connections for corrosion and dam age Read out the fault memory using the KTM diag nostics tool x High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary Engine oil level too high Check the engine oil level p 96 Engine oil too thin low viscosity Change the engine oil and oil filter clean the oil screen x p 97 Piston and cylinder worn Me...

Page 107: ...ning lamp MIL flashes 1x long 3x short Error level condition Intake air temperature sensor input signal too low Intake air temperature sensor input signal too high Blink code FI warning lamp MIL 15 FI warning lamp MIL flashes 1x long 5x short Error level condition Rollover sensor A D type input signal too low Rollover sensor A D type input signal too high Blink code FI warning lamp MIL 33 FI warni...

Page 108: ...5th gear 25 22 6th gear 26 20 Alternator 12 V 168 W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Spark plug NGK LMAR9AI 8 Spark plug electrode gap 0 8 mm 0 031 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid Kick starter and electric starter 23 2 Engine tightening torques Nozzle crank chamber ventilation M4 2 Nm 1 ...

Page 109: ... 18 4 lbf ft Loctite 243 Screw timing chain tensioning rail M8 15 Nm 11 1 lbf ft Loctite 243 Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701 Plug oil channel M10x1 15 Nm 11 1 lbf ft Loctite 243 Rotor screw M10x1 70 Nm 51 6 lbf ft Thread oiled with engine oil cone degreased Screw plug cam lever axis M10x1 10 Nm 7 4 lbf ft Screw unlocking of timing chain ten sioner M10x1 10 Nm 7 4 lbf ft Sp...

Page 110: ... 335 mm 13 19 in Fork offset 20 mm 0 79 in Shock absorber WP Suspension PDS 5018 DCC Brake system Disc brakes brake calipers on floating bearings Brake discs diameter Front 260 mm 10 24 in Rear 220 mm 8 66 in Brake discs wear limit Front 2 5 mm 0 098 in Rear 3 5 mm 0 138 in Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi Road tire pressure Front 1 5 bar 22 psi Rear 1 5 bar 22 p...

Page 111: ...ection under http www ktm com 23 7 Fork Fork part number 14 18 7L 67 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 22 clicks Standard 20 clicks Sport 18 clicks Rebound damping Comfort 20 clicks Standard 18 clicks Sport 16 clicks Spring preload Preload Adjuster Comfort 1 turn Standard 2 turns Sport 2 turns Spring length with preload spacer s Weight of rider 65 75 kg 143 1...

Page 112: ...2 lbf ft Spoke nipple front wheel M4 5 6 Nm 4 4 lbf ft Spoke nipple rear wheel M4 5 6 Nm 4 4 lbf ft Screw battery terminal M5 2 5 Nm 1 84 lbf ft Screw intake air temperature sensor M5 2 Nm 1 5 lbf ft Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft Screw spoiler on fuel tank M5x12 1 5 Nm 1 11 lbf ft Nut cable on starter motor M6 4 Nm 3 lbf ft Remaining nuts chassis M6 10 Nm 7 4 lbf ft Remain...

Page 113: ... Engine attachment bolt M10 60 Nm 44 3 lbf ft Remaining nuts chassis M10 45 Nm 33 2 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw handlebar holder M10 40 Nm 29 5 lbf ft Loctite 243 Nut fuel pump fixation M12 15 Nm 11 1 lbf ft Screw bottom shock absorber M12 80 Nm 59 lbf ft Loctite 2701 Screw top shock absorber M12 80 Nm 59 lbf ft Loctite 2701 Nut seat fixing M12x1 20 Nm 14 8 lbf ft N...

Page 114: ...sion inhibitor antifreeze 50 distilled water Coolant mixed ready to use Antifreeze 38 C 36 F Recommended supplier Motorex COOLANT M5 0 Engine oil SAE 10W 60 00062010035 Standard classification JASO T903 MA p 116 SAE p 116 SAE 10W 60 KTM LC4 2007 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corre sponding properties...

Page 115: ...E 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe ...

Page 116: ...ke Grease 2000 Motorcycle cleaner Recommended supplier Motorex Moto Clean Off road chain spray Recommended supplier Motorex Chainlube Offroad Oil for foam air filter Recommended supplier Motorex Racing Bio Liquid Power Preserving materials for paints metal and rubber Recommended supplier Motorex Moto Protect Rubber grip adhesive 00062030051 Recommended supplier KTM Sportmotorcycle AG GRIP GLUE Spe...

Page 117: ...25 AUXILIARY SUBSTANCES 115 Universal oil spray Recommended supplier Motorex Joker 440 Synthetic ...

Page 118: ...rvice intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils...

Page 119: ... Chassis number 14 Clutch fluid level checking correcting 67 fluid changing 68 Clutch lever 16 basic position adjusting 67 Compression damping fork adjusting 45 Compression damping high speed shock absorber adjusting 42 Compression damping low speed shock absorber adjusting 41 Coolant draining 92 refilling 93 Coolant level checking 91 92 Cooling system 91 Customer service 11 D Difficult riding con...

Page 120: ...19 L Light switch 16 Lower triple clamp installing 52 removing 51 M Main fuse changing 85 Main silencer glass fiber yarn filling changing 59 installing 59 removing 59 Motorcycle cleaning 100 raising with lift stand 48 removing from lift stand 48 O Oil filter changing 97 Oil screen cleaning 97 Operating substances 11 Overview of indicator lamps 17 Owner s Manual 10 P Play in throttle cable checking...

Page 121: ...02 Swingarm checking 66 T Technical data capacities 108 chassis 108 chassis tightening torques 110 electrical system 109 engine 106 engine tightening torques 106 fork 109 shock absorber 110 tires 109 Throttle cable play adjusting 94 Throttle cable routing checking 66 Throttle grip 16 Tire air pressure checking 81 Tire condition checking 80 Transport 37 Troubleshooting 103 104 Turn signal bulb chan...

Page 122: ... 3213182en 3213182en 05 2014 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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