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KTM 350 EXC-F 2017, Owner'S Manual

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KTM 350 EXC-F 2017 Owner'S Manual Download Page 81

13

BRAKE SYSTEM

79

Info

Never use DOT 5 brake fluid. It is silicone-based and purple 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.
Only use clean brake fluid from a sealed container.

Preparatory work

–

Check the rear brake linings. (

p. 79)

K00565-10

Main work

–

Stand the vehicle upright.

–

Remove screw cap

with membrane

and the O-ring.

–

Add brake fluid to level

.

Brake fluid DOT 4 / DOT 5.1 (

p. 117)

–

Mount the screw cap with the membrane and the O-ring.

Info

Clean up overflowed or spilled brake fluid immediately with water.

13.12

Checking the rear brake linings

Warning

Danger of accidents

 

Worn-out brake linings reduce the braking effect.

–

Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.)

E00349-10

–

Check the brake linings for minimum thickness

.

Minimum thickness

≥

1 mm (

≥

0.04 in)

» If the minimum thickness is less than specified:

–

Change the rear brake linings.

(

p. 79)

–

Check the brake linings for damage and cracking.
» If damage or cracking is visible:

–

Change the rear brake linings.

(

p. 79)

13.13

Changing the rear brake linings

Warning

Danger of accidents

 

Incorrect maintenance will cause the brake system to fail.

–

Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.)

Summary of Contents for 350 EXC-F 2017

Page 1: ...OWNER S MANUAL 2017 350 EXC F Art no 3213481en ...

Page 2: ......

Page 3: ...ns 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 devi ations from illustrations and descriptions misprints and other errors The models portrayed partly contain special equipment t...

Page 4: ...D H service hours 25 7 9 Setup menu 26 7 10 Setting the unit of measurement 26 7 11 Display mode SPEED CLK time 27 7 12 Setting the clock 27 7 13 Display mode SPEED LAP lap time 27 7 14 Viewing the lap time 28 7 15 Display mode SPEED ODO odometer 28 7 16 Display mode SPEED TR1 trip master 1 28 7 17 Display mode SPEED TR2 trip master 2 29 7 18 Setting TR2 trip master 2 29 7 19 Display mode SPEED A1...

Page 5: ...fluid level of the hydraulic clutch 71 12 44 Changing the hydraulic clutch fluid 72 13 BRAKE SYSTEM 73 13 1 Checking free travel of hand brake lever 73 13 2 Adjusting free travel of hand brake lever 73 13 3 Checking the brake discs 73 13 4 Checking the brake fluid level of the front brake 74 13 5 Adding front brake fluid 74 13 6 Checking the front brake linings 75 13 7 Changing the front brake lin...

Page 6: ...ques 111 22 3 Capacities 113 22 3 1 Engine oil 113 22 3 2 Coolant 113 22 3 3 Fuel 113 22 4 Chassis 113 22 5 Electrical system 114 22 6 Tires 114 22 7 Fork 114 22 8 Shock absorber 115 22 9 Chassis tightening torques 115 23 SUBSTANCES 117 24 AUXILIARY SUBSTANCES 119 25 STANDARDS 120 26 INDEX OF SPECIAL TERMS 121 27 LIST OF ABBREVIATIONS 122 28 LIST OF SYMBOLS 123 28 1 Yellow and orange symbols 123 2...

Page 7: ...e 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 Indicates information with more details or tips Indicates the result of a testing step 1 2 Formats used The typographical formats used in this document are explained below Specific name Identifies a proprietary...

Page 8: ...ore read 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 Indicates a danger t...

Page 9: ...8 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 E00511 01 Canada type label E00512 01 USA type label ...

Page 10: ...FETY ADVICE 8 S00026 10 Brake fluid information 101516 01 Information on chain tension F00491 10 Information on starting up E00513 01 Information on emissions control E00514 01 Information on noise emission ...

Page 11: ... 2 7 Operating noise warning This product should be checked for necessary repair or replacement parts if the motorcycle noise has increased significantly through use Otherwise the owner may become subject to penalties under the applicable ordinances 2 8 Consumer rights Warranty claims should be submitted to a KTM workshop If you are not satisfied please contact KTM North America Inc Customer Suppo...

Page 12: ...thing such as helmet boots gloves as well as trousers and a jacket with protectors on all rides Always wear protective clothing that is in good condition and meets the legal regulations In the interest of your own safety KTM recommends that you only operate the vehicle while wearing protective clothing 2 12 Work rules Special tools are necessary for certain tasks The tools are not contained in the...

Page 13: ... then will you find out how to cus tomize the vehicle ideally for your own use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it as needed If you would like to know more about the vehicle or have questions on the material you read please contact an authorized KTM dealer The Owner s Manual is an important component of the vehicl...

Page 14: ...he current KTM 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 dama...

Page 15: ...4 VIEW OF VEHICLE 13 4 1 View of vehicle front left example E00500 10 1 Hand brake lever p 17 2 Clutch lever p 17 3 Filler cap 4 Side stand p 21 5 Engine number p 15 6 Shift lever p 20 ...

Page 16: ...ht example E00501 10 1 Horn button p 17 1 Light switch p 17 1 Turn signal switch p 18 2 Emergency OFF switch p 18 2 Electric starter button p 18 3 Throttle grip p 17 4 Fork part number p 16 5 Foot brake lever p 21 6 Shock absorber article number p 16 ...

Page 17: ...ng head The additional type label for Canada is fixed to the front of the front pipe 5 3 Key number 402246 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 H01047 10 Engine number is embossed on the left side of the engine over the engine sprocket ...

Page 18: ...47 10 The fork part number is stamped on the inner side of the fork stub 5 6 Shock absorber article number 0 0 1 1 401948 10 Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 19: ...s fitted on the right side of the handlebar 6 4 Horn button V00449 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 V00449 12 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 posi...

Page 20: ...cuit is closed and the engine can be started 6 8 Electric starter button S01301 10 The electric starter button is fitted on the right side of the handlebar Possible states Electric starter button in basic position Electric starter button pressed the electric starter is actuated in this position 6 9 Indicator lamps overview V00451 01 Possible states The high beam indicator lamp lights up blue The h...

Page 21: ... consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Warning Environmental hazard Improper hand...

Page 22: ... Possible states The cold start button is activated The cold start button is pushed in all the way The cold start button is deactivated The cold start button is in its basic position 6 14 Idle speed adjusting screw S01309 10 The idle setting of the throttle valve body has a big influence on the vehicle s starting behavior on stable idling and on vehicle response when the throttle is opened An engi...

Page 23: ... is used to activate the rear brake 6 17 Side stand 401943 10 The side stand is attached to the left side of the vehicle 401944 10 The side stand 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 S01311 10 Steering lock is fitted on the left side of the steering head The steering lock is used to lock the ste...

Page 24: ...egularly Universal oil spray p 119 Insert the key in the steering lock p 21 turn it to the left press 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 p 21 turn it to the left pull it out and turn it to the right Remove the key You can now steer the bi...

Page 25: ...ircumference 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 ...

Page 26: ...he 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 flashes...

Page 27: ...y When an impulse comes from the front wheel the left side of the speedometer display changes to the SPEED mode and the current speed is shown 7 8 Display mode SPEED H service hours 400316 01 Condition 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 c...

Page 28: ...econds Changes to the next display without changes Wait 10 12 sec onds Setup menu starts stores the settings and changes to H or ODO 7 10 Setting the unit of measurement 400329 01 Condition The motorcycle is stationary Repeatedly press the button briefly until H appears at the bottom right of the display Press the button for 2 3 seconds Repeatedly press the button briefly until Km h Mph flashes In...

Page 29: ... button Increases the value Press the button for 2 3 seconds Reduces the value Briefly press the button Reduces the value Wait 3 5 seconds Changes to the next value Wait 10 12 sec onds Closes the SETUP menu 7 13 Display mode SPEED LAP lap time 400320 01 Repeatedly press the button briefly until LAP appears at the bottom right of the display In the LAP display mode up to 10 lap times can be timed w...

Page 30: ...display mode ODO Press the button for 2 3 seconds No function Briefly press the button Next display mode Press the button for 2 3 seconds No function Briefly press the button No function 7 16 Display mode SPEED TR1 trip master 1 400323 01 Repeatedly press the button briefly until TR1 appears at the top right of the dis play TR1 trip master 1 runs constantly and counts up to 999 9 You can use it to...

Page 31: ...R2 value can also be corrected manually during the journey with the but ton and the button If 999 9 is exceeded the value of TR2 is automatically reset to 0 0 Press the button for 2 3 seconds Increases value of TR2 Briefly press the button Increases value of TR2 Press the button for 2 3 seconds Reduces value of TR2 Briefly press the button Reduces value of TR2 Wait 10 12 sec onds Saves and closes ...

Page 32: ... shows the riding time based on TR1 and continues running as soon as an impulse arrives from the wheel speed sensor The calculation of this value starts with the first impulse from 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...

Page 33: ...ETUP menu Display mode SPEED LAP lap time The stop watch and the lap time are reset Next display mode Stops the clock Starts the stop watch or stop the current lap time measure ment stores it and the stop watch starts the next lap Viewing the lap time The stop watch and the lap time are reset Select a lap from 1 10 No function View the next lap time Display mode SPEED ODO odometer No function Next...

Page 34: ...Setup menu Setting the unit of measurement Setting the clock Display mode SPEED LAP lap time Viewing the lap time Display mode SPEED TR1 trip master 1 Display mode SPEED TR2 trip master 2 Setting TR2 trip master 2 Display mode SPEED A1 average speed 1 Display mode SPEED A2 average speed 2 Display mode SPEED S1 stop watch 1 Display mode SPEED S2 stop watch 2 ...

Page 35: ... of accidents The brake system fails in the event of overheating If the foot brake lever is not released the brake linings drag continuously Take your foot off the foot brake lever when you are not braking Warning Danger of accidents Total weight and axle loads influence the handling characteristic Do not exceed the maximum permissible overall weight or the axle loads Warning Risk of misappropriat...

Page 36: ...Lithium ion batteries are far lighter than lead batteries have a low self discharge rate and have more starting power at temperatures over 15 C 60 F At low temperatures however the starting power of lithium ion batteries drops to below that of lead batter ies Multiple starting attempts may be needed Press the electric starter button for 5 sec onds and wait 30 seconds between attempts The pauses ar...

Page 37: ...rides on dry sand 102136 01 Fit a dust cover on the air filter Dust cover for air filter 79006920000 Info See the KTM PowerParts fitting instructions 102138 01 Fit a sand cover on the air filter Sand cover for air filter 79006922000 Info See the KTM PowerParts fitting instructions 600868 01 Clean the chain Chain cleaner p 119 Fit the steel sprocket Tip Do not grease the chain Clean the radiator fi...

Page 38: ... motorcycle p 106 Straighten bent radiator fins carefully 8 8 Preparing for rides at high temperature and slow speed 600868 01 Adjust the secondary drive to the road conditions Info 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 119 Clean the radiator fins Straighten bent radiator fins carefully Chec...

Page 39: ...rrect spoke tension will strongly impair riding safety Clean the dust boots of the fork legs p 51 Bleed the fork legs p 50 Check the air filter Check the settings of all controls and ensure that they can be operated smoothly Check all screws nuts and hose clamps regularly for tightness Check the fuel level 9 2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result...

Page 40: ...r reaching maximum speed by fully opening the throttle grip turn the throttle back so it is open This will barely reduce the speed but fuel consumption will be considerably lower Always open the throttle only as much as the engine can handle abrupt throttle opening increases fuel consumption To shift down apply the brakes and close the throttle at the same time Pull the clutch lever and shift into...

Page 41: ... a fire hazard and explosion risk Do not park the vehicle near to materials which are highly flammable or explosive Allow the vehicle to cool down before covering it Note Material damage The vehicle may be damaged by incorrect procedure when parking Significant damage may be caused if the vehicle rolls away or falls over The components for parking the vehicle are designed only for the weight of th...

Page 42: ...es thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Note Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged In some countries and regions the available fuel quality and cleanliness may not be sufficient This will result in problems with the fuel system Refuel only with clean fu...

Page 43: ... Check the rim run out Check the spoke tension p 86 Check the chain rear sprocket engine sprocket and chain guide p 68 Check the chain tension p 66 Grease all moving parts e g side stand hand lever chain and check for smooth operation Check correct the fluid level of the hydraulic clutch p 71 Check the brake fluid level of the front brake p 74 Check the free travel of the hand brake lever p 73 Che...

Page 44: ...urs Change the front brake fluid Change the rear brake fluid Change the hydraulic clutch fluid p 72 Lubricate the steering head bearing p 56 Clean the spark arrestor p 61 Service the fork Service the shock absorber Change the fuel filter Perform engine service including removing and installing the engine Change the spark plug and spark plug connector Change the piston Check measure the cylinder Ch...

Page 45: ...heel 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 quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses slowly These two ranges can be adjusted separately although the transition between high speed and low speed is g...

Page 46: ...he number of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort 2 5 turns Standard 2 turns Sport 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 11 5 Adjusting the rebound damping of the shock absorber Caution Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly...

Page 47: ...e the motorcycle from the lift stand p 50 11 7 Checking the static sag of the shock absorber 402416 10 Measure dimension of rear wheel unloaded p 45 Hold the motorcycle upright with the aid of an assistant Again measure the distance between the rear axle and marking SAG on the rear fender using the sag gauge Note down the value as dimension Info The static sag is the difference between measurement...

Page 48: ...ck absorber is disassembled incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized KTM workshop will be glad to help Info Before changing the spring preload make a note of the present setting e g by measuring the length of the spring Preparatory work Raise the motorcycle with the lift stand p 50 Remove shock absorber p 57 Aft...

Page 49: ...g of the shock absorber p 46 Adjust the rebound damping of the shock absorber p 44 11 11 Checking the basic setting of the fork Info For various reasons no exact riding sag can be determined for the fork 401000 01 As with the shock absorber smaller differences in the rider s weight can be com pensated by the spring preload However if the fork frequently bottoms out hard end stop on compression har...

Page 50: ...ght fork leg The rebound damping is located in right fork leg REB red adjusting screw The compression damping is located in left fork leg COMP white adjusting screw Turn counterclockwise by the number of clicks corresponding to the fork type Guideline Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damp in...

Page 51: ...one side Info Cover the components to protect them against damage Do not kink 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 a...

Page 52: ... damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 401943 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle 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 the fork legs Preparatory work...

Page 53: ...he dust boots and inner fork tubes of both fork legs Universal oil spray p 119 Press the dust boots back into their installation position Remove excess oil Finishing work Install the fork protector p 51 Remove the motorcycle from the lift stand p 50 12 5 Removing the fork protector V00332 10 Remove screws and take off the clamp Remove screws on the left fork leg and take off the left fork protecto...

Page 54: ...tion the fork legs Bleeder screws are positioned toward the front 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 with the top edge of the upper triple clamp V00452 11 Tighten screws Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Tighten screws Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft K00546 10 Posi...

Page 55: ...diator and detach the wiring harness Loosen screw Remove screw Take off the upper triple clamp with the handlebar and set it aside Info Cover the components to protect them against damage Do not kink the cables and lines E00381 10 Remove O ring and protective ring Take off the lower triple clamp with the steering stem Remove the upper steering head bearing 12 10 Installing the lower triple clamp B...

Page 56: ...tioned toward the front 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 with the top edge of the upper triple clamp V00464 10 Tighten screws Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft V00465 11 Tighten screw Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft V00465 10 Tighten screw Guideline Screw to...

Page 57: ...eristic and damages components Correct incorrect steering head bearing play immediately Your authorized KTM workshop will be glad to help Info If the vehicle is operated for a lengthy period with play in the steering head bearing the bearings and the bearing seats in the frame can become damaged over time Preparatory work Raise the motorcycle with the lift stand p 50 H01167 01 Main work Move the h...

Page 58: ...hten screws Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Tighten screw Guideline Screw top steering stem M8 20 Nm 14 8 lbf ft Finishing work Check the play of the steering head bearing p 55 Remove the motorcycle from the lift stand p 50 12 13 Lubricating the steering head bearing 800010 10 Remove the lower triple clamp p 53 Install the lower triple clamp p 53 12 14 Removing the front fend...

Page 59: ... as far as possible without blocking the rear wheel Fix the rear wheel in this position Remove screw push splash protector to the side and remove the shock absorber 12 17 Installing the shock absorber K00551 11 Main work Push splash protector to the side and position the shock absorber Mount and tighten screw Guideline Screw top shock absorber M12 80 Nm 59 lbf ft Loctite 2701 Mount and tighten scr...

Page 60: ...ar bushing of the fuel tank lower the seat at the rear and push the seat forward Make sure that the seat is correctly locked in V00342 10 Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 12 20 Removing the air filter box cover K00554 10 Condition The air filter box cover is secured Remove screw K00554 11 Pull off the air filter box cover in area sideways and remove i...

Page 61: ... will enter the engine without an air filter Never start to use the vehicle without an air filter Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regu lations Preparatory work Remove the air filter box cover p 58 K00552 10 Main work Detach retaining tab R...

Page 62: ...s Info Do not clean the air filter with fuel or petroleum since these substances attack the foam Preparatory work Remove the air filter box cover p 58 Remove the air filter p 59 102191 01 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 119 Info Only press the air filter to dry it never wring it out Oil the dry air filter with a ...

Page 63: ...connect spring Spring hook 50305017000 Remove screws and take off main silencer 12 28 Installing the main silencer K00575 11 Position the main silencer Mount screws but do not tighten yet Reconnect spring Spring hook 50305017000 Tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 12 29 Cleaning the spark arrestor Warning Danger of burns The exhaust system gets very hot when the v...

Page 64: ...w O ring on silencer cap Position silencer cap Mount and tighten screws Guideline Screws on the main silencer M5 7 Nm 5 2 lbf ft Finishing work Install the main silencer p 61 12 30 Changing the glass fiber yarn filling in the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehi...

Page 65: ...in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health...

Page 66: ...anger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warnin...

Page 67: ...h the collar bushings Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft E00509 10 Plug in connector for the fuel pump Remove the wash cap set Thoroughly clean the plug in connection of the fuel line using compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Lubricate the O ring and connect plug in connection for the fu...

Page 68: ...intenance Preparatory work Raise the motorcycle with the lift stand p 50 400725 01 Main work Clean the chain regularly and then treat with chain spray Chain cleaner p 119 Off road chain spray p 119 Finishing work Remove the motorcycle from the lift stand p 50 12 35 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents If the chai...

Page 69: ...ome components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Raise the motorcycle with the lift stand p 50 Check the chain tension p 66 E00330 10 Main work Loo...

Page 70: ...sure the distance of 18 chain links in the lower chain section Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance at the longest chain section 272 mm 10 71 in If the distance is greater than the specified measurement Change the drivetrain kit Info When the chain is replaced the rear sprocket and engine sprocket should also be chan...

Page 71: ...ont of the chain guide If the light part of the chain guide is worn Change the chain guide E00333 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the screws on the chain guide Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Remaining nuts chassis M6 10 Nm 7 4 lbf ft Finishing work Remove the motorcycle from the lift stand p 50 12 38 Checking the frame S013...

Page 72: ...y Both throttle cables must be secured behind the fuel tank contact area rubber band If the throttle cable routing is not as specified Correct throttle cable routing Finishing work Install the fuel tank p 64 Mount the seat p 58 12 41 Checking the rubber grip 401197 01 Check the rubber grips on the handlebar for damage wear and looseness Info The rubber grips are vulcanized onto a sleeve on the lef...

Page 73: ...kin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regu lations Info The fluid...

Page 74: ... It is silicone based and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container V00456 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane E00515 10 Fill bleeding syring...

Page 75: ...w 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 Worn out brake discs reduce the braking effect Make sure that worn out brake discs are replaced immediately Yo...

Page 76: ...e system and do not continue riding until the problem is eliminated Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid...

Page 77: ...front brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail Ensure that service work and repairs are performed professionally Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake f...

Page 78: ... lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container K00574 11 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Press the brake caliper onto the brake disc by hand in order to push back the brake pistons E...

Page 79: ... 2 in If the free travel does not meet specifications Adjust the basic position of the foot brake lever p 77 Reconnect spring 13 9 Adjusting the basic position of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the fo...

Page 80: ...arking or the specified value the brake system is leaking or the brake lin ings are worn down Check the brake system and do not continue riding until the problem is eliminated Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow bra...

Page 81: ...e fluid immediately with water 13 12 Checking the rear brake linings Warning Danger of accidents Worn out brake linings reduce the braking effect Ensure that worn out brake linings are replaced immediately Your authorized KTM workshop will be glad to help E00349 10 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change th...

Page 82: ...es The structure and friction coefficient of the brake linings and thus their brake power may vary greatly from that of original brake linings If brake linings are used that differ from the original equipment compliance with the original homologation is not guaranteed In this case the vehicle no longer corresponds to its condition at delivery and the warranty shall be void Only use brake linings a...

Page 83: ... the pin and mount the cotter pins Info Always change the brake linings in pairs Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point K00565 10 Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 117 Mount screw cap with membrane and O ring Info Clean up overflowed or spilled brake fluid immediately with water ...

Page 84: ... braking effect Always lay the wheel down in such a way that the brake disc is not dam aged Holding the front wheel 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 H00934 10 Remove spacers 14 2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Alway...

Page 85: ...0 V00366 10 Main work Press the brake caliper onto the brake disc by hand in order to push 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 as possible Remove the chain f...

Page 86: ...sition the rear wheel and insert wheel spindle The brake linings are correctly positioned Mount the chain V00368 10 Position chain adjuster Mount nut but do not tighten it yet Make sure that chain adjusters are fitted correctly on adjusting screws Check the chain tension p 66 Tighten nut Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters ...

Page 87: ...pth Change the tires H01144 01 Check the tire age Info The tire date of manufacture is usually contained in the tire label and is indicated by the last four digits of the DOT number The first two digits indi cate the week of manufacture and the last two digits the year of manufac ture KTM recommends that the tires be changed after 5 years at the latest regardless of the actual state of wear If the...

Page 88: ...articular on a new vehicle Your authorized KTM workshop will be glad to help 400694 01 Strike each spoke briefly using a screwdriver blade Info The frequency of the sound depends on the spoke length and spoke diame ter If you hear different tone frequencies from different spokes of equal length and diameter this is an indication of different spoke tensions You should hear a high note If the spoke ...

Page 89: ...from inflammable materials when charg ing batteries Minimum clearance 1 m 3 ft Do not charge deeply discharged batteries if charge is already below the minimum voltage Minimum voltage before the start of the charge 9 V Dispose of batteries with less than the minimum voltage correctly Disconnect negative cable from the battery Pull back positive terminal cover and disconnect the positive cable from...

Page 90: ...ediately Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 58 Remove the battery p 87 S00863 10 Main work Warning Risk of injury Batteries contain harmful substances Keep batteries out of the reach of children Keep sparks and open flames away from the batteries Only charge batteries in well ventilated rooms Maintain a minimum clearance from inflammable mat...

Page 91: ... be longer at low temperatures This battery charger is not suitable for the trickle charging of lithium ion batteries Switch off the battery charger after charging and disconnect from the battery Finishing work Install the battery p 87 Mount the seat p 58 15 4 Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system Only use fuses with the required ampere value Do ...

Page 92: ... individual power consumers is located under the seat Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 58 E00394 10 Main work Pull EFI control unit from the holder and hang it to one side E00395 10 Open fuse box cover Remove the defective fuse Guideline Fuse 1 10 A EFI control unit speedometer fuel injection diagnostics connec tor fuse 4 Fuse 2 10 A high ...

Page 93: ...ol unit on the holder Finishing work Mount the seat p 58 15 6 Removing the headlight mask with the headlight V00469 10 Switch off all power consumers and switch off the engine Detach the brake line and wiring harness from the headlight mask Release rubber bands Slide the headlight mask up and swing it forward V00459 10 Detach plug in connectors and take off the headlight mask with the headlight 15...

Page 94: ...ap together with the underlying bulb socket counterclockwise all the way and remove it Pull bulb socket of the parking light out of the reflector E00359 10 Pull out headlight bulb Insert the new headlight bulb Headlight HS1 socket PX43t p 114 Insert the protection cap with the bulb socket into the reflector and turn it clock wise all the way Info Ensure that O ring is seated properly Insert the bu...

Page 95: ...ark at the height of the center of the low beam headlight Make another mark at a distance under the first mark Guideline Distance 5 cm 2 in Position the vehicle vertically at 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...

Page 96: ...ward Speedometer battery CR 2430 p 114 Check the O ring of the protection cap for correct seating V00372 10 Position protection cap and turn all the way clockwise using a coin Press any button on the speedometer The speedometer is activated Position the speedometer in the holder Mount and tighten the screws with washers Finishing work Install the headlight mask with the headlight p 91 Check the he...

Page 97: ...radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the a...

Page 98: ...ight on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level above the radiator fins 10 mm 0 39 in If the coolant level does not match the specified value Correct the coolant level Coolant p 117 Mount the radiator cap 16 4 Draining the coolant Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not ...

Page 99: ...e into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing K00543 10 Main work Make sure that the screw is tigh...

Page 100: ...nning the engine in an enclosed space Start the engine and let it run 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 p 98 17 2 Adjusting the play in the throttle cable Info If the correct routing of the throttle cables has already been secured the fuel tank does not need to be removed ...

Page 101: ... 2 Black guide plate 79002014100 Info The gray guide plate opens the throttle valve more slowly The black guide plate opens the throttle valve more quickly The gray guide plate is mounted upon delivery S01320 10 Clean the outside of the handlebar and the inside of the grip tube Mount the grip tube on the handlebar Attach the throttle cables to the guide plate and route correctly Position half shel...

Page 102: ...are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Allow the vehicle to idle The malfunction indicator lamp stops flashing once teaching is completed Info If the engine becomes too hot perform a cool down ride ...

Page 103: ...f the shift lever and shift shaft Mount the shift lever on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle compo nents during the shift procedure Mount and tighten screw with the washers Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 ...

Page 104: ...m Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system E00506 10 Clean plug in connection of the fuel line thoroughly 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 fu...

Page 105: ...warm water Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regu lations Info Drain engine oil with engine at operating temperature Preparatory work Park the motorcycle on a level surface K00567 10 Main work Place a suitable container under the engine Remo...

Page 106: ... the O ring of the oil filter cover and mount it with oil filter cover Mount and tighten the screws Guideline Screw oil filter cover M6 10 Nm 7 4 lbf ft Stand the motorcycle upright 401955 12 Remove filler plug with the O ring from the clutch cover and fill up with engine oil Engine oil 1 0 l 1 1 qt Engine oil SAE 10W 50 p 117 Alternative engine oil for harsh oper ating conditions and increased pe...

Page 107: ...7 Alternative 1 Engine oil SAE 10W 60 00062010035 p 117 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 death Always make sure there is sufficient ventilation when runn...

Page 108: ...ormal commercial engine cleaner and then brush off with a soft brush Motorcycle cleaner p 119 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the vehicle with water first After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the closure of the exhaust system Warning Danger ...

Page 109: ...torcycle p 106 Clean the brake system Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings in the cooled down and installed state with cold water and dry carefully After riding on salted roads thoroughly wash the vehicle with cold water and dry it well Treat the engine swingarm and all other bright and zinc plated parts except for the brake discs with a wax ba...

Page 110: ...otorcycle out of service add fuel additive Fuel additive p 119 Refuel p 40 Clean the motorcycle p 106 Change the engine oil and oil filter clean the oil screen p 103 Check the antifreeze and coolant level p 95 Check the tire air pressure p 85 Remove the battery p 87 Recharge the battery p 88 Guideline Storage temperature of battery without direct sunlight 0 35 C 32 95 F Store the vehicle in a dry ...

Page 111: ...ystem Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool Ignition system defective Ignition coil check the secondary winding Check the spark plug connector Check the stator winding of the alternator Engine has too little power Air filter heavily ...

Page 112: ...ose bent Route the vent hose without bends or replace it if necessary Engine oil level too high Check the engine oil level p 102 Engine oil too thin low viscosity Change the engine oil and oil filter clean the oil screen p 103 Piston and cylinder worn Measure the piston cylinder mounting clear ance Battery discharged Battery is not being charged by alter nator Check the charging voltage Check the ...

Page 113: ...ar 10 23 PM Fifth gear 25 22 Sixth gear 26 20 Alternator 12 V 168 W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Spark plug NGK LMAR9AI 10 Spark plug electrode gap 1 0 mm 0 039 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid Electric starter 22 2 Engine tightening torques Nozzle crank chamber ventilation M4 2 Nm 1 ...

Page 114: ...f ft Screw auto decompression M7x1 15 Nm 11 1 lbf ft Loctite 243 Screw camshaft bearing bridge M7x1 14 Nm 10 3 lbf ft Lubricated with engine oil Screw plug crankshaft location M8 10 Nm 7 4 lbf ft 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...

Page 115: ... 2 in Fork offset 22 mm 0 87 in Shock absorber WP Performance Systems 4618 PDS 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 2 0 bar 29 psi...

Page 116: ...tinental TKC 80 The tires specified represent one of the possible series production tires Additional information is available in the Service section under http www ktm com 22 7 Fork Fork part number 14 18 8Q 67 Fork WP Performance Systems MXMA 4860 upside down Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clic...

Page 117: ...S1 p 118 22 9 Chassis tightening torques Screw air filter box cover EJOT PT K60x20 Z 3 Nm 2 2 lbf ft Screw pressure regulator EJOT PT K60x25 Z 3 Nm 2 2 lbf ft Screw fixed grip M4 5 Nm 3 7 lbf ft Loctite 243 Spoke nipple front wheel M4 5 6 Nm 4 4 lbf ft Spoke nipple rear wheel M4 5 6 Nm 4 4 lbf ft Remaining nuts chassis M5 5 Nm 3 7 lbf ft Remaining screws chassis M5 5 Nm 3 7 lbf ft Screw battery te...

Page 118: ... 11 1 lbf ft Screw side stand attachment M8 35 Nm 25 8 lbf ft Loctite 2701 Screw subframe M8 35 Nm 25 8 lbf ft Loctite 2701 Screw top steering stem M8 20 Nm 14 8 lbf ft Screw top triple clamp M8 20 Nm 14 8 lbf ft 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 Locti...

Page 119: ...0 Engine oil SAE 10W 60 00062010035 Standard classification JASO T903 MA p 120 SAE p 120 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 Synthetic engine oil Recommended supplier Motorex Cross Power 4T Engine oil SAE 10W 50 Standard classification JASO T903 MA p 120 SA...

Page 120: ...and that exhibit 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 to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E1...

Page 121: ...otorex Bike 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 Special cleaner for glossy and matte paint finishes metal and plastic surfaces Re...

Page 122: ...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 123: ...26 INDEX OF SPECIAL TERMS 121 OBD On board diagnosis Vehicle system that monitors emission and safety related values ...

Page 124: ...27 LIST OF ABBREVIATIONS 122 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 125: ...alfunction indicator lamp lights up flashes yellow The OBD has detected an emission or safety critical fault The fuel level warning lamp lights up yellow The fuel level has reached the reserve mark 28 2 Green and blue symbols Green and blue symbols reflect information The high beam indicator lamp lights up blue The high beam is switched on Turn signal indicator lamp flashes green The turn signal i...

Page 126: ...aracteristic map of the throttle response adjusting 99 Chassis number 15 Clutch fluid level checking correcting 71 fluid changing 72 Clutch lever 17 basic position adjusting 71 Cold start button 20 Compression damping fork adjusting 47 Compression damping high speed shock absorber adjusting 44 Compression damping low speed shock absorber adjusting 43 Coolant antifreeze and coolant level checking 9...

Page 127: ... 6 K Key number 15 L Light switch 17 Lower triple clamp installing 53 removing 53 M Main fuse changing 89 Main silencer glass fiber yarn filling changing 62 installing 61 removing 61 spark arrestor cleaning 61 Motorcycle cleaning 106 raising with lift stand 50 removing from lift stand 50 O Oil filter changing 103 Oil screen cleaning 103 Operating substances 12 Owner s Manual 11 P Preparing for use...

Page 128: ...nical data capacities 113 chassis 113 chassis tightening torques 115 electrical system 114 engine 111 engine tightening torques 111 fork 114 shock absorber 115 tires 114 Throttle cable play adjusting 98 checking 98 Throttle cable routing checking 70 Throttle grip 17 Throttle valve position teaching 100 Tire air pressure checking 85 Tire condition checking 85 Transport 39 Troubleshooting 109 110 Tu...

Page 129: ... 3213481en 3213481en 08 2016 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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