KTM 350 SX-F Cairoli replica Owner'S Manual Download

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TECHNICAL DATA

22.2

Engine tightening torques

Nozzle, crank chamber ventilation

2 Nm (1.5 lbf ft)

Loctite

243™

Oil nozzle for alternator cooling

2 Nm (1.5 lbf ft)

Loctite

243™

Oil nozzle for balancer shaft lubrication M4

2 Nm (1.5 lbf ft)

Loctite

243™

Oil nozzle for conrod bearing lubrica-
tion

2 Nm (1.5 lbf ft)

Loctite

243™

Screw, oil nozzle for piston cooling

2 Nm (1.5 lbf ft)

Loctite

243™

Screw, stator

4 Nm (3 lbf ft)

Loctite

648™

Locking screw for bearing

6 Nm (4.4 lbf ft)

Loctite

243™

Oil nozzle for cam lever lubrication

3 Nm (2.2 lbf ft)

Loctite

243™

Oil nozzle for clutch lubrication

6 Nm (4.4 lbf ft)

Loctite

243™

Oil nozzle, piston cooling

2 Nm (1.5 lbf ft)

Loctite

243™

Screw cap, oil channel in alternator
cover

3 Nm (2.2 lbf ft)

Loctite

243™

Screw, bearing bolt, oil pump idler
gear

6 Nm (4.4 lbf ft)

Loctite

243™

Screw, crankshaft position sensor

6 Nm (4.4 lbf ft)

Loctite

243™

Screw, locking lever

6 Nm (4.4 lbf ft)

Loctite

243™

Screw, oil pump cover

6 Nm (4.4 lbf ft)

Loctite

243™

Nut, cylinder head

10 Nm (7.4 lbf ft)

Lubricated with engine oil

Nut, water-pump wheel

6 Nm (4.4 lbf ft)

Loctite

243™

Screw, alternator cover

10 Nm (7.4 lbf ft)

–

Screw, clutch cover

10 Nm (7.4 lbf ft)

–

Screw, clutch slave cylinder

10 Nm (7.4 lbf ft)

–

Screw, clutch spring

10 Nm (7.4 lbf ft)

–

Screw, cover of torque limiter

10 Nm (7.4 lbf ft)

–

Screw, engine case

10 Nm (7.4 lbf ft)

–

Screw, exhaust flange

10 Nm (7.4 lbf ft)

Loctite

243™

Screw, oil filter cover

10 Nm (7.4 lbf ft)

–

Screw, shift drum locating

10 Nm (7.4 lbf ft)

Loctite

243™

Screw, shift lever

14 Nm (10.3 lbf ft)

Loctite

243™

Screw, starter motor

10 Nm (7.4 lbf ft)

–

Screw, timing chain guide rail

10 Nm (7.4 lbf ft)

Loctite

243™

Screw, timing chain securing guide

10 Nm (7.4 lbf ft)

Loctite

243™

Screw, valve cover

8 Nm (5.9 lbf ft)

–

Screw, water pump cover

10 Nm (7.4 lbf ft)

–

Stud, cylinder head

10 Nm (7.4 lbf ft)

–

Screw, camshaft bearing bridge

M7x1

14 Nm (10.3 lbf ft)

Lubricated with engine oil

Screw plug, crankshaft location

10 Nm (7.4 lbf ft)

–

Screw, timing chain tensioning rail

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)

–

Spark plug

M10x1

10… 12 Nm (7.4…
8.9 lbf ft)

–

Summary of Contents for 350 SX-F Cairoli replica

Page 1: ...OWNER S MANUAL 2014 350 SX F EU 350 SX F USA 350 XC F USA Art no 3213032en ...

Page 2: ......

Page 3: ...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 as well as misprints and other errors The models portrayed partly contain spe ci...

Page 4: ...6 10 1 Checking the basic chassis setting with the rider s weight 26 10 2 Compression damping of the shock absorber 26 10 3 Adjusting the low speed compression damping of the shock absorber 26 10 4 Adjusting the high speed compression damping of the shock absorber 27 10 5 Adjusting the rebound damping of the shock absorber 28 10 6 Measuring rear wheel sag unloaded 28 10 7 Checking the static sag o...

Page 5: ...inings x 65 13 WHEELS TIRES 67 13 1 Removing the front wheel x 67 13 2 Installing the front wheel x 67 13 3 Removing the rear wheel x 68 13 4 Installing the rear wheel x 68 13 5 Checking the tire condition 69 13 6 Checking the tire air pressure 70 13 7 Checking the spoke tension 70 14 ELECTRICAL SYSTEM 71 14 1 Removing the battery x 71 14 2 Installing the battery x 71 14 3 Charging the battery x 7...

Page 6: ...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 7: ... that will lead to environmental damage if the appropriate measures are not taken 2 4 Tampering warning Tampering with the noise control system is prohibited Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new veh...

Page 8: ... 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 8 Environment If you use your motorcycle responsibly you can ensure that problems and conflicts do not occur To protect th...

Page 9: ...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 10: ...LE 8 4 1 View of vehicle front left example B01411 10 1 Hand brake lever p 11 2 Clutch lever p 11 3 Filler cap 4 Plug in stand p 15 5 Air filter box lid 6 Engine number p 10 7 Shift lever p 14 8 Cold start button p 13 ...

Page 11: ...ght example B01412 10 1 Kill switch p 11 2 Electric starter button p 11 3 Throttle grip p 11 4 Chassis number p 10 4 Type label p 10 5 Fork part number p 10 6 Foot brake lever p 15 7 Idle speed adjusting screw p 14 8 Shock absorber part number p 10 ...

Page 12: ...steering head 5 3 Engine number B01449 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket 5 4 Fork part number B01450 10 The fork part number 1 is stamped on the inner side of the axle clamp 5 5 Shock absorber part number B01451 10 The shock absorber part number 1 is stamped on the top of the shock absorber above the adjusting ring on the engine side ...

Page 13: ...dlebar 6 4 Kill switch C00217 10 Kill switch 1 is fitted on the left side of the handlebar Possible states Kill switch in basic position In this position the ignition circuit is closed and the engine can be started Kill switch pressed In this position the ignition circuit is interrupted a run ning engine stops and a non running engine will not start 6 5 Electric starter button B01414 11 Electric s...

Page 14: ... 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 water If fuel is swallowed contact a physician immediately Cha...

Page 15: ...ithout kinks 6 9 Cold start button B01180 10 The cold start button 1 is fitted on the left on the throttle valve body The injection system extends the injection time if the engine is cold and the outside temperature is low The engine can only burn the increased fuel quantity if it receives more air It obtains more air by pulling the cold start button Possible states The cold start button is activa...

Page 16: ...justed with idle speed adjusting screw 1 Turning the adjusting screw clockwise increases the idle speed Turning the adjusting screw counterclockwise lowers the idle speed 6 11 Shift lever B01455 10 Shift lever 1 is mounted on the left side of the engine B01455 11 All SX F models The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears B014...

Page 17: ...10 The holder for the plug in stand 1 is the left side of the wheel spindle The plug in stand is used to park the motorcycle Info Remove the plug in stand before starting on a trip 6 14 Side stand XC F B01457 10 The side stand 1 is on the left side of the vehicle B01458 10 The side stand is used to park the motorcycle Info When you are riding side stand 1 must be folded up and secured with rubber ...

Page 18: ...ing Take your foot off the foot brake lever when you are 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 ot...

Page 19: ... difficult riding conditions Info Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces can lead to considerably more rapid wear of components such 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 using the specified engine oil when riding u...

Page 20: ...arts fitting instructions 600868 01 Clean the chain Chain cleaner p 98 Fit the steel sprocket Tip Do not grease the chain Clean the radiator fins Straighten bent radiator fins carefully 7 5 Preparing for rides on wet sand B00437 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 clea...

Page 21: ...at high temperature and slow speed 600868 01 Adjust the secondary drive to the road conditions Info The engine oil quickly gets hot if the clutch has to be operated very often due to an excessively high secondary drive Clean the chain Chain cleaner p 98 Clean radiator fins Straighten bent radiator fins carefully Check the coolant level p 74 7 8 Preparing for rides at low temperatures or in snow B0...

Page 22: ...and ensure that they can be operated smoothly Check all screws nuts and hose clamps regularly for tightness Check the fuel supply 8 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 effec...

Page 23: ...o be standing for a long time Guideline 1 min Avoid frequent and longer slipping of the clutch This heats the engine oil the engine and the cooling system Ride with a lower engine speed instead of with a high engine speed and a slipping clutch 8 5 Applying the brakes Warning Danger of accidents If you brake too hard the wheels can lock Adapt your braking to the traffic situation and the road condi...

Page 24: ...ing over 8 8 Refueling Danger Fire hazard Fuel is highly flammable Never refuel the 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 ...

Page 25: ...tank with fuel up to measurement A Guideline Measurement of A 35 mm 1 38 in Total fuel tank capacity approx All SX F models 7 5 l 1 98 US gal Super unleaded ROZ 95 RON 95 PON 91 p 97 Total fuel tank capacity approx XC F 9 l 2 4 US gal Super unleaded ROZ 95 RON 95 PON 91 p 97 Close the filler cap p 13 ...

Page 26: ...vice XC F x Service the shock absorber x Check the tire condition p 69 Check the tire air pressure p 70 Check the wheel bearing for play x Check the wheel hubs x Check the rim run out x Check the spoke tension p 70 Check the chain rear sprocket engine sprocket and chain guide p 54 Check the chain tension p 53 Grease all moving parts e g hand lever chain and check for smooth operation x Check corre...

Page 27: ... record x One time interval Periodic interval 9 2 Service work as additional order Annually Every 100 operating hours corresponds to about 700 liters of fuel 185 US gal Every 50 operating hours corresponds to about 350 liters of fuel 92 5 US gal Change the front brake fluid x Change the rear brake fluid x Change the hydraulic clutch fluid x p 58 Grease the steering head bearing x p 42 Change the s...

Page 28: ...low speed refer to the compression 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 separate...

Page 29: ...filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help Info The high speed setting can be seen during the fast compression of the shock absorber B01460 10 Turn adjusting screw 1 all the way clockwise with a socket wrench Info Do not loosen fitting 2 Turn back counterclockwise by the number of turns corresponding to the shock absorber ...

Page 30: ...absorber type Guideline Rebound damping SX F EU Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping SX F USA Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping XC F Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 10 6 Measuring rear wheel sag unloaded Preparatory work Raise the ...

Page 31: ...on feet on footrests and bounces up and down a few times The rear wheel suspension levels out Another person now measures the distance between the rear axle and the fixed point Note down the value as dimension C Info The riding sag is the difference between measurements A and C Check the riding sag Riding sag SX F EU 90 mm 3 54 in Riding sag SX F USA 100 mm 3 94 in Riding sag XC F 100 mm 3 94 in I...

Page 32: ...g preload XC F 12 mm 0 47 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 1 Guideline Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft Finishing work Install the shock absorber x p 44 Install the manifold x p 48 Install the main silencer p 49 Remove the motorcycle from the lift stand p 35 10 10 Adjusting t...

Page 33: ...b 60 N mm 343 lb in Info The spring rate is shown on the outside of the spring Finishing work Install the shock absorber x p 44 Install the manifold x p 48 Install the main silencer p 49 Check the static sag of the shock absorber p 29 Check the riding sag of the shock absorber p 29 Adjust the rebound damping of the shock absorber p 28 Remove the motorcycle from the lift stand p 35 10 11 Checking t...

Page 34: ...clicks Sport 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping B01488 10 XC F Turn the white adjusting screw 2 all the way clockwise Info Adjusting screw 2 is located at the upper end of the left fork leg The compression damping is located in the left fork leg COMP white adjusting screw The rebound damping is located in the right fork leg REB red adjusting s...

Page 35: ...g screw 3 is located at the upper end of the right fork leg The rebound damping is located in the right fork leg REB red adjusting screw The compression damping is located in the left fork leg COMP white adjusting screw Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline Rebound damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Info Turn clockwise...

Page 36: ...les and lines Remove screws 2 Remove the handlebar supports Place the handlebar supports in the required position Mount and tighten screws 2 Guideline Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Info Position the left and right handlebar supports evenly Position the handlebar Info Make sure cables and wiring are positioned correctly Position the handlebar clamps Fit and evenly tighte...

Page 37: ... F models Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle insert plug in stand 1 into the left side of the wheel spindle Info Remove the plug in stand before riding B01457 10 XC F Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand 1 to the ground with your foot and lean the motorcycle on it Info When you ar...

Page 38: ...l the dust boots and inner fork tube of both fork legs Universal oil spray p 99 Press the dust boots back into their normal position Remove excess oil Finishing work Position the fork protection p 36 Remove the motorcycle from the lift stand p 35 11 5 Loosening the fork protection B00298 10 Remove screws 1 and take off the clamp Remove screws 2 on the left fork leg Push the fork protection downwar...

Page 39: ...ion the fork legs Position bleeder screws 1 toward the front Info Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the top edge of the upper triple clamp B01421 10 XC F Position the fork legs Position bleeder screws 1 toward the front Info The rebound damping is located in the right fork leg red adjusting screw The compress...

Page 40: ...move the screws on the right fork leg Remove the fork protector from above 11 10 Installing the fork protector x B00306 10 Main work Position the fork protection on the left fork leg Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the fork protection on the right fork leg Mount and tighten the screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 41: ...1540 10 Main work Clean the bearing and sealing elements check for damage and grease High viscosity grease p 98 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing Check whether the upper steering head seal 1 is correctly positioned Slide on protective ring 2 and O ring 3 B01463 11 Position the upper triple clamp with the handlebar Mount screw 4 but do not ti...

Page 42: ... screws 6 Guideline Screw bottom triple clamp M8 12 Nm 8 9 lbf ft B01467 10 Tighten screw 4 Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft B01467 11 Mount and tighten screw 7 Guideline Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 243 B01466 11 Using a plastic hammer tap lightly on the upper triple clamp to avoid strains Tighten screws 8 Guideline Screw top triple clamp M8 17 Nm...

Page 43: ...avel No play should be noticeable in the steering head bearing If there is noticeable play present Adjust the play of the steering head bearing x p 41 Move the handlebar to and fro over the entire steering range The handlebar must be able to move easily over the entire steering range No resting locations should be noticeable If click positions are noticeable Adjust the play of the steering head be...

Page 44: ... Removing the start number plate C00419 10 Remove screw 1 and take off the clamp Remove screw 2 Take off the start number plate 11 17 Installing the start number plate C00418 10 Position the start number plate Mount and tighten screw 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft The holding lugs engage Position the brake line and clamp Mount and tighten screw 2 11 18 Removing the front ...

Page 45: ...2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the start number plate p 42 11 20 Removing the shock absorber x Preparatory work Raise the motorcycle with the lift stand p 35 Remove the main silencer p 49 Remove the manifold x p 47 B01471 10 Main work Remove the cable binder of the frame protector Remove screw 1 Take off the frame protector Info Pay attention to the...

Page 46: ...the frame protector with the cable binder Finishing work Install the manifold x p 48 Install the main silencer p 49 Remove the motorcycle from the lift stand p 35 11 22 Removing the seat 101279 10 Remove screw 1 Lift up the seat at the rear pull it back and then remove it from above 11 23 Mounting the seat C00172 01 Hook in the front of the seat at the collar bushing of the fuel tank lower it at t...

Page 47: ...x lid is secured Mount and tighten screws 1 Guideline Screw air filter box lid EJOT PT K60x20 Z 3 Nm 2 2 lbf ft 11 26 Removing the air filter x Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear Warning Environmental hazard Hazardous s...

Page 48: ... 45 S00044 10 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 98 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 foam air filter p 99 Clean the air filter box Clean the intake flange and check it for damage and tightness Finishing work Install the air filt...

Page 49: ...uideline Diameter 6 mm 0 24 in Finishing work Install the air filter box lid p 45 11 30 Sealing the air filter box x 401527 10 Seal the air filter box in the marked area A 11 31 Removing the manifold x Preparatory work Raise the motorcycle with the lift stand p 35 Remove the main silencer p 49 B01473 10 Main work Remove screw 1 Remove screw connection 2 B01474 10 Press angle lever 3 toward the rea...

Page 50: ...talling the manifold x B01475 11 Main work Slip in the manifold and position it Position the shock absorber and mount and tighten screw 1 Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 B01189 11 Mount screw 2 but do not tighten yet Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft Attach springs 3 Spring hooks 50305017000 Tighten screw 2 Guideline Remaining screws chas...

Page 51: ...p 49 Remove the motorcycle from the lift stand p 35 11 33 Removing 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 Do not touch hot components B01429 10 Disconnect spring 1 Spring hooks 50305017000 Remove screws 2 and take off the main silencer 11 34 Installing the main silencer B01429 11 Position the main ...

Page 52: ...outer tube Mount and tighten all screws Finishing work Install the main silencer p 49 11 36 Removing the fuel tank x Danger Fire hazard Fuel is highly flammable Never refuel the 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 ...

Page 53: ...he tube from the fuel tank breather B01193 10 Remove screws 3 with the collar bushing C00168 10 Remove screw 4 with the rubber bushing C00169 01 Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank 11 37 Installing the fuel tank x Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the e...

Page 54: ...unt the fuel tank breather Mount and tighten screw 1 with the rubber bushing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft B01193 11 Mount and tighten screws 2 with the collar bushing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft B01431 10 Connect the electrical plug in connection 3 Remove the wash cap set Thoroughly clean the plug in connection of the fuel line using compressed ...

Page 55: ...ncorrect chain tension If the chain is too taut the components of the secondary power transmission chain engine sprocket rear sprocket bear ings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme cases If the chain is too loose however it may fall off the engine s...

Page 56: ...s 3 left and right Guideline Chain tension 55 58 mm 2 17 2 28 in Turn adjusting screws 3 on the left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks A The rear wheel is then correctly aligned Tighten nuts 2 Make sure that chain adjusters 4 are fitted correctly on adjusting screws 3 Tighten nut 1 Guideline Nut rear wheel ...

Page 57: ...as well New chains wear more rapidly on old worn rear sprockets and engine sprockets B00346 01 Check the chain sliding guard for wear If the lower edge of the chain pin is at the level of or below the chain sliding guard Change the chain sliding guard x Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the chain sliding guard Guideline Screw chain slid...

Page 58: ...00284 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 11 44 Checking the swingarm x 500285 01 Check the swingarm for damage cracking and deformation If the swingarm shows signs o...

Page 59: ...47 Additionally securing the rubber grip Preparatory work Check the rubber grip p 57 401198 01 Main work Secure the rubber grip at two points using the securing wire Securing wire 54812016000 Wire twister forceps U6907854 The twisted wire ends face away from the hands and are bent toward the rub ber grip 11 48 Adjusting the basic position of the clutch lever C00237 10 Adjust the basic setting of t...

Page 60: ...mage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations B00040 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 B01288 10 Fill bleeding syringe 4 with the appropriate hydraulic fluid Bleed syringe 50329050000 Brake fluid DOT 4 DOT 5 1 p 96 On the clutch sla...

Page 61: ...e distance between the hand brake lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the hand brake 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 3 Checking the brake discs Warning Danger of accidents Reduced braking efficiency du...

Page 62: ...specified value this is an indication 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 ...

Page 63: ...p will be glad to help B00350 10 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified Change the front brake linings x p 61 Check the brake linings for damage and cracking If damage or cracking is visible Change the front brake linings x p 61 12 7 Changing the front brake linings x Warning Danger of accident Brake system f...

Page 64: ... B01438 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 B00351 10 Manually press the brake caliper to the brake disc to push back the brake pistons Ensure that brake fluid does not flow out of the brake fluid reservoir extracting it by suction if it does Info Make sure when pushing back the brake pistons that you do...

Page 65: ... free travel A Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the basic position of the foot brake lever x p 63 Reconnect spring 1 12 9 Adjusting the basic position of the foot brake lever x Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake cir...

Page 66: ...he brake fluid level drops below marking A Add rear brake fluid x p 64 12 11 Adding rear brake fluid x Warning Danger of accidents Brake system failure If the brake fluid level drops below the specified marking or the specified value this is an indication 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 autho...

Page 67: ... in If the minimum thickness is less than specified Change the rear brake linings x p 65 Check the brake linings for damage and cracking If damage or cracking is visible Change the rear brake linings x p 65 12 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...

Page 68: ...rake caliper against the spokes Remove cotter pins 3 pull out pin 4 and remove the brake linings Clean the brake caliper and brake caliper support B00358 10 Check that leaf spring 5 in the brake caliper and sliding plate 6 in the brake caliper support are seated correctly Info The arrow on the leaf spring points in the rotation direction of the brake disc B00359 10 Insert the brake linings insert ...

Page 69: ...e lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged B00304 10 Remove spacers 3 13 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 of oil and grease and clean them with brake cleaner when necessary B00304 11 Check the wheel be...

Page 70: ... brake piston Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut 1 Remove chain adjuster 2 Withdraw wheel spindle 3 only enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket Holding the rear wheel withdraw the wheel spindle Take the rear wheel o...

Page 71: ... Chain adjusters 3 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 pressure point Finishing work Remove the motorcycle from the lift stand p 35 13 5 Checking the tire condition Info Only mount tires approved and or recommended by KTM Other tires could have a negative effect on handling characteristics The type c...

Page 72: ...the tire pressure does not meet specifications Correct the tire pressure Mount the protection cap 13 7 Checking the spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that the spoke tension is correct Your authorized KTM workshop will be glad to help Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes If the spokes are too...

Page 73: ...ery up and out 14 2 Installing the battery x C00246 10 Main work Insert the battery into the battery compartment with the terminals facing to the front All SX F models Battery YTX4L BS p 91 XC F Battery YTX5L BS p 91 Reconnect rubber band 1 Connect positive cable 2 and negative cable 3 Guideline Screw battery terminal M5 2 5 Nm 1 84 lbf ft Info Contact disks A must be mounted between screws 4 and ...

Page 74: ... battery is maintenance free which means that the acid level does not need to be checked Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 44 Disconnect the negative cable of the battery to avoid damage to the onboard elec tronics 400240 10 Main work Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 You ca...

Page 75: ...se wire A A reserve fuse 6 is located in the starter relay Install a new main fuse Fuse 58011109110 p 91 Check that the electrical equipment is functioning properly Tip Insert the spare fuse so that it is available if needed Mount the protection caps Mount the starter relay onto the holder and lay the cable Position the rear fairing Mount and tighten the screw Guideline Remaining screws chassis M6...

Page 76: ...nge clothing that is contaminated with coolant Keep coolant out of reach of children Condition The engine is cold 400243 10 Stand the motorcycle upright on a horizontal surface Remove the radiator cap Check antifreeze of coolant 25 45 C 13 49 F If the antifreeze of the coolant does not meet specifications Correct the antifreeze of the coolant Check the coolant level in the radiator Coolant level A...

Page 77: ... Allow the engine and cooling system 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...

Page 78: ...he 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 B01200 10 Make sure that screw 1 is tightened Position the motorcycle upright Pour coolant in up to measurement A above the radiator fins Guideline Dimension A over the radiator fins 10 mm 0 39 in Coolant 0 95 l 1 qt Coolant p ...

Page 79: ...e 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 77 16 2 Adjusting the play in the throttle cable x Preparatory work Remove the seat p 44 Remove the fuel tank x p 50 Check the throttle cable routing p 56 B01480 10 Main work Move the handlebar to the straight ahead position Push back sleeves ...

Page 80: ... and the shift lever Distance between shift lever and upper edge of boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the basic position of the shift lever x p 78 16 5 Adjusting the basic position of the shift lever x B01481 10 Remove screw 1 and take off shift lever 2 B01482 10 Clean gear teeth A of the shift lever and shift shaft Mount the shift lever on the shift sh...

Page 81: ...1 of the fuel line thoroughly with compressed air Info Under no circumstances should dirt enter into the fuel line Dirt clogs the injection valve Disconnect the plug in connection of the fuel line Pull fuel screen 2 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 poiso...

Page 82: ...gulations Info Drain the engine oil only when the engine is warm Preparatory work Park the motorcycle on a level surface B01483 10 Main work Place a suitable container under the engine Remove oil drain plug 1 with the magnet and seal ring Info Do not remove screws 2 on both sides B01484 10 Remove plug 3 with oil screen 4 and the O rings Completely drain the engine oil Thoroughly clean the parts an...

Page 83: ...right B01487 10 Remove the oil filler plug 8 with the O ring from the clutch cover and fill up with engine oil Engine oil 1 10 l 1 16 qt Engine oil SAE 10W 50 p 96 Alternative engine oil for harsh oper ating conditions and increased per formance Engine oil SAE 10W 60 00062010035 p 96 Info Too little engine oil or poor quality engine oil results in premature wear to the engine Install and tighten t...

Page 84: ...l SAE 10W 60 00062010035 p 96 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 ...

Page 85: ... a normal motorcycle cleaner and then clean with a paintbrush Motorcycle cleaner p 98 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 Reduce...

Page 86: ...otorcycle out of service add fuel additive Fuel additive p 98 Refuel p 22 Clean the motorcycle p 83 Change the engine oil and oil filter clean the oil screen x p 80 Check the antifreeze and coolant level p 74 Check the tire air pressure p 70 Remove the battery x p 71 Charge the battery x p 71 Guideline Storage temperature of battery without direct sunlight 0 35 C 32 95 F Store the vehicle in a dry...

Page 87: ... Change the fuel filter x Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x Exhaust system leaky deformed or too little glass fiber yarn filling in main silencer Check exhaust system for damage Change the glass fiber yarn filling of the main silencer x p 50 Valve clearance too little Adjust the valve clearance x Engine dies during the trip Lack of fuel Ref...

Page 88: ...20 TROUBLESHOOTING 86 Faults Possible cause Action Battery is discharged Unwanted power consumer Check the quiescent current x ...

Page 89: ...oo low Engine coolant temperature sensor input signal too high Blink code FI warning lamp MIL 13 FI warning lamp MIL flashes 1x long 3x short Error level condition Intake air temperature sensor input signal to 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 si...

Page 90: ...ht alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with two Eaton pumps Primary transmission 24 73 Clutch Multidisc clutch in oil bath hydraulically activated Gearbox All SX F models 5 gear claw shifted Gearbox XC F 6 gear claw shifted Transmission ratio All SX F models 1st gear 14 28 2nd gear 16 26 3rd gear 18 24 4th gear 21 24 5th gear...

Page 91: ...tite 243 Screw alternator cover M6 10 Nm 7 4 lbf ft Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch slave cylinder M6 10 Nm 7 4 lbf ft Screw clutch spring M6 10 Nm 7 4 lbf ft Screw cover of torque limiter M6 10 Nm 7 4 lbf ft Screw engine case M6 10 Nm 7 4 lbf ft Screw exhaust flange M6 10 Nm 7 4 lbf ft Loctite 243 Screw oil filter cover M6 10 Nm 7 4 lbf ft Screw shift drum locating M6 10 Nm 7 ...

Page 92: ...cover M24x1 5 18 Nm 13 3 lbf ft 22 3 Capacities 22 3 1 Engine oil Engine oil 1 10 l 1 16 qt Engine oil SAE 10W 50 p 96 Alternative engine oil for harsh operating conditions and increased performance Engine oil SAE 10W 60 00062010035 p 96 22 3 2 Coolant Coolant 0 95 l 1 qt Coolant p 96 Coolant mixed ready to use p 96 22 3 3 Fuel Total fuel tank capacity approx All SX F models 7 5 l 1 98 US gal Supe...

Page 93: ...l approx XC F 107 7 kg 237 4 lb Maximum permissible front axle load 145 kg 320 lb Maximum permissible rear axle load 190 kg 419 lb Maximum permissible overall weight 335 kg 739 lb 22 5 Electrical system Battery All SX F models YTX4L BS Battery voltage 12 V Nominal capacity 3 Ah Maintenance free Battery XC F YTX5L BS Battery voltage 12 V Nominal capacity 4 Ah Maintenance free Fuse 58011109110 10 A ...

Page 94: ...ridge 390 ml 13 19 fl oz Fork oil SAE 4 48601166S1 p 97 22 7 2 SX F USA Fork part number 14 18 7N 57 Fork WP Suspension Up Side Down 4860 MXMA CC Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Spring length with preload spacer s 490 mm 19 29 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 6 N mm 26 ...

Page 95: ... Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping high speed Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload Comfort 13 mm 0 51 in Standard 12 mm 0 47 in Sport 13 mm 0 51 in Spring rate Weight of rider 65 75 kg 143 165 lb 54 N mm 308 lb in Weight of rider 75 85 kg 165 187 lb 57 N mm 325 l...

Page 96: ...ock absorber oil SAE 2 5 50180342S1 p 97 22 8 3 XC F Shock absorber part number 18 18 7M 77 Shock absorber WP Suspension 5018 BAVP DCC Compression damping low speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping high speed Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 12 mm 0 47 in Sp...

Page 97: ...m 18 4 lbf ft Screw bottom triple clamp M8 12 Nm 8 9 lbf ft Screw chain sliding piece M8 15 Nm 11 1 lbf ft Screw engine brace M8 33 Nm 24 3 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw side stand attachment XC F M8 45 Nm 33 2 lbf ft Loctite 2701 Screw subframe M8 35 Nm 25 8 lbf ft Loctite 270...

Page 98: ...orrosion inhibitor antifreeze 50 distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Supplier Motorex COOLANT G48 Engine oil SAE 10W 60 00062010035 According to JASO T903 MA p 100 SAE p 100 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 KTM recommends Moto...

Page 99: ...uideline 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 According to 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...

Page 100: ...ds Motorex products Supplier Motorex Protect Shine Fuel additive Guideline KTM recommends Motorex products Supplier Motorex Fuel Stabilizer High viscosity grease Guideline KTM recommends SKF products Supplier SKF LGHB 2 Long life grease Guideline KTM recommends Motorex products Supplier Motorex Bike Grease 2000 Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clea...

Page 101: ... Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean Polish Rubber grip adhesive 00062030051 Supplier KTM Sportmotorcycle AG GRIP GLUE Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Synthetic ...

Page 102: ...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 103: ...king correcting the fluid level 58 fluid changing 58 Clutch lever 11 basic position adjusting 57 Cold start button 13 Compression damping fork adjusting 32 Compression damping high speed shock absorber adjusting 27 Compression damping low speed shock absorber adjusting 26 Coolant draining 75 refilling 76 Coolant level checking 74 Cooling system 74 Customer service 7 D Difficult riding conditions 1...

Page 104: ...es 7 Overview of indicator lamps 12 Owner s Manual 6 P Play in throttle cable adjusting 77 Plug in stand 15 Preparing for use advice on first use 16 after storage 84 checks and maintenance work when preparing for use 20 Protective clothing 6 R Rear sprocket checking 54 Rear wheel installing 68 removing 68 Rebound damping fork adjusting 32 shock absorber adjusting 28 Refueling fuel 22 Riding sag ad...

Page 105: ...ghtening torques 95 electrical system 91 engine 88 engine tightening torques 89 fork 92 shock absorber 93 tires 91 Throttle cable play checking 77 Throttle cable routing checking 56 Throttle grip 11 Tire air pressure checking 70 Tire condition checking 69 Transport 22 Troubleshooting 85 86 Type label 10 U Use definition 5 V View of vehicle front left 8 rear right 9 W Warranty 7 Work rules 6 ...

Page 106: ... 3213032en 3213032en 03 2013 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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KTM 350 SX-F Cairoli replica, Owner'S Manual

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