KTM F6375T5 Owner'S Manual Download

Page: 59 / 147

SERVICE WORK ON THE CHASSIS 11

V01706-10

–

Remove nut

and pull out the swingarm pivot.

–

Push the link fork back and secure it against falling over.

V01707-10

–

Hold the shock absorber and remove screw

V01708-10

–

Remove the shock absorber carefully at the bottom.

11.19

Installing the shock absorber

V01708-11

Main work

–

Carefully position the shock absorber into the vehicle from the
bottom.

V01707-11

–

Mount and tighten screw

Guideline

Screw, top
shock absorber

M10

60 Nm (44.3 lbf ft)

Loctite

2701™

Summary of Contents for F6375T5

Page 1: ...OWNER S MANUAL 2020 250 XC TPI 300 XC TPI Art no 3214002en...

Page 2: ......

Page 3: ...materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop produc tion of a particular model without prior notic...

Page 4: ...vice hour counter 19 7 PREPARING FOR USE 20 7 1 Advice on preparing for first use 20 7 2 Running in the engine 21 7 3 Starting power of lithium ion batteries at low temperatures 21 7 4 Preparing the v...

Page 5: ...hanging the glass fiber yarn filling of the main silencer 64 11 31 Removing the fuel tank 65 11 32 Installing the fuel tank 67 11 33 Checking the chain for dirt 68 11 34 Cleaning the chain 68 11 35 Ch...

Page 6: ...E ENGINE 112 17 1 Changing the fuel screen 112 17 2 Checking 2 stroke oil level 113 17 3 Priming oil pump 113 17 4 Cleaning the oil screen in the oil tank 115 17 5 Checking the gear oil level 118 17 6...

Page 7: ...ned experts using the auxiliary 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 t...

Page 8: ...ate the product described safely Therefore read this instruction and all further instructions included carefully The safety instructions are highlighted in the text and are referred to at the relevant...

Page 9: ...e operation Danger Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others Do not operate the vehicle if you are not fit to ride due to alcohol drugs or medicati...

Page 10: ...cts do not occur To protect the future of the motorcycle sport make sure that you use your motorcycle legally display environmental conscious ness and respect the rights of others When disposing of us...

Page 11: ...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 M...

Page 12: ...4 VIEW OF VEHICLE 10 4 1 View of vehicle front left example V01730 10 1 Clutch lever p 14 2 Fuel tank filler cap 3 Air filter box cover 4 Side stand p 18 5 Shift lever p 17 6 Engine number p 12...

Page 13: ...2 View of vehicle rear right example V01731 10 1 2 stroke oil tank cap 2 Switch off button p 14 3 Start button p 15 4 Throttle grip p 14 5 Hand brake lever p 14 6 Foot brake lever p 18 7 Level viewer...

Page 14: ...side of the steering head 5 2 Type label 401946 10 The type label 1 is fixed to the front of the steering head 5 3 Engine number H01047 10 The engine number 1 is embossed on the left side of the engin...

Page 15: ...SERIAL NUMBERS 5 13 5 5 Shock absorber article number 401948 10 Shock absorber article number 1 is stamped on the top of the shock absorber above the adjusting ring towards the engine side...

Page 16: ...he hand brake lever 6 3 Throttle grip V01645 10 Throttle grip 1 is fitted on the right side of the handlebar 6 4 Switch off button V01642 10 Switch off button 1 is fitted on the left side of the handl...

Page 17: ...uel 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 re...

Page 18: ...d turn it clockwise until the release but ton engages Info Route fuel tank breather hose 2 without kinks 6 9 Opening 2 stroke oil tank cap V01647 10 Fold loop 1upward Turn the 2 stroke oil tank cap co...

Page 19: ...n back to the basic position 6 12 Idle speed adjusting screw V01649 11 The idle setting of the throttle valve body substantially influences the vehicle s starting behavior a stable idle speed and the...

Page 20: ...er 401956 10 Foot brake lever 1 is located in front of the right footrest The foot brake lever is used to activate the rear brake 6 15 Side stand 401943 10 The side stand 1 is located on the left of t...

Page 21: ...itted in front of the handlebar It shows the total number of service hours of the engine The service hour counter begins counting when the engine is started and stops when the engine is switched off I...

Page 22: ...your riding speed to the road conditions and your riding ability Warning Danger of accidents The vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of accidents Th...

Page 23: ...5 Info The spoke tension must be checked after half an hour of operation Run in the engine p 21 7 2 Running in the engine During the running in phase do not exceed the specified engine performance Gui...

Page 24: ...ge it if necessary Difficult operating conditions are Rides on dry sand p 22 Rides on wet sand p 23 Rides on wet and muddy circuits p 24 Riding at high temperatures or slow riding p 25 Riding at low t...

Page 25: ...ons for KTM PowerParts 600868 01 Clean the chain Chain cleaner p 136 Mount the steel sprocket Grease the chain Universal oil spray p 137 Clean the radiator fins Straighten the bent radiator fins caref...

Page 26: ...ea affected immediately with lukewarm water Change the radiator cap M01106 01 Mount the air filter rain cover Air filter rain cover 79006921000 Info Observe the fitting instructions for KTM PowerParts...

Page 27: ...ses or other cooling system components if the engine or the cooling system are at operat ing temperature Allow the cooling system and the engine to cool down before you open the radiator the radiator...

Page 28: ...PARING FOR USE 26 7 9 Preparing the vehicle for low temperatures or snow M01106 01 Mount the air filter rain cover Air filter rain cover 79006921000 Info Observe the fitting instructions for KTM Power...

Page 29: ...he tire condition p 94 Check tire pressure p 94 Check the spoke tension p 95 Info The spoke tension must be checked regularly as incor rect spoke tension will strongly impair riding safety Clean the d...

Page 30: ...p Pull the clutch lever shift into first gear release the clutch lever slowly and at the same time open the throt tle carefully 8 4 Shifting riding Warning Danger of accidents If you change down at hi...

Page 31: ...ed KTM workshop will be glad to help Warning Danger of accidents Moisture and dirt impair the brake system Brake carefully several times to dry out and remove dirt from the brake linings and the brake...

Page 32: ...le on firm ground 8 7 Transporting Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface Note Fire hazard Hot vehicle components pose a fire...

Page 33: ...ler cap p 15 400382 10 Fill the fuel tank with fuel up to level A Guideline Dimension A 35 mm 1 38 in Total fuel tank capacity approx 8 5 l 2 25 US gal Super unleaded ROZ 95 RON 95 PON 91 p 135 Info D...

Page 34: ...ING INSTRUCTIONS 32 V01651 10 Fill the 2 stroke oil tank up to the lower edge A of the filler neck 2 stroke oil tank con tent approx 0 6 l 0 6 qt Engine oil 2 stroke p 134 Close 2 stroke oil tank cap...

Page 35: ...81 Check the brake linings of the rear brake p 87 Check the brake discs p 78 Check the brake lines for damage and leakage Check the rear brake fluid level p 85 Check the free travel of the foot brake...

Page 36: ...rror memory after the test ride using the KTM diagnostics tool Make a service entry in KTM Dealer net One time interval Periodic interval 9 3 Recommended work Every 80 operating hours Every 40 operati...

Page 37: ...perating hours every 12 months Perform major engine service including removing and installing the engine Change the piston and check the cylinder Change the connecting rod conrod bearing and crank pin...

Page 38: ...fork leg and damp ing in the right fork leg As fork springs are no longer required a significant weight advantage is achieved when compared to conventional forks The response on slightly uneven surfac...

Page 39: ...difications in the high speed range affect the compression damping in the low speed range and vice versa 10 4 Adjusting the low speed compression damping of the shock absorber Caution Risk of injury P...

Page 40: ...e number of turns corresponding to the shock absorber type Guideline Highspeed compression damping Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Info Turn clockwise to increase the damping turn c...

Page 41: ...the rear wheel dimension unloaded Preparatory work Raise the motorcycle with a lift stand p 47 402415 10 Main work Position the sag gage in the rear axle and measure the distance to marking SAG on th...

Page 42: ...ad of the shock absorber p 41 10 9 Checking the riding sag of the shock absorber 402417 10 Measure dimension A of rear wheel unloaded p 39 With another person holding the motorcycle the rider wear ing...

Page 43: ...lift stand p 47 Remove the shock absorber p 56 After removing the shock absorber clean it thoroughly 402659 10 Main work Loosen screw 1 Turn adjusting ring 2 until the spring is no longer under ten s...

Page 44: ...l the shock absorber p 57 Remove the motorcycle from the lift stand p 47 Check the static sag of the shock absorber p 40 Check the riding sag of the shock absorber p 40 Adjust the rebound damping of t...

Page 45: ...right fork leg Preparatory work Raise the motorcycle with a lift stand p 47 V01654 10 Main work Remove protection cap 1 Push together fork airpump 2 fully Fork airpump 79412966100 Info The fork airpu...

Page 46: ...ise all the way Info Adjuster 1 is located at the upper end of the right fork leg Turn counterclockwise by the number of clicks corresponding to the fork type Guideline Compression damping Comfort 17...

Page 47: ...t a distance of A from the center Hole distance A 3 5 mm 0 138 in The handlebar can be mounted in 2 different positions In this way the handlebar can be mounted in the most comfortable posi tion for t...

Page 48: ...and higher on one side Position the left and right handlebar supports evenly Mount and tighten screws 2 Guideline Screw handle bar support M10 40 Nm 29 5 lbf ft Loctite 243 Position the handlebar Info...

Page 49: ...rcycle against falling over 11 2 Removing the motorcycle from the lift stand Note Material damage The vehicle may be damaged by incorrect procedure when parking Significant damage may be caused if the...

Page 50: ...oots remove dust and coarse dirt particles from the inside fork tubes Over time dirt can accumu late behind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Da...

Page 51: ...ws 4 Remove the right fork leg 11 6 Installing the fork legs H01182 10 Main work Position the fork legs Air bleeder screw 1 of the right fork leg is positioned to the front Valve A of the left fork le...

Page 52: ...ight fork protector 11 8 Installing the fork protector V01656 11 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 Pos...

Page 53: ...ring 5 Remove the lower triple clamp with the steering stem Remove the upper steering head bearing 11 10 Installing the lower triple clamp 102146 10 Main work Clean the bearing and sealing elements c...

Page 54: ...e second milled groove from the top must be flush with the upper edge of the upper triple clamp V01698 10 Tighten screws 6 Guideline Screw bottom triple clamp M8 12 Nm 8 9 lbf ft Secure the wiring har...

Page 55: ...s 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 h...

Page 56: ...ic hammer tap lightly on the upper triple clamp to avoid stresses Tighten screws 1 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Mount and tighten screw 2 Guideline Screw top steering stem M8...

Page 57: ...rt number plate Position the start number plate The holding lugs engage in the fender Mount and tighten screw 1 11 16 Removing front fender Preparatory work Remove the start number plate p 55 M01144 1...

Page 58: ...the right frame protector to the front and take off at the bottom V01692 11 Remove screw 3 Remove fitting 4 Info Raise the wheel slightly to be able to remove the screws more easily V01704 10 Press a...

Page 59: ...V01707 10 Hold the shock absorber and remove screw 9 V01708 10 Remove the shock absorber carefully at the bottom 11 19 Installing the shock absorber V01708 11 Main work Carefully position the shock a...

Page 60: ...V01710 10 Position the foot brake cylinder Push rod 3 engages in the foot brake cylinder The dust boot is correctly positioned Mount and tighten screws 4 Guideline Remaining screws chassis M6 10 Nm 7...

Page 61: ...rew 8 Guideline Screw frame protec tor M5 3 Nm 2 2 lbf ft Mount the new cable ties Finishing work Remove the motorcycle from the lift stand p 47 11 20 Removing the seat K01133 10 Remove screw 1 H02218...

Page 62: ...r filter box cover Condition The air filter box cover is secured Remove the seat p 59 V01727 10 Remove screw 1 V01727 11 Pull off the air filter box cover in area A sideways and take off toward the fr...

Page 63: ...not secured Insert the air filter box cover in area A and clip it into area B 11 24 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the en...

Page 64: ...o 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 60 Remove the air filter p 61 K00518 01 Main work Wash th...

Page 65: ...air filter is not mounted correctly dust and dirt may enter the engine and result in damage Finishing work Install the air filter box cover p 61 11 27 Preparing air filter box cover for securing Prep...

Page 66: ...aining screws chassis M6 10 Nm 7 4 lbf ft 11 30 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the...

Page 67: ...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...

Page 68: ...e fuel line Dirt in the fuel line clogs the injection valve V01661 10 Disconnect the plug in connection of the fuel line Info Remaining fuel may flow out of the fuel hose Mount wash cap set 3 Wash cap...

Page 69: ...nd a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty...

Page 70: ...in connection 4 for the fuel line Info Route the cable and fuel line at a safe distance from the exhaust system Finishing work Mount the seat p 59 11 33 Checking the chain for dirt 400678 01 Check the...

Page 71: ...sion damages components and results in accidents If the chain is tensioned too much the chain engine sprocket rear sprocket transmission and rear wheel bearings wear more quickly Some components may b...

Page 72: ...paratory work Raise the motorcycle with a lift stand p 47 Check the chain tension p 69 V01663 10 Main work Loosen nut 1 Loosen nuts 2 Adjust the chain tension by turning adjusting screws 3 left and ri...

Page 73: ...er 400987 10 Pull on the top section of the chain with the specified weight A Guideline Weight chain wear measure ment 10 15 kg 22 33 lb Measure distance B of 18 chain rollers in the lower chain secti...

Page 74: ...m 4 4 lbf ft Loctite 243 V01664 10 Check the chain sliding piece for wear If the lower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece Check that...

Page 75: ...ue to a mechanical impact Repair of the frame is not authorized by KTM 11 39 Checking the link fork S02305 01 Check the link fork for damage cracking and deformation If the link fork exhibits damage c...

Page 76: ...work Install the fuel tank p 67 Mount the seat p 59 11 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...

Page 77: ...nsult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult...

Page 78: ...spills on to your clothing change the clothing Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly a...

Page 79: ...xtract fluid from the master cylinder reservoir to prevent overflow Remove the bleeding syringe Mount and tighten screws bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid l...

Page 80: ...ic position of the hand brake lever V01644 12 Check the free travel of the hand brake lever p 78 Adjust the basic position of the hand brake lever to your hand size by turning adjusting screw 1 Info T...

Page 81: ...n insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings...

Page 82: ...ter in the event of contact with the skin 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 ch...

Page 83: ...nings reduce the braking effect Ensure that worn out brake linings are replaced immediately Your authorized KTM workshop will be glad to help H01333 10 Check the brake linings for minimum thickness A...

Page 84: ...ciency Not all brake linings are tested and approved for KTM motorcycles The structure and friction coefficient of the brake linings and thus their brake power may vary greatly from that of original b...

Page 85: ...e caliper and the brake caliper bracket 100397 01 Check that spring plate 6 in the brake caliper and sliding plate 7 in the brake caliper bracket are seated correctly V01714 10 Insert the new brake li...

Page 86: ...Set the free travel on the foot brake lever in accordance with the specification 402026 10 Disconnect spring 1 Move the foot brake lever back and forth between the end stop and the contact to the foot...

Page 87: ...n nut 2 Guideline Remaining nuts chassis M6 10 Nm 7 4 lbf ft Attach spring 1 12 10 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brak...

Page 88: ...if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid c...

Page 89: ...eck the brake linings for damage and cracking If damage or wear is encountered Change the rear brake linings p 87 12 13 Changing the rear brake linings Warning Danger of accidents Incorrect servicing...

Page 90: ...uid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container K01196 10 Stand the vehicle upright Remove screw cap 1 with membrane 2 and the O ring 101740 10 Manua...

Page 91: ...7 is mounted on the piston side brake lining Operate the foot brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point K01185 10 Add brake flui...

Page 92: ...the brake pistons V01675 10 Loosen screw 1 by several rotations Loosen screws 2 Press on screw 1 to push the wheel spindle out of the axle clamp Remove screw 1 V01715 10 Warning Danger of accidents D...

Page 93: ...t the spacers Clean and grease the wheel spindle Long life grease p 136 V01675 11 Position the front wheel and insert the wheel spindle The brake linings are correctly positioned Mount and tighten scr...

Page 94: ...sprocket Info Cover the components to protect them against damage Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc...

Page 95: ...Mount the chain V01718 10 Position chain adjuster 3 Mount nut 4 but do not tighten it yet Make sure that chain adjusters 3 are fitted correctly on adjusting screws 5 Check the chain tension p 69 Tight...

Page 96: ...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 indicate the week of manufacture and the l...

Page 97: ...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 diameter If you hear different ton...

Page 98: ...hold the switch off button while the engine is idling until the engine stops Remove the seat p 59 F00138 10 Main work Disconnect negative cable 1 from the 12 V battery Pull back positive terminal cov...

Page 99: ...eries as household waste Dispose of 12 V batteries at a collection point for used batteries Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fue...

Page 100: ...ng used 6 months Battery charger 79629974000 This battery charger tests whether the 12 V battery retains its voltage It is also impossible to overcharge the 12 V battery with this battery charger The...

Page 101: ...to the side Pull starter relay 3 from the holder V01678 10 Take off protection caps 4 Remove faulty main fuse 5 Info A faulty fuse has a burned out fuse wire A A spare fuse 6 is located in the starte...

Page 102: ...electronic fuel injection diagnostics connector Fuse 2 not assigned Fuse 3 not assigned Fuse 4 5 A fuel pump Fuses SPARE 10 A 5 A spare fuse Info A faulty fuse has a burned out fuse wire A Warning Fi...

Page 103: ...nse 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 conta...

Page 104: ...ter 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 Condition...

Page 105: ...er the water pump cover V01679 11 Remove screw 1 Take off radiator cap 2 Completely drain the coolant Mount and tighten screw 1 with a new seal ring Guideline Screw water pump cover M6 10 Nm 7 4 lbf f...

Page 106: ...ine Screw cylinder head temperature sensor M10x1 25 12 Nm 8 9 lbf ft Plug in connector 3 Position protection cap 2 400243 10 Pour coolant in up to measurement A above the radiator fins Guideline 10 mm...

Page 107: ...COOLING SYSTEM 15 105 Finishing work Check the coolant level p 102...

Page 108: ...engine in an enclosed space Start the engine and let it run at idle speed Move the handle bar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust...

Page 109: ...nged by changing the guide plate A guide plate with a different characteristic map is supplied V01685 10 Main work Push back sleeve 1 Remove screws 2 and half shells 3 Detach the throttle cables and t...

Page 110: ...go out spontaneously if the idle speed is set too low Set the idle speed to the specified value Your authorized KTM workshop will be glad to help V01649 11 Run the engine until warm The cold start bu...

Page 111: ...tilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Info If the vehicle is ridden with the engine running at various heights abov...

Page 112: ...f the ignition timing map adjustment is joined to achieve higher performance 16 7 Changing the ignition timing map Preparatory work Remove the seat p 59 Remove the fuel tank p 65 V01720 10 Switching t...

Page 113: ...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 p 111 16 9 Adjusting the basic position of the shift lever 401950 12 Remove scre...

Page 114: ...eyes Change your clothing in case of fuel spills on them Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the s...

Page 115: ...il tank Info For one tank of fuel the 2 stroke oil tank must be filled up to at least the upper edge A The 2 stroke oil tank must be completely filled if possible If the 2 stroke oil level is too low...

Page 116: ...in wake up connector 5 for priming the oil pump to the diagnostics connector 6 Info The connector is included as part of the motorcycle s separate enclosure Wait for at least five seconds Release the...

Page 117: ...reen in the oil tank Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the...

Page 118: ...ut of the intake flange and hang it to the side V01725 10 Open hose clamp 7 using a screwdriver Pull off the angle piece and collect the 2 stroke oil in a suit able container V01724 10 Remove oil scre...

Page 119: ...frame bottom M8x18 30 Nm 22 1 lbf ft Loctite 2701 Remove screws 3 Mount and tighten screws 3 Guideline Screw sub frame top M8x20 35 Nm 25 8 lbf ft Loctite 2701 V01721 10 Position the frame protector...

Page 120: ...r suitable protective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Note Environmental hazard Hazardous substances cause environmental dam...

Page 121: ...engine and check for tightness Finishing work Check the gear oil level p 118 17 7 Adding the gear oil Info Too little gear oil or poor quality gear oil results in premature wear to the transmission G...

Page 122: ...ases are toxic and inhal ing them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or run...

Page 123: ...d direct sunshine when cleaning the motorcycle 401061 01 Close off the exhaust system to keep water from entering Remove the coarse dirt particles with a gentle water jet Spray heavily soiled parts wi...

Page 124: ...exhaust sys tem with a corrosion inhibitor Preserving materials for paints metal and rubber p 136 Treat all plastic parts and powder coated parts with a mild cleaning and care product Special cleaner...

Page 125: ...tion and wear If service repairs or replacements are necessary you should do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of...

Page 126: ...cause the engine will not warm up sufficiently the water vapor produced during combustion will condense caus ing engine parts and the exhaust system to rust 19 2 Preparing for use after storage 401059...

Page 127: ...ystem defective Check the ignition coil Check the spark plug connector Short circuit cable in wiring harness frayed switch off but ton faulty Check the switch off button The connector or ignition coil...

Page 128: ...gnition coil is loose or oxidized Clean the connector and treat it with contact spray Ambient pressure is incorrectly stored Program ambient pressure p 109 Engine overheats Too little coolant in cooli...

Page 129: ...49 0 mm 1 929 in Z distance height of control flap 300 XC TPI US 49 5 mm 1 949 in Primary transmission 26 73 Clutch Multidisc clutch in oil bath hydraulically activated Transmission 6 gear transmissio...

Page 130: ...m 5 9 lbf ft Loctite 243 Screw exhaust flange M6 8 Nm 5 9 lbf ft Screw gear oil level monitoring M6 10 Nm 7 4 lbf ft Screw intake flange reed valve housing M6 6 Nm 4 4 lbf ft Screw intermediate clutch...

Page 131: ...Total fuel tank capacity approx 8 5 l 2 25 US gal Super unleaded ROZ 95 RON 95 PON 91 p 135 Fuel reserve approx 1 5 l 1 6 qt 2 stroke oil tank content approx 0 6 l 0 6 qt Engine oil 2 stroke p 134 21...

Page 132: ...110 10 A Fuse 75011088010 10 A 21 6 Tires Front tire Rear tire 80 100 21 51M TT Dunlop GEOMAX AT81F 110 100 18 64M TT Dunlop GEOMAX AT81 The tires specified represent one of the possible series produc...

Page 133: ...er 75 85 kg 165 187 lb 42 N mm 240 lb in Weight of rider 85 95 kg 187 209 lb 45 N mm 257 lb in Spring length 260 mm 10 24 in Gas pressure 10 bar 145 psi Static sag 35 mm 1 38 in Riding sag 105 mm 4 13...

Page 134: ...r brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw throttle grip M6 5 Nm 3 7 lbf ft Fitting fuel pump M8 15 Nm 11 1 lbf ft Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Nut rear sprocket screw M8 35...

Page 135: ...Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Nut fuel pump M12 15 Nm 11 1 lbf ft Nut angle lever to link fork M14x1 5 60 Nm 44 3 lbf ft Nut frame on linkage lever M14x1 5 60 Nm 44 3 lbf...

Page 136: ...stated see specifications on the container and that has the relevant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Us...

Page 137: ...fication SAE p 138 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties Super unleaded ROZ 95 RON...

Page 138: ...High viscosity grease Recommended supplier SKF LGHB 2 Long life grease Recommended supplier MOTOREX Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX Moto Clean Off road chain spray Re...

Page 139: ...and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Special grease 00062010053 Recommended supplier Kl ber Lubrication KL BERFOOD NH1 34 401 Universal oil s...

Page 140: ...motorcycle engines the transmission and clutch are lubricated with the same oil The JASO T903 MA2 standard meets these special requirements SAE The SAE viscosity classes were defined by the Society o...

Page 141: ...transfer ducts Trans fer Port Injection Electronic fuel injection in which two injection valves in the transfer ducts of the cylinders are used OBD On board diagnosis Vehicle system which monitors the...

Page 142: ...26 LIST OF ABBREVIATIONS 140 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 143: ...pportunity refuel with 2 stroke oil 27 2 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention Active driving aids are also represented by y...

Page 144: ...ing 85 Brake linings front brake checking 81 of front brake changing 81 of rear brake changing 87 rear brake checking 87 C Capacity coolant 104 129 gear oil 119 129 Chain checking 71 cleaning 68 Chain...

Page 145: ...asic position adjusting 78 free travel checking 78 Handlebar position 45 adjusting 45 High speed compression damping shock absorber adjusting 38 I Idle speed adjusting 108 Idle speed adjusting screw 1...

Page 146: ...ension checking 95 Start button 15 Start number plate installing 55 removing 55 Starting 27 Starting power of lithium ion batteries at low tempera tures 21 Steering head bearing lubricating 54 Steerin...

Page 147: ...3214002en 3214002en 05 2019 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KISKA KTM...

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