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KTM F8203R2, Owner'S Manual, Page: 150 / 174

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KTM F8203R2 Owner'S Manual Download Page 150

21 TROUBLESHOOTING

148

Faults

Possible cause

Action

The high beam, low beam, tail
light, parking light, and license
plate lamp are not working

Fuse

2

blown

–

Change the fuses of individual power
consumers. (

p. 120)

The horn, brake light, turn sig-
nal, and radiator fan (optional)
are not working

Fuse

3

blown

–

Change the fuses of individual power
consumers. (

p. 120)

Summary of Contents for F8203R2

Page 1: ...OWNER S MANUAL 2018 350 EXC F 350 EXC F Six Days Art no 3213648en...

Page 2: ......

Page 3: ...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 deliver...

Page 4: ...start button 20 6 15 Idle speed adjusting screw 20 6 16 Shift lever 21 6 17 Foot brake lever 21 6 18 Side stand 21 6 19 Steering lock 22 6 20 Locking the steering 22 6 21 Unlocking the steering 23 7...

Page 5: ...etension of the fork EXC F Six Days 58 11 15 Handlebar position 59 11 16 Adjusting the handlebar position 59 12 SERVICE WORK ON THE CHASSIS 62 12 1 Raising the motorcycle with the lift stand 62 12 2 R...

Page 6: ...e rear wheel 110 14 5 Checking the tire condition 112 14 6 Checking the tire air pressure 112 14 7 Checking spoke tension 113 15 ELECTRICAL SYSTEM 114 15 1 Removing the battery 114 15 2 Installing the...

Page 7: ...154 23 3 2 Coolant 154 23 3 3 Fuel 154 23 4 Chassis 154 23 5 Electrical system 155 23 6 Tires 156 23 7 Fork 156 23 7 1 EXC F EU AU BR 156 23 7 2 EXC F Six Days 156 23 8 Shock absorber 157 23 9 Chassis...

Page 8: ...red for there by specially trained experts using the auxiliary tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or t...

Page 9: ...cification for the respective use 2 3 Safety advice A number of safety instructions need to be followed to operate the vehicle safely Therefore read this manual carefully The safety instructions are h...

Page 10: ...ger 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 medication Do not operate the...

Page 11: ...If you use your motorcycle responsibly you can ensure that problems and conflicts do not occur To protect the future of the motorcycle sport make sure that you use your motorcycle legally display envi...

Page 12: ...products are specified in parentheses in the descriptions Your authorized KTM dealer will be glad to advise you The current KTM PowerParts for your vehicle can be found on the KTM website Internation...

Page 13: ...ustomer service Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM A list of authorized KTM dealers can be found on the KTM website International KTM...

Page 14: ...4 VIEW OF VEHICLE 12 4 1 View of vehicle front left example A00059 10 1 Hand brake lever p 16 2 Clutch lever p 16 3 Filler cap 4 Engine number p 14 5 Side stand p 21 6 Shift lever p 21...

Page 15: ...p 17 2 Emergency OFF switch p 17 2 Electric starter button p 18 3 Throttle grip p 16 4 Chassis number p 14 4 Type label p 14 5 Fork part number p 15 6 Idle speed adjusting screw p 20 7 Foot brake lev...

Page 16: ...the right 5 2 Type label 401946 10 The type label 1 is fixed to the front of the steering head 5 3 Key number 402247 10 The key number 1 for the steering lock is stamped onto the key connector 5 4 Eng...

Page 17: ...10 The fork part number 1 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 1 is stamped on the top of the shock absorber...

Page 18: ...lever is used to activate the front brake 6 3 Throttle grip S01308 10 The throttle grip 1 is fitted on the right side of the handlebar 6 4 Kill switch S01302 10 Kill switch 1 is fitted on the left sid...

Page 19: ...the high beam and the tail light are switched on 6 7 Turn signal switch S01304 10 The turn signal switch 1 is fitted on the left side of the handle bar Possible states Turn signal off Turn signal swit...

Page 20: ...control is activated when LED 2 and TC light up Warning Voiding of the government approval for road use and the insurance coverage If the combination switch is installed the vehicle s approval for roa...

Page 21: ...ng 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 of water Rinse the eyes thoroughly with wate...

Page 22: ...utton has returned to its basic position 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...

Page 23: ...be seen in the photograph The neutral or idle position is between the first and second gears 6 17 Foot brake lever 401956 10 The foot brake lever 1 is attached in front of the right footrest The foot...

Page 24: ...ng and there fore riding is no longer possible 6 20 Locking the steering Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 400732 01 Park...

Page 25: ...ocking the steering 400731 01 Insert the key in the steering lock p 22 turn it to the left pull it out and turn it to the right Remove the key You can now steer the bike again Info Never leave the key...

Page 26: ...ly 400314 01 WS wheel size After the display function check the wheel circumference WS is displayed briefly Info The number 2205 equals the circumference of the 21 front wheel with standard tires The...

Page 27: ...s at the bottom right of the display Press the button for 2 3 seconds The Setup menu is displayed and the active functions are shown Info If no button is pressed for 10 12 seconds the settings are aut...

Page 28: ...is pressed for 15 20 seconds or if an impulse comes from the wheel speed sensor the settings are automatically saved and the setup menu is closed 7 6 Viewing the lap time Info This function can only b...

Page 29: ...ode H the service hours of the engine are displayed The service hour counter stores the total traveling time Info The service hour counter is necessary for ensuring that service work is carried out at...

Page 30: ...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...

Page 31: ...y until CLK appears at the bottom right of the display Press the button for 2 3 seconds Press the but ton for 2 3 seconds Increases the value Briefly press the button Increases the value Press the but...

Page 32: ...P appears at the bottom right of the display Briefly press the button Press the but ton for 2 3 seconds The stop watch and the lap time are reset Briefly press the button Select a lap from 1 10 Press...

Page 33: ...ction Briefly press the button No function 7 17 Display mode SPEED TR2 trip master 2 400324 01 Repeatedly press the button briefly until TR2 appears at the top right of the display TR2 trip master 2 r...

Page 34: ...average speed 1 shows the average speed calculated using TR1 trip master 1 and S1 stop watch 1 The calculation of this value is activated by the first impulse of the wheel speed sensor and ends 3 sec...

Page 35: ...mpulse from the wheel speed sensor and ends 3 seconds after the last impulse Press the but ton for 2 3 seconds Displays of TR1 A1 and S1 are reset to 0 0 Briefly press the button Next display mode Pre...

Page 36: ...display Changes to the next dis play changes from selec tion to the Setup menu Stores and closes the Setup menu Display mode SPEED CLK time The display changes to the Setup menu of the clock Next dis...

Page 37: ...age speed 2 No function Next display mode No function No function Display mode SPEED S1 stop watch 1 Displays of TR1 A1 and S1 are reset to 0 0 Next display mode No function No function Display mode...

Page 38: ...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 The brake syst...

Page 39: ...sure you fix it firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels Info Motorcycles react sensitively to any changes of weig...

Page 40: ...arting power increases as the battery warms up 8 4 Preparing the vehicle for difficult riding conditions Info Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces...

Page 41: ...lter Sand cover for air filter 79006922000 Info See the KTM PowerParts fitting instructions 600868 01 Clean the chain Chain cleaner p 162 Fit the steel sprocket Tip Do not grease the chain Clean the r...

Page 42: ...006921000 Info See the KTM PowerParts fitting instructions 600868 01 Fit the steel sprocket Clean the motorcycle p 142 Straighten bent radiator fins carefully 8 8 Preparing for rides at high temperatu...

Page 43: ...R USE 41 8 9 Preparing for rides at low temperature or in snow 102137 01 Fit a waterproofing device on the air filter Waterproofing device for air filter 79006921000 Info See the KTM PowerParts fittin...

Page 44: ...ck the tire condition p 112 Check the tire air pressure p 112 Check the spoke tension p 113 Info The spoke tension must be checked regularly as incor rect spoke tension will strongly impair riding saf...

Page 45: ...tton Info Press the electric starter button for a maximum of 5 seconds Wait for 30 seconds before a further attempt at starting During the starting process the malfunction indica tor lamp lights up 9...

Page 46: ...ons allow incline road situation etc you can shift into a higher gear To do so release the throttle while simultaneously pulling the clutch lever shift into the next gear release the clutch and open t...

Page 47: ...ng parking Warning Risk of misappropriation People who act without authorization endanger themselves and others Do not leave the vehicle unattended if the engine is running Protect the vehicle against...

Page 48: ...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 i...

Page 49: ...allow fuel to enter the groundwater the soil or the sewage system Switch off the engine Open the filler cap p 19 401226 10 Fill the fuel tank with fuel up to level A Guideline Level A 35 mm 1 38 in T...

Page 50: ...the swingarm p 91 Check the swingarm bearing for play Check the heim joint for play Check the tire condition p 112 Check the tire air pressure p 112 Check the wheel bearing for play Check the wheel h...

Page 51: ...val Periodic interval 10 3 Recommended work Annually Every 135 operating hours Every 70 operating hours when used for motorsports Once after 20 operating hours Once after 10 operating hours Change the...

Page 52: ...ping of the shock absorber is divided into two ranges high speed and low speed High speed and low speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed The hig...

Page 53: ...y Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your au...

Page 54: ...rn counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damp...

Page 55: ...preload of the shock absorber p 54 11 8 Checking the riding sag of the shock absorber 402417 10 Measure dimension A of rear wheel unloaded p 52 With another person holding the motorcycle the rider wea...

Page 56: ...Remove shock absorber p 76 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 sion Hook wrench 9012...

Page 57: ...nging the spring preload Finishing work Install the shock absorber p 76 Remove the motorcycle from the lift stand p 62 Check the static sag of the shock absorber p 53 Check the riding sag of the shock...

Page 58: ...by the number of clicks correspond ing to the fork type Guideline Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping turn counter clockwis...

Page 59: ...g is located in left fork leg COMP white adjusting screw Turn counterclockwise by the number of clicks correspond ing to the fork type Guideline Rebound damping Comfort 18 clicks Standard 15 clicks Sp...

Page 60: ...a tool Make the same adjustment on both fork legs Turn the adjusting wings clockwise Guideline Spring preload Preload Adjuster Comfort 0 Standard 0 Sport 3 The adjusting wings engage noticeably at the...

Page 61: ...XC F Six Days On the upper triple clamp there are 2 holes at a distance of A to each other Hole distance A 15 mm 0 59 in The holes on the handlebar supports are placed at a distance of B from the cent...

Page 62: ...lebar supports Place the handlebar supports in the required position Mount and tighten screws 2 Guideline Screw handle bar holder M10 40 Nm 29 5 lbf ft Loctite 243 Info Position the left and right han...

Page 63: ...lebar supports Place the handlebar supports in the required position Mount and tighten screws 2 Guideline Screw handle bar holder M10 40 Nm 29 5 lbf ft Loctite 243 Info Position the left and right han...

Page 64: ...mage 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 s...

Page 65: ...nts Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when nec essary Clean and oil the dust boots...

Page 66: ...ghten screws 3 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 12 7 Removing the fork legs Preparatory work Remove the headlight mask with the headlight p 122 Raise the motorcycle with the lift...

Page 67: ...the top edge of the upper triple clamp V00452 11 Tighten screws 2 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft 40255...

Page 68: ...headlight setting p 124 12 9 Removing the lower triple clamp EXC F EU AU BR Preparatory work Remove the headlight mask with the headlight p 122 Raise the motorcycle with the lift stand p 62 Remove the...

Page 69: ...nder p 74 Remove the handlebar cushion E00382 10 Main work Open the cable holder in front of the right radiator and detach the wiring harness Remove screws 1 and hang the voltage regulator to the side...

Page 70: ...0548 11 Position the upper triple clamp with the handlebar Mount screw 4 but do not tighten yet Secure wiring harness and clutch line with cable holder Position the voltage regulator and mount and tig...

Page 71: ...ighten screws bl Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount the cable tie s Position the brake line wiring harness and clamp Mount and tighten screws bm Finishing work...

Page 72: ...do not tighten yet Secure wiring harness and clutch line with cable holder Position the voltage regulator and mount and tighten screws 5 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft H01672...

Page 73: ...mount and tighten screws bl Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount the cable tie s Position the brake line wiring harness and clamp Mount and tighten screws bm Fini...

Page 74: ...k Move the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel Play should not be detectable on the steering head bear ing If there is detectable play EXC...

Page 75: ...Screw top steering stem M8 20 Nm 14 8 lbf ft Finishing work Check the play of the steering head bearing p 72 Remove the motorcycle from the lift stand p 62 12 15 Adjusting the steering head bearing p...

Page 76: ...F EU AU BR Remove the lower triple clamp p 66 Install the lower triple clamp p 68 EXC F Six Days Remove the lower triple clamp p 67 Install the lower triple clamp p 70 12 17 Removing front fender Pre...

Page 77: ...ten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft V00341 10 Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft K00576 10 EXC F Six Days Position front...

Page 78: ...the side and remove the shock absorber 12 20 Installing the shock absorber K00551 11 Main work Push splash protector 1 to the side and position the shock absorber Mount and tighten screw 2 Guideline...

Page 79: ...3 10 Mount the front of the seat on the collar 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...

Page 80: ...filter box cover EJOT PT K60x20 Z 3 Nm 2 2 lbf ft 12 25 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine Dust and dirt will ente...

Page 81: ...ning tab 2 Retaining pin 3 is secured by retaining tab 2 Info If the air filter is not mounted correctly dust and dirt may enter the engine and result in damage Finishing work Install the air filter b...

Page 82: ...ke flange for damage and firm seating Finishing work Install the air filter p 79 Install the air filter box cover p 78 12 28 Sealing the air filter box Preparatory work Remove the air filter box cover...

Page 83: ...encer Mount screws 1 but do not tighten yet Reconnect spring 2 Spring hook 50305017000 Tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 12 32 Changing the glass fiber yarn filli...

Page 84: ...verfilled 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...

Page 85: ...essed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Disconnect the plug in connection of the fuel line Info Remaining fuel may fl...

Page 86: ...ning Danger of poisoning Fuel is poisonous and 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...

Page 87: ...and connect plug 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 77 12 35 Checking for chain dirt accumu...

Page 88: ...apply chain spray Off road chain spray p 162 Finishing work Remove the motorcycle from the lift stand p 62 12 37 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages...

Page 89: ...chain tension p 87 Finishing work Remove the motorcycle from the lift stand p 62 12 38 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results i...

Page 90: ...s 3 Tighten nut 1 Guideline Nut rear wheel spin dle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain l...

Page 91: ...in If the distance B is greater than the specified measure ment Change the drivetrain kit Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear o...

Page 92: ...in sliding piece Guideline Screw chain slid ing piece M8 15 Nm 11 1 lbf ft 401760 01 Check the chain guide for wear Info Wear is visible on the front of the chain guide If the light part of the chain...

Page 93: ...f the swingarm shows signs of damage cracking or defor mation Change the swingarm Info Always change a damaged swingarm Repair of the swingarm is not authorized by KTM 12 42 Checking throttle cable ro...

Page 94: ...oose Change the rubber grip K00547 10 Check that screw 1 is firmly seated Guideline Screw fixed grip M4 5 Nm 3 7 lbf ft Loctite 243 Diamond A must be located at the top 12 44 Adjusting the basic posit...

Page 95: ...Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info The fluid level rises with increasing wear of the clutch facing dis...

Page 96: ...othing 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...

Page 97: ...ydraulic clutch Guideline Fluid level below container rim 4 mm 0 16 in Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immediately wit...

Page 98: ...2 Adjusting free travel of hand brake lever V00803 10 Check the free travel of the hand brake lever p 96 Adjust the free travel of the hand brake lever with adjusting screw 1 Info Turn the adjusting...

Page 99: ...sc 13 4 Checking the brake fluid level of the front brake Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the spe...

Page 100: ...ct with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear...

Page 101: ...intenance 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 ca...

Page 102: ...ntal hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never u...

Page 103: ...805 12 Correct the brake fluid quantity to level A Guideline Level A brake fluid level below reservoir rim 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 160 Position the cover with the membrane Mount and ti...

Page 104: ...e builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification K00563 10 Disconnect spring 1 Loosen nut 4 and with push rod 5 turn i...

Page 105: ...id 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 are worn down Check the...

Page 106: ...the vehicle upright Remove screw cap 1 with membrane 2 and the O ring Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 160 Mount the screw cap with the membrane and the O ring Info Clean up ove...

Page 107: ...Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Warning Dang...

Page 108: ...ke caliper against the spokes E00351 10 Remove cotter pins 3 pull out pin 4 and remove the brake linings Clean the brake caliper and brake caliper support E00352 10 Check that leaf spring 5 in the bra...

Page 109: ...BRAKE SYSTEM 107 M01506 10 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 160 Mount screw cap 1 with membrane 2 and O ring Info Clean up overflowed or spilled brake fluid immediately with wat...

Page 110: ...g back the brake pistons V00364 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 V00365 10 Warning Danger of accid...

Page 111: ...and grease the wheel spindle Long life grease p 162 Insert the spacers Position the front wheel and insert the wheel spindle The brake linings are correctly positioned V00364 11 Mount and tighten scre...

Page 112: ...ar 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 di...

Page 113: ...d Mount the chain V00368 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 86 Tig...

Page 114: ...k the tread depth Info Adhere to the legally required minimum tread depth Minimum tread depth 2 mm 0 08 in If the tread depth is less than the minimum tread depth Change the tires H01144 01 Check the...

Page 115: ...the spokes is too low then lateral and radial run out will form in the wheel Other spokes will become looser as a result Check spoke tension regularly and in particular on a new vehicle Your authorize...

Page 116: ...F00138 10 Main work All EU AU models 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 c...

Page 117: ...attery gases get into the eyes Disconnect negative cable 1 from the battery Pull back positive terminal cover 2 and disconnect the positive cable from the battery Remove screw 3 Pull holding bracket 4...

Page 118: ...zard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Even when ther...

Page 119: ...e is already below the minimum voltage Minimum voltage before the start of the charge 9 V Dispose of batteries with less than the mini mum voltage correctly Check the battery voltage Battery voltage 9...

Page 120: ...s Switch off the battery charger after charging and discon nect from the battery 400240 10 All BR models Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteri...

Page 121: ...cked Never remove cover 1 Charge the battery to a maximum of 10 of the capacity specified on battery housing 2 Switch off the battery charger after charging and discon nect from the battery Guideline...

Page 122: ...heck that the electrical equipment is functioning properly Tip Insert a spare fuse so that it is available if needed Mount the protection caps Mount the starter relay onto the holder and route the cab...

Page 123: ...gnostics connector fuse 4 Fuse 2 10 A high beam low beam parking light tail light license plate lamp Fuse 3 5 A fuel pump Fuse 4 10 A radiator fan optional horn brake light turn signal Fuses res 10 A...

Page 124: ...with the headlight V00458 10 Detach the brake line and wiring harness from the headlight mask Release rubber bands 1 Slide the headlight mask up and swing it forward E00356 10 Detach plug in connector...

Page 125: ...the bulbs with your bare hands Preparatory work Remove the headlight mask with the headlight p 122 E00358 10 Main work Turn protection cap 1 together with the underlying bulb socket counterclockwise...

Page 126: ...ck the headlight setting The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider If the light dark border does not meet specifications Adjust the headlight ra...

Page 127: ...e socket turn it counterclockwise by about 30 and take it out of the socket Info Do not touch the reflector with your fingers and keep it free from grease Press the new turn signal bulb carefully into...

Page 128: ...osition protection cap 2 and turn all the way clockwise using a coin Press any button on the combination instrument The combination instrument is activated Position the combination instrument in the h...

Page 129: ...hot and is under pressure Do not open the radiator the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature Allow the cooling system and...

Page 130: ...ne to cool down before you open the 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 Dange...

Page 131: ...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...

Page 132: ...r 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 M...

Page 133: ...inal posi tion Adjust the play in the throttle cable p 131 Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness and death Always make sure there is suffi...

Page 134: ...there is play in the throttle cable at the throttle grip Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Tighten nut 2 Slide on sleeve 1 Check the throttle grip for smooth operation Finishing work...

Page 135: ...osition half shells 3 mount and tighten screws 2 Guideline Screw throttle grip M6 5 Nm 3 7 lbf ft Slide on sleeve 1 and check the throttle grip for ease of movement Finishing work Check the play in th...

Page 136: ...ur authorized KTM workshop will be glad to help H02254 10 Run the engine until warm The cold start button is deactivated The cold start but ton is in its basic position p 20 Danger Danger of poisoning...

Page 137: ...lashing once teach ing is completed Info If the engine becomes too hot perform a cool down ride at medium revs Then do not switch off the engine after this but leave it running at idle speed until tea...

Page 138: ...A of 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 int...

Page 139: ...se 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 spi...

Page 140: ...e oil is at a level between the lower edge A and the middle of the level viewer B If the engine oil is not up to the lower edge A of the level viewer Add engine oil p 141 18 3 Changing the engine oil...

Page 141: ...osition oil screen 4 with the O rings on a pin wrench Position the pin wrench through the drilled hole of the screw plug in the opposite section of the engine case Push the oil screen all the way into...

Page 142: ...r with the O ring and fill up with engine oil Engine oil 1 0 l 1 1 qt Engine oil SAE 10W 50 p 161 Engine oil Alternative engine oil for harsh operat ing conditions and increased performance Engine oil...

Page 143: ...5 p 160 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 o...

Page 144: ...e of the motorcycle over a long period clean it regularly Avoid direct sunshine when cleaning the motorcycle 401061 01 Close off the exhaust system to keep water from entering Remove coarse dirt parti...

Page 145: ...oads You should therefore take precautions against aggressive road salt If the vehicle was operated in road salt clean it with cold water after riding Warm water would enhance the corrosive effects of...

Page 146: ...times at the start of the new season 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 162 Refuel p 46 Clean the motorcycle p 142...

Page 147: ...145 20 2 Preparing for use after storage 401059 01 Remove the motorcycle from the lift stand p 62 Install the battery p 115 Perform checks and maintenance measures when preparing for use p 42 Take a...

Page 148: ...g oily or wet Clean and dry the spark plug or replace if necessary Electrode distance plug gap of spark plug too wide Adjust the plug gap Guideline Spark plug electrode gap 1 0 mm 0 039 in Ignition sy...

Page 149: ...ent radiator hose Change the radiator hose Thermostat defective Check the thermostat Guideline Opening temperature 70 C 158 F Defect in radiator fan system EXC F Six Days Check the radiator fan fuse C...

Page 150: ...m tail light parking light and license plate lamp are not working Fuse 2 blown Change the fuses of individual power consumers p 120 The horn brake light turn sig nal and radiator fan optional are not...

Page 151: ...nifold absolute pressure sensor cylinder 1 input signal too low Manifold absolute pressure sensor cylinder 1 input signal too high Blink code for malfunction indicator lamp 12 Malfunction indicator la...

Page 152: ...ion indicator lamp flashes 3x long 3x short Error level condition Injector cylinder 1 circuit fault Blink code for malfunction indicator lamp 37 Malfunction indicator lamp flashes 3x long 7x short Err...

Page 153: ...ring Plain bearing Piston pin bearing No bearing bushes DLC coated piston pins Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lub...

Page 154: ...zle piston cooling M5 2 Nm 1 5 lbf ft Loctite 243 Screw bearing bolt oil pump idler gear M5 6 Nm 4 4 lbf ft Loctite 243 Screw clutch spring M5 6 Nm 4 4 lbf ft Screw crankshaft position sensor M5 6 Nm...

Page 155: ...crew 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 tensioner M10x1 8 Nm 5 9 lbf ft Spark plug M10...

Page 156: ...ype C ROZ 95 RON 95 PON 91 p 161 All BR models Fuel reserve approx 1 5 l 1 6 qt 23 4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork EXC F EU AU BR WP Performance SystemsX...

Page 157: ...ermissible front axle load 145 kg 320 lb Maximum permissible rear axle load 190 kg 419 lb Maximum permissible overall weight 335 kg 739 lb 23 5 Electrical system Battery All EU AU models HJTZ5S FP Lit...

Page 158: ...8 Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring length with preload spacer s 474 mm 18 66 in Spri...

Page 159: ...sXplor PDS Compression damping low speed Comfort 18 clicks Standard 15 clicks Sport 12 clicks Compression damping high speed Comfort 2 5 turns Standard 2 turns Sport 1 turn Rebound damping Comfort 18...

Page 160: ...ng nuts chassis M6 10 Nm 7 4 lbf ft Remaining screws chassis M6 10 Nm 7 4 lbf ft Screw ball joint of push rod on foot brake cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw chain sliding guard M6 14 Nm...

Page 161: ...ft Screw top triple clamp EXC F EU AU BR 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 S...

Page 162: ...coolant that complies with the requirements 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 adjus...

Page 163: ...ifications on the container 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...

Page 164: ...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 165: ...ARY SUBSTANCES 163 Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommended supplier Motorex Quick Cleaner Universal oil spray Recommended supplier Motorex Joker 440...

Page 166: ...ong service intervals are demanded for automobile engines the focus for motorcycle engines is on high performance at high engine speeds In most motorcycle engines the transmission and the clutch are l...

Page 167: ...27 INDEX OF SPECIAL TERMS 165 OBD On board diagnosis Vehicle system which monitors the specified parame ters of the vehicle electronics...

Page 168: ...28 LIST OF ABBREVIATIONS 166 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 169: ...ts up flashes yellow The OBD has detected a fault in the vehicle electronics Come safely to a halt and contact an authorized KTM workshop The fuel level warning lamp lights up yellow The fuel level ha...

Page 170: ...8 cleaning 85 Chain guide checking 88 Chain tension adjusting 87 checking 86 Characteristic map of the throttle response adjusting 132 Chassis number 14 Clutch fluid level checking correcting 93 fluid...

Page 171: ...Fuel tank installing 84 removing 82 Fuse individual power consumers changing 120 main fuse changing 119 H Hand brake lever 16 free travel adjusting 96 free travel checking 96 Handlebar position 59 ad...

Page 172: ...r installing 76 removing 76 riding sag checking 53 spring preload adjusting 54 static sag checking 53 Side stand 21 Spare parts 10 Spoke tension checking 113 Starting 42 Starting power of lithium ion...

Page 173: ...INDEX 171 U Use definition 7 V View of vehicle front left 12 rear right 13 W Warranty 10 Winter operation checks and maintenance steps 143 Work rules 9...

Page 174: ...3213648en 3213648en 05 2017 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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