KTM Freeride 350 2013 Owner'S Manual Download Page 54 | Manualshive

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KTM Freeride 350 2013 Owner'S Manual Download Page 54

12

SERVICE WORK ON THE CHASSIS

52

12.31

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 engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

–

The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.

Warning

Danger of poisoning

Fuel is poisonous and a health hazard.

–

Fuel must not come into contact with 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. Change clothing that is contaminated with fuel.

B01078-11

Main work

–

Check the throttle cable routing. (

–

Make sure that no cables are trapped or damaged.

–

Attach connector

1

of the fuel pump.

B01077-11

–

Position the fuel tank.

–

Position the intake flange on the throttle valve body.

–

Tighten hose clamp

2

.

B01076-11

–

Plug in connector

3

.

–

Position engine breather hose

4

.

B01075-11

–

Mount and tighten screws

5

on both sides.

Guideline

Screw, fuel tank

M8

15 Nm
(11.1 lbf ft)

Loctite

®

243™

–

Mount and tighten screw

6

.

Guideline

Remaining screws, chassis

M6

10 Nm (7.4 lbf ft)

–

Mount the fuel tank breather.

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Summary of Contents for Freeride 350 2013

Page 1: ...OWNER S MANUAL 2014 Freeride 350 EU Freeride 350 AUS Art no 3213042en ...

Page 2: ......

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

Page 4: ... 23 9 RIDING INSTRUCTIONS 24 9 1 Checks and maintenance work when preparing for use 24 9 2 Starting 24 9 3 Starting off 25 9 4 Shifting riding 25 9 5 Applying the brakes 25 9 6 Stopping parking 26 9 7 Transport 26 9 8 Refueling 27 10 SERVICE SCHEDULE 28 10 1 Service schedule 28 10 2 Service work as additional order 29 11 TUNING THE CHASSIS 30 11 1 Checking the basic chassis setting with the rider ...

Page 5: ...HEELS TIRES 70 14 1 Removing the front wheel x 70 14 2 Installing the front wheel x 70 14 3 Removing the rear wheel x 71 14 4 Installing the rear wheel x 71 14 5 Checking the tire condition 72 14 6 Checking the tire air pressure 73 14 7 Checking the spoke tension 73 15 ELECTRICAL SYSTEM 74 15 1 Removing the battery x 74 15 2 Installing the battery x 74 15 3 Recharging the battery x 75 15 4 Changin...

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: ...us injury if the appropriate measures are not taken Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken 2 4 Tamperi...

Page 8: ...but can be ordered under the number in paren theses E g bearing puller 15112017000 During assembly non reusable parts e g self locking screws and nuts seals and seal rings O rings pins lock washers must be replaced by new parts In some instances a thread locker e g Loctite is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and...

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: ... 602789 10 1 Speedometer 2 Clutch lever p 12 3 Filler cap 4 Seat 5 Seat release 6 Shock absorber compression adjustment 7 Shock absorber rebound adjustment 8 Side stand p 16 9 Battery 10 Shift lever p 15 11 Idle speed adjusting screw p 15 12 Steering lock p 16 ...

Page 11: ...Kill switch p 12 1 Horn button p 12 1 Light switch p 13 1 Turn signal switch p 13 2 Electric starter button p 13 3 Throttle grip p 12 4 Hand brake lever p 12 5 Fork rebound adjustment 6 Fork compression adjustment 7 Foot brake lever p 15 8 Level viewer for brake fluid rear ...

Page 12: ...l 1 is fixed to the frame at the front right 5 3 Key number 500125 10 The key number 1 for the steering lock is stamped onto the key connector 5 4 Engine number B01006 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket 5 5 Fork part number B01007 10 The fork part number 1 is stamped on the inner side of the axle clamp ...

Page 13: ...5 SERIAL NUMBERS 11 5 6 Shock absorber part number B01132 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 14: ... the right side of the handlebar 6 4 Kill switch B01658 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 Horn button B01658...

Page 15: ...button Freeride 350 AUS 602794 10 Electric starter button 1 is fitted on the right side of the handlebar Possible states Electric starter button in basic position Electric starter button pressed In this position the electric starter is actuated 6 9 Turn signal switch 602801 10 Turn signal switch 1 is fitted on the left side of the handlebar Possible states Turn signal light off Turn signal switch ...

Page 16: ...anger 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 Change clothing that is contaminated wi...

Page 17: ...RPM increase activated Idle speed adjusting screw is pulled out all the way RPM increase deactivated Idle speed adjusting screw is pushed in all the way 6 15 Shift lever B01023 11 Shift lever 1 is mounted on the left side of the engine B01023 10 The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears 6 16 Foot brake lever B01024 10 Foot b...

Page 18: ...ering head The steering lock is used to lock the steering Steering and therefore riding is no longer possible 6 19 Locking the steering Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 400732 01 Park the vehicle Turn the handlebar as far as possible to the right Insert the key in the steering lock turn it to the left press it i...

Page 19: ... Unlocking the steering 400731 01 Insert the key in the steering lock turn it to the left pull it out and turn it to the right Remove the key You can now steer the bike again Info Never leave the key in the steering lock ...

Page 20: ...the speedometer Battery voltage of the speedometer is too low Change the battery Service A service is due Contact an authorized KTM workshop 7 4 Setting the speedometer Condition The motorcycle is stationary 401909 01 Press both buttons for 3 5 seconds The Setup menu is displayed The UNIT display flashes Press one of the buttons to select UNIT for the speed in kilometers KM H or miles M H 401911 0...

Page 21: ...hortening the service interval Press the left button The value decreases Extending the service interval Press the right button The value increases 401914 01 Switching off the service interval display Press and hold the left button off appears on the display 7 5 Setting kilometers or miles Info If you change the unit of measure the ODO value is retained and converted accordingly Condition The motor...

Page 22: ...value decreases Advancing the time Press the right button The value increases 7 7 Setting the service display Condition The motorcycle is stationary 401913 01 Press both buttons for 3 5 seconds The Setup menu is displayed The UNIT display flashes Wait for the menu of the service display to flash Set the service Guideline One time service after 1 h Service every 20 h Shortening the service interval...

Page 23: ...ince the last reset such as between two refueling stops Info If the value of 39999 9 is exceeded DST2 is automatically reset to 0 0 Press the left but ton briefly Next display mode Press the left but ton for 3 5 sec onds DST2 can be preset to a value between 0 0 and 39999 9 by pressing the buttons Press the right but ton briefly Next display mode Press the right but ton for 3 5 sec onds DST2 is re...

Page 24: ...e not braking Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permissible weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons Info When using your motorcycle remember that others may feel disturbed by excessive noise Make sure th...

Page 25: ... 617 lb Maximum permissible front axle load 135 kg 298 lb Maximum permissible rear axle load 175 kg 386 lb Run the engine in p 23 8 2 Running in the engine During the running in phase do not exceed the specified engine speed and engine performance Guideline Maximum engine speed During the first operating hour 7 000 rpm Maximum engine performance During the first 3 operating hours 75 Avoid fully op...

Page 26: ...sure that they can be operated smoothly Check all screws nuts and hose clamps regularly for tightness Check the fuel supply 9 2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective e...

Page 27: ...ttle opening increases fuel consumption To shift down brake and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Switch off the engine if you expect to be standing for a long time Guideline 2 min Avoid frequent and longer slipping of the clutch This heats the engine oil the engine and the cool...

Page 28: ... run Always let the vehicle cool first Note Material damage Damage to or destruction of components due to excessive load The side stand is only designed for the weight of the motorcycle Do no sit on the motorcycle when it is resting on the side stand The side stand or the frame may become damaged and the motorcycle may fall over Brake the motorcycle Shift gear to neutral Press and hold the kill sw...

Page 29: ...l is swallowed contact a physician immediately Change clothing that is contaminated with fuel Note Material damage Premature clogging of the fuel filter In some countries and regions the available fuel quality and cleanliness may not be sufficient This will result in problems with the fuel system Your authorized KTM workshop will be glad to help Only refuel with clean fuel that meets the specified...

Page 30: ... e g side stand hand lever chain and check for smooth operation x Check the fluid level of the hydraulic clutch p 58 Check the brake fluid level of the front brake p 62 Check the free travel of the hand brake lever p 61 Check the steering head bearing play p 42 Check the valve clearance x Check the clutch x Change the shaft seal rings of the water pump x Change the fuel screen x p 87 Check the fue...

Page 31: ...service x Service the shock absorber x Change the spark plug and spark plug connector x Change the piston x Check measure the cylinder x Check the cylinder head x Change the valves valve springs and valve spring seats x Check the camshaft and cam lever x Change the connecting rod conrod bearing and crank pin x Check the transmission and shift mechanism x Check the oil pressure regulator valve x Ch...

Page 32: ...the rear wheel suspension and not to the vehicle speed The high speed setting for example has an effect on the landing after a jump the rear wheel suspension compresses more quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses more slowly These two ranges can be adjusted separately although the transition between high spee...

Page 33: ...sen nut 2 Turn back counterclockwise by the number of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort 2 5 turns Standard 2 turns Sport 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing Finishing work Install the shock absorber x p 44 Lock the seat p 45 Remove the motorcycle from the lift stand p 37 11 5 Adjusting...

Page 34: ...as dimension A Finishing work Remove the motorcycle from the lift stand p 37 11 7 Checking the static sag of the shock absorber 400989 10 Measure distance A of rear wheel unloaded p 32 Hold the motorcycle upright with the aid of an assistant Measure the distance between the rear axle and the fixed point again Note down the value as dimension B Info The static sag is the difference between measurem...

Page 35: ...can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help Info Before changing the spring preload make a note of the present setting e g by measuring the length of the spring Preparatory work Raise the motorcycle with the lift stand p 37 Fold the seat up p 45 Remove the shock absorber x p 44 After...

Page 36: ...o The spring rate is shown on the outside of the spring Smaller weight differences can be compensated by changing the spring preload Finishing work Install the shock absorber x p 44 Lock the seat p 45 Remove the motorcycle from the lift stand p 37 Check the static sag of the shock absorber p 32 Check the riding sag of the shock absorber p 33 Adjust the rebound damping of the shock absorber p 31 11...

Page 37: ...he rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior B01034 10 Turn adjusting screws 1 clockwise all the way Info Adjusting screws 1 are located at the top end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline Rebound damping Comfort 25 clicks S...

Page 38: ...attachments against damage by covering them Do not bend the cables and lines Remove the two screws 2 Remove the handlebar supports Place the handlebar supports in the required position Fit and tighten the two 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...

Page 39: ...arked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 602799 10 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 are riding the side stand must be folded up and secured with the rubber band 12 3 Bleeding the fork legs Preparatory w...

Page 40: ...nd grease and clean them with brake cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray p 106 Press the dust boots back into their normal position Remove excess oil Finishing work Remove the motorcycle from the lift stand p 37 12 5 Removing the fork legs x Preparatory work Remove the headlight mask with the headlight p 77 Raise the motorcyc...

Page 41: ...8 Nm 13 3 lbf ft 602805 11 Position brake caliper and mount and tighten screws 4 Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount cable binder 5 Position the brake line wiring harness and clamp Mount and tighten screws 6 Finishing work Install the front wheel x p 70 Refit the headlight mask with the headlight p 78 Check the headlight setting p 80 12 7 Removing the fork pr...

Page 42: ... clamp x Preparatory work Remove the headlight mask with the headlight p 77 Raise the motorcycle with the lift stand p 37 Remove the front wheel x p 70 Remove the fork legs x p 38 Remove the front fender p 44 B01056 10 Main work Open the cable holder in front of the radiator and detach the wiring harness Remove screw 1 Remove screw 2 take off the upper triple clamp with the handlebar and set it as...

Page 43: ...y positioned Slide on protective ring 2 and O ring 3 B01056 11 Position the upper triple clamp with the steering Mount screw 4 but do not tighten yet Position the clutch line and wiring harness 602804 10 Position the fork legs Info The lowest milled groove in the fork leg must be flush with the top edge of the upper triple clamp Position bleeder screws 5 toward the front B01054 12 Tighten screws 6...

Page 44: ...l the front wheel x p 70 Refit the headlight mask with the headlight p 78 Check that the wiring harness cables and brake and clutch lines can move freely and are routed correctly Check the steering head bearing play p 42 Remove the motorcycle from the lift stand p 37 Check the headlight setting p 80 12 11 Checking the steering head bearing play Warning Danger of accidents Unstable vehicle handling...

Page 45: ...lace if required Finishing work Remove the motorcycle from the lift stand p 37 12 12 Adjusting the play of the steering head bearing x Preparatory work Raise the motorcycle with the lift stand p 37 B01034 11 Main work Loosen screws 1 Remove screw 2 Loosen and retighten screw 3 Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to...

Page 46: ... the shock absorber Mount and tighten screw 2 Guideline Screw top shock absorber M12 80 Nm 59 lbf ft Loctite 243 Mount and tighten screw 3 Guideline Screw bottom shock absorber M12 80 Nm 59 lbf ft Loctite 243 Info The heim joint for the shock absorber at the swing arm is Teflon coated It must not be greased with grease or with other lubricants Lubricants dis solve the Teflon coating thereby drasti...

Page 47: ... Nm 7 4 lbf ft Info Make sure the holding lugs engage in the headlight mask 12 18 Folding the seat up B01021 10 Press release lever 1 Lift the seat and fold it up 12 19 Locking the seat B01022 10 Fold down the seat and push it down The seat engages with an audible click Finally check that the seat is correctly locked 12 20 Taking off the spoiler Preparatory work Fold the seat up p 45 305979 10 Mai...

Page 48: ... tighten screw 1 Mount and tighten screw 2 305979 11 Mount and tighten screws 3 Repeat the operation on the opposite side Finishing work Lock the seat p 45 12 22 Removing the air filter housing 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 inc...

Page 49: ...unted correctly dust and dirt may enter the engine and cause damage Finishing work Lock the seat p 45 12 24 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 substances ...

Page 50: ... Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Do not clean the air filter with fuel or petroleum since these substances attack the foam Preparatory work Fold the seat up p 45 Remove the air filter housing x p 46 Remove the air filter x p 47 B01065 01 Main work Wash the air filter thoroughly in special cleaning liquid and allow ...

Page 51: ...spoiler Disconnect connector 1 of the lambda sensor 306091 10 Disconnect spring 2 Remove screws 3 and take off the main silencer 306092 10 Remove the left main silencer Disconnect spring 4 Remove screws 5 and take off the main silencer 12 28 Installing the main silencer 306091 11 Install the right main silencer Position the main silencer Mount and tighten screws 1 Guideline Remaining screws chassi...

Page 52: ...e the main silencer p 49 B01068 10 Main work Remove screws 1 Take off connecting cap 2 Pull silencer cap 3 out together with the perforated pipe and glass fiber yarn fill ings 4 and 5 Clean the parts that need to be reinstalled and check for damage Position the new glass fiber yarn fillings 4 and 5 on the perforated pipe Mount silencer cap 3 with the perforated pipe in the main silencer Mount conn...

Page 53: ...hildren Preparatory work Fold the seat up p 45 B01074 10 Main work Thoroughly clean the plug in connection of the fuel line using compressed air Info Under no circumstances should dirt enter the fuel line Dirt in the fuel line clogs the injection valve Disconnect the plug in connection of the fuel line Mount wash cap set 1 Wash cap set 81212016000 B01075 10 Remove the tube from the fuel tank breat...

Page 54: ...rs If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel B01078 11 Main work Check the throttle cable routing p 57 Make sure that no cables are trapped or damaged Attach connector 1 of the fuel pump B...

Page 55: ...s very dirty Clean the chain p 53 12 33 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Environm...

Page 56: ...tension Warning Danger of accidents Danger caused by incorrect 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 c...

Page 57: ... 33 lb Measure the distance B of 18 chain links in the lower chain section Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance B at the longest chain section 272 mm 10 71 in If the distance B is greater than the specified measurement Change the power set x Info When the chain is replaced the rear sprocket and engine sprocket should...

Page 58: ...f the chain guide If the light part of the chain guide is worn Change the chain guide x B01713 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the chain guide Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Remaining nuts chassis M6 10 Nm 7 4 lbf ft Finishing work Remove the motorcycle from the lift stand p 37 12 37 Checking the frame x 401462 01 Check the...

Page 59: ...the fuel tank x p 50 B01080 10 Main work Check the throttle cable routing Both throttle cables must be routed to the throttle valve body side by side behind the handlebars and below the seat fixing If the throttle cable is not routed as specified Correct the throttle cable routing Finishing work Install the fuel tank x p 52 Lock the seat p 45 12 40 Checking the rubber grip 401197 01 Check the rubb...

Page 60: ...stment is limited Turn the adjusting screw by hand only and do not apply force Do not make any adjustments while riding 12 43 Checking fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch facing discs B01711 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Check the fluid level in viewer 1 If the fluid has dropped bel...

Page 61: ...2 with membrane 3 B01083 10 Fill bleeding syringe 4 with the appropriate hydraulic fluid Bleed syringe 50329050000 Brake fluid DOT 4 DOT 5 1 p 103 On the clutch slave cylinder remove bleeder screw 5 and mount bleeding syringe 4 B01708 10 Inject the liquid into the system until it escapes from opening A of the master cylinder without bubbles To prevent overflow drain fluid occasionally from the mas...

Page 62: ...the front 12 47 Installing the engine guard B01072 10 Position the engine guard on the frame at the front and mount screws 1 but do not tighten yet Position the engine guard on the frame at the rear and mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 63: ... moves away from the handlebar Turn the adjustment screw counterclockwise to increase free travel The pressure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply force Do not make any adjustments while riding 13 3 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc s Change t...

Page 64: ... 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 and goggl...

Page 65: ...ll be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brak...

Page 66: ...iper backwards from the brake disc Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir B01698 10 Remove cotter pin 5 Remove bolt 6 Take off retainer spring 7 and remove the brake linings Clean the brake caliper Position the brake linings Info Always change the brake linings in pairs Position retaining spring 7 Mount bolt 6 Mo...

Page 67: ... not meet specifications Adjust the basic position of the foot brake lever x p 65 Reconnect spring 1 13 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 circuit The rear brake can fail due to overheating Adjust the free travel on foot brake lever accordin...

Page 68: ...g or that the brake linings are completely worn down Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the...

Page 69: ...sible Change the rear brake linings x p 67 13 13 Changing the rear brake linings x Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitab...

Page 70: ...5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container B01689 10 Stand the vehicle upright Remove screws 1 Remove cover with membrane 2 Press the brake piston back to its basic position and make sure that n...

Page 71: ...SYSTEM 69 B01692 10 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 103 Mount the cover with the membrane 2 Mount and tighten screws 1 Info Clean up overflowed or spilt brake fluid immediately with water ...

Page 72: ... 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 B01046 11 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the wheel bearing x Clean and grease the shaft seal rings 1 and contact surface A of the spacers Long life grease p 105 Insert the spacers B01044 1...

Page 73: ...eel withdraw the wheel spindle Take the rear wheel out of the swing arm Info Do not operate the foot brake when the rear wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged B01048 10 Remove spacers 4 14 4 Installing the rear wheel x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs fre...

Page 74: ...ion Info Only mount tires approved and or recommended by KTM Other tires could have a negative effect on handling characteristics The type condition and air pressure of the tires all have a major impact on the handling characteristics of the motorcycle The tires mounted on the front and rear wheels must have a similar profile Worn tires have a negative effect on riding behavior especially on wet s...

Page 75: ...i If the tire pressure does not meet specifications Correct the tire pressure Mount protection cap 14 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 to...

Page 76: ...and contact a physician B01102 10 Switch off all power consumers and switch off the engine Remove screw 1 Take off fastening plate 2 B01103 10 Take the battery out of the battery compartment Disconnect negative cable 3 of the battery Pull back the positive terminal cover 4 and disconnect the positive plus cable of the battery 15 2 Installing the battery x B01104 10 Attach positive cable Guideline ...

Page 77: ...load on the battery it discharges steadily The charge state and the type of charge are very important for the service life of the battery Rapid recharging with a high charging current shortens the battery s service life If the charging current charging voltage and charging time are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted f...

Page 78: ...Main work Remove protection caps 1 B01110 10 Remove the faulty main fuse 2 Info A defective fuse is indicated by a burned out fuse wire A A reserve fuse 3 is located in the starter relay Install a new main fuse Fuse 58011109120 p 100 Check that the electrical equipment is functioning properly Tip Insert the spare fuse so that it is available if needed Mount the protection caps Finishing work Insta...

Page 79: ...ed out fuse wire A Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Use spare fuses with the correct rating only Fuse 75011088010 p 100 Tip Replace the spare fuse in the fuse box so that it is available if needed Check that the power consumer is functioning properly Close the fuse box c...

Page 80: ... and fix it with the rubber band 3 Info Make sure that the holding lugs engage in the fender Position the brake line and wiring harness 4 Finishing work Check the headlight setting p 80 15 8 Changing the headlight bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before moun...

Page 81: ...amage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting 800137 10 Main work Remove the screw on the rear of the turn signal housing Carefully remove diffuser 1 Lightly squeeze orange cap 2 in the area of the holding lugs and take it off Press the turn signal bulb carefully in...

Page 82: ...e headlight range Preparatory work Check the headlight setting p 80 B01043 10 Main work Adjust the beam distance of the headlight by turning screw 1 Guideline For a motorcycle with rider the light dark boundary must be exactly on the lower mark the mark is created in Checking the headlight setting Info Turn clockwise to increase the headlight range turn counterclockwise to reduce the headlight ran...

Page 83: ...kwise using a coin Press any button on the speedometer The speedometer is activated Position the speedometer in the holder Mount and tighten the screws with washers Finishing work Refit the headlight mask with the headlight p 78 Check the headlight setting p 80 Set the speedometer p 18 ...

Page 84: ...g 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 coolant is swal lowed conta...

Page 85: ...vel does not meet specifications Correct the coolant level Alternative 1 Coolant p 103 Alternative 2 Coolant mixed ready to use p 103 Mount the radiator cap 16 4 Draining the coolant x Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow th...

Page 86: ... on the skin with soap and water If coolant is swal lowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children B01116 10 Main work Make sure that screw 1 is tightened Stand the motorcycle upright Pour coolant in up to measurement A above the radiator fins Guideline 10 mm 0 39 in Coolant 0 7 l 0 7 qt Coolant p 103 Coolant mixed read...

Page 87: ...d do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and let it run idle Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable x p 85 17 2 Adjusting the play in the throttle cable x Preparatory work Fold the seat up p 45 Remove the f...

Page 88: ...ge of your boot 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 86 17 5 Adjusting the basic position of the shift lever x B01107 10 Remove screw 1 and remove shift lever 2 B01108 10 Clean gear teeth A of the shift lever and shift shaft Mount shift lever 2 on t...

Page 89: ...ection of the fuel line using compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Disconnect the plug in connection of the fuel line Pull fuel screen 1 out of the connecting piece Slide a new fuel screen into the connecting piece Lubricate the O ring and connect plug in connection of the fuel line Finishing work Danger Dan...

Page 90: ...mediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Drain the engine oil only when the engine is warm Preparatory work Park the motorcycle on a level surface Remove the engine guard p 60 B01125 10 Main work Place a suitable conta...

Page 91: ...bout full with engine oil Insert the oil filter into the oil filter housing Oil the O ring of the oil filter cover and mount it with oil filter cover 6 Mount and tighten the screws Guideline Screw oil filter cover M6 10 Nm 7 4 lbf ft Stand the motorcycle upright B01119 11 Remove the oil filler plug 7 with the O ring from the clutch cover and fill up with engine oil Engine oil 1 20 l 1 27 qt Engine...

Page 92: ...103 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 the O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the e...

Page 93: ... then clean with a paintbrush Motorcycle cleaner p 105 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry vehicle always rinse with water first After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the plug from the exhaust system Warning Danger of accidents Reduced braking efficiency due to a w...

Page 94: ...he brakes Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts are cooled down and while they are installed After riding on salted roads thoroughly wash the motorcycle with cold water and dry it well Treat the engine swingarm and all other bright and zinc plated parts except for the brake di...

Page 95: ...aking the motorcycle out of service add fuel additive Fuel additive p 105 Refuel p 27 Clean the motorcycle p 91 Change the engine oil and oil filter clean the oil screen x p 88 Check the antifreeze and coolant level p 82 Check the tire air pressure p 73 Remove the battery x p 74 Recharge the battery x p 75 Guideline Storage temperature of battery without direct sunlight 0 35 C 32 95 F Store the ve...

Page 96: ... fuel injection system Read out the fault memory using the KTM diag nostics tool x Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x Engine has too little power Air filter is very dirty Clean the air filter and air filter housing x p 48 Fuel filter is very dirty Change the fuel filter x Fuel screen is very dirty Change the fuel scr...

Page 97: ...ngine oil and oil filter clean the oil screen x p 88 Piston and cylinder worn Measure the piston cylinder mounting clear ance x Battery is discharged Battery is not being charged by alter nator Check the charging voltage x Check the stator winding of the alternator x Unwanted power consumer Check the quiescent current x Speedometer values deleted time stop watch lap times The battery in the speedo...

Page 98: ...p MIL 06 FI warning lamp MIL flashes 6x short Error level condition Throttle position sensor circuit A input signal too low Throttle position sensor circuit A input signal too high Blink code FI warning lamp MIL 17 FI warning lamp MIL flashes 1x long 7x short Error level condition Lambda sensor cylinder 1 sensor 1 circuit fault Blink code FI warning lamp MIL 33 FI warning lamp MIL flashes 3x long ...

Page 99: ...ear 23 28 5th gear 23 23 6th gear 26 20 Alternator 12 V 196 W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Spark plug NGK LMAR9AI 10 Spark plug electrode gap 1 0 mm 0 039 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid Electric starter 23 2 Engine tightening torques Nozzle crank chamber ventilation M4 2 Nm 1 5 lbf ...

Page 100: ...7 4 lbf ft Screw timing chain tensioning rail M8 15 Nm 11 1 lbf ft Loctite 243 Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701 Plug oil channel M10x1 15 Nm 11 1 lbf ft Loctite 243 Rotor screw M10x1 70 Nm 51 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...

Page 101: ...DCC Brake system Front Disc brake with radially mounted four piston brake caliper Rear Disc brake with radially mounted dual piston brake caliper Brake discs diameter Front 260 mm 10 24 in Rear 210 mm 8 27 in Brake discs wear limit Front 2 5 mm 0 098 in Rear 3 5 mm 0 138 in Tire air pressure off road Front 0 9 bar 13 psi Rear 0 7 bar 10 psi Tire air pressure road Front 1 5 bar 22 psi Rear 1 5 bar ...

Page 102: ... available in the Service section under http www ktm com 23 7 Fork Fork part number 05 18 7N 40 fork WP Suspension 4357 MXMA Compression damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Rebound damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Spring length with preload spacer s Weight of rider 65 75 kg 143 165 lb 445 mm 17 52 in Weight of rider 75 85 kg 165 187 lb 445 mm 17...

Page 103: ...E 2 5 50180342S1 p 104 23 9 Chassis tightening torques Screw fuel pump EJOT 2 3 Nm 1 7 lbf ft Spoke nipple M4 5 5 6 Nm 3 7 4 4 lbf ft Screw battery terminal M5 2 5 Nm 1 84 lbf ft Screw intake air temperature sensor M5 2 Nm 1 5 lbf ft Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft Nut cable on starter motor M6 4 Nm 3 lbf ft Remaining nuts chassis M6 10 Nm 7 4 lbf ft Remaining screws chassis...

Page 104: ...et screw M10 60 Nm 44 3 lbf ft Nut fuel tank attachment M10 10 Nm 7 4 lbf ft Remaining nuts chassis M10 45 Nm 33 2 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw cross bar M10 45 Nm 33 2 lbf ft Screw foot brake lever M10 30 Nm 22 1 lbf ft Loctite 243 Screw footrest bracket M10 45 Nm 33 2 lbf ft Loctite 243 Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Screw upper subframe ...

Page 105: ...orrosion inhibitor antifreeze 50 distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Supplier Motorex COOLANT G48 Engine oil SAE 10W 50 According to JASO T903 MA p 107 SAE p 107 SAE 10W 50 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 Motorex products Synthetic en...

Page 106: ...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 107: ...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 108: ... 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 109: ...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 110: ...10 Clutch fluid level checking 58 fluid level correcting 58 fluid changing 59 Clutch lever 12 basic position adjusting 58 Combination instrument overview 18 Compression damping fork adjusting 35 Compression damping high speed shock absorber adjusting 31 Compression damping low speed shock absorber adjusting 30 Coolant draining 83 refilling 84 Coolant level checking 82 83 Cooling system 82 Customer...

Page 111: ...ning 91 raising with lift stand 37 removing from lift stand 37 O Oil filter changing 88 Oil screen cleaning 88 Operating substances 7 Overview of indicator lamps 14 Owner s Manual 6 P Play in the throttle cable adjusting 85 checking 85 Preparing for use advice on first use 22 after storage 93 checks and maintenance work when preparing for use 24 Protective clothing 6 R Rear sprocket checking 55 Re...

Page 112: ...s 99 chassis tightening torques 101 electrical system 100 engine 97 engine tightening torques 97 fork 100 shock absorber 101 tires 100 Throttle cable routing checking 57 Throttle grip 12 Tire air pressure checking 73 Tire condition checking 72 Transport 26 Troubleshooting 94 95 Turn signal bulb changing 79 Turn signal switch 13 Type label 10 U Use definition 5 V View of vehicle left front 8 rear r...

Page 113: ... 3213042en 3213042en 08 2013 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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