KTM Freeride 350 AU Owner'S Manual Download

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AUXILIARY SUBSTANCES

107

Universal oil spray

Recommended supplier
Motorex

–

Joker 440 Synthetic

Summary of Contents for Freeride 350 AU

Page 1: ...OWNER S MANUAL 2016 Freeride 350 EU Freeride 350 AU Art no 3213340en...

Page 2: ......

Page 3: ...specifications 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 p...

Page 4: ...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 Tr...

Page 5: ...70 14 3 Removing the rear wheel 71 14 4 Installing the rear wheel 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...

Page 6: ...your motorcycle will be opti mally cared for by specially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page Indicates i...

Page 7: ...us injury if the appropriate measures are not taken Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken Note Indicates a danger that will lead to consi...

Page 8: ...ut 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 mus...

Page 9: ...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 se...

Page 10: ...M00465 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...

Page 11: ...ill 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 compressio...

Page 12: ...el is mounted on the frame at the front right 5 3 Key number 402247 10 The key number for the steering lock is stamped onto the key connector 5 4 Engine number 401949 10 The engine number is stamped o...

Page 13: ...5 SERIAL NUMBERS 11 5 6 Shock absorber article number 0 0 1 1 401948 10 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring towards the engine side...

Page 14: ...the right side of the handlebar 6 4 Kill switch M00468 10 Kill switch is fitted on the left side of the handlebar Possible states Kill switch in basic position In this position the ignition circuit i...

Page 15: ...rgency OFF switch Freeride 350 AU 602794 11 The emergency OFF switch is fitted on the right side of the handlebar Possible states Ignition off In this position the ignition circuit is interrupted a ru...

Page 16: ...nger 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 wate...

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 401950 10 Shift lever is mount...

Page 18: ...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 fi...

Page 19: ...ocking the steering 400731 01 Insert the key in the steering lock p 16 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 20: ...he 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 stat...

Page 21: ...ice 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...

Page 22: ...vancing 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 displa...

Page 23: ...nce 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 t...

Page 24: ...g 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 vehicl...

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...

Page 26: ...ure 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...

Page 27: ...n 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 expe...

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 th...

Page 29: ...el 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 fu...

Page 30: ...nd hand lever chain and check for smooth operation 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...

Page 31: ...absorber Change the spark plug and spark plug connector Change the piston Check measure the cylinder Check the cylinder head Change the valves valve springs and valve spring seats Check the camshaft...

Page 32: ...of the rear wheel suspension and not to the vehicle speed The high speed setting for example has an effect on the landing after a jump the rear wheel suspension compresses more quickly The low speed...

Page 33: ...t loosen nut Turn 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 cl...

Page 34: ...value as dimension 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 of rear wheel unloaded p 32 Hold the moto...

Page 35: ...an 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 m...

Page 36: ...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 p 44 Lock the seat p 45 Rem...

Page 37: ...cks Standard 20 clicks Sport 15 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing Mount protection covers 11 13 Adjusting the rebound damping of the fork Info The...

Page 38: ...bar can break Always replace handle bar M01029 11 Remove screws Remove the handlebar clamps Take off the handlebar and lay it to one side Info Cover the components to protect them against damage Do no...

Page 39: ...mage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 401943 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle...

Page 40: ...them with brake cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray p 107 Press the dust boots back into their normal position Remove excess o...

Page 41: ...8 18 Nm 13 3 lbf ft M00477 10 Position the brake caliper Mount and tighten screws with the spacers Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Connect the plug in connector an...

Page 42: ...paratory work Remove the headlight mask with the headlight p 78 Raise the motorcycle with the lift stand p 37 Remove the front wheel p 70 Remove the fork legs p 38 Remove the front fender p 44 M00481...

Page 43: ...rotective ring and O ring S00836 10 Position the upper triple clamp with the steering Mount screw but do not tighten yet Position the clutch line and wiring harness 602804 10 Position the fork legs Bl...

Page 44: ...Mount and tighten screws Finishing work Install the front fender p 44 Install the front wheel p 70 Refit the headlight mask with the headlight p 78 Check that the wiring harness cables and brake and...

Page 45: ...required Finishing work Remove the motorcycle from the lift stand p 37 12 12 Adjusting the play of the steering head bearing Preparatory work Raise the motorcycle with the lift stand p 37 S00839 10 Ma...

Page 46: ...blocking the rear wheel Fix the rear wheel in this position Remove screw Push splash protector to the side and remove the shock absorber 12 17 Installing the shock absorber M00502 11 Main work Push s...

Page 47: ...e seat and fold it up 12 19 Locking the seat M00498 01 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 s...

Page 48: ...tighten screws Guideline Screw for spoiler front EJOT PT K60x30 Z 3 Nm 2 2 lbf ft Repeat the operation on the opposite side Finishing work Lock the seat p 45 12 22 Removing the air filter housing Not...

Page 49: ...Unfiltered intake air has a negative effect on the service life of the engine Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to increased wear Warning...

Page 50: ...45 Remove the air filter housing p 46 Remove the air filter p 47 B01065 01 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 106 In...

Page 51: ...40 10 Install the right main silencer Position the main silencer Mount screws but do not tighten yet Attach springs Tighten screws Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft M00538 11 Plu...

Page 52: ...Position the connection cap Mount and tighten screws Guideline Screws on the main silencer M5 7 Nm 5 2 lbf ft Finishing work Install the main silencer p 49 12 30 Removing the fuel tank Danger Fire ha...

Page 53: ...0 Unplug connector Pull off engine breather hose B01077 10 Release hose clamp Detach the intake flange from the throttle valve body M00511 10 Pull up the fuel tank slightly and disconnect the connecto...

Page 54: ...mp B01077 11 Position the fuel tank Position the intake flange on the throttle valve body Tighten hose clamp M00510 11 Plug in connector Position engine breather hose M00509 11 Mount and tighten screw...

Page 55: ...s largely on its maintenance Preparatory work Raise the motorcycle with the lift stand p 37 400725 01 Main work Clean the chain regularly and then treat with chain spray Chain cleaner p 106 Off road c...

Page 56: ...n to break in extreme cases If the chain is too loose however it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine Ensure that the chain tension is correc...

Page 57: ...ain links in the lower chain section Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance at the longest chain section 272 mm 10 71 in...

Page 58: ...nt of the chain guide If the light part of the chain guide is worn Change the chain guide B01713 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the fitting on the c...

Page 59: ...e fuel tank p 50 M00516 01 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...

Page 60: ...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 incr...

Page 61: ...er with membrane M00519 10 Fill bleeding syringe with the appropriate hydraulic fluid Bleed syringe 50329050000 Brake fluid DOT 4 DOT 5 1 p 104 On the clutch slave cylinder remove bleeder screw and mo...

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 but do not tighten yet Position the engine guard on the frame at the rear and...

Page 63: ...moves away from the handlebar When the adjusting screw is turned counterclockwise the free travel increases The pressure point moves towards the handlebar The range of adjustment is limited Turn the a...

Page 64: ...e 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...

Page 65: ...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...

Page 66: ...efully pull the brake caliper 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 Remov...

Page 67: ...5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the basic position of the foot brake lever p 65 Reconnect spring 13 9 Adjusting the basic position of the foot brake lever Warni...

Page 68: ...aking 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 cau...

Page 69: ...le Change the rear brake linings p 67 13 13 Changing the rear brake linings Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Your authori...

Page 70: ...ever use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid att...

Page 71: ...SYSTEM 69 B01692 10 Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 104 Position the cover with the membrane Mount and tighten screws Info Clean up overflowed or spilt brake fluid immediately wi...

Page 72: ...er 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 M00490 11 Check t...

Page 73: ...age Holding the rear wheel 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...

Page 74: ...tire condition 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...

Page 75: ...psi 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 spok...

Page 76: ...witch off all power consumers and switch off the engine Remove screw Remove fastening plate B01103 10 Remove the battery from the battery compartment Disconnect negative cable from the battery Pull ba...

Page 77: ...stipulated in applicable regulations Info Even when there is no load on the battery it discharges steadily The charge state and the type of charge are very important for the service life of the batter...

Page 78: ...behind the battery Preparatory work Switch off all power consumers and switch off the engine Raise the motorcycle with the lift stand p 37 Fold the seat up p 45 Remove the shock absorber p 44 M00525...

Page 79: ...ctor Fuse 2 10 A EFI control unit fuel pump Fuse 3 10 A high beam low beam parking light tail light license plate lamp Fuse 4 10 A horn turn signal brake light radiator fan Fuses res 10 A spare fuses...

Page 80: ...ke line and wiring harness Release rubber band Slide the headlight mask up and swing it forward 602812 10 Disconnect the plug in connectors for the turn signals and for the head light 15 7 Refitting t...

Page 81: ...the headlight mask with the headlight p 78 602813 10 Main work Turn rubber cap together with the underlying bulb socket counterclockwise all the way and remove it Pull bulb socket of the parking ligh...

Page 82: ...nge cap Position the diffuser Insert the screw and first turn it counterclockwise until it engages in the thread Tighten the screw slightly Finishing work Check that the turn signal system is function...

Page 83: ...mask with the headlight p 78 602815 10 Main work Remove screws Pull the speedometer upward out of the holder 602816 10 Using a coin turn protection cap all the way counterclockwise and remove it Remo...

Page 84: ...t Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come...

Page 85: ...s 10 mm 0 39 in If the coolant level does not meet specifications Correct the coolant level Coolant p 104 Mount the radiator cap 16 4 Draining the coolant Warning Danger of scalding During motorcycle...

Page 86: ...contaminated areas on the skin with soap and water If fuel is swal lowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children M00531...

Page 87: ...and 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 rang...

Page 88: ...ll be subject to an excessive load 400692 10 Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the shift lever Distance between shift lever and u...

Page 89: ...17 TUNING THE ENGINE 87 Mount and tighten screw with the washers Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243...

Page 90: ...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 f...

Page 91: ...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 appli...

Page 92: ...er housing to about 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 the oil filter cover Mount and tighten the screws Gu...

Page 93: ...4 Engine oil SAE 10W 60 00062010035 p 104 Info In order to achieve optimal engine performance it is not advisable to mix different engine oils We recommended changing the engine oil when necessary Ins...

Page 94: ...cle cleaner and then clean with a paintbrush Motorcycle cleaner p 106 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry vehicle alway...

Page 95: ...rake system 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 t...

Page 96: ...fore taking the motorcycle out of service add fuel additive Fuel additive p 106 Refuel p 27 Clean the motorcycle p 92 Change the engine oil and oil filter clean the oil screen p 89 Check the antifreez...

Page 97: ...cal system Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM di...

Page 98: ...he engine oil and oil filter clean the oil screen p 89 Piston or cylinder worn Measure the piston cylinder mounting clear ance Battery is discharged Battery is not being charged by alter nator Check t...

Page 99: ...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 warnin...

Page 100: ...r 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...

Page 101: ...location M8 10 Nm 7 4 lbf ft Screw timing chain tensioning rail M8 15 Nm 11 1 lbf ft Loctite 243 Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701 Plug oil channel M10x1 15 Nm 11 1 lbf ft Locti...

Page 102: ...ystem 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 Br...

Page 103: ...ilable in the Service section under http www ktm com 23 7 Fork Fork part number 05 18 7N 40 Fork WP Performance Systems 4357 MXMA Compression damping Comfort 25 clicks Standard 20 clicks Sport 15 clic...

Page 104: ...p 105 23 9 Chassis tightening torques Screw for spoiler front EJOT PT K60x30 Z 3 Nm 2 2 lbf ft Screw for spoiler top EJOT PT K60x20AL 3 Nm 2 2 lbf ft Screw pressure regulator EJOT PT K60x25 Z 3 Nm 2...

Page 105: ...g stem M8 17 Nm 12 5 lbf ft Loctite 243 Screw top triple clamp M8 22 Nm 16 2 lbf ft Engine bracket screw M10 60 Nm 44 3 lbf ft Nut fuel tank attachment M10 10 Nm 7 4 lbf ft Remaining nuts chassis M10...

Page 106: ...Engine oil SAE 10W 50 Standard classification JASO T903 MA p 108 SAE p 108 SAE 10W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and t...

Page 107: ...nd that exhibit the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equiv...

Page 108: ...ecommended supplier SKF LGHB 2 Long life grease Recommended supplier Motorex Bike Grease 2000 Motorcycle cleaner Recommended supplier Motorex Moto Clean Off road chain spray Recommended supplier Motor...

Page 109: ...25 AUXILIARY SUBSTANCES 107 Universal oil spray Recommended supplier Motorex Joker 440 Synthetic...

Page 110: ...vice 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 wi...

Page 111: ...27 LIST OF ABBREVIATIONS 109 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 112: ...ymbols FI warning lamp MIL lights up flashes orange The OBD has detected an emission or safety critical fault The fuel level warning lamp lights up orange The fuel level has reached the reserve mark 2...

Page 113: ...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 Compr...

Page 114: ...g 92 raising with lift stand 37 removing from the lift stand 37 O Oil filter changing 89 Oil screen cleaning 89 Operating substances 7 Overview of indicator lamps 14 Owner s Manual 6 P Play in the thr...

Page 115: ...100 chassis tightening torques 102 electrical system 101 engine 98 engine tightening torques 98 fork 101 shock absorber 102 tires 101 Throttle cable routing checking 57 Throttle grip 12 Tire air pres...

Page 116: ...3213340en 3213340en 04 2015 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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KTM Freeride 350 AU, Owner'S Manual

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