KTM Freeride 350 Owner'S Manual Download

Page: 65 / 113

BRAKES

B01093-10

–

Add brake fluid to level

Guideline

Level

(brake fluid level below con-

tainer rim)

5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 (

p. 103)

–

Position the cover with the membrane. Mount and tighten the screws.

Info

Clean up overflowed or spilt brake fluid immediately with water.

11.8

Checking the free travel of foot brake lever

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 free travel on foot brake lever according to specifications.

B01094-10

–

Disconnect spring

–

Move the foot brake lever back and forth between the end stop and the contact to
the foot brake cylinder piston and check free travel

Guideline

Free travel at foot brake lever

3… 5 mm (0.12… 0.2 in)

» If the free travel does not meet specifications:

–

Adjust the basic position of the foot brake lever.

(

p. 63)

–

Reconnect spring

11.9

Adjusting the basic position of the foot brake lever

Warning

Danger of accidents

Brake system failure.

–

B01095-10

–

Disconnect spring

–

Loosen nut

and, with push rod

, turn it back until you have maximum free

travel.

–

To adjust the basic position of the foot brake lever individually, loosen nut

and

turn screw

accordingly.

Info

The range of adjustment is limited.

–

Turn push rod

accordingly until you have free travel

. If necessary, adjust the

basic position of the foot brake lever.
Guideline

Free travel at foot brake lever

3… 5 mm (0.12… 0.2 in)

–

Hold screw

and tighten nut

Guideline

Nut, foot brake lever stop

20 Nm
(14.8 lbf ft)

–

Hold push rod

and tighten nut

Guideline

Remaining nuts, chassis

10 Nm (7.4 lbf ft)

–

Reconnect spring

Summary of Contents for Freeride 350

Page 1: ...OWNER S MANUAL 2012 Freeride 350 Art no 3211720en...

Page 2: ......

Page 3: ...ical 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 o...

Page 4: ...30 Adjusting the low speed compression damping of the shock absorber 30 Adjusting the high speed compression damping of the shock absorber 31 Adjusting the rebound damping of the shock absorber 31 Me...

Page 5: ...Recharging the battery x 73 Changing the main fuse 74 Changing the fuses of individual power consumers 74 Removing the headlight mask with the headlight 76 Refitting the headlight mask with the headli...

Page 6: ...tanding In the interest of your own safety have these jobs performed by an authorized KTM workshop There your motorcycle will be ser viced optimally by specially trained experts using the specialist t...

Page 7: ...ions and or alterations to the vehicle Fuel oils etc You should use the fuels oils and greases according to specifications as listed in the owner s manual Spare parts accessories For your own safety o...

Page 8: ...a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken Warning Identifies a danger that is likely to lead to fatal or seriou...

Page 9: ...CLE 7 3 1 View of vehicle front left example B01011 10 1 Filler cap 2 Seat 3 Seat release 4 Shock absorber compression adjustment 5 Shock absorber rebound adjustment 6 Side stand p 20 7 Battery 8 Shif...

Page 10: ...ll switch p 11 1 Horn button p 11 1 Light switch p 12 1 Turn signal switch p 12 2 Electric starter button p 12 3 Throttle grip p 11 4 Hand brake lever p 11 5 Fork rebound adjustment 6 Fork compression...

Page 11: ...1 is fixed to the frame at the front right 4 3 Key number 500125 10 The key number 1 for the steering lock is stamped onto the key connector 4 4 Engine number B01006 10 The engine number 1 is stamped...

Page 12: ...SERIAL NUMBERS 10 4 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 13: ...he right side of the handlebar 5 4 Kill switch B01015 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 i...

Page 14: ...central position Turn signal light left on Turn signal switch is turned to the left Turn signal light right on Turn signal switch is turned to the right 5 8 Electric starter button B01017 10 Electric...

Page 15: ...ce of the 21 front wheel with a series production tire The display then changes to the last selected mode 5 12 Tripmaster switch You can use the trip master switch to control the functions of the spee...

Page 16: ...e automatically saved and the Setup menu is closed 5 15 Adjusting the speedometer functions Info When the vehicle is delivered only the SPEED H and SPEED ODO display modes are activated Condition The...

Page 17: ...ph Info Making the setting according to the country When an impulse comes from the front wheel the left side of the speedometer display changes to the SPEED mode and the current speed is shown 5 18 Di...

Page 18: ...next lap Press the button for 3 5 seconds The stop watch and the lap time are reset Press the button briefly Next display mode 5 21 Display mode SPEED ODO odometer 400317 01 Press the button briefly...

Page 19: ...peatedly until A1 appears at the top right of the display A1 average speed 1 shows the average speed calculated on the basis of TR1 trip mas ter 1 and S1 stop watch 1 The calculation of this value is...

Page 20: ...erating hours No function No function The display changes to the Setup menu of the speedometer functions Next display mode Display mode SPEED CLK clock No function No function The display changes to t...

Page 21: ...uel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immedi ately with water and contact a doctor Wash...

Page 22: ...ng screw is pulled out all the way RPM increase deactivated Idle speed adjusting screw is pushed in all the way 5 31 Shift lever B01023 11 Shift lever 1 is mounted on the left side of the engine B0102...

Page 23: ...mage 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 t...

Page 24: ...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...

Page 25: ...17 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 6 2 Running in the engine During the running in phase do not exceed the...

Page 26: ...ttings of all controls and ensure that they can be operated smoothly Check all screws nuts and hose clamps regularly for tightness Check the fuel supply 7 2 Starting Danger Danger of poisoning Exhaust...

Page 27: ...an handle abrupt throttle 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 slow...

Page 28: ...ch while the engine is idling until the engine stops Park the motorcycle on firm ground 7 7 Refueling Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning c...

Page 29: ...Fill the fuel tank with fuel up to measurement A Guideline Measurement of A 30 mm 1 18 in Total fuel tank capacity approx 4 8 l 1 27 US gal Super unleaded ROZ 95 RON 95 PON 91 p 104 Subsequent work Cl...

Page 30: ...r smooth operation x Check the fluid level of the hydraulic clutch p 56 Check the brake fluid level of the front brake p 60 Check the free travel of the hand brake lever p 59 Check the steering head b...

Page 31: ...n 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 cran...

Page 32: ...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...

Page 33: ...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 clo...

Page 34: ...n A Follow up work Remove the motorcycle from the lift stand p 37 9 7 Checking the static sag of the shock absorber 400989 10 Measure distance A of rear wheel unloaded p 32 Hold the motorcycle upright...

Page 35: ...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 s...

Page 36: ...n be compensated by changing the spring preload Subsequent work Install the shock absorber x p 43 Lock the seat p 45 Remove the motorcycle from the lift stand p 37 Check the static sag of the shock ab...

Page 37: ...termines 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...

Page 38: ...achments 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 th...

Page 39: ...vehicle on a firm and even surface B01025 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 motorc...

Page 40: ...back into their normal position Remove excess oil Follow up work Remove the motorcycle from the lift stand p 37 10 5 Removing the fork legs x Preliminary work Remove the headlight mask with the headl...

Page 41: ...rness and clamp Mount and tighten screws 6 Subsequent work Install the front wheel x p 68 Refit the headlight mask with the headlight p 76 Check the headlight setting p 78 10 7 Removing the fork prote...

Page 42: ...tor and detach the wiring harness Loosen screw 1 Remove screw 2 take off the upper triple clamp with the handlebar and set it aside Info Protect the motorcycle and its attachments against damage by co...

Page 43: ...p edge of the upper triple clamp Position bleeder screws 5 toward the front B01054 12 Tighten screws 6 Guideline Screw bottom triple clamp M8 18 Nm 13 3 lbf ft B01106 10 Tighten screw 4 Guideline Scre...

Page 44: ...orized KTM workshop will be glad to help Info If the bike is ridden with play in the steering head bearing the bearing and the bearing seats in the frame can become dam aged over time Preliminary work...

Page 45: ...ower triple clamp x p 40 Install the lower triple clamp x p 40 10 14 Removing the shock absorber x Preliminary work Raise the motorcycle with the lift stand p 37 Fold the seat up p 44 B01053 10 Main w...

Page 46: ...Lock the seat p 45 Remove the motorcycle from the lift stand p 37 10 16 Removing the front fender B01030 10 Remove screws 1 Remove the front fender Ensure that the spacers remain in place 10 17 Insta...

Page 47: ...re filter is incorrectly mounted or not mounted at all the air fuel mixture will be different This has a negative effect on the service life of the engine Make sure the pre filter is seated correctly...

Page 48: ...quent work Install the air filter housing x p 45 Lock the seat p 45 10 24 Cleaning the air filter and air filter housing x Warning Environmental hazard Hazardous substances cause environmental damage...

Page 49: ...silencer 10 26 Installing the main silencer B01066 10 Position the main silencer Mount and tighten screws 1 Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft Attach springs 2 Plug in the lambda...

Page 50: ...hen warm and can escape if the tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do...

Page 51: ...ilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See the notes on refueling Warning Danger of p...

Page 52: ...unt the fuel tank breather B01079 10 Thoroughly clean the plug in connection of the fuel line using compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel lin...

Page 53: ...caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bear ings in transmission and rear wheel are under a...

Page 54: ...ideline Chain tension 36 40 mm 1 42 1 57 in Turn adjusting screws 3 on the left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference...

Page 55: ...also be changed New chains wear out faster on old worn sprockets B01069 10 Check the chain sliding guard for wear If the bottom edge of the chain bolt is in line with or below the chain sliding guard...

Page 56: ...stand p 37 10 35 Adjusting the chain guide x B01071 10 Remove the nut of screw 1 Remove screws 1 and 2 Take off the chain guide Condition Number of teeth 44 teeth Insert nut 3 in hole A Position the...

Page 57: ...rmation If the swingarm shows signs of damage cracking or deformation Change the swingarm x Info A damaged swingarm must always be changed Repair of the swingarm is not authorized by KTM 10 38 Checkin...

Page 58: ...clutch lever B01073 10 Adjust the basic position of the clutch lever to your hand size by turning adjusting screw 1 Info Turn the adjusting screw clockwise to increase the distance between the clutch...

Page 59: ...rease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations B01082 11 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Re...

Page 60: ...alling 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...

Page 61: ...way 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...

Page 62: ...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 63: ...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 64: ...ackwards 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 B01092 10 Remove cotter pin 5 Remove bolt 6 Ta...

Page 65: ...eet specifications Adjust the basic position of the foot brake lever x p 63 Reconnect spring 1 11 9 Adjusting the basic position of the foot brake lever x Warning Danger of accidents Brake system fail...

Page 66: ...rake linings 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...

Page 67: ...ge the rear brake linings x p 65 11 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...

Page 68: ...ke 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 onl...

Page 69: ...S 67 B01097 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...

Page 70: ...ficiency 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 we...

Page 71: ...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 no...

Page 72: ...n 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...

Page 73: ...the tire pressure does not meet specifications Correct the tire pressure Mount the dust cap 12 7 Checking the spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension...

Page 74: ...ontact 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 neg...

Page 75: ...e 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 ser...

Page 76: ...in 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 m...

Page 77: ...ed Fuses res 10 A spare fuses Info A defective fuse is indicated by a burned out fuse wire A Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with...

Page 78: ...rness 1 Release rubber band 2 Slide the headlight mask up and swing it forward B01136 10 Pull bulb socket 3 out of the high beam indicator lamp Disconnect the connectors of the turn signals and headli...

Page 79: ...e headlight mask with the headlight p 76 B01113 10 Main work Turn rubber cap 1 together with the underlying bulb socket counterclockwise all the way and remove it Pull bulb socket 2 of the parking lig...

Page 80: ...ight range Preliminary work Check the headlight setting p 78 B01043 10 Main work Adjust the beam distance of the headlight by turning screw 1 Guideline For a motorcycle with rider the light dark bound...

Page 81: ...on on the speedometer The speedometer is activated Position the speedometer in the bracket Mount and tighten the screws with washers Follow up work Refit the headlight mask with the headlight p 76 Che...

Page 82: ...d 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 Avoid contact between coolant and skin eyes...

Page 83: ...l 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 14 4 Draining the coolant x Warning Danger of...

Page 84: ...ely with soap and water If coolant is swallowed contact a doctor immedi ately Change clothes that have come into contact with coolants Keep coolant out of the reach of children B01116 10 Make sure tha...

Page 85: ...djust the play in the throttle cable x p 83 15 2 Adjusting the play in the throttle cable x Preliminary work Fold the seat up p 44 Remove the fuel tank x p 48 Check the throttle cable routing p 55 B01...

Page 86: ...he basic position of the shift lever x p 84 15 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...

Page 87: ...o 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 S...

Page 88: ...cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Drain the engine oil only when the engine is warm Preliminary work Park the motorcycle on a level surface R...

Page 89: ...r 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...

Page 90: ...ifferent 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 poisonous and inhaling them may r...

Page 91: ...normal motorcycle cleaner and then clean with a paintbrush Motorcycle cleaner p 105 Info Use warm water containing normal motorcycle cleaner and a soft sponge After rinsing the motorcycle with a gentl...

Page 92: ...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...

Page 93: ...cycle p 89 Change the engine oil and oil filter clean the oil screen x p 86 Check the antifreeze and coolant level p 80 Drain the fuel from the tank into a suitable container Check the tire air pressu...

Page 94: ...el 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 Eng...

Page 95: ...ne oil and oil filter clean the oil screen x p 86 Piston and cylinder worn Piston cylinder determine the mounting clear ance x Battery is discharged Battery is not being charged by alter nator Check t...

Page 96: ...level condition Throttle position sensor circuit A input signal too low Throttle position sensor circuit A input signal too high Blink code of FI warning lamp MIL 33 FI warning lamp MIL flashes 3x lon...

Page 97: ...ston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with two Eaton pumps Primary transmission 24 73 Clutch Multidisc clutch in oil bath hydraulically a...

Page 98: ...M6 10 Nm 7 4 lbf ft Screw engine case M6 10 Nm 7 4 lbf ft Screw exhaust flange M6 10 Nm 7 4 lbf ft Loctite 243 Screw oil filter cover M6 10 Nm 7 4 lbf ft Screw shift drum locating M6 10 Nm 7 4 lbf ft...

Page 99: ...magnet M12x1 5 20 Nm 14 8 lbf ft Plug oil pressure regulator valve M12x1 5 20 Nm 14 8 lbf ft Oil drain plug M14x1 5 15 Nm 11 1 lbf ft Nut inner clutch hub M18x1 5 100 Nm 73 8 lbf ft Loctite 243 Nut p...

Page 100: ...condary ratio 11 48 Chain 5 8 x 1 4 X ring Rear sprockets available 46 48 50 Steering head angle 67 Wheelbase 1 428 10 mm 56 22 0 39 in Ground clearance unloaded 325 mm 12 8 in Seat height unloaded 89...

Page 101: ...Dunlop D 803 F 4 00 R 18 M C 64M TL Dunlop D 803 Additional information is available in the Service section under http www ktm com 23 3 Capacity fuel Total fuel tank capacity approx 4 8 l 1 27 US gal...

Page 102: ...f rider 65 75 kg 143 165 lb 445 mm 17 52 in Weight of rider 75 85 kg 165 187 lb 445 mm 17 52 in Weight of rider 85 95 kg 187 209 lb 445 mm 17 52 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 4...

Page 103: ...20 clicks Standard 15 clicks Sport 10 clicks Spring preload Comfort 10 mm 0 39 in Standard 10 mm 0 39 in Sport 10 mm 0 39 in Spring rate Weight of rider 65 75 kg 143 165 lb 58 N mm 331 lb in Weight o...

Page 104: ...ake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw fuel tank M8 15 Nm 11 1 lbf ft Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw side stand attachment M8 35 Nm 25 8 lbf ft Loctite 243 Screw subframe...

Page 105: ...rosion 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 G...

Page 106: ...ng to SAE p 107 SAE 2 5 Guideline 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...

Page 107: ...roducts Supplier Motorex Protect Shine High viscosity grease Guideline KTM recommends SKF products Supplier SKF LGHB 2 Long life grease Guideline KTM recommends Motorex products Supplier Motorex Bike...

Page 108: ...es 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 spra...

Page 109: ...ce intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated wi...

Page 110: ...fluid changing 57 Clutch lever 11 basic position adjusting 56 Compression damping fork adjusting 34 Compression damping high speed shock absorber adjusting 31 Compression damping low speed shock abso...

Page 111: ...amps 12 Owner s manual 6 P Play in the throttle cable checking 83 Play in throttle cable adjusting 83 Preparing for use advice on first use 22 after storage 91 checks and maintenance work when prepari...

Page 112: ...100 shock absorber 101 Throttle cable routing checking 55 Throttle grip 11 Tire air pressure checking 71 Tire condition checking 70 Transport 5 Troubleshooting 92 93 Turn signal switch 12 Type label...

Page 113: ...3211720en 3211720en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 03 2012 Photo Mitterbauer...

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KTM Freeride 350, Owner'S Manual

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