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STANDARDS

99

JASO T903 MA

Different technical development directions required a new specification for 4-stroke motorcycles

–

the JASO T903 MA Standard. Ear-

lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi-
cation. Whereas long service 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 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 according to their vis-
cosity. The viscosity describes only one property of oil and says nothing about quality.

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Содержание 350 SC-F

Страница 1: ...OWNER S MANUAL 2012 350 SX F EU 350 SX F CAIROLI REPLICA EU 350 SX F USA 350 XC F USA Art no 3211814en ...

Страница 2: ......

Страница 3: ... 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 partly contain spe cial eq...

Страница 4: ...ing of the fork 29 Adjusting the rebound damping of the fork 30 Handlebar position 30 Adjusting the handlebar position x 30 Activating the Factory Start SX F CAIROLI REPLICA 31 SERVICE WORK ON THE CHASSIS 32 Raising the motorcycle with the lift stand 32 Removing the motorcycle from the lift stand 32 Bleeding the fork legs 32 Cleaning the dust boots of the fork legs 33 Loosening the fork protection...

Страница 5: ...el 70 Checking the coolant level 70 Draining the coolant x 71 Refilling coolant x 71 TUNING THE ENGINE 73 Checking the play in the throttle cable 73 Adjusting the play in the throttle cable x 73 Adjusting the idle speed x 73 Checking the basic position of the shift lever 74 Adjusting the basic position of the shift lever x 74 SERVICE WORK ON THE ENGINE 75 Changing the fuel screen x 75 Checking the...

Страница 6: ...standing 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 tools required Indicates a page reference more information is provided on the specified page Formats used The typographical formats used in this document are explained below Specific name Identifies a...

Страница 7: ...ions as listed in the owner s manual Spare parts accessories For your own safety only use spare parts and accessory products that are approved and or recommended by KTM and have them installed by an authorized KTM workshop KTM accepts no liability for other products and any resulting damage or loss Certain spare parts and accessory products are specified in parentheses in the descriptions Your KTM...

Страница 8: ... serious permanent injury if the appropriate measures are not taken Warning Identifies a danger that is likely to lead to fatal or serious 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 measure...

Страница 9: ...3 1 View of vehicle front left example 101273 10 1 Hand brake lever p 10 2 Clutch lever p 10 3 Filler cap 4 Plug in stand p 13 5 Air filter box lid 6 Engine number p 9 7 Shift lever p 12 8 Idle speed adjusting screw p 12 ...

Страница 10: ... 1 Kill switch p 10 2 Electric starter button p 10 3 Fork compression adjustment 4 Fork rebound adjustment 5 Foot brake lever p 13 6 Level viewer engine oil 7 Shock absorber compression adjustment 8 Level viewer for brake fluid rear 9 Shock absorber rebound adjustment ...

Страница 11: ...teering head 4 3 Engine number B00263 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket 4 4 Fork part number B00265 01 The fork part number 1 is stamped on the inner side of the axle clamp 4 5 Shock absorber part number B00264 10 The shock absorber part number 1 is stamped on the top of the shock absorber above the adjusting ring on the engine side ...

Страница 12: ...lebar 5 4 Kill switch B00373 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 5 5 Electric starter button B00374 10 Electric st...

Страница 13: ...isoning Fuel 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 affected skin areas immediately with soap and water If fuel is swallowed con tact a doctor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister ...

Страница 14: ...this point on the fork operates as if the Factory Start were deacti vated or not installed 5 10 Idle speed adjusting screw 401096 10 Idle speed adjusting screw 1 is located on the throttle valve body at the top left The idle speed adjusting screw has two functions Turning it controls the idle speed Pulling it out all the way raises the idle speed during a cold start Possible states RPM increase ac...

Страница 15: ...old the upper part of the kick starter toward the engine 5 13 Foot brake lever B00282 10 Foot brake lever 1 is located in front of the right footrest The foot brake lever is used to activate the rear brake 5 14 Plug in stand All SX F models B00283 10 The holder for the plug in stand 1 is the left side of the wheel spindle The plug in stand is used to park the motorcycle Info Remove the plug in sta...

Страница 16: ...ice hour counter SX F CAIROLI REPLICA 101614 10 The service hour counter 1 is attached to the battery below the seat It shows the total number of service hours of the engine The service hour counter begins counting when the engine is started and stops when the engine is switched off Info The value indicated by the service hour counter cannot be cleared or adjusted ...

Страница 17: ...ake your foot off the foot brake lever when you are 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 ...

Страница 18: ... fully opening the throttle 6 3 Preparing vehicle for difficult riding conditions Info Using a motorcycle in difficult conditions can lead to excessive wear of components such as the power train or brakes For this reason it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached KTM recommends that you use the specified engine oil for difficu...

Страница 19: ...eaner p 97 Fit the steel sprocket Tip Do not grease the chain Clean radiator fins Straighten bent radiator fins carefully If used in sand regularly replace the piston every 20 operating hours 6 5 Preparing for rides on wet sand B00437 01 Fit a waterproofing device on the air filter Waterproofing device for air filter 77206921000 Info See the KTM PowerParts fitting instructions 600868 01 Clean the ...

Страница 20: ...t high temperature and slow speed 600868 01 Adjust the secondary drive to the road conditions Info The engine oil quickly gets hot if the clutch has to be operated very often due to an excessively high secondary drive Clean the chain Chain cleaner p 97 Clean radiator fins Straighten bent radiator fins carefully Check the coolant level p 70 6 8 Preparing for rides at low temperatures or in snow B00...

Страница 21: ...ly Check all screws nuts and hose clamps regularly for tightness Check the fuel supply 7 2 Starting Danger Danger of poisoning Exhaust gases are poisonous 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 exhaust extraction system Note Eng...

Страница 22: ...ing for a long time Guideline 1 min Avoid frequent and longer slipping of the clutch This heats the engine oil the engine and the cooling system Ride with a lower engine speed instead of with a high engine speed and a slipping clutch 7 5 Applying the brakes Warning Danger of accidents If you brake too hard the wheels can lock Adapt your braking to the traffic situation and the road conditions Warn...

Страница 23: ...el with skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse imme diately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doctor immediately Change clothing that has come into contact with fuel Note Material damage Premature clogging of the fuel filter In some countries and regions the available f...

Страница 24: ...he free travel of the hand brake lever p 54 Check the steering head bearing play p 37 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 75 Check the fuel pressure x Check all hoses e g fuel cooling bleeding drainage and sleeves for tearing leaks and incorrect routing x Check the antifreeze and coolant level p 70 Check the cabl...

Страница 25: ...e 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 Change the suction oil pump x Check the oil pumps and lubrication system x Replace the timing chain x Check the timing assembly x Change all engine bearings x S20N Once after 20 operating hours corresponds to about 140 liters of f...

Страница 26: ...low speed refer to the compression speed 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 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 separate...

Страница 27: ...filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help Info The high speed setting can be seen during the fast compression of the shock absorber B00289 10 Turn adjusting screw 1 all the way clockwise with a socket wrench Info Do not loosen nut 2 Turn back counterclockwise by the number of turns corresponding to the shock absorber type...

Страница 28: ...r type Guideline Rebound damping All SX F EU models Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping SX F USA Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping XC F Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 9 6 Measuring rear wheel sag unloaded Preliminary work Raise t...

Страница 29: ...tting position feet on footrests and bounces up and down a few times The rear wheel suspension levels out Another person now measures the distance between the rear axle and a fixed point Note down the value as dimension C Info The riding sag is the difference between measurements A and C Check the riding sag Riding sag All SX F EU models 90 mm 3 54 in Riding sag SX F USA 100 mm 3 94 in Riding sag ...

Страница 30: ...43 Remove the motorcycle from the lift stand p 32 9 10 Adjusting the riding sag x Preliminary work Raise the motorcycle with the lift stand p 32 Remove the main silencer p 43 Remove the shock absorber x p 39 After removing the shock absorber clean it thoroughly B00292 10 Main work Choose and mount a suitable spring Guideline Spring rate All SX F EU models Weight of rider 65 75 kg 143 165 lb 51 N m...

Страница 31: ... compression harder springs must be fit to avoid damage to the fork and frame 9 12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior 101275 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 counterclockwis...

Страница 32: ...unterclockwise to reduce damp ing Mount protection covers 1 9 14 Handlebar position 800116 10 On the upper triple clamp there are two holes at a distance of A to each other Hole distance A 15 mm 0 59 in The holes on the handlebar support are placed at a distance of B from the center Hole distance B 3 5 mm 0 138 in The handlebar can be mounted in four different positions In this way the handlebar c...

Страница 33: ...t 9 16 Activating the Factory Start SX F CAIROLI REPLICA Info In cold weather the lock button may freeze up preventing it from being released during compression 101078 10 Check lock button 1 to ensure it can move easily Bend over the handlebars while sitting on the motorcycle Grip the rim and com press the fork Press lock button 1 and decompress slowly until the lock button engages in lock ring 2 ...

Страница 34: ...dels Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle insert plug in stand 1 into the left side of the wheel spindle Info Remove the plug in stand before riding B00602 10 XC F 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 rid...

Страница 35: ... the dust boots and inner fork tube of both fork legs Universal oil spray p 98 Press the dust boots back into their normal position Remove excess oil Follow up work Position the fork protection p 33 Remove the motorcycle from the lift stand p 32 10 5 Loosening the fork protection B00298 10 Remove screws 1 and take off the clamp Remove screws 2 on the left fork leg Push the fork protection downward...

Страница 36: ...rk leg 10 8 Installing the fork legs x 101276 10 Main work Position the fork legs Info The topmost milled groove in the fork leg must be flush with the top edge of the upper triple clamp Position bleeder screws 1 toward the front B00339 11 Tighten screws 2 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 12 Nm 8 9 lbf ft B00300 11 Positi...

Страница 37: ...k leg Mount and tighten the screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Subsequent work Install the fork legs x p 34 Install the front wheel x p 62 10 11 Removing the lower triple clamp x Preliminary work Raise the motorcycle with the lift stand p 32 Remove the front wheel x p 62 Remove the fork legs x p 34 Remove the start number plate p 39 Remove the front fender p 39 Remove th...

Страница 38: ...l 1 is correctly positioned Slide on protective ring 2 and O ring 3 B00376 10 Position the upper triple clamp with the steering Mount screw 4 but do not tighten yet B00377 10 Position the fork legs Info The topmost 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 B00378 10 Fully tighten screws 6 Guideline Screw botto...

Страница 39: ...he start number plate p 39 Install the front wheel x p 62 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 37 Remove the motorcycle from the lift stand p 32 10 13 Checking the steering head bearing play Warning Danger of accidents Unstable vehicle handling from incorrect steering head bearing play Adjust...

Страница 40: ...emove the motorcycle from the lift stand p 32 10 14 Adjusting the play of the steering head bearing x Preliminary work Raise the motorcycle with the lift stand p 32 Remove the handlebar cushion 101277 10 Main work Loosen screw 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 avoi...

Страница 41: ...nder Position the brake line and clamp Mount and tighten screw 2 10 18 Removing the front fender B00307 10 Remove screws 1 Remove the front fender Ensure that the spacers remain in place 10 19 Installing the front fender B00307 10 Ensure that the spacers are mounted in the fender Position the front fender Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Info Make s...

Страница 42: ...nd remove the exhaust manifold Remove the shock absorber from the top 10 21 Installing the shock absorber x B00272 10 Main work Insert the shock absorber from above Turn the shock absorber toward the rear and position the exhaust manifold Position the shock absorber Mount and tighten screw 1 Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 B00269 11 Mount and tighten screw 2 G...

Страница 43: ...e seat at the rear pull it back and then remove it from above 10 23 Mounting the seat B00318 01 Hook in the front of the seat at the collar bushing of the fuel tank lower it at the rear and simultaneously it push forward Make sure that the seat is correctly locked in Mount and tighten the screw of the seat fixing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 10 24 Removing the air filter ...

Страница 44: ...ir filter from the air filter support 10 27 Installing the air filter x 301262 10 Main work Mount the clean air filter onto the air filter support Apply grease to the air filter around area A Long life grease p 97 B00324 10 Put in both parts together position them and fix them with air filter holder 1 Info If the air filter is not mounted correctly dust and dirt may enter the engine and cause dama...

Страница 45: ...e exhaust system to cool down Do not touch hot components 101280 10 Disconnect spring 1 Spring hooks 50305017000 Remove screws 2 and take off the main silencer 10 30 Installing the main silencer 101280 11 Position the main silencer Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Reconnect spring 2 Spring hooks 50305017000 10 31 Changing the glass fiber yarn fillin...

Страница 46: ...be 3 over the glass fiber yarn filling Insert locking cap 2 into the outer tube Position steel bands 1 and mount the rivets Follow up work Install the main silencer p 43 10 32 Removing 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 v...

Страница 47: ... tube from the fuel tank breather B00315 10 Remove screws 3 with the collar bushing B00316 10 Remove screw 4 with the rubber bushing B00319 10 Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank 10 33 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 eng...

Страница 48: ...d or damaged Mount the fuel tank breather Mount and tighten screw 1 with the rubber bushing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft B00315 11 Mount and tighten screws 2 with the collar bushing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft B00314 11 Connect the electrical plug in connection 3 Thoroughly clean the plug in connection of the fuel line using compressed air Info ...

Страница 49: ... 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 additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On the other hand if the chain is loose it can fall off the engine spr...

Страница 50: ...hain tension 55 58 mm 2 17 2 28 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 marks A The rear wheel is then correctly aligned Tighten nuts 2 Make sure that chain adjusters 4 are fitted correctly on adjusting screws 3 Tighten nut 1 Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 lbf f...

Страница 51: ... be changed New chains wear out faster on old worn sprockets B00346 01 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 Change the chain sliding guard x Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the chain sliding guard Guideline Screw chain sliding guard M6 6 Nm 4 4 lbf...

Страница 52: ...ve screw 2 Swing the chain guide down Condition Number of teeth 44 teeth Insert collar bushing 3 in hole A Position the chain guide Mount and tighten screw 2 Tighten screw 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Condition Number of teeth 45 teeth Insert collar bushing 3 in hole B Position the chain guide Mount and tighten screw 2 Tighten screw 1 Guideline Remaining screws chassis ...

Страница 53: ...the handlebars and above the tank bearing If the throttle cable is not routed as specified Correct the throttle cable routing Subsequent work Install the fuel tank x p 45 Mount the seat p 41 10 43 Checking the rubber grip 401197 01 Check the rubber grips on the handlebar for damage and wear and to ensure they are firmly seated If a rubber grip is damaged worn or loose Change and secure the rubber ...

Страница 54: ...ed on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 Check the fluid level Fluid level below container rim 4 mm 0 16 in If the fluid level does not meet specifications Correct the fluid level of the hydraulic clutch Brake fluid DOT 4 DOT 5 1 p 95 Position the cover with the membrane Mount and tighten the screws 10 47 Changing the hydraulic clutch fluid x Warn...

Страница 55: ...he hydraulic clutch Guideline Fluid level below container rim 4 mm 0 16 in Position the cover with the membrane Mount and tighten the screws 10 48 Removing the engine guard SX F CAIROLI REPLICA B00597 10 Remove screws 1 and the holding bracket Remove the engine guard 10 49 Installing the engine guard SX F CAIROLI REPLICA B00598 01 Attach the engine guard on the frame at the rear and swing up at th...

Страница 56: ...he hand brake lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 11 3 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc...

Страница 57: ...e brake system or worn out brake 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 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 thorou...

Страница 58: ...rake linings for damage and cracking If damage or cracking is visible Change the front brake linings x p 56 11 7 Changing the front 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 wit...

Страница 59: ... cover 2 with membrane 3 B00351 10 Press the brake caliper toward the brake disc to push back the brake pistons and ensure that no brake fluid runs out of the brake fluid reservoir sucking it off if it does Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes Remove the locking split pins 4 pull out the pin 5 and remove the brake linings Cle...

Страница 60: ... travel A 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 x p 58 Reconnect spring 1 11 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 ...

Страница 61: ...ke fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake 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 with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles...

Страница 62: ...ation 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 brake fluid Change the brake fluid of the...

Страница 63: ...brake caliper and sliding plate 6 in the brake caliper support are seated correctly Info The arrow on the leaf spring points in the rotation direction of the brake disc B00359 10 Insert the brake linings insert pin 4 and mount locking split pins 3 Info Make sure that the decoupling plate 7 is mounted on the piston side of the brake lining Operate the foot brake lever repeatedly until the brake lin...

Страница 64: ...hand brake lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged B00304 10 Remove spacers 3 12 2 Installing the front wheel x 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 B00304 11 Check the...

Страница 65: ... Preliminary work Raise the motorcycle with the lift stand p 32 B00340 10 Main work Press the brake caliper onto the brake disc by hand in order to push back the brake piston Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut 1 Remove chain adjuster 2 Withdraw wheel spindle 3 only enough to allow the rear wheel to be pushed forwa...

Страница 66: ...n adjusting screws 5 Check the chain tension p 47 Tighten nut 4 Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 18 in enables different secondary ratios with the same chain length Chain adjusters 3 can be turned by 180 Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there i...

Страница 67: ...and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life 400695 01 Remove the dust cap Check the tire air pressure when the tires are cold Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi If the tire pressure does not meet specifications Correct the tire pressure Mount the dust cap 12 7 Checking the spoke tension Warning ...

Страница 68: ...sion varies Correct the spoke tension x Check the spoke torque Guideline Spoke nipple front wheel M4 5 5 6 Nm 3 7 4 4 lbf ft Spoke nipple rear wheel M4 5 5 6 Nm 3 7 4 4 lbf ft Torque wrench with various accessories in set 58429094000 ...

Страница 69: ...our counter aside B00361 10 Main work Disconnect the negative minus cable 1 of the battery Pull back the positive terminal cover 2 and disconnect the positive plus cable of the battery Detach rubber band 3 at the bottom Lift the battery up and out 13 2 Installing the battery x 101394 10 Main work Insert the battery into the battery compartment with the terminals facing to the front All SX F models...

Страница 70: ...h 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 from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become...

Страница 71: ...rew 1 101088 10 Lift rear fairing 2 slightly and pull starter relay 3 out of the bracket 101089 10 Remove protection caps 4 Remove the faulty main fuse 5 Info A defective fuse can be identified by the burned out fuse wire A A reserve fuse 6 is located in the starter relay Install a new main fuse Fuse 58011109110 p 88 Check that the electrical equipment is functioning properly Tip Insert the spare ...

Страница 72: ...into contact with coolants Keep coolant out of the reach of children Condition The engine is cold 400243 10 Stand the motorcycle upright on a horizontal surface Remove the radiator cap Check antifreeze of coolant 25 45 C 13 49 F If the antifreeze of the coolant does not meet specifications Correct the antifreeze of the coolant Check the coolant level in the radiator Coolant level A above radiator ...

Страница 73: ... clothing If it gets into your eyes rinse immediately with water and con tact a doctor Wash affected skin areas immediately 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 Condition The engine is cold 302770 10 Position the motorcycle upright Place a suitable container under...

Страница 74: ... motorcycle upright Pour coolant in up to measurement A above the radiator fins Guideline Dimension A over the radiator fins 10 mm 0 39 in Coolant 0 95 l 1 qt Coolant p 95 Coolant mixed ready to use p 95 Mount the radiator cap Take a short test ride Check the coolant level p 70 ...

Страница 75: ...15 2 Adjusting the play in the throttle cable x Preliminary work Remove the seat p 41 Remove the fuel tank x p 44 Check the throttle cable routing p 51 B00599 10 Main work Move the handlebar to the straight ahead position Push back sleeves 1 Loosen nut 2 Turn adjusting screw 3 in as far as possible Loosen nut 4 Turn adjusting screw 5 so that there is play in the throttle cable at the throttle grip...

Страница 76: ...the basic position of the shift lever x p 74 15 5 Adjusting the basic position of the shift lever x B00364 10 Remove screw 1 and take off shift lever 2 B00365 10 Clean gear teeth A of the shift lever and shift shaft Mount the shift lever on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into contact with any oth...

Страница 77: ...t has come into contact with fuel Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Preliminary work Remove the seat p 41 Remove the fuel tank x p 44 101544 10 Main work Thoroughly clean the vehicle in the vicinity of the throttle valve body Release screw clamp 1 and pull off the fuel...

Страница 78: ... the engine oil is not up to the middle A of the level viewer Add engine oil p 78 16 3 Changing the engine oil and oil filter cleaning the oil screen x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous subst...

Страница 79: ...move the oil filter cover with the O ring B00332 11 Pull oil filter 6 out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing area B00333 11 Lay the motorcycle on its side and fill the oil filter housing to about full with engine oil Fill the oil filter with engine oil and place it in the oil filter housing Oil the O r...

Страница 80: ...il Info Too little engine oil or poor quality engine oil results in premature wear to the engine B00327 10 Remove the oil filler plug 1 with the O ring from the clutch cover Add the same engine oil that was used when the motor was changed Engine oil SAE 10W 50 p 95 Alternative 1 Engine oil SAE 10W 60 00062010035 p 95 Info For optimal performance of the engine oil do not mix different types of engi...

Страница 81: ...leaner and then clean with a paintbrush Motorcycle cleaner p 97 Info Use warm water containing normal motorcycle cleaner and a soft sponge After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently After cleaning ride a short dist...

Страница 82: ... p 79 Change the engine oil and oil filter clean the oil screen x p 76 Check the antifreeze and coolant level p 70 Drain the fuel from the tanks into a suitable container Check the tire air pressure p 65 Remove the battery x p 67 Charge the battery x p 68 Guideline Storage temperature of battery without direct sunlight 0 35 C 32 95 F Store the vehicle in a dry location that is not subject to large...

Страница 83: ...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 box x p 42 Fuel filter is very dirty Change the fuel filter x Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x Exhaust system leaky deformed or too little glass fiber yarn filling in main silencer Check exhaust system for damag...

Страница 84: ...onsumption Piston and cylinder worn Piston cylinder determine the mounting clear ance Battery is discharged Battery is not charging Check the charging voltage x Check the stator winding of the alternator x Unwanted power consumer Check the quiescent current x ...

Страница 85: ... low Engine coolant temperature sensor input signal too high Blink code FI warning lamp MIL 13 FI warning lamp MIL flashes 1x long 3x short Error level condition Intake air temperature sensor input signal to low Intake air temperature sensor input signal too high Blink code FI warning lamp MIL 15 FI warning lamp MIL flashes 1x long 5x short Error level condition Rollover sensor A D type input sign...

Страница 86: ... 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 activated Gearbox All SX F models 5 gear claw shifted Gearbox XC F 6 gear claw shifted Transmission ratio All SX F models 1st gear 14 28 2nd gear 16 26 3rd gear 18 24 4th gear 21 24 5th gear 22 21 Transmission rat...

Страница 87: ...ine oil 1 10 l 1 16 qt Engine oil SAE 10W 50 p 95 Alternative engine oil for harsh operating conditions and increased performance Engine oil SAE 10W 60 00062010035 p 95 21 2 Capacity coolant Coolant 0 95 l 1 qt Coolant p 95 Coolant mixed ready to use p 95 ...

Страница 88: ...e cylinder M6 10 Nm 7 4 lbf ft Screw clutch spring M6 10 Nm 7 4 lbf ft Screw cover of torque limiter 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 kick starter stop XC F 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 Loctite 243 Screw shift lever M6 14 Nm...

Страница 89: ...M12x1 80 Nm 59 lbf ft Loctite 243 cone degreased Engine coolant temperature sensor M12x1 5 12 Nm 8 9 lbf ft Oil drain plug with 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 primary gear M18LHx1 5 100 Nm 73 8 lbf ft Loctite 243 Screw plug oil scree...

Страница 90: ... 14 50 Chain 5 8 x 1 4 Rear sprockets available 38 40 42 45 48 49 50 51 52 Steering head angle 63 5 Wheelbase 1 495 10 mm 58 86 0 39 in Seat height unloaded 992 mm 39 06 in Ground clearance unloaded 375 mm 14 76 in Weight without fuel approx All SX F EU models 105 4 kg 232 4 lb Weight without fuel approx SX F USA 106 kg 234 lb Weight without fuel approx XC F 107 8 kg 237 7 lb Maximum permissible f...

Страница 91: ...2M TT Dunlop GEOMAX MX51 XC F 80 100 21 51M TT Dunlop GEOMAX MX51 110 100 18 64M TT Dunlop GEOMAX MX51 Additional information is available in the Service section under http www ktm com 23 3 Capacity fuel Total fuel tank capacity approx All SX F models 7 5 l 1 98 US gal Super unleaded ROZ 95 RON 95 PON 91 p 96 Total fuel tank capacity approx XC F 9 5 l 2 51 US gal Super unleaded ROZ 95 RON 95 PON 9...

Страница 92: ... 195 ml 6 59 fl oz Fork oil SAE 5 p 96 Oil capacity fork leg without cartridge 390 ml 13 19 fl oz Fork oil SAE 5 p 96 24 2 SX F USA Fork part number 14 18 7L 57 Fork WP Suspension Up Side Down 4860 MXMA CC Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Spring length with preload spacer s 494 mm 19 45 in ...

Страница 93: ...10 clicks Spring length with preload spacer s 492 mm 19 37 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 4 N mm 25 1 lb in Weight of rider 75 85 kg 165 187 lb 4 6 N mm 26 3 lb in Weight of rider 85 95 kg 187 209 lb 4 8 N mm 27 4 lb in Gas pressure 1 2 bar 17 psi Fork length 940 mm 37 01 in Oil capacity per cartridge 195 ml 6 59 fl oz Fork oil SAE 5 p 96 Oil capacity fork leg without cartrid...

Страница 94: ...s pressure 10 bar 145 psi Static sag 30 mm 1 18 in Riding sag 90 mm 3 54 in Fitted length 490 mm 19 29 in Shock absorber oil Shock absorber oil SAE 2 5 50180342S1 p 96 25 2 SX F USA Shock absorber part number 18 18 7L 57 Shock absorber WP Suspension 5018 BAVP DCC Compression damping low speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping high speed Comfort 2 5 turns Stan...

Страница 95: ...peed Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 12 mm 0 47 in Spring rate Weight of rider 65 75 kg 143 165 lb 51 N mm 291 lb in Weight of rider 75 85 kg 165 187 lb 54 N mm 308 lb in Weight of rider 85 95 kg 187 209 lb 57 N mm 325 lb in Spring length 260 mm 10 24 in Gas pressure 10 bar 145 psi Static sag 34 ...

Страница 96: ...m 11 1 lbf ft Screw engine brace M8 33 Nm 24 3 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw side stand attachment XC F M8 45 Nm 33 2 lbf ft Loctite 2701 Screw subframe M8 35 Nm 25 8 lbf ft Loctite 2701 Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 243 Screw top triple clamp M8 17 Nm 12...

Страница 97: ...on inhibitor antifreeze 50 distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Supplier Motorex COOLANT G48 Engine oil SAE 10W 60 00062010035 According to JASO T903 MA p 99 SAE p 99 SAE 10W 60 KTM LC4 2007 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 prod...

Страница 98: ...ng to SAE p 99 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 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...

Страница 99: ...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 Grease 2000 Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Off road chain spray Guideline KTM recommends Motorex products Supplier Motorex Chainlube Offro...

Страница 100: ...hes 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 ...

Страница 101: ...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 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 ...

Страница 102: ...ting 52 Compression damping fork adjusting 29 Compression damping high speed shock absorber adjusting 25 Compression damping low speed shock absorber adjusting 24 Coolant draining 71 refilling 71 Coolant level checking 70 Cooling system 70 D Difficult riding conditions 16 dry sand 17 high temperature 18 low temperature 18 muddy surfaces 18 slow speed 18 snow 18 wet sand 17 wet surfaces 18 E Electr...

Страница 103: ... Preparing for use advice on first use 15 after storage 80 checks and maintenance work when preparing for use 19 R Rear sprocket checking 48 Rear wheel installing 64 removing 63 Rebound damping fork adjusting 30 shock absorber adjusting 26 Refueling fuel 21 Riding sag adjusting 28 Rubber grip checking 51 securing 51 S Seat mounting 41 removing 41 Service 5 Service hour counter 14 Service schedule ...

Страница 104: ...fork 90 91 shock absorber 92 93 Throttle cable play checking 73 Throttle cable routing checking 51 Throttle grip 10 Tire air pressure checking 65 Tire condition checking 64 Transport 5 Troubleshooting 81 82 Type label 9 U Use definition 5 V View of vehicle front left side 7 rear right side 8 W Warranty 5 Work rules 5 ...

Страница 105: ... 3211814en 3211814en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 12 2011 Photo Mitterbauer ...

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