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12 SERVICE WORK ON THE CHASSIS

V01785-10

Main work

–

Pull the fuel tank breather hose out of the steering head screw.

–

Open the cable holder in front of the left radiator and detach
the wiring harness.

–

Loosen screw

–

Remove screw

–

Take off the upper triple clamp with the handlebar and set it
aside.

Info

Cover the components to protect them against damage.
Do not kink the cables and lines.

V01757-10

–

Remove O-ring

and protective ring

–

Take off the lower triple clamp with the steering stem.

–

Remove the upper steering head bearing.

12.10

Installing the lower triple clamp

B01605-10

Main work

–

Clean the bearing and sealing elements, check for damage,
and grease.

High viscosity grease (

p. 149)

–

Insert the lower triple clamp with the steering stem. Mount
upper steering head bearing.

–

Check whether upper steering head seal

is correctly posi-

tioned.

–

Slide on protective ring

and O-ring

Содержание F8275V9

Страница 1: ...OWNER S MANUAL 2022 350 EXC F Art no 3214425en...

Страница 2: ......

Страница 3: ...forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop produc tion of a particular model without prior...

Страница 4: ...button 20 6 9 Overview of indicator lamps 21 6 10 Ignition lock 21 6 11 Opening the fuel tank filler cap 21 6 12 Closing the fuel tank filler cap 22 6 13 Cold start button 22 6 14 Idle speed adjustin...

Страница 5: ...on 58 11 15 Adjusting the handlebar position 58 12 SERVICE WORK ON THE CHASSIS 60 12 1 Raising the motorcycle with the lift stand 60 12 2 Removing the motorcycle from the lift stand 60 12 3 Bleeding t...

Страница 6: ...ght mask with the headlight 114 15 8 Changing the headlight bulb 114 15 9 Checking the headlight setting 115 15 10 Adjusting the headlight range 115 15 11 Changing the turn signal bulb 116 15 12 Chang...

Страница 7: ...3 SUBSTANCES 147 24 AUXILIARY SUBSTANCES 149 25 STANDARDS 151 26 INDEX OF SPECIAL TERMS 152 27 LIST OF ABBREVIATIONS 153 28 LIST OF SYMBOLS 154 28 1 Yellow and orange symbols 154 28 2 Green and blue s...

Страница 8: ...ned experts using the auxiliary tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a t...

Страница 9: ...ety advice A number of safety instructions need to be followed to operate the product described safely Therefore read this instruction and all further instructions included carefully The safety instru...

Страница 10: ...labels A01017 10 1 Canada type label 2 USA type label 3 Brake fluid information 4 Information on chain tension 5 Information on starting up 6 Information on emissions control 7 Information on noise em...

Страница 11: ...SAFETY ADVICE 2 9 A01021 10 USA type label S00026 10 Brake fluid information 101516 01 Information on chain tension F00491 10 Information on starting up A01023 10 Information on emissions control...

Страница 12: ...www ktmusa com KTM Canada Inc Customer Support 8701 Rue Samuel Hatt Chambly QC J3L 6V4 Canada Phone 450 441 4451 www ktmcanada com 2 8 Operating noise warning This product should be checked for neces...

Страница 13: ...its the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of servicing repair or replace ment of any device or element of design incorp...

Страница 14: ...gine must be at a standstill models without ignition lock or remote key Special tools are necessary for certain tasks The tools are not a component of the vehicle but can be ordered using the number i...

Страница 15: ...hat you can read it whenever you need to If you would like to know more about the vehicle or have questions on the material you read please contact an authorized KTM dealer The Owner s Manual is an im...

Страница 16: ...4 Service A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly carried out as described in the Owner s...

Страница 17: ...VIEW OF VEHICLE 4 15 4 1 View of vehicle front left example A01018 10 1 Clutch lever p 19 2 Fuel tank filler cap 3 Air filter box cover 4 Side stand p 24 5 Engine number p 18 6 Shift lever p 23...

Страница 18: ...iew of vehicle rear right example A01019 10 1 Horn button p 19 2 Turn signal switch p 20 3 Light switch p 20 4 Start button p 20 5 Emergency OFF switch p 20 6 Throttle grip p 19 7 Hand brake lever p 1...

Страница 19: ...2 Type label M00994 10 Type label 1 is fixed to the front of the steering head The additional type label for Canada 2 is fixed to the front of the chest tube 5 3 Key number V00852 10 Key number 1 for...

Страница 20: ...engine over the engine sprocket 5 5 Fork part number 401947 10 The fork part number 1 is stamped on the inner side of the fork stub 5 6 Shock absorber article number H02222 10 Shock absorber article n...

Страница 21: ...e lever 1 is fitted on the right side of the handle bar The hand brake lever is used to activate the front brake 6 3 Throttle grip E01206 10 The throttle grip 1 is fitted on the right side of the hand...

Страница 22: ...ter activation Turn signal light right on The turn signal switch is pressed to the right The turn signal switch returns to the middle position after activation To switch off the turn signal press the...

Страница 23: ...filler cap Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not fuel the vehicle in the vicinity of open flames or lit cigarettes...

Страница 24: ...the injection time if the engine is cold and the ambient temperature is low To help the engine burn the increased fuel quantity it must be supplied with additional oxygen by pushing the cold start bu...

Страница 25: ...to start than an engine with the idle speed set incorrectly The idle speed is adjusted using the idle speed adjusting screw 1 Increase the idle speed by turning the idle speed adjusting screw clockwis...

Страница 26: ...stand 1 is attached to the left side of the vehicle 401944 10 The side stand is used for parking the motorcycle Info When you are riding side stand 1 must be folded up and secured with rubber strap 2...

Страница 27: ...into the steering lock p 24 turn it to the left push it in and turn it to the right Pull out the key for the steering lock Steering is no longer possible Info Never leave the key for the steering loc...

Страница 28: ...heel size After the display function check the wheel circumference WS is displayed briefly Info The number 2205 equals the circumference of the 21 front wheel with standard tires The display then chan...

Страница 29: ...ight of the display Press the button for 2 3 seconds The Setup menu is displayed and the active functions are shown Info If no button is pressed for 10 12 seconds the settings are automatically saved...

Страница 30: ...ressed for 15 20 seconds or if an impulse comes from the wheel speed sensor the settings are automatically saved and the setup menu is closed 7 6 Viewing the lap time Info This function can only be op...

Страница 31: ...ode H the service hours of the engine are displayed The service hour counter stores the total traveling time Info The service hour counter is necessary for ensuring that service work is carried out at...

Страница 32: ...changes to H or ODO 7 10 Setting the unit of measurement 400329 01 Condition The motorcycle is stationary Repeatedly press the button briefly until H appears at the bottom right of the display Press...

Страница 33: ...ly until CLK appears at the bottom right of the display Press the button for 2 3 seconds Press the but ton for 2 3 seconds Increases the value Briefly press the button Increases the value Press the bu...

Страница 34: ...P appears at the bottom right of the display Briefly press the button Press the but ton for 2 3 seconds The stop watch and the lap time are reset Briefly press the button Select a lap from 1 10 Press...

Страница 35: ...tion Briefly press the button No function 7 17 Display mode SPEED TR2 trip master 2 400324 01 Repeatedly press the button briefly until TR2 appears at the top right of the display TR2 trip master 2 ru...

Страница 36: ...s the average speed calculated using TR1 trip master 1 and S1 stop watch 1 The calculation of this value is activated by the first impulse of the wheel speed sensor and ends 3 seconds after the last i...

Страница 37: ...speed sensor and ends 3 seconds after the last impulse Press the but ton for 2 3 seconds Displays of TR1 A1 and S1 are reset to 0 0 Briefly press the button Next display mode Press the but ton for 2...

Страница 38: ...to the Setup menu Stores and closes the Setup menu Display mode SPEED CLK time The display changes to the Setup menu of the clock Next display mode No function No function Setting the clock Increases...

Страница 39: ...ion Display mode SPEED S1 stop watch 1 Displays of TR1 A1 and S1 are reset to 0 0 Next display mode No function No function Display mode SPEED S2 stop watch 2 The displays of S2 and A2 are set to 0 0...

Страница 40: ...t your riding speed to the road conditions and your riding ability Warning Danger of accidents The vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of accidents...

Страница 41: ...e make sure you fix it firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels Info Motorcycles react sensitively to any changes...

Страница 42: ...ncreases as the battery warms up 8 4 Preparing the vehicle for difficult operating conditions Info Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces can result...

Страница 43: ...al oil spray p 150 Clean the radiator fins Straighten the bent radiator fins carefully 8 6 Preparing the vehicle for riding on wet sand 102137 01 Mount the air filter rain cover Air filter rain cover...

Страница 44: ...cle for high temperatures or slow riding 600868 01 Adjust the secondary drive to the road conditions Info The engine oil heats up quickly when the clutch is operated frequently due to an excessively h...

Страница 45: ...eck tire condition p 105 Check tire pressure p 105 Check the spoke tension p 106 Info The spoke tension must be checked regularly as incor rect spoke tension will strongly impair riding safety Clean t...

Страница 46: ...to first gear release the clutch lever slowly and at the same time open the throt tle carefully 9 4 Shifting riding Warning Danger of accidents If you change down at high engine speed the rear wheel b...

Страница 47: ...move dirt from the brake linings and the brake discs On sandy wet or slippery surfaces use the rear brake Always finish braking before you go into a bend Change down to a lower gear appropriate to you...

Страница 48: ...ehicle can roll away or fall over Park the vehicle on a firm and level surface Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk Do not park the vehicle near to materials w...

Страница 49: ...ly become clogged In some countries and regions the available fuel quality and cleanliness may not be sufficient This will result in problems with the fuel system Refuel only with clean fuel that meet...

Страница 50: ...lines for damage and leakage Check the rear brake fluid level p 96 Check the free travel of the foot brake lever p 95 Check the frame p 85 Check the link fork p 85 Check the fork bearing for play Chec...

Страница 51: ...ing p 115 Change the fuel screen p 127 Check the fuel pressure Check idle Check that the radiator fan is functioning properly Check the inlet membrane Final check Check the vehicle is roadworthy and t...

Страница 52: ...linder head Change the valves valve springs and valve spring seats Check the camshaft and cam lever Change the connecting rod conrod bearing and crank pin Change the radial shaft seal rings of the wat...

Страница 53: ...divided into two ranges high speed and low speed High speed and low speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed The high speed compression adjuster h...

Страница 54: ...of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorize...

Страница 55: ...se by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase the damping turn coun...

Страница 56: ...preload of the shock absorber p 55 11 8 Checking the riding sag of the shock absorber 402417 10 Measure dimension A of rear wheel unloaded p 53 With another person holding the motorcycle the rider wea...

Страница 57: ...moving the shock absorber clean it thoroughly 402659 10 Main work Loosen screw 1 Turn adjusting ring 2 until the spring is no longer under ten sion Hook wrench 90129051000 Info If the spring cannot be...

Страница 58: ...nsated by changing the spring preload Finishing work Install the shock absorber p 69 Remove the motorcycle from the lift stand p 60 Check the static sag of the shock absorber p 54 Check the riding sag...

Страница 59: ...ression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping turn counterclock wise to reduce damping during compression 11 13 Adjusting the rebound dam...

Страница 60: ...A 15 mm 0 59 in The holes on the handlebar supports are placed at a distance of B from the center Hole distance B 3 5 mm 0 138 in The handlebar holders can be mounted in four different positions 11 1...

Страница 61: ...pports Place the handlebar supports in the required position Mount and tighten screws 2 Guideline Screw handle bar holder M10 40 Nm 29 5 lbf ft Loctite 243 Info Position the left and right handlebar s...

Страница 62: ...ge The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 401943 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press sid...

Страница 63: ...nts Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when nec essary Clean and oil the dust boots...

Страница 64: ...unt and tighten screws 3 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 12 7 Removing the fork legs Preparatory work Remove the headlight mask with the headlight p 113 Raise the motorcycle wit...

Страница 65: ...mp M8 15 Nm 11 1 lbf ft K00546 10 Position the brake caliper and mount and tighten screws 4 Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount the cable ties Position the brake...

Страница 66: ...against damage Do not kink the cables and lines V01757 10 Remove O ring 3 and protective ring 4 Take off the lower triple clamp with the steering stem Remove the upper steering head bearing 12 10 Ins...

Страница 67: ...e compression damping is located in left fork leg COMP white adjuster Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the up...

Страница 68: ...ning Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam ages components Correct incorrect steering head bearing play immediately Your authorized KTM w...

Страница 69: ...p steering head M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid stresses Tighten screws 1 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Tighten s...

Страница 70: ...ove screws 2 Remove front fender 12 15 Installing front fender V00340 10 Main work Position front fender Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft V00341 10 Mou...

Страница 71: ...01014 11 Main work Push splash protector 1 to the side and position the shock absorber Mount and tighten screw 2 Guideline Screw top shock absorber M12 80 Nm 59 lbf ft Loctite 2701 Mount and tighten s...

Страница 72: ...seat on the collar bushings of the fuel tank lower the seat at the rear and push the seat forward Make sure the seat is locked in correctly S03480 10 Mount and tighten screw 1 Guideline Remaining scre...

Страница 73: ...d take it off at the front 12 21 Installing the air filter box cover V01815 12 Condition The air filter box cover is secured Insert the air filter box cover in area A and clip it into area B V01815 10...

Страница 74: ...regulations Preparatory work Remove the air filter box cover p 70 V01812 10 Main work Detach retaining tab 1 Remove air filter with air filter sup port Remove air filter from air filter support 12 23...

Страница 75: ...061 10 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 149 Info Only press the air filter to dry it never wring it out Oil the dry...

Страница 76: ...n silencer S02101 10 Position the catalytic converter in the main silencer V01814 11 Position the main silencer Mount screws 1 but do not tighten yet Attach spring 2 Spring hook 50305017000C1 Tighten...

Страница 77: ...alth Soot particles irritate the eyes and mucuous membranes Wear suitable breathing and eye protection when cleaning the main silencer and carbon screen Clean main silencer sleeve 4 and screen 5 of th...

Страница 78: ...fiber yarn filling Clean the parts that need to be reinstalled and check for dam age Mount the new glass fiber yarn filling 4 in the main silencer Mount the O ring on the silencer cap Position the si...

Страница 79: ...els correctly in a suitable canister and out of the reach of children Preparatory work Remove the seat p 69 V01824 10 Main work Unplug connector 1 of the fuel pump Clean quick release coupling 2 thoro...

Страница 80: ...t off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor...

Страница 81: ...he quick release coupling thoroughly with compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Spray silicone spray onto a li...

Страница 82: ...otorcycle with the lift stand p 60 400725 01 Main work Rinse off loose dirt with a soft jet of water Remove old grease residue with chain cleaner Chain cleaner p 149 After drying apply chain spray Off...

Страница 83: ...ain tension p 81 Finishing work Remove the motorcycle from the lift stand p 60 12 35 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in a...

Страница 84: ...Guideline Nut rear wheel spin dle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Chain adjus...

Страница 85: ...n 272 mm 10 71 in If distance B is greater than the specified measurement Change the drivetrain kit Info When a new chain is mounted the rear sprocket and engine sprocket should also be changed New ch...

Страница 86: ...sliding piece Guideline Screw chain slid ing piece M8 15 Nm 11 1 lbf ft 401760 01 Check the chain guide for wear Info Wear can be seen on the front of the chain guide If the light part of the chain gu...

Страница 87: ...Info Always replace a damaged link fork Repairing the link fork is not authorized by KTM 12 39 Checking the throttle cable routing Preparatory work Remove the seat p 69 Remove the fuel tank p 76 E005...

Страница 88: ...461 10 Check that screw 1 is firmly seated Guideline Screw fixed grip M4 5 Nm 3 7 lbf ft Loctite 243 Diamond A must be located at the top 12 41 Adjusting the basic position of the clutch lever E00842...

Страница 89: ...ispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info The fluid level rises with increasing wear of the clutch facing disc...

Страница 90: ...ronmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Ne...

Страница 91: ...master cylinder reser voir to prevent overflowing Remove the bleeding syringe Mount and tighten the bleeder screw Mount the protection cap Correct the fluid level of the hydraulic clutch Guideline Flu...

Страница 92: ...djusting the free travel of the handbrake lever K01343 11 Check the free travel of the hand brake lever p 90 Adjust the free travel of the handbrake lever with adjustment screw 1 Info Turn the adjusti...

Страница 93: ...rning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is le...

Страница 94: ...tact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rea...

Страница 95: ...er of accidents Incorrect servicing will cause the brake system to fail Ensure that service work and repairs are performed professionally Your authorized KTM workshop will be glad to help Warning Skin...

Страница 96: ...Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Inf...

Страница 97: ...5 1 p 147 Position the cover with the membrane Mount and tighten the screws Info Use water to immediately clean up any brake fluid that has overflowed or spilled 13 8 Checking the free travel of foot...

Страница 98: ...cord ingly Info The range of adjustment is limited Turn push rod 5 accordingly until you have free travel A If necessary adjust the basic position of the foot brake lever Guideline Free travel at foot...

Страница 99: ...ective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected ar...

Страница 100: ...aking effect Ensure that worn out brake linings are replaced immediately Your authorized KTM workshop will be glad to help E00349 10 Check the brake linings for minimum thickness A Minimum thickness A...

Страница 101: ...inings are tested and approved for KTM motorcycles The structure and friction coefficient of the brake linings and thus their brake power may vary greatly from that of original brake linings If brake...

Страница 102: ...r rectly E00353 01 Insert the new brake linings insert the pin and mount the cot ter pins Info Always change the brake linings in pairs Operate the foot brake lever repeatedly until the brake lin ings...

Страница 103: ...g back the brake pistons V00364 10 Loosen screw 1 by several rotations Loosen screws 2 Press on screw 1 to push the wheel spindle out of the axle clamp Remove screw 1 V00365 10 Warning Danger of accid...

Страница 104: ...lightly grease the wheel spindle Long life grease p 149 Insert the spacers Position the front wheel and insert the wheel spindle The brake linings are correctly positioned V00364 11 Mount and tighten...

Страница 105: ...sprocket Info Cover the components to protect them against damage Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc...

Страница 106: ...ned Mount the chain V00368 10 Position chain adjuster 3 Mount nut 4 but do not tighten it yet Make sure that chain adjusters 3 are fitted correctly on adjusting screws 5 Check the chain tension p 80 T...

Страница 107: ...nge the tires Check tread depth Info Adhere to the legally required minimum tread depth Minimum tread depth 2 mm 0 08 in If the tread depth is less than the minimum tread depth Change the tires H01144...

Страница 108: ...in the spokes is too low then lateral and radial run out will form in the wheel Other spokes will become looser as a result Check spoke tension regularly and in particular on a new vehicle Your autho...

Страница 109: ...contain harmful sub stances Keep 12 V batteries out of the reach of children Keep sparks and open flames away from 12 V bat teries Only charge 12 V batteries in well ventilated rooms Maintain a minimu...

Страница 110: ...ry 15 2 Installing the 12 V battery V01779 11 Main work Insert the 12 V battery into the battery compartment with the terminals facing forward and secure with holding bracket 1 12 V battery HJTZ5S FP...

Страница 111: ...V batteries as household waste Dispose of 12 V batteries at a collection point for used batteries Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filte...

Страница 112: ...charge the 12 V battery Replace the 12 V battery and dispose of the old 12 V battery properly If the specifications have been met Battery voltage 9 V Connect a battery charger to the 12 V battery Swit...

Страница 113: ...nance free Never remove cover 1 Switch off the battery charger after charging and disconnect it from the 12 V battery Finishing work Install the 12 V battery p 108 Mount the seat p 70 15 4 Changing ma...

Страница 114: ...70 15 5 Changing the fuses of individual electrical power consumers Info The fuse box containing the fuses of individual electrical power consumers is located under the seat Preparatory work Remove th...

Страница 115: ...ut a spare fuse in the fuse box so that it is available if needed Check the function of the electrical power consumer Close the fuse box cover Finishing work Mount the seat p 70 15 6 Removing the head...

Страница 116: ...p 115 15 8 Changing the headlight bulb Note Damage to reflector Grease on the reflector reduces the light intensity Grease on the bulb will evaporate due to the heat and be deposited on the reflector...

Страница 117: ...e on a horizontal surface in front of a light colored wall and make a mark at the height of the center of the low beam headlight Make another mark at a distance B under the first marking Guideline Dis...

Страница 118: ...be deposited on the reflector Clean and degrease the bulbs before mounting Do not touch the bulbs with your bare hands E00499 10 Main work Remove the screw and carefully take off turn signal glass 1...

Страница 119: ...pward Combination instrument battery CR 2430 p 143 Check the O ring of the protection cap for correct seating V00372 10 Position protection cap 2 and turn all the way clockwise using a coin Press any...

Страница 120: ...to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger...

Страница 121: ...with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your...

Страница 122: ...Mount and tighten screw 1 with a new seal ring Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft 16 5 Refilling coolant Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant...

Страница 123: ...ontact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eye...

Страница 124: ...al posi tion Adjust the play in the throttle cable p 122 Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness and death Always make sure there is suffici...

Страница 125: ...here is play in the throttle cable at the throttle grip Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Tighten nut 2 Slide on sleeve 1 Check the throttle grip for smooth operation Finishing work...

Страница 126: ...upon delivery V01803 10 Clean the outside of the handlebar and the inside of the grip tube Mount the grip tube on the handlebar Attach the throttle cables to the guide plate and route cor rectly Posi...

Страница 127: ...aises the idle speed 17 5 Programming the throttle valve position Info If the control unit detects that the throttle valve position at idle speed needs to be reprogrammed then the malfunction indicato...

Страница 128: ...he boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the basic position of the shift lever p 126 17 7 Adjusting the basic position of the shift lever 401950 12 Remove scre...

Страница 129: ...d area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Note Environmental hazar...

Страница 130: ...the level The engine oil is at a level between the lower edge A and the middle of the level viewer B If the engine oil is not up to the lower edge A of the level viewer Add engine oil p 131 18 3 Chang...

Страница 131: ...K00569 10 Position oil screen 4 with the O rings on a pin wrench Position the pin wrench through the drill hole of the screw plug in the opposite section of the engine case Push the oil screen all the...

Страница 132: ...10 Nm 7 4 lbf ft Stand the motorcycle upright 401955 12 Remove filler plug 8 from the clutch cover together with the O ring and fill up with engine oil Engine oil 1 0 l 1 1 qt Engine oil SAE 10W 50 p...

Страница 133: ...al engine oil performance it is not advisable to mix different engine oils KTM recommends changing the engine oil where neces sary Mount and tighten the filler plug together with the O ring Danger Dan...

Страница 134: ...Avoid direct sunshine when cleaning the motorcycle 401061 01 Close off the exhaust system to keep water from entering Remove the coarse dirt particles with a gentle water jet Spray the heavily soiled...

Страница 135: ...erefore take precautions against aggressive road salt If the vehicle was operated in road salt clean it with cold water after riding Warm water would enhance the corrosive effects of salt 401060 01 Cl...

Страница 136: ...this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 401058 01 When refueling for the last time before taking the...

Страница 137: ...e water vapor produced during combustion condenses and causes valves and the exhaust system to rust 20 2 Preparing for use after storage 401059 01 Remove the motorcycle from the lift stand p 60 Instal...

Страница 138: ...e Spark plug electrode gap 1 0 mm 0 039 in Ignition system defective Check the ignition system Short circuit cable in wiring harness frayed stop button or emergency OFF switch faulty Check the wiring...

Страница 139: ...fuse 4 Check the radiator fan Malfunction indicator lamp lights up or flashes Error in the electronic fuel injection Check wiring for damage and electrical plug in connectors for corrosion and damage...

Страница 140: ...TROUBLESHOOTING 138 Faults Possible cause Action The horn brake light turn sig nal and radiator fan optional are not working Fuse 3 blown Change the fuses of individual electri cal power consumers p 1...

Страница 141: ...ng Plain bearing Piston pin bearing Bearing bush Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with 2 trochoidal pum...

Страница 142: ...ng bolt oil pump idler gear M5 6 Nm 4 4 lbf ft Loctite 243 Screw clutch spring retainer M5 6 Nm 4 4 lbf ft Screw crankshaft speed sensor M5 6 Nm 4 4 lbf ft Loctite 243 Screw gear position sensor M5 5...

Страница 143: ...ted with engine oil Crankshaft clamp screw plug M8 10 Nm 7 4 lbf ft Screw tensioning rail M8 15 Nm 11 1 lbf ft Loctite 243 Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 243 Plug oil channel M10x...

Страница 144: ...el Total fuel tank capacity approx 8 5 l 2 25 US gal Super unleaded ROZ 95 p 148 Fuel reserve approx 1 5 l 1 6 qt 22 4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork WPXP...

Страница 145: ...Battery voltage 12 V Nominal capacity 2 0 Ah Maintenance free Combination instrument battery CR 2430 Battery voltage 3 V Fuse 75011088005 5 A Fuse 75011088010 10 A Fuse 58011109120 20 A Headlight HS1...

Страница 146: ...10 ml 21 5 0 34 fl oz Fork oil SAE 4 48601166S1 p 148 22 8 Shock absorber Shock absorber article number 0797C461V305000 Shock absorber WP XPLOR PDS Low speed compression damping Comfort 18 clicks Stan...

Страница 147: ...9 lbf ft Screw light switch M5 1 Nm 0 7 lbf ft Screw spoiler on fuel tank M5x12 2 Nm 1 5 lbf ft Screw turn signal switch M5 1 Nm 0 7 lbf ft Nut starter motor M6 4 Nm 3 lbf ft Remaining nuts chassis M6...

Страница 148: ...ft Screw top triple clamp M8 20 Nm 14 8 lbf ft Engine attachment bolt M10 60 Nm 44 3 lbf ft Remaining nuts chassis M10 45 Nm 33 2 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw handlebar...

Страница 149: ...Only use coolant that complies with the requirements stated see specifications on the container and that has the relevant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must...

Страница 150: ...n SAE p 151 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties Super unleaded ROZ 95 Standard cl...

Страница 151: ...High viscosity grease Recommended supplier SKF LGHB 2 Long life grease Recommended supplier MOTOREX Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX Moto Clean Off road chain spray Re...

Страница 152: ...ray Recommended supplier MOTOREX Silicone Spray Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Universal oil spray Recommende...

Страница 153: ...ce intervals are demanded for automobile engines the focus for motorcycle engines is on high performance at high engine speeds In most motorcycle engines the transmission and clutch are lubricated wit...

Страница 154: ...26 INDEX OF SPECIAL TERMS 152 OBD On board diagnosis Vehicle system which monitors the specified parame ters of the vehicle electronics...

Страница 155: ...LIST OF ABBREVIATIONS 27 153 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Страница 156: ...s up flashes yellow The OBD has detected an error in the vehicle electronics Come safely to a halt and contact an authorized KTM workshop The fuel level warning lamp lights up yellow The fuel level ha...

Страница 157: ...hecking 82 cleaning 80 Chain guide checking 82 Chain tension adjusting 81 checking 80 Characteristic map of the throttle response adjusting 123 Clutch fluid level checking correcting 87 fluid changing...

Страница 158: ...ng 90 free travel checking 90 Handlebar position 58 adjusting 58 Headlight range adjusting 115 Headlight bulb changing 114 Headlight mask with headlight installing 114 removing 113 Headlight setting c...

Страница 159: ...static sag checking 54 Side stand 24 Spare parts 14 Spoke tension checking 106 Start button 20 Starting 43 Starting power of lithium ion batteries at low tempera tures 40 Steering locking 25 unlocking...

Страница 160: ...3214425en 3214425en 04 2021 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria KTM COM Photo Mitterbauer KISKA KTM...

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KTM F8275V9, Руководство пользователя

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