OWNER'S MANUAL
2011
350 SX
‑
F EU
F CAIROLI REPLICA EU
F USA
350 XC-F USA
Art. no. 3211624en
Страница 1: ...OWNER S MANUAL 2011 350 SX F EU 350 SX F CAIROLI REPLICA EU 350 SX F USA 350 XC F USA Art no 3211624en...
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...
Страница 4: ...of the fork 30 Handlebar position 31 Adjusting the handlebar position x 31 Activating the Factory Start SX F CAIROLI REPLICA 32 SERVICE WORK ON THE CHASSIS 33 Raising the motorcycle with the lift stan...
Страница 5: ...lling coolant x 71 TUNING THE ENGINE 72 Checking the play in the throttle cable 72 Adjusting the play in the throttle cable x 72 Adjusting the idle speed x 72 Checking the basic position of the shift...
Страница 6: ...understanding In the interest of your own safety have these jobs done in an authorized KTM workshop There your motorcycle will be serviced optimally by specially trained experts using the specialist t...
Страница 7: ...ons 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 au...
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 Ident...
Страница 9: ...1 View of vehicle front left example B00366 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 a...
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 Le...
Страница 11: ...teering head 4 3 Engine number B00263 10 The engine number is stamped on the left side of the engine under the engine sprocket 4 4 Fork part number B00265 01 The fork part number is stamped on the inn...
Страница 12: ...bar 5 4 Kill switch B00373 10 Kill switch is fitted on the left side of the handlebar Possible states Kill switch in basic position In this position the ignition circuit is closed and the engine can b...
Страница 13: ...poisoning 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...
Страница 14: ...is 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 is located on the throttle valve body at t...
Страница 15: ...fold the upper part of the kick starter toward the engine 5 13 Foot brake lever B00282 10 Foot brake lever is located in front of the right footrest The foot brake lever is used to activate the rear b...
Страница 16: ...CONTROLS 14 B00603 10 The side stand is used to park the motorcycle Info When you are riding side stand must be folded up and secured with rubber band...
Страница 17: ...Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons Info When using your motorcycle remember that others may feel disturbed by excessive noise M...
Страница 18: ...ervice or replace worn parts before the limit specified in the service schedule is reached KTM recommends that you use the specified engine oil for difficult riding conditions and to increase performa...
Страница 19: ...ter approx every 30 minutes 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: ...filter and air filter box x p 43 Info Check the air filter approx every 30 minutes 600868 01 Adjust the secondary drive to the road conditions Info The engine oil quickly gets hot if the clutch has t...
Страница 21: ...PREPARING FOR USE 19 B00437 01 Fit a waterproofing device on the air filter Waterproofing device for air filter 77206921000 Info See the KTM PowerParts fitting instructions...
Страница 22: ...e 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...
Страница 23: ...ng 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 en...
Страница 24: ...l 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...
Страница 25: ...front brake fluid level p 54 Check the free travel of the hand brake lever p 53 Check the steering head bearing play p 38 Check the valve clearance x Check the clutch x Change the shaft seal rings of...
Страница 26: ...the camshaft and cam lever x Change the connecting rod conrod bearing and crank pin x Check the transmission and shift mechanism x Check the oil pressure regulator valve x Change the suction oil pump...
Страница 27: ...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 co...
Страница 28: ...ed 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 abso...
Страница 29: ...he shock absorber 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 R...
Страница 30: ...g sits on the seat in a normal sitting 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 axl...
Страница 31: ...ving the shock absorber clean it thoroughly B00292 10 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 mm 291 lb in Weight of rider...
Страница 32: ...t the top end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline Compression damping All SX F model...
Страница 33: ...the handlebar can be mounted in the position that is most comfortable for the rider 9 15 Adjusting the handlebar position x 0 0 2 2 0 0 1 1 0 0 2 2 1 1 B00375 10 Remove the four screws Remove the han...
Страница 34: ...ng released during compression 101078 10 Check lock button 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 a...
Страница 35: ...e B00283 10 All SX F models Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle insert plug in stand into the left side of the wheel spindle Info Remove the plug in...
Страница 36: ...normal position Remove excess oil Position the fork protection p 34 Remove the motorcycle from the lift stand p 33 10 5 Loosening the fork protection B00298 10 Remove screws and take off the clamp Rem...
Страница 37: ...deline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws Guideline Screw bottom triple clamp M8 12 Nm 8 9 lbf ft B00300 11 Position the brake caliper Mount and tighten screws Guideline Screw...
Страница 38: ...10 Remove screw Remove screw Take off the top triple clamp with the handlebar and set it aside Info Protect the motorcycle and its attachments against damage by covering them Do not bend the cables an...
Страница 39: ...op edge of the upper triple clamp Position bleeder screws toward the front B00378 10 Fully tighten screws Guideline Screw bottom triple clamp M8 12 Nm 8 9 lbf ft B00380 10 Tighten screw Guideline Scre...
Страница 40: ...andlebar to the straight ahead position Move the fork legs to and fro in the direction of travel No play should be noticeable in the steering head bearing If there is noticeable play present Adjust th...
Страница 41: ...and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Info Make sure that the holding lugs engage in the fender Position the brake line and clamp Mount and tighten screw 10 18 Remo...
Страница 42: ...etach springs Spring hooks 50305017000 Remove screw B00270 10 Remove screw Turn the shock absorber toward the rear and remove the exhaust manifold Remove the shock absorber from the top 10 21 Installi...
Страница 43: ...ain silencer p 43 Remove the motorcycle from the lift stand p 33 10 22 Removing the seat B00317 10 Remove screw Lift up the seat at the rear pull it back and then remove it from above 10 23 Mounting t...
Страница 44: ...rs fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Remove the air filter box lid p 41 B00324 10 Detach air filter holder at the bottom and swing it to one s...
Страница 45: ...press the air filter to dry it never wring it out Oil the dry air filter with a high quality filter oil Oil for foam air filter p 94 Clean the air filter box Clean the intake flange and check it for d...
Страница 46: ...rom the inner tube Clean the parts that are to be reinstalled Mount the new glass fiber yarn filling on the inner tube Slide the outer tube over the glass fiber yarn filling Insert locking cap into th...
Страница 47: ...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 i...
Страница 48: ...oap and water If fuel is swallowed contact a doctor immediately Change clothing that has come into contact with fuel Check the throttle cable routing p 50 B00316 11 Position the fuel tank and fit the...
Страница 49: ...hain regularly and then treat with chain spray Chain cleaner p 94 Off road chain spray p 94 10 36 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the...
Страница 50: ...st the chain tension by turning adjusting screws left and right Guideline Chain tension 55 58 mm 2 17 2 28 in Turn adjusting screws on the left and right so that the markings on the left and right cha...
Страница 51: ...should also 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...
Страница 52: ...de down Condition Number of teeth 44 teeth Insert collar bushing in hole Position the chain guide Mount and tighten screw Tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Condition...
Страница 53: ...r mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Check the fluid level Fluid level below container rim 4 mm 0 16 in If the fluid level does not meet specifi...
Страница 54: ...e 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 44 Removing the engine guard SX F CAIROLI REPLICA B00597...
Страница 55: ...and 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 adjustin...
Страница 56: ...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...
Страница 57: ...ings for damage and cracking If damage or cracking is visible Change the front brake linings x p 55 11 7 Changing the front brake linings x Warning Danger of accident Brake system failure Maintenance...
Страница 58: ...Remove cover with membrane 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...
Страница 59: ...ee 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 x p 57 Reconnect spring 11 9 Ad...
Страница 60: ...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 he...
Страница 61: ...on 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 conta...
Страница 62: ...he brake caliper and sliding plate 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 lin...
Страница 63: ...er 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 12 2 Installing the front wheel x Warning Danger of accidents Re...
Страница 64: ...rear wheel x Raise the motorcycle with the lift stand p 33 B00340 10 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 bra...
Страница 65: ...adjusting screws Check the chain tension p 47 Tighten nut 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 differen...
Страница 66: ...nd 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...
Страница 67: ...ion 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 variou...
Страница 68: ...6 Reconnect rubber band Attach the positive cable and replace the positive terminal cover Attach negative cable Mount the seat p 41 13 3 Charging the battery x Warning Risk of injury Battery acid and...
Страница 69: ...board elec tronics 400240 10 Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 You can also use the battery charger to test the open circuit voltage...
Страница 70: ...ve fuse is located in the starter relay Install a new main fuse Fuse 58011109110 p 86 Check that the electrical equipment is functioning properly Tip Insert the spare fuse so that it is available if n...
Страница 71: ...t have come 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 Che...
Страница 72: ...ine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact...
Страница 73: ...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 302801 10 Make sure that screw is tig...
Страница 74: ...just the play in the throttle cable x p 72 15 2 Adjusting the play in the throttle cable x Check the throttle cable routing p 50 B00599 10 Move the handlebar to the straight ahead position Push back s...
Страница 75: ...Adjust the basic position of the shift lever x p 73 15 5 Adjusting the basic position of the shift lever x B00364 10 Remove screw and take off shift lever B00365 10 Clean gear teeth of the shift leve...
Страница 76: ...r If the engine oil is not up to the middle of the level viewer Add engine oil p 76 16 2 Changing the engine oil and oil filter cleaning the oil screen x Warning Danger of scalding Engine oil and gear...
Страница 77: ...emove the oil filter cover with the O ring B00332 11 Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sea...
Страница 78: ...Too little engine oil or poor quality engine oil results in premature wear to the engine B00327 10 Remove the oil filler plug with the O ring from the clutch cover Add the same engine oil that was us...
Страница 79: ...aner and then clean with a paintbrush Motorcycle cleaner p 94 Info Use warm water containing normal motorcycle cleaner and a soft sponge After rinsing the motorcycle with a gentle spray of water allow...
Страница 80: ...p 77 Change the engine oil and oil filter clean the oil screen x p 74 Check the antifreeze and coolant level p 69 Drain the fuel from the tanks into a suitable container Check the tire air pressure p...
Страница 81: ...emory 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 43 Fuel filter is very dirty Change the fuel filter x Defect in...
Страница 82: ...nsumption 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 alternat...
Страница 83: ...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 sig...
Страница 84: ...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...
Страница 85: ...ne oil 1 10 l 1 16 qt Engine oil SAE 10W 50 p 92 Alternative engine oil for harsh operating conditions and increased performance Engine oil SAE 10W 60 00062010035 p 92 21 2 Capacity coolant Coolant 0...
Страница 86: ...r 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 2...
Страница 87: ...12x1 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...
Страница 88: ...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 models 104 4 kg 230 2 lb Weight without fuel approx XC F 106 2 kg...
Страница 89: ...7 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 93 Total fuel tank capacity approx XC F 9 5 l 2 51 US gal Super unleaded RO...
Страница 90: ...195 ml 6 59 fl oz Fork oil SAE 5 p 93 Oil capacity fork leg without cartridge 380 ml 12 85 fl oz Fork oil SAE 5 p 93 24 2 XC F Fork part number 14 18 7K 22 Fork WP Suspension Up Side Down 4860 MXMA CC...
Страница 91: ...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 93 25 2 SX F USA Shock absorber part...
Страница 92: ...eed 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...
Страница 93: ...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 40 Nm 29 5 lbf ft...
Страница 94: ...n inhibitor antifreeze 50 distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Supplier Motorex Anti Freeze Engine oil SAE 10W 60 00062010035 According to JASO T903 MA p 96 SAE p 96 SAE 10W...
Страница 95: ...responding properties KTM recommends Motorex products Supplier Motorex Racing Fork Oil Shock absorber oil SAE 2 5 50180342S1 According to SAE p 96 SAE 2 5 Guideline Use only oils that comply with the...
Страница 96: ...oducts 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 G...
Страница 97: ...olish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean Polish Universal oil spray Guideline KTM recommends Motorex pro...
Страница 98: ...e 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 wit...
Страница 99: ...1 Compression damping fork adjusting 30 Compression damping high speed shock absorber adjusting 26 Compression damping low speed shock absorber adjusting 25 Coolant draining 70 refilling 71 Coolant le...
Страница 100: ...and maintenance work when preparing for use 20 R Rear sprocket checking 48 Rear wheel installing 63 removing 62 Rebound damping fork adjusting 30 shock absorber adjusting 27 Refueling fuel 22 Riding...
Страница 101: ...e cable routing checking 50 Throttle grip 10 Tire air pressure checking 64 Tire condition checking 63 Transport 5 Troubleshooting 79 80 Type label 9 U Use definition 5 V View of vehicle front left sid...
Страница 102: ...3211624en 3211624en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 11 2010 Photo Mitterbauer...
