KTM 350 EXC-F Owner's Manual
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KTM 350 EXC-F Owner's Manual

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OWNER'S MANUAL
2013
350 EXC‑F USA
Art. no. 3211867en

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Summary of Contents for KTM 350 EXC-F

  • Page 1 OWNER'S MANUAL 2013 350 EXC‑F USA Art. no. 3211867en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 6.11.15 Display mode SPEED/A1 (average speed 1) ... 22 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 6.11.16 Display mode SPEED/A2 (average speed 2) ... 22 Symbols used ........... 5 6.11.17 Display mode SPEED/S1 (stop watch 1)..23 Formats used............
  • Page 5 TABLE OF CONTENTS 10.15 Handlebar position.......... 43 12.7 Changing the front brake linings ....68 10.16 Adjusting handlebar position ....... 44 12.8 Checking the free travel of foot brake lever ..70 11 SERVICE WORK ON THE CHASSIS......45 12.9 Adjusting the basic position of the foot brake lever ............
  • Page 6 TABLE OF CONTENTS 22.3 Capacities ............ 103 22.3.1 Engine oil ..........103 22.3.2 Coolant ............ 103 22.3.3 Fuel ............103 22.4 Chassis ............103 22.5 Electrical system........... 104 22.6 Tires ............104 22.7 Fork............. 104 22.8 Shock absorber ..........105 22.9 Chassis tightening torques ......

  • Page 7: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required.

  • Page 8: Safety Advice

    SAFETY ADVICE Use definition - intended use KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply with currently valid regulations and categories of the top international motorsport organizations.

  • Page 9: Overview Of Labels

    SAFETY ADVICE Overview of labels B01245-10 Canada type label USA type label Brake fluid information Information on chain tension Information on starting up Information on emissions control Information on noise emission B01246-01 Canada type label B01247-01 USA type label...
  • Page 10 SAFETY ADVICE Brake fluid information S00026-10 Information on chain tension 101516-01 Information on starting up 700210-01 B01248-01 Information on emissions control B01249-01 Information on noise emission...

  • Page 11: Reporting Safety Defects

    Noise emission warranty KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA noise standards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.

  • Page 12: Protective Clothing

    Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.

  • Page 13: Important Notes

    Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 14: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) B01243-10 Filler cap Fork compression adjustment Shift lever ( p. 25) Engine number ( p. 14) Side stand ( p. 26)

  • Page 15: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) B01244-10 Fork rebound adjustment and spring preload adjustment Clutch lever ( p. 16) Light switch ( p. 16) Turn signal switch ( p. 17) Horn button ( p. 16) Emergency OFF switch ( p.

  • Page 16: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. C00125-10 Type label The type label USA is fixed to the front of the steering head. 101477-10 The type label Canada is fixed to the front of the front pipe. 101478-10 Key number Key number...

  • Page 17: Fork Part Number

    SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub. B00265-01 Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side. 101292-10...

  • Page 18: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. S00052-11 Hand brake lever Hand brake lever is located on the right side of the handlebar. The hand brake lever is used to activate the front brake. 101629-10 Throttle grip The throttle grip...

  • Page 19: Turn Signal Switch

    CONTROLS Turn signal switch Turn signal switch is fitted on the left side of the handlebar. Possible states Turn signal light off Turn signal light, left, on – The turn signal switch is pressed to the left. The turn signal switch returns to the middle position after activation. Turn signal light, right, on –...

  • Page 20: Speedometer

    CONTROLS 6.11 Speedometer 6.11.1 Overview – Press the button to change the display mode or change to one of the Setup menus. – Press the button to control different functions. – Press the button to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.

  • Page 21: Adjusting The Speedometer Functions

    CONTROLS Adjusting Mph – Press the button – Press the button for 3 - 5 seconds. The settings are stored and the Setup menu is closed. Info If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu is closed.

  • Page 22: Querying Lap Time

    CONTROLS Info If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu is closed. 6.11.7 Querying lap time Info This function can be called up only if lap times are measured. Condition The motorcycle is stationary.

  • Page 23: Display Mode Speed/Clk (Clock)

    CONTROLS 6.11.10 Display mode SPEED/CLK (clock) – Press the button briefly and repeatedly until CLK appears at the bottom right of the display. The time is displayed in CLK display mode. Press the button . No function Press the button .

  • Page 24: Display Mode Speed/Tr2 (Trip Master 2)

    CONTROLS 6.11.14 Display mode SPEED/TR2 (trip master 2) – Press the button briefly and repeatedly until TR2 appears at the top right of the display. TR2 (trip master 2) runs constantly and counts up to 999.9. The displayed value can be set manually with the button and the button .

  • Page 25: Display Mode Speed/S1 (Stop Watch 1)

    CONTROLS 6.11.17 Display mode SPEED/S1 (stop watch 1) – Press the button briefly and repeatedly until S1 appears at the top right of the display. S1 (stop watch 1) displays the journey time on the basis of TR1 and continues when an impulse is received from the wheel speed sensor.

  • Page 26: 6.11.20 Table Of Conditions And Menu Activation

    CONTROLS 6.11.20 Table of conditions and menu activation Display The motorcycle is Menu can be acti- stationary. vated Display mode SPEED/H (operating hours) • Display mode SPEED/CLK (clock) • Display mode SPEED/LAP (lap time) • Display mode SPEED/TR1 (trip master 1) •...

  • Page 27: Idle Speed Adjusting Screw

    CONTROLS 6.14 Idle speed adjusting screw The idle speed adjusting screw 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 activated –...

  • Page 28: Foot Brake Lever

    CONTROLS 6.17 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 101310-10 6.18 Side stand The side stand is on the left side of the vehicle. 101311-10 The side stand is used to park the motorcycle.

  • Page 29: Unlocking The Steering

    CONTROLS – Park the vehicle. – Turn the handlebar as far as possible to the right. – Insert the key in the steering lock, turn it to the left, press it in and turn it to the right. Remove the key. Steering is no longer possible.

  • Page 30: Preparing For Use

    When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover.

  • Page 31: Running-In The Engine

    For this reason, it may be neces- sary to inspect or replace parts before the next scheduled service. – KTM recommends that you use the specified engine oil for difficult riding conditions and to increase performance. Engine oil (SAE 10W/60) (00062010035) ( p. 107) –...

  • Page 32: Preparing For Rides On Wet Sand

    PREPARING FOR USE – Fit a sand cover on the air filter. Sand protection device for air filter (59006022000) Info See the KTM PowerParts fitting instructions. 600871-01 – Clean the chain. Chain cleaner ( p. 109) – Fit the steel sprocket.

  • Page 33: Preparing For Rides At High Temperature And Slow Speed

    – Check the coolant level. ( p. 87) Preparing for rides at low temperature or in snow – Fit a waterproofing device on the air filter. Waterproofing device for air filter (77206921000) Info See the KTM PowerParts fitting instructions. 600870-01...

  • Page 34: Riding Instructions

    RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p. 91) –...

  • Page 35: Starting Off

    Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines.

  • Page 36: Stopping, Parking

    RIDING INSTRUCTIONS Stopping, parking 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. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. –...

  • Page 37: Refueling

    – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards.

  • Page 38: Service Schedule

    Final check: Check the vehicle for roadworthiness and take a test ride. • • • Read out the fault memory using the KTM diagnostics tool after a test ride. • • • Make the service entry in KTM DEALER.NET and in the service record.

  • Page 39: Service Work (As Additional Order)

    SERVICE SCHEDULE Service work (as additional order) S15N S45A S105A Change the front brake fluid. • Change the rear brake fluid. • Change the hydraulic clutch fluid. p. 64) • Grease the steering head bearing. p. 51) • Clean the spark arrestor. •...

  • Page 40: Tuning The Chassis

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber.

  • Page 41: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber.

  • Page 42: Measuring Rear Wheel Sag Unloaded

    TUNING THE CHASSIS 10.6 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with the lift stand. ( p. 45) Main work – Measure the distance – as vertically as possible – between the rear axle and a fixed point such as a mark on the side cover.

  • Page 43: Adjusting The Spring Preload Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.

  • Page 44: Checking Basic Setting Of Fork

    TUNING THE CHASSIS Finishing work – Install the shock absorber. p. 52) – Remove the motorcycle from the lift stand. ( p. 45) – Check the static sag of the shock absorber. ( p. 40) – Check the riding sag of the shock absorber. ( p.

  • Page 45: Adjusting The Spring Preload Of The Fork

    TUNING THE CHASSIS – Turn adjusting screws clockwise all the way. Info Adjusting screws are located at 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 Rebound damping 101316-10...

  • Page 46: Adjusting Handlebar Position

    TUNING THE CHASSIS 10.16 Adjusting handlebar position Warning Danger of accidents Handlebar breakage. – If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle- bar. – Remove the four screws . Remove the handlebar clamps. Remove the handlebar and lay it to one side.

  • Page 47: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (54829055000) The wheels should no longer touch the ground.

  • Page 48: Loosening The Fork Protector

    SERVICE WORK ON THE CHASSIS 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. – Clean and lubricate the dust boot and inside fork tube on both fork legs.

  • Page 49: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS – Release screws . Take out the left fork leg. – Release screws . Take out the right fork leg. 101489-10 11.8 Installing the fork legs Main work – Position the fork legs. Info Grooves are milled into the side of the upper end of the fork legs. The sec- ond milled groove (from the top) must be flush with the top edge of the upper triple clamp.

  • Page 50: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS Main work – Remove screws on the left fork leg. Remove the fork protector upwards. – Remove the screws on the right fork leg. Remove the fork protector upwards. 101327-10 11.10 Installing the fork protector Main work –...

  • Page 51: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11.12 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 109) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

  • Page 52: Checking The Steering Head Bearing Play

    Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam- aged over time.

  • Page 53: Adjusting The Play Of The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS Main work – Move the handlebar 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: –...

  • Page 54: Removing The Front Fender

    SERVICE WORK ON THE CHASSIS 11.16 Removing the front fender – Remove screws . Remove the front fender. – Make sure the spacers remain in place. 101345-10 11.17 Installing the front fender – Ensure that the spacers are mounted in the fender. –...

  • Page 55: Removing The Seat

    SERVICE WORK ON THE CHASSIS 11.20 Removing the seat – Remove screw – Lift up the seat at the rear, pull it back and then remove it from above. 101346-10 11.21 Mounting the seat – Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear and simultaneously push it forward.

  • Page 56: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS Main work – Detach air filter holder at the bottom and swing it to one side. Remove the air filter with the air filter support. – Remove the air filter from the air filter support. S00043-10 11.25 Installing the air filter...

  • Page 57: Sealing The Air Filter Box

    SERVICE WORK ON THE CHASSIS – Check the intake flange for damage and firm seating. Finishing work – Install the air filter. p. 54) – Install the air filter box lid. ( p. 53) 11.27 Sealing the air filter box –...

  • Page 58: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS Main work – Remove screws of connecting cap – Take off the connecting cap with the perforated pipe, O-ring and glass fiber yarn filling – Remove screws and silencer cap with O-ring – Remove screw and remove insert together with stuffing yarn –...

  • Page 59: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS – Remove screws with the collar bushings and horn. 101356-10 – Remove screw with the rubber bushing. 101357-10 – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. 101358-01 11.32 Installing the fuel tank...

  • Page 60: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS – Position the horn, and fit and tighten screws with collar bushings. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 101356-11 – Connect the electrical plug-in connection – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Never let dirt enter the fuel line.

  • Page 61: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 109) Off-road chain spray ( p. 109) 400725-01 11.35 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. –...

  • Page 62: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

    SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust 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 chain adjusters are in the same position relative to the reference marks .
  • Page 63 SERVICE WORK ON THE CHASSIS – 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. – Check that the chain sliding guard is firmly seated. »...

  • Page 64: Adjusting The Chain Guide

    If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by KTM. 401340-01 11.40 Checking the swingarm –...

  • Page 65: Checking The Throttle Cable Routing

    SERVICE WORK ON THE CHASSIS 11.41 Checking the throttle cable routing Preparatory work – Remove the seat. ( p. 53) – Remove the fuel tank. p. 56) Main work – Check the throttle cable routing. Both throttle cables must be routed side by side behind the handlebars and above the fuel tank bearing to the throttle valve body.

  • Page 66: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS 11.44 Adjusting the basic position of the clutch lever – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.
  • Page 67 SERVICE WORK ON THE CHASSIS – Inject the liquid into the system until it escapes from openings of the master cylinder without bubbles. – To prevent overflow, drain fluid occasionally from the master cylinder reservoir. – Remove the bleeding syringe. Mount and tighten screws bleeder screw. –...

  • Page 68: Brake System

    Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disk...

  • Page 69: Checking The Front Brake Fluid Level

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 70: Checking The Front Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
  • Page 71 BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Manually press the brake caliper toward the brake disc to push back the brake pis- tons.

  • Page 72: Checking The Free Travel Of Foot Brake Lever

    Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)

  • Page 73: Adding Brake Fluid To The Rear Brake Circuit

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 74: Checking The Rear Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
  • Page 75 BRAKE SYSTEM – Stand the vehicle upright. – Remove screw cap with membrane and the O-ring. – Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.

  • Page 76: Wheels, Tires

    WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 45) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

  • Page 77: Removing The Rear Wheel

    WHEELS, TIRES – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc.

  • Page 78: Checking The Tire Condition

    Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have a significant impact on the handling characteristics of the motorcycle.

  • Page 79: Checking Tire Air Pressure

    Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.
  • Page 80 WHEELS, TIRES 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)

  • Page 81: Electrical System

    ELECTRICAL SYSTEM 14.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...

  • Page 82: Charging The Battery

    – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 83: Changing The Main Fuse

    ELECTRICAL SYSTEM 14.4 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box cover.

  • Page 84: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM 14.5 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat.

  • Page 85: Refitting The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM – Pull out the electric plug connector and remove the headlight mask with the headlight. C00124-11 14.7 Refitting the headlight mask with the headlight Main work – Connect the electric plug connector C00124-10 – Position the headlight mask and fix it with the rubber band Info Ensure that the retaining lugs engage in the fender.

  • Page 86: Checking The Headlight Setting

    ELECTRICAL SYSTEM – Press headlight bulb into the lamp socket lightly, turn it counterclockwise all the way and pull it out. – Insert a new headlight bulb. Headlight (S2 / socket BA20d) ( p. 104) – Insert the rubber cap together with the lamp socket into the reflector and turn it clockwise all the way.

  • Page 87: Changing The Speedometer Battery

    ELECTRICAL SYSTEM 14.11 Changing the speedometer battery Preparatory work – Remove the headlight mask with the headlight. ( p. 82) Main work – Remove screws – Pull the speedometer upward out of the holder. 101405-10 – Using a coin, turn protection cap all the way counterclockwise and remove it.

  • Page 88: Cooling System

    COOLING SYSTEM 15.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant tem- perature will not result in a risk of malfunctions.

  • Page 89: Checking The Coolant Level

    COOLING SYSTEM 15.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 90: Refilling Coolant

    COOLING SYSTEM 15.5 Refilling coolant Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and 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.

  • Page 91: Tuning The Engine

    TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3…...

  • Page 92: Adjusting The Idle Speed

    TUNING THE ENGINE 16.3 Adjusting the idle speed – Run the engine warm and push the idle speed adjusting screw all the way in. – Set the desired idle speed by turning the idle speed adjusting screw. Guideline Idle speed 1,950…...

  • Page 93: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 17.1 Changing the fuel screen 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 vehicle components. Clean up spilt fuel immediately. –...

  • Page 94: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    SERVICE WORK ON THE ENGINE The engine oil is at a level between the middle and upper edge of the level viewer. » If the engine oil is not up to the middle of the level viewer: – Add engine oil. ( p.
  • Page 95 SERVICE WORK ON THE ENGINE – Remove screws . Remove the oil filter cover with the O-ring. 101419-10 – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) – Completely drain the engine oil. – Thoroughly clean the parts and sealing area. 101420-10 –...

  • Page 96: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 17.4 Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – Remove the oil filler plug 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.

  • Page 97: Cleaning, Care

    CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts.

  • Page 98: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE 18.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

  • Page 99: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 45) – Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materi- als since they prevent humidity from escaping, thus causing corrosion.

  • Page 100: Troubleshooting

    – Check the electrical system. switch defective – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool.
  • Page 101 – Check the cabling for damage and the electri- cal plug-in connections for corrosion and dam- age. – Read out the fault memory using the KTM diag- nostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary.

  • Page 102: Blink Code

    BLINK CODE Blink code FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Crankshaft position sensor - circuit fault Blink code FI warning lamp (MIL) 06 FI warning lamp (MIL) flashes 6x short Error level condition Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high Blink code FI warning lamp (MIL)

  • Page 103: Technical Data

    TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 349.7 cm³ (21.34 cu in) Stroke 57.5 mm (2.264 in) Bore 88 mm (3.46 in) Compression ratio 12.3:1 Idle speed 1,950… 2,050 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 36.3 mm (1.429 in)
  • Page 104 TECHNICAL DATA ® Screw, locking lever 6 Nm (4.4 lbf ft) Loctite 243™ ® Screw, oil pump cover 6 Nm (4.4 lbf ft) Loctite 243™ ® Screw, stator 6 Nm (4.4 lbf ft) Loctite 243™ Nut, cylinder head 10 Nm (7.4 lbf ft) Lubricated with engine oil ®...

  • Page 105: Capacities

    TECHNICAL DATA 22.3 Capacities 22.3.1 Engine oil Engine oil 1.20 l (1.27 qt.) Engine oil (SAE 10W/50) ( p. 107) Alternative engine oil for harsh Engine oil (SAE 10W/60) operating conditions and (00062010035) ( p. 107) increased performance 22.3.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant (...

  • Page 106: Electrical System

    Rear tires 80/100 - 21 M/C 51M TT 140/80 - 18 M/C 70R TT MAXXIS MAXX CROSS SI MAXXIS MAXX ENDURO Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork Fork part number 14.18.7L.67 Fork WP Suspension Up Side Down 4860 MXMA PA...

  • Page 107: Shock Absorber

    TECHNICAL DATA 22.8 Shock absorber Shock absorber part number 12.18.7L.67 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1.25 turns Rebound damping Comfort 28 clicks...
  • Page 108 TECHNICAL DATA – Screw, chain sliding piece 15 Nm (11.1 lbf ft) – Screw, engine brace 33 Nm (24.3 lbf ft) – Screw, fork stub 15 Nm (11.1 lbf ft) ® Screw, front brake caliper 25 Nm (18.4 lbf ft) Loctite 243™...

  • Page 109: Substances

    Brake fluid DOT 4 / DOT 5.1 According to – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Castrol and Motorex ® products. Supplier Castrol –...
  • Page 110 SUBSTANCES Fork oil (SAE 4) (48601166S1) According to – SAE ( p. 111) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Shock absorber oil (SAE 2.5) (50180342S1) According to –...

  • Page 111: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Dirt Bio Remover Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline –...
  • Page 112 AUXILIARY SUBSTANCES Oil for foam air filter Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Liquid Bio Power Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline – KTM recommends Motorex ®...

  • Page 113: Standards

    STANDARDS 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.

  • Page 114: Index

    INDEX fluid, changing ......64 INDEX Clutch lever ........16 Accessories .
  • Page 115 INDEX removing ....... . . 46 Main silencer spring preload, adjusting ..... . 43 glass fiber yarn filling, changing .
  • Page 116 INDEX Spare parts ........11 Work rules ........10 Speedometer adjusting .
  • Page 117 *3211867en* 3211867en 07/2012 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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