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

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OWNER'S MANUAL
2014
350 SX‑F EU
350 SX‑F USA
350 XC‑F USA
Art. no. 3213032en

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Summary of Contents for KTM 350 SX-F

  • Page 1 OWNER'S MANUAL 2014 350 SX‑F EU 350 SX‑F USA 350 XC‑F USA Art. no. 3213032en...
  • 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 Shifting, riding ..........21 TABLE OF CONTENTS MEANS OF REPRESENTATION ........4 Applying the brakes......... 21 Symbols used ........... 4 Stopping, parking..........21 Formats used............ 4 Transport ............22 SAFETY ADVICE............5 Refueling ............22 Use definition - intended use ......5 SERVICE SCHEDULE ..........
  • Page 5 TABLE OF CONTENTS 16 TUNING THE ENGINE..........77 11.31 Removing the manifold ....... 47 16.1 Checking the play in the throttle cable ....77 11.32 Installing the manifold ........ 48 16.2 Adjusting the play in the throttle cable ..77 11.33 Removing the main silencer ......

  • Page 6: 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 7: 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 8: 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 9: 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 & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 10: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) B01411-10 Hand brake lever ( p. 11) Clutch lever ( p. 11) Filler cap Plug-in stand ( p. 15) Air filter box lid Engine number ( p. 10) Shift lever ( p.

  • Page 11: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) B01412-10 Kill switch ( p. 11) Electric starter button ( p. 11) Throttle grip ( p. 11) Chassis number ( p. 10) Type label ( p. 10) Fork part number ( p.

  • Page 12: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. B01448-10 Type label The type label is fixed to the front of the steering head. B01448-11 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.

  • Page 13: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. C00214-10 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. B01413-10 Throttle grip The throttle grip...

  • Page 14: Overview Of Indicator Lamps

    CONTROLS Overview of indicator lamps Possible states FI warning lamp (MIL) lights up/flashes orange – The OBD (on-board diagnosis) has detected an emission- or safety-critical error. (XC‑F) The fuel level warning lamp lights up orange – The fuel level has reached the reserve mark.

  • Page 15: Closing The Filler Cap

    CONTROLS Closing the filler cap (All SX‑F models) – Mount the filler cap and turn it clockwise until the tank is firmly closed. Info Run the fuel tank breather hose without kinks. B01452-11 (XC‑F) – Replace the filler cap and turn clockwise until the release button locks in place.

  • Page 16: Idle Speed Adjusting Screw

    CONTROLS 6.10 Idle speed adjusting screw The idle setting of the throttle valve body has a big influence on the starting behavior, stable idling and the response to throttle opening. This means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly. The idle speed is adjusted with idle speed adjusting screw Turning the adjusting screw clockwise increases the idle speed.

  • Page 17: Foot Brake Lever

    CONTROLS 6.12 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. B01456-10 6.13 Plug-in stand (All SX‑F models) The holder for the plug-in stand is the left side of the wheel spindle.

  • Page 18: 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 19: Running In The Engine

    For this reason, it may be neces- sary to inspect or replace parts before the next scheduled service. – KTM recommends using the specified engine oil when riding under difficult conditions and to enhance performance. Engine oil (SAE 10W/60) (00062010035) ( p. 96) –...

  • Page 20: Preparing For Rides On Dry Sand

    – Fit a dust cover on the air filter. Dust protection device for air filter (77206920000) Info See the KTM PowerParts fitting instructions. B00435-01 – Fit a sand cover on the air filter. Sand protection device for air filter (77206922000) Info See the KTM PowerParts fitting instructions.

  • Page 21: Preparing For Rides On Wet And Muddy Surfaces

    Preparing for rides on wet and muddy surfaces – Fit a waterproofing device on the air filter. Waterproofing device for air filter (77206921000) Info See the KTM PowerParts fitting instructions. B00437-01 – Fit the steel sprocket. – Clean the motorcycle. ( p.

  • Page 22: 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. 79) –...

  • Page 23: 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 24: Transport

    – 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 25 RIDING INSTRUCTIONS – Switch off the engine. – Open the filler cap. ( p. 12) – Fill the fuel tank with fuel up to measurement Guideline Measurement of 35 mm (1.38 in) Total fuel tank 7.5 l Super unleaded (ROZ 95/RON 95/PON capacity, approx.

  • Page 26: Service Schedule

    Once after 1 operating hour - corresponds to about 7 liters of fuel (1.8 US gal) ○ ● ● ● ● Read out the fault memory using the KTM diagnostics tool. ● ● ● ● Check and charge the battery.

  • Page 27: Service Work (As Additional Order)

    Final check: Check the vehicle for safe operation 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 28: 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 29: 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 30: Adjusting The Rebound Damping Of The Shock Absorber

    Adjusting the rebound 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.) – Turn adjusting screw clockwise up to the last perceptible click.

  • Page 31: Checking The Static Sag 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 32: Adjusting The Riding Sag

    TUNING THE CHASSIS – After removing the shock absorber, clean it thoroughly. Main work – Loosen screw – Turn adjusting ring until the spring is no longer under tension. Hook wrench (T106S) – Measure the overall spring length while the spring is not under tension. –...

  • Page 33: Checking The Basic Setting Of The Fork

    TUNING THE CHASSIS Guideline Spring rate (SX‑F EU) Weight of rider: 65… 75 kg (143… 54 N/mm (308 lb/in) 165 lb.) Weight of rider: 75… 85 kg (165… 57 N/mm (325 lb/in) 187 lb.) Weight of rider: 85… 95 kg (187… 60 N/mm (343 lb/in) 209 lb.) Spring rate (SX‑F USA)

  • Page 34: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 10.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. (All SX‑F models) – 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.

  • Page 35: Handlebar Position

    TUNING THE CHASSIS (All SX‑F models) – Remove protection caps – Turn adjusting screws clockwise all the way. Info Adjusting screws are located at the bottom 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.

  • Page 36: Adjusting The Handlebar Position

    TUNING THE CHASSIS 10.15 Adjusting the handlebar position – Remove the four screws . Remove the handlebar clamp. Remove the handlebar and lay it to one side. Info Protect the motorcycle and its attachments against damage by covering them. Do not bend the cables and lines. –...

  • Page 37: 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. The wheels must no longer touch the ground.

  • Page 38: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS 11.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 35) – Loosen the fork protection. ( p. 36) Main work – Push dust boots of both fork legs downward.

  • Page 39: Removing The Fork Legs

    SERVICE WORK ON THE CHASSIS 11.7 Removing the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 35) – Remove the front wheel. p. 67) Main work – Remove screws and take off the clamp. –...

  • Page 40: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS – Position the brake caliper. Mount and tighten screws Guideline Screw, front brake caliper 25 Nm Loctite ® 243™ (18.4 lbf ft) – Position the brake line and clamp. Mount and tighten screws B00300-11 Finishing work –...

  • Page 41: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS Main work – 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 and lines. B01463-10 –...

  • Page 42: Position The Brake Caliper. Mount And Tighten Screws

    SERVICE WORK ON THE CHASSIS (XC‑F) – Position the fork legs. Position bleeder screws toward the front. Info The rebound damping is located in the right fork leg (red adjusting screw). The compression damping is located in the left fork leg (white adjusting screw).

  • Page 43: 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 44: Greasing The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS Finishing work – Mount the handlebar cushion. – Remove the motorcycle from the lift stand. ( p. 35) 11.15 Greasing the steering head bearing – Remove the lower triple clamp. p. 38) – Install the lower triple clamp. p.

  • Page 45: Installing The Front Fender

    SERVICE WORK ON THE CHASSIS Main work – Remove screws . Remove the front fender. B01469-10 11.19 Installing the front fender Main work – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) B01470-10 Finishing work –...

  • Page 46: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS – Carefully take the shock absorber upward out of the vehicle. B01472-01 11.21 Installing the shock absorber Main work – Carefully position the shock absorber into the vehicle from above. B01472-01 – Position the frame protector. Info Pay attention to the holding lugs.

  • Page 47: Removing The Air Filter Box Lid

    SERVICE WORK ON THE CHASSIS 11.24 Removing the air filter box lid Condition The air filter box lid is secured. – Remove screws B01423-10 – Pull off the air filter box lid in area sideways and remove it toward the front. B01424-10 11.25 Installing the air filter box lid...

  • Page 48: Cleaning The Air Filter And Air Filter Box

    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. B01426-10 11.27 Cleaning the air filter and air filter box...

  • Page 49: Securing The Air Filter Box Lid

    SERVICE WORK ON THE CHASSIS Finishing work – Install the air filter box lid. ( p. 45) 11.29 Securing the air filter box lid Preparatory work – Remove the air filter box lid. ( p. 45) Main work – Drill a hole at markings Guideline Diameter 6 mm (0.24 in)

  • Page 50: Installing The Manifold

    SERVICE WORK ON THE CHASSIS – Detach springs Spring hooks (50305017000) – Remove screw B01189-10 – Raise the swingarm. B01427-10 – Remove screw – Turn the shock absorber and lower it. – Take off the manifold. B01475-10 11.32 Installing the manifold Main work –...

  • Page 51: Removing The Main Silencer

    SERVICE WORK ON THE CHASSIS – Lower the swingarm. B01427-11 – Position the angle lever and linkage lever. – Mount and tighten screw connection Guideline Nut, linkage lever to angle lever M14x1.5 80 Nm (59 lbf ft) – Mount and tighten screw Guideline Screw, bottom shock 60 Nm...

  • Page 52: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    SERVICE WORK ON THE CHASSIS 11.35 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. Info Over time, the fibers of the glass fiber yarn escape and the damper "burns"...

  • Page 53: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS Main work – Disconnect electric plug-in connection of the fuel pump. – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve.

  • Page 54: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water.

  • Page 55: Cleaning The Chain

    SERVICE WORK ON THE CHASSIS 11.39 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. –...

  • Page 56: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 11.41 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear- ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases.
  • Page 57 SERVICE WORK ON THE CHASSIS – Pull at the top part of the chain with the specified weight Guideline Weight, chain wear measurement 10… 15 kg (22… 33 lb.) – Measure distance of 18 chain rollers on the lower chain section. Info Chains do not always wear evenly, which is why the measurement should be repeated at several locations on the chain.

  • Page 58: Checking The Frame

    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. 500284-01 11.44 Checking the swingarm –...

  • Page 59: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS Main work – Check the throttle cable routing. Both throttle cables must be routed to the throttle valve body side by side behind the handlebars and above the fuel tank bracket. » If the throttle cable is not routed as specified: –...

  • Page 60: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS 11.49 Checking/correcting the fluid level of the hydraulic clutch Info The fluid level rises with increased wear of the clutch lining discs. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...

  • Page 61: 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 62: Checking The Brake Fluid Level Of The Front Brake

    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.) Preparatory work –...

  • Page 63: Checking The Front Brake Linings

    Changing the front brake linings Warning Danger of accident Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid can cause skin irritation on contact. –...
  • Page 64 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 65: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM – Add brake fluid to level Guideline Dimension (brake fluid level below 5 mm (0.2 in) top edge of container) Brake fluid DOT 4 / DOT 5.1 ( p. 96) – Position cover with membrane – Mount and tighten screws Info Clean up overflowed or spilt brake fluid immediately with water.

  • Page 66: Checking The Rear Brake Fluid Level

    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.) Preparatory work –...

  • Page 67: 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 Environmental hazard Hazardous substances cause environmental damage.
  • Page 68 BRAKE SYSTEM Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.

  • Page 69: Wheels, Tires

    WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 35) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

  • Page 70: Removing The Rear Wheel

    WHEELS, TIRES – 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. – Remove the motorcycle from the lift stand. ( p.

  • Page 71: 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 an important impact on the handling characteristics of the motorcycle.

  • Page 72: Checking The 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 causes wheel imbalance and rapidly leads to more loose spokes.

  • Page 73: 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 74: Changing The Main Fuse

    – Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 75 ELECTRICAL SYSTEM Main work – Remove screw B01426-12 – Lift rear fairing slightly and pull starter relay out of the holder. B01444-10 – Remove protection caps – Remove the faulty main fuse Info A defective fuse can be identified by the burned-out fuse wire A reserve fuse is located in the starter relay.

  • Page 76: 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 77: Draining The Coolant

    COOLING SYSTEM Condition The engine is cold. – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the coolant level in the radiator. Coolant level above radiator fins. 10 mm (0.39 in) » If the coolant level does not meet specifications: –...

  • Page 78: Refilling Coolant

    COOLING SYSTEM 15.5 Refilling coolant Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water imme- diately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swal- lowed, contact a physician immediately.

  • Page 79: 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 80: Adjusting The Idle Speed

    TUNING THE ENGINE 16.3 Adjusting the idle speed – Run the engine until warm. – Set the desired idle speed by turning the idle speed adjusting screw Guideline Idle speed 2,250… 2,350 rpm Tachometer (45129075000) Info Turning counterclockwise lowers the idle speed. Turning clockwise raises the idle speed.

  • Page 81: 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 82: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    SERVICE WORK ON THE ENGINE The engine oil level is between the middle of the level viewer and the upper edge of the level viewer » If the engine oil does not reach the middle of the level viewer – Add engine oil.
  • Page 83 SERVICE WORK ON THE ENGINE – Remove screws . Remove the oil filter cover with the O-ring. B01485-10 – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) – Completely drain the engine oil. – Thoroughly clean the parts and sealing surface. B01486-10 –...

  • Page 84: 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 85: 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 86: 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. 35) – Cover the vehicle with a tarp or a cover that is permeable to air.

  • Page 87: Troubleshooting

    – Check the electrical system. – 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 88 TROUBLESHOOTING Faults Possible cause Action – Battery is discharged Unwanted power consumer Check the quiescent current.

  • Page 89: 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 90: 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 13,65:1 Idle speed 2,250… 2,350 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 36.3 mm (1.429 in)

  • Page 91: Engine Tightening Torques

    TECHNICAL DATA 22.2 Engine tightening torques ® Nozzle, crank chamber ventilation 2 Nm (1.5 lbf ft) Loctite 243™ ® Oil nozzle for alternator cooling 2 Nm (1.5 lbf ft) Loctite 243™ ® Oil nozzle for balancer shaft lubrication M4 2 Nm (1.5 lbf ft) Loctite 243™...

  • Page 92: Capacities

    TECHNICAL DATA Nut, cylinder head M10x1.25 Tightening sequence: Thread, oiled with engine Tighten diagonally. oil/cone greased 1st tightening stage 10 Nm (7.4 lbf ft) 2nd tightening stage 30 Nm (22.1 lbf ft) 3rd tightening stage 50° ® Stud, cylinder head M10x1.25 20 Nm (14.8 lbf ft) Loctite...

  • Page 93: Electrical System

    80/100 - 21 51M TT 110/90 - 19 62M TT Dunlop GEOMAX MX51FA Dunlop GEOMAX MX51 (XC‑F) 80/100 - 21 51M TT 110/100 - 18 64M TT Dunlop GEOMAX MX51FA Dunlop GEOMAX MX51 Additional information is available in the Service section under: http://www.ktm.com...

  • Page 94: Fork

    TECHNICAL DATA 22.7 Fork 22.7.1 SX‑F EU Fork part number 14.18.7N.07 Fork WP Suspension Up Side Down 4860 MXMA CC Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Spring length with preload spacer(s) 490 mm (19.29 in)

  • Page 95: Shock Absorber

    TECHNICAL DATA Standard 13 clicks Sport 11 clicks Rebound damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Spring length with preload spacer(s) 470 mm (18.5 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 4.4 N/mm (25.1 lb/in) Weight of rider: 75…...

  • Page 96: Xc-F

    TECHNICAL DATA Standard 15 clicks Sport 13 clicks Compression damping, high-speed 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.) 54 N/mm (308 lb/in) Weight of rider: 75…...

  • Page 97: Chassis Tightening Torques

    TECHNICAL DATA 22.9 Chassis tightening torques – EJOT PT ® Screw, air filter box lid K60x20-Z 3 Nm (2.2 lbf ft) – Screw, pressure regulator EJOT PT ® 3 Nm (2.2 lbf ft) – Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) –...

  • Page 98: 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 99 SUBSTANCES Fork oil (SAE 4) (48601166S1) According to – SAE ( p. 100) (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 100: 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 101 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 102: 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 103: Index

    INDEX Clutch lever ........11 INDEX basic position, adjusting ..... . 57 Accessories .
  • Page 104 INDEX Fork protector Operating substances ......7 installing ....... . . 38 Overview of indicator lamps .
  • Page 105 INDEX Starting ........20 Steering head bearing greasing .
  • Page 106 *3213032en* 3213032en 03/2013 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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