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

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OWNER'S MANUAL
2016
350 SX‑F EU
350 SX‑F US
350 XC‑F US
Art. no. 3213332en

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Summary of Contents for KTM 350 XC-F

  • Page 1 OWNER'S MANUAL 2016 350 SX‑F EU 350 SX‑F US 350 XC‑F US Art. no. 3213332en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, misprints, and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Preparing for rides at low temperatures or in TABLE OF CONTENTS MEANS OF REPRESENTATION ........4 snow.............. 20 Symbols used ........... 4 RIDING INSTRUCTIONS..........21 Formats used............ 4 Checks and maintenance work when preparing SAFETY ADVICE............5 for use ............
  • Page 5 TABLE OF CONTENTS 11.20 Removing the seat .......... 47 15 COOLING SYSTEM ............. 79 11.21 Mounting the seat ........... 47 15.1 Cooling system ..........79 11.22 Removing the air filter box lid ......48 15.2 Checking the antifreeze and coolant level ..79 11.23 Installing the air filter box lid ......

  • 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

    Use definition - intended use (All SX‑F models) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations.

  • Page 8: Safe Operation

    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) K00181-10 Hand brake lever ( p. 11) Map‑Select switch for ride mode ( p. 12) Clutch lever ( p. 11) Filler cap Plug-in stand ( p. 15) Air filter box lid Engine number ( p.

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

    VIEW OF VEHICLE View of vehicle, rear right (example) K00182-10 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. 401945-10 Type label The type label  is fixed to the front of the steering head. 401946-10 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. 102124-10 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.

  • Page 14: Map-Select Switch For The Basic Setting (All Sx-F Models)

    CONTROLS Map‑Select switch for the basic setting (All SX‑F models)  The Map‑Select switch for basic setting is fitted under the air filter box lid. Possible states SOFT – The mapping with reduced peak performance for better ride- ability is activated. The Launch Control can be activated. ADVANCED –...

  • Page 15: Opening The Filler Cap

    CONTROLS 6.10 Opening the filler cap 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 16: Cold Start Button

    CONTROLS 6.12 Cold start button  The cold start button (yellow) is fitted on the bottom of the throttle valve body. The injection system extends the injection time if the engine is cold and the outside temperature is low. If the cold start button is pulled out, additional oxygen is fed to the engine to ensure optimal combustion of the increased fuel quantity.

  • Page 17: Foot Brake Lever

    CONTROLS (All SX‑F models) The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-13 (XC‑F US) The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.15 Foot brake lever...
  • Page 18 CONTROLS 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 401944-10...

  • Page 19: 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 booklet at vehicle handover.

  • Page 20: Running In The Engine

    For this reason, it may be neces- sary to inspect or replace parts before the next scheduled service. – Use the specified engine oil when riding under difficult conditions and to enhance performance, as recommended by KTM. Engine oil (SAE 10W/60) (00062010035) ( p. 103) –...

  • Page 21: 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. 102136-01 – Fit a sand cover on the air filter. Sand protection device for air filter (77206922000) Info See the KTM PowerParts fitting instructions.

  • Page 22: 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. 102137-01 – Fit the steel sprocket. – Clean the motorcycle. ( p.

  • Page 23: 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. 86) –...

  • Page 24: Activating Launch Control

    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 25: Applying The Brakes

    Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. – 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 a wet or dirty brake system.

  • Page 26: 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 27: Service Schedule

    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 the KTM Dealer.net and in the Service and Warranty Booklet.

  • Page 28: Recommended Work

    SERVICE SCHEDULE ○ One-time interval ● Periodic interval Recommended work Annually Every 100 operating hours Every 50 operating hours Every 40 operating hours Once after 20 operating hours Once after 10 operating hours ● Change the front brake fluid. ● Change the rear brake fluid.

  • Page 29: Tuning The Chassis

    For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swingarm and frame, the basic settings of the suspension components must match the rider's weight. – As delivered, KTM offroad motorcycles are adjusted for an average rider's weight (with full protective clothing). Guideline Standard rider weight 75…...

  • Page 30: 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 low-speed setting can be seen during the slow to normal compression of the shock absorber.

  • Page 31: 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.) – ...

  • Page 32: Measuring Rear Wheel Sag Unloaded

    TUNING THE CHASSIS 10.7 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with a lift stand. ( p. 37) Main work – Position the sag gauge in the rear axle and measure the distance to marking SAG on the rear fender.

  • Page 33: Checking The Riding 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 34: Adjusting The Riding Sag

    TUNING THE CHASSIS – Remove the motorcycle from the lift stand. ( p. 37) 10.11 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 37) – Remove the shock absorber. p. 45) – After removing the shock absorber, clean it thoroughly.

  • Page 35: Adjusting Fork Air Pressure (Sx-F Eu)

    A little air escapes from the fork when connecting. S00861-10 Info This is due to the volume of the hose and not due to a defect in the fork pump or the fork. Read the accompanying KTM PowerParts instructions. – Adjust air pressure as specified. Guideline Air pressure Weight of rider: 65…...

  • Page 36: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 10.14 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. (SX‑F EU) –  Turn adjusting screw clockwise all the way. Info  The adjusting screw is located at the upper end of the right fork leg. –...

  • Page 37: Handlebar Position

    TUNING THE CHASSIS (SX‑F EU) –  Remove protection cap –  Turn adjusting screw clockwise all the way. Info  The adjusting screw is located at the lower end of the right fork leg. – Turn counterclockwise by the number of clicks corresponding to the fork type. Guideline M01100-10 Rebound damping...

  • Page 38: Adjusting The Handlebar Position

    TUNING THE CHASSIS 10.17 Adjusting the handlebar position Preparatory work – Remove the handlebar cushion. Main work –  Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against damage. Do not kink the cables and lines.

  • Page 39: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with a 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 (78129955100) Neither wheel is in contact with the ground.

  • Page 40: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS (SX‑F US, XC‑F US) –  Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws. 402556-10 Finishing work – Remove the motorcycle from the lift stand. ( p.

  • Page 41: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11.6 Installing the fork protector –  Position the fork protection on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) –  Position the brake line and clamp. Mount and tighten screws –...

  • Page 42: Removing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS –  Tighten screws Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) –  Tighten screws Guideline Screw, bottom triple clamp 12 Nm (8.9 lbf ft) 102150-11 –  Position the brake caliper. Mount and tighten screws Guideline Loctite ®...

  • Page 43: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 105) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

  • Page 44: 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-...

  • Page 45: Adjusting The Play Of The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with a lift stand. ( p. 37) 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.

  • Page 46: Removing The Start Number Plate

    SERVICE WORK ON THE CHASSIS 11.14 Removing the start number plate –  Remove screw – Unhook the start number plate from the brake line and remove it. 102160-10 11.15 Installing the start number plate – Attach the start number plate to the brake line. –...

  • Page 47: Installing The Front Fender

    SERVICE WORK ON THE CHASSIS 11.17 Installing the front fender Main work –   Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 102162-11 Finishing work – Install the start number plate. ( p.

  • Page 48: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS – Remove the connecting link of the chain. – Take off the chain. S00857-10 –  Remove nut and pull out the swingarm pivot. – Push the swingarm back and secure it against falling over. 102166-10 –...

  • Page 49: Removing The Seat

    SERVICE WORK ON THE CHASSIS – Mount the chain. –  Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel. S00854-10 – Position the foot brake cylinder. ...

  • Page 50: Removing The Air Filter Box Lid

    SERVICE WORK ON THE CHASSIS 11.22 Removing the air filter box lid Condition The air filter box lid is secured. – Remove screw  K00188-10 –  Pull out the air filter box lid sideways in area and remove it downwards. K00188-11 11.23 Installing the air filter box lid...

  • Page 51: Cleaning The Air Filter And Air Filter Box

    SERVICE WORK ON THE CHASSIS Main work –  Detach retaining tab . Remove air filter with air filter support. – Take off air filter from air filter support. 102177-10 11.25 Cleaning the air filter and air filter box Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 52: Securing The Air Filter Box Lid

    SERVICE WORK ON THE CHASSIS Finishing work – Install the air filter box lid. ( p. 48) 11.27 Securing the air filter box lid Preparatory work – Remove the air filter box lid. ( p. 48) Main work –  Drill a hole at the marking Guideline Diameter...

  • Page 53: Installing The Main Silencer

    SERVICE WORK ON THE CHASSIS 11.30 Installing the main silencer – Position the main silencer. –  Mount screws but do not tighten yet. –  Reconnect spring Spring hooks (50305017000) –  Tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 102180-11 11.31 Changing the glass fiber yarn filling of the main silencer...
  • Page 54 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: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11.33 Installing the fuel tank 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 56: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS 11.34 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 54) 400678-01 11.35 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. –...

  • Page 57: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS Main work – Pull the chain at the end of the chain sliding component upwards to measure chain  tension Info  The lower chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 58: Checking The Chain, Rear Sprocket, Motor Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 11.38 Checking the chain, rear sprocket, motor sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 37) Main work – Shift the transmission to idle. – Check the rear sprocket and engine sprocket for wear. »...

  • Page 59: 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. S00867-01...

  • Page 60: Checking The Swingarm

    If the swingarm shows signs of damage, cracking, or deformation: – Change the swingarm. Info A damaged swingarm must always be changed. Repair of the swingarm is not authorized by KTM. 401520-01 11.41 Checking the throttle cable routing Preparatory work –...

  • Page 61: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS 11.43 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 counterclockwise to decrease the distance between the clutch lever and the handlebar.
  • Page 62 SERVICE WORK ON THE CHASSIS –  Inject the liquid into the system until it escapes from drill hole of the master cylinder without bubbles. – Drain fluid occasionally from the master cylinder reservoir, to prevent overflow. – Remove the bleeding syringe. Mount and tighten screws bleeder screw. –...

  • Page 63: 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 64: 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 65: 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 66 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 67: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM –  Add brake fluid to level Guideline 5 mm (0.2 in)  Dimension (brake fluid level below top edge of container) Brake fluid DOT 4 / DOT 5.1 ( p. 103) –   Position cover with membrane –...

  • Page 68: 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 69: 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 70: Changing 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 71 BRAKE SYSTEM –   Insert the new brake linings, insert pin , and mount cotter pins Info Always change the brake linings in pairs. Make sure that the decoupling plate  is mounted on the piston side of the brake lining. –...

  • Page 72: Wheels, Tires

    WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 37) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

  • Page 73: Removing The Rear Wheel

    WHEELS, TIRES –  Mount and tighten screw Guideline Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) – Operate the hand brake lever several times until the brake linings are lying correctly against the brake disc. – Remove the motorcycle from the lift stand. ( p.

  • Page 74: Installing The Rear Wheel

    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 75: 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 76 WHEELS, TIRES » If the spoke tension varies: – Correct the spoke tension. – Check the spoke torque. Guideline Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft) Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft) Torque wrench with various accessories in set (58429094000)

  • Page 77: Electrical System

    ELECTRICAL SYSTEM 14.1 Removing the battery Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the battery. – Only charge in well-ventilated rooms. – Maintain the minimum clearance to inflammable materials while charging. Minimum clearance 1 m (3 ft) –...

  • Page 78: Recharging The Battery

    – Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly 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 79 ELECTRICAL SYSTEM Main work (All SX‑F models) – Check the battery voltage. » Battery voltage: < 9 V – Do not charge the battery. – Replace the battery and dispose of the old battery properly. » If the specifications have been met: Battery voltage: ≥...

  • Page 80: 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 bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the seat. Preparatory work –...

  • Page 81: 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 temperature will not result in a risk of malfunctions.

  • Page 82: Draining The Coolant

    COOLING SYSTEM – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the coolant level in the radiator. 10 mm (0.39 in)  Coolant level above the radiator fins » If the coolant level does not match the specified value: –...
  • Page 83 COOLING SYSTEM –  Make sure that screw is tightened. – Position the motorcycle upright. –  Pour coolant in up to measurement above the radiator fins. Guideline 10 mm (0.39 in)  Dimension over the radiator fins Coolant 0.95 l (1 qt.) Coolant ( p.

  • Page 84: 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. Turn the throttle grip back and  forth slightly and determine the play in throttle cable Play in throttle cable 3…...

  • Page 85: Setting The Characteristic Map Of The Throttle Response

    TUNING THE ENGINE 16.3 Setting the characteristic map of the throttle response Info On the throttle grip, the characteristic map of the throttle response is changed by changing the guide plate. A guide plate with a different characteristic map is supplied. Main work –...

  • Page 86: Programing Throttle Valve Position

    TUNING THE ENGINE – 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. M00778-10 16.5 Programing throttle valve position...
  • Page 87 TUNING THE ENGINE –  Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle compo- nents during the shift procedure.

  • Page 88: 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 89: 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 –...
  • Page 90 SERVICE WORK ON THE ENGINE –  Remove screws . Remove the oil filter cover with the O-ring. S00714-10 –  Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) – Completely drain the engine oil. –...

  • Page 91: 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.

  • Page 92: 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 93: 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 a lift stand. ( p. 37) – Cover the vehicle with a tarp or a cover that is permeable to air.

  • Page 94: 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 95 TROUBLESHOOTING Faults Possible cause Action – Battery is discharged Battery is not charging Check the charging voltage. – Check the stator winding of the alternator. – Unwanted power consumer Check the quiescent current.

  • Page 96: Blink Code

    BLINK CODE Blink code of FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Crankshaft position sensor - circuit fault Blink code of 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...

  • Page 97: 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 14.0:1 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 98: Engine Tightening Torques

    TECHNICAL DATA 22.2 Engine tightening torques Loctite ® 243™ Nozzle, crank chamber ventilation 2 Nm (1.5 lbf ft) 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 ®...

  • Page 99: 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 Nm (36.9 lbf ft) Stud, cylinder head M10x1.25 20 Nm (14.8 lbf ft)

  • Page 100: Electrical System

    Dunlop GEOMAX MX32 (XC‑F US) 90/90 - 21 M/C 54M TT 110/100 - 18 M/C 64M TT Dunlop GEOMAX AT81F Dunlop GEOMAX AT81 Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork 22.7.1 SX‑F EU Fork part number 34.18.8P.05...

  • Page 101: Sx-F Us

    TECHNICAL DATA Comfort 20 clicks Standard 17 clicks Sport 12 clicks Air pressure Weight of rider: 65… 75 kg (143… 165 lb.) 10.3 bar (149 psi) +0.5 −1.5 −22 Weight of rider: 75… 85 kg (165… 187 lb.) 10.6 bar (154 psi) −0.8 −12...

  • Page 102: Shock Absorber

    TECHNICAL DATA 22.8 Shock absorber 22.8.1 SX‑F EU Shock absorber part number 18.18.7P.05 Shock absorber WP Performance Systems 5018 DCC Link Compression damping, low-speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport 1.5 turns...

  • Page 103: Xc-F Us

    TECHNICAL DATA Weight of rider: 75… 85 kg (165… 187 lb.) 247 mm (9.72 in) Weight of rider: 85… 95 kg (187… 209 lb.) 252 mm (9.92 in) Gas pressure 10 bar (145 psi) Static sag 40 mm (1.57 in) Riding sag 110 mm (4.33 in) Fitted length...
  • Page 104 TECHNICAL DATA Loctite ® 243™ Screw, chain sliding guard 6 Nm (4.4 lbf ft) – Screw, electric starter cable connec- 4 Nm (3 lbf ft) tion Loctite 243™ Screw, front brake disc 14 Nm (10.3 lbf ft) ® Screw, rear brake disc 14 Nm (10.3 lbf ft) Loctite ®...

  • Page 105: Substances

    106) – SAE ( p. 106) (SAE 10W/60) – KTM LC4 2007+ Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre- sponding properties. Synthetic engine oil...
  • Page 106 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 106) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification –...

  • Page 107: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier Motorex ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier Motorex...

  • Page 108: 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 109: List Of Abbreviations

    LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 110: Index

    INDEX Chassis number ....... 10 INDEX Clutch Accessories ........7 checking/correcting the fluid level .
  • Page 111 INDEX bleeding ....... . . 37 removing from lift stand .
  • Page 112 INDEX Start number plate installing ....... . . 44 removing ....... . . 44 Starting .
  • Page 113 *3213332en* 3213332en 05/2015 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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