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Related Manuals for KTM 350 EXC-F 2017
Summary of Contents for KTM 350 EXC-F 2017
- Page 1 OWNER'S MANUAL 2017 350 EXC-F Art. no. 3213481en...
- Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.
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Page 4: Table Of Contents
TABLE OF CONTENTS Setting the clock..........24 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 Viewing the lap time........24 Symbols used ........... 5 Display mode SPEED (speed) ......25 Formats used............ 5 Display mode SPEED/H (service hours) ..... 25 SAFETY ADVICE............ - Page 5 TABLE OF CONTENTS 11.9 Adjusting the spring preload of the shock 13.3 Checking the brake discs ......... 73 absorber ............. 46 13.4 Checking the brake fluid level of the front 11.10 Adjusting the riding sag ....... 47 brake ............. 74 11.11 Checking the basic setting of the fork ....
- Page 6 TABLE OF CONTENTS 19.2 Checks and maintenance steps for winter operation............107 20 STORAGE ..............108 20.1 Storage ............108 20.2 Preparing for use after storage......108 21 TROUBLESHOOTING ..........109 22 TECHNICAL DATA............ 111 22.1 Engine ............111 22.2 Engine tightening torques ......
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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 E00508-10 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 E00511-01 Canada type label E00512-01 USA type label... - Page 10 SAFETY ADVICE Brake fluid information S00026-10 Information on chain tension 101516-01 Information on starting up F00491-10 Information on emissions control E00513-01 E00514-01 Information on noise emission...
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Page 11: Reporting Safety Defects
Hotline. Noise emission warranty KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise stan- dards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers. -
Page 12: Safe Operation
– Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. 2.12 Work rules Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren- theses. -
Page 13: Owner's Manual
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 14: Important Notes
Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the warranty. -
Page 15: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) E00500-10 Hand brake lever ( p. 17) Clutch lever ( p. 17) Filler cap Side stand ( p. 21) Engine number ( p. 15) Shift lever ( p. 20) -
Page 16: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) E00501-10 Horn button ( p. 17) Light switch ( p. 17) Turn signal switch ( p. 18) Emergency OFF switch ( p. 18) Electric starter button ( p. 18) Throttle grip ( p. -
Page 17: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. 401945-10 Type label The type label is fixed to the front of the steering head. The additional type label for Canada is fixed to the front of the front pipe. -
Page 18: Fork Part Number
SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub. 401947-10 Shock absorber article number Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. -
Page 19: Controls
CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. S01305-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. The hand brake lever is used to activate the front brake. -
Page 20: 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 21: Opening The Filler Cap
CONTROLS 6.11 Opening the filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –... -
Page 22: Cold Start Button
CONTROLS 6.13 Cold start button Cold start button 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. To help the engine burn the increased amount of fuel, it must be supplied with additional oxygen by pushing the cold start button. -
Page 23: Foot Brake Lever
CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.16 Foot brake lever The foot brake lever is attached in front of the right footrest. The foot brake lever is used to activate the rear brake. -
Page 24: Locking The Steering
CONTROLS 6.19 Locking the steering Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Park the vehicle. – Turn the handlebar as far as possible to the right. –... -
Page 25: Speedometer
SPEEDOMETER Speedometer overview – 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. 401761-01 Activation and test Activating the speedometer The speedometer is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor. -
Page 26: Setting The Speedometer Functions
SPEEDOMETER Setting the speedometer functions Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is stationary. – Repeatedly press the button briefly until H appears at the bottom right of the display. -
Page 27: Display Mode Speed (Speed)
SPEEDOMETER – Repeatedly press the button briefly until LAP appears at the bottom right of the display. – Briefly press the button LAP 1 appears on the left side of the display. – The laps 1–10 can be viewed with the button –... -
Page 28: Setup Menu
SPEEDOMETER Setup menu Condition • The motorcycle is stationary. – Repeatedly press the button briefly until H appears at the bottom right of the display. – Press the button for 2–3 seconds. The Setup menu displays the active functions. Info Repeatedly press the button briefly until the desired function is reached. -
Page 29: Display Mode Speed/Clk (Time)
SPEEDOMETER 7.11 Display mode SPEED/CLK (time) – Repeatedly press the button briefly until CLK appears at the bottom right of the display. The time is shown in display mode CLK. Press the button The display changes to the Setup menu of the clock. for 2–3 seconds. -
Page 30: Viewing The Lap Time
SPEEDOMETER 7.14 Viewing the lap time Condition • The motorcycle is stationary. – Repeatedly press the button briefly until LAP appears at the bottom right of the display. – Briefly press the button Press the button The stop watch and the lap time are reset. for 2–3 seconds. -
Page 31: Display Mode Speed/Tr2 (Trip Master 2)
SPEEDOMETER 7.17 Display mode SPEED/TR2 (trip master 2) – Repeatedly press the button briefly until TR2 appears at the top right of the dis- play. TR2 (trip master 2) runs constantly and counts up to 999.9. Press the button Clears the values TR2 and A2. for 2–3 seconds. -
Page 32: Display Mode Speed/A2 (Average Speed 2)
SPEEDOMETER 7.20 Display mode SPEED/A2 (average speed 2) – Repeatedly press the button briefly until A2 appears at the top right of the dis- play. A2 (average speed 2) shows the average speed on the basis of the current speed if the stop watch S2 (stop watch 2) is running. -
Page 33: Table Of Functions
SPEEDOMETER 7.23 Table of functions Display Press the but- Briefly press the Press the but- Briefly press the Wait 3–5 sec- Wait 10–12 sec- for 2–3 button for 2–3 button onds onds seconds. seconds. Display mode The display Next display No function No function SPEED/H (service... -
Page 34: Table Of Conditions And Menu Activation
SPEEDOMETER 7.24 Table of conditions and menu activation Display The motorcycle is Menu can be acti- stationary. vated Display mode SPEED/H (service hours) • Setup menu • Setting the unit of measurement • Setting the clock • Display mode SPEED/LAP (lap time) •... -
Page 35: 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 and Warranty Booklet at vehicle handover. -
Page 36: 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. 117) –... -
Page 37: Preparing For Rides On Dry Sand
Preparing for rides on dry sand – Fit a dust cover on the air filter. Dust cover for air filter (79006920000) Info See the KTM PowerParts fitting instructions. 102136-01 – Fit a sand cover on the air filter. Sand cover for air filter (79006922000) Info See the KTM PowerParts fitting instructions. -
Page 38: 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 (79006921000) Info See the KTM PowerParts fitting instructions. 102137-01 – Fit the steel sprocket. – Clean the motorcycle. ( p. -
Page 39: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –... -
Page 40: Starting Off
Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system. -
Page 41: Stopping, Parking
RIDING INSTRUCTIONS – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. – Make use of the braking effect of the engine when driving down long downhill stretches. To do so, shift back one or two gears, but do not overrev the engine. -
Page 42: 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. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Improper handling of fuel is a danger to the environment. -
Page 43: Service Schedule
Every 30 operating hours/after every race Every 15 operating hours Once after 1 operating hour ○ ● ● ● Read out the fault memory using the KTM diagnostics tool. ○ ● ● ● Check that the electrical system is functioning properly. ●... -
Page 44: Recommended Work
Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval 10.3... -
Page 45: Tuning The Chassis
The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber. -
Page 46: Adjusting The High-Speed Compression Damping Of The Shock Absorber
The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber. -
Page 47: Measuring The Rear Wheel Dimension Unloaded
TUNING THE CHASSIS 11.6 Measuring the rear wheel dimension unloaded Preparatory work – Raise the motorcycle with the lift stand. ( p. 50) Main work – Position the sag gauge in the rear axle and measure the distance to marking SAG on the rear fender. -
Page 48: Checking The Riding Sag Of The Shock Absorber
The shock absorber is filled with highly compressed nitrogen. – Please follow 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 49: Adjusting The Riding Sag
TUNING THE CHASSIS – Remove the motorcycle from the lift stand. ( p. 50) 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with the lift stand. ( p. 50) – Remove shock absorber. p. 57) – After removing the shock absorber, clean it thoroughly. Main work –... -
Page 50: Adjusting The Rebound Damping Of The Fork
TUNING THE CHASSIS – Turn counterclockwise by the number of clicks corresponding to the fork type. Guideline Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. 11.13 Adjusting the rebound damping of the fork Info... -
Page 51: Adjusting The Handlebar Position
TUNING THE CHASSIS 11.15 Adjusting the handlebar position Warning Danger of accidents A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result. – Change the handlebar if the handlebar is damaged or bent. –... -
Page 52: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (78129955100) Neither wheel is in contact with the ground. -
Page 53: Cleaning The Dust Boots Of The Fork Legs
SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 50) – Remove the fork protector. ( p. 51) Main work – Push dust boots of both fork legs downward. -
Page 54: Removing The Fork Legs
SERVICE WORK ON THE CHASSIS 12.7 Removing the fork legs Preparatory work – Remove the headlight mask with the headlight. ( p. 91) – Raise the motorcycle with the lift stand. ( p. 50) – Remove the front wheel. p. 82) Main work –... -
Page 55: Removing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS 12.9 Removing the lower triple clamp Preparatory work – Remove the headlight mask with the headlight. ( p. 91) – Raise the motorcycle with the lift stand. ( p. 50) – Remove the front wheel. p. - Page 56 SERVICE WORK ON THE CHASSIS – Position the upper triple clamp with the handlebar. – Mount screw but do not tighten yet. – Secure wiring harness and clutch line with cable holder. – Position the voltage regulator, and mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft)
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Page 57: Checking The Play Of The Steering Head Bearing
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time. -
Page 58: Adjusting The Steering Head Bearing Play
SERVICE WORK ON THE CHASSIS 12.12 Adjusting the steering head bearing play Preparatory work – Raise the motorcycle with the lift stand. ( p. 50) Main work – Loosen screws – Loosen and retighten screw Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) –... -
Page 59: Installing The Front Fender
SERVICE WORK ON THE CHASSIS 12.15 Installing the front fender Main work – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) V00340-10 – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) V00341-10 Finishing work... -
Page 60: Removing The Seat
SERVICE WORK ON THE CHASSIS 12.18 Removing the seat – Remove screws – Raise the rear of the seat, pull the seat back, and lift it off. V00342-10 12.19 Mounting the seat – Mount the front of the seat on the collar bushing of the fuel tank, lower the seat at the rear, and push the seat forward. -
Page 61: Installing The Air Filter Box Cover
SERVICE WORK ON THE CHASSIS 12.21 Installing the air filter box cover – Insert the air filter box cover in area and clip it into area K00554-12 Condition The air filter box cover is secured. – Mount and tighten screw Guideline Screw, air filter box cover EJOT PT... -
Page 62: Cleaning The Air Filter And Air Filter Box
SERVICE WORK ON THE CHASSIS – Insert air filter and position retaining pin in bushing The air filter is correctly positioned. – Insert retaining tab Retaining pin is secured by retaining tab Info If the air filter is not mounted correctly, dust and dirt may enter the engine and result in damage. -
Page 63: Securing The Air Filter Box Cover
SERVICE WORK ON THE CHASSIS 12.26 Securing the air filter box cover Preparatory work – Remove the air filter box cover. ( p. 58) Main work – Drill a hole at marking Guideline Diameter 6 mm (0.24 in) S00846-10 Finishing work –... -
Page 64: Changing The Glass Fiber Yarn Filling In The Main Silencer
SERVICE WORK ON THE CHASSIS H01763-10 Main work – Remove screws and take off silencer cap with O-ring Info Do not remove glass fiber yarn. Warning Danger to health Soot particles irritate the eyes and mucuous membranes. – Wear suitable breathing and eye protection when cleaning the main silencer and carbon screen. -
Page 65: Removing The Fuel Tank
SERVICE WORK ON THE CHASSIS Main work – Remove all screws on the main silencer. – Take off silencer cap with with screen and O-ring – Take off outer tube and O-ring – Remove glass fiber yarn filling from inner tube with connecting cap –... -
Page 66: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS – 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! – Disconnect the plug-in connection of the fuel line. –... -
Page 67: Checking For Chain Dirt Accumulation
SERVICE WORK ON THE CHASSIS Main work – Check throttle cable routing. ( p. 70) – Position the fuel tank and fit the two spoilers to the sides in front of the radiator bracket. – Make sure that no cables or throttle cables are trapped or damaged. –... -
Page 68: Cleaning The Chain
SERVICE WORK ON THE CHASSIS 12.34 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. – Remove the lubricant from the tires using a suitable cleaning agent. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –... -
Page 69: 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. When the chain guard is mounted, it must be possible to pull up the chain ... -
Page 70: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide
SERVICE WORK ON THE CHASSIS Finishing work – Remove the motorcycle from the lift stand. ( p. 50) 12.37 Checking the chain, rear sprocket, engine sprocket and chain guide Preparatory work – Raise the motorcycle with the lift stand. ( p. -
Page 71: Checking The Frame
If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by KTM. S01316-10... -
Page 72: Checking The Swingarm
» If the swingarm shows signs of damage, cracking, or deformation: – Change the swingarm. Info Always change a damaged swingarm. Repair of the swingarm is not authorized by KTM. S01317-10 12.40 Checking throttle cable routing Preparatory work – Remove the seat. ( p. -
Page 73: Adjusting The Basic Position Of The Clutch Lever
SERVICE WORK ON THE CHASSIS 12.42 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 74: Changing The Hydraulic Clutch Fluid
SERVICE WORK ON THE CHASSIS 12.44 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. –... -
Page 75: Brake System
Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at multiple points on each ... -
Page 76: Checking The Brake Fluid Level Of The Front Brake
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect. -
Page 77: Checking The Front Brake Linings
Changing the front brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation. –... - Page 78 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
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Page 79: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM – Correct the brake fluid quantity to level Guideline 5 mm (0.2 in) Level (brake fluid level below reser- voir rim) Brake fluid DOT 4 / DOT 5.1 ( p. 117) – Position the cover with the membrane. Mount and tighten the screws. Info K00574-12 Clean up overflowed or spilled brake fluid immediately with water. -
Page 80: Checking The Rear Brake Fluid Level
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect. -
Page 81: Checking The Rear Brake Linings
79) E00349-10 13.13 Changing the rear brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.) - Page 82 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
- Page 83 BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. E00352-10 – Insert the new brake linings, insert the pin, and mount the cotter pins. Info Always change the brake linings in pairs.
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Page 84: Wheels, Tires
WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 50) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. -
Page 85: Removing The Rear Wheel
WHEELS, TIRES – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. – 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 seated cor- rectly against the brake disc. -
Page 86: Installing The Rear Wheel
WHEELS, TIRES 14.4 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Main work –... -
Page 87: Checking The Tire Condition
DOT number. The first two digits indi- cate the week of manufacture and the last two digits the year of manufac- ture. KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear. H01144-01 »... -
Page 88: Checking Spoke Tension
Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.) – Strike each spoke briefly using a screwdriver blade. -
Page 89: Electrical System
ELECTRICAL SYSTEM 15.1 Removing the battery Warning Environmental hazard Batteries contain environmentally-hazardous materials. – Do not dispose of batteries as household waste. – Dispose of batteries at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu- lations. -
Page 90: Recharging The Battery
ELECTRICAL SYSTEM Contact disks must be mounted under screws and cable sockets with the claws toward the battery terminal. Finishing work – Mount the seat. ( p. 58) 15.3 Recharging the battery Warning Environmental hazard Batteries contain environmentally-hazardous materials. –... -
Page 91: Changing The Main Fuse
ELECTRICAL SYSTEM Info If the charging current, charging voltage, or charging time are exceeded, the battery will be destroyed. If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfated, destroying the battery. The battery is maintenance-free. -
Page 92: Changing The Fuses Of Individual Power Consumers
ELECTRICAL SYSTEM – Take off protection caps – Remove faulty main fuse Info You can recognize a defective fuse by a burned-out fuse wire A spare fuse is located in the starter relay. – Install a new main fuse. Fuse (58011109120) ( p. -
Page 93: Removing The Headlight Mask With The Headlight
ELECTRICAL SYSTEM – Use spare fuses with the correct rating only. Fuse (75011088010) ( p. 114) Fuse (58011109105) ( p. 114) Replace the spare fuse in the fuse box so that it is available if needed. – Check that the power consumer is functioning properly. –... -
Page 94: Changing The Headlight Bulb
ELECTRICAL SYSTEM – Position the headlight mask and fix it with rubber bands The holding lugs engage in the fender. – Position the brake line and wiring harness in the brake line guide. V00469-11 Finishing work – Check the headlight setting. ( p. -
Page 95: Checking The Headlight Setting
ELECTRICAL SYSTEM Main work – Remove the screw and carefully remove diffuser – Press the turn signal bulb carefully into the socket, turn it counterclockwise by about 30°, and take it out of the socket. Info Do not touch the reflector with your fingers, and keep it free from grease. –... -
Page 96: Changing The Speedometer Battery
ELECTRICAL SYSTEM 15.12 Changing the speedometer battery Preparatory work – Remove the headlight mask with the headlight. ( p. 91) Main work – Remove screws with the washers. – Pull the speedometer upward out of the holder. V00370-10 – ... -
Page 97: Cooling System
COOLING SYSTEM 16.1 Cooling system The 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 98: Checking The Coolant Level
COOLING SYSTEM 16.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature. -
Page 99: Refilling Coolant
COOLING SYSTEM – Position the motorcycle upright. – Place a suitable container under the water pump cover. – Remove screw . Take off radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Screw, water pump cover 10 Nm (7.4 lbf ft) -
Page 100: Tuning The Engine
TUNING THE ENGINE 17.1 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 101: Setting The Characteristic Map Of The Throttle Response
17.4 Adjusting the idle speed Warning Danger of accidents The engine may go out spontaneously if the idle speed is set too low. – Set the idle speed to the specified value. (Your authorized KTM workshop will be glad to help.) -
Page 102: Teaching The Throttle Valve Position
TUNING THE ENGINE – Run the engine until warm. The cold start button is deactivated – The cold start button is in its basic posi- tion. ( p. 20) Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. -
Page 103: Adjusting The Basic Position Of The Shift Lever
TUNING THE ENGINE 17.7 Adjusting the basic position of the shift lever – Remove screw with washers and take off shift lever 401950-12 – 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. -
Page 104: Service Work On The Engine
SERVICE WORK ON THE ENGINE 18.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –... -
Page 105: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen
SERVICE WORK ON THE ENGINE Condition The engine is at operating temperature. – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level. The engine oil is at a level between the lower edge and the middle of the ... - Page 106 SERVICE WORK ON THE ENGINE – Mount and tighten screw plug with the O-ring. Guideline Screw plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) – Mount and tighten oil drain plug with the magnet and a new seal ring. Guideline Oil drain plug with magnet M12x1.5...
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Page 107: Adding Engine Oil
SERVICE WORK ON THE ENGINE – Start the engine and check that it is oil-tight. Finishing work – Check the engine oil level. ( p. 102) 18.4 Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. Main work –... -
Page 108: Cleaning, Care
CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –... -
Page 109: Checks And Maintenance Steps For Winter Operation
CLEANING, CARE 19.2 Checks and maintenance steps for winter operation Info If you use the vehicle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt. -
Page 110: 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. 50) – Preferably cover the vehicle with a tarp or similar cover that is permeable to air. -
Page 111: 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 112 – Check the cabling for damage and the electri- cal plug-in connectors 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.
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Page 113: 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 114 TECHNICAL DATA Loctite ® 243™ Screw, crankshaft position sensor 6 Nm (4.4 lbf ft) Screw, gear position sensor 5 Nm (3.7 lbf ft) Loctite ® 243™ Screw, locking lever 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, oil pump cover 6 Nm (4.4 lbf ft) Loctite ®...
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Page 115: Capacities
TECHNICAL DATA 22.3 Capacities 22.3.1 Engine oil Engine oil 1.0 l (1.1 qt.) Engine oil (SAE 10W/50) ( p. 117) Alternative engine oil for harsh Engine oil (SAE 10W/60) operating conditions and (00062010035) ( p. 117) increased performance 22.3.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant (... -
Page 116: Electrical System
120/90 - 18 M/C 65R M+S TT Continental TKC 80 Continental TKC 80 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork Fork part number 14.18.8Q.67... -
Page 117: Shock Absorber
TECHNICAL DATA 22.8 Shock absorber Shock absorber article number 12.18.7Q.63 Shock absorber WP Performance Systems 4618 PDS DCC Compression damping, low-speed Comfort 18 clicks Standard 15 clicks Sport 12 clicks Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport 1 turn Rebound damping Comfort... - Page 118 TECHNICAL DATA – Fuel connection on fuel pump 10 Nm (7.4 lbf ft) – Nut, foot brake lever stop 20 Nm (14.8 lbf ft) Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite ® 2701™ – Nut, rim lock 12 Nm (8.9 lbf ft) –...
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Page 119: Substances
120) – SAE ( p. 120) (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 120 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 120) (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 –...
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Page 121: 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 122: 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 123: Index Of Special Terms
INDEX OF SPECIAL TERMS On-board diagnosis Vehicle system that monitors emission- and safety-related values... -
Page 124: 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 125: List Of Symbols
LIST OF SYMBOLS 28.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols. Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an emission- or safety-critical fault. -
Page 126: Index
INDEX Clutch INDEX fluid level, checking/correcting ....71 Accessories ........12 fluid, changing . - Page 127 INDEX Fork legs removing ....... . . 53 basic setting, checking ..... . . 47 bleeding .
- Page 128 INDEX Side stand ........21 Spare parts ........12 View of vehicle Speedometer front left .
- Page 129 *3213481en* 3213481en 08/2016 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...
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