KTM 350 EXC-F EU 2018 Owner's Manual
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KTM 350 EXC-F EU 2018 Owner's Manual

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OWNER'S MANUAL
2018
350 EXC-F
350 EXC‑F Six Days
Art. no. 3213648en

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Summary of Contents for KTM 350 EXC-F EU 2018

  • Page 1 OWNER'S MANUAL 2018 350 EXC-F 350 EXC‑F Six Days Art. no. 3213648en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art DEAR KTM CUSTOMER sports motorcycle that will give you enormous pleasure if you service and maintain it properly. We hope you enjoy your new vehicle! Please enter the serial number of your vehicle below.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 6.15 Idle speed adjusting screw ....20 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 6 6.16 Shift lever ........21 Symbols used ........6 6.17 Foot brake lever ....... 21 Formats used........6 6.18 Side stand........21 SAFETY ADVICE..........
  • Page 5 TABLE OF CONTENTS Preparing for rides on wet sand ..39 11.14 Adjusting the spring pretension of the fork (EXC‑F Six Days)....58 Preparing for rides on wet and muddy surfaces ....... 40 11.15 Handlebar position......59 Preparing for rides at high 11.16 Adjusting the handlebar position ..
  • Page 6 TABLE OF CONTENTS 12.35 Checking for chain dirt 15.2 Installing the battery ....115 accumulation........85 15.3 Recharging the battery ....116 12.36 Cleaning the chain ......85 15.4 Changing the main fuse ....119 12.37 Checking the chain tension ....86 15.5 Changing the fuses of individual 12.38 Adjusting the chain tension....
  • Page 7 TABLE OF CONTENTS 20 STORAGE ..........144 20.1 Storage ......... 144 20.2 Preparing for use after storage..145 21 TROUBLESHOOTING ........ 146 22 BLINK CODE ..........149 23 TECHNICAL DATA........151 23.1 Engine .......... 151 23.2 Engine tightening torques ....152 23.3 Capacities ........

  • Page 8: 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! Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary tools required.

  • Page 9: Safety Advice

    2 SAFETY ADVICE Use definition – intended use This vehicle is designed and built to withstand the normal stresses and strains of competitive use. This vehicle complies with the currently valid regulations and categories of the top international motorsport organizations. Info This vehicle is only authorized for operation on public roads in the homologated (restricted) version.

  • Page 10: Tampering Warning

    An appropriate driver's license is needed to ride the vehicle on public roads. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.

  • Page 11: Protective Clothing

    – 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. Work rules Special tools are necessary for certain tasks.

  • Page 12: 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.

  • Page 13: Customer Service

    3 IMPORTANT NOTES Customer service Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM. A list of authorized KTM dealers can be found on the KTM website. International KTM Website: http://www.ktm.com...

  • Page 14: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) A00059-10 Hand brake lever ( p. 16) Clutch lever ( p. 16) Filler cap Engine number ( p. 14) Side stand ( p. 21) Shift lever ( p. 21)

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

    4 VIEW OF VEHICLE View of vehicle, rear right (example) A00057-10 Kill switch ( p. 16) Horn button ( p. 17) Light switch ( p. 17) Turn signal switch ( p. 17) Emergency OFF switch ( p. 17) Electric starter button ( p.

  • Page 16: Serial Numbers

    5 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. 401946-10 Key number The key number for the steering lock is stamped onto the key connector.

  • Page 17: Fork Part Number

    5 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. 0 0 1 401948-10...

  • Page 18: Controls

    6 CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automati- cally. V00800-10 Hand brake lever The hand brake lever is fitted on the right side of the handle- bar.

  • Page 19: Horn Button

    6 CONTROLS Horn button The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed – The horn is operated in this posi- • Horn button tion. S01303-10 Light switch The light switch is fitted on the left side of the handlebar.

  • Page 20: Electric Starter Button

    – The OBD has detected a fault in the vehicle elec- tronics. Come safely to a halt, and contact an autho- rized KTM workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

  • Page 21: Opening The Filler Cap

    6 CONTROLS Turn signal indicator lamp flashes green – The turn signal is switched on. 6.12 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. –...

  • Page 22: Cold Start Button

    6 CONTROLS 6.14 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: Shift Lever

    6 CONTROLS 6.16 Shift lever The shift lever is fitted on the left side of the engine. 401950-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.17 Foot brake lever The foot brake lever...

  • Page 24: Steering Lock

    6 CONTROLS The side stand is used to park the motorcycle. Info When you are riding, the side stand must be folded up and secured with the rubber band 401944-10 6.19 Steering lock Steering lock is fitted on the left side of the steering head. The steering lock is used to lock the steering.

  • Page 25: Unlocking The Steering

    6 CONTROLS 6.21 Unlocking the steering – Insert the key in the steering lock ( p. 22), turn it to the left, pull it out, and turn it to the right. Remove the key. You can now steer the bike again. Info Never leave the key in the steering lock.

  • Page 26: Combination Instrument

    7 COMBINATION INSTRUMENT Combination instrument 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. V00799-01 Activation and test Activating combination instrument The combination instrument is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor.

  • Page 27: Adjusting The Combination Instrument

    7 COMBINATION INSTRUMENT Setting the Mph – Press the button – Wait 3 - 5 seconds. The settings are stored. Info If no button is pressed for 10 -12 seconds, or if an impulse comes from the wheel speed sensor, the settings are automatically saved and the setup menu is closed.

  • Page 28: Setting The Clock

    7 COMBINATION INSTRUMENT Setting the clock Condition The motorcycle is stationary. – Repeatedly press the button briefly until CLK appears at the bottom right of the display. – Press the button for 2–3 seconds. The hour display flashes. – Set the hour display with the button and/or button –...

  • Page 29: Display Mode Speed (Speed)

    7 COMBINATION INSTRUMENT Display mode SPEED (speed) – Repeatedly press the button briefly until SPEED appears on the left side of the display. The current speed is displayed in the SPEED display mode. The current speed can be displayed in Km/h or Mph. Info Make the setting according to the country.

  • Page 30: Setting The Unit Of Measurement

    7 COMBINATION INSTRUMENT Info Repeatedly press the button briefly until the desired function is reached. If no button is pressed for 20 seconds, the settings are automatically saved. Briefly press Activates the flashing display and changes to the button the next display Press the but- No function for 2–3...

  • Page 31: Display Mode Speed/Clk (Time)

    7 COMBINATION INSTRUMENT 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 but- The display changes to the Setup menu of the for 2–3 clock.

  • Page 32: Viewing The Lap Time

    7 COMBINATION INSTRUMENT Press the but- The stop watch and the lap time are reset. for 2–3 seconds. Briefly press Next display mode the button Press the but- Stops the clock. for 2–3 seconds. Briefly press Starts the stop watch or stop the current lap the button time measurement, stores it and the stop watch starts the next lap.

  • Page 33: Display Mode Speed/Tr1 (Trip Master 1)

    7 COMBINATION INSTRUMENT 7.16 Display mode SPEED/TR1 (trip master 1) – Repeatedly press the button briefly until TR1 appears at the top right of the display. TR1 (trip master 1) runs constantly and counts up to 999.9. You can use it to measure trips or the distance between refueling stops.

  • Page 34: Display Mode Speed/A1 (Average Speed 1)

    7 COMBINATION INSTRUMENT Info The TR2 value can also be corrected manually during the journey with the button and the button If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0. Press the but- Increases value of TR2. for 2–3 seconds.

  • Page 35: Display Mode Speed/S1 (Stop Watch 1)

    7 COMBINATION INSTRUMENT Briefly press Next display mode the button Press the but- No function for 2–3 seconds. Press the but- No function for 2–3 seconds. Briefly press No function the button 7.21 Display mode SPEED/S1 (stop watch 1) – Repeatedly press the button briefly until S1 appears at the top right of the display.

  • Page 36: Table Of Functions

    7 COMBINATION INSTRUMENT 7.23 Table of functions Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12 for 2–3 the button for 2–3 the button seconds. seconds. seconds. seconds. Display mode The display Next display No function...

  • Page 37: Table Of Conditions And Menu Activation

    7 COMBINATION INSTRUMENT Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12 for 2–3 the button for 2–3 the button seconds. seconds. seconds. seconds. Display mode Clears the Next display Reduces Reduces SPEED/TR2 (trip...

  • Page 38: 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 39: Running-In The Engine

    8 PREPARING FOR USE – Adjust the basic position of the foot brake lever. p. 102) – Adjust the basic position of the shift lever. p. 136) – Get used to handling the motorcycle on a suitable surface before undertaking a more challenging trip. Info When off road, it is recommended that you are accompanied by another person on another vehicle so that you can help each other.

  • Page 40: Starting Power Of Lithium-Ion Batteries At Low Temperatures (All Eu/Au Models)

    For this reason, it may be necessary 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 recom- mended by KTM. Engine oil (SAE 10W/60) (00062010035) ( p. 160) –...

  • Page 41: 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 42: 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 43: Preparing For Rides At Low Temperature Or In Snow

    8 PREPARING FOR USE Preparing for rides at low temperature or in snow – Fit a waterproofing device on the air filter. Waterproofing device for air filter (79006921000) Info See the KTM PowerParts fitting instructions. 102137-01...

  • Page 44: Riding Instructions

    9 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 45: Activating Traction Control (Exc-F Six Days)

    9 RIDING INSTRUCTIONS – Take the motorcycle off side stand and secure the side stand with rubber band – Shift transmission to neutral. – Turn the emergency OFF switch to the position Condition Ambient temperature: < 20 °C (< 68 °F) –...

  • Page 46: Starting Off

    Do not change into a low gear at high engine speed. Info If unusual noises occur 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 47: Braking

    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 48: Transporting

    9 RIDING INSTRUCTIONS – Park the motorcycle on firm ground. Transporting Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. –...
  • Page 49 9 RIDING INSTRUCTIONS – 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. – Do not allow fuel to enter the groundwater, the soil, or the sewage system.

  • Page 50: 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 51: 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 52: 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 53: 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 54: Adjusting The Rebound Damping Of The Shock Absorber

    Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.

  • Page 55: Checking The Static Sag Of The Shock Absorber

    11 TUNING THE CHASSIS 11.7 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 52) – Hold the motorcycle upright with the aid of an assistant. – Again measure the distance between the rear axle and mark- ing SAG on the rear fender using the sag gauge.

  • Page 56: Adjusting The Spring Preload 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 57: Adjusting The Riding Sag

    11 TUNING THE CHASSIS 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with the lift stand. ( p. 62) – Remove shock absorber. p. 76) – After removing the shock absorber, clean it thoroughly. Main work – Choose and mount a suitable spring.

  • Page 58: Adjusting The Compression Damping Of The Fork

    11 TUNING THE CHASSIS 11.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. (EXC‑F EU/AU/BR) – Turn white adjusting screw clockwise as far as it will Info Adjusting screw is located at the upper end of the left fork leg.

  • Page 59: Adjusting The Rebound Damping Of The Fork

    11 TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counter- clockwise to reduce damping. 11.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. (EXC‑F EU/AU/BR) – Turn red adjusting screw clockwise as far as it will go.

  • Page 60: Adjusting The Spring Pretension Of The Fork (Exc-F Six Days)

    11 TUNING THE CHASSIS Guideline Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise to increase damping; turn counter- clockwise to reduce damping. 11.14 Adjusting the spring pretension of the fork (EXC‑F Six Days) Preparatory work –...

  • Page 61: Handlebar Position

    11 TUNING THE CHASSIS 11.15 Handlebar position (EXC‑F EU/AU/BR) On the upper triple clamp, there are 2 holes at a distance to each other. 15 mm (0.59 in) Hole distance The holes on the handlebar supports are placed at a distance from the center.
  • Page 62 11 TUNING THE CHASSIS (EXC‑F EU/AU/BR) – Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against dam- age. Do not kink the cables and lines. –...
  • Page 63 11 TUNING THE CHASSIS (EXC‑F Six Days) – Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against dam- age. Do not kink the cables and lines. –...

  • Page 64: Service Work On The Chassis

    12 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 65: Cleaning The Dust Boots Of The Fork Legs

    12 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. 62) – Remove the fork protector. ( p. 63) Main work – Push dust boots of both fork legs downward.

  • Page 66: Installing The Fork Protector

    12 SERVICE WORK ON THE CHASSIS 12.6 Installing the fork protector – Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position the brake line, wiring harness, and clamp. Mount and tighten screws –...

  • Page 67: Installing The Fork Legs

    12 SERVICE WORK ON THE CHASSIS (EXC‑F Six Days) – Loosen screws . Take out the left fork leg. – Loosen screws . Take out the right fork leg. E00378-10 12.8 Installing the fork legs Main work (EXC‑F EU/AU/BR) – Position the fork legs.

  • Page 68: Removing The Lower Triple Clamp (Exc-F Eu/Au/Br)

    12 SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, top triple 17 Nm clamp (12.5 lbf ft) – Tighten screws Guideline Screw, bottom triple 15 Nm clamp (11.1 lbf ft) E00378-11 – Position the brake caliper, and mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft)

  • Page 69: (Exc-F Six Days)

    12 SERVICE WORK ON THE CHASSIS – Remove O-ring and protective ring – Take off the lower triple clamp with the steering stem. – Remove the upper steering head bearing. E00381-10 12.10 Removing the lower triple clamp (EXC‑F Six Days) Preparatory work –...

  • Page 70: Installing The Lower Triple Clamp (Exc-F Eu/Au/Br)

    12 SERVICE WORK ON THE CHASSIS 12.11 Installing the lower triple clamp (EXC‑F EU/AU/BR) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 162) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.
  • Page 71 12 SERVICE WORK ON THE CHASSIS – Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head V00465-11 – Tighten screw Guideline Screw, top steering 20 Nm (14.8 lbf ft) stem V00465-10 – Tighten screws Guideline Screw, top triple 20 Nm (14.8 lbf ft) clamp –...

  • Page 72: Installing The Lower Triple Clamp (Exc-F Six Days)

    12 SERVICE WORK ON THE CHASSIS 12.12 Installing the lower triple clamp (EXC‑F Six Days) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 162) – Position the lower triple clamp with the steering stem. Mount the upper steering head bearing.
  • Page 73 12 SERVICE WORK ON THE CHASSIS – Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head E00387-10 – Mount and tighten screw Guideline Screw, top 17 Nm (12.5 lbf ft) Loctite 243™ ® steering stem E00388-10 –...

  • Page 74: Checking The Play Of The Steering Head Bearing

    Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam- ages 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 75: Adjusting The Steering Head Bearing Play (Exc-F Eu/Au/Br)

    12 SERVICE WORK ON THE CHASSIS 12.14 Adjusting the steering head bearing play (EXC‑F EU/AU/BR) Preparatory work – Raise the motorcycle with the lift stand. ( p. 62) Main work – Loosen screws – Loosen and retighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head...

  • Page 76: Lubricating The Steering Head Bearing

    12 SERVICE WORK ON THE CHASSIS Finishing work – Check the play of the steering head bearing. ( p. 72) – Remove the motorcycle from the lift stand. ( p. 62) 12.16 Lubricating the steering head bearing (EXC‑F EU/AU/BR) – Remove the lower triple clamp.

  • Page 77: Installing Front Fender

    12 SERVICE WORK ON THE CHASSIS – Remove screws . Remove front fender. S01321-10 12.18 Installing front fender Main work (EXC‑F EU/AU/BR) – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00340-10 –...

  • Page 78: Removing The Shock Absorber

    12 SERVICE WORK ON THE CHASSIS Finishing work – Install the headlight mask with the headlight. ( p. 122) – Check the headlight setting. ( p. 124) 12.19 Removing the shock absorber Preparatory work – Raise the motorcycle with the lift stand. ( p.

  • Page 79: Removing The Seat

    12 SERVICE WORK ON THE CHASSIS 12.21 Removing the seat – Remove screws – Raise the rear of the seat, pull the seat back, and lift it off. V00342-10 12.22 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 80: Installing The Air Filter Box Cover

    12 SERVICE WORK ON THE CHASSIS – Pull off the air filter box cover in area sideways and take off toward the front. K00554-11 12.24 Installing the air filter box cover – Insert the air filter box cover in area and clip it into area K00554-12...

  • Page 81: Installing The Air Filter

    12 SERVICE WORK ON THE CHASSIS Main work – Detach retaining tab . Remove air filter with air filter sup- port. – Remove air filter from air filter support. A00060-10 12.26 Installing the air filter Main work – Mount the clean air filter on the air filter support. –...

  • Page 82: Sealing The Air Filter Box

    12 SERVICE WORK ON THE CHASSIS Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 162) Info Only press the air filter to dry it, never wring it out. –...

  • Page 83: Removing Main Silencer

    12 SERVICE WORK ON THE CHASSIS 12.30 Removing main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. – Disconnect spring Spring hook (50305017000) –...

  • Page 84: Removing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS Main work – Remove screws – Take off silencer cap with O-ring – Remove old glass fiber yarn filling. – Clean the parts that need to be reinstalled and check for dam- age. – Fit new glass fiber yarn filling into the main silencer.
  • Page 85 12 SERVICE WORK ON THE CHASSIS Main work – Unplug connector of the fuel pump. – Remove the tube from the fuel tank breather. K00555-10 – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line.

  • Page 86: Installing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS – Pull both spoilers off the sides of the radiator bracket and lift off the fuel tank. K00559-10 12.34 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. –...

  • Page 87: Checking For Chain Dirt Accumulation

    12 SERVICE WORK ON THE CHASSIS – Position the horn with the horn bracket. – Mount and tighten screws with the collar bushings. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis K00558-11 – Plug in connector for the fuel pump. –...

  • Page 88: Checking The Chain Tension

    12 SERVICE WORK ON THE CHASSIS 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 regulations. Info The service life of the chain depends largely on its maintenance. Preparatory work –...

  • Page 89: Adjusting The Chain Tension

    12 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 at least to the point where it makes contact with chain guard Chain wear is not always even, so you should repeat...

  • Page 90: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

    12 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55 … 58 mm (2.17 … 2.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks...
  • Page 91 12 SERVICE WORK ON THE CHASSIS – Pull on the upper part of the chain with the specified weight Guideline Weight of chain wear mea- 10 … 15 kg (22 … 33 lb.) surement – Measure the distance of 18 chain links in the lower chain section.
  • Page 92 12 SERVICE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the bottom edge of the chain bolt is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated.

  • Page 93: Checking The Frame

    If the swingarm shows signs of damage, cracking, or defor- mation: – Change the swingarm. Info Always change a damaged swingarm. Repair of the swingarm is not authorized by KTM. S01317-10 12.42 Checking throttle cable routing Preparatory work – Remove the seat. ( p.

  • Page 94: Checking The Rubber Grip

    12 SERVICE WORK ON THE CHASSIS Finishing work – Install the fuel tank. p. 84) – Mount the seat. ( p. 77) 12.43 Checking the rubber grip – Check the rubber grips on the handlebar for damage, wear, and looseness. Info The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the...

  • Page 95: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    12 SERVICE WORK ON THE CHASSIS 12.45 Checking/correcting the fluid level of the hydraulic clutch Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. –...

  • Page 96: Changing The Hydraulic Clutch Fluid

    12 SERVICE WORK ON THE CHASSIS 12.46 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 97: Removing The Engine Guard (Exc-F Au, Exc-F Six Days)

    12 SERVICE WORK ON THE CHASSIS – Inject the liquid into the system until it escapes from open- ings of the master cylinder without bubbles. – Now and then, extract fluid from the master cylinder reservoir to prevent overflow. – Remove the bleeding syringe.

  • Page 98: Brake System

    Do not make any adjustments while riding! 13.3 Checking the brake discs Warning 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.)

  • Page 99: Checking The Brake Fluid Level Of The Front Brake

    – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 100: Adding Front Brake Fluid

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 101: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 102 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 103: Checking The Free Travel Of Foot Brake Lever

    13 BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 100397-01 – Insert the new brake linings, insert the pin, and mount the cot- ter pins. Info Always change the brake linings in pairs.

  • Page 104: Adjusting The Basic Position Of The Foot Brake Lever

    13 BRAKE SYSTEM – Disconnect spring – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in) »...

  • Page 105: Checking The Rear Brake Fluid Level

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.

  • Page 106: Checking The Rear Brake Linings

    Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...

  • Page 107: Changing The Rear Brake Linings

    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 108 13 BRAKE SYSTEM – Stand the vehicle upright. – Remove screw cap with membrane and the O-ring. – Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir, extracting it if necessary.
  • Page 109 13 BRAKE SYSTEM – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 160) – Mount screw cap with membrane and O-ring. Info Clean up overflowed or spilled brake fluid immediately with water. M01506-10...

  • Page 110: Wheels, Tires

    14 WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 62) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake...

  • Page 111: Installing The Front Wheel

    14 WHEELS, TIRES 14.2 Installing the front 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. –...

  • Page 112: Installing The Rear Wheel

    14 WHEELS, TIRES Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes. –...
  • Page 113 14 WHEELS, TIRES Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surface of the spacers. Long-life grease ( p.

  • Page 114: Checking The Tire Condition

    DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. KTM recommends that the tires be changed after 5 H01144-01 years at the latest, regardless of the actual state of wear.

  • Page 115: 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.) –...

  • Page 116: Electrical System

    15 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. –...

  • Page 117: Installing The Battery

    15 ELECTRICAL SYSTEM (All BR models) 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 safety glasses. – Avoid contact with battery acid and battery gases.

  • Page 118: Recharging The Battery

    15 ELECTRICAL SYSTEM Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) Contact disks must be mounted under screws cable sockets with the claws toward the battery termi- nal. Finishing work – Mount the seat. ( p. 77) 15.3 Recharging the battery Warning Environmental hazard Batteries contain environmentally-hazardous materials.
  • Page 119 15 ELECTRICAL SYSTEM Main work (All EU/AU models) Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batteries. S00863-10 – Only charge batteries in well-ventilated rooms. –...
  • Page 120 15 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 bat- tery.

  • Page 121: Changing The Main Fuse

    15 ELECTRICAL SYSTEM You can also use the battery charger to test the open-circuit voltage and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the battery. Info If the charging current, charging voltage and charg- ing time are exceeded, electrolyte escapes through the safety valves.

  • Page 122: Changing The Fuses Of Individual Power Consumers

    15 ELECTRICAL SYSTEM Main work – Pull starter relay from the holder. E00361-10 – Take off protection caps – Remove faulty main fuse Info You can recognize a faulty fuse by a burned-out fuse wire A spare fuse is located in the starter relay. –...
  • Page 123 15 ELECTRICAL SYSTEM Main work – Pull engine electronics control unit from the holder and hang it to the side. E00394-10 – Open fuse box cover – Remove the defective fuse. Guideline (All EU models) Fuse 1 ‑ 10 A – EFI control unit, lambda sensor, com- bination instrument, combination switch (optional), fuel injection, diagnostics connector, fuse 4 (EXC‑F AU, All BR models)

  • Page 124: Removing The Headlight Mask With The Headlight

    15 ELECTRICAL SYSTEM – Mount engine electronics control unit on the holder. E00394-10 Finishing work – Mount the seat. ( p. 77) 15.6 Removing the headlight mask with the headlight – Detach the brake line and wiring harness from the headlight mask.

  • Page 125: Changing The Headlight Bulb

    15 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. V00458-11 Finishing work – Check the headlight setting. ( p.

  • Page 126: Checking The Headlight Setting

    15 ELECTRICAL SYSTEM 15.9 Checking the headlight setting – Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight. – Make another mark at a distance under the first mark.

  • Page 127: Changing The Turn Signal Bulb

    15 ELECTRICAL SYSTEM 15.11 Changing the turn signal bulb Note Damage to reflector Grease on the reflector reduces the brightness. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. – Clean and degrease the bulbs before mounting. –...

  • Page 128: Diagnostics Connector

    15 ELECTRICAL SYSTEM – Using a coin, turn protection cap all the way counterclock- wise and remove it. – Remove combination instrument – Insert the combination instrument with the label facing upward. Combination instrument battery (CR 2430) ( p. 155) –...

  • Page 129: Cooling System

    16 COOLING SYSTEM 16.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 130: Checking The Coolant Level

    16 COOLING SYSTEM – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: –...

  • Page 131: Draining The Coolant

    16 COOLING SYSTEM 16.4 Draining the coolant 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 132: Refilling Coolant

    16 COOLING SYSTEM 16.5 Refilling coolant Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. –...

  • Page 133: Tuning The Engine

    17 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 134: Setting The Characteristic Map Of The Throttle Response

    17 TUNING THE ENGINE Main work – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut – Push cold start button all the way to the stop. –...

  • Page 135: Changing The Mapping (Exc-F Six Days)

    17 TUNING THE ENGINE – Remove guide plate from handle tube – Position the required guide plate on the grip tube. Guideline The label OUTSIDE must be visible. Marking must be positioned at marking Alternative 1 Grey guide plate (79002014000) Alternative 2 Black guide plate (79002014100) Info...

  • Page 136: Adjusting The Idle Speed

    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.) – Run the engine until warm.

  • Page 137: Teaching The Throttle Valve Position

    17 TUNING THE ENGINE 17.6 Teaching the throttle valve position Info If the control unit detects that the throttle valve idle position needs to be retaught, then the malfunction indicator lamp flashes 2x per second. Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death.

  • Page 138: Adjusting The Basic Position Of The Shift Lever

    17 TUNING THE ENGINE 17.8 Adjusting the basic position of the shift lever – Remove screw with the 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 139: Service Work On The Engine

    18 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 140: Checking The Engine Oil Level

    18 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space.
  • Page 141 18 SERVICE WORK ON THE ENGINE Main work – Place a suitable container under the engine. – Remove oil drain plug with the magnet and seal ring. Info Do not remove screws K00567-10 – Remove screw plug with oil screen and the O-rings.
  • Page 142 18 SERVICE WORK ON THE ENGINE – 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. K00572-10 – Lay the motorcycle on its right side and fill the oil filter hous- ing approx.

  • Page 143: Adding Engine Oil

    18 SERVICE WORK ON THE ENGINE 18.4 Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. Main work – Remove the oil filler plug with the O-ring from the clutch cover.

  • Page 144: Cleaning, Care

    19 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 145: Checks And Maintenance Steps For Winter Operation

    19 CLEANING, CARE – After the motorcycle has cooled off, lubricate all moving parts and bearings. – Clean the chain. ( p. 85) – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p.

  • Page 146: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 62) – Preferably cover the vehicle with a tarp or similar cover that is permeable to air.

  • Page 147: Preparing For Use After Storage

    20 STORAGE 20.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 62) – Install the battery. p. 115) – Perform checks and maintenance measures when preparing for use. ( p. 42) – Take a test ride. 401059-01...

  • Page 148: Troubleshooting

    Check the electrical system. tive – Defect in fuel injection system Read out the fault memory using the KTM diagnostics tool. – Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diagnostics tool.
  • Page 149 – Read out the fault memory using the KTM diagnostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary.
  • Page 150 21 TROUBLESHOOTING Faults Possible cause Action – The high beam, low beam, tail Fuse 2 blown Change the fuses of individual power light, parking light, and license consumers. ( p. 120) plate lamp are not working – The horn, brake light, turn sig- Fuse 3 blown Change the fuses of individual power nal, and radiator fan (optional)

  • Page 151: Blink Code

    22 BLINK CODE Info The blink codes are only displayed by the derestricted version of the vehicle. Blink code for malfunction indicator lamp 02a Malfunction indicator lamp flashes 2x per second Error level condition Teaching of throttle valve position required Blink code for malfunction indicator lamp 02 Malfunction indicator lamp flashes 2x short...
  • Page 152 22 BLINK CODE Blink code for malfunction indicator lamp 22 Malfunction indicator lamp flashes 2x long, 2x short Error level condition Gear position sensor - input voltage too high Gear position sensor - input voltage too low Blink code for malfunction indicator lamp 33 Malfunction indicator lamp flashes 3x long, 3x short Error level condition...

  • Page 153: Technical Data

    23 TECHNICAL DATA 23.1 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 154: Engine Tightening Torques

    23 TECHNICAL DATA 23.2 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 lubri- 2 Nm (1.5 lbf ft) Loctite ®...
  • Page 155 23 TECHNICAL DATA Screw, shift lever 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, starter motor 10 Nm (7.4 lbf ft) Screw, timing chain guide rail 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, timing chain securing guide M6 10 Nm (7.4 lbf ft) Loctite ®...

  • Page 156: Capacities

    23 TECHNICAL DATA Screw, alternator cover M24x1.5 18 Nm (13.3 lbf ft) 23.3 Capacities 23.3.1 Engine oil Engine oil 1.0 l (1.1 qt.) Engine oil (SAE 10W/50) p. 161) Engine oil Engine oil (SAE 10W/60) Alternative engine oil for harsh (00062010035) ( p.

  • Page 157: Electrical System

    23 TECHNICAL DATA front 1.0 bar (15 psi) rear 1.0 bar (15 psi) Road tire pressure front 1.5 bar (22 psi) rear 1.5 bar (22 psi) Final drive (All EU/AU models) 14:52 (13:52) Final drive (All BR models) 13:52 Chain 5/8 x 1/4"...

  • Page 158: Tires

    140/80 - 18 M/C 70M M+S TT Metzeler MCE 6 Days Extreme Metzeler MCE 6 Days Extreme The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 23.7 Fork 23.7.1 EXC‑F EU/AU/BR Fork article number 14.18.8R.67...

  • Page 159: Shock Absorber

    23 TECHNICAL DATA Comfort Standard Sport Spring length with preload spacer(s) 474 mm (18.66 in) Spring rate Weight of rider: 65 … 75 kg (143 … 165 lb.) 4.2 N/mm (24 lb/in) Weight of rider: 75 … 85 kg (165 … 187 lb.) 4.4 N/mm (25.1 lb/in) Weight of rider: 85 …...

  • Page 160: Chassis Tightening Torques

    23 TECHNICAL DATA 23.9 Chassis tightening torques EJOT PT Screw, air filter box cover ® K60x20-Z 3 Nm (2.2 lbf ft) EJOT PT Screw, pressure regulator ® K60x25‑Z 3 Nm (2.2 lbf ft) EJOT EJOFORM PT ® Screw, seat fixing K60x23/18 2.5 Nm (1.84 lbf ft) Screw, emergency OFF switch...
  • Page 161 23 TECHNICAL DATA Screw, front brake caliper 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, handlebar clamp 20 Nm (14.8 lbf ft) Screw, manifold on cylinder head 15 Nm (11.1 lbf ft) brace Screw, side stand attachment 35 Nm (25.8 lbf ft) Loctite ®...

  • Page 162: Substances

    JASO T903 MA ( p. 164) – SAE ( p. 164) (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 corresponding properties. Synthetic engine oil...
  • Page 163 24 SUBSTANCES Engine oil (SAE 10W/50) Standard/classification – JASO T903 MA ( p. 164) – SAE ( p. 164) (SAE 10W/50) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties.

  • Page 164: Auxiliary Substances

    25 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...
  • Page 165 25 AUXILIARY SUBSTANCES Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ® – Quick Cleaner Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic...

  • Page 166: Standards

    26 STANDARDS JASO T903 MA Different technical development directions required a separate specification for 4-stroke motorcycles – the JASO T903 MA standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no sepa- rate motorcycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 167: Index Of Special Terms

    27 INDEX OF SPECIAL TERMS On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics...

  • Page 168: List Of Abbreviations

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

  • Page 169: List Of Symbols

    Malfunction indicator lamp lights up/flashes yellow – The OBD has detected a fault in the vehicle electronics. Come safely to a halt, and contact an authorized KTM workshop. The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

  • Page 170: Index

    INDEX Chain guide INDEX checking ......88 Accessories ......10 Chain tension Air filter adjusting .
  • Page 171 INDEX Engine running-in ......37 Hand brake lever ..... . . 16 Engine guard free travel, adjusting .
  • Page 172 INDEX static sag, checking ....53 Side stand ......21 Oil filter Spare parts .
  • Page 173 INDEX Use definition ......7 View of vehicle front left ......12 rear right .
  • Page 174 *3213648en* 3213648en 05/2017 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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