KTM 350 EXC-F 2023 Owner's Manual
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KTM 350 EXC-F 2023 Owner's Manual

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OWNER'S MANUAL
2023
350 EXC-F
Art. no. 3214648en

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  • Page 1 OWNER'S MANUAL 2023 350 EXC-F Art. no. 3214648en...
  • 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 sporty motorcycle that you will continue to enjoy for a long time if you maintain it properly.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Overview of indicator lamps ....21 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 6 6.10 Ignition lock ........21 Symbols used ........6 6.11 Opening the fuel tank filler cap ..21 Formats used........6 6.12 Closing the fuel tank filler cap... 22 SAFETY ADVICE..........
  • Page 5 TABLE OF CONTENTS Preparing the vehicle for difficult 11.14 Adjusting the spring preload of the operating conditions......40 fork ..........58 Preparing the vehicle for riding on 11.15 Handlebar position......59 dry sand.......... 40 11.16 Adjusting the handlebar position ..59 Preparing the vehicle for riding on 12 SERVICE WORK ON THE CHASSIS....
  • Page 6 TABLE OF CONTENTS 12.39 Checking the throttle cable routing ..86 15.13 Diagnostics connector ....118 12.40 Checking the rubber grip ....87 16 COOLING SYSTEM ........119 12.41 Adjusting the basic position of the clutch lever ........88 16.1 Cooling system ......
  • Page 7 TABLE OF CONTENTS 22.9 Chassis tightening torques ....145 23 SUBSTANCES .......... 147 24 AUXILIARY SUBSTANCES ......149 25 STANDARDS ..........151 26 INDEX OF SPECIAL TERMS ....... 152 27 LIST OF ABBREVIATIONS......153 28 LIST OF SYMBOLS........154 28.1 Yellow and orange symbols....

  • Page 8: Means Of Representation

    Indicates work that requires expert knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be cared for there to the highest degree by specially trained experts using the special tools required.

  • Page 9: Safety Advice 2

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

  • Page 10: Overview Of Labels

    2 SAFETY ADVICE Overview of labels A01253-10 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 A01041-10 Canada type label...
  • Page 11 SAFETY ADVICE 2 A01042-10 USA type label Brake fluid information S00026-10 Information on chain tension 101516-01 Information on starting up F00491-10 Information on emissions control A01043-10...

  • Page 12: Reporting Safety Defects

    Washington, DC 20590, USA. You can also obtain other information about motor vehicle safety from the hotline. Noise emission warranty KTM warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise stan- dards.

  • Page 13: Consumer Rights

    SAFETY ADVICE 2 Please note that KTM is entitled to reject warranty claims if your motorcycle or a part fails due to misuse, neg- ligence, an accident, participation in racing or similar events, improper maintenance or unauthorized modifica- tions. Scope of the manufacturer’s warranty –...

  • Page 14: 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. 2.14...

  • Page 15: Owner's Manual

    The Owner's Manual can be downloaded several times using the QR code or the link on the delivery certificate. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. A printed copy can also be ordered from your authorized KTM dealer.

  • Page 16: Important Notes

    Manufacturer warranty, implied warranty The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con- firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

  • Page 17: View Of Vehicle 4

    VIEW OF VEHICLE 4 View of vehicle, front left (example) A01251-10 Hand brake lever ( p. 19) Clutch lever ( p. 19) Fuel tank filler cap Air filter box cover Side stand ( p. 24) Engine number ( p. 18) Shift lever ( p.

  • Page 18: View Of Vehicle, Rear Right (Example)

    4 VIEW OF VEHICLE View of vehicle, rear right (example) A01252-10 Fork compression adjuster Horn button ( p. 19) Light switch ( p. 20) Turn signal switch ( p. 20) Start button ( p. 20) Emergency OFF switch ( p. 20) Throttle grip ( p.

  • Page 19: Serial Numbers 5

    SERIAL NUMBERS 5 Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Type label Type label is fixed to the front of the steering head. The additional type label for Canada is fixed to the front of the chest tube.

  • Page 20: Engine Number

    5 SERIAL NUMBERS Engine number Engine number is embossed on the left side of the engine over the engine sprocket. H01047-10 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 21: Controls 6

    CONTROLS 6 Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automati- cally. A00345-10 Hand brake lever The hand brake lever is fitted on the right side of the handle- bar.

  • Page 22: Light Switch

    6 CONTROLS Light switch The light switch is fitted on the left side of the handlebar. Possible states Low beam on – The light switch is turned downward. In this position, the low beam and tail light are switched on. High beam on –...

  • Page 23: Overview Of Indicator Lamps

    – The OBD has detected an error 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 24: Closing The Fuel Tank Filler Cap

    6 CONTROLS – Press release button , turn the fuel tank filler cap counter- clockwise, and lift it off. K01334-10 6.12 Closing the fuel tank filler cap – Mount the fuel tank filler cap and turn it clockwise until release button engages.

  • Page 25: Idle Speed Adjusting Screw

    CONTROLS 6 6.14 Idle speed adjusting screw The idle setting of the throttle valve body substantially influences the vehicle’s starting behavior, a stable idle speed, and the vehi- cle’s response when the throttle is opened. An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly.

  • Page 26: Foot Brake Lever

    6 CONTROLS 6.16 Foot brake lever Foot brake lever is located in front of the right footrest. The rear brake is engaged with the foot brake lever. 401956-10 6.17 Side stand The side stand is attached to the left side of the vehicle. 401943-10 The side stand is used for parking the motorcycle.

  • Page 27: Locking The Steering

    CONTROLS 6 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 handlebar as far as possible to the right. –...

  • Page 28: 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 29: Setting The Combination Instrument

    COMBINATION INSTRUMENT 7 – 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 30: Viewing The Lap Time

    7 COMBINATION INSTRUMENT – 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. – Adjust hour display with the button and/or button – Wait 3 - 5 seconds.

  • Page 31: Display Mode Speed (Speed)

    COMBINATION INSTRUMENT 7 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 32: 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 33: Display Mode Speed/Clk (Time)

    COMBINATION INSTRUMENT 7 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 34: Viewing The Lap Time

    7 COMBINATION INSTRUMENT 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 35: Display Mode Speed/Tr1 (Trip Master 1)

    COMBINATION INSTRUMENT 7 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 36: 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 37: Display Mode Speed/S1 (Stop Watch 1)

    COMBINATION INSTRUMENT 7 Press the but- No function for 2–3 seconds. Briefly press No function the button 7.21 Display mode SPEED/S1 (stop watch 1) – briefly until S1 appears at the Repeatedly press the button top right of the display. S1 (Stop watch 1) shows the riding time based on TR1 and contin- ues running as soon as an impulse arrives from the wheel speed sensor.
  • Page 38 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. Setup menu No function Activates No function Deactivates Changes to Setup menu...

  • Page 39: Table Of Conditions And Menu Activation

    COMBINATION INSTRUMENT 7 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 Displays of Next display No function No function SPEED/S1 (stop...

  • Page 40: Preparing For Use

    When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-sales inspection work has been carried out by an authorized KTM workshop. You will receive a delivery certificate when the vehicle is handed over.

  • Page 41: Running-In The Engine

    PREPARING FOR USE 8 – Adjust the basic position of the foot brake lever. p. 97) – Adjust the basic position of the shift lever. p. 127) – Get used to the handling characteristics of the motorcycle on a suitable surface before undertaking more chal- lenging trips.

  • Page 42: Starting Power Of Lithium-Ion Batteries At Low Temperatures

    – Riding at low temperatures and in snow. ( p. 42) Preparing the vehicle for riding on dry sand – Mount the air filter dust cover. Air filter dust cover (79006920000) Info Observe the fitting instructions for KTM PowerParts. 102136-01...

  • Page 43: Preparing The Vehicle For Riding On Wet Sand

    PREPARING FOR USE 8 – Mount the air filter sand cover. Air filter sand cover (79006922000) Info Observe the fitting instructions for KTM PowerParts. 102138-01 – Clean the chain. Chain cleaner ( p. 149) – Mount the steel sprocket. –...

  • Page 44: Preparing The Vehicle For Riding On Wet And Muddy Circuits

    Preparing the vehicle for riding on wet and muddy circuits – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the fitting instructions for KTM PowerParts. 102137-01 – Mount the steel sprocket. – Clean the motorcycle. ( p.

  • Page 45: Riding Instructions 9

    RIDING INSTRUCTIONS 9 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 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 and 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 Note Material damage The vehicle may be damaged by incorrect procedure when parking. Significant damage may be caused if the vehicle rolls away or falls over. The components for parking the vehicle are designed only for the weight of the vehicle. –...
  • Page 49 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.) Note Environmental hazard Improper handling of fuel is a danger to the environment.

  • Page 50: 10 Service Schedule

    Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.

  • Page 51: Recommended Work

    Final check: Check the vehicle is roadworthy and take a test ride. ○ ● ● ● Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● Make a service entry in KTM Dealer.net.
  • Page 52 10 SERVICE SCHEDULE ○ One-time interval ● Periodic interval...

  • Page 53: Tuning The Chassis 11

    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 compression adjuster can be seen in slow to normal compression of the shock...

  • Page 54: 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 compression adjuster can be seen in the fast compression of the shock absorber.

  • Page 55: Adjusting The Rebound Damping Of The Shock Absorber

    Risk of injury Parts of the shock absorber will move around if the shock absorber is detached 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 56: 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. 53) – Hold the motorcycle upright with aid of an assistant. – Measure the distance again between the rear axle and mark- ing SAG on the rear fender using the sag gage.

  • Page 57: 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 spring length.

  • Page 58: Adjusting The Riding Sag

    11 TUNING THE CHASSIS 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with the lift stand. ( p. 61) – Remove the shock absorber. p. 70) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 59: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 11 11.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn white adjuster clockwise as far as it will go. Info Adjuster is located at the upper end of the left fork leg.

  • Page 60: Adjusting The Spring Preload Of The Fork

    11 TUNING THE CHASSIS Info Turn clockwise to increase the damping; turn counter- clockwise to reduce damping when the shock absorber rebounds. 11.14 Adjusting the spring preload of the fork Preparatory work – Raise the motorcycle with the lift stand. ( p.

  • Page 61: Handlebar Position

    TUNING THE CHASSIS 11 11.15 Handlebar position On the upper triple clamp, there are 2 holes at a distance of each other. 15 mm (0.59 in) Hole distance The holes on the handlebar supports are placed at a distance from the center. 3.5 mm (0.138 in) Hole distance The handlebar holders can be mounted in four different positions.
  • Page 62 11 TUNING THE CHASSIS – Position the handlebar clamps. Mount screws and tighten evenly. Guideline Screw, handlebar 20 Nm (14.8 lbf ft) clamp Info Make sure the gap widths are even.

  • Page 63: Service Work On The Chassis 12

    SERVICE WORK ON THE CHASSIS 12 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 64: 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. 61) – Remove the fork protector. ( p. 62) Main work – Push dust boots of both fork legs downward.

  • Page 65: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS 12 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 66: Installing The Fork Legs

    12 SERVICE WORK ON THE CHASSIS 12.8 Installing the fork legs Main work – Position the fork legs. Bleeder screws are positioned toward the front. Info Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from the top) must be flush with the upper edge of the upper triple clamp.

  • Page 67: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 12 Main work – Pull the fuel tank breather hose out of the steering head screw. – Open the cable holder in front of the left radiator and detach the wiring harness. – Loosen screw –...
  • Page 68 12 SERVICE WORK ON THE CHASSIS – Position the upper triple clamp with the handlebar. – Mount screw , but do not tighten yet. – Secure the wiring harness and the clutch line with the cable holder. V01785-11 – Position the fork legs. Bleeder screws are positioned toward the front.

  • Page 69: Checking The Steering Head Bearing Play

    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 70: Adjusting The Steering Head Bearing Play

    12 SERVICE WORK ON THE CHASSIS – Check the steering head bearing and replace if neces- sary. – Check the steering stop bolts for correct adjustment and lock- ing. Finishing work – Remove the motorcycle from the lift stand. ( p.

  • Page 71: Removing Front Fender

    SERVICE WORK ON THE CHASSIS 12 12.14 Removing front fender Preparatory work – Remove the headlight mask with the headlight. ( p. 114) Main work – Remove screws V00340-10 – Remove screws . Remove front fender. V00341-10 12.15 Installing front fender Main work –...

  • Page 72: Removing The Shock Absorber

    12 SERVICE WORK ON THE CHASSIS 12.16 Removing the shock absorber Preparatory work – Raise the motorcycle with the lift stand. ( p. 61) Main work – Remove screw and lower the rear wheel with the link fork as far as possible without blocking the rear wheel. Secure the rear wheel in this position.

  • Page 73: Mounting The Seat

    SERVICE WORK ON THE CHASSIS 12 – Raise the rear of the seat, pull the seat back, and lift it off. H02218-10 12.19 Mounting the seat – Mount the front of the seat on the collar bushings of the fuel tank, lower the seat at the rear, and push the seat forward.

  • Page 74: Installing The Air Filter Box Cover

    12 SERVICE WORK ON THE CHASSIS – Pull off the air filter box cover in area laterally and take it off at the front. V01815-11 Condition The air filter box cover is not secured. – Pull off the air filter box cover in area laterally and take it off at the front.

  • Page 75: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 12 12.22 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter. – Only operate the vehicle if it is equipped with an air filter. Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 76: Cleaning The Air Filter And Air Filter Box

    12 SERVICE WORK ON THE CHASSIS 12.24 Cleaning the air filter and air filter box Note 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 Do not clean the air filter with fuel or petroleum since these substances attack the foam.

  • Page 77: Removing The Main Silencer

    SERVICE WORK ON THE CHASSIS 12 12.26 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. –...
  • Page 78 12 SERVICE WORK ON THE CHASSIS V01736-10 Main work – Remove screws and take off silencer cap with O-ring Info Do not remove the glass fiber yarn filling. Caution 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 79: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    SERVICE WORK ON THE CHASSIS 12 12.29 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. Info Over time, the fibers of the glass fiber yarn filling escape and the damper "burns"...
  • Page 80 12 SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is harmful to health. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – Rinse the affected area immediately with plenty of water in the event of contact with the skin. –...

  • Page 81: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 12 – Pull both spoilers laterally off the radiator and lift off the fuel tank. V01767-10 12.31 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 82: Checking For Chain Dirt Accumulation

    12 SERVICE WORK ON THE CHASSIS – Attach the fuel tank breather hose. – Mount and tighten screw with the rubber bushing. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V01766-11 – Position the horn with the horn bracket. –...

  • Page 83: Cleaning The Chain

    SERVICE WORK ON THE CHASSIS 12 12.33 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip. – Remove lubricants from the tires using a suitable cleaning agent. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –...

  • Page 84: Adjusting The Chain Tension

    12 SERVICE WORK ON THE CHASSIS Main work – Pull the chain at the end of the chain sliding piece upward to measure chain tension Info 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 85: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 12 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 86 12 SERVICE WORK ON THE CHASSIS – Pull on the top section of the chain with the specified weight Guideline Weight of chain wear mea- 10 … 15 kg (22 … 33 lb.) surement – Measure distance of 18 chain rollers in the lower chain section.
  • Page 87 SERVICE WORK ON THE CHASSIS 12 – Check chain sliding piece for wear. » If the lower edge of the chain pins 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 88: Checking The Frame

    If the link fork exhibits damage, cracking, or deformation: – Change the link fork. Info Always replace a damaged link fork. Repairing the link fork is not authorized by KTM. S01317-10 12.39 Checking the throttle cable routing Warning Danger of accidents The throttle cable can become kinked, trapped or blocked if it is not routed cor- rectly.

  • Page 89: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS 12 Main work – Check the throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars and above the fuel tank bracket, to the throttle valve body. Both throttle cables must be secured behind the rubber strap of the fuel tank support.

  • Page 90: Adjusting The Basic Position Of The Clutch Lever

    12 SERVICE WORK ON THE CHASSIS 12.41 Adjusting the basic position of the clutch lever – Adjust the basic position 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 91: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 12 Brake fluid DOT 4 / DOT 5.1 ( p. 147) – Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilled brake fluid immediately with water. 12.43 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation.
  • Page 92 12 SERVICE WORK ON THE CHASSIS – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p. 147) – On the clutch slave cylinder, remove the protection cap, remove bleeder screw and mount bleeding syringe V01817-10 –...

  • Page 93: Brake System 13

    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 94: Checking The Front Brake Fluid Level

    – 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 95: Adding The 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.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 96: 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 97 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 98: Checking The Free Travel Of Foot Brake Lever

    13 BRAKE SYSTEM – Check that spring plate in the brake caliper and brake pad sliding plate in the brake caliper bracket are seated cor- rectly. 100397-01 – Insert the new brake linings, insert the pin, and mount the cot- ter pins.

  • Page 99: Adjusting The Basic Position Of The Foot Brake Lever

    KTM workshop will be glad to help.) Warning 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.)

  • Page 100: Adding Rear 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.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 101: 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 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 BRAKE SYSTEM 13 – Remove cotter pin , pull out pin , and remove the brake linings. – Clean the brake caliper and the brake caliper bracket. E00351-10 – Check that spring plate in the brake caliper and brake pad sliding plate in the brake caliper bracket are seated cor- rectly.

  • Page 104: 14 Wheels, Tires

    14 WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 61) Main work – Manually press the brake caliper toward the brake disc 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 pistons.

  • Page 105: Installing The Front Wheel

    WHEELS, TIRES 14 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 106: Installing The Rear Wheel

    14 WHEELS, TIRES Main work – Manually press the brake caliper toward the brake disc to push back the brake piston. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston. –...
  • Page 107 WHEELS, TIRES 14 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 surfaces of the spacers. Long-life grease ( p.

  • Page 108: 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 years at the latest, regardless of the actual state of H01144-01 wear.

  • Page 109: 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 110: 15 Electrical System

    15 ELECTRICAL SYSTEM 15.1 Removing the 12-V battery Note Environmental hazard 12 V batteries contain environmentally hazardous materials. – Do not dispose of 12 V batteries as household waste. – Dispose of 12 V batteries at a collection point for used batteries. Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 111: Installing The 12-V Battery

    ELECTRICAL SYSTEM 15 – Detach wiring harness , disconnect relays and hang them to the side. V01778-10 – Remove screw and detach the battery compartment. – Lift out the 12-V battery. V01779-10 15.2 Installing the 12-V battery Main work – Insert the 12-V battery into the battery compartment with the terminals facing forward and secure with holding bracket 12-V battery (HJTZ5S-FP-C) (...

  • Page 112: Charging The 12-V Battery

    15 ELECTRICAL SYSTEM – Connect the positive cable to the 12-V battery. Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) Info Contact disk must be mounted under screw cable lug with the claws toward the battery termi- nal. – Slide positive terminal cover over the positive terminal.
  • Page 113 It is also impossible to overcharge the 12-V battery with this battery charger. The charging time may be longer at low temperatures. This battery charger is only suitable for lithium iron phosphate batteries. Read the accompanying KTM Pow- erParts instructions.

  • Page 114: Changing Main Fuse

    15 ELECTRICAL SYSTEM Info If the charging current, charging voltage, or charging time is exceeded, the 12 V battery will be destroyed. If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged and suffer a loss of capacity, destroying the battery.

  • Page 115: Changing The Fuses Of Individual Electrical Power Consumers

    ELECTRICAL SYSTEM 15 – Take off protection caps – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the starter relay. – Insert a new main fuse. Fuse (58011109120) ( p.

  • Page 116: Removing The Headlight Mask With The Headlight

    15 ELECTRICAL SYSTEM Warning Fire hazard Incorrect fuses overload the electrical sys- tem. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. – Insert the spare fuse with the correct rating. Fuse (75011088010) ( p.

  • Page 117: Installing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 15 15.7 Installing the headlight mask with the headlight Main work – Join plug-in connectors S01328-11 – Position the headlight mask and secure it with rubber straps The holding lugs engage in the fender. – Position the brake line and wiring harness in the brake line guide.

  • Page 118: Checking The Headlight Setting

    15 ELECTRICAL SYSTEM – Pull out headlight bulb – Insert the new headlight bulb. Headlight (HS1 / socket PX43t) ( p. 143) – Insert the protection cap with the bulb socket into the reflector and turn it clockwise all the way. Info Ensure that O-ring is seated properly.

  • Page 119: Changing The Turn Signal Bulb

    ELECTRICAL SYSTEM 15 Info A change in weight on the vehicle may require a correc- tion of the headlight range. – Tighten screw 15.11 Changing the turn signal bulb Note Damage to reflector Grease on the reflector reduces the light intensity. Grease on the bulb will evaporate due to the heat and be deposited on the reflector.

  • Page 120: Diagnostics Connector

    15 ELECTRICAL SYSTEM Main work – Remove screws with the washers. – Pull the combination instrument upward out of the holder. V01807-10 – Using a coin, turn protection cap all the way counterclock- wise and take it off. – Remove combination instrument battery –...

  • Page 121: Cooling System 16

    COOLING SYSTEM 16 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 122: Checking The Coolant Level

    16 COOLING SYSTEM – Mount the radiator cap. 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 123: Refilling Coolant

    COOLING SYSTEM 16 Warning Danger of poisoning Coolant is harmful to health. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...

  • Page 124: Changing The Coolant

    16 COOLING SYSTEM 16.6 Changing 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 125: Tuning The Engine 17

    TUNING THE ENGINE 17 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 126: Adjusting 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 127: Adjusting The Idle Speed

    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 128: Programming The Throttle Valve Position

    17 TUNING THE ENGINE – Run the engine until warm. The cold start button is deactivated – The cold start but- ton is in its basic position. ( p. 22) Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. –...

  • Page 129: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 17 17.6 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load. –...

  • Page 130: 18 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 fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 131: Checking The Engine Oil Level

    SERVICE WORK ON THE ENGINE 18 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 effective exhaust extraction when starting or running the engine in an enclosed space.
  • Page 132 18 SERVICE WORK ON THE ENGINE Main work – Position an appropriate 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 133 SERVICE WORK ON THE ENGINE 18 – Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) – Allow the engine oil to drain completely. – Thoroughly clean the parts and the sealing surface. K00572-10 – Lay the motorcycle on its right side and fill the oil filter hous- ing approx.

  • Page 134: Adding Engine Oil

    147) Info In order to achieve optimal engine oil performance, it is not advisable to mix different engine oils. KTM recommends changing the engine oil where neces- sary. – Mount and tighten the filler plug together with the O-ring.

  • Page 135: Cleaning, Care 19

    CLEANING, CARE 19 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 136: Checks And Maintenance Steps For Winter Operation

    19 CLEANING, CARE – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p. 149) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 137: Storage 20

    – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the lift stand. ( p. 61) – Preferably cover the motorcycle with a tarp or similar cover that is permeable to air.

  • Page 138: Preparing For Use After Storage

    20 STORAGE 20.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 61) – Install the 12-V battery. p. 109) – Perform checks and maintenance measures when preparing for use. ( p. 43) – Take a test ride.

  • Page 139: Troubleshooting 21

    Check the electrical system. – Error in the electronic fuel Read out the fault memory using the injection KTM diagnostics tool. – Engine does not speed up Error in the electronic fuel Read out the fault memory using the injection KTM diagnostics tool.
  • Page 140 – 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 141: Technical Data 22

    TECHNICAL DATA 22 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 349.7 cm³ (21.34 cu in) Stroke 57.5 mm (2.264 in) Bore 88 mm (3.46 in) Compression ratio 13.5:1 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 142: Engine Tightening Torques

    22 TECHNICAL DATA 22.2 Engine tightening torques Nozzle, crank chamber ventilation 2 Nm (1.5 lbf ft) Loctite ® 243™ Oil nozzle for clutch lubrication 2 Nm (1.5 lbf ft) Loctite ® 243™ Oil nozzle for conrod bearing lubri- 2 Nm (1.5 lbf ft) cation Loctite ®...
  • Page 143 TECHNICAL DATA 22 Screw, oil filter cover 10 Nm (7.4 lbf ft) Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, shift lever 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, starter motor 10 Nm (7.4 lbf ft) Screw, starter motor - intermediate 10 Nm (7.4 lbf ft) gear...

  • Page 144: Capacities

    22 TECHNICAL DATA Oil drain plug M14x1.5 15 Nm (11.1 lbf ft) Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft) Loctite ® 243™ Nut, primary gear wheel M18LHx1.5 120 Nm (88.5 lbf ft) Loctite ® 243™ Screw plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) Plug, timing chain tensioner...

  • Page 145: Electrical System

    The tires specified represent one of the possible series production tires. For alternative manufacturers, if any, contact an authorized dealer or qualified tire dealership. If local road approval regulations apply, these and the respective technical specifications must be observed. Additional information is available in the Service section under: KTM.COM...

  • Page 146: Fork

    22 TECHNICAL DATA 22.7 Fork Fork article number 0797C168V401000 WPXPLOR OC Fork Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring length with preload spacer(s) 474 mm (18.66 in) Spring rate Weight of rider: 65 …...

  • Page 147: Chassis Tightening Torques

    TECHNICAL DATA 22 Fitted length 415 mm (16.34 in) Damper oil Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 148) 22.9 Chassis tightening torques Remaining screws, chassis EJOT PT ® K60x25‑Z 2 Nm (1.5 lbf ft) Screw, active carbon filter 5 Nm (3.7 lbf ft) Screw, air filter box cover EJOT PT...
  • Page 148 22 TECHNICAL DATA Screw, engine brace on frame M8x15 25 Nm (18.4 lbf ft) Loctite ® 2701™ Screw, fork stub 15 Nm (11.1 lbf ft) 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)

  • Page 149: Substances 23

    SUBSTANCES 23 Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX ®...
  • Page 150 23 SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 151) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –...

  • Page 151: Auxiliary Substances 24

    AUXILIARY SUBSTANCES 24 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 152 24 AUXILIARY SUBSTANCES Silicone spray Recommended supplier MOTOREX ® – Silicone Spray 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 153: Standards 25

    STANDARDS 25 JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 154: 26 Index Of Special Terms

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

  • Page 155: List Of Abbreviations 27

    LIST OF ABBREVIATIONS 27 Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 156: 28 List Of Symbols

    Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error 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 157: Index

    INDEX Chain tension INDEX adjusting ......82 checking ......81 12-V battery charging .
  • Page 158 INDEX Engine oil level Headlight bulb checking ......129 changing ......115 Engine sprocket Headlight mask with headlight checking .
  • Page 159 INDEX Overview of indicator lamps ....21 Starting ......43 Owner's Manual .
  • Page 160 *3214648en* 3214648en 15.06.2022 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.COM...

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