KTM 350 XCF-W Owner's Manual
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KTM 350 XCF-W Owner's Manual

KTM 350 XCF-W Owner's Manual

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OWNER'S MANUAL
2020
350 EXC-F
350 XCF‑W
350 EXC‑F Six Days
Art. no. 3214010en

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Summary of Contents for KTM 350 XCF-W

  • Page 1 OWNER'S MANUAL 2020 350 EXC-F 350 XCF‑W 350 EXC‑F Six Days Art. no. 3214010en...
  • Page 3 KTM accepts no liability for delivery options, deviations from fig- ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 6.13 Overview of indicator lamps TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 6 (XCF‑W) .......... 20 Symbols used ........6 6.14 Opening the fuel tank filler cap ..21 Formats used........6 6.15 Closing the fuel tank filler cap... 21 6.16 Cold start button......
  • Page 5 TABLE OF CONTENTS Starting power of lithium-ion 11.11 Checking the basic setting of the batteries at low temperatures fork ..........57 (XCF‑W, All EU models)....40 11.12 Adjusting the compression damping Preparing the vehicle for difficult of the fork ........58 riding conditions ......
  • Page 6 TABLE OF CONTENTS 12.31 Cleaning the spark arrestor 14.3 Removing the rear wheel ..... 116 (XCF‑W) .......... 83 14.4 Installing the rear wheel ....117 12.32 Changing the glass fiber yarn filling 14.5 Checking the tire condition ..... 119 of the main silencer ......
  • Page 7 TABLE OF CONTENTS 19 CLEANING, CARE ........151 19.1 Cleaning the motorcycle ....151 19.2 Checks and maintenance steps for winter operation......152 20 STORAGE ..........153 20.1 Storage ......... 153 20.2 Preparing for use after storage..154 21 TROUBLESHOOTING ........ 155 22 BLINK CODE ..........

  • 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 2 Use definition – intended use (All EU/BR models) This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies 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: Degrees Of Risk And Symbols

    2 SAFETY ADVICE Degrees of risk and symbols Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

  • 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: Owner's Manual

    The Owner's Manual is an important component of the vehicle and must be handed over to the new owner if the vehicle is sold. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. International KTM Website: http://www.ktm.com...

  • Page 13: Important Notes 3

    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 the KTM Dealer.net, otherwise any warranty coverage will become void.

  • Page 14: 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 15: View Of Vehicle 4

    VIEW OF VEHICLE 4 View of vehicle, front left (example) V01826-10 Clutch lever ( p. 17) Fuel tank filler cap Air filter box cover Side stand ( p. 23) Engine number ( p. 15) Shift lever ( p. 23)

  • Page 16: View Of Vehicle, Rear Right (Example)

    4 VIEW OF VEHICLE View of vehicle, rear right (example) V01827-10 Switch-off button ( p. 17) Horn button ( p. 18) (All EU/BR models) Light switch ( p. 18) (All EU/BR models) Turn signal switch ( p. 19) (All EU/BR models) Start button ( p.

  • Page 17: 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 (All EU models) The Europe type label is fixed to the front of the steering head. The Canada type label is fixed to the front of the chest tube.

  • Page 18: 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. H02222-10...

  • Page 19: 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 20: Horn Button (All Eu/Br Models)

    6 CONTROLS (XCF‑W) Switch-off button is fitted on the left side of the handle- bar. Possible states is in the basic position – In this • The switch-off button position, the ignition circuit is closed and the engine can be started.

  • Page 21: Turn Signal Switch (All Eu/Br Models)

    CONTROLS 6 Turn signal switch (All EU/BR models) The turn signal switch is fitted on the left side of the handle- bar. Possible states Turn signal off – Turn signal switch is in the central position. Turn signal, left, on – The turn signal switch is turned to the left.

  • Page 22: Combination Switch (All Six Days 8 Models, Xcf-W)

    Possible states Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle elec- tronics. Stop and contact an authorized KTM work- shop. Fuel level warning lamp lights up orange – The fuel level has reached the reserve mark.

  • Page 23: Opening The Fuel Tank Filler Cap

    CONTROLS 6 6.14 Opening the fuel tank filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 24: Cold Start Button

    6 CONTROLS 6.16 Cold start button The cold start button is fitted to the bottom of the throttle valve body. The electronic fuel injection system extends the injection time if the engine is cold and the ambient temperature is low. To help the engine burn the increased fuel quantity, it must be supplied with additional oxygen by pushing the cold start button.

  • Page 25: Shift Lever

    CONTROLS 6 6.18 Shift lever Shift lever is mounted on the left of the engine. 401950-10 The gear positions can be seen in the figure. The neutral or idle position is between the first and second gears. 401950-11 6.19 Foot brake lever Foot brake lever is located in front of the right footrest.

  • Page 26: Steering Lock (All Eu/Br Models)

    6 CONTROLS The side stand is used for parking the motorcycle. Info When you are riding, side stand must be folded up and secured with rubber strap 401944-10 6.21 Steering lock (All EU/BR models) Steering lock is fitted on the left side of the steering head. The steering lock is used to lock the steering.

  • Page 27: Unlocking The Steering (All Eu/Br Models)

    CONTROLS 6 6.23 Unlocking the steering (All EU/BR models) – Insert the key for the steering lock into the steering lock p. 24), turn it to the left, pull it out, and turn it to the right. Pull out the key for the steering lock. The handlebar can now be moved again.

  • 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: 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. – Adjust hour display with the button and/or button –...

  • 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 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 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. 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 38: 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 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. Setting TR2 Increases Increases Reduces Reduces Stores and (trip master 2) value of TR2.

  • 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 (All EU/BR models) – Adjust the free travel of the handbrake lever. ( p. 100) (XCF‑W) – Adjust the basic position of the hand brake lever. ( p. 101) – Adjust the basic position of the foot brake lever. p.

  • Page 42: Starting Power Of Lithium-Ion Batteries At Low Temperatures (Xcf-W, All Eu Models)

    – 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. 171) – 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 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: Activating Traction Control (All Six Days Models, Xcf-W)

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

  • Page 47: 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 48: 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 49: Transporting

    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.)
  • Page 50 9 RIDING INSTRUCTIONS Note 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. – Switch off the engine. – Open the fuel tank filler cap. ( p.

  • Page 51: Service Schedule 10

    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 52: 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 53 SERVICE SCHEDULE 10 Every 135 operating hours Every 70 operating hours when used for motorsports After 20 operating hours After 10 operating hours every 12 months ● ● Perform engine service including removing and installing the engine. (Change the spark plug and spark plug connector.

  • Page 54: 11 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 compression adjuster can be seen in slow to normal compression of the shock...

  • Page 55: 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 fast compression of the shock absorber.

  • Page 56: 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 57: Checking The Static Sag Of The Shock Absorber

    TUNING THE CHASSIS 11 11.7 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 54) – 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 58: 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 59: Adjusting The Riding Sag

    TUNING THE CHASSIS 11 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with the lift stand. ( p. 64) – Remove the shock absorber. p. 78) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 60: 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/BR, XCF‑W) – Turn white adjuster clockwise as far as it will go. Info Adjuster is located at the upper end of the left fork leg.

  • Page 61: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS 11 11.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. (EXC‑F EU/BR, XCF‑W) – Turn red adjuster clockwise as far as it will go. Info Adjuster is located at the upper end of the right fork leg.

  • Page 62: Adjusting The Spring Preload Of The Fork (All Six Days Models)

    11 TUNING THE CHASSIS 11.14 Adjusting the spring preload of the fork (All Six Days models) Preparatory work – Raise the motorcycle with the lift stand. ( p. 64) Main work – Turn T-grips counterclockwise all the way. The marking +0 aligns with the right wing. Info Make the adjustment by hand only.

  • Page 63: Handlebar Position

    TUNING THE CHASSIS 11 11.15 Handlebar position (EXC‑F EU/BR, XCF‑W) 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 64 11 TUNING THE CHASSIS (EXC‑F EU/BR, XCF‑W) – 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 65 TUNING THE CHASSIS 11 (All Six Days models) – 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 66: 12 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 67: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS 12 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 64) – Remove the fork protector. ( p. 65) Main work – Push dust boots of both fork legs downward.

  • Page 68: 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 69: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS 12 (All Six Days models) – Loosen screws . Take out the left fork leg. – Loosen screws . Take out the right fork leg. V01784-10 12.8 Installing the fork legs Main work (EXC‑F EU/BR, XCF‑W) –...

  • Page 70: Removing The Lower Triple Clamp (Exc-F Eu/Br, Xcf-W)

    12 SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, top triple 17 Nm clamp (12.5 lbf ft) – Tighten screws Guideline Screw, bottom 15 Nm triple clamp (11.1 lbf ft) V01784-11 – Position the brake caliper, and mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft)

  • Page 71: Removing The Lower Triple Clamp (All Six Days Models)

    SERVICE WORK ON THE CHASSIS 12 – Remove O-ring and protective ring – Take off the lower triple clamp with the steering stem. – Remove the upper steering head bearing. V01757-10 12.10 Removing the lower triple clamp (All Six Days models) Preparatory work –...

  • Page 72: Installing The Lower Triple Clamp (Exc-F Eu/Br, Xcf-W)

    12 SERVICE WORK ON THE CHASSIS 12.11 Installing the lower triple clamp (EXC‑F EU/BR, XCF‑W) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 171) – Insert the lower triple clamp with the steering stem. Mount upper steering head bearing.
  • Page 73 SERVICE WORK ON THE CHASSIS 12 – Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head – Tighten screw Guideline Screw, top steering 20 Nm (14.8 lbf ft) stem V01789-10 – Tighten screws Guideline Screw, top triple 20 Nm (14.8 lbf ft) clamp V01790-11...

  • Page 74: Installing The Lower Triple Clamp (All Six Days Models)

    12 SERVICE WORK ON THE CHASSIS 12.12 Installing the lower triple clamp (All Six Days models) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 171) – Position the lower triple clamp with the steering stem. Mount upper steering head bearing.

  • Page 75: Checking The Steering Head Bearing Play

    12.13 Checking the steering head bearing play Warning 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.)

  • Page 76: Adjusting The Steering Head Bearing Play (Exc-F Eu/Br, Xcf-W)

    12 SERVICE WORK ON THE CHASSIS 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. Preparatory work – Raise the motorcycle with the lift stand.

  • Page 77: Adjusting The Steering Head Bearing Play (All Six Days Models)

    SERVICE WORK ON THE CHASSIS 12 Guideline Screw, top steering 20 Nm (14.8 lbf ft) stem Finishing work – Check the steering head bearing play. ( p. 73) – Remove the motorcycle from the lift stand. ( p. 64) 12.15 Adjusting the steering head bearing play (All Six Days models) Preparatory work...

  • Page 78: Removing Front Fender

    12 SERVICE WORK ON THE CHASSIS 12.17 Removing front fender Preparatory work – Press and hold the switch-off button while the engine is idling until the engine stops. – Remove the headlight mask with the headlight. ( p. 130) Main work (EXC‑F EU/BR, XCF‑W) –...

  • Page 79: Installing Front Fender

    SERVICE WORK ON THE CHASSIS 12 12.18 Installing front fender Main work (EXC‑F EU/BR, XCF‑W) – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00340-10 – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00341-10...

  • Page 80: Removing The Shock Absorber

    12 SERVICE WORK ON THE CHASSIS 12.19 Removing the shock absorber Preparatory work – Raise the motorcycle with the lift stand. ( p. 64) 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 81: 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 12.22 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 82: 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 83: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 12 12.25 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. – Never start to use the vehicle without an air filter. Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 84: Cleaning The Air Filter And Air Filter Box

    12 SERVICE WORK ON THE CHASSIS 12.27 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 85: Removing The Main Silencer

    SERVICE WORK ON THE CHASSIS 12 12.29 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. (All EU models) –...
  • Page 86 12 SERVICE WORK ON THE CHASSIS Info Soot particles accumulate on the screen of the spark arrestor over time. This changes the performance characteristics. Preparatory work – Remove main silencer. ( p. 83) V01736-10 Main work – Remove screws and take off silencer cap with O-ring Info Do not remove the glass fiber yarn filling.

  • Page 87: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    SERVICE WORK ON THE CHASSIS 12 12.32 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 escape and the damper “burns”...

  • Page 88: Removing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS Finishing work – Install the main silencer. ( p. 83) 12.33 Removing 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 89: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 12 (All EU/BR models) – Remove screws – Hang the horn and horn bracket to one side. V01764-10 (XCF‑W) – Remove screws V01765-10 – Remove screw with the rubber bushing. – Remove the hose from the fuel tank breather. V01766-10 –...
  • Page 90 12 SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. –...

  • Page 91: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS 12 – Plug in connector for the fuel pump. – Remove the wash cap set. – 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 92: Checking The Chain Tension

    12 SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with the lift stand. ( p. 64) Main work – Rinse off loose dirt with a soft jet of water. – Remove old grease residue with chain cleaner. Chain cleaner ( p.

  • Page 93: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 12 12.38 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 94: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    12 SERVICE WORK ON THE CHASSIS 12.39 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with the lift stand. ( p. 64) Main work – Shift the transmission into neutral. – Check the chain, rear sprocket, and engine sprocket for wear. »...
  • Page 95 SERVICE WORK ON THE CHASSIS 12 – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with, or below, the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated.

  • Page 96: 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 12.42 Checking throttle cable routing Preparatory work –...

  • Page 97: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS 12 Main work – Check 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 98: Adjusting The Basic Position Of The Clutch Lever

    12 SERVICE WORK ON THE CHASSIS – Check that screw is firmly seated. Guideline Screw, fixed 5 Nm (3.7 lbf ft) Loctite ® 243™ grip Diamond must be located at the top. V01768-10 12.44 Adjusting the basic position of the clutch lever –...

  • Page 99: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 12 – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Check the fluid level. Fluid level below container 4 mm (0.16 in) »...

  • Page 100: Removing The Engine Guard (All Six Days Models, Xcf-W)

    12 SERVICE WORK ON THE CHASSIS – Move the hydraulic clutch fluid reservoir mounted on the han- dlebar into a horizontal position. – Remove screws – Take off cover with membrane V00456-10 – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 101: Installing The Engine Guard (All Six Days Models, Xcf-W)

    SERVICE WORK ON THE CHASSIS 12 12.48 Installing the engine guard (All Six Days models, XCF‑W) – Attach the engine guard on the frame at the rear and swing up at the front. – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis H01638-10...

  • Page 102: 13 Brake System

    13 BRAKE SYSTEM 13.1 Checking the free travel of the hand brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. –...

  • Page 103: Adjusting The Basic Position Of The Hand Brake Lever (Xcf-W)

    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.) – Check the front and rear brake disc thickness at multiple...

  • Page 104: Checking The Front 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.) (All EU/BR models) –...
  • Page 105 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 106: 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 107 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 Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons. – Remove cotter pin , pull out pin , and remove the brake linings. – Clean the brake caliper and the brake caliper bracket. E00344-10 –...
  • Page 109 BRAKE SYSTEM 13 – Correct the brake fluid quantity to level Guideline 5 mm (0.2 in) Level (brake fluid level below reservoir rim) Brake fluid DOT 4 / DOT 5.1 ( p. 169) – Position the cover with the membrane. Mount and tighten the screws.

  • Page 110: Checking The Free Travel Of Foot Brake Lever

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

  • Page 111: Adjusting The Basic Position Of The Foot Brake Lever

    BRAKE SYSTEM 13 – 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 112: 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 113: 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 114: 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 115 BRAKE SYSTEM 13 – Stand the vehicle upright. – Remove screw cap with membrane and the O-ring. – Press the brake piston back into the basic position and ensure that brake fluid does not flow out of the brake fluid reservoir; extract some if necessary.
  • Page 116 13 BRAKE SYSTEM – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 169) – Mount screw cap with membrane and O-ring. Info Clean up overflowed or spilled brake fluid immediately with water. K01347-10...

  • Page 117: Wheels, Tires 14

    WHEELS, TIRES 14 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 64) 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 118: 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 119: Installing The Rear Wheel

    WHEELS, TIRES 14 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 120 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 121: 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 122: 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 123: Electrical System 15

    ELECTRICAL SYSTEM 15 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 124 15 ELECTRICAL SYSTEM (All BR models) Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep 12 V batteries out of the reach of chil- dren. – Wear suitable protective clothing and safety glasses. – Avoid contact with battery acid and battery gases.

  • Page 125: Installing The 12-V Battery

    ELECTRICAL SYSTEM 15 – 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 (XCF‑W, All EU models) 12-V battery (HJTZ5S-FP-C) ( p.

  • Page 126: 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 127 ELECTRICAL SYSTEM 15 Main work (XCF‑W, All EU models) Warning Risk of injury 12 V batteries contain harmful sub- stances. – Keep 12 V batteries out of the reach of chil- dren. – Keep sparks and open flames away from 12 V F01568-10 batteries.
  • Page 128 The charging time may be longer at low tempera- tures. This battery charger is only suitable for lithium iron phosphate batteries. Read the accompanying KTM PowerParts instructions. Info If the charging current, charging voltage, or charging time is exceeded, the 12 V battery will be destroyed.

  • Page 129: Changing The Main Fuse

    ELECTRICAL SYSTEM 15 You can also use the battery charger to test the open-circuit voltage and starting ability of the 12-V battery, and to test the alternator. In addition, you cannot overcharge the 12-V battery with this device. Info If the charging current, charging voltage and charg- ing time are exceeded, electrolyte escapes through the safety valves.

  • Page 130: Changing The Fuses Of Individual Power Consumers

    15 ELECTRICAL SYSTEM Main work – Pull starter relay from the holder. V01776-11 – 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. –...
  • Page 131 ELECTRICAL SYSTEM 15 Guideline (All EU models) Fuse 1 ‑ 10 A - EFI control unit, lambda sensor, combi- nation instrument, combination switch (optional), elec- tronic fuel injection, diagnostics connector, evaporate emission control system, fuse 4 Fuse 2 - 10 A - high beam, low beam, position light, tail light, license plate lamp Fuse 3 - 10 A - radiator fan (optional), horn, brake light, turn signal...

  • Page 132: Removing The Headlight Mask With The Headlight

    15 ELECTRICAL SYSTEM – Check that the power consumer is functioning properly. – Close the fuse box cover. Finishing work – Mount the seat. ( p. 79) 15.6 Removing the headlight mask with the headlight Preparatory work – Press and hold the switch-off button while the engine is idling until the engine stops.

  • Page 133: Changing The Headlight Bulb

    ELECTRICAL SYSTEM 15 (XCF‑W) – Join plug-in connector V01802-11 – 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. V01782-11 Finishing work –...

  • Page 134: Checking The Headlight Setting

    15 ELECTRICAL SYSTEM – Pull out headlight bulb – Insert the new headlight bulb. Headlight (HS1 / socket PX43t) ( p. 164) – 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 135: Changing The Turn Signal Bulb (All Eu/Br Models)

    ELECTRICAL SYSTEM 15 Main work – Loosen screw – Adjust the headlight range by pivoting the headlight. Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider (instructions on how to apply the mark: Checking the headlight setting). Info V00369-10 A change in weight on the vehicle may require a correc-...

  • Page 136: Changing The Combination Instrument Battery

    15 ELECTRICAL SYSTEM 15.12 Changing the combination instrument battery Preparatory work – Press and hold the switch-off button while the engine is idling until the engine stops. – Remove the headlight mask with the headlight. ( p. 130) Main work –...

  • Page 137: Diagnostics Connector

    ELECTRICAL SYSTEM 15 15.13 Diagnostics connector Diagnostics connector is located under the seat. H00933-12...

  • Page 138: 16 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 139: Checking The Coolant Level

    COOLING SYSTEM 16 Coolant ( p. 169) – 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 140: Refilling Coolant

    16 COOLING SYSTEM 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. – Consult a doctor immediately if coolant is swallowed. –...
  • Page 141 COOLING SYSTEM 16 (All Six Days models, XCF‑W) – Install the engine guard. ( p. 99)

  • Page 142: 17 Tuning The Engine

    17 TUNING THE ENGINE 17.1 Checking the throttle cable play – 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 Throttle cable play 3 …...

  • Page 143: Adjusting The Characteristic Map Of The Throttle Response

    TUNING THE ENGINE 17 Main work (All EU/BR models) – 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 144: Changing The Mapping (All Six Days Models)

    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 Grey guide plate (79002014000) Alternative 1 Black guide plate (79002014100) Info The gray guide plate opens the throttle valve more...

  • Page 145: 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 146: 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 position at idle speed needs to be retaught, then the mal- function 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 147: Adjusting The Basic Position Of The Shift Lever

    TUNING THE ENGINE 17 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 gearing.

  • Page 148: 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 refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 149: Checking The Engine Oil Level

    SERVICE WORK ON THE ENGINE 18 18.2 Checking the engine oil level Preparatory work – Stand the motorcycle upright on a horizontal surface. Condition The engine is at operating temperature. – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level.
  • Page 150 18 SERVICE WORK ON THE ENGINE – Remove screw plug with oil screen and the O-rings. – Allow the engine oil to drain completely. – Thoroughly clean the parts and the sealing surfaces. K00568-10 – Position oil screen with the O-rings on a pin wrench. –...

  • Page 151: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 18 – Lay the motorcycle on its right side and fill the oil filter hous- ing approx. ⅓ full with engine oil. – Place the oil filter into the oil filter housing. – Oil the O-ring of the oil filter cover and mount it together with oil filter cover –...
  • Page 152 18 SERVICE WORK ON THE ENGINE Main work – Remove oil filler plug with the O-ring from the clutch cover. – Fill engine oil to the middle of the level viewer. Engine oil (SAE 10W/50) ( p. 169) Info In order to achieve optimal engine performance, it is not advisable to mix different engine oils.

  • Page 153: 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 154: 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. 171) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 155: 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. 64) – Preferably cover the motorcycle with a tarp or similar cover that is permeable to air.

  • Page 156: Preparing For Use After Storage

    20 STORAGE Info Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and the exhaust system to rust. 20.2 Preparing for use after storage –...

  • Page 157: Troubleshooting 21

    Check the electrical system. faulty – 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 158 – 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 159 TROUBLESHOOTING 21 Faults Possible cause Action – The horn, brake light, turn sig- Fuse 3 blown Change the fuses of individual power nal, and radiator fan (optional) consumers. ( p. 128) are not working...

  • Page 160: 22 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 161 BLINK CODE 22 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 162: 23 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 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 163: Engine Tightening Torques

    TECHNICAL DATA 23 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 164 23 TECHNICAL DATA Screw, exhaust flange 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, guide rail 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, oil filter cover 10 Nm (7.4 lbf ft) Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite ®...

  • Page 165: Capacities

    TECHNICAL DATA 23 Screw plug, oil pressure control M12x1.5 20 Nm (14.8 lbf ft) valve 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...

  • Page 166: Electrical System

    23 TECHNICAL DATA front 2.5 mm (0.098 in) rear 3.5 mm (0.138 in) Brake discs - wear limit (All Six Days models) front 2.5 mm (0.098 in) rear 3.7 mm (0.146 in) Offroad tire pressure front 1.0 bar (15 psi) rear 1.0 bar (15 psi) Street tire pressure (All EU/BR models)

  • Page 167: Tires

    140/80 - 18 M/C 70R M+S TT Maxxis Maxx EnduPro Maxxis Maxx EnduPro The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com Validity Front tire Rear tire 90/90 - 21 M/C 54S M+S TT 120/90 - 18 M/C 65R M+S TT (XCF‑W)

  • Page 168: Shock Absorber

    23 TECHNICAL DATA Sport 12 clicks Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring preload - Preload Adjuster 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.) 4.0 N/mm (22.8 lb/in) Weight of rider: 75 …...

  • Page 169: Chassis Tightening Torques

    TECHNICAL DATA 23 Damper oil Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 170) 23.9 Chassis tightening torques Remaining screws, chassis EJOT PT ® K60x25‑Z 2 Nm (1.5 lbf ft) Screw, active carbon filter (XCF‑W) 5 Nm (3.7 lbf ft) Screw, air filter box cover EJOT PT ®...
  • Page 170 23 TECHNICAL DATA Screw, bottom triple clamp (All 15 Nm (11.1 lbf ft) Six Days models) Screw, bottom triple clamp 15 Nm (11.1 lbf ft) (EXC‑F EU/BR, XCF‑W) Screw, chain sliding piece 15 Nm (11.1 lbf ft) Screw, engine brace on engine M8x20 25 Nm (18.4 lbf ft) Loctite...

  • Page 171: Substances 24

    SUBSTANCES 24 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 172 24 SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 173) (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 173: Auxiliary Substances 25

    AUXILIARY SUBSTANCES 25 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 174 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 175: Standards 26

    STANDARDS 26 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 176: 27 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 177: List Of Abbreviations 28

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

  • Page 178: 29 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 179: Index

    INDEX Chain guide INDEX checking ......92 12-V battery Chain tension charging ......124 adjusting .
  • Page 180 INDEX Engine oil Handlebar position ..... . 61 adding ......149 adjusting .
  • Page 181 INDEX Spoke tension checking ......120 Oil filter Start button ......19 changing .
  • Page 182 INDEX Vehicle identification number ....15 View of vehicle front left ......13 rear right .
  • Page 183 *3214010en* 3214010en 06/2019 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

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