Related Manuals for KTM 350 EXC-F EU 2013
Summary of Contents for KTM 350 EXC-F EU 2013
- Page 1 OWNER'S MANUAL 2013 350 EXC‑F EU 350 EXC‑F AUS 350 EXC‑F SIX DAYS EU 350 XCF‑W USA Art. no. 3211863en...
- Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.
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Page 4: Table Of Contents
TABLE OF CONTENTS 6.15.15 Display mode SPEED/A1 (average speed 1) ... 21 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 6.15.16 Display mode SPEED/A2 (average speed 2) ... 21 Symbols used ........... 5 6.15.17 Display mode SPEED/S1 (stop watch 1)..22 Formats used............ - Page 5 TABLE OF CONTENTS 10.14 Adjusting the spring preload of the fork 11.48 Changing the hydraulic clutch fluid ....68 (EXC‑F EU, EXC‑F AUS, XCF‑W) ....... 43 11.49 Removing the engine guard (EXC‑F AUS, 10.15 Handlebar position.......... 43 EXC-F SIX DAYS) ..........68 10.16 Adjusting handlebar position .......
- Page 6 TABLE OF CONTENTS 17 SERVICE WORK ON THE ENGINE ....... 96 17.1 Changing the fuel screen ......96 17.2 Checking the engine oil level......96 17.3 Changing the engine oil and oil filter, cleaning the oil screen ..........97 17.4 Adding engine oil ..........
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Page 7: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required. -
Page 8: Safety Advice
Use definition - intended use (All EXC‑F models) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations. -
Page 9: Safe Operation
Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements. 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 10: Owner's Manual
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer. -
Page 11: Important Notes
Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle. -
Page 12: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) B01209-10 Filler cap Air filter box lid Shift lever ( p. 24) Engine number ( p. 12) Side stand ( p. 25) Chain guide... -
Page 13: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) B01210-10 Kill switch ( p. 14) Horn button ( p. 15) Light switch ( p. 15) Turn signal switch ( p. 16) Emergency OFF switch ( p. 16) Electric starter button ( p. -
Page 14: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. C00125-10 Type label The type label is fixed to the front of the steering head. 101290-10 Key number (All EXC‑F models) The key number for the steering lock is stamped onto the key connector. -
Page 15: Shock Absorber Part Number
SERIAL NUMBERS Shock absorber part number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side. 101292-10... -
Page 16: Controls
CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 101628-10 Hand brake lever Hand brake lever is located on the right side of the handlebar. The hand brake lever is used to activate the front brake. 101629-10 Throttle grip The throttle grip... -
Page 17: Horn Button (All Exc-F Models)
CONTROLS Horn button (All EXC‑F models) The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed – the horn is actuated in this position. • Horn button 101631-11 Light switch (All EXC‑F models) The light switch is fitted on the left side of the handlebar. -
Page 18: Turn Signal Switch (All Exc-F Models)
CONTROLS 6.11 Turn signal switch (All EXC‑F models) Turn signal switch is fitted on the left side of the handlebar. Possible states Turn signal light off – Turn signal switch is in the central position. Turn signal light, left, on – Turn signal switch is turned to the left. Turn signal light, right, on –... -
Page 19: Speedometer
CONTROLS 6.15 Speedometer 6.15.1 Overview – Press the button to change the display mode or change to one of the Setup menus. – 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. -
Page 20: Adjusting The Speedometer Functions
CONTROLS Adjusting Mph – Press the button – Press the button for 3 - 5 seconds. The settings are stored and the Setup menu is closed. Info If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu is closed. -
Page 21: Querying Lap Time
CONTROLS Info If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu is closed. 6.15.7 Querying lap time Info This function can be called up only if lap times are measured. Condition The motorcycle is stationary. -
Page 22: Display Mode Speed/Clk (Clock)
CONTROLS 6.15.10 Display mode SPEED/CLK (clock) – Press the button briefly and repeatedly until CLK appears at the bottom right of the display. The time is displayed in CLK display mode. Press the button . No function Press the button . -
Page 23: Display Mode Speed/Tr2 (Trip Master 2)
CONTROLS 6.15.14 Display mode SPEED/TR2 (trip master 2) – Press the button briefly and repeatedly until TR2 appears at the top right of the display. TR2 (trip master 2) runs constantly and counts up to 999.9. The displayed value can be set manually with the button and the button . -
Page 24: Display Mode Speed/S1 (Stop Watch 1)
CONTROLS 6.15.17 Display mode SPEED/S1 (stop watch 1) – Press the button briefly and repeatedly until S1 appears at the top right of the display. S1 (stop watch 1) displays the journey time on the basis of TR1 and continues when an impulse is received from the wheel speed sensor. -
Page 25: 6.15.20 Table Of Conditions And Menu Activation
CONTROLS 6.15.20 Table of conditions and menu activation Display The motorcycle is Menu can be acti- stationary. vated Display mode SPEED/H (operating hours) • Display mode SPEED/CLK (clock) • Display mode SPEED/LAP (lap time) • Display mode SPEED/TR1 (trip master 1) •... -
Page 26: Idle Speed Adjusting Screw
CONTROLS 6.18 Idle speed adjusting screw The idle speed adjusting screw is located on the throttle valve body at the top left. The idle speed adjusting screw has two functions. Turning it controls the idle speed. Pulling it out all the way raises the idle speed during a cold start. Possible states RPM increase activated –... -
Page 27: Foot Brake Lever
CONTROLS 6.21 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 101310-10 6.22 Side stand The side stand is on the left side of the vehicle. 101311-10 The side stand is used to park the motorcycle. -
Page 28: Unlocking The Steering (All Exc-F Models)
CONTROLS – Park the vehicle. – Turn the handlebar as far as possible to the right. – Insert the key in the steering lock, turn it to the left, press it in and turn it to the right. Remove the key. Steering is no longer possible. -
Page 29: Preparing For Use
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover. -
Page 30: Running-In The Engine
For this reason, it may be neces- sary to inspect or replace parts before the next scheduled service. – KTM recommends that you use the specified engine oil for difficult riding conditions and to increase performance. Engine oil (SAE 10W/60) (00062010035) ( p. 114) –... -
Page 31: Preparing For Rides On Dry Sand
– Fit a dust cover on the air filter. Dust protection device for air filter (77206920000) Info See the KTM PowerParts fitting instructions. 600869-01 – Fit a sand cover on the air filter. Sand protection device for air filter (59006022000) Info See the KTM PowerParts fitting instructions. -
Page 32: Preparing For Rides On Wet And Muddy Surfaces
Preparing for rides on wet and muddy surfaces – Fit a waterproofing device on the air filter. Waterproofing device for air filter (77206921000) Info See the KTM PowerParts fitting instructions. 600870-01 – Fit the steel sprocket. – Clean the motorcycle. ( p. -
Page 33: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p. 96) –... -
Page 34: Starting Off
Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines. -
Page 35: Stopping, Parking
RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. –... -
Page 36: Refueling
– In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards. -
Page 37: Service Schedule
Final check: Check the vehicle for roadworthiness and take a test ride. • • • Read out the fault memory using the KTM diagnostics tool after a test ride. • • • Make the service entry in KTM DEALER.NET and in the service record. -
Page 38: Service Work (As Additional Order)
SERVICE SCHEDULE Service work (as additional order) S15N S45A S105A Change the front brake fluid. • Change the rear brake fluid. • Change the hydraulic clutch fluid. p. 68) • Grease the steering head bearing. p. 54) • Clean the spark arrestor. (XCF‑W) •... -
Page 39: Tuning The Chassis
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. -
Page 40: Adjusting The High-Speed Compression Damping Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber. -
Page 41: Measuring Rear Wheel Sag Unloaded
TUNING THE CHASSIS 10.6 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with the lift stand. ( p. 45) Main work – Measure the distance – as vertically as possible – between the rear axle and a fixed point such as a mark on the side cover. -
Page 42: Adjusting The Spring Preload Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. -
Page 43: Checking Basic Setting Of Fork
TUNING THE CHASSIS Finishing work – Install the shock absorber. p. 55) – Remove the motorcycle from the lift stand. ( p. 45) – Check the static sag of the shock absorber. ( p. 39) – Check the riding sag of the shock absorber. ( p. -
Page 44: Adjusting The Rebound Damping Of The Fork
TUNING THE CHASSIS Guideline Compression damping Comfort 24 clicks Standard 22 clicks Sport 16 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 10.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. (EXC‑F EU, EXC‑F AUS, XCF‑W) –... -
Page 45: Adjusting The Spring Preload Of The Fork (Exc-F Eu, Exc-F Aus, Xcf-W)
TUNING THE CHASSIS 10.14 Adjusting the spring preload of the fork (EXC‑F EU, EXC‑F AUS, XCF‑W) – Turn the adjusting screws counterclockwise all the way. Info Make the same adjustment on both fork legs. – Turn back clockwise by the number of turns corresponding to the fork type. Guideline Spring preload - Preload Adjuster Comfort... - Page 46 TUNING THE CHASSIS – Position the handlebar clamps. Fit and evenly tighten the four screws Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) Info Make sure the gap width is even.
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Page 47: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (54829055000) The wheels should no longer touch the ground. -
Page 48: Loosening The Fork Protector
SERVICE WORK ON THE CHASSIS Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. – Clean and lubricate the dust boot and inside fork tube on both fork legs. -
Page 49: Installing The Fork Legs
SERVICE WORK ON THE CHASSIS (EXC‑F EU, EXC‑F AUS, XCF‑W) – Release screws . Take out the left fork leg. – Release screws . Take out the right fork leg. 101323-10 (EXC-F SIX DAYS) – Release screws . Take out the left fork leg. –... -
Page 50: Removing The Fork Protector
SERVICE WORK ON THE CHASSIS – Position the brake caliper and mount and tighten screws Guideline Screw, front brake caliper 25 Nm Loctite ® 243™ (18.4 lbf ft) – Mount cable binder – Position the brake line, wiring harness and clamp. Mount and tighten screws 101326-10 Finishing work –... -
Page 51: Removing The Lower Triple Clamp (Exc-Fsix Days)
SERVICE WORK ON THE CHASSIS Main work – Open the cable holder in front of the right radiator and detach the wiring harness. – Remove screws and hang the voltage regulator to one side. – Release screw and remove screw . -
Page 52: Installing The Lower Triple Clamp (Exc-F Eu, Exc-F Aus, Xcf-W)
SERVICE WORK ON THE CHASSIS 11.13 Installing the lower triple clamp (EXC‑F EU, EXC‑F AUS, XCF‑W) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 116) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. - Page 53 SERVICE WORK ON THE CHASSIS – Tighten screw Guideline Screw, top steering stem 20 Nm (14.8 lbf ft) 101334-11 – Tighten screws Guideline Screw, top triple clamp 20 Nm (14.8 lbf ft) – Secure the wiring harness with cable holder 101333-11 –...
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Page 54: Days)
SERVICE WORK ON THE CHASSIS 11.14 Installing the lower triple clamp (EXC-F SIX DAYS) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 116) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. -
Page 55: Adjusting The Play Of The Steering Head Bearing
SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Screw, top steering stem 17 Nm Loctite ® 243™ (12.5 lbf ft) B01233-10 – Tighten screws Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) – Secure the wiring harness with cable holder B01227-13 –... -
Page 56: Adjusting The Play Of The Steering Head Bearing (Exc-F Six Days)
SERVICE WORK ON THE CHASSIS Finishing work – Check the steering head bearing play. – Remove the motorcycle from the lift stand. ( p. 45) 11.16 Adjusting the play of the steering head bearing (EXC-F SIX DAYS) Preparatory work – Raise the motorcycle with the lift stand. -
Page 57: Installing The Front Fender
SERVICE WORK ON THE CHASSIS 11.19 Installing the front fender – Ensure that the spacers are mounted in the fender. – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) Info Make sure the holding lugs engage in the start number plate or headlight mask. -
Page 58: Mounting The Seat
SERVICE WORK ON THE CHASSIS 11.23 Mounting the seat – Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear and simultaneously push it forward. – Make sure that the seat is correctly locked in. –... -
Page 59: Installing The Air Filter
SERVICE WORK ON THE CHASSIS 11.27 Installing the air filter Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area Long-life grease ( p. 116) 101351-10 – Insert both parts together, position them and fasten them using air filter holder The arrow of marking UP faces up. -
Page 60: Sealing The Air Filter Box
SERVICE WORK ON THE CHASSIS 11.29 Sealing the air filter box – Seal the air filter box in the marked area 401527-10 11.30 Removing main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. –... -
Page 61: Removing The Fuel Tank
SERVICE WORK ON THE CHASSIS Main work (All EXC‑F models) – Remove screws of connecting cap – Take off the connecting cap with the perforated pipe, O-ring , and glass fiber yarn filling – Remove screws and take off silencer cap with O-ring and stuffing yarn... -
Page 62: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS Main work – Disconnect electric plug-in connection of the fuel pump. – Remove the tube from the fuel tank breather. 101354-10 – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Never let dirt enter the fuel line. -
Page 63: Checking For Chain Dirt Accumulation
SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme- diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. -
Page 64: Cleaning The Chain
SERVICE WORK ON THE CHASSIS 11.36 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. –... -
Page 65: Adjusting The Chain Tension
SERVICE WORK ON THE CHASSIS Finishing work – Remove the motorcycle from the lift stand. ( p. 45) 11.38 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel) are under additional load. - Page 66 SERVICE WORK ON THE CHASSIS – Pull on the upper part of the chain with the specified weight Guideline Weight of chain wear measurement 10… 15 kg (22… 33 lb.) – Measure the distance of 18 chain links in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions.
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Page 67: Adjusting The Chain Guide
SERVICE WORK ON THE CHASSIS – Check the chain guide for wear. Info Wear is visible on the front of the chain guide. » If the light part of the chain guide is worn: – Change the chain guide. 400985-01 –... -
Page 68: Checking The Frame
If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by KTM. 401340-01 11.42 Checking the swingarm –... -
Page 69: Checking The Rubber Grip
SERVICE WORK ON THE CHASSIS 11.44 Checking the rubber grip – Check the rubber grips on the handlebar for damage and wear and to ensure they are firmly seated. » If a rubber grip is damaged, worn or loose: – Change and secure the rubber grip. -
Page 70: Changing The Hydraulic Clutch Fluid
SERVICE WORK ON THE CHASSIS 11.48 Changing the hydraulic clutch fluid Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –... -
Page 71: Brake System
BRAKE SYSTEM 12.1 Checking free travel of hand brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating. -
Page 72: Checking The Brake Discs
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. -
Page 73: Checking The Front Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. - Page 74 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
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Page 75: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM – Insert the brake linings, insert the pin, and mount the cotter pin. – Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. 100398-10 –... -
Page 76: Checking The Rear Brake Fluid Level
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright. -
Page 77: Checking The Rear Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 78: Changing The Rear Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. - Page 79 BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 100407-10 – Insert the brake linings, insert the pin, and mount the cotter pin. – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.
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Page 80: Wheels, Tires
WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 45) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. -
Page 81: Removing The Rear Wheel
WHEELS, TIRES – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc. -
Page 82: Checking The Tire Condition
Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have a significant impact on the handling characteristics of the motorcycle. -
Page 83: Checking Tire Air Pressure
Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time. - Page 84 WHEELS, TIRES Guideline Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) Spoke nipple, rear wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) Torque wrench with various accessories in set (58429094000)
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Page 85: Electrical System
ELECTRICAL SYSTEM 14.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –... -
Page 86: Charging The Battery
– Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 87: Changing The Main Fuse
ELECTRICAL SYSTEM 14.4 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box cover. -
Page 88: Changing The Fuses Of Individual Power Consumers
ELECTRICAL SYSTEM 14.5 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. -
Page 89: Removing Headlight Mask With Headlight
ELECTRICAL SYSTEM Main work – Remove protection. Info The radiator fan fuse is in the area of the right-hand radiator. – Remove the defective fuse. – Insert a new fuse. Fuse (58011109105) ( p. 110) 101400-10 Info Replace a faulty fuse by an equivalent fuse only. –... -
Page 90: Changing The Headlight Bulb
ELECTRICAL SYSTEM Finishing work – Check the headlight setting. ( p. 88) 14.9 Changing the headlight bulb Note Damage to reflector Reduced luminance. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting. -
Page 91: Adjusting The Headlight Range
ELECTRICAL SYSTEM 14.11 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 88) Main work – Loosen screw – Adjust the headlight range of the headlight by moving it up or down. Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with driver (instructions on how to apply the mark: Checking the headlight setting). - Page 92 ELECTRICAL SYSTEM – Using a coin, turn protection cap all the way counterclockwise and remove it. – Remove speedometer battery – Insert the new battery with the label facing upward. Speedometer battery (CR 2430) ( p. 110) – Check the O-ring of the protection cap for correct seating. 101406-10 –...
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Page 93: Cooling System
COOLING SYSTEM 15.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant tem- perature will not result in a risk of malfunctions. -
Page 94: Checking The Coolant Level
COOLING SYSTEM 15.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. -
Page 95: Refilling Coolant
COOLING SYSTEM 15.5 Refilling coolant Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con- tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi- ately. -
Page 96: Tuning The Engine
TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3…... -
Page 97: Adjusting The Idle Speed
TUNING THE ENGINE 16.3 Adjusting the idle speed – Run the engine warm and push the idle speed adjusting screw all the way in. – Set the desired idle speed by turning the idle speed adjusting screw. Guideline Idle speed 1,950…... -
Page 98: Service Work On The Engine
SERVICE WORK ON THE ENGINE 17.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –... -
Page 99: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen
SERVICE WORK ON THE ENGINE The engine oil is at a level between the middle and upper edge of the level viewer. » If the engine oil is not up to the middle of the level viewer: – Add engine oil. ( p. - Page 100 SERVICE WORK ON THE ENGINE – Mount and tighten screw plug with the O-ring. Guideline Screw plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) – Mount and tighten the oil drain plug with the magnet and a new seal ring. Guideline Oil drain plug with magnet M12x1.5...
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Page 101: Adding Engine Oil
SERVICE WORK ON THE ENGINE – Start the engine and check that it is oil-tight. Finishing work (EXC‑F AUS, EXC-F SIX DAYS) – Install the engine guard. ( p. 68) – Check the engine oil level. ( p. 96) 17.4 Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. -
Page 102: Cleaning, Care
CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts. -
Page 103: Checks And Maintenance Steps For Winter Operation
CLEANING, CARE 18.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt. -
Page 104: Storage
– Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 45) – Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materi- als since they prevent humidity from escaping, thus causing corrosion. -
Page 105: Troubleshooting
– Check the electrical system. switch defective – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. - Page 106 – Check the cabling for damage and the electri- cal plug-in connections for corrosion and dam- age. – Read out the fault memory using the KTM diag- nostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary.
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Page 107: Blink Code
BLINK CODE Blink code FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Crankshaft position sensor - circuit fault Blink code FI warning lamp (MIL) 06 FI warning lamp (MIL) flashes 6x short Error level condition Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high Blink code FI warning lamp (MIL) - Page 108 BLINK CODE Blink code FI warning lamp (MIL) 45 FI warning lamp (MIL) flashes 4x long, 5x short Error level condition EXC‑F EU, EXC-F SIX DAYS Lambda sensor heater cylinder 1, sensor 1 - short circuit to ground or open circuit EXC‑F EU, EXC-F SIX DAYS Lambda sensor heater cylinder 1, sensor 1 - input signal too high...
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Page 109: Technical Data
TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 349.7 cm³ (21.34 cu in) Stroke 57.5 mm (2.264 in) Bore 88 mm (3.46 in) Compression ratio 12.3:1 Idle speed 1,950… 2,050 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 36.3 mm (1.429 in) - Page 110 TECHNICAL DATA ® Screw, locking lever 6 Nm (4.4 lbf ft) Loctite 243™ ® Screw, oil pump cover 6 Nm (4.4 lbf ft) Loctite 243™ ® Screw, stator 6 Nm (4.4 lbf ft) Loctite 243™ Nut, cylinder head 10 Nm (7.4 lbf ft) Lubricated with engine oil ®...
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Page 111: Capacities
TECHNICAL DATA 22.3 Capacities 22.3.1 Engine oil Engine oil 1.20 l (1.27 qt.) Engine oil (SAE 10W/50) ( p. 114) Alternative engine oil for harsh Engine oil (SAE 10W/60) operating conditions and (00062010035) ( p. 114) increased performance 22.3.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant (... -
Page 112: Electrical System
MAXXIS MAXX ENDURO 80/100 - 21 51M TT 110/100 - 18 64M TT (XCF‑W) Dunlop GEOMAX MX51 Dunlop GEOMAX MX51 Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork 22.7.1 EXC‑F EU, EXC‑F AUS, XCF‑W Fork part number 14.18.7L.67... -
Page 113: Exc-F Six Days
TECHNICAL DATA Weight of rider: 75… 85 kg (165… 187 lb.) 513 mm (20.2 in) Weight of rider: 85… 95 kg (187… 209 lb.) 513 mm (20.2 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 114: Chassis Tightening Torques
TECHNICAL DATA Gas pressure 10 bar (145 psi) Static sag 33… 35 mm (1.3… 1.38 in) Riding sag 105… 115 mm (4.13… 4.53 in) Fitted length 417 mm (16.42 in) Damper oil Shock absorber oil (SAE 2.5) (50180342S1) ( p. 115) 22.9 Chassis tightening torques –... - Page 115 TECHNICAL DATA Loctite ® 2701 Screw, bottom shock absorber 80 Nm (59 lbf ft) Screw, top shock absorber 80 Nm (59 lbf ft) Loctite ® 2701 – Nut, seat fixing M12x1 20 Nm (14.8 lbf ft) – Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) –...
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Page 116: Substances
Brake fluid DOT 4 / DOT 5.1 According to – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Castrol and Motorex ® products. Supplier Castrol –... - Page 117 SUBSTANCES Fork oil (SAE 4) (48601166S1) According to – SAE ( p. 118) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Shock absorber oil (SAE 2.5) (50180342S1) According to –...
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Page 118: Auxiliary Substances
AUXILIARY SUBSTANCES Air filter cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Dirt Bio Remover Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline –... - Page 119 AUXILIARY SUBSTANCES Oil for foam air filter Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Liquid Bio Power Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline – KTM recommends Motorex ®...
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Page 120: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation. -
Page 121: Index
INDEX fluid, changing ......68 INDEX Clutch lever ........14 Accessories . - Page 122 INDEX bleeding ....... . . 45 removing ....... 48-49 dust boots, cleaning .
- Page 123 INDEX removing ....... . . 55 riding sag, checking ......39 View of vehicle spring preload, adjusting .
- Page 124 *3211863en* 3211863en 07/2012 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...
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