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Related Manuals for KTM Freeride 350 2017
Summary of Contents for KTM Freeride 350 2017
- Page 1 OWNER'S MANUAL 2017 Freeride 350 Art. no. 3213484en...
- Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, misprints, and other errors.
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Page 4: Table Of Contents
TABLE OF CONTENTS 7.10 AVG average speed, ART operating hours, and TABLE OF CONTENTS MEANS OF REPRESENTATION ........4 ODO total distance covered ......22 Symbols used ........... 4 PREPARING FOR USE..........23 Formats used............ 4 Advice on first use .......... 23 SAFETY ADVICE............ - Page 5 TABLE OF CONTENTS 12.22 Removing the air filter housing ..... 47 15.6 Removing the headlight mask with the headlight............81 12.23 Installing the air filter housing ...... 48 15.7 Refitting the headlight mask with the 12.24 Removing the air filter .........
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Page 6: 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 7: Safety Advice
SAFETY ADVICE Use definition - intended use KTM sport motorcycles are designed and built to withstand the normal stresses and strains of offroad use. Info The motorcycle is authorized for public road traffic in the homologous (reduced) version only. In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. -
Page 8: Safe Operation
– Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren- theses. -
Page 9: 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 10: Important Notes
Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the warranty. -
Page 11: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) E00287-10 Speedometer Clutch lever ( p. 13) Filler cap Seat Seat release Shock absorber compression adjustment Shock absorber rebound adjustment Side stand ( p. 17) Battery Shift lever ( p. 16) Idle speed adjusting screw ( p. -
Page 12: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) E00288-10 Kill switch ( p. 13) Horn button ( p. 13) Light switch ( p. 14) Turn signal switch ( p. 14) Electric starter button ( p. 14) Throttle grip ( p. -
Page 13: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. 401946-10 Type label The type label is mounted on the frame at the front right. 402270-10 Key number The key number for the steering lock is stamped onto the key connector. -
Page 14: Shock Absorber Article Number
SERIAL NUMBERS Shock absorber article number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 0 0 1 401948-10... -
Page 15: Controls
CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. M00467-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. -
Page 16: Light Switch
CONTROLS Light switch The light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is in the central position. In this position, the low beam and tail light are switched on. High beam on –... -
Page 17: Overview Of Indicator Lamps
CONTROLS 6.11 Overview of indicator lamps Possible states High beam indicator light lights up blue – High beam is switched on. FI warning lamp (MIL) lights up/flashes orange – The OBD has detected an emission- or safety-critical fault. The fuel level warning lamp lights up orange – The fuel level has reached the reserve mark. -
Page 18: Closing The Filler Cap
CONTROLS 6.13 Closing the filler cap Main work – Replace the filler cap and turn clockwise until the release button locks in place. Info Run the fuel tank breather hose without kinks. 602797-10 Finishing work – Lock the seat. ( p. -
Page 19: Foot Brake Lever
CONTROLS 6.16 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. 401956-10 6.17 Side stand The side stand is on the left side of the vehicle. 401943-10 The side stand is used to park the motorcycle. -
Page 20: Unlocking The Steering
CONTROLS – Park the vehicle. – Turn the handlebar as far as possible to the right. – Grease steering lock regularly. Universal oil spray ( p. 110) – Insert the key in the steering lock ( p. 17), turn it to the left, press it in, and turn it to the right. -
Page 21: Speedometer
Message on the speedometer Possible states Battery voltage of the speedometer – Battery voltage of the speedometer is too low. Change the battery. Service – A service is due. Contact an authorized KTM workshop. 401901-01 Setting the speedometer Condition The motorcycle is stationary. -
Page 22: Setting The Kilometers Or Miles
SPEEDOMETER – Wait for 5 seconds. The speedometer changes to the next menu item. The symbol flashes. Resetting the time – Press the left button. The value decreases. Advancing the time – Press the right button. The value increases. 401912-01 –... -
Page 23: Setting The Clock
SPEEDOMETER Setting the clock Condition The motorcycle is stationary. – Press both buttons for 3–5 seconds. The Setup menu is displayed. The UNIT display flashes. – Wait for the menu of the clock to flash. – Press one of the buttons to select the 24h or 12h display of the clock. 401911-01 –... -
Page 24: Speed, Time, And Dst Distance 1
SPEEDOMETER Speed, time, and DST distance 1 – Press one of the buttons until DST appears on the speedometer. KM/H or M/H shows the speed. shows the time. DST shows the distance since the last reset, such as between two refueling stops. Info If the value of 39999.9 is exceeded, DST is automatically reset to 0.0. -
Page 25: Preparing For Use
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover. -
Page 26: Running In The Engine
PREPARING FOR USE – Try also to ride as slowly as possible and in a standing position to get a better feeling for the motorcycle. – Do not make any off-road trips that exceed your ability and experience. – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. –... -
Page 27: 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. 91) –... -
Page 28: Starting Off
Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system. -
Page 29: Stopping, Parking
RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation People who act without authorization endanger themselves and others. – Do not leave the vehicle unattended if the engine is running. – Protect the vehicle against access by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. –... -
Page 30: Refueling
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Improper handling of fuel is a danger to the environment. -
Page 31: Service Schedule
● ● Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval... -
Page 32: Service Work (As Additional Order)
SERVICE SCHEDULE 10.2 Service work (as additional order) Annually Every 160 operating hours Every 40 operating hours Once after 20 operating hours ● Change the front brake fluid. ● Change the rear brake fluid. ● ● Change the foot brake cylinder seals. ●... -
Page 33: 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 low-speed setting can be seen during the slow to normal compression of the shock absorber. -
Page 34: Adjusting The High-Speed Compression Damping Of The Shock Absorber
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber. -
Page 35: Measuring Rear Wheel Sag Unloaded
TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. 11.6 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with the lift stand. ( p. 38) Main work – Measure the distance – as vertical as possible – between the rear axle and a fixed point, for example, a mark on the rear fairing. -
Page 36: Checking The Riding Sag Of The Shock Absorber
The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. -
Page 37: Adjusting The Riding Sag
TUNING THE CHASSIS Finishing work – Install the shock absorber. p. 45) – Lock the seat. ( p. 46) – Remove the motorcycle from the lift stand. ( p. 38) 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with the lift stand. ( p. -
Page 38: Adjusting The Compression Damping Of The Fork
TUNING THE CHASSIS 11.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Remove protection caps – Turn adjusting screws clockwise all the way. Info Adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs. -
Page 39: Handlebar Position
TUNING THE CHASSIS 11.14 Handlebar position On the upper triple clamp, there are two holes at a distance of to each other. 15 mm (0.59 in) Hole distance The holes on the handlebar supports are placed at a distance of from the center. -
Page 40: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (78929955100) Neither wheel is in contact with the ground. -
Page 41: Cleaning The Dust Boots Of The Fork Legs
SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 38) – Remove the fork protector. ( p. 40) Main work – Push dust boots of both fork legs downward. -
Page 42: Installing The Fork Legs
SERVICE WORK ON THE CHASSIS 12.6 Installing the fork legs Main work – Position the fork legs. Bleeder screws are positioned toward the front. Info Grooves are milled into the side of the upper end of the fork legs. The sec- ond milled groove (from the top) must be flush with the top edge of the upper triple clamp. -
Page 43: Installing The Fork Protector
SERVICE WORK ON THE CHASSIS 12.8 Installing the fork protector – Position the fork protection on the right fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) M00480-11 – Position the fork protection on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) -
Page 44: Installing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS 12.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 109) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. -
Page 45: Checking The Steering Head Bearing Play
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam-... -
Page 46: Adjusting The Play Of The Steering Head Bearing
SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with the lift stand. ( p. 38) Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. -
Page 47: Removing The Front Fender
SERVICE WORK ON THE CHASSIS 12.14 Removing the front fender – Remove screws . Remove the front fender. B01030-10 12.15 Installing the front 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 headlight mask. -
Page 48: Folding The Seat Up
SERVICE WORK ON THE CHASSIS Finishing work – Lock the seat. ( p. 46) – Remove the motorcycle from the lift stand. ( p. 38) 12.18 Folding the seat up – Press release lever – Lift the seat and fold it up. M00497-10 12.19 Locking the seat... -
Page 49: Mounting The Spoiler
SERVICE WORK ON THE CHASSIS 12.21 Mounting the spoiler Main work – Position the spoiler and hook it in at area M00504-10 – Mount and tighten screw Guideline EJOT PT ® Screw for spoiler, top 3 Nm (2.2 lbf ft) K60x20AL –... -
Page 50: Installing The Air Filter Housing
SERVICE WORK ON THE CHASSIS 12.23 Installing the air filter housing Main work – Position pre-filter on the air filter housing. Note Engine failure If the pre-filter is mounted incorrectly or not mounted at all, the air-fuel mixture will change. This has a negative effect on the service life of the engine. -
Page 51: Cleaning The Air Filter And Air Filter Housing
SERVICE WORK ON THE CHASSIS – Insert both parts together and close air filter housing by turning clockwise. Info If the air filter is not mounted correctly, dust and dirt may enter the engine and cause damage. M00507-10 Finishing work –... -
Page 52: Installing The Main Silencer
SERVICE WORK ON THE CHASSIS Remove the right main silencer: – Take off the spoiler. ( p. 46) Info Only remove the right spoiler. – Disconnect plug-in connector of the lambda sensor. M00538-10 – Detach spring – Remove screws and take off the main silencer. -
Page 53: Changing The Glass Fiber Yarn Filling Of The Main Silencer
SERVICE WORK ON THE CHASSIS 12.29 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. Info Over a period, the fibers of the glass fiber yarn vanish into the air, and the silencer "burns out". - Page 54 SERVICE WORK ON THE CHASSIS Preparatory work – Fold the seat up. ( p. 46) Main work – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! –...
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Page 55: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS 12.31 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –... -
Page 56: Checking For Chain Dirt Accumulation
SERVICE WORK ON THE CHASSIS – Insert the fuel tank breather hose into the steering head screw. – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! –... -
Page 57: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS 12.34 Checking 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. -
Page 58: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide
SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws on the left and right. Guideline Chain tension 36… 40 mm (1.42… 1.57 in) Turn adjusting screws ... - Page 59 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the bottom edge of the chain bolt is in line with or below the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated. »...
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Page 60: Checking The Frame
If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by KTM. 401462-01 12.38 Checking the swingarm –... -
Page 61: Checking The Rubber Grip
SERVICE WORK ON THE CHASSIS 12.40 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 62: Correcting The Fluid Level Of The Hydraulic Clutch
SERVICE WORK ON THE CHASSIS 12.44 Correcting the fluid level of the hydraulic clutch Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. -
Page 63: Removing The Engine Guard
SERVICE WORK ON THE CHASSIS Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container. -
Page 64: Installing The Engine Guard
SERVICE WORK ON THE CHASSIS 12.47 Installing the engine guard – Position the engine guard on the frame at the front and mount screws but do not tighten yet. – Position the engine guard on the frame at the rear and mount and tighten ... -
Page 65: Brake System
Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disk ... -
Page 66: Checking The Brake Fluid Level Of The Front Brake
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect. -
Page 67: Checking The Front Brake Linings
Changing the front brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation. –... - Page 68 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
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Page 69: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM – Position the brake caliper. Mount screws with the spacers but do not tighten yet. – Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. Fix the hand brake lever in the acti- vated position. -
Page 70: Checking The Rear Brake Fluid Level
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect. -
Page 71: Checking The Rear Brake Linings
Clean up overflowed or spilled brake fluid immediately with water. E00297-10 13.12 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.) -
Page 72: 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 73 BRAKE SYSTEM – Stand the vehicle upright. – Remove screws – Remove cover with membrane – Press the brake piston back into the basic position and ensure that brake fluid does not flow out of the brake fluid reservoir, sucking it away if necessary. E00298-10 –...
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Page 74: Wheels, Tires
WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 38) Main work – Loosen screw by several rotations. – Loosen screws – Press on screw to push the wheel spindle out of the axle clamp. –... -
Page 75: Removing The Rear Wheel
WHEELS, TIRES – Operate the hand brake lever several times until the brake linings are seated cor- rectly against the brake disc. – Remove the motorcycle from the lift stand. ( p. 38) – Operate the front brake and compress the fork a few times firmly. The fork legs straighten. -
Page 76: 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 major impact on the handling of the motorcycle. -
Page 77: Checking The Tire Air Pressure
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.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes. - Page 78 WHEELS, TIRES – Briefly strike each spoke with the tip of a screwdriver. Info The tone frequency depends on the length of the spoke and the spoke diam- eter. If you hear different tone frequencies from different spokes of equal length and diameter, this is an indication of different spoke tensions.
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Page 79: Electrical System
ELECTRICAL SYSTEM 15.1 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 80: Recharging The Battery
– Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 81: Changing The Main Fuse
ELECTRICAL SYSTEM Guideline The charging current, charging voltage, and charging time must not be exceeded. Charge the battery regularly when the 3 months motorcycle is not in use Finishing work – Install the battery. p. 77) 15.4 Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system. -
Page 82: Changing The Fuses Of Individual Power Consumers
ELECTRICAL SYSTEM 15.5 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 – Press and hold the kill switch while the engine is idling until the engine stops. –... -
Page 83: Removing The Headlight Mask With The Headlight
ELECTRICAL SYSTEM 15.6 Removing the headlight mask with the headlight – Switch off all power consumers. – Detach the brake line and wiring harness – Release rubber band . Slide the headlight mask up and swing it forward. S00842-10 –... -
Page 84: Changing The Headlight Bulb
ELECTRICAL SYSTEM – Position the headlight mask and secure it with rubber bands The holding lugs on the fender engage in the headlight mask. – Attach the brake line and wiring harness S00843-10 Finishing work – Check the headlight setting. ( p. -
Page 85: Changing The Turn Signal Bulb
ELECTRICAL SYSTEM 15.9 Changing the turn signal bulb Note Damage to reflector Reduced brightness. – 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. Main work –... -
Page 86: Changing The Speedometer Battery
ELECTRICAL SYSTEM Main work – Adjust the beam distance of the headlight by turning screw Guideline For a motorcycle with rider, the light/dark boundary must be exactly on the lower mark (the mark is created in: Checking the headlight setting). Info Turn clockwise to increase the headlight range, turn counterclockwise to reduce the headlight range. -
Page 87: Cooling System
COOLING SYSTEM 16.1 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 temperature will not result in a risk of malfunctions. -
Page 88: Checking The Coolant Level
COOLING SYSTEM – Mount the radiator cap. 16.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature. -
Page 89: Refilling Coolant
COOLING SYSTEM – Position the motorcycle upright. – Place a suitable container under the water pump cover. – Remove screw . Take off radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Screw, water pump cover 10 Nm (7.4 lbf ft) -
Page 90: Tuning The Engine
TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Throttle cable play 3…... -
Page 91: Adjusting The Idle Speed
TUNING THE ENGINE 17.3 Adjusting the idle speed – Run the engine warm and push idle speed adjusting screw all the way in. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. –... - Page 92 TUNING THE ENGINE – Mount and tighten screw with the washers. Guideline Screw, shift lever 14 Nm Loctite ® 243™ (10.3 lbf ft)
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Page 93: Service Work On The Engine
SERVICE WORK ON THE ENGINE 18.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –... -
Page 94: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen
SERVICE WORK ON THE ENGINE » If the engine oil is not up to the lower edge of the level viewer: – Add engine oil. ( p. 94) 18.3 Changing the engine oil and oil filter, cleaning the oil screen Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden. - Page 95 SERVICE WORK ON THE ENGINE – Position oil screen with the O-rings on a pin wrench. – Position the pin wrench through the drilled hole of the screw plug in the opposite section of the engine case. – Push the oil screen all the way into the engine case. B01127-10 –...
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Page 96: Adding Engine Oil
SERVICE WORK ON THE ENGINE 18.4 Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. Main work – Remove the oil filler plug with the O-ring from the clutch cover. –... -
Page 97: Cleaning, Care
CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –... -
Page 98: Checks And Maintenance Steps For Winter Operation
CLEANING, CARE 19.2 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 99: 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. 38) – 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 100: Troubleshooting
– Check the electrical system. – 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 101 See blink code – Check the cabling for damage and the connec- tors for corrosion and damage. – 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 change it if necessary.
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Page 102: Blink Code
BLINK CODE Blink code FI warning lamp (MIL) 45 FI warning lamp (MIL) flashes 4x long, 5x short Error level condition Lambda sensor heater cylinder 1, sensor 1 - short circuit to ground or open circuit Lambda sensor heater cylinder 1, sensor 1 - input signal too high Blink code FI warning lamp (MIL) 09 FI warning lamp (MIL) flashes 9x short Error level condition... -
Page 103: Technical Data
TECHNICAL DATA 23.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 349.7 cm³ (21.34 cu in) Stroke 57.5 mm (2.264 in) Bore 88 mm (3.46 in) Compression ratio 12.3:1 Idle speed 1,800… 1,900 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 36.3 mm (1.429 in) - Page 104 TECHNICAL DATA Loctite ® 243™ Screw, locking lever 6 Nm (4.4 lbf ft) 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 Nut, water-pump wheel 5 Nm (3.7 lbf ft)
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Page 105: Capacities
TECHNICAL DATA 23.3 Capacities 23.3.1 Engine oil Engine oil 1.0 l (1.1 qt.) Engine oil (SAE 10W/50) ( p. 107) Alternative engine oil Engine oil (SAE 10W/60) (00062010035) ( p. 107) 23.3.2 Coolant Coolant 0.7 l (0.7 qt.) Coolant ( p. -
Page 106: Electrical System
Rear tires 2.75 - 21 M/C 45M TT 4.00 R 18 M/C 64M TL MAXXIS TRIALMAXX MAXXIS TRIALMAXX Additional information is available in the Service section under: http://www.ktm.com 23.7 Fork Fork part number 05.18.7N.40 Fork WP Performance Systems 4357 MXMA... -
Page 107: Shock Absorber
TECHNICAL DATA 23.8 Shock absorber Shock absorber part number 15.18.7N.40 Shock absorber WP Performance Systems 4618 PDS DCC Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 5 clicks Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport 1 turn Rebound damping Comfort... - Page 108 TECHNICAL DATA Loctite ® 2701™ Nut, rear sprocket screw 35 Nm (25.8 lbf ft) – Nut, rim lock 10 Nm (7.4 lbf ft) – Remaining nuts, chassis 25 Nm (18.4 lbf ft) – Remaining screws, chassis 25 Nm (18.4 lbf ft) Screw of rear brake caliper 25 Nm (18.4 lbf ft) Loctite...
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Page 109: Substances
111) – SAE ( p. 111) (SAE 10W/60) – KTM LC4 2007+ Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre- sponding properties. Synthetic engine oil... - Page 110 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 111) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification –...
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Page 111: Auxiliary Substances
Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Grip adhesive (00062030051) Recommended supplier KTM AG – GRIP GLUE High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier Motorex ® –... - Page 112 AUXILIARY SUBSTANCES Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic...
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Page 113: 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 114: List Of Abbreviations
LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly... -
Page 115: List Of Symbols
LIST OF SYMBOLS 28.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols. FI warning lamp (MIL) lights up/flashes orange – The OBD has detected an emission- or safety-critical fault. The fuel level warning lamp lights up orange –... -
Page 116: Index
INDEX Clutch lever ........13 INDEX basic position, adjusting ..... . 59 Accessories . - Page 117 INDEX Front fender removing from the lift stand ....38 installing ....... . . 45 removing .
- Page 118 INDEX service display, setting ..... . . 21 setting ........19 Spoiler mounting .
- Page 119 *3213484en* 3213484en 04/2016 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...
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