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

KTM 350 EXC-F WESS Owner's Manual

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OWNER'S MANUAL
2021
350 EXC-F
350 XCF‑W
350 EXC-F Six Days
350 EXC-F WESS
Art. no. 3214224en

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Summary of Contents for KTM 350 EXC-F WESS

  • Page 1 OWNER'S MANUAL 2021 350 EXC-F 350 XCF‑W 350 EXC-F Six Days 350 EXC-F WESS Art. no. 3214224en...
  • 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 6.11 Combination switch TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 6 (EXC‑F WESS EU, All Six Days Symbols used ........6 models, XCF‑W) ....... 19 Formats used........6 6.12 Overview of indicator lamps (All EU/BR/CN models)..... 19 SAFETY ADVICE..........
  • Page 5 TABLE OF CONTENTS PREPARING FOR USE......... 37 11.8 Checking the static sag of the shock absorber.......... 55 Advice on preparing for first use ..37 11.9 Checking the riding sag of the shock Running-in the engine ...... 38 absorber.......... 55 Starting power of lithium-ion 11.10 Adjusting the spring preload of the batteries at low temperatures (all...
  • Page 6 TABLE OF CONTENTS 12.21 Removing the seat ......81 13.8 Changing the brake linings of the front brake ......... 107 12.22 Mounting the seat ......81 13.9 Checking the free travel of foot 12.23 Removing the air filter box cover ..82 brake lever ........
  • Page 7 TABLE OF CONTENTS 17.3 Adjusting the characteristic map of 28 LIST OF ABBREVIATIONS......180 the throttle response ....145 29 LIST OF SYMBOLS........181 17.4 Changing the mapping (EXC‑F WESS EU, All Six Days 29.1 Yellow and orange symbols....181 models).........

  • 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/CN 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 Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key).

  • Page 12: Owner's Manual

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

  • Page 13: Important Notes 3

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

  • Page 14: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) V01826-10 Clutch lever ( p. 16) Fuel tank filler cap Air filter box cover Side stand ( p. 22) Engine number ( p. 14) Shift lever ( p. 22)

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

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) V01827-10 Stop button ( p. 16) Horn button ( p. 17) (All EU/BR/CN models) Light switch ( p. 17) (All EU/BR/CN models) Turn signal switch ( p. 18) (All EU/BR/CN models) Start button ( p.

  • Page 16: Serial Numbers

    5 SERIAL NUMBERS 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 17: Fork Part Number

    SERIAL NUMBERS 5 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 18: Controls

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

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

    CONTROLS 6 (XCF‑W) The stop button is fitted on the left side of the handlebar. Possible states is in the basic position – In this position, • The stop button the ignition circuit is closed and the engine can be started. pressed –...

  • Page 20: Turn Signal Switch (All Eu/Br/Cn Models)

    6 CONTROLS Turn signal switch (All EU/BR/CN 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 21: Combination Switch (Exc-F Wess Eu, All Six Days 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 22: Opening The Fuel Tank Filler Cap

    6 CONTROLS 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 fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 23: Cold Start Button

    CONTROLS 6 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 24: Shift Lever

    6 CONTROLS 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 25: Steering Lock (All Eu Models, All Br Models)

    CONTROLS 6 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 models, All BR models) Steering lock is fitted on the left side of the steering head. The steering lock is used to lock the steering.

  • Page 26: Unlocking The Steering (All Eu Models, All Br Models)

    6 CONTROLS 6.23 Unlocking the steering (All EU models, All BR models) – Insert the key for the steering lock into the steering lock p. 23), 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 27: Combination Instrument 7

    COMBINATION INSTRUMENT 7 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 28: Setting The Combination Instrument

    7 COMBINATION INSTRUMENT – 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 29: Setting The Clock

    COMBINATION INSTRUMENT 7 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 30: Display Mode Speed (Speed)

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

  • Page 31: Setting The Unit Of Measurement

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

    7 COMBINATION INSTRUMENT 7.11 Display mode SPEED/CLK (time) – Repeatedly press the button briefly until CLK appears at the bottom right of the display. The time is shown in display mode CLK. Press the but- The display changes to the Setup menu of the for 2–3 clock.

  • Page 33: Viewing The Lap Time

    COMBINATION INSTRUMENT 7 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 34: Display Mode Speed/Tr1 (Trip Master 1)

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

  • Page 35: Display Mode Speed/A1 (Average Speed 1)

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

    7 COMBINATION INSTRUMENT 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 37: Table Of Functions

    COMBINATION INSTRUMENT 7 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 38: Table Of Conditions And Menu Activation

    7 COMBINATION INSTRUMENT Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12 for 2–3 the button for 2–3 the button seconds. seconds. seconds. seconds. Adjusting TR2 Increases Increases Reduces Reduces Stores and (trip master 2) value of TR2.

  • Page 39: Preparing For Use 8

    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 40: Running-In The Engine

    8 PREPARING FOR USE (All EU/BR/CN models) – Adjust the free travel of the handbrake lever. ( p. 103) (XCF‑W) – Adjust the basic position of the hand brake lever. ( p. 104) – Adjust the basic position of the foot brake lever. p.

  • Page 41: Starting Power Of Lithium-Ion Batteries At Low Temperatures (All Eu/Cn Models, Xcf-W)

    – Riding at low temperatures and in snow. ( p. 41) 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 42: Preparing The Vehicle For Riding On Wet Sand

    8 PREPARING FOR USE – 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. 176) – Mount the steel sprocket. –...

  • Page 43: Preparing The Vehicle For Riding On Wet And Muddy Circuits

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

  • Page 44: Riding Instructions

    9 RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 45: Activating Traction Control (Exc-F Wess Eu, All Six Days Models, Xcf-W)

    RIDING INSTRUCTIONS 9 – 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 46: Starting Off

    Do not change into a low gear at high engine speed. Info If unusual noises occur while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First-gear is used for starting off and for steep inclines. –...

  • Page 47: Braking

    Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system.

  • Page 48: Transporting

    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 49 RIDING INSTRUCTIONS 9 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 50: 10 Service Schedule

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

  • Page 51: Recommended Work

    Final check: Check the vehicle is roadworthy and take a test ride. ○ ● ● ● ● Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● ● Make a service entry in KTM Dealer.net.
  • Page 52 10 SERVICE SCHEDULE every 48 months every 12 months Every 135 operating hours Every 70 operating hours when used for motorsports After 20 operating hours After 10 operating hours ● ● Perform engine service including removing and installing the engine. (Change the spark plug and spark plug connector.

  • Page 53: Tuning The Chassis 11

    – As delivered, KTM offroad motorcycles are adjusted for an average rider's weight (with full protective clothing). Guideline Standard rider weight 75 …...

  • Page 54: 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 low-speed compression adjuster can be seen in slow to normal compression of the shock absorber.

  • 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: Measuring The Dimension Of The Rear Wheel Unloaded

    11 TUNING THE CHASSIS Info Turn clockwise to increase the damping; turn counter- clockwise to reduce damping when the shock absorber rebounds. 11.7 Measuring the dimension of the rear wheel unloaded Preparatory work – Raise the motorcycle with the lift stand. ( p.

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

    TUNING THE CHASSIS 11 11.8 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 11.11 Adjusting the riding sag Preparatory work – Raise the motorcycle with the lift stand. ( p. 66) – Remove the shock absorber. p. 80) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 60: Adjusting The Compression Damping Of The Fork

    11 TUNING THE CHASSIS 11.13 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. (EXC‑F WESS EU) – Turn adjuster clockwise all the way to the stop. Info Adjuster is located at the upper end of the right fork leg.

  • Page 61: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS 11 (all Six Days models, XCF-W, EXC-F EU) – Turn white adjuster clockwise as far as it will go. Info Adjuster is located at the upper end of the left fork leg. The compression damping is located in left fork leg COM (white adjuster).
  • Page 62 11 TUNING THE CHASSIS (EXC‑F BR) – Turn red adjuster clockwise as far as it will go. Info Adjuster is located at the upper end of the right fork leg. The rebound damping is located in right fork leg REB (red adjuster). The compression damping is located in left fork leg COMP (white adjuster).

  • Page 63: Adjusting The Spring Preload Of The Fork (All Six Days Models, Xcf-W, Exc-F Eu)

    TUNING THE CHASSIS 11 11.15 Adjusting the spring preload of the fork (all Six Days models, XCF-W, EXC-F EU) Preparatory work – Raise the motorcycle with the lift stand. ( p. 66) Main work – Turn T-grips counterclockwise all the way. The marking +0 aligns with the right wing.
  • Page 64 A little air escapes from the fork leg when connecting. Info This is due to the volume of the hose and not due to a defect in the fork airpump or the fork. Read the accompanying KTM PowerParts instructions. – Adjust the air pressure as specified. Guideline...

  • Page 65: Handlebar Position

    TUNING THE CHASSIS 11 11.17 Handlebar position (EXC‑F EU, XCF‑W, EXC‑F BR) On the upper triple clamp, there are 2 holes at a distance to each other. 15 mm (0.59 in) Hole distance The holes on the handlebar supports are placed at a distance from the center.
  • Page 66 11 TUNING THE CHASSIS (EXC‑F EU, XCF‑W, EXC‑F BR) – Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against dam- age. Do not kink the cables and lines. –...
  • Page 67 TUNING THE CHASSIS 11 (EXC‑F WESS EU, 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 68: 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 69: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS 12 (EXC‑F WESS EU) – Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws. H01182-12 Finishing work – Remove the motorcycle from the lift stand. ( p.

  • Page 70: Removing The Fork Protector

    12 SERVICE WORK ON THE CHASSIS 12.5 Removing the fork protector – Remove screws and take off the clamp. – Remove screws on the left fork leg and take off the left fork protector. – Remove screws on the right fork leg and take off the right fork protector.

  • Page 71: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS 12 (EXC‑F EU, XCF‑W, EXC‑F BR) – Loosen screws . Take out the left fork leg. – Loosen screws . Take out the right fork leg. V01756-10 (EXC‑F WESS EU, All Six Days models) – Loosen screws .

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

    12 SERVICE WORK ON THE CHASSIS (EXC‑F EU, XCF‑W, EXC‑F BR) – Tighten screws Guideline Screw, top triple 20 Nm clamp (14.8 lbf ft) – Tighten screws Guideline Screw, bottom 15 Nm V01756-11 triple clamp (11.1 lbf ft) (EXC‑F WESS EU, All Six Days models) –...

  • Page 73: Models)

    SERVICE WORK ON THE CHASSIS 12 Main work – Pull the fuel tank breather hose out of the steering head screw. – Open the cable holder in front of the left radiator and detach the wiring harness. – Loosen screw –...

  • Page 74: Installing The Lower Triple Clamp (Exc-F Eu, Xcf-W, Exc-F Br)

    12 SERVICE WORK ON THE CHASSIS – Remove O-ring and protective ring – Take off the lower triple clamp with the steering stem. – Remove the upper steering head bearing. V01788-10 12.11 Installing the lower triple clamp (EXC‑F EU, XCF‑W, EXC‑F BR) Main work –...
  • Page 75 SERVICE WORK ON THE CHASSIS 12 – Tighten screws Guideline Screw, bottom triple 15 Nm (11.1 lbf ft) clamp V01790-10 – 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...

  • Page 76: Installing The Lower Triple Clamp (Exc-F Wess Eu, All Six Days Models)

    12 SERVICE WORK ON THE CHASSIS 12.12 Installing the lower triple clamp (EXC‑F WESS EU, All Six Days models) Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 176) – Position the lower triple clamp with the steering stem.
  • Page 77 SERVICE WORK ON THE CHASSIS 12 (EXC‑F WESS EU) – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front. Valve of the left fork leg faces the front. Info Grooves are milled into the side of the upper end of the fork legs.

  • Page 78: Checking The Steering Head Bearing Play

    Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam- ages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.

  • Page 79: Adjusting The Steering Head Bearing Play (Exc-F Eu, Xcf-W, Exc-F Br)

    SERVICE WORK ON THE CHASSIS 12 It must be possible to move the handlebar easily over the entire steering range. There should be no detectable detent positions. » If detent positions are detected: (EXC‑F EU, XCF‑W, EXC‑F BR) – Adjust the steering head bearing play. p.

  • Page 80: Lubricating The Steering Head Bearing

    12 SERVICE WORK ON THE CHASSIS Main work – Loosen screws – Remove screw – Loosen and retighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head – Using a plastic hammer, tap lightly on the upper triple clamp V01795-10 to avoid stresses.

  • Page 81: Installing Front Fender

    SERVICE WORK ON THE CHASSIS 12 – Remove screws . Remove front fender. V00341-10 (EXC‑F WESS EU, All Six Days models) – Remove screws K00576-10 – Remove screws . Remove front fender. S01321-10 12.18 Installing front fender Main work (EXC‑F EU, XCF‑W, EXC‑F BR) –...

  • Page 82: Removing The Shock Absorber

    12 SERVICE WORK ON THE CHASSIS (EXC‑F WESS EU, All Six Days models) – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis K00576-10 – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis S01321-10 Finishing work...

  • Page 83: Removing The Seat

    SERVICE WORK ON THE CHASSIS 12 Info The heim joint for the shock absorber on the link fork is Teflon coated. It must not be lubricated with grease, nor with any other lubricants. Lubricants dissolve the Teflon coating, thereby drastically reducing the service life.

  • Page 84: Removing The Air Filter Box Cover

    12 SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis S03480-10 12.23 Removing the air filter box cover Condition The air filter box cover is secured. – Remove the seat. ( p.

  • Page 85: Installing The Air Filter Box Cover

    SERVICE WORK ON THE CHASSIS 12 12.24 Installing the air filter box cover Condition The air filter box cover is secured. – Insert the air filter box cover in area and clip it into area V01815-12 – Mount and tighten screw Guideline Screw, air filter box EJOT PT...

  • Page 86: Installing The Air Filter

    12 SERVICE WORK ON THE CHASSIS Main work – Detach retaining tab . Remove air filter with air filter sup- port. – Remove air filter from air filter support. V01812-10 12.26 Installing the air filter Main work – Mount the clean air filter on the air filter support. –...

  • Page 87: Preparing Air Filter Box Cover For Securing

    SERVICE WORK ON THE CHASSIS 12 Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 176) Info Only press the air filter to dry it, never wring it out. –...

  • Page 88: Installing The Main Silencer

    12 SERVICE WORK ON THE CHASSIS – Remove screws and take off the main silencer. 12.30 Installing the main silencer (All EU models) – Position the catalytic converter in the main silencer. S02101-10 – Position the main silencer. Mount screws , but do not tighten yet.
  • Page 89 SERVICE WORK ON THE CHASSIS 12 V01736-10 Main work – Remove screws and take off silencer cap with O-ring Info Do not remove the glass fiber yarn filling. Caution Danger to health Soot particles irritate the eyes and mucuous membranes. – Wear suitable breathing and eye protection when cleaning the main silencer and carbon screen.

  • Page 90: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    12 SERVICE WORK ON THE CHASSIS 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 filling escape and the damper "burns"...

  • Page 91: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 12 Finishing work – Install the main silencer. ( p. 86) 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 92: Installing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS (All EU/BR/CN 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 93 SERVICE WORK ON THE CHASSIS 12 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 94: Checking For Chain Dirt Accumulation

    12 SERVICE WORK ON THE CHASSIS – Plug in connector for the fuel pump. – Remove the wash cap set. – Clean the quick release coupling thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line.

  • Page 95: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 12 Info The service life of the chain depends largely on its maintenance. Preparatory work – Raise the motorcycle with the lift stand. ( p. 66) Main work – Rinse off loose dirt with a soft jet of water. –...

  • Page 96: Adjusting The Chain Tension

    12 SERVICE WORK ON THE CHASSIS Main work – Pull the chain at the end of the chain sliding piece upward to measure chain tension Info Lower chain section must be taut. When the chain guard is mounted, it must be possible to pull up the chain at least to the point where it makes contact with chain guard Chain wear is not always even, so you should repeat...

  • Page 97: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 12 Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55 … 58 mm (2.17 … 2.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks...
  • Page 98 12 SERVICE WORK ON THE CHASSIS – Pull on the top section of the chain with the specified weight Guideline Weight of chain wear mea- 10 … 15 kg (22 … 33 lb.) surement – Measure distance of 18 chain rollers in the lower chain section.
  • Page 99 SERVICE WORK ON THE CHASSIS 12 – Check chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated. »...

  • Page 100: 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 the throttle cable routing Preparatory work –...

  • Page 101: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS 12 12.43 Checking the rubber grip – Check the rubber grips on the handlebar for damage, wear, and looseness. Info The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the right.

  • Page 102: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

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

  • Page 103: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 12 12.46 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. –...

  • Page 104: Removing The Engine Guard (Exc-F Wess Eu, All Six Days Models, Xcf-W)

    12 SERVICE WORK ON THE CHASSIS – Now inject fluid into the system until it escapes from the opening of the master cylinder without bubbles. – Occasionally extract the fluid from the master cylinder reser- voir to prevent overflowing. – Remove the bleeding syringe.

  • Page 105: Brake System 13

    BRAKE SYSTEM 13 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 106: 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 107: 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/CN models) –...
  • Page 108 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 109: 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 110 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 111 BRAKE SYSTEM 13 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 112 13 BRAKE SYSTEM – Correct the brake fluid level to level Guideline 5 mm (0.2 in) Level (brake fluid level below reservoir rim) Brake fluid DOT 4 / DOT 5.1 ( p. 174) – Position cover with membrane . Mount and tighten screws Info Use water to immediately clean up any brake fluid...

  • Page 113: Checking The Free Travel Of Foot Brake Lever

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

  • Page 114: Adjusting The Basic Position Of The Foot Brake Lever

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

  • Page 115: 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 116: 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 117: 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 118 13 BRAKE SYSTEM – Position 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, extracting some if necessary.
  • Page 119 BRAKE SYSTEM 13 – Correct brake fluid level to marking Brake fluid DOT 4 / DOT 5.1 ( p. 174) – Mount screw cap with membrane and O-ring. Info Use water to immediately clean up any brake fluid that has overflowed or spilled. K01347-10...

  • Page 120: 14 Wheels, Tires

    14 WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 66) 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 121: Installing The Front Wheel

    WHEELS, TIRES 14 (EXC‑F WESS EU) – Remove spacer and brake disc guard H01890-10 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. –...

  • Page 122: Removing The Rear Wheel

    14 WHEELS, TIRES – Align the brake disc guard so that distance equal in size. S01633-10 – Mount and tighten screw Guideline Screw, front wheel M20x1.5 35 Nm (25.8 lbf ft) spindle – Operate the hand brake lever several times until the brake lin- ings are seated correctly against the brake disc.

  • Page 123: Installing The Rear Wheel

    WHEELS, TIRES 14 Warning Danger of accidents Damaged brake discs reduce the braking effect. – Always lay the wheel down in such a way that the brake disc is not damaged. – Hold the rear wheel and remove the wheel spindle. Take the rear wheel out of the link fork.

  • Page 124: 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 pressure of the tires all have a major impact on the handling characteristic of the motorcycle.

  • Page 125: Checking Tire 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.)
  • Page 126 14 WHEELS, TIRES – Strike each spoke briefly using a screwdriver blade. Info The frequency of the sound depends on the spoke length and spoke diameter. If you hear different tone frequencies from different spokes of equal length and diameter, this is an indica- tion of different spoke tensions.

  • Page 127: 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 128 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 129: 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 (all EU/CN models, XCF-W) 12-V battery (HJTZ5S-FP-C) ( p.

  • Page 130: 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 131 ELECTRICAL SYSTEM 15 Main work (all EU/CN models, XCF-W) 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 132 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 133: Changing Main Fuse

    ELECTRICAL SYSTEM 15 Info If the charging current, charging voltage and charg- ing time are exceeded, electrolyte escapes through the safety valves. This reduces the capacity of the 12-V battery. If the 12-V battery is left in a discharged state for an extended period, it will become deeply dis- charged and sulfating occurs, destroying the bat- tery.

  • Page 134: Changing The Fuses Of Individual Electrical Power Consumers

    15 ELECTRICAL SYSTEM – Take off protection caps – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the starter relay. – Insert a new main fuse. Fuse (58011109120) ( p.
  • Page 135 ELECTRICAL SYSTEM 15 (All BR/CN models) Fuse 1 – 10 A – EFI control unit, combination instru- ment, combination switch (optional), electronic fuel injection, diagnostics connector, 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 136: Removing The Headlight Mask With The Headlight

    15 ELECTRICAL SYSTEM 15.6 Removing the headlight mask with the headlight – Detach the brake line and wiring harness from the headlight mask. – Loosen rubber straps . Slide the headlight mask up and swing it forward. V01782-10 (All EU/BR/CN models) –...

  • Page 137: Changing The Headlight Bulb

    ELECTRICAL SYSTEM 15 – 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 – Check the headlight setting. ( p.

  • Page 138: Checking The Headlight Setting

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

  • Page 139: Changing The Turn Signal Bulb (All Eu/Br/Cn Models)

    ELECTRICAL SYSTEM 15 15.11 Changing the turn signal bulb (All EU/BR/CN models) Note Damage to reflector Grease on the reflector reduces the light intensity. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. – Clean and degrease the bulbs before mounting.

  • Page 140: Diagnostics Connector

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

  • Page 141: Cooling System 16

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

  • Page 142: Checking The Coolant Level

    16 COOLING SYSTEM Coolant ( p. 174) – 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 143: Refilling Coolant

    COOLING SYSTEM 16 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 144: Changing The Coolant

    16 COOLING SYSTEM (EXC‑F WESS EU, All Six Days models, XCF‑W) – Install the engine guard. ( p. 102) 16.6 Changing the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
  • Page 145 COOLING SYSTEM 16 (EXC‑F WESS EU, All Six Days models, XCF‑W) – Install the engine guard. ( p. 102)

  • Page 146: 17 Tuning The Engine

    17 TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3 …...
  • Page 147 TUNING THE ENGINE 17 Main work – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut – Push cold start button all the way to the stop. –...

  • Page 148: Changing The Mapping

    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 149: 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 150: Position

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

  • Page 151: 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 152: Service Work On The Engine

    18 SERVICE WORK ON THE ENGINE 18.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 153: Checking The Engine Oil Level

    SERVICE WORK ON THE ENGINE 18 Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.
  • Page 154 18 SERVICE WORK ON THE ENGINE Main work – Position an appropriate container under the engine. – Remove oil drain plug with the magnet and seal ring. Info Do not remove screws K00567-10 – Remove screw plug with oil screen and the O-rings.
  • Page 155 SERVICE WORK ON THE ENGINE 18 – Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) – Allow the engine oil to drain completely. – Thoroughly clean the parts and the sealing surface. K00572-10 – Lay the motorcycle on its right side and fill the oil filter hous- ing approx.

  • Page 156: Adding Engine Oil

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

  • Page 157: 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 158: 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. 176) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 159: 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. 66) – Preferably cover the motorcycle with a tarp or similar cover that is permeable to air.

  • Page 160: 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 161: Troubleshooting

    Check the electrical system. – Error in the electronic fuel Read out the fault memory using the injection KTM diagnostics tool. – Engine does not speed up Error in the electronic fuel Read out the fault memory using the injection KTM diagnostics tool.
  • Page 162 – 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 163 TROUBLESHOOTING 21 Faults Possible cause Action – The horn, brake light, turn sig- Fuse 3 blown Change the fuses of individual electri- nal, and radiator fan (optional) cal power consumers. ( p. 132) are not working...

  • Page 164: 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 Throttle valve position programming necessary Blink code for malfunction indicator lamp 02 Malfunction indicator lamp flashes 2x short Crankshaft speed sensor –...
  • Page 165 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 166: 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 167: 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 168 23 TECHNICAL DATA Screw, fuel vapor retention system 6 Nm (4.4 lbf ft) Loctite ® 2701™ lock (All EU/BR/CN models) 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 169: 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 170: Electrical System

    23 TECHNICAL DATA front 2.5 mm (0.098 in) rear 3.5 mm (0.138 in) Brake discs - wear limit (EXC‑F WESS EU, 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/CN models)

  • Page 171: Tires

    (EXC‑F EU) 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 (XCF‑W) 80/100 - 21 M/C 51M M+S TT...

  • Page 172: Exc-F Br

    23 TECHNICAL DATA 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 … 85 kg (165 … 187 lb.) 4.2 N/mm (24 lb/in) Weight of rider: 85 …...

  • Page 173: Shock Absorber

    TECHNICAL DATA 23 Oil capacity external mechanism ml (7.78 fl. oz.) Fork oil (SAE 4) (48601166S1) + 10 + 0.34 − 50 − 1.69 right p. 175) Oil capacity external mechanism ml (7.78 fl. oz.) Fork oil (SAE 4) (48601166S1) + 10 + 0.34 −...
  • Page 174 23 TECHNICAL DATA Screw, intake air temperature sen- EJOT DELTA PT ® 45x12‑Z 0.7 Nm (0.52 lbf ft) sor (All EU/BR/CN models) Screw, pressure regulator EJOT PT ® K60x25‑Z 2.3 Nm (1.7 lbf ft) Screw, seat fixing EJOT EJOFORM PT ®...
  • Page 175 TECHNICAL DATA 23 Screw, front brake caliper 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, handlebar clamp 20 Nm (14.8 lbf ft) Screw, manifold on cylinder head 15 Nm (11.1 lbf ft) brace Screw, side stand attachment 33 Nm (24.3 lbf ft) Loctite ®...

  • Page 176: 24 Substances

    24 SUBSTANCES 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 177 SUBSTANCES 24 Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 178) (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 178: 25 Auxiliary Substances

    25 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier MOTOREX ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier...
  • Page 179 AUXILIARY SUBSTANCES 25 Silicone spray Recommended supplier MOTOREX ® – Silicone Spray Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier MOTOREX ® – Quick Cleaner Special grease (00062010053) Recommended supplier Klüber Lubrication ® – KLÜBERFOOD NH1 34‑401 Universal oil spray Recommended supplier...

  • Page 180: 26 Standards

    26 STANDARDS 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 181: Index Of Special Terms 27

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

  • Page 182: Adjusting The Characteristic Map Of 28 List Of Abbreviations

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

  • Page 183: 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 184: Programming The Throttle Valve Index

    INDEX cleaning ......92 INDEX Chain guide 12-V battery checking ......95 charging .
  • Page 185 INDEX removing ......102 Engine number ......14 Hand brake lever .
  • Page 186 INDEX Misuse ....... 7 Shock absorber installing ......80 Motorcycle removing .
  • Page 187 INDEX Turn signal bulb changing ......137 Turn signal switch ..... . . 18 Type label .
  • Page 188 *3214224en* 3214224en 09/2020 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

This manual is also suitable for:

350 xcf-w350 exc-f six days350 exc-f

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