KTM 350 EXC-F 2021 Owner's Manual
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KTM 350 EXC-F 2021 Owner's Manual

KTM 350 EXC-F 2021 Owner's Manual

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OWNER'S MANUAL
2021
350 EXC-F
350 XCF‑W
350 EXC-F Six Days
Art. no. 3214223en

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Summary of Contents for KTM 350 EXC-F 2021

  • Page 1 OWNER'S MANUAL 2021 350 EXC-F 350 XCF‑W 350 EXC-F Six Days Art. no. 3214223en...
  • 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 6.12 Overview of indicator lamps TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 6 (All EU/BR/CN models)..... 19 Symbols used ........6 6.13 Overview of indicator lamps Formats used........6 (XCF‑W) .......... 19 6.14 Opening the fuel tank filler cap ..20 SAFETY ADVICE..........
  • Page 5 TABLE OF CONTENTS Running-in the engine ...... 38 11.11 Checking the basic setting of the fork ..........56 Starting power of lithium-ion batteries at low temperatures 11.12 Adjusting the compression damping (XCF‑W, All EU/CN models)....39 of the fork ........57 Preparing the vehicle for difficult 11.13 Adjusting the rebound damping of operating conditions......
  • Page 6 TABLE OF CONTENTS 12.30 Installing the main silencer....81 14.2 Installing the front wheel .... 114 12.31 Cleaning the spark arrestor 14.3 Removing the rear wheel ..... 114 (XCF‑W) .......... 82 14.4 Installing the rear wheel ....115 12.32 Changing the glass fiber yarn filling 14.5 Checking the tire condition .....
  • Page 7 TABLE OF CONTENTS 18.3 Changing the engine oil and oil filter, cleaning the oil screen ..146 18.4 Adding engine oil ......149 19 CLEANING, CARE ........150 19.1 Cleaning the motorcycle ....150 19.2 Checks and maintenance steps for winter operation......

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

  • Page 13: Important Notes 3

    Manufacturer and implied warranty The work 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 Switch-off 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) Switch-off button is fitted on the left side of the handle- bar. Possible states is in the basic position – In this • The switch-off button position, the ignition circuit is closed and the engine can be started.

  • Page 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 (All Six Days 8 Models, Xcf-W)

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

  • Page 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. Setting 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. 98) (XCF‑W) – Adjust the basic position of the hand brake lever. ( p. 99) – Adjust the basic position of the foot brake lever. p.

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

    – 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. 170) – 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 (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 135 operating hours Every 70 operating hours when used for motorsports After 20 operating hours After 10 operating hours every 48 months every 12 months ● ● Perform engine service including removing and installing the engine. (Change the spark plug and spark plug connector.

  • Page 53: Tuning The Chassis 11

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock...

  • Page 54: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the high-speed compression adjuster can be seen in fast compression of the shock absorber.

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

    Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.

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

    11 TUNING THE CHASSIS 11.7 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 53) – Hold the motorcycle upright with aid of an assistant. – Measure the distance again between the rear axle and mark- ing SAG on the rear fender using the sag gage.

  • Page 57: Adjusting The Spring Preload Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the spring length.

  • Page 58: Adjusting The Riding Sag

    11 TUNING THE CHASSIS 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with the lift stand. ( p. 63) – Remove the shock absorber. p. 76) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 59: Adjusting The Compression Damping Of The Fork

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

  • Page 60: Adjusting The Rebound Damping Of The Fork

    11 TUNING THE CHASSIS 11.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. (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.

  • Page 61: Adjusting The Spring Preload Of The Fork (All Six Days Models, Xcf-W, All Eu/Cn Models)

    TUNING THE CHASSIS 11 11.14 Adjusting the spring preload of the fork (All Six Days models, XCF‑W, All EU/CN models) Preparatory work – Raise the motorcycle with the lift stand. ( p. 63) Main work – Turn T-grips counterclockwise all the way. The marking +0 aligns with the right wing.

  • Page 62: Handlebar Position

    11 TUNING THE CHASSIS 11.15 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 63 TUNING THE CHASSIS 11 (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 64 11 TUNING THE CHASSIS (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 65: Service Work On The Chassis 12

    SERVICE WORK ON THE CHASSIS 12 12.1 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (78129955100) Neither wheel is in contact with the ground.

  • Page 66: Cleaning The Dust Boots Of The Fork Legs

    12 SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 63) – Remove the fork protector. ( p. 64) Main work – Push dust boots of both fork legs downward.

  • Page 67: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS 12 12.6 Installing the fork protector – Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position the brake line, wiring harness, and clamp. Mount and tighten screws –...

  • Page 68: Installing The Fork Legs

    12 SERVICE WORK ON THE CHASSIS (All Six Days models) – Loosen screws . Take out the left fork leg. – Loosen screws . Take out the right fork leg. V01784-10 12.8 Installing the fork legs Main work – Position the fork legs. Bleeder screws are positioned toward the front.

  • Page 69: (Exc-F Eu, Xcf-W, Exc-F Br)

    SERVICE WORK ON THE CHASSIS 12 Finishing work – Install the front wheel. p. 114) – Install the headlight mask with the headlight. ( p. 128) – Check the headlight setting. ( p. 130) 12.9 Removing the lower triple clamp (EXC‑F EU, XCF‑W, EXC‑F BR) Preparatory work –...

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

    12 SERVICE WORK ON THE CHASSIS Main work – Open the cable holder in front of the left radiator and detach the wiring harness. – Remove screw – Remove screw – Take off the upper triple clamp with the handlebar and set it aside.
  • Page 71 SERVICE WORK ON THE CHASSIS 12 – Position the upper triple clamp with the handlebar. – Mount screw but do not tighten yet. – Secure the wiring harness and the clutch line with the cable holder. V01785-11 – Position the fork legs. Bleeder screws are positioned toward the front.

  • Page 72: Installing The Lower Triple Clamp (All Six Days Models)

    12 SERVICE WORK ON THE CHASSIS – Position the brake caliper, and mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) Loctite ® 243™ brake caliper – Mount the cable ties. – Position the brake line, the wiring harness, and the clamp. Mount and tighten screws V01792-10 Finishing work...
  • Page 73 SERVICE WORK ON THE CHASSIS 12 – Position the upper triple clamp with the handlebar. – Mount screw but do not tighten yet. – Secure the wiring harness and the clutch line with the cable holder. V01787-12 – Position the fork legs. Bleeder screws are positioned toward the front.

  • Page 74: 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 75: Adjusting The Steering Head Bearing Play (Exc-F Eu, Xcf-W, Exc-F Br)

    SERVICE WORK ON THE CHASSIS 12 » If detent positions are detected: (EXC‑F EU, XCF‑W, EXC‑F BR) – Adjust the steering head bearing play. p. 73) (All Six Days models) – Adjust the steering head bearing play. p. 73) – Check the steering head bearing and replace if neces- sary.

  • Page 76: Lubricating The Steering Head Bearing

    12 SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, top triple 17 Nm (12.5 lbf ft) clamp – Mount and tighten screw Guideline Screw, top 17 Nm (12.5 lbf ft) Loctite ® 243™ steering stem Finishing work – Check the steering head bearing play.

  • Page 77: Installing Front Fender

    SERVICE WORK ON THE CHASSIS 12 (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) – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft)

  • Page 78: Removing The Shock Absorber

    12 SERVICE WORK ON THE CHASSIS – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis S01321-10 Finishing work – Install the headlight mask with the headlight. ( p. 128) – Check the headlight setting. ( p.

  • Page 79: Removing The Seat

    SERVICE WORK ON THE CHASSIS 12 12.21 Removing the seat – Remove screw S03480-10 – Raise the rear of the seat, pull the seat back, and lift it off. H02218-10 12.22 Mounting the seat – Mount the front of the seat on the collar bushings of the fuel tank, lower the seat at the rear, and push the seat forward.

  • Page 80: Removing The Air Filter Box Cover

    12 SERVICE WORK ON THE CHASSIS 12.23 Removing the air filter box cover Condition The air filter box cover is secured. – Remove the seat. ( p. 77) – Remove screw V01815-10 – Pull off the air filter box cover in area laterally and take it off at the front.

  • Page 81: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 12 – Mount and tighten screw Guideline Screw, air filter box EJOT PT ® 3 Nm (2.2 lbf ft) cover K60x20-Z – Mount the seat. ( p. 77) V01815-10 Condition The air filter box cover is not secured. –...

  • Page 82: Installing The Air Filter

    12 SERVICE WORK ON THE CHASSIS 12.26 Installing the air filter Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area Long-life grease ( p. 170) H02459-01 – Insert air filter and position retaining pin in bushing The air filter is correctly positioned.

  • Page 83: Preparing Air Filter Box Cover For Securing

    SERVICE WORK ON THE CHASSIS 12 Finishing work – Install the air filter. p. 80) – Install the air filter box cover. ( p. 78) 12.28 Preparing air filter box cover for securing Preparatory work – Remove the air filter box cover. ( p.

  • Page 84: Cleaning The Spark Arrestor (Xcf-W)

    12 SERVICE WORK ON THE CHASSIS – Position the main silencer. Mount screws , but do not tighten yet. – Attach spring Spring hook (50305017000C1) – Tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V01814-11 12.31 Cleaning the spark arrestor (XCF‑W) Warning Danger of burns The exhaust system gets very hot when the vehicle is driven.

  • Page 85: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    SERVICE WORK ON THE CHASSIS 12 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 86: Removing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS (XCF‑W) – Remove screws – Take off silencer cap with O-ring – Remove the old glass fiber yarn filling. – Clean the parts that need to be reinstalled and check for damage. – Mount the new glass fiber yarn filling in the main silencer.
  • Page 87 SERVICE WORK ON THE CHASSIS 12 Main work – Unplug connector of the fuel pump. – Clean plug-in connection of the fuel line thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! V01824-10 –...

  • Page 88: Installing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS – Pull both spoilers laterally off the radiator and lift off the fuel tank. V01767-10 12.34 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. –...
  • Page 89 SERVICE WORK ON THE CHASSIS 12 – Attach the fuel tank breather hose. – Mount and tighten screw with the rubber bushing. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V01766-11 (All EU/BR/CN models) – Position the horn with the horn bracket. –...

  • Page 90: Checking For Chain Dirt Accumulation

    12 SERVICE WORK ON THE CHASSIS 12.35 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 88) 400678-01 12.36 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip.

  • Page 91: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 12 12.37 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. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 92: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    12 SERVICE WORK ON THE CHASSIS 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 93 SERVICE WORK ON THE CHASSIS 12 – 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 94 12 SERVICE WORK ON THE CHASSIS – 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 95: Checking The Frame

    » If the link fork exhibits damage, cracking, or deformation: – Change the link fork. Info Always replace a damaged link fork. Repairing the link fork is not authorized by KTM. S01317-10 12.42 Checking throttle cable routing Preparatory work –...

  • Page 96: Checking The Rubber Grip

    12 SERVICE WORK ON THE CHASSIS – Mount the seat. ( p. 77) 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 97: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS 12 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 98: Changing The Hydraulic Clutch Fluid

    12 SERVICE WORK ON THE CHASSIS 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 99: Removing The Engine Guard (All Six Days Models, Xcf-W)

    SERVICE WORK ON THE CHASSIS 12 – 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 100: 13 Brake System

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

  • Page 101: 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 102: 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 103 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 104: 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 105 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 106 13 BRAKE SYSTEM Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons. – Remove cotter pin , pull out pin , and remove the brake linings. – Clean the brake caliper and the brake caliper bracket. E00344-10 –...
  • Page 107 BRAKE SYSTEM 13 – 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. 168) – Position cover with membrane . Mount and tighten screws Info Immediately clean up any brake fluid that has over-...

  • Page 108: Checking The Free Travel Of Foot Brake Lever

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

  • Page 109: Adjusting The Basic Position Of The Foot Brake Lever

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

  • Page 110: 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 111: 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 112: 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 113 BRAKE SYSTEM 13 – Stand the vehicle upright. – Remove screw cap with membrane and the O-ring. – Press the brake piston back into the basic position and ensure that brake fluid does not flow out of the brake fluid reservoir; extract some if necessary.
  • Page 114 13 BRAKE SYSTEM – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 168) – Mount screw cap with membrane and O-ring. Info Clean up overflowed or spilled brake fluid immediately with water. K01347-10...

  • Page 115: Wheels, Tires 14

    WHEELS, TIRES 14 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 63) 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 116: Installing The Front Wheel

    14 WHEELS, TIRES 14.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –...

  • Page 117: Installing The Rear Wheel

    WHEELS, TIRES 14 Main work – Manually press the brake caliper toward the brake disc to push back the brake piston. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston. –...
  • Page 118 14 WHEELS, TIRES Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surface of the spacers. Long-life grease ( p.

  • Page 119: Checking The Tire Condition

    DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. KTM recommends that the tires be changed after 5 H01144-01 years at the latest, regardless of the actual state of wear.

  • Page 120: Checking Spoke Tension

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.) –...

  • Page 121: 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 122 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 123: Installing The 12-V Battery

    ELECTRICAL SYSTEM 15 – Remove screw and detach the battery compartment. – Lift out the 12-V battery. V01779-10 15.2 Installing the 12-V battery Main work – Insert the 12-V battery into the battery compartment with the terminals facing forward and secure with holding bracket (XCF‑W, All EU/CN models) 12-V battery (HJTZ5S-FP-C) ( p.

  • Page 124: 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 125 ELECTRICAL SYSTEM 15 Main work (XCF‑W, All EU/CN models) Warning Risk of injury 12 V batteries contain harmful sub- stances. – Keep 12 V batteries out of the reach of chil- dren. – Keep sparks and open flames away from 12 V F01568-10 batteries.
  • Page 126 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 127: Changing The 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 128: Changing The Fuses Of Individual Power Consumers

    15 ELECTRICAL SYSTEM Main work – Pull starter relay from the holder. V01776-11 – Take off protection caps – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the starter relay. –...
  • Page 129 ELECTRICAL SYSTEM 15 Guideline (All EU models) Fuse 1 ‑ 10 A - EFI control unit, lambda sensor, combi- nation instrument, combination switch (optional), elec- tronic fuel injection, diagnostics connector, 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 130: Removing The Headlight Mask With The Headlight

    15 ELECTRICAL SYSTEM – Check that the power consumer is functioning properly. – Close the fuse box cover. Finishing work – Mount the seat. ( p. 77) 15.6 Removing the headlight mask with the headlight Preparatory work – Press and hold the switch-off button while the engine is idling until the engine stops.

  • Page 131: Changing The Headlight Bulb

    ELECTRICAL SYSTEM 15 (XCF‑W) – Join plug-in connector V01802-11 – Position the headlight mask and secure it with rubber straps The holding lugs engage in the fender. – Position the brake line and wiring harness in the brake line guide. V01782-11 Finishing work –...

  • Page 132: Checking The Headlight Setting

    15 ELECTRICAL SYSTEM – Pull out headlight bulb – Insert the new headlight bulb. Headlight (HS1 / socket PX43t) ( p. 162) – Insert the protection cap with the bulb socket into the reflector and turn it clockwise all the way. Info Ensure that O-ring is seated properly.

  • Page 133: Changing The Turn Signal Bulb (All Eu/Br/Cn Models)

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

  • Page 134: Changing The Combination Instrument Battery

    15 ELECTRICAL SYSTEM 15.12 Changing the combination instrument battery Preparatory work – Press and hold the switch-off button while the engine is idling until the engine stops. – Remove the headlight mask with the headlight. ( p. 128) Main work –...

  • Page 135: Diagnostics Connector

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

  • Page 136: 16 Cooling System

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

  • Page 137: Checking The Coolant Level

    COOLING SYSTEM 16 Coolant ( p. 168) – 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 138: Refilling Coolant

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

  • Page 139: Changing The Coolant

    COOLING SYSTEM 16 (All Six Days models, XCF‑W) – Install the engine guard. ( p. 97) 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 140 16 COOLING SYSTEM (All Six Days models, XCF‑W) – Install the engine guard. ( p. 97)

  • Page 141: Tuning The Engine 17

    TUNING THE ENGINE 17 17.1 Checking the throttle cable play – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Throttle cable play 3 …...

  • Page 142: Adjusting The Characteristic Map Of The Throttle Response

    17 TUNING THE ENGINE Main work – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut – Push cold start button all the way to the stop. –...

  • Page 143: Changing The Mapping (All Six Days Models)

    TUNING THE ENGINE 17 – 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 144: 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 145: Teaching The Throttle Valve Position

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

  • Page 146: Adjusting The Basic Position Of The Shift Lever

    17 TUNING THE ENGINE 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 147: Service Work On The Engine 18

    SERVICE WORK ON THE ENGINE 18 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 148: Checking The Engine Oil Level

    18 SERVICE WORK ON THE ENGINE 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 149 SERVICE WORK ON THE ENGINE 18 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 150 18 SERVICE WORK ON THE ENGINE – 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 151: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 18 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 152: 19 Cleaning, Care

    19 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 153: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE 19 – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p. 170) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 154: 20 Storage

    – 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. 63) – Preferably cover the motorcycle with a tarp or similar cover that is permeable to air.

  • Page 155: Preparing For Use After Storage

    STORAGE 20 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 156: 21 Troubleshooting

    Check the electrical system. faulty – Error in the electronic fuel Read out the fault memory using the injection KTM diagnostics tool. – Engine does not speed up Error in the electronic fuel Read out the fault memory using the injection KTM diagnostics tool.
  • Page 157 – 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 158: 22 Blink Code

    22 BLINK CODE Info The blink codes are only displayed by the derestricted version of the vehicle. Blink code for malfunction indicator lamp 02a Malfunction indicator lamp flashes 2x per second Error level condition Teaching of throttle valve position required Blink code for malfunction indicator lamp 02 Malfunction indicator lamp flashes 2x short...
  • Page 159 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 160: 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 161: 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 162 23 TECHNICAL DATA Screw, exhaust flange 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, guide rail 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, oil filter cover 10 Nm (7.4 lbf ft) Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite ®...

  • Page 163: 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 164: Electrical System

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

  • Page 165: Tires

    140/80 - 18 M/C 70R M+S TT MAXXIS Maxx EnduPro MAXXIS Maxx EnduPro The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com Validity Front tire Rear tire 80/100 - 21 M/C 51M M+S TT 110/100 - 18 M/C 64M M+S TT (XCF‑W)

  • Page 166: Exc-F Br

    23 TECHNICAL DATA 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 167: Chassis Tightening Torques

    TECHNICAL DATA 23 Spring preload 8 mm (0.31 in) Spring rate Weight of rider: 65 … 75 kg (143 … 165 lb.) 60 … 66 N/mm (343 … 377 lb/in) Weight of rider: 75 … 85 kg (165 … 187 lb.) 63 …...
  • Page 168 23 TECHNICAL DATA Screw, rear brake disc 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, throttle grip 5 Nm (3.7 lbf ft) Fuel connection on fuel pump 15 Nm (11.1 lbf ft) Nut, foot brake lever stop 20 Nm (14.8 lbf ft) Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite...
  • Page 169 TECHNICAL DATA 23 Nut, fork pivot M16x1.5 100 Nm (73.8 lbf ft) Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft) Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) Screw-in fitting, cooling system M24x1.5 18 Nm (13.3 lbf ft)

  • Page 170: 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 171 SUBSTANCES 24 Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 172) (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 172: 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 173 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 Universal oil spray Recommended supplier MOTOREX ® – Joker 440 Synthetic...

  • Page 174: 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 175: 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 176: 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 177: List Of Symbols 29

    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 178: Index

    INDEX Chain guide INDEX checking ......90 12-V battery Chain tension charging ......122 adjusting .
  • Page 179 INDEX Engine number ......14 Handlebar position ..... . 60 adjusting .
  • Page 180 INDEX Spoke tension checking ......118 Oil filter Start button ......18 changing .
  • Page 181 INDEX View of vehicle front left ......12 rear right ......13 Winter operation checks and maintenance steps .
  • Page 182 *3214223en* 3214223en 05/2020 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

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