KTM 350 SX-F 2018 Owner's Manual
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KTM 350 SX-F 2018 Owner's Manual

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OWNER'S MANUAL
2018
350 SX‑F
350 XC‑F
Art. no. 3213640en

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Summary of Contents for KTM 350 SX-F 2018

  • Page 1 OWNER'S MANUAL 2018 350 SX‑F 350 XC‑F Art. no. 3213640en...
  • Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS RIDING INSTRUCTIONS..........22 TABLE OF CONTENTS MEANS OF REPRESENTATION ........4 Checks and maintenance measures when Symbols used ........... 4 preparing for use..........22 Formats used............ 4 Starting............22 SAFETY ADVICE............5 Activating launch control ......... 23 Use definition –...
  • Page 5 TABLE OF CONTENTS 11.22 Removing the air filter box cover ...... 50 15.3 Checking the coolant level ....... 83 11.23 Installing the air filter box cover ....... 50 15.4 Draining the coolant ........83 11.24 Removing the air filter ......... 51 15.5 Refilling coolant ..........

  • Page 6: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required.

  • Page 7: Safety Advice

    SAFETY ADVICE Use definition – intended use (All SX‑F models) This vehicle is designed and built to withstand the normal stresses and strains of competitive use. This vehicle complies with the currently valid regulations and categories of the top international motorsport organizations. Info Only operate this vehicle in closed-off areas remote from public road traffic.

  • Page 8: Safe Operation

    – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren- theses.

  • Page 9: Owner's Manual

    Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.

  • Page 10: Important Notes

    Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the warranty.

  • Page 11: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) F01018-10 Hand brake lever ( p. 12) Clutch lever ( p. 12) Filler cap Air filter box cover Cold start button ( p. 15) Engine number ( p. 11) Shift lever ( p.

  • Page 12: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) F01019-10 Shock absorber compression adjustment Combination switch ( p. 13) Kill switch ( p. 12) Electric starter button ( p. 12) Throttle grip ( p. 12) Chassis number ( p. 11) Type label ( p.

  • Page 13: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. 401945-10 Type label The type label is fixed to the front of the steering head. 401946-10 Engine number Engine number is located on the left side of the engine over the engine sprocket. H01047-10 Fork part number The fork part number...

  • Page 14: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. S01192-10 Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. S01193-10 Throttle grip The throttle grip...

  • Page 15: Combination Switch

    CONTROLS Combination switch The combination switch is fitted on the left side of the handlebar. Possible states STANDARD – STANDARD mapping is activated when LED 1 lights up. STANDARD with TC – STANDARD mapping with traction control is acti- vated when LED 1 and TC light up. ADVANCED –...

  • Page 16: Closing The Filler Cap

    CONTROLS 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. – In case of skin contact, rinse the affected area with plenty of water. –...

  • Page 17: Cold Start Button

    CONTROLS 6.11 Cold start button (All SX‑F models) Cold start button is fitted on the bottom of the throttle valve body. F01032-10 (XC‑F US) Cold start button is fitted on the bottom of the throttle valve body. The injection system extends the injection time if the engine is cold and the outside temperature is low.

  • Page 18: Idle Speed Adjusting Screw

    CONTROLS 6.12 Idle speed adjusting screw The idle setting of the throttle valve body has a big influence on the vehicle's starting behavior, on stable idling, and on vehicle response when the throttle is opened. An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly.

  • Page 19: Foot Brake Lever

    CONTROLS 6.14 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 401956-10 6.15 Plug-in stand (All SX‑F models) Support for plug-in stand is the left side of the wheel spindle. The plug-in stand is used to park the motorcycle.

  • Page 20: Preparing For Use

    When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.

  • Page 21: Running In The Engine

    For this reason, it may be neces- sary to inspect or replace parts before the next scheduled service. – Use the specified engine oil when riding under difficult conditions and to enhance performance, as recommended by KTM. Engine oil (SAE 10W/60) (00062010035) ( p. 108) –...

  • Page 22: Preparing For Rides On Dry Sand

    Preparing for rides on dry sand – Fit a dust cover on the air filter. Dust cover for air filter (79006920000) Info See the KTM PowerParts fitting instructions. 102136-01 – Fit a sand cover on the air filter. Sand cover for air filter (79006922000) Info See the KTM PowerParts fitting instructions.

  • Page 23: Preparing For Rides On Wet And Muddy Surfaces

    Preparing for rides on wet and muddy surfaces – Fit a waterproofing device on the air filter. Waterproofing device for air filter (79006921000) Info See the KTM PowerParts fitting instructions. 102137-01 – Fit the steel sprocket. – Clean the motorcycle. ( p.

  • Page 24: Riding Instructions

    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 25: Activating Launch Control

    RIDING INSTRUCTIONS (XC‑F US) – Take the motorcycle off side stand and secure the side stand with rubber band – Shift the transmission to idle. Condition Ambient temperature: < 20 °C (< 68 °F) – Push the cold start button in all the way. 401944-10 –...

  • Page 26: Starting Off

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

  • Page 27: Stopping, Parking

    RIDING INSTRUCTIONS – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. – On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine. In this way, you have to apply the brakes far less frequently and the brake system does not overheat.

  • Page 28: Refueling

    In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Improper handling of fuel is a danger to the environment.

  • Page 29: Service Schedule

    Every 20 operating hours Every 10 operating hours/after every race Once after 1 operating hour ○ ● ● ● ● Read out the fault memory using the KTM diagnostics tool. ● ● ● ● Check and charging the battery. ● ●...

  • Page 30: Recommended Work

    Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● ● ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval Recommended work...

  • Page 31: Tuning The Chassis

    For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swingarm and frame, the basic settings of the suspension components must match the rider's weight. – As delivered, KTM offroad motorcycles are adjusted for an average rider's weight (with full protective clothing). Guideline Standard rider weight 75…...

  • Page 32: Adjusting The Low-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 low-speed setting can be seen in slow to normal compression of the shock absorber.

  • Page 33: Adjusting The Rebound Damping Of The Shock Absorber

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

  • Page 34: Measuring Rear Wheel Sag Unloaded

    TUNING THE CHASSIS 10.7 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with a lift stand. ( p. 39) Main work – Position the sag gauge in the rear axle and measure the distance to marking SAG on the rear fender.

  • Page 35: Checking The Riding Sag Of The Shock Absorber

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

  • Page 36: Adjusting The Riding Sag

    TUNING THE CHASSIS – Check the free travel of the foot brake lever. ( p. 69) – Remove the motorcycle from the lift stand. ( p. 39) 10.11 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p.

  • Page 37: Adjusting The Fork Air Pressure

    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 pump or the fork. Read the accompanying KTM PowerParts instructions. – Adjust the air pressure as specified. Guideline Air pressure (SX‑F EU)

  • Page 38: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 10.14 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn adjusting screw clockwise all the way. Info Adjusting screw is located at the upper end of the right fork leg. –...

  • Page 39: Handlebar Position

    TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. – Mount protection cap 10.16 Handlebar position The holes on the handlebar supports are placed at a distance of from the center. Hole distance A 3.5 mm (0.138 in) The handlebar can be mounted in 2 different positions.
  • Page 40 TUNING THE CHASSIS Finishing work – Mount the handlebar cushion.

  • Page 41: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with a lift stand Note Material damage The vehicle may be damaged by incorrect procedure when parking. Significant damage may be caused if the vehicle rolls away or falls over. The components for parking the vehicle are designed only for the weight of the vehicle. –...

  • Page 42: Bleeding The Fork Legs

    SERVICE WORK ON THE CHASSIS 11.3 Bleeding the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 39) Main work – Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws.

  • Page 43: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11.6 Installing the fork protector – Position the fork protection on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the brake line and clamp. Mount and tighten screws –...

  • Page 44: Removing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS – Position the brake caliper. Mount and tighten screws Guideline Screw, front brake caliper 25 Nm Loctite ® 243™ (18.4 lbf ft) – Position the brake line and clamp. Mount and tighten screws S01267-11 Finishing work –...

  • Page 45: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 110) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

  • Page 46: Checking The Steering Head Bearing Play

    Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam- aged over time.

  • Page 47: Adjusting The Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: –...

  • Page 48: Removing The Start Number Plate

    SERVICE WORK ON THE CHASSIS 11.14 Removing the start number plate – Remove screw – Unhook the start number plate from the brake line and remove it. S01234-10 11.15 Installing the start number plate – Position the brake line in holders on the start number plate.

  • Page 49: Installing The Front Fender

    SERVICE WORK ON THE CHASSIS 11.17 Installing the front fender Main work – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) S01218-10 Finishing work – Install the start number plate. ( p.

  • Page 50: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS – Remove the connecting link of the chain. – Take off the chain. S01222-10 – Remove nut and pull out the swingarm pivot. – Push the swingarm back and secure it against falling over. S01223-10 –...

  • Page 51: Removing The Seat

    SERVICE WORK ON THE CHASSIS – Position the foot brake cylinder. Push rod engages in the foot brake cylinder. Info Ensure that the dust boot is correctly seated. – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) S01228-10 –...

  • Page 52: Mounting The Seat

    SERVICE WORK ON THE CHASSIS 11.21 Mounting the seat – Mount the front of the seat on the collar bushing of the fuel tank, lower the seat at the rear, and push the seat forward. H02218-11 – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft)

  • Page 53: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS Condition The air filter box cover is secured. – Mount and tighten screw Guideline Screw, air filter box cover EJOT PT ® 3 Nm (2.2 lbf ft) K60x20-Z F01025-10 11.24 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine.

  • Page 54: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS – Clean the air filter box. – Clean the intake flange and check it for damage and tightness. Finishing work – Install the air filter. p. 52) – Install the air filter box cover. ( p.

  • Page 55: Removing The Main Silencer

    SERVICE WORK ON THE CHASSIS 11.29 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. – Detach spring Spring hook (50305017000) –...

  • Page 56: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS Main work – Remove all screws on the main silencer. – Take off silencer cap and O-ring – Take off outer tube and O-ring – Pull glass fiber yarn filling off of inner tube – Clean the parts that need to be reinstalled and check for damage.
  • Page 57 SERVICE WORK ON THE CHASSIS – Disconnect the plug-in connection of the fuel line. Info Remaining fuel may flow out of the fuel hose. – Mount wash cap set Wash cap set (81212016100) – Pull the fuel tank breather hose off the tank lid. S01240-10 –...

  • Page 58: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS – Pull both spoilers off the sides of the radiator bracket and lift off the fuel tank. S01245-10 11.33 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 59: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS – Plug in connector for the fuel pump. – Remove the wash cap set. Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! –...

  • Page 60: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu- lations. Info The service life of the chain depends largely on its maintenance. Preparatory work –...

  • Page 61: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 11.37 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly.
  • Page 62 SERVICE WORK ON THE CHASSIS – Pull at the top part of the chain with the specified weight Guideline Weight, chain wear measurement 10… 15 kg (22… 33 lb.) – Measure distance of 18 chain rollers in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 63: Checking The Frame

    If the frame exhibits cracks or deformation due to a mechanical impact: – Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by KTM. F01029-01 11.40 Checking the swingarm –...

  • Page 64: Checking The Rubber Grips

    SERVICE WORK ON THE CHASSIS Main work – Check the throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars and above the fuel tank bracket, to the throttle valve body. Both throttle cables must be secured behind the fuel tank contact area rubber band.

  • Page 65: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS 11.44 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. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
  • Page 66 SERVICE WORK ON THE CHASSIS – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane F00158-10 (All SX‑F models) – Fill bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 67: Brake System

    Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at multiple points on each...

  • Page 68: Checking The Brake Fluid Level Of The Front Brake

    If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect.

  • Page 69: 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 ≥ 1 mm (≥ 0.04 in) Minimum thickness »...

  • Page 70: Changing The Front Brake Linings

    Changing the front brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation. –...

  • Page 71: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. B00352-10 – Insert the new brake linings, insert pin , and mount cotter pins Info Always change the brake linings in pairs. –...

  • Page 72: Adjusting The Basic Position Of The Foot Brake Lever

    If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect.

  • Page 73: Adding Rear Brake Fluid

    If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation.

  • Page 74: Changing The Rear Brake Linings

    Changing the rear brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation. –...
  • Page 75 BRAKE SYSTEM – Manually press the brake caliper to the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.

  • Page 76: Wheels, Tires

    WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 39) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

  • Page 77: Removing The Rear Wheel

    WHEELS, TIRES – Clean and grease the wheel spindle. Long-life grease ( p. 110) – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw Guideline Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft)

  • Page 78: Installing The Rear Wheel

    WHEELS, TIRES 13.4 Installing the rear 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. Main work –...

  • Page 79: Checking The Tire Condition

    The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low, then lateral and radial run-out will form in the wheel. 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 80 WHEELS, TIRES – Strike each spoke briefly using a screwdriver blade. Info The frequency of the sound depends on the spoke length and spoke diame- ter. If you hear different tone frequencies from different spokes of equal length and diameter, this is an indication of different spoke tensions. You should hear a high note.

  • Page 81: Electrical System

    ELECTRICAL SYSTEM 14.1 Removing the battery Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batteries. – Only charge batteries in well-ventilated rooms. – Maintain a minimum clearance from inflammable materials when charging batteries.

  • Page 82: Recharging The Battery

    ELECTRICAL SYSTEM 14.3 Recharging the battery Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batteries. – Only charge batteries in well-ventilated rooms. – Maintain a minimum clearance from inflammable materials when charging batteries.

  • Page 83: Changing The Main Fuse

    ELECTRICAL SYSTEM – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test the open-circuit voltage and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the battery.

  • Page 84: Cooling System

    COOLING SYSTEM 15.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 85: Checking The Coolant Level

    COOLING SYSTEM 15.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 86: Refilling Coolant

    COOLING SYSTEM – Position the motorcycle upright. – Place a suitable container under the water pump cover. – Remove screw . Take off radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Screw, water pump cover 10 Nm (7.4 lbf ft)

  • Page 87: Tuning The Engine

    TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3…...

  • Page 88: Setting The Characteristic Map Of The Throttle Response

    TUNING THE ENGINE – Check the throttle grip for smooth operation. (XC‑F US) – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut –...

  • Page 89: Changing The Mapping

    16.5 Adjusting the idle speed Warning 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.)

  • Page 90: Teaching The Throttle Valve Position

    TUNING THE ENGINE – Run the engine until warm. The cold start button is deactivated – The cold start button is in its basic posi- tion. ( p. 15) Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

  • Page 91: Adjusting The Basic Position Of The Shift Lever

    TUNING THE ENGINE – Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the shift lever. Distance between shift lever and upper 10… 20 mm (0.39… 0.79 in) edge of boot »...

  • Page 92: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 17.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 93: Checking The Engine Oil Level

    SERVICE WORK ON THE ENGINE (XC‑F US) – 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! – Disconnect the plug-in connection of the fuel line.

  • Page 94: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    SERVICE WORK ON THE ENGINE 17.3 Changing the engine oil and oil filter, cleaning the oil screen Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden. – Wear suitable protective clothing and safety gloves. –...
  • Page 95 SERVICE WORK ON THE ENGINE – Remove screws . Remove the oil filter cover with the O-ring. S01274-10 – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) – Completely drain the engine oil. – Thoroughly clean the parts and sealing surfaces. S01275-10 –...

  • Page 96: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 17.4 Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear of the engine. – Remove oil filler plug with the O-ring from the clutch cover. – Add the same engine oil used when the last oil change was carried out. Engine oil (SAE 10W/50) ( p.

  • Page 97: Cleaning, Care

    CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...

  • Page 98: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with a lift stand. ( p. 39) – Cover the vehicle with a tarp or similar cover that is permeable to air.

  • Page 99: Preparing For Use After Storage

    STORAGE 19.2 Preparing for use after storage – Install the battery. p. 79) – Remove the motorcycle from the lift stand. ( p. 39) – Perform checks and maintenance measures when preparing for use. ( p. 22) – Make a test ride. 401059-01...

  • Page 100: Troubleshooting

    – Check the electrical system. – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool.
  • Page 101 TROUBLESHOOTING Faults Possible cause Action – Battery is discharged Battery is not charging Check the charging voltage. – Check the stator winding of the alternator. – Unwanted power consumer Check the open-circuit current.

  • Page 102: Technical Data

    TECHNICAL DATA 21.1 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 14.0:1 Idle speed 2,250… 2,350 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 36.3 mm (1.429 in)

  • Page 103: Engine Tightening Torques

    TECHNICAL DATA 21.2 Engine tightening torques Loctite ® 243™ Nozzle, crank chamber ventilation 2 Nm (1.5 lbf ft) Oil nozzle for alternator cooling 2 Nm (1.5 lbf ft) Loctite ® 243™ Oil nozzle for balancer shaft lubrication M4 2 Nm (1.5 lbf ft) Loctite ®...

  • Page 104: Capacities

    TECHNICAL DATA Nut, cylinder head M10x1.25 Tightening sequence: Thread, oiled with engine Tighten diagonally. oil/cone greased 1st tightening stage 10 Nm (7.4 lbf ft) 2nd tightening stage 30 Nm (22.1 lbf ft) 3rd tightening stage 50 Nm (36.9 lbf ft) Stud, cylinder head M10x1.25 20 Nm (14.8 lbf ft)

  • Page 105: Electrical System

    110/100 - 18 64M TT Dunlop GEOMAX AT81F Dunlop GEOMAX AT81 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 21.7 Fork 21.7.1 SX‑F EU Fork article number 34.18.8R.07...

  • Page 106: Sx-F Us

    TECHNICAL DATA Grease capacity, left cartridge 11 ml (0.37 fl. oz.) Multi-purpose grease (00062010051) ( p. 110) 21.7.2 SX‑F US Fork article number 34.18.8R.57 WP Performance Systems Upside down AER 48 Fork Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Rebound damping...

  • Page 107: Sx-F Us

    TECHNICAL DATA Comfort 2 turns Standard 1.5 turns Sport 1 turn Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 10 mm (0.39 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 39 N/mm (223 lb/in) Weight of rider: 75…...

  • Page 108: Chassis Tightening Torques

    TECHNICAL DATA Standard 15 clicks Sport 13 clicks Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport 1.5 turns Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 10 mm (0.39 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 39 N/mm (223 lb/in) Weight of rider: 75…...
  • Page 109 TECHNICAL DATA – Remaining screws, chassis 25 Nm (18.4 lbf ft) – Screw, bottom triple clamp 12 Nm (8.9 lbf ft) – Screw, chain sliding piece 15 Nm (11.1 lbf ft) Screw, engine brace 25 Nm (18.4 lbf ft) Loctite ®...

  • Page 110: Substances

    112) – SAE ( p. 112) (SAE 10W/60) – KTM LC4 2007+ Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre- sponding properties. Synthetic engine oil...
  • Page 111 SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 112) (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 112: Auxiliary Substances

    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 Motorex...
  • Page 113 AUXILIARY SUBSTANCES Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic...

  • Page 114: Standards

    STANDARDS JASO T903 MA Different technical development directions required a separate specification for 4-stroke motorcycles – the JASO T903 MA standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation.

  • Page 115: Index Of Special Terms

    INDEX OF SPECIAL TERMS On-board diagnosis Vehicle system that monitors emission- and safety-related values...

  • Page 116: List Of Abbreviations

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

  • Page 117: List Of Symbols

    LIST OF SYMBOLS 27.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols. Malfunction indicator lamp lights up/flashes orange – The OBD has detected an emission- or safety-critical fault.

  • Page 118: Index

    INDEX Clutch INDEX fluid level, checking/correcting ....63 Accessories ........8 fluid, changing .
  • Page 119 INDEX Fork protector lift stand, raising with ......39 installing ....... . . 41 lift stand, removing from .
  • Page 120 INDEX Shock absorber article number ..... 11 Side stand ........17 Spare parts .
  • Page 121 *3213640en* 3213640en 03/2017 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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