Table of Contents
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Table of Contents
Related Manuals for KTM Freeride 350 AU
Summary of Contents for KTM Freeride 350 AU
- Page 1 OWNER'S MANUAL 2016 Freeride 350 EU Freeride 350 AU Art. no. 3213340en...
- Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, misprints, and other errors.
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Page 4: Table Of Contents
11.15 Adjusting the handlebar position ....36 Emergency OFF switch (Freeride 350 AU) ..13 12 SERVICE WORK ON THE CHASSIS......37 Electric starter button (Freeride 350 EU) ..13 12.1 Raising the motorcycle with the lift stand ..37 6.10 Electric starter button (Freeride 350 AU) .. - Page 5 TABLE OF CONTENTS 12.22 Removing the air filter housing ..... 46 15.6 Removing the headlight mask with the headlight............78 12.23 Installing the air filter housing ...... 47 15.7 Refitting the headlight mask with the 12.24 Removing the air filter .........
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Page 6: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required. -
Page 7: Safety Advice
SAFETY ADVICE Use definition - intended use KTM sport motorcycles are designed and built to withstand the normal stresses and strains of offroad use. Info The motorcycle is authorized for public road traffic in the homologous (reduced) version only. In the derestricted version, the motorcycle must be used only on closed off property remote from public road traffic. -
Page 8: Safe Operation
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 9: Important Notes
Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM Dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle. -
Page 10: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) M00465-10 Speedometer Clutch lever ( p. 12) Filler cap Seat Seat release Shock absorber compression adjustment Shock absorber rebound adjustment Side stand ( p. 16) Battery Shift lever ( p. 15) Idle speed adjusting screw ( p. -
Page 11: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) M00466-10 Kill switch ( p. 12) Horn button ( p. 12) Light switch ( p. 13) Turn signal switch ( p. 13) Electric starter button ( p. 13) Throttle grip ( p. -
Page 12: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. 401946-10 Type label The type label is mounted on the frame at the front right. 402270-10 Key number The key number for the steering lock is stamped onto the key connector. -
Page 13: Shock Absorber Article Number
SERIAL NUMBERS Shock absorber article number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 0 0 1 401948-10... -
Page 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. M00467-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. -
Page 15: Light Switch
Ignition on – In this position, the ignition circuit is closed and the engine can be started. 602794-11 Electric starter button (Freeride 350 EU) Electric starter button is fitted on the right side of the handlebar. -
Page 16: Overview Of Indicator Lamps
CONTROLS 6.11 Overview of indicator lamps Possible states High beam indicator light lights up blue – High beam is switched on. FI warning lamp (MIL) lights up/flashes orange – The OBD has detected an emission- or safety-critical fault. The fuel level warning lamp lights up orange – The fuel level has reached the reserve mark. -
Page 17: Idle Speed Adjusting Screw
CONTROLS 6.14 Idle speed adjusting screw Idle speed adjusting screw is located on the throttle valve body at the top left. The idle speed adjusting screw has two functions. Turning it controls the idle speed. Pulling it out all the way raises the idle speed during a cold start. Possible states RPM increase activated –... -
Page 18: Side Stand
CONTROLS 6.17 Side stand The side stand is on the left side of the vehicle. 401943-10 The side stand is used to park the motorcycle. Info When you are riding, side stand must be folded up and secured with rubber ... -
Page 19: Unlocking The Steering
CONTROLS 6.20 Unlocking the steering – Insert the key in the steering lock ( p. 16), turn it to the left, pull it out, and turn it to the right. Remove the key. You can now steer the bike again. Info Never leave the key in the steering lock. -
Page 20: Speedometer
Message on the speedometer Possible states Battery voltage of the speedometer – Battery voltage of the speedometer is too low. Change the battery. Service – A service is due. Contact an authorized KTM workshop. 401901-01 Setting the speedometer Condition The motorcycle is stationary. -
Page 21: Setting Kilometers Or Miles
SPEEDOMETER – Wait for 5 seconds. The speedometer changes to the next menu item. The symbol flashes. Resetting the time – Press the left button. The value decreases. Advancing the time – Press the right button. The value increases. 401912-01 –... -
Page 22: Setting The Clock
SPEEDOMETER Setting the clock Condition The motorcycle is stationary. – Press both buttons for 3–5 seconds. The Setup menu is displayed. The UNIT display flashes. – Wait for the menu of the clock to flash. – Press one of the buttons to select the 24h or 12h display of the clock. 401911-01 –... -
Page 23: Speed, Time, And Dst Distance 1
SPEEDOMETER Speed, time, and DST distance 1 – Press one of the buttons until DST appears on the speedometer. KM/H or M/H shows the speed. shows the time. DST shows the distance since the last reset, such as between two refueling stops. Info If the value of 39999.9 is exceeded, DST is automatically reset to 0.0. -
Page 24: 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 25: Running In The Engine
PREPARING FOR USE Info Motorcycles react sensitively to any changes of weight distribution. – Do not exceed the overall maximum permitted weight and the axle loads. Guideline Maximum permissible overall weight 280 kg (617 lb.) Maximum permissible front axle load 135 kg (298 lb.) Maximum permissible rear axle load 175 kg (386 lb.) -
Page 26: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p. 88) –... -
Page 27: Starting Off
Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines. -
Page 28: Stopping, Parking
RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. –... -
Page 29: Refueling
– In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards. -
Page 30: Service Schedule
● ● Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval... -
Page 31: Service Work (As Additional Order)
SERVICE SCHEDULE 10.2 Service work (as additional order) Annually Every 160 operating hours Every 40 operating hours Once after 20 operating hours ● Change the front brake fluid. ● Change the rear brake fluid. ● ● Change the foot brake cylinder seals. ●... -
Page 32: Tuning The Chassis
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. -
Page 33: Adjusting The High-Speed Compression Damping Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber. -
Page 34: Measuring Rear Wheel Sag Unloaded
TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. 11.6 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with the lift stand. ( p. 37) Main work – Measure the distance – as vertical as possible – between the rear axle and a fixed point, for example, a mark on the rear fairing. -
Page 35: Checking The Riding Sag Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. -
Page 36: Adjusting The Riding Sag
TUNING THE CHASSIS Finishing work – Install the shock absorber. p. 44) – Lock the seat. ( p. 45) – Remove the motorcycle from the lift stand. ( p. 37) 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with the lift stand. ( p. -
Page 37: Adjusting The Compression Damping Of The Fork
TUNING THE CHASSIS 11.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Remove protection caps – Turn adjusting screws clockwise all the way. Info Adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs. -
Page 38: Handlebar Position
TUNING THE CHASSIS 11.14 Handlebar position On the upper triple clamp, there are two holes at a distance of to each other. 15 mm (0.59 in) Hole distance The holes on the handlebar supports are placed at a distance of from the center. -
Page 39: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (78929955100) Neither wheel is in contact with the ground. -
Page 40: Cleaning The Dust Boots Of The Fork Legs
SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 37) – Remove the fork protector. ( p. 39) Main work – Push dust boots of both fork legs downward. -
Page 41: Installing The Fork Legs
SERVICE WORK ON THE CHASSIS 12.6 Installing the fork legs Main work – Position the fork legs. Bleeder screws face forward. Info Grooves are milled into the side of the upper end of the fork legs. The sec- ond milled groove (from the top) must be flush with the top edge of the upper triple clamp. -
Page 42: Installing The Fork Protector
SERVICE WORK ON THE CHASSIS 12.8 Installing the fork protector – Position the fork protection on the right fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) M00480-11 – Position the fork protection on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) -
Page 43: Installing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS 12.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 106) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. -
Page 44: Checking The Steering Head Bearing Play
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam-... -
Page 45: Adjusting The Play Of The Steering Head Bearing
SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with the lift stand. ( p. 37) Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. -
Page 46: Removing The Front Fender
SERVICE WORK ON THE CHASSIS 12.14 Removing the front fender – Remove screws . Remove the front fender. B01030-10 12.15 Installing the front fender – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) Info Make sure the holding lugs engage in the headlight mask. -
Page 47: Folding The Seat Up
SERVICE WORK ON THE CHASSIS Finishing work – Lock the seat. ( p. 45) – Remove the motorcycle from the lift stand. ( p. 37) 12.18 Folding the seat up – Press release lever – Lift the seat and fold it up. M00497-10 12.19 Locking the seat... -
Page 48: Mounting The Spoiler
SERVICE WORK ON THE CHASSIS 12.21 Mounting the spoiler Main work – Position the spoiler and hook it in at area M00504-10 – Mount and tighten screw Guideline EJOT PT ® Screw for spoiler, top 3 Nm (2.2 lbf ft) K60x20AL –... -
Page 49: Installing The Air Filter Housing
SERVICE WORK ON THE CHASSIS 12.23 Installing the air filter housing Main work – Position pre-filter on the air filter housing. Note Engine failure If the pre-filter is mounted incorrectly or not mounted at all, the air-fuel mixture will change. This has a negative effect on the service life of the engine. -
Page 50: Cleaning The Air Filter And Air Filter Housing
SERVICE WORK ON THE CHASSIS – Insert both parts together and close air filter housing by turning clockwise. Info If the air filter is not mounted correctly, dust and dirt may enter the engine and cause damage. M00507-10 Finishing work –... -
Page 51: Installing The Main Silencer
SERVICE WORK ON THE CHASSIS – Disconnect spring – Remove screws and take off the main silencer. M00539-10 Remove the left main silencer: – Disconnect spring – Remove screws and take off the main silencer. M00541-10 12.28 Installing the main silencer Install the right main silencer:... -
Page 52: Changing The Glass Fiber Yarn Filling Of The Main Silencer
SERVICE WORK ON THE CHASSIS 12.29 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. Info Over a period, the fibers of the glass fiber yarn vanish into the air, and the silencer "burns out". -
Page 53: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS Main work – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter the fuel line. Dirt in the fuel line clogs the injection valve. – Disconnect the plug-in connection of the fuel line. - Page 54 SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water.
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Page 55: Checking For Chain Dirt Accumulation
SERVICE WORK ON THE CHASSIS 12.32 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 53) 400678-01 12.33 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. –... -
Page 56: Adjusting The Chain Tension
SERVICE WORK ON THE CHASSIS Main work – Pull the chain at the end of the chain sliding component upwards to measure chain tension Info The lower chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions. -
Page 57: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide
SERVICE WORK ON THE CHASSIS 12.36 Checking the chain, rear sprocket, engine sprocket and chain guide Preparatory work – Raise the motorcycle with the lift stand. ( p. 37) Main work – Shift gear to neutral. – Check the rear sprocket and engine sprocket for wear. »... -
Page 58: Checking The Frame
If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by KTM. 401462-01... -
Page 59: Checking The Swingarm
» If the swingarm shows signs of damage, cracking, or deformation: – Change the swingarm. Info Always change a damaged swingarm. Repair of the swingarm is not authorized by KTM. 401463-01 12.39 Checking the throttle cable routing Preparatory work –... -
Page 60: Additionally Securing The Rubber Grip
SERVICE WORK ON THE CHASSIS 12.41 Additionally securing the rubber grip Preparatory work – Check the rubber grip. ( p. 57) Main work – Secure the rubber grip at two points using the securing wire. Securing wire (54812016000) Wire twister forceps (U6907854) The twisted wire ends face away from the hands and are bent toward the rub- ber grip. -
Page 61: Changing The Hydraulic Clutch Fluid
SERVICE WORK ON THE CHASSIS Info Clean up overflowed or spilt brake fluid immediately with water. 12.45 Changing the hydraulic clutch fluid Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. –... -
Page 62: Removing The Engine Guard
SERVICE WORK ON THE CHASSIS 12.46 Removing the engine guard – Remove screws – Lower the engine guard at the rear and remove it toward the front. B01072-10 12.47 Installing the engine guard – Position the engine guard on the frame at the front and mount screws but do not tighten yet. -
Page 63: Brake System
Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disk ... -
Page 64: Checking The Brake Fluid Level Of The Front Brake
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. -
Page 65: Checking The Front Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. - Page 66 BRAKE SYSTEM Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
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Page 67: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM – Remove the fixation of the hand brake lever. – Add brake fluid to level Guideline 5 mm (0.2 in) Level (brake fluid level below con- tainer rim) Brake fluid DOT 4 / DOT 5.1 ( p. -
Page 68: Checking The Rear Brake Fluid Level
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright. -
Page 69: Checking The Rear Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. - Page 70 Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
- Page 71 BRAKE SYSTEM – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 104) – Position the cover with the membrane – Mount and tighten screws Info Clean up overflowed or spilt brake fluid immediately with water. B01692-10...
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Page 72: Wheels, Tires
WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 37) Main work – Loosen screw by several rotations. – Release screws – Press on screw to push the wheel spindle on the axle clamp. –... -
Page 73: Removing The Rear Wheel
WHEELS, TIRES – Pull the front brake and compress the fork forcefully a few times. The fork legs straighten. – Tighten screw Guideline Screw, fork stub 15 Nm (11.1 lbf ft) 14.3 Removing the rear wheel Preparatory work – Raise the motorcycle with the lift stand. -
Page 74: Checking The Tire Condition
Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition, and air pressure of the tires all have a major impact on the handling characteristics of the motorcycle. -
Page 75: Checking The Tire Air Pressure
Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes. -
Page 76: Electrical System
ELECTRICAL SYSTEM 15.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –... -
Page 77: Recharging The Battery
– Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 78: Changing The Main Fuse
ELECTRICAL SYSTEM Guideline The charging current, charging voltage, and charging time must not be exceeded. Charge the battery regularly when the 3 months motorcycle is not in use Finishing work – Install the battery. p. 74) 15.4 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. -
Page 79: Changing The Fuses Of Individual Power Consumers
ELECTRICAL SYSTEM 15.5 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work – Switch off all power consumers and switch off the engine. – Fold the seat up. -
Page 80: Removing The Headlight Mask With The Headlight
ELECTRICAL SYSTEM 15.6 Removing the headlight mask with the headlight – Switch off all power consumers. – Detach the brake line and wiring harness – Release rubber band . Slide the headlight mask up and swing it forward. S00842-10 –... -
Page 81: Changing The Headlight Bulb
ELECTRICAL SYSTEM – Position the headlight mask and secure it with rubber bands The holding lugs on the fender engage in the headlight mask. – Attach the brake line and wiring harness S00843-10 Finishing work – Check the headlight setting. ( p. -
Page 82: Changing The Turn Signal Bulb
ELECTRICAL SYSTEM 15.9 Changing the turn signal bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting. Main work –... -
Page 83: Changing The Speedometer Battery
ELECTRICAL SYSTEM Main work – Adjust the beam distance of the headlight by turning screw Guideline For a motorcycle with rider, the light/dark boundary must be exactly on the lower mark (the mark is created in: Checking the headlight setting). Info Turn clockwise to increase the headlight range, turn counterclockwise to reduce the headlight range. -
Page 84: Cooling System
COOLING SYSTEM 16.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions. -
Page 85: Checking The Coolant Level
COOLING SYSTEM 16.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. -
Page 86: Refilling Coolant
COOLING SYSTEM 16.5 Refilling coolant Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water imme- diately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swal- lowed, contact a physician immediately. -
Page 87: Tuning The Engine
TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Throttle cable play 3…... -
Page 88: Adjusting The Idle Speed
TUNING THE ENGINE 17.3 Adjusting the idle speed – Run the engine warm and push the idle speed adjusting screw all the way in. – Set the desired idle speed by turning the idle speed adjusting screw. Guideline Idle speed 1,800…... - Page 89 TUNING THE ENGINE – Mount and tighten screw with the washers. Guideline Screw, shift lever 14 Nm Loctite ® 243™ (10.3 lbf ft)
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Page 90: Service Work On The Engine
SERVICE WORK ON THE ENGINE 18.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –... -
Page 91: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen
SERVICE WORK ON THE ENGINE The engine oil is at a level between the middle and upper edge of the level viewer. » If the engine oil is not up to the middle of the level viewer: –... - Page 92 SERVICE WORK ON THE ENGINE – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) – Completely drain the engine oil. – Thoroughly clean the parts and sealing area. B01129-10 – Position oil screen with the O-rings on a pin wrench.
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Page 93: Adding Engine Oil
SERVICE WORK ON THE ENGINE – Start the engine and check that it is oil-tight. Finishing work – Install the engine guard. ( p. 60) – Check the engine oil level. ( p. 88) 18.4 Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. Main work –... -
Page 94: Cleaning, Care
CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts. -
Page 95: Checks And Maintenance Steps For Winter Operation
CLEANING, CARE 19.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt. -
Page 96: Storage
– Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 37) – Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materi- als since they prevent humidity from escaping, thus causing corrosion. -
Page 97: 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 98 See blink code – Check the cabling for damage and the connec- tors for corrosion and damage. – Read out the fault memory using the KTM diag- nostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary.
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Page 99: Blink Code
BLINK CODE Blink code FI warning lamp (MIL) 45 FI warning lamp (MIL) flashes 4x long, 5x short Error level condition Lambda sensor heater cylinder 1, sensor 1 - short circuit to ground or open circuit Lambda sensor heater cylinder 1, sensor 1 - input signal too high Blink code FI warning lamp (MIL) 09 FI warning lamp (MIL) flashes 9x short Error level condition... -
Page 100: Technical Data
TECHNICAL DATA 23.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 349.7 cm³ (21.34 cu in) Stroke 57.5 mm (2.264 in) Bore 88 mm (3.46 in) Compression ratio 12.3:1 Idle speed 1,800… 1,900 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 36.3 mm (1.429 in) - Page 101 TECHNICAL DATA Loctite ® 243™ Screw, locking lever 6 Nm (4.4 lbf ft) Screw, oil pump cover 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, stator 6 Nm (4.4 lbf ft) Loctite ® 243™ Nut, cylinder head 10 Nm (7.4 lbf ft) Lubricated with engine oil Nut, water-pump wheel 5 Nm (3.7 lbf ft)
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Page 102: Capacities
TECHNICAL DATA 23.3 Capacities 23.3.1 Engine oil Engine oil 1.0 l (1.1 qt.) Engine oil (SAE 10W/50) ( p. 104) Alternative engine oil Engine oil (SAE 10W/60) (00062010035) ( p. 104) 23.3.2 Coolant Coolant 0.7 l (0.7 qt.) Coolant ( p. -
Page 103: Electrical System
Rear tires 2.75 - 21 M/C 45M TT 4.00 R 18 M/C 64M TL MAXXIS TRIALMAXX MAXXIS TRIALMAXX Additional information is available in the Service section under: http://www.ktm.com 23.7 Fork Fork part number 05.18.7N.40 Fork WP Performance Systems 4357 MXMA... -
Page 104: Shock Absorber
TECHNICAL DATA 23.8 Shock absorber Shock absorber part number 15.18.7N.40 Shock absorber WP Performance Systems 4618 PDS DCC Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 5 clicks Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport 1 turn Rebound damping Comfort... - Page 105 TECHNICAL DATA Loctite ® 2701™ Nut, rear sprocket screw 35 Nm (25.8 lbf ft) – Nut, rim lock 10 Nm (7.4 lbf ft) – Remaining nuts, chassis 25 Nm (18.4 lbf ft) – Remaining screws, chassis 25 Nm (18.4 lbf ft) Screw of rear brake caliper 25 Nm (18.4 lbf ft) Loctite...
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Page 106: Substances
108) – SAE ( p. 108) (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 107 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 108) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification –...
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Page 108: Auxiliary Substances
Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Grip adhesive (00062030051) Recommended supplier KTM Motorrad AG – GRIP GLUE High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier Motorex ®... - Page 109 AUXILIARY SUBSTANCES Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic...
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Page 110: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation. -
Page 111: 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 112: Lisy Of Symbols
LISY OF SYMBOLS 28.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols. FI warning lamp (MIL) lights up/flashes orange – The OBD has detected an emission- or safety-critical fault. The fuel level warning lamp lights up orange –... -
Page 113: Index
INDEX Clutch lever ........12 INDEX basic position, adjusting ..... . 58 Accessories . - Page 114 INDEX Front fender installing ....... . . 44 Oil filter removing .
- Page 115 INDEX setting ........18 Spoiler mounting ....... . 46 removing .
- Page 116 *3213340en* 3213340en 04/2015 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...
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