OWNER'S MANUAL 2013

Freeride 350 EU
Freeride 350 AUS
Art. no. 3211907en
DEAR KTM CUSTOMER 1

Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
DEAR KTM CUSTOMER

give you enormous pleasure if you service and maintain it accordingly.

We wish you a lot of enjoyment in riding this vehicle!

Enter the serial numbers of your vehicle below.

Chassis number ( p. 11) Dealer's stamp

Engine number ( p. 11)

Key number ( p. 11)

The owner's manual contained the latest information for this model at the time of going to print. Slight deviations resulting from con-
tinuing development and design of the motorcycles can, however, not be completely excluded.

All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not belong to the regular scope of delivery.

© 2012 KTM-Sportmotorcycle AG, Mattighofen Austria

All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.

ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service

KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS 2

6.12.19 Table of functions....................................... 20

TABLE OF CONTENTS

1 MEANS OF REPRESENTATION ..................................... 5

1.1 Symbols used ................................................... 5 6.12.20 Table of conditions and menu activation ....... 21
1.2 Formats used.................................................... 5 6.13 Opening the filler cap...................................... 21
2 SAFETY ADVICE........................................................... 6 6.14 Closing the filler cap ....................................... 22
2.1 Use definition - intended use ............................. 6 6.15 Idle speed adjusting screw ............................... 22
2.2 Safety advice.................................................... 6 6.16 Shift lever ...................................................... 22
2.3 Degrees of risk and symbols ............................... 6 6.17 Foot brake lever .............................................. 23
2.4 Tampering warning............................................ 6 6.18 Side stand...................................................... 23
2.5 Safe operation .................................................. 7 6.19 Steering lock .................................................. 23
2.6 Protective clothing ............................................ 7 6.20 Locking the steering ........................................ 24
2.7 Work rules........................................................ 7 6.21 Unlocking the steering..................................... 24
2.8 Environment..................................................... 7 7 PREPARING FOR USE................................................ 25
2.9 Owner's Manual ................................................ 7 7.1 Advice on first use .......................................... 25
3 IMPORTANT NOTES..................................................... 8 7.2 Running in the engine ..................................... 26
3.1 Guarantee, warranty .......................................... 8 8 RIDING INSTRUCTIONS............................................. 27
3.2 Operating and auxiliary substances ..................... 8 8.1 Checks and maintenance work when preparing
3.3 Spare parts, accessories .................................... 8 for use ........................................................... 27
3.4 Service ............................................................ 8 8.2 Starting.......................................................... 27
3.5 Figures ............................................................ 8 8.3 Starting off..................................................... 28
3.6 Customer service............................................... 8 8.4 Shifting, riding ............................................... 28
4 VIEW OF VEHICLE ....................................................... 9 8.5 Applying the brakes......................................... 28
4.1 View of vehicle, front left (example) .................... 9 8.6 Stopping, parking............................................ 29
4.2 View of vehicle, rear right (example) ................. 10 8.7 Transport ....................................................... 29
5 SERIAL NUMBERS .................................................... 11 8.8 Refueling ....................................................... 30
5.1 Chassis number .............................................. 11 9 SERVICE SCHEDULE ................................................. 31
5.2 Type label ...................................................... 11 9.1 Service schedule............................................. 31
5.3 Key number.................................................... 11 9.2 Service work (as additional order) ..................... 32
5.4 Engine number ............................................... 11 10 TUNING THE CHASSIS .............................................. 33
5.5 Fork part number ............................................ 11 10.1 Checking the basic chassis setting with the
5.6 Shock absorber part number ............................ 12 rider's weight.................................................. 33
6 CONTROLS................................................................ 13 10.2 Compression damping of the shock absorber...... 33
6.1 Clutch lever.................................................... 13 10.3 Adjusting the low-speed compression damping
of the shock absorber ...................................... 33
6.2 Hand brake lever............................................. 13
10.4 Adjusting the high-speed compression
6.3 Throttle grip ................................................... 13
damping of the shock absorber......................... 34
6.4 Kill switch...................................................... 13
10.5 Adjusting the rebound damping of the shock
6.5 Horn button.................................................... 13 absorber......................................................... 34
6.6 Light switch ................................................... 14 10.6 Measuring rear wheel sag unloaded................... 35
6.7 Electric starter button (Freeride 350 EU) .......... 14 10.7 Checking the static sag of the shock absorber .... 35
6.8 Electric starter button (Freeride 350 AUS) ........ 14 10.8 Checking the riding sag of the shock absorber.... 36
6.9 Turn signal switch........................................... 14 10.9 Adjusting the spring preload of the shock
6.10 Emergency OFF switch (Freeride 350 AUS) ....... 14 absorber ....................................................
x 36
6.11 Overview of indicator lamps ............................. 15 10.10 Adjusting the riding sag x.............................. 37
6.12 Speedometer .................................................. 15 10.11 Checking the basic setting of the fork ............... 37
6.12.1 Overview .................................................... 15 10.12 Adjusting the compression damping of the
6.12.2 Activation and test ...................................... 15 fork ............................................................... 38
6.12.3 Tripmaster switch ....................................... 15 10.13 Adjusting the rebound damping of the fork ........ 38
6.12.4 Setting kilometers or miles .......................... 16 10.14 Handlebar position.......................................... 38
6.12.5 Adjusting the speedometer functions ............ 16 10.15 Adjusting the handlebar position x ................. 39
6.12.6 Setting the clock ........................................ 17 11 SERVICE WORK ON THE CHASSIS.............................. 40
6.12.7 Querying lap time ....................................... 17 11.1 Raising the motorcycle with the lift stand.......... 40
6.12.8 Display mode SPEED (speed)....................... 17 11.2 Removing the motorcycle from the lift stand...... 40
6.12.9 Display mode SPEED/H (operating hours)...... 18 11.3 Bleeding the fork legs...................................... 40
6.12.10 Display mode SPEED/CLK (clock)................. 18 11.4 Cleaning the dust boots of the fork legs............. 41
6.12.11 Display mode SPEED/LAP (lap time)............. 18 11.5 Removing the fork legs x ............................... 41
6.12.12 Display mode SPEED/ODO (odometer) .......... 19 11.6 Installing the fork legs x................................ 42
6.12.13 Display mode SPEED/TR1 (trip master 1)...... 19 11.7 Removing the fork protector x ........................ 42
6.12.14 Display mode SPEED/TR2 (trip master 2)...... 19 11.8 Installing the fork protector x......................... 43
6.12.15 Display mode SPEED/A1 (average speed 1) ... 19 11.9 Removing the lower triple clamp x .................. 43
6.12.16 Display mode SPEED/A2 (average speed 2) ... 20 11.10 Installing the lower triple clamp x .................. 44
6.12.17 Display mode SPEED/S1 (stop watch 1)........ 20 11.11 Checking the steering head bearing play............ 45
6.12.18 Display mode SPEED/S2 (stop watch 2)........ 20
TABLE OF CONTENTS 3

11.12 Adjusting the play of the steering head 13 WHEELS, TIRES ........................................................ 74
bearing .....................................................
x 46 13.1 Removing the front wheel x ........................... 74
11.13 Greasing the steering head bearing x .............. 46 13.2 Installing the front wheel x ............................ 74
11.14 Removing the shock absorber x ...................... 47 13.3 Removing the rear wheel x ............................. 75
11.15 Installing the shock absorber x....................... 47 13.4 Installing the rear wheel .............................. 75
x
11.16 Removing the front fender ............................... 47 13.5 Checking the tire condition .............................. 76
11.17 Installing the front fender ................................ 48 13.6 Checking the tire air pressure........................... 77
11.18 Folding the seat up ......................................... 48 13.7 Checking the spoke tension.............................. 77
11.19 Locking the seat ............................................. 48 14 ELECTRICAL SYSTEM ................................................ 78
11.20 Taking off the spoiler....................................... 48 14.1 Removing the battery .................................. 78
x
11.21 Mounting the spoiler ....................................... 49 14.2 Installing the battery x.................................. 78
11.22 Removing the air filter housing x .................... 49 14.3 Recharging the battery ................................ 79
x
11.23 Installing the air filter housing x..................... 50 14.4 Changing the main fuse ................................... 80
11.24 Removing the air filter x................................ 50 14.5 Changing the fuses of individual power
11.25 Installing the air filter .................................
x 51 consumers...................................................... 80
11.26 Cleaning the air filter and air filter 14.6 Removing the headlight mask with the
housing .....................................................
x 51 headlight........................................................ 82
11.27 Removing the main silencer ............................. 52 14.7 Refitting the headlight mask with the
11.28 Installing the main silencer.............................. 52 headlight........................................................ 82
11.29 Changing the glass fiber yarn filling of the 14.8 Changing the headlight bulb ............................ 83
main silencer .............................................
x 53 14.9 Changing the turn signal bulb .......................... 84
11.30 Removing the fuel tank x............................... 53 14.10 Checking the headlight setting ......................... 84
11.31 Installing the fuel tank ................................
x 55 14.11 Adjusting the headlight range........................... 84
11.32 Checking for chain dirt accumulation ................ 56 14.12 Changing the speedometer battery .................... 85
11.33 Cleaning the chain .......................................... 56 15 COOLING SYSTEM ..................................................... 86
11.34 Checking the chain tension .............................. 57 15.1 Cooling system ............................................... 86
11.35 Adjusting the chain tension.............................. 57 15.2 Checking the antifreeze and coolant level .......... 86
11.36 Checking the chain, rear sprocket, engine 15.3 Checking the coolant level ............................... 87
sprocket and chain guide ................................. 58 15.4 Draining the coolant x................................... 87
11.37 Adjusting the chain guide x ........................... 60 15.5 Refilling coolant ......................................... 88
x
11.38 Checking the frame ....................................
x 60 16 TUNING THE ENGINE................................................ 89
11.39 Checking the swingarm x ............................... 60 16.1 Checking the play in the throttle cable .............. 89
11.40 Checking the throttle cable routing ................... 61 16.2 Adjusting the play in the throttle cable x ......... 89
11.41 Checking the rubber grip ................................. 61 16.3 Adjusting the idle speed x ............................. 90
11.42 Additionally securing the rubber grip................. 61 16.4 Checking the basic position of the shift lever ..... 90
11.43 Adjusting the basic position of the clutch 16.5 Adjusting the basic position of the shift
lever .............................................................. 62 lever ......................................................... 90
x
11.44 Checking the fluid level of the hydraulic 17 SERVICE WORK ON THE ENGINE ............................... 91
clutch ............................................................ 62 17.1 Changing the fuel screen x ............................ 91
11.45 Correcting the fluid level of the hydraulic 17.2 Checking the engine oil level............................ 91
clutch ............................................................ 62
17.3 Changing the engine oil and oil filter, cleaning
11.46 Changing the hydraulic clutch fluid .............. x 62 the oil screen ............................................. 92
x
11.47 Removing the engine guard.............................. 63 17.4 Adding engine oil ............................................ 94
11.48 Installing the engine guard .............................. 64 18 CLEANING, CARE ...................................................... 95
12 BRAKE SYSTEM ........................................................ 65 18.1 Cleaning the motorcycle .................................. 95
12.1 Checking the free travel of the hand brake 18.2 Checks and maintenance steps for winter
lever .............................................................. 65 operation........................................................ 96
12.2 Adjusting the free travel of the handbrake 19 STORAGE .................................................................. 97
lever .............................................................. 65 19.1 Storage .......................................................... 97
12.3 Checking the brake discs ................................. 65 19.2 Preparing for use after storage.......................... 97
12.4 Checking the brake fluid level of the front 20 TROUBLESHOOTING ................................................. 98
brake ............................................................. 66
21 BLINK CODE ........................................................... 100
12.5 Adding front brake fluid ..............................
x 66
22 TECHNICAL DATA.................................................... 102
12.6 Checking the front brake linings ....................... 67
22.1 Engine ......................................................... 102
12.7 Changing the front brake linings x .................. 67
22.2 Engine tightening torques .............................. 102
12.8 Checking the free travel of foot brake lever ........ 69
22.3 Capacities .................................................... 104
12.9 Adjusting the basic position of the foot brake
22.3.1 Engine oil ................................................ 104
lever .........................................................
x 69
22.3.2 Coolant .................................................... 104
12.10 Checking the rear brake fluid level.................... 70
22.3.3 Fuel ........................................................ 104
12.11 Adding rear brake fluid x............................... 70
22.4 Chassis ........................................................ 104
12.12 Checking the rear brake linings ........................ 71
22.5 Electrical system........................................... 105
12.13 Changing the rear brake linings x ................... 71
22.6 Tires ............................................................ 105
TABLE OF CONTENTS 4

22.7 Fork............................................................. 105

22.8 Shock absorber ............................................. 106
22.9 Chassis tightening torques ............................. 106
23 SUBSTANCES ......................................................... 108
24 AUXILIARY SUBSTANCES ........................................ 110
25 STANDARDS ........................................................... 112
INDEX ............................................................................ 113
1 MEANS OF REPRESENTATION 5

1.1 Symbols used

The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).

Indicates an unexpected reaction (e.g. of a work step or a function).

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.

Indicates a page reference (more information is provided on the specified page).

1.2 Formats used

The typographical formats used in this document are explained below.
Specific name Identifies a proprietary name.

Name® Identifies a protected name.

Brand™ Identifies a brand available on the open market.

2 SAFETY ADVICE 6

2.1 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.
The motorcycle is designed for trial riding and difficult offroad terrain and not for motocross.

2.2 Safety advice

A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety
instructions are highlighted in the text and are referred to at the relevant passages.

Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If
they are missing, you or others may not recognize dangers and may therefore be injured.

2.3 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.

Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.

2.4 Tampering warning

Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:

1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device
or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate
purchaser or while it is in use, or
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases.
2 Removal or puncturing of any part of the intake system.
3 Lack of proper maintenance.
4 Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the
manufacturer.
2 SAFETY ADVICE 7

2.5 Safe operation

Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally
impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.

Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these
components to cool down before starting work on them.

Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmen-
tally compatible manner.
An appropriate driver's license is needed to ride the vehicle on public roads.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.

2.6 Protective clothing

Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always
wear protective clothing that is in good condition and meets the legal requirements.

In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.

2.7 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. E.g.: bearing puller (15112017000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.

2.8 Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcy-
cle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the
respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that
pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.

2.9 Owner's Manual

It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains
useful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to cus-
tomize the vehicle ideally for your own use and how you can protect yourself from injury.
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.
The Owner's Manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold.
3 IMPORTANT NOTES 8

3.1 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 record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage
resulting from manipulations and/or alterations to the vehicle.
Additional information on the guarantee or warranty and the procedures involved can be found in the service record.

3.2 Operating and auxiliary substances

Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.

Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.

3.3 Spare parts, accessories

For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them
installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise
you.

The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com

3.4 Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the engine and
chassis is properly carried out as described in the Owner's Manual. Incorrect adjustment and tuning of the engine and chassis can
lead to damage and breakage of components.
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can lead to considerably more rapid wear
of components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or
replace parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a
much longer service life for your motorcycle.

3.5 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to dis-
assemble the component to perform the activity in question. Please follow the instructions in the text.

3.6 Customer service

Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.

A list of authorized KTM dealers can be found on the KTM website.

International KTM Website: http://www.ktm.com
4 VIEW OF VEHICLE 9

4.1 View of vehicle, front left (example)

B01011-10

1 Speedometer
2 Clutch lever ( p. 13)
3 Filler cap
4 Seat
5 Seat release
6 Shock absorber compression adjustment
7 Shock absorber rebound adjustment
8 Side stand ( p. 23)
9 Battery
10 Shift lever ( p. 22)
11 Idle speed adjusting screw ( p. 22)
12 Steering lock ( p. 23)
4 VIEW OF VEHICLE 10

4.2 View of vehicle, rear right (example)

B01004-10

1 Kill switch ( p. 13)

1 Horn button ( p. 13)
1 Light switch ( p. 14)
1 Turn signal switch ( p. 14)
2 Electric starter button ( p. 14)
3 Throttle grip ( p. 13)
4 Hand brake lever ( p. 13)
5 Fork rebound adjustment
6 Fork compression adjustment
7 Foot brake lever ( p. 23)
8 Level viewer for brake fluid, rear
5 SERIAL NUMBERS 11

5.1 Chassis number

The chassis number 1 is stamped on the right side of the steering head.

B01005-10

5.2 Type label

The type label 1 is fixed to the frame at the front right.

B01124-10

5.3 Key number

The key number 1 for the steering lock is stamped onto the key connector.

500125-10

5.4 Engine number

The engine number 1 is stamped on the left side of the engine under the engine
sprocket.

B01006-10

5.5 Fork part number

The fork part number 1 is stamped on the inner side of the axle clamp.

B01007-10
5 SERIAL NUMBERS 12

5.6 Shock absorber part number

The shock absorber part number 1 is stamped on the top of the shock absorber above
the adjusting ring on the engine side.

B01132-10
6 CONTROLS 13

6.1 Clutch lever

The clutch lever 1 is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.

B01012-10

6.2 Hand brake lever

Hand brake lever 1 is located on the right side of the handlebar.
The front brake is engaged using the hand brake lever.

B01013-10

6.3 Throttle grip

The throttle grip 1 is fitted on the right side of the handlebar.

B01014-10

6.4 Kill switch

Kill switch 1 is fitted on the left side of the handlebar.
Possible states
• Kill switch in basic position – In this position, the ignition circuit is closed and
the engine can be started.
• Kill switch pressed – In this position, the ignition circuit is interrupted, a run-
ning engine stops, and a non-running engine will not start.

B01015-10

6.5 Horn button

The horn button 1 is fitted on the left side of the handlebar.
Possible states
• Horn button in neutral position
• Horn button pressed – The horn is operated in this position.

B01015-11
6 CONTROLS 14

6.6 Light switch

The light switch 1 is fitted on the left side of the handlebar.
Possible states
Light off – Light switch is turned to the right. In this position, the light
is switched off.

Low beam on – Light switch is in the central position. In this position,

the low beam and tail light are switched on.

High beam on – Light switch is turned to the left. In this position, the
high beam and the tail light are switched on.
B01015-12

6.7 Electric starter button (Freeride 350 EU)

Electric starter button 1 is fitted on the right side of the handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button pressed – In this position, the electric starter is actuated.

B01017-10

6.8 Electric starter button (Freeride 350 AUS)

Electric starter button 1 is fitted on the right side of the handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button pressed – In this position, the electric starter is actuated.

B01240-11

6.9 Turn signal switch

Turn signal switch 1 is fitted on the left side of the handlebar.
Possible states
Turn signal light off – Turn signal switch is in the central position.
Turn signal light, left, on – Turn signal switch is turned to the left.

Turn signal light, right, on – Turn signal switch is turned to the right.

B01016-10

6.10 Emergency OFF switch (Freeride 350 AUS)

The emergency OFF switch 1 is fitted on the right side of the handlebar.
Possible states
Ignition off – In this position, the ignition circuit is interrupted, a run-
ning engine stops, and a non-running engine will not start.

Ignition on – In this position, the ignition circuit is closed and the

engine can be started.

B01240-10
6 CONTROLS 15

6.11 Overview of indicator lamps

Possible states
The high beam indicator lamp lights up blue – The high beam is
switched on.

Turn signal indicator light flashes green – The turn signal is switched
on.

FI warning lamp (MIL) lights up/flashes orange – The OBD (on-board

diagnosis) has detected an emission- or safety-critical error.

The fuel level warning lamp lights up orange – The fuel level has
reached the reserve mark.

B01018-01

6.12 Speedometer
6.12.1 Overview
– Press the button to change the display mode or change to one of the Setup
menus.
– 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.

400312-01

6.12.2 Activation and test

Activating the speedometer
The speedometer is activated when one of the buttons is pressed or an impulse comes
from the wheel speed sensor.
Display test
To enable you to check that the display is functioning properly, all display segments
light up briefly.

400313-01

WS (wheel size)
After the display function check, the wheel size WS is displayed briefly.

Info
The number 2205 equals the circumference of the 21" front wheel with stan-
dard tires.

The display then changes to the last selected mode.

400314-01

6.12.3 Tripmaster switch

You can use the trip master switch to control the functions of the speedometer from the handlebar.
6 CONTROLS 16

Info
The trip master is an optional accessory.

6.12.4 Setting kilometers or miles

Info
If you change the unit of measure, the ODO value is retained and converted accordingly.
The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed.

Condition
The motorcycle is stationary.
– Press the button briefly and repeatedly until H appears at the bottom right of the
display.
– Press the button for 3 - 5 seconds.
The Setup menu is displayed and the active functions are shown.
– Press the button repeatedly until the Km/h/Mph display flashes.
Adjusting Km/h
– Press the button .
Adjusting Mph
400329-01 – Press the button .
– Press the button for 3 - 5 seconds.
The settings are stored and the Setup menu is closed.

Info
If no button is pressed for 20 seconds, or if no impulse comes from the
wheel speed sensor, the settings are automatically saved and the Setup
menu is closed.

6.12.5 Adjusting the speedometer functions

Info
When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.

Condition
The motorcycle is stationary.
– Press the button briefly and repeatedly until H appears at the bottom right of the
display.
– Press the button for 3 - 5 seconds.
The Setup menu is displayed and the activated functions are shown.
– Change to the desired function by pressing the button briefly.
The selected function flashes.
Activating a function
– Press the button .
400318-01 The symbol remains on the screen and the display changes to the next
function.
Deactivating the function
– Press the button .
The symbol on the screen goes out and the display changes to the next
function.
– All desired functions are activated or deactivated accordingly.
– Press the button for 3 - 5 seconds.
The settings are stored and the Setup menu is closed.

Info
If no button is pressed for 20 seconds, or if no impulse comes from the
wheel speed sensor, the settings are automatically saved and the Setup
menu is closed.
6 CONTROLS 17

6.12.6 Setting the clock

Condition
The motorcycle is stationary.
– Press the button briefly and repeatedly until CLK appears at the bottom right of
the display.
– Press the button for 3 - 5 seconds.
The hour display flashes.
– Set the hour display with the button and/or button .
– Press the button briefly.
The next segment of the display flashes and can be set.
– You can set the following segments in the same way as the hours by pressing
400330-01 the button and the button .

Info
The seconds can only be set to zero.

– Press the button for 3 - 5 seconds.

The settings are stored and the Setup menu is closed.

Info
If no button is pressed for 20 seconds, or if no impulse comes from the
wheel speed sensor, the settings are automatically saved and the Setup
menu is closed.

6.12.7 Querying lap time

Info
This function can be called up only if lap times are measured.

Condition
The motorcycle is stationary.
– Press the button briefly and repeatedly until LAP appears at the bottom right of
the display.
– Press the button briefly.
LAP 1 appears on the left side of the display.
– Laps 1-10 can be displayed by pressing the button .
– The button has no function.
– Press the button briefly.
Next display mode
400321-01
Info
If an impulse is received from the wheel speed sensor, the left side of the
display changes back to the SPEED mode.

6.12.8 Display mode SPEED (speed)

– Press the button briefly and repeatedly 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
Making the setting according to the country.
When an impulse comes from the front wheel, the left side of the speedometer
display changes to the SPEED mode and the current speed is shown.
400317-02
6 CONTROLS 18

6.12.9 Display mode SPEED/H (operating hours)

Condition
• The motorcycle is stationary.
– Press the button briefly and repeatedly until H appears at the bottom right of the
display.
In display mode H, the operating hours of the engine are displayed.
The operating hours counter stores the total traveling time.

Info
The operating hour counter is necessary for ensuring that service work is carried
400316-01 out at the right intervals.
If the speedometer is in H display mode at the start of the journey, it automati-
cally changes to the ODO display mode.
The H display mode is suppressed during the journey.

Press the button . No function

Press the button . No function
Press the button The display changes to the Setup menu of the speedometer
for 3 - 5 seconds. functions.
Press the button Next display mode
briefly.

6.12.10 Display mode SPEED/CLK (clock)

– Press the button briefly and repeatedly until CLK appears at the bottom right of
the display.
The time is displayed in CLK display mode.
Press the button . No function
Press the button . No function
Press the button The display changes to the Setup menu of the clock.
for 3 - 5 seconds.
Press the button Next display mode
400319-01 briefly.

6.12.11 Display mode SPEED/LAP (lap time)

– Press the button briefly and repeatedly until LAP appears at the bottom right of
the display.
In the LAP display mode, up to 10 lap times can be timed with the stop watch.

Info
If the lap time continues after you press the button , 9 memory locations are
already occupied.
Lap 10 must be timed with the button .

400320-01 Press the button . Starts or stops the clock.

Press the button . Stops the current lap time and saves it, and the stop watch
starts the next lap.
Press the button The stop watch and the lap time are reset.
for 3 - 5 seconds.
Press the button Next display mode
briefly.
6 CONTROLS 19

6.12.12 Display mode SPEED/ODO (odometer)

– Press the button briefly and repeatedly until ODO appears at the bottom right of
the display.
The total distance traveled is displayed in the ODO display mode.
Press the button . No function
Press the button . No function
Press the button –
for 3 - 5 seconds.
Press the button Next display mode
400317-01 briefly.

6.12.13 Display mode SPEED/TR1 (trip master 1)

– Press the button briefly and repeatedly until TR1 appears at the top right of the
display.
TR1 (trip master 1) runs constantly and counts to 999.9.
You can use it to measure trips or the distance between refueling stops.
TR1 is coupled with A1 (average speed 1) and S1 (stop watch 1).

Info
If 999.9 is exceeded, the values of TR1, A1 and S1 are automatically reset to
0.0.
400323-01
Press the button . No function
Press the button . No function
Press the button The TR1, A1 and S1 displays are reset to 0.0.
for 3 - 5 seconds.
Press the button Next display mode
briefly.

6.12.14 Display mode SPEED/TR2 (trip master 2)

– Press the button briefly and repeatedly until TR2 appears at the top right of the
display.
TR2 (trip master 2) runs constantly and counts up to 999.9.
The displayed value can be set manually with the button and the button . This is a
very practical function when riding using the road book.

Info
The TR2 value can also be corrected manually during the journey with the but-
ton and the button .
400324-01 If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0.

Press the button . Increases value of TR2.

Press the button . Reduces value of TR2.
Press the button Deletes value of TR2.
for 3 - 5 seconds.
Press the button Next display mode
briefly.

6.12.15 Display mode SPEED/A1 (average speed 1)

– Press the button briefly and repeatedly until A1 appears at the top right of the
display.
A1 (average speed 1) shows the average speed calculated on the basis of TR1 (trip mas-
ter 1) and S1 (stop watch 1).
The calculation of this value is activated by the first impulse of the wheel speed sensor
and ends 3 seconds after the last impulse.
Press the button . No function
Press the button . No function
400325-01 Press the button The TR1, A1 and S1 displays are reset to 0.0.
for 3 - 5 seconds.
6 CONTROLS 20

Press the button Next display mode

briefly.

6.12.16 Display mode SPEED/A2 (average speed 2)

– Press the button briefly and repeatedly until A2 appears at the top right of the
display.
A2 (average speed 2) shows the average speed on the basis of the current speed if the
stop watch S2 (stop watch 2) is running.

Info
The displayed value can differ from the actual average speed if S2 is not
stopped after the ride.

400326-01 Press the button . No function

Press the button . No function
Press the button –
for 3 - 5 seconds.
Press the button Next display mode
briefly.

6.12.17 Display mode SPEED/S1 (stop watch 1)

– Press the button briefly and repeatedly until S1 appears at the top right of the
display.
S1 (stop watch 1) displays the journey time on the basis of TR1 and continues when an
impulse is received from the wheel speed sensor.
The calculation of this value starts with the first impulse of the wheel speed sensor and
ends 3 seconds after the last impulse.
Press the button . No function
Press the button . No function
400327-01 Press the button Displays of TR1, A1 and S1 are reset to 0.0.
for 3 - 5 seconds.
Press the button Next display mode
briefly.

6.12.18 Display mode SPEED/S2 (stop watch 2)

– Press the button briefly and repeatedly until S2 appears at the top right of the
display.
S2 (stop watch 2) is a manual stop watch.
If S2 is running in the background, the S2 display flashes in the speedometer display.
Press the button . Starts or stops S2.
Press the button . No function
Press the button Displays of S2 and A2 are reset to 0.0.
for 3 - 5 seconds.
400328-01 Press the button Next display mode
briefly.

6.12.19 Table of functions

Display Press the button . Press the button . Press the button for 3 - Press the button
5 seconds. briefly.
Display mode SPEED/H No function No function The display changes to Next display mode
(operating hours) the Setup menu of the
speedometer functions.
Display mode SPEED/CLK No function No function The display changes to Next display mode
(clock) the Setup menu of the
clock.
6 CONTROLS 21

Display Press the button . Press the button . Press the button for 3 - Press the button
5 seconds. briefly.
Display mode SPEED/LAP Starts or stops the Stops the current lap The stop watch and the Next display mode
(lap time) clock. time and saves it, and lap time are reset.
the stop watch starts
the next lap.
Display mode No function No function – Next display mode
SPEED/ODO (odometer)
Display mode SPEED/TR1 No function No function The TR1, A1 and S1 dis- Next display mode
(trip master 1) plays are reset to 0.0.
Display mode SPEED/TR2 Increases value of TR2. Reduces value of TR2. Deletes value of TR2. Next display mode
(trip master 2)
Display mode SPEED/A1 No function No function The TR1, A1 and S1 dis- Next display mode
(average speed 1) plays are reset to 0.0.
Display mode SPEED/A2 No function No function – Next display mode
(average speed 2)
Display mode SPEED/S1 No function No function Displays of TR1, A1 and Next display mode
(stop watch 1) S1 are reset to 0.0.
Display mode SPEED/S2 Starts or stops S2. No function Displays of S2 and A2 Next display mode
(stop watch 2) are reset to 0.0.

6.12.20 Table of conditions and menu activation

Display The motorcycle is Menu can be acti-
stationary. vated
Display mode SPEED/H (operating hours) •
Display mode SPEED/CLK (clock) •
Display mode SPEED/LAP (lap time) •
Display mode SPEED/TR1 (trip master 1) •
Display mode SPEED/TR2 (trip master 2) •
Display mode SPEED/A1 (average speed 1) •
Display mode SPEED/A2 (average speed 2) •
Display mode SPEED/S1 (stop watch 1) •
Display mode SPEED/S2 (stop watch 2) •

6.13 Opening the filler cap

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.
– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.

Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.

Preparatory work
– Fold the seat up. ( p. 48)
6 CONTROLS 22

Main work
– Press release button 1, turn the filler cap counterclockwise, and lift it free.

B01019-10

6.14 Closing the filler cap

Main work
– Replace the filler cap and turn clockwise until the release button 1 locks in place.

Info
Run the fuel tank breather hose 2 without kinks.

B01020-10

Finishing work
– Lock the seat. ( p. 48)

6.15 Idle speed adjusting screw

Idle speed adjusting screw 1 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 – Idle speed adjusting screw is pulled out all the way.
• RPM increase deactivated – Idle speed adjusting screw is pushed in all the way.

B01241-10

6.16 Shift lever

Shift lever 1 is mounted on the left side of the engine.

B01023-11
6 CONTROLS 23

The gear positions can be seen in the photograph.

The neutral or idle position is between the first and second gears.

B01023-10

6.17 Foot brake lever

Foot brake lever 1 is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.

B01024-10

6.18 Side stand

The side stand 1 is on the left side of the vehicle.

B01025-10

The side stand is used to park the motorcycle.

Info
When you are riding, side stand 1 must be folded up and secured with rubber
band 2.

B01026-10

6.19 Steering lock

Steering lock 1 is fitted on the left side of the steering head.
The steering lock is used to lock the steering. Steering, and therefore riding, is no
longer possible.

B01027-10
6 CONTROLS 24

6.20 Locking the steering

Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.

– Park the vehicle.

– Turn the handlebar as far as possible to the right.
– Insert the key in the steering lock, turn it to the left, press it in, and turn it to the
right. Remove the key.
Steering is no longer possible.

Info
Never leave the key in the steering lock.

400732-01

6.21 Unlocking the steering

– Insert the key in the steering lock, 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.

400731-01
7 PREPARING FOR USE 25

7.1 Advice on first use

Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally
impaired.
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always
wear protective clothing that is in good condition and meets the legal requirements.
Warning
Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidents Critical riding behavior due to inappropriate riding.
– Adapt your riding speed to the road conditions and your riding ability.
Warning
Danger of accidents Accident risk caused by presence of a passenger.
– Your vehicle is not designed to carry passengers. Do not ride with a passenger.
Warning
Danger of accidents Failure of brake system.
– If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take
your foot off the foot brake lever when you are not braking.
Warning
Danger of accidents Unstable riding behavior.
– Do not exceed the maximum permissible weight and axle loads.

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.

Info
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 record at vehicle handover.
– Before your first trip, read the entire operating instructions carefully.
– Get to know the controls.
– Adjust the basic position of the clutch lever. ( p. 62)
– Adjust the free travel of the handbrake lever. ( p. 65)
– Adjust the basic position of the foot brake lever. x( p. 69)
– Adjust the basic position of the shift lever. x( p. 90)
– Get used to handling the motorcycle on a suitable piece of land before making a longer trip.

Info
Offroad, you should be accompanied by another person on another machine so that you can help each other.

– Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.
– Do not make any offroad trips that over-stress your ability and experience.
– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
– If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis-
tribution between the front and rear wheels.
7 PREPARING FOR USE 26

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.)
– Run the engine in. ( p. 26)

7.2 Running in the engine

– During the running-in phase, do not exceed the specified engine speed and engine performance.
Guideline
Maximum engine speed
During the first operating hour 7,000 rpm
Maximum engine performance
During the first 3 operating hours ≤ 75 %
– Avoid fully opening the throttle!
8 RIDING INSTRUCTIONS 27

8.1 Checks and maintenance work when preparing for use

Info
Before riding the vehicle, always check its condition and operating safety.
The vehicle must be in perfect technical condition when used.

– Check the engine oil level. ( p. 91)

– Check the electrical system.
– Check the brake fluid level of the front brake. ( p. 66)
– Check the rear brake fluid level. ( p. 70)
– Check the front brake linings. ( p. 67)
– Check the rear brake linings. ( p. 71)
– Check that the brake system is functioning properly.
– Check the coolant level. ( p. 87)
– Check for chain dirt accumulation. ( p. 56)
– Check the chain, rear sprocket, engine sprocket and chain guide. ( p. 58)
– Check the chain tension. ( p. 57)
– Check the tire condition. ( p. 76)
– Check the tire air pressure. ( p. 77)
– Check the spoke tension. ( p. 77)
– Clean the dust boots of the fork legs. ( p. 41)
– Bleed the fork legs. ( p. 40)
– Check the air filter.
– Check the settings of all controls and ensure that they can be operated smoothly.
– Check all screws, nuts, and hose clamps regularly for tightness.
– Check the fuel supply.

8.2 Starting

Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.

Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
– Always warm up the engine at low engine speeds.

– Raise the motorcycle off of the stand and secure the stand with the rubber band 1.
– Shift gear to neutral.
(Freeride 350 AUS)
– Press the emergency OFF switch into the position .
Condition
Ambient temperature: < 20 °C (< 68 °F)
– Pull the idle speed adjusting screw all the way out.

B01026-11

(Freeride 350 EU)

– Press the electric starter button .
(Freeride 350 AUS)
– Press the electric starter button .

Info
Press the electric starter button for at most 5 seconds. Wait for a least 5
seconds before trying again.
FI warning lamp lights up briefly as a functional control when starting.
400733-01
8 RIDING INSTRUCTIONS 28

8.3 Starting off

Info
If your bike has lights, switch them on before riding. You will then be seen earlier by other motorists.
When you are riding, the side stand must be folded up and secured with the rubber band.

– Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.

8.4 Shifting, riding

Warning
Danger of accidents If you change down at high engine speed, the rear wheel can lock up.
– 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.

– When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simulta-
neously pulling the clutch lever, shift into the next gear, release the clutch, and open the throttle.
– After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This will barely reduce the
speed but fuel consumption will be considerably lower.
– Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel consumption.
– To shift down, brake and close the throttle at the same time.
– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and open the throttle or shift again.
– Switch off the engine if you expect to be standing for a long time.
Guideline
≥ 2 min
– Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine, and the cooling system.
– Ride with a lower engine speed instead of with a high engine speed and a slipping clutch.

8.5 Applying the brakes

Warning
Danger of accidents If you brake too hard, the wheels can lock.
– Adapt your braking to the traffic situation and the road conditions.
Warning
Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake.
– Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

Warning
Danger of accidents Reduced braking efficiency due to a wet or dirty brake system.
– Clean or dry a dirty or wet brake system by riding and braking gently.

– On sandy, wet or slippery surfaces, use the rear brake.

– 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.
8 RIDING INSTRUCTIONS 29

8.6 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.
– Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these
components to cool down before starting work on them.
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from
being run. Always let the vehicle cool first.

Note
Material damage Damage and destruction of components by excessive load.
– The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side
stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over.

– Brake the motorcycle.

– Shift gear to neutral.
– Press and hold the kill switch while the engine is idling until the engine stops.
– Park the motorcycle on firm ground.

8.7 Transport

Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.

Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from
being run. Always let the vehicle cool first.

– Switch off the engine.

– Use tension belts or other suitable devices to secure the motorcycle against acci-
dents or falling over.

401475-01
8 RIDING INSTRUCTIONS 30

8.8 Refueling

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.
– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
Note
Material damage Premature clogging of the fuel filter.
– 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.

Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.

Preparatory work
– Switch off the engine.
– Fold the seat up. ( p. 48)
– Open the filler cap. ( p. 21)
Main work
– Fill the fuel tank with fuel up to measurement A.
Guideline
Measurement of A 30 mm (1.18 in)

Total fuel tank 4.8 l Super unleaded (ROZ 95/RON 95/PON

capacity, approx. (1.27 US gal) 91) ( p. 109)

401474-10

Finishing work
– Close the filler cap. ( p. 22)
– Lock the seat. ( p. 48)
9 SERVICE SCHEDULE 31

9.1 Service schedule

S1N S20A S40A
Read out the fault memory using the KTM diagnostics tool. x • • •
Check that the electrical equipment is functioning properly. • • •
Check and charge the battery. x • •
Change the engine oil and oil filter, clean the oil screen. x( p. 92) • • •
Check the front brake linings. ( p. 67) • •
Check the rear brake linings. ( p. 71) • •
Check the brake discs. ( p. 65) • •
Check the brake lines for damage and leakage. • •
Check the rear brake fluid level. ( p. 70) • •
Check the free travel of the foot brake lever. ( p. 69) • •
Check the frame and swingarm. x • •
Check the swingarm bearing. x •
Check the heim joints at the top and bottom of the shock absorber. x • •
Check the tire condition. ( p. 76) • • •
Check the tire air pressure. ( p. 77) • • •
Check the wheel bearing for play. x • •
Check the wheel hubs. x • •
Check the rim run-out. x • • •
Check the spoke tension. ( p. 77) • • •
Check the chain, rear sprocket, engine sprocket and chain guide. ( p. 58) • •
Check the chain tension. ( p. 57) • • •
Grease all moving parts (e.g., side stand, hand lever, chain, ...) and check for smooth operation. x • •
Check the fluid level of the hydraulic clutch. ( p. 62) • •
Check the brake fluid level of the front brake. ( p. 66) • •
Check the free travel of the hand brake lever. ( p. 65) • •
Check the steering head bearing play. ( p. 45) • • •
Check the valve clearance. x • •
Check the clutch. x •
Change the shaft seal rings of the water pump. x •
Change the fuel screen. x( p. 91) • • •
Check the fuel pressure. x • •
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and incorrect
• • •
routing. x
Check the antifreeze and coolant level. ( p. 86) • • •
Check the cables for damage and routing without sharp bends. x • •
Check that the cables are undamaged, routed without sharp bends and set correctly. • • •
Clean the air filter and air filter box. x • •
Change the glass fiber yarn filling of the main silencer. x( p. 53) •
Check the screws and nuts for tightness. x • • •
Check the headlight setting. ( p. 84) • • •
Check idle. x • • •
Final check: Check the vehicle for roadworthiness and take a test ride. • • •
Read out the fault memory using the KTM diagnostics tool after a test ride. x • • •
Make the service entry in KTM DEALER.NET and in the service record. x • • •
S1N: Once after 1 operating hour
S20A: Every 20 operating hours
S40A: Every 40 operating hours
9 SERVICE SCHEDULE 32

9.2 Service work (as additional order)

S20N S60A S120A J1A
Change the front brake fluid.x •
Change the rear brake fluid. x •
Change the foot brake cylinder seals. x • •
Change the hydraulic clutch fluid. x ( p. 62) •
Grease the steering head bearing. x ( p. 46) •
Perform a fork service. x • • •
Service the shock absorber. x • •
Change the spark plug and spark plug connector. x •
Change the piston. x •
Check/measure the cylinder. x •
Check the cylinder head. x •
Change the valves, valve springs and valve spring seats. x •
Check the camshaft and cam lever. x •
Change the connecting rod, conrod bearing and crank pin. x •
Check the transmission and shift mechanism. x •
Check the oil pressure regulator valve. x •
Change the suction pump. x •
Check the pressure pump and lubrication system. x •
Replace the timing chain. x •
Check the timing assembly. x •
Change all engine bearings. x •
S20N: Once after 20 operating hours
S60A: Every 60 operating hours
S120A: Every 120 operating hours
J1A: Annually
10 TUNING THE CHASSIS 33

10.1 Checking the basic chassis setting with the rider's weight

Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.

– 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… 85 kg (165… 187 lb.)
– If the rider's weight is above or below this range, the basic setting of the suspen-
sion components must be adjusted accordingly.
– Small weight differences can be compensated by adjusting the spring preload, but
in the case of large weight differences, the springs must be replaced.

401030-01

10.2 Compression damping of the shock absorber

The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.
High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.
The high-speed setting, for example, has an effect on the landing after a jump: the rear wheel suspension compresses more quickly.
The low-speed setting, for example, has an effect when riding over long ground swells: the rear wheel suspension compresses more
slowly.
These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, changes in
the high-speed range affect the compression damping in the low-speed range and vice versa.

10.3 Adjusting the low-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 low-speed setting can be seen during the slow to normal compression of the shock absorber.

– Turn adjusting screw 1 clockwise with a screwdriver up to the last perceptible

click.

Info
Do not loosen nut 2!

– Turn back counterclockwise by the number of clicks corresponding to the shock

absorber type.
Guideline
B01028-10 Compression damping, low-speed
Comfort 20 clicks
Standard 15 clicks
Sport 5 clicks
10 TUNING THE CHASSIS 34

Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.

10.4 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.

Preparatory work
– Raise the motorcycle with the lift stand. ( p. 40)
– Fold the seat up. ( p. 48)
– Remove the shock absorber. x( p. 47)
Main work
– Turn adjusting screw 1 all the way clockwise with a socket wrench.

Info
Do not loosen nut 2!

– Turn back counterclockwise by the number of turns corresponding to the shock

absorber type.
Guideline
B01031-10 Compression damping, high-speed
Comfort 2.5 turns
Standard 2 turns
Sport 1 turn

Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.

Finishing work
– Install the shock absorber. x( p. 47)
– Lock the seat. ( p. 48)
– Remove the motorcycle from the lift stand. ( p. 40)

10.5 Adjusting the rebound 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.)

– Turn adjusting screw 1 clockwise up to the last perceptible click.

– Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
B01032-10
10 TUNING THE CHASSIS 35

Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.

10.6 Measuring rear wheel sag unloaded

Preparatory work
– Raise the motorcycle with the lift stand. ( p. 40)
Main work
– Measure the distance – as vertical as possible – between the rear axle and a fixed
point, for example, a mark on the side cover.
– Note down the value as dimension A.

400988-10

Finishing work
– Remove the motorcycle from the lift stand. ( p. 40)

10.7 Checking the static sag of the shock absorber

– Measure distance A of rear wheel unloaded. ( p. 35)
– Hold the motorcycle upright with the aid of an assistant.
– Measure the distance between the rear axle and the fixed point again.
– Note down the value as dimension B.

Info
The static sag is the difference between measurements A and B.

– Check the static sag.

Static sag 15 mm (0.59 in)
» If the static sag is less or more than the specified value:
– Adjust the spring preload of the shock absorber. x( p. 36)

400989-10
10 TUNING THE CHASSIS 36

10.8 Checking the riding sag of the shock absorber

– Measure distance A of rear wheel unloaded. ( p. 35)
– With another person holding the motorcycle, the rider, wearing full protective cloth-
ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up
and down a few times.
The rear wheel suspension levels out.
– Another person now measures the distance between the rear axle and a fixed point.
– Note down the value as dimension C.

Info
The riding sag is the difference between measurements A and C.

– Check the riding sag.

Riding sag 75 mm (2.95 in)
» If the riding sag differs from the specified measurement:
– Adjust the riding sag. x( p. 37)

400990-10

10.9 Adjusting the spring preload of the shock absorber x

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.

Preparatory work
– Raise the motorcycle with the lift stand. ( p. 40)
– Fold the seat up. ( p. 48)
– Remove the shock absorber. x( p. 47)
– After removing the shock absorber, clean it thoroughly.
Main work
– Loosen screw 1.
– Turn adjusting ring 2 until the spring is no longer under tension.
Hook wrench (T106S)
– Measure the overall spring length while the spring is not under tension.
– Tighten the spring by turning adjusting ring 2 to measurement A.
Guideline
Spring preload
Comfort 10 mm (0.39 in)
Standard 10 mm (0.39 in)
Sport 10 mm (0.39 in)

Info
Depending on the static sag and/or the riding sag, it may be necessary to
increase or decrease the spring preload.

– Tighten screw 1.
401026-10 Guideline
Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft)
10 TUNING THE CHASSIS 37

Finishing work
– Install the shock absorber. x( p. 47)
– Lock the seat. ( p. 48)
– Remove the motorcycle from the lift stand. ( p. 40)

10.10 Adjusting the riding sag x

Preparatory work
– Raise the motorcycle with the lift stand. ( p. 40)
– Fold the seat up. ( p. 48)
– Remove the shock absorber. x( p. 47)
– After removing the shock absorber, clean it thoroughly.
Main work
– Choose and mount a suitable spring.
Guideline
Spring rate
Weight of rider: 65… 75 kg (143… 58 N/mm (331 lb/in)
165 lb.)
Weight of rider: 75… 85 kg (165… 62 N/mm (354 lb/in)
187 lb.)
B00292-10 Weight of rider: 85… 95 kg (187… 66 N/mm (377 lb/in)
209 lb.)

Info
The spring rate is shown on the outside of the spring.
Smaller weight differences can be compensated by changing the spring
preload.

Finishing work
– Install the shock absorber. x( p. 47)
– Lock the seat. ( p. 48)
– Remove the motorcycle from the lift stand. ( p. 40)
– Check the static sag of the shock absorber. ( p. 35)
– Check the riding sag of the shock absorber. ( p. 36)
– Adjust the rebound damping of the shock absorber. ( p. 34)

10.11 Checking the basic setting of the fork

Info
For various reasons, no exact riding sag can be determined for the forks.

– As with the shock absorber, smaller differences in the rider's weight can be com-
pensated by the spring preload.
– However, if the fork is often overloaded (hard end stop on compression), harder
springs must be fit to avoid damage to the fork and frame.

401000-01
10 TUNING THE CHASSIS 38

10.12 Adjusting the compression damping of the fork

Info
The hydraulic compression damping determines the fork suspension behavior.

– Remove protection caps 1.

– Turn adjusting screws 2 clockwise all the way.

Info
Adjusting screws 2 are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.

– Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
B01033-10 Compression damping
Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks

Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.

– Mount protection covers 1.

10.13 Adjusting the rebound damping of the fork

Info
The hydraulic rebound damping determines the fork suspension behavior.

– Turn adjusting screws 1 clockwise all the way.

Info
Adjusting screws 1 are located at the top end of the fork legs.
Make the same adjustment on both fork legs.

– Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
B01034-10 Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks

Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.

10.14 Handlebar position

On the upper triple clamp, there are two holes at a distance of A to each other.
Hole distance A 15 mm (0.59 in)
The holes on the handlebar supports are placed at a distance of B from the center.
Hole distance B 3.5 mm (0.138 in)
0 The handlebar supports can be mounted in four different positions.

B01035-10
10 TUNING THE CHASSIS 39

10.15 Adjusting the handlebar position x

Warning
Danger of accidents Handlebar breakage.
– If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle-
bar.

– Remove the four screws 1. Remove the handlebar clamp. Remove the handlebar
and lay it to one side.
0
Info
Protect the motorcycle and its attachments against damage by covering
them.
Do not bend the cables and lines.

– Remove the two screws 2. Remove the handlebar supports.

B01036-10
– Place the handlebar supports in the required position. Fit and tighten the two
screws 2.
Guideline
Screw, handlebar support M10 40 Nm Loctite® 243™
(29.5 lbf ft)

Info
Position the left and right handlebar supports evenly.

– Position the handlebar.

Info
Make sure cables and wiring are positioned correctly.

– Position the handlebar clamps. Fit and evenly tighten the four screws 1.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)

Info
Make sure the gap width is even.
11 SERVICE WORK ON THE CHASSIS 40

11.1 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 (54829055000)
The wheels must no longer touch the ground.
– Secure the motorcycle against falling over.

B01029-10

11.2 Removing the motorcycle from 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.

– Remove the motorcycle from the lift stand.

– Remove the lift stand.
– To park the motorcycle, press side stand 1 to the ground with your foot and lean
the motorcycle on it.

Info
When you are riding, the side stand must be folded up and secured with the
rubber band.

B01025-10

11.3 Bleeding the fork legs

Preparatory work
– Raise the motorcycle with the lift stand. ( p. 40)
Main work
– Remove bleeder screws 1 briefly.
Any excess pressure escapes from the interior of the fork.
– Mount and tighten bleeder screws.

B01037-10

Finishing work
– Remove the motorcycle from the lift stand. ( p. 40)
11 SERVICE WORK ON THE CHASSIS 41

11.4 Cleaning the dust boots of the fork legs

Preparatory work
– Raise the motorcycle with the lift stand. ( p. 40)
Main work
– Push dust boots 1 of both fork legs downward.

Info
The dust boots remove dust and coarse dirt particles from the inside fork
tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not
removed, the shaft seal rings behind can start to leak.

Warning
B01038-10 Danger of accidents Reduced braking efficiency due to oil or grease on the
brake discs.
– Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.

– Clean and oil the dust boots and inner fork tube of both fork legs.
Universal oil spray ( p. 111)
– Press the dust boots back into their normal position.
– Remove excess oil.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 40)

11.5 Removing the fork legs x

Preparatory work
– Remove the headlight mask with the headlight. ( p. 82)
– Raise the motorcycle with the lift stand. ( p. 40)
– Remove the front wheel. x( p. 74)
Main work
– Remove screws 1 and take off the clamp.
– Remove cable binder 2.
– Remove screws 3 and take off the brake caliper.
– Allow the brake caliper and brake line to hang tension-free to the side.

B01105-10

– Release screws 4. Take out the left fork leg.

– Release screws 5. Take out the right fork leg.

B01054-10
11 SERVICE WORK ON THE CHASSIS 42

11.6 Installing the fork legs x

Main work
– Position the fork legs.

Info
The lowest milled groove in the fork leg must be flush with the top edge of
the upper triple clamp.
Position bleeder screws 1 toward the front.

B01055-10

– Tighten screws 2.
Guideline
Screw, top triple clamp M8 22 Nm
(16.2 lbf ft)
– Tighten screws 3.
Guideline
Screw, bottom triple clamp M8 18 Nm
(13.3 lbf ft)
B01054-11

– Position brake caliper, and mount and tighten screws 4.

Guideline
Screw, front brake caliper M8 25 Nm Loctite® 243™
(18.4 lbf ft)
– Mount cable binder 5.
– Position the brake line, wiring harness, and clamp. Mount and tighten screws 6.

B01105-11

Finishing work
– Install the front wheel. x( p. 74)
– Refit the headlight mask with the headlight. ( p. 82)
– Check the headlight setting. ( p. 84)

11.7 Removing the fork protector x

– Remove screws 1. Take off the clamp.
– Remove screws 2 on the left fork leg. Take off the fork protector.

B01039-10

– Remove screws 3 on the right fork leg. Take off the fork protector.

B01040-10
11 SERVICE WORK ON THE CHASSIS 43

11.8 Installing the fork protector x

– Position the fork protection on the right fork leg. Mount and tighten screws 1.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

B01040-11

– Position the fork protection on the left fork leg. Mount and tighten screws 2.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
– Position the brake line, wiring harness, and clamp. Mount and tighten screws 3.

B01039-11

11.9 Removing the lower triple clamp x

Preparatory work
– Remove the headlight mask with the headlight. ( p. 82)
– Raise the motorcycle with the lift stand. ( p. 40)
– Remove the front wheel.x ( p. 74)
– Remove the fork legs. x ( p. 41)
– Remove the front fender. ( p. 47)
Main work
– Open the cable holder in front of the radiator and detach the wiring harness.
– Loosen screw 1.
– Remove screw 2, take off the upper triple clamp with the handlebar and set it
aside.

Info
Protect the motorcycle and its attachments against damage by covering
them.
B01056-10 Do not bend the cables and lines.

– Remove O-ring 3. Remove protective ring 4.

– Take out the lower triple clamp with the steering stem.
– Take out the upper steering head bearing.

B01057-10
11 SERVICE WORK ON THE CHASSIS 44

11.10 Installing the lower triple clamp x

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
0 bearing.
– Check whether the top steering head seal 1 is correctly positioned.
– Slide on protective ring 2 and O-ring 3.

B01058-10

– Position the upper triple clamp with the steering.

– Mount screw 4 but do not tighten yet.
– Position the clutch line and wiring harness.

B01056-11

– Position the fork legs.

Info
The lowest milled groove in the fork leg must be flush with the top edge of
the upper triple clamp.
Position bleeder screws 5 toward the front.

B01059-10

– Tighten screws 6.
Guideline
Screw, bottom triple clamp M8 18 Nm
(13.3 lbf ft)

B01054-12

– Tighten screw 4.
Guideline
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft)

B01106-10
11 SERVICE WORK ON THE CHASSIS 45

– Mount and tighten screw 7.

Guideline
Screw, top steering stem M8 17 Nm Loctite® 243™
(12.5 lbf ft)

B01106-11

– Tighten screws 8.
Guideline
Screw, top triple clamp M8 22 Nm
(16.2 lbf ft)
– Secure the wiring harness with the cable holder.

B01054-13

– Position the brake caliper. Mount and tighten screws 9.

Guideline
Screw, front brake caliper M8 25 Nm Loctite® 243™
(18.4 lbf ft)
– Mount cable binder bk.
– Position the brake line, wiring harness, and clamp. Mount and tighten screws bl.

B01105-12

Finishing work
– Install the front fender. ( p. 48)
– Install the front wheel. x( p. 74)
– Refit the headlight mask with the headlight. ( p. 82)
– Check that the wiring harness, cables, and brake and clutch lines can move freely
and are routed correctly.
– Check the steering head bearing play. ( p. 45)
– Remove the motorcycle from the lift stand. ( p. 40)
– Check the headlight setting. ( p. 84)

11.11 Checking the steering head bearing play

Warning
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-
aged over time.

Preparatory work
– Raise the motorcycle with the lift stand. ( p. 40)
11 SERVICE WORK ON THE CHASSIS 46

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:
– Adjust the play of the steering head bearing. x( p. 46)
– Move the handlebar to and fro over the entire steering range.

400738-11 The handlebar must be able to move easily over the entire steering range. No
resting locations should be noticeable.
» If click positions are noticeable:
– Adjust the play of the steering head bearing. x( p. 46)
– Check the steering head bearing and replace if required.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 40)

11.12 Adjusting the play of the steering head bearing x

Preparatory work
– Raise the motorcycle with the lift stand. ( p. 40)
Main work
– Loosen screws 1. Remove screw 2.
– Loosen and retighten screw 3.
Guideline
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft)
– Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
– Tighten screws 1.
Guideline
B01034-11
Screw, top triple clamp M8 22 Nm
(16.2 lbf ft)
– Mount and tighten screw 2.
Guideline
Screw, top steering stem M8 17 Nm Loctite® 243™
(12.5 lbf ft)
Finishing work
– Check the steering head bearing play. ( p. 45)
– Remove the motorcycle from the lift stand. ( p. 40)

11.13 Greasing the steering head bearing x

– Remove the lower triple clamp. x ( p. 43)
– Install the lower triple clamp. x ( p. 44)

800010-10
11 SERVICE WORK ON THE CHASSIS 47

11.14 Removing the shock absorber x

Preparatory work
– Raise the motorcycle with the lift stand. ( p. 40)
– Fold the seat up. ( p. 48)
Main work
– Remove screw 1.
– Remove screw 2 and lower the rear wheel with the swing arm as far as possible
without blocking the rear wheel. Fix the rear wheel in this position.
– Remove screw 3.
– Push splash protector 4 to the side and remove the shock absorber.

B01053-10

11.15 Installing the shock absorber x

Main work
– Push splash protector 1 to the side and position the shock absorber. Mount and
tighten screw 2.
Guideline
Screw, top shock absorber M12 80 Nm Loctite® 243™
(59 lbf ft)
– Mount and tighten screw 3.
Guideline
B01053-11 Screw, bottom shock M12 80 Nm Loctite® 243™
absorber (59 lbf ft)

Info
The heim joint for the shock absorber at the swing arm is Teflon coated. It
must not be greased with grease or with other lubricants. Lubricants dis-
solve the Teflon coating, thereby drastically reducing the service life.

– Mount and tighten screw 4.

Guideline
Screw, upper subframe M10 45 Nm Loctite® 243™
(33.2 lbf ft)
Finishing work
– Lock the seat. ( p. 48)
– Remove the motorcycle from the lift stand. ( p. 40)

11.16 Removing the front fender

– Remove screws 1. Remove the front fender.
– Ensure that the spacers remain in place.

B01030-10
11 SERVICE WORK ON THE CHASSIS 48

11.17 Installing the front fender

– Ensure that the spacers are mounted in the fender.
– Position the front fender. Mount and tighten screws 1.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

Info
Make sure the holding lugs engage in the headlight mask.

B01030-10

11.18 Folding the seat up

– Press release lever 1.
– Lift the seat and fold it up.

B01021-10

11.19 Locking the seat

– Fold down the seat and push it down.
The seat engages with an audible click.
– Finally, check that the seat is correctly locked.

B01022-10

11.20 Taking off the spoiler

Preparatory work
– Fold the seat up. ( p. 48)
Main work
– Remove screws 1.

305979-10
11 SERVICE WORK ON THE CHASSIS 49

– Remove screw 2.
– Remove screw 3.
– Take off the spoiler.
– Repeat the operation on the opposite side.

305978-10

11.21 Mounting the spoiler

Main work
– Position the spoiler and hook it in at area A.

305980-10

– Mount and tighten screw 1.

– Mount and tighten screw 2.

305978-11

– Mount and tighten screws 3.

– Repeat the operation on the opposite side.

305979-11

Finishing work
– Lock the seat. ( p. 48)

11.22 Removing the air filter housing x

Note
Engine failure Unfiltered intake air has a negative effect on the service life of the engine.
– Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.

Preparatory work
– Fold the seat up. ( p. 48)
11 SERVICE WORK ON THE CHASSIS 50

Main work
– Pull off air filter housing 1 and pre-filter 2 toward the top.

B01060-10

11.23 Installing the air filter housing x

Main work
– Position pre-filter 1 on the air filter housing.

Note
Engine failure If the pre-filter is incorrectly mounted or not mounted at all, the air-
fuel mixture will be different. This has a negative effect on the service life of the
engine.
– Make sure the pre-filter is seated correctly.

B01061-10
– Attach air filter housing 2 to the inlet flange together with the mounted pre-filter.

Info
If the air filter housing is not mounted correctly, dust and dirt may enter the
engine and cause damage.

Finishing work
– Lock the seat. ( p. 48)

11.24 Removing the air filter x

Note
Engine failure Unfiltered intake air has a negative effect on the service life of the engine.
– Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.

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.

Preparatory work
– Fold the seat up. ( p. 48)
– Remove the air filter housing. x( p. 49)
Main work
– Take off pre-filter 1.
– Open air filter housing 2 and take out air filter 4 with air filter support 3.
– Take off air filter 4 from air filter support 3.

B01062-10
11 SERVICE WORK ON THE CHASSIS 51

11.25 Installing the air filter x

Main work
– Mount the clean air filter onto the air filter support.
– Apply grease to the air filter around area A.
Long-life grease ( p. 110)

B01063-10

– Insert both parts together and close air filter housing 1.

Info
If the air filter is not mounted correctly, dust and dirt may enter the engine
and cause damage.

B01064-10

Finishing work
– Install the air filter housing. x( p. 50)
– Lock the seat. ( p. 48)

11.26 Cleaning the air filter and air filter housing x

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
Do not clean the air filter with fuel or petroleum since these substances attack the foam.

Preparatory work
– Fold the seat up. ( p. 48)
– Remove the air filter housing. x( p. 49)
– Remove the air filter. x( p. 50)
Main work
– Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.
Air filter cleaner ( p. 110)

Info
Only press the air filter to dry it, never wring it out.

– Oil the dry air filter with a high quality filter oil.

B01065-01 Oil for foam air filter ( p. 111)

– Clean the air filter housing.
– Check the intake flange for damage and ensure it is firmly seated.
Finishing work
– Install the air filter. x( p. 51)
– Install the air filter housing. x( p. 50)
– Lock the seat. ( p. 48)
11 SERVICE WORK ON THE CHASSIS 52

11.27 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. Do not touch hot components.

Remove the right main silencer:

– Take off the spoiler. ( p. 48)

Info
Only remove the right spoiler.

– Disconnect connector 1 of the lambda sensor.

305976-10

– Disconnect spring 2.
– Remove screws 3 and take off the main silencer.

306091-10

Remove the left main silencer:

– Disconnect spring 4.
– Remove screws 5 and take off the main silencer.

306092-10

11.28 Installing the main silencer

Install the right main silencer:
– Position the main silencer. Mount and tighten screws 1.
Guideline
Remaining screws, chassis M8 25 Nm
(18.4 lbf ft)
– Attach springs 2.

306091-11

– Plug in connector 3 of the lambda sensor.

– Mount the spoiler. ( p. 49)

305976-11
11 SERVICE WORK ON THE CHASSIS 53

Install the left main silencer:

– Position the main silencer. Mount and tighten screws 4.
Guideline
Remaining screws, chassis M8 25 Nm
(18.4 lbf ft)
– Attach springs 5.

306092-11

11.29 Changing the glass fiber yarn filling of the main silencer x
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".
Not only is the noise level higher, the performance characteristic changes.
The operations are the same for the left and right sides.

Preparatory work
– Remove the main silencer. ( p. 52)
Main work
– Remove screws 1.
– Take off connecting cap 2.
– Pull silencer cap 3 out together with the perforated pipe and glass fiber yarn fill-
ings 4 and 5.
– Clean the parts that need to be reinstalled and check for damage.
– Position the new glass fiber yarn fillings 4 and 5 on the perforated pipe.
– Mount silencer cap 3 with the perforated pipe in the main silencer.
– Mount connecting cap 2.
– Mount and tighten screws 1.

B01068-10

Finishing work
– Install the main silencer. ( p. 52)

11.30 Removing the fuel tank x

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.
– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
11 SERVICE WORK ON THE CHASSIS 54

Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.

Preparatory work
– Fold the seat up. ( p. 48)
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.

– Mount wash cap set 1.
B01074-10 Wash cap set (81212016000)
– Remove the tube from the fuel tank breather.
– Remove screws 2 on both sides.
– Remove screw 3.

B01075-10

– Disconnect connector 4.
– Pull off engine breather hose 5.

B01076-10

– Release hose clamp 6.

– Detach the intake flange from the throttle valve body.

B01077-10

– Pull up the fuel tank slightly and disconnect connector 7 of the fuel pump.
– Remove the fuel tank from above.

B01078-10
11 SERVICE WORK ON THE CHASSIS 55

11.31 Installing the fuel tank x

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.
– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.

Main work
– Check the throttle cable routing. ( p. 61)
– Make sure that no cables are trapped or damaged.
– Attach connector 1 of the fuel pump.

B01078-11

– Position the fuel tank.

– Position the intake flange on the throttle valve body.
– Tighten hose clamp 2.

B01077-11

– Plug in connector 3.
– Position engine breather hose 4.

B01076-11

– Mount and tighten screws 5 on both sides.

Guideline
Screw, fuel tank M8 15 Nm
(11.1 lbf ft)
– Mount and tighten screw 6.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

B01075-11 – Mount the fuel tank breather.

11 SERVICE WORK ON THE CHASSIS 56

– 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.

– Remove the wash cap set. Lubricate the O-ring and connect plug-in connection 7
of the fuel line.

Info
B01079-10
Route the cable and fuel line at a safe distance from the exhaust system.

Finishing work
– Lock the seat. ( p. 48)

11.32 Checking for chain dirt accumulation

– Check the chain for coarse dirt accumulation.
» If the chain is very dirty:
– Clean the chain. ( p. 56)

400678-01

11.33 Cleaning the chain

Warning
Danger of accidents Oil or grease on the tires reduces their grip.
– Remove oil and grease with a suitable cleaning material.
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

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
The service life of the chain depends largely on its maintenance.

– Clean the chain regularly and then treat with chain spray.
Chain cleaner ( p. 110)
Off-road chain spray ( p. 110)

400725-01
11 SERVICE WORK ON THE CHASSIS 57

11.34 Checking the chain tension

Warning
Danger of accidents Danger caused by incorrect chain tension.
– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-
ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces-
sary.

Preparatory work
– Raise the motorcycle with the lift stand. ( p. 40)
Main work
– Push the chain at the end of the chain sliding component upwards to measure the
chain tension A.

Info
The lower chain section 1 must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.

B01051-10
Chain tension 36… 40 mm (1.42… 1.57 in)
» If the chain tension does not meet specifications:
– Adjust the chain tension. ( p. 57)
Finishing work
– Remove the motorcycle from the lift stand. ( p. 40)

11.35 Adjusting the chain tension

Warning
Danger of accidents Danger caused by incorrect chain tension.
– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-
ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces-
sary.

Preparatory work
– Raise the motorcycle with the lift stand. ( p. 40)
– Check the chain tension. ( p. 57)
Main work
– Loosen nut 1.
– Loosen nuts 2.
– Adjust the chain tension by turning adjusting screws 3 on the left and right.
Guideline
Chain tension 36… 40 mm (1.42… 1.57 in)
Turn adjusting screws 3 on the left and right so that the markings on the left
and right chain adjusters are in the same position relative to the reference
marks A. The rear wheel is then correctly aligned.
– Tighten nuts 2.
– Make sure that chain adjusters 4 are fitted correctly on adjusting screws 3.
– Tighten nut 1.
Guideline
Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft)

Info
The wide adjustment range of the chain adjusters enables different sec-
ondary ratios with the same chain length.
B01050-11
Chain adjusters 4 can be turned by 180°.
11 SERVICE WORK ON THE CHASSIS 58

Finishing work
– Remove the motorcycle from the lift stand. ( p. 40)

11.36 Checking the chain, rear sprocket, engine sprocket and chain guide
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 40)
Main work
– Shift gear to neutral.
– Check the rear sprocket and engine sprocket for wear.
» If the rear sprocket and engine sprocket are worn:
– Replace the rear sprocket or engine sprocket. x
Info
The engine sprocket, rear sprocket and chain should always be
replaced together.
400227-01

– Pull on the upper part of the chain with the specified weight A.
Guideline
Weight, chain wear measurement 10… 15 kg (22… 33 lb.)
– Measure the distance B of 18 chain links in the lower chain section.

Info
Chain wear is not always even, so you should repeat this measurement at
different chain positions.

Maximum distance B at the longest 272 mm (10.71 in)

chain section
» If the distance B is greater than the specified measurement:
– Replace the chain. x
Info
When the chain is replaced, the rear sprocket and engine sprocket
should also be changed.
New chains wear out faster on old, worn sprockets.

400987-10

– Check the chain sliding guard for wear.

» If the bottom edge of the chain bolt is in line with or below the chain sliding
guard:
– Change the chain sliding guard. x
– Check that the chain sliding guard is firmly seated.
» If the chain sliding guard is loose:
– Tighten the chain sliding guard.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)

B01069-10
11 SERVICE WORK ON THE CHASSIS 59

– Check the chain sliding piece for wear.

» If the bottom edge of the chain bolt is in line with or below the chain sliding
piece:
– Change the chain sliding piece. x
– Check that the chain sliding piece is firmly seated.
» If the chain sliding piece is loose:
– Tighten the chain sliding piece.
Guideline
Screw, chain sliding piece M8 15 Nm
(11.1 lbf ft)

401470-01

– Check the chain guide for wear.

Info
Wear can be seen on the front of the chain guide.

» If the light part of the chain guide is worn:

– Change the chain guide. x
400985-01

– Check that the chain guide is firmly seated.

» If the chain guide is loose:
– Tighten the chain guide.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
Remaining nuts, chassis M6 10 Nm
(7.4 lbf ft)
B01070-01

Finishing work
– Remove the motorcycle from the lift stand. ( p. 40)
11 SERVICE WORK ON THE CHASSIS 60

11.37 Adjusting the chain guide x

– Remove the nut of screw 1.
– Remove screws 1 and 2. Take off the chain guide.
Condition
Number of teeth: ≤ 44 teeth
– Insert nut 3 in hole A. Position the chain guide.
– Mount and tighten screws 1 and 2.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
– Mount the nut on screw 1 and tighten.
Guideline
Remaining nuts, chassis M6 10 Nm
(7.4 lbf ft)
Condition
Number of teeth: ≥ 45 teeth
– Insert nut 3 in hole B. Position the chain guide.
– Mount and tighten screws 1 and 2.
B01071-10 Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
– Mount the nut on screw 1 and tighten.
Guideline
Remaining nuts, chassis M6 10 Nm
(7.4 lbf ft)

11.38 Checking the frame x

– Check the frame for cracking and deformation.
» If the frame exhibits cracking or deformation due to a mechanical impact:
– Change the frame. x
Info
A frame that has been damaged due to a mechanical impact must
always be changed. Repair of the frame is not authorized by KTM.

401462-01

11.39 Checking the swingarm x

– Check the swingarm for damage, cracking, and deformation.
» If the swingarm shows signs of damage, cracking, or deformation:
– Change the swingarm. x
Info
A damaged swingarm must always be changed. Repair of the
swingarm is not authorized by KTM.

401463-01
11 SERVICE WORK ON THE CHASSIS 61

11.40 Checking the throttle cable routing

Preparatory work
– Fold the seat up. ( p. 48)
– Remove the fuel tank. x( p. 53)
Main work
– Check the throttle cable routing.
Both throttle cables must be routed to the throttle valve body side by side behind
the handlebars and above the fuel tank bearing.
» If the throttle cable is not routed as specified:
– Correct the throttle cable routing.

B01080-10

Finishing work
– Install the fuel tank. x( p. 55)
– Lock the seat. ( p. 48)

11.41 Checking the rubber grip

– Check the rubber grips on the handlebar for damage and wear and to ensure they
are firmly seated.
» If a rubber grip is damaged, worn or loose:
– Change and secure the rubber grip.
Rubber grip adhesive (00062030051) ( p. 111)

401197-01

11.42 Additionally securing the rubber grip

Preparatory work
– Check the rubber grip. ( p. 61)
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.

401198-01
11 SERVICE WORK ON THE CHASSIS 62

11.43 Adjusting the basic position of the clutch lever

– Adjust the basic position of the clutch lever to your hand size by turning adjusting
screw 1.

Info
Turn the adjusting screw clockwise to increase the distance between the
clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the clutch lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply force.
B01073-10
Do not make any adjustments while riding!

11.44 Checking the fluid level of the hydraulic clutch

Info
The fluid level rises with increasing wear of the clutch facing discs.

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Check the fluid level in viewer 1.
» If the fluid has dropped below marking A in the viewer:
– Correct the fluid level of the hydraulic clutch. ( p. 62)

B01081-10

11.45 Correcting the fluid level of the hydraulic clutch

Info
The fluid level rises with increasing wear of the clutch facing discs.

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws 1.
– Remove cover 2 with membrane 3.
– Add fluid to level A.
Guideline
Level A (fluid level below container 4 mm (0.16 in)
rim)

B01174-10 Brake fluid DOT 4 / DOT 5.1 ( p. 108)

– Position the cover with the membrane. Mount and tighten the screws.

Info
Clean up overflowed or spilt brake fluid immediately with water.

11.46 Changing the hydraulic clutch fluid x

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.
11 SERVICE WORK ON THE CHASSIS 63

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws 1.
– Remove cover 2 with membrane 3.

B01082-11

– Fill bleeding syringe 4 with the appropriate hydraulic fluid.

Bleed syringe (50329050000)
Brake fluid DOT 4 / DOT 5.1 ( p. 108)
– On the clutch slave cylinder, remove bleeder screw 5 and mount bleeding
syringe 4.

B01083-10

– Remove screw 6 with the O-ring.

– Inject the liquid into the system until it escapes from opening A of the master
cylinder without bubbles.
– To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
– Mount and tighten screw 6 with the O-ring.
– Remove the bleeding syringe. Mount and tighten screws bleeder screw.
– Correct the fluid level of the hydraulic clutch.
Guideline
B01084-10
Fluid level below container rim 4 mm (0.16 in)
– Position the cover with the membrane. Mount and tighten the screws.

11.47 Removing the engine guard

– Remove screws 1 and 2.
– Lower the engine guard at the rear and remove it toward the front.

B01072-10
11 SERVICE WORK ON THE CHASSIS 64

11.48 Installing the engine guard

– Position the engine guard on the frame at the front and mount screws 1 but do not
tighten yet.
– Position the engine guard on the frame at the rear and mount and tighten
screws 2.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
– Tighten screws 1.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

B01072-10
12 BRAKE SYSTEM 65

12.1 Checking the free travel of the hand brake lever

Warning
Danger of accidents Brake system failure.
– If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due
to overheating. Adjust the free travel on hand brake lever according to specifications.

– Push the hand brake to the handlebar and check free travel A.
Free travel of hand brake lever ≥ 3 mm (≥ 0.12 in)
» If the free travel does not meet specifications:
– Adjust the free travel of the handbrake lever. ( p. 65)

B01086-10

12.2 Adjusting the free travel of the handbrake lever

– Check the free travel of the hand brake lever. ( p. 65)
– Adjust the free travel of the handbrake lever with adjustment screw 1.

Info
Turn the adjustment screw clockwise to reduce free travel. The pressure
point moves away from the handlebar.
Turn the adjustment screw counterclockwise to increase free travel. The
pressure point moves towards the handlebar.
The range of adjustment is limited.
B01085-10 Turn the adjusting screw by hand only, and do not apply force.
Do not make any adjustments while riding!

12.3 Checking the brake discs

Warning
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
to see if it conforms to measurement A.

Info
Wear reduces the thickness of the brake disc around the area used by the
brake linings.

Brake discs - wear limit

Front 2.5 mm (0.098 in)
400257-10 Rear 3.5 mm (0.138 in)
» If the brake disc thickness is less than the specified value:
– Change the brake disc.
– Check the front and rear brake discs for damage, cracking and deformation.
» If the brake disc shows signs of damage, cracking, or deformation:
– Change the brake disc.
12 BRAKE SYSTEM 66

12.4 Checking the brake fluid level of the front brake

Warning
Danger of accidents Brake system failure.
– If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system
is leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding. (Your
authorized KTM workshop will be glad to help.)

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.
– Check the brake fluid level in the viewer 1.
» If the brake fluid has dropped below marking A:
– Add front brake fluid. x( p. 66)

B01087-10

12.5 Adding front brake fluid x

Warning
Danger of accidents Brake system failure.
– If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system
is leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding. (Your
authorized KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
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
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.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.
12 BRAKE SYSTEM 67

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws 1.
– Remove cover 2 with membrane 3.
– Add brake fluid to level A.
Guideline
Level A (brake fluid level below con- 5 mm (0.2 in)
tainer rim)

B01088-10 Brake fluid DOT 4 / DOT 5.1 ( p. 108)

– Position the cover with the membrane. Mount and tighten the screws.

Info
Clean up overflowed or spilt brake fluid immediately with water.

12.6 Checking the front brake linings

Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
– Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)

– Check the brake linings for minimum thickness A.

Minimum thickness A ≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the front brake linings. x( p. 67)
– Check the brake linings for damage and cracking.
» If damage or cracking is visible:
– Change the front brake linings. x( p. 67)
B01089-10

12.7 Changing the front brake linings x

Warning
Danger of accident Brake system failure.
– Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
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.
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidents Reduced braking efficiency due to use of non-approved brake linings.
– 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. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
12 BRAKE SYSTEM 68

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.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws 1.
– Remove cover 2 with membrane 3.

B01088-11

– Remove screws 4 and spacers.

– Press back the brake linings with a light lateral tilting of the brake caliper on the
brake disc. Carefully pull the brake caliper backwards from the brake disc.
– Press the brake piston back to its basic position and make sure that no brake fluid
overflows from the brake fluid reservoir.

B01091-10

– Remove cotter pin 5.

– Remove bolt 6.
– Take off retainer spring 7 and remove the brake linings.
– Clean the brake caliper.
– Position the brake linings.

Info
Always change the brake linings in pairs.
B01092-10
– Position retaining spring 7.
– Mount bolt 6.
– Mount spring connector 5.

Info
To make it easier to mount the bolt, push the retaining spring down.
Make sure the retaining spring is seated correctly.

– Position the brake caliper. Mount screws 4 with the spacers but do not tighten yet.
– Operate the hand brake lever repeatedly until the brake linings are in contact with
the brake disc and there is a pressure point. Fix the hand brake lever in the acti-
vated position.
The brake caliper straightens.
– Tighten screws 4.
Guideline
Screw, front brake caliper M8 25 Nm Loctite® 243™
B01091-10 (18.4 lbf ft)
– Remove the fixation of the hand brake lever.
12 BRAKE SYSTEM 69

– Add brake fluid to level A.

Guideline
Level A (brake fluid level below con- 5 mm (0.2 in)
tainer rim)

Brake fluid DOT 4 / DOT 5.1 ( p. 108)

– Position the cover with the membrane. Mount and tighten the screws.

Info
B01093-10
Clean up overflowed or spilt brake fluid immediately with water.

12.8 Checking the free travel of foot brake lever

Warning
Danger of accidents Brake system failure.
– If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust the free travel on foot brake lever according to specifications.

– Disconnect spring 1.
– 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 A.
Guideline
Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)
» If the free travel does not meet specifications:
– Adjust the basic position of the foot brake lever. x( p. 69)
– Reconnect spring 1.
B01094-10

12.9 Adjusting the basic position of the foot brake lever x

Warning
Danger of accidents Brake system failure.
– If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust the free travel on foot brake lever according to specifications.

– Disconnect spring 1.
– Loosen nut 4 and, with push rod 5, turn it back until you have maximum free
travel.
– To adjust the basic position of the foot brake lever individually, loosen nut 2 and
turn screw 3 accordingly.

Info
The range of adjustment is limited.

– Turn push rod 5 accordingly until you have free travel A. If necessary, adjust the
basic position of the foot brake lever.
Guideline
Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)
– Hold screw 3 and tighten nut 2.
Guideline
Nut, foot brake lever stop M8 20 Nm
(14.8 lbf ft)
– Hold push rod 5 and tighten nut 4.
B01095-10 Guideline
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft)
– Reconnect spring 1.
12 BRAKE SYSTEM 70

12.10 Checking the rear brake fluid level

Warning
Danger of accidents Failure of the brake system.
– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

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.

– Check the brake fluid level in the viewer 1.
» When in the viewer 1 an air bubble is visible:
– Add rear brake fluid. x( p. 70)

B01096-10

12.11 Adding rear brake fluid x

Warning
Danger of accidents Failure of the brake system.
– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
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
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.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.
12 BRAKE SYSTEM 71

– Stand the vehicle upright.

– Remove screws 1.
– Remove cover with membrane 2.
– Add brake fluid to level A.
Brake fluid DOT 4 / DOT 5.1 ( p. 108)
– Mount the cover with the membrane.
– Mount and tighten the screws.

Info
Clean up overflowed or spilt brake fluid immediately with water.

B01097-10

12.12 Checking the rear brake linings

Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
– Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)

– Check the brake linings for minimum thickness A.

Minimum thickness A ≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the rear brake linings. x( p. 71)
– Check the brake linings for damage and cracking.
» If damage or cracking is visible:
– Change the rear brake linings. x( p. 71)
B01098-10

12.13 Changing the rear brake linings x

Warning
Danger of accident Brake system failure.
– Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
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.
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
12 BRAKE SYSTEM 72

Warning
Danger of accidents Reduced braking efficiency due to use of non-approved brake linings.
– 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. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

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.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.

– Stand the vehicle upright.

– Remove screws 1.
– Remove cover with membrane 2.
– Press the brake piston back to its basic position and make sure that no brake fluid
overflows from the brake fluid reservoir.

B01099-10

– Take off spring connector 3 and remove bolt 4.

– Take off retainer spring 5 and remove the brake linings.
– Clean the brake caliper.

B01100-10

– Position the brake linings.

Info
Always change the brake linings in pairs.

B01101-01

– Position retaining spring 5.

– Mount bolt 4.
– Mount spring connector 3.

Info
To make it easier to mount the bolt, push the retaining spring down.
Make sure the retaining spring is seated correctly.

– Operate the foot brake lever repeatedly until the brake linings are in contact with
B01100-10 the brake disc and there is a pressure point.
12 BRAKE SYSTEM 73

– Add brake fluid to level A.

Brake fluid DOT 4 / DOT 5.1 ( p. 108)
– Mount the cover with the membrane 2.
– Mount and tighten screws 1.

Info
Clean up overflowed or spilt brake fluid immediately with water.

B01097-10
13 WHEELS, TIRES 74

13.1 Removing the front wheel x

Preparatory work
– Raise the motorcycle with the lift stand. ( p. 40)
Main work
– Remove screw 1.
– Release screws 2.

B01044-10

– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.

Info
Do not pull the hand brake lever when the front wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam-
aged.

B01045-10

– Remove spacers 3.

B01046-10

13.2 Installing the front wheel x

Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

– Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:
– Change the wheel bearing. x
– Clean and grease the shaft seal rings 1 and contact surface A of the spacers.
Long-life grease ( p. 110)
– Insert the spacers.

B01046-11

– Lift the front wheel into the fork, position it, and insert the wheel spindle.
– Mount and tighten screw 2.
Guideline
Screw, front wheel spindle M20x1.5 35 Nm
(25.8 lbf ft)
– Activate the hand brake lever multiple times until the brake linings are in contact
with the brake disc.
– Remove the motorcycle from the lift stand. ( p. 40)
B01044-11
13 WHEELS, TIRES 75

– Pull the front wheel brake and push down hard on the fork several times to align
the fork legs.
– Tighten screw 3.
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)

13.3 Removing the rear wheel x

Preparatory work
– Raise the motorcycle with the lift stand. ( p. 40)
Main work
– Remove nut 1.
– Remove chain adjuster 2. Withdraw wheel spindle 3 only enough to allow the rear
wheel to be pushed forward.
– Push the rear wheel forward as far as possible. Remove the chain from the rear
sprocket.
– Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of the
swing arm.

Info
Do not operate the foot brake when the rear wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam-
aged.

B01047-10

– Remove spacers 4.

B01048-10

13.4 Installing the rear wheel x

Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Main work
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Change the wheel bearing. x
– Clean and grease the shaft seal rings 1 and contact surface A of the spacers.
Long-life grease ( p. 110)
– Insert the spacers.
B01048-11
13 WHEELS, TIRES 76

– Lift the rear wheel into the swing arm, position it, and insert the wheel spindle 2.
– Put the chain on.

B01049-10

– Position chain adjuster 3. Mount nut 4, but do not tighten it yet.

– Make sure that chain adjusters 3 are fitted correctly on adjusting screws 5.
– Check the chain tension. ( p. 57)
– Tighten nut 4.
Guideline
Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft)

Info
The wide adjustment range of the chain adjusters enables different sec-
ondary ratios with the same chain length.
Chain adjusters 3 can be turned by 180°.

– Operate the foot brake lever repeatedly until the brake linings are in contact with
the brake disc and there is a pressure point.

B01050-10

Finishing work
– Remove the motorcycle from the lift stand. ( p. 40)

13.5 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.
The tires mounted on the front and rear wheels must have a similar profile.
Worn tires have a negative effect on riding behavior, especially on wet surfaces.
If used regularly on public roads, tires wear much faster and the minimum tread depth and general condition of the tires must
be checked more frequently.

– Check the front and rear tires for cuts, run-in objects, and other damage.
» If the tires exhibit cuts, run-in objects, or other damage:
– Change the tires.
– Check the depth of the tread.

Info
Note local national regulations concerning the minimum tread depth.

Minimum tread depth ≥ 2 mm (≥ 0.08 in)

400602-10
» If the tread depth is less than the minimum permissible depth:
– Change the tires.
– Check the age of the tires.
13 WHEELS, TIRES 77

Info
The tire's date of manufacture is usually part of the tire markings and is
indicated by four digits. The first two digits refer to the week of manufac-
ture and last two digits refer to the year of manufacture.
KTM recommends that the tires be changed after 5 years at the latest,
regardless of the actual state of wear.

» If a tire is more than 5 years old:

– Change the tires.

13.6 Checking the tire air pressure

Info
Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.

– Remove the dust cap.

– Check the tire air pressure when the tires are cold.
Tire air pressure off road
Front 0.9 bar (13 psi)
Rear 0.7 bar (10 psi)

Tire air pressure, road

Front 1.5 bar (22 psi)
400695-01
Rear 1.5 bar (22 psi)
» If the tire pressure does not meet specifications:
– Correct the tire pressure.
– Mount the dust cap.

13.7 Checking the spoke tension

Warning
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.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.

– Briefly strike each spoke with the tip of a screwdriver.

Info
The tone frequency depends on the length of the spoke and the spoke diam-
eter.
If you hear different tone frequencies from different spokes of equal length
and diameter, this is an indication of different spoke tensions.

You should hear a high note.

400694-01 » If the spoke tension varies:
– Correct the spoke tension. x
– Check the spoke torque.
Guideline
Spoke nipple M4.5 5… 6 Nm (3.7…
4.4 lbf ft)

Torque wrench with various accessories in set (58429094000)

14 ELECTRICAL SYSTEM 78

14.1 Removing the battery x

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.
– Keep the battery away from sparks or open flames. Charge only in well-ventilated areas.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.

– Switch off all power consumers and switch off the engine.
– Remove screw 1.
– Take off fastening plate 2.

B01102-10

– Take the battery out of the battery compartment.

– Disconnect negative cable 3 of the battery.
– Pull back the positive terminal cover 4 and disconnect the positive (plus) cable of
the battery.

B01103-10

14.2 Installing the battery x

– Attach positive cable.
Guideline
Screw, battery terminal M5 2.5 Nm
(1.84 lbf ft)
– Slide positive terminal cover 3 over the positive terminal.
– Attach negative cable.
Guideline
Screw, battery terminal M5 2.5 Nm
(1.84 lbf ft)

Battery (YTX4L-BS) ( p. 105)

Info
Contact disk A must be mounted between screw 1 and cable socket 2
with the claws facing down.

B01104-10
14 ELECTRICAL SYSTEM 79

– Position the battery in the battery compartment.

– Attach fixing flap 4.
– Mount and tighten screw 5.

B01102-11

14.3 Recharging the battery x

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.
– Keep the battery away from sparks or open flames. Charge only in well-ventilated areas.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.
Warning
Environmental hazard The battery contains elements that are harmful to the environment.
– Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner.
Give the battery to your KTM dealer or to a recycling center that accepts used batteries.

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
Even when there is no load on the battery, it discharges steadily.
The charge state and the type of charge are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the battery's service life.
If the charging current, charging voltage, and charging time are exceeded, electrolyte escapes through the safety valves. This
reduces the battery capacity.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the
battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.

Preparatory work
– Remove the battery. x( p. 78)
Main work
– 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 rest potential and starting ability of
the battery, and to test the alternator. With this device, you cannot overcharge the
battery.

Info
400240-10
Never remove lid 1.
Charge the battery with a maximum of 10% of the capacity specified on the
battery housing 2.

– Switch off the charger after charging. Disconnect the battery.

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
14 ELECTRICAL SYSTEM 80

Finishing work
– Install the battery. x( p. 78)

14.4 Changing the main fuse

Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are used.
– Use only fuses with the prescribed amperage. Never by-pass or repair fuses.

Info
The main fuse protects all power consumers of the vehicle. It is located behind the battery.

Preparatory work
– Switch off all power consumers and switch off the engine.
– Raise the motorcycle with the lift stand. ( p. 40)
– Fold the seat up. ( p. 48)
– Remove the shock absorber. x( p. 47)
Main work
– Remove protection caps 1.

B01109-10

– Remove the faulty main fuse 2.

Info
A defective fuse is indicated by a burned-out fuse wire A.
A reserve fuse 3 is located in the starter relay.

– Install a new main fuse.

Fuse (58011109120) ( p. 105)
– Check that the electrical equipment is functioning properly.
B01110-10

Tip
Insert the spare fuse so that it is available if needed.

– Mount the protection caps.

Finishing work
– Install the shock absorber. x( p. 47)
– Lock the seat. ( p. 48)
– Remove the motorcycle from the lift stand. ( p. 40)

14.5 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. ( p. 48)
14 ELECTRICAL SYSTEM 81

Main work
– Pull the EFI control unit 1 from the holder and hang it to one side.
– Open fuse box cover 2.

B01111-10

– Remove the defective fuse.

Guideline
Fuse 1 - 10 A - EFI control unit
Fuse 2 - 10 A - fuel pump
Fuse 3 - 10 A - high beam, low beam, parking light, tail light, license plate lamp
Fuse 4 - 10 A - horn, brake light, turn signal, radiator fan, speedometer
Fuse 5 - not used

B01112-10
Fuses res - 10 A - spare fuses

Info
A defective fuse is indicated by a burned-out fuse wire A.

Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are
used.
– Use only fuses with the prescribed amperage. Never by-pass or repair
fuses.

– Use spare fuses with the correct rating only.

Fuse (58011109110) ( p. 105)

Tip
Replace the spare fuse in the fuse box so that it is available if needed.

– Check that the power consumer is functioning properly.

– Close the fuse box cover.
– Position the EFI control unit.
Finishing work
– Lock the seat. ( p. 48)
14 ELECTRICAL SYSTEM 82

14.6 Removing the headlight mask with the headlight

– Switch off all power consumers.
– Detach the brake line and wiring harness 1.
– Release rubber band 2. Slide the headlight mask up and swing it forward.

B01041-10

– Pull bulb socket 3 out of the high beam indicator lamp.

– Disconnect the connectors of the turn signals and headlight.

B01169-11

14.7 Refitting the headlight mask with the headlight

Main work
– Insert bulb socket 1 into the high beam indicator lamp.
– Plug in connector.

B01169-12
14 ELECTRICAL SYSTEM 83

– Position the headlight mask and fix it with the rubber band 3.

Info
Make sure that the holding lugs engage in the fender.

– Position the brake line and wiring harness 4.

B01041-11

Finishing work
– Check the headlight setting. ( p. 84)

14.8 Changing the headlight bulb

Note
Damage to reflector Reduced luminance.
– 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.

Preparatory work
– Remove the headlight mask with the headlight. ( p. 82)
Main work
– Turn rubber cap 1 together with the underlying bulb socket counterclockwise all
the way and remove it.
– Pull bulb socket 2 of the parking light out of the reflector.

B01113-10

– Press headlight bulb 3 lightly into the bulb socket, turn it counterclockwise, and
pull it out.
– Insert the new headlight bulb.
Headlight (S2/socket BA20d) ( p. 105)
– Insert the rubber cap with the bulb socket into the reflector and turn it clockwise
all the way.

Info
100862-10 Ensure that O-ring 4 is seated properly.

– Insert the bulb socket of the parking light into the reflector.
Finishing work
– Refit the headlight mask with the headlight. ( p. 82)
– Check the headlight setting. ( p. 84)
14 ELECTRICAL SYSTEM 84

14.9 Changing the turn signal bulb

Note
Damage to reflector Reduced luminance.
– 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
– Remove the screw on the rear of the turn signal housing.
– Carefully remove diffuser 1.
– Lightly squeeze orange cap 2 in the area of the holding lugs and take it off.
– Press the turn signal bulb carefully into the socket, turn it counterclockwise by
about 30°, and take it out of the socket.

Info
Do not touch the reflector with your fingers, and keep it free from grease.
800137-10
– Press the new turn signal bulb carefully into the socket and turn it clockwise until
it stops.
Turn signal (R10W/socket BA15s) ( p. 105)
– Mount the orange cap.
– Position the diffuser.
– Insert the screw and first turn it counterclockwise until it engages in the thread.
Tighten the screw slightly.
Finishing work
– Check that the turn signal system is functioning properly.

14.10 Checking the headlight setting

– Position the vehicle upright on a horizontal surface in front of a light wall and make
a mark at the height of the center of the low beam headlight.
A
0 – Make another mark at a distance B under the first mark.
Guideline
Distance B 5 cm (2 in)
0
B – Position the vehicle vertically a distance A away from the wall.
Guideline
Distance A 5 m (16 ft)
400726-10
– The rider now sits down on the motorcycle.
– Switch on the low beam.
– Check the headlight setting.
The boundary between light and dark must be exactly on the lower mark for a
motorcycle with driver.
» If the boundary between light and dark does not meet specifications:
– Adjust the headlight range. ( p. 84)

14.11 Adjusting the headlight range

Preparatory work
– Check the headlight setting. ( p. 84)
Main work
– Adjust the beam distance of the headlight by turning screw 1.
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).

B01043-10
14 ELECTRICAL SYSTEM 85

Info
Turn clockwise to increase the headlight range, turn counterclockwise to
reduce the headlight range.
A change in weight on the vehicle may require a correction of the headlight
range.

14.12 Changing the speedometer battery

Preparatory work
– Remove the headlight mask with the headlight. ( p. 82)
Main work
– Remove screws 1.
– Pull the speedometer upward out of the holder.

B01133-10

– Using a coin, turn protection cap 2 all the way counterclockwise and remove it.
– Remove speedometer battery 3.
– Insert the new battery with the label facing upward.
Speedometer battery (CR 2430) ( p. 105)
– Check the O-ring of the protection cap for correct seating.

B01134-10

– Position protection cap 2 and turn all the way clockwise using a coin.
– Press any button on the speedometer.
The speedometer is activated.
– Position the speedometer in the holder.
– Mount and tighten the screws with washers.

B01135-10

Finishing work
– Refit the headlight mask with the headlight. ( p. 82)
– Check the headlight setting. ( p. 84)
– Set kilometers or miles. ( p. 16)
– Adjust the speedometer functions. ( p. 16)
– Set the clock. ( p. 17)
15 COOLING SYSTEM 86

15.1 Cooling system

Water pump 1 in the engine circulates the coolant.
The pressure resulting from the warming of the cooling system is regulated by a valve
in radiator cap 2. This ensures that operating the vehicle at the specified coolant tem-
perature will not result in a risk of malfunctions.
120 °C (248 °F)
Cooling is effected by the air stream.
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cool-
ing effect.
The radiator fan provides extra cooling. It is controlled by a thermoswitch.

B01114-10

15.2 Checking the antifreeze and 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. In case of scalding, rinse immediately with lukewarm water.

Warning
Danger of poisoning Coolant is poisonous and a health hazard.
– Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.

Condition
The engine is cold.
– Stand the motorcycle upright on a horizontal surface.
– Remove the radiator cap.
– Check the coolant antifreeze.
−25… −45 °C (−13… −49 °F)
» If the antifreeze of the coolant does not meet specifications:
– Correct the coolant antifreeze.
– Check the coolant level in the radiator.
400243-10 Coolant level A above radiator fins. 10 mm (0.39 in)
» If the coolant level does not meet specifications:
– Correct the coolant level.
Alternative 1
Coolant ( p. 108)
Alternative 2
Coolant (mixed ready to use) ( p. 108)
– Mount the radiator cap.
15 COOLING SYSTEM 87

15.3 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. In case of scalding, rinse immediately with lukewarm water.

Warning
Danger of poisoning Coolant is poisonous and a health hazard.
– Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.

Condition
The engine is cold.
– Stand the motorcycle upright on a horizontal surface.
– Remove the radiator cap.
– Check the coolant level in the radiator.
Coolant level A above radiator fins. 10 mm (0.39 in)
» If the coolant level does not meet specifications:
– Correct the coolant level.
Alternative 1
400243-10 Coolant ( p. 108)
Alternative 2
Coolant (mixed ready to use) ( p. 108)
– Mount the radiator cap.

15.4 Draining the coolant x

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. In case of scalding, rinse immediately with lukewarm water.

Warning
Danger of poisoning Coolant is poisonous and a health hazard.
– Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.

Condition
The engine is cold.
– Stand the motorcycle upright.
– Place a suitable container under the water pump cover.
– Remove screw 1. Take off radiator cap 2.
– Completely drain the coolant.
– Mount screw 1 with a new seal ring and tighten it.
Guideline
Screw, water pump cover M6 10 Nm (7.4 lbf ft)

B01115-10
15 COOLING SYSTEM 88

15.5 Refilling coolant x

Warning
Danger of poisoning Coolant is poisonous and a health hazard.
– Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.

Main work
– Make sure that screw 1 is tightened.
– Stand the motorcycle upright.
– Pour coolant in up to measurement A above the radiator fins.
Guideline
10 mm (0.39 in)

Coolant 0.7 l (0.7 qt.) Coolant ( p. 108)

B01116-10 Coolant (mixed ready to use)
( p. 108)
– Mount the radiator cap.
Finishing work
– Take a short test ride.
– Check the coolant level. ( p. 87)
16 TUNING THE ENGINE 89

16.1 Checking the play in the throttle cable

– Check the throttle grip for smooth operation.
– Move the handlebar to the straight-ahead position. Move the throttle grip back-
wards and forwards to ascertain the play in the throttle cable.
Throttle cable play 3… 5 mm (0.12… 0.2 in)
» If the throttle cable play does not meet specifications:
– Adjust the play in the throttle cable. x( p. 89)

Danger
400192-10 Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.

– Start the engine and let it run idle. Move the handlebar to and fro over the entire
steering range.
The idle speed must not change.
» If the idle speed changes:
– Adjust the play in the throttle cable. x( p. 89)

16.2 Adjusting the play in the throttle cable x

Preparatory work
– Fold the seat up. ( p. 48)
– Remove the fuel tank. x( p. 53)
– Check the throttle cable routing. ( p. 61)
Main work
– Move the handlebar to the straight-ahead position.
– Loosen nut 1. Turn adjusting screw 2 so that there is play in the throttle cable at
the throttle grip.
Guideline
Throttle cable play 3… 5 mm (0.12… 0.2 in)
– Tighten nut 1.
– Check the throttle grip for smooth operation.
B01175-10

Finishing work
– Install the fuel tank. x( p. 55)
– Lock the seat. ( p. 48)
16 TUNING THE ENGINE 90

16.3 Adjusting the idle speed x

– Run the engine warm and push the idle speed adjusting screw 1 all the way in.
– Set the desired idle speed by turning the idle speed adjusting screw.
Guideline
Idle speed 1,800… 1,900 rpm

Info
Turn counterclockwise to increase the idle speed.
Turn clockwise to decrease the idle speed.

B01241-10

16.4 Checking the basic position of the shift lever

– Sit on the vehicle in the riding position and determine distance A 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
» If the distance does not meet specifications:
– Adjust the basic position of the shift lever. x( p. 90)

400692-10

16.5 Adjusting the basic position of the shift lever x

– Remove screw 1 and remove shift lever 2.

B01107-10

– Clean gear teeth A of the shift lever and shift shaft.

– Mount shift lever 2 on the shift shaft in the required position and engage the gear-
ing.

Info
The range of adjustment is limited.
The shift lever must not come into contact with any other vehicle compo-
nents during the shift procedure.

B01108-10
– Mount and tighten screw 1.
Guideline
Screw, shift lever M6 14 Nm Loctite® 243™
(10.3 lbf ft)
17 SERVICE WORK ON THE ENGINE 91

17.1 Changing the fuel screen x

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.
– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.

Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.

Main work
– Thoroughly clean the plug-in connection of the fuel line using compressed air.

Info
Under no circumstances should dirt enter into the fuel line. Dirt in the fuel
line clogs the injection valve.

– Disconnect the plug-in connection of the fuel line.

– Pull fuel screen 1 out of the connecting piece.
B01117-10 – Slide a new fuel screen into the connecting piece.
– Lubricate the O-ring and connect plug-in connection of the fuel line.
Finishing work

Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.

– Start the engine and check the response.

17.2 Checking the engine oil level

Info
The engine oil level can be checked when the engine is cold or warm.

Preparatory work
– Stand the motorcycle upright on a horizontal surface.
Condition
The engine is cold.
– Check the engine oil level.
The engine oil level is up to the middle A of the level viewer.
» If the engine oil is not up to the middle of the level viewer:
– Add engine oil. ( p. 94)
Condition
The engine is at operating temperature.
B01118-10
– Check the engine oil level.

Info
After switching off the engine, wait one minute before checking the
level.
17 SERVICE WORK ON THE ENGINE 92

The engine oil is at a level between the middle A and upper edge B of the
level viewer.
» If the engine oil is not up to the middle A of the level viewer:
– Add engine oil. ( p. 94)

17.3 Changing the engine oil and oil filter, cleaning the oil screen x
Warning
Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.
– Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.

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
Drain the engine oil only when the engine is warm.

Preparatory work
– Park the motorcycle on a level surface.
– Remove the engine guard. ( p. 63)
Main work
– Place a suitable container under the engine.
– Remove the oil drain plug 1 with the magnet and seal ring.

Info
Do not remove screws A on both sides.

B01125-10

– Remove plug 2 with oil screen 3 and the O-rings.

B01126-10

– Remove screws 4. Remove the oil filter cover with the O-ring.

B01128-10
17 SERVICE WORK ON THE ENGINE 93

– Pull oil filter 5 out of the oil filter housing.

Circlip pliers reverse (51012011000)
– Completely drain the engine oil.
– Thoroughly clean the parts and sealing area.

B01129-10

– Push oil screen 3 with the O-rings onto a pin wrench.

– Push the pin wrench through the opening into the drill hole of the opposite engine
case wall and push the oil screen as far as possible into the engine case.

B01127-10

– Mount and tighten screw plug 2 with the O-ring.

Guideline
Screw plug, oil screen M20x1.5 15 Nm
(11.1 lbf ft)
– Mount and tighten the oil drain plug 1 with the magnet and a new seal ring.
Guideline
Oil drain plug with magnet M12x1.5 20 Nm
(14.8 lbf ft)
B01131-10

– Lay the motorcycle on its side and fill the oil filter housing to about ⅓ full with
engine oil.
– Insert the oil filter into the oil filter housing.
– Oil the O-ring of the oil filter cover and mount it with oil filter cover 6.
– Mount and tighten the screws.
Guideline
Screw, oil filter cover M6 10 Nm (7.4 lbf ft)
– Stand the motorcycle upright.
B01130-10

– Remove the oil filler plug 7 with the O-ring from the clutch cover and fill up with
engine oil.
Engine oil 1.20 l (1.27 qt.) Engine oil (SAE 10W/50) ( p. 108)
Alternative engine Engine oil
oil (SAE 10W/60)
(00062010035)
( p. 108)
– Install and tighten the oil filler plug with the O-ring.
B01119-11
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.

– Start the engine and check that it is oil-tight.

Finishing work
– Install the engine guard. ( p. 64)
– Check the engine oil level. ( p. 91)
17 SERVICE WORK ON THE ENGINE 94

17.4 Adding engine oil

Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.

– Remove the oil filler plug 1 with the O-ring from the clutch cover and fill up with
engine oil.
Engine oil (SAE 10W/50) ( p. 108)
Engine oil (SAE 10W/60) (00062010035) ( p. 108)

Info
For optimal performance of the engine oil, do not mix different types of
engine oil.
B01119-10
If appropriate, change the engine oil.

– Install and tighten the oil filler plug with the O-ring.

Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.

– Start the engine and check that it is oil-tight.

18 CLEANING, CARE 95

18.1 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.

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
If you clean the motorcycle regularly, its value and appearance will be maintained over a long period.
Avoid direct sunshine on the motorcycle during cleaning.

– Close off the exhaust system to keep water from entering.

– First remove coarse dirt particles with a gentle spray of water.
– Spray very dirty areas with a normal motorcycle cleaner and then clean with a
paintbrush.
Motorcycle cleaner ( p. 110)

Info
Use warm water containing normal motorcycle cleaner and a soft sponge.
401061-01 Never apply motorcycle cleaner to the dry vehicle; always rinse with water
first.

– After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly.
– Remove the plug from the exhaust system.

Warning
Danger of accidents Reduced braking efficiency due to a wet or dirty brake
system.
– Clean or dry a dirty or wet brake system by riding and braking gently.

– After cleaning, ride a short distance until the engine reaches operating tempera-
ture.

Info
The heat produced causes water at inaccessible locations in the engine and
the brake system to evaporate.

– After the motorcycle has cooled off, lubricate all moving parts and bearings.
– Clean the chain. ( p. 56)
– Treat bare metal parts (except for the brake discs and exhaust system) with anti-
corrosion materials.
Cleaning and preserving materials for metal, rubber and plastic ( p. 110)
– Treat all plastic parts and powder-coated parts with a mild cleaning and care prod-
uct.
Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic
surfaces ( p. 111)
18 CLEANING, CARE 96

18.2 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.

– Clean the motorcycle. ( p. 95)

– Clean the brakes.

Info
After EVERY trip on salted roads, thoroughly wash the brake calipers and
brake linings with cold water and dry carefully. This should be done after
the parts are cooled down and while they are installed.
After riding on salted roads, thoroughly wash the motorcycle with cold water
and dry it well.
401060-01
– Treat the engine, swingarm, and all other bright and zinc-plated parts (except for
the brake discs) with a wax-based corrosion inhibitor.

Info
Corrosion inhibitor is not permitted to come in contact with the brake discs
as this would greatly reduce the braking force.

– Clean the chain. ( p. 56)

19 STORAGE 97

19.1 Storage

Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.

Info
If you want to garage the motorcycle for a longer period, take the following steps.
Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you
should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the
start of the new season.

– When refueling for the last time before taking the motorcycle out of service, add
fuel additive.
Fuel additive ( p. 110)
– Clean the motorcycle. ( p. 95)
– Change the engine oil and oil filter, clean the oil screen. x( p. 92)
– Check the antifreeze and coolant level. ( p. 86)
– Drain the fuel from the tank into a suitable container.
401058-01 – Check the tire air pressure. ( p. 77)
– Remove the battery. x( p. 78)
– Recharge the battery. x( p. 79)
Guideline
Storage temperature of battery without 0… 35 °C (32… 95 °F)
direct sunlight
– 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. 40)

– 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.

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 exhaust system to rust.

19.2 Preparing for use after storage

– Remove the motorcycle from the lift stand. ( p. 40)
– Install the battery. x( p. 78)
– Refuel. ( p. 30)
– Perform checks and maintenance work when preparing the vehicle for use.
( p. 27)
– Take a test ride.

401059-01
20 TROUBLESHOOTING 98

Faults Possible cause Action

The engine cannot be cranked (elec- Operating error – Carry out the start procedure. ( p. 27)
tric starter) Battery is discharged – Recharge the battery. x( p. 79)
– Check the charging voltage. x
– Check the quiescent current. x
– Check the stator winding of the alternator. x
Main fuse blown – Change the main fuse. ( p. 80)
Starter relay defective – Check the starter relay.x
Starter motor defective – Check the starter motor. x
Engine turns but does not start Operating error – Carry out the start procedure. ( p. 27)
Coupling of fuel hose connection not – Join the fuel hose connection.
joined together
Fuse 1 blown – Change the fuses of individual power
consumers. ( p. 80)
Fuse 2 blown – Change the fuses of individual power
consumers. ( p. 80)
Idle speed is not set correctly – Adjust the idle speed. x( p. 90)
Spark plug oily or wet – Clean and dry the spark plug, or change it if
necessary.
Electrode distance (plug gap) of spark – Adjust the plug gap.
plug too wide Guideline
Spark plug electrode gap
1.0 mm (0.039 in)
Short circuit cable in wiring harness – Check the wiring harness. (visual check)
frayed, kill switch defective – Check the electrical system.
Defect in fuel injection system – Read out the fault memory using the KTM diag-
nostics tool. x
Engine does not speed up Defect in fuel injection system – Read out the fault memory using the KTM diag-
nostics tool. x
Engine has too little power Air filter is very dirty – Clean the air filter and air filter housing. x
( p. 51)
Fuel filter is very dirty – Change the fuel filter. x
Fuel screen is very dirty – Change the fuel screen. x ( p. 91)
Defect in fuel injection system – Read out the fault memory using the KTM diag-
nostics tool. x
Exhaust system leaky, deformed or – Check exhaust system for damage.
too little glass fiber yarn filling in – Change the glass fiber yarn filling of the main
main silencer silencer. ( p. 53)
x
Valve clearance too little – Adjust the valve clearance. x
Engine dies during the trip Lack of fuel – Refuel. ( p. 30)
Fuse 1 blown – Change the fuses of individual power
consumers. ( p. 80)
Fuse 2 blown – Change the fuses of individual power
consumers. ( p. 80)
Engine overheats Too little coolant in cooling system – Check the cooling system for leaks.
– Check the coolant level. ( p. 87)
Too little air stream – Switch off the engine when standing.
Radiator fins very dirty – Clean the radiator fins.
Foam formation in cooling system – Drain the coolant. x( p. 87)
– Refill the coolant. x ( p. 88)
Bent radiator hose – Change the radiator hose.x
Defect in radiator fan system – Check fuse 4.
– Check the radiator fan. x
20 TROUBLESHOOTING 99

Faults Possible cause Action

FI warning lamp (MIL) lights Defect in fuel injection system – Stop the motorcycle and identify the faulty part
up/flashes using the blink code.

Info
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. x
High oil consumption Engine vent hose bent – Route the vent hose without bends or change it
if necessary.
Engine oil level too high – Check the engine oil level. ( p. 91)
Engine oil too thin (low viscosity) – Change the engine oil and oil filter, clean the
oil screen.x ( p. 92)
Piston and cylinder worn – Measure the piston/cylinder mounting clear-
ance. x
Battery is discharged Battery is not being charged by alter- – Check the charging voltage.x
nator – Check the stator winding of the alternator. x
Unwanted power consumer – Check the quiescent current. x
Speedometer values deleted (time, The battery in the speedometer is – Change the speedometer battery. ( p. 85)
stop watch, lap times) discharged
The high beam, low beam, parking Fuse 3 blown – Change the fuses of individual power
light, tail light, and license plate consumers. ( p. 80)
lamp are not working
The speedometer, horn, brake light, Fuse 4 blown – Change the fuses of individual power
turn signal, and radiator fan are not consumers. ( p. 80)
functional
21 BLINK CODE 100

Blink code of FI warning

lamp (MIL)
45 FI warning lamp (MIL) flashes 4x long, 5x short
Error level condition Freeride 350 EU
Lambda sensor heater cylinder 1, sensor 1 - short circuit to ground or open circuit
Freeride 350 EU
Lambda sensor heater cylinder 1, sensor 1 - input signal too high

Blink code of FI warning

lamp (MIL)
09 FI warning lamp (MIL) flashes 9x short
Error level condition Manifold absolute pressure sensor cylinder 1 - input signal too low
Manifold absolute pressure sensor cylinder 1 - input signal too high

Blink code of FI warning

lamp (MIL)
13 FI warning lamp (MIL) flashes 1x long, 3x short
Error level condition Intake air temperature sensor - input signal too low
Intake air temperature sensor - input signal too high

Blink code of FI warning

lamp (MIL)
12 FI warning lamp (MIL) flashes 1x long, 2x short
Error level condition Engine coolant temperature sensor - input signal too low
Engine coolant temperature sensor - input signal too high

Blink code of FI warning

lamp (MIL)
06 FI warning lamp (MIL) flashes 6x short
Error level condition Throttle position sensor circuit A - input signal too low
Throttle position sensor circuit A - input signal too high

Blink code of FI warning

lamp (MIL)
17 FI warning lamp (MIL) flashes 1x long, 7x short
Error level condition Freeride 350 EU
Lambda sensor cylinder 1, sensor 1 - circuit fault

Blink code of FI warning

lamp (MIL)
33 FI warning lamp (MIL) flashes 3x long, 3x short
Error level condition Injector cylinder 1 - circuit fault

Blink code of FI warning

lamp (MIL)
02 FI warning lamp (MIL) flashes 2x short
Error level condition Crankshaft position sensor - circuit fault

Blink code of FI warning

lamp (MIL)
37 FI warning lamp (MIL) flashes 3x long, 7x short
Error level condition Ignition coil 1, cylinder 1 - circuit fault

Blink code of FI warning

lamp (MIL)
41 FI warning lamp (MIL) flashes 4x long, 1x short
Error level condition Fuel pump relay - short circuit to ground or open circuit
Fuel pump control - input signal too low
21 BLINK CODE 101

Blink code of FI warning

lamp (MIL)
15 FI warning lamp (MIL) flashes 1x long, 5x short
Error level condition Rollover sensor (A/D type) - input signal too low
Rollover sensor (A/D type) - input signal too high
22 TECHNICAL DATA 102

22.1 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)
Valve diameter, exhaust 29.1 mm (1.146 in)
Valve clearance
Intake at: 20 °C (68 °F) 0.10… 0.15 mm (0.0039… 0.0059 in)
Exhaust at: 20 °C (68 °F) 0.13… 0.18 mm (0.0051… 0.0071 in)
Crankshaft bearing 2 cylinder bearings
Conrod bearing Needle bearing
Piston pin bearing Not a bearing bush - DLC-plated piston pins
Pistons Forged light alloy
Piston rings 1 compression ring, 1 oil scraper ring
Engine lubrication Pressure circulation lubrication with two Eaton pumps
Primary transmission 24:73
Clutch Multidisc clutch in oil bath/hydraulically activated
Transmission ratio
1st gear 14:32
2nd gear 16:26
3rd gear 20:25
4th gear 22:23
5th gear 25:22
6th gear 26:20
Alternator 12 V, 168 W
Ignition Contactless controlled fully electronic ignition with digital igni-
tion adjustment
Spark plug NGK LMAR9AI-10
Spark plug electrode gap 1.0 mm (0.039 in)
Cooling Water cooling, permanent circulation of coolant by water pump
Starting aid Electric starter

22.2 Engine tightening torques

Jet, crank chamber ventilation M4 2 Nm (1.5 lbf ft) Loctite® 243™
Oil jet for alternator cooling M4 2 Nm (1.5 lbf ft) Loctite® 243™
Oil jet for balancer shaft lubrication M4 2 Nm (1.5 lbf ft) Loctite® 243™
Oil nozzle for conrod bearing lubrica- M4 2 Nm (1.5 lbf ft) Loctite® 243™
tion
Screw, oil jet for piston cooling M4 2 Nm (1.5 lbf ft) Loctite® 243™
Locking screw for bearing M5 6 Nm (4.4 lbf ft) Loctite® 243™
Oil jet for cam lever lubrication M5 3 Nm (2.2 lbf ft) Loctite® 243™
Oil jet for clutch lubrication M5 6 Nm (4.4 lbf ft) Loctite® 243™
Oil jet, piston cooling M5 2 Nm (1.5 lbf ft) Loctite® 243™
Screw cap, oil channel in alternator M5 3 Nm (2.2 lbf ft) Loctite® 243™
cover
Screw, clutch spring M5 6 Nm (4.4 lbf ft) –
Screw, crankshaft position sensor M5 6 Nm (4.4 lbf ft) Loctite® 243™
22 TECHNICAL DATA 103

Screw, locking lever M5 6 Nm (4.4 lbf ft) Loctite® 243™

Screw, oil pump cover M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, stator M5 6 Nm (4.4 lbf ft) Loctite® 243™
Nut, cylinder head M6 10 Nm (7.4 lbf ft) Lubricated with engine oil
Nut, water-pump wheel M6 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, alternator cover M6 6 Nm (4.4 lbf ft) –
Screw, clutch cover M6 10 Nm (7.4 lbf ft) –
Screw, clutch slave cylinder M6 10 Nm (7.4 lbf ft) –
Screw, engine case M6 10 Nm (7.4 lbf ft) –
Screw, exhaust flange M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, oil filter cover M6 10 Nm (7.4 lbf ft) –
Screw, shift drum locating M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, shift lever M6 14 Nm (10.3 lbf ft) Loctite® 243™
Screw, starter motor M6 10 Nm (7.4 lbf ft) –
Screw, timing chain guide rail M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, timing chain securing guide M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, valve cover M6 8 Nm (5.9 lbf ft) –
Screw, water pump cover M6 10 Nm (7.4 lbf ft) –
Stud, cylinder head M6 10 Nm (7.4 lbf ft) –
Screw, camshaft bearing bridge M7x1 14 Nm (10.3 lbf ft) Lubricated with engine oil
Screw plug, crankshaft location M8 10 Nm (7.4 lbf ft) –
Screw, timing chain tensioning rail M8 15 Nm (11.1 lbf ft) Loctite® 243™
Screw, engine sprocket M10 60 Nm (44.3 lbf ft) Loctite® 2701
Plug, oil channel M10x1 15 Nm (11.1 lbf ft) Loctite® 243™
Rotor screw M10x1 70 Nm (51.6 lbf ft) Thread, oiled with engine
oil/cone degreased
Screw plug, cam lever axis M10x1 10 Nm (7.4 lbf ft) –
Screw, unlocking of timing chain ten- M10x1 10 Nm (7.4 lbf ft) –
sioner
Spark plug M10x1 10… 12 Nm (7.4… –
8.9 lbf ft)
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) Loctite® 243™
Screw, camshaft drive sprocket M12x1 70 Nm (51.6 lbf ft) Loctite® 243™/cone
degreased
Engine coolant temperature sensor M12x1.5 12 Nm (8.9 lbf ft) –
Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –
Plug, oil pressure regulator valve M12x1.5 20 Nm (14.8 lbf ft) –
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 M18LHx1.5 100 Nm (73.8 lbf ft) Loctite® 243™
Screw plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) –
Plug, timing chain tensioner M24x1.5 25 Nm (18.4 lbf ft) –
Screw, alternator cover M24x1.5 18 Nm (13.3 lbf ft) –
22 TECHNICAL DATA 104

22.3 Capacities
22.3.1 Engine oil
Engine oil 1.20 l (1.27 qt.) Engine oil (SAE 10W/50) ( p. 108)
Alternative engine oil Engine oil (SAE 10W/60)
(00062010035) ( p. 108)

22.3.2 Coolant
Coolant 0.7 l (0.7 qt.) Coolant ( p. 108)
Coolant (mixed ready to use) ( p. 108)

22.3.3 Fuel
Total fuel tank capacity, 4.8 l (1.27 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 109)
approx.

Fuel reserve, approx. 1.5 l (1.6 qt.)

22.4 Chassis
Frame Perimeter, steel-aluminum composite frame
fork WP Suspension 4357 MXMA
Suspension travel
Front 250 mm (9.84 in)
Rear 260 mm (10.24 in)
Fork offset 20 mm (0.79 in)
Shock absorber WP Suspension 4618 BAVP DCC
Brake system
Front Disc brake with radially mounted four-piston brake caliper
Rear Disc brake with radially mounted dual-piston brake caliper
Brake discs - diameter
Front 260 mm (10.24 in)
Rear 210 mm (8.27 in)
Brake discs - wear limit
Front 2.5 mm (0.098 in)
Rear 3.5 mm (0.138 in)
Tire air pressure off road
Front 0.9 bar (13 psi)
Rear 0.7 bar (10 psi)
Tire air pressure, road
Front 1.5 bar (22 psi)
Rear 1.5 bar (22 psi)
Secondary ratio 11:48
Chain 5/8 x 1/4” X‑ring
Rear sprockets available 46, 48, 50
Steering head angle 67°
Wheelbase 1,428±10 mm (56.22±0.39 in)
Ground clearance, unloaded 325 mm (12.8 in)
Seat height, unloaded 895 mm (35.24 in)
Weight without fuel, approx. 101 kg (223 lb.)
Maximum permissible front axle load 135 kg (298 lb.)
Maximum permissible rear axle load 175 kg (386 lb.)
Maximum permissible overall weight 280 kg (617 lb.)
22 TECHNICAL DATA 105

22.5 Electrical system

Battery YTX4L-BS Battery voltage: 12 V
Nominal capacity: 3 Ah
Maintenance-free
Speedometer battery CR 2430 Battery voltage: 3 V
Fuse 58011109110 10 A
Fuse 58011109120 20 A
Headlight S2/socket BA20d 12 V
35/35 W
Parking light W5W/socket W2.1x9.5d 12 V
5W
Indicator lamps W2.3W/socket W2x4.6d 12 V
2.3 W
Turn signal R10W/socket BA15s 12 V
10 W
Brake/tail light LED
License plate lamp W5W/socket W2.1x9.5d 12 V
5W

22.6 Tires
Front tires Rear tires
2.75 - 21 M/C 45M TT 4.00 R 18 M/C 64M TL
Dunlop D 803 F Dunlop D 803
Additional information is available in the Service section under:
http://www.ktm.com

22.7 Fork
Fork part number 05.18.7L.40
fork WP Suspension 4357 MXMA
Compression damping
Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Rebound damping
Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Spring length with preload spacer(s)
Weight of rider: 65… 75 kg (143… 165 lb.) 445 mm (17.52 in)
Weight of rider: 75… 85 kg (165… 187 lb.) 445 mm (17.52 in)
Weight of rider: 85… 95 kg (187… 209 lb.) 445 mm (17.52 in)
Spring rate
Weight of rider: 65… 75 kg (143… 165 lb.) 4.4 N/mm (25.1 lb/in)
Weight of rider: 75… 85 kg (165… 187 lb.) 4.6 N/mm (26.3 lb/in)
Weight of rider: 85… 95 kg (187… 209 lb.) 4.8 N/mm (27.4 lb/in)
Fork length 835 mm (32.87 in)
Air chamber length 120+10 +0.39
−40 mm (4.72−1.57 in)

Fork oil per fork leg 375 ml (12.68 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 109)
22 TECHNICAL DATA 106

22.8 Shock absorber

Shock absorber part number 15.18.7L.40
Shock absorber WP Suspension 4618 BAVP 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 20 clicks
Standard 15 clicks
Sport 10 clicks
Spring preload
Comfort 10 mm (0.39 in)
Standard 10 mm (0.39 in)
Sport 10 mm (0.39 in)
Spring rate
Weight of rider: 65… 75 kg (143… 165 lb.) 58 N/mm (331 lb/in)
Weight of rider: 75… 85 kg (165… 187 lb.) 62 N/mm (354 lb/in)
Weight of rider: 85… 95 kg (187… 209 lb.) 66 N/mm (377 lb/in)
Spring length 215 mm (8.46 in)
Gas pressure 10 bar (145 psi)
Static sag 15 mm (0.59 in)
Riding sag 75 mm (2.95 in)
Fitted length 367 mm (14.45 in)

Shock absorber oil Shock absorber oil (SAE 2.5) (50180342S1) ( p. 109)

22.9 Chassis tightening torques

Spoke nipple M4.5 5… 6 Nm (3.7… 4.4 lbf ft) –
Screw, battery terminal M5 2.5 Nm (1.84 lbf ft) –
Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft) –
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft) –
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –
Screw, ball joint of push rod on foot M6 10 Nm (7.4 lbf ft) Loctite® 243™
brake cylinder
Screw, front brake disc M6 14 Nm (10.3 lbf ft) Loctite® 243™
Screw, rear brake disc M6 14 Nm (10.3 lbf ft) Loctite® 243™
Screws, throttle grip M6 3 Nm (2.2 lbf ft) –
Fuel connection on fuel pump M8 10 Nm (7.4 lbf ft) –
Nut, foot brake lever stop M8 20 Nm (14.8 lbf ft) –
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite® 243™
Nut, rim lock M8 10 Nm (7.4 lbf ft) –
Remaining nuts, chassis M8 25 Nm (18.4 lbf ft) –
Remaining screws, chassis M8 25 Nm (18.4 lbf ft) –
Screw of rear brake caliper M8 25 Nm (18.4 lbf ft) Loctite® 243™
Screw, bottom triple clamp M8 18 Nm (13.3 lbf ft) –
Screw, chain sliding piece M8 15 Nm (11.1 lbf ft) –
Screw, fork stub M8 15 Nm (11.1 lbf ft) –
22 TECHNICAL DATA 107

Screw, front brake caliper M8 25 Nm (18.4 lbf ft) Loctite® 243™

Screw, fuel tank M8 15 Nm (11.1 lbf ft) –
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –
Screw, side stand attachment M8 25 Nm (18.4 lbf ft) Loctite® 243™
Screw, subframe M8 30 Nm (22.1 lbf ft) Loctite® 243™
Screw, top steering stem M8 17 Nm (12.5 lbf ft) Loctite® 243™
Screw, top triple clamp M8 22 Nm (16.2 lbf ft) –
Nut, fuel tank attachment M10 10 Nm (7.4 lbf ft) –
Remaining nuts, chassis M10 45 Nm (33.2 lbf ft) –
Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –
Screw, cross bar M10 45 Nm (33.2 lbf ft) –
Screw, engine bracket screw M10 60 Nm (44.3 lbf ft) –
Screw, foot brake lever M10 30 Nm (22.1 lbf ft) Loctite® 243™
Screw, footrest bracket M10 45 Nm (33.2 lbf ft) Loctite® 243™
Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite® 243™
Screw, upper subframe M10 45 Nm (33.2 lbf ft) Loctite® 243™
Nut, fuel pump fixation M12 15 Nm (11.1 lbf ft) –
Screw, bottom shock absorber M12 80 Nm (59 lbf ft) Loctite® 243™
Screw, top shock absorber M12 80 Nm (59 lbf ft) Loctite® 243™
Nut, swingarm pivot M14x1.5 75 Nm (55.3 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) –
23 SUBSTANCES 108

Brake fluid DOT 4 / DOT 5.1

According to
– DOT
Guideline
– Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre-
sponding properties. KTM recommends Castrol and Motorex® products.
Supplier
Castrol
– RESPONSE BRAKE FLUID SUPER DOT 4
Motorex®
– Brake Fluid DOT 5.1

Coolant
Guideline
– Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foam-
ing. KTM recommends Motorex® products.
Mixture ratio
Antifreeze protection: −25… −45 °C (−13… 50 % corrosion inhibitor/antifreeze
−49 °F) 50 % distilled water

Coolant (mixed ready to use)

Antifreeze −40 °C (−40 °F)
Supplier
Motorex®
– COOLANT G48

Engine oil (SAE 10W/50)

According to
– JASO T903 MA ( p. 112)
– SAE ( p. 112) (SAE 10W/50)
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre-
sponding properties. KTM recommends Motorex® products.
Synthetic engine oil
Supplier
Motorex®
– Cross Power 4T

Engine oil (SAE 10W/60) (00062010035)

According to
– JASO T903 MA ( p. 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. KTM recommends Motorex® products.
Synthetic engine oil
Supplier
Motorex®
– Cross Power 4T
23 SUBSTANCES 109

Fork oil (SAE 4) (48601166S1)

According to
– SAE ( p. 112) (SAE 4)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding
properties.

Shock absorber oil (SAE 2.5) (50180342S1)

According to
– SAE ( p. 112) (SAE 2.5)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding
properties.

Super unleaded (ROZ 95/RON 95/PON 91)

According to
– DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
– Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
– Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.

Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).
24 AUXILIARY SUBSTANCES 110

Air filter cleaner

Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Twin Air Dirt Bio Remover

Chain cleaner
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Chain Clean

Cleaning and preserving materials for metal, rubber and plastic

Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Protect & Shine

Fuel additive
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Fuel Stabilizer

High viscosity grease

Guideline
– KTM recommends SKF® products.
Supplier
SKF®
– LGHB 2

Long-life grease
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Bike Grease 2000

Motorcycle cleaner
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Moto Clean 900

Off-road chain spray

Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Chainlube Offroad
24 AUXILIARY SUBSTANCES 111

Oil for foam air filter

Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Twin Air Liquid Bio Power

Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Clean & Polish

Rubber grip adhesive (00062030051)

Supplier
KTM-Sportmotorcycle AG
– GRIP GLUE

Universal oil spray

Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Joker 440 Synthetic
25 STANDARDS 112

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. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the fore-
ground for motorcycle engines. In most motorcycles, the gearbox and the clutch are lubricated with the same oil as the engine. The
JASO MA Standard meets these special requirements.

SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis-
cosity. The viscosity describes only one property of oil and says nothing about quality.
INDEX 113

Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INDEX

A basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 62

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Compression damping
Air filter fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Compression damping, high-speed
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 34
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Compression damping, low-speed
Air filter housing shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 33
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Coolant
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Antifreeze
Coolant level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86-87
Auxiliary substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
B Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Basic chassis setting E
checking with rider's weight . . . . . . . . . . . . . . . . . . . . 33 Electric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Battery Emergency OFF switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Engine
recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Engine guard
Blink code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-101 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Brake discs removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Brake fluid Engine oil
front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 66 adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 70 changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Brake fluid level Engine oil level
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 66 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 70
Engine sprocket
Brake linings checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
front brake, changing . . . . . . . . . . . . . . . . . . . . . . . . 67
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 67
rear brake, changing .. . . . . . . . . . . . . . . . . . . . . . . . 71 F
rear brake, checking .. . . . . . . . . . . . . . . . . . . . . . . . 71 Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-73 Filler cap
C closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Capacity
Filling up
coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88, 104
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93, 104
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30, 104 Foot brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 69
Chain
free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 69
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Fork legs
basic setting, checking . . . . . . . . . . . . . . . . . . . . . . . 37
Chain guide
bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
dust boots, cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 41
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Chain tension removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fork protector
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Clutch Frame
fluid level, checking . . . . . . . . . . . . . . . . . . . . . . . . . 62 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
fluid level, correcting . . . . . . . . . . . . . . . . . . . . . . . . 62
Front fender
fluid, changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
INDEX 114

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 O
Front wheel Oil filter
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Oil screen
Fuel screen cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Operating substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel tank Overview of indicator lamps . . . . . . . . . . . . . . . . . . . . . . . 15
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Owner's Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
P
Fuse
individual power consumers, changing . . . . . . . . . . . . . 80 Play in the throttle cable
main fuse, changing . . . . . . . . . . . . . . . . . . . . . . . . . 80 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
H
Preparing for use
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . 25
free travel, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 65 after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 65 checks and maintenance work when preparing for use . . 27
Handlebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Protective clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
R
Headlight
headlight range, adjusting . . . . . . . . . . . . . . . . . . . . . 84 Rear sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Headlight bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Rear wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Headlight mask with headlight
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Rebound damping
fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Headlight setting
shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 34
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Riding sag
Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
I
Rubber grip
Idle speed checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Idle speed adjusting screw . . . . . . . . . . . . . . . . . . . . . . . . 22 S
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
K Seat
Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 folding up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Kill switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
L Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-32

Lower triple clamp Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 90
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 basic position, checking . . . . . . . . . . . . . . . . . . . . . . 90

M Shock absorber
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Main fuse removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 riding sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 36
Main silencer spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . . 36
glass fiber yarn filling, changing . . . . . . . . . . . . . . . . . 53 static sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 35
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Motorcycle Speedometer
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 adjusting . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . 16
raising with lift stand . . . . . . . . . . . . . . . . . . . . . . . . 40 battery, changing . . . . . . .... . . . . . . . . . . . . . . . . . 85
removing from lift stand . . . . . . . . . . . . . . . . . . . . . . 40 clock, setting . . . . . . . . . .... . . . . . . . . . . . . . . . . . 17
kilometers or miles, setting ... . . . . . . . . . . . . . . . . . 16
overview . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . 15
INDEX 115

Spoiler
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Spoke tension
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Steering
locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Steering head bearing
greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Steering head bearing play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Swingarm
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
T
Technical data
capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
chassis tightening torques . . . . . . . . . . . . . . . . . . . . 106
electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . 105
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
engine tightening torques . . . . . . . . . . . . . . . . . . . . 102
fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Throttle cable routing
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Throttle grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Tire air pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98-99
Turn signal bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Turn signal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
U
Use definition ................................. 6
V
View of vehicle
left front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
rear right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Winter operation
checks and maintenance steps . . . . . . . . . . . . . . . . . . 96
Work rules ................................... 7
*3211907en*
3211907en

07/2012

KTM-Sportmotorcycle AG
5230 Mattighofen/Austria Photo: Mitterbauer/KTM
http://www.ktm.com