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• Page 1
  REPAIR MANUAL 2012 350 EXC‑F EU 350 EXC‑F AUS 350 EXC‑F SIX DAYS EU 350 XCF‑W USA 350 EXC‑F USA Art. no. 3206111en…
• Page 3
  KTM accepts no liability for deliv- ery options, deviations from illustrations and descriptions, as well as for printing and other errors.

• Page 4: Table Of Contents

  TABLE OF CONTENTS Adjusting the low-speed compression damping of the TABLE OF CONTENTS MEANS OF REPRESENTATION ……….6 shock absorber ………….. 41 IMPORTANT NOTES …………7 Adjusting the rebound damping of the shock absorber..42 SERIAL NUMBERS………….. 8 Measuring rear wheel sag unloaded ……… 42 Chassis number……………

• Page 5
  TABLE OF CONTENTS Checking the tire condition……….82 Removing the torque limiter ……… 120 Checking tire air pressure ……….82 Positioning the engine at ignition top dead center… 121 Checking spoke tension……….83 Removing the timing chain tensioner……121 10/REAR WHEEL ………….. 84 Removing the camshaft……….
• Page 6
  TABLE OF CONTENTS Preassembling the shift shaft……..152 39/IGNITION SYSTEM …………. 186 Disassembling the main shaft ……..152 Ignition coil — checking the secondary winding….186 Disassembling the countershaft ……..153 Checking the spark plug connector…….. 186 Checking the transmission……….153 Alternator — checking the stator winding……
• Page 7
  TABLE OF CONTENTS Page 4 of 7 (XCF‑W) ………… 260 Page 5 of 7 (XCF‑W) ………… 262 Page 6 of 7 (XCF‑W) ………… 264 Page 7 of 7 (XCF‑W) ………… 266 SUBSTANCES…………..268 AUXILIARY SUBSTANCES……….270 SPECIAL TOOLS………….. 272 STANDARDS…………..285 INDEX …………….

• Page 8: Means Of Representation

  MEANS OF REPRESENTATION 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). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips.

• Page 9: Important Notes

  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 claim can be honored for damage resulting from manipulation and/or other changes to the vehicle.

• Page 10: Serial Numbers

  SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. C00125-10 Type label (XCF‑W, EXC‑F EU/AUS, EXC-F SIX DAYS) The type label is fixed to the front of the steering head. 101290-10 (EXC-F USA) The type label USA is fixed to the front of the steering head.

• Page 11: Engine Number

  SERIAL NUMBERS (EXC-F USA) Key number for the ignition and steering lock is indicated on the KEYCODECARD. Info You need the key number to order a replacement key. Keep the KEYCODE- CARD in a safe place. 101543-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.

• Page 12: Motorcycle

  MOTORCYCLE 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) ( p.

• Page 13: Starting The Motorcycle For A Check

  MOTORCYCLE Starting the motorcycle for a check Danger Danger of poisoning Exhaust gases are poisonous 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.

• Page 14: 01/Fork, Triple Clamp

  01/FORK, TRIPLE CLAMP Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Remove protection caps – Turn adjusting screws clockwise all the way. Info Adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs.

• Page 15: Bleeding Fork Legs

  01/FORK, TRIPLE CLAMP Info Turn clockwise to increase spring preload; turn counterclockwise to reduce spring preload. Adjusting the spring preload has no influence on the absorption setting of the rebound damping. Basically, however, you should set the rebound damping higher with a higher spring preload.

• Page 16: Loosening The Fork Protector

  01/FORK, TRIPLE CLAMP Loosening the fork protector – Remove screws and remove the clamp. – Remove screws on the left fork leg. Push the fork protector downwards. – Remove the screws on the right fork leg. Push the fork protector downwards. 101321-10 Positioning the fork protection –…

• Page 17: Installing The Fork Legs

  01/FORK, TRIPLE CLAMP (EXC-F SIX DAYS) – Release screws . Take out the left fork leg. – Release screws . Take out the right fork leg. 101324-10 Installing the fork legs Main work – Position the fork legs. Info The topmost milled groove in the fork leg must be flush with the top edge of the upper triple clamp.

• Page 18: Removing The Fork Protector

  01/FORK, TRIPLE CLAMP – Position the brake line, wiring harness, and clamp. Mount and tighten screws Subsequent work – Install the front wheel. ( p. 80) Removing the fork protector 5.10 Preliminary work – Remove the headlight mask with the headlight. ( p.

• Page 19: Disassembling The Fork Legs

  01/FORK, TRIPLE CLAMP – Disassemble the fork legs. ( p. 17) – Disassemble the cartridge. ( p. 20) – Check the fork legs. ( p. 22) – Assemble the cartridge. ( p. 24) – Assemble the fork legs. ( p. 26) 200979-01 Disassembling the fork legs 5.13…

• Page 20
  01/FORK, TRIPLE CLAMP – Take out the fork leg and clamp with the axle clamp. Info Use soft jaws. 200690-10 – Push the outer tube downward. – Pull the spring downward. Place the special tool on the hexagonal part. Open-end wrench (T14032) ( p.
• Page 21
  01/FORK, TRIPLE CLAMP – Clamp the fork leg with the axle clamp. – Unscrew and remove the compression damping fitting Info Place a fluid collector beneath it, as usually some oil will drain out. 200691-10 – Remove the cartridge. 201350-10 –…

• Page 22: Cartridge Disassembly

  01/FORK, TRIPLE CLAMP – Take off the lower sliding bushing – Take off support ring – Take off seal ring – Take off lock ring – Take off dust boot – Take out the fork leg. 200659-11 Cartridge disassembly 5.14 Info The steps are identical for both fork legs.

• Page 23: Disassembling The Compression Damping Fitting

  01/FORK, TRIPLE CLAMP – Degrease the piston rod. – Clamp the piston rod with the special tool. Clamping stand (T14016S) ( p. 282) 200697-10 – Remove nut – Remove shim stack completely. 200698-10 – Remove piston – Remove shim stack completely.

• Page 24: Checking The Fork Legs

  01/FORK, TRIPLE CLAMP Main work – Clamp the compression damping fitting in a bench vise using soft jaws. – Remove nut – Remove the spring. – Remove washer 200702-10 – Remove piston – Remove shim stack 200703-10 – Remove O-ring and seal ring from the compression damping fitting.

• Page 25: Assembling The Compression Damping Fitting

  01/FORK, TRIPLE CLAMP – Measure the run-out of the inner tube. ≤ 0.20 mm (≤ 0.0079 in) Inner tub run-out » If the measured value is greater than the specified value: – Change the inner tube. 200685-10 – Check the outer tube for damage. »…

• Page 26: Assembling The Cartridge

  01/FORK, TRIPLE CLAMP – Mount shim stack Info Mount the smaller shims below. – Mount pistons with O-ring Info The side with the largest inside diameter faces upward. 200705-10 – Grease the piston O-ring. Fork oil (SAE 5) ( p. 269) –…

• Page 27
  01/FORK, TRIPLE CLAMP Info The side with the largest inside diameter faces downward. – Mount shim stack Info Align the triangular plate exactly with the piston opening. – Mount and tighten nut Guideline Tap rebound nut M6x0.5 5 Nm (3.7 lbf ft) 200720-10 Info Mount the nut with the collar facing downward.

• Page 28: Assembling The Fork Legs

  01/FORK, TRIPLE CLAMP Assembling the fork legs 5.19 Info The steps are identical for both fork legs. Preliminary work – Check the fork legs. ( p. 22) – Assemble the cartridge. ( p. 24) – Assemble the compression damping fitting. ( p.

• Page 29
  01/FORK, TRIPLE CLAMP – Position the support ring. – Hold the seal ring with the shorter shoulder of the special tool. Assembly tool (T1402S) ( p. 283) – Press the outer tube all the way in. 201355-10 – Mount lock ring Info The lock ring must audibly lock into place.
• Page 30
  01/FORK, TRIPLE CLAMP – Clamp in the fork vertically. – Fill with fork oil. Fork oil per fork 620 ml Fork oil (SAE 5) ( p. 269) (20.96 fl. oz.) Info Pull out the piston rod and push back in a number of times to bleed the car- tridge.
• Page 31
  01/FORK, TRIPLE CLAMP – Push the outer tube upward. – Clamp the outer tube in the area of lower triple clamp. Clamping stand (T1403S) ( p. 283) – Grease the Preload Adjuster O-ring. Lubricant (T158) ( p. 270) – Screw on and tighten the Preload Adjuster. Guideline 200744-10 Preload Adjuster on the outer tube…

• Page 32: Greasing The Steering Head Bearing

  01/FORK, TRIPLE CLAMP Greasing the steering head bearing 5.20 (EXC-F SIX DAYS) – Remove the lower triple clamp. ( p. 30) – Install the lower triple clamp. ( p. 31) (EXC‑F EU/AUS/USA, XCF‑W) – Remove the lower triple clamp. ( p.

• Page 33: Installing The Lower Triple Clamp (Exc-F Six Days)

  01/FORK, TRIPLE CLAMP Installing the lower triple clamp (EXC-F SIX DAYS) 5.22 Main work – Clean the bearing and sealing elements, check for damage, and grease. 0 0 3 High viscosity grease ( p. 270) 0 0 2 – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

• Page 34: Removing The Lower Triple Clamp (Exc-F Eu/Aus/Usa, Xcf-W)

  01/FORK, TRIPLE CLAMP – Mount and tighten screw Guideline Screw, top steering stem 17 Nm Loctite ® 243™ (12.5 lbf ft) 101341-10 – Tighten screws Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) – Secure the wiring harness with cable holder 101339-11 –…

• Page 35: Installing The Lower Triple Clamp (Exc-F Eu/Aus/Usa, Xcf-W)

  01/FORK, TRIPLE CLAMP – Remove O-ring . Remove protective ring – Take out the lower triple clamp with the steering stem. – Take out the upper steering head bearing. 101329-10 Installing the lower triple clamp (EXC‑F EU/AUS/USA, XCF‑W) 5.24 Main work –…

• Page 36
  01/FORK, TRIPLE CLAMP (EXC-F USA) – Tighten screw Guideline Screw, bottom triple clamp 15 Nm (11.1 lbf ft) 101490-10 – Tighten screw Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) 101428-10 – Tighten screw Guideline Screw, top steering stem 20 Nm (14.8 lbf ft) 101334-11…

• Page 37: Checking The Steering Head Bearing Play

  01/FORK, TRIPLE CLAMP Subsequent work – 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. 35) – Remove the motorcycle from the lift stand. ( p.

• Page 38: Adjusting The Play Of The Steering Head Bearing (Exc-F Eu/Aus/Usa, Xcf-W)

  01/FORK, TRIPLE CLAMP Subsequent work – Check the steering head bearing play. ( p. 35) – Remove the motorcycle from the lift stand. ( p. 10) Adjusting the play of the steering head bearing (EXC‑F EU/AUS/USA, XCF‑W) 5.27 Preliminary work –…

• Page 39: 02/Handlebar, Instruments

  02/HANDLEBAR, INSTRUMENTS Handlebar position On the upper triple clamp, there are two holes at a distance of to each other. Hole distance 15 mm (0.59 in) The holes on the handlebar supports are placed at a distance of from the center. 0 0 A Hole distance 3.5 mm (0.138 in)

• Page 40: Checking The Throttle Cable Routing

  02/HANDLEBAR, INSTRUMENTS Checking the throttle cable routing Preliminary work – Remove the seat. ( p. 69) – Remove the fuel tank. ( p. 70) (XCF‑W, EXC‑F EU/AUS, EXC-F SIX DAYS) – 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 tank bearing.

• Page 41: Adjusting The Play In The Throttle Cable

  02/HANDLEBAR, INSTRUMENTS Danger Danger of poisoning Exhaust gases are poisonous 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.

• Page 42: 03/Frame

  03/FRAME Removing the engine guard (EXC‑F AUS, EXC-F SIX DAYS) – Turn quick release counterclockwise until it disengages. Remove the engine guard. 101368-10 Installing the engine guard (EXC‑F AUS, EXC-F SIX DAYS) – Attach the engine guard on the frame at the rear and swing up at the front. –…

• Page 43: 04/Shock Absorber, Swingarm

  04/SHOCK ABSORBER, SWINGARM 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. Info The high-speed setting can be seen during the fast compression of the shock absorber. –…

• Page 44: Adjusting The Rebound Damping Of The Shock Absorber

  04/SHOCK ABSORBER, SWINGARM 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. – Turn adjusting screw clockwise up to the last perceptible click.

• Page 45: Checking The Riding Sag Of The Shock Absorber

  04/SHOCK ABSORBER, SWINGARM Checking the riding sag of the shock absorber – Measure distance of rear wheel unloaded. ( p. 42) – 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 0 0 A and down a few times.

• Page 46: Adjusting The Riding Sag

  04/SHOCK ABSORBER, SWINGARM Adjusting the riding sag Preliminary work – Raise the motorcycle with the lift stand. ( p. 10) – Remove shock absorber. ( p. 44) – After removing the shock absorber, clean it thoroughly. Main work – Choose and mount a suitable spring. Guideline Spring rate Weight of rider: 65……

• Page 47: Servicing The Shock Absorber

  04/SHOCK ABSORBER, SWINGARM Subsequent work – Remove the motorcycle from the lift stand. ( p. 10) Servicing the shock absorber 8.11 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. Condition The shock absorber has been removed.

• Page 48: Disassembling The Damper

  04/SHOCK ABSORBER, SWINGARM Disassembling the damper 8.13 Preliminary work – Remove the spring. ( p. 45) Main work – Note down the present state of rebound damping and compression damping – Completely open the adjustment elements of the rebound damping and compres- sion damping.

• Page 49: Disassembling The Piston Rod

  04/SHOCK ABSORBER, SWINGARM – Remove the piston rod. Drain the remaining oil. 201620-10 – Remove adjusting ring with the intermediate washer. 201621-10 – Remove compression adjuster . Remove the spring and piston. 200760-10 Disassembling the piston rod 8.14 Preliminary work –…

• Page 50: Disassembling The Seal Ring Retainer

  04/SHOCK ABSORBER, SWINGARM – Unscrew and remove mount – Remove rebound damping shim stack Info Guide the rebound damping shim stack onto a screwdriver and put them aside together. 200763-10 – Remove piston – Remove compression damping shim stack Info Guide the compression damping shim stack onto a screwdriver and put them aside together.

• Page 51: Replacing The Pilot Bushing

  04/SHOCK ABSORBER, SWINGARM – Remove seal ring – Remove washer from seal ring 200786-10 – Remove washer – Remove O-ring – Remove dust boot 200787-10 Replacing the pilot bushing 8.16 Preliminary work – Remove the spring. ( p. 45) – Disassemble the damper.

• Page 52: Checking The Damper

  04/SHOCK ABSORBER, SWINGARM Checking the damper 8.17 Condition The damper has been disassembled. – Measure the inside diameter on both ends and in the middle of the damper car- tridge. Damper tube Diameter 50.08 mm (1.9716 in) » If the measured value is greater than the specified value: –…

• Page 53: Removing The Heim Joint

  04/SHOCK ABSORBER, SWINGARM – Remove screwsleeve – Remove adjusting screw Info Do not lose balls and spring. 200806-10 – Remove rubber plug – From the opposite side, press rebound needle out of the piston rod. 200807-10 Removing the heim joint 8.19 Condition The shock absorber has been demounted.

• Page 54: Installing The Heim Joint

  04/SHOCK ABSORBER, SWINGARM – Place special tool underneath and press out heim joint using special tool Pressing tool (T1207S) ( p. 281) 200802-10 Installing the heim joint 8.20 – Position new heim joint and special tool. Pressing tool (T1206) ( p.

• Page 55: Assembling The Rebound Adjuster

  04/SHOCK ABSORBER, SWINGARM Assembling the rebound adjuster 8.21 – Grease O-ring of the rebound needle. Lubricant (T158) ( p. 270) – Mount rebound needle in the piston rod. Info Push in the rebound needle to the point where it is possible to mount the rebound damping adjusting screw.

• Page 56: Assembling The Piston Rod

  04/SHOCK ABSORBER, SWINGARM – Position washer on seal ring – Grease the seal ring and mount with the washer facing downward. Lubricant (T511) ( p. 270) 200794-10 – Mount centering disk – Mount rebound rubber 200795-10 Assembling the piston rod 8.23 Preliminary work –…

• Page 57: Assembling The Damper

  04/SHOCK ABSORBER, SWINGARM – Mount rebound damping shim stack with the smaller shims at the top. – Apply thread locker to the threads of the piston rod. Loctite ® 2701 – Screw on mount to the point where the piston can still be turned. 200769-10 –…

• Page 58
  04/SHOCK ABSORBER, SWINGARM Main work – Slide the spring and piston onto compression adjuster – Grease the O-ring. Lubricant (T158) ( p. 270) – Grease the threads. Lubricant (T159) ( p. 270) – Mount and tighten the compression adjuster. 200774-10 Guideline Compression adjuster M31x1…
• Page 59
  04/SHOCK ABSORBER, SWINGARM – Mount rubber cap of the reservoir. – Turn adjusting ring completely down toward the bottom. 201623-10 Alternative 1 – Turn adjusting screw clockwise with a screwdriver up to the last perceptible click. – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type.

• Page 60: Bleeding And Filling The Damper

  04/SHOCK ABSORBER, SWINGARM Bleeding and filling the damper 8.25 Info Before working with the vacuum pump, carefully read the vacuum pump operating manual. Completely open the adjusters of the rebound and compression damping. – Remove the screw from the filling port. –…

• Page 61
  04/SHOCK ABSORBER, SWINGARM – When the pressure gauge reaches the required value, turn control lever Damper to Vacuum. Guideline 3 bar The pressure gauge drops to the required value. 0 bar 200269-10 – When the pressure gauge reaches the required value, turn control lever Oil reser- voir to Vacuum.

• Page 62: Filling The Damper With Nitrogen

  04/SHOCK ABSORBER, SWINGARM Info When the piston rod is fully extended, the floating piston must be at pre- cisely this position; otherwise, damage will occur when the shock absorber compresses and rebounds. – Remove the special tool. – Remove adapter from connector of the vacuum pump.

• Page 63: Installing The Spring

  04/SHOCK ABSORBER, SWINGARM Installing the spring 8.27 – Ensure that adjusting ring is screwed on with the intermediate washer. 201614-10 – Measure the overall spring length when not under tension. – Position the spring. Guideline Spring rate Weight of rider: 65… 75 kg (143… 66 N/mm (377 lb/in) 165 lb.) Weight of rider: 75……

• Page 64: Changing The Heim Joint

  04/SHOCK ABSORBER, SWINGARM Changing the heim joint 8.28 Preliminary work – Raise the motorcycle with the lift stand. ( p. 10) Main work – Remove screw and lower the rear wheel with the swingarm as far as possible without blocking the rear wheel. Fix the rear wheel in this position. Info Raise the wheel slightly to make it easier to remove the screw.

• Page 65
  04/SHOCK ABSORBER, SWINGARM – Press in shaft seal rings on both sides with the open side facing inward. Info The heim joint for the shock absorber at the swingarm 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.

• Page 66: 05/Exhaust

  05/EXHAUST Removing the manifold Preliminary work – Raise the motorcycle with the lift stand. ( p. 10) – Remove shock absorber. ( p. 44) – Remove the main silencer. ( p. 65) Main work – Remove springs 305065-10 – Remove screw and take off the manifold.

• Page 67: Removing Main Silencer

  05/EXHAUST Removing 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. – Disconnect spring – Remove screws and take off main silencer. 101353-10 Installing the main silencer –…

• Page 68
  05/EXHAUST (EXC‑F EU/AUS, EXC-F SIX DAYS) 0 0 6 – Remove screws of connecting cap 0 0 8 – Take off the connecting cap with the perforated pipe, O-ring , and glass fiber 0 0 7 yarn filling – Remove screws and take off silencer cap with O-ring and stuffing…

• Page 69: 06/Air Filter

  06/AIR FILTER Removing the air filter box lid 10.1 – Pull off the air filter box lid in area to the side and remove to the front. 101348-10 Installing the air filter box lid 10.2 – Insert the air filter box lid into the rear area and clip it into the front area 101349-10 Removing the air filter…

• Page 70: Cleaning The Air Filter And Air Filter Box

  06/AIR FILTER – Put in both parts together, position them and fix them with air filter holder Info If the air filter is not correctly mounted, dust and dirt can penetrate into the engine and can cause damage. 101350-10 Subsequent work –…

• Page 71: 07/Fuel Tank, Seat, Trim

  07/FUEL TANK, SEAT, TRIM Opening filler cap 11.1 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –…

• Page 72: Mounting The Seat

  07/FUEL TANK, SEAT, TRIM Mounting the seat 11.4 – Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear and simultaneously push it forward. – Make sure that the seat is correctly locked in. –…

• Page 73: Installing The Fuel Tank

  07/FUEL TANK, SEAT, TRIM – Remove screw with the rubber bushing. 101357-10 – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. 101358-01 Installing the fuel tank 11.6 Danger Fire hazard Fuel is highly flammable. –…

• Page 74: Changing The Fuel Screen

  07/FUEL TANK, SEAT, TRIM – Connect the electrical plug-in connection – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Never let dirt enter the fuel line. Dirt in the fuel line clogs the injection valve. –…

• Page 75: Changing The Fuel Filter

  07/FUEL TANK, SEAT, TRIM Danger Danger of poisoning Exhaust gases are poisonous 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.

• Page 76
  07/FUEL TANK, SEAT, TRIM – Press lock – Pull back fuel pump housing 305317-10 – Change fuel screen – Mount the fuel pump housing. 305318-10 – Mount fuel filter Arrow points away from the fuel pump. – Mount hose clamps Hose clamp pliers (60029057000) ( p.

• Page 77: Changing The Fuel Pump

  07/FUEL TANK, SEAT, TRIM Changing the fuel pump 11.9 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –…

• Page 78: Checking The Fuel Pressure

  07/FUEL TANK, SEAT, TRIM – Mount and tighten screws Guideline Screw, fuel pump EJOT 3 Nm (2.2 lbf ft) 305314-10 Checking the fuel pressure 11.10 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.

• Page 79
  07/FUEL TANK, SEAT, TRIM – In the KTM diagnostics tool, read the information page and start the actuator test with «Continue». Guideline Maximum duration of the actuator test 3 min – Check the fuel pressure with the filler cap closed.

• Page 80: 08/Mask, Fender

  08/MASK, FENDER Removing the front fender 12.1 – Remove screws . Remove the front fender. – Make sure the spacers remain in place. 101345-10 Installing the front fender 12.2 – Ensure that the spacers are mounted in the fender. – Position the front fender.

• Page 81
  08/MASK, FENDER – Position the headlight mask and fix it with the rubber band Info Ensure that the retaining lugs engage in the fender. – Position the brake line and wiring harness. Put the clamp on, mount and tighten screw 101401-11 Subsequent work –…

• Page 82: 09/Front Wheel

  09/FRONT WHEEL Removing the front wheel 13.1 Preliminary work – Raise the motorcycle with the lift stand. ( p. 10) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

• Page 83: Checking The Brake Discs

  09/FRONT WHEEL – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc.

• Page 84: Installing The Front Brake Disc

  DOT marking. The first two digits indi- cate the week of manufacture and the last two digits the year of manufac- ture. KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear. »…

• Page 85: Checking Spoke Tension

  09/FRONT WHEEL – Remove the dust cap. – Check tire air pressure when tires are cold. Tire air pressure off road Front 1.0 bar (15 psi) Rear 1.0 bar (15 psi) Road tire pressure (All EXC‑F models) Front 1.5 bar (22 psi) 400695-01 Rear 1.5 bar (22 psi)

• Page 86: 10/Rear Wheel

  10/REAR WHEEL Removing the rear wheel 14.1 Preliminary work – Raise the motorcycle with the lift stand. ( p. 10) Main work – Press the brake caliper by hand on to the brake disc in order to press back the brake piston.

• Page 87: Removing The Rear Brake Disc

  10/REAR WHEEL – Position chain adjuster . Mount nut but do not tighten it yet. – Make sure that chain adjusters are fitted correctly on adjusting screws – Check the chain tension. ( p. 85) – Tighten nut Guideline Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft) Info…

• Page 88: Adjusting The Chain Tension

  10/REAR WHEEL Main work – Push the chain at the end of the chain sliding component upwards to measure the chain tension Info The lower chain section must be taut. When the chain guard is mounted, it must be possible to pull up the chain at least to the point where it makes contact with chain guard Chain wear is not always even, so you should repeat this measurement at different chain positions.

• Page 89: Adjusting The Chain Guide

  10/REAR WHEEL Adjusting the chain guide 14.7 – Remove the nut of screw – Remove screws . Take off the chain guide. Condition Number of teeth: ≤ 44 teeth – Insert nut in hole . Position the chain guide. – Mount and tighten screws Guideline Remaining screws, chassis…

• Page 90
  10/REAR WHEEL – Pull on the upper part of the chain with the specified weight Guideline Weight of chain wear measurement 10… 15 kg (22… 33 lb.) 0 0 A – Measure the distance 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.

• Page 91: Checking For Chain Dirt Accumulation

  10/REAR WHEEL – Check the chain guide for wear. Info Wear is visible on the front of the chain guide. » If the light part of the chain guide is worn: – Change the chain guide. 400985-01 – Check that the chain guide is firmly seated. »…

• Page 92: 11/Wiring Harness, Battery

  11/WIRING HARNESS, BATTERY Removing the main fuse 15.1 Preliminary work – Switch off all power consumers and switch off the engine. – Remove the air filter box lid. ( p. 67) Main work – Remove the protection cover Info The main fuse is located in the starter relay under the filter box cover.

• Page 93: Changing The Fuse Of The Radiator Fan (Exc-F Six Days)

  11/WIRING HARNESS, BATTERY (EXC-F USA) Fuse 5 — 10 A — ignition Fuses res — 10 A — spare fuses Info A defective fuse can be identified by the burned-out fuse wire Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used.

• Page 94: Removing The Battery

  11/WIRING HARNESS, BATTERY Removing the battery 15.5 Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –…

• Page 95
  – 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.

• Page 96: 13/Brake System

  Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

• Page 97
  13/BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

• Page 98: Checking Free Travel Of Hand Brake Lever

  13/BRAKE SYSTEM Checking free travel of hand brake lever 16.3 Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up in the front brake circuit. The front brake can fail due to overheating.

• Page 99: Checking The Front Brake Fluid Level

  13/BRAKE SYSTEM Checking the front brake fluid level 16.6 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.

• Page 100: Changing The Front Brake Fluid

  13/BRAKE SYSTEM – Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water. Changing the front brake fluid 16.8 Warning Skin irritation Brake fluid can cause skin irritation on contact. –…

• Page 101: Checking The Rear Brake Linings

  13/BRAKE SYSTEM – Tighten the bleeder screw. – Close shut-off valve – Open the bleeder screw again until no more brake fluid emerges. Info This prevents overfilling of the brake fluid reservoir. – Tighten the bleeder screw. Remove the hose of the bleeder bottle. Attach the dust cap.

• Page 102
  Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

• Page 103: Checking The Free Travel Of Foot Brake Lever

  13/BRAKE SYSTEM – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 268) – Mount screw cap with membrane and the O-ring. Info Clean up overflowed or spilt brake fluid immediately with water. 101380-10 Checking the free travel of foot brake lever 16.11 Warning Danger of accidents Brake system failure.

• Page 104: Checking The Rear Brake Fluid Level

  13/BRAKE SYSTEM – Disconnect spring – Loosen nut and, with push rod , turn it back until you have maximum free travel. – To adjust the basic position of the foot brake lever individually, loosen nut turn screw accordingly. Info The range of adjustment is limited.

• Page 105: Changing The Rear Brake Fluid

  13/BRAKE SYSTEM Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

• Page 106
  13/BRAKE SYSTEM – Mount bleeder cover Bleeder cover (00029013006) ( p. 272) – Connect the bleeding device. Bleeding device (00029013100) ( p. 272) 201602-10 – Open shut-off valve Info Follow the operating instructions of the bleeding device. – Ensure that the filling pressure is correctly set at pressure gauge .

• Page 107: 14/Lighting System, Instruments

  14/LIGHTING SYSTEM, INSTRUMENTS Adjusting the speedometer functions 17.1 Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is stationary. – briefly and repeatedly until H appears at the bottom right of the Press the button display.

• Page 108: Activating The Additional Functions

  14/LIGHTING SYSTEM, INSTRUMENTS Activating the additional functions 17.3 Danger Voiding of the government approval for road use and the insurance coverage The vehicle is only authorized for operation on pub- lic roads in the homologated version. – If the vehicle is modified in any way, it may only be used on designated tracks away from public roads. Advise the vehicle owner and rider of this.

• Page 109: Setting The Clock

  14/LIGHTING SYSTEM, INSTRUMENTS – Press the button The wheel circumference is displayed in millimeters. Enlarging the wheel circumference – Press the button Reducing the wheel circumference – Press the button – Press the button briefly. – Press the button for 3 — 5 seconds. The settings are stored and the setup menu is closed.

• Page 110: Adjusting The Headlight Range

  14/LIGHTING SYSTEM, INSTRUMENTS Adjusting the headlight range 17.7 Preliminary work – Check the headlight setting. ( p. 107) Main work – Loosen screw – Adjust the headlight range of the headlight by moving it up or down. Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with a rider (mark is applied under: Checking the headlight setting).

• Page 111: 30/Engine

  30/ENGINE Removing the engine 18.1 Preliminary work – Drain the coolant. ( p. 179) – Raise the motorcycle with the lift stand. ( p. 10) – Remove the main silencer. ( p. 65) – Remove the seat. ( p. 69) –…

• Page 112
  30/ENGINE – Remove screw – Loosen screw – Repeat the operation on the opposite side. 305073-10 – Swing up the subframe and secure it. 305074-10 – Remove screw – Swing back the shock absorber. 305075-10 – Remove springs Spring hooks (50305017000) ( p.
• Page 113
  30/ENGINE – Slide back cover. – Remove nut – Detach the cable. 305078-10 – Loosen hose clip – Take off the radiator hose. 305079-10 – Disconnect spring 305080-10 – Remove screw – Remove screw – Take off the engine sprocket cover. 305081-10 –…
• Page 114
  30/ENGINE – Detach connector – Detach connector – Detach connector – Pull of the spark plug connector. 305084-10 – Loosen hose clip – Pull off the throttle valve body from the rear. 305085-10 – Loosen hose clip – Take off the radiator hose. 305086-10 –…

• Page 115: Installing The Engine

  30/ENGINE Installing the engine 18.2 Main work – Position the engine in the frame. – Mount screws but do not tighten yet. Guideline Engine attachment bolt 60 Nm (44.3 lbf ft) – Position the swingarm. – Mount the swingarm pivot. 305088-11 –…

• Page 116
  30/ENGINE – Position the clutch slave cylinder with the gasket. – Mount and tighten screws Guideline Screw, clutch slave cylinder 10 Nm (7.4 lbf ft) 305083-11 – Mount the chain. – Connect the chain with connecting link 305089-10 – Position the engine sprocket cover. –…
• Page 117
  30/ENGINE – Position the manifold and mount springs Spring hooks (50305017000) ( p. 272) 305076-11 – Mount and tighten screw Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) 305077-11 – Position the shock absorber. – Mount and tighten screw Guideline Screw, top shock absorber 80 Nm…
• Page 118
  30/ENGINE – Plug in connector 305071-11 – Position and tighten hose clip 305070-11 – Connect negative cable of the battery. Guideline Screw, battery terminal 2.5 Nm (1.84 lbf ft) Info Contact disk must be mounted between battery terminal and cable socket with the claws facing up.
• Page 119
  30/ENGINE – Read out the fault memory using the KTM diagnostics tool. – Check the engine for leakage. – Check the engine oil level. ( p. 181) – Check the coolant level. ( p. 179)

• Page 120: 30/Disassembling The Engine

  30/DISASSEMBLING THE ENGINE Preparations 19.1 – Mount the special tool on the engine mounting block. Engine fixing arm (77229002000) ( p. 276) Engine assembly stand (61229001000) ( p. 275) – Mount the engine on the special tool. Info Work with an assistant or a motorized hoist. 304918-10 Removing the clutch push rod 19.2…

• Page 121: Removing The Oil Filter

  30/DISASSEMBLING THE ENGINE Removing the oil filter 19.5 – Remove screws . Remove the oil filter cover with the O-ring. 304925-10 – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) ( p. 273) 304926-10 Removing the spark plug 19.6 –…

• Page 122: Removing The Kick Starter

  30/DISASSEMBLING THE ENGINE Removing the kick starter 19.8 – Remove screw with the washer. – Take off the kick starter. 304932-10 – Remove distance sleeve 304933-10 Removing the alternator cover 19.9 – Remove screws – Remove the alternator cover. 304930-10 –…

• Page 123: Positioning The Engine At Ignition Top Dead Center

  30/DISASSEMBLING THE ENGINE Positioning the engine at ignition top dead center 19.11 – Turn the crankshaft counterclockwise until markings on the cylinder head are located flush above the flat areas of the camshafts. 304940-10 – Remove screw with the washer. Info Check through the hole whether the position notch of the crankshaft is visi- ble.

• Page 124: Removing The Cylinder Head

  30/DISASSEMBLING THE ENGINE – Take the timing chain off the camshaft gear. – Remove the camshafts. 304955-10 Removing the cylinder head 19.14 – Remove nut with the washer. 304956-10 – Loosen nuts in a crisscross pattern and remove them with the washers. –…

• Page 125: Removing The Starter Drive

  30/DISASSEMBLING THE ENGINE – Take off cylinder base gasket 304960-10 Removing the starter drive 19.16 – Remove screw 304963-10 – Insert special tool in the crankshaft. Protection cover (75029090000) ( p. 276) – Attach special tool to the rotor. Hold the special tool and pull off the rotor by turning in the screw.

• Page 126: Removing The Suction Pump

  30/DISASSEMBLING THE ENGINE – Take off gasket 304968-10 – Remove screws – Take off the starter motor. 304969-10 Removing the suction pump 19.17 – Remove screws – Take off oil pump cover 304972-10 – Remove O-ring 304973-10 – Remove suction pump 304974-10 –…

• Page 127: Removing The Water Pump Wheel

  30/DISASSEMBLING THE ENGINE Removing the water pump wheel 19.18 – Remove screws . Take off the water pump cover. 304976-10 – Remove nut – Take off the two-part water pump impeller 304977-10 Removing the clutch cover 19.19 – Remove screws –…

• Page 128: Removing The Outer Clutch Hub

  30/DISASSEMBLING THE ENGINE – Take off pretension ring 304983-10 – Take off pressure cap 304984-10 – Completely remove clutch disc pack – Remove clutch pressure piece 304987-10 Removing the outer clutch hub 19.21 – Bend up the lock washer. – Hold the inner clutch hub with the special tool.

• Page 129: Removing The Intermediate Kick Starter Gear

  30/DISASSEMBLING THE ENGINE Removing the intermediate kick starter gear 19.22 – Detach kick starter spring – Turn kick starter shaft counterclockwise and pull it out. Info The stop disk of the kick starter shaft usually sticks to the bearing. 304992-10 Removing the intermediate kick starter gear 19.23 –…

• Page 130: Removing The Force Pump

  30/DISASSEMBLING THE ENGINE Removing the force pump 19.27 – Remove lock ring – Take off washer – Take off oil pump idler gear with the washer. 304999-10 – Remove lock ring – Take off washer – Remove oil pump gear 305000-10 –…

• Page 131: Removing The Timing Chain

  30/DISASSEMBLING THE ENGINE Removing the timing chain 19.29 – Remove screws – Remove the timing chain tensioning rail – Remove the timing chain guide rail 305019-10 – Remove screw – Take off balancer shaft with the timing chain and timing chain securing guide. Info If the timing chain is going to be used again, mark its direction of travel.

• Page 132: Removing The Shift Rails

  30/DISASSEMBLING THE ENGINE – Take off the left section of the engine case. – Remove the dowels. – Remove the special tools. Removing the shift rails 19.32 – Remove shift rail together with upper spring 305025-10 – Remove shift rail together with upper spring and the lower spring.

• Page 133: Removing The Crankshaft

  30/DISASSEMBLING THE ENGINE – Pull both transmission shafts out of the bearing seats together. 305031-10 Removing the crankshaft 19.36 – Take out crankshaft – Take off the right section of the engine case. 305032-10…

• Page 134: 30/Engine — Work On The Individual Parts

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS Work on the right section of the engine case 20.1 – Remove all dowels. – Remove shaft seal ring of the crankshaft. – Remove jet – Remove oil jet for conrod bearing lubrication. –…

• Page 135: Working On The Left Section Of The Engine Case

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS – Position all bearing locks. – Mount and tighten screws Guideline Locking screw for bearing 6 Nm Loctite ® 243™ (4.4 lbf ft) – Blow out the oil channel with compressed air and check that it is clear. 400997-01 Working on the left section of the engine case 20.2…

• Page 136: Work On The Clutch Cover

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS – Mount and tighten oil jet Guideline Oil jet, piston cooling 2 Nm Loctite ® 243™ (1.5 lbf ft) – Position all bearing locks. – Mount and tighten screws Guideline Loctite ® 243™ Locking screw for bearing 6 Nm (4.4 lbf ft)

• Page 137: Checking The Oil Pressure Regulator Valve

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS – Press the new bearing all the way in from the inside to the outside using a suit- able tool. 302694-10 – Press in shaft seal ring all the way, with the open side facing outward. 302692-10 –…

• Page 138: Checking The Lubrication System

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS Checking the lubrication system 20.5 305003-10 – Check the internal rotor and external rotor of oil pumps for damage and wear. » If there is damage or wear: – Change the oil pumps. –…

• Page 139: Changing The Connecting Rod, Conrod Bearing And Crank Pin

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS – Repeat the operation on the opposite side. – Ensure that the new crankshaft bearing inner race is flush. Info After replacing the crankshaft bearings, the crankshaft end play must be measured. Changing the connecting rod, conrod bearing and crank pin 20.8 Main work –…

• Page 140: Checking The Crankshaft Run-Out At The Bearing Pin

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS – Position special tool with the heel pointing down. Insert for crankshaft pressing tool (77229008000) ( p. 277) – Press in the upper crank web as far as possible. Info The press mandrel must be positioned over the crank pin. –…

• Page 141: Cylinder — Nikasil ® Coating

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS ® Cylinder — Nikasil coating 20.12 ® Nikasil is a surface protection layer for a coating procedure developed by Mahle. The name is derived from the two materials used in this procedure — a layer of nickel into which is embedded the particularly hard silicone carbide.

• Page 142: Measuring The Piston/Cylinder Mounting Clearance

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS – Check the piston rings for damage. » If the piston ring is damaged: – Replace the piston ring. Info Mount the piston ring with the marking facing upward. – Check the piston pins for discoloration or signs of wear. »…

• Page 143: Changing The Camshaft Bearing

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS – Change the piston ring. – Mount the piston ring with the marking facing toward the piston head. Changing the camshaft bearing 20.17 – Clamp special tool into a vise. Adjustment bush bridge (77229050000) ( p.

• Page 144: Removing The Valves

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS – Position the camshafts. The valves are not activated. – Insert the Plastigauge clearance gauge in area Plastigauge measuring strips (60029012000) ( p. 274) 302706-10 – Position camshaft bearing bridge . Mount and tighten the screws. Guideline Screw, camshaft bearing M7x1…

• Page 145: Checking The Valves

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS – Pre-tension the valve spring using the special tool. Valve spring compressor (59029019000) ( p. 274) Insert for valve spring lever (77229060100) ( p. 279) – Remove the valve keys and unload the valve spring. 302711-10 –…

• Page 146: Checking The Valve Springs

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS Checking the valve springs 20.22 – Check the valve springs for breakage and wear (visual check). » If the valve spring is broken or worn: – Change the valve spring. – Measure the length of the valve springs. Valve spring Minimum length 41.10 mm (1.6181 in)

• Page 147: Installing The Valves

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS – Check sealing seat of the valves. Valve — sealing seat width Intake 1.40 mm (0.0551 in) Valve — sealing seat width Exhaust 1.40 mm (0.0551 in) » If the measured value does not meet specifications: –…

• Page 148: Checking The Freewheel

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS Checking the freewheel 20.27 – Insert freewheel gear into the freewheel hub, turning the freewheel gear clock- wise; do not wedge. – Check the locking action of starter wheel » If the freewheel gear does not turn clockwise or if it does not lock counterclock- wise: –…

• Page 149: Checking The Electric Starter Drive

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS – Mount driving hub 301004-10 – Position kick starter spring and hook it into drill hole 301005-10 Checking the electric starter drive 20.29 305006-10 – Check the gear mesh and bearing of starter idler gear for damage and wear.

• Page 150: Checking The Timing Assembly

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS – Change O-ring of the starter motor. – Connect the negative cable of a 12 volt power supply to the housing of the starter motor. Connect the positive cable of the power supply briefly with the connector of the starter motor. »…

• Page 151: Preparing The Timing Chain Tensioner For Installation

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS Preparing the timing chain tensioner for installation 20.31 – Press the timing chain tensioner together completely. Info This requires some force, as the oil must be pressed out. – Release the timing chain tensioner. Without pressure, the timing chain tensioner expands fully.

• Page 152
  30/ENGINE — WORK ON THE INDIVIDUAL PARTS – Change the spring retainer. – Check the pretension ring for damage and wear. » If there is damage or wear: – Change the pretension ring. – Check spring washer for damage and wear. »…

• Page 153: Checking The Shift Mechanism

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS Checking the shift mechanism 20.33 305008-10 – Check shift forks on disc for damage and wear (visual check). » If there is damage or wear: – Change the shift fork. – Check shift grooves of shift drum for wear.

• Page 154: Preassembling The Shift Shaft

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS – Preassemble the shift shaft. ( p. 152) – Check clearance between the sliding plate and the shift quadrant. Shift shaft — sliding plate/shift quad- 0.40… 0.80 mm (0.0157… rant clearance 0.0315 in) »…

• Page 155: Disassembling The Countershaft

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS Disassembling the countershaft 20.36 305012-10 – Fix the countershaft in the vice with the toothed end facing downward. Guideline Use soft jaws – Remove stop disk and 1st-gear idler gear – Remove needle bearing –…

• Page 156
  30/ENGINE — WORK ON THE INDIVIDUAL PARTS 305013-10 – Check needle bearings for damage and wear. » If there is damage or wear: – Change the needle bearings. – Check the pivot points of main shaft and countershaft for damage and wear. »…

• Page 157: Assembling The Main Shaft

  30/ENGINE — WORK ON THE INDIVIDUAL PARTS Assembling the main shaft 20.38 Info Use new lock rings with every repair. Preliminary work – Carefully lubricate all parts before assembling. – Check the transmission. ( p. 153) 305011-11 Main work – Secure the main shaft with the toothed end facing downward in the vise.

• Page 158
  30/ENGINE — WORK ON THE INDIVIDUAL PARTS 305012-11 Main work – Fix the countershaft in the vice with the toothed end facing downward. Guideline Use soft jaws – Mount needle bearing – Mount 2nd-gear idler gear – Mount stop disk and lock ring –…

• Page 159: 30/Engine Assembly

  30/ENGINE ASSEMBLY Installing the crankshaft 21.1 – Position the right section of the engine case in the engine work stand. – Oil the bearing. Engine oil (SAE 10W/50) ( p. 268) – Push crankshaft into the bearing seat. 305032-10 Installing the transmission shafts 21.2 –…

• Page 160: Installing The Shift Drum

  30/ENGINE ASSEMBLY Installing the shift drum 21.4 – Push shift drum into the bearing seat. – Put shift forks in the shift drum. Info Do not misplace the shift rollers. 305027-11 Installing the shift rails 21.5 – Install shift rail together with upper spring and the lower spring.

• Page 161: Installing The Spacer

  30/ENGINE ASSEMBLY – Tighten screws , and Guideline Screw, engine case 10 Nm (7.4 lbf ft) – Mount the screw connection of the engine fixing arm. Installing the spacer 21.7 – Grease the shaft seal ring. Long-life grease ( p. 270) –…

• Page 162: Installing The Primary Gear

  30/ENGINE ASSEMBLY Installing the primary gear 21.9 – Position primary gear The wide tooth of the primary gear engages in the wide cut-out of the crankshaft. Markings are aligned. – Set the crankshaft to top dead center and lock it with screw –…

• Page 163: Installing The Suction Pump

  30/ENGINE ASSEMBLY – Mount oil pump idler gear with the washer. – Mount washers – Mount lock ring 304999-11 Installing the suction pump 21.11 – Insert needle roller 304975-11 – Position suction pump – Crank the oil pump gear and ensure that it can move easily. 304974-11 –…

• Page 164: Installing The Locking Lever

  30/ENGINE ASSEMBLY Installing the locking lever 21.12 – Mount locking lever with the washer, sleeve and spring. – Mount and tighten screw Guideline Screw, locking lever 6 Nm Loctite ® 243™ (4.4 lbf ft) 304998-10 Installing the shift drum locating unit 21.13 –…

• Page 165: Installing The Outer Clutch Hub

  30/ENGINE ASSEMBLY Main work – Slide the premounted kick starter shaft into the bearing seat. Info The kick starter ratchet wheel should not be in contact with stop plate 304993-10 – Turn kick starter shaft clockwise all the way. – Tension kick starter spring and attach.

• Page 166: Installing The Clutch Discs

  30/ENGINE ASSEMBLY Installing the clutch discs 21.18 – Thoroughly oil the clutch facing discs. – Beginning with an intermediate disc, alternately insert all other clutch facing discs and intermediate discs into the outer clutch hub. – Mount pressure piece 304987-11 –…

• Page 167: Installing The Clutch Cover

  30/ENGINE ASSEMBLY – Using a straightedge and the special tool, check the spring washer for distortion. Feeler gauge (59029041100) ( p. 274) Spring washer distortion 0… 0.10 mm (0… 0.0039 in) » If the specified value is not reached: – Remove screws and mount spring retainer with marking II.

• Page 168: Installing The Starter Drive

  30/ENGINE ASSEMBLY – Mount screw with the washer but to not tighten yet. Guideline Screw, water pump cover M6x25 10 Nm (7.4 lbf ft) – Tighten all screws in a crisscross pattern. Installing the starter drive 21.21 – Grease the O-ring of the starter motor. Long-life grease ( p.

• Page 169: Installing The Piston

  30/ENGINE ASSEMBLY – Mount the starter idler gear with the washer. – Mount lock ring 304965-11 – Position the rotor. Info Ensure that the spring washer is seated properly. – Mount and tighten screw Guideline Rotor screw M10x1 70 Nm Thread, oiled with (51.6 lbf ft) engine oil/cone…

• Page 170: Installing The Cylinder Head

  30/ENGINE ASSEMBLY – Cover the engine case opening with a cloth. Thread the timing chain through the chain shaft. Mount the piston pin. Info In order to present them more clearly, the following steps are shown with a removed piston. 304961-10 –…

• Page 171: Installing The Camshafts

  30/ENGINE ASSEMBLY – Mount nut with the washers and tighten in a crisscross pattern. Guideline Nut, cylinder head M10x1.25 Tightening Thread, oiled with sequence: engine oil/cone Tighten diago- greased nally. 1st tightening stage 10 Nm (7.4 lbf ft) 304957-10 2nd tighten- ing stage 30 Nm (22.1 lbf ft)

• Page 172: Checking The Valve Timing

  30/ENGINE ASSEMBLY Checking the valve timing 21.25 Condition Camshaft gears were not loosened. – Mount the special tool and tension the timing chain. Insert, timing chain tensioner (77229035000) ( p. 278) – Position special tool Adjustment bush bridge (77229050000) ( p.

• Page 173: Installing The Timing Chain Tensioner

  30/ENGINE ASSEMBLY – Tighten screws Guideline Screw, camshaft drive M12x1 80 Nm Loc- tite ® 243™/cone sprocket (59 lbf ft) degreased 304948-10 – Remove screws – Remove the special tool. Adjustment bush bridge (77229050000) ( p. 278) 304949-10 – Mount and tighten screws Guideline Screw, camshaft bearing M7x1…

• Page 174: Checking The Valve Clearance

  30/ENGINE ASSEMBLY – Mount and tighten screw plug with the seal ring. Guideline Plug, timing chain tensioner M24x1.5 25 Nm (18.4 lbf ft) – Remove screw 304945-11 – Press the timing chain tensioner toward the timing chain using special tool Release device for timing chain tensioner (77329051000) ( p.

• Page 175: Adjusting The Valve Clearance

  30/ENGINE ASSEMBLY – Mount and tighten screw with the washer. Guideline Screw plug, crankshaft location 10 Nm (7.4 lbf ft) 304941-10 Adjusting the valve clearance 21.29 Main work – Remove the timing chain tensioner. ( p. 121) – Remove the camshaft. ( p.

• Page 176: Installing The Kick Starter

  30/ENGINE ASSEMBLY – Mount screw with the seal ring and tighten all screws in a crisscross pattern. Guideline Screw, alternator cover M6x25 6 Nm (4.4 lbf ft) Installing the kick starter 21.32 – Mount distance sleeve 304933-11 – Position the kick starter. Mount and tighten screw Guideline Screw, kick starter 25 Nm…

• Page 177: Installing The Spark Plug

  30/ENGINE ASSEMBLY Installing the spark plug 21.34 – Mount and tighten the spark plug with special tool Guideline Spark plug M10x1 10… 12 Nm (7.4… 8.9 lbf ft) Spark plug wrench (77229072000) ( p. 279) 304927-10 Installing the oil filter 21.35 –…

• Page 178: Installing The Spacer

  30/ENGINE ASSEMBLY – Mount and tighten screw plug with the O-ring. Guideline Screw plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) 304921-11 Installing the spacer 21.37 – Grease the shaft seal ring before mounting. Long-life grease ( p. 270) –…

• Page 179: 32/Clutch

  32/CLUTCH Checking the fluid level of the hydraulic clutch 22.1 Info The fluid level rises with increased wear of the clutch lining discs. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws –…

• Page 180: 35/Water Pump, Cooling System

  35/WATER PUMP, COOLING SYSTEM Cooling system 23.1 Water pump in the engine circulates the coolant. The water cycle through the radiator is controlled on the basis of the coolant temper- ature. The cooling system is subdivided into two circuits. In the warming-up phase, the engine circulates the water through the smaller cooling circuit.

• Page 181: Checking The Coolant Level

  35/WATER PUMP, COOLING SYSTEM Checking the coolant level 23.3 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

• Page 182: Refilling Coolant

  35/WATER PUMP, COOLING SYSTEM Refilling coolant 23.5 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.

• Page 183: 38/Lubrication System

  38/LUBRICATION SYSTEM Oil circuit 24.1 401362-60 Oil screen Force pump Oil pressure regulator valve Oil filter Oil jet, conrod lubrication Oil jet for cam lever lubrication Oil jet, piston cooling Oil jet for alternator cooling Oil jet for clutch lubrication Suction pump Oil channel, transmission lubrication Timing chain tensioner…

• Page 184: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

  38/LUBRICATION SYSTEM » If the engine oil is not up to the middle of the level viewer: – Add engine oil. ( p. 184) Changing the engine oil and oil filter, cleaning the oil screen 24.3 Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. –…

• Page 185
  38/LUBRICATION SYSTEM – Remove screws . Remove the oil filter cover with the O-ring. 101419-10 – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) ( p. 273) – Completely drain the engine oil. – Thoroughly clean the parts and sealing area. 101420-10 –…
• Page 186
  38/LUBRICATION SYSTEM Adding engine oil 24.4 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – Remove the oil filler plug with the O-ring from the clutch cover. – Add the same engine oil that was used when the motor was changed. Engine oil (SAE 10W/50) ( p.
• Page 187
  38/LUBRICATION SYSTEM Warning Danger of burns Some vehicle components get very hot when the machine is driven. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. – Remove the special tools. – Mount and tighten the chain adjuster release screw. Guideline Screw, unlocking of timing chain ten- M10x1…

• Page 188: 39/Ignition System

  39/IGNITION SYSTEM Ignition coil — checking the secondary winding 25.1 Condition Ignition coil cylinder 1 is disconnected. Spark plug connector cylinder 1 has been removed. Ignition coil cylinder 1 — check the secondary winding resistance – Measure the resistance between the specified points. Ignition coil pin 2 (−) –…

• Page 189: Removing The Stator And Ignition Pulse Generator

  39/IGNITION SYSTEM 601211-10 600897-10 Stator winding — check for a short circuit to ground (terminal 31) – Measure the resistance between the specified points. Stator, connector EZ pin 1 – Measuring point Ground (−) ∞ Ω Resistance » If the value displayed does not meet specifications: –…

• Page 190: Installing The Stator And Ignition Pulse Generator

  39/IGNITION SYSTEM Installing the stator and ignition pulse generator 25.5 – Blow out oil jet with compressed air and check that it is clear. Guideline Oil jet for alternator cool- 2 Nm Loctite ® 243™ (1.5 lbf ft) 305322-10 – Position the stator in the alternator cover.

• Page 191: 40/Electric Starter

  40/ELECTRIC STARTER Checking the starter motor 26.1 Condition The starter motor has been removed. – Connect the negative cable of a 12 volt power supply to the housing of the starter motor. Connect the positive cable of the power supply briefly to connector of the starter motor.

• Page 192: 41/Throttle Valve Body

  41/THROTTLE VALVE BODY Throttle position sensor circuit A — checking the basic settings 27.1 Condition The diagnostics tool is connected and running. – Select the model. – Select «ECU Diagnostics». – Highlight the «Injection management EXC» control unit. – Press «Continue». –…

• Page 193
  41/THROTTLE VALVE BODY Danger Danger of poisoning Exhaust gases are poisonous 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.

• Page 194: Technical Data — Engine

  TECHNICAL DATA — 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 1,950… 2,050 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 36.3 mm (1.429 in)

• Page 195: Technical Data — Tolerance, Wear Limits Of Engine

  TECHNICAL DATA — TOLERANCE, WEAR LIMITS OF ENGINE Valve — run-out ≤ 0.05 mm (≤ 0.002 in) At the valve plate ≤ 0.05 mm (≤ 0.002 in) At the valve stem Valve spring Minimum length 41.10 mm (1.6181 in) Valve — sealing seat width Intake 1.40 mm (0.0551 in) Exhaust…

• Page 196: Technical Data — Engine Tightening Torques

  TECHNICAL DATA — ENGINE TIGHTENING TORQUES ® Jet, crank chamber ventilation 2 Nm (1.5 lbf ft) Loctite 243™ ® Oil jet for alternator cooling 2 Nm (1.5 lbf ft) Loctite 243™ ® Oil jet for balancer shaft lubrication 2 Nm (1.5 lbf ft) Loctite 243™…

• Page 197
  TECHNICAL DATA — ENGINE TIGHTENING TORQUES – Stud, cylinder head M10x1.25 20 Nm (14.8 lbf ft) ® Screw, camshaft drive sprocket M12x1 80 Nm (59 lbf ft) Loctite 243™/cone degreased – Engine coolant temperature sensor M12x1.5 12 Nm (8.9 lbf ft) –…

• Page 198: Technical Data — Chassis

  TECHNICAL DATA — CHASSIS Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Suspension Up Side Down 4860 MXMA PA Suspension travel Front 300 mm (11.81 in) Rear 335 mm (13.19 in) Fork offset 20 mm (0.79 in) Shock absorber WP Suspension PDS 5018 DCC Brake system…

• Page 199: Lighting Equipment

  80/100 — 21 51M TT 110/100 — 18 64M TT Dunlop GEOMAX MX51 Dunlop GEOMAX MX51 Additional information is available in the Service section under: http://www.ktm.com Capacity — fuel 31.3 Total fuel tank capacity, 8.5 l (2.25 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p.

• Page 200: Technical Data — Fork

  TECHNICAL DATA — FORK Fork part number 14.18.7L.67 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 24 clicks Standard 22 clicks Sport 20 clicks Rebound damping Comfort 22 clicks Standard 20 clicks Sport 18 clicks Spring preload — Preload Adjuster Comfort 1 turn Standard…

• Page 201: Technical Data — Shock Absorber

  TECHNICAL DATA — SHOCK ABSORBER Shock absorber part number 12.18.7L.67 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1.25 turns Rebound damping Comfort 28 clicks…

• Page 202: Technical Data — Chassis Tightening Torques

  TECHNICAL DATA — CHASSIS TIGHTENING TORQUES – Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Screw, battery terminal 2.5 Nm (1.84 lbf ft) – Screw, intake air temperature sensor 2 Nm (1.5 lbf ft) – Screw, shock absorber adjusting ring 5 Nm (3.7 lbf ft) –…

• Page 203: Cleaning, Care

  CLEANING, CARE Cleaning the motorcycle 35.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.

• Page 204: Checks And Maintenance Steps For Winter Operation

  CLEANING, CARE Checks and maintenance steps for winter operation 35.2 Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

• Page 205: Storage

  – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 10) – Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materi- als since they prevent humidity from escaping, thus causing corrosion.

• Page 206: Service Schedule

  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. • • • Make the service entry in KTM DEALER.NET and in the service record.

• Page 207: Service Work (As Additional Order)

  SERVICE SCHEDULE Service work (as additional order) 37.2 S15N S45A S105A Change the front brake fluid. ( p. 98) • Change the rear brake fluid. ( p. 103) • Change the foot brake cylinder seals. (EXC‑F EU/AUS/USA, XCF‑W) • Change the hydraulic clutch fluid. ( p.

• Page 208: Wiring Diagram

  WIRING DIAGRAM Page 1 of 8 (EXC‑F EU, EXC-F SIX DAYS) 38.1 bu-rd wh-rd wh-rd wh-rd wh-rd wh-rd wh-rd bl-bu bl-bu bu-rd bl-ye bl-ye bl-ye bl-ye 601641-01…

• Page 209
  WIRING DIAGRAM Components: EFI control unit Fuse Battery Starter relay with main fuse Starter motor Electric starter button…

• Page 210: Exc-F Eu, Exc-F Six Days)

  WIRING DIAGRAM Page 2 of 8 (EXC‑F EU, EXC-F SIX DAYS) 38.2 wh-rd wh-pk wh-rd wh-rd wh-pk wh-bl EY/3 EZ/3 wh-bl wh-bl wh-rd wh-bl wh-rd ye-rd 601642-01…

• Page 211
  WIRING DIAGRAM Components: EFI control unit Alternator Light relay Power relay Voltage regulator X295 Diagnostics connector…

• Page 212: Exc-F Eu, Exc-F Six Days)

  WIRING DIAGRAM Page 3 of 8 (EXC‑F EU, EXC-F SIX DAYS) 38.3 ye-bu ye-bu ye-bu br-rd br-rd 601643-01…

• Page 213
  WIRING DIAGRAM Components: Fuel tank sensor Temperature switch for radiator fan (optional) Fuse Fuse (optional) Radiator fan (optional) Low fuel warning lamp X285 Connector for radiator fan (optional)

• Page 214: Exc-F Eu, Exc-F Six Days)

  WIRING DIAGRAM Page 4 of 8 (EXC‑F EU, EXC-F SIX DAYS) 38.4 ye-bu ye-bu ye-bu ye-bu DA/4 DB/4 ye-bu CX/2 CW/2 601644-01…

• Page 215
  WIRING DIAGRAM Components: Wheel speed sensor, front Fuse Speedometer Tripmaster switch (optional)

• Page 216: Exc-F Eu, Exc-F Six Days)

  WIRING DIAGRAM Page 5 of 8 (EXC‑F EU, EXC-F SIX DAYS) 38.5 ye-bu bl-ye ye-bu wh-gn ye-bu wh-gn wh-gn 601645-01…

• Page 217
  WIRING DIAGRAM Components: Brake light switch, front Brake light switch, rear Low beam, high beam License plate lamp Horn High beam indicator light Parking light Brake/tail light Light switch, horn button, kill switch…

• Page 218: Exc-F Eu, Exc-F Six Days)

  WIRING DIAGRAM Page 6 of 8 (EXC‑F EU, EXC-F SIX DAYS) 38.6 ye-bu ye-rd ye-rd 601646-01…

• Page 219
  WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Turn signal switch…

• Page 220: Exc-F Eu, Exc-F Six Days)

  WIRING DIAGRAM Page 7 of 8 (EXC‑F EU, EXC-F SIX DAYS) 38.7 ye-rd bl-bu bl-bu wh-bu wh-bu wh-bu bl-bu bl-gr bl-gr gn-rd gn-rd br-pu br-pu bu-gr bu-gr 601647-01…

• Page 221
  WIRING DIAGRAM Components: EFI control unit Lambda sensor (cylinder 1) Fuse Fuel pump Injector (cylinder 1) CAN-bus terminating resistor 1 FI warning lamp (MIL) X295 Diagnostics connector…

• Page 222: Exc-F Eu, Exc-F Six Days)

  WIRING DIAGRAM Page 8 of 8 (EXC‑F EU, EXC-F SIX DAYS) 38.8 DV/2 bl-br bl-br rd-pu rd-pu wh-pu wh-pu ye-bu ye-bu wh-ye wh-ye ye-rd ye-rd 601648-01…

• Page 223
  WIRING DIAGRAM Components: EFI control unit Throttle position sensor circuit A Intake air temperature sensor Engine coolant temperature sensor (cylinder 1) Rollover sensor Ignition pulse generator Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map‑Select switch for riding mode (optional) Map‑Select switch for basic setting (optional) Cable colors: Black…

• Page 224: Exc-F Aus)

  WIRING DIAGRAM Page 1 of 8 (EXC‑F AUS) 38.9 bu-rd wh-rd wh-rd wh-rd wh-rd wh-rd wh-rd bl-bu bl-bu bu-rd bl-ye bl-ye bl-ye bl-ye 601671-01…

• Page 225
  WIRING DIAGRAM Components: EFI control unit Fuse Battery Starter relay with main fuse Starter motor Emergency OFF switch, electric starter button…

• Page 226: Exc-F Aus)

  WIRING DIAGRAM Page 2 of 8 (EXC‑F AUS) 38.10 wh-rd wh-pk wh-rd wh-rd wh-pk wh-bl EY/3 EZ/3 wh-bl wh-bl wh-rd wh-bl wh-rd ye-rd 601672-01…

• Page 227
  WIRING DIAGRAM Components: EFI control unit Alternator Light relay Power relay Voltage regulator X295 Diagnostics connector…

• Page 228: Exc-F Aus)

  WIRING DIAGRAM Page 3 of 8 (EXC‑F AUS) 38.11 ye-bu ye-bu ye-bu br-rd br-rd 601673-01…

• Page 229
  WIRING DIAGRAM Components: Fuel tank sensor Fuse Low fuel warning lamp X285 Connector for radiator fan (optional)

• Page 230: Exc-F Aus)

  WIRING DIAGRAM Page 4 of 8 (EXC‑F AUS) 38.12 ye-bu ye-bu ye-bu ye-bu DA/4 DB/4 ye-bu CX/2 CW/2 601674-01…

• Page 231
  WIRING DIAGRAM Components: Wheel speed sensor, front Fuse Speedometer Tripmaster switch (optional)

• Page 232: Exc-F Aus)

  WIRING DIAGRAM Page 5 of 8 (EXC‑F AUS) 38.13 ye-bu bl-ye ye-bu wh-gn ye-bu wh-gn wh-gn 601675-01…

• Page 233
  WIRING DIAGRAM Components: Brake light switch, front Brake light switch, rear Low beam, high beam License plate lamp Horn High beam indicator light Parking light Brake/tail light Light switch, horn button, kill switch…

• Page 234: Exc-F Aus)

  WIRING DIAGRAM Page 6 of 8 (EXC‑F AUS) 38.14 ye-bu ye-rd ye-rd 601676-01…

• Page 235
  WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Turn signal switch…

• Page 236: Exc-F Aus)

  WIRING DIAGRAM Page 7 of 8 (EXC‑F AUS) 38.15 ye-rd bl-bu bl-bu wh-bu wh-bu wh-bu bl-bu bl-gr bl-gr gn-rd gn-rd br-pu br-pu bu-gr bu-gr 601677-01…

• Page 237
  WIRING DIAGRAM Components: EFI control unit Fuse Fuel pump Injector (cylinder 1) CAN-bus terminating resistor 1 FI warning lamp (MIL) X295 Diagnostics connector…

• Page 238: Exc-F Aus)

  WIRING DIAGRAM Page 8 of 8 (EXC‑F AUS) 38.16 DV/2 bl-br bl-br rd-pu rd-pu wh-pu wh-pu ye-bu ye-bu wh-ye wh-ye ye-rd ye-rd 601678-01…

• Page 239
  WIRING DIAGRAM Components: EFI control unit Throttle position sensor circuit A Intake air temperature sensor Engine coolant temperature sensor (cylinder 1) Rollover sensor Ignition pulse generator Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map‑Select switch for riding mode (optional) Map‑Select switch for basic setting (optional) Cable colors: Black…

• Page 240: Exc-F Usa)

  WIRING DIAGRAM Page 1 of 8 (EXC-F USA) 38.17 ye-br wh-rd bu-rd wh-rd wh-rd wh-rd wh-rd bl-bu bl-bu bu-rd ye-br bl-ye bl-ye bl-ye bl-ye bl-ye wh-or wh-or wh-or wh-or wh-rd 601691-01…

• Page 241
  WIRING DIAGRAM Components: EFI control unit Fuse Fuse Battery Starter relay with main fuse Starter motor Ignition lock Emergency OFF switch, electric starter button…

• Page 242: Exc-F Usa)

  WIRING DIAGRAM Page 2 of 8 (EXC-F USA) 38.18 wh-pk wh-rd wh-bl wh-pk wh-rd wh-pk wh-bl EY/3 EZ/3 wh-bl wh-bl ye-br wh-bl wh-rd ye-rd 601692-01…

• Page 243
  WIRING DIAGRAM Components: EFI control unit Alternator Light relay Power relay Voltage regulator X295 Diagnostics connector…

• Page 244: Exc-F Usa)

  WIRING DIAGRAM Page 3 of 8 (EXC-F USA) 38.19 ye-bu ye-bu ye-bu br-rd br-rd 601733-01…

• Page 245
  WIRING DIAGRAM Components: Fuel tank sensor Temperature switch for radiator fan (optional) Fuse Fuse (optional) Radiator fan (optional) Low fuel warning lamp X285 Connector for radiator fan (optional)

• Page 246: Exc-F Usa)

  WIRING DIAGRAM Page 4 of 8 (EXC-F USA) 38.20 ye-bu ye-bu ye-bu ye-bu DA/4 DB/4 ye-bu CX/2 CW/2 601694-01…

• Page 247
  WIRING DIAGRAM Components: Wheel speed sensor, front Fuse Speedometer Tripmaster switch (optional)

• Page 248: Exc-F Usa)

  WIRING DIAGRAM Page 5 of 8 (EXC-F USA) 38.21 ye-bu ye-bu wh-gn ye-bu wh-gn wh-gn 601695-01…

• Page 249
  WIRING DIAGRAM Components: Brake light switch, front Brake light switch, rear Low beam, high beam License plate lamp Horn High beam indicator light Parking light Brake/tail light Light switch, horn button, turn signal switch…

• Page 250: Exc-F Usa)

  WIRING DIAGRAM Page 6 of 8 (EXC-F USA) 38.22 ye-bu ye-rd ye-rd 601696-01…

• Page 251
  WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Light switch, horn button, turn signal switch…

• Page 252: Exc-F Usa)

  WIRING DIAGRAM Page 7 of 8 (EXC-F USA) 38.23 ye-rd bl-bu bl-bu wh-bu wh-bu wh-bu bl-bu bl-gr bl-gr br-pu br-pu bu-gr bu-gr 601697-01…

• Page 253
  WIRING DIAGRAM Components: EFI control unit Fuse Fuel pump Fuel evaporation valve Injector (cylinder 1) CAN-bus terminating resistor 1 FI warning lamp (MIL) X295 Diagnostics connector…

• Page 254: Exc-F Usa)

  WIRING DIAGRAM Page 8 of 8 (EXC-F USA) 38.24 DV/2 bl-br bl-br rd-pu rd-pu wh-pu wh-pu ye-bu ye-bu wh-ye wh-ye ye-rd ye-rd 601698-01…

• Page 255
  WIRING DIAGRAM Components: EFI control unit Throttle position sensor circuit A Intake air temperature sensor Engine coolant temperature sensor (cylinder 1) Rollover sensor Ignition pulse generator Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map‑Select switch for riding mode (optional) Map‑Select switch for basic setting (optional) Cable colors: Black…

• Page 256: Xcf-W)

  WIRING DIAGRAM Page 1 of 7 (XCF‑W) 38.25 bu-rd wh-rd wh-rd wh-rd wh-rd wh-rd wh-rd bl-bu bl-bu bu-rd bl-ye bl-ye 601681-01…

• Page 257
  WIRING DIAGRAM Components: EFI control unit Fuse Battery Starter relay with main fuse Starter motor Kill switch Electric starter button…

• Page 258: Xcf-W)

  WIRING DIAGRAM Page 2 of 7 (XCF‑W) 38.26 wh-rd wh-pk wh-rd wh-rd wh-pk wh-bl EY/3 EZ/3 wh-bl wh-bl wh-rd wh-bl wh-rd ye-rd 601682-01…

• Page 259
  WIRING DIAGRAM Components: EFI control unit Alternator Light relay Power relay Voltage regulator X295 Diagnostics connector…

• Page 260: Xcf-W)

  WIRING DIAGRAM Page 3 of 7 (XCF‑W) 38.27 ye-bu ye-bu ye-bu br-rd br-rd 601743-01…

• Page 261
  WIRING DIAGRAM Components: Fuel tank sensor Temperature switch for radiator fan (optional) Fuse Fuse (optional) Radiator fan (optional) Low fuel warning lamp X285 Connector for radiator fan (optional)
• Page 262
  WIRING DIAGRAM Page 4 of 7 (XCF‑W) 38.28 ye-bu ye-bu DA/4 DB/4 ye-bu CX/2 CW/2 601684-01…
• Page 263
  WIRING DIAGRAM Components: Wheel speed sensor, front Fuse Speedometer Tripmaster switch (optional)

• Page 264: Xcf-W)

  WIRING DIAGRAM Page 5 of 7 (XCF‑W) 38.29 601685-01…

• Page 265
  WIRING DIAGRAM Components: Low beam Parking light Tail light Light switch…

• Page 266: Xcf-W)

  WIRING DIAGRAM Page 6 of 7 (XCF‑W) 38.30 ye-rd bl-bu bl-bu wh-bu wh-bu wh-bu bl-bu bl-gr bl-gr gn-rd gn-rd br-pu br-pu bu-gr bu-gr 601686-01…

• Page 267
  WIRING DIAGRAM Components: EFI control unit Fuse Fuel pump Injector (cylinder 1) CAN-bus terminating resistor 1 FI warning lamp (MIL) X295 Diagnostics connector…

• Page 268: Xcf-W)

  WIRING DIAGRAM Page 7 of 7 (XCF‑W) 38.31 DV/2 bl-br bl-br rd-pu rd-pu wh-pu wh-pu ye-bu ye-bu wh-ye wh-ye ye-rd ye-rd 601687-01…

• Page 269
  WIRING DIAGRAM Components: EFI control unit Throttle position sensor circuit A Intake air temperature sensor Engine coolant temperature sensor (cylinder 1) Rollover sensor Ignition pulse generator Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map‑Select switch for riding mode (optional) Map‑Select switch for basic setting (optional) Cable colors: Black…

• Page 270: Substances

  – 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 ®…

• Page 271
  SAE ( p. 285) (SAE 5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding ® properties. KTM recommends Motorex products. Supplier ® Motorex – Racing Fork Oil Shock absorber oil (SAE 2.5) (50180342S1)

• Page 272: Auxiliary Substances

  AUXILIARY SUBSTANCES 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 –…

• Page 273
  AUXILIARY SUBSTANCES Lubricant (T625) Guideline – ® KTM recommends Molykote products. Supplier ® Molykote – 33 Medium Lubricant (T152) Guideline – ® KTM recommends Bel‑Ray products. Supplier ® Bel‑Ray – ® Molylube Anti‑Seize Motorcycle cleaner Guideline – ® KTM recommends Motorex products.

• Page 274: Special Tools

  SPECIAL TOOLS Bleeder cover Art. no.: 00029013005 201597-10 Bleeder cover Art. no.: 00029013006 201598-10 Bleeding device Art. no.: 00029013100 201491-10 Spring hooks Art. no.: 50305017000 400363-01 Mounting tool, heim joint Art. no.: 50329000044 201428-01…

• Page 275
  SPECIAL TOOLS Bleed syringe Art. no.: 50329050000 400058-01 Circlip pliers reverse Art. no.: 51012011000 400059-01 Clutch holder Art. no.: 51129003000 400289-01 Lift stand Art. no.: 54829055000 500071-01 Extractor Art. no.: 58012009000 400073-01…
• Page 276
  SPECIAL TOOLS Tool for inner bearing race Art. no.: 58429037037 400082-01 Torque wrench with various accessories in set Art. no.: 58429094000 200910-10 Valve spring compressor Art. no.: 59029019000 400101-01 Feeler gauge Art. no.: 59029041100 400110-01 Plastigauge measuring strips Art. no.: 60029012000 400122-01…
• Page 277
  SPECIAL TOOLS Piston ring mounting tool Art. no.: 60029015000 400123-01 Hose clamp pliers Art. no.: 60029057000 400142-01 Testing hose Art. no.: 61029093000 201314-01 Pressure testing tool Art. no.: 61029094000 400149-01 Engine assembly stand Art. no.: 61229001000 200306-01…
• Page 278
  SPECIAL TOOLS Pressing device for crankshaft, complete Art. no.: 75029047000 400185-01 Protection cover Art. no.: 75029090000 400167-01 Extractor, camshaft gear Art. no.: 77229001044 302768-10 Engine fixing arm Art. no.: 77229002000 301487-10 Mounting sleeve Art. no.: 77229005000 305092-10…
• Page 279
  SPECIAL TOOLS Insert for crankshaft pressing tool Art. no.: 77229008000 302926-10 Extrude plate, base Art. no.: 77229009000 302925-10 Pliers for valve stem seals Art. no.: 77229010000 302943-10 Limit plug gauge Art. no.: 77229026000 303164-10 Insert, piston pin lock ring Art. no.: 77229030000 302721-10…
• Page 280
  SPECIAL TOOLS Protection cap Art. no.: 77229031000 302921-10 Separator plate Art. no.: 77229032000 302922-10 Insert, timing chain tensioner Art. no.: 77229035000 302769-10 Puller Art. no.: 77229048000 302723-10 Adjustment bush bridge Art. no.: 77229050000 302722-10…
• Page 281
  SPECIAL TOOLS Insert for valve spring lever Art. no.: 77229060100 400129-01 Spark plug wrench Art. no.: 77229072000 400170-01 Oil pressure adapter Art. no.: 77329006000 400176-01 Release device for timing chain tensioner Art. no.: 77329051000 400181-01 Pin wrench Art. no.: T103 200734-10…
• Page 282
  SPECIAL TOOLS Hook wrench Art. no.: T106S 301085-01 Depth micrometer Art. no.: T107S 300577-10 Art. no.: T120 201235-10 Mounting sleeve Art. no.: T1204 200788-10 Calibration pin Art. no.: T1205 200790-10…
• Page 283
  SPECIAL TOOLS Pressing tool Art. no.: T1206 200583-10 Pressing tool Art. no.: T1207S 200585-01 Centering sleeve Art. no.: T1214 200777-10 Mounting sleeve Art. no.: T1215 300568-10 Disassembly tool Art. no.: T1216 200816-10…
• Page 284
  SPECIAL TOOLS Vacuum pump Art. no.: T1240S 200273-10 Protecting sleeve Art. no.: T1401 200635-10 Clamping stand Art. no.: T14015S 200733-10 Clamping stand Art. no.: T14016S 200688-10 Gripping tool Art. no.: T14026S1 200639-10…
• Page 285
  SPECIAL TOOLS Assembly tool Art. no.: T1402S 200634-10 Open-end wrench Art. no.: T14032 200640-10 Clamping stand Art. no.: T1403S 200637-10 Press drift Art. no.: T1504 200789-10 Assembly tool Art. no.: T150S 200791-10…
• Page 286
  SPECIAL TOOLS Nitrogen filling tool Art. no.: T170S1 300574-10…

• Page 287: Standards

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

• Page 288: Index

  INDEX fluid, changing ……177 INDEX Clutch lever Accessories ……..7 basic position, adjusting .

• Page 289
  INDEX stator, removing ……187 left section of the engine case, removing ..129 timing assembly, checking .
• Page 290
  INDEX removing ……. . . 16 Main silencer glass fiber yarn filling, changing ….65 Fork service, performing .
• Page 291
  INDEX seal ring retainer, disassembling ….48 page 3 of 7 ……258 shock absorber, servicing .
• Page 292
  *3206111en* 3206111en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com…

• Page 1
  REPAIR MANUAL 2015 350 EXC‑F EU 350 EXC‑F SIX DAYS EU 350 EXC‑F AU 350 EXC‑F BR 350 EXC‑F US 350 XCF‑W US 350 XCF‑W SIX DAYS US Art. no. 3206200en…
• Page 3
  KTM accepts no liability for delivery options, deviations from illustrations and descriptions, misprints, and other errors.

• Page 4: Table Of Contents

  TABLE OF CONTENTS 6.13.6 Disassembling the hydrostop unit ….41 TABLE OF CONTENTS MEANS OF REPRESENTATION ……..6 6.13.7 Disassembling the seal ring retainer….41 Symbols used ……….. 6 6.13.8 Checking the fork legs ……… 42 Formats used………… 6 6.13.9 Assembling the seal ring retainer….

• Page 5
  TABLE OF CONTENTS 10 EXHAUST …………..81 15.8 Checking the quiescent current …… 115 10.1 Removing the manifold……..81 16 BRAKE SYSTEM …………116 10.2 Installing the manifold ……..81 16.1 Checking the front brake linings ….. 116 10.3 Removing main silencer……..82 16.2 Changing the front brake linings …..
• Page 6
  TABLE OF CONTENTS 18.3.24 Removing the shift shaft……151 18.4.38 Disassembling the main shaft ….178 18.3.25 Removing the shift drum locating unit ..151 18.4.39 Disassembling the countershaft….179 18.3.26 Removing the locking lever ……151 18.4.40 Checking the transmission ……179 18.3.27 Removing the force pump……
• Page 7
  TABLE OF CONTENTS 21.4 Adding engine oil ………. 211 29.16 Page 8 of 8 (EXC‑F AU) ……… 264 21.5 Checking the engine oil pressure ….211 29.17 Page 1 of 8 (EXC‑F BR) ……… 266 22 IGNITION SYSTEM……….. 213 29.18 Page 2 of 8 (EXC‑F BR) ……… 268 22.1 Ignition coil — checking the secondary 29.19 Page 3 of 8 (EXC‑F BR) ………

• Page 8: Means Of Representation

  MEANS OF REPRESENTATION 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). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips.

• Page 9: Safety Advice

  Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle. This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available. Safety advice A number of safety instructions need to be followed to operate the vehicle safely.

• Page 10: Important Notes

  Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer’s Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle.

• Page 11: Serial Numbers

  SERIAL NUMBERS Chassis number  The chassis number is stamped on the steering head on the right. 401945-10 Type label (EXC‑F EU/AUS/BR, EXC-F SIX DAYS, XCF-W)  The type label is fixed to the front of the steering head. 401946-10 (EXC-F US) …

• Page 12: Engine Number

  SERIAL NUMBERS (EXC-F US)  Key number for the ignition and steering lock is indicated on the KEYCODECARD. Info You need the key number to order a replacement key. Keep the KEYCODECARD in a safe place. 101543-10 Engine number The engine number …

• Page 13: Motorcycle

  MOTORCYCLE 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) ( p.

• Page 14: Starting The Motorcycle For A Check

  MOTORCYCLE – Press the electric starter button or press the kick starter robustly through its full range. Info Press the electric starter button for at most 5 seconds. Wait for a least 5 seconds before trying again. Warning lamp FI lights up briefly as a functional control when starting. 400733-01 Starting the motorcycle for a check Danger…

• Page 15: Fork, Triple Clamp

  FORK, TRIPLE CLAMP Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. (EXC‑F EU/AUS/BR/US, XCF‑W) –  Remove protection caps –  Turn adjusting screws clockwise all the way. Info Adjusting screws …

• Page 16: Adjusting The Spring Preload Of The Fork (Exc-F Eu/Aus/Br/Us, Xcf-W)

  FORK, TRIPLE CLAMP (EXC‑F EU/AUS/BR/US, XCF‑W) –  Turn adjusting screws clockwise all the way. Info  Adjusting screws 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.

• Page 17: Bleeding Fork Legs

  FORK, TRIPLE CLAMP Bleeding fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 11) Main work –  Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws. M00160-10 Finishing work –…

• Page 18: Loosening The Fork Protector

  FORK, TRIPLE CLAMP Loosening the fork protector –  Remove screws and remove the clamp. –  Remove screws on the left fork leg. Push the fork protector downwards. – Remove the screws on the right fork leg. Push the fork protector downwards. B01515-10 Positioning the fork protector –…

• Page 19: Installing The Fork Legs

  FORK, TRIPLE CLAMP (All SIX DAYS models) –  Release screws . Take out the left fork leg. –  Release screws . Take out the right fork leg. M00138-10 Installing the fork legs Main work (EXC‑F EU/AUS/BR, XCF‑W) – Position the fork legs.

• Page 20: Removing The Fork Protector

  FORK, TRIPLE CLAMP –  Tighten screws Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) –  Tighten screws Guideline Screw, bottom triple clamp 15 Nm (11.1 lbf ft) M00138-11 –  Position the brake caliper and mount and tighten screws Guideline Loctite ®…

• Page 21: Exc-F Eu/Aus/Br/Us, Xcf-W

  FORK, TRIPLE CLAMP 6.12 EXC‑F EU/AUS/BR/US, XCF‑W 6.12.1 Performing a fork service Info These operations are the same on both fork legs. Condition The fork legs have been removed. – Disassemble the fork legs. ( p. 19) – Disassemble the cartridge. ( p.

• Page 22
  FORK, TRIPLE CLAMP –  Loosen Preload Adjuster Pin wrench (T103) ( p. 349) Info The Preload Adjuster cannot be taken off yet. 200737-10 – Take out the fork leg and clamp with the axle clamp. Info Use soft jaws. 200690-10 –…
• Page 23
  FORK, TRIPLE CLAMP – Drain the fork oil. Info Pull out and push in the piston rod a few times to empty the cartridge. 201349-10 – Clamp the fork leg with the axle clamp. Guideline Use soft jaws. –  Unscrew and remove the compression damping fitting Info Place a fluid collector beneath it, as usually some oil will drain out.

• Page 24: Cartridge Disassembly

  FORK, TRIPLE CLAMP –  Remove upper sliding bushing Info Gently pull them apart without using any tool. 200658-01 –  Take off the lower sliding bushing –  Take off support ring – Take off seal ring  – …

• Page 25
  FORK, TRIPLE CLAMP – Degrease the cartridge and clamp using the pecial tool. Clamping stand (T14015S) ( p. 352) –  Warm up the cartridge in the area of Guideline 50 °C (122 °F) – Unscrew and remove screwsleeve  Info 200749-10 This step is unnecessary for the further disassembly.

• Page 26: Disassembling The Compression Damping Fitting

  FORK, TRIPLE CLAMP 6.12.4 Disassembling the compression damping fitting Info The steps are identical for both fork legs. Preparatory work – Disassemble the fork legs. ( p. 19) Main work – Clamp the compression damping fitting in a bench vise using soft jaws. –…

• Page 27: Assembling The Compression Damping Fitting

  FORK, TRIPLE CLAMP – Measure the run-out of the inner tube. ≤ 0.20 mm (≤ 0.0079 in) Inner tub run-out » If the measured value is greater than the specified value: – Change the inner tube. 200685-10 – Check the outer tube for damage. »…

• Page 28: Assembling The Cartridge

  FORK, TRIPLE CLAMP –  Mount shim stack Info Mount the smaller shims below. –   Mount pistons with O-ring Info  The side with the largest inside diameter faces upward. 200705-10 – Grease the piston O-ring. Fork oil (SAE 4) (48601166S1) ( p.

• Page 29: Assembling The Fork Legs

  FORK, TRIPLE CLAMP Info The side with the largest inside diameter faces downward. – Mount shim stack  Info Align the triangular plate exactly with the piston opening. –  Mount and tighten nut Guideline Tap rebound nut M6x0.5 5 Nm (3.7 lbf ft) 200720-10 Info Mount the nut with the collar facing downward.

• Page 30
  FORK, TRIPLE CLAMP Preparatory work – Check the fork legs. ( p. 24) – Assemble the cartridge. ( p. 26) – Assemble the compression damping fitting. ( p. 25) Main work – Clamp in the inner tube with the axle clamp. Guideline Use soft jaws.
• Page 31
  FORK, TRIPLE CLAMP – Position the support ring. – Hold the seal ring with the shorter shoulder of the special tool. Assembly tool (T1402S) ( p. 352) – Press the outer tube all the way in. 201355-10 –  Mount lock ring Info The lock ring must audibly lock into place.
• Page 32
  FORK, TRIPLE CLAMP – Clamp in the fork vertically. – Fill with fork oil. Fork oil per fork 620 ml Fork oil (SAE 4) (48601166S1) (20.96 fl. oz.) p. 339) Info Pull out the piston rod and push back in a number of times to bleed the car- tridge.

• Page 33: Greasing The Steering Head Bearing

  FORK, TRIPLE CLAMP – Push the outer tube upward. – Clamp the outer tube in the area of lower triple clamp. Clamping stand (T1403S) ( p. 353) – Grease the Preload Adjuster O-ring. Lubricant (T158) ( p. 340) – Screw on and tighten the Preload Adjuster. Guideline 200744-10 Preload Adjuster on the outer tube…

• Page 34: Removing The Lower Triple Clamp

  FORK, TRIPLE CLAMP 6.12.10 Removing the lower triple clamp Preparatory work – Remove the headlight mask with the headlight. ( p. 98) – Raise the motorcycle with the lift stand. ( p. 11) – Remove the front wheel. ( p. 103) –…

• Page 35
  FORK, TRIPLE CLAMP – Position the fork legs.  Bleeder screws face forward. Info Grooves are milled into the side of the upper end of the fork legs. The sec- ond milled groove (from the top) must be flush with the top edge of the upper triple clamp.

• Page 36: Checking The Steering Head Bearing Play

  FORK, TRIPLE CLAMP (EXC-F US) –  Tighten screws Guideline Screw, top triple clamp 20 Nm (14.8 lbf ft) –  Secure the wiring harness with cable holder M00173-11 –  Position the brake caliper. Mount and tighten screws Guideline Loctite ®…

• Page 37: Adjusting The Play Of The Steering Head Bearing

  FORK, TRIPLE CLAMP 6.12.13 Adjusting the play of the steering head bearing Preparatory work – Raise the motorcycle with the lift stand. ( p. 11) Main work (EXC‑F EU/AUS/BR, XCF‑W) –   Loosen screws – Loosen and retighten screw …

• Page 38: Disassembling The Fork Legs

  FORK, TRIPLE CLAMP – Disassemble the fork legs. ( p. 36) – Remove the spring. ( p. 38) – Disassemble the cartridge. ( p. 39) – Disassemble the piston rod. ( p. 40) – Disassemble the hydrostop unit. ( p. 41) –…

• Page 39
  FORK, TRIPLE CLAMP – Unclamp the fork leg. – Push the outer tube down. Drain the fork oil. 201702-10 – Clamp the fork leg with the axle clamp. –  Release hydrostop unit and remove it. Info Do not use an impact wrench. Place a pan underneath since oil will run out.

• Page 40: Removing The Spring

  FORK, TRIPLE CLAMP –  Remove the upper sliding bushing Info Do not use a tool; pull the ends apart slightly by hand. 201708-10 –  Take off the lower sliding bushing –  Take off support ring – Take off seal ring …

• Page 41: Disassembling The Cartridge

  FORK, TRIPLE CLAMP 6.13.4 Disassembling the cartridge Info The steps are identical for both fork legs. Preparatory work – Disassemble the fork legs. ( p. 36) – Remove the spring. ( p. 38) Main work –  Degrease piston rod and clamp it in the vise.

• Page 42: Disassembling The Piston Rod

  FORK, TRIPLE CLAMP –   Remove seal rings and O-ring –  Remove pilot bushings 201798-11 6.13.5 Disassembling the piston rod Info The steps are identical for both fork legs, except for the hydrostop needle and valve. Preparatory work –…

• Page 43: Disassembling The Hydrostop Unit

  FORK, TRIPLE CLAMP –  Remove valve needle from the piston rod. Info The adjusting tube can be used for this. 201789-10 6.13.6 Disassembling the hydrostop unit Info The steps are identical for both fork legs. Preparatory work – Disassemble the fork legs. ( p.

• Page 44: Checking The Fork Legs

  FORK, TRIPLE CLAMP Main work –  Remove pilot bushing support –   Remove O-ring and seal ring 201799-10 6.13.8 Checking the fork legs Condition The fork legs have been disassembled. – Check the inner tube and axle clamp for damage. »…

• Page 45: Assembling The Seal Ring Retainer

  FORK, TRIPLE CLAMP – Check the surface of the sliding bushings. »   If the bronze-colored layer under sliding layer is visible or the surface is rough: – Change the sliding bushings. 200665-10 – Check the spring length. Guideline Spring length with preload spacer(s) 472 mm (18.58 in) »…

• Page 46: Assembling The Piston Rod

  FORK, TRIPLE CLAMP –  Mount shim stack with the smaller washers facing downward. –  Mount and tighten sleeve Guideline Hydrostop unit sleeve M6x0.5 7 Nm (5.2 lbf ft) 201785-10 –   Check distance and total length of the hydrostop. Guideline ≥…

• Page 47: Assembling The Cartridge

  FORK, TRIPLE CLAMP – Grind the piston on both sides on a surfacing plate using 1200 grit sandpaper. – Clean the piston. – Lubricate the piston ring. Fork oil (SAE 4) (48601166S1) ( p. 339) –  Mount the piston with chamfer facing down.

• Page 48: Assembling The Fork Legs

  FORK, TRIPLE CLAMP –  Position sleeve in the reservoir. – Clamp the tube of the cartridge into a vise. Clamping stand (T14049S) ( p. 353) –  Slide reservoir onto the tube. Info Hold the sleeve in the reservoir to prevent it from sliding out. –…

• Page 49
  FORK, TRIPLE CLAMP –  Lubricate and mount dust boot Lubricant (T511) ( p. 340) Info Always change the dust boot, seal ring, lock ring and support ring. Mount the sealing lip with the spring expander facing downward. – Slide on lock ring …
• Page 50
  FORK, TRIPLE CLAMP –  Mount lock ring Info The lock ring must engage audibly. 201706-11 –  Mount dust boot –  Mount fork protection ring 201705-11 – Lubricate the O-ring. Slide the cartridge all the way into the fork leg. Fork oil (SAE 4) (48601166S1) ( p.
• Page 51
  FORK, TRIPLE CLAMP – Pull out the piston rod and push it back in numerous times while pressing it to one side slightly. Air bubbles emerge and the cartridge is bled. – Keep bleeding until no more air bubbles emerge. The piston rod moves out automatically to the middle of the total stroke distance.

• Page 52: Greasing The Steering Head Bearing

  FORK, TRIPLE CLAMP Guideline Rebound damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Compression damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks – Turn counterclockwise by the number of clicks corresponding to the fork type. Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seri- ously alter the vehicle’s ride behavior.

• Page 53: Installing The Lower Triple Clamp

  FORK, TRIPLE CLAMP –   Remove O-ring . Remove protective ring – Take off the lower triple clamp with the steering stem. – Remove the upper steering head bearing. B01229-10 6.13.16 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease.

• Page 54: Checking The Steering Head Bearing Play

  FORK, TRIPLE CLAMP –  Tighten screw Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) B01232-10 –  Mount and tighten screw Guideline Loctite ® 243™ Screw, top steering stem 17 Nm (12.5 lbf ft) B01233-10 – …

• Page 55: Adjusting The Play Of The Steering Head Bearing

  FORK, TRIPLE CLAMP Preparatory work – Raise the motorcycle with the lift stand. ( p. 11) Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. »…

• Page 56: Handlebar, Controls

  HANDLEBAR, CONTROLS Handlebar position  On the upper triple clamp, there are two holes at a distance of to each other. 15 mm (0.59 in)  Hole distance  The holes on the handlebar supports are placed at a distance of from the center.

• Page 57: Checking The Throttle Cable Routing

  HANDLEBAR, CONTROLS Checking the throttle cable routing Preparatory work – Remove the seat. ( p. 88) – Remove the fuel tank. ( p. 89) Main work (EXC‑F EU/AUS/BR, EXC-F SIX DAYS, XCF-W) – 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.

• Page 58: Adjusting The Play In The Throttle Cable

  HANDLEBAR, CONTROLS 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.

• Page 59: Frame

  Change the frame. 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. 401340-01 Removing the engine guard (EXC‑F AU, All SIX DAYS models) –…

• Page 60: Shock Absorber, Swingarm

  SHOCK ABSORBER, SWINGARM 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. Info The high-speed setting can be seen during the fast compression of the shock absorber. –…

• Page 61: Adjusting The Rebound Damping Of The Shock Absorber

  SHOCK ABSORBER, SWINGARM 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. –  Turn adjusting screw clockwise up to the last perceptible click.

• Page 62: Checking The Riding Sag Of The Shock Absorber

  SHOCK ABSORBER, SWINGARM Checking the riding sag of the shock absorber –  Measure distance of rear wheel unloaded. ( p. 59) – 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.

• Page 63: Adjusting The Riding Sag

  SHOCK ABSORBER, SWINGARM Adjusting the riding sag Preparatory work – Raise the motorcycle with the lift stand. ( p. 11) – Remove shock absorber. ( p. 61) – After removing the shock absorber, clean it thoroughly. Main work – Choose and mount a suitable spring. Guideline Spring rate Weight of rider: 65……

• Page 64: Servicing The Shock Absorber

  SHOCK ABSORBER, SWINGARM Finishing work – Remove the motorcycle from the lift stand. ( p. 11) 9.11 Servicing 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. Condition The shock absorber has been removed.

• Page 65: Disassembling The Damper

  SHOCK ABSORBER, SWINGARM 9.13 Disassembling the damper Preparatory work – Remove the spring. ( p. 62) Main work –  Note down the present state of rebound damping and compression  damping – Completely open the adjustment elements of the rebound damping and compres- sion damping.

• Page 66: Disassembling The Piston Rod

  SHOCK ABSORBER, SWINGARM – Remove the piston rod. Drain the remaining oil. 201620-10 –  Remove adjusting ring with the intermediate washer. 201621-10 –  Remove compression adjuster . Remove the spring and piston. 200760-10 9.14 Disassembling the piston rod Preparatory work –…

• Page 67: Disassembling The Seal Ring Retainer

  SHOCK ABSORBER, SWINGARM –  Unscrew and remove mount –  Remove rebound damping shim stack Info Guide the rebound damping shim stack onto a screwdriver and put them aside together. 200763-10 –  Remove piston –  Remove compression damping shim stack Info Guide the compression damping shim stack onto a screwdriver and put them aside together.

• Page 68: Replacing The Pilot Bushing

  SHOCK ABSORBER, SWINGARM –  Remove seal ring –   Remove washer from seal ring 200786-10 –  Remove washer –  Remove O-ring – Remove dust boot  200787-10 9.16 Replacing the pilot bushing Preparatory work – Remove the spring. ( p.

• Page 69: Checking The Damper

  SHOCK ABSORBER, SWINGARM 9.17 Checking the damper Condition The damper has been disassembled. – Measure the inside diameter on both ends and in the middle of the damper car- tridge. Damper cartridge Diameter 50.08 mm (1.9716 in) » If the measured value is greater than the specified value: –…

• Page 70: Removing The Heim Joint

  SHOCK ABSORBER, SWINGARM –  Remove screwsleeve –  Remove adjusting screw Info  Do not lose balls and spring. 200806-10 –  Remove rubber plug –  From the opposite side, press rebound needle out of the piston rod. 200807-10 9.19 Removing the heim joint…

• Page 71: Installing The Heim Joint

  SHOCK ABSORBER, SWINGARM –   Place special tool underneath and press out heim joint using special tool  Pressing tool (T1207S) ( p. 351) 200802-10 9.20 Installing the heim joint – Position new heim joint  and special tool. Pressing tool (T1206) ( p.

• Page 72: Assembling The Rebound Adjuster

  SHOCK ABSORBER, SWINGARM 9.21 Assembling the rebound adjuster –  Grease O-ring of the rebound needle. Lubricant (T158) ( p. 340) –  Mount rebound needle in the piston rod. Info Push in the rebound needle to the point where it is possible to mount the rebound damping adjusting screw.

• Page 73: Assembling The Piston Rod

  SHOCK ABSORBER, SWINGARM –   Position washer on seal ring – Grease the seal ring and mount with the washer facing downward. Lubricant (T511) ( p. 340) 200794-10 –  Mount centering disk –  Mount rebound rubber 200795-10 9.23 Assembling the piston rod Preparatory work…

• Page 74: Assembling The Damper

  SHOCK ABSORBER, SWINGARM –  Mount rebound damping shim stack with the smaller shims at the top. – Apply thread locker to the threads of the piston rod. Loctite ® 2701™ –  Screw on mount to the point where the piston can still be turned. 200769-10 –…

• Page 75
  SHOCK ABSORBER, SWINGARM Main work –  Slide the spring and piston onto compression adjuster – Grease the O-ring. Lubricant (T158) ( p. 340) – Grease the threads. Lubricant (T159) ( p. 340) – Mount and tighten the compression adjuster. 200774-10 Guideline Compression adjuster…
• Page 76
  SHOCK ABSORBER, SWINGARM –  Mount rubber cap of the reservoir. –  Turn adjusting ring completely down toward the bottom. 201623-10 Alternative 1 –  Turn adjusting screw clockwise with a screwdriver up to the last perceptible click. – Turn counterclockwise by the number of clicks corresponding to the shock absorber type.

• Page 77: Bleeding And Filling The Damper

  SHOCK ABSORBER, SWINGARM 9.25 Bleeding and filling the damper Info Before working with the vacuum pump, carefully read the vacuum pump operating manual. Completely open the adjusters of the rebound and compression damping. – Remove the screw from the filling port. –…

• Page 78
  SHOCK ABSORBER, SWINGARM –  When the pressure gauge reaches the required value, turn control lever Damper to Pressure. Guideline 0 bar Oil is pumped into the damper. The pressure gauge increases to the required value. 3 bar 200268-10 – …

• Page 79: Filling The Damper With Nitrogen

  SHOCK ABSORBER, SWINGARM –   Slide O-ring to the end of the special tool by the specified value (distance minus specified value). Guideline 10 mm Depth micrometer (T107S) ( p. 350) – Push the floating piston into the reservoir to the distance described above using the special tool.

• Page 80: Installing The Spring

  SHOCK ABSORBER, SWINGARM –  Screw the filling port shut with tap handle –  Close spigot and remove the damper from the special tool. – Tighten the screw of the filling port. Guideline Reservoir filling port screw 3.5 Nm (2.58 lbf ft) 9.27 Installing the spring…

• Page 81: Changing The Heim Joint

  SHOCK ABSORBER, SWINGARM –  Tighten screw Guideline Screw, shock absorber adjusting ring 5 Nm (3.7 lbf ft) 201613-11 9.28 Changing the heim joint Preparatory work – Raise the motorcycle with the lift stand. ( p. 11) Main work – …

• Page 82
  SHOCK ABSORBER, SWINGARM – Position the new heim joint. –  Mount special tool Mounting tool, heim joint (50329000044) ( p. 342) – Press in the heim joint by screwing in the screw. G01333-10 –  Press in shaft seal rings on both sides with the open side facing inward.

• Page 83: Exhaust

  EXHAUST 10.1 Removing the manifold Preparatory work – Raise the motorcycle with the lift stand. ( p. 11) – Remove shock absorber. ( p. 61) – Remove the main silencer. ( p. 82) Main work –  Remove springs G01389-10 –…

• Page 84: Removing Main Silencer

  EXHAUST 10.3 Removing 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. –  Disconnect spring –  Remove screws and take off main silencer.

• Page 85: Cleaning Spark Arrestor

  EXHAUST Main work (EXC‑F EU/AUS/BR, EXC-F SIX DAYS) –    Remove screws and take off silencer cap with O-ring – Remove the old glass fiber yarn filling. – Clean the parts that need to be reinstalled and check for damage. –…

• Page 86
  EXHAUST 402269-10 Main work –    Remove screws and take off silencer cap with O-ring Warning Danger to health Soot particles irritate the eyes and mucuous membranes. – Wear suitable breathing and eye protection when cleaning the main silencer and carbon screen. –…

• Page 87: Air Filter

  AIR FILTER 11.1 Removing the air filter box lid (EXC‑F EU/AUS/BR, EXC-F SIX DAYS, XCF-W) –  Pull off the air filter box lid in area sideways and remove it toward the front. L02467-10 (EXC-F US) –  Pull off the air filter box lid in area sideways and remove it toward the front.

• Page 88: Removing The Air Filter

  AIR FILTER 11.4 Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to increased wear. Warning Environmental hazard Hazardous substances cause environmental damage.

• Page 89
  AIR FILTER Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 340) Info Only press the air filter to dry it, never wring it out. – Oil the dry air filter with a high quality filter oil.

• Page 90: Fuel Tank, Seat, Trim

  FUEL TANK, SEAT, TRIM 12.1 Opening 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. –…

• Page 91: Mounting The Seat

  FUEL TANK, SEAT, TRIM 12.4 Mounting the seat – Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear and simultaneously push it forward. – Make sure that the seat is correctly locked in. –…

• Page 92: Installing The Fuel Tank

  FUEL TANK, SEAT, TRIM (EXC‑F EU/AUS/BR, EXC-F SIX DAYS) – Disconnect the connector of the horn. – Remove screws  with the collar bushings and horn. B01530-10 (EXC-F US, All XCF-W models) – Disconnect the connector of the horn. – …

• Page 93
  FUEL TANK, SEAT, TRIM Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water.

• Page 94: Changing The Fuel Screen

  FUEL TANK, SEAT, TRIM –  Lubricate the O-ring and connect plug-in connection of the fuel line. Info Route the cable and fuel line at a safe distance from the exhaust sys- tem. Finishing work – Mount the seat. ( p.

• Page 95: Changing The Fuel Filter

  FUEL TANK, SEAT, TRIM (EXC-F US) –  Clean the plug-in connection of the fuel line thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve. –…

• Page 96
  FUEL TANK, SEAT, TRIM –  Remove screws – Pull out the fuel pump. 305314-10 –  Remove hose clamps –  Remove fuel filter 305315-10 –  Press lock –  Pull back fuel pump housing 305317-10 –  Change fuel screen –…

• Page 97: Changing The Fuel Pump

  FUEL TANK, SEAT, TRIM –  Tighten fuel connection Guideline Fuel connection on fuel pump 10 Nm (7.4 lbf ft) –  Mount and tighten screws Guideline EJOT PT ® Screw, fuel pump 3 Nm (2.2 lbf ft) 305314-10 Finishing work –…

• Page 98: Checking The Fuel Pressure

  FUEL TANK, SEAT, TRIM – Position the fuel pump. –  Mount fuel connection with the gasket but do not tighten yet. Guideline Fuel connection on fuel pump 10 Nm (7.4 lbf ft) –  Mount and tighten nut with the gasket. Guideline Nut, fuel pump fixation 15 Nm…

• Page 99
  FUEL TANK, SEAT, TRIM –  Mount special tool 0 0 3 Pressure testing tool (61029094000) ( p. 345) –  Mount special tool with nozzle label 0,60. Testing hose (61029093000) ( p. 345) – Position the hose end in a fuel cannister. 0 0 2 Guideline Minimum size of fuel cannister…

• Page 100: Mask, Fender

  MASK, FENDER 13.1 Removing the front fender Preparatory work – Remove the headlight mask with the headlight. ( p. 98) Main work –  Remove screws L02485-10 –  Remove screws . Remove the front fender. B01603-11 13.2 Installing the front fender Main work –…

• Page 101: Refitting The Headlight Mask With The Headlight

  MASK, FENDER –  Detach electrical plug-in connector and take off the headlight mask with the headlight. M00127-10 (EXC-F US) – Switch off all electrical equipment. –  Remove screw and take off the clamp. –  Release rubber straps .

• Page 102
  MASK, FENDER –  Position the headlight mask and fix it with rubber straps Info Ensure the holding lugs engage in the fender. – Position the brake line and wiring harness. Put the clamp on and mount and  tighten screw M00188-11 Finishing work –…

• Page 103: Wheels

  DOT marking. The first two digits indi- cate the week of manufacture and the last two digits the year of manufac- ture. KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear. »…

• Page 104: Checking The Brake Discs

  WHEELS 14.3 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. – Check the thickness of the front and rear brake discs at several places on the disk …

• Page 105: Front Wheel

  WHEELS 14.5 Front wheel 14.5.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 11) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

• Page 106: Removing The Front Brake Disc

  WHEELS – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw  Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc.

• Page 107: Installing The Rear Wheel

  WHEELS Main work – Press the brake caliper by hand on to the brake disc in order to press back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes. –…

• Page 108: Removing The Rear Brake Disc

  WHEELS –   Position chain adjuster . Mount nut but do not tighten it yet. –   Make sure that chain adjusters are fitted correctly on adjusting screws – Check the chain tension. ( p. 107) –  Tighten nut Guideline Nut, rear wheel spindle…

• Page 109: Checking The Chain Tension

  WHEELS 14.6.5 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear- ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases.

• Page 110: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

  WHEELS Main work –  Loosen nut –  Loosen nuts –  Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55… 58 mm (2.17… 2.28 in) Turn adjusting screws  on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference …

• Page 111
  WHEELS – 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. – Check that the chain sliding guard is firmly seated. »…

• Page 112: Checking For Chain Dirt Accumulation

  WHEELS 14.6.8 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 110) 400678-01 14.6.9 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. –…

• Page 113: Wiring Harness, Battery

  WIRING HARNESS, BATTERY 15.1 Removing the main fuse Preparatory work – Switch off all power consumers and switch off the engine. – Remove the air filter box lid. ( p. 85) Main work –  Remove the protection cover Info The main fuse …

• Page 114: Removing The Battery

  WIRING HARNESS, BATTERY – 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 (optional) (EXC-F US) Fuse 5 — 10 A — ignition…

• Page 115: Installing The Battery

  – Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

• Page 116: Checking The Charging Voltage

  WIRING HARNESS, BATTERY Info Even when there is no load on the battery, it still loses power 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.

• Page 117: Checking The Quiescent Current

  WIRING HARNESS, BATTERY 15.8 Checking the quiescent current Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. ( p. 88) Main work – Disconnect the negative cable from the battery. – Measure the current between battery ground (−) and the negative cable. Info The value of the quiescent current applies only to vehicles in the original state, i.e.

• Page 118: Brake System

  Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

• Page 119
  BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. –  Remove screws –   Remove cover with membrane – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

• Page 120: Checking Free Travel Of Hand Brake Lever

  BRAKE SYSTEM 16.3 Checking free travel of 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.

• Page 121: Checking The Brake Fluid Level Of The Front Brake

  BRAKE SYSTEM 16.6 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.

• Page 122: Changing The Front Brake Fluid

  BRAKE SYSTEM Brake fluid DOT 4 / DOT 5.1 ( p. 338) – Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water. 16.8 Changing the front brake fluid Warning Skin irritation Brake fluid can cause skin irritation on contact.

• Page 123: Checking The Rear Brake Linings

  BRAKE SYSTEM –  Pull off protection cap of the brake caliper bleeder screw. Connect the hose of the bleeder bottle. Bleeding device (00029013100) ( p. 342) –  Open bleeder screw by approx. one-half turn. Info Bleed until fresh brake fluid emerges from the bleeder bottle hose without bubbles.

• Page 124
  Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

• Page 125: Checking The Free Travel Of Foot Brake Lever

  BRAKE SYSTEM – Insert the new brake linings, insert the pin, and mount the cotter pins. Info Always change the brake linings in pairs. – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. M00115-01 –…

• Page 126: Checking The Rear Brake Fluid Level

  BRAKE SYSTEM –  Disconnect spring –   Loosen nut and, with push rod , turn it back until you have maximum free travel. –  To adjust the basic position of the foot brake lever individually, loosen nut …

• Page 127: Changing The Rear Brake Fluid

  BRAKE SYSTEM 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. 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.

• Page 128
  BRAKE SYSTEM – Cover the painted parts. –  Remove screw cap with membrane and the O-ring. – Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid. Bleed syringe (50329050000) ( p.

• Page 129: Lighting System, Instruments

  LIGHTING SYSTEM, INSTRUMENTS 17.1 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. –  Make another mark a distance under the first mark.

• Page 130: Speedometer Overview

  LIGHTING SYSTEM, INSTRUMENTS 17.3 Speedometer overview – Press the button to control different functions. – Press the button to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. 401761-01 17.4 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.

• Page 131: Setting The Speedometer Functions

  LIGHTING SYSTEM, INSTRUMENTS 17.6 Setting 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. – Repeatedly press the button briefly until H appears at the bottom right of the display.

• Page 132: Setting The Wheel Circumference

  LIGHTING SYSTEM, INSTRUMENTS Main work –  Expose connector CZ 301287-10 –  Sever the black/brown cable – Insulate both cable ends. 301288-10 Finishing work – Refit the headlight mask with the headlight. ( p. 99) – Check the headlight setting. ( p.

• Page 133
  LIGHTING SYSTEM, INSTRUMENTS – Repeatedly press the button briefly until LAP appears at the bottom right of the display. – Briefly press the button LAP 1 appears on the left side of the display. – The laps 1–10 can be viewed with the button –…

• Page 134: Engine

  ENGINE 18.1 Removing the engine Preparatory work – Drain the coolant. ( p. 206) – Raise the motorcycle with the lift stand. ( p. 11) – Remove the main silencer. ( p. 82) – Remove the seat. ( p. 88) –…

• Page 135
  ENGINE –  Push back hose clamp – Pull off the vent hose. G01429-10 –  Remove screw –  Loosen screw – Repeat the operation on the opposite side. G01430-10 – Swing up the subframe and secure it. G01431-10 –…
• Page 136
  ENGINE – Unplug the connector of the lambda sensor. – Remove the cable binder(s) and expose the cable. – Remove screw  – Remove the manifold. G01434-10 – Slide back cover. –  Remove nut – Detach the cable. G01435-10 –…
• Page 137
  ENGINE –  Remove screws – Take off the clutch slave cylinder and hang it to the side. Info Do not kink the clutch line. Do not activate the clutch lever if the clutch slave cylinder has been removed. G01440-10 –…

• Page 138: Installing The Engine

  ENGINE –  Remove screws G01446-10 – Lift out the engine from the side. Info You should have an assistant for this step. Make sure that the engine is sufficiently secured against falling over. Protect the frame and attachments from damage. G01447-10 18.2 Installing the engine…

• Page 139
  ENGINE Guideline Engine attachment bolt 60 Nm (44.3 lbf ft) Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) – Mount the radiator hose. –  Position and tighten hose clip G01443-11 – Mount the throttle valve body. –  Position and tighten hose clip G01442-11 –…
• Page 140
  ENGINE – Position the engine sprocket cover. –  Mount and tighten screw Guideline Screw, clutch slave cylinder 10 Nm (7.4 lbf ft) –  Mount and tighten screw Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) G01438-11 – …
• Page 141
  ENGINE – Position the shock absorber. –  Mount and tighten screw Guideline Screw, top shock absorber 80 Nm Loctite ® 2701™ (59 lbf ft) G01432-11 – Remove the fixation and position the subframe. Info Watch out for the intake flange. –…
• Page 142
  ENGINE – Position the frame protector on both sides. Info Pay attention to the holding lugs. –  Mount and tighten screws with the washers. Guideline Screw, frame protector 3 Nm (2.2 lbf ft) G01425-11 –  Connect negative cable of the battery.

• Page 143: Engine Disassembly

  ENGINE Finishing work – Take a test ride. – Read out the fault memory using the KTM diagnostics tool. – Check the engine for leakage. – Check the engine oil level. ( p. 208) – Check the coolant level. ( p.

• Page 144: Removing The Oil Filter

  ENGINE –  Remove oil drain plug with the magnet. – Completely drain the engine oil. 308570-10 18.3.5 Removing the oil filter –   Remove screws . Remove the oil filter cover with the O-ring. 308572-10 – Pull oil filter …

• Page 145: Removing The Kick Starter

  ENGINE – Remove the spark plug shaft insert. 308576-10 18.3.8 Removing the kick starter –  Remove screw with the washer. – Take off the kick starter. 308577-10 – Remove distance sleeve  308578-10 18.3.9 Removing the alternator cover – …

• Page 146: Removing The Torque Limiter

  ENGINE 18.3.10 Removing the torque limiter –  Remove torque limiter 308581-10 18.3.11 Positioning the engine at ignition top dead center –  Turn the crankshaft counterclockwise until markings on the cylinder head are  located flush above the flat areas of the camshafts.

• Page 147: Removing The Camshaft

  ENGINE 18.3.13 Removing the camshaft –  Loosen screws from the outside to the inside and remove. – Take off guide rail  – Take off the camshaft bearing bridge. 308594-10 – Take the timing chain off the camshaft gear. –…

• Page 148: Removing The Piston

  ENGINE 18.3.15 Removing the piston – Push the cylinder upward. Info Only push the cylinder as far up as necessary to take the piston pin out. –  Remove the piston pin retainer – Remove the piston pin. – Take off the cylinder and piston. –…

• Page 149: Removing The Suction Pump

  ENGINE –  Remove freewheel gear 308607-10 –  Remove screws – Remove the inside alternator cover. 308608-10 –  Take off gasket 308609-10 –  Remove screws – Take off the starter motor. 308610-10 18.3.17 Removing the suction pump –…

• Page 150: Removing The Water Pump Wheel

  ENGINE –  Remove suction pump 308614-10 –  Remove needle roller 308615-10 18.3.18 Removing the water pump wheel – Remove screws  . Take off the water pump cover. 308616-10 –  Remove nut –  Take off the two-part water pump impeller 308617-10 18.3.19 Removing the clutch cover –…

• Page 151: Removing The Clutch Discs

  ENGINE 18.3.20 Removing the clutch discs –  Remove screws – Take off spring retainer  308619-10 –  Take off spring washer 308620-10 –  Take off pretension ring 308621-10 –  Take off pressure cap 308622-10 – Completely remove clutch disc pack …

• Page 152: Removing The Clutch Basket

  ENGINE 18.3.21 Removing the clutch basket – Bend open lock washer. –  Hold the inner clutch hub with the special tool. Loosen nut Clutch holder (51129003000) ( p. 343) – Remove the nut with the lock washer. Dispose of the lock washer. 308624-10 –…

• Page 153: Removing The Shift Shaft

  ENGINE 18.3.24 Removing the shift shaft –   Push sliding plate away from the shift drum locating unit . Remove shift  shaft with the washer. 308632-10 18.3.25 Removing the shift drum locating unit –  Remove screw – …

• Page 154: Removing The Primary Gear

  ENGINE –  Remove pin –  Remove screws – Take off the oil pump cover. 308639-10 –  Remove pin –  Push oil pump shaft inward and take it out of the engine from the alternator side. – …

• Page 155: Removing The Spacer

  ENGINE 18.3.30 Removing the spacer –  Remove spacer of the crankshaft. – Remove screw  308644-10 18.3.31 Removing the left section of the engine case –  Remove screws – Tilt the left section of the engine case upward and remove the screw connections of the engine fixing arm.

• Page 156: Removing The Shift Drum

  ENGINE –   Remove shift rail together with upper spring and the lower spring. 308650-10 18.3.33 Removing the shift drum –  Tilt shift forks to the side. Info Do not misplace the shift rollers. –  Remove shift drum 308651-10 18.3.34 Removing the shift forks –…

• Page 157: Removing The Crankshaft

  ENGINE 18.3.36 Removing the crankshaft –  Take out crankshaft – Take off the right section of the engine case. 308656-10 18.4 Work on individual parts 18.4.1 Work on the right section of the engine case – Remove all dowels. –…

• Page 158: Work On The Left Section Of The Engine Case

  ENGINE Guideline Nozzle, crank chamber 2 Nm Loctite ® 243™ ventilation (1.5 lbf ft) –  Mount and tighten oil nozzle Guideline Loctite 243™ Oil nozzle for conrod bear- 2 Nm ® ing lubrication (1.5 lbf ft) – Mount the oil nozzle for piston cooling. –…

• Page 159: Work On The Clutch Cover

  ENGINE Info If the bearings are not firmly seated after cooling, it is likely that they will rotate in the engine case when warm. In this case, the engine case must be renewed. – Mount the dowels. –  Press in shaft seal ring of the crankshaft with the open side facing out so it is flush.

• Page 160
  ENGINE –  Press out bearing toward the inside. 308679-10 –  Mount lock ring –  Press the shaft seal ring all the way in from the inside to the outside with the open side facing in. 302693-10 – …

• Page 161: Checking The Oil Pressure Regulator Valve

  ENGINE –  Mount lock ring – Blow out the oil channel with compressed air and check that it is clear. 308680-10 18.4.4 Checking the oil pressure regulator valve –   Remove screw plug with sealing washer –  …

• Page 162: Checking The Lubrication System

  ENGINE 18.4.5 Checking the lubrication system 305003-10 –  Check the internal rotor and external rotor of oil pumps for damage and wear. » If there is damage or wear: – Change the oil pumps. – Check oil pump shaft …

• Page 163: Changing The Connecting Rod, Conrod Bearing And Crank Pin

  ENGINE – Repeat the operation on the opposite side. – Ensure that the new crankshaft bearing inner race is flush. Info After replacing the crankshaft bearings, the crankshaft end play must be measured. 18.4.8 Changing the connecting rod, conrod bearing and crank pin Main work –…

• Page 164: Checking The Crankshaft Run-Out At The Bearing Pin

  ENGINE –  Position special tool with the heel pointing down. Insert for crankshaft pressing tool (77229008000) ( p. 347) – Press in the upper crank web as far as possible. Info The press mandrel must be positioned over the crank pin. –…

• Page 165: Removing The Drive Wheel Of The Balancer Shaft

  ENGINE 18.4.11 Removing the drive wheel of the balancer shaft –  Position the balancer shaft in the press with special tool Separator plate (77229032000) ( p. 348) –  Mount special tool Protection cap (77229031000) ( p. 348) – Press out the drive wheel of the balancer shaft.

• Page 166: Checking/Measuring The Piston

  ENGINE – Using a straightedge and the special tool, check the sealing area of the cylinder head for distortion. Feeler gauge (59029041100) ( p. 344) ≤ 0.10 mm (≤ 0.0039 in) Cylinder/cylinder head — distortion of sealing area » If the measured value does not meet specifications: –…

• Page 167: Measuring The Piston/Cylinder Mounting Clearance

  ENGINE 18.4.16 Measuring the piston/cylinder mounting clearance – Check/measure the cylinder. ( p. 163) – Check/measure the piston. ( p. 164) – The smallest piston/cylinder mounting clearance equals the smallest cylinder bore diameter minus the largest piston diameter. The largest piston/cylinder mount- ing clearance equals the largest cylinder bore diameter minus the smallest piston diameter.

• Page 168: Checking The Camshafts

  ENGINE –  Mount screw but do not tighten yet. Guideline Screw, camshaft drive M12x1 70 Nm Loc- sprocket (51.6 lbf ft) tite ® 243™/cone degreased – Repeat these steps for the second camshaft. 308666-11 18.4.19 Checking the camshafts – Check the camshaft for damage and wear.

• Page 169: Removing The Valves

  ENGINE –  Remove camshaft bearing bridge again. Compare the Plastigauge clearance gauge with the specifications on the packaging. Guideline Camshaft bearing — sleeve bearing Radial clearance 0.020… 0.054 mm (0.00079… 0.00213 in) Wear limit 0.065 mm (0.00256 in) Info 308671-10 The width of the Plastigauge clearance gauge is a measure of the bearing play.

• Page 170: Checking The Valves

  ENGINE – Mark the valves according to their normal built-in position. Info Place the valves into a box according to the installation position and label the box. 300117-10 18.4.22 Checking the valves – Check the valve plate for run-out. Valve — run-out ≤…

• Page 171: Checking The Cam Levers

  ENGINE 18.4.25 Checking the cam levers – Check the cam levers and cam lever shafts for damage and wear. » If there is damage or wear: – Change the cam levers and/or cam lever shafts. 302718-10 18.4.26 Checking the cylinder head –…

• Page 172: Checking The Freewheel

  ENGINE – Pre-tension the valve spring using the special tool. Valve spring compressor (59029019000) ( p. 344) Insert for valve spring lever (77229060000) ( p. 349) 302711-10 –  Mount valve keys Info When mounting the valve keys, ensure that they are seated properly; it is recommended to adhere the valve keys to the valves with a small amount of grease.

• Page 173: Removing The Freewheel

  ENGINE 18.4.29 Removing the freewheel –  Remove lock ring 308674-10 –  Press expansion ring together with suitable pliers and take off. 308675-10 –  Take freewheel out of the primary gear. 308676-10 18.4.30 Installing the freewheel – Thoroughly oil all parts. –…

• Page 174: Preassembling The Kick Starter Shaft

  ENGINE –  Ensure that all lugs of the expansion ring pass through slots of the freewheel and engage in groove  of the primary gear. 308678-10 –  Mount lock ring 308674-11 18.4.31 Preassembling the kick starter shaft – Mount washer …

• Page 175: Checking The Electric Starter Drive

  ENGINE –  Mount driving hub 301004-10 –   Position kick starter spring and hook it into drill hole 301005-10 18.4.32 Checking the electric starter drive 305006-10 –  Check the gear mesh and bearing of starter idler gear for damage and wear.

• Page 176: Checking The Timing Assembly

  ENGINE –  Change O-ring of the starter motor. – Connect the negative cable of a 12 volt power supply to the housing of the starter motor. Connect the positive cable of the power supply briefly with the connector of the starter motor. »…

• Page 177: Preparing The Timing Chain Tensioner For Installation

  ENGINE 18.4.34 Preparing the timing chain tensioner for installation – Press the timing chain tensioner together completely. Info This requires some force, as the oil must be pressed out. – Release the timing chain tensioner. Without pressure, the timing chain tensioner expands fully. 200171-10 –…

• Page 178
  ENGINE » If there is damage or wear: – Change the spring retainer. – Check the pretension ring  for damage and wear. » If there is damage or wear: – Change the pretension ring. –  Check spring washer for damage and wear.

• Page 179: Checking The Shift Mechanism

  ENGINE 18.4.36 Checking the shift mechanism 305008-10 –   Check shift forks on disc for damage and wear (visual check). » If there is damage or wear: – Change the shift fork. – Check shift grooves  of shift drum …

• Page 180: Preassembling The Shift Shaft

  ENGINE – Change the sliding plate. – Preassemble the shift shaft. ( p. 178) –  Check clearance between the sliding plate and the shift quadrant. Shift shaft — sliding plate/shift quad- 0.40… 0.80 mm (0.0157… rant clearance 0.0315 in) »…

• Page 181: Disassembling The Countershaft

  ENGINE –  Remove 6th-gear idler gear –  Remove needle bearing 18.4.39 Disassembling the countershaft 305012-10 – Fix the countershaft in the vice with the toothed end facing downward. Guideline Use soft jaws –   Remove stop disk and 1st-gear idler gear –…

• Page 182: Assembling The Main Shaft

  ENGINE 305013-10 –  Check needle bearings for damage and wear. » If there is damage or wear: – Change the needle bearings. –   Check the pivot points of main shaft and countershaft for damage and wear. » If there is damage or wear: –…

• Page 183: Assembling The Countershaft

  ENGINE Preparatory work – Carefully lubricate all parts before assembling. – Check the transmission. ( p. 179) 305011-11 Main work – Secure the main shaft with the toothed end facing downward in the vise. Guideline Use soft jaws – Mount needle bearing …

• Page 184: Engine Assembly

  ENGINE 305012-11 Main work – Fix the countershaft in the vice with the toothed end facing downward. Guideline Use soft jaws –  Mount needle bearing –  Mount 2nd-gear idler gear –   Mount stop disk and lock ring –…

• Page 185: Installing The Transmission Shafts

  ENGINE 18.5.2 Installing the transmission shafts – Oil the bearing. –  Slide both transmission shafts into the bearing seats together. 308655-11 –  Mount lock ring 308654-11 18.5.3 Installing the shift forks –  Shift fork has a smaller inside diameter; mount this in the shift groove of the main shaft.

• Page 186: Installing The Shift Rails

  ENGINE 18.5.5 Installing the shift rails –   Install shift rail together with upper spring and the lower spring. 308650-11 –   Install shift rail together with upper spring 308649-11 18.5.6 Installing the left engine case – Mount the dowels. –…

• Page 187: Installing The Spacer

  ENGINE 18.5.7 Installing the spacer – Grease the shaft seal ring. Long-life grease ( p. 340) –  Mount spacer 308644-11 18.5.8 Installing the timing chain –  Mount balancer shaft with the timing chain and timing chain securing guide. Info If the timing chain was used before, ensure it is running in the correct direction.

• Page 188: Installing The Force Pump

  ENGINE 18.5.10 Installing the force pump – Oil the oil pump shaft, internal rotor and external rotor before assembly. –  Position force pump Info The rounded side of the force pump faces the engine case. – Mount oil pump shaft …

• Page 189: Installing The Locking Lever

  ENGINE –  Position suction pump – Crank the oil pump gear wheel and ensure that it can move easily. 308614-11 –  Mount O-ring 308613-10 –  Position oil pump cover –  Mount and tighten screws Guideline Loctite ®…

• Page 190: Installing The Shift Shaft

  ENGINE 18.5.14 Installing the shift shaft –  Slide shift shaft with the washer into the bearing seat. – Push sliding plate  away from the shift drum locating unit  . Insert the shift shaft all the way. – Let the sliding plate engage in the shift drum locating unit.

• Page 191: Installing The Clutch Discs

  ENGINE –  Slide the outer clutch hub onto the gearbox main shaft. Turn oil pump gear kick starter gear  until the teeth of the outer clutch hub mesh. 308627-10 –   Slide on washer and inner clutch hub 308625-11 –…

• Page 192: Installing The Clutch Cover

  ENGINE –  Position spring washer 308620-11 –  Position spring retainer with the I marking. 308628-10 –  Install the screws and tighten them diagonally. Guideline Screw, clutch spring 6 Nm (4.4 lbf ft) 308619-11 – Using a straightedge and the special tool, check the spring washer for distortion. Feeler gauge (59029041100) ( p.

• Page 193: Installing The Water Pump Cover

  ENGINE –  Mount screws but do not tighten them yet. Guideline Screw, clutch cover M6x40 10 Nm (7.4 lbf ft) – Tighten all screws in a crisscross pattern. 18.5.20 Installing the water pump cover – Mount the two-part water pump impeller …

• Page 194: Installing The Piston

  ENGINE – Position the inside alternator cover. –  Mount and tighten screws Guideline Screw, inside alternator cover 6 Nm (4.4 lbf ft) 308608-11 –  Mount screws but do not tighten yet. Guideline Screw, starter motor 10 Nm (7.4 lbf ft) 308611-10 –…

• Page 195
  ENGINE – Position the piston on the cylinder using the special tool. – Push the piston carefully into the cylinder from above. Info The piston rings should not catch or they will be damaged. 303078-10 –  Ensure that piston mark faces the exhaust side.

• Page 196: Installing The Cylinder Head

  ENGINE – Insert the special tool and press it forcefully to the piston. – Turn the special tool clockwise, thereby pushing the piston pin retainer into the groove. Insertion for piston ring lock (77229030000) ( p. 347) – Ensure that the piston pin retainer is seated properly on both sides. 302807-10 –…

• Page 197: Installing The Camshafts

  ENGINE –  Mount and tighten nut with the washer. Guideline Nut, cylinder head 10 Nm Lubricated with (7.4 lbf ft) engine oil 308596-11 18.5.24 Installing the camshafts –  Pull up the timing chain and insert intake camshaft – Place the timing chain over the camshaft gear of the intake camshaft.

• Page 198: Adjusting The Valve Timing

  ENGINE – Remove the special tool. Adjustment bush bridge (77229050044) ( p. 348) Insert, timing chain tensioner (77229035000) ( p. 348) 18.5.26 Adjusting the valve timing Condition Camshaft gears were loosened. –  Mount special tool and tension the timing chain. Insert, timing chain tensioner (77229035000) ( p.

• Page 199: Installing The Timing Chain Tensioner

  ENGINE –  Mount and tighten screws Guideline Screw, camshaft bearing M7x1 14 Nm Lubricated with bridge (10.3 lbf ft) engine oil 308591-10 –  Remove special tool Insert, timing chain tensioner (77229035000) ( p. 348) 308590-10 18.5.27 Installing the timing chain tensioner Preparatory work –…

• Page 200: Checking The Valve Clearance

  ENGINE 18.5.28 Checking the valve clearance –  Remove screw – Crank over the engine repeatedly. 308583-10 – Position the engine at ignition top dead center.   Markings on the cylinder head are flush above the flat areas of the camshafts.

• Page 201: Installing The Torque Limiter

  ENGINE 18.5.30 Installing the torque limiter –  Position torque limiter 308581-10 18.5.31 Installing the alternator cover –  Position alternator cover gasket 308580-11 –  Position the alternator cover. Mount screws and tighten once all of the alterna- tor cover screws have been mounted. Guideline Screw, alternator cover M6x30…

• Page 202: Installing The Valve Cover

  ENGINE 18.5.33 Installing the valve cover – Grease the O-rings and mount the spark plug shaft insert. 308576-10 –  Apply a thin layer of sealing compound in area Loctite ® 5910 303076-10 – Position the valve cover with the gasket. –…

• Page 203: Installing The Oil Screen

  ENGINE – Oil the O-ring of the oil filter cover. –  Mount oil filter cover –  Mount and tighten screws Guideline Screw, oil filter cover 10 Nm (7.4 lbf ft) 308572-11 18.5.36 Installing the oil screen –  Mount and tighten the oil drain plug with the magnet and the new seal ring.

• Page 204: Installing The Clutch Push Rod

  ENGINE 18.5.38 Installing the clutch push rod –  Mount clutch push rod 308567-10 18.5.39 Removing the engine from the engine assembly stand – Remove the screw connection from the special tool. Engine fixing arm (77229002000) ( p. 346) – Remove the engine from the engine assembly stand.

• Page 205: Clutch

  CLUTCH 19.1 Checking/correcting the fluid level of the hydraulic clutch Info The fluid level rises with increased wear of the clutch lining discs. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –  Remove screws –…

• Page 206
  CLUTCH –  Inject the liquid into the system until it escapes from openings of the master cylinder without bubbles. – To prevent overflow, drain fluid occasionally from the master cylinder reservoir. – Remove the bleeding syringe. Mount and tighten screws bleeder screw. –…

• Page 207: Water Pump, Cooling System

  WATER PUMP, COOLING SYSTEM 20.1 Cooling system  Water pump in the engine circulates the coolant. The water flow through the radiator is controlled as a function of the coolant temper- ature. The cooling system is divided into two circuits. In the warming-up phase of the engine, the coolant flows through the small cooling circuit.

• Page 208: Checking The Coolant Level

  WATER PUMP, COOLING SYSTEM 20.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

• Page 209: Refilling Coolant

  WATER PUMP, COOLING SYSTEM (EXC‑F EU/AUS/BR, EXC-F SIX DAYS, XCF-W) – Position the motorcycle upright. – Place a suitable container under the water pump cover. –   Remove screw . Take off radiator cap – Completely drain the coolant. –…

• Page 210: Lubrication System

  LUBRICATION SYSTEM 21.1 Oil circuit 401362-60 Oil screen Force pump Oil pressure regulator valve Oil filter Oil nozzle, conrod lubrication Oil nozzle for cam follower lubrication Oil nozzle, piston cooling Oil nozzle for alternator cooling Oil nozzle for clutch lubrication Suction pump Oil channel, transmission lubrication Timing chain tensioner…

• Page 211: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

  LUBRICATION SYSTEM  The engine oil is at a level between the lower edge and the upper  edge of the level viewer. »  If the engine oil is not up to the lower edge of the level viewer: –…

• Page 212
  LUBRICATION SYSTEM –  Mount and tighten screw plug with the O-ring. Guideline Screw plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) –  Mount and tighten the oil drain plug with the magnet and a new seal ring. Guideline Oil drain plug with magnet M12x1.5…

• Page 213: Adding Engine Oil

  LUBRICATION SYSTEM – Start the engine and check that it is oil-tight. Finishing work (EXC‑F AU, All SIX DAYS models) – Install the engine guard. ( p. 57) – Check the engine oil level. ( p. 208) 21.4 Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine.

• Page 214
  LUBRICATION SYSTEM Engine oil temperature: 80 °C 2.5 bar (36 psi) (176 °F) Engine speed: 6,000 rpm » If the measured value is less than the specification: – Check the oil pump for wear. Check all oil holes for free flow. –…

• Page 215: Ignition System

  IGNITION SYSTEM 22.1 Ignition coil — checking the secondary winding Condition Ignition coil cylinder 1 is disconnected. Spark plug connector cylinder 1 has been removed. Ignition coil cylinder 1 — check the secondary winding resistance – Measure the resistance between the specified points. Ignition coil cylinder 1 pin 2 (−) –…

• Page 216: Removing The Stator And Ignition Pulse Generator

  IGNITION SYSTEM 601211-10 G00959-10 Stator winding — check for a short circuit to ground (terminal 31) – Measure the resistance between the specified points. Stator, connector EZ pin 1 – Measuring point Ground (−) ∞ Ω Resistance » If the value displayed does not meet specifications: –…

• Page 217: Installing The Stator And Ignition Pulse Generator

  IGNITION SYSTEM 22.5 Installing the stator and ignition pulse generator –  Blow out oil nozzle with compressed air and check that it is clear. Guideline Oil nozzle for alternator 2 Nm Loctite ® 243™ cooling (1.5 lbf ft) 305322-10 –…

• Page 218: Electric Starter

  ELECTRIC STARTER 23.1 Checking the starter motor Condition The starter motor has been removed. – Connect the negative cable of a 12 volt power supply to the housing of the starter  motor. Connect the positive cable of the power supply briefly to connector the starter motor.

• Page 219: Throttle Valve Body

  THROTTLE VALVE BODY 24.1 Adjusting the idle speed (EXC‑F EU/AUS/BR, EXC-F SIX DAYS, XCF-W) –  Run the engine warm and push the idle speed adjusting screw all the way – Set the desired idle speed by turning the idle speed adjusting screw. Guideline Idle speed 1,950……

• Page 220: Throttle Position Sensor — Adjusting The Basic Settings

  THROTTLE VALVE BODY 24.3 Throttle position sensor — adjusting the basic settings Condition The diagnostics tool is connected and running. – «Select the measured values» > «Throttle position sensor voltage circuit (THAD)» and «Throttle position sensor signal circuit (ATP)». – Push back protection cap …

• Page 221
  THROTTLE VALVE BODY Info Do not operate the throttle grip during the initialization process. – As soon as the specified temperature is reached, switch off the ignition. Info If the initialization is not completed or the initialization process is inter- rupted, the entire process must be restarted.

• Page 222: Technical Data

  TECHNICAL DATA 25.1 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 1,950… 2,050 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 36.3 mm (1.429 in)

• Page 223: Engine Tightening Torques

  TECHNICAL DATA Size II 87.976… 87.985 mm (3.46362… 3.46397 in) Cylinder — drill hole diameter Size I 88.000… 88.012 mm (3.46456… 3.46503 in) Size II 88.012… 88.025 mm (3.46503… 3.46554 in) Piston/cylinder — mounting clearance Size I 0.025… 0.047 mm (0.00098… 0.00185 in) Size II 0.027……

• Page 224: Capacities

  TECHNICAL DATA – Screw, valve cover 8 Nm (5.9 lbf ft) – Screw, water pump cover 10 Nm (7.4 lbf ft) – Stud, cylinder head 10 Nm (7.4 lbf ft) Screw, camshaft bearing bridge M7x1 14 Nm (10.3 lbf ft) Lubricated with engine oil –…

• Page 225: Chassis

  TECHNICAL DATA Total fuel tank capacity, 8.5 l (2.25 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 339) approx. (EXC-F US, All XCF-W models) Fuel reserve, approx. 1.5 l (1.6 qt.) 25.5 Chassis Frame Central tube frame made of chrome molybdenum steel tubing WP Suspension Up Side Down 4860 MXMA PA Fork (EXC‑F EU/AUS/BR/US, XCF‑W) Fork (All SIX DAYS models)

• Page 226: Electrical System

  Metzeler MCE 6 Days Extreme (All XCF-W models) 90/90 — 21 54M TT 110/100 — 18 64M TT Dunlop GEOMAX AT81F Dunlop GEOMAX AT81 Additional information is available in the Service section under: http://www.ktm.com 25.8 Fork 25.8.1 EXC‑F EU/AUS/BR/US, XCF‑W Fork part number 14.18.7L.67…

• Page 227: All Six Days Models

  TECHNICAL DATA Weight of rider: 75… 85 kg (165… 187 lb.) 513 mm (20.2 in) Weight of rider: 85… 95 kg (187… 209 lb.) 513 mm (20.2 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 4.0 N/mm (22.8 lb/in) Weight of rider: 75……

• Page 228: Chassis Tightening Torques

  TECHNICAL DATA Gas pressure 10 bar (145 psi) Static sag 33… 35 mm (1.3… 1.38 in) Riding sag 105… 115 mm (4.13… 4.53 in) Fitted length 417 mm (16.42 in) Damper oil Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 339) 25.10 Chassis tightening torques –…

• Page 229
  TECHNICAL DATA – Nut, fuel pump fixation 15 Nm (11.1 lbf ft) Screw, bottom shock absorber 80 Nm (59 lbf ft) Loctite ® 2701™ Screw, top shock absorber 80 Nm (59 lbf ft) Loctite ® 2701™ – Nut, seat fixing M12x1 20 Nm (14.8 lbf ft) –…

• Page 230: Cleaning, Care

  CLEANING, CARE 26.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts.

• Page 231: Checks And Maintenance Steps For Winter Operation

  CLEANING, CARE 26.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

• Page 232: Storage

  – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 11) – Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materi- als since they prevent humidity from escaping, thus causing corrosion.

• Page 233: Service Schedule

  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. ○ ● ● Make the service entry in KTM DEALER.NET and in the service record.

• Page 234: Service Work (As Additional Order)

  SERVICE SCHEDULE 28.2 Service work (as additional order) Annually Every 135 operating hours/every 70 operating hours when used for motorsports Every 45 operating hours Once after 15 operating hours ● Change the front brake fluid. ( p. 120) ● Change the rear brake fluid. ( p.

• Page 236: Wiring Diagram

  WIRING DIAGRAM 29.1 Page 1 of 8 (EXC‑F EU) bu-rd wh-rd wh-rd wh-rd wh-rd , wh-rd bu-rd P00001-01…

• Page 237
  WIRING DIAGRAM Components: Battery Starter relay with main fuse Starter motor Electric starter button…

• Page 238: Exc-F Eu)

  WIRING DIAGRAM 29.2 Page 2 of 8 (EXC‑F EU) wh-rd wh-pk wh-rd gn , gn wh-rd wh-pk wh-bl EY/3 EZ/3 wh-bl wh-bl wh-rd bu-br bu-br wh-rd wh-bl wh-rd ye-rd ye-bu CD/2 BL/2 ye-bu ye-bu , ye-bu ye-bu ye-bu ye-bu P00002-01…

• Page 239
  WIRING DIAGRAM Components: EFI control unit Radiator fan temperature switch Fuse Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector…

• Page 240: Exc-F Eu)

  WIRING DIAGRAM 29.3 Page 3 of 8 (EXC‑F EU) ye-bu wh-gr wh-gr wh-gr wh-gr bu , bu br , br P00003-01…

• Page 241
  WIRING DIAGRAM Components: EFI control unit Low beam, high beam Horn High beam indicator lamp Parking light Light switch, horn button, kill switch…

• Page 242: Exc-F Eu)

  WIRING DIAGRAM 29.4 Page 4 of 8 (EXC‑F EU) ye-bu wh-gn ye-bu wh-gn wh-gn wh-gn , wh-gn wh , wh wh-gn ye-bu ye-bu P00004-01…

• Page 243
  WIRING DIAGRAM Components: Brake light switch, front Brake light switch, rear License plate lamp Brake/tail light…

• Page 244: Exc-F Eu)

  WIRING DIAGRAM 29.5 Page 5 of 8 (EXC‑F EU) ye-bu P00005-01…

• Page 245
  WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Turn signal switch…

• Page 246: Exc-F Eu)

  WIRING DIAGRAM 29.6 Page 6 of 8 (EXC‑F EU) ye-rd gn-rd gn-rd br-rd br-rd P00006-01…

• Page 247
  WIRING DIAGRAM Components: EFI control unit Fuel level sensor Lambda sensor (cylinder 1) Fuse FI warning lamp and low fuel warning lamp…

• Page 248: Exc-F Eu)

  WIRING DIAGRAM 29.7 Page 7 of 8 (EXC‑F EU) DA/4 DB/4 CX/2 CW/2 bl-gr bl-gr wh-bu bl-bu bl-rd bl-rd bl-bu bl-bu wh-bu wh-bu br-pu br-pu br-pu br-pu bu-gr bu-gr P00007-01…

• Page 249
  WIRING DIAGRAM Components: EFI control unit Front wheel speed sensor Fuel pump Injector (cylinder 1) CAN-bus terminating resistor 1 Speedometer Tripmaster switch X295 Diagnostics connector…

• Page 250: Exc-F Eu)

  WIRING DIAGRAM 29.8 Page 8 of 8 (EXC‑F EU) DV/2 bl-br bl-br bl-ye bl-ye wh-pu wh-pu ye-bu ye-bu wh-ye wh-ye ye-or ye-or ye-gn ye-gn P00008-01…

• Page 251
  WIRING DIAGRAM Components: EFI control unit Throttle position sensor circuit A Intake air temperature sensor Coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map‑Select switch for ride mode (optional) Map‑Select switch for basic position (optional) Cable colors: Black…

• Page 252: Exc-F Au)

  WIRING DIAGRAM 29.9 Page 1 of 8 (EXC‑F AU) bu-rd wh-rd wh-rd wh-rd wh-rd , wh-rd bu-rd 202514-01…

• Page 253
  WIRING DIAGRAM Components: Battery Starter relay with main fuse Starter motor Emergency OFF switch, electric starter button…

• Page 254: Exc-F Au)

  WIRING DIAGRAM 29.10 Page 2 of 8 (EXC‑F AU) wh-rd wh-pk wh-rd gn , gn wh-rd wh-pk wh-bl EY/3 EZ/3 wh-bl wh-bl wh-rd bu-br bu-br wh-rd wh-bl wh-rd ye-rd ye-bu CD/2 BL/2 ye-bu ye-bu , ye-bu ye-bu ye-bu ye-bu 202515-01…

• Page 255
  WIRING DIAGRAM Components: EFI control unit Radiator fan temperature switch Fuse Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector…

• Page 256: Exc-F Au)

  WIRING DIAGRAM 29.11 Page 3 of 8 (EXC‑F AU) ye-bu wh-gr wh-gr wh-gr wh-gr BA/1 BF/1 bu , bu br , br 202516-01…

• Page 257
  WIRING DIAGRAM Components: EFI control unit Low beam, high beam Horn High beam indicator lamp Parking light Light switch, horn button, kill switch Emergency OFF switch, electric starter button…

• Page 258: Exc-F Au)

  WIRING DIAGRAM 29.12 Page 4 of 8 (EXC‑F AU) ye-bu wh-gn ye-bu wh-gn wh-gn wh-gn , wh-gn wh , wh wh-gn ye-bu ye-bu 202517-01…

• Page 259
  WIRING DIAGRAM Components: Brake light switch, front Brake light switch, rear License plate lamp Brake/tail light…

• Page 260: Exc-F Au)

  WIRING DIAGRAM 29.13 Page 5 of 8 (EXC‑F AU) ye-bu 202518-01…

• Page 261
  WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Turn signal switch…

• Page 262: Exc-F Au)

  WIRING DIAGRAM 29.14 Page 6 of 8 (EXC‑F AU) ye-rd gn-rd gn-rd br-rd br-rd 202519-01…

• Page 263
  WIRING DIAGRAM Components: EFI control unit Fuel level sensor Fuse FI warning lamp and low fuel warning lamp…

• Page 264: Exc-F Au)

  WIRING DIAGRAM 29.15 Page 7 of 8 (EXC‑F AU) DA/4 DB/4 CX/2 CW/2 bl-gr bl-gr wh-bu bl-bu bl-rd bl-rd bl-bu bl-bu wh-bu wh-bu br-pu br-pu br-pu br-pu bu-gr bu-gr 202520-01…

• Page 265
  WIRING DIAGRAM Components: EFI control unit Front wheel speed sensor Fuel pump Injector (cylinder 1) CAN-bus terminating resistor 1 Speedometer Tripmaster switch X295 Diagnostics connector…

• Page 266: Exc-F Au)

  WIRING DIAGRAM 29.16 Page 8 of 8 (EXC‑F AU) DV/2 bl-br bl-br bl-ye bl-ye wh-pu wh-pu ye-bu ye-bu wh-ye wh-ye ye-or ye-or ye-gn ye-gn 202521-01…

• Page 267
  WIRING DIAGRAM Components: EFI control unit Throttle position sensor circuit A Intake air temperature sensor Engine coolant temperature sensor (cylinder 1) Rollover sensor Ignition pulse generator Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map‑Select switch for riding mode (optional) Map‑Select switch for basic setting (optional) Cable colors: Black…

• Page 268: Exc-F Br)

  WIRING DIAGRAM 29.17 Page 1 of 8 (EXC‑F BR) bu-rd wh-rd wh-rd wh-rd wh-rd , wh-rd bu-rd G00561-01…

• Page 269
  WIRING DIAGRAM Components: Battery Starter relay with main fuse Starter motor Electric starter button…

• Page 270: Exc-F Br)

  WIRING DIAGRAM 29.18 Page 2 of 8 (EXC‑F BR) wh-rd wh-pk wh-rd gn , gn wh-rd wh-pk wh-bl EY/3 EZ/3 wh-bl wh-bl wh-rd bu-br bu-br wh-rd wh-bl wh-rd ye-rd ye-bu CD/2 BL/2 ye-bu ye-bu , ye-bu ye-bu ye-bu ye-bu G00562-01…

• Page 271
  WIRING DIAGRAM Components: EFI control unit Radiator fan temperature switch Fuse Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector…

• Page 272: Exc-F Br)

  WIRING DIAGRAM 29.19 Page 3 of 8 (EXC‑F BR) ye-bu wh-gr wh-gr wh-gr wh-gr bu , bu br , br G00563-01…

• Page 273
  WIRING DIAGRAM Components: EFI control unit Low beam, high beam Horn High beam indicator lamp Parking light Light switch, horn button, kill switch…

• Page 274: Exc-F Br)

  WIRING DIAGRAM 29.20 Page 4 of 8 (EXC‑F BR) ye-bu wh-gn ye-bu wh-gn wh-gn wh-gn , wh-gn wh , wh wh-gn ye-bu ye-bu G00564-01…

• Page 275
  WIRING DIAGRAM Components: Front brake light switch Rear brake light switch License plate lamp Brake/tail light…

• Page 276: Exc-F Br)

  WIRING DIAGRAM 29.21 Page 5 of 8 (EXC‑F BR) ye-bu G00565-01…

• Page 277
  WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Front left turn signal Front right turn signal Rear left turn signal Rear right turn signal Turn signal switch…

• Page 278: Exc-F Br)

  WIRING DIAGRAM 29.22 Page 6 of 8 (EXC‑F BR) ye-rd gn-rd gn-rd br-rd br-rd G00566-01…

• Page 279
  WIRING DIAGRAM Components: EFI control unit Fuel level sensor Lambda sensor (cylinder 1) Fuse FI warning lamp and low fuel warning lamp…

• Page 280: Exc-F Br)

  WIRING DIAGRAM 29.23 Page 7 of 8 (EXC‑F BR) DA/4 DB/4 CX/2 CW/2 bl-gr bl-gr wh-bu bl-bu bl-rd bl-rd bl-bu bl-bu wh-bu wh-bu br-pu br-pu br-pu br-pu bu-gr bu-gr G00567-01…

• Page 281
  WIRING DIAGRAM Components: EFI control unit Front wheel speed sensor Fuel pump Injector (cylinder 1) CAN-bus terminating resistor 1 Speedometer Tripmaster switch X295 Diagnostics connector…

• Page 282: Exc-F Br)

  WIRING DIAGRAM 29.24 Page 8 of 8 (EXC‑F BR) DV/2 bl-br bl-br bl-ye bl-ye wh-pu wh-pu ye-bu ye-bu wh-ye wh-ye ye-or ye-or ye-gn ye-gn G00568-01…

• Page 283
  WIRING DIAGRAM Components: EFI control unit Throttle position sensor circuit A Intake air temperature sensor Engine coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map‑Select Switch for ride mode (optional) Map‑Select Switch for basic position (optional) Cable colors: Black…

• Page 284: Exc-F Us)

  WIRING DIAGRAM 29.25 Page 1 of 8 (EXC-F US) ye-br wh-rd bu-rd wh-rd wh-rd , wh-rd bu-rd ye-br wh-or wh-or wh-or wh-rd wh-or P00021-01…

• Page 285
  WIRING DIAGRAM Components: Fuse Battery Starter relay with main fuse Starter motor Ignition lock Emergency OFF switch, electric starter button…

• Page 286: Exc-F Us)

  WIRING DIAGRAM 29.26 Page 2 of 8 (EXC-F US) wh-pk wh-rd wh-pk wh-bl wh-rd wh-pk wh-bl EY/3 EZ/3 wh-bl wh-bl wh-rd bu-br bu-br ye-br wh-bl wh-rd ye-rd ye-bu CD/2 BL/2 ye-bu ye-bu ye-bu ye-bu ye-bu ye-bu P00022-01…

• Page 287
  WIRING DIAGRAM Components: EFI control unit Radiator fan temperature switch Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector…

• Page 288: Exc-F Us)

  WIRING DIAGRAM 29.27 Page 3 of 8 (EXC-F US) ye-bu wh-gr wh-gr wh-gr wh-gr bu , bu br , br P00023-01…

• Page 289
  WIRING DIAGRAM Components: EFI control unit Low beam, high beam Horn High beam indicator lamp Parking light Light switch, horn button, turn signal switch…

• Page 290: Exc-F Us)

  WIRING DIAGRAM 29.28 Page 4 of 8 (EXC-F US) ye-bu wh-gn ye-bu wh-gn wh-gn wh-gn , wh-gn wh , wh wh-gn ye-bu ye-bu P00024-01…

• Page 291
  WIRING DIAGRAM Components: Front brake light switch Rear brake light switch License plate lamp Brake/tail light…

• Page 292: Exc-F Us)

  WIRING DIAGRAM 29.29 Page 5 of 8 (EXC-F US) ye-bu P00025-01…

• Page 293
  WIRING DIAGRAM Components: Turn signal relay Turn signal switch Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Light switch, horn button, turn signal switch…

• Page 294: Exc-F Us)

  WIRING DIAGRAM 29.30 Page 6 of 8 (EXC-F US) ye-rd br-rd br-rd P00026-01…

• Page 295
  WIRING DIAGRAM Components: EFI control unit Fuel level sensor Fuse FI warning lamp and low fuel warning lamp…

• Page 296: Exc-F Us)

  WIRING DIAGRAM 29.31 Page 7 of 8 (EXC-F US) DA/4 DB/4 CX/2 CW/2 bl-gr bl-gr wh-bu bl-bu bl-rd bl-rd bl-bu bl-bu wh-bu wh-bu br-pu br-pu br-pu br-pu bu-gr bu-gr P00027-01…

• Page 297
  WIRING DIAGRAM Components: EFI control unit Front wheel speed sensor Fuel pump Fuel evaporation valve Injector cylinder 1 Speedometer Tripmaster switch CAN-bus terminating resistor 1 X295 Diagnostics connector…

• Page 298: Exc-F Us)

  WIRING DIAGRAM 29.32 Page 8 of 8 (EXC-F US) DV/2 bl-br bl-br bl-ye bl-ye wh-pu wh-pu ye-bu ye-bu wh-ye wh-ye ye-or ye-or ye-gn ye-gn P00028-01…

• Page 299
  WIRING DIAGRAM Components: EFI control unit Throttle position sensor circuit A Intake air temperature sensor Engine coolant temperature sensor (cylinder 1) Rollover sensor Ignition pulse generator Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map‑Select switch for riding mode (optional) Map‑Select switch for basic setting (optional) Cable colors: Black…

• Page 300: Exc-F Six Days)

  WIRING DIAGRAM 29.33 Page 1 of 8 (EXC-F SIX DAYS) bu-rd wh-rd wh-rd wh-rd wh-rd , wh-rd bu-rd P00011-01…

• Page 301
  WIRING DIAGRAM Components: Battery Starter relay with main fuse Starter motor Electric starter button…

• Page 302: Exc-F Six Days)

  WIRING DIAGRAM 29.34 Page 2 of 8 (EXC-F SIX DAYS) wh-rd wh-pk wh-rd gn , gn wh-rd wh-pk wh-bl EY/3 EZ/3 wh-bl wh-bl wh-rd bu-br bu-br wh-rd wh-bl wh-rd ye-rd ye-bu CD/2 BL/2 ye-bu ye-bu , ye-bu ye-bu ye-bu ye-bu P00012-01…

• Page 303
  WIRING DIAGRAM Components: EFI control unit Radiator fan temperature switch Fuse Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector…

• Page 304: Exc-F Six Days)

  WIRING DIAGRAM 29.35 Page 3 of 8 (EXC-F SIX DAYS) ye-bu wh-gr wh-gr wh-gr wh-gr bu , bu br , br P00013-01…

• Page 305
  WIRING DIAGRAM Components: EFI control unit Low beam, high beam Speedometer Horn Parking light Light switch, horn button, kill switch…

• Page 306: Exc-F Six Days)

  WIRING DIAGRAM 29.36 Page 4 of 8 (EXC-F SIX DAYS) ye-bu wh-gn ye-bu wh-gn wh-gn wh-gn , wh-gn wh , wh wh-gn ye-bu ye-bu P00014-01…

• Page 307
  WIRING DIAGRAM Components: Front brake light switch Rear brake light switch License plate lamp Brake/tail light…

• Page 308: Exc-F Six Days)

  WIRING DIAGRAM 29.37 Page 5 of 8 (EXC-F SIX DAYS) ye-bu P00015-01…

• Page 309
  WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Turn signal switch…

• Page 310: Exc-F Six Days)

  WIRING DIAGRAM 29.38 Page 6 of 8 (EXC-F SIX DAYS) ye-rd gn-rd gn-rd br-rd br-rd P00016-01…

• Page 311
  WIRING DIAGRAM Components: EFI control unit Fuel level sensor Lambda sensor (cylinder 1) Fuse Speedometer…

• Page 312: Exc-F Six Days)

  WIRING DIAGRAM 29.39 Page 7 of 8 (EXC-F SIX DAYS) bl-gr bl-gr wh-bu bl-bu bl-rd bl-rd bl-bu bl-bu wh-bu wh-bu br-pu br-pu br-pu br-pu bu-gr bu-gr P00017-01…

• Page 313
  WIRING DIAGRAM Components: EFI control unit Front wheel speed sensor Fuel pump Injector (cylinder 1) CAN-bus terminating resistor 1 Speedometer X295 Diagnostics connector…

• Page 314: Exc-F Six Days)

  WIRING DIAGRAM 29.40 Page 8 of 8 (EXC-F SIX DAYS) DV/2 bl-br bl-br bl-ye bl-ye wh-pu wh-pu ye-bu ye-bu wh-ye wh-ye ye-or ye-or ye-gn ye-gn P00018-01…

• Page 315
  WIRING DIAGRAM Components: EFI control unit Throttle position sensor circuit A Intake air temperature sensor Engine coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map‑Select switch for driving mode (optional) Map‑Select switch for basic position (optional) Cable colors: Black…

• Page 316: Xcf-W)

  WIRING DIAGRAM 29.41 Page 1 of 6 (XCF‑W) bu-rd wh-rd wh-rd wh-rd wh-rd , wh-rd bu-rd 202985-01…

• Page 317
  WIRING DIAGRAM Components: Battery Starter relay with main fuse Starter motor Electric starter button…

• Page 318: Xcf-W)

  WIRING DIAGRAM 29.42 Page 2 of 6 (XCF‑W) wh-rd wh-pk wh-rd gn , gn wh-rd wh-pk wh-bl EY/3 EZ/3 wh-bl wh-bl wh-rd bu-br bu-br wh-rd wh-bl wh-rd ye-rd ye-bu CD/2 BL/2 ye-bu ye-bu , ye-bu ye-bu 202986-01…

• Page 319
  WIRING DIAGRAM Components: EFI control unit Radiator fan temperature switch Fuse Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector…

• Page 320: Xcf-W)

  WIRING DIAGRAM 29.43 Page 3 of 6 (XCF‑W) wh-gr wh-gr br , br 202987-01…

• Page 321
  WIRING DIAGRAM Components: EFI control unit Low beam Parking light Tail light Kill switch Light switch…

• Page 322: Xcf-W)

  WIRING DIAGRAM 29.44 Page 4 of 6 (XCF‑W) ye-rd gn-rd gn-rd br-rd br-rd 202988-01…

• Page 323
  WIRING DIAGRAM Components: EFI control unit Fuel level sensor Fuse FI warning lamp and low fuel warning lamp…

• Page 324: Xcf-W)

  WIRING DIAGRAM 29.45 Page 5 of 6 (XCF‑W) DA/4 DB/4 CX/2 CW/2 bl-gr bl-gr wh-bu bl-bu bl-rd bl-rd bl-bu bl-bu wh-bu wh-bu br-pu br-pu br-pu br-pu bu-gr bu-gr 202989-01…

• Page 325
  WIRING DIAGRAM Components: EFI control unit Front wheel speed sensor Fuel pump Injector (cylinder 1) CAN-bus terminating resistor 1 Speedometer Tripmaster switch X295 Diagnostics connector…

• Page 326: Xcf-W)

  WIRING DIAGRAM 29.46 Page 6 of 6 (XCF‑W) DV/2 bl-br bl-br bl-ye bl-ye wh-pu wh-pu ye-bu ye-bu wh-ye wh-ye ye-or ye-or ye-gn ye-gn 202990-01…

• Page 327
  WIRING DIAGRAM Components: EFI control unit Throttle position sensor circuit A Intake air temperature sensor Engine coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map‑Select switch for driving mode (optional) Map‑Select switch for basic position (optional) Cable colors: Black…

• Page 328: Xcf-W Six Days)

  WIRING DIAGRAM 29.47 Page 1 of 6 (XCF-W SIX DAYS) bu-rd wh-rd wh-rd wh-rd wh-rd , wh-rd bu-rd P00031-01…

• Page 329
  WIRING DIAGRAM Components: Battery Starter relay with main fuse Starter motor Electric starter button…

• Page 330: Xcf-W Six Days)

  WIRING DIAGRAM 29.48 Page 2 of 6 (XCF-W SIX DAYS) wh-rd wh-pk wh-rd gn , gn wh-rd wh-pk wh-bl EY/3 EZ/3 wh-bl wh-bl wh-rd bu-br bu-br wh-rd wh-bl wh-rd ye-rd ye-bu CD/2 BL/2 ye-bu ye-bu , ye-bu ye-bu P00032-01…

• Page 331
  WIRING DIAGRAM Components: EFI control unit Radiator fan temperature switch Fuse Fuse Fuse Alternator Light relay Power relay Radiator fan Voltage regulator X295 Diagnostics connector…

• Page 332: Xcf-W Six Days)

  WIRING DIAGRAM 29.49 Page 3 of 6 (XCF-W SIX DAYS) wh-gr wh-gr br , br P00033-01…

• Page 333
  WIRING DIAGRAM Components: EFI control unit Low beam Parking light Tail light Kill switch Light switch…

• Page 334: Xcf-W Six Days)

  WIRING DIAGRAM 29.50 Page 4 of 6 (XCF-W SIX DAYS) ye-rd gn-rd gn-rd br-rd br-rd P00034-01…

• Page 335
  WIRING DIAGRAM Components: EFI control unit Fuel level sensor Fuse Speedometer…

• Page 336: Xcf-W Six Days)

  WIRING DIAGRAM 29.51 Page 5 of 6 (XCF-W SIX DAYS) bl-gr bl-gr wh-bu bl-bu bl-rd bl-rd bl-bu bl-bu wh-bu wh-bu br-pu br-pu br-pu br-pu bu-gr bu-gr P00035-01…

• Page 337
  WIRING DIAGRAM Components: EFI control unit Front wheel speed sensor Fuel pump Injector (cylinder 1) CAN-bus terminating resistor 1 Speedometer X295 Diagnostics connector…

• Page 338: Xcf-W Six Days)

  WIRING DIAGRAM 29.52 Page 6 of 6 (XCF-W SIX DAYS) DV/2 bl-br bl-br bl-ye bl-ye wh-pu wh-pu ye-bu ye-bu wh-ye wh-ye ye-or ye-or ye-gn ye-gn P00036-01…

• Page 339
  WIRING DIAGRAM Components: EFI control unit Throttle position sensor circuit A Intake air temperature sensor Engine coolant temperature sensor (cylinder 1) Rollover sensor Crankshaft position sensor Manifold absolute pressure sensor (cylinder 1) Ignition coil (cylinder 1) Map‑Select switch for driving mode (optional) Map‑Select switch for basic position (optional) Cable colors: Black…

• Page 340: Substances

  355) – SAE ( p. 355) (SAE 10W/60) – KTM LC4 2007+ Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre- sponding properties. Synthetic engine oil…

• Page 341
  SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 355) (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 fluid (SAE 2.5) (50180751S1) Standard/classification –…

• Page 342: Auxiliary Substances

  AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier Motorex ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier Motorex…

• Page 343
  AUXILIARY SUBSTANCES Off-road chain spray Recommended supplier Motorex ® – Chainlube Offroad Oil for foam air filter Recommended supplier Motorex ® – Racing Bio Liquid Power Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex…

• Page 344: Special Tools

  SPECIAL TOOLS Bleeder cover Art. no.: 00029013005 201597-10 Bleeder cover Art. no.: 00029013006 201598-10 Bleeding device Art. no.: 00029013100 201491-10 Spring hooks Art. no.: 50305017000 400363-01 Mounting tool, heim joint Art. no.: 50329000044 201428-01…

• Page 345
  SPECIAL TOOLS Bleed syringe Art. no.: 50329050000 400058-01 Circlip pliers reverse Art. no.: 51012011000 400059-01 Clutch holder Art. no.: 51129003000 400289-01 Lift stand Art. no.: 54829055000 500071-01 Extractor Art. no.: 58012009000 400073-01…
• Page 346
  SPECIAL TOOLS Tool for inner bearing race Art. no.: 58429037037 400082-01 Torque wrench with various accessories in set Art. no.: 58429094000 200910-10 Valve spring compressor Art. no.: 59029019000 400101-01 Feeler gauge Art. no.: 59029041100 400110-01 Plastigauge measuring strips Art. no.: 60029012000 400122-01…
• Page 347
  SPECIAL TOOLS Piston ring mounting tool Art. no.: 60029015000 400123-01 Hose clamp pliers Art. no.: 60029057000 400142-01 Testing hose Art. no.: 61029093000 201314-01 Pressure testing tool Art. no.: 61029094000 400149-01 Engine assembly stand Art. no.: 61229001000 200306-01…
• Page 348
  SPECIAL TOOLS Release device for timing chain tensioner Art. no.: 61229021000 200317-01 Pressing device for crankshaft, complete Art. no.: 75029047000 400185-01 Protection cover Art. no.: 75029090000 400167-01 Extractor, camshaft gear Art. no.: 77229001044 302768-10 Engine fixing arm Art. no.: 77229002000 301487-10…
• Page 349
  SPECIAL TOOLS Insert for crankshaft pressing tool Art. no.: 77229008000 302926-10 Extrude plate, base Art. no.: 77229009000 302925-10 Pliers for valve stem seals Art. no.: 77229010000 302943-10 Limit plug gauge Art. no.: 77229026000 303164-10 Insertion for piston ring lock Art. no.: 77229030000 302721-10…
• Page 350
  SPECIAL TOOLS Protection cap Art. no.: 77229031000 302921-10 Separator plate Art. no.: 77229032000 302922-10 Insert, timing chain tensioner Art. no.: 77229035000 302769-10 Puller Art. no.: 77229048000 302723-10 Adjustment bush bridge Art. no.: 77229050044 302722-10…
• Page 351
  SPECIAL TOOLS Insert for valve spring lever Art. no.: 77229060000 400129-01 Spark plug wrench Art. no.: 77229072000 400170-01 Oil pressure adapter Art. no.: 77329006000 400176-01 Pin wrench Art. no.: T103 200734-10 Hook wrench Art. no.: T106S 301085-01…
• Page 352
  SPECIAL TOOLS Depth micrometer Art. no.: T107S 300577-10 Art. no.: T120 201235-10 Mounting sleeve Art. no.: T1204 200788-10 Calibration pin Art. no.: T1205 200790-10 Pressing tool Art. no.: T1206 200583-10…
• Page 353
  SPECIAL TOOLS Pressing tool Art. no.: T1207S 200585-01 Centering sleeve Art. no.: T1214 200777-10 Mounting sleeve Art. no.: T1215 300568-10 Disassembly tool Art. no.: T1216 200816-10 Vacuum pump Art. no.: T1240S 200273-10…
• Page 354
  SPECIAL TOOLS Protecting sleeve Art. no.: T1401 200635-10 Clamping stand Art. no.: T14015S 200733-10 Clamping stand Art. no.: T14016S 200688-10 Gripping tool Art. no.: T14026S1 200639-10 Assembly tool Art. no.: T1402S 200634-10…
• Page 355
  SPECIAL TOOLS Open-end wrench Art. no.: T14032 200640-10 Clamping stand Art. no.: T1403S 200637-10 Mounting tool Art. no.: T14040S 200634-10 Special socket Art. no.: T14047 201710-01 Clamping stand Art. no.: T14049S 202338-10…
• Page 356
  SPECIAL TOOLS Press-out tool Art. no.: T14051 201779-10 Press drift Art. no.: T1504 200789-10 Assembly tool Art. no.: T150S 200791-10 Nitrogen filling tool Art. no.: T170S1 300574-10…

• Page 357: Standards

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

• Page 358: Index

  INDEX Chain tension INDEX adjusting ……. . 107 Accessories ……..8 checking .

• Page 359
  INDEX kick starter shaft, preassembling ….172 water pump cover, installing ….191 left engine case section .
• Page 360
  INDEX Fork legs Headlight assembling ……27, 46 headlight range, adjusting ….127 bleeding .
• Page 361
  INDEX Preparing for use Spring after storage ……230 fork legs, removing ……38 Starter motor checking .
• Page 362
  *3206200en* 3206200en 06/2014 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com…