KTM Freeride 350 (2013) manuale d’uso

OWNER'S MANUAL 2013 Freeride 350 EU Freeride 350 AUS Art. no. 3211907en[...]

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DEAR KTM CUSTOMER 1 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-ar t sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment in riding this vehicle! Enter the serial numbers of your vehicle below. Ch[...]

TABLE OF CONTENTS 2 TABLE OF CONTENTS 1 MEANS OF REPRESENTAT ION ............................ ......... 5 1.1 Symbols used ....................................... ............ 5 1.2 Formats used ................................ .................... 5 2 SAFETY ADVICE ...................................... ..................... 6 2.1 Use definition -[...]

TABLE OF CONTENTS 3 11.12 Adjusting the play of the steering head bearing x .............................................. ....... 46 11.13 Greasing the steering head bearing x .............. 46 11.14 Removing the shock absorber x ...................... 47 11.15 Installing the shock absorber x .................... ... 47 11.16 Removing the front fe[...]

TABLE OF CONTENTS 4 22.7 Fork................................................ ............. 105 22.8 Shock absorber ................................ ............. 106 22.9 Chass is tightening torques ............................. 106 23 SUBSTANCES ......................... ............................ .... 108 24 AUXILIARY SUBSTANCES ..............[...]

1 MEANS OF REPRESENTATIO N 5 1.1 Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of you[...]

2 SAFETY ADVICE 6 2.1 Use definition - intended use KTM sport motorcycles are designed and built to withstand the normal stresses and strains of offroad use. Info The motorcycle is authorized for public road traffic in the homologous (reduced) version only. In the derestricted version, the motorcycle must be used only on closed off property remote [...]

2 SAFETY ADVICE 7 2.5 Safe operation Danger Danger of accidents   Danger arising from the rider's judgement being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired. Danger Danger of poisoning   Exhaust gases are toxic and inhaling them may result [...]

3 IMPORTA NT NOTES 8 3.1 Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net ; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulatio ns and[...]

4 VIEW OF VEHICLE 9 4.1 View of vehicle, front left (example) B01011-10 1 Speedometer 2 Clutch lever ( p. 13) 3 Filler cap 4 Seat 5 Seat release 6 Shock absorber compression adjustment 7 Shock absorber rebound adjustment 8 Side stand ( p. 23) 9 Battery 10 Shift lever ( p. 22) 11 Idle speed adjusting screw ( p. 22) 12 Steering lock ( p. 23)[...]

4 VIEW OF VEHICLE 10 4.2 View of vehicle, rear right (example) B01004-10 1 Kill switch ( p. 13) 1 Horn button ( p. 13) 1 Light switch ( p. 14) 1 Turn signal switch ( p. 14) 2 Electric starter button ( p. 14) 3 Throttle grip ( p. 13) 4 Hand brake lever ( p. 13) 5 Fork rebound adjustment 6 Fork compression adjustment 7 Foot brake lever ( p. 23) 8 Lev[...]

5 SERIAL NUMBERS 11 5.1 Chassis number B01005-10 The chassis number 1 is stamped on the right side of the steering head. 5.2 Type label B01124-10 The type label 1 is fixed to the frame at the front right. 5.3 Key number 500125-10 The key number 1 for the steering lock is stamped onto the key connector. 5.4 Engine number B01006-10 The engine number [...]

5 SERIAL NUMBERS 12 5.6 Shock absorber part number B01132-10 The shock absorber part number 1 is stamped on the top of the shock absorber above the adjusting ring on the engine side.[...]

6 CONTROL S 13 6.1 Clutch lever B01012-10 The clutch lever 1 is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 6.2 Hand brake lever B01013-10 Hand brake lever 1 is located on the right side of the handlebar. The front brake is engaged using the hand brake lever. 6.3 Throttle grip B01014-10 The thr[...]

6 CONTROL S 14 6.6 Light switch B01015-12 The light switch 1 is fitted on the left side of the handlebar. Possible states Light off – Light switch is turned to the right. In this position, the light is switched off. Low beam on – Light switch is in the central position. In this position, the low beam and tail light are switched on. High beam on[...]

6 CONTROL S 15 6.11 Overview of indicator lamps B01018-01 Possible states The high beam indicator lamp lights up blue – The high beam is switched on. Turn signal indicator light flashes green – The turn signal is switched on. FI warning lamp ( MIL ) lights up/flashes orange – The OBD (on-board diagnosis) has detected an emission- or safety-cr[...]

6 CONTROL S 16 Info The trip master is an optional accessory. 6.12.4 Setting kilometers or miles Info If you change the unit of measure, the ODO value is retained and converted accordingly. The values TR1 , TR2 , A1 , A2 and S1 are cleared when the unit of measure is changed. Condition The motorcycle is stationary. 400329-01 – Press the button br[...]

6 CONTROL S 17 6.12.6 Setting the clock Condition The motorcycle is stationary. 400330-01 – Press the button briefly and repeatedly until CLK appears at the bottom right of the display. – Press the button for 3 - 5 seconds. The hour display flashes. – Set the hour display with the button and/or button . – Press the button briefly. The next [...]

6 CONTROL S 18 6.12.9 Display mode SPEED/H (operating hours) 400316-01 Condition • The motorcycle is stationary. – Press the button briefly and repeatedly until H appears at the bottom right of the display. In display mode H , the operating hours of the engine are displayed. The operating hours counter stores the total traveling time. Info The [...]

6 CONTROL S 19 6.12.12 Display mode SPEED/ODO (odometer) 400317-01 – Press the button briefly and repeatedly until ODO appears at the bottom right of the display. The total distance traveled is displayed in the ODO display mode. Press the button . No function Press the button . No function Press the button for 3 - 5 seconds. – Press the button [...]

6 CONTROL S 20 Press the button briefly. Next display mode 6.12.16 Display mode SPEED/A2 (average speed 2) 400326-01 – Press the button briefly and repeatedly until A2 appears at the top right of the display. A2 (average speed 2) shows the average speed on the basis of the current speed if the stop watch S2 (stop watch 2) is running. Info The dis[...]

6 CONTROL S 21 Display Press the button . Press the button . Press the button for 3 - 5 seconds. Press the button briefly. Display mode SPEED/LAP (lap time) Starts or stops the clock. Stops the current lap time and saves it, and the stop watch starts the next lap. The stop watch and the lap time are reset. Next display mode Display mode SPEED/ODO ([...]

6 CONTROL S 22 B01019-10 Main work – Press release button 1 , turn the filler cap counterclockwise, and lift it free. 6.14 Closing the filler cap B01020-10 Main work – Replace the filler cap and turn clockwise until the release button 1 locks in place. Info Run the fuel tank breather hose 2 without kinks. Finishing work – Lock the seat. ( p. [...]

6 CONTROL S 23 B01023-10 The gear positions can be seen in the photograph . The neutral or idle position is between the first and second gears. 6.17 Foot brake lever B01024-10 Foot brake lever 1 is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 6.18 Side stand B01025-10 The side stand 1 is on the le[...]

6 CONTROL S 24 6.20 Locking the steering Note Danger of damage   The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. 400732-01 – Park the vehicle. – Turn the handlebar as far as possible to the right. – Insert the key in the steering lock, turn it to the left, press it in, and turn it to t[...]

7 PREPARIN G FOR USE 25 7.1 Advice on first use Danger Danger of accidents   Danger arising from the rider's judgement being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired. Warning Risk of injury   Missing or poor protective clothing presents a[...]

7 PREPARIN G FOR USE 26 Info Motorcycles react sensitively to any changes of weight distribution. – Do not exceed the overall maximum permitted weight and the axle loads. Guideline Maximum permissible overall weight 280 kg (617 lb.) Maximum permissible front axle load 135 kg (298 lb.) Maximum permissible rear axle load 175 kg (386 lb.) – Run th[...]

8 RIDING INSTRUCTIO NS 27 8.1 Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p. 91) – Check the electrical system. – Check the brake fluid level of the front brake. [...]

8 RIDING INSTRUCTIO NS 28 8.3 Starting off Info If your bike has lights, switch them on before riding. You will then be seen earlier by other motorists. When you are riding, the side stand must be folded up and secured with the rubber band. – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throt[...]

8 RIDING INSTRUCTIO NS 29 8.6 Stopping, parking Warning Risk of misappropriation   Usage by unauthorize d persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns   Some vehicle components become very hot when the vehicle is operated. – Do not touch hot c[...]

8 RIDING INSTRUCTIO NS 30 8.8 Refueling Danger Fire hazard   Fue l is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. – Fuel in the fuel tank expands when warm an[...]

9 SERVICE SCHEDUL E 31 9.1 Service schedule S1N S20A S40A Read out the fault memory using the KTM diagnostics tool. x • • • Check that the electrical equipment is functioning properly. • • • Check and charge the battery. x • • Change the engine oil and oil filter, clean the oil screen. x ( p. 92) • • • Check the front brake li[...]

9 SERVICE SCHEDUL E 32 9.2 Service work (as addition al order) S20N S60A S120A J1A Change the front brake fluid. x • Change the rear brake fluid. x • Change the foot brake cylinder seals. x • • Change the hydraulic clutch fluid. x ( p. 62) • Grease the steering head bearing. x ( p. 46) • Perform a fork service. x • • • Service the[...]

10 TUNING THE CHASSIS 33 10.1 Checking the basic chassis setting with the rider's weight Info When adjusting the basic chassis setting, first adjust the shock absorber and then the fork. 401030-01 – For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swingarm and frame, the basic settings of the suspe[...]

10 TUNING THE CHASSIS 34 Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. 10.4 Adjusting the high-speed compression damping of the shock absorber Caution Danger of accidents   Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the descripti[...]

10 TUNING THE CHASSIS 35 Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. 10.6 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with the lift stand. ( p. 40) 400988-10 Main work – Measure the distance – as vertical as possible – between the rear axle and a fixed point, for example,[...]

10 TUNING THE CHASSIS 36 10.8 Checking the riding sag of the shock absorber 400990-10 – Measure distance A of rear wheel unloaded. ( p. 35) – With another person holding the motorcycle, the rider, wearing full protective cloth- ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times. The rear w[...]

10 TUNING THE CHASSIS 37 Finishing work – Install the shock absorber. x ( p. 47) – Lock the seat. ( p. 48) – Remove the motorcycle from the lift stand. ( p. 40) 10.10 Adjusting the riding sag x Preparatory work – Raise the motorcycle with the lift stand. ( p. 40) – Fold the seat up. ( p. 48) – Remove the shock absorber. x ( p. 47) – A[...]

10 TUNING THE CHASSIS 38 10.12 Adjusting the compression damping of the fork Info The hydraulic compressio n damping determines the fork suspension behavior. B01033-10 – Remove protection caps 1 . – Turn adjusting screws 2 clockwise all the way. Info Adjusting screws 2 are located at the bottom end of the fork legs. Make the same adjustment on [...]

10 TUNING THE CHASSIS 39 10.15 Adjusting the handlebar position x Warning Danger of accidents   Handlebar breakage. – If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle- bar. 0 0 B01036-10 – Remove the four screws 1 . Remove the handlebar clamp. Remove the handlebar and [...]

11 SERVICE WORK ON THE CHASSIS 40 11.1 Raising the motorcycle with the lift stand Note Danger of damage   The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. B01029-10 – Raise the motorcycle at the frame underneath the engine. Lift stand (54829055000) The wheels must no longer touch the ground[...]

11 SERVICE WORK ON THE CHASSIS 41 11.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 40) B01038-10 Main work – Push dust boots 1 of both fork legs downward. Info The dust boots remove dust and coarse dirt particles from the inside fork tubes. Over time, dirt can penetrate behind the d[...]

11 SERVICE WORK ON THE CHASSIS 42 11.6 Installing the fork legs x B01055-10 Main work – Position the fork legs. Info The lowest milled groove in the fork leg must be flush with the top edge of the upper triple clamp. Position bleeder screws 1 toward the front. B01054-11 – Tighten screws 2 . Guideline Screw, top triple clamp M8 22 Nm (16.2 lbf f[...]

11 SERVICE WORK ON THE CHASSIS 43 11.8 Installing the fork protect or x B01040-11 – Position the fork protection on the right fork leg. Mount and tighten screws 1 . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) B01039-11 – Position the fork protection on the left fork leg. Mount and tighten screws 2 . Guideline Remaining screws, cha[...]

11 SERVICE WORK ON THE CHASSIS 44 11.10 Installing the lower triple clamp x 0 0 B01058-10 Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 110) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. – Check whether the top steering head seal 1 [...]

11 SERVICE WORK ON THE CHASSIS 45 B01106-11 – Mount and tighten screw 7 . Guideline Screw, top steering stem M8 17 Nm (12.5 lbf ft) Loctite ® 243™ B01054-13 – Tighten screws 8 . Guideline Screw, top triple clamp M8 22 Nm (16.2 lbf ft) – Secure the wiring harness with the cable holder. B01105-12 – Position the brake caliper. Mount and tig[...]

11 SERVICE WORK ON THE CHASSIS 46 400738-11 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. » If there is noticeable play present: – Adjust the play of the steering head bearing. x ( p. 46) – Move the handlebar [...]

11 SERVICE WORK ON THE CHASSIS 47 11.14 Removing the shock absorber x Preparatory work – Raise the motorcycle with the lift stand. ( p. 40) – Fold the seat up. ( p. 48) B01053-10 Main work – Remove screw 1 . – Remove screw 2 and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel. Fix the rear wheel in[...]

11 SERVICE WORK ON THE CHASSIS 48 11.17 Installing the front fender B01030-10 – Ensure that the spacers are mounted in the fender. – Position the front fender. Mount and tighten screws 1 . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) Info Make sure the holding lugs engage in the headlight mask. 11.18 Folding the seat up B01021-10 ?[...]

11 SERVICE WORK ON THE CHASSIS 49 305978-10 – Remove screw 2 . – Remove screw 3 . – Take off the spoiler. – Repeat the operation on the opposite side. 11.21 Mounting the spoiler 305980-10 Main work – Position the spoiler and hook it in at area A . 305978-11 – Mount and tighten screw 1 . – Mount and tighten screw 2 . 305979-11 – Moun[...]

11 SERVICE WORK ON THE CHASSIS 50 B01060-10 Main work – Pull off air filter housing 1 and pre-filter 2 toward the top. 11.23 Installing the air filter housing x B01061-10 Main work – Position pre-filter 1 on the air filter housing. Note Engine failure   If the pre-filter is incorrectly mounted or not mounted at all, the air- fuel mixture will[...]

11 SERVICE WORK ON THE CHASSIS 51 11.25 Installing the air filter x B01063-10 Main work – Mount the clean air filter onto the air filter support. – Apply grease to the air filter around area A . Long-life grease ( p. 110) B01064-10 – Insert both parts together and close air filter housing 1 . Info If the air filter is not mounted correctly, d[...]

11 SERVICE WORK ON THE CHASSIS 52 11.27 Removing the main silencer Warning Danger of burns   The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. 305976-10 Remove the right main silencer: – Take off the spoiler. ( p. 48) Info Only remove the right spoiler. – Disco[...]

11 SERVICE WORK ON THE CHASSIS 53 306092-11 Install the left main silencer: – Position the main silencer. Mount and tighten screws 4 . Guideline Remaining screws, chassis M8 25 Nm (18.4 lbf ft) – Attach springs 5 . 11.29 Changing the glass fiber yarn filling of the main silencer x Warning Danger of burns   The exhaust system gets very hot whe[...]

11 SERVICE WORK ON THE CHASSIS 54 Warning Danger of poisoning   Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi- ately with water and contact a doctor. Wash affected skin areas immediate ly with soap and water. If fuel is swallo[...]

11 SERVICE WORK ON THE CHASSIS 55 11.31 Installing the fuel tank x Danger Fire hazard   Fue l is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. – Fuel in the fue[...]

11 SERVICE WORK ON THE CHASSIS 56 B01079-10 – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve. – Remove the wash cap set. Lubricate the O-ring and connect plug-in connection 7 of the fuel line. Info Ro[...]

11 SERVICE WORK ON THE CHASSIS 57 11.34 Checking the chain tension Warning Danger of accidents   Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel) are under additional load. Apart from premat[...]

11 SERVICE WORK ON THE CHASSIS 58 Finishing work – Remove the motorcycle from the lift stand. ( p. 40) 11.36 Checking the chain, rear sprocket , engine sprocket and chain guide Preparatory work – Raise the motorcycle with the lift stand. ( p. 40) 400227-01 Main work – Shift gear to neutral. – Check the rear sprocket and engine sprocket for [...]

11 SERVICE WORK ON THE CHASSIS 59 401470-01 – Check the chain sliding piece for wear. » If the bottom edge of the chain bolt is in line with or below the chain sliding piece: – Change the chain sliding piece. x – Check that the chain sliding piece is firmly seated. » If the chain sliding piece is loose: – Tighten the chain sliding piece. [...]

11 SERVICE WORK ON THE CHASSIS 60 11.37 Adjusting the chain guide x B01071-10 – Remove the nut of screw 1 . – Remove screws 1 and 2 . Take off the chain guide. Condition Number of teeth: ≤ 44 teeth – Insert nut 3 in hole A . Position the chain guide. – Mount and tighten screws 1 and 2 . Guideline Remaining screws, chassis M6 10 Nm (7.4 lb[...]

11 SERVICE WORK ON THE CHASSIS 61 11.40 Checking the throttle cable routing Preparatory work – Fold the seat up. ( p. 48) – Remove the fuel tank. x ( p. 53) B01080-10 Main work – Check the throttle cable routing. Both throttle cables must be routed to the throttle valve body side by side behind the handlebars and above the fuel tank bearing. [...]

11 SERVICE WORK ON THE CHASSIS 62 11.43 Adjusting the basic position of the clutch lever B01073-10 – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw 1 . Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw counterclockwise t[...]

11 SERVICE WORK ON THE CHASSIS 63 B01082-11 – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws 1 . – Remove cover 2 with membrane 3 . B01083-10 – Fill bleeding syringe 4 with the appropriate hydraulic fluid. Bleed syringe (503290500 00) Brake fluid DOT 4 / DOT 5.1 ( p. 108) – On the clutch[...]

11 SERVICE WORK ON THE CHASSIS 64 11.48 Installing the engine guard B01072-10 – Position the engine guard on the frame at the front and mount screws 1 but do not tighten yet. – Position the engine guard on the frame at the rear and mount and tighten screws 2 . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) – Tighten screws 1 . Guid[...]

12 BRAKE SYSTEM 65 12.1 Checking the free travel of the hand brake lever Warning Danger of accidents   Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating. Adjust the free travel on hand brake lever according to specifications. B01[...]

12 BRAKE SYSTEM 66 12.4 Checking the brake fluid level of the front brake Warning Danger of accidents   Brake system failure. – If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system is leaking or that the brake linings are completely worn down. Check the brake system and d[...]

12 BRAKE SYSTEM 67 B01088-10 – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws 1 . – Remove cover 2 with membrane 3 . – Add brake fluid to level A . Guideline Level A (brake fluid level below con- tainer rim) 5 mm (0.2 in) Brake fluid DOT 4 / DOT 5.1 ( p. 108) – Position the cover with the[...]

12 BRAKE SYSTEM 68 Warning Environmental hazard   Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DO[...]

12 BRAKE SYSTEM 69 B01093-10 – Add brake fluid to level A . Guideline Level A (brake fluid level below con- tainer rim) 5 mm (0.2 in) Brake fluid DOT 4 / DOT 5.1 ( p. 108) – Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water. 12.8 Checking the free travel of f[...]

12 BRAKE SYSTEM 70 12.10 Checking the rear brake fluid level Warning Danger of accidents   Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help[...]

12 BRAKE SYSTEM 71 B01097-10 – Stand the vehicle upright. – Remove screws 1 . – Remove cover with membrane 2 . – Add brake fluid to level A . Brake fluid DOT 4 / DOT 5.1 ( p. 108) – Mount the cover with the membrane. – Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water. 12.12 Checking the [...]

12 BRAKE SYSTEM 72 Warning Danger of accidents   Reduced braking efficiency due to use of non-approved brake linings. – Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from[...]

12 BRAKE SYSTEM 73 B01097-10 – Add brake fluid to level A . Brake fluid DOT 4 / DOT 5.1 ( p. 108) – Mount the cover with the membrane 2 . – Mount and tighten screws 1 . Info Clean up overflowed or spilt brake fluid immediately with water.[...]

13 WHEELS, TIRES 74 13.1 Removing the front wheel x Preparatory work – Raise the motorcycle with the lift stand. ( p. 40) B01044-10 Main work – Remove screw 1 . – Release screws 2 . B01045-10 – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. Info Do not pull the hand brake lever when the front whee[...]

13 WHEELS, TIRES 75 – Pull the front wheel brake and push down hard on the fork several times to align the fork legs. – Tighten screw 3 . Guideline Screw, fork stub M8 15 Nm (11.1 lbf ft) 13.3 Removing the rear wheel x Preparatory work – Raise the motorcycle with the lift stand. ( p. 40) B01047-10 Main work – Remove nut 1 . – Remove chain[...]

13 WHEELS, TIRES 76 B01049-10 – Lift the rear wheel into the swing arm, position it, and insert the wheel spindle 2 . – Put the chain on. B01050-10 – Position chain adjuster 3 . Mount nut 4 , but do not tighten it yet. – Make sure that chain adjusters 3 are fitted correctly on adjusting screws 5 . – Check the chain tension. ( p. 57) – T[...]

13 WHEELS, TIRES 77 Info The tire's date of manufacture is usually part of the tire markings and is indicated by four digits. The first two digits refer to the week of manufac- ture and last two digits refer to the year of manufacture. KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear.[...]

14 ELECTRIC AL SYSTEM 78 14.1 Removing the battery x Warning Risk of injury   Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. – Keep the battery away from sparks or open flames. [...]

14 ELECTRIC AL SYSTEM 79 B01102-11 – Position the battery in the battery compartment. – Attach fixing flap 4 . – Mount and tighten screw 5 . 14.3 Recharging the battery x Warning Risk of injury   Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothin[...]

14 ELECTRIC AL SYSTEM 80 Finishing work – Install the battery. x ( p. 78) 14.4 Changing the main fuse Warning Fire hazard   The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is loc[...]

14 ELECTRIC AL SYSTEM 81 B01111-10 Main work – Pull the EFI control unit 1 from the holder and hang it to one side. – Open fuse box cover 2 . B01112-10 – Remove the defective fuse. Guideline Fuse 1 - 10 A - EFI control unit Fuse 2 - 10 A - fuel pump Fuse 3 - 10 A - high beam, low beam, parking light, tail light, license plate lamp Fuse 4 - 10[...]

14 ELECTRIC AL SYSTEM 82 14.6 Removing the headlight mask with the headlight B01041-10 – Switch off all power consumers. – Detach the brake line and wiring harness 1 . – Release rubber band 2 . Slide the headlight mask up and swing it forward. B01169-11 – Pull bulb socket 3 out of the high beam indicator lamp. – Disconnect the connectors [...]

14 ELECTRIC AL SYSTEM 83 B01041-11 – Position the headlight mask and fix it with the rubber band 3 . Info Make sure that the holding lugs engage in the fender. – Position the brake line and wiring harness 4 . Finishing work – Check the headlight setting. ( p. 84) 14.8 Changing the headlight bulb Note Damage to reflector   Reduced luminance.[...]

14 ELECTRIC AL SYSTEM 84 14.9 Changing the turn signal bulb Note Damage to reflector   Reduced luminance. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting. 800137-10 Main work – Remove the screw on the rear of the turn signal housing. – Carefully[...]

14 ELECTRIC AL SYSTEM 85 Info Turn clockwise to increase the headlight range, turn counterclockwise to reduce the headlight range. A change in weight on the vehicle may require a correction of the headlight range. 14.12 Changing the speedometer battery Preparatory work – Remove the headlight mask with the headlight. ( p. 82) B01133-10 Main work ?[...]

15 COOLING SYSTEM 86 15.1 Cooling system B01114-10 Water pump 1 in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap 2 . This ensures that operating the vehicle at the specified coolant tem- perature will not result in a risk of malfunctions. 120 °C (248 °F) Co[...]

15 COOLING SYSTEM 87 15.3 Checking the coolant level Warning Danger of scalding   During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse i[...]

15 COOLING SYSTEM 88 15.5 Refilling coolant x Warning Danger of poisoning   Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con- tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, cont[...]

16 TUNING THE ENGINE 89 16.1 Checking the play in the throttle cable 400192-10 – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Throttle cable play 3… 5 mm (0.12… 0.2 in) » If the throttle cable p[...]

16 TUNING THE ENGINE 90 16.3 Adjusting the idle speed x B01241-10 – Run the engine warm and push the idle speed adjusting screw 1 all the way in. – Set the desired idle speed by turning the idle speed adjusting screw. Guideline Idle speed 1,800… 1,900 rpm Info Turn counterclockwise to increase the idle speed. Turn clockwise to decrease the id[...]

17 SERVICE WORK ON THE ENGINE 91 17.1 Changing the fuel screen x Danger Fire hazard   Fue l is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. – Fuel in the fuel [...]

17 SERVICE WORK ON THE ENGINE 92 The engine oil is at a level between the middle A and upper edge B of the level viewer. » If the engine oil is not up to the middle A of the level viewer: – Add engine oil. ( p. 94) 17.3 Changing the engine oil and oil filter, cleaning the oil screen x Warning Danger of scalding   Engine oil and gear oil get ve[...]

17 SERVICE WORK ON THE ENGINE 93 B01129-10 – Pull oil filter 5 out of the oil filter housing. Circlip pliers reverse (51012011000) – Completely drain the engine oil. – Thoroughly clean the parts and sealing area. B01127-10 – Push oil screen 3 with the O-rings onto a pin wrench. – Push the pin wrench through the opening into the drill hole[...]

17 SERVICE WORK ON THE ENGINE 94 17.4 Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. B01119-10 – Remove the oil filler plug 1 with the O-ring from the clutch cover and fill up with engine oil. Engine oil (SAE 10W/50) ( p. 108) Engine oil (SAE 10W/60) (00062010035) ( p. 108) Info Fo[...]

18 CLEANING , CARE 95 18.1 Cleaning the motorcycle Note Material damage   Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between t[...]

18 CLEANING , CARE 96 18.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of s[...]

19 STORAGE 97 19.1 Storage Warning Danger of poisoning   Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi- ately with water and contact a doctor. Wash affected skin areas immediate ly with soap and water. If fuel is swallowed, co[...]

20 TROUBLE SHOOTING 98 Faults Possible cause Action The engine cannot be cranked (elec- tric starter) Operating error – Carry out the start procedure. ( p. 27) Battery is discharged – Recharge the battery. x ( p. 79) – Check the charging voltage. x – Check the quiescent current. x – Check the stator winding of the alternator. x Main fuse [...]

20 TROUBLE SHOOTING 99 Faults Possible cause Action FI warning lamp ( MIL ) lights up/flashes Defect in fuel injection system – Stop the motorcycle and identify the faulty part using the blink code. Info See blink code – Check the cabling for damage and the connec- tors for corrosion and damage. – Read out the fault memory using the KTM diag-[...]

21 BLINK CODE 100 Blink code of FI warning lamp (MIL) 45 FI warning lamp ( MIL ) flashes 4x long, 5x short Error level condition Freeride 350 EU Lambda sensor heater cylinder 1, sensor 1 - short circuit to ground or open circuit Freeride 350 EU Lambda sensor heater cylinder 1, sensor 1 - input signal too high Blink code of FI warning lamp (MIL) 09 [...]

21 BLINK CODE 101 Blink code of FI warning lamp (MIL) 15 FI warning lamp ( MIL ) flashes 1x long, 5x short Error level condition Rollover sensor (A/D type) - input signal too low Rollover sensor (A/D type) - input signal too high[...]

22 TECHNICA L DATA 102 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 349.7 cm³ (21.34 cu in) Stroke 57.5 mm (2.264 in) Bore 88 mm (3.46 in) Compression ratio 12.3:1 Idle speed 1,800… 1,900 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 36.3 mm (1.429 in) Valve diam[...]

22 TECHNICA L DATA 103 Screw, locking lever M5 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, oil pump cover M5 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, stator M5 6 Nm (4.4 lbf ft) Loctite ® 243™ Nut, cylinder head M6 10 Nm (7.4 lbf ft) Lubricated with engine oil Nut, water-pump wheel M6 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, alternator cover [...]

22 TECHNICA L DATA 104 22.3 Capacities 22.3.1 Engine oil Engine oil 1.20 l (1.27 qt.) Engine oil (SAE 10W/50) ( p. 108) Alternative engine oil Engine oil (SAE 10W/60) (00062010035) ( p. 108) 22.3.2 Coolant Coolant 0.7 l (0.7 qt.) Coolan t ( p. 108) Coolant (mixed ready to use) ( p. 108) 22.3.3 Fuel Total fuel tank capacity, approx. 4.8 l (1.27 US g[...]

22 TECHNICA L DATA 105 22.5 Electrical system Battery YTX4L-BS Battery voltage: 12 V Nominal capacity: 3 Ah Maintenance-free Speedometer battery CR 2430 Battery voltage: 3 V Fuse 58011109110 10 A Fuse 58011109120 20 A Headlight S 2/socket BA20d 12 V 35/35 W Parking light W5W/socket W2.1x9.5d 12 V 5 W Indicator lamps W2.3W/socket W2x4.6d 12 V 2.3 W [...]

22 TECHNICA L DATA 106 22.8 Shock absorber Shock absorber part number 15.18.7L.40 Shock absorber WP Suspension 4618 BAVP DCC Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 5 clicks Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport 1 turn Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 [...]

22 TECHNICA L DATA 107 Screw, front brake caliper M8 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, fuel tank M8 15 Nm (11.1 lbf ft) – Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) – Screw, side stand attachment M8 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, subframe M8 30 Nm (22.1 lbf ft) Loctite ® 243™ Screw, top steering stem M8 17 Nm (12.[...]

23 SUBSTAN CES 108 Brake fluid DOT 4 / DOT 5.1 According to – DOT Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Castrol and Motorex ® products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ® –[...]

23 SUBSTAN CES 109 Fork oil (SAE 4) (48601166S1) According to – SAE ( p. 112) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Shock absorber oil (SAE 2.5) (50180342S1) According to – SAE ( p. 112) (SAE 2.5) Guideline – Use only oi[...]

24 AUXILIAR Y SUBSTANCES 110 Air filter cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Dirt Bio Remover Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline – KTM recommends Motorex ?[...]

24 AUXILIAR Y SUBSTANCES 111 Oil for foam air filter Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Liquid Bio Power Paint cleaner and polish for high-gloss and matte finishes , bare metal and plastic surfaces Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Clean & Polish Rubber grip[...]

25 STANDAR DS 112 JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation. Whereas long service intervals are demanded fo[...]

INDEX 113 INDEX A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Air filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 A[...]

INDEX 114 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Front wheel installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Fuel screen changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Fu[...]

INDEX 115 Spoiler mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Spoke tension checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 St[...]

*321 190 7en* 3211907en 07/2012 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com Photo: Mitterbauer/KTM[...]