KTM Freeride 350 2012 Handbuch

SETUP INSTRUCTIONS 2012

Freeride 350

Art. no. 3211891en

INTRODUCTION 1

INTRODUCTION

The work described in these setup instructions must be performed before the vehicle is delivered to the customer.

Read the setup instructions in their entirety before beginning work.

Print out the current PDI form found on the KTM DEALER.NET.

These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter-

est of technical advancement without at the same time updating this manual.

We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.

It is assumed that the work will be performed by a fully trained mechanic.

All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-

tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt

these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery

options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-

cial equipment that does not belong to the regular scope of supply.

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

owner.

ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead

to the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM-Sportmotorcycle AG

5230 Mattighofen, Austria

1 MEANS OF REPRESENTATION 2

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).

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

Indicates information with more details or tips.

Indicates the result of a testing step.

Denotes a voltage measurement.

Denotes a current measurement.

Denotes a resistance measurement.

1.2 Formats used

The typographical formats used in this document are explained below.

Proprietary name Identifies a proprietary name.

Name®Identifies a protected name.

Brand™ Identifies a trademark.

2 SAFETY ADVICE 3

2.1 Work rules

Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren-

theses. E.g.: bearing puller (15112017000)

During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be

replaced by new parts.

In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed.

After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.

After you complete the repair or service work, check the operating safety of the vehicle.

2.2 Safety advice

A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety

instructions are highlighted in the text and are referred to at the relevant passages.

Info

The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If

they are missing, you or others may not recognize dangers and may therefore be injured.

2.3 Degrees of risk and symbols

Danger

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures

are not taken.

Warning

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Note

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

Warning

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

2.4 Operating and auxiliary substances

Warning

Environmental hazard Improper handling of fuel is a danger to the environment.

–Do not allow fuel to get into the ground water, the ground, or the sewage system.

Use the operating and auxiliary substances (such as fuel and lubricants) as specified in the manual.

3 SETUP 4

3.1 Unpacking and setting up the vehicle

B01160-01

Packaging 2

–Remove the box and the plastic packaging.

Info

An assistant prevents the motorcycle from falling over.

To avoid damaging the motorcycle during setup, leave the protective

film on the vehicle until you have finished.

–Remove the separate enclosure and unpack it. Check that the scope of delivery

is complete on the basis of the enclosed packing list.

–Have a lift stand available.

Lift stand (54829055000)

–Carefully loosen and remove the footrest bracket.

Info

An assistant prevents the motorcycle from falling over.

–Together with an assistant, take the vehicle off the pallet.

–Position the vehicle on a lift stand.

–Check the vehicle for transport damage.

B01161-01

Package 12

–Remove the box and the plastic packaging.

Info

An assistant prevents the motorcycle from falling over.

To avoid damaging the motorcycle during setup, leave the protective

film on the vehicle until you have finished.

–Remove the separate enclosure and unpack it. Check that the scope of delivery

is complete on the basis of the enclosed packing list.

–Have a lift stand available.

Lift stand (54829055000)

–Together with an assistant, take the vehicle off the pallet.

–Position the vehicle on a lift stand.

–Check the vehicle for transport damage.

B01162-01

–Install the shock absorber. ( p. 8)

B01163-01

–Route the clutch line with the clutch master cylinder toward the front between

the upper and lower triple clamps.

–Position the fork legs and tighten the screws of the triple clamp.

Guideline

Screw, top triple clamp M8 22 Nm

(16.2 lbf ft)

Screw, bottom triple clamp M8 18 Nm

(13.3 lbf ft)

Info

The lowest milled groove in the fork leg must be flush with the top edge

of the upper triple clamp.

Position the bleeder screws toward the front.

3 SETUP 5

B01036-10

–Remove screws 1. Remove the handlebar clamp.

–Remove screws 2. Remove the handlebar holders.

–Place the handlebar holders in the required position. Mount and tighten screws 2.

Guideline

Screw, handlebar support M10 40 Nm

(29.5 lbf ft)

Loctite®243™

Info

Position the left and right handlebar holders evenly.

B01164-01

–Position the handlebar.

Info

Make sure cables and wiring are positioned correctly.

–Position the handlebar clamps. Mount and tighten the screws.

Guideline

Screw, handlebar clamp M8 20 Nm

(14.8 lbf ft)

Info

The markings on the handlebar should be at the center of the handlebar

clamps.

Keep the gap widths equal when tightening.

–Install the front wheel. ( p. 8)

–Mount the handlebar cushion.

B01165-10

–Attach connector holder 3and the speedometer to the upper triple clamp.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

B01176-01

–Remove the fuel tank. ( p. 9)

–Position the turn signal wiring harness on the main wiring harness and secure with

cable binders.

Info

The figure shows how to route the wiring harness.

–Connect all connectors to connector holder 3.

–Install the fuel tank. ( p. 10)

B01177-10

–Insert bulb 4, included in the separate enclosure, into the socket with the black

and violet cable colors and position in the turn signal indicator lamp 5.

3 SETUP 6

B01167-01

–Position the controls of the right half of the handlebar.

Info

The routing of the cables can be seen in the figure.

B01168-01

–Position the controls of the left half of the handlebar.

Info

The figure shows how to route the clutch line and wiring harness.

401382-01

–Mount the turn signal switch.

B01169-10

–Insert the indicator lamp with the blue and brown cable colors into socket 6.

–Position the turn signals on both sides and mount and tighten nuts 7.

–Connect plug-in connection 8of the right turn signal with the black and brown

cable colors.

–Connect plug-in connection 9of the left turn signal with the violet and brown

cable colors.

–Install the front fender. ( p. 13)

–Refit the headlight mask with the headlight. ( p. 13)

800042-10

–Mount the footrests with the springs and bolts. Secure the bolts using the washers

and pins.

Pliers for footrest spring (58429083000)

3 SETUP 7

B01170-01

–Mount the license plate holder with the license plate lamp, turn signals, and reflec-

tor.

–Connect the electrical components.

–Connect the connector of the left turn signal with connector that is marked red.

–Connect the connector of the right turn signal with connector that is marked green.

B01173-01

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

–Keep batteries out of the reach of children.

–Wear suitable protective clothing and goggles.

–Avoid contact with battery acid and battery gases.

–Keep the battery away from sparks or open flames. Charge only in well-

ventilated areas.

–In the event of skin contact, rinse with large amounts of water. If battery

acid gets in the eyes, rinse with water for at least 15 minutes and con-

tact a physician.

–Fill the battery.

Info

Read the notes in the battery package.

–Recharge the battery. ( p. 12)

–Install the battery. ( p. 13)

–Unpack and mount the KTM PowerParts included in the delivery (optional).

Info

Read the accompanying KTM PowerParts installation instructions.

–Apply the label included in the delivery (optional).

B01172-01

–Mount the mirror clamps on both sides.

B01171-01

–Mount and tighten the rear mirrors on both sides.

–Position all controls in their exact positions on the handlebar. Tighten all screws.

–Refuel. ( p. 15)

–Print out the current PDI form found on KTM DEALER.NET and perform the delivery

inspection.

4 SERVICE WORK ON THE CHASSIS 8

4.1 Installing the shock absorber

B01053-11

Main work

–Push splash protector 1to the side and position the shock absorber. Mount and

tighten screw 2.

Guideline

Screw, top shock absorber M12 80 Nm

(59 lbf ft)

Loctite®243™

–Mount and tighten screw 3.

Guideline

Screw, bottom shock

absorber

M12 80 Nm

(59 lbf ft)

Loctite®243™

Info

The heim joint for the shock absorber at the swing arm is Teflon coated. It

must not be greased with grease or with other lubricants. Lubricants dis-

solve the Teflon coating, thereby drastically reducing the service life.

–Mount and tighten screw 4.

Guideline

Screw, upper subframe M10 45 Nm

(33.2 lbf ft)

Loctite®243™

Subsequent work

–Lock the seat. ( p. 9)

–Remove the motorcycle from the lift stand.

4.2 Installing the front wheel

Warning

Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.

–Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

B01046-11

–Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:

–Change the wheel bearing.

–Clean and grease the shaft seal rings 1and contact surface Aof the spacers.

Long-life grease ( p. 19)

–Insert the spacers.

B01044-11

–Lift the front wheel into the fork, position it, and insert the wheel spindle.

–Mount and tighten screw 2.

Guideline

Screw, front wheel spindle M20x1.5 35 Nm

(25.8 lbf ft)

–Activate the hand brake lever multiple times until the brake linings are in contact

with the brake disc.

–Remove the motorcycle from the lift stand.

–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)

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