KTM 350 EXC-F EU 2019 Manual

SETUP INSTRUCTIONS 2019
350 EXC‑F
350 EXC‑F Six Days
Art. no. 3213898en

INTRODUCTION
*3213898en*
3213898en
03/2018
INTRODUCTION
Perform the work described in these setup instructions before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make
changes in the interest 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 GmbH specifically reserves the right to modify or delete
technical specifications, 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 descrip-
tions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to
the regular scope of supply.
© 2018 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission
of the copyright owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assur-
ance processes that lead to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
350 EXC‑F EU (F8203S9)
350 EXC‑F AU (F8260S9)
350 EXC‑F US (F8275S9)
350 EXC‑F BR (F8240S9)
350 EXC‑F Six Days EU (F8203S2)
350 EXC‑F Six Days BR (F8240S2)

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.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates a resistance measurement.
Indicates the end of an activity including potential rework.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name®Indicates a protected name.
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
are explained in the glossary.

SETUP 2
3
2.1 Transport mode
H02712-01
This vehicle was blocked for transport in the software.
To operate the vehicle, the vehicle electronics must be enabled.
This process is conducted during initial setup in KTM Dealer.net.
Enabling ensures that the initial setup in KTM Dealer.net is docu-
mented.
Enabling can be performed either temporarily, e.g. for a test ride,
or permanently for vehicle handover.
Info
Make sure that the vehicle is permanently enabled before
handing it over to the customer.
2.2 Unpacking and setting up the vehicle
E00851-10
Condition
Packaging V2
–Remove the box and the plastic packaging.
Info
To avoid damaging the motorcycle during the setup,
leave the protective film on the vehicle until you
have finished.
–Remove the separate enclosure and unpack it. Check
that the scope of supply is complete on the basis of the
enclosed packing list.
–Have a lift stand available.
Lift stand (78129955100)
–Carefully loosen and remove the tension belt of the footrest
mount.
Info
An assistant prevents the motorcycle from falling
over.
402050-01
–Together with an assistant, take the vehicle off the palette.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.

2 SETUP
4
H01768-10
–Position turn signal indicator lamp 1in the speedometer
bracket.
–Remove the headlight mask with the headlight. ( p. 20)
E00850-10
Condition
Packaging V12
–Remove the box and the plastic packaging.
Info
An assistant prevents the motorcycle from falling
over.
To avoid damaging the motorcycle during the setup,
leave the protective film on the vehicle until you
have finished.
–Remove and unpack the separate enclosure and attach-
ments. Check that the scope of supply is complete on the
basis of the enclosed packing list.
–Remove the two cable ties on the triple clamp.
–Have a lift stand available.
Lift stand (78129955100)
402051-01
–Together with an assistant, take the vehicle off the palette.
–Position the vehicle on a lift stand.
–Check the vehicle and attachments for transport damage.
–Install the shock absorber. ( p. 23)
H01768-10
–Position turn signal indicator lamp 1in the speedometer
bracket.

SETUP 2
5
402736-10
–Mount the connector retainer and speedometer on the
upper triple clamp.
–Mount and tighten screws 2.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Route the clutch line with the clutch master cylinder
toward the front between the upper and lower triple
clamps.
–Install the fork legs. ( p. 24)
S01414-10
(EXC‑F EU/AU/US/BR)
–Remove screws 3and take off handlebar supports.
–Move the handlebar supports to the desired position and
mount and tighten screws 3.
Guideline
Screw, handle-
bar holder
M10 40 Nm (29.5 lbf ft)
Loctite®243™
Info
Position the left and right handlebar supports
evenly.
E00483-01
Warning
Danger of accidents A repaired handlebar poses a
safety risk.
If the handlebar is bent or straightened, the mate-
rial becomes fatigued. The handlebar may break
as a result.
–Change the handlebar if the handlebar is dam-
aged or bent.
–Position the handlebar.
Info
Make sure the cables and wiring are positioned cor-
rectly.
–Position the handlebar clamps. Mount and tighten the
screws evenly.
Guideline
Screw, handlebar
clamp
M8 20 Nm
(14.8 lbf ft)

2 SETUP
6
Info
The markings on the handlebar should be at the
center of the handlebar clamps.
Keep the gap widths equal when tightening.
S01415-10
(All Six Days models)
–Remove screws 3and take off handlebar supports.
–Move the handlebar supports to the desired position and
mount and tighten screws 3.
Guideline
Screw, handle-
bar holder
M10 40 Nm (29.5 lbf ft)
Loctite®243™
Info
Position the left and right handlebar supports
evenly.
S01413-01
Warning
Danger of accidents A repaired handlebar poses a
safety risk.
If the handlebar is bent or straightened, the mate-
rial becomes fatigued. The handlebar may break
as a result.
–Change the handlebar if the handlebar is dam-
aged or bent.
–Position the handlebar.
Info
Make sure the cables and wiring are positioned cor-
rectly.
–Position the handlebar clamps. Mount and tighten the
screws evenly.
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.

SETUP 2
7
E00468-01
(EXC‑F EU/AU/BR, All Six Days models)
–Position the controls on the right half of the handlebar.
E01235-01
(EXC-F US)
–Position the controls on the right half of the handlebar.
S01423-01
(EXC‑F EU/AU/BR, All Six Days models)
–Position the controls on the left half of the handlebar.
S01422-01
(All Six Days models)
Warning
Voiding of the government approval for road use and
the insurance coverage If the combination switch
is installed, the vehicle's approval for road use is
invalidated.
–Only operate the vehicle in closed-off areas
remote from public road traffic if the combina-
tion switch is installed.
–(Optional) Mount the left side combination switch.
Info
The figure shows a possible installation position of
the left side combination switch.

2 SETUP
8
S01410-01
(EXC-F US)
–Position the controls on the left half of the handlebar.
402390-01
(EXC‑F EU/AU/BR, All Six Days models)
–Mount the turn signal switch.
S01409-10
Condition
Packaging V12
–Connect all plug-in connectors to the connector retainer.
–Route the cable without tension and secure with cable tie.
S01411-01
(All Six Days models)
Warning
Voiding of the government approval for road use and
the insurance coverage If the combination switch
is installed, the vehicle's approval for road use is
invalidated.
–Only operate the vehicle in closed-off areas
remote from public road traffic if the combina-
tion switch is installed.
–(Optional) Remove the protection cap and join the combi-
nation switch plug-in connector.

SETUP 2
9
S01412-10
–Route the cable without tension and secure with cable ties and
cable holder.
H01060-01
–Mount the mirror clamps on both sides.
E00474-01
–Mount both rear mirrors with the adapter.

2 SETUP
10
E00852-01
–Preassemble the hand guards on the left and right.
F01077-10
–Mount the left hand guard.
–Mount the right hand guard.
E00482-01
–Secure the handlebar cushion with two cable ties.
–Install front fender. ( p. 26)
–Install the front wheel. ( p. 25)
(EXC‑F EU/AU/US, EXC‑F Six Days EU)
–Remove the battery. ( p. 27)
–Recharge the battery. ( p. 29)

SETUP 2
11
(All BR models)
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 safety
glasses.
–Avoid contact with battery acid and battery
gases.
–Keep sparks or open flames away from the bat-
tery.
–Only charge batteries in well-ventilated rooms.
–Rinse the affected area immediately with
plenty of water in the event of contact with the
skin.
–Rinse eyes with water for at least 15 minutes
and consult a doctor immediately if battery
acid and battery gases get into the eyes.
–Fill the battery.
Info
Read the notes in the battery package.
–Recharge the battery. ( p. 31)
(EXC-F US)
–Install the headlight mask with the headlight. ( p. 21)
–Install the battery. ( p. 29)
(EXC‑F EU/AU/BR, All Six Days models)
–Remove the fuel tank. ( p. 32)
S01393-10
–Position the turn signal wiring harness.
–Insert the indicator lamp with the black and violet cable
colors into socket 4.
E00484-10
–Position turn signal on the headlight mask on both sides,
mount and tighten nuts with washers.
–Join the plug-in connector of the right turn signal with the
black and brown cables of the turn signal wiring harness.
–Join the plug-in connector of the left turn signal with the
violet and brown cables of the turn signal wiring harness.
Info
Pay attention to the brake lines routing when doing
so.
–Join plug-in connector of the headlight.
–Join plug-in connector of the turn signal switch.

2 SETUP
12
–Secure turn signal relay 5with a cable tie and plug in
the connector.
–Install the headlight mask with the headlight. ( p. 21)
S01394-10
–Route the turn signal wiring harness from front to back as
far as the battery compartment.
–Position and secure the turn signal wiring harness under
the rubber bands of the fuel tank contact area on the main
wiring harness.
E00494-10
–Remove screw 6.
–Remove screw 7.
–Pull off the side cover in area Aand in area Band
remove it toward the rear.
E00487-10
–Detach spring 8.
Spring hook (5030501700004)
–Remove screws 9with washers and take off main
silencer.
S01417-10
–Pull off engine electronics control unit from the holder and
hang it to the side.
–Disconnect and remove plug-in connector bk on the main
wiring harness.
–Join the plug-in connector of the turn signal wiring harness
with the plug-in connector of the main wiring harness.

SETUP 2
13
E00489-10
–Remove screw bl with the collar sleeve.
–Remove screw bm.
–Remove screw bn with negative cable and contact disk.
S01416-10
–Remove screws bo.
–Carefully remove the tail light cable from the frame and in
doing so pay attention to the connector.
–Remove license plate holder with tail light to the rear.
E00491-10
–Remove screws bp and hang the tail light to the side.
–Drill a hole at the marking Cthe size of the marking.

2 SETUP
14
E00492-10
–Route the turn signal wiring harness toward to rear and
pass through the frame, pay attention to the connector
when doing so.
–Route the turn signal wiring harness on the license plate
holder and pass the turn signal wiring harness through the
hole.
–Position the tail light on the license plate holder and
mount and tighten screws bp.
E00495-10
–Carefully guide the tail light cable through the frame and
in doing so pay attention to the connector.
–Position license plate holder on the rear.
–Mount and tighten screws bo.

SETUP 2
15
E00489-10
–Mount and tighten screw bl with the collar bushing.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Mount and tighten screw bm.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Mount and tighten screw bn with negative cable and con-
tact disk.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
E00498-10
–Join the plug-in connector of the tail light with the plug-in
connector of the turn signal wiring harness.
–Mount engine electronics control unit on the holder.
Info
The wiring harness runs under the engine electron-
ics control unit.
E00487-10
–Position the main silencer. Mount screws 9with the
washers, but do not tighten yet.
–Attach spring 8.
Spring hook (5030501700004)
–Tighten screws 9.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
E00494-10
–Attach the side cover in area Aand engage it in area B.
–Mount and tighten screw 7.
Guideline
Screw, sub-
frame
M8 35 Nm (25.8 lbf ft)
Loctite®2701™
–Mount and tighten screw 6.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Install the battery. ( p. 29)
–Install the fuel tank. ( p. 34)

2 SETUP
16
E00496-10
–Position turn signal on both sides, mount and tighten nuts
with washers.
–Position license plate lamp on the license plate holder,
mount and tighten screws bq.
–Mount reflector br on the license plate holder.
–Guide cable through the license plate holder.
E00497-10
–Position license plate holder on the license plate bracket.
–Join the plug-in connector of the license plate lamp.
–Join the plug-in connector of the left turn signal which is
marked red.
–Join the plug-in connector of the right turn signal which is
marked green.
–Mount and tighten screws bo.
D02151-10
–Position the right footrest and pin.
Info
Only insert the pins to the extent that the spring can
still be mounted.
S01395-10
–Position spring as shown.
Spring Dengages in area E.

SETUP 2
17
S01396-10
–Press the spring with special tool bs.
Footrest spring plier (79029083000)
The special tool is applied to area Fon the footrest.
–Mount pin bt.
S01397-10
–Mount the washer and split pin ck.
S01398-10
–Position the left footrest and pin.
Info
Only insert the pins to the extent that the spring can
still be mounted.
S01399-10
–Position spring as shown.
Spring Gengages in area H.

2 SETUP
18
F01080-10
–Press the spring with special tool bs.
Footrest spring plier (79029083000)
The special tool is applied to area Ion the footrest.
–Mount pin cl.
F01081-10
–Mount the washer and split pin cm.
F01079-10
–Position the frame protector on both sides.
–Mount and tighten screws cn.
Guideline
Screw, frame protec-
tor
M5 3 Nm (2.2 lbf ft)
–Mount and tighten screws co with the washers.
Guideline
Screw, frame protec-
tor
M5 3 Nm (2.2 lbf ft)
–Mount the cable binder.
(EXC‑F AU, All Six Days models)
–Install the engine guard. ( p. 37)
–Unpack and mount the KTM PowerParts included in the deliv-
ery (optional).
Info
Read the accompanying KTM PowerParts fitting instruc-
tions.
–Apply the label included in the delivery (optional).
–Set kilometers or miles. ( p. 39)
–Adjust the combination instrument. ( p. 40)
–Set the clock. ( p. 40)
–Refuel. ( p. 38)
–Position all controls in their exact positions on the handlebar.
Tighten all screws.
–Prepare the vehicle according to the specifications in the
KTM Dealer.net for handover to the customer.