KTM F8101S5 Owner's Manual
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KTM F8101S5 Owner's Manual

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OWNER'S MANUAL
2019
250 SX-F
250 XC‑F
Art. no. 3213849en

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Summary of Contents for KTM F8101S5

  • Page 1 OWNER'S MANUAL 2019 250 SX-F 250 XC‑F Art. no. 3213849en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art DEAR KTM CUSTOMER sports motorcycle that will give you enormous pleasure if you service and maintain it properly. We hope you enjoy riding this motorcycle! Enter the serial numbers of your vehicle below.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS PREPARING FOR USE......... 23 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 Advice on preparing for first use ..23 Symbols used ........5 Running in the engine ...... 24 Formats used........5 Starting power of lithium-ion SAFETY ADVICE..........
  • Page 5 TABLE OF CONTENTS 10.10 Adjusting the spring preload of the 11.33 Checking for chain dirt shock absorber ......43 accumulation........73 10.11 Adjusting the riding sag ....44 11.34 Cleaning the chain ......73 10.12 Checking the basic setting of the 11.35 Checking the chain tension ....
  • Page 6 TABLE OF CONTENTS 15.2 Checking the antifreeze and 22.8 Shock absorber ......134 coolant level ........104 22.8.1 SX‑F EU........134 15.3 Checking the coolant level ....105 22.8.2 SX‑F US........134 15.4 Draining the coolant ....105 22.8.3 XC‑F US........135 15.5 Refilling coolant ......

  • Page 7: Means Of Representation 1

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary tools required.

  • Page 8: Safety Advice

    2 SAFETY ADVICE Use definition – intended use (All SX‑F models) This vehicle is designed and built to withstand the normal stresses and strains of competitive use. This vehi- cle complies with the currently valid regulations and categories of the top international motorsport organiza- tions.

  • Page 9: Degrees Of Risk And Symbols

    SAFETY ADVICE 2 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.

  • Page 10: Protective Clothing

    – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks.

  • Page 11: Owner's Manual

    The Owner's Manual is an important component of the vehicle and must be handed over to the new owner if the vehicle is sold. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. International KTM Website: http://www.ktm.com...

  • Page 12: Important Notes

    Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void.
  • Page 13 IMPORTANT NOTES 3 A list of authorized KTM dealers can be found on the KTM website. International KTM Website: http://www.ktm.com...

  • Page 14: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) E01234-10 Hand brake lever ( p. 16) Clutch lever ( p. 16) Filler cap Air filter box cover p. 22) (All SX‑F models) Plug-in stand ( Cold start button ( p.

  • Page 15: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) E01233-10 Shock absorber compression adjustment Combination switch ( p. 17) Kill switch ( p. 16) Electric starter button ( p. 17) Throttle grip ( p. 16) Chassis number ( p. 14) Type label ( p.

  • Page 16: Serial Numbers

    5 SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steer- ing head. 401945-10 Type label The type label is fixed to the front of the steering head. 401946-10 Engine number Engine number is located on the left side of the engine over the engine sprocket.

  • Page 17: Shock Absorber Article Number

    SERIAL NUMBERS 5 Shock absorber article number Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 0 0 1 401948-10...

  • Page 18: Controls

    6 CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. S01192-10 Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. S01193-10 Throttle grip The throttle grip...

  • Page 19: Electric Starter Button

    CONTROLS 6 Electric starter button The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position pressed – In this position, the elec- • Electric starter button tric starter is actuated. S01195-10 Combination switch The combination switch is fitted on the left side of the handlebar.

  • Page 20: Service Hour Counter

    6 CONTROLS Service hour counter Service hour counter is fitted in front of the handlebar. It shows the total number of service hours of the engine. The service hour counter begins counting when the engine is started and stops when the engine is switched off. Info The value indicated by the service hour counter cannot be cleared or adjusted.

  • Page 21: Closing The Filler Cap

    CONTROLS 6 (XC‑F US) – Press release button , turn the filler cap counterclock- wise, and lift it off. F01557-10 6.10 Closing the filler cap (All SX‑F models) – Mount filler cap and turn it clockwise until the fuel tank is tightly closed. Info Route fuel tank breather hose without kinks.

  • Page 22: Cold Start Button

    6 CONTROLS 6.11 Cold start button (All SX‑F models) The cold start button is fitted on the bottom of the throttle valve body. F01578-10 (XC‑F US) The cold start button is fitted on the bottom of the throttle valve body. The injection system extends the injection time if the engine is cold and the outside temperature is low.

  • Page 23: Idle Speed Adjusting Screw

    CONTROLS 6 6.12 Idle speed adjusting screw The idle setting of the throttle valve body has a big influence on the vehicle's starting behavior, on stable idling, and on vehicle response when the throttle is opened. An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly.

  • Page 24: Foot Brake Lever

    6 CONTROLS 6.14 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 401956-10 6.15 Plug-in stand (All SX‑F models) Support for plug-in stand is the left side of the wheel spindle. The plug-in stand is used to park the motorcycle.

  • Page 25: Preparing For Use 7

    When using the motorcycle, remember that others may feel disturbed by excessive noise. – Ensure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. The delivery certificate and the Service and Manufacturer Warranty Booklet must be transferred with the...

  • Page 26: Running In The Engine

    7 PREPARING FOR USE Info The delivery certificate and the Service and Manufacturer Warranty Booklet are regarded as evidence of warranty services. – Read the entire Owner's Manual before riding for the first time. – Get to know the controls. –...

  • Page 27: Starting Power Of Lithium-Ion Batteries At Low Temperatures

    Riding at low temperatures and in snow. ( p. 27) Preparing vehicle for rides on dry sand – Mount a dust cover on the air filter. Dust protection device for air filter (79006920000) Info Observe fitting instructions for KTM PowerParts. 102136-01...

  • Page 28: Preparing Vehicle For Rides On Wet Sand

    7 PREPARING FOR USE – Mount a sand cover on the air filter. Sand protection device for air filter (79006922000) Info Observe fitting instructions for KTM PowerParts. 102138-01 – Clean the chain. Chain cleaner ( p. 140) – Mount the steel sprocket.

  • Page 29: Preparing Vehicle For Rides On Wet And Muddy Circuits

    Preparing vehicle for rides on wet and muddy circuits – Fit a rain cover on the air filter. Waterproofing device for air filter (79006921000) Info Observe fitting instructions for KTM PowerParts. 102137-01 – Mount the steel sprocket. – Clean the motorcycle. ( p.

  • Page 30: Riding Instructions

    8 RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 31: Activating Launch Control

    RIDING INSTRUCTIONS 8 (All SX‑F models) – Remove the plug-in stand H02629-10 (XC‑F US) – Take the motorcycle off side stand and secure the side stand with rubber band – Shift the transmission to idle. Condition Ambient temperature: < 20 °C (< 68 °F) –...

  • Page 32: Activating Traction Control

    8 RIDING INSTRUCTIONS – Press and hold the MAP and TC buttons simultaneously. The malfunction indicator lamp flashes orange rapidly. Info The launch control is deactivated automatically for a few seconds after the vehicle has started. The launch control is also deactivated in the following cases (malfunction indicator lamp no longer flashes): if the throttle valve is closed more than 1/3 of the way H02884-01...

  • Page 33: Shifting, Riding

    If unusual noises occur while riding, stop immediately (taking care not to endanger yourself or other road users in the process), switch off the engine and contact an authorized KTM workshop. First gear is used for starting off and for steep inclines.

  • Page 34: Stopping, Parking

    8 RIDING INSTRUCTIONS – Use the braking effect of the engine on long downhill stretches. Shift back one or two gears, but do not over- rev the engine when doing so. This means that significantly less braking is required and the brake system does not overheat.

  • Page 35: Refueling

    In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.)
  • Page 36 8 RIDING INSTRUCTIONS Note Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to enter the groundwater, the soil, or the sewage system. – Switch off the engine. – Open the filler cap. ( p.

  • Page 37: Service Schedule 9

    Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.

  • Page 38: Recommended Work

    Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Book- let. ○ One-time interval ● Periodic interval Recommended work...
  • Page 39 SERVICE SCHEDULE 9 Annually Every 100 operating hours Every 50 operating hours Once after 20 operating hours Once after 10 operating hours ● Perform major engine service including removing and installing engine. (Change valves, valve springs, valve spring seats and valve spring retainers. Change the connecting rod, conrod bearing, and crank pin.

  • Page 40: 10 Tuning The Chassis

    – As delivered, KTM offroad motorcycles are adjusted for an average rider's weight (with full protective clothing). Guideline Standard rider weight 75 …...

  • Page 41: Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber.

  • Page 42: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber.

  • Page 43: Adjusting The Rebound Damping Of The Shock Absorber

    Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.

  • Page 44: Checking The Static Sag Of The Shock Absorber

    10 TUNING THE CHASSIS Main work – Position the sag gauge in the rear axle and measure the distance to marking SAG on the rear fender. Sag gauge (00029090000) Pin for sag gauge (00029990010) – Note down the value as dimension 402415-10 Finishing work –...

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

    Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info Note the current adjustment before changing the spring preload -–e.g. measure the spring length.

  • Page 46: Adjusting The Riding Sag

    10 TUNING THE CHASSIS Main work – Loosen screw – Turn adjusting ring until the spring is no longer under ten- sion. Holding wrench (90129051000) – Measure the overall spring length while the spring is not under tension. – Tighten the spring by turning adjusting ring to measure- ment Guideline...

  • Page 47: Checking The Basic Setting Of The Fork

    TUNING THE CHASSIS 10 Guideline Spring rate (SX‑F EU) Weight of rider: 65 … 39 N/mm (223 lb/in) 75 kg (143 … 165 lb.) Weight of rider: 75 … 42 N/mm (240 lb/in) 85 kg (165 … 187 lb.) Weight of rider: 85 … 45 N/mm (257 lb/in) 95 kg (187 …...

  • Page 48: Adjusting The Fork Air Pressure

    A little air escapes from the fork leg when connecting. Info This is due to the volume of the hose and not due to a defect in the fork airpump or the fork. Read the accompanying KTM PowerParts instructions. – Adjust the air pressure as specified. Guideline Air pressure (SX‑F EU)

  • Page 49: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 10 – Disconnect the fork airpump from the left fork leg. When disconnecting, excess pressure will escape from the hose – the fork leg itself does not lose any air. The fork airpump indicator switches off automatically after 80 seconds.

  • Page 50: Adjusting The Rebound Damping Of The Fork

    10 TUNING THE CHASSIS 10.15 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. – Remove protection cap – Turn adjusting screw clockwise all the way. Info Adjusting screw is located at the lower end of the right fork leg.

  • Page 51: Adjusting The Handlebar Position

    TUNING THE CHASSIS 10 10.17 Adjusting the handlebar position Warning Danger of accidents A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result. – Change the handlebar if the handlebar is damaged or bent. Preparatory work –...

  • Page 52: 11 Service Work On The Chassis

    11 SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with a lift stand Note Material damage The vehicle may be damaged by incorrect procedure when parking. Significant damage may be caused if the vehicle rolls away or falls over. The components for parking the vehicle are designed only for the weight of the vehicle. –...

  • Page 53: Bleeding The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 11.3 Bleeding the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 50) Main work – Release bleeder screws Any excess pressure escapes from the interior of the fork. –...

  • Page 54: Removing The Fork Protector

    11 SERVICE WORK ON THE CHASSIS 11.5 Removing the fork protector – Remove screws and take off the clamp. – Remove screws and take off the left fork protector. – Remove screws and take off the right fork protector. S01208-10 11.6 Installing the fork protector –...

  • Page 55: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 – Loosen screws . Take out the left fork leg. – Unscrew screws . Take out the right fork leg. F01559-10 11.8 Installing the fork legs Main work – Position the fork legs. Air release screw of the right fork leg is positioned to the front.

  • Page 56: Removing The Lower Triple Clamp

    11 SERVICE WORK ON THE CHASSIS 11.9 Removing the lower triple clamp Preparatory work – Raise the motorcycle with a lift stand. ( p. 50) – Remove the front wheel. p. 94) – Remove the fork legs. p. 52) – Remove the start number plate.

  • Page 57: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11 11.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 140) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.
  • Page 58 11 SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, bottom triple 12 Nm (8.9 lbf ft) clamp F01572-10 – Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head F01563-10 – Mount and tighten screw Guideline Screw, top 20 Nm (14.8 lbf ft)

  • Page 59: Checking The Steering Head Bearing Play

    Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam- ages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become damaged over time.

  • Page 60: Adjusting The Steering Head Bearing Play

    11 SERVICE WORK ON THE CHASSIS 11.12 Adjusting the steering head bearing play Preparatory work – Raise the motorcycle with a lift stand. ( p. 50) – Remove the handlebar cushion. Main work – Loosen screws – Remove screw – Loosen and retighten screw Guideline Screw, top steering...

  • Page 61: Removing The Start Number Plate

    SERVICE WORK ON THE CHASSIS 11 11.14 Removing the start number plate – Remove screw – Unhook the start number plate from the brake line and remove F01524-10 11.15 Installing the start number plate – Position the brake line in holders on the start number plate.

  • Page 62: Installing Front Fender

    11 SERVICE WORK ON THE CHASSIS 11.17 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis F01526-10 Finishing work – Install the start number plate. ( p. 59) 11.18 Removing the shock absorber Preparatory work...

  • Page 63: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 – Remove screws – Pull off foot brake cylinder from the push rod. F01582-10 – Remove the connecting link of the chain. – Take off the chain. S01222-10 – Remove nut and pull out the swingarm pivot. –...
  • Page 64 11 SERVICE WORK ON THE CHASSIS – Position the swingarm and mount the swingarm pivot. Info Pay attention to flat area – Mount and tighten nut Guideline Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) F01586-10 – Mount the chain. –...

  • Page 65: Removing The Seat

    SERVICE WORK ON THE CHASSIS 11 – Position left frame protector. – Insert right frame protector from below and push to the rear. – Mount and tighten screws with the washers. Guideline Screw, frame protec- 3 Nm (2.2 lbf ft) –...

  • Page 66: Removing The Air Filter Box Cover

    11 SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis F01533-10 11.22 Removing the air filter box cover Condition The air filter box cover is secured. – Remove the seat. ( p.

  • Page 67: Installing The Air Filter Box Cover

    SERVICE WORK ON THE CHASSIS 11 11.23 Installing the air filter box cover Condition The air filter box cover is secured. – Insert the air filter box cover in area and clip it into area F01588-12 – Mount and tighten screw Guideline Screw, air filter box EJOT PT...

  • Page 68: Cleaning The Air Filter And Air Filter Box

    11 SERVICE WORK ON THE CHASSIS Main work – Detach retaining tab – Remove air filter with air filter support. – Remove air filter from air filter support. F01536-10 11.25 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage. –...

  • Page 69: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 11.26 Installing the air filter Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area Long-life grease ( p. 140) 102178-10 – Insert air filter and position retaining pin in bushing The air filter is correctly positioned.

  • Page 70: Installing The Main Silencer

    11 SERVICE WORK ON THE CHASSIS – Detach spring Spring hook (5030501700004) – Remove screws with the washers and take off the main silencer. F01590-10 11.29 Installing the main silencer – Position the main silencer. – Mount screws with the washers, but do not tighten yet. –...

  • Page 71: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 Main work – Remove all the screws on the silencer cap. – Take off silencer cap and O-ring – Pull glass fiber yarn filling out of the silencer cap. – Pull glass fiber yarn filling from the inner tube.
  • Page 72 11 SERVICE WORK ON THE CHASSIS Main work (All SX‑F models) – Unplug connector of the fuel pump. – Clean 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 F01591-10 valve! –...

  • Page 73: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 – Remove screw with the rubber bushing. F01565-10 – Remove screws with the collar bushings. F01541-10 – Pull both spoilers off the sides of the radiator bracket and lift off the fuel tank. F01542-10 11.32 Installing the fuel tank Danger...
  • Page 74 11 SERVICE WORK ON THE CHASSIS Main work – Check the throttle cable routing. ( p. 78) – Position the fuel tank and fit the two spoilers to the sides of the radiator bracket. – Make sure that no cables or throttle cables are trapped or dam- aged.

  • Page 75: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS 11 – Plug in connector for the fuel pump. – Remove the wash cap set. Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line.

  • Page 76: Checking The Chain Tension

    11 SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with a lift stand. ( p. 50) Main work – Rinse off loose dirt with a soft jet of water. – Remove old grease residue with chain cleaner. Chain cleaner ( p.

  • Page 77: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 11.36 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 78: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    11 SERVICE WORK ON THE CHASSIS 11.37 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 50) Main work – Shift the transmission to idle. – Check the chain, rear sprocket and engine sprocket for wear. »...
  • Page 79 SERVICE WORK ON THE CHASSIS 11 – Check the chain sliding guard for wear. » If the lower edge of the chain pins 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 80: Checking The Frame

    If the swingarm shows signs of damage, cracking, or defor- mation: – Change the swingarm. Info Always change a damaged swingarm. Repair of the swingarm is not authorized by KTM. S02305-01 11.40 Checking the throttle cable routing Preparatory work –...

  • Page 81: Checking The Rubber Grips

    SERVICE WORK ON THE CHASSIS 11 Main work – Check the throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars and above the fuel tank bracket, to the throttle valve body. Both throttle cables must be secured behind the fuel tank contact area rubber band.

  • Page 82: Adjusting The Basic Position Of The Clutch Lever

    11 SERVICE WORK ON THE CHASSIS 11.42 Adjusting the basic position of the clutch lever – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handle- bar.

  • Page 83: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 11 Info Clean up overflowed or spilled brake fluid immediately with water. 11.44 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. –...
  • Page 84 11 SERVICE WORK ON THE CHASSIS (XC‑F US) – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p. 138) – On the clutch slave cylinder, remove the protection cap and mount bleeding syringe with appropriate hose piece at the bleeder screw F01598-10...

  • Page 85: Brake System 12

    Do not make any adjustments while riding. 12.3 Checking the brake discs Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.)

  • Page 86: Checking The Front Brake Fluid Level

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Preparatory work –...

  • Page 87: Adding Front Brake Fluid

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 88: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 89 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 90: Checking The Free Travel Of Foot Brake Lever

    12 BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 100397-01 – Insert the new brake linings, insert pin , and mount the cotter pins Info Always change the brake linings in pairs. –...

  • Page 91: Adjusting The Basic Position Of The Foot Brake Lever

    BRAKE SYSTEM 12 – Disconnect spring – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in) »...

  • Page 92: Checking The Rear Brake Fluid Level

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Preparatory work –...

  • Page 93: Checking The Brake Linings Of The Rear Brake

    Checking the brake linings of the rear brake Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...

  • Page 94: Changing The Rear Brake Linings

    Changing the rear brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation.
  • Page 95 BRAKE SYSTEM 12 – Manually press the brake caliper to the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.

  • Page 96: 13 Wheels, Tires

    13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 50) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake...

  • Page 97: Installing The Front Wheel

    WHEELS, TIRES 13 13.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –...

  • Page 98: Installing The Rear Wheel

    13 WHEELS, TIRES Main work – Press the brake caliper onto the brake disc by hand in order to push 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 99 WHEELS, TIRES 13 Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surfaces of the spacers. Long-life grease ( p.

  • Page 100: Checking The Tire Condition

    DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of H01144-01 wear.

  • Page 101: Checking Spoke Tension

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.) –...

  • Page 102: 14 Electrical System

    14 ELECTRICAL SYSTEM 14.1 Removing the battery Caution Danger of burns The voltage regulator gets very hot when the vehicle is driven. – Allow the voltage regulator to cool down before performing any work. Note Environmental hazard Batteries contain environmentally-hazardous materials. – Do not dispose of batteries as household waste.

  • Page 103: Recharging The Battery

    ELECTRICAL SYSTEM 14 Finishing work – Mount the seat. ( p. 63) 14.3 Recharging the battery Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batteries. –...

  • Page 104: Changing The Main Fuse

    It is also impossible to overcharge the bat- tery with these battery chargers. The charging time may be longer at low temperatures. These battery chargers are only suitable for lithium iron phosphate batteries. Read the accompanying KTM Pow- erParts instructions. Info Never remove cover –...
  • Page 105 ELECTRICAL SYSTEM 14 Main work – Pull starter relay from the holder. S02303-10 – Take off protection caps – Remove faulty main fuse Info You can recognize a faulty fuse by a burned-out fuse wire A spare fuse is located in the starter relay. –...

  • Page 106: 15 Cooling System

    15 COOLING SYSTEM 15.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 107: Checking The Coolant Level

    COOLING SYSTEM 15 15.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 108: Refilling Coolant

    15 COOLING SYSTEM Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...

  • Page 109: Changing The Coolant

    COOLING SYSTEM 15 15.6 Changing the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 110: Tuning The Engine

    16 TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Throttle cable play 3 …...
  • Page 111 TUNING THE ENGINE 16 Main work (All SX‑F models) – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut – Push cold start button all the way to the stop.
  • Page 112 16 TUNING THE ENGINE 16.3 Adjusting the characteristic map of the throttle response Info On the throttle grip, the characteristic map of the throttle response is changed by changing the guide plate. A guide plate with a different characteristic map is supplied. Main work –...

  • Page 113: Changing The Mapping

    16.5 Adjusting the idle speed Warning Danger of accidents The engine may go out spontaneously if the idle speed is set too low. – Set the idle speed to the specified value. (Your authorized KTM workshop will be glad to help.)

  • Page 114: Teaching The Throttle Valve Position

    16 TUNING THE ENGINE – Run the engine until warm. The cold start button is deactivated – The cold start but- ton is in its basic position. ( p. 20) Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. –...

  • Page 115: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 16 16.7 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load. –...

  • Page 116: Service Work On The Engine

    17 SERVICE WORK ON THE ENGINE 17.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...
  • Page 117 SERVICE WORK ON THE ENGINE 17 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 118: Checking The Engine Oil Level

    17 SERVICE WORK ON THE ENGINE 17.2 Checking the engine oil level Info The engine oil level can be checked when the engine is cold or warm. Preparatory work – Stand the motorcycle upright on a horizontal surface. Condition The engine is cold. –...
  • Page 119 SERVICE WORK ON THE ENGINE 17 Main work – Place a suitable container under the engine. – Remove oil drain plug with the magnet and seal ring. Info Do not remove screws E01240-10 – Remove screw plug with oil screen and the O-rings.
  • Page 120 17 SERVICE WORK ON THE ENGINE – Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) – Completely drain the engine oil. – Thoroughly clean the parts and sealing surfaces. E01245-10 – Lay the motorcycle on its side and fill the oil filter housing to about ⅓...

  • Page 121: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 17 17.4 Adding engine oil Info Too little engine oil or poor-quality engine oil will result in premature wear of the engine. – Remove oil filler plug with the O-ring from the clutch cover. – Add the same engine oil used when the last oil change was carried out.

  • Page 122: Cleaning, Care

    18 CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...
  • Page 123 CLEANING, CARE 18 – After the motorcycle has cooled off, lubricate all moving parts and bearings. – Clean the chain. ( p. 73) – Treat bare metal parts (except for brake discs and the exhaust system) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p.

  • Page 124: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with a lift stand. ( p. 50) –...

  • Page 125: Putting Into Operation After Storage

    STORAGE 19 Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and the exhaust system to rust.

  • Page 126: 20 Troubleshooting

    – Check the electrical system. – Defect in fuel injection system Read out the fault memory using the KTM diagnostics tool. – Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diagnostics tool.
  • Page 127 – Read out the fault memory using the KTM diagnostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary.

  • Page 128: 21 Blink Code

    21 BLINK CODE Blink code for malfunction indicator lamp 02a Malfunction indicator lamp flashes 2x per second Error level condition Teaching of throttle valve position required Blink code for malfunction indicator lamp 02 Malfunction indicator lamp flashes 2x short Crankshaft position sensor – circuit fault Error level condition Blink code for malfunction indicator lamp...
  • Page 129 BLINK CODE 21 Blink code for malfunction indicator lamp 33 Malfunction indicator lamp flashes 3x long, 3x short Injection valve cylinder 1 – circuit fault Error level condition Blink code for malfunction indicator lamp 37 Malfunction indicator lamp flashes 3x long, 7x short Ignition coil –...

  • Page 130: 22 Technical Data

    22 TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 249.91 cm³ (15.2505 cu in) Stroke 52.3 mm (2.059 in) Bore 78 mm (3.07 in) Compression ratio 14.4:1 Idle speed 2,250 … 2,350 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 32.5 mm (1.28 in)

  • Page 131: Engine Tightening Torques

    TECHNICAL DATA 22 22.2 Engine tightening torques Nozzle, crank chamber ventilation 2 Nm (1.5 lbf ft) Loctite ® 243™ Oil nozzle for alternator cooling 2 Nm (1.5 lbf ft) Loctite ® 243™ Oil nozzle for balancer shaft lubri- 2 Nm (1.5 lbf ft) Loctite ®...
  • Page 132 22 TECHNICAL DATA Screw, shift lever 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, starter motor 10 Nm (7.4 lbf ft) Screw, timing chain guide rail 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, timing chain securing guide M6 10 Nm (7.4 lbf ft) Loctite ®...

  • Page 133: Capacities

    TECHNICAL DATA 22 Fixing nut for main bearing inner M27x1 60 Nm (44.3 lbf ft) Loctite ® 243™ ring 22.3 Capacities 22.3.1 Engine oil Engine oil 1.0 l (1.1 qt.) Engine oil (SAE 10W/50) p. 138) 22.3.2 Coolant Coolant 0.95 l (1 qt.) Coolant ( p.

  • Page 134: Electrical System

    110/100 - 18 64M TT Dunlop GEOMAX AT81F Dunlop GEOMAX AT81 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork 22.7.1 SX‑F EU Fork article number 34.18.8S.05...

  • Page 135: Sx-F Us

    TECHNICAL DATA 22 Oil capacity, right cartridge 380 ml (12.85 fl. oz.) Fork oil (SAE 4) (48601166S1) p. 139) Grease capacity, left cartridge 5 g (0.18 oz) Multi-purpose grease (00062010051) ( p. 140) 22.7.2 SX‑F US Fork article number 34.18.8S.55 Fork WP Suspension Upside down AER 48 Compression damping...

  • Page 136: Sx-F Eu

    22 TECHNICAL DATA Grease capacity, left cartridge 5 g (0.18 oz) Multi-purpose grease (00062010051) ( p. 140) 22.8 Shock absorber 22.8.1 SX‑F EU Shock absorber article number 18.18.7S.05 Shock absorber WP Suspension 5018 DCC Link Compression damping, low-speed Comfort 17 clicks Standard 15 clicks Sport...

  • Page 137: Xc-F Us

    TECHNICAL DATA 22 Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 9 mm (0.35 in) Spring rate Weight of rider: 65 … 75 kg (143 … 165 lb.) 39 N/mm (223 lb/in) Weight of rider: 75 … 85 kg (165 … 187 lb.) 42 N/mm (240 lb/in) Weight of rider: 85 …...

  • Page 138: Chassis Tightening Torques

    22 TECHNICAL DATA 22.9 Chassis tightening torques EJOT PT Screw, air filter box cover ® K60x20-Z 3 Nm (2.2 lbf ft) EJOT PT Screw, combination switch ® K50x18 T20 2 Nm (1.5 lbf ft) EJOT DELTA PT ® Screw, intake air temperature sen- 45x12‑Z 0.7 Nm (0.52 lbf ft) EJOT PT...
  • Page 139 TECHNICAL DATA 22 Screw, front brake caliper 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, handlebar clamp 20 Nm (14.8 lbf ft) Screw, manifold on cylinder head 15 Nm (11.1 lbf ft) brace Screw, subframe 35 Nm (25.8 lbf ft) Loctite ®...

  • Page 140: Substances

    23 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 Motorex ®...
  • Page 141 SUBSTANCES 23 Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 142) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –...

  • Page 142: Auxiliary Substances

    24 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...
  • Page 143 AUXILIARY SUBSTANCES 24 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 ® – Quick Cleaner Universal oil spray Recommended supplier Motorex ®...

  • Page 144: Standards

    25 STANDARDS JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 145: Adjusting The Play In The Throttle

    INDEX OF SPECIAL TERMS 26 Launch control Vehicles electronics functions for achieving the best possible acceleration from a standing position On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics...

  • Page 146: Adjusting The Characteristic Map Of

    27 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 147: List Of Symbols

    LIST OF SYMBOLS 28 28.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols. Malfunction indicator lamp lights up/flashes orange – The OBD has detected an error in the vehicle electronics.

  • Page 148: Index

    INDEX Chain tension INDEX adjusting ......75 Accessories ......10 checking .
  • Page 149 INDEX opening ......18 Foot brake lever ......22 Kill switch .
  • Page 150 INDEX Rear wheel Storage ......122 installing ......96 Swingarm removing .
  • Page 151 *3213849en* 3213849en 03/2018 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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