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KTM F8201W5 Owner's Manual

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OWNER'S MANUAL
2023
350 SX-F
350 XC‑F
Art. no. 3214641en

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Summary of Contents for KTM F8201W5

  • Page 1 OWNER'S MANUAL 2023 350 SX-F 350 XC‑F Art. no. 3214641en...
  • 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 vehicle which, with appropriate care, will bring you pleasure for a long time to come. We wish you good and safe riding at all times! Enter the serial numbers of your vehicle below.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS PREPARING FOR USE......... 21 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 Advice on preparing for first use ..21 Symbols used ........5 Running in the engine ...... 22 Formats used........5 Starting power of lithium-ion SAFETY ADVICE..........
  • Page 5 TABLE OF CONTENTS 10.9 Checking the riding sag of the shock 11.32 Installing the fuel tank ....70 absorber.......... 40 11.33 Checking for chain dirt 10.10 Adjusting the spring preload of the accumulation........71 shock absorber ......41 11.34 Cleaning the chain ......71 10.11 Adjusting the riding sag ....
  • Page 6 TABLE OF CONTENTS 14.4 Changing the main fuse ....102 22.4 Chassis ......... 131 14.5 Changing the fuse of the fuel 22.5 Electrical system......132 pump..........103 22.6 Tires ..........132 14.6 Diagnostics connector ....104 22.7 Fork..........133 22.7.1 SX‑F EU/AR ......

  • Page 7: Means Of Representation 1

    Indicates work that requires expert knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be cared for there to the highest degree by specially trained experts using the special tools required.

  • Page 8: Safety Advice

    2 SAFETY ADVICE Use definition – intended use (All SX‑F models) This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations. Info Only operate this vehicle in closed-off areas remote from public road traffic.

  • Page 9: Tampering Warning

    Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides. – 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.

  • Page 10: Work Rules

    The Owner's Manual can be downloaded several times using the QR code or the link on the delivery certificate. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. A printed copy can also be ordered from your authorized KTM dealer.

  • Page 11: Important Notes 3

    Manufacturer warranty, implied warranty The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con- firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

  • Page 12: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) S05319-01 Hand brake lever ( p. 14) Clutch lever ( p. 14) Fuel tank filler cap Air filter box cover Cold start button ( p. 18) Shift lever ( p. 19)

  • Page 13: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) S05320-01 Shock absorber compression adjuster Combination switch ( p. 15) Stop button ( p. 14) Start button ( p. 15) Throttle grip ( p. 14) Vehicle identification number ( p. 12) Steering head label ( p.

  • Page 14: Serial Numbers

    5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Steering head label The steering head label is attached 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 15: Shock Absorber Article Number

    SERIAL NUMBERS 5 Shock absorber article number The shock absorber article number is stamped on the top of the shock absorber. F03756-10...

  • Page 16: 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. F03647-10 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. F03648-10 Throttle grip The throttle grip...

  • Page 17: Start Button

    CONTROLS 6 Start button Start button is fitted on the right side of the handlebar. Possible states • The start button is in the basic position is pressed – In this position, the starter • The start button motor is actuated. F03650-10 Combination switch The combination switch is fitted on the left side of the handlebar.

  • Page 18: Combination Instrument

    6 CONTROLS Combination instrument The combination instrument is attached in front of the handle- bar. The combination instrument shows the total number of operating hours of the engine. The operating hour counter begins counting when the engine is started and stops when the engine is switched off. Info Nothing can be cleared or adjusted on the combination instrument.

  • Page 19: Closing The Fuel Tank Filler Cap

    CONTROLS 6 (XC‑F US) – Press release button , turn the fuel tank filler cap coun- terclockwise, and lift it off. S05374-10 6.10 Closing the fuel tank filler cap (All SX‑F models) – Mount fuel tank filler cap and turn it clockwise until the fuel tank is tightly closed.

  • Page 20: Cold Start Button

    6 CONTROLS 6.11 Cold start button The cold start button is fitted to the bottom of the throttle valve body. The electronic fuel injection system extends the injection time if the engine is cold and the ambient temperature is low. To help the engine burn the increased fuel quantity, it must be supplied with additional oxygen by pushing the cold start button.

  • Page 21: Shift Lever

    CONTROLS 6 6.13 Shift lever Shift lever is mounted on the left side of the engine. 401950-10 (All SX‑F models) The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears.

  • Page 22: Plug-In Stand (All Sx-F Models)

    6 CONTROLS 6.15 Plug-in stand (All SX‑F models) The support for plug-in stand is the left side of the wheel spin- dle. The plug-in stand is used to park the motorcycle. The plug-in stand is used as a fork locker when transporting the motorcycle.

  • Page 23: Preparing For Use 7

    When using the motorcycle, remember that others may be disturbed by excessive noise. – Ensure that the pre-sales inspection work has been carried out by an authorized KTM workshop. You will receive a delivery certificate when the vehicle is handed over.

  • Page 24: Running In The Engine

    7 PREPARING FOR USE – Adjust the basic position of the foot brake lever. p. 87) – Adjust the basic position of the shift lever. p. 114) – Get used to the handling characteristic of the motorcycle on suitable terrain before undertaking a more chal- lenging ride.

  • Page 25: Preparing The Vehicle For Difficult Operating Conditions

    Preparing the vehicle for rides on dry sand – Mount the air filter dust cover. Air filter dust cover (A46006920000) Info Observe the fitting instructions for KTM PowerParts. F03669-01 – Mount the air filter sand cover. Air filter sand cover (A46006922000) Info Observe the fitting instructions for KTM PowerParts.

  • Page 26: Preparing The Vehicle For Rides On Wet Sand

    600868-01 Preparing the vehicle for rides on wet sand – Mount the air filter rain cover. Air filter rain cover (A46006921000) Info Observe the fitting instructions for KTM PowerParts. F03668-01 – Clean the chain. Chain cleaner ( p. 141) –...

  • Page 27: Preparing Vehicle For High Temperatures Or Slow Riding

    Straighten bent radiator fins carefully. – Check the coolant level. ( p. 106) Preparing the vehicle for low temperatures or snow – Mount the air filter rain cover. Air filter rain cover (A46006921000) Info Observe the fitting instructions for KTM PowerParts. F03668-01...

  • Page 28: 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 29: Activating Launch Control

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

  • Page 30: Activating Traction Control

    8 RIDING INSTRUCTIONS – Press and hold the TC button and the QS button simultaneously. The TC indicator lamp and the QS indicator lamp flash when launch control is activated. Info The launch control is deactivated automatically for a few seconds after the vehicle has started. Launch control is also deactivated in the following cases: if the throttle valve is closed more than 1/3 of F03760-13...

  • Page 31: Quickshifter (All Sx-F Models)

    Do not change into a low gear at high engine speed. Info If unusual noises occur while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First-gear is used for starting off and for steep inclines. –...

  • Page 32: Applying The Brakes

    Warning Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)

  • Page 33: Stopping, Parking

    RIDING INSTRUCTIONS 8 Warning Danger of accidents Moisture and dirt impair the brake system. – Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs. – On sandy, wet, or slippery surfaces, use mostly the rear brake. –...

  • Page 34: Transporting

    8 RIDING INSTRUCTIONS 8.11 Transporting Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive.
  • Page 35 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.) Note Environmental hazard Improper handling of fuel is a danger to the environment.

  • Page 36: Service Schedule

    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 37 ● ● Take a test ride. ○ ● ● ● ● Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● ● Make a service entry in KTM Dealer.net. ○ One-time interval ●...

  • Page 38: 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 39: 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 compression adjuster can be seen in slow to normal compression of the shock absorber.

  • Page 40: 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 compression adjuster can be seen in the fast compression of the shock absorber.

  • Page 41: Measuring The Dimension Of The Rear Wheel Unloaded

    TUNING THE CHASSIS 10 – Turn adjuster clockwise up to the last perceptible click. – Turn counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping (SX‑F EU/AR) Comfort 17 clicks Standard 15 clicks Sport 13 clicks F03640-10 Rebound damping (SX‑F US)

  • Page 42: Checking The Static Sag Of The Shock Absorber

    10 TUNING THE CHASSIS 10.8 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 39) – Hold the motorcycle upright with aid of an assistant. – Measure the distance again between the rear axle and mark- ing SAG on the rear fender using the sag gage.

  • Page 43: Adjusting The Spring Preload 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 Note the current adjustment before changing the spring preload - e.g. measure the spring length.

  • Page 44: Adjusting The Riding Sag

    10 TUNING THE CHASSIS – Install the main silencer. ( p. 67) 10.11 Adjusting the riding sag Preparatory work – Remove main silencer. ( p. 67) – Raise the motorcycle with a lift stand. ( p. 49) – Remove the shock absorber. p.

  • Page 45: Checking The Basic Setting Of The Fork

    TUNING THE CHASSIS 10 10.12 Checking the basic setting of the fork Info For various reasons, no exact riding sag can be determined for the fork. – Smaller differences in the rider's weight can be compensated for by the fork air pressure. –...

  • Page 46: Adjusting The Compression Damping Of The Fork

    10 TUNING THE CHASSIS 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/AR)

  • Page 47: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS 10 Guideline Compression damping (SX‑F EU/AR) Comfort 17 clicks Standard 12 clicks Sport 7 clicks Compression damping (SX‑F US) Comfort 17 clicks Standard 12 clicks Sport 7 clicks Compression damping (XC‑F US) Comfort 17 clicks Standard 12 clicks Sport 7 clicks Info...

  • Page 48: Handlebar Position

    10 TUNING THE CHASSIS Info Turn clockwise to increase the damping; turn counter- clockwise to reduce damping when the shock absorber rebounds. 10.16 Handlebar position The holes on the handlebar support are placed at a distance from the center. Hole distance A 3.5 mm (0.138 in) The handlebar can be mounted in 2 different positions.
  • Page 49 TUNING THE CHASSIS 10 Main work – Remove screws . Take off handlebar clamp . Take off the handlebar and lay it to one side. Info Cover the components to protect them against damage. Do not kink the cables and lines. –...
  • Page 50 10 TUNING THE CHASSIS Adjusting the handlebar position with the handlebar clamp – Place the handlebar support in the required position. Info The handlebar support is longer and higher on one side. – Mount and tighten the screws with the bushings Guideline Screw, handle- 40 Nm (29.5 lbf ft)

  • Page 51: Service Work On The Chassis 11

    SERVICE WORK ON THE CHASSIS 11 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 52: Bleeding The Fork Legs

    11 SERVICE WORK ON THE CHASSIS (XC‑F US) – Remove the motorcycle from the lift stand. – Remove the lift stand. – To park the motorcycle, press side stand to the ground with your foot and lean the motorcycle on it. Info When you are riding, the side stand must be folded up and secured with the rubber strap.

  • Page 53: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11 Universal oil spray ( p. 142) – Press the dust boots back into their installation position. – Remove excess oil. Finishing work – Install the fork protector. ( p. 51) – Remove the motorcycle from the lift stand. ( p.

  • Page 54: Installing The Fork Legs

    11 SERVICE WORK ON THE CHASSIS – Loosen screws . Remove the left fork leg. – Loosen screws . Remove the right fork leg. S05331-10 11.8 Installing the fork legs Main work – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front.

  • Page 55: Removing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11 11.9 Removing the lower triple clamp Preparatory work – Raise the motorcycle with a lift stand. ( p. 49) – Remove the front wheel. p. 93) – Remove the fork legs. p. 51) – Remove the start number plate.
  • Page 56 11 SERVICE WORK ON THE CHASSIS – Position the upper triple clamp and handlebar. – Mount screw , but do not tighten it yet. Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head S05332-11 – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front.

  • Page 57: 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 vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.

  • Page 58: Adjusting The Steering Head Bearing Play

    11 SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable on the steering head bearing. » If there is detectable play: –...

  • Page 59: Lubricating The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS 11 11.13 Lubricating the steering head bearing – Remove the lower triple clamp. p. 53) – Install the lower triple clamp. p. 53) Info The steering head bearing is cleaned and lubricated in the course of removal and installation of the lower triple clamp.

  • Page 60: Installing Front Fender

    11 SERVICE WORK ON THE CHASSIS Main work – Remove screws . Take off the front fender. S05339-10 11.17 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis S05339-10 Finishing work...

  • Page 61: Removing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 11.18 Removing the shock absorber Preparatory work – Remove main silencer. ( p. 67) – Raise the motorcycle with a lift stand. ( p. 49) Main work – Remove the cable ties. – Remove screws with the washers.

  • Page 62: Installing The Shock Absorber

    11 SERVICE WORK ON THE CHASSIS – Remove nut and the swingarm pivot. – Push the link fork back and secure it against falling over. S05345-10 – Hold the shock absorber and remove screw – Remove the shock absorber carefully at the bottom. S05346-10 11.19 Installing the shock absorber...
  • Page 63 SERVICE WORK ON THE CHASSIS 11 – Position the foot brake cylinder. Push rod engages in the foot brake cylinder. Info Ensure that the dust boot is correctly seated. – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) S05356-10 chassis –...

  • Page 64: Removing The Seat

    11 SERVICE WORK ON THE CHASSIS 11.20 Removing the seat 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. – Remove screw S05350-10 –...

  • Page 65: Removing The Air Filter Box Cover

    SERVICE WORK ON THE CHASSIS 11 – Mount and tighten screw Guideline Screw, seat fixing 8 Nm (5.9 lbf ft) S05350-10 11.22 Removing the air filter box cover Condition The air filter box cover is secured. – Remove screw S05353-10 –...

  • Page 66: Installing The Air Filter Box Cover

    11 SERVICE WORK ON THE CHASSIS 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 Info An air filter box cover with openings for greater air- flow and a more direct response is included.

  • Page 67: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 11.24 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter. – Only operate the vehicle if it is equipped with an air filter. Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 68: Installing The Air Filter

    11 SERVICE WORK ON THE CHASSIS Finishing work – Install the air filter. p. 66) – Install the air filter box cover. ( p. 64) 11.26 Installing the air filter Main work – Mount the clean air filter on the air filter support. Info The marking on the air filter support must face upwards.

  • Page 69: Preparing Air Filter Box Cover For Securing

    SERVICE WORK ON THE CHASSIS 11 11.27 Preparing air filter box cover for securing Preparatory work – Remove the air filter box cover. ( p. 63) Main work – Drill a hole at marking Guideline Diameter 6 mm (0.24 in) F03679-10 Finishing work –...

  • Page 70: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    11 SERVICE WORK ON THE CHASSIS 11.30 Changing the glass fiber yarn filling of 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 before performing any work on the vehicle. Info Over time, the fibers of the glass fiber yarn filling escape and the damper "burns"...
  • Page 71 SERVICE WORK ON THE CHASSIS 11 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. –...

  • Page 72: Installing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS – Pull both spoilers laterally off the radiator and lift off the fuel tank. S05361-10 11.32 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. –...

  • Page 73: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS 11 – Mount and tighten screw with the rubber bushing. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis S05377-11 – Plug in fuel pump connector – Remove the wash cap set. Clean the quick release coupling thoroughly with compressed air.

  • Page 74: Checking The Chain Tension

    11 SERVICE WORK ON THE CHASSIS Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info The service life of the chain depends largely on its maintenance. Preparatory work –...

  • Page 75: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 Finishing work – Remove the motorcycle from the lift stand. ( p. 49) 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.

  • Page 76: 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. 49) Main work – Shift the transmission into neutral. – Check the chain, rear sprocket and engine sprocket for wear. »...
  • Page 77 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 78: Checking The Frame

    If the link fork exhibits damage, cracking, or deformation: – Change the link fork. Info Always replace a damaged link fork. Repairing the link fork is not authorized by KTM. F03646-01 11.40 Checking the throttle cable routing Warning Danger of accidents The throttle cable can become kinked, trapped or blocked if it is not routed cor- rectly.

  • Page 79: 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 rubber strap of the fuel tank support.

  • Page 80: Programming The Quickshifter (All Sx-F Models)

    11 SERVICE WORK ON THE CHASSIS 11.42 Programming the quickshifter (All SX‑F models) Info If the shifting performance of the quickshifter starts to decrease, it must be reprogrammed. – Carry out start procedure. ( p. 26) – Press and hold the QS button for at least 10 seconds.

  • Page 81: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 11 Info The fluid level rises with increasing wear of the clutch facing discs. Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts.
  • Page 82 11 SERVICE WORK ON THE CHASSIS – Move the hydraulic clutch fluid reservoir mounted on the han- dlebar into a horizontal position. – Remove screws – Take off cover with membrane H04933-10 – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 83: 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 84: 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 85: 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 86: 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 87 – 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.) Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect.
  • Page 88 12 BRAKE SYSTEM Info Do not operate the hand brake lever if the brake caliper has been removed. – Remove cotter pins , pull out pin , and remove the brake linings. – Clean the brake caliper and the brake caliper bracket. F03696-10 –...

  • Page 89: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 12 – Add brake fluid up to level Guideline 5 mm (0.2 in) Level (brake fluid level below reservoir rim) Brake fluid DOT 4 / DOT 5.1 ( p. 139) – Position cover with membrane – Mount and tighten screws Info Use water to immediately clean up any brake fluid that has overflowed or spilled.

  • Page 90: 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 91: Adding Rear 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 92: 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 93 – 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.) Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect.
  • Page 94 12 BRAKE SYSTEM – Manually press the brake caliper toward the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir; extract some if necessary. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston.

  • Page 95: Wheels, Tires 13

    WHEELS, TIRES 13 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 49) Main work – Manually press the brake caliper toward the brake disc 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 pistons.

  • Page 96: Installing The Front Wheel

    13 WHEELS, TIRES 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 97: Installing The Rear Wheel

    WHEELS, TIRES 13 Main work – Manually press the brake caliper toward the brake disc to push back the brake piston. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston. –...
  • Page 98 13 WHEELS, TIRES 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 99: 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 100: Checking The 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 101: Electrical System 14

    ELECTRICAL SYSTEM 14 14.1 Removing the 12-V 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 12 V batteries contain environmentally hazardous materials. –...

  • Page 102: Installing The 12-V Battery

    14 ELECTRICAL SYSTEM 14.2 Installing the 12-V battery Main work – Pull up the battery holding bracket , insert the 12-V bat- tery into the battery compartment with the terminals facing upwards and secure with the battery holding bracket 12-V battery (HJTZ5S-FP-C) ( p.

  • Page 103: Charging The 12-V Battery

    ELECTRICAL SYSTEM 14 14.3 Charging the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V batteries. – Only charge 12 V batteries in well-ventilated rooms.

  • Page 104: Changing The Main Fuse

    It is also impossible to overcharge the 12 V battery 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: Changing The Fuse Of The Fuel Pump

    ELECTRICAL SYSTEM 14 Main work – Pull starter relay from the holder. F03751-10 – Take off protection caps – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the starter relay. –...

  • Page 106: Diagnostics Connector

    14 ELECTRICAL SYSTEM Main work – Take off protection cap – Remove the faulty fuse Info A faulty fuse has a burned-out fuse wire – Insert the new fuse for the fuel pump. Fuse (58011109105) ( p. 132) – Check that the electrical system is functioning properly. –...

  • Page 107: Cooling System 15

    COOLING SYSTEM 15 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 108: Checking The Coolant Level

    15 COOLING SYSTEM 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 109: Refilling With Coolant

    COOLING SYSTEM 15 Warning Danger of poisoning Coolant is harmful to health. – 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 110: Changing The Coolant

    15 COOLING SYSTEM 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 111: Tuning The Engine 16

    TUNING THE ENGINE 16 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 Play in throttle cable 3 …...

  • Page 112: Adjusting The Characteristic Map Of The Throttle Response

    16 TUNING THE ENGINE 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 113 TUNING THE ENGINE 16 – Remove guide plate from handle tube – Position the required guide plate on the grip tube. Guideline The label OUTSIDE must be visible. Marking must be positioned at marking Black guide plate (A46002014000) Alternative 1 Gray guide plate (A48002014000) Info The gray guide plate opens the throttle valve more...

  • Page 114: 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 115: Programming The Throttle Valve Position

    TUNING THE ENGINE 16 – Run the engine until warm. The cold start button is deactivated – The cold start but- ton is in its basic position. ( p. 18) Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. –...

  • Page 116: Checking The Basic Position Of The Shift Lever

    16 TUNING THE ENGINE 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. If the shift lever is permanently touching the boot, the transmission will be subject to excessive load; this can cause a malfunction of the quickshifter.

  • Page 117: Service Work On The Engine 17

    SERVICE WORK ON THE ENGINE 17 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 fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 118: Checking The Engine Oil Level

    17 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.
  • Page 119 SERVICE WORK ON THE ENGINE 17 Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Drain the engine oil while the engine is at operating temperature. Preparatory work –...
  • Page 120 17 SERVICE WORK ON THE ENGINE – Remove screws . Take off the oil filter cover with the O- ring. H04995-10 – Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) – Allow the engine oil to drain completely. –...

  • Page 121: Adding Engine Oil

    Engine oil (SAE 10W/50) ( p. 139) Info For optimal performance of the engine oil, do not mix different types of engine oil. KTM recommends changing the engine oil where neces- 401955-10 sary. – Mount and tighten the filler plug together with the O-ring.

  • Page 122: 18 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 down, lubricate all moving parts and pivot points. – Clean the chain. ( p. 71) – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p.

  • Page 124: 19 Storage

    97) – 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. 49) – Cover the vehicle with a tarp or similar cover that is permeable to air.

  • Page 125: Putting Into Operation After Storage

    STORAGE 19 19.2 Putting into operation after storage – Install the 12-V battery. p. 100) – Remove the motorcycle from the lift stand. ( p. 49) – Perform checks and maintenance measures when preparing for use. ( p. 26) – Take a test ride.

  • Page 126: 20 Troubleshooting

    – Check the electrical system. – Malfunction in the electronic Read out fault memory using the KTM fuel injection diagnostics tool. – Engine does not speed up Malfunction in the electronic Read out fault memory using the KTM fuel injection diagnostics tool.
  • Page 127 Check the wiring for damage and the lights up or flashes fuel injection electrical plug-in connections for corro- sion and damage. – Read out 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 Combination switch, left side – buttons pressed longer than 20 seconds Error level condition Blink code for malfunction indicator lamp Malfunction indicator lamp flashes continuously THREF – malfunction Error level condition Blink code for malfunction indicator lamp 02 Malfunction indicator lamp flashes 2x short Crankshaft speed sensor –...
  • 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 349.7 cm³ (21.34 cu in) Stroke 57.5 mm (2.264 in) Bore 88 mm (3.46 in) Compression ratio 14.6:1 Idle speed 2,250 … 2,350 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 36.3 mm (1.429 in)

  • Page 131: Engine Tightening Torques

    TECHNICAL DATA 22 22.2 Engine tightening torques Hose clip, intake flange 3 Nm (2.2 lbf ft) Nozzle, crank chamber ventilation 2 Nm (1.5 lbf ft) Loctite ® 243™ Oil nozzle for clutch lubrication 2 Nm (1.5 lbf ft) Loctite ® 243™...
  • Page 132 22 TECHNICAL DATA Screw, outer clutch cover M6x45 10 Nm (7.4 lbf ft) Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, shift lever 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, starter motor 10 Nm (7.4 lbf ft) Screw, starter motor - intermediate 10 Nm (7.4 lbf ft) gear...

  • Page 133: Capacities

    TECHNICAL DATA 22 Stud, cylinder head M10x1.25 20 Nm (14.8 lbf ft) Loctite ® 243™ Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) Screw plug, oil pressure control M12x1.5 20 Nm (14.8 lbf ft) valve Oil drain plug M14x1.5 15 Nm (11.1 lbf ft) Nut, inner clutch hub...

  • Page 134: Electrical System

    The tires specified represent one of the possible series production tires. For alternative manufacturers, if any, contact an authorized dealer or qualified tire dealership. If local road approval regulations apply, these and the respective technical specifications must be observed. Additional information is available in the Service section under: KTM.COM...

  • Page 135: Fork

    TECHNICAL DATA 22 22.7 Fork 22.7.1 SX‑F EU/AR Fork article number A460C107W406000 WP XACT 5448 Fork Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Air pressure 10.3 bar (149 psi) Fork length 950 mm (37.4 in)

  • Page 136: Xc-F Us

    22 TECHNICAL DATA 22.7.3 XC‑F US Fork article number A460C177W406000 Fork WP XACT 5448 Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Air pressure 9.9 bar (144 psi) Fork length 950 mm (37.4 in) Oil capacity external mechanism...

  • Page 137: Sx-F Us

    TECHNICAL DATA 22 Static sag 35 mm (1.38 in) Riding sag 105 mm (4.13 in) Fitted length 456.3 mm (17.965 in) Shock absorber oil Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 140) 22.8.2 SX‑F US Shock absorber article number A460C457W408000 Shock absorber WP XACT 5750...

  • Page 138: Chassis Tightening Torques

    22 TECHNICAL DATA Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 8 mm (0.31 in) Spring rate Weight of rider: 65 … 75 kg (143 … 165 lb.) 42 N/mm (240 lb/in) Weight of rider: 75 … 85 kg (165 … 187 lb.) 45 N/mm (257 lb/in) Weight of rider: 85 …...
  • Page 139 TECHNICAL DATA 22 Screw, ball joint of push rod on 10 Nm (7.4 lbf ft) foot brake cylinder Loctite ® 243™ Screw, battery support bracket 6 Nm (4.4 lbf ft) Screw, brake line guide on link 6 Nm (4.4 lbf ft) fork Screw, chain guide on link fork at M6x45...
  • Page 140 22 TECHNICAL DATA Remaining screws, chassis 45 Nm (33.2 lbf ft) Screw, bottom shock absorber 60 Nm (44.3 lbf ft) Loctite ® 2701™ Screw, handlebar support 40 Nm (29.5 lbf ft) Loctite ® 243™ Screw, top shock absorber 60 Nm (44.3 lbf ft) Loctite ®...

  • Page 141: Substances 23

    SUBSTANCES 23 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 142 23 SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 143) (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 143: Auxiliary Substances 24

    AUXILIARY SUBSTANCES 24 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 144 24 AUXILIARY SUBSTANCES Silicone spray Recommended supplier MOTOREX ® – Silicone Spray Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier MOTOREX ® – Quick Cleaner Special grease (00062010053) Recommended supplier Klüber Lubrication ® – KLÜBERFOOD NH1 34‑401 Universal oil spray Recommended supplier...

  • Page 145: Standards 25

    STANDARDS 25 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 146: 26 Index Of Special Terms

    26 INDEX OF SPECIAL TERMS 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 Quickshifter Function of the engine electronics for shifting up with- out clutch actuation Traction Control Auxiliary function of the motor control that reduces...

  • Page 147: List Of Abbreviations 27

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

  • Page 148: 28 List Of Symbols

    28 LIST OF SYMBOLS 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 a malfunction in the vehicle electronics.

  • Page 149: Index

    INDEX Chain guide INDEX checking ......74 12-V battery Chain tension installing ......100 adjusting .
  • Page 150 INDEX Foot brake lever ......19 Indicator lamps basic position, adjusting ....87 overview .
  • Page 151 INDEX Putting into operation Start number plate after storage ..... . 123 installing ......57 removing .
  • Page 152 *3214641en* 3214641en 26.04.2022 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.COM...

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