KTM 450 XC-F Owner's Manual
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- Owner's manual (110 pages) ,
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- Owner's manual (107 pages)
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Table of Contents
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Summary of Contents for KTM 450 XC-F
- Page 1 OWNER'S MANUAL 2016 450 SX‑F 450 XC‑F Art. no. 3213333en...
- Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.
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Page 4: Table Of Contents
TABLE OF CONTENTS Preparing for rides at low temperatures or in TABLE OF CONTENTS MEANS OF REPRESENTATION ........4 snow.............. 19 Symbols used ........... 4 RIDING INSTRUCTIONS..........20 Formats used............ 4 Checks and maintenance work when preparing SAFETY ADVICE............5 for use ............ - Page 5 TABLE OF CONTENTS 11.21 Mounting the seat ........... 47 15.2 Checking the antifreeze and coolant level ..78 11.22 Removing the air filter box lid ......47 15.3 Checking the coolant level ....... 78 11.23 Installing the air filter box lid ......48 15.4 Draining the coolant ........
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Page 6: Means Of Representation
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. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required. -
Page 7: Safety Advice
Use definition - intended use (All SX‑F models) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations. -
Page 8: Safe Operation
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer. -
Page 9: Important Notes
Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM Dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle. -
Page 10: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) S00845-10 Kill switch ( p. 11) Clutch lever ( p. 11) Filler cap Air filter box lid Chain guide Cold start button ( p. 14) Shift lever ( p. 14) -
Page 11: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) S00844-10 Electric starter button ( p. 11) Map‑Select switch for vehicle operation ( p. 12) Hand brake lever ( p. 11) Fork part number ( p. 10) Foot brake lever ( p. -
Page 12: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. 401945-10 Type label The type label is fixed to the front of the steering head. 401946-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket. -
Page 13: Controls
CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 102124-10 Hand brake lever Hand brake lever is located on the right side of the handlebar. The hand brake lever is used to activate the front brake. -
Page 14: Map-Select Switch For The Basic Setting (All Sx-F Models)
CONTROLS Map‑Select switch for the basic setting (All SX‑F models) The Map‑Select switch for basic setting is fitted under the air filter box lid. Possible states SOFT – The mapping with reduced peak performance for better ride- ability is activated. The Launch Control can be activated. ADVANCED –... -
Page 15: Opening The Filler Cap
CONTROLS 6.10 Opening the filler cap Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –... -
Page 16: Cold Start Button
CONTROLS 6.12 Cold start button The cold start button (yellow) 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. To help the engine burn the increased amount of fuel, it must be supplied with additional oxygen by pushing the cold start button. -
Page 17: Foot Brake Lever
CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-13 6.15 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 6.16 Plug-in stand (All SX‑F models) -
Page 18: Preparing For Use
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service booklet at vehicle handover. -
Page 19: Running In The Engine
PREPARING FOR USE (All SX‑F models) – Do not take luggage along. (XC‑F US) – If you carry any luggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels. -
Page 20: Preparing For Rides On Dry Sand
– Fit a dust cover on the air filter. Dust protection device for air filter (79006920000) Info See the KTM PowerParts fitting instructions. 102136-01 – Fit a sand cover on the air filter. Sand protection device for air filter (79006922000) Info See the KTM PowerParts fitting instructions. -
Page 21: Preparing For Rides On Wet And Muddy Surfaces
Preparing for rides on wet and muddy surfaces – Fit a waterproofing device on the air filter. Waterproofing device for air filter (79006921000) Info See the KTM PowerParts fitting instructions. 102137-01 – Fit the steel sprocket. – Clean the motorcycle. ( p. -
Page 22: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p. 85) –... -
Page 23: Activating Launch Control
Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines. -
Page 24: Applying The Brakes
Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. – Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system. -
Page 25: Transport
– In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards. -
Page 26: Service Schedule
Final check: Check the vehicle for safe operation and take a test ride. ○ ● ● ● Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. -
Page 27: Recommended Work
SERVICE SCHEDULE ○ One-time interval ● Periodic interval Recommended work Annually Every 100 operating hours Every 50 operating hours Every 40 operating hours Once after 20 operating hours Once after 10 operating hours ● Change the front brake fluid. ● Change the rear brake fluid. -
Page 28: Tuning The Chassis
For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swingarm and frame, the basic settings of the suspension components must match the rider's weight. – As delivered, KTM offroad motorcycles are adjusted for an average rider's weight (with full protective clothing). Guideline Standard rider weight 75…... -
Page 29: Compression Damping Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. -
Page 30: Adjusting The Rebound Damping Of The Shock Absorber
Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) – ... -
Page 31: Measuring Rear Wheel Sag Unloaded
TUNING THE CHASSIS 10.7 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with a lift stand. ( p. 36) Main work – Position the sag gauge in the rear axle and measure the distance to marking SAG on the rear fender. -
Page 32: Checking The Riding Sag Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. -
Page 33: Adjusting The Riding Sag
TUNING THE CHASSIS – Remove the motorcycle from the lift stand. ( p. 36) 10.11 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 36) – Remove the shock absorber. p. 44) – After removing the shock absorber, clean it thoroughly. -
Page 34: Adjusting The Fork Air Pressure (Sx-F Eu)
S00861-10 Info This is due to the volume of the hose and not due to a defect in the fork pump or the fork. Read the accompanying KTM PowerParts instructions. – Adjust the air pressure as specified. Guideline Air pressure 10.8 bar (157 psi) -
Page 35: Adjusting The Rebound Damping Of The Fork
TUNING THE CHASSIS (SX‑F EU) – Turn adjusting screw clockwise all the way. Info The adjusting screw is located at the upper end of the right fork leg. – Turn counterclockwise by the number of clicks corresponding to the fork type. Guideline Compression damping S00860-10... -
Page 36: Handlebar Position
TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. – Mount protection caps (SX‑F US, XC‑F US) – Turn the red adjusting screw all the way clockwise. Info The adjusting screw is located at the upper end of the right fork leg. The rebound damping is located in the right fork leg REB (red adjusting screw). - Page 37 TUNING THE CHASSIS Main work – Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against damage. Do not kink the cables and lines. –...
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Page 38: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (78129955100) Neither wheel is in contact with the ground. -
Page 39: Cleaning The Dust Boots Of The Fork Legs
SERVICE WORK ON THE CHASSIS (SX‑F US, XC‑F US) – Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws. 402556-10 Finishing work – Remove the motorcycle from the lift stand. ( p. -
Page 40: Installing The Fork Protector
SERVICE WORK ON THE CHASSIS 11.6 Installing the fork protector – Position the fork protection on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the brake line and clamp. Mount and tighten screws –... -
Page 41: Removing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) – Tighten screws Guideline Screw, bottom triple clamp 12 Nm (8.9 lbf ft) 102150-11 – Position the brake caliper. Mount and tighten screws Guideline Loctite ®... -
Page 42: Installing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS 11.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 104) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. -
Page 43: Checking The Steering Head Bearing Play
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (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 dam-... -
Page 44: Adjusting The Play Of The Steering Head Bearing
SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with a lift stand. ( p. 36) Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. -
Page 45: Removing The Start Number Plate
SERVICE WORK ON THE CHASSIS 11.14 Removing the start number plate – Remove screw – Unhook the start number plate from the brake line and remove it. 102160-10 11.15 Installing the start number plate – Attach the start number plate to the brake line. –... -
Page 46: Installing The Front Fender
SERVICE WORK ON THE CHASSIS 11.17 Installing the front fender Main work – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 102162-10 Finishing work – Install the start number plate. ( p. -
Page 47: Installing The Shock Absorber
SERVICE WORK ON THE CHASSIS – Remove the connecting link of the chain. – Take off the chain. S00857-10 – Remove nut and pull out the swingarm pivot. – Push the swingarm back and secure it against falling over. 102166-10 –... -
Page 48: Removing The Seat
SERVICE WORK ON THE CHASSIS – Mount the chain. – Connect the chain with connecting link Guideline The closed side of the chain joint lock must face in the direction of travel. S00854-10 – Position the foot brake cylinder. ... -
Page 49: Mounting The Seat
SERVICE WORK ON THE CHASSIS – Raise the rear of the seat, push the seat back, and lift it off. 102174-01 11.21 Mounting the seat – Hook in the front of the seat at the collar bushing of the fuel tank, lower it at the rear and simultaneously push it forward. -
Page 50: Installing The Air Filter Box Lid
SERVICE WORK ON THE CHASSIS 11.23 Installing the air filter box lid – Insert the air filter box lid into upper area and clip it into the lower area K00189-10 Condition The air filter box lid is secured. –... -
Page 51: Installing The Air Filter
SERVICE WORK ON THE CHASSIS Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 104) Info Only press the air filter to dry it, never wring it out. –... -
Page 52: Sealing The Air Filter Box
SERVICE WORK ON THE CHASSIS 11.28 Sealing the air filter box Preparatory work – Remove the air filter box lid. ( p. 47) Main work – Seal the air filter box in marked area S00847-10 Finishing work – Install the air filter box lid. ( p. -
Page 53: Removing The Fuel Tank
SERVICE WORK ON THE CHASSIS Main work – Remove all screws on the main silencer. – Take off silencer cap and O-ring – Take off outer tube and O-ring – Pull glass fiber yarn filling off of inner tube –... -
Page 54: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS – Remove screws with the collar bushing. K00225-10 – Remove screw with the rubber bushing. K00226-10 – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. 102185-01 11.33 Installing the fuel tank... -
Page 55: Checking For Chain Dirt Accumulation
SERVICE WORK ON THE CHASSIS – Mount and tighten screws with the collar bushing. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 102183-11 – Plug in the connector for the fuel pump. – Remove the wash cap set. Thoroughly clean the plug-in connection of the fuel line using compressed air. -
Page 56: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS Main work – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 104) Off-road chain spray ( p. 104) 400725-01 Finishing work – Remove the motorcycle from the lift stand. ( p. -
Page 57: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide
SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55… 58 mm (2.17… 2.28 in) Turn adjusting screws ... - Page 58 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower edge of the chain pin is at the level of or below the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated.
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Page 59: Checking The Frame
If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by KTM. S00867-01 11.40 Checking the swingarm –... -
Page 60: Checking The Rubber Grip
SERVICE WORK ON THE CHASSIS 11.42 Checking the rubber grip – Check the rubber grips on the handlebar for damage and wear and to ensure they are firmly seated. Info The rubber grips are vulcanized onto a sleeve on the left and onto the han- dle tube of the throttle grip on the right. -
Page 61: Changing The Hydraulic Clutch Fluid
SERVICE WORK ON THE CHASSIS 11.45 Changing the hydraulic clutch fluid Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –... -
Page 62: Brake System
Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disk ... -
Page 63: Checking The Brake Fluid Level Of The Front Brake
KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Preparatory work –... -
Page 64: Checking The Front Brake Linings
Changing the front brake linings Warning Danger of accident Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid can cause skin irritation on contact. –... - Page 65 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
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Page 66: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM – Add brake fluid to level Guideline 5 mm (0.2 in) Dimension (brake fluid level below top edge of container) Brake fluid DOT 4 / DOT 5.1 ( p. 102) – Position cover with membrane –... -
Page 67: Checking The Rear Brake Fluid Level
KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Preparatory work –... -
Page 68: Checking The Rear Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 69: Changing The Rear Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. - Page 70 BRAKE SYSTEM – Insert the new brake linings, insert pin , and mount cotter pins Info Always change the brake linings in pairs. Make sure that the decoupling plate is mounted on the piston side of the brake lining. –...
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Page 71: Wheels, Tires
WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 36) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. -
Page 72: Removing The Rear Wheel
WHEELS, TIRES – Mount and tighten screw Guideline Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) – Operate the hand brake lever several times until the brake linings are lying correctly against the brake disc. – Remove the motorcycle from the lift stand. ( p. -
Page 73: Installing The Rear Wheel
Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition and air pressure of the tires all have an important impact on the handling characteristics of the motorcycle. -
Page 74: Checking The Tire Air Pressure
Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes. - Page 75 WHEELS, TIRES » If the spoke tension varies: – Correct the spoke tension. – Check the spoke torque. Guideline Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft) Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft) Torque wrench with various accessories in set (58429094000)
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Page 76: Electrical System
ELECTRICAL SYSTEM 14.1 Removing 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 battery. – Only charge in well-ventilated rooms. – Maintain the minimum clearance to inflammable materials while charging. Minimum clearance 1 m (3 ft) –... -
Page 77: Recharging The Battery
– Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. - Page 78 ELECTRICAL SYSTEM Main work (All SX‑F models) – Check the battery voltage. » Battery voltage: < 9 V – Do not charge the battery. – Replace the battery and dispose of the old battery properly. » If the specifications have been met: Battery voltage: ≥...
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Page 79: Changing The Main Fuse
ELECTRICAL SYSTEM 14.4 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the seat. Preparatory work –... -
Page 80: Cooling System
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 operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions. -
Page 81: Draining The Coolant
COOLING SYSTEM – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the coolant level in the radiator. 10 mm (0.39 in) Coolant level above the radiator fins » If the coolant level does not match the specified value: –... - Page 82 COOLING SYSTEM – Make sure that screw is tightened. – Position the motorcycle upright. – Pour coolant in up to measurement above the radiator fins. Guideline 10 mm (0.39 in) Dimension over the radiator fins Coolant 1.20 l (1.27 qt.) Coolant ( p.
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Page 83: Tuning The Engine
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 Play in throttle cable 3…... -
Page 84: Setting The Characteristic Map Of The Throttle Response
TUNING THE ENGINE 16.3 Setting 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 85: Teaching The Throttle Valve Position
TUNING THE ENGINE – Run the engine until warm. The cold start button is deactivated. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. -
Page 86: Adjusting The Basic Position Of The Shift Lever
TUNING THE ENGINE 16.7 Adjusting the basic position of the shift lever – Remove screw and take off shift lever 401950-12 – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing. -
Page 87: Service Work On The Engine
SERVICE WORK ON THE ENGINE 17.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –... -
Page 88: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens
SERVICE WORK ON THE ENGINE Condition The engine is at operating temperature. – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level. The engine oil is at a level between the middle and upper edge of the level viewer. - Page 89 SERVICE WORK ON THE ENGINE – Mount and tighten screw plug with the short oil screen and the O-rings. Guideline Screw plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) 102234-10 – Position oil screen with the O-rings on a pin wrench. –...
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Page 90: Adding Engine Oil
SERVICE WORK ON THE ENGINE – Remove the oil filler plug with the O-ring from the clutch cover and fill up with engine oil. Engine oil 1.30 l (1.37 qt.) Engine oil (SAE 10W/50) ( p. 102) Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. -
Page 91: Cleaning, Care
CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts. -
Page 92: Storage
– Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with a lift stand. ( p. 36) – Cover the vehicle with a tarp or a cover that is permeable to air. -
Page 93: Troubleshooting
– Check the electrical system. – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. - Page 94 TROUBLESHOOTING Faults Possible cause Action – Battery is discharged Battery is not charging Check the charging voltage. – Check the stator winding of the alternator. – Unwanted power consumer Check the quiescent current.
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Page 95: Blink Code
BLINK CODE Blink code of FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Crankshaft position sensor - circuit fault Blink code of FI warning lamp (MIL) 06 FI warning lamp (MIL) flashes 6x short Error level condition Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high... -
Page 96: Technical Data
TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 449.9 cm³ (27.455 cu in) Stroke 63.4 mm (2.496 in) Bore 95 mm (3.74 in) Compression ratio 12.75:1 Idle speed 2,250… 2,350 rpm Control OHC, 4 valves controlled via rocker arm Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust... - Page 97 TECHNICAL DATA Loctite ® 648™ Screw, stator 6 Nm (4.4 lbf ft) Screw, suction pump cover 6 Nm (4.4 lbf ft) Loctite ® 243™ Nut, water-pump wheel 8 Nm (5.9 lbf ft) Loctite ® 243™ – Screw, alternator cover 10 Nm (7.4 lbf ft) Screw, bearing bolt, torque limiter 10 Nm (7.4 lbf ft) Loctite...
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Page 98: Capacities
TECHNICAL DATA 22.3 Capacities 22.3.1 Engine oil Engine oil 1.30 l (1.37 qt.) Engine oil (SAE 10W/50) ( p. 102) 22.3.2 Coolant Coolant 1.20 l (1.27 qt.) Coolant ( p. 102) 22.3.3 Fuel Total fuel tank capacity, 7.5 l (1.98 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. -
Page 99: Electrical System
Dunlop GEOMAX MX 32 (XC‑F US) 90/90 - 21 54M TT 110/100 - 18 64M TT Dunlop GEOMAX AT81F Dunlop GEOMAX AT81 Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork 22.7.1 SX‑F EU Fork part number 34.18.8P.09... -
Page 100: Xc-F Us
TECHNICAL DATA Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring length with preload spacer(s) 477 mm (18.78 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 4.6 N/mm (26.3 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 4.8 N/mm (27.4 lb/in) Weight of rider: 85…... -
Page 101: Sx-F Us
TECHNICAL DATA Weight of rider: 75… 85 kg (165… 187 lb.) 48 N/mm (274 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 51 N/mm (291 lb/in) Spring length Weight of rider: 65… 75 kg (143… 165 lb.) 247 N/mm (1,410 lb/in) Weight of rider: 75…... -
Page 102: Chassis Tightening Torques
TECHNICAL DATA Standard 2 turns Sport 1.5 turns Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 7 mm (0.28 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 45 N/mm (257 lb/in) Weight of rider: 75…... - Page 103 TECHNICAL DATA Loctite ® 2701™ Screw, engine brace 25 Nm (18.4 lbf ft) – Screw, fork stub 15 Nm (11.1 lbf ft) Screw, front brake caliper 25 Nm (18.4 lbf ft) Loctite ® 243™ – Screw, handlebar clamp 20 Nm (14.8 lbf ft) Screw, subframe 35 Nm (25.8 lbf ft) Loctite...
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Page 104: Substances
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 corre- sponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®... - Page 105 SUBSTANCES Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification – DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e.
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Page 106: Auxiliary Substances
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 Motorex... -
Page 107: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation. -
Page 108: List Of Abbreviations
LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly... -
Page 109: Index
INDEX Chassis number ....... 10 INDEX Clutch Accessories ........7 checking/correcting the fluid level . - Page 110 INDEX compression damping, adjusting ....32 dust boots, cleaning ......37 Oil filter installing .
- Page 111 INDEX Spoke tension checking ....... . . 72 Start number plate installing .
- Page 112 *3213333en* 3213333en 07/2015 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...
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