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Table of Contents
Related Manuals for KTM 2015 450 SX-F EU
Summary of Contents for KTM 2015 450 SX-F EU
- Page 1 OWNER'S MANUAL 2015 450 SX‑F EU 450 SX‑F USA 450 XC-F USA Art. no. 3213176en...
- Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.
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Page 4: Table Of Contents
TABLE OF CONTENTS Shifting, riding ..........21 TABLE OF CONTENTS MEANS OF REPRESENTATION ........4 Applying the brakes......... 21 Symbols used ........... 4 Stopping, parking..........22 Formats used............ 4 Transport ............22 SAFETY ADVICE............5 Refueling ............22 Use definition - intended use ......5 SERVICE SCHEDULE .......... - Page 5 TABLE OF CONTENTS 11.31 Changing the glass fiber yarn filling of the 16.5 Adjusting the basic position of the shift main silencer ..........47 lever ............77 17 SERVICE WORK ON THE ENGINE ....... 78 11.32 Removing the fuel tank .......
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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 (SX‑F EU, SX‑F USA) 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) 102050-10 Kill switch ( p. 11) Clutch lever ( p. 11) Filler cap Air filter box lid Cold start button ( p. 13) Shift lever ( p. 14) Chain guide... -
Page 11: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) 102051-10 Electric starter button ( p. 11) Hand brake lever ( p. 11) Level viewer for brake fluid, rear Shock absorber part number ( p. 10) Foot brake lever ( p. 15) Fork part number ( 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. C00214-10 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: Overview Of Indicator Lamps
CONTROLS Overview of indicator lamps Possible states FI warning lamp (MIL) lights up/flashes orange – The OBD (on-board diagnosis) has detected an emission- or safety-critical error. (XC‑F) The fuel level warning lamp lights up orange – The fuel level has reached the reserve mark. -
Page 15: Closing The Filler Cap
CONTROLS Closing the filler cap (SX‑F EU, SX‑F USA) – Mount filler cap and turn it clockwise until the fuel tank is tightly closed. Info Run the fuel tank breather hose without kinks. C00397-10 (XC‑F) – Replace the filler cap and turn clockwise until the release button locks in place. -
Page 16: Idle Speed Adjusting Screw
CONTROLS 6.10 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. This means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly. -
Page 17: Foot Brake Lever
CONTROLS 6.12 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 6.13 Side stand (XC‑F) The side stand is on the left side of the vehicle. 401943-10 The side stand is used to park the motorcycle. -
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 record at vehicle handover. -
Page 19: Running In The Engine
PREPARING FOR USE (SX‑F EU, SX‑F USA) – Do not transport luggage. (XC‑F) – If you carry any baggage, 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. Info Motorcycles react sensitively to any changes of weight distribution. -
Page 20: Preparing For Rides On Dry Sand
– Fit a dust cover on the air filter. Dust protection device for air filter (77206920000) Info See the KTM PowerParts fitting instructions. B00435-01 – Fit a sand cover on the air filter. Sand protection device for air filter (77206922000) 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 (77206921000) Info See the KTM PowerParts fitting instructions. B00437-01 – 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. 78) –... -
Page 23: Starting Off
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: Stopping, Parking
RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. –... - Page 25 – 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.
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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 KTM DEALER.NET and in the service record. -
Page 27: Service Work (As Additional Order)
SERVICE SCHEDULE ○ One-time interval ● Periodic interval Service work (as additional order) Annually Every 100 operating hours - corresponds to about 700 liters of fuel (185 US gal) Every 50 operating hours - corresponds to about 350 liters of fuel (92.5 US gal) Every 40 operating hours - corresponds to about 280 liters of fuel (74 US gal) Once after 20 operating hours ●... -
Page 28: Tuning The Chassis
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 29: Adjusting The High-Speed 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 high-speed setting can be seen during the fast 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: Checking The Static 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 32: Adjusting The Riding Sag
TUNING THE CHASSIS – After removing the shock absorber, clean it thoroughly. Main work – Loosen screw – Turn adjusting ring until the spring is no longer under tension. Hook wrench (T106S) – Measure the overall spring length while the spring is not under tension. –... -
Page 33: Checking The Basic Setting Of The Fork
TUNING THE CHASSIS Info The spring rate is shown on the outside of the spring. Finishing work – Install the shock absorber. p. 43) – Install the manifold. – Check the static sag of the shock absorber. ( p. 29) –... -
Page 34: Adjusting The Rebound Damping Of The Fork
TUNING THE CHASSIS – Turn counterclockwise by the number of clicks corresponding to the fork type. Guideline Compression damping (SX‑F USA) Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping (XC‑F) Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase damping;... -
Page 35: Handlebar Position
TUNING THE CHASSIS Guideline Rebound damping (SX‑F USA) Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping (XC‑F) Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 10.14 Handlebar position ... -
Page 36: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with the 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. The wheels must no longer touch the ground. -
Page 37: Cleaning The Dust Boots Of The Fork Legs
SERVICE WORK ON THE CHASSIS 11.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 34) – Remove the fork protector. ( p. 35) Main work – Push dust boots of both fork legs downward. -
Page 38: Removing The Fork Legs
SERVICE WORK ON THE CHASSIS 11.7 Removing the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 34) – Remove the front wheel. p. 65) Main work – Remove screws and take off the clamp. –... -
Page 39: Removing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS – Position the brake caliper. Mount and tighten screws Guideline Screw, front brake caliper 25 Nm Loctite ® 243™ (18.4 lbf ft) – Position the brake line and clamp. Mount and tighten screws M00016-11 Finishing work –... -
Page 40: 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. 0 0 3 High viscosity grease ( p. 97) – Insert the lower triple clamp with the steering stem. Mount the upper steering head 0 0 2 bearing. -
Page 41: 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 42: Adjusting The Play Of The Steering Head Bearing
SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with the lift stand. ( p. 34) 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 43: Removing The Start Number Plate
SERVICE WORK ON THE CHASSIS 11.14 Removing the start number plate – Remove screw and take off the clamp. – Remove screw . Take off the start number plate. C00419-10 11.15 Installing the start number plate – Position the start number plate. Mount and tighten screw ... -
Page 44: 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) C00420-10 Finishing work – Install the start number plate. ( p. -
Page 45: Installing The Shock Absorber
SERVICE WORK ON THE CHASSIS – Remove the cable binder of the frame protector. – Remove screw – Remove the frame protector. Info Pay attention to the holding lugs. 102065-10 – Remove screw – Carefully remove the shock absorber upward out of the vehicle. 102066-10 11.19 Installing the shock absorber... -
Page 46: Removing The Seat
SERVICE WORK ON THE CHASSIS Finishing work – Install the manifold. – Remove the motorcycle from the lift stand. ( p. 34) 11.20 Removing the seat – Remove screw – Lift up the seat at the rear, pull it back and then remove it from above. C00427-10 11.21 Mounting the seat... -
Page 47: Removing The Air Filter
SERVICE WORK ON THE CHASSIS Condition The air filter box lid is secured. – Mount and tighten screws Guideline Screw, air filter box lid EJOT PT ® 3 Nm (2.2 lbf ft) K60x20-Z EJOT PT screw (0017060204) 102058-10 11.24 Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. -
Page 48: Cleaning The Air Filter And Air Filter Box
SERVICE WORK ON THE CHASSIS 11.26 Cleaning the air filter and air filter box 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. Info Do not clean the air filter with fuel or petroleum since these substances attack the foam. -
Page 49: Removing The Main Silencer
SERVICE WORK ON THE CHASSIS 11.29 Removing 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. Do not touch hot components. – Disconnect spring Spring hooks (50305017000) –... -
Page 50: Removing The Fuel Tank
SERVICE WORK ON THE CHASSIS Main work – Remove all screws from the main silencer. – Remove silencer cap and O-ring – Remove outer tube and O-ring – Pull the glass fiber yarn filling from the inner tube –... -
Page 51: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS – Remove the tube from the fuel tank breather. – Remove screws with the collar bushing. C00165-11 – Remove screw with the rubber bushing. C00437-10 – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. C00169-01 11.33 Installing the fuel tank... -
Page 52: 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) C00165-10 – Plug in connector of the fuel pump. – Remove the wash cap set. Thoroughly clean the plug-in connection of the fuel line using compressed air. -
Page 53: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS Main work – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 97) Off-road chain spray ( p. 97) 400725-01 Finishing work – Remove the motorcycle from the lift stand. ( p. -
Page 54: 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 55 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 56: 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. 401519-01 11.40 Checking the swingarm –... -
Page 57: 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. » If a rubber grip is damaged, worn or loose: – Change and secure the rubber grip. -
Page 58: Changing The Hydraulic Clutch Fluid
SERVICE WORK ON THE CHASSIS 11.46 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 59: 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 60: 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 61: 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 62 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 63: 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. 95) – Position cover with membrane –... -
Page 64: 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 65: 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 66 BRAKE SYSTEM Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.
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Page 67: Wheels, Tires
WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 34) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. -
Page 68: Removing The Rear Wheel
WHEELS, TIRES – Mount and tighten screw Guideline Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) – Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc. – Remove the motorcycle from the lift stand. ( p. -
Page 69: 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 70: 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 71 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 72: Electrical System
ELECTRICAL SYSTEM 14.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –... -
Page 73: Changing The Main Fuse
– Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible 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 74 ELECTRICAL SYSTEM Main work – Remove screw G01575-10 – Lift rear fairing slightly and pull starter relay out of the holder. S00046-10 – Remove protection caps – Remove the faulty main fuse Info A defective fuse can be identified by the burned-out fuse wire ...
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Page 75: 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 76: Draining The Coolant
COOLING SYSTEM Condition The engine is cold. – 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 radiator fins. » If the coolant level does not meet specifications: –... -
Page 77: Refilling Coolant
COOLING SYSTEM 15.5 Refilling coolant Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water imme- diately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swal- lowed, contact a physician immediately. -
Page 78: 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 79: Adjusting The Idle Speed
TUNING THE ENGINE 16.3 Adjusting the idle speed – Run the engine until warm. – Set the desired idle speed by turning the idle speed adjusting screw Guideline Idle speed 2,250… 2,350 rpm Tachometer (45129075000) Info Turn counterclockwise to decrease the idle speed. Turn clockwise to increase the idle speed. -
Page 80: 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 81: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens
SERVICE WORK ON THE ENGINE 17.3 Changing the engine oil and oil filter, cleaning the oil screens Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage. - Page 82 SERVICE WORK ON THE ENGINE – Position oil screen with the O-rings on a pin wrench. – Position the pin wrench through the drilled hole of the screw plug in the opposite section of the engine case. – Push the oil screen all the way into the engine case. 102074-10 –...
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Page 83: Adding Engine Oil
SERVICE WORK ON THE ENGINE 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 84: 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 85: 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 the lift stand. ( p. 34) – Cover the vehicle with a tarp or a cover that is permeable to air. -
Page 86: 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 87 TROUBLESHOOTING Faults Possible cause Action – High oil consumption Piston and cylinder worn Piston/cylinder - determine the mounting clear- ance. – Battery is discharged Battery is not charging Check the charging voltage. – Check the stator winding of the alternator. –...
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Page 88: Blink Code
BLINK CODE Blink code FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Crankshaft position sensor - circuit fault Blink code 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 Blink code FI warning lamp (MIL) -
Page 89: Technical Data
TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 449.3 cm³ (27.418 cu in) Stroke 63.4 mm (2.496 in) Bore 95 mm (3.74 in) Compression ratio 12.6:1 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 90 TECHNICAL DATA Loctite ® 243™ Screw, locking lever 6 Nm (4.4 lbf ft) – Screw, oil filter cover 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 ®...
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Page 91: Capacities
TECHNICAL DATA 22.3 Capacities 22.3.1 Engine oil Engine oil 1.50 l (1.59 qt.) Engine oil (SAE 10W/50) ( p. 95) 22.3.2 Coolant Coolant 1.20 l (1.27 qt.) Coolant ( p. 95) Coolant (mixed ready to use) ( p. 95) 22.3.3 Fuel Total fuel tank capacity, 7.5 l (1.98 US gal) -
Page 92: Electrical System
Dunlop GEOMAX MX 52 (XC‑F) 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 14.18.7O.09... -
Page 93: Xc-F
TECHNICAL DATA Standard 15 clicks Sport 13 clicks Spring length with preload spacer(s) 480 mm (18.9 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 94: Sx-F Usa
TECHNICAL DATA Spring length 260 mm (10.24 in) Gas pressure 10 bar (145 psi) Static sag 30 mm (1.18 in) Riding sag 100 mm (3.94 in) Fitted length 490 mm (19.29 in) Shock absorber oil Shock absorber fluid (SAE 2.5) (50180751S1) ( p. -
Page 95: Chassis Tightening Torques
TECHNICAL DATA Weight of rider: 65… 75 kg (143… 165 lb.) 54 N/mm (308 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 57 N/mm (325 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 60 N/mm (343 lb/in) Spring length 260 mm (10.24 in) Gas pressure... - Page 96 TECHNICAL DATA – Nut, linkage lever on swingarm M14x1.5 80 Nm (59 lbf ft) – Nut, linkage lever to angle lever M14x1.5 80 Nm (59 lbf ft) – Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) – Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) –...
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Page 97: 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 possesses the corre- sponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®... - Page 98 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 99: Auxiliary Substances
Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Rubber grip adhesive (00062030051) Recommended supplier KTM-Sportmotorcycle AG – GRIP GLUE Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ® –... - Page 100 AUXILIARY SUBSTANCES Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic...
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Page 101: 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 102: Index
INDEX Clutch lever ........11 INDEX basic position, adjusting ..... . 55 Accessories . - Page 103 INDEX Fork protector installing ....... . . 35 Play in throttle cable Frame adjusting .
- Page 104 INDEX Steering head bearing play adjusting ....... . . 40 checking .
- Page 105 *3213176en* 3213176en 4/2014 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...