KTM 450 SX-F FACTORY EDITION Owner's Manual
  1. Manuals
  2. Brands
  3. KTM Manuals
  4. Motorcycle
  5. 450 SX-F
  6. Owner's manual

KTM 450 SX-F FACTORY EDITION Owner's Manual

Hide thumbs Also See for 450 SX-F FACTORY EDITION:
Table of Contents

Advertisement

Quick Links

OWNER'S MANUAL
2022
450 SX-F FACTORY EDITION
Art. no. 3214419en

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 450 SX-F FACTORY EDITION and is the answer not in the manual?

Questions and answers

Related Manuals for KTM 450 SX-F FACTORY EDITION

Summary of Contents for KTM 450 SX-F FACTORY EDITION

  • Page 1 OWNER'S MANUAL 2022 450 SX-F FACTORY EDITION Art. no. 3214419en...
  • 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......... 20 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 Advice on preparing for first use ..20 Symbols used ........5 Running in the engine ...... 21 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 Changing the glass fiber yarn filling absorber.......... 39 of the main silencer ...... 67 10.10 Adjusting the spring preload of the 11.33 Removing the fuel tank ....68 shock absorber ......
  • Page 6 TABLE OF CONTENTS 14.2 Installing the 12-V battery ... 100 22.3.3 Fuel ......... 132 14.3 Charging the 12-V battery ... 101 22.4 Chassis ......... 133 14.4 Changing the main fuse ....102 22.5 Electrical system......133 14.5 Changing the fuse of the fuel 22.6 Tires ..........

  • 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 This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle com- plies 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) H05023-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Fuel tank filler cap Air filter box cover Cold start button ( p. 17) Engine number ( p. 12) Shift lever ( p.

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

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) H05024-10 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 embossed on the left side of the engine above 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 6.10 Closing the fuel tank filler cap – Mount fuel tank filler cap and turn it clockwise until the fuel tank is tightly closed. Info Route fuel tank breather hose without kinks. F03653-10 6.11 Cold start button The cold start button is fitted to the bottom of the throttle valve body.

  • Page 20: Idle Speed Adjusting Screw

    6 CONTROLS 6.12 Idle speed adjusting screw The idle setting of the throttle valve body substantially influences the vehicle’s starting behavior, a stable idle speed, and the vehi- cle’s response when the throttle is opened. An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly.

  • Page 21: Foot Brake Lever

    CONTROLS 6 6.14 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 401956-10 6.15 Plug-in stand The support for plug-in stand is the left side of the wheel spin- dle.

  • Page 22: Preparing For Use

    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 23: Running In The Engine

    PREPARING FOR USE 7 – Adjust the basic position of the foot brake lever. p. 87) – Adjust the basic position of the shift lever. p. 115) – Get used to the handling characteristic of the motorcycle on suitable terrain before undertaking a more chal- lenging ride.

  • Page 24: 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 25: 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. 140) –...

  • Page 26: 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 27: Riding Instructions 8

    RIDING INSTRUCTIONS 8 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 28: Activating Launch Control

    8 RIDING INSTRUCTIONS – Remove plug-in stand – Shift the transmission into neutral. Condition Ambient temperature: < 20 °C (< 68 °F) – Push the cold start button in all the way. H02629-10 – Press start button Info Press the start button for a maximum of 5 seconds. Wait for 15 seconds before a further attempt at start- ing.

  • Page 29: Activating Traction Control

    RIDING INSTRUCTIONS 8 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 the way after full throttle, and/or if there is no start within 3 minutes.

  • Page 30: Starting Off

    8 RIDING INSTRUCTIONS – Check lock button to ensure it can move easily. – Bend over the handlebars while sitting on the motorcycle. Grip the rim and compress the fork. Press lock button and decompress slowly until the lock button engages in lock ring When the fork compresses for the first time, the lock but- ton is released automatically.

  • Page 31: Shifting, Riding

    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

    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.) Warning Danger of accidents Moisture and dirt impair the brake system.

  • Page 33: Transporting

    RIDING INSTRUCTIONS 8 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. – Park the vehicle on a firm and level surface. –...

  • Page 34: Refueling

    In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Improper handling of fuel is a danger to the environment.

  • Page 35: Service Schedule 9

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

  • Page 37: Tuning The Chassis 10

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

  • Page 38: 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 39: Adjusting The Rebound Damping Of The Shock Absorber

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

  • Page 40: Measuring The Dimension Of The Rear Wheel Unloaded

    10 TUNING THE CHASSIS 10.7 Measuring the dimension of the rear wheel unloaded Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) Main work – Position the sag gage in the rear axle and measure the distance to marking SAG on the rear fender.

  • Page 41: Checking The Riding Sag 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 42: Adjusting The Riding Sag

    10 TUNING THE CHASSIS Main work – Loosen screw – Turn adjusting ring until the spring is no longer under ten- sion. Hook wrench (90129051000) Info If the spring cannot be fully released, the spring must be removed to accurately measure the spring length. –...

  • Page 43: Checking The Basic Setting Of The Fork

    TUNING THE CHASSIS 10 Info The spring rate is shown on the outside of the spring. Finishing work – Install the shock absorber. p. 59) – Check the free travel of the foot brake lever. ( p. 87) – Install the main silencer. ( p.
  • Page 44 A little air escapes from the fork leg when connecting. Info This is due to the volume of the hose and not due to a defect in the fork airpump or the fork. Read the accompanying KTM PowerParts instructions. – Adjust the air pressure as specified. Guideline Air pressure 10.9 bar (158 psi)

  • Page 45: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 10 10.14 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn adjuster clockwise all the way to the stop. Info Adjuster is located at the upper end of the right fork leg.

  • Page 46: Handlebar Position

    10 TUNING THE CHASSIS 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. This allows the handlebar to be mounted in the most comfortable position for the rider.
  • Page 47 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 48 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 49: 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 50: Cleaning The Dust Boots Of The Fork Legs

    11 SERVICE WORK ON THE CHASSIS Main work – Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws. F03665-10 Finishing work – Remove the motorcycle from the lift stand. ( p. 47) 11.4 Cleaning the dust boots of the fork legs Preparatory work...

  • Page 51: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11 11.5 Removing the fork protector Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) – Remove the front wheel. p. 93) Main work – Remove screws and take off the clamp. –...

  • Page 52: Removing The Engine Guard

    11 SERVICE WORK ON THE CHASSIS 11.7 Removing the engine guard – Remove screws with the bushings. – Remove screws . Take off the engine guard. F03768-10 11.8 Installing the engine guard – Position the engine guard on the frame. –...

  • Page 53: Removing The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 11.9 Removing the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) – Remove the front wheel. p. 93) Main work – Remove screws and take off the clamp. –...

  • Page 54: Removing The Lower Triple Clamp

    11 SERVICE WORK ON THE CHASSIS – Position the brake caliper. Mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) brake caliper Loctite ® 243™ – Position the brake line and the clamp. Mount and tighten screws F03657-11 Finishing work –...

  • Page 55: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11 11.12 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 140) – Insert the lower triple clamp with the steering stem. Mount upper steering head bearing.
  • Page 56 11 SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, bottom triple 12 Nm (8.9 lbf ft) clamp F03664-10 – Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head F03663-10 – Mount and tighten screw Guideline Screw, top 20 Nm (14.8 lbf ft)

  • 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: Lubricating The Steering Head Bearing

    11 SERVICE WORK ON THE CHASSIS Main work – Loosen screws – Remove screw – Loosen and retighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head – Using a plastic hammer, tap lightly on the upper triple clamp F03667-10 to avoid stresses.

  • Page 59: Installing The Start Number Plate

    SERVICE WORK ON THE CHASSIS 11 11.17 Installing the start number plate – Position the brake line in holders on the start number plate. – Position the start number plate. Mount and tighten screw The holding lugs engage in the fender. F03674-10 11.18 Removing front fender...

  • Page 60: Installing Front Fender

    11 SERVICE WORK ON THE CHASSIS 11.19 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis F03675-10 Finishing work – Install the start number plate. ( p. 57) 11.20 Removing the shock absorber Preparatory work...

  • Page 61: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 – Remove screws – Pull off foot brake cylinder from the push rod. H05030-10 – Remove the connecting link of the chain. – Take off the chain. Info Cover the components to protect them against damage. F03702-01 –...
  • Page 62 11 SERVICE WORK ON THE CHASSIS – Position the link fork and mount the swingarm pivot. Info Pay attention to flat area – Mount and tighten nut Guideline Nut, fork pivot M16x1.5 100 Nm (73.8 lbf ft) H05033-10 – Mount the chain. –...

  • Page 63: Removing The Seat

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

  • Page 64: Mounting The Seat

    11 SERVICE WORK ON THE CHASSIS 11.23 Mounting the seat – Attach the seat to the collar bushings at the front and simulta- neously push it back. The holding lugs engage in the recesses at the back. – Make sure the seat is latched in place correctly. H05037-10 –...

  • Page 65: Installing The Air Filter Box Cover

    SERVICE WORK ON THE CHASSIS 11 Condition The air filter box cover is not secured. – Pull off the air filter box cover in area and push it side- ways and forward. Take off the air filter box cover. H05038-11 11.25 Installing the air filter box cover Condition...

  • Page 66: Removing The Air Filter

    11 SERVICE WORK ON THE CHASSIS Condition The air filter box cover is not 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: Cleaning The Air Filter And Air Filter Box

    SERVICE WORK ON THE CHASSIS 11 11.27 Cleaning the air filter and air filter box 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 Do not clean the air filter with fuel or petroleum since these substances attack the foam.

  • Page 68: Installing The Air Filter

    11 SERVICE WORK ON THE CHASSIS 11.28 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. – Grease the air filter in area Long-life grease ( p.

  • Page 69: Removing The Main Silencer

    SERVICE WORK ON THE CHASSIS 11 Finishing work – Install the air filter box cover. ( p. 63) 11.30 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 before performing any work on the vehicle. –...

  • Page 70: Removing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS Main work – Remove the screws on the main silencer. – Take off silencer cap and O-ring – Pull glass fiber yarn filling out of the silencer cap. – Pull glass fiber yarn filling from the inner tube.
  • Page 71 SERVICE WORK ON THE CHASSIS 11 Main work – Unplug fuel pump connector – Clean quick release coupling thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! H05043-10 –...

  • Page 72: Installing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS 11.34 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. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 73: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS 11 – Plug in fuel pump connector – Remove the wash cap set. Clean the quick release coupling thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! –...

  • Page 74: Checking The Chain Tension

    11 SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) Main work – Rinse off loose dirt with a soft jet of water. – Remove old grease residue with chain cleaner. Chain cleaner ( p.

  • Page 75: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 11.38 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 76: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    11 SERVICE WORK ON THE CHASSIS 11.39 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) 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

    11 SERVICE WORK ON THE CHASSIS – Check that the chain guide is firmly seated. » If the chain guide is loose: – Tighten the screws on the chain guide. Guideline Screw, chain M6x16 10 Nm guide on link fork (7.4 lbf ft) at the rear Screw, chain...

  • 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: Program The Quickshifter

    11 SERVICE WORK ON THE CHASSIS 11.44 Program the Quickshifter Info If the shifting performance of the quickshifter starts to decrease, it must be reprogrammed. – Carry out start procedure. ( p. 25) – 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. 138) – 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. 47) 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: Removing The Rear Wheel

    WHEELS, TIRES 13 13.3 Removing the rear wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) 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: Installing The Rear Wheel

    13 WHEELS, TIRES 13.4 Installing the rear 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. Main work –...

  • 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 , put 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 – Put in the new fuse for the fuel pump. Fuse (58011109105) ( p. 133) – 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 Finishing work – Install the engine guard. ( p. 50) 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 COOLING SYSTEM 15 Finishing work – Install the engine guard. ( p. 50)

  • Page 112: 16 Tuning The Engine

    16 TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3 …...

  • Page 113: Adjusting The Characteristic Map Of The Throttle Response

    TUNING THE ENGINE 16 Main work – 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 114 16 TUNING THE ENGINE – 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 Gray guide plate (A48002014000) Alternative 1 Black guide plate (A46002014000) Info The gray guide plate opens the throttle valve more...

  • Page 115: 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 116: Programming The Throttle Valve Position

    16 TUNING THE ENGINE – Run the engine until warm. The cold start button is deactivated – The cold start but- ton is in its basic position. ( p. 17) Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. –...

  • Page 117: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 16 16.7 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. 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 118: 17 Service Work On The Engine

    17 SERVICE WORK ON THE ENGINE 17.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 119: Checking The Engine Oil Level

    SERVICE WORK ON THE ENGINE 17 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 120 17 SERVICE WORK ON THE ENGINE 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 121 SERVICE WORK ON THE ENGINE 17 – Position long oil screen with the O-rings on a pin wrench. – Position the pin wrench through the drill hole of the screw plug in the opposite section of the engine case. – Push the oil screen all the way into the engine case.

  • Page 122: Adding Engine Oil

    Engine oil (SAE 10W/50) ( p. 138) 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 123 SERVICE WORK ON THE ENGINE 17 – Start the engine and check for leaks.

  • Page 124: 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 125 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 126: 19 Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with a lift stand. ( p. 47) – Cover the vehicle with a tarp or similar cover that is permeable...

  • Page 127: Preparing For Use After Storage

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

  • Page 128: 20 Troubleshooting

    Check the electrical system. – Malfunction in the electronic Read out the fault memory using the fuel injection KTM diagnostics tool. – Engine does not speed up Malfunction in the electronic Read out the fault memory using the fuel injection KTM diagnostics tool.
  • Page 129 – Read out the fault memory using the KTM diagnostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary.

  • Page 130: 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 131 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 132: 22 Technical Data

    22 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 13.1:1 Idle speed 2,100 … 2,200 rpm Control OHC, 4 valves controlled via rocker arm Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust...

  • Page 133: Engine Tightening Torques

    TECHNICAL DATA 22 22.2 Engine tightening torques Screw, oil nozzle for piston cooling 2 Nm (1.5 lbf ft) Loctite ® 243™ Crankshaft speed sensor screw and 6 Nm (4.4 lbf ft) cable retainer Loctite ® 243™ Oil nozzle for clutch lubrication 2.5 Nm (1.84 lbf ft) Oil nozzle for piston cooling 2 Nm (1.5 lbf ft)

  • Page 134: Capacities

    22 TECHNICAL DATA Screw, water pump cover 10 Nm (7.4 lbf ft) Plug, oil channel 9 Nm (6.6 lbf ft) Loctite ® 243™ Screw, rocker arm bearing M7x1 15 Nm (11.1 lbf ft) Crankshaft clamp screw plug 10 Nm (7.4 lbf ft) Plug, timing chain tensioner 8 Nm (5.9 lbf ft) Plug, oil channel...

  • Page 135: Chassis

    TECHNICAL DATA 22 22.4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork WP XACT 5448 Suspension travel front 310 mm (12.2 in) rear 300 mm (11.81 in) Fork offset 22 mm (0.87 in) WP XACT 5750 Shock absorber Brake system Disc brakes, floating brake calipers...

  • Page 136: Tires

    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 22.7 Fork Fork article number...

  • Page 137: Chassis Tightening Torques

    TECHNICAL DATA 22 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 138 22 TECHNICAL DATA 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 10 Nm (7.4 lbf ft) the front Screw, chain guide on link fork at M6x16 10 Nm (7.4 lbf ft) the rear...
  • Page 139 TECHNICAL DATA 22 Screw, handlebar support 40 Nm (29.5 lbf ft) Loctite ® 243™ Screw, top shock absorber 60 Nm (44.3 lbf ft) Loctite ® 2701™ Nut, angle lever to link fork M16x1.5 60 Nm (44.3 lbf ft) Nut, fork pivot M16x1.5 100 Nm (73.8 lbf ft) Nut, frame on linkage lever...

  • Page 140: 23 Substances

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

  • Page 142: 24 Auxiliary Substances

    24 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier MOTOREX ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier...
  • Page 143 AUXILIARY SUBSTANCES 24 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 144: 25 Standards

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

  • Page 145: Index Of Special Terms 26

    INDEX OF SPECIAL TERMS 26 Launch control Vehicles electronics functions for achieving the best possible acceleration from a standing position On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics Quickshifter Function of the engine electronics for shifting up with- out clutch actuation Traction Control Auxiliary function of the motor control that reduces...

  • Page 146: 27 List Of Abbreviations

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

  • Page 147: List Of Symbols 28

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

  • Page 148: Index

    INDEX Chain guide INDEX checking ......74 12-V battery Chain tension charging ......101 adjusting .
  • Page 149 INDEX Engine sprocket Handlebar position ..... . 44 checking ......74 adjusting .
  • Page 150 INDEX spring preload, adjusting ....39 static sag, checking ....38 Play in throttle cable Shock absorber article number .
  • Page 151 INDEX Vehicle identification number ....12 View of vehicle front left ......10 rear right .
  • Page 152 *3214419en* 3214419en 03/2022 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.COM...

Table of Contents

Save PDF