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KTM 250 SX-F 2020 Owner's Manual

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OWNER'S MANUAL
2020
250 SX-F
250 XC‑F
Art. no. 3214003en

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Summary of Contents for KTM 250 SX-F 2020

  • Page 1 OWNER'S MANUAL 2020 250 SX-F 250 XC‑F Art. no. 3214003en...
  • Page 3 KTM accepts no liability for delivery options, deviations from fig- ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS PREPARING FOR USE......... 22 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 Advice on preparing for first use ..22 Symbols used ........5 Running in the engine ...... 23 Formats used........5 Starting power of lithium-ion SAFETY ADVICE..........
  • Page 5 TABLE OF CONTENTS 10.10 Adjusting the spring preload of the 11.33 Checking for chain dirt shock absorber ......42 accumulation........72 10.11 Adjusting the riding sag ....43 11.34 Cleaning the chain ......72 10.12 Checking the basic setting of the 11.35 Checking the chain tension ....
  • Page 6 TABLE OF CONTENTS 15 COOLING SYSTEM ........103 22.7.3 XC‑F US........132 22.8 Shock absorber ......133 15.1 Cooling system ......103 22.8.1 SX‑F EU........133 15.2 Checking the antifreeze and 22.8.2 SX‑F US........133 coolant level ........103 22.8.3 XC‑F US........

  • Page 7: Means Of Representation 1

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

  • Page 8: Safety Advice

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

  • Page 9: Degrees Of Risk And Symbols

    SAFETY ADVICE 2 Degrees of risk and symbols Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

  • Page 10: Protective Clothing

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

  • Page 11: Owner's Manual

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

  • Page 12: Important Notes

    Manufacturer and implied warranty The work 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 13: View Of Vehicle 4

    VIEW OF VEHICLE 4 View of vehicle, front left (example) E01234-10 Hand brake lever ( p. 15) Clutch lever ( p. 15) Fuel tank filler cap Air filter box cover p. 21) (All SX‑F models) Plug-in stand ( Cold start button ( p.

  • Page 14: View Of Vehicle, Rear Right (Example)

    4 VIEW OF VEHICLE View of vehicle, rear right (example) E01233-10 Shock absorber compression adjustment Combination switch ( p. 16) Kill switch ( p. 15) Electric starter button ( p. 16) Throttle grip ( p. 15) Vehicle identification number ( p.

  • Page 15: Serial Numbers 5

    SERIAL NUMBERS 5 Vehicle identification number The vehicle identification 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 Engine number is located on the left side of the engine over the engine sprocket.

  • Page 16: Shock Absorber Article Number

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

  • Page 17: Controls 6

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

  • Page 18: Electric Starter Button

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

  • Page 19: Service Hour Counter

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

  • Page 20: Closing The Fuel Tank Filler Cap

    6 CONTROLS (XC‑F US) – Press release button , turn the fuel tank filler cap coun- terclockwise, and lift it off. F01557-10 6.10 Closing the fuel tank filler cap (All SX‑F models) – Mount fuel tank filler cap and turn it clockwise until the fuel tank is tightly closed.

  • Page 21: Cold Start Button

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

  • Page 22: 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 23: 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 (All SX‑F models) The support for plug-in stand is the left side of the wheel spin- dle.

  • Page 24: 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 25: Running In The Engine

    PREPARING FOR USE 7 – Adjust the basic position of the foot brake lever. p. 88) – Adjust the basic position of the shift lever. p. 112) – Get used to the handling characteristic of the motorcycle on suitable terrain before undertaking a more chal- lenging ride.

  • Page 26: Preparing The Vehicle For Difficult Operating Conditions

    Preparing the vehicle for riding on dry sand – Mount the air filter dust cover. Air filter dust cover (79006920000) Info Observe the fitting instructions for KTM PowerParts. 102136-01 – Mount the air filter sand cover. Air filter sand cover (79006922000) Info Observe the fitting instructions for KTM PowerParts.

  • Page 27: Preparing The Vehicle For Riding On Wet Sand

    Change the piston every 20 operating hours. Preparing the vehicle for riding on wet sand – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the fitting instructions for KTM PowerParts. 102137-01 – Clean the chain. Chain cleaner ( p. 139) –...

  • Page 28: Preparing Vehicle For High Temperatures Or Slow Riding

    Straighten bent radiator fins carefully. – Check the coolant level. ( p. 104) Preparing the vehicle for low temperatures or snow – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the fitting instructions for KTM PowerParts. 102137-01...

  • Page 29: 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 30: Activating Launch Control

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

  • Page 31: Activating Traction Control

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

  • Page 32: Shifting, Riding

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

  • Page 33: Stopping, Parking

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

  • Page 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.)
  • Page 35 RIDING INSTRUCTIONS 8 Note Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to enter the groundwater, the soil, or the sewage system. – Switch off the engine. – Open fuel tank filler cap. ( p.

  • Page 36: Service Schedule

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

  • Page 37: Recommended Work

    Final check: Check the vehicle for operating safety and take a test ride. ○ ● ● ● ● ● Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● ● ● Make a service entry in the KTM Dealer.net.
  • Page 38 9 SERVICE SCHEDULE Every 100 operating hours Every 50 operating hours After 20 operating hours After 10 operating hours every 12 months ● Perform major engine service including removing and installing the engine. (Change valves, valve springs, valve spring seats, and valve spring retainers. Change the connect- ing rod, conrod bearing and crank pin.

  • Page 39: 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 40: Compression Damping Of The Shock Absorber

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

  • Page 41: Adjusting The High-Speed Compression Damping Of The Shock Absorber

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

  • Page 42: Adjusting The Rebound Damping Of The Shock Absorber

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

  • Page 43: Checking The Static Sag Of The Shock Absorber

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

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

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

  • Page 45: Adjusting The Riding Sag

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

  • Page 46: Checking The Basic Setting Of The Fork

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

  • Page 47: Adjusting The Fork Air Pressure

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

  • Page 48: Adjusting The Compression Damping Of The Fork

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

  • Page 49: Adjusting The Rebound Damping Of The Fork

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

  • Page 50: Adjusting The Handlebar Position

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

  • Page 51: Service Work On The Chassis 11

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

  • Page 52: Bleeding The Fork Legs

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

  • Page 53: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11 Universal oil spray ( p. 140) – Press the dust boots back into their installation position. – Remove excess oil. Finishing work – Install the fork protector. ( p. 51) – Remove the motorcycle from the lift stand. ( p.

  • Page 54: Installing The Fork Legs

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

  • Page 55: Removing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11 11.9 Removing the lower triple clamp Preparatory work – Raise the motorcycle with a lift stand. ( p. 49) – Remove the front wheel. p. 93) – Remove the fork legs. p. 51) – Remove the start number plate.

  • Page 56: Installing The Lower Triple Clamp

    11 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. 139) – Insert the lower triple clamp with the steering stem. Mount upper steering head bearing.
  • Page 57 SERVICE WORK ON THE CHASSIS 11 – Tighten screws Guideline Screw, bottom triple 12 Nm (8.9 lbf ft) clamp F01572-10 – Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head F01563-10 – Mount and tighten screw Guideline Screw, top 20 Nm (14.8 lbf ft)

  • Page 58: 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 59: Adjusting Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 11 11.12 Adjusting steering head bearing play Preparatory work – Raise the motorcycle with a lift stand. ( p. 49) – Remove the handlebar cushion. Main work – Loosen screws – Remove screw – Loosen and retighten screw Guideline Screw, top steering M20x1.5...

  • Page 60: Removing The Start Number Plate

    11 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 F01524-10 11.15 Installing the start number plate – Position the brake line in holders on the start number plate.

  • Page 61: Installing Front Fender

    SERVICE WORK ON THE CHASSIS 11 11.17 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis F01526-10 Finishing work – Install the start number plate. ( p. 58) 11.18 Removing the shock absorber Preparatory work...

  • Page 62: Installing The Shock Absorber

    11 SERVICE WORK ON THE CHASSIS – Remove screws – Pull off foot brake cylinder from the push rod. F01582-10 – Remove the connecting link of the chain. – Take off the chain. Info Cover the components to protect them against damage. S01222-10 –...
  • Page 63 SERVICE WORK ON THE CHASSIS 11 – 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) F01586-10 – Mount the chain. –...

  • Page 64: Removing The Seat

    11 SERVICE WORK ON THE CHASSIS – 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 65: Mounting The Seat

    SERVICE WORK ON THE CHASSIS 11 11.21 Mounting the seat – Mount the front of the seat on the collar bushing of the fuel tank, lower the seat at the rear, and push the seat forward. H02218-11 – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft)

  • Page 66: Installing The Air Filter Box Cover

    11 SERVICE WORK ON THE CHASSIS Condition The air filter box cover is not secured. – Pull off the air filter box cover in area sideways and take off toward the front. F01589-10 11.23 Installing the air filter box cover Condition The air filter box cover is secured.

  • Page 67: Cleaning The Air Filter And Air Filter Box

    SERVICE WORK ON THE CHASSIS 11 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. Preparatory work – Remove the air filter box cover. ( p.

  • Page 68: Installing The Air Filter

    11 SERVICE WORK ON THE CHASSIS 11.26 Installing the air filter Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area Long-life grease ( p. 139) H02459-01 – Insert air filter and position retaining pin in bushing The air filter is correctly positioned.

  • Page 69: Installing The Main Silencer

    SERVICE WORK ON THE CHASSIS 11 – Detach spring Spring hook (50305017000C1) – Remove screws with the washers and take off the main silencer. F01590-10 11.29 Installing the main silencer – Position the main silencer. – Mount screws with the washers, but do not tighten yet. –...

  • Page 70: Removing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS Main work – Remove all the screws on the silencer cap. – Take off silencer cap and O-ring – Pull glass fiber yarn filling out of the silencer cap. – Pull glass fiber yarn filling from the inner tube.
  • Page 71 SERVICE WORK ON THE CHASSIS 11 Main work (All SX‑F models) – Unplug connector of the fuel pump. – Clean plug-in connection of the fuel line thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection F01591-10 valve! –...

  • Page 72: Installing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS – Remove screw with the rubber bushing. F01565-10 – Remove screws with the collar bushings. F01541-10 – Pull both spoilers laterally off the radiator and take off the fuel tank upwards. F01542-10 11.32 Installing the fuel tank Danger Fire hazard Fuel is highly flammable.
  • Page 73 SERVICE WORK ON THE CHASSIS 11 Main work – Check throttle cable routing. ( p. 77) – Position the fuel tank and fit the two spoilers laterally to the radiator. – Make sure that no cables or throttle cables are trapped or dam- aged.

  • Page 74: Checking For Chain Dirt Accumulation

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

  • Page 75: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 Preparatory work – Raise the motorcycle with a lift stand. ( p. 49) Main work – Rinse off loose dirt with a soft jet of water. – Remove old grease residue with chain cleaner. Chain cleaner ( p.

  • Page 76: Adjusting The Chain Tension

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

  • Page 77: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 11 11.37 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 49) Main work – Shift the transmission into neutral. – Check the chain, rear sprocket and engine sprocket for wear. »...
  • Page 78 11 SERVICE WORK ON THE CHASSIS – 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 79: Checking The Frame

    » If the link fork exhibits damage, cracking, or deformation: – Change the link fork. Info Always replace a damaged link fork. Repairing the link fork is not authorized by KTM. S02305-01 11.40 Checking throttle cable routing Preparatory work –...

  • Page 80: Checking The Rubber Grips

    11 SERVICE WORK ON THE CHASSIS Main work – Check 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 81: Adjusting The Basic Position Of The Clutch Lever

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

  • Page 82: Changing The Hydraulic Clutch Fluid

    11 SERVICE WORK ON THE CHASSIS Info Clean up overflowed or spilled brake fluid immediately with water. 11.44 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. –...
  • Page 83 SERVICE WORK ON THE CHASSIS 11 (XC‑F US) – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p. 137) – On the clutch slave cylinder, remove the protection cap and mount bleeding syringe with appropriate hose piece at the bleeder screw F01598-10...

  • Page 84: 12 Brake System

    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 85: 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 86: 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 87: 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 88 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 89: Checking The Free Travel Of Foot Brake Lever

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

  • Page 90: Adjusting The Basic Position Of The Foot Brake Lever

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

  • Page 91: 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 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: Changing The Rear Brake Linings

    Changing the rear brake linings Warning Danger of accidents Incorrect servicing will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation.
  • Page 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, if necessary extract excess. Info Make sure that you do not press the brake calipers against the spokes when pushing back the brake pis- ton.

  • Page 95: Wheels, Tires 13

    WHEELS, TIRES 13 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 49) Main work – Manually press the brake caliper toward the brake disc to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons.

  • Page 96: Installing The Front Wheel

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

  • Page 97: Installing The Rear Wheel

    WHEELS, TIRES 13 Main work – Manually press the brake caliper toward the brake disc to push back the brake piston. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston. –...
  • Page 98 13 WHEELS, TIRES Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surfaces of the spacers. Long-life grease ( p.

  • Page 99: Checking The Tire Condition

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

  • Page 100: Checking Spoke Tension

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

  • Page 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: Charging The 12-V Battery

    14 ELECTRICAL SYSTEM Finishing work – Mount the seat. ( p. 63) 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. –...

  • Page 103: 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 104 14 ELECTRICAL SYSTEM Main work – Pull starter relay from the holder. S02303-10 – 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 105: 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 106: 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 107: Refilling With Coolant

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

  • Page 108: Changing The Coolant

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

  • Page 109: Tuning The Engine

    TUNING THE ENGINE 16 16.1 Checking throttle cable play – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Throttle cable play 3 …...
  • Page 110 16 TUNING THE ENGINE Main work (All SX‑F models) – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut – Push cold start button all the way to the stop.

  • Page 111: Adjusting The Characteristic Map Of The Throttle Response

    TUNING THE ENGINE 16 16.3 Adjusting the characteristic map of the throttle response Info On the throttle grip, the characteristic map of the throttle response is changed by changing the guide plate. A guide plate with a different characteristic map is supplied. Main work –...

  • Page 112: 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 113: Teaching The Throttle Valve

    TUNING THE ENGINE 16 – Run the engine until warm. The cold start button is deactivated – The cold start but- ton is in its basic position. ( p. 19) Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. –...

  • Page 114: Checking The Basic Position Of The Shift Lever

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

  • Page 115: Service Work On The Engine 17

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

  • Page 116: Checking The Engine Oil Level

    17 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.

  • Page 117: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    SERVICE WORK ON THE ENGINE 17 Condition The engine is cold. – Check the engine oil level. The engine oil reaches the middle of level viewer » If the engine oil does not reach the middle of the level viewer: –...
  • Page 118 17 SERVICE WORK ON THE ENGINE – Remove screw plug with oil screen and the O-rings. – Allow the engine oil to drain completely. – Thoroughly clean the parts and sealing surfaces. E01241-10 – Position oil screen with the O-rings on a pin wrench. –...

  • Page 119: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 17 – Lay the motorcycle on its side and fill the oil filter housing to about ⅓ full with engine oil. – Fill the oil filter with engine oil and position the oil filter in the housing.
  • Page 120 17 SERVICE WORK ON THE ENGINE Info For optimal performance of the engine oil, do not mix different types of engine oil. We recommended changing the engine oil when neces- sary. – Mount and tighten the filler plug together with the O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death.

  • Page 121: Cleaning, Care 18

    CLEANING, CARE 18 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 122 18 CLEANING, CARE – After the motorcycle has cooled off, lubricate all moving parts and bearings. – Clean the chain. ( p. 72) – Treat bare metal parts (except for brake discs and the exhaust system) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p.

  • Page 123: Storage 19

    – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with a lift stand. ( p. 49) – Cover the vehicle with a tarp or similar cover that is permeable...

  • Page 124: Putting Into Operation After Storage

    19 STORAGE 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 125: Troubleshooting 20

    – Check the electrical system. – Error in the electronic fuel Read out fault memory using the KTM injection diagnostics tool. – Engine does not speed up Error in the electronic fuel Read out fault memory using the KTM injection diagnostics tool.
  • Page 126 Check the wiring for damage and the lights up or flashes injection electrical plug-in connections for corro- sion and damage. – Read out fault memory using the KTM diagnostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary.

  • Page 127: Blink Code 21

    BLINK CODE 21 Blink code for malfunction indicator lamp 02a Malfunction indicator lamp flashes 2x per second Error level condition Teaching of throttle valve position required Blink code for malfunction indicator lamp 02 Malfunction indicator lamp flashes 2x short Crankshaft speed sensor – circuit fault Error level condition Blink code for malfunction indicator lamp...
  • Page 128 21 BLINK CODE 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 129: Technical Data 22

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

  • Page 130: Engine Tightening Torques

    22 TECHNICAL DATA 22.2 Engine tightening torques Nozzle, crank chamber ventilation 2 Nm (1.5 lbf ft) Loctite ® 243™ Oil nozzle for alternator cooling 2 Nm (1.5 lbf ft) Loctite ® 243™ Oil nozzle for balancer shaft lubri- 2 Nm (1.5 lbf ft) Loctite ®...
  • Page 131 TECHNICAL DATA 22 Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, shift lever 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, starter motor 10 Nm (7.4 lbf ft) Screw, timing chain failure protec- 10 Nm (7.4 lbf ft) Loctite ®...

  • Page 132: Capacities

    22 TECHNICAL DATA Plug, timing chain tensioner M24x1.5 40 Nm (29.5 lbf ft) Screw, alternator cover M24x1.5 18 Nm (13.3 lbf ft) Fixing nut for main bearing inner M27x1 60 Nm (44.3 lbf ft) Loctite ® 243™ ring 22.3 Capacities 22.3.1 Engine oil Engine oil...

  • Page 133: Electrical System

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

  • Page 134: Xc-F Us

    22 TECHNICAL DATA Oil capacity external mechanism ml (7.44 fl. oz.) Fork oil (SAE 4) (48601166S1) + 20 + 0.68 − 40 − 1.35 left p. 138) Oil capacity, right cartridge 380 ml (12.85 fl. oz.) Fork oil (SAE 4) (48601166S1) p.

  • Page 135: Shock Absorber

    TECHNICAL DATA 22 Oil capacity, right cartridge 380 ml (12.85 fl. oz.) Fork oil (SAE 4) (48601166S1) p. 138) Grease capacity, left cartridge 5 g (0.18 oz) Special grease (00062010053) p. 140) 22.8 Shock absorber 22.8.1 SX‑F EU Shock absorber article number 18.18.7T.05 Shock absorber WP XACT 5750...

  • Page 136: Xc-F Us

    22 TECHNICAL DATA Sport 1.5 turns Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 9 mm (0.35 in) Spring rate Weight of rider: 65 … 75 kg (143 … 165 lb.) 39 N/mm (223 lb/in) Weight of rider: 75 …...

  • Page 137: Chassis Tightening Torques

    TECHNICAL DATA 22 22.9 Chassis tightening torques EJOT PT Screw, air filter box cover ® K60x20-Z 3 Nm (2.2 lbf ft) EJOT PT Screw, combination switch ® K50x18 T20 2 Nm (1.5 lbf ft) EJOT DELTA PT ® Screw, intake air temperature sen- 45x12‑Z 0.7 Nm (0.52 lbf ft) Fitting, E-starter button...
  • Page 138 22 TECHNICAL DATA Screw, front brake caliper 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, handlebar clamp 20 Nm (14.8 lbf ft) Screw, manifold on cylinder head 15 Nm (11.1 lbf ft) brace Screw, side stand attachment 33 Nm (24.3 lbf ft) Loctite ®...

  • Page 139: Substances

    SUBSTANCES 23 Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX ®...
  • Page 140 23 SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 141) (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 141: Auxiliary Substances

    AUXILIARY SUBSTANCES 24 Air filter cleaner Recommended supplier MOTOREX ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier...
  • Page 142 24 AUXILIARY SUBSTANCES 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 MOTOREX ®...

  • Page 143: Standards

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

  • Page 144: Index Of Special Terms

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

  • Page 145: List Of Abbreviations

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

  • Page 146: List Of Symbols

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

  • Page 147: Index

    INDEX Chain guide INDEX checking ......75 12-V battery Chain tension installing ......99 adjusting .
  • Page 148 INDEX Foot brake lever ......21 Indicator lamps basic position, adjusting ....88 overview .
  • Page 149 INDEX Steering head bearing play checking ......56 Rear sprocket setting ......57 checking .
  • Page 150 *3214003en* 3214003en 04/2019 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

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