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Related Manuals for KTM 450 SX-F 2018
Summary of Contents for KTM 450 SX-F 2018
- Page 1 OWNER'S MANUAL 2018 450 SX‑F 450 XC-F Art. no. 3213641en...
- Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.
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Page 4: Table Of Contents
TABLE OF CONTENTS RIDING INSTRUCTIONS..........22 TABLE OF CONTENTS MEANS OF REPRESENTATION ........4 Checks and maintenance measures when Symbols used ........... 4 preparing for use..........22 Formats used............ 4 Starting............22 SAFETY ADVICE............5 Activating launch control ......... 23 Use definition –... - Page 5 TABLE OF CONTENTS 11.22 Removing the air filter box cover ...... 49 15.3 Checking the coolant level ....... 82 11.23 Installing the air filter box cover ....... 50 15.4 Draining the coolant ........82 11.24 Removing the air filter ......... 50 15.5 Refilling coolant ..........
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Page 6: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required. -
Page 7: Safety Advice
SAFETY ADVICE Use definition – intended use (All SX‑F models) This vehicle is designed and built to withstand the normal stresses and strains of competitive use. This vehicle complies with the currently valid regulations and categories of the top international motorsport organizations. Info Only operate this vehicle in closed-off areas remote from public road traffic. -
Page 8: Safe Operation
– 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. The tools are not contained in the vehicle but can be ordered under the number in paren- theses. -
Page 9: Owner's Manual
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer. -
Page 10: Important Notes
Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the warranty. -
Page 11: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) A00042-10 Hand brake lever ( p. 12) Clutch lever ( p. 12) Filler cap Air filter box cover Cold start button ( p. 15) Engine number ( p. 11) Shift lever ( p. -
Page 12: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) A00041-10 Shock absorber compression adjustment Combination switch ( p. 13) Kill switch ( p. 12) Electric starter button ( p. 12) Throttle grip ( p. 12) Chassis number ( p. 11) Type label ( p. -
Page 13: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. 401945-10 Type label The type label is fixed to the front of the steering head. 401946-10 Engine number The engine number is stamped on the left side of the engine. H00940-10 Fork part number The fork part number... -
Page 14: Controls
CONTROLS 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 15: Combination Switch
CONTROLS Combination switch The combination switch is fitted on the left side of the handlebar. Possible states STANDARD – STANDARD mapping is activated when LED 1 lights up. STANDARD with TC – STANDARD mapping with traction control is acti- vated when LED 1 and TC light up. ADVANCED –... -
Page 16: Closing The Filler Cap
CONTROLS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. –... -
Page 17: Cold Start Button
CONTROLS 6.11 Cold start button (All SX‑F models) Cold start button is fitted on the bottom of the throttle valve body. F01046-10 (XC‑F US) Cold start button is fitted on the bottom of the throttle valve body. The injection system extends the injection time if the engine is cold and the outside temperature is low. -
Page 18: Idle Speed Adjusting Screw
CONTROLS 6.12 Idle speed adjusting screw The idle setting of the throttle valve body has a big influence on the vehicle's starting behavior, on stable idling, and on vehicle response when the throttle is opened. An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly. -
Page 19: Foot Brake Lever
CONTROLS 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) Support for plug-in stand is the left side of the wheel spindle. The plug-in stand is used to park the motorcycle. -
Page 20: Preparing For Use
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover. -
Page 21: Running In The Engine
PREPARING FOR USE – Try also to ride as slowly as possible and in a standing position to get a better feeling for the motorcycle. – Do not make any off-road trips that exceed your ability and experience. – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. (All SX‑F models) –... -
Page 22: Preparing For Rides On Dry Sand
– Fit a dust cover on the air filter. Dust protection device for air filter (79006920000) Info See the KTM PowerParts fitting instructions. 102136-01 – Fit a sand cover on the air filter. Sand protection device for air filter (79006922000) Info See the KTM PowerParts fitting instructions. -
Page 23: Preparing For Rides On Wet And Muddy Surfaces
Preparing for rides on wet and muddy surfaces – Fit a waterproofing device on the air filter. Waterproofing device for air filter (79006921000) Info See the KTM PowerParts fitting instructions. 102137-01 – Fit the steel sprocket. – Clean the motorcycle. ( p. -
Page 24: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –... -
Page 25: Activating Launch Control
RIDING INSTRUCTIONS (XC‑F US) – Take the motorcycle off side stand and secure the side stand with rubber band – Shift the transmission to idle. Condition Ambient temperature: < 20 °C (< 68 °F) – Push the cold start button in all the way. 401944-10 –... -
Page 26: Starting Off
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 27: Stopping, Parking
RIDING INSTRUCTIONS – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. – On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine. In this way, you have to apply the brakes far less frequently and the brake system does not overheat. -
Page 28: 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.) Warning Environmental hazard Improper handling of fuel is a danger to the environment. -
Page 29: Service Schedule
Every 20 operating hours Every 10 operating hours/after every race Once after 1 operating hour ○ ● ● ● ● Read out the fault memory using the KTM diagnostics tool. ● ● ● ● Check and charge the battery. ● ●... -
Page 30: Recommended Work
Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● ● ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval Recommended work... -
Page 31: Tuning The Chassis
For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swingarm and frame, the basic settings of the suspension components must match the rider's weight. – As delivered, KTM offroad motorcycles are adjusted for an average rider's weight (with full protective clothing). Guideline Standard rider weight 75…... -
Page 32: Adjusting The Low-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 low-speed setting can be seen in slow to normal compression of the shock absorber. -
Page 33: Adjusting The Rebound Damping Of The Shock Absorber
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled 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 34: Measuring Rear Wheel Sag Unloaded
TUNING THE CHASSIS 10.7 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with a lift stand. ( p. 39) Main work – Position the sag gauge in the rear axle and measure the distance to marking SAG on the rear fender. -
Page 35: 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 Before changing the spring pretension, make a note of the present setting, e.g., by measuring the length of the spring. -
Page 36: Adjusting The Riding Sag
TUNING THE CHASSIS – Check the free travel of the foot brake lever. ( p. 68) – Remove the motorcycle from the lift stand. ( p. 39) 10.11 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. -
Page 37: 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 pump or the fork. Read the accompanying KTM PowerParts instructions. – Adjust the air pressure as specified. Guideline Air pressure (SX‑F EU) -
Page 38: Adjusting The Compression Damping Of The Fork
TUNING THE CHASSIS 10.14 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn adjusting screw clockwise all the way. Info Adjusting screw is located at the upper end of the right fork leg. –... -
Page 39: Handlebar Position
TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. – Mount protection cap 10.16 Handlebar position The holes on the handlebar supports are placed at a distance of from the center. Hole distance A 3.5 mm (0.138 in) The handlebar can be mounted in 2 different positions. - Page 40 TUNING THE CHASSIS Finishing work – Mount the handlebar cushion.
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Page 41: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (78129955100) Neither wheel is in contact with the ground. -
Page 42: Cleaning The Dust Boots Of The Fork Legs
SERVICE WORK ON THE CHASSIS 11.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 39) – Remove the fork protector. ( p. 40) Main work – Push dust boots of both fork legs downward. -
Page 43: Removing The Fork Legs
SERVICE WORK ON THE CHASSIS 11.7 Removing the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 39) – Remove the front wheel. p. 73) Main work – Remove screws and take off the clamp. –... -
Page 44: Removing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS 11.9 Removing the lower triple clamp Preparatory work – Raise the motorcycle with a lift stand. ( p. 39) – Remove the front wheel. p. 73) – Remove the fork legs. p. 41) – Remove the start number plate. ( p. - Page 45 SERVICE WORK ON THE CHASSIS – Position the upper triple clamp with the handlebar. – Mount screw but do not tighten yet. S01213-10 – Position the fork legs. Bleeder screw of the right fork leg is positioned to the front. Valve of the left fork leg faces the front.
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Page 46: Checking The Steering Head Bearing Play
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam- aged over time. -
Page 47: Greasing The Steering Head Bearing
SERVICE WORK ON THE CHASSIS Main work – Loosen screws – Remove screw – Loosen and retighten screw Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) – Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses. –... -
Page 48: Removing The Front Fender
SERVICE WORK ON THE CHASSIS 11.16 Removing the front fender Preparatory work – Remove the start number plate. ( p. 45) Main work – Remove screws . Remove the front fender. S01218-10 11.17 Installing the front fender Main work – Position the front fender. -
Page 49: Installing The Shock Absorber
SERVICE WORK ON THE CHASSIS – Remove screw – Remove fitting Info Raise the wheel slightly to be able to remove the screws more easily. S01220-10 – Remove screws – Pull off foot brake cylinder from the push rod. V00289-10 –... - Page 50 SERVICE WORK ON THE CHASSIS – Position the swingarm and mount the swingarm pivot. Info Pay attention to flat area – Mount and tighten nut Guideline Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) V00292-10 – Mount the chain. –...
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Page 51: Removing The Seat
SERVICE WORK ON THE CHASSIS 11.20 Removing the seat – Remove screws S01230-10 – Raise the rear of the seat, pull the seat back, and lift it off. H02218-10 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. -
Page 52: Installing The Air Filter Box Cover
SERVICE WORK ON THE CHASSIS – Pull off the air filter box cover in area sideways and remove it toward the front. V00310-11 11.23 Installing the air filter box cover – Insert the air filter box cover in area and clip it into area V00310-12 Condition The air filter box cover is secured. -
Page 53: Cleaning The Air Filter And Air Filter Box
SERVICE WORK ON THE CHASSIS 11.25 Cleaning the air filter and air filter box Warning 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 regu- lations. -
Page 54: Securing The Air Filter Box Cover
SERVICE WORK ON THE CHASSIS 11.27 Securing the air filter box cover Preparatory work – Remove the air filter box cover. ( p. 49) Main work – Drill a hole at marking Guideline Diameter 6 mm (0.24 in) S00846-10 Finishing work –... -
Page 55: Changing The Glass Fiber Yarn Filling Of The Main Silencer
SERVICE WORK ON THE CHASSIS 11.31 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. Info Over time, the fibers of the glass fiber yarn escape and the damper "burns"... - Page 56 SERVICE WORK ON THE CHASSIS 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 valve! V00293-10 –...
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Page 57: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS – Remove screws with the collar bushings. S01241-10 – Pull both spoilers off the sides of the radiator bracket and lift off the fuel tank. S01245-10 11.33 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. -
Page 58: Checking For Chain Dirt Accumulation
SERVICE WORK ON THE CHASSIS (All SX‑F models) – Mount and tighten screw with the rubber bushing. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) S01242-11 – 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. -
Page 59: Cleaning The Chain
SERVICE WORK ON THE CHASSIS 11.35 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. – Remove the lubricant from the tires using a suitable cleaning agent. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –... -
Page 60: Adjusting The Chain Tension
SERVICE WORK ON THE CHASSIS » If the chain tension does not meet specifications: – Adjust the chain tension. ( p. 58) Finishing work – Remove the motorcycle from the lift stand. ( p. 39) 11.37 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. - Page 61 SERVICE WORK ON THE CHASSIS – Pull at the top part of the chain with the specified weight Guideline Weight, chain wear measurement 10… 15 kg (22… 33 lb.) – Measure distance of 18 chain rollers in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions.
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Page 62: Checking The Frame
If the frame exhibits cracks or deformation due to a mechanical impact: – Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by KTM. F01029-01 11.40 Checking the swingarm –... -
Page 63: Checking The Rubber Grips
SERVICE WORK ON THE CHASSIS 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 fuel tank contact area rubber band. -
Page 64: Checking/Correcting The Fluid Level Of The Hydraulic Clutch
SERVICE WORK ON THE CHASSIS 11.44 Checking/correcting the fluid level of the hydraulic clutch Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. - Page 65 SERVICE WORK ON THE CHASSIS – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane F00158-10 (All SX‑F models) – Fill bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p.
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Page 66: Brake System
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.) – Check the thickness of the front and rear brake discs at multiple points on each... -
Page 67: Checking The Brake Fluid Level Of The Front Brake
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. – 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 Old brake fluid reduces the braking effect. -
Page 68: 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 ≥ 1 mm (≥ 0.04 in) Minimum thickness »... -
Page 69: Changing The Front Brake Linings
Changing the front brake linings Warning Danger of accidents Incorrect maintenance 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 70: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. B00352-10 – Insert the new brake linings, insert pin , and mount cotter pins Info Always change the brake linings in pairs. –... -
Page 71: Adjusting The Basic Position Of The Foot Brake Lever
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. – 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 Old brake fluid reduces the braking effect. -
Page 72: Adding Rear Brake Fluid
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation. -
Page 73: Changing The Rear Brake Linings
Changing the rear brake linings Warning Danger of accidents Incorrect maintenance 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 74 BRAKE SYSTEM – Manually press the brake caliper to the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.
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Page 75: Wheels, Tires
WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 39) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. -
Page 76: Removing The Rear Wheel
WHEELS, TIRES – Clean and grease the wheel spindle. Long-life grease ( p. 109) – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw Guideline Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) -
Page 77: Installing The Rear Wheel
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 78: Checking The Tire Condition
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low, then lateral and radial run-out will form in the wheel. 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 79 WHEELS, TIRES – Strike each spoke briefly using a screwdriver blade. Info The frequency of the sound depends on the spoke length and spoke diame- ter. If you hear different tone frequencies from different spokes of equal length and diameter, this is an indication of different spoke tensions. You should hear a high note.
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Page 80: Electrical System
ELECTRICAL SYSTEM 14.1 Removing the battery Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batteries. – Only charge batteries in well-ventilated rooms. – Maintain a minimum clearance from inflammable materials when charging batteries. -
Page 81: Recharging The Battery
ELECTRICAL SYSTEM 14.3 Recharging the battery Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batteries. – Only charge batteries in well-ventilated rooms. – Maintain a minimum clearance from inflammable materials when charging batteries. -
Page 82: Changing The Main Fuse
ELECTRICAL SYSTEM – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test the open-circuit voltage and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the battery. -
Page 83: Cooling System
COOLING SYSTEM 15.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions. -
Page 84: Checking The Coolant Level
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 85: Refilling Coolant
COOLING SYSTEM – Position the motorcycle upright. – Place a suitable container under the water pump cover. – Remove screw . Take off radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Screw, water pump cover 10 Nm (7.4 lbf ft) -
Page 86: Tuning The Engine
TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3…... -
Page 87: Setting The Characteristic Map Of The Throttle Response
TUNING THE ENGINE – Check the throttle grip for smooth operation. (XC‑F US) – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut –... -
Page 88: 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 89: Teaching The Throttle Valve Position
TUNING THE ENGINE – Run the engine until warm. The cold start button is deactivated – The cold start button is in its basic posi- tion. ( p. 15) Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. -
Page 90: Adjusting The Basic Position Of The Shift Lever
TUNING THE ENGINE – Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the shift lever. Distance between shift lever and upper 10… 20 mm (0.39… 0.79 in) edge of boot »... -
Page 91: Service Work On The Engine
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 refuel the vehicle in the vicinity of open flames or lit cigarettes. –... -
Page 92: Checking The Engine Oil Level
SERVICE WORK ON THE ENGINE (XC‑F US) – 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 valve! – Disconnect the plug-in connection of the fuel line. -
Page 93: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens
SERVICE WORK ON THE ENGINE 17.3 Changing the engine oil and oil filter, cleaning the oil screens Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden. – Wear suitable protective clothing and safety gloves. –... - Page 94 SERVICE WORK ON THE ENGINE – Position oil screen with the O-rings on a pin wrench. – Position the pin wrench through the drilled hole of the screw plug in the opposite section of the engine case. – Push the oil screen all the way into the engine case. V00306-10 –...
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Page 95: Adding Engine Oil
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 an effective exhaust extraction system when starting or running the engine in an enclosed space. -
Page 96: Cleaning, Care
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 97: Storage
– Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with a lift stand. ( p. 39) – Cover the vehicle with a tarp or similar cover that is permeable to air. -
Page 98: Preparing For Use After Storage
STORAGE 19.2 Preparing for use after storage – Install the battery. p. 78) – Remove the motorcycle from the lift stand. ( p. 39) – Perform checks and maintenance measures when preparing for use. ( p. 22) – Make a test ride. 401059-01... -
Page 99: Troubleshooting
– Check the electrical system. – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. - Page 100 TROUBLESHOOTING Faults Possible cause Action – Battery is discharged Battery is not charging Check the charging voltage. – Check the stator winding of the alternator. – Unwanted power consumer Check the open-circuit current.
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Page 101: Technical Data
TECHNICAL DATA 21.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 449.9 cm³ (27.455 cu in) Stroke 63.4 mm (2.496 in) Bore 95 mm (3.74 in) Compression ratio 12.75:1 Idle speed 2,250… 2,350 rpm Control OHC, 4 valves controlled via rocker arm Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust... - Page 102 TECHNICAL DATA Loctite ® 243™ Screw, gear position sensor 5 Nm (3.7 lbf ft) Screw, locking lever 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, stator 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, suction pump cover 6 Nm (4.4 lbf ft) Loctite ®...
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Page 103: Capacities
TECHNICAL DATA 21.3 Capacities 21.3.1 Engine oil Engine oil 1.20 l (1.27 qt.) Engine oil (SAE 10W/50) ( p. 107) 21.3.2 Coolant Coolant 1.20 l (1.27 qt.) Coolant ( p. 107) 21.3.3 Fuel Total fuel tank capacity, 7 l (1.8 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. -
Page 104: 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 21.7 Fork 21.7.1 SX‑F EU Fork article number 34.18.8R.09... -
Page 105: Xc-F Us
TECHNICAL DATA Standard 12 clicks Sport 7 clicks Air pressure 10.8 bar (157 psi) Fork length 950 mm (37.4 in) Oil capacity external mecha- ml (6.76 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 107) +1.35 −20 −0.68 nism right Oil capacity external mecha- ml (6.76 fl. -
Page 106: Sx-F Us
TECHNICAL DATA Weight of rider: 85… 95 kg (187… 209 lb.) 48 N/mm (274 lb/in) Spring length 260 mm (10.24 in) Gas pressure 10 bar (145 psi) Static sag 35 mm (1.38 in) Riding sag 105 mm (4.13 in) Fitted length 477 mm (18.78 in) Shock absorber oil Shock absorber fluid (SAE 2.5) (50180751S1) (... -
Page 107: Chassis Tightening Torques
TECHNICAL DATA Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 39 N/mm (223 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 45 N/mm (257 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 48 N/mm (274 lb/in) Spring length 260 mm (10.24 in) Gas pressure... - Page 108 TECHNICAL DATA Loctite ® 2701™ Screw, subframe 35 Nm (25.8 lbf ft) Screw, top steering stem 20 Nm (14.8 lbf ft) Loctite ® 243™ – Screw, top triple clamp 17 Nm (12.5 lbf ft) – Engine carrying screw 60 Nm (44.3 lbf ft) –...
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Page 109: Substances
SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corre- sponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 Motorex ®... - Page 110 SUBSTANCES Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification – DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e.
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Page 111: Auxiliary Substances
AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier Motorex ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier Motorex... - Page 112 AUXILIARY SUBSTANCES Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic...
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Page 113: Standards
STANDARDS JASO T903 MA Different technical development directions required a separate specification for 4-stroke motorcycles – the JASO T903 MA standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation. -
Page 114: Index Of Special Terms
INDEX OF SPECIAL TERMS On-board diagnosis Vehicle system that monitors emission- and safety-related values... -
Page 115: List Of Abbreviations
LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly... -
Page 116: List Of Symbols
LIST OF SYMBOLS 27.1 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 emission- or safety-critical fault. -
Page 117: Index
INDEX Clutch INDEX fluid level, checking/correcting ....62 Accessories ........8 fluid, changing . - Page 118 INDEX Fork protector raising with lift stand ......39 installing ....... . . 40 removing from lift stand .
- Page 119 INDEX Spare parts ........8 Spoke tension checking .
- Page 120 *3213641en* 3213641en 03/2017 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...