KTM 450 SX-F 2020 Owner's Manual
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KTM 450 SX-F 2020 Owner's Manual

KTM 450 SX-F 2020 Owner's Manual

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OWNER'S MANUAL
2020
450 SX‑F
450 XC-F
Art. no. 3214005en

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Summary of Contents for KTM 450 SX-F 2020

  • Page 1 OWNER'S MANUAL 2020 450 SX‑F 450 XC-F Art. no. 3214005en...
  • 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 ........104 22.8 Shock absorber ......133 22.8.1 SX‑F EU........133 15.1 Cooling system ......104 22.8.2 SX‑F US........134 15.2 Checking the antifreeze and 22.8.3 XC‑F US........135 coolant level ........104 22.9 Chassis tightening torques ....

  • 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) F01516-10 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) F01517-10 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 The engine number is stamped on the left side of the engine.

  • 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. F01520-10 (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. 113) – 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 Riding Conditions

    Preparing the vehicle for rides 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 Rides On Wet Sand

    600868-01 Preparing the vehicle for rides 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. 140) –...

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

    Straighten bent radiator fins carefully. – Check the coolant level. ( p. 105) 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 to the neutral position. 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 the 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 fault memory using the KTM diagnostics tool after a test ride. ○ ● ● ● ● ● Make a service entry in 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 down 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. – Tension 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 11.3 Bleeding the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 49) Main work – Release bleeder screws Any excess pressure escapes from the interior of the fork. –...

  • Page 53: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11 11.5 Removing the fork protector – Remove screws and take off the clamp. – Remove screws and take off the left fork protector. – Remove screws and take off the right fork protector. S01208-10 11.6 Installing the fork protector –...

  • 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. 94) – 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. 140) – 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 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: Lubricating The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS 11 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 F02213-10 to avoid stresses.

  • Page 60: Installing The Start Number Plate

    11 SERVICE WORK ON THE CHASSIS 11.15 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. F01525-10 11.16 Removing front fender...

  • 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. F01554-10 – 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 fork pivot. Info Pay attention to flat area – Mount and tighten nut Guideline Nut, fork pivot M16x1.5 100 Nm (73.8 lbf ft) F01532-10 – 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 laterally and take it off at the front. F01535-10 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. 140) H02459-01 – Insert air filter and position retaining pin in bushing The air filter is correctly positioned.

  • Page 69: Installing The Silencer

    SERVICE WORK ON THE CHASSIS 11 – Detach spring Spring hook (50305017000C1) – Remove screws with the washers and take off the silencer. F01538-10 11.29 Installing the silencer – Position the 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 main silencer. – Take off silencer cap and O-ring – Take off outer tube and O-ring – Pull glass fiber yarn filling off of inner tube –...
  • Page 71 SERVICE WORK ON THE CHASSIS 11 (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! F01539-10 –...

  • 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 to the neutral position. –...
  • 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

    – Change the frame. Info Always replace a frame that has been dam- aged due to a mechanical impact. Repair of the frame is not authorized by KTM. S02306-01 11.39 Checking the link fork – Check the link fork for damage, cracking, and deformation.

  • 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 Info Immediately clean up any brake fluid that has over- flowed or spilled with water. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container. (XC‑F US) –...

  • 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 – 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 89 BRAKE SYSTEM 12 – Remove cotter pins , pull out pin , and remove the brake linings. – Clean the brake caliper and the brake caliper bracket. – Check that spring plate in the brake caliper and sliding plate in the brake caliper bracket are seated properly. 100397-01 –...

  • Page 90: Checking The Free Travel Of Foot Brake Lever

    12 BRAKE SYSTEM 12.8 Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.

  • 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 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 93: 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 94 12 BRAKE SYSTEM 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 Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
  • Page 95 BRAKE SYSTEM 12 – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 138) – Mount and tighten screw cap with membrane and the O-ring. Info Immediately clean up any brake fluid that has over- flowed or spilled with water.

  • Page 96: 13 Wheels, Tires

    13 WHEELS, TIRES 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 97: Installing The Front Wheel

    WHEELS, TIRES 13 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 98: Installing The Rear Wheel

    13 WHEELS, TIRES 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 99 WHEELS, TIRES 13 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 100: 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 101: 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 102: 14 Electrical System

    14 ELECTRICAL SYSTEM 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 103: Charging The 12 V Battery

    ELECTRICAL SYSTEM 14 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 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 ELECTRICAL SYSTEM 14 Preparatory work – Press and hold the kill switch while the engine is idling until the engine stops. – Remove the seat. ( p. 62) Main work – Pull starter relay from the holder. S02303-10 – Take off protection caps –...

  • Page 106: 15 Cooling System

    15 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 operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 107: Checking The Coolant Level

    COOLING SYSTEM 15 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 108: Refilling With Coolant

    15 COOLING SYSTEM 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 109: Changing The Coolant

    COOLING SYSTEM 15 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 110: Tuning The Engine

    16 TUNING THE ENGINE 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 111 TUNING THE ENGINE 16 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 112: Adjusting The Characteristic Map Of

    16 TUNING THE ENGINE 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 113: 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 114: Teaching 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. 19) Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. –...

  • Page 115: 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. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load. –...

  • Page 116: 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 refuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 117: Checking The Engine Oil Level

    SERVICE WORK ON THE ENGINE 17 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 118: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens

    17 SERVICE WORK ON THE ENGINE 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 119 SERVICE WORK ON THE ENGINE 17 – Remove screw plug with the short oil screen and the O- rings. Info Do not remove screw S02288-10 – Remove screw plug with long oil screen and the O- rings. – Allow the engine oil to drain completely. –...
  • Page 120 17 SERVICE WORK ON THE ENGINE – Remove screws . Remove the oil filter cover with the O-ring. S02293-10 – Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) – Allow the engine oil to drain completely. –...

  • Page 121: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 17 Finishing work – Check the engine oil level. ( p. 115) 17.4 Adding engine oil Info Too little engine oil or poor-quality engine oil will result in premature wear of the engine. – Remove filler plug with the O-ring.

  • Page 122: 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 123 CLEANING, CARE 18 – 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 124: 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. 49) – Cover the vehicle with a tarp or similar cover that is permeable...

  • Page 125: 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 126: Troubleshooting

    Check the electrical system. – Error in the electronic fuel Read out the fault memory using the injection KTM diagnostics tool. – Engine does not speed up Error in the electronic fuel Read out the fault memory using the injection KTM diagnostics tool.
  • Page 127 – 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 128: Blink Code

    21 BLINK CODE 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 129 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 130: 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 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 131: Engine Tightening Torques

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

  • Page 132: Capacities

    22 TECHNICAL DATA Screw, water pump cover 10 Nm (7.4 lbf ft) Oil nozzle for conrod bearing lubri- M6x0.75 2 Nm (1.5 lbf ft) cation Plug, oil channel 9 Nm (6.6 lbf ft) Loctite ® 243™ Screw, rocker arm bearing 15 Nm (11.1 lbf ft) Plug, crankshaft location 10 Nm (7.4 lbf ft)

  • Page 133: Chassis

    TECHNICAL DATA 22 22.4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork WP XACT 5548 Suspension travel front 310 mm (12.2 in) rear 300 mm (11.81 in) Fork offset 22 mm (0.87 in) Shock absorber WP XACT 5750 Brake system Disc brakes, floating brake calipers Brake discs - diameter...

  • Page 134: Tires

    110/100 - 18 64M TT (XC‑F US) 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.09...

  • Page 135: Shock Absorber

    TECHNICAL DATA 22 Sport 13 clicks Air pressure 10.5 bar (152 psi) Fork length 950 mm (37.4 in) Oil capacity external mechanism ml (6.76 fl. oz.) Fork oil (SAE 4) (48601166S1) + 40 + 1.35 − 20 − 0.68 right p.

  • Page 136: Sx-F Us

    22 TECHNICAL DATA Sport 1 turn Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 8 mm (0.31 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 22.8.3 XC‑F US Shock absorber article number 18.18.7T.79 Shock absorber WP XACT 5750 Lowspeed compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Highspeed compression damping Comfort 2.5 turns Standard 2 turns Sport 1.5 turns Rebound damping Comfort 17 clicks...
  • Page 138 22 TECHNICAL DATA Screw, frame protector 3 Nm (2.2 lbf ft) Screw, shock absorber adjusting 5 Nm (3.7 lbf ft) ring Nut, cable on starter motor 4 Nm (3 lbf ft) Remaining nuts, chassis 10 Nm (7.4 lbf ft) Remaining screws, chassis 10 Nm (7.4 lbf ft) Screw, ball joint of push rod on 10 Nm (7.4 lbf ft)
  • 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, fuel pump 15 Nm (11.1 lbf ft) Nut, angle lever to link fork M14x1.5 60 Nm (44.3 lbf ft) Nut, frame on linkage lever...

  • Page 140: 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: 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 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 144: 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

    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...

  • Page 146: Adjusting The Throttle Cable

    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

    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 an error in the vehicle electronics.

  • Page 148: Index

    INDEX cleaning ......72 INDEX Chain guide 12 V battery checking ......75 charging .
  • Page 149 INDEX Idle speed adjusting screw ....20 Implied warranty ......10 Figures .
  • Page 150 INDEX Starting power of lithium-ion batteries at low tempera- tures ....... 23 Rear sprocket Steering head bearing checking .
  • Page 151 *3214005en* 3214005en 04/2019 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

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