KTM 250 SX-F 2021 Owner's Manual
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KTM 250 SX-F 2021 Owner's Manual

KTM 250 SX-F 2021 Owner's Manual

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OWNER'S MANUAL
2021
250 SX-F
250 XC‑F
250 SX‑F TROY LEE DESIGNS
Art. no. 3214213en

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Summary of Contents for KTM 250 SX-F 2021

  • Page 1 OWNER'S MANUAL 2021 250 SX-F 250 XC‑F 250 SX‑F TROY LEE DESIGNS Art. no. 3214213en...
  • 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 6.16 Plug-in stand (all SX‑F models) ..21 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 6.17 Side stand (XC‑F US) ....... 21 Symbols used ........5 PREPARING FOR USE......... 22 Formats used........5 Advice on preparing for first use ..22 SAFETY ADVICE..........
  • Page 5 TABLE OF CONTENTS 10.8 Checking the static sag of the shock 11.29 Cleaning the air filter and air filter absorber.......... 41 ..........69 10.9 Checking the riding sag of the shock 11.30 Installing the air filter ....70 absorber.......... 42 11.31 Preparing air filter box cover for 10.10 Adjusting the spring preload of the securing...
  • Page 6 TABLE OF CONTENTS 13.6 Checking tire pressure ....105 22.2 Engine tightening torques ....137 13.7 Checking the spoke tension..... 105 22.3 Capacities ........139 22.3.1 Engine oil ......... 139 14 ELECTRICAL SYSTEM ....... 107 22.3.2 Coolant ........139 14.1 Removing the 12-V battery ..

  • 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 Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key).

  • Page 11: Owner's Manual

    The Owner's Manual can be downloaded several times using the QR code or the link on the delivery certificate. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. A printed copy can also be ordered from your authorized KTM dealer.

  • Page 12: Important Notes

    Manufacturer warranty, implied warranty The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con- firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

  • Page 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) Stop button ( p. 15) Start button ( p. 16) Throttle grip ( p. 15) Vehicle identification number ( p. 13) Type label ( 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: Start Button

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

  • Page 19: Service Hour Counter

    Connectivity unit (TROY LEE DESIGNS) The connectivity unit is attached to the handlebar in the han- dlebar cushion. The KTM MY RIDE app guides you through operation of the connec- tivity unit. Possible states Connectivity unit indicator lamp lights up / flashes red –...

  • Page 20: Closing The Fuel Tank Filler Cap

    6 CONTROLS (all SX‑F models) – Turn fuel tank filler cap counterclockwise and lift it off. F01518-10 (XC‑F US) – Press release button , turn the fuel tank filler cap coun- terclockwise, and lift it off. F01557-10 6.11 Closing the fuel tank filler cap (all SX‑F models) –...

  • Page 21: Cold Start Button

    CONTROLS 6 6.12 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 6.13 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 6.15 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 6.16 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. 94) – Adjust the basic position of the shift lever. p. 121) – 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. 150) –...

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

    Straighten bent radiator fins carefully. – Check the coolant level. ( p. 112) 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 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 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 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 48 months every 12 months Every 100 operating hours Every 50 operating hours After 20 operating hours After 10 operating hours ● ● Perform minor engine service including removing and installing engine. (Change spark plug and spark plug connector. Change piston, check and measure cylin- der;...

  • 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 compression adjuster 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 compression adjuster 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) Pin, sag scale (00029990010) – Note the value as dimension 402415-10 Finishing work –...

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

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

  • Page 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) Info If the spring cannot be fully released, the spring must be removed to accurately measure the spring length. –...

  • Page 46: Checking The Basic Setting Of The Fork

    10 TUNING THE CHASSIS Main work – Choose and mount a suitable spring. Guideline Spring rate (All EU models) 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 …...

  • 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.

  • Page 48: Adjusting The Compression Damping Of The Fork

    10 TUNING THE CHASSIS Guideline Air pressure (All EU models) 10.4 bar (151 psi) Air pressure (SX‑F US) 10.5 bar (152 psi) Air pressure (XC‑F US) 9.8 bar (142 psi) Gradual changing of the air 0.2 bar (3 psi) pressure in steps of Minimum air pressure 7 bar (102 psi) Maximum air pressure...

  • Page 49: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS 10 Guideline Compression damping (All EU models) Comfort 17 clicks Standard 12 clicks Sport 7 clicks Compression damping (SX‑F US) Comfort 17 clicks Standard 12 clicks Sport 7 clicks Compression damping (XC‑F US) Comfort 17 clicks Standard 12 clicks Sport 7 clicks...

  • Page 50: Handlebar Position

    10 TUNING THE CHASSIS Info Turn clockwise to increase the damping; turn counter- clockwise to reduce damping when the shock absorber rebounds. 10.16 Handlebar position The holes on the handlebar supports are placed at a distance from the center. Hole distance A 3.5 mm (0.138 in) The handlebar can be mounted in 2 different positions.
  • Page 51 TUNING THE CHASSIS 10 Info Make sure the cables and wiring are positioned cor- rectly. – Position the handlebar clamp. – Mount screws but do not tighten yet. – First bolt the handlebar clamp with screws onto the longer, higher side of the handlebar supports so that both parts touch. –...

  • Page 52: 11 Service Work On The Chassis

    11 SERVICE WORK ON THE CHASSIS 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 53: Bleeding The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 (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 54: Removing The Handlebar Cushion (Troy Lee Designs)

    11 SERVICE WORK ON THE CHASSIS Universal oil spray ( p. 151) – Press the dust boots back into their installation position. – Remove excess oil. Finishing work – Install the fork protector. ( p. 53) – Remove the motorcycle from the lift stand. ( p.

  • Page 55: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11 11.8 Installing the fork protector – Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position the brake line and clamp. Mount and tighten screws –...

  • Page 56: Removing The Fork Legs

    11 SERVICE WORK ON THE CHASSIS – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis F02589-11 11.11 Removing the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 50) – Remove the front wheel.

  • Page 57: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 11.12 Installing the fork legs Main work – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front. Valve of the left fork leg faces the front. Info Grooves are milled into the side of the upper end of the fork legs.

  • Page 58: Removing The Lower Triple Clamp

    11 SERVICE WORK ON THE CHASSIS 11.13 Removing the lower triple clamp Preparatory work – Raise the motorcycle with a lift stand. ( p. 50) – Remove the front wheel. p. 100) – Remove the fork legs. p. 54) – Remove the start number plate.

  • Page 59: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11 11.14 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 150) – Insert the lower triple clamp with the steering stem. Mount upper steering head bearing.
  • Page 60 11 SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, bottom 12 Nm (8.9 lbf ft) triple 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 61 SERVICE WORK ON THE CHASSIS 11 – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front. Valve of the left fork leg faces the front. Info Grooves are milled into the side of the upper end of the fork legs.

  • Page 62: 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 63: Adjusting The Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 11 Finishing work – Remove the motorcycle from the lift stand. ( p. 50) 11.16 Adjusting the steering head bearing play Preparatory work – Raise the motorcycle with a lift stand. ( p. 50) – Remove the handlebar cushion.

  • Page 64: Lubricating The Steering Head Bearing

    11 SERVICE WORK ON THE CHASSIS – Remove the motorcycle from the lift stand. ( p. 50) 11.17 Lubricating the steering head bearing – Remove the lower triple clamp. p. 56) – Install the lower triple clamp. p. 57) Info The steering head bearing is cleaned and lubricated in the course of removal and installation of the lower triple clamp.

  • Page 65: Installing Front Fender

    SERVICE WORK ON THE CHASSIS 11 Main work – Remove screws . Take off the front fender. F01526-10 11.21 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...

  • Page 66: Removing The Shock Absorber

    11 SERVICE WORK ON THE CHASSIS 11.22 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 50) Main work – Remove the cable ties. – Remove screws with the washers. – Remove screw –...

  • Page 67: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 – Hold the shock absorber and remove screw – Remove the shock absorber carefully at the bottom. F01584-10 11.23 Installing the shock absorber Main work – Carefully position the shock absorber into the vehicle from the bottom.

  • Page 68: Removing The Seat

    11 SERVICE WORK ON THE CHASSIS – Position the angle lever and linkage lever. – Mount and tighten fitting Guideline Nut, linkage lever on M14x1.5 60 Nm (44.3 lbf ft) angle lever Info Pay attention to flat area S01229-10 – Mount and tighten screw Guideline Screw, bottom...

  • Page 69: Mounting The Seat

    SERVICE WORK ON THE CHASSIS 11 – Remove screw F01533-10 – Raise the rear of the seat, pull the seat back, and lift it off. H02218-10 11.25 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 70: Installing The Air Filter Box Cover

    11 SERVICE WORK ON THE CHASSIS – Remove screw F01588-10 – Pull off the air filter box cover in area sideways and take off toward the front. F01588-11 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.

  • Page 71: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 Condition The air filter box cover is not secured. – Insert the air filter box cover in area and clip it into area F01589-11 11.28 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter.

  • Page 72: Installing The Air Filter

    11 SERVICE WORK ON THE CHASSIS Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 150) Info Only press the air filter to dry it, never wring it out. –...

  • Page 73: Preparing Air Filter Box Cover For Securing

    SERVICE WORK ON THE CHASSIS 11 11.31 Preparing air filter box cover for securing Preparatory work – Remove the air filter box cover. ( p. 67) Main work – Drill a hole at marking Guideline Diameter 6 mm (0.24 in) S02308-10 Finishing work –...

  • Page 74: Installing The Main Silencer

    11 SERVICE WORK ON THE CHASSIS 11.33 Installing the main silencer (SX‑F EU/US, XC-F US) – Position the main silencer. – Mount screws with the washers, but do not tighten yet. – Attach spring Spring hook (50305017000C1) – Tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft)
  • Page 75 SERVICE WORK ON THE CHASSIS 11 Main work (SX‑F EU/US, XC-F US) – Remove all the screws on the main silencer. – Take off silencer cap and O-ring – Pull glass fiber yarn filling out of the silencer cap. – Pull glass fiber yarn filling from the inner tube.

  • Page 76: Removing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS 11.35 Removing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...
  • Page 77 SERVICE WORK ON THE CHASSIS 11 – Remove screw with the rubber bushing. K01034-10 (XC‑F US) – Unplug connector of the fuel pump. – Clean quick release coupling thoroughly with com- pressed air. Info Under no circumstances should dirt enter into the fuel line.

  • Page 78: Installing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS – Pull both spoilers laterally off the radiator and lift off the fuel tank. F01542-10 11.36 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 79 SERVICE WORK ON THE CHASSIS 11 (all SX‑F models) – Mount and tighten screw with the rubber bushing. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis K01034-11 – Plug in connector for the fuel pump. – Remove the wash cap set. Clean the quick release coupling thoroughly with compressed air.

  • Page 80: Checking For Chain Dirt Accumulation

    11 SERVICE WORK ON THE CHASSIS Info Route the cable and fuel line at a safe distance from the exhaust system. Finishing work – Mount the seat. ( p. 67) 11.37 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. »...

  • Page 81: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 Finishing work – Remove the motorcycle from the lift stand. ( p. 50) 11.39 Checking 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.

  • Page 82: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    11 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 55 … 58 mm (2.17 … 2.28 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks...
  • Page 83 SERVICE WORK ON THE CHASSIS 11 – Pull on the top section of the chain with the specified weight Guideline Weight, chain wear measure- 10 … 15 kg (22 … 33 lb.) ment – Measure distance of 18 chain rollers in the lower chain section.
  • Page 84 11 SERVICE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated.

  • Page 85: 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 11.44 Checking the throttle cable routing Preparatory work –...

  • Page 86: Checking The Rubber Grips

    11 SERVICE WORK ON THE CHASSIS 11.45 Checking the rubber grips – Check the rubber grips on the handlebar for damage, wear, and looseness. Info The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the right.

  • Page 87: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS 11 11.47 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. –...

  • Page 88: Changing The Hydraulic Clutch Fluid

    11 SERVICE WORK ON THE CHASSIS 11.48 Changing the hydraulic clutch fluid 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 89 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 90: 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 91: 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 92: 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 93: 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 94 – 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 95 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 correctly. 100397-01 –...

  • Page 96: 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 97: 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 98 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 99: 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 100 12 BRAKE SYSTEM Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.
  • Page 101 BRAKE SYSTEM 12 – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 148) – Mount and tighten screw cap with membrane and the O-ring. Info Use water to immediately clean up any brake fluid that has overflowed or spilled.

  • Page 102: 13 Wheels, Tires

    13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 50) 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 103: Installing The Front Wheel

    WHEELS, TIRES 13 (TROY LEE DESIGNS) – Remove spacer and brake disc guard H01890-10 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. –...

  • Page 104: Removing The Rear Wheel

    13 WHEELS, TIRES – Align the brake disc guard so that distance equal in size. S01633-10 – Mount and tighten screw Guideline Screw, front wheel M20x1.5 35 Nm (25.8 lbf ft) spindle – Operate the hand brake lever several times until the brake lin- ings are seated correctly against the brake disc.

  • Page 105: Installing The Rear Wheel

    WHEELS, TIRES 13 Warning Danger of accidents Damaged brake discs reduce the braking effect. – Always lay the wheel down in such a way that the brake disc is not damaged. – Hold the rear wheel and remove the wheel spindle. Take the rear wheel out of the link fork.

  • Page 106: Checking The Tire Condition

    Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcycle.

  • Page 107: Checking Tire Pressure

    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 108 13 WHEELS, TIRES – Strike each spoke briefly using a screwdriver blade. Info The frequency of the sound depends on the spoke length and spoke diameter. If spokes of the same length and diameter vibrate with a different tone, this is an indication that the spoke tensions differ.

  • Page 109: 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 110: Charging The 12-V Battery

    14 ELECTRICAL SYSTEM Finishing work – Mount the seat. ( p. 67) 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 111: Changing 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 112: Diagnostics Connector

    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 113: 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 114: 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 115: 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 116: Changing The Coolant

    15 COOLING SYSTEM Finishing work (TROY LEE DESIGNS) – Install the motor guard. ( p. 53) 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 117 COOLING SYSTEM 15 – Go for a short test ride. – Check the coolant level. ( p. 112) Finishing work (TROY LEE DESIGNS) – Install the motor guard. ( p. 53)

  • Page 118: 16 Tuning The Engine

    16 TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3 …...
  • Page 119 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 120: Adjusting The Characteristic Map Of The Throttle Response

    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 121: 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 122: Programming The Throttle Valve Position

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

  • Page 123: 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 124: 17 Service Work On The Engine

    17 SERVICE WORK ON THE ENGINE 17.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...
  • Page 125 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 126: Checking The Engine Oil Level

    17 SERVICE WORK ON THE ENGINE 17.2 Checking the engine oil level Info The engine oil level can be checked when the engine is cold or warm. Preparatory work – Stand the motorcycle upright on a horizontal surface. Condition The engine is cold. –...
  • Page 127 SERVICE WORK ON THE ENGINE 17 Main work – Position an appropriate container under the engine. – Remove oil drain plug with the magnet and seal ring. Info Do not remove screws E01240-10 – Remove screw plug with oil screen and the O-rings.
  • Page 128 17 SERVICE WORK ON THE ENGINE – Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) – Allow the engine oil to drain completely. – Thoroughly clean the parts and the sealing surfaces. E01245-10 – Lay the motorcycle on its side and fill the oil filter housing to about ⅓...

  • Page 129: Adding Engine Oil

    148) Info For optimal performance of the engine oil, do not mix different types of engine oil. 401955-10 KTM recommends changing the engine oil where neces- sary. – Mount and tighten the filler plug together with the O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhal-...

  • Page 130: 18 Cleaning, Care

    18 CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...
  • Page 131 CLEANING, CARE 18 – After the motorcycle has cooled down, lubricate all moving parts and pivot points. – Clean the chain. ( p. 78) – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p.

  • Page 132: 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. 50) – Cover the vehicle with a tarp or similar cover that is permeable...

  • Page 133: Putting Into Operation 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 134: 20 Troubleshooting

    – Check the electrical system. – Malfunction in the electronic Read out fault memory using the KTM fuel injection diagnostics tool. – Engine does not speed up Malfunction in the electronic Read out fault memory using the KTM fuel injection diagnostics tool.
  • Page 135 Check the wiring for damage and the lights up or flashes fuel 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 136: 21 Blink Code

    21 BLINK CODE Blink code for malfunction indicator lamp 02a Malfunction indicator lamp flashes 2x per second Error level condition Throttle valve position programming necessary 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 137 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 138: 22 Technical Data

    22 TECHNICAL DATA 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 139: Engine Tightening Torques

    TECHNICAL DATA 22 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 140 22 TECHNICAL DATA 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 141: Capacities

    TECHNICAL DATA 22 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 142: 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 All EU models Fork article number 34.18.8U.05...

  • Page 143: Sx-F Us

    TECHNICAL DATA 22 Oil capacity external mechanism ml (7.78 fl. oz.) Fork oil (SAE 4) (48601166S1) + 10 + 0.34 − 50 − 1.69 right p. 149) Oil capacity external mechanism ml (7.78 fl. oz.) Fork oil (SAE 4) (48601166S1) + 10 + 0.34 −...

  • Page 144: Shock Absorber

    22 TECHNICAL DATA Oil capacity external mechanism ml (7.78 fl. oz.) Fork oil (SAE 4) (48601166S1) + 10 + 0.34 − 50 − 1.69 left p. 149) Oil capacity, right cartridge 380 ml (12.85 fl. oz.) Fork oil (SAE 4) (48601166S1) p.

  • Page 145: Xc-F Us

    TECHNICAL DATA 22 Standard 2 turns 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 146: Chassis Tightening Torques

    22 TECHNICAL DATA Shock absorber oil Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 149) 22.9 Chassis tightening torques Screw, air filter box cover EJOT PT ® K60x20-Z 3 Nm (2.2 lbf ft) Screw, combination switch EJOT PT ® K50x18 T20 2 Nm (1.5 lbf ft) Screw, intake air temperature sen- EJOT DELTA PT...
  • Page 147 TECHNICAL DATA 22 Nut, foot brake lever stop 20 Nm (14.8 lbf ft) Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite ® 2701™ Nut, rim lock 12 Nm (8.9 lbf ft) Remaining nuts, chassis 25 Nm (18.4 lbf ft) Remaining screws, chassis 25 Nm (18.4 lbf ft) Screw, bottom triple clamp...

  • Page 148: 23 Declarations Of Conformity

    The functional and equipment scope is model-dependent and may not include all wireless systems and application areas referred to. KTM AG hereby declares that the Connectivity Control Unit wireless system conforms with the relevant guidelines. The full text of the Declaration of Conformity is available at the following Internet address.

  • Page 149: Country-Specific Declarations Of Conformity

    DECLARATIONS OF CONFORMITY 23 23.3 Country-specific declarations of conformity A00757-10...

  • Page 150: 24 Substances

    24 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 151 SUBSTANCES 24 Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 152) (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 152: 25 Auxiliary Substances

    25 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 153 AUXILIARY SUBSTANCES 25 Silicone spray Recommended supplier MOTOREX ® – Silicone Spray Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier MOTOREX ® – Quick Cleaner Special grease (00062010053) Recommended supplier Klüber Lubrication ® – KLÜBERFOOD NH1 34‑401 Universal oil spray Recommended supplier...

  • Page 154: 26 Standards

    26 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 155: Index Of Special Terms 27

    INDEX OF SPECIAL TERMS 27 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 156: 28 List Of Abbreviations

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

  • Page 157: List Of Symbols 29

    LIST OF SYMBOLS 29 29.1 Red symbols Red symbols indicate an error condition that requires immediate intervention. Connectivity unit indicator lamp lights up / flashes red – Error in the connectivity unit 29.2 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.

  • Page 158: Index

    INDEX Chain guide INDEX checking ......80 12-V battery Chain tension installing ......107 adjusting .
  • Page 159 INDEX Figures ......10 Idle speed Foot brake lever ......21 adjusting .
  • Page 160 INDEX Plug-in stand ......21 Start button ......16 Preparing for use Start number plate advice on preparing for first use .
  • Page 161 *3214213en* 3214213en 11/2020 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

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