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KTM 450 XC-F 2023 Owner's Manual
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KTM 450 XC-F 2023 Owner's Manual

KTM 450 XC-F 2023 Owner's Manual

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OWNER'S MANUAL
2023
450 SX‑F
450 XC-F
Art. no. 3214642en

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Summary of Contents for KTM 450 XC-F 2023

  • Page 1 OWNER'S MANUAL 2023 450 SX‑F 450 XC-F Art. no. 3214642en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art DEAR KTM CUSTOMER sports vehicle which, with appropriate care, will bring you pleasure for a long time to come. We wish you good and safe riding at all times! Enter the serial numbers of your vehicle below.
  • Page 4 TABLE OF CONTENTS PREPARING FOR USE......... 21 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 Advice on preparing for first use ..21 Symbols used ........5 Running in the engine ...... 22 Formats used........5 Starting power of lithium-ion SAFETY ADVICE..........
  • Page 5 TABLE OF CONTENTS 10.9 Checking the riding sag of the shock 11.32 Installing the fuel tank ....70 absorber.......... 40 11.33 Checking for chain dirt 10.10 Adjusting the spring preload of the accumulation........71 shock absorber ......41 11.34 Cleaning the chain ......71 10.11 Adjusting the riding sag ....
  • Page 6 TABLE OF CONTENTS 14.5 Changing the fuse of the fuel 22.6 Tires ..........132 pump..........103 22.7 Fork..........132 14.6 Diagnostics connector ....104 22.7.1 SX‑F EU........132 22.7.2 SX‑F US........133 15 COOLING SYSTEM ........105 22.7.3 XC‑F US........133 15.1 Cooling system ......
  • Page 7 Indicates work that requires expert knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be cared for there to the highest degree by specially trained experts using the special tools required.
  • Page 8 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 Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides. – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.
  • Page 10 The Owner's Manual can be downloaded several times using the QR code or the link on the delivery certificate. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. A printed copy can also be ordered from your authorized KTM dealer.
  • Page 11 Manufacturer warranty, implied warranty The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con- firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.
  • Page 12 4 VIEW OF VEHICLE View of vehicle, front left (example) S05381-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Fuel tank filler cap Air filter box cover Engine number ( p. 12) Shift lever ( p. 19)
  • Page 13 VIEW OF VEHICLE 4 View of vehicle, rear right (example) S05382-10 Shock absorber compression adjuster Fork air pressure adjuster Combination switch ( p. 15) Stop button ( p. 14) Start button ( p. 15) Throttle grip ( p. 14) Fork compression adjuster Vehicle identification number ( p.
  • Page 14 5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Steering head label The steering head label is attached to the front of the steering head. 401946-10 Engine number Engine number is embossed on the left side of the engine above the engine sprocket.
  • Page 15 SERIAL NUMBERS 5 Shock absorber article number The shock absorber article number is stamped on the top of the shock absorber. F03756-10...
  • Page 16 6 CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. F03647-10 Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. F03648-10 Throttle grip The throttle grip...
  • Page 17 CONTROLS 6 Start button Start button is fitted on the right side of the handlebar. Possible states • The start button is in the basic position is pressed – In this position, the starter • The start button motor is actuated. F03650-10 Combination switch The combination switch is fitted on the left side of the handlebar.
  • Page 18 6 CONTROLS Combination instrument The combination instrument is attached in front of the handle- bar. The combination instrument shows the total number of operating hours of the engine. The operating hour counter begins counting when the engine is started and stops when the engine is switched off. Info Nothing can be cleared or adjusted on the combination instrument.
  • Page 19 CONTROLS 6 (XC‑F US) – Press release button , turn the filler cap counterclock- wise, and take it off. S05374-10 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 20 6 CONTROLS 6.11 Cold start button 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. To help the engine burn the increased fuel quantity, it must be supplied with additional oxygen by pushing the cold start button.
  • Page 21 CONTROLS 6 6.13 Shift lever Shift lever is mounted on the left of the engine. 401950-10 The gear positions can be seen in the figure. The neutral or idle position is between the first and second gears. 401950-13 6.14 Foot brake lever Foot brake lever is located in front of the right footrest.
  • Page 22 6 CONTROLS 6.16 Side stand (XC‑F US) The side stand is located on the left of the vehicle. 401943-10 The side stand is used for parking the motorcycle. Info When you are riding, side stand must be folded up and secured with rubber strap 401944-10...
  • Page 23 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 24 7 PREPARING FOR USE – Adjust the basic position of the foot brake lever. p. 87) – Adjust the basic position of the shift lever. p. 114) – Get used to the handling characteristic of the motorcycle on suitable terrain before undertaking a more chal- lenging ride.
  • Page 25 Preparing the vehicle for rides on dry sand – Mount the air filter dust cover. Air filter dust cover (A46006920000) Info Observe the fitting instructions for KTM PowerParts. F03669-01 – Mount the air filter sand cover. Air filter sand cover (A46006922000) Info Observe the fitting instructions for KTM PowerParts.
  • Page 26 600868-01 Preparing the vehicle for rides on wet sand – Mount the air filter rain cover. Air filter rain cover (A46006921000) Info Observe the fitting instructions for KTM PowerParts. F03668-01 – Clean the chain. Chain cleaner ( p. 140) –...
  • Page 27 Straighten bent radiator fins carefully. – Check the coolant level. ( p. 106) Preparing the vehicle for low temperatures or snow – Mount the air filter rain cover. Air filter rain cover (A46006921000) Info Observe the fitting instructions for KTM PowerParts. F03668-01...
  • Page 28 8 RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...
  • Page 29 RIDING INSTRUCTIONS 8 (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 30 8 RIDING INSTRUCTIONS – Press and hold the TC button and the QS button simultaneously. The TC indicator lamp and the QS indicator lamp flash when launch control is activated. Info The launch control is deactivated automatically for a few seconds after the vehicle has started. Launch control is also deactivated in the following cases: if the throttle valve is closed more than 1/3 of F03760-13...
  • Page 31 Do not change into a low gear at high engine speed. Info If unusual noises occur while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First-gear is used for starting off and for steep inclines. –...
  • Page 32 Warning Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)
  • Page 33 RIDING INSTRUCTIONS 8 Warning Danger of accidents Moisture and dirt impair the brake system. – Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs. – On sandy, wet, or slippery surfaces, use mostly the rear brake. –...
  • Page 34 8 RIDING INSTRUCTIONS 8.11 Transporting Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive.
  • Page 35 In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Improper handling of fuel is a danger to the environment.
  • Page 36 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 ● ● Take a test ride. ○ ● ● ● ● Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● ● ● ● Make a service entry in KTM Dealer.net. ○ One-time interval ●...
  • Page 38 – As delivered, KTM offroad motorcycles are adjusted for an average rider's weight (with full protective clothing). Guideline Standard rider weight 75 …...
  • Page 39 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 40 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 the fast compression of the shock absorber.
  • Page 41 TUNING THE CHASSIS 10 – Turn adjuster clockwise up to the last perceptible click. – Turn counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping (SX‑F EU) Comfort 17 clicks Standard 15 clicks Sport 13 clicks F03640-10 Rebound damping (SX‑F US)
  • Page 42 10 TUNING THE CHASSIS 10.8 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 39) – Hold the motorcycle upright with aid of an assistant. – Measure the distance again between the rear axle and mark- ing SAG on the rear fender using the sag gage.
  • Page 43 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 44 10 TUNING THE CHASSIS 10.11 Adjusting the riding sag Preparatory work – Remove main silencer. ( p. 67) – Raise the motorcycle with a lift stand. ( p. 49) – Remove the shock absorber. p. 59) – After removing the shock absorber, clean it thoroughly. Main work –...
  • Page 45 TUNING THE CHASSIS 10 10.12 Checking the basic setting of the fork Info For various reasons, no exact riding sag can be determined for the fork. – Smaller differences in the rider's weight can be compensated for by the fork air pressure. –...
  • Page 46 10 TUNING THE CHASSIS 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 47 TUNING THE CHASSIS 10 Guideline Compression damping (SX‑F EU) 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 Info...
  • Page 48 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 support are placed at a distance from the center. Hole distance A 3.5 mm (0.138 in) The handlebar can be mounted in 2 different positions.
  • Page 49 TUNING THE CHASSIS 10 Main work – Remove screws . Take off handlebar clamp . Take off the handlebar and lay it to one side. Info Cover the components to protect them against damage. Do not kink the cables and lines. –...
  • Page 50 10 TUNING THE CHASSIS Adjusting the handlebar position with the handlebar clamp – Place the handlebar support in the required position. Info The handlebar support is longer and higher on one side. – Mount and tighten the screws with the bushings Guideline Screw, handle- 40 Nm (29.5 lbf ft)
  • Page 51 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 11 SERVICE WORK ON THE CHASSIS (XC‑F US) – Remove the motorcycle from the lift stand. – Remove the lift stand. – To park the motorcycle, press side stand to the ground with your foot and lean the motorcycle on it. Info When you are riding, the side stand must be folded up and secured with the rubber strap.
  • Page 53 SERVICE WORK ON THE CHASSIS 11 Universal oil spray ( p. 141) – Press the dust boots back into their installation position. – Remove excess oil. Finishing work – Install the fork protector. ( p. 51) – Remove the motorcycle from the lift stand. ( p.
  • Page 54 11 SERVICE WORK ON THE CHASSIS – Loosen screws . Remove the left fork leg. – Loosen screws . Remove the right fork leg. S05331-10 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 SERVICE WORK ON THE CHASSIS 11 11.9 Removing the lower triple clamp Preparatory work – Raise the motorcycle with a lift stand. ( p. 49) – Remove the front wheel. p. 93) – Remove the fork legs. p. 51) – Remove the start number plate.
  • Page 56 11 SERVICE WORK ON THE CHASSIS – Position the upper triple clamp and handlebar. – Mount screw , but do not tighten it yet. Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head S05332-11 – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front.
  • Page 57 Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam- ages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.
  • Page 58 11 SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable on the steering head bearing. » If there is detectable play: –...
  • Page 59 SERVICE WORK ON THE CHASSIS 11 11.13 Lubricating the steering head bearing – Remove the lower triple clamp. p. 53) – Install the lower triple clamp. p. 53) Info The steering head bearing is cleaned and lubricated in the course of removal and installation of the lower triple clamp.
  • Page 60 11 SERVICE WORK ON THE CHASSIS Main work – Remove screws . Take off front fender. S05339-10 11.17 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis S05339-10 Finishing work –...
  • Page 61 SERVICE WORK ON THE CHASSIS 11 11.18 Removing the shock absorber Preparatory work – Remove main silencer. ( p. 67) – Raise the motorcycle with a lift stand. ( p. 49) Main work – Remove the cable ties. – Remove screws with the washers.
  • Page 62 11 SERVICE WORK ON THE CHASSIS – Remove nut and the swingarm pivot. – Push the link fork back and secure it against falling over. S05387-10 – Hold the shock absorber and remove screw – Remove the shock absorber carefully at the bottom. S05346-10 11.19 Installing the shock absorber...
  • Page 63 SERVICE WORK ON THE CHASSIS 11 – Position the foot brake cylinder. Push rod engages in the foot brake cylinder. Info Ensure that the dust boot is correctly seated. – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) S05389-10 chassis –...
  • Page 64 11 SERVICE WORK ON THE CHASSIS 11.20 Removing the seat 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. – Remove screw S05350-10 –...
  • Page 65 SERVICE WORK ON THE CHASSIS 11 – Mount and tighten screw Guideline Screw, seat fixing 8 Nm (5.9 lbf ft) S05350-10 11.22 Removing the air filter box cover Condition The air filter box cover is secured. – Remove screw S05392-10 –...
  • Page 66 11 SERVICE WORK ON THE CHASSIS 11.23 Installing the air filter box cover Condition The air filter box cover is secured. – Insert the air filter box cover in area and clip it into area Info An air filter box cover with openings for greater air- flow and a more direct response is included.
  • Page 67 SERVICE WORK ON THE CHASSIS 11 11.24 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. – Only operate the vehicle if it is equipped with an air filter. Note Environmental hazard Hazardous substances cause environmental damage.
  • Page 68 11 SERVICE WORK ON THE CHASSIS Finishing work – Install the air filter. p. 66) – Install the air filter box cover. ( p. 64) 11.26 Installing the air filter Main work – Mount the clean air filter on the air filter support. Info The marking on the air filter support must face upwards.
  • Page 69 SERVICE WORK ON THE CHASSIS 11 11.27 Preparing air filter box cover for securing Preparatory work – Remove the air filter box cover. ( p. 63) Main work – Drill a hole at marking Guideline Diameter 6 mm (0.24 in) F03679-10 Finishing work –...
  • Page 70 11 SERVICE WORK ON THE CHASSIS 11.30 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. Info Over time, the fibers of the glass fiber yarn filling escape and the damper "burns"...
  • Page 71 SERVICE WORK ON THE CHASSIS 11 Warning Danger of poisoning Fuel is harmful to health. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – Rinse the affected area immediately with plenty of water in the event of contact with the skin. –...
  • Page 72 11 SERVICE WORK ON THE CHASSIS – Pull both spoilers laterally off the radiator and lift off the fuel tank. S05361-10 11.32 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 73 SERVICE WORK ON THE CHASSIS 11 – Mount and tighten screw with the rubber bushing. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis S05377-11 – Plug in fuel pump connector – Remove the wash cap set. Clean the quick release coupling thoroughly with compressed air.
  • Page 74 11 SERVICE WORK ON THE CHASSIS 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 The service life of the chain depends largely on its maintenance. Preparatory work –...
  • Page 75 SERVICE WORK ON THE CHASSIS 11 Finishing work – Remove the motorcycle from the lift stand. ( p. 49) 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.
  • Page 76 11 SERVICE WORK ON THE CHASSIS 11.37 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 49) Main work – Shift the transmission into neutral. – Check the chain, rear sprocket and engine sprocket for wear. »...
  • Page 77 SERVICE WORK ON THE CHASSIS 11 – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with, or below, the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated.
  • Page 78 11 SERVICE WORK ON THE CHASSIS – Check that the chain guide is firmly seated. » If the chain guide is loose: – Tighten the screws on the chain guide. Guideline Screw, chain M6x16 10 Nm guide on link fork (7.4 lbf ft) at the rear Screw, chain...
  • Page 79 SERVICE WORK ON THE CHASSIS 11 Main work – Check the throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars and above the fuel tank bracket, to the throttle valve body. Both throttle cables must be secured behind the rubber strap of the fuel tank support.
  • Page 80 11 SERVICE WORK ON THE CHASSIS 11.42 Programming the quickshifter Info If the shifting performance of the quickshifter starts to decrease, it must be reprogrammed. – Carry out start procedure. ( p. 26) – Press and hold the QS button for at least 10 seconds.
  • Page 81 SERVICE WORK ON THE CHASSIS 11 Info The fluid level rises with increasing wear of the clutch facing discs. Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts.
  • Page 82 11 SERVICE WORK ON THE CHASSIS – Move the hydraulic clutch fluid reservoir mounted on the han- dlebar into a horizontal position. – Remove screws – Take off cover with membrane H04933-10 – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p.
  • Page 83 Do not make any adjustments while riding. 12.3 Checking the brake discs Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.)
  • Page 84 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Preparatory work –...
  • Page 85 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.
  • Page 86 Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 87 – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect.
  • Page 88 12 BRAKE SYSTEM Info Do not operate the hand brake lever if the brake caliper has been removed. – Remove cotter pins , pull out pin , and remove the brake linings. – Clean the brake caliper and the brake caliper bracket. F03696-10 –...
  • Page 89 BRAKE SYSTEM 12 – Add brake fluid up to level Guideline 5 mm (0.2 in) Level (brake fluid level below reservoir rim) Brake fluid DOT 4 / DOT 5.1 ( p. 138) – Position cover with membrane – Mount and tighten screws Info Use water to immediately clean up any brake fluid that has overflowed or spilled.
  • Page 90 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Preparatory work –...
  • Page 91 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.
  • Page 92 Checking the brake linings of the rear brake Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 93 – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect.
  • Page 94 12 BRAKE SYSTEM – Manually press the brake caliper toward the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir; extract some if necessary. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston.
  • Page 95 WHEELS, TIRES 13 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 49) Main work – Manually press the brake caliper toward the brake disc to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons.
  • Page 96 13 WHEELS, TIRES 13.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –...
  • Page 97 WHEELS, TIRES 13 Main work – Manually press the brake caliper toward the brake disc to push back the brake piston. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston. –...
  • Page 98 13 WHEELS, TIRES Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surfaces of the spacers. Long-life grease ( p.
  • Page 99 DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of H01144-01 wear.
  • Page 100 Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.) –...
  • Page 101 ELECTRICAL SYSTEM 14 14.1 Removing the 12-V battery Caution Danger of burns The voltage regulator gets very hot when the vehicle is driven. – Allow the voltage regulator to cool down before performing any work. Note Environmental hazard 12 V batteries contain environmentally hazardous materials. –...
  • Page 102 14 ELECTRICAL SYSTEM 14.2 Installing the 12-V battery Main work – Pull up the battery holding bracket , put the 12-V bat- tery into the battery compartment with the terminals facing upwards and secure with the battery holding bracket 12 V battery (HJTZ5S-FP-C) ( p.
  • Page 103 ELECTRICAL SYSTEM 14 14.3 Charging the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V batteries. – Only charge 12 V batteries in well-ventilated rooms.
  • Page 104 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 Main work – Pull starter relay from the holder. F03751-10 – Take off protection caps – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the starter relay. –...
  • Page 106 14 ELECTRICAL SYSTEM Main work – Take off protection cap – Remove the faulty fuse Info A faulty fuse has a burned-out fuse wire – Put in the new fuse for the fuel pump. Fuse (58011109105) ( p. 132) – Check that the electrical system is functioning properly.
  • Page 107 COOLING SYSTEM 15 15.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.
  • Page 108 15 COOLING SYSTEM 15.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
  • Page 109 COOLING SYSTEM 15 Warning Danger of poisoning Coolant is harmful to health. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...
  • Page 110 15 COOLING SYSTEM 15.6 Changing the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
  • Page 111 TUNING THE ENGINE 16 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 112 16 TUNING THE ENGINE Main work (All SX‑F models) – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut – Push cold start button all the way to the stop.
  • Page 113 TUNING THE ENGINE 16 – Remove guide plate from handle tube – Position the required guide plate on the grip tube. Guideline The label OUTSIDE must be visible. Marking must be positioned at marking Gray guide plate (A48002014000) Alternative 1 Black guide plate (A46002014000) Info The gray guide plate opens the throttle valve more...
  • Page 114 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 115 TUNING THE ENGINE 16 – Run the engine until warm. The cold start button is deactivated – The cold start but- ton is in its basic position. ( p. 18) Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. –...
  • Page 116 16 TUNING THE ENGINE 16.7 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. If the shift lever is permanently touching the boot, the transmission will be subject to excessive load; this can cause a malfunction of the quickshifter.
  • Page 117 SERVICE WORK ON THE ENGINE 17 17.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...
  • Page 118 17 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or running the engine in an enclosed space.
  • Page 119 SERVICE WORK ON THE ENGINE 17 Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Drain the engine oil while the engine is at operating temperature. Preparatory work –...
  • Page 120 17 SERVICE WORK ON THE ENGINE – Position long oil screen with the O-rings on a pin wrench. – Position the pin wrench through the drill hole of the screw plug in the opposite section of the engine case. – Push the oil screen all the way into the engine case.
  • Page 121 Engine oil (SAE 10W/50) ( p. 138) Info For optimal performance of the engine oil, do not mix different types of engine oil. KTM recommends changing the engine oil where neces- 401955-10 sary. – Mount and tighten the filler plug together with the O-ring.
  • Page 122 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 down, lubricate all moving parts and pivot points. – Clean the chain. ( p. 71) – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p.
  • Page 124 – 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 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 Check the electrical system. – Malfunction in the electronic Read out the fault memory using the fuel injection KTM diagnostics tool. – Engine does not speed up Malfunction in the electronic Read out the fault memory using the fuel injection KTM diagnostics tool.
  • Page 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 21 BLINK CODE Combination switch, left side – buttons pressed longer than 20 seconds Error level condition Blink code for malfunction indicator lamp Malfunction indicator lamp flashes continuously THREF – malfunction Error level condition Blink code for malfunction indicator lamp 02 Malfunction indicator lamp flashes 2x short Crankshaft speed sensor –...
  • Page 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 22 TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 449.9 cm³ (27.455 cu in) Stroke 63.4 mm (2.496 in) Bore 95 mm (3.74 in) Compression ratio 13.1:1 Idle speed 2,100 … 2,200 rpm Control OHC, 4 valves controlled via rocker arm Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust...
  • Page 131 TECHNICAL DATA 22 22.2 Engine tightening torques Oil nozzle for the clutch lubrication 0.8 Nm (0.59 lbf ft) (alternator cover sealing surface) Screw, oil nozzle bent for piston 2 Nm (1.5 lbf ft) cooling Loctite 243™ ® Crankshaft speed sensor screw and 6 Nm (4.4 lbf ft) cable retainer Loctite...
  • Page 132 22 TECHNICAL DATA Screw, timing chain clip 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, timing chain tensioner 10 Nm (7.4 lbf ft) Screw, torque governor 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, valve cover 10 Nm (7.4 lbf ft) Screw, water pump cover M6x20 10 Nm (7.4 lbf ft)
  • Page 133 TECHNICAL DATA 22 22.3 Capacities 22.3.1 Engine oil Engine oil 1.20 l (1.27 qt.) Engine oil (SAE 10W/50) p. 138) 22.3.2 Coolant Coolant 0.95 l (1 qt.) Coolant ( p. 138) 22.3.3 Fuel Total fuel tank capacity, approx. (All SX‑F models) Super unleaded (ROZ 95) ( p.
  • Page 134 The tires specified represent one of the possible series production tires. For alternative manufacturers, if any, contact an authorized dealer or qualified tire dealership. If local road approval regulations apply, these and the respective technical specifications must be observed. Additional information is available in the Service section under: KTM.COM 22.7 Fork 22.7.1 SX‑F EU...
  • Page 135 TECHNICAL DATA 22 Oil capacity external mechanism ml (7.78 fl. oz.) Fork oil (SAE 4) (48601166S1) + 10 + 0.34 − 50 − 1.69 left p. 139) Oil capacity, right cartridge 380 ml (12.85 fl. oz.) Fork oil (SAE 4) (48601166S1) p.
  • Page 136 22 TECHNICAL DATA Oil capacity, right cartridge 380 ml (12.85 fl. oz.) Fork oil (SAE 4) (48601166S1) p. 139) Grease capacity, left cartridge 5 g (0.18 oz) Special grease (00062010053) p. 141) 22.8 Shock absorber 22.8.1 SX‑F EU Shock absorber article number A460C409W408000 Shock absorber WP XACT 5750...
  • Page 137 TECHNICAL DATA 22 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.) 42 N/mm (240 lb/in) Weight of rider: 75 … 85 kg (165 … 187 lb.) 45 N/mm (257 lb/in) Weight of rider: 85 …...
  • Page 138 22 TECHNICAL DATA 22.9 Chassis tightening torques EJOT PT Screw, air filter box cover ® K60x20-Z 3 Nm (2.2 lbf ft) EJOT PT Screw, air filter box, on subframe ® K60x20AL 5 Nm (3.7 lbf ft) EJOT PT ® Screw, combination switch K50x18 T20 2 Nm (1.5 lbf ft) Screw, fuel pump on fuel tank...
  • Page 139 TECHNICAL DATA 22 Screw, rear brake disc 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, seat fixing 8 Nm (5.9 lbf ft) Screw, starter cable to starter relay 6 Nm (4.4 lbf ft) Screw, throttle grip 5 Nm (3.7 lbf ft) Nut, foot brake lever stop 20 Nm (14.8 lbf ft) Nut, rear sprocket screw...
  • Page 140 23 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX ®...
  • Page 141 SUBSTANCES 23 Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 142) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –...
  • Page 142 24 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier MOTOREX ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier...
  • Page 143 AUXILIARY SUBSTANCES 24 Silicone spray Recommended supplier MOTOREX ® – Silicone Spray Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier MOTOREX ® – Quick Cleaner Special grease (00062010053) Recommended supplier Klüber Lubrication ® – Klüberfood NH1 34‑401 Universal oil spray Recommended supplier...
  • Page 144 25 STANDARDS JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.
  • Page 145 INDEX OF SPECIAL TERMS 26 Launch control Vehicles electronics functions for achieving the best possible acceleration from a standing position On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics Quickshifter Function of the engine electronics for shifting up with- out clutch actuation Traction Control Auxiliary function of the motor control that reduces...
  • Page 146 27 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...
  • Page 147 LIST OF SYMBOLS 28 28.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols. Malfunction indicator lamp lights up/flashes orange – The OBD has detected a malfunction in the vehicle electronics.
  • Page 148 INDEX Chain guide INDEX checking ......74 12-V battery Chain tension charging ......101 adjusting .
  • Page 149 INDEX Figures ....... 9 Idle speed Foot brake lever ......19 adjusting .
  • Page 150 INDEX Preparing for use Spoke tension advice on preparing for first use ..21 checking ......98 after storage .
  • Page 151 INDEX rear right ......11 Work rules ......8...
  • Page 152 *3214642en* 3214642en 14.06.2022 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.COM...

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