KTM 450 SX-F EU Owner's Manual
2013 year
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Also See for 450 SX-F EU:
- Owner's manual (98 pages) ,
- Owner's manual (98 pages) ,
- Repair manual (245 pages)
Related Manuals for KTM 450 SX-F EU
Summary of Contents for KTM 450 SX-F EU
- Page 1 OWNER'S MANUAL 2013 450 SX‑F EU 450 SX‑F EU FACTORY EDITION 450 SX‑F USA 450 SX‑F USA FACTORY EDITION 450 XC-F USA Art. no. 3211931en...
- Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.
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Page 4: Table Of Contents
TABLE OF CONTENTS Preparing for rides at low temperatures or in TABLE OF CONTENTS MEANS OF REPRESENTATION ........4 snow.............. 20 Symbols used ........... 4 RIDING INSTRUCTIONS..........21 Formats used............ 4 Checks and maintenance work when preparing SAFETY ADVICE............5 for use ............ - Page 5 TABLE OF CONTENTS 11.22 Removing the seat .......... 44 15 COOLING SYSTEM ............. 74 11.23 Mounting the seat ........... 44 15.1 Cooling system ..........74 11.24 Removing the air filter box lid ......45 15.2 Checking the antifreeze and coolant level ..74 11.25 Installing the air filter box lid ......
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Page 6: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required. -
Page 7: Safety Advice
SAFETY ADVICE Use definition - intended use KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply with currently valid regulations and categories of the top international motorsport organizations. -
Page 8: Protective Clothing
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer. -
Page 9: Important Notes
Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle. -
Page 10: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) C00213-01 Hand brake lever ( p. 11) Clutch lever ( p. 11) Filler cap Plug-in stand ( p. 16) Air filter box lid Engine number ( p. 10) Shift lever ( p. -
Page 11: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) C00212-01 Kill switch ( p. 11) Electric starter button ( p. 11) Fork compression adjustment Fork rebound adjustment Foot brake lever ( p. 16) Level viewer, engine oil Shock absorber compression adjustment Level viewer for brake fluid, rear Shock absorber rebound adjustment... -
Page 12: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. S00141-10 Type label The type label is fixed to the front of the steering head. S00141-11 Engine number The engine number is stamped on the left side of the engine under the engine sprocket. -
Page 13: Controls
CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. C00214-10 Hand brake lever Hand brake lever is located on the right side of the handlebar. The hand brake lever is used to activate the front brake. C00215-10 Throttle grip The throttle grip... -
Page 14: Map-Select Switch For The Basic Setting (Sx-F Factory Edition)
CONTROLS Map‑Select switch for the basic setting (SX‑F Factory Edition) The Map‑Select switch for the basic setting is fitted under the seat. Possible states SOFT – The mapping with reduced peak performance for better ride- ability is activated. ADVANCED – The mapping for performance with a very direct response is activated. -
Page 15: Closing The Filler Cap
CONTROLS (All SX‑F models) – Turn filler cap counterclockwise and lift it off. 601831-10 (XC‑F) – Press release button , turn the filler cap counterclockwise, and lift it free. B00277-10 6.10 Closing the filler cap (All SX‑F models) – Mount the filler cap and turn it clockwise until the fuel tank is firmly closed. Info Run the fuel tank breather hose without kinks. -
Page 16: Factory Start (Sx-F Factory Edition)
CONTROLS 6.11 Factory Start (SX‑F Factory Edition) The Factory Start is mounted on the right fork protector. Possible states Factory Start is deactivated – The fork is in the normal operating mode. • Factory Start is activated – The fork is compressed and the front of the motor- •... -
Page 17: Idle Speed Adjusting Screw
CONTROLS 6.13 Idle speed adjusting screw The idle setting of the throttle valve body has a big influence on the starting behavior, stable idling and the response to throttle opening. This means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly. The idle speed is adjusted with idle speed adjusting screw Turning the adjusting screw clockwise increases the idle speed. -
Page 18: Foot Brake Lever
CONTROLS 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. 601840-10 6.16 Side stand (XC‑F) The side stand is on the left side of the vehicle. C00222-10 The side stand is used to park the motorcycle. -
Page 19: Preparing For Use
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover. -
Page 20: Running In The Engine
PREPARING FOR USE (All SX‑F models) – Do not transport luggage. (XC‑F) – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels. Info Motorcycles react sensitively to any changes of weight distribution. -
Page 21: Preparing For Rides On Dry Sand
– Fit a dust cover on the air filter. Dust protection device for air filter (77206920000) Info See the KTM PowerParts fitting instructions. B00435-01 – Fit a sand cover on the air filter. Sand protection device for air filter (77206922000) Info See the KTM PowerParts fitting instructions. -
Page 22: Preparing For Rides On Wet And Muddy Surfaces
Preparing for rides on wet and muddy surfaces – Fit a waterproofing device on the air filter. Waterproofing device for air filter (77206921000) Info See the KTM PowerParts fitting instructions. B00437-01 – Fit the steel sprocket. – Clean the motorcycle. ( p. -
Page 23: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p. 79) –... -
Page 24: Starting Off
Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines. -
Page 25: Transport
– In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards. - Page 26 RIDING INSTRUCTIONS – Switch off the engine. – Open the filler cap. ( p. 12) – Fill the fuel tank with fuel up to measurement Guideline Measurement of 35 mm (1.38 in) Total fuel tank 7.5 l Super unleaded (ROZ 95/RON 95/PON capacity, approx.
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Page 27: Service Schedule
• • • • • • Read out the fault memory using the KTM diagnostics tool after a test ride. Make the service entry in KTM DEALER.NET and in the service record. • • • • S1N: Once after 1 operating hour - corresponds to about 7 liters of fuel (1.8 US gal) S10A: Every 10 operating hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race... -
Page 28: Service Work (As Additional Order)
SERVICE SCHEDULE Service work (as additional order) S20N S40A S50A S100A Change the front brake fluid. • Change the rear brake fluid. • Change the hydraulic clutch fluid. p. 57) • Grease the steering head bearing. p. 42) • Service the shock absorber. •... -
Page 29: Tuning The Chassis
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. -
Page 30: Adjusting The High-Speed Compression Damping Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber. -
Page 31: Adjusting The Rebound Damping Of The Shock Absorber
Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click. -
Page 32: Checking The Static Sag Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. -
Page 33: Adjusting The Riding Sag
TUNING THE CHASSIS – After removing the shock absorber, clean it thoroughly. Main work – Loosen screw – Turn adjusting ring until the spring is no longer under tension. Hook wrench (T106S) – Measure the overall spring length while the spring is not under tension. –... -
Page 34: Checking The Basic Setting Of The Fork
TUNING THE CHASSIS Info The spring rate is shown on the outside of the spring. Finishing work – Install the shock absorber. p. 44) – Install the manifold. – Install the main silencer. ( p. 48) – Check the static sag of the shock absorber. ( p. -
Page 35: Adjusting The Rebound Damping Of The Fork
TUNING THE CHASSIS 10.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. – Remove protection caps – Turn adjusting screws clockwise all the way. Info Adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs. -
Page 36: Activating The Factory Start (Sx-F Factory Edition)
TUNING THE CHASSIS Info Position the left and right handlebar supports evenly. – Position the handlebar. Info Make sure cables and wiring are positioned correctly. – Position the handlebar clamps. Fit and evenly tighten the four screws Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) 10.16... -
Page 37: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. (All SX‑F models) – Raise the motorcycle at the frame underneath the engine. -
Page 38: Bleeding The Fork Legs
SERVICE WORK ON THE CHASSIS 11.3 Bleeding the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 35) Main work – Release bleeder screws Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. -
Page 39: Positioning The Fork Protection
SERVICE WORK ON THE CHASSIS 11.6 Positioning the fork protection – Position the fork protection on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the brake line and clamp. Mount and tighten screws –... -
Page 40: Removing The Fork Protector
SERVICE WORK ON THE CHASSIS – Position the brake caliper. Mount and tighten screws Guideline Screw, front brake caliper 25 Nm Loctite ® 243™ (18.4 lbf ft) – Position the brake line and clamp. Mount and tighten screws B00300-11 Finishing work –... -
Page 41: Installing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS Main work – Remove screw – Remove screw – Take off the top triple clamp with the handlebar and set it aside. Info Protect the motorcycle and its attachments against damage by covering them. Do not bend the cables and lines. S00144-10 –... -
Page 42: Position The Brake Caliper. Mount And Tighten Screws
SERVICE WORK ON THE CHASSIS – Fully tighten screws Guideline Screw, bottom triple clamp 12 Nm (8.9 lbf ft) S00146-10 – Tighten screw Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) C00232-10 – Mount and tighten screw Guideline Screw, top steering stem 17 Nm... -
Page 43: Checking The Steering Head Bearing Play
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam- aged over time. -
Page 44: Greasing The Steering Head Bearing
SERVICE WORK ON THE CHASSIS 11.15 Greasing the steering head bearing – Remove the lower triple clamp. p. 38) – Install the lower triple clamp. p. 39) 800010-10 11.16 Removing the start number plate – Remove screw and take off the clamp. –... -
Page 45: Installing The Front Fender
SERVICE WORK ON THE CHASSIS 11.19 Installing the front fender Main work – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) C00153-10 Finishing work – Install the start number plate. ( p. -
Page 46: Installing The Shock Absorber
SERVICE WORK ON THE CHASSIS 11.21 Installing the shock absorber Main work – Carefully position the shock absorber into the vehicle from above. S00127-10 – Position the frame protector. Info Pay attention to the holding lugs. – Mount and tighten screw Guideline Screw, frame protector 3 Nm (2.2 lbf ft) -
Page 47: Removing The Air Filter Box Lid
SERVICE WORK ON THE CHASSIS 11.24 Removing the air filter box lid Condition The air filter box lid is secured. – Remove screws C00230-10 – Pull off the air filter box lid in area sideways and remove it toward the front. S00147-10 11.25 Installing the air filter box lid... -
Page 48: Installing The Air Filter
SERVICE WORK ON THE CHASSIS Main work – Detach air filter holder at the bottom and swing it to one side. Remove the air filter with the air filter support. – Remove the air filter from the air filter support. C00171-10 11.27 Installing the air filter... -
Page 49: Securing The Air Filter Box Lid
SERVICE WORK ON THE CHASSIS – Clean the intake flange and check it for damage and tightness. Finishing work – Install the air filter. p. 46) – Install the air filter box lid. ( p. 45) 11.29 Securing the air filter box lid Preparatory work –... -
Page 50: Installing The Main Silencer
SERVICE WORK ON THE CHASSIS 11.32 Installing the main silencer – Position the main silencer. – Mount screws but do not tighten yet. – Reconnect spring Spring hooks (50305017000) – Tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) S00128-11 11.33 Changing the glass fiber yarn filling of the main silencer... -
Page 51: Removing The Fuel Tank
SERVICE WORK ON THE CHASSIS (SX‑F Factory Edition) – Drill out all rivets on the main silencer and remove steel bands . Carefully hammer the rivets inward. – Remove locking cap and outer tube – Pull the glass fiber yarn filling from the inner tube –... -
Page 52: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS – Remove the tube from the fuel tank breather. – Remove screws with the collar bushing. C00165-11 – Remove screw with the rubber bushing. S00178-10 – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. C00169-01 11.35 Installing the fuel tank... -
Page 53: Checking For Chain Dirt Accumulation
SERVICE WORK ON THE CHASSIS – Mount and tighten screws with the collar bushing. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) C00165-10 – Connect the electrical plug-in connection – Remove the wash cap set. Thoroughly clean the plug-in connection of the fuel line using compressed air. -
Page 54: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 99) Off-road chain spray ( p. 99) 400725-01 11.38 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. –... -
Page 55: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide
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 the reference marks . - Page 56 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the bottom edge of the chain bolt is in line with or below the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated. »...
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Page 57: Adjusting The Chain Guide
If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by KTM. 401519-01 11.43 Checking the swingarm –... -
Page 58: Checking The Rubber Grip
SERVICE WORK ON THE CHASSIS Finishing work – Install the fuel tank. p. 50) – Mount the seat. ( p. 44) 11.45 Checking the rubber grip – Check the rubber grips on the handlebar for damage and wear and to ensure they are firmly seated. -
Page 59: Changing The Hydraulic Clutch Fluid
SERVICE WORK ON THE CHASSIS 11.49 Changing the hydraulic clutch fluid Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –... -
Page 60: Brake System
Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disk... -
Page 61: Checking The Front Brake Fluid Level
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Preparatory work –... -
Page 62: Checking The Front Brake Linings
Changing the front brake linings Warning Danger of accident Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid can cause skin irritation on contact. –... - Page 63 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
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Page 64: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM – Add brake fluid to level Guideline Dimension (brake fluid level below 5 mm (0.2 in) top edge of container) Brake fluid DOT 4 / DOT 5.1 ( p. 97) – Position cover with membrane – Mount and tighten screws Info Clean up overflowed or spilt brake fluid immediately with water. -
Page 65: Checking The Rear Brake Fluid Level
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Preparatory work –... -
Page 66: Checking The Rear Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. - Page 67 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! Use only clean brake fluid from a sealed container.
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Page 68: Wheels, Tires
WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 35) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. -
Page 69: Removing The Rear Wheel
WHEELS, TIRES (SX‑F Factory Edition) – Align the brake disc guard so that gaps are the same size. 101868-10 – Mount and tighten screw Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc. -
Page 70: Installing The Rear Wheel
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 air pressure of the tires all have an important impact on the handling characteristics of the motorcycle. -
Page 71: Checking The Tire Air Pressure
Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes. - Page 72 WHEELS, TIRES » If the spoke tension varies: – Correct the spoke tension. – Check the spoke torque. Guideline Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) Spoke nipple, rear wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) Torque wrench with various accessories in set (58429094000)
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Page 73: Electrical System
ELECTRICAL SYSTEM 14.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –... -
Page 74: Charging The Battery
– Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 75: Changing The Main Fuse
ELECTRICAL SYSTEM 14.4 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box lid. Preparatory work –... -
Page 76: Cooling System
COOLING SYSTEM 15.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant tem- perature will not result in a risk of malfunctions. -
Page 77: Draining The Coolant
COOLING SYSTEM Condition The engine is cold. – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the coolant level in the radiator. Coolant level above radiator fins. 10 mm (0.39 in) » If the coolant level does not meet specifications: –... -
Page 78: Refilling Coolant
COOLING SYSTEM 15.5 Refilling coolant Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con- tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi- ately. -
Page 79: Tuning The Engine
TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3…... -
Page 80: Adjusting The Idle Speed
TUNING THE ENGINE 16.3 Adjusting the idle speed – Run the engine until warm. – Set the desired idle speed by turning the idle speed adjusting screw Guideline Idle speed 2,250… 2,350 rpm Tachometer (45129075000) Info Turn counterclockwise to decrease the idle speed. Turn clockwise to increase the idle speed. -
Page 81: Service Work On The Engine
SERVICE WORK ON THE ENGINE 17.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –... -
Page 82: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens
SERVICE WORK ON THE ENGINE 17.3 Changing the engine oil and oil filter, cleaning the oil screens Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage. - Page 83 SERVICE WORK ON THE ENGINE – Place the long oil screen with the O-rings onto a pin wrench. – Push the pin wrench through the opening into the drill hole of the opposite engine case wall and push the engine oil screen as far as possible into the engine case. C00236-10 –...
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Page 84: Adding Engine Oil
SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. -
Page 85: Cleaning, Care
CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts. -
Page 86: Storage
– Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 35) – Cover the vehicle with a tarp or a cover that is permeable to air. -
Page 87: Preparing For Use After Storage
STORAGE 19.2 Preparing for use after storage – Install the battery. p. 71) – Refuel. ( p. 23) – Remove the motorcycle from the lift stand. ( p. 35) – Perform checks and maintenance work when preparing the vehicle for use. p. -
Page 88: Troubleshooting
– Check the electrical system. – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. - Page 89 TROUBLESHOOTING Faults Possible cause Action – Battery is discharged Unwanted power consumer Check the quiescent current.
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Page 90: Blink Code
BLINK CODE Blink code FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Crankshaft position sensor - circuit fault Blink code FI warning lamp (MIL) 06 FI warning lamp (MIL) flashes 6x short Error level condition Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high Blink code FI warning lamp (MIL) -
Page 91: Technical Data
TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 449.3 cm³ (27.418 cu in) Stroke 63.4 mm (2.496 in) Bore 95 mm (3.74 in) Compression ratio 12.6:1 Idle speed 2,250… 2,350 rpm Control OHC, 4 valves controlled via rocker arm Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust... - Page 92 TECHNICAL DATA ® Screw, locking lever 6 Nm (4.4 lbf ft) Loctite 243™ – Screw, oil filter cover 6 Nm (4.4 lbf ft) ® Screw, suction pump cover 6 Nm (4.4 lbf ft) Loctite 243™ ® Nut, water-pump wheel 8 Nm (5.9 lbf ft) Loctite 243™...
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Page 93: Capacities
TECHNICAL DATA 22.3 Capacities 22.3.1 Engine oil Engine oil 1.50 l (1.59 qt.) Engine oil (SAE 10W/50) ( p. 97) 22.3.2 Coolant Coolant 1.20 l (1.27 qt.) Coolant ( p. 97) Coolant (mixed ready to use) ( p. 97) 22.3.3 Fuel Total fuel tank capacity, 7.5 l (1.98 US gal) -
Page 94: Electrical System
(All USA models) 80/100 - 21 M/C 51M TT 110/90 - 19 62M TT Dunlop GEOMAX MX 51 F Dunlop GEOMAX MX 51 F Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork 22.7.1 SX‑F EU Fork part number 14.18.7M.09... -
Page 95: Xc-F
TECHNICAL DATA Standard 12 clicks Sport 10 clicks Spring length with preload spacer(s) 494 mm (19.45 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 4.8 N/mm (27.4 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 5.0 N/mm (28.6 lb/in) Weight of rider: 85…... -
Page 96: Sx-F Usa
TECHNICAL DATA Spring preload 14 mm (0.55 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 54 N/mm (308 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 57 N/mm (325 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 60 N/mm (343 lb/in) Spring length 260 mm (10.24 in) -
Page 97: Chassis Tightening Torques
TECHNICAL DATA Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 12 mm (0.47 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 54 N/mm (308 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 57 N/mm (325 lb/in) Weight of rider: 85…... - Page 98 TECHNICAL DATA ® Screw, handlebar support 40 Nm (29.5 lbf ft) Loctite 243™ Screw, top shock absorber 60 Nm (44.3 lbf ft) Loctite ® 2701 – Nut, fuel pump 15 Nm (11.1 lbf ft) – Nut, seat fixing M12x1 20 Nm (14.8 lbf ft) –...
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Page 99: Substances
Brake fluid DOT 4 / DOT 5.1 According to – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Castrol and Motorex ® products. Supplier Castrol –... - Page 100 SUBSTANCES Super unleaded (ROZ 95/RON 95/PON 91) According to – DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e.
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Page 101: Auxiliary Substances
AUXILIARY SUBSTANCES Air filter cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Dirt Bio Remover Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline –... - Page 102 AUXILIARY SUBSTANCES Oil for foam air filter Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Liquid Bio Power Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline – KTM recommends Motorex ®...
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Page 103: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation. -
Page 104: Index
INDEX Clutch lever ........11 INDEX basic position, adjusting ..... . 56 Accessories . - Page 105 INDEX rebound damping, adjusting ....33 Oil screens removing ....... . . 37 cleaning .
- Page 106 INDEX Start number plate installing ....... . . 42 removing ....... . . 42 Starting .
- Page 107 *3211931en* 3211931en 12/2012 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...