TABLE OF CONTENTS Adjusting the rebound damping of the fork....... 28 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........4 Handlebar position ............29 IMPORTANT INFORMATION ..........5 Adjusting the handlebar position ........ 29 VIEW OF VEHICLE............... 7 SERVICE WORK ON THE CHASSIS ........31 View of vehicle, front left (example)........
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TABLE OF CONTENTS Checking the free travel of foot brake lever....... 55 SUBSTANCES..............90 Adjusting the basic position of the foot brake lever ..55 AUXILIARY SUBSTANCES..........92 STANDARDS..............94 Checking the rear brake fluid level ........56 INDEX ................95 Adding rear brake fluid ..........
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.
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.
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IMPORTANT INFORMATION Environment Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such prob- lems and conflicts do not have to occur.
VIEW OF VEHICLE View of vehicle, front left (example) 101282-10 Hand brake lever ( p. 10) Clutch lever ( p. 10) Filler cap Fork rebound adjustment Idle speed adjusting screw ( p. 12) Shift lever ( p. 12) Air filter box lid Plug-in stand ( p.
SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. B00262-10 Type label The type label is fixed to the front of the steering head. B00262-20 Engine number The engine number is stamped on the left side of the engine under the engine ...
CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 100904-10 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.
CONTROLS Overview of indicator lamps Possible states FI warning lamp (MIL) lights up/flashes orange – The OBD (onboard diagnosis) has identified an emissions- or safety-critical fault. (XC‑F) Fuel level warning lamp lights up orange – Fuel level has reached the reserve mark. 101081-10 Opening the filler cap Danger...
CONTROLS Idle speed adjusting screw Idle speed adjusting screw is located on the throttle valve body at the top left. The idle speed adjusting screw has two functions. Turning it controls the idle speed. Pulling it out all the way raises the idle speed during a cold start. Possible states RPM increase activated –...
CONTROLS Plug-in stand (All SX‑F models) 5.13 The holder for the plug-in stand is the left side of the wheel spindle. The plug-in stand is used to park the motorcycle. Info Remove the plug-in stand before starting on a trip. 100950-10 Side stand (XC‑F) 5.14...
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.
– KTM recommends that you use the specified engine oil for difficult riding conditions and to increase performance. Engine oil (SAE 10W/60) (00062010035) ( p.
PREPARING FOR USE – Fit a sand protection device on the air filter. Sand protection device for air filter (77206922000) Info See the KTM PowerParts fitting instructions. B00436-01 – Clean the chain. Chain cleaner ( p. 92) – Fit the steel sprocket.
– Check the coolant level. ( p. 66) Preparing for rides at low temperatures or in snow – Fit a waterproofing device on the air filter. Waterproofing device for air filter (77206921000) Info See the KTM PowerParts fitting instructions. B00437-01...
RIDING INSTRUCTIONS Checks and maintenance before putting into operation 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 used. – Check the engine oil level. ( p.
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.
– 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.
• • • • • • 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 service hour - corresponds to about 7 liters of fuel (1.8 US gal) S10A: Every 10 service hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race...
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. 50) • Grease the steering head bearing. p. 37) • Service 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 low-speed setting can be seen during the slow to normal compression 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.
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.
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.
TUNING THE CHASSIS – 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. – Tighten the spring by turning adjusting ring to measurement ...
TUNING THE CHASSIS Checking the basic setting of the fork 9.11 Info For various reasons, no exact riding sag can be determined for the forks. – As with the shock absorber, smaller differences in the rider's weight can be com- pensated by the spring preload.
TUNING THE CHASSIS – 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. – Turn back counterclockwise by the number of clicks corresponding to the fork type.
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TUNING THE CHASSIS Info Make sure cables and wiring are positioned correctly. – Position the handlebar clamp. Mount and evenly tighten the four screws Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft)
SERVICE WORK ON THE CHASSIS Raising the motorcycle with the lift stand 10.1 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. The wheels must no longer touch the ground.
SERVICE WORK ON THE CHASSIS Cleaning the dust boots of the fork legs 10.4 – Raise the motorcycle with the lift stand. ( p. 31) – Loosen the fork protection. ( p. 32) – Push dust boots of both fork legs downwards. ...
SERVICE WORK ON THE CHASSIS – Loosen screws . Take out the left fork leg. – Unscrew screws . Take out the right fork leg. B00339-10 Installing the fork legs 10.8 – Position the fork legs. Info The upper milled groove in the fork leg must be flush with the top edge of the upper triple clamp.
SERVICE WORK ON THE CHASSIS Installing the fork protector 10.10 – 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 fork protection on the right fork leg. Mount and tighten the screws. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft)
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SERVICE WORK ON THE CHASSIS – Position the upper triple clamp with the steering. – Mount screw but do not tighten yet. B00376-10 – Position the fork legs. Info The upper milled groove in the fork leg must be flush with the top edge of the upper triple clamp.
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.
SERVICE WORK ON THE CHASSIS – Mount the handlebar cushion. Greasing the steering head bearing 10.15 – Remove the lower triple clamp. p. 34) – Install the lower triple clamp. p. 34) 800010-10 Removing the start number plate 10.16 – Remove screw and take off the clamp.
SERVICE WORK ON THE CHASSIS Removing the shock absorber 10.20 – Raise the motorcycle with the lift stand. ( p. 31) – Remove the main silencer. ( p. 41) – Remove screw – Remove screw cap 100914-10 – Press angle lever toward the rear.
SERVICE WORK ON THE CHASSIS – Position the exhaust manifold. – Attach springs Spring hooks (50305017000) – Mount and tighten screw Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) 100916-11 – Position the angle lever and linkage lever. –...
SERVICE WORK ON THE CHASSIS Installing the air filter box lid 10.25 – Insert the air filter box lid into the rear area and clip it into the front area 100920-10 Removing the air filter 10.26 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. –...
SERVICE WORK ON THE CHASSIS Cleaning the air filter and air filter box 10.28 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. Info Do not clean the air filter with fuel or petroleum since these substances attack the foam.
SERVICE WORK ON THE CHASSIS Changing the glass fiber yarn filling of the main silencer 10.31 Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. Info Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out".
SERVICE WORK ON THE CHASSIS – Disconnect the plug-in connection of the fuel line. – Mount wash cap set Wash cap set (81212016000) – Remove the tube from the fuel tank breather. 100949-10 – Remove screws with the collar bushing. ...
SERVICE WORK ON THE CHASSIS – Position the fuel tank and fit the two spoilers to the sides of the radiator bracket. – Make sure that no cables are trapped or damaged. – Mount the fuel tank breather. – Mount and tighten screw with the rubber bushing.
SERVICE WORK ON THE CHASSIS Info The service life of the chain depends largely on its maintenance. – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 92) Off-road chain spray ( p. 92) 400725-01 Checking the chain tension 10.36 Warning...
SERVICE WORK ON THE CHASSIS – Loosen nut – Loosen nuts – Adjust the chain tension by turning the 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 ...
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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. »...
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. 500284-01 Checking the swingarm 10.41 –...
SERVICE WORK ON THE CHASSIS Checking the rubber grip 10.43 – Check the rubber grips on the handlebar for damage and wear and to ensure they are firmly seated. » If a rubber grip is damaged, worn or loose: – Change and secure the rubber grip.
SERVICE WORK ON THE CHASSIS Changing the hydraulic clutch fluid 10.47 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. –...
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 to see if it conforms to measurement ...
Warning Danger of accidents Reduced braking effect caused by 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.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Warning Danger of accidents Reduced braking effect caused by 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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BRAKES 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. 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.
Warning Danger of accidents Reduced braking effect caused by 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.) – Stand the vehicle upright.
Warning Danger of accidents Reduced braking effect caused by 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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BRAKES 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.
WHEELS, TIRES Removing the front wheel 12.1 – Raise the motorcycle with the lift stand. ( p. 31) – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.
WHEELS, TIRES – 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. – Remove the motorcycle from the lift stand. ( p.
12.5 Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.
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.
– 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.
ELECTRICAL SYSTEM Info Even when there is no load on the battery, it still loses power steadily. The charge state and the type of charge are very important for the service life of the battery. Rapid recharging with a high charging current shortens the battery's service life. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves.
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ELECTRICAL SYSTEM – Lift rear fairing slightly and pull starter relay out of the bracket. 101088-10 – Remove protection caps – Remove the faulty main fuse Info A defective fuse is indicated by a burned-out fuse wire ...
COOLING SYSTEM Cooling system 14.1 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- ...
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: –...
COOLING SYSTEM Refilling coolant 14.5 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.
TUNING THE ENGINE Checking the play in the throttle cable 15.1 – 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. Throttle cable play 3…...
TUNING THE ENGINE Checking the basic position of the shift lever 15.4 – Sit on the vehicle in the riding position and determine the distance between the upper edge of your boot and the shift lever. Distance between shift lever and upper 10…...
SERVICE WORK ON THE ENGINE Checking the engine oil level 16.1 Info The engine oil level can be checked when the engine is cold or warm. – Stand the motorcycle upright on a horizontal surface. Condition The engine is cold. –...
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SERVICE WORK ON THE ENGINE – Remove screws . Remove the oil filter cover with the O-ring. 100941-10 – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) – Completely drain the engine oil. –...
SERVICE WORK ON THE ENGINE – Remove filler plug with the O-ring on the clutch cover and add engine oil to the upper edge of the level viewer. Engine oil 1.20 l (1.27 qt.) Engine oil (SAE 10W/50) ( p.
CLEANING, CARE Cleaning the motorcycle 17.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
– 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. 31) – Cover the vehicle with a tarp or a cover that is permeable to air.
– 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.
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TROUBLESHOOTING Faults Possible cause Action – High oil consumption Piston and cylinder worn Piston/cylinder - determine the mounting clear- ance. – Battery discharged Battery is not charging Check the charging voltage. – Check the stator winding of the alternator. – Unwanted power consumer Check the open-circuit current.
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)
TECHNICAL DATA - CHASSIS Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Suspension Up Side Down 4860 MXMA CC Suspension travel Front 300 mm (11.81 in) Suspension travel (SX‑F EU) Rear 330 mm (12.99 in) Suspension travel (SX‑F USA, XC‑F) Rear 317 mm (12.48 in) Fork offset...
100/100 - 18 64M TT (XC‑F) Dunlop GEOMAX MX51F Dunlop GEOMAX MX51 Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 23.3 Total fuel tank capacity, 7.5 l (1.98 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p.
TECHNICAL DATA - FORK SX‑F EU 24.1 Fork part number 14.18.7L.05 Fork WP Suspension Up Side Down 4860 MXMA CC Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Spring length with preload spacer(s) 494 mm (19.45 in)
TECHNICAL DATA - FORK XC‑F 24.3 Fork part number 14.18.7L.75 Fork WP Suspension Up Side Down 4860 MXMA CC Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Spring length with preload spacer(s) 492 mm (19.37 in) Spring rate...
TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS – 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) – Screw, intake air temperature sensor 2 Nm (1.5 lbf ft) –...
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– 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 – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
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SAE ( p. 94) (SAE 5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding ® properties. KTM recommends Motorex products. Supplier ® Motorex – Racing Fork Oil...
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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 –...
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AUXILIARY SUBSTANCES Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Clean & Polish Rubber grip adhesive (00062030051) Supplier KTM-Sportmotorcycle AG – GRIP GLUE...
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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.
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INDEX Compression damping, low-speed INDEX shock absorber, adjusting ..... 23 Accessories ........5 Coolant Air filter draining .
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INDEX removing ....... . . 59 removing ....... . . 60 Fuel tank Rebound damping installing .