KTM 2015 450 SC-F USA Owner'S Manual Download | Manualshive

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11

SERVICE WORK ON THE CHASSIS

51

400725-01

Main work

–

Clean the chain regularly and then treat with chain spray.

Chain cleaner (

Off-road chain spray (

Finishing work

–

Remove the motorcycle from the lift stand. (

11.36

Checking the chain tension

Warning

Danger of accidents

Danger caused by incorrect chain tension.

–

If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear-
ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause
the chain or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may fall
off the engine sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension is
correct and adjust it if necessary.

Preparatory work

–

Raise the motorcycle with the lift stand. (

M00047-10

Main work

–

Push the chain at the end of the chain sliding component upwards to measure the
chain tension



.

Info

The lower chain section



must be taut.

Chain wear is not always even, so you should repeat this measurement at
different chain positions.

Chain tension

55… 58 mm (2.17… 2.28 in)

» If the chain tension does not meet specifications:

–

Adjust the chain tension. (

Finishing work

–

Remove the motorcycle from the lift stand. (

11.37

Adjusting the chain tension

Warning

Danger of accidents

Danger caused by incorrect chain tension.

–

If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear-
ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause
the chain or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may fall
off the engine sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension is
correct and adjust it if necessary.

Preparatory work

–

Raise the motorcycle with the lift stand. (

–

Check the chain tension. (

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Summary of Contents for 2015 450 SC-F USA

Page 1: ...OWNER S MANUAL 2015 450 SX F EU 450 SX F USA 450 XC F USA Art no 3213176en ...

Page 2: ......

Page 3: ...ca tions prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for delivery options deviations from illustrations and descriptions as well as misprints and other errors The models portrayed partly contain spe...

Page 4: ...SIS 26 10 1 Checking the basic chassis setting with the rider s weight 26 10 2 Compression damping of the shock absorber 26 10 3 Adjusting the low speed compression damping of the shock absorber 26 10 4 Adjusting the high speed compression damping of the shock absorber 27 10 5 Adjusting the rebound damping of the shock absorber 28 10 6 Measuring rear wheel sag unloaded 28 10 7 Checking the static ...

Page 5: ...Installing the front wheel x 65 13 3 Removing the rear wheel x 66 13 4 Installing the rear wheel x 67 13 5 Checking the tire condition 67 13 6 Checking the tire air pressure 68 13 7 Checking the spoke tension 68 14 ELECTRICAL SYSTEM 70 14 1 Removing the battery x 70 14 2 Installing the battery x 70 14 3 Charging the battery x 70 14 4 Changing the main fuse 71 15 COOLING SYSTEM 73 15 1 Cooling syst...

Page 6: ...standing 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 Indicates a page reference more information is provided on the specified page 1 2 Formats used The typographical formats used in this document are explained below Specific name Identif...

Page 7: ...serious permanent injury if the appropriate measures are not taken Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures...

Page 8: ...dered under the number in paren theses E g bearing puller 15112017000 During assembly non reusable parts e g self locking screws and nuts seals and seal rings O rings pins lock washers must be replaced by new parts In some instances a thread locker e g Loctite is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them f...

Page 9: ...M PowerParts for your vehicle can be found on the KTM website International KTM Website http www ktm com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly carried out as described in the Owner s Manual Incorrect adjustment and tuning of the engine and chassis can lead to damage and breaka...

Page 10: ...4 VIEW OF VEHICLE 8 4 1 View of vehicle front left example 102050 10 1 Kill switch p 11 2 Clutch lever p 11 3 Filler cap 4 Air filter box lid 5 Cold start button p 13 6 Shift lever p 14 7 Chain guide ...

Page 11: ...4 2 View of vehicle rear right example 102051 10 1 Electric starter button p 11 2 Hand brake lever p 11 3 Level viewer for brake fluid rear 4 Shock absorber part number p 10 5 Foot brake lever p 15 6 Fork part number p 10 ...

Page 12: ...ering head 5 3 Engine number 401949 10 The engine number is stamped on the left side of the engine under the engine sprocket 5 4 Fork part number 401947 10 The fork part number is stamped on the inner side of the axle clamp 5 5 Shock absorber part number 0 0 1 1 401948 10 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side ...

Page 13: ...lebar 6 4 Kill switch C00393 10 Kill switch is fitted on the left side of the handlebar Possible states Kill switch in basic position In this position the ignition circuit is closed and the engine can be started Kill switch pressed In this position the ignition circuit is interrupted a run ning engine stops and a non running engine will not start 6 5 Electric starter button C00453 10 Electric star...

Page 14: ...he instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately C...

Page 15: ...ose without kinks 6 9 Cold start button 102052 10 The cold start button is fitted on the left on the throttle valve body When the engine is cold and outside temperatures are low the injection system extends the injection time To combust the increased amount of fuel the engine is supplied with additional oxygen by pulling the cold start button Possible states The cold start button is activated The ...

Page 16: ...djusted with idle speed adjusting screw Increase the idle speed by turning the idle speed adjusting screw clockwise Decrease the idle speed by turning the idle speed adjusting screw counterclockwise 6 11 Shift lever 401950 10 Shift lever is mounted on the left side of the engine 401950 13 SX F USA XC F The gear positions can be seen in the photograph The neutral or idle position is between the fir...

Page 17: ...nd is on the left side of the vehicle 401944 10 The side stand is used to park the motorcycle Info When you are riding side stand must be folded up and secured with rubber band 6 14 Plug in stand SX F EU SX F USA 0 0 1 1 402001 10 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 ...

Page 18: ...ing Take your foot off the foot brake lever when you are not braking Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permissible weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons Info When using your motorcycle remember that ot...

Page 19: ...ting hours 75 Avoid fully opening the throttle 7 3 Preparing the vehicle for difficult riding conditions Info Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces can lead to considerably more rapid wear of components such as the drive train brake system or suspension components For this reason it may be neces sary to inspect or replace parts before the next s...

Page 20: ...arts fitting instructions 600868 01 Clean the chain Chain cleaner p 97 Fit the steel sprocket Tip Do not grease the chain Clean the radiator fins Straighten bent radiator fins carefully 7 5 Preparing for rides on wet sand B00437 01 Fit a rain cover on the air filter Waterproofing device for air filter 77206921000 Info See the KTM PowerParts fitting instructions 600868 01 Clean the chain Chain clea...

Page 21: ...at high temperature and slow speed 600868 01 Adjust the secondary drive to the road conditions Info The engine oil quickly gets hot if the clutch has to be operated very often due to an excessively high secondary drive Clean the chain Chain cleaner p 97 Clean radiator fins Straighten bent radiator fins carefully Check the coolant level p 73 7 8 Preparing for rides at low temperatures or in snow B0...

Page 22: ...he fork legs p 35 Bleed the fork legs p 34 Check the air filter Check the settings of all controls and ensure that they can be operated smoothly Check all screws nuts and hose clamps regularly for tightness Check the fuel supply 8 2 Starting 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...

Page 23: ...bly Always open the throttle only as much as the engine can handle abrupt throttle opening increases fuel consumption To shift down brake and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Switch off the engine if you expect to be standing for a long time Guideline 1 min Avoid frequent and l...

Page 24: ...cle may roll away or fall over Always place the vehicle on a firm and even surface Note Fire hazard Some vehicle components become very hot when the vehicle is operated Do not park the vehicle near flammable or explosive substances Do not place objects on the vehicle while it is still warm from being run Always let the vehicle cool first 401475 01 Switch off the engine Use tension belts or other s...

Page 25: ...ds Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Switch off the engine Open the filler cap p 12 A A 401522 10 Fill the fuel tank with fuel up to measurement Guideline Measurement of 35 mm 1 38 in Total fuel tank capacity approx SX F EU SX F USA 7 5 l 1 98 US gal Super unleaded ROZ...

Page 26: ... Check the wheel hubs x Check the rim run out x Check the spoke tension p 68 Check the chain rear sprocket engine sprocket and chain guide p 52 Check the chain tension p 51 Grease all moving parts e g hand lever chain and check for smooth operation x Check correct the fluid level of the hydraulic clutch p 55 Check the brake fluid level of the front brake p 58 Check the free travel of the hand brak...

Page 27: ...ease the steering head bearing x p 40 Service the shock absorber x Change the spark plug and spark plug connector x Change the piston x Check measure the cylinder x Check the cylinder head x Change the valves valve springs and valve spring seats x Check the camshaft and rocker arm x Change the connecting rod conrod bearing and crank pin x Change the shaft seal rings of the water pump x Check the t...

Page 28: ... and low speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed The high speed setting for example has an effect on the landing after a jump the rear wheel suspension compresses more quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses more slowly These two ranges can be adjusted sep...

Page 29: ... 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 102061 10 Turn adjusting screw all the way clockwise with a socket wrench Info Do not loosen fitting Turn counterclockwise by the number of turns corresponding to the shock absorber type ...

Page 30: ...sorber type Guideline Rebound damping SX F EU Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping SX F USA Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping XC F Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 10 6 Measuring rear wheel sag unloaded Preparatory work Raise the mo...

Page 31: ... sitting position feet on footrests and bounces up and down a few times The rear wheel suspension levels out Another person now remeasures the distance between the rear axle and a fixed point Note down the value as dimension Info The riding sag is the difference between measurements and Check the riding sag Riding sag SX F EU 100 mm 3 94 in Riding sag SX F USA 100 mm 3 94 in Riding sag XC F 100 mm...

Page 32: ...43 Install the manifold x Remove the motorcycle from the lift stand p 34 10 10 Adjusting the riding sag x Preparatory work Raise the motorcycle with the lift stand p 34 Remove the manifold x Remove the shock absorber x p 42 After removing the shock absorber clean it thoroughly B00292 10 Main work Choose and mount a suitable spring Guideline Spring rate SX F EU Weight of rider 65 75 kg 143 165 lb 5...

Page 33: ... be fit to avoid damage to the fork and frame 10 12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior M00073 10 SX F EU Turn adjusting screws clockwise all the way Info Adjusting screws are located at the top end of the fork legs Make the same adjustment on both fork legs Turn counterclockwise by the number of clicks corres...

Page 34: ... the way Info Adjusting screws are located at the bottom end of the fork legs Make the same adjustment on both fork legs Turn counterclockwise by the number of clicks corresponding to the fork type Guideline Rebound damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping Mount protection caps C00407 11 SX F USA XC...

Page 35: ...In this way the handlebar can be mounted in the position that is most comfortable for the rider 10 15 Adjusting the handlebar position x B00375 10 Remove screws Take off the handlebar clamps Take off the handlebar and lay it to one side Info Protect the components against damage by covering them Do not bend the cables and lines Remove screws Remove the handlebar supports Place the handlebar suppor...

Page 36: ... 10 SX F EU SX F USA Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle insert plug in stand into the left side of the wheel spindle Info Remove the plug in stand before riding 401943 10 XC F 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...

Page 37: ...cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray p 98 Press the dust boots back into their normal position Remove excess oil Finishing work Install the fork protector p 35 Remove the motorcycle from the lift stand p 34 11 5 Removing the fork protector M00039 10 Remove screws Take off the clamp Remove screws Take off the left fork protect...

Page 38: ...ork legs Position bleeder screws toward the front Info Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the top edge of the upper triple clamp M00079 10 SX F USA XC F Position the fork legs Position bleeder screws toward the front Info The rebound damping is located in the right fork leg red adjusting screw The compression ...

Page 39: ...le with the lift stand p 34 Remove the front wheel x p 65 Remove the fork legs x p 36 Remove the start number plate p 41 Remove the front fender p 41 Remove the handlebar cushion 102057 10 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 li...

Page 40: ...019 11 SX F EU Position the fork legs Bleeder screws face forward Info Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the top edge of the upper triple clamp C00415 10 SX F USA XC F Position the fork legs Bleeder screws face forward Info The rebound damping is located in the right fork leg red adjusting screw The compressi...

Page 41: ...and tighten screws Finishing work Install the front fender p 42 Mount the handlebar cushion Install the start number plate p 41 Install the front wheel x p 65 Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check the steering head bearing play p 39 Remove the motorcycle from the lift stand p 34 11 11 Checking the steering head beari...

Page 42: ...d change if necessary Finishing work Remove the motorcycle from the lift stand p 34 11 12 Adjusting the play of the steering head bearing x Preparatory work Raise the motorcycle with the lift stand p 34 Remove the handlebar cushion M00022 10 Main work Loosen screw Remove screw Loosen and retighten screw Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly o...

Page 43: ...ling the start number plate C00418 10 Position the start number plate Mount and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft The holding lugs engage Position the brake line and clamp Mount and tighten screw 11 16 Removing the front fender Preparatory work Remove the start number plate p 41 C00420 10 Main work Remove screws and Remove the front fender ...

Page 44: ...ning screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the start number plate p 41 11 18 Removing the shock absorber x Preparatory work Raise the motorcycle with the lift stand p 34 Remove the manifold x 102055 11 Main work Remove screw Remove fitting 102063 10 Press angle lever toward the rear Press linkage lever downward 102064 10 Lift the swingarm ...

Page 45: ...hicle Mount and tighten screw Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 102065 11 Position the frame protector Info Pay attention to the holding lugs Mount and tighten screw Guideline Screw frame protector M5 3 Nm 2 2 lbf ft Attach the frame protector with a cable binder 102064 11 Lower the swingarm 102055 12 Position the angle lever and linkage lever Mount and tighten ...

Page 46: ...fuel tank lower it at the rear and simultaneously it push forward Make sure that the seat is correctly locked in Mount and tighten the screw of the seat fixing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 22 Removing the air filter box lid 102058 10 Condition The air filter box lid is secured Remove screws 102058 11 Pull off the air filter box lid in area sideways and remove it toward...

Page 47: ...ners brake fluid etc should be disposed of as stipulated in applicable regulations Preparatory work Remove the air filter box lid p 44 C00171 10 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 11 25 Installing the air filter x L00943 10 Main work Mount the clean air filter ...

Page 48: ... Air filter cleaner p 97 Info Only press the air filter to dry it never wring it out Oil the dry air filter with a high quality filter oil Oil for foam air filter p 97 Clean the air filter box Clean the intake flange and check it for damage and tightness Finishing work Install the air filter x p 45 Install the air filter box lid p 44 11 27 Securing the air filter box lid x Preparatory work Remove ...

Page 49: ...n silencer Mount screws but do not tighten yet Reconnect spring Spring hooks 50305017000 Tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 31 Changing the glass fiber yarn filling of the main silencer x 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 time the fiber...

Page 50: ...l in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin ...

Page 51: ...may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed ...

Page 52: ...ng for chain dirt accumulation 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 50 11 35 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the ...

Page 53: ...Push the chain at the end of the chain sliding component upwards to measure the chain tension Info The lower chain section must be taut Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 55 58 mm 2 17 2 28 in If the chain tension does not meet specifications Adjust the chain tension p 51 Finishing work Remove the motorcycle from the lift ...

Page 54: ...he chain rear sprocket engine sprocket and chain guide Preparatory work Raise the motorcycle with the lift stand p 34 400227 01 Main work Shift gear to neutral Check the rear sprocket and engine sprocket for wear If the rear sprocket or engine sprocket are worn Change the power set x Info The engine sprocket rear sprocket and chain should only be replaced together 400987 10 Pull at the top part of...

Page 55: ... chain pin is at the level of or below the chain sliding piece Change the chain sliding piece x Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 lbf ft 401760 01 Check the chain guide for wear Info The wear can be found on the front of the chain guide If the light part of the ch...

Page 56: ...ormation If the swingarm shows signs of damage cracking or deformation Change the swingarm x Info A damaged swingarm must always be changed Repair of the swingarm is not authorized by KTM 11 41 Checking the throttle cable routing Preparatory work Remove the seat p 44 Remove the fuel tank x p 48 102054 10 Main work Check the throttle cable routing Both throttle cables must be routed to the throttle...

Page 57: ...ze by turning adjusting screw Info Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 11 45 Check...

Page 58: ... bleeding syringe with the appropriate hydraulic fluid Bleed syringe 50329050000 Brake fluid DOT 4 DOT 5 1 p 95 On the clutch slave cylinder remove bleeder screw and mount bleeding syringe C00445 10 Inject the liquid into the system until it escapes from hole of the master cylin der without bubbles To prevent overflow drain fluid occasionally from the master cylinder reservoir Remove the bleeding ...

Page 59: ... distance between the hand brake lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 12 3 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due...

Page 60: ...ecified value this is an indication that the brake system is leaking or that the brake linings are completely worn down Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing an...

Page 61: ...l be glad to help M00052 10 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the front brake linings x p 59 Check the brake linings for damage and cracking If damage or cracking is visible Change the front brake linings x p 59 12 7 Changing the front brake linings x Warning Danger of accident Brake system failure Ma...

Page 62: ...the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane M00053 10 Manually press the brake caliper to the brake disc to push back the brake pistons Ensure that brake fluid does not flow out of the brake fluid reservoir extracting it by suction if it does Info Make sure when pushing back the brake pistons that you do not press the brake c...

Page 63: ...eck free travel Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the basic position of the foot brake lever x p 61 Reconnect spring 12 9 Adjusting the basic position of the foot brake lever x Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circ...

Page 64: ...ake fluid level drops below marking Add rear brake fluid x p 62 12 11 Adding rear brake fluid x Warning Danger of accidents Brake system failure If the brake fluid level drops below the specified marking or the specified value this is an indication that the brake system is leaking or that the brake linings are completely worn down Check the brake system and do not continue riding Your authorized K...

Page 65: ...f the minimum thickness is less than specified Change the rear brake linings x p 63 Check the brake linings for damage and cracking If damage or cracking is visible Change the rear brake linings x p 63 12 13 Changing the rear brake linings x Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Your authorized KTM workshop will be glad to h...

Page 66: ...gainst the spokes Remove cotter pins pull out pin and remove the brake linings Clean the brake caliper and brake caliper support M00062 10 Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly Info The arrow on the leaf spring points in the rotation direction of the brake disc M00063 10 Insert the new brake linings insert pin and mount cott...

Page 67: ... out of the fork Info Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged M00064 10 Remove spacers 13 2 Installing the front wheel x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleane...

Page 68: ...ress the brake caliper onto the brake disc by hand in order to push back the brake piston Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut Remove chain adjuster Withdraw wheel spindle only enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket I...

Page 69: ...tly on adjusting screws Check the chain tension p 51 Tighten nut Guideline Nut rear wheel spindle M25x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 18 in enables different secondary ratios with the same chain length Chain adjusters can be turned by 180 Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is...

Page 70: ...overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life 400695 01 Remove the protection cap Check the tire air pressure when the tires are cold Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi If the tire pressure does not meet specifications Correct the tire pressure Mount the protection cap 13 7 Checking the spoke tension ...

Page 71: ...poke tension varies Correct the spoke tension x Check the spoke torque Guideline Spoke nipple front wheel M4 5 6 Nm 4 4 lbf ft Spoke nipple rear wheel M4 5 6 Nm 4 4 lbf ft Torque wrench with various accessories in set 58429094000 ...

Page 72: ...y up and out 14 2 Installing the battery x C00246 10 Main work Insert the battery into the battery compartment with the terminals facing to the front SX F EU SX F USA Battery YTX4L BS p 90 XC F Battery YTX5L BS p 90 Reconnect rubber band Connect positive cable and negative cable Guideline Screw battery terminal M5 2 5 Nm 1 84 lbf ft Info Contact disks must be mounted between screws and cable sock ...

Page 73: ...he battery is maintenance free which means that the acid level does not need to be checked Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 44 Disconnect the negative cable of the battery to avoid damage to the onboard elec tronics 400240 10 Main work Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 You ...

Page 74: ...wire A reserve fuse is located in the starter relay Install a new main fuse Fuse 58011109110 p 90 Check that the electrical equipment is functioning properly Tip Insert the spare fuse so that it is available if needed Mount the protection caps Mount the starter relay onto the holder and lay the cable Position the rear fairing Mount and tighten the screw Guideline Remaining screws chassis M6 10 Nm ...

Page 75: ...e clothing that is contaminated with coolant Keep coolant out of reach of children Condition The engine is cold 400243 10 Stand the motorcycle upright on a horizontal surface Remove the radiator cap Check antifreeze of coolant 25 45 C 13 49 F If the antifreeze of the coolant does not meet specifications Correct the antifreeze of the coolant Check the coolant level in the radiator Coolant level abo...

Page 76: ...ot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water ...

Page 77: ... the skin with soap and water If coolant is swal lowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children C00158 10 Make sure that screw is tightened Position the motorcycle upright Pour coolant in up to measurement above the radiator fins Guideline Dimension over the radiator fins 10 mm 0 39 in Coolant 1 20 l 1 27 qt Coolant p 9...

Page 78: ... idle Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable x p 76 16 2 Adjusting the play in the throttle cable x Preparatory work Remove the seat p 44 Remove the fuel tank x p 48 Check the throttle cable routing p 54 C00499 10 Main work Move the handlebar to the straight ahead position Push back...

Page 79: ...oot and the shift lever Distance between shift lever and upper edge of boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the basic position of the shift lever x p 77 16 5 Adjusting the basic position of the shift lever x 401950 12 Remove screw and take off shift lever 401951 10 Clean gear teeth of the shift lever and shift shaft Mount the shift lever on the shift shaft...

Page 80: ... 102069 10 Thoroughly clean plug in connection of the fuel line using compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Disconnect the plug in connection of the fuel line Pull fuel screen out of the connecting piece Push the new fuel screen all the way into the connecting piece Lubricate the O ring and connect plug in co...

Page 81: ... of as stipulated in applicable regulations Info Drain the engine oil only when the engine is warm Preparatory work Park the motorcycle on a level surface 102070 10 Main work Place a suitable container under the engine Remove oil drain plug with the magnet and seal ring 102071 10 Remove screw plug with the short oil screen and the O rings Info Do not remove screw 102072 10 Remove screw plug with t...

Page 82: ...filter out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing area 102078 10 Lay the motorcycle on its side and fill the oil filter housing to about full with engine oil Insert the oil filter into the oil filter housing Lubricate the O ring of the oil filter cover and mount it with the oil filter cover Mount and tight...

Page 83: ...remature wear to the engine 601829 10 Remove the oil filler plug with the O ring from the clutch cover Add the same engine oil that was used when the motor was changed Engine oil SAE 10W 50 p 95 Info For optimal performance of the engine oil do not mix different types of engine oil If appropriate change the engine oil Install and tighten the oil filler plug with O ring Danger Danger of poisoning E...

Page 84: ...an with a paintbrush Motorcycle cleaner p 97 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry vehicle always rinse with water first After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the plug from the exhaust system Warning Danger of accidents Reduced braking efficiency due to a wet or dirt...

Page 85: ...e motorcycle out of service add fuel additive Fuel additive p 97 Refuel p 22 Clean the motorcycle p 82 Change the engine oil and oil filter and clean the oil screens x p 79 Check the antifreeze and coolant level p 73 Check the tire air pressure p 68 Remove the battery x p 70 Charge the battery x p 70 Guideline Storage temperature of battery without direct sunlight 0 35 C 32 95 F Store the vehicle ...

Page 86: ...ool x Engine has too little power Air filter is very dirty Clean the air filter and air filter box x p 46 Fuel filter is very dirty Change the fuel filter x Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x Exhaust system leaky deformed or too little glass fiber yarn filling in main silencer Check exhaust system for damage Change the glass fiber yarn filli...

Page 87: ... consumption Piston and cylinder worn Piston cylinder determine the mounting clear ance Battery is discharged Battery is not charging Check the charging voltage x Check the stator winding of the alternator x Unwanted power consumer Check the quiescent current x ...

Page 88: ... too low Engine coolant temperature sensor input signal too high Blink code FI warning lamp MIL 13 FI warning lamp MIL flashes 1x long 3x short Error level condition Intake air temperature sensor input signal to low Intake air temperature sensor input signal too high Blink code FI warning lamp MIL 15 FI warning lamp MIL flashes 1x long 5x short Error level condition Rollover sensor A D type input ...

Page 89: ...Gearbox SX F USA XC F 5 gear claw shifted Transmission ratio SX F EU 1st gear 16 32 2nd gear 18 30 3rd gear 20 28 4th gear 22 26 Transmission ratio SX F USA XC F 1st gear 16 32 2nd gear 18 30 3rd gear 20 28 4th gear 22 26 5th gear 24 24 Alternator 12 V 75 W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment Spark plug NGK LKAR8AI 9 Spark plug electrode gap ...

Page 90: ...iming chain tensioner M6 10 Nm 7 4 lbf ft Screw timing chain tensioning rail M6 10 Nm 7 4 lbf ft Loctite 243 Screw valve cover M6 10 Nm 7 4 lbf ft Screw water pump cover M6 10 Nm 7 4 lbf ft Oil nozzle for conrod bearing lubrica tion M6x0 75 4 Nm 3 lbf ft Plug oil channel M7 9 Nm 6 6 lbf ft Loctite 243 Screw rocker arm bearing M7 15 Nm 11 1 lbf ft Plug timing chain tensioner M8 8 Nm 5 9 lbf ft Scre...

Page 91: ... in Fork offset 22 mm 0 87 in Shock absorber WP Suspension 5018 BAVP DCC Brake system Disc brakes brake calipers on floating bearings Brake discs diameter Front 260 mm 10 24 in Rear 220 mm 8 66 in Brake discs wear limit Front 2 5 mm 0 098 in Rear 3 5 mm 0 138 in Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi Secondary ratio SX F EU 14 50 Secondary ratio SX F USA XC F 14 52 Cha...

Page 92: ...spension 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 490 mm 19 29 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 6 N mm 26 3 lb in Weight of rider 75 85 kg 165 187 lb 4 8 N mm 27 4 lb in Weight of rider 85 95 kg 187 209 lb 5 0 N mm 28...

Page 93: ... s 480 mm 18 9 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 4 N mm 25 1 lb in Weight of rider 75 85 kg 165 187 lb 4 6 N mm 26 3 lb in Weight of rider 85 95 kg 187 209 lb 4 8 N mm 27 4 lb in Fork length 940 mm 37 01 in Oil capacity per fork leg 680 ml 22 99 fl oz Fork oil SAE 4 48601166S1 p 95 22 8 Shock absorber 22 8 1 SX F EU Shock absorber part number 18 18 7O 09 Shock absorber WP Suspen...

Page 94: ...preload 8 mm 0 31 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 Gas pressure 10 bar 145 psi Static sag 30 mm 1 18 in Riding sag 100 mm 3 94 in Fitted length 490 mm 19 29 in Shock absorber oil Shock absorber fluid SAE 2 5 50180751S1 p 95 22...

Page 95: ...243 Screw rear brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw throttle grip M6 5 Nm 3 7 lbf ft Fuel connection on fuel tank M8 10 Nm 7 4 lbf ft Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Nut rear sprocket screw M8 35 Nm 25 8 lbf ft Loctite 2701 Nut rim lock M8 12 Nm 8 9 lbf ft Remaining nuts chassis M8 25 Nm 18 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft Screw bottom triple clamp...

Page 96: ...angle lever M14x1 5 80 Nm 59 lbf ft Nut swingarm pivot M16x1 5 100 Nm 73 8 lbf ft Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Screw in nozzles cooling system M20x1 5 12 Nm 8 9 lbf ft Loctite 243 Nut rear wheel spindle M25x1 5 80 Nm 59 lbf ft ...

Page 97: ...ixed ready to use Antifreeze 38 C 36 F Recommended supplier Motorex COOLANT M5 0 Engine oil SAE 10W 50 Standard classification JASO T903 MA p 99 SAE p 99 SAE 10W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corre sponding properties Synthetic engine oil Recommended supplier Motorex Cross Power 4T Fork oil SAE 4 ...

Page 98: ...8 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 g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 ...

Page 99: ...e Grease 2000 Motorcycle cleaner Recommended supplier Motorex Moto Clean Off road chain spray Recommended supplier Motorex Chainlube Offroad Oil for foam air filter Recommended supplier Motorex Racing Bio Liquid Power Preserving materials for paints metal and rubber Recommended supplier Motorex Moto Protect Rubber grip adhesive 00062030051 Recommended supplier KTM Sportmotorcycle AG GRIP GLUE Spec...

Page 100: ...24 AUXILIARY SUBSTANCES 98 Universal oil spray Recommended supplier Motorex Joker 440 Synthetic ...

Page 101: ...rvice intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils...

Page 102: ...king correcting the fluid level 55 fluid changing 56 Clutch lever 11 basic position adjusting 55 Cold start button 13 Compression damping fork adjusting 31 Compression damping high speed shock absorber adjusting 27 Compression damping low speed shock absorber adjusting 26 Coolant draining 74 refilling 75 Coolant level checking 73 Cooling system 73 Customer service 7 D Difficult riding conditions 1...

Page 103: ...nual 6 P Play in throttle cable adjusting 76 Plug in stand 15 Preparing for use advice on first use 16 after storage 83 checks and maintenance work when preparing for use 20 Protective clothing 6 R Rear sprocket checking 52 Rear wheel installing 67 removing 66 Rebound damping fork adjusting 32 shock absorber adjusting 28 Refueling fuel 22 Riding sag adjusting 30 Rubber grip checking 55 securing 55...

Page 104: ...rical system 90 engine 87 engine tightening torques 87 fork 90 shock absorber 91 tires 90 Throttle cable play checking 76 Throttle cable routing checking 54 Throttle grip 11 Tire air pressure checking 68 Tire condition checking 67 Transport 22 Troubleshooting 84 85 Type label 10 U Use definition 5 V View of vehicle front left side 8 rear right 9 W Warranty 7 Work rules 6 ...

Page 105: ... 3213176en 3213176en 4 2014 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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