KTM 250 SX-F 2016 Owner'S Manual Download

Page: 54 / 118

SERVICE WORK ON THE CHASSIS

102191-01

Main work

–

Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.

Air filter cleaner (

p. 108)

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. 108)

–

Clean the air filter box.

–

Clean the intake flange and check it for damage and tightness.

Finishing work

–

Install the air filter.

(

p. 52)

–

Install the air filter box cover. (

p. 51)

11.26

Installing the air filter

102178-10

Main work

–

Mount the clean air filter on the air filter support.

–

Grease the air filter in area



Long-life grease (

p. 108)

M01112-10

–

Insert air filter and position retaining pin



in bushing



The air filter is correctly positioned.

–

Insert



retaining tab.

Retaining pin



is secured by the



retaining tab.

Info

If the air filter is not mounted correctly, dust and dirt may enter the engine
and result in damage.

Finishing work

–

Install the air filter box cover. (

p. 51)

11.27

Securing the air filter box cover

Preparatory work

–

Remove the air filter box cover. (

p. 50)

S00846-10

Main work

–

Drill a hole at the marking



Guideline

Diameter

6 mm (0.24 in)

Finishing work

–

Install the air filter box cover. (

p. 51)

Summary of Contents for 250 SX-F 2016

Page 1: ...OWNER S MANUAL 2016 250 SX F 250 XC F Art no 3213331en ...

Page 2: ......

Page 3: ...pment 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 devi ations from illustrations and descriptions misprints and other errors The models portrayed partly contain special equipment that does not belong to the regular scope of supply 201...

Page 4: ...ation 22 8 2 Starting 22 8 3 Activating Launch Control 23 8 4 Starting off 23 8 5 Shifting riding 23 8 6 Applying the brakes 24 8 7 Stopping parking 24 8 8 Transport 25 8 9 Refueling 25 9 SERVICE SCHEDULE 27 9 1 Additional information 27 9 2 Required work 27 9 3 Recommended work 28 10 TUNING THE CHASSIS 29 10 1 Checking the basic chassis setting with the rider s weight 29 10 2 Air suspension AER 4...

Page 5: ... Removing the front wheel 73 13 2 Installing the front wheel 73 13 3 Removing the rear wheel 74 13 4 Installing the rear wheel 75 13 5 Checking the tire condition 76 13 6 Checking the tire air pressure 76 13 7 Checking spoke tension 76 14 ELECTRICAL SYSTEM 78 14 1 Removing the battery 78 14 2 Installing the battery 78 14 3 Recharging the battery 79 14 4 Changing the main fuse 80 15 COOLING SYSTEM ...

Page 6: ...e 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 Indicates information with more details or tips Indicates the result of a testing step 1 2 Formats used The typographical formats used in this document are explained below Specific name Identifies a proprietary...

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

Page 8: ...helmet boots gloves as well as trousers and a jacket with protectors on all rides Always wear protective clothing that is in good condition and meets the legal regulations In the interest of your own safety KTM recommends that you only operate the vehicle while wearing protective clothing 2 7 Work rules Special tools are necessary for certain tasks The tools are not contained in the vehicle but ca...

Page 9: ...then will you find out how to cus tomize the vehicle ideally for your own use and how you can protect yourself from injury 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 The Owner s Manual is an important component of the vehicle...

Page 10: ...e current KTM 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 damag...

Page 11: ...OF VEHICLE 9 4 1 View of vehicle front left side example C00916 10 1 Hand brake lever p 12 2 Clutch lever p 12 3 Filler cap 4 Air filter box lid 5 Engine number p 11 6 Shift lever p 16 7 Cold start button p 15 ...

Page 12: ...2 Kill switch p 12 3 Electric starter button p 12 4 Map Select switch for ride mode p 13 5 Throttle grip p 12 6 Type label p 11 7 Fork part number p 11 8 Foot brake lever p 16 9 Engine oil level viewer 10 Idle speed adjusting screw p 15 11 Shock absorber rebound adjustment 12 Shock absorber article number p 11 ...

Page 13: ...ng 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 article number 0 0 1 1 401948 10 Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 14: ...6 4 Kill switch 102127 10 Kill switch is fitted on the left side of the handlebar Possible states Kill switch in the 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 C00913 10 The electric st...

Page 15: ...ch for vehicle operation This change is activated while the engine is idling or on restarting In addition the Map Select switch controls the Launch Control p 13 6 8 Launch control The Launch Control assists the rider in optimally starting the motorcycle at the beginning of a race The maximum speed of the engine with the throttle valve fully opened full throttle is reduced After the start it is gra...

Page 16: ... fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not ...

Page 17: ... button returns to its original posi tion Info Check whether the cold start button has returned to its basic position Possible states The cold start button is activated The cold start button is pushed in all the way The cold start button is deactivated The cold start button is in its basic position 6 13 Idle speed adjusting screw M00778 10 The idle setting of the throttle valve body has a big infl...

Page 18: ... positions can be seen in the photograph The neutral or idle position is between the first and second gears 6 15 Foot brake lever 401956 10 Foot brake lever is located in front of the right footrest The foot brake lever is used to activate the rear brake 6 16 Plug in stand All SX F models 0 0 1 1 402001 10 Support for plug in stand is the left side of the wheel spindle The plug in stand is used to...

Page 19: ...7 Side stand XC F US 401943 10 The side stand 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 ...

Page 20: ...m fails in the event of overheating If the foot brake lever is not released the brake linings drag continuously Take your foot off the foot brake lever when you are not braking Warning Danger of accidents Total weight and axle loads influence the handling characteristic Do not exceed the maximum permissible overall weight or the axle loads Warning Risk of misappropriation People who act without au...

Page 21: ...n lead batteries have a low self discharge rate and have more starting power at temperatures over 15 C 60 F At low temperatures however the starting power of lithium ion batteries drops to below that of lead batter ies Multiple starting attempts may be needed Press the electric starter button for 5 sec onds and wait 30 seconds between attempts The pauses are necessary so that the created heat can ...

Page 22: ...n the air filter Dust protection device for air filter 79006920000 Info See the KTM PowerParts fitting instructions 102138 01 Fit a sand cover on the air filter Sand protection device for air filter 79006922000 Info See the KTM PowerParts fitting instructions 600868 01 Clean the chain Chain cleaner p 108 Fit the steel sprocket Tip Do not grease the chain Clean the radiator fins Straighten bent rad...

Page 23: ... Fit the steel sprocket Clean the motorcycle p 93 Straighten bent radiator fins carefully 7 8 Preparing for rides at high temperatures and low speeds 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 108 Clean the radiator fins Straig...

Page 24: ... of the fork legs p 40 Bleed the fork legs p 39 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 reserves 8 2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient venti...

Page 25: ...rol to function the throttle must be fully opened at the start If the throttle valve is closed by more than 1 3 of the way following full throttle Launch Control is deactivated FI warning lamp no longer flashes Several seconds after the vehicle starts Launch Control is deactivated auto matically To reactivate Launch Control the engine must first be switched off for at least 10 seconds for safety r...

Page 26: ...refully several times to dry out and remove dirt from the brake linings and the brake discs On sandy wet or slippery surfaces use the rear brake Braking should always be completed before you go into a bend Change down to a lower gear appropriate to your road speed On long downhill stretches use the braking effect of the engine Change down one or two gears but do not overstress the engine In this w...

Page 27: ... spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of f...

Page 28: ...urement Guideline Measurement of 35 mm 1 38 in Total fuel tank capacity approx All SX F models 7 5 l 1 98 US gal Super unleaded ROZ 95 RON 95 PON 91 p 107 Total fuel tank capacity approx XC F US 8 5 l 2 25 US gal Super unleaded ROZ 95 RON 95 PON 91 p 107 Close the filler cap p 14 ...

Page 29: ...n guide p 58 Check the chain tension p 57 Grease all moving parts e g hand lever chain and check for smooth operation Check correct the fluid level of the hydraulic clutch p 62 Check the front brake fluid level p 65 Check the free travel of the hand brake lever p 64 Check the steering head bearing play p 44 Check the valve clearance Check the clutch Change the cover seal and shaft seal rings of th...

Page 30: ...nor engine service including removing and installing engine Change spark plug and spark plug connector Change piston check and measure cylinder check cylinder head Check camshaft and cam lever Check timing assembly Change intake flange Perform major engine service including removing and installing engine Change valves valve springs valve spring seats and valve spring retainers Change the connectin...

Page 31: ... frequently overloaded then the air pressure in the fork must be increased to avoid damage to the fork and frame The air pressure in the fork can be quickly adjusted for the rider s weight surface conditions and the rider s preference using a fork pump The fork does not have to be detached The time consuming mounting of harder or softer fork springs is not required If the air chamber loses air due...

Page 32: ...t 17 clicks Standard 15 clicks Sport 13 clicks Compression damping low speed SX F US Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping low speed XC F US Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 10 5 Adjusting the high speed compression damping of the shock absorber Caution Risk of in...

Page 33: ...will fly off if the shock absorber is disassembled incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized KTM workshop will be glad to help 102141 10 Turn adjusting screw clockwise up to the last perceptible click Turn counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping ...

Page 34: ...10 8 Checking the static sag of the shock absorber 402416 10 Measure distance of rear wheel unloaded p 32 Hold the motorcycle upright with the aid of an assistant Again measure the distance between the rear axle and marking SAG on the rear fender using the sag gauge Note down the value as dimension Info The static sag is the difference between measurements and Check the static sag Static sag SX F ...

Page 35: ...r will fly off if the shock absorber is disassembled incorrectly The shock absorber is filled with highly compressed nitrogen Please follow 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 Preparatory work Raise the motorcycle with a lift stand p 39 Remove ...

Page 36: ...n Spring rate XC F US Weight of rider 65 75 kg 143 165 lb 42 N mm 240 lb in Weight of rider 75 85 kg 165 187 lb 45 N mm 257 lb in Weight of rider 85 95 kg 187 209 lb 48 N mm 274 lb in Info The spring rate is shown on the outside of the spring Finishing work Install the shock absorber p 48 Check the free travel of the foot brake lever p 68 Check the static sag of the shock absorber p 32 Check the r...

Page 37: ...ogether fully Fork pump 79412966000 Connect the fork pump to the left fork leg The fork pump indicator switches on automatically A little air escapes from the fork leg when connecting Info This is due to the volume of the hose and not due to a defect in the fork pump or the fork Read the accompanying KTM PowerParts instructions Adjust the air pressure as specified Guideline Air pressure 10 6 bar 1...

Page 38: ...e rebound damping is located in the right fork leg REB red adjusting screw Turn counterclockwise by the number of clicks corresponding to the fork type Guideline Compression damping SX F US Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping XC F US Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damp...

Page 39: ...licks corresponding to the fork type Guideline Rebound damping SX F US Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping XC F US Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 10 16 Handlebar position 102144 10 The holes on the handlebar support are placed at a distance of from the center Hole ...

Page 40: ...ngs and push through nuts from below Place the handlebar support in the required position Mount and tighten screws Guideline Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Position the handlebar Info Make sure the cables and wiring are positioned correctly Position the handlebar clamps Mount screws Screw the handlebar clamps all the way onto the front and tighten all of the screws Guide...

Page 41: ... 0 1 1 402001 10 All SX F models 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 starting on a trip 401943 10 XC F US Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand to the ground with your foot and lean the...

Page 42: ...umulate behind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Clean and oil the dust boots and inner fork tubes of both fork legs Universal oil spray p 108 Press the dust...

Page 43: ... Take out the left fork leg Unscrew screws Take out the right fork leg 11 8 Installing the fork legs S00867 10 Main work SX F EU Position the fork legs The air release screw of the right fork leg is positioned to the front The left fork leg valve is offset by approx 20 to 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...

Page 44: ...1 9 Removing the lower triple clamp Preparatory work Raise the motorcycle with a lift stand p 39 Remove the front wheel p 73 Remove the fork legs p 41 Remove the start number plate p 46 Remove the front fender p 46 Remove the handlebar cushion 102152 10 Main work Remove the holder with FI warning lamp Remove screw Remove screw Remove the upper triple clamp with the handlebar and set aside Info Cov...

Page 45: ...ew of the right fork leg is positioned to the front The left fork leg valve is offset by approx 20 to 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 402556 11 SX F US XC F US Position the fork legs Bleeder screws are positioned toward the front Info The rebound damping...

Page 46: ...he brake line and clamp Mount and tighten screws Finishing work Install the front fender p 47 Mount the handlebar cushion Install the start number plate p 46 Install the front wheel p 73 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 44 Remove the motorcycle from the lift stand p 39 11 11 Chec...

Page 47: ...nd change if necessary Finishing work Remove the motorcycle from the lift stand p 39 11 12 Adjusting the steering head bearing play Preparatory work Raise the motorcycle with a lift stand p 39 Remove the handlebar cushion 102159 10 Main work Loosen screws 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 on the upp...

Page 48: ...d remove it 11 15 Installing the start number plate 102161 10 Attach the start number plate to the brake line Position the start number plate Mount and tighten screw The holding lugs engage in the fender 11 16 Removing the front fender Preparatory work Remove the start number plate p 46 102162 10 Main work Remove screws and Remove the front fender ...

Page 49: ...nstall the start number plate p 46 11 18 Removing the shock absorber Preparatory work Raise the motorcycle with a lift stand p 39 K00221 10 Main work Remove the cable ties Remove screws with the washers Take off frame protector on both sides S00701 10 Remove screw and fitting Info Raise the wheel slightly to make it easier to remove the screw S00702 10 Remove screws Pull off foot brake cylinder fr...

Page 50: ...ake the shock absorber out of the vehicle toward the bottom 11 19 Installing the shock absorber S00706 10 Main work Carefully position the shock absorber into the vehicle from the bottom Mount and tighten screw Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 S00707 10 Position the swingarm and mount the swingarm pivot Info Pay attention to the flat area Mount and tighten the ...

Page 51: ...6 10 Position the angle lever and linkage lever Mount and tighten screw cap Guideline Nut linkage lever to angle lever M14x1 5 80 Nm 59 lbf ft Info Pay attention to the flat area Mount and tighten screw Guideline Screw bottom shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 K00222 10 Position the frame protector on the left and right Mount and tighten screws with washers Guideline Screw frame pro...

Page 52: ... collar bushing of the fuel tank lower the seat at the rear and push the seat forward 102173 10 Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 22 Removing the air filter box cover K00188 10 Condition The air filter box cover is secured Remove screw M00779 10 Pull off the air filter box cover in area sideways and remove it toward the front ...

Page 53: ...ubstances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regu lations Preparatory work Remove the air filter box cover p 50 102177 10 Main work Detach retaining tab Remove air filter with air filter support Take off air filter from air filter support 11 25 Cleaning the air filter and air filter box Warn...

Page 54: ...the air filter 102178 10 Main work Mount the clean air filter on the air filter support Grease the air filter in area Long life grease p 108 M01112 10 Insert air filter and position retaining pin in bushing The air filter is correctly positioned Insert retaining tab Retaining pin is secured by the retaining tab Info If the air filter is not mounted correctly dust and dirt may enter the engine and ...

Page 55: ...move screws and take off the main silencer 11 30 Installing the main silencer 102180 11 Position the main silencer Mount screws but do not tighten yet Attach spring Spring hook 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 Warning Danger of burns The exhaust system gets very hot when the vehicle is...

Page 56: ...igarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors ...

Page 57: ...el tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard A...

Page 58: ...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 Lubricate the O ring and connect the plug in connection for the fuel line Info Route the cable and fuel line at a safe distance from the exhaust system Finishing work Mount the seat p 50 11 34 Checking for chain dirt accumulation 400678 01 Check the chain ...

Page 59: ...chain is tensioned too much the chain engine sprocket rear sprocket transmission and rear wheel bearings wear more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the speci...

Page 60: ...tension 55 58 mm 2 17 2 28 in Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks The rear wheel is then correctly aligned Tighten nuts Make sure that chain adjusters are fitted correctly on adjusting screws Tighten nut Guideline Nut rear wheel spindle M25x1 5 80 Nm 59 lbf ft Info The wide adjus...

Page 61: ... New chains wear out faster on an old worn rear sprocket or engine sprocket 102189 01 Check the chain sliding guard for wear If the lower edge of the chain pins is in line with or below the chain sliding guard Change the chain sliding guard Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the screws on the chain sliding guard Guideline Screw chain sli...

Page 62: ...p 39 11 39 Checking the frame S00867 01 Check the frame for cracks and deformation If the frame exhibits cracks or deformation due to a mechanical impact Change the frame Info Always replace a frame that has been damaged due to a mechanical impact Repair of the frame is not authorized by KTM 11 40 Checking the swingarm 401520 01 Check the swingarm for damage cracking and deformation If the swingar...

Page 63: ...the throttle grip on the right The left sleeve is clamped onto the handlebar The rubber grip can only be replaced with the sleeve or the throttle tube If a rubber grip is damaged or worn Change the rubber grip 102245 10 Check that screw is firmly seated Guideline Screw fixed grip M4 5 Nm 3 7 lbf ft Loctite 243 Diamond must be located at the top 11 43 Adjusting the basic position of the clutch leve...

Page 64: ...tch lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container 102195 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Check the fluid level Fluid level below container rim 4 mm 0 16 in If the fluid level doe...

Page 65: ...fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 102197 10 Inject the liquid into the system until it escapes from drill hole of the master cylinder without bubbles Drain fluid occasionally from the master cylinder reservoir to prevent overflow Remove the bleeding syringe Mount and tighten screws bleeder screw Correct the fluid level of the hydra...

Page 66: ...d 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 Only turn the adjusting screw by hand and do not use force Do not make any adjustments while riding 12 3 Checking the brake discs Warning Danger of accidents Worn out brake discs reduce the braking effect Make sure that worn out brake ...

Page 67: ...he brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake lin ings are worn down Check the brake system and do not continue riding until the problem is eliminated Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protect...

Page 68: ...l brake fluid level below reser voir rim 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 106 102201 10 Position cover with membrane Mount and tighten screws Info Clean up overflowed or spilled brake fluid immediately with water 12 6 Checking the front brake linings Warning Danger of accidents Worn out brake linings reduce the braking effect Ensure that worn out brake linings are replaced immediately Your ...

Page 69: ... rear brake is changed in accordance with the service schedule Your autho rized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regu lations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil se...

Page 70: ...Mount and tighten screws Info Clean up overflowed or spilled brake fluid immediately with water 12 8 Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the ...

Page 71: ...t Guideline Remaining nuts chassis M6 10 Nm 7 4 lbf ft Hold screw and tighten nut Guideline Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Attach spring 12 10 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaki...

Page 72: ...e fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your autho rized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regu lations I...

Page 73: ...ed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed ...

Page 74: ...ake 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 102212 10 Insert the new brake linings insert pin and mount cotter pins Info Always change the brake linings in pairs Make sure that decoupling plate is mounted on the piston side brake lining Operate the foot brake lever repeatedly un...

Page 75: ...braking effect Always lay the wheel down in such a way that the brake disc is not dam aged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork Info Do not pull the hand brake lever when the front wheel is removed H00003 10 Remove spacers 13 2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always...

Page 76: ...H00004 10 Main work Press 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 fro...

Page 77: ...sition the rear wheel and insert wheel spindle The brake linings are correctly positioned Mount the chain H00007 10 Position chain adjuster Mount nut but do not tighten it yet Make sure that chain adjusters are fitted correctly on adjusting screws Check the chain tension p 57 Tighten nut Guideline Nut rear wheel spindle M25x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters ...

Page 78: ...te the week of manufacture and the last two digits the year of manufac ture KTM recommends that the tires be changed after 5 years at the latest regardless of the actual state of wear If the tires are more than 5 years old Change the tires 13 6 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal ridi...

Page 79: ... tone frequencies from different spokes of equal length and diameter this is an indication of different spoke tensions You should hear a high note If the spoke tension differs Correct the spoke tension 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 80: ... negative cable from the battery Pull back positive terminal cover and disconnect the positive cable from the battery Remove screw Pull holding bracket forward and remove battery toward the top K00191 10 XC F US Disconnect negative cable from the battery Pull back positive terminal cover and disconnect the positive cable from the battery Remove screw Pull holding bracket forward and remove battery...

Page 81: ...pose of it at a collection point for used batteries Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regu lations Info Even when there is no load on the battery it discharges steadily The charging level and the method of charging are very important for the...

Page 82: ... been met Battery voltage 9 V Recharge the battery Guideline The charging current charging voltage and charging time must not be exceeded Maximum charging voltage 14 4 V Maximum charging current 3 0 A Charge the battery regularly when the motorcycle is not in use 6 months Info Never remove cover Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 Yo...

Page 83: ... Remove the faulty main fuse Info A defective fuse is indicated by a burned out fuse wire A spare fuse is located in the starter relay Install a new main fuse Fuse 58011109110 p 101 Check that the electrical equipment is functioning 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 Finishing work Mount th...

Page 84: ...ponents of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of ...

Page 85: ...ight on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level above the radiator fins 10 mm 0 39 in If the coolant level does not match the specified value Correct the coolant level Coolant p 106 Mount the radiator cap 15 4 Draining the coolant Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not ...

Page 86: ...o contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing C00881 10 Make sure that screw is tightened Position the ...

Page 87: ...ing the engine in an enclosed space Start the engine and let it run 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 p 85 16 2 Adjusting the play in the throttle cable Info If the correct routing of the throttle cables has already been secured the fuel tank does not need to be removed Pr...

Page 88: ...te 79002014100 Info The gray guide plate opens the throttle valve more slowly The black guide plate opens the throttle valve more quickly The black guide plate is already mounted when the vehicle is delivered H00030 10 Clean the outside of the handlebar and the inside of the grip tube Mount the grip tube on the handlebar Attach the throttle cables to the guide plate and route correctly Position ha...

Page 89: ...ective exhaust extraction system when starting or running the engine in an enclosed space Set the idle speed by turning idle speed adjusting screw Guideline Idle speed 2 250 2 350 rpm Tachometer 45129075000 Info Turning counterclockwise lowers the idle speed Turning clockwise raises the idle speed 16 6 Teaching the throttle valve position Info If the control unit detects that the throttle valve id...

Page 90: ...per 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 p 88 16 8 Adjusting the basic position of the shift lever 401950 12 Remove screw with washers 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 in the required position and engage the gearing I...

Page 91: ...er handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system C00882 10 Clean plug in connection of the fuel line thoroughly with 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 Info Remaining fuel may flow ...

Page 92: ...n Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden Wear suitable protective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance wi...

Page 93: ...ng Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing area S00714 11 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 Oil the O ring of the oil filter cover and mount it with the oil filter cover Mount and tighten the screws Guideline Screw oil filter...

Page 94: ... of the engine 0 0 401955 10 Remove oil filler plug with the O ring from the clutch cover Add the same engine oil used when the last oil change was carried out Engine oil SAE 10W 50 p 106 Alternative 1 Engine oil SAE 10W 60 00062010035 p 106 Info For optimal performance of the engine oil do not mix different types of engine oil We recommended changing the engine oil when necessary Install and tigh...

Page 95: ... with a normal motorcycle cleaner and then clean with a paintbrush Motorcycle cleaner p 108 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the vehicle with water first After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the closure of the exhaust system Warning Danger of...

Page 96: ...g workshop waiting times at the start of the new season 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 108 Refuel p 25 Clean the motorcycle p 93 Change the engine oil and oil filter clean the oil screen p 90 Check the antifreeze and coolant level p 82 Check the tire air pressure p 76 Remove the battery p 78 Recharge the batt...

Page 97: ...5 19 2 Putting into operation after storage 401059 01 Install the battery p 78 Remove the motorcycle from the lift stand p 39 Perform checks and maintenance steps before putting into operation p 22 Take a test ride ...

Page 98: ...ittle power Air filter is very dirty Clean the air filter and air filter box p 51 Fuel filter is very dirty Change the fuel filter Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool Exhaust system leaky deformed or too little glass fiber yarn filling in main silencer Check exhaust system for damage Change the glass fiber yarn filling of the main silencer p 53...

Page 99: ...LESHOOTING 97 Faults Possible cause Action 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 ...

Page 100: ... alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with two Eaton pumps Primary transmission 24 73 Clutch Multidisc clutch in oil bath hydraulically activated Gearbox All SX F models 5 gear claw shifted Gearbox XC F US 6 gear claw shifted Transmission ratio All SX F models 1st gear 13 32 2nd gear 16 32 3rd gear 17 28 4th gear 19 26 5th gea...

Page 101: ...wheel M6 5 Nm 3 7 lbf ft Loctite 243 Screw alternator cover M6 10 Nm 7 4 lbf ft Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch slave cylinder M6 10 Nm 7 4 lbf ft Screw clutch spring M6 10 Nm 7 4 lbf ft Screw engine case M6 10 Nm 7 4 lbf ft Screw exhaust flange M6 10 Nm 7 4 lbf ft Loctite 243 Screw oil filter cover M6 10 Nm 7 4 lbf ft Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 S...

Page 102: ...rating conditions and increased performance Engine oil SAE 10W 60 00062010035 p 106 21 3 2 Coolant Coolant 0 95 l 1 qt Coolant p 106 21 3 3 Fuel Total fuel tank capacity approx All SX F models 7 5 l 1 98 US gal Super unleaded ROZ 95 RON 95 PON 91 p 107 Total fuel tank capacity approx XC F US 8 5 l 2 25 US gal Super unleaded ROZ 95 RON 95 PON 91 p 107 Fuel reserve approx XC F US 1 5 l 1 6 qt 21 4 C...

Page 103: ...e overall weight 335 kg 739 lb 21 5 Electrical system Battery All SX F models C22S Lithium ion battery Battery voltage 12 V Nominal capacity 2 2 Ah maintenance free Battery XC F US HJTZ5S FP Lithium ion battery Battery voltage 12 V Nominal capacity 2 0 Ah maintenance free Fuse 58011109110 10 A FI warning lamp LED Remaining indicator lamps XC F US W2 3W socket W2x4 6d 12 V 2 3 W 21 6 Tires Validity...

Page 104: ... 13 clicks Spring length with preload spacer s 475 mm 18 7 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 670 ml 22 65 fl oz Fork oil SAE 4 48601166S1 p 106 21 7 3 XC F US Fork part number 24 18 7P 75 Fork WP P...

Page 105: ...ngth 247 mm 9 72 in Gas pressure 10 bar 145 psi Static sag 38 mm 1 5 in Riding sag 110 mm 4 33 in Fitted length 477 mm 18 78 in Shock absorber oil Shock absorber fluid SAE 2 5 50180751S1 p 107 21 8 2 SX F US Shock absorber article number 18 18 7P 55 Shock absorber WP Performance Systems 5018 DCC Link Compression damping low speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression dam...

Page 106: ...r 75 85 kg 165 187 lb 245 mm 9 65 in Weight of rider 85 95 kg 187 209 lb 247 mm 9 72 in Gas pressure 10 bar 145 psi Static sag 40 mm 1 57 in Riding sag 110 mm 4 33 in Fitted length 477 mm 18 78 in Shock absorber oil Shock absorber fluid SAE 2 5 50180751S1 p 107 21 9 Chassis tightening torques Screw air intake temperature sensor EJOT DELTA PT 45x12 Z 2 Nm 1 5 lbf ft Screw air filter box cover EJOT ...

Page 107: ... 18 4 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw subframe M8 35 Nm 25 8 lbf ft Loctite 2701 Screw top steering stem M8 20 Nm 14 8 lbf ft Loctite 243 Screw top triple clamp M8 17 Nm 12 5 lbf ft Engine carrying screw M10 60 Nm 44 3 lbf ft Remaining nuts chassis M10 45 Nm 33 2 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw bottom shock absorber M10 60 Nm 44 3 lbf...

Page 108: ...0 Engine oil SAE 10W 60 00062010035 Standard classification JASO T903 MA p 109 SAE p 109 SAE 10W 60 KTM LC4 2007 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 Engine oil SAE 10W 50 Standard classification JASO T903 MA p 109 SA...

Page 109: ...andards see specifications on the container and that exhibit the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 Standard classification 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 g M15 M85 M10...

Page 110: ...otorex Bike 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 Special cleaner for glossy and matte paint finishes metal and plastic surfaces Re...

Page 111: ...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 112: ...X OF SPECIAL TERMS 110 MIL Malfunction indicator lamp Indicator lamp that supports vehicle diagnostics through flash codes OBD On board diagnosis Vehicle system that monitors emission and safety related values ...

Page 113: ...26 LIST OF ABBREVIATIONS 111 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 114: ...ondition that requires prompt intervention Active driving aids are also represented by yellow or orange symbols FI warning lamp MIL lights up flashes orange The OBD has detected an emission or safety critical fault The low fuel warning lamp lights up orange The fuel level has reached the reserve mark ...

Page 115: ...adjusting 58 checking 57 Characteristic map of the throttle response adjusting 86 Chassis number 11 Clutch fluid level checking correcting 62 fluid changing 62 Clutch lever 12 basic position adjusting 61 Cold start button 15 Compression damping fork adjusting 35 Compression damping high speed shock absorber adjusting 30 Compression damping low speed shock absorber adjusting 30 Coolant antifreeze a...

Page 116: ...ng changing 86 Map Select switch for the basic setting 13 Motorcycle cleaning 93 raising with lift stand 39 removing from lift stand 39 O Oil filter changing 90 Oil screen cleaning 90 Operating substances 8 Overview of indicator lamps 13 Owner s Manual 7 P Plug in stand 16 Preparing for use advice on first use 18 Protective clothing 6 Putting into operation after storage 95 checks and maintenance ...

Page 117: ...hecking 44 Storage 94 Swingarm checking 60 T Technical data capacities 100 chassis 100 chassis tightening torques 104 electrical system 101 engine 98 engine tightening torques 99 fork 101 shock absorber 103 tires 101 Throttle cable play adjusting 85 checking 85 Throttle cable routing checking 60 Throttle grip 12 Throttle valve position teaching 87 Tire air pressure checking 76 Tire condition check...

Page 118: ... 3213331en 3213331en 04 2016 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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