KTM 250 SX-F US Owner'S Manual Download

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TUNING THE ENGINE

16.7

Adjusting the basic position of the shift lever

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 in the required position and engage the
gearing.

Info

The range of adjustment is limited.
The shift lever must not come into contact with any other vehicle compo-
nents during the shift procedure.

–

Mount and tighten screw.
Guideline

Screw, shift lever

14 Nm
(10.3 lbf ft)

Loctite

243™

Summary of Contents for 250 SX-F US

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

Page 2: ......

Page 3: ...uipment 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 2...

Page 4: ...eration 21 8 2 Starting 21 8 3 Activating Launch Control 22 8 4 Starting off 22 8 5 Shifting riding 22 8 6 Applying the brakes 23 8 7 Stopping parking 23 8 8 Transport 24 8 9 Refueling 24 9 SERVICE SCHEDULE 25 9 1 Additional information 25 9 2 Required work 25 9 3 Recommended work 26 10 TUNING THE CHASSIS 27 10 1 Checking the basic chassis setting with the rider s weight 27 10 2 Air suspension AER...

Page 5: ... 12 13 Changing the rear brake linings 68 13 WHEELS TIRES 70 13 1 Removing the front wheel 70 13 2 Installing the front wheel 70 13 3 Removing the rear wheel 71 13 4 Installing the rear wheel 72 13 5 Checking the tire condition 72 13 6 Checking the tire air pressure 73 13 7 Checking the spoke tension 73 14 ELECTRICAL SYSTEM 75 14 1 Removing the battery 75 14 2 Installing the battery 75 14 3 Rechar...

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: ...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: ...OF VEHICLE 8 4 1 View of vehicle front left side example C00916 10 1 Hand brake lever p 11 2 Clutch lever p 11 3 Filler cap 4 Air filter box lid 5 Engine number p 10 6 Shift lever p 14 7 Cold start button p 14 ...

Page 11: ... 2 Kill switch p 11 3 Electric starter button p 11 4 Map Select switch for ride mode p 12 5 Throttle grip p 11 6 Type label p 10 7 Fork part number p 10 8 Foot brake lever p 15 9 Engine oil level viewer 10 Idle speed adjusting screw p 14 11 Shock absorber rebound adjustment 12 Shock absorber 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: ...r 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 ...

Page 14: ...le operation This change is activated while the engine is idling or on restarting In addition the Map Select switch controls the Launch Control p 12 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 gradually incre...

Page 15: ...d areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that has been contaminated with fuel Store fuel properly in a suitable canister and keep away from children 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 K00180 10 All SX F...

Page 16: ...n 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 influence on the vehicle s starting behavior on stable idling and on vehicle response when the throttle is opened This means that an engine with a correctly s...

Page 17: ...nd 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 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 6 17 Sid...

Page 18: ...6 CONTROLS 16 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 19: ...g 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 othe...

Page 20: ... 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 distribute through the lithium ion battery and the battery is not dam aged If the charged lithium ion battery does not or only weakly turns over the electric starter when temperatures are below 15 C 60 F then the battery is not faulty but needs to b...

Page 21: ...tions 600868 01 Clean the chain Chain cleaner p 104 Fit the steel sprocket Tip Do not grease the chain Clean the radiator fins Straighten bent radiator fins carefully If used in sand regularly replace the piston every 20 operating hours 7 6 Preparing for rides on wet sand 102137 01 Fit a waterproofing device on the air filter Waterproofing device for air filter 79006921000 Info See the KTM PowerPa...

Page 22: ...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 104 Clean the radiator fins Straighten bent radiator fins carefully Check the coolant level p 79 7 9 Preparing for rides at low temperatures or in snow...

Page 23: ...rk legs p 38 Bleed the fork legs p 37 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 or death When running the engine always make sure there is...

Page 24: ... seconds after the vehicle starts Launch Control is deactivated automatically To reactivate Launch Control the engine must first be switched off for at least 10 seconds for safety reasons This must occur regardless of whether the engine was started or not 8 4 Starting off Pull the clutch lever engage 1st gear release the clutch lever slowly and simultaneously open the throttle carefully 8 5 Shifti...

Page 25: ...ted 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 way you have to apply the brakes far less frequently and the brake system does not overheat 8 7 Stopping parking Warning Risk of misappropriation Usage by unauthorized persons N...

Page 26: ...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 Change clothing that is contaminated with fuel Note Material damage Premature clogging of the fuel filter ...

Page 27: ...ain tension p 55 Grease all moving parts e g hand lever chain and check for smooth operation Check rectify the fluid level of the hydraulic clutch p 59 Check the front brake fluid level p 62 Check the free travel of the hand brake lever p 61 Check the steering head bearing play p 42 Check the valve clearance Check the clutch Change the cover seal and shaft seal rings of the water pump Change the e...

Page 28: ... Service the shock absorber Change the spark plug and spark plug connector Change the piston Check measure the cylinder Check the cylinder head Change the valves valve springs and valve spring seats Check the camshaft and cam lever Change the connecting rod conrod bearing and crank pin Check the transmission and shift mechanism Check the oil pressure regulator valve Change the suction pump Check t...

Page 29: ... are no longer required a significant weight advantage is achieved when compared to conventional forks The response on slightly uneven surfaces is signifi cantly improved In normal driving mode suspension is provided exclusively by an air cushion A steel spring is located in the left fork leg as an end stop Info If the fork is frequently overloaded then the air pressure in the fork must be increas...

Page 30: ...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 102139 10 Turn adjusting screw clockwise with a screwdriver up to the last perceptible click Info Do not loosen fitting Turn counterclockwise by the number of clicks corresponding to the shock absorb...

Page 31: ...mp ing 10 6 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 102141 10 Turn adjusting screw clockwise up to the last perceptible click Turn counterclockwise by the number of cl...

Page 32: ...10 8 Checking the static sag of the shock absorber 402416 10 Measure distance of rear wheel unloaded p 30 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 33: ...d 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 Preparatory work Raise the motorcycle with a lift stand p 37 Remove the shock absorber p 45 After removing the shoc...

Page 34: ...ht 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 46 Check the free travel of the foot brake lever p 65 Check the static sag of the shock absorber p 30 Check the riding sag of the shock abs...

Page 35: ...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 36: ...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 37: ...mber of clicks 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 cen...

Page 38: ...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 39: ...rface 0 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 l...

Page 40: ...irt can penetrate behind the dust boots If this dirt is not removed the oil seals behind can start to leak 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 cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray p 104 Press...

Page 41: ...d brake lever when the front wheel is removed 102150 10 Loosen screws 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 Bleeder screws are positioned toward the front The left fork leg valve is positioned approx 20 further forward Info Grooves are milled into the side of the upper end of the fork l...

Page 42: ...oving the lower triple clamp Preparatory work Raise the motorcycle with a lift stand p 37 Remove the front wheel p 70 Remove the fork legs p 39 Remove the start number plate p 44 Remove the front fender p 44 Remove the handlebar cushion 102152 10 Main work Remove the holder with FI warning lamp Remove screw Remove screw Pull off the upper triple clamp with the handlebar and hang to the side Info P...

Page 43: ...crews are positioned toward the front The left fork leg valve is positioned approx 20 further 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 402556 11 SX F US XC F US Position the fork legs Bleeder screws are positioned toward the front Info The rebound damping is locate...

Page 44: ...e 243 Position the brake line and clamp Mount and tighten screws Finishing work Install the front fender p 45 Mount the handlebar cushion Install the start number plate p 44 Install the front wheel p 70 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 42 Remove the motorcycle from the lift stand...

Page 45: ...and change if necessary Finishing work Remove the motorcycle from the lift stand p 37 11 12 Adjusting the play of the steering head bearing Preparatory work Raise the motorcycle with a lift stand p 37 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...

Page 46: ... the start number plate 102161 10 Attach the start number plate to the brake line Position the start number plate Mount and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft The holding lugs engage in the fender 11 16 Removing the front fender Preparatory work Remove the start number plate p 44 102162 10 Main work Remove screws and Remove the front fender ...

Page 47: ... lbf ft Finishing work Install the start number plate p 44 11 18 Removing the shock absorber Preparatory work Raise the motorcycle with a lift stand p 37 K00221 10 Main work Remove screws with the washer Remove the cable tie s 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 ...

Page 48: ... take 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 nu...

Page 49: ... 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 the washers Guideline Screw frame ...

Page 50: ...f the fuel tank lower it at the rear and simultaneously push it forward Seat is correctly latched 102173 10 Mount and tighten seat fixing screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 22 Removing the air filter box lid K00188 10 Condition The air filter box lid is secured Remove screw M00779 10 Pull off the air filter box lid in area sideways and remove it toward the front ...

Page 51: ...ronmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Preparatory work Remove the air filter box lid p 48 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 ...

Page 52: ...ling 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 104 M01112 10 Insert air filter and position retaining pin into socket The air filter is correctly positioned Insert retaining tab Retaining pin is secured by the retaining tab Info If the air filter is not correctly mounted dust and dirt can enter the engin...

Page 53: ...silencer 11 30 Installing the main silencer 102180 11 Position the main silencer Mount screws but do not tighten them yet Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 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 Warning Danger of burns The exhaust system get...

Page 54: ...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 contact a phys...

Page 55: ...nstructions 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 Chang...

Page 56: ...for chain dirt accumulation 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 54 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 bra...

Page 57: ...rk Pull the chain at the end of the chain sliding component upwards to measure 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 55 Finishing work Remove the motorcycle from the lift s...

Page 58: ...he chain rear sprocket engine sprocket and chain guide Preparatory work Raise the motorcycle with a lift stand p 37 400227 01 Main work Shift the transmission to idle Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the drivetrain kit Info The engine sprocket rear sprocket and chain should always be replaced together 1 2 3 16 17 18 0 0 0...

Page 59: ...s is in line with or below the chain sliding piece Change the chain sliding piece 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 402421 10 Check the chain guide with a slide gauge for dimension Minimum thickness of the chain guide 6 mm 0 24 in If the measured value is l...

Page 60: ...ation If the swingarm shows signs of damage cracking or deformation Change the swingarm 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 47 Remove the fuel tank p 52 H00042 10 Main work Check the throttle cable routing Both throttle cables must be routed to the throttle valve ...

Page 61: ...usting 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 44 Checking rectifying th...

Page 62: ...rew with a suitable hose piece On the clutch slave cylinder only release bleeder screw to the point where fill ing is possible Info Wash off overflowing or spilled brake fluid immediately with water Avoid contact between brake 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 openin...

Page 63: ...istance 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 t...

Page 64: ...ue 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 and goggles I...

Page 65: ...shop will be glad to help 102202 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 p 63 Check the brake linings for damage and cracking If damage or cracking is visible Change the front brake linings p 63 12 7 Changing the front brake linings Warning Danger of accident Brake system failure ...

Page 66: ...the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane 102203 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 67: ...just the free travel on foot brake lever according to specifications 402026 10 Disconnect spring Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check 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 p 65 Recon...

Page 68: ...ue 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 Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop...

Page 69: ...als 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 Preparatory work Check the rear brake linings p 67 102208 10 Main work Stand the vehicle upright Remove screw cap with membrane and the O ring Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 102 Mount and ti...

Page 70: ...s 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 Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 102210 10 Stand the vehicle upright Remove screw cap...

Page 71: ...te is mounted on the piston side of the brake lining Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point 102208 10 Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 102 Mount and tighten screw cap with membrane and the O ring Info Clean up overflowed or spilt brake fluid immediately with water ...

Page 72: ...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 H00003 10 Remove spacers 13 2 Installing the front wheel 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 cleaner w...

Page 73: ... 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 from the rea...

Page 74: ...itted correctly on adjusting screws Check the chain tension p 55 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 26 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 ...

Page 75: ...d 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 offroad 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 76: ...spoke tension varies 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 77: ...t 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 toward the top 14 2 Installing the battery 102222 10 Main work All SX F models ...

Page 78: ...attery contains elements that are harmful to the environment Do not dispose of batteries with the household waste Dispose of a defective battery in an environmentally friendly manner Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners br...

Page 79: ...arge the battery regularly when the motorcycle is not in use 6 months S00863 10 XC F US Check the battery voltage Battery voltage 9 V Do not charge the battery Replace the battery and dispose of the old battery properly If the specifications have been met Battery voltage 9 V Recharge the battery Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 Yo...

Page 80: ...l power consumers and switch off the engine Remove the seat p 47 102224 10 Main work Pull the starter relay from the holder 102225 10 Remove protection caps 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 97 Check that the electrical equipment is functioning Tip Insert t...

Page 81: ...Change 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 the antifreeze of the coolant 25 45 C 13 49 F If the antifreeze in the coolant does not match the specified value Correct the antifreeze of the coolant Check the coolant level in the radiato...

Page 82: ...ed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Condition The motor is cold C00880 10 Position the motorcycle upright Place a suitable container beneath the water pump cover Remove screw Take off radiator cap Completely drain the coolant Mount and tighten screw with a new seal ring Guideline Screw water pump cover M6 10 Nm ...

Page 83: ...ring range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable p 81 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 Preparatory work Remove the seat p 47 Remove the fuel tank p 52 Check the throttle cable routing p 58 H00028 10 Main work Mov...

Page 84: ...79002014000 Alternative 2 Black guide plate 79002014100 Info The gray guide plate opens the throttle valve more slowly The black guide plate opens the throttle valve more quickly The grey guide plate is mounted upon delivery 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 corre...

Page 85: ...the MIL briefly lights up 2 x per sec ond Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Allow the vehicle to idle Illumination of the MIL disappears as soon a...

Page 86: ...of the shift lever and shift shaft Mount the shift lever on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle compo nents during the shift procedure Mount and tighten screw Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 ...

Page 87: ...ection 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 out of the fuel hose Pull fuel screen out of the connecting piece Slide the new fuel screen all the way into the connecting piece Lubricate the O ring a...

Page 88: ...ous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed 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 S00710 10 Main work Place a suitable container under the engine Remove oil drain plug with the magnet and seal ring Info Do not remove s...

Page 89: ...of the oil filter cover and mount it with the oil filter cover Mount and tighten the screws Guideline Screw oil filter cover M6 10 Nm 7 4 lbf ft Stand the motorcycle upright S00716 11 Remove the oil filler plug with the O ring from the clutch cover and fill up with engine oil Engine oil 1 10 l 1 16 qt Engine oil SAE 10W 50 p 102 Alternative engine oil for harsh oper ating conditions and increased ...

Page 90: ...ne oil SAE 10W 50 p 102 Alternative 1 Engine oil SAE 10W 60 00062010035 p 102 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 Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always ma...

Page 91: ...paintbrush Motorcycle cleaner p 104 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 accidents Reduced braking efficiency due to a wet or di...

Page 92: ...taking the motorcycle out of service add fuel additive Fuel additive p 104 Refuel p 24 Clean the motorcycle p 89 Change the engine oil and oil filter clean the oil screen p 86 Check the antifreeze and coolant level p 79 Check the tire air pressure p 73 Remove the battery p 75 Recharge the battery p 76 Guideline Storage temperature of battery without direct sunlight 0 35 C 32 95 F Store the vehicle...

Page 93: ...e power Air filter is very dirty Clean the air filter and air filter box p 49 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 51 Val...

Page 94: ...LESHOOTING 92 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 95: ...take air temperature sensor input signal too low Intake air temperature sensor input signal too high Blink code of FI warning lamp MIL 15 FI warning lamp MIL flashes 1x long 5x short Error level condition Rollover sensor A D type input signal too low Rollover sensor A D type input signal too high Blink code of FI warning lamp MIL 21 FI warning lamp MIL flashes 2x long 1x short Error level conditio...

Page 96: ... 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 97: ...wheel M6 6 Nm 4 4 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 98: ...erating conditions and increased performance Engine oil SAE 10W 60 00062010035 p 102 22 3 2 Coolant Coolant 0 95 l 1 qt Coolant p 102 22 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 103 Total fuel tank capacity approx XC F US 8 5 l 2 25 US gal Super unleaded ROZ 95 RON 95 PON 91 p 103 Fuel reserve approx XC F US 1 5 l 1 6 qt 22 4 ...

Page 99: ...l system Battery 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 22 6 Tires Validity Front tires Rear tires All SX F models 80 100 21 51M TT Dunl...

Page 100: ...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 102 22 7 3 XC F US Fork part number 24 18 7P 75 Fork WP Performance Systems...

Page 101: ...gth 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 103 22 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 damp...

Page 102: ... 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 103 22 9 Chassis tightening torques Screw air intake temperature sensor EJOT DELTA PT 45x12 Z 2 Nm 1 5 lbf ft Screw air filter box lid EJOT PT K60x20...

Page 103: ... 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 104: ...0 Engine oil SAE 10W 60 00062010035 Standard classification JASO T903 MA p 105 SAE p 105 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 105 SA...

Page 105: ...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 106: ...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 107: ...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 108: ...26 LIST OF ABBREVIATIONS 106 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 109: ... 96 fuel 24 96 Chain checking 56 cleaning 54 Chain guide checking 56 Chain tension adjusting 55 checking 55 Characteristic map of the throttle response adjusting 82 Chassis number 10 Clutch fluid level checking correcting 59 fluid changing 60 Clutch lever 11 basic position adjusting 59 Cold start button 14 Compression damping fork adjusting 33 Compression damping high speed shock absorber adjustin...

Page 110: ...moving 51 Motorcycle cleaning 89 raising with lift stand 37 removing from lift stand 37 O Oil filter changing 86 Oil screen cleaning 86 Operating substances 7 Overview of indicator lamps 12 Owner s Manual 6 P Plug in stand 15 Preparing for use advice on first use 17 Protective clothing 6 Putting into operation after storage 90 checks and maintenance before putting into operation 21 R Rear sprocket...

Page 111: ...king 58 T Technical data capacities 96 chassis 96 chassis tightening torques 100 electrical system 97 engine 94 engine tightening torques 95 fork 97 shock absorber 99 tires 97 Throttle cable play adjusting 81 checking 81 Throttle cable routing checking 58 Throttle grip 11 Tire air pressure checking 73 Tire condition checking 72 Transport 24 Troubleshooting 91 92 Type label 10 U Use definition 5 V ...

Page 112: ... 3213331en 3213331en 07 2015 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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