KTM 350 XC-F Owner'S Manual Download | Manualshive

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12

BRAKE SYSTEM

61

12.1

Checking the free travel of the hand brake lever

Warning

Danger of accidents

Brake system failure.

–

If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due
to overheating. Adjust the free travel on hand brake lever according to specifications.

H00019-10

–

Push the hand brake lever forward and check free travel



.

Free travel of hand brake lever

≥

3 mm (

≥

0.12 in)

» If the free travel does not meet specifications:

–

Adjust the basic position of the hand brake lever. (

12.2

Adjusting the basic position of the hand brake lever

Preparatory work

–

Check the free travel of the hand brake lever. (

H00020-10

Main work

–

Adjust the basic setting of the hand brake lever to your hand size by turning adjust-
ing screw



.

Info

Turn the adjusting screw clockwise to increase the distance between the
hand brake lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the hand brake lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!

12.3

Checking the brake discs

Warning

Danger of accidents

Reduced braking efficiency due to worn brake disc(s).

–

Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.)

A

A

402404-10

–

Check the thickness of the front and rear brake discs at several places on the disk
to see if it conforms to measurement



.

Info

Wear reduces the thickness of the brake disc around the area used by the
brake linings.

Brake discs - wear limit

Front

2.5 mm (0.098 in)

Rear

3.5 mm (0.138 in)

» If the brake disc thickness is less than the specified value:

–

Change the brake disc.

–

Check the front and rear brake discs for damage, cracking and deformation.
» If the brake disc shows signs of damage, cracking or deformation:

–

Change the brake disc.

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Summary of Contents for 350 XC-F

Page 1: ...OWNER S MANUAL 2016 350 SX F EU 350 SX F US 350 XC F US Art no 3213332en ...

Page 2: ......

Page 3: ...lors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for delivery options deviations from illustrations and descriptions misprints and other errors The models portrayed partly contain special equip ment that does not...

Page 4: ... use 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 48...

Page 5: ...nings 67 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 ...

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: ...icle front left example K00181 10 1 Hand brake lever p 11 2 Map Select switch for ride mode p 12 3 Clutch lever p 11 4 Filler cap 5 Plug in stand p 15 6 Air filter box lid 7 Engine number p 10 8 Shift lever p 14 9 Cold start button p 14 ...

Page 11: ...ght example K00182 10 1 Kill switch p 11 2 Electric starter button p 11 3 Throttle grip p 11 4 Chassis number p 10 4 Type label p 10 5 Fork part number p 10 6 Foot brake lever p 15 7 Idle speed adjusting screw p 14 8 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: ...lebar 6 4 Kill switch 102127 10 Kill switch is fitted on the left side of the handlebar Possible states Kill switch in basic position In this position the ignition circuit is closed and the engine can be started Kill switch pressed In this position the ignition circuit is interrupted a run ning engine stops and a non running engine will not start 6 5 Electric starter button C00913 10 Electric star...

Page 14: ...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 increased up to the maximum engine speed Throughout this procedure the rider opens the ...

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: ...ton is activated The cold start button is pulled out all the way The cold start button is deactivated The cold start button is pushed in all the way 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 correctl...

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: ...hat 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 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...

Page 21: ... the KTM PowerParts fitting instructions 102138 01 Fit a sand cover on the air filter Sand protection device for air filter 77206922000 Info See the KTM PowerParts fitting instructions 600868 01 Clean the chain Chain cleaner p 105 Fit the steel sprocket Tip Do not grease the chain Clean the radiator fins Straighten bent radiator fins carefully 7 6 Preparing for rides on wet sand 102137 01 Fit a ra...

Page 22: ...refully 7 8 Preparing for rides at high temperature and slow speed 600868 01 Adjust the secondary drive to the road conditions Info The engine oil quickly gets hot if the clutch has to be operated very often due to an excessively high secondary drive Clean the chain Chain cleaner p 105 Clean radiator fins Straighten bent radiator fins carefully Check the coolant level p 79 7 9 Preparing for rides ...

Page 23: ...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 supply 8 2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is suff...

Page 24: ...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 reasons This must occ...

Page 25: ...Clean or dry a dirty or wet brake system by riding and braking gently 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 way you have to apply t...

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: ... 54 Grease all moving parts e g hand lever chain and check for smooth operation Check correct the fluid level of the hydraulic clutch p 59 Check the brake fluid level of the front brake 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: ... 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 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 increased to avoid d...

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 45 N mm 257 lb in Weight of rider 75 85 kg 165 187 lb 48 N mm 274 lb in Weight of rider 85 95 kg 187 209 lb 51 N mm 291 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: ...emove protection cap Push the fork pump together fully Connect the fork pump to the left fork leg Fork pump 79412966000 The fork pump indicator switches on automatically A little air escapes from the fork 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 air pressure as specified ...

Page 36: ...US XC F US Turn the white adjusting screw all the way clockwise Info The adjusting screw is located at the upper end of the left fork leg The compression damping is located in the left fork leg COMP white adjusting screw The 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 dam...

Page 37: ...fork leg The rebound damping is located in the right fork leg REB red adjusting screw The compression damping is located in the left fork leg COMP white adjusting screw Turn counterclockwise by the number 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 ...

Page 38: ...ebar support Position rubber bushings and push through nuts from below Place the handlebar supports 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 so that both parts touch at...

Page 39: ...ven surface 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 riding 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 th...

Page 40: ...rt 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 105 Press ...

Page 41: ...s 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 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 mu...

Page 42: ... 9 Removing 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 Remove the upper triple clamp with the handlebar and set aside Info Cove...

Page 43: ... of the right fork leg is positioned to 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 dampi...

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 screw Remove screw Loosen and retighten screw Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly 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: ...crews and Guideline Remaining screws chassis M6 10 Nm 7 4 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 102163 10 Main work Remove frame protector on the left and right H00012 10 Remove screw and fitting 102165 10 Remove screws ...

Page 48: ... take the shock absorber out of the vehicle toward the bottom 11 19 Installing the shock absorber H00014 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 102170 10 Position the swingarm and mount the swingarm pivot Info Pay attention to flat area Mount and tighten the nu...

Page 49: ...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 Position the frame protector on the left and right Finishing work Check the free travel of the foot brake lever p 65 Remove the motorcycle from the lift stand p 37 11 20 Removing the seat 102173 10 Remove screws Raise the rear of the seat push the s...

Page 50: ... lid is secured Mount and tighten screws Guideline Screw air filter box lid EJOT PT K60x20 Z 3 Nm 2 2 lbf ft 11 24 Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to increased wear Warning Environmental hazard Hazardous substances...

Page 51: ...y in special cleaning liquid and allow it to dry properly Air filter cleaner p 105 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 105 Clean the air filter box Clean the intake flange and check it for damage and tightness Finishing work Install the air filter p 49 Install the air filter box lid p 48 11 26 I...

Page 52: ... box lid p 48 11 28 Sealing the air filter box Preparatory work Remove the air filter box lid p 48 S00847 10 Main work Seal the air filter box in the marked area Finishing work Install the air filter box lid p 48 11 29 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down Do not touch hot components 1021...

Page 53: ... Main work Remove all screws on the main silencer Take off silencer cap and O ring Take off outer tube and O ring Pull glass fiber yarn filling off of inner tube Clean the parts that need to be reinstalled Mount new glass fiber yarn on inner tube Slide O ring and outer tube over the glass fiber yarn filling Insert O ring and silencer cap into outer tube Mount and tighten all of the screws Guidelin...

Page 54: ...ly in a suitable canister and keep away from children Preparatory work Remove the seat p 47 M00781 10 Main work Unplug connector of the fuel pump Clean the 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 M00782 10 Disconnect the plug in connection of the fuel line Mou...

Page 55: ...ed contact a physician immediately Change clothing that is contaminated with fuel Main work Check the throttle cable routing p 58 102184 11 Position the fuel tank and fit the two spoilers to the sides of the radiator bracket Make sure that no cables are trapped or damaged Mount the fuel tank breather Mount and tighten screw with the rubber bushing Guideline Remaining screws chassis M6 10 Nm 7 4 lb...

Page 56: ...ends largely on its maintenance Preparatory work Raise the motorcycle with a lift stand p 37 400725 01 Main work Clean the chain regularly and then treat with chain spray Chain cleaner p 105 Off road chain spray p 105 Finishing work Remove the motorcycle from the lift stand p 37 11 36 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain is to...

Page 57: ... to break in extreme cases If the chain is too loose however it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine Ensure that the chain tension is correct and adjust it if necessary Preparatory work Raise the motorcycle with a lift stand p 37 Check the chain tension p 54 H00016 10 Main work Loosen nut Loosen nuts Adjust the chain tension by turning adj...

Page 58: ...8 chain links in the lower chain section Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance at the longest chain section 272 mm 10 71 in If the distance is greater than the specified measurement Change the power set Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out fas...

Page 59: ...imum thickness of the chain guide 6 mm 0 24 in If the measured value is less than the specification Change the chain guide 102192 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the chain guide Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Remove the motorcycle from the lift stand p 37 11 39 Checking the frame S00867 01 Check the frame for...

Page 60: ...dlebars and above the fuel tank bracket If the throttle cable is not routed as specified Correct the throttle cable routing Finishing work Install the fuel tank p 53 Mount the seat p 47 11 42 Checking the rubber grip 401197 01 Check the rubber grips on the handlebar for damage wear and looseness Info The rubber grips are vulcanized onto a sleeve on the left and onto the han dle tube of the throttl...

Page 61: ...tainer rim 4 mm 0 16 in If the fluid level does not meet specifications Correct the fluid level of the hydraulic clutch Brake fluid DOT 4 DOT 5 1 p 103 Position the cover with the membrane Mount and tighten the screws 11 45 Changing the hydraulic clutch fluid Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disp...

Page 62: ...r 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 hydraulic clutch Guideline Fluid level below container rim 4 mm 0 16 in Position the cover with the membrane Mount and tighten the screws ...

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

Page 65: ...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 Maint...

Page 66: ...the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane H00021 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: ...lue 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 worksho...

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 103 Mount and ti...

Page 70: ... 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: ...e 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 103 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: ...ress the brake caliper onto the brake disc by hand in order to push back the brake piston Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut Remove chain adjuster Withdraw wheel spindle only enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket I...

Page 74: ...ly on adjusting screws Check the chain tension p 54 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 and there is ...

Page 75: ...overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life 400695 01 Remove the protection cap Check the tire air pressure when the tires are cold Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi If the tire pressure does not meet specifications Correct the tire pressure Mount the protection cap 13 7 Checking the spoke tension ...

Page 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: ...ect 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 model...

Page 78: ...tery 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 brak...

Page 79: ...harge 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 Y...

Page 80: ...7 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 98 Check that the electrical equipment is functioning properly Tip Insert a spare fuse so that it is available if needed Check th...

Page 81: ...y 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 antifreeze of 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 radiator Cool...

Page 82: ...h the eyes rinse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swal lowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Condition The motor is cold K00194 10 Position the motorcycle upright Place a suitable container under the water pump cover ...

Page 83: ...tened Position the motorcycle upright Pour coolant in up to measurement above the radiator fins Guideline Dimension over the radiator fins 10 mm 0 39 in Coolant 0 95 l 1 qt Coolant p 103 Mount the radiator cap Take a short test ride Check the coolant level p 79 ...

Page 84: ...ring range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable p 82 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 51 Check the throttle cable routing p 58 K00199 10 Main work Mov...

Page 85: ...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 gray 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 86: ...o idle Illumination of the MIL disappears as soon as programming is complete Info If the vehicle becomes too warm then carry out a cooling ride at moderate speed Do not then park the vehicle but let it continue running at idle speed 16 6 Checking the basic position of the shift lever 400692 10 Sit on the vehicle in the riding position and determine the distance between the upper edge of your boot ...

Page 87: ... 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 88: ...n of the fuel line thoroughly with compressed air Info Under no circumstances should dirt enter into the fuel line Dirt clogs the injection valve Disconnect the plug in connection of the fuel line Pull fuel screen out of the connecting piece Insert the new fuel screen all the way into the connecting piece Lubricate the O ring and connect plug in connection of the fuel line Danger Danger of poisoni...

Page 89: ...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 motor Remove oil drain plug with the magnet and seal ring Info Do not remove screws on both sides S00711 10 Remove screw plug with oil screen and the O rings Completely drain the engine oil Thoroughly clean the parts and sealing sur...

Page 90: ...ht K00196 10 Remove the oil filler plug with the O ring from the clutch cover and fill up with engine oil Engine oil 1 0 l 1 1 qt Engine oil SAE 10W 50 p 103 Alternative engine oil for harsh oper ating conditions and increased per formance Engine oil SAE 10W 60 00062010035 p 103 Info Too little engine oil or poor quality engine oil results in premature wear to the engine Install and tighten the oi...

Page 91: ... SAE 10W 60 00062010035 p 103 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 make sure there is sufficient ventila tion and do ...

Page 92: ...n with a paintbrush Motorcycle cleaner p 105 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry vehicle always rinse with water first After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the plug from the exhaust system Warning Danger of accidents Reduced braking efficiency due to a wet or dirt...

Page 93: ...taking the motorcycle out of service add fuel additive Fuel additive p 105 Refuel p 24 Clean the motorcycle p 90 Change the engine oil and oil filter clean the oil screen p 87 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 94: ...oo little 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 ...

Page 95: ...LESHOOTING 93 Faults Possible cause Action Battery is discharged Battery is not charging Check the charging voltage Check the stator winding of the alternator Unwanted power consumer Check the quiescent current ...

Page 96: ...Intake air temperature sensor input signal to 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 conditi...

Page 97: ...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 14 28 2nd gear 16 26 3rd gear 18 24 4th gear 21 24 5th gear...

Page 98: ...ctite 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 Screw shift lever M6 14 Nm 1...

Page 99: ...ns and increased performance Engine oil SAE 10W 60 00062010035 p 103 22 3 2 Coolant Coolant 0 95 l 1 qt Coolant p 103 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 104 Total fuel tank capacity approx XC F US 8 5 l 2 25 US gal Super unleaded ROZ 95 RON 95 PON 91 p 104 Fuel reserve approx XC F US 1 5 l 1 6 qt 22 4 Chassis Frame Ce...

Page 100: ...ght 335 kg 739 lb 22 5 Electrical system Battery All SX F models C22S Battery voltage 12 V Nominal capacity 2 2 Ah Maintenance free Battery XC F US HJTZ5S FP Battery voltage 12 V Nominal capacity 1 2 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 SX F EU 80 100 21 M C 51M TT ...

Page 101: ...oad spacer s 475 mm 18 7 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 6 N mm 26 3 lb in Weight of rider 75 85 kg 165 187 lb 4 8 N mm 27 4 lb in Weight of rider 85 95 kg 187 209 lb 5 0 N mm 28 6 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 103 22 7 3 XC F US Fork part number 24 18 7P 77 Fork WP Performance Systems Up Side Down 48...

Page 102: ...h 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 104 22 8 2 SX F US Shock absorber part number 18 18 7P 57 Shock absorber WP Performance Systems 5018 DCC Link Compression damping low speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping h...

Page 103: ... 209 lb 51 N mm 291 lb in Spring length Weight of rider 65 75 kg 143 165 lb 245 mm 9 65 in Weight of rider 75 85 kg 165 187 lb 247 mm 9 72 in Weight of rider 85 95 kg 187 209 lb 252 mm 9 92 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 104 22 9 Chassis tightening torques S...

Page 104: ...clamp M8 20 Nm 14 8 lbf ft Screw side stand attachment XC F US M8 35 Nm 25 8 lbf ft Loctite 2701 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 shoc...

Page 105: ...0 Engine oil SAE 10W 60 00062010035 Standard classification JASO T903 MA p 106 SAE p 106 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 106 SA...

Page 106: ...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 M100 or more than 10 ethanol e g E15 E25 E85 E1...

Page 107: ...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 108: ...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 109: ...26 LIST OF ABBREVIATIONS 107 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 110: ...hecking 54 Characteristic map of the throttle response adjusting 83 Chassis number 10 Clutch checking correcting the fluid level 59 fluid changing 59 Clutch lever 11 basic position adjusting 59 Cold start button 14 Compression damping fork adjusting 34 Compression damping high speed shock absorber adjusting 28 Compression damping low speed shock absorber adjusting 28 coolant draining 80 refilling ...

Page 111: ...cle cleaning 90 raising with lift stand 37 removing from lift stand 37 O Oil filter changing 87 Oil screen cleaning 87 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 after storage 91 checks and maintenance work when preparing for use 21 Protective clothing 6 R Rear sprocket checking 56 Rear wheel installing 72 remo...

Page 112: ...hnical data capacities 97 chassis 97 chassis tightening torques 101 electrical system 98 engine 95 engine tightening torques 96 fork 98 shock absorber 100 tires 98 Throttle cable play adjusting 82 checking 82 Throttle cable routing checking 58 Throttle grip 11 Tire air pressure checking 73 Tire condition checking 72 Transport 24 Troubleshooting 92 93 Type label 10 U Use definition 5 V View of vehi...

Page 113: ... 3213332en 3213332en 05 2015 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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