KTM 450 SX-F 2019 Owner'S Manual Download Page 98

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12 BRAKE SYSTEM

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 specification.

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. 96)

–

Reconnect spring

12.9

Adjusting the basic position of the 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 specification.

F01544-10

–

Detach spring

–

Loosen nut

and, with push rod

, turn it back until you

have maximum free travel.

–

To adjust the basic position of the foot brake lever to individ-
ual requirements, loosen nut

and turn screw

accord-

ingly.

Info

The range of adjustment is limited.

–

Turn push rod

accordingly until you have free travel

. If

necessary, adjust the basic position of the foot brake lever.
Guideline

Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in)

–

Hold push rod

and tighten nut

Guideline

Remaining nuts,
chassis

10 Nm (7.4 lbf ft)

–

Hold screw

and tighten nut

Summary of Contents for 450 SX-F 2019

Page 1: ...OWNER S MANUAL 2019 450 SX F 450 XC F 450 SX F HERLINGS REPLICA 450 SX F FACTORY EDITION Art no 3214029en ...

Page 2: ......

Page 3: ...ior 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 figures and descriptions misprints and other errors The models portrayed partly contain special equipment that does not belong to the regular scope of supply 2018 KTM Sportmotorcycle GmbH ...

Page 4: ... Side stand XC F US 22 6 17 Factory Start HERLINGS REPLICA FACTORY EDITION 23 7 PREPARING FOR USE 24 7 1 Advice on preparing for first use 24 7 2 Running in the engine 25 7 3 Starting power of lithium ion batteries at low temperatures 26 7 4 Preparing the vehicle for difficult riding conditions 26 7 5 Preparing the vehicle for rides on dry sand 26 7 6 Preparing the vehicle for rides on wet sand 27...

Page 5: ... 70 11 25 Installing the air filter box cover 71 11 26 Removing the air filter 71 11 27 Cleaning the air filter and air filter box 72 11 28 Installing the air filter 73 11 29 Preparing air filter box cover for securing 73 11 30 Removing the main silencer 73 11 31 Installing the main silencer 74 11 32 Changing the glass fiber yarn filling of the main silencer 75 11 33 Removing the fuel tank 76 11 3...

Page 6: ...17 SERVICE WORK ON THE ENGINE 124 17 1 Changing the fuel screen 124 17 2 Checking the engine oil level 125 17 3 Changing the engine oil and oil filter cleaning the oil screens 126 17 4 Adding engine oil 129 18 CLEANING CARE 130 18 1 Cleaning the motorcycle 130 19 STORAGE 132 19 1 Storage 132 19 2 Preparing for use after storage 133 20 TROUBLESHOOTING 134 21 BLINK CODE 136 22 TECHNICAL DATA 138 22 ...

Page 7: ...ined experts using the auxiliary 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 Indicates a voltage measurement Indicates a current measurement Indicates the end of an activity including potential rework 1 2 Formats used The typographical formats used in this documen...

Page 8: ...ance competition and not primarily for use in motocross 2 2 Misuse The vehicle must only be used as intended Dangers can arise for people property and the environment through use not as intended Any use of the vehicle beyond the intended and defined use constitutes misuse Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respective ...

Page 9: ...f noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below 1 Removal or puncturing of the main silencers baffles header pipes or any other components which conduct exh...

Page 10: ...hing 2 8 Work rules Special tools are necessary for certain tasks The tools are not a component of the vehicle but can be ordered using the number in parentheses Example bearing puller 15112017000 During assembly use new parts to replace parts which cannot be reused e g self locking screws and nuts seals sealing rings O rings pins and lock washers In the case of certain screws a screw adhesive e g...

Page 11: ...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 and must be handed over to the new owner if the vehicle is sold The Owner...

Page 12: ...ur authorized KTM dealer will be glad to advise you The 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 ...

Page 13: ...IMPORTANT NOTES 3 11 A list of authorized KTM dealers can be found on the KTM website International KTM Website http www ktm com ...

Page 14: ...of vehicle front left example F01516 10 1 Hand brake lever p 16 2 Clutch lever p 16 3 Fuel tank filler cap 4 Air filter box cover 5 Plug in stand p 22 all SX F models 6 Cold start button p 20 7 Engine number p 14 8 Shift lever p 21 ...

Page 15: ... switch p 17 3 Kill switch p 16 4 Electric starter button p 17 5 Throttle grip p 16 6 Vehicle identification number p 14 6 Type label p 14 7 Fork article number p 14 8 Idle speed adjusting screw p 21 9 Foot brake lever p 22 bk Engine oil level viewer bl Shock absorber rebound adjustment bm Shock absorber article number p 15 ...

Page 16: ... the right side of the steering head 5 2 Type label 401946 10 The type label 1 is fixed to the front of the steering head 5 3 Engine number H00940 10 The engine number 1 is stamped on the left side of the engine 5 4 Fork article number 401947 10 The fork article number 1 is stamped on the inside of the axle clamp ...

Page 17: ...SERIAL NUMBERS 5 15 5 5 Shock absorber article number 0 0 1 1 401948 10 Shock absorber article number 1 is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 18: ...s engaged using the hand brake lever 6 3 Throttle grip S01193 11 The throttle grip 1 is fitted on the right side of the handlebar 6 4 Kill switch S01194 10 Kill switch 1 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 i...

Page 19: ...ivated when LED 1 and TC light up 2 ADVANCED ADVANCED mapping is activated when LED 2 lights up 2 TC ADVANCED with TC ADVANCED mapping with trac tion control is activated when LED 2 and TC light up The engine characteristic can be changed using button MAP on the combination switch The launch control and the traction control can also be activated using the combination switch 6 7 Overview of indicat...

Page 20: ...rly 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 In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoro...

Page 21: ... 10 All SX F standard models FACTORY EDITION Mount fuel tank filler cap 1 and turn it clockwise until the fuel tank is tightly closed Info Route fuel tank breather hose 2 without kinks A00516 10 HERLINGS REPLICA Mount fuel tank filler cap 1 and turn it clockwise until the fuel tank is tightly closed F01556 10 XC F US Mount the fuel tank filler cap and turn it clockwise until release button 1 engag...

Page 22: ... the engine burn the increased fuel quantity it must be supplied with additional oxygen by pushing the cold start button After briefly opening up the throttle and then releasing the throttle grip again or turning the throttle grip towards the front the cold start button returns to its original position Info Check whether the cold start button has returned to its basic position Possible states The ...

Page 23: ...djusted using the idle speed adjusting screw 1 Increase the idle speed by turning the idle speed adjusting screw clockwise Decrease the idle speed by turning the idle speed adjusting screw counterclockwise 6 13 Shift lever 401950 10 Shift lever 1 is mounted on the left of the engine 401950 14 SX F EU HERLINGS REPLICA The gear positions can be seen in the figure The neutral or idle position is betw...

Page 24: ...l spin dle The plug in stand is used to park the motorcycle The plug in stand is used as a fork locker when transporting the motorcycle Info Remove the plug in stand before riding The tool can be attached to the plug in stand holders 6 16 Side stand XC F US 401943 10 The side stand 1 is located on the left of the vehicle 401944 10 The side stand is used for parking the motorcycle Info When you are...

Page 25: ...Factory Start is activated The fork is compressed and the front of the motorcycle is lowered Activating the Factory Start lowers the front of the motorcycle which then causes the front wheel to lift off the ground when accelerating When the fork compresses for the first time the Factory Start lock button is released automatically From this point on the fork oper ates as if the Factory Start were d...

Page 26: ...nger of accidents An unadapted riding style impairs the handling characteristic Adapt your riding speed to the road conditions and your riding ability Warning Danger of accidents The vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of accidents The brake system fails in the event of overheating If the foot brake lever is not released the brake linings drag co...

Page 27: ...cle Do not undertake any off road trips that exceed your ability and experience Hold the handlebar firmly with both hands and keep your feet on the footrests when riding all SX F models Do not carry the luggage XC F US If luggage is carried ensure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels Info Motorcyc...

Page 28: ...s up 7 4 Preparing the vehicle for difficult riding conditions Info Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces can lead to considerably more rapid wear of components such as the drive train brake system or suspension compo nents For this reason it may be necessary to inspect or replace parts before the next scheduled service Clean the air filter and ...

Page 29: ...rsal oil spray p 153 Clean the radiator fins Straighten the bent radiator fins carefully 7 6 Preparing the vehicle for rides on wet sand 102137 01 Mount the air filter rain cover Air filter rain cover 79006921000 Info Observe the fitting instructions for KTM PowerParts 600868 01 Clean the chain Chain cleaner p 152 Mount the steel sprocket Grease the chain Universal oil spray p 153 Clean the radiat...

Page 30: ...ehicle for high temperatures or slow riding 600868 01 Adjust the secondary drive to the road conditions Info The engine oil heats up quickly when the clutch is operated frequently due to an excessively high sec ondary ratio Clean the chain Chain cleaner p 152 Clean the radiator fins Straighten bent radiator fins carefully Check the coolant level p 114 7 9 Preparing the vehicle for low temperatures...

Page 31: ...e tire condition p 106 Check tire pressure p 107 Check the spoke tension p 107 Info The spoke tension must be checked regularly as incor rect spoke tension will strongly impair riding safety Clean the dust boots of the fork legs p 54 Bleed the fork legs p 54 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 r...

Page 32: ... 15 C 60 F several attempts at starting may be necessary to warm up the lithium ion battery and thereby increase the starting power During the starting process the malfunction indicator lamp lights up 8 3 Activating launch control Info The launch control helps the rider to generate optimum motorcycle acceleration at the beginning of a race The maximum speed of the engine with the throttle valve fu...

Page 33: ...n control Info The traction control reduces excessive slip on the rear wheel in favor of more control and propulsion par ticularly in wet conditions When traction control is switched off the rear wheel may spin more during high acceleration and on sur faces with low grip Traction control can be switched on or off during the ride The setting most recently selected is activated again when restarting...

Page 34: ...incline road situation etc To do so release the throttle while simultaneously pulling the clutch lever shift into the next gear release the clutch lever and open the throttle If the cold start button was pushed while starting open the throttle briefly and release the throttle grip or turn the throttle grip forward The cold start button goes to the basic position After reaching maximum speed by ful...

Page 35: ...Warning Risk of misappropriation People who act without authorization endanger themselves and others Do not leave the vehicle unattended if the engine is running Protect the vehicle against access by unauthorized persons Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch any parts such as the exhaust system radiator engine shock absorber or br...

Page 36: ...1475 01 Use tension belts or other suitable devices to secure the motorcycle against falling over or rolling away Info Only tighten the tension belts to the point that the plug in stand is in contact with the fender and tires Pay attention to the alignment of the plug in stand to the fender XC F US Switch off the engine Use tension belts or other suitable devices to secure the motorcycle against f...

Page 37: ... in problems with the fuel system Refuel only with clean fuel that meets the specified standards Your authorized KTM workshop will be glad to help Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system Switch off the engine Open the fuel tank filler cap p 18 A A 401522 10 Fill the fuel tank with fu...

Page 38: ...ings p 93 Check the brake linings of the rear brake p 99 Check the brake discs p 90 Check the brake lines for damage and leakage Check the rear brake fluid level p 97 Check the free travel of the foot brake lever p 96 Check the frame p 85 Check the link fork p 85 Check the fork bearing for play Check the heim joint for play Check the shock absorber linkage Check the tire condition p 106 Check tire...

Page 39: ... pressure Check the idle speed Final check Check the vehicle for operating safety and take a test ride Read out the fault memory using the KTM diagnostics tool after a test ride Make the service entry in KTM Dealer net and in the Service Manufacturer War ranty Booklet One time interval Periodic interval 9 3 Recommended work Annually Every 100 operating hours Every 50 operating hours Once after 20 ...

Page 40: ... valves valve springs valve spring seats and valve spring retainers Change the connect ing rod conrod bearing and crank pin Check the transmission and shift mechanism Check the oil pressure control valve Change the suction pump Check the force pump and lubrication system Change the timing chain Change all engine bearings Change the shaft seal rings and bearing seals of the main bearing One time in...

Page 41: ...ted in the left fork leg and damp ing in the right fork leg As fork springs are no longer required a significant weight advantage is achieved when compared to conventional forks The response on slightly uneven surfaces is significantly 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 ...

Page 42: ...eparately although the transition between high speed and low speed is grad ual Thus modifications in the high speed range affect the compression damping in the low speed range and vice versa 10 4 Adjusting the low speed compression damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorber is fi...

Page 43: ... Turn clockwise to increase the damping turn counter clockwise to reduce the damping 10 5 Adjusting the high speed compression damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized KTM workshop ...

Page 44: ... EDITION Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Info Turn clockwise to increase the damping turn counter clockwise to reduce the damping 10 6 Adjusting the rebound damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the d...

Page 45: ...ort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping HERLINGS REPLICA Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping FACTORY EDITION Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase the damping turn counter clockwise to reduce the damping 10 7 Measuring the rear wheel dimension unloaded Preparatory work Raise the motorcycle with...

Page 46: ...unloaded p 43 Hold the motorcycle upright with aid of an assistant Measure the distance again between the rear axle and mark ing SAG on the rear fender using the sag gage Note the value as dimension B Info The static sag is the difference between measurements A and B Check the static sag Static sag SX F EU 35 mm 1 38 in Static sag SX F US 35 mm 1 38 in Static sag XC F US 35 mm 1 38 in Static sag H...

Page 47: ...05 mm 4 13 in Riding sag SX F US 105 mm 4 13 in Riding sag XC F US 105 mm 4 13 in Riding sag HERLINGS REPLICA 105 mm 4 13 in Riding sag FACTORY EDI TION 105 mm 4 13 in If the riding sag differs from the specified measurement Adjust the riding sag p 46 10 10 Adjusting the spring preload of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber i...

Page 48: ...GS REPLICA 7 mm 0 28 in Spring preload FACTORY EDITION 7 mm 0 28 in Info Depending on the static sag and or the riding sag it may be necessary to increase or decrease the spring preload Tighten screw 1 Guideline Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft Finishing work Install the shock absorber p 67 Check the free travel of the foot brake lever p 96 Remove the motorcycle from the lift...

Page 49: ...09 lb 48 N mm 274 lb in Spring rate HERLINGS REPLICA Weight of rider 65 75 kg 143 165 lb 36 N mm 206 lb in Weight of rider 75 85 kg 165 187 lb 39 N mm 223 lb in Weight of rider 85 95 kg 187 209 lb 42 N mm 240 lb in Spring rate FACTORY EDITION 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 l...

Page 50: ...to the suspension setting may cause a serious deterioration in the handling char acteristic and overload components Only make adjustments within the recommended range Ride slowly to start with after making adjustments to get the feel of the new handling characteristic Info Check or adjust the air pressure under the same conditions at the earliest 5 minutes after switching off the engine The air su...

Page 51: ...sure to a value outside the stated range Disconnect the fork airpump from the left fork leg When disconnecting excess pressure will escape from the hose the fork leg itself does not lose any air The fork airpump indicator switches off automatically after 80 seconds Mount the protection cap Info Only mount the protection cap by hand Finishing work Remove the motorcycle from the lift stand p 53 10 1...

Page 52: ... clicks Sport 7 clicks Compression damping FACTORY EDITION Comfort 17 clicks Standard 12 clicks Sport 7 clicks Info Turn clockwise to increase damping turn counterclock wise to reduce damping 10 15 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior M01100 10 Remove protection cap 1 Turn adjusting screw 2 clockwise all the way Info A...

Page 53: ...ndard 12 clicks Sport 7 clicks Rebound damping FACTORY EDITION Comfort 23 clicks Standard 18 clicks Sport 13 clicks Info Turn clockwise to increase the damping turn counter clockwise to reduce the damping Mount protection cap 1 10 16 Handlebar position H01188 10 The holes on the handlebar supports are placed at a distance of A from the center Hole distance A 3 5 mm 0 138 in The handlebar can be mo...

Page 54: ... 2 Take off handlebar supports 3 Position rubber bushings 4 and push through nuts 5 from below Place the handlebar supports in the required position Info The handlebar supports are longer and higher on one side Position the left and right handlebar supports evenly Mount and tighten screws 2 Guideline Screw handle bar support M10 40 Nm 29 5 lbf ft Loctite 243 Position the handlebar Info Make sure t...

Page 55: ...ise the motorcycle at the frame underneath the engine Lift stand 78129955100 Neither wheel is in contact with the ground Secure the motorcycle against falling over 11 2 Removing the motorcycle from the lift stand Note Material damage The vehicle may be damaged by incorrect procedure when parking Significant damage may be caused if the vehicle rolls away or falls over The components for parking the...

Page 56: ...shing work Remove the motorcycle from the lift stand p 53 11 4 Cleaning the dust boots of the fork legs Preparatory work Raise the motorcycle with a lift stand p 53 Remove the fork protector p 55 S01207 10 Main work Push dust boots 1 of both fork legs downward Info The dust boots remove dust and coarse dirt particles from the inside fork tubes Over time dirt can accumu late behind the dust boots I...

Page 57: ...ff the left fork protector Remove screws 3 and take off the right fork protector 11 6 Installing the fork protector S01208 11 Position the fork protection on the left fork leg Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line and clamp Mount and tighten screws 2 Position the fork protector on the right fork leg Mount and tighten screws 3 Guid...

Page 58: ... Nm 7 4 lbf ft K01029 11 Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 9 Removing fork legs Preparatory work Raise the motorcycle with a lift stand p 53 Remove the front wheel p 102 K01014 10 Main work Remove screws 1 and take off the clamp Remove screws 2 and take off the brake caliper Allow the brake caliper and brake line to hang loosely to the side Info D...

Page 59: ...er screw 1 of the right fork leg is positioned to the front Valve A of the left fork leg faces 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 upper edge of the upper triple clamp The air suspension is located in the left fork leg The pressure and rebound damping is located in the right fork leg F01559 1...

Page 60: ...en screws 5 Finishing work Install the front wheel p 103 11 11 Removing the lower triple clamp Preparatory work Raise the motorcycle with a lift stand p 53 Remove the front wheel p 102 Remove the fork legs p 56 Remove the start number plate p 64 Remove front fender p 65 Remove the handlebar cushion F01561 10 Main work All SX F standard models XC F US Open cable holder 1 on the left and detach the ...

Page 61: ...nk the cables and lines F01560 10 Remove O ring 4 Remove protective ring 5 Remove the lower triple clamp with steering stem Remove the upper steering head bearing 11 12 Installing the lower triple clamp S02307 10 Main work Clean the bearing and sealing elements check for damage and grease High viscosity grease p 152 Insert the lower triple clamp with the steering stem Mount upper steering head bea...

Page 62: ...d into the side of the upper end of the fork legs The second milled groove from the top must be flush with the upper edge of the upper triple clamp The air suspension is located in the left fork leg The pressure and rebound damping is located in the right fork leg F01572 10 Tighten screws 6 Guideline Screw bottom triple clamp M8 12 Nm 8 9 lbf ft F01563 10 Tighten screw 4 Guideline Screw top steeri...

Page 63: ...1 Position the fork legs Air bleeder screw 5 of the right fork leg is positioned to the front Valve A of the left fork leg faces 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 upper edge of the upper triple clamp The air suspension is located in the left fork leg The pressure and rebound damping is loca...

Page 64: ...tite 243 Position the brake line and the clamp Mount and tighten screws bl Finishing work Install front fender p 66 Mount the handlebar cushion Install the start number plate p 65 Install the front wheel p 103 Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check steering head bearing play p 62 Remove the motorcycle from the lift st...

Page 65: ...ily over the entire steering range There should be no detectable detent positions If detent positions are detected Adjust the steering head bearing play p 63 Check the steering head bearing and adjust if neces sary Finishing work Remove the motorcycle from the lift stand p 53 11 14 Adjusting the steering head bearing play Preparatory work Raise the motorcycle with a lift stand p 53 Remove the hand...

Page 66: ...hten screws 1 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Check steering head bearing play p 62 Finishing work Mount the handlebar cushion Remove the motorcycle from the lift stand p 53 11 15 Lubricating the steering head bearing H02387 01 Remove the lower triple clamp p 58 Install the lower triple clamp p 59 Info The steering head bearing is cleaned and lubricated in the course of remov...

Page 67: ... the brake line in holders A on the start number plate Position the start number plate Mount and tighten screw 1 The holding lugs engage in the fender 11 18 Removing front fender Preparatory work Remove the start number plate p 64 F01526 10 Main work Remove screws 1 and 2 Take off front fender ...

Page 68: ...rt number plate p 65 11 20 Removing the shock absorber Preparatory work Raise the motorcycle with a lift stand p 53 F01527 10 Main work Remove the cable ties Remove screws 1 with the washers Remove screw 2 Take off the left frame protector Push the right frame protector to the front and take off at the bottom S01220 10 Remove screw 3 Remove fitting 4 Info Raise the wheel slightly to be able to rem...

Page 69: ...F01529 10 Remove nut 6 and pull out the fork pivot Push the link fork back and secure it against falling over F01530 10 Hold the shock absorber and remove screw 7 Remove the shock absorber carefully at the bottom 11 21 Installing the shock absorber F01531 10 Main work Carefully position the shock absorber into the vehicle from the bottom Mount and tighten screw 1 Guideline Screw top shock absorber...

Page 70: ... Position the foot brake cylinder Push rod 4 engages in the foot brake cylinder Info Ensure that the dust boot is correctly seated Mount and tighten screws 5 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft S01229 10 Position the angle lever and linkage lever Mount and tighten fitting 6 Guideline Nut linkage lever on angle lever M14x1 5 60 Nm 44 3 lbf ft Info Pay attention to flat area B Mou...

Page 71: ...9 Guideline Screw frame protec tor M5 3 Nm 2 2 lbf ft Mount the new cable ties Finishing work Check the free travel of the foot brake lever p 96 Remove the motorcycle from the lift stand p 53 11 22 Removing the seat Caution Danger of burns The voltage regulator gets very hot when the vehicle is driven Allow the voltage regulator to cool down before performing any work F01533 10 Remove screw 1 H022...

Page 72: ...t the rear and push the seat forward F01533 10 Mount and tighten screw 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 24 Removing the air filter box cover Condition The air filter box cover is secured Remove the seat p 69 F01534 10 Remove screw 1 F01534 11 Pull off the air filter box cover in area A sideways and take off toward the front ...

Page 73: ... A and clip it into area B F01534 10 Mount and tighten screw 1 Guideline Screw air filter box cover EJOT PT K60x20 Z 3 Nm 2 2 lbf ft Mount the seat p 70 F01535 11 Condition The air filter box cover is not secured Insert the air filter box cover in area A and clip it into area B 11 26 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the e...

Page 74: ...ose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Do not clean the air filter with fuel or petroleum since these substances attack the foam Preparatory work Remove the air filter box cover p 70 Remove the air filter p 71 F01027 01 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry pr...

Page 75: ... 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 71 11 29 Preparing air filter box cover for securing Preparatory work Remove the air filter box cover p 70 S02308 10 Main work Drill a hole at marking A Guideline Diameter 6 mm 0 24 in Finishing work Install the air filter box cover p 71 11 30 Removing ...

Page 76: ...n silencer 11 31 Installing the main silencer F01538 11 All SX F standard models XC F US Position the main silencer Mount screws 1 with the washers but do not tighten yet Attach spring 2 Spring hook 5030501700004 Tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft F01839 11 HERLINGS REPLICA FACTORY EDITION Position the main silencer Mount screws 1 with the washers but do not ti...

Page 77: ...hat need to be reinstalled and check for damage Mount new glass fiber yarn filling 5 on inner tube 6 Slide O ring 4 and outer tube 3 over glass fiber yarn filling 5 Insert O ring 2 and silencer cap 1 into outer tube 3 Mount and tighten all of the screws Guideline Screws on main silencer M5 7 Nm 5 2 lbf ft H03387 10 HERLINGS REPLICA FACTORY EDITION Drill out all rivets on the main silencer and remo...

Page 78: ...o 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 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 Preparatory work Remove the seat p 69 Main work All SX F standard models All US m...

Page 79: ...y with compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve F01567 10 Disconnect the plug in connection of the fuel line Info Remaining fuel may flow out of the fuel hose Mount wash cap set 3 Wash cap set 81212016100 F01565 10 Remove screw 4 with the rubber bushing F01541 10 Remove screws 5 with the collar bushings ...

Page 80: ...ing 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 fuel contact with the eyes Change your clothing in case of fuel spills on them Main work Check thro...

Page 81: ...ection 4 for the fuel line Info Route the cable and fuel line at a safe distance from the exhaust system F01565 11 XC F US Mount and tighten screw 2 with the rubber bushing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft F01564 11 Plug in connector 3 for the fuel pump Remove the wash cap set Thoroughly clean the plug in connection of the fuel line using compressed air Info Under no circumst...

Page 82: ...free of oil and grease Clean the brake discs with brake cleaner when necessary Note 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 regulations Info The service life of the chain depends largely on its maintenance Preparatory work Raise the motorcycle with a lift...

Page 83: ...fo Lower chain section 1 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 the specification Adjust the chain tension p 81 Finishing work Remove the motorcycle from the lift stand p 53 11 38 Adjusting the chain tension Warning Danger of accidents Incorrect chain tensio...

Page 84: ...deline Nut rear wheel spin dle 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 4 can be turned by 180 Finishing work Remove the motorcycle from the lift stand p 53 11 39 Checking the chain rear sprocket engine sprocket and chain guide Preparatory work Raise the motorcycle with ...

Page 85: ... in If distance B is greater than the specified measurement Change the drivetrain kit Info When a new chain is mounted the rear sprocket and engine sprocket should also be changed New chains wear out faster on an old worn rear sprocket or engine sprocket S01249 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 ...

Page 86: ...e chain sliding piece Guideline Screw chain slid ing piece M8 15 Nm 11 1 lbf ft 402421 10 Check the chain guide with a slide gauge for dimension C Minimum thickness C of the chain guide 6 mm 0 24 in If the measured value is less than the specification Change the chain guide F01553 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the screws on the chain guide Guide...

Page 87: ...racking or deformation Change the link fork Info Always replace a damaged link fork Repair ing the link fork is not authorized by Husqvarna Motorcycles 11 42 Checking throttle cable routing Preparatory work Remove the seat p 69 Remove the fuel tank p 76 F01566 01 Main work Check throttle cable routing Both throttle cables must be routed side by side on the back of the handlebars and above the fuel...

Page 88: ...er grip F01035 10 Check that screw 1 is firmly seated Guideline Screw fixed grip M4 5 Nm 3 7 lbf ft Loctite 243 Diamond A must be located at the top 11 44 Adjusting the basic position of the clutch lever F00157 10 Adjust the basic position of the clutch lever to your hand size by turning adjusting screw 1 Info Turn the adjusting screw counterclockwise to decrease the distance between the clutch le...

Page 89: ...othing change the clothing Info The fluid level rises with increasing wear of the clutch facing discs Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and clutch 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 F00158 10 Move the clutch fluid re...

Page 90: ...uel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info The fluid level rises with increasing wear of the clutch facing discs Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean b...

Page 91: ... the clutch slave cylinder to the point where filling is possible F00166 10 Now press the fluid into the system until it emerges from hole 6 of the master cylinder without bubbles Now and then extract the fluid from the master cylinder reser voir to prevent overflow Tighten the bleeder screw and remove the bleeding syringe with the hose Mount the protection cap Correct the fluid level of the hydra...

Page 92: ...f the hand brake lever Preparatory work Check the free travel of the hand brake lever p 90 F00153 10 Main work Adjust the basic position of the hand brake lever to your hand size by turning adjusting screw 1 Info Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the han dlebar Turn the adjusting screw counterclockwise to decrease the distance between the ...

Page 93: ... 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 leaking or the brake linings 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 Danger of accidents Old brake fluid reduces ...

Page 94: ...er 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 in accordance with the service schedule Your authorized KTM workshop will be glad to help Note Environmental hazard ...

Page 95: ...orn out brake linings are replaced immediately Your authorized KTM workshop will be glad to help H01333 10 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified Change the front brake linings p 93 Check the brake linings for damage and cracking If damage or wear is encountered Change the front brake linings p 93 12 7 Changi...

Page 96: ...ake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Note 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 regulations Info Never use DOT 5 brake fluid It is silicone based ...

Page 97: ...ngs insert pin 5 and mount cotter pins 4 Info Always change the brake linings in pairs Operate the hand brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point F00148 10 Add brake fluid up to level A Guideline Level A brake fluid level below reservoir rim 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 150 Position cover 2 with membrane 3 Mount and ...

Page 98: ... Adjusting the basic position of the 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 specification F01544 10 Detach spring 1 Loosen nut 4 and with push rod 5 turn it back until ...

Page 99: ...e sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your authorized KTM workshop will be glad to help Preparatory work Check the brake linings of the rear brake p 99 F01545 10 Main work Stand the vehicle upright Check the brake fluid level in the viewer 1 If the brake fluid level drops below marking A Add rear brake fluid p 97 12 11 Adding rear b...

Page 100: ...nged in accordance with the service schedule Your authorized KTM workshop will be glad to help Note 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 regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are...

Page 101: ...ldren Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed 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 ...

Page 102: ...nfo Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston Remove cotter pins 3 pull out pin 4 and remove the brake linings Clean the brake caliper and the brake caliper bracket S01251 10 Check that spring plate 5 in the brake caliper and sliding plate 6 in the brake caliper bracket are seated properly Info The arrow on the spring plate points in th...

Page 103: ...101 F01546 10 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 150 Mount and tighten screw cap 1 with membrane 2 and the O ring Info Immediately clean up any brake fluid that has over flowed or spilled with water ...

Page 104: ...ons F00141 10 Loosen screw 1 by several rotations Loosen screws 2 Press on screw 1 to push the wheel spindle out of the axle clamp Remove screw 1 F00140 10 Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Hold the front wheel and remove the wheel spindle Take the front wheel out of the fork Info Do ...

Page 105: ... shaft seal rings 1 and contact sur faces A of the spacers Long life grease p 152 Insert the spacers Clean and grease the wheel spindle Long life grease p 152 Position the front wheel and insert the wheel spindle The brake linings are correctly positioned S01631 10 HERLINGS REPLICA FACTORY EDITION Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change front whee...

Page 106: ...ghten Tighten screws 3 Guideline Screw fork stub M8 15 Nm 11 1 lbf ft 13 3 Removing the rear wheel Preparatory work Raise the motorcycle with a lift stand p 53 V00296 10 Main work Manually press the brake caliper toward the brake disc to push back the brake piston Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston Remove nut 1 Take off chai...

Page 107: ...f 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 H03001 10 Main work Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the rear wheel bearing Clean and grease shaft seal rings 1 and contact surfaces A of the spacers Long life gre...

Page 108: ...he brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand p 53 13 5 Checking the tire condition Info Only mount tires approved and or recommended by KTM Other tires could have a negative effect on handling characteristics The type condition and pressure of the tires all have a major impact on the handling characteristic of the motorcycle The tires mounted...

Page 109: ...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 spoke tension Warning Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in sec ondary damage The spokes break due to being overloaded if they are too tightly tensioned If the tension in the spokes is too low t...

Page 110: ...ES 108 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 kit 58429094000 ...

Page 111: ... positive terminal cover 2 and disconnect the posi tive cable from the 12 V battery Remove screw 3 Pull holding bracket 4 forward and remove the 12 V battery upwards 14 2 Installing the 12 V battery H00386 10 Main work Insert the 12 V battery into the battery compartment with the terminals facing forward and secure with holding bracket 1 12 V battery HJTZ5S FP C p 142 Mount and tighten screw 2 Gui...

Page 112: ... the 12 V battery it discharges steadily The charging level and the method of charging are very important for the service life of the 12 V battery Rapid recharging with a high charging current shortens the service life of the battery If the charging current charging voltage or charging time is exceeded the 12 V battery will be destroyed If the 12 V battery is depleted by repeated starting the 12 V...

Page 113: ...temperatures These battery chargers are only suitable for lithium iron phosphate batteries Read the accompanying KTM Pow erParts instructions Info Never remove cover 1 Switch off the battery charger after charging and disconnect from the 12 V battery Finishing work Install the 12 V battery p 109 Mount the seat p 70 14 4 Changing the main fuse Warning Fire hazard Incorrect fuses overload the electr...

Page 114: ... protection caps 2 Remove faulty main fuse 3 Info A faulty fuse has a burned out fuse wire A A spare fuse 4 is located in the starter relay Insert a new main fuse Fuse 58011109110 p 142 Check that the electrical system is functioning properly Tip Insert a spare fuse so that it is available if needed Mount the protection caps Mount the starter relay onto the holder and route the cable Finishing wor...

Page 115: ...mponents 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 116: ...ater 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 Condition The engine is cold 400243 10 Stand the motorcycle upright on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level A above the radiator fins 10 mm 0 39 i...

Page 117: ... Completely drain the coolant Mount and tighten screw 1 with a new seal ring Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft 15 5 Refilling with coolant 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 Rins...

Page 118: ...o 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 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 Condition The engine is cold Preparatory work H...

Page 119: ...COOLING SYSTEM 15 117 Go for a short test ride Check the coolant level p 114 Finishing work HERLINGS REPLICA FACTORY EDITION Install the engine guard p 56 ...

Page 120: ...nal posi tion Adjust the throttle cable play p 118 Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Start the engine and let it run at idle speed Move the handle bar to and fro...

Page 121: ...ay 3 5 mm 0 12 0 2 in Tighten nut 2 Slide on sleeve 1 Check the throttle grip for smooth operation F01569 10 XC F US Move the handlebar to the straight ahead position Push back sleeve 1 Loosen nut 2 Turn adjusting screw 3 in as far as possible Loosen nut 4 Push cold start button 6 all the way to the stop Turn adjusting screw 5 so that the cold start button moves to the basic position when the thro...

Page 122: ...label OUTSIDE must be visible Marking A must be positioned at marking B Grey guide plate 79002014000 Alternative 1 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 F01576 01 Clean the outside of the handlebar and the inside of the grip tube Mount the...

Page 123: ...so be changed during the ride H02889 01 Activating STANDARD mapping Press button MAP until LED 1 lights up Guideline Engine speed 4 000 rpm STANDARD balanced response H02886 01 Activating ADVANCED mapping Press button MAP until LED 2 lights up Guideline Engine speed 4 000 rpm ADVANCED direct response 16 5 Adjusting the idle speed Warning Danger of accidents The engine may go out spontaneously if t...

Page 124: ...kwise raises the idle speed 16 6 Teaching the throttle valve position Info If the control unit detects that the throttle valve position at idle speed needs to be retaught then the mal function indicator lamp flashes 2x per second H02263 10 Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness and death Always make sure there is sufficient ventilation w...

Page 125: ...e 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 123 16 8 Adjusting the basic position of the shift lever 401950 12 Remove screw 1 with the washers and take off shift lever 2 401951 10 Clean gear teeth A of the shift lever and shift shaft Mount the shift lever on the shift shaft in the required position and engage gearing I...

Page 126: ...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 Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system F01551 10 all SX F models Clean plug i...

Page 127: ...t the plug in connection of the fuel line Info Remaining fuel may flow out of the fuel hose Pull fuel screen 2 out of the connecting piece Insert the new fuel screen all the way into the connecting piece Lubricate the O ring and join the plug in connection of the fuel line Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure ...

Page 128: ...ng the engine oil and oil filter cleaning the oil screens 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 Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning ...

Page 129: ...nd the O rings Guideline Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ft S02291 10 Position long oil screen 4 with the O rings on a pin wrench Position the pin wrench through the drill hole of the screw plug in the opposite section of the engine case Push the oil screen all the way into the engine case S02292 10 Mount and tighten screw plug 3 with the O ring Guideline Screw plug oil screen M20x1 5...

Page 130: ... screws Guideline Screw oil filter cover M6 10 Nm 7 4 lbf ft Stand the motorcycle upright 401955 12 Remove filler plug 8 from the clutch cover together with the O ring and fill up with engine oil Engine oil 1 20 l 1 27 qt Engine oil SAE 10W 50 p 150 Info Too little engine oil or poor quality engine oil will result in premature wear of the engine Mount and tighten the filler plug together with the ...

Page 131: ...change was carried out Engine oil SAE 10W 50 p 150 Info For optimal performance of the engine oil do not mix different types of engine oil We recommended changing the engine oil when neces sary Mount and tighten the filler plug together with the O ring Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness and death Always make sure there is sufficient ...

Page 132: ...iod Avoid direct sunshine on the motorcycle during cleaning 401061 01 Close off the exhaust system to prevent water from entering First remove coarse dirt particles with a gentle spray of water Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush Motorcycle cleaner p 152 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motor...

Page 133: ...Treat bare metal parts except for brake discs and the exhaust system with a corrosion inhibitor Preserving materials for paints metal and rubber p 152 Treat all plastic parts and powder coated parts with a mild cleaning and care agent Special cleaner for glossy and matte paint finishes metal and plastic surfaces p 153 ...

Page 134: ...ce repairs or replacements are necessary you should do this during the storage period less workshop overload In this way you can avoid long 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 152 Refuel p 34 Clean the motorcycle p 130 Change the engine oil and oil filter clean...

Page 135: ...e only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and the exhaust system to rust 19 2 Preparing for use after storage 401059 01 Install the 12 V battery p 109 Remove the motorcycle from the lift stand p 53 Perform checks and maintenance measures when preparing for use p 29 Make a test ride ...

Page 136: ...ed kill switch defective Check the wiring harness visual check Check the electrical system Error in the electronic fuel injection Read out the fault memory using the KTM diagnostics tool Engine does not speed up Error in the electronic fuel injection Read out the fault memory using the KTM diagnostics tool Engine has too little power Air filter is very dirty Clean the air filter and air filter box...

Page 137: ...onsumption Engine vent hose bent Route the vent hose without bends or change it if necessary Engine oil level too high Check the engine oil level p 125 Engine oil too thin low viscos ity Change the engine oil and oil filter clean the oil screens p 126 Piston or cylinder worn Measure the piston cylinder mounting clearance 12 V battery discharged 12 V battery is not charging Check the charging volta...

Page 138: ...ion indicator lamp 12 Malfunction indicator lamp flashes 1x long 2x short Error level condition Coolant temperature sensor circuit fault Coolant temperature sensor input signal too low Blink code for malfunction indicator lamp 13 Malfunction indicator lamp flashes 1x long 3x short Error level condition Intake air temperature sensor circuit fault Intake air temperature sensor input signal too low B...

Page 139: ...on Ignition coil circuit fault Blink code for malfunction indicator lamp 41 Malfunction indicator lamp flashes 4x long 1x short Error level condition Fuel pump controller short circuit to ground open circuit Open short circuit to plus Blink code for malfunction indicator lamp 65 Malfunction indicator lamp flashes 6x long 5x short Error level condition EEPROM error Blink code for malfunction indica...

Page 140: ... bush Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with two Eaton pumps Primary transmission 31 76 Clutch Multidisc clutch in oil bath hydraulically activated Gearbox SX F EU HERLINGS REPLICA 4 gear transmission claw shifted Gearbox All US models 5 gear transmission claw shifted Transmission ratio SX F EU HERLINGS...

Page 141: ...octite 243 Screw suction pump cover M5 6 Nm 4 4 lbf ft Loctite 243 Nut water pump impeller 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 cylinder head 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 pressure pump co...

Page 142: ...f ft Thread oiled with engine oil cone degreased Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Screw plug oil pressure control valve M12x1 5 20 Nm 14 8 lbf ft Nut inner clutch hub M18x1 5 80 Nm 59 lbf ft Nut primary gear wheel M20LHx1 5 100 Nm 73 8 lbf ft Loctite 243 Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ft 22 3 Capacities 22 3 1 Engine oil Engine oil 1 20 l 1 27 qt Engine oil SAE 10...

Page 143: ...ameter front 260 mm 10 24 in rear 220 mm 8 66 in Brake discs wear limit front 2 5 mm 0 098 in rear 3 5 mm 0 138 in Offroad tire pressure front 1 0 bar 15 psi rear 1 0 bar 15 psi Secondary ratio 13 48 Chain 5 8 x 1 4 Rear sprockets available 45 47 48 49 50 51 52 Steering head angle 63 9 Wheelbase 1 485 10 mm 58 46 0 39 in Ground clearance unloaded 370 mm 14 57 in Seat height unloaded 950 mm 37 4 in...

Page 144: ... specified represent one of the possible series production tires Additional information is available in the Service section under http www ktm com 22 7 Fork 22 7 1 SX F EU Fork article number 34 18 8S 09 Fork WP Suspension Upside down AER 48 Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Air pressure 10 7 ...

Page 145: ...l oz Fork oil SAE 4 48601166S1 p 151 Grease capacity left cartridge 5 g 0 18 oz Special grease 00062010053 p 153 22 7 3 XC F US Fork article number 34 18 8S 79 Fork WP Suspension Upside down AER 48 Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Air pressure 10 1 bar 146 psi Fork length 950 mm 37 4 in Oil c...

Page 146: ... oz Fork oil SAE 4 48601166S1 p 151 Grease capacity left cartridge 5 g 0 18 oz Special grease 00062010053 p 153 22 7 5 FACTORY EDITION Fork article number 34 18 8S 99 Fork WP Suspension XACT 5548 AER 48 Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Air pressure 10 9 bar 158 psi Fork length 950 mm 37 4 in...

Page 147: ...m 223 lb in Weight of rider 75 85 kg 165 187 lb 42 N mm 240 lb in Weight of rider 85 95 kg 187 209 lb 45 N mm 257 lb in Spring length 260 mm 10 24 in Gas pressure 10 bar 145 psi Static sag 35 mm 1 38 in Riding sag 105 mm 4 13 in Fitted length 477 mm 18 78 in Shock absorber oil Shock absorber fluid SAE 2 5 50180751S1 p 151 22 8 2 SX F US Shock absorber article number 18 18 7S 59 Shock absorber WP S...

Page 148: ...compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Highspeed compression damping Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 8 mm 0 31 in Spring rate 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 ...

Page 149: ... kg 143 165 lb 255 mm 10 04 in Weight of rider 75 85 kg 165 187 lb 260 mm 10 24 in Weight of rider 85 95 kg 187 209 lb 260 mm 10 24 in Gas pressure 10 bar 145 psi Static sag 35 mm 1 38 in Riding sag 105 mm 4 13 in Fitted length 477 mm 18 78 in Shock absorber oil Shock absorber fluid SAE 2 5 50180751S1 p 151 22 8 5 FACTORY EDITION Shock absorber article number 18 18 7S 99 Shock absorber WP Suspensi...

Page 150: ...rip M4 5 Nm 3 7 lbf ft Loctite 243 Screw service hour counter M4 1 Nm 0 7 lbf ft Spoke nipple front wheel M4 5 6 Nm 4 4 lbf ft Spoke nipple rear wheel M4 5 6 Nm 4 4 lbf ft Remaining nuts chassis M5 5 Nm 3 7 lbf ft Remaining screws chassis M5 5 Nm 3 7 lbf ft Screw battery terminal M5 2 5 Nm 1 84 lbf ft Screw frame protector M5 3 Nm 2 2 lbf ft Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft N...

Page 151: ...01 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 ft Loctite 2701 Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Screw top shock absorber M10 60 Nm 44 3...

Page 152: ...s Only use coolant that complies with the requirements stated see specifications on the container and that has the relevant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications f...

Page 153: ...E 2 5 Guideline Use only oils that comply with the specified standards 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 ...

Page 154: ...r High viscosity grease Recommended supplier SKF LGHB 2 Long life grease Recommended supplier MOTOREX 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...

Page 155: ...y and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Special grease 00062010053 Recommended supplier Klüber Lubrication KLÜBERFOOD NH1 34 401 Universal oil spray Recommended supplier MOTOREX Joker 440 Synthetic ...

Page 156: ...ice intervals are demanded for automobile engines the focus for motorcycle engines is on high performance at high engine speeds In most motorcycle engines the transmission and clutch are lubricated with the same oil The JASO T903 MA2 standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils accordin...

Page 157: ... 155 Launch control Vehicles electronics functions for achieving the best possible acceleration from a standing position OBD On board diagnosis Vehicle system which monitors the specified parame ters of the vehicle electronics ...

Page 158: ...27 LIST OF ABBREVIATIONS 156 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 159: ...n Active driving aids are also represented by yellow or orange symbols Malfunction indicator lamp lights up flashes orange The OBD has detected an error in the vehicle electronics Malfunction indicator lamp flashes orange rapidly Launch control is activated Fuel level warning lamp lights up orange The fuel level has reached the reserve mark ...

Page 160: ...140 engine oil 128 140 fuel 35 140 Chain checking 82 cleaning 80 Chain guide checking 82 Chain tension adjusting 81 checking 81 Characteristic map of the throttle response adjusting 120 Clutch fluid level checking correcting 87 fluid changing 88 Clutch lever 16 basic position adjusting 86 Cold start button 20 Compression damping fork adjusting 49 Coolant antifreeze and coolant level checking 113 c...

Page 161: ...Hand brake lever 16 basic position adjusting 90 free travel checking 90 Handlebar position 51 adjusting 52 High speed compression damping shock absorber adjusting 41 I Idle speed adjusting 121 Idle speed adjusting screw 21 Implied warranty 10 Indicator lamps Overview 17 Intended use 6 K Kill switch 16 L Launch control activating 30 Link fork checking 85 Lithium ion battery Starting power at low te...

Page 162: ...checking 45 spring preload adjusting 45 static sag checking 44 Shock absorber article number 15 Side stand 22 Spare parts 10 Spoke tension checking 107 Start number plate installing 65 removing 64 Starting 29 Starting power of lithium ion batteries at low tempera tures 26 Steering head bearing lubricating 64 Steering head bearing play adjusting 63 checking 62 Storage 132 T Technical data capacitie...

Page 163: ... 3214029en 3214029en 11 2018 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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KTM 450 SX-F 2019, Owner'S Manual

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