KTM 450 SX-F Owner'S Manual Download Page 118

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17 SERVICE WORK ON THE ENGINE

116

17.1

Changing the fuel screen

Danger

Fire hazard

Fuel is highly flammable.

The fuel in the fuel tank expands when warm and can escape if overfilled.

–

Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.

–

Switch off the engine for refueling.

–

Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.

–

If any fuel is spilled, wipe it off immediately.

–

Observe the specifications for refueling.

Warning

Danger of poisoning

Fuel is poisonous and a health hazard.

–

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.

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.

F03792-10

–

Clean quick release coupling

thoroughly with compressed

air.

Info

Under no circumstances should dirt enter into the fuel
line. Dirt in the fuel line clogs the injection valve!

–

Disconnect the quick release coupling.

Info

Remaining fuel may flow out of the fuel hose.

–

Pull fuel screen

out of the connecting piece.

–

Insert the new fuel screen all the way into the connecting
piece.

–

Spray silicone spray onto a lint-free cleaning cloth and lightly
lubricate the O-ring of the quick-release coupling.

Silicone spray (

p. 141)

–

Join quick release coupling

Summary of Contents for 450 SX-F

Page 1: ...OWNER S MANUAL 2022 450 SX F FACTORY EDITION Art no 3214419en ...

Page 2: ......

Page 3: ...vices designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop produc tion of a particular model without prior notice KTM Sportmotorcycle accepts no liability for delivery options devi ations from figures and descriptions as well as misprints and other errors The models portrayed partly contain special equipment that does not b...

Page 4: ...R USE 20 7 1 Advice on preparing for first use 20 7 2 Running in the engine 21 7 3 Starting power of lithium ion batteries at low temperatures 21 7 4 Preparing the vehicle for difficult operating conditions 22 7 5 Preparing the vehicle for rides on dry sand 22 7 6 Preparing the vehicle for rides on wet sand 23 7 7 Preparing the vehicle for rides on wet and muddy circuits 23 7 8 Preparing vehicle f...

Page 5: ...6 11 29 Preparing air filter box cover for securing 66 11 30 Removing the main silencer 67 11 31 Installing the main silencer 67 11 32 Changing the glass fiber yarn filling of the main silencer 67 11 33 Removing the fuel tank 68 11 34 Installing the fuel tank 70 11 35 Checking for chain dirt accumulation 71 11 36 Cleaning the chain 71 11 37 Checking the chain tension 72 11 38 Adjusting the chain t...

Page 6: ...ft lever 115 16 8 Adjusting the basic position of the shift lever 115 17 SERVICE WORK ON THE ENGINE 116 17 1 Changing the fuel screen 116 17 2 Checking the engine oil level 117 17 3 Changing the engine oil and oil filter cleaning the oil screens 117 17 4 Adding engine oil 120 18 CLEANING CARE 122 18 1 Cleaning the motorcycle 122 19 STORAGE 124 19 1 Storage 124 19 2 Preparing for use after storage ...

Page 7: ...ned experts using the special 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 document a...

Page 8: ...s instruction and all further instructions included carefully The safety instructions are highlighted in the text and are referred to at the relevant passages Info Various information and warning labels are attached in prominent locations on the product described Do not remove any information or warning labels If they are missing you or others may not recognize dangers and may therefore be injured...

Page 9: ...icle if you are physically or mentally impaired Danger Danger of poisoning Exhaust gases are toxic and inhaling 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 Warning Danger of burns Some vehicle components become very hot when the vehicle...

Page 10: ...ake sure that you use your motorcycle legally display environmental conscious ness and respect the rights of others When disposing of used oil other operating and auxiliary fluids and used components comply with the laws and regulations of the respective country Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles there are no legal regulations that per...

Page 11: ...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 An incorrect suspension setting can lead to damage and breakage of chassis components Use of the vehicle under difficult conditions such as on sand or on wet dusty and muddy surfaces can resul...

Page 12: ...EHICLE 10 4 1 View of vehicle front left example H05023 10 1 Hand brake lever p 14 2 Clutch lever p 14 3 Fuel tank filler cap 4 Air filter box cover 5 Cold start button p 17 6 Engine number p 12 7 Shift lever p 18 ...

Page 13: ... adjuster 2 Combination switch p 15 3 Stop button p 14 3 Start button p 15 4 Throttle grip p 14 5 Vehicle identification number p 12 5 Steering head label p 12 6 Fork article number p 12 7 Idle speed adjusting screw 8 Foot brake lever p 19 9 Engine oil level viewer bk Shock absorber rebound adjuster ...

Page 14: ... steering head 5 2 Steering head label 401946 10 The steering head label 1 is attached to the front of the steering head 5 3 Engine number H01047 10 Engine number 1 is embossed on the left side of the engine above the engine sprocket 5 4 Fork article number 401947 10 The fork article number 1 is stamped on the inside of the axle clamp ...

Page 15: ...SERIAL NUMBERS 5 13 5 5 Shock absorber article number F03756 10 The shock absorber article number 1 is stamped on the top of the shock absorber ...

Page 16: ...d using the hand brake lever 6 3 Throttle grip F03648 11 The throttle grip 1 is fitted on the right side of the handlebar 6 4 Stop button F03650 11 The stop button 1 is located on the right side of the handlebar Possible states The stop button is in the basic position In this position the ignition circuit is closed and the engine can be started Stop button pressed In this position the ignition cir...

Page 17: ...lamp light up The engine characteristic can be changed using button 1 and button 2 on the combination switch Traction control can be activated using the TC button 3 on the combination switch Launch control and the quickshifter can also be activated using the combination switch 6 7 Overview of indicator lights F03758 10 Possible states Malfunction indicator lamp lights up flashes orange The OBD has...

Page 18: ...t no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty...

Page 19: ... the ambient temperature is low To help 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 ...

Page 20: ... to start than an engine with the idle speed set incorrectly The idle speed is adjusted 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 13 The gear positions can be ...

Page 21: ...be attached to the plug in stand holders 6 16 Factory Start H04998 10 The Factory Start 1 is mounted on the right fork protector Possible states A Factory Start is deactivated The fork is in the normal operating mode B 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 fr...

Page 22: ...ic 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 continuously Take your foot off the foot brake lever if you do not want to brak...

Page 23: ...ar axle load 190 kg 419 lb Run in the engine p 21 7 2 Running in the engine During the running in phase do not exceed the specified engine speed and engine performance Guideline Maximum engine speed During the first operating hour 7 000 rpm Maximum engine performance During the first 3 operating hours 75 Avoid fully opening the throttle 7 3 Starting power of lithium ion batteries at low temperatur...

Page 24: ... securing p 66 Check the electrical connector for humidity and corrosion and to ensure it is firmly seated If humidity corrosion or damage is found Clean and dry the connector or change it if necessary Difficult operating conditions are Rides on dry sand p 22 Rides on wet sand p 23 Rides on wet and muddy circuits p 23 Rides at high temperatures or slow riding p 24 Riding at low temperatures and in...

Page 25: ...er rain cover Air filter rain cover A46006921000 Info Observe the fitting instructions for KTM PowerParts 600868 01 Clean the chain Chain cleaner p 140 Mount the steel sprocket Grease the chain Universal oil spray p 141 Clean the radiator fins Straighten the bent radiator fins carefully 7 7 Preparing the vehicle for rides on wet and muddy circuits F03668 01 Mount the air filter rain cover Air filt...

Page 26: ...tions 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 140 Clean the radiator fins Straighten bent radiator fins carefully Check the coolant level p 106 7 9 Preparing the vehicle for low temperatures or snow F03668 01 Mount the air filter rain cover Air filter rain cover A46006921000 Info Observe...

Page 27: ...hain tension p 72 Check the tire condition p 97 Check tire pressure p 97 Check the spoke tension p 98 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 48 Bleed the fork legs p 47 Check the air filter and clean if necessary Check the settings of all controls and ensure that they can be operated sm...

Page 28: ...check the vehicle for other errors instead 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 fully opened full throttle is reduced After the start it is gradually increased up to the m...

Page 29: ...ear 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 F03760 11 Press the TC button 1 to switch traction control on or o...

Page 30: ...the clutch lever must be used when shifting up instead Even if the quickshifter is activated you need to use the clutch lever to shift down Because there is no need to close the throttle grip uninterrupted gear shifts are possible The quickshifter uses the shifter shaft position to check whether or not a shift should be initiated and sends a corresponding signal to the engine control If the quicks...

Page 31: ... the basic position After reaching maximum speed by fully opening the throttle grip turn the throttle back so it is open This will barely reduce the speed but fuel consumption will be considerably lower Only open the throttle as much as the engine can handle abrupt throttle grip opening increases fuel consumption To shift down apply the brakes and close the throttle at the same time Pull the clutc...

Page 32: ...ng Danger of accidents Moisture and dirt impair the brake system Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs On sandy wet or slippery surfaces use mostly the rear brake Always finish braking before you go into a bend Shift down to a lower gear appropriate to your speed Use the braking effect of the engine on long downhill stretches Shift back...

Page 33: ...otorcycle on firm ground 8 12 Transporting Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk Do not park the vehicle near to materials which are highly flammable or explosive Allow the vehicle to cool down before covering it H02628 01 Switch off the engine Mo...

Page 34: ...oroughly 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 Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged In some countries and regions the available fuel quality and cleanliness may not be sufficient This will result in problems with the fuel system Refuel only with clean fuel th...

Page 35: ...m is functioning properly Check and charge the 12 V battery Check the front brake linings p 84 Check the brake linings of the rear brake p 90 Check the brake discs p 81 Check the brake lines for damage and tightness Check the front brake fluid level p 82 Change the front brake fluid Check the rear brake fluid level p 88 Change the rear brake fluid Check correct the fluid level of the hydraulic clu...

Page 36: ...the steering head bearing for play p 55 Lubricate the steering head bearing p 56 Perform minor engine service including removing and installing the engine Change the piston check measure the cylinder Check the cylinder head Check the camshafts and valve train system components Check the timing assembly Change the radial shaft seal rings of the water pump Change the crankshaft seal ring Change the ...

Page 37: ...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 is freq...

Page 38: ...peed 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 will be glad to help Info The effect of the low speed compression adjuster can be seen in slow to normal compr...

Page 39: ...sting 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 description provided Your authorized KTM workshop will be glad to help F03640 10 Turn adjuster 1 clockwise up to the last perceptible click Turn counterclockwi...

Page 40: ...le from the lift stand p 47 10 8 Checking the static sag of the shock absorber 402416 10 Measure dimension A of rear wheel unloaded p 38 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...

Page 41: ...between measurements A and C Check riding sag Riding sag 105 mm 4 13 in If the riding sag differs from the specified measurement Adjust the riding sag p 40 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 is detached incorrectly The shock absorber is filled with highly compressed nitrogen Please follo...

Page 42: ... or decrease the spring preload Tighten bolt 1 Guideline Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft Finishing work Install the shock absorber p 59 Check the free travel of the foot brake lever p 87 Remove the motorcycle from the lift stand p 47 Install the main silencer p 67 10 11 Adjusting the riding sag Preparatory work Remove main silencer p 67 Raise the motorcycle with a lift stand...

Page 43: ...must be increased within the specified values to avoid damage to the fork and frame If the fork feels unusually hard after extended periods of oper ation the fork legs need to be bled 10 13 Adjusting the fork air pressure Warning Danger of accident Modifications to the suspension setting may seriously alter the handling characteris tic Extreme modifications to the suspension setting may cause a se...

Page 44: ...mpanying KTM PowerParts instructions Adjust the air pressure as specified Guideline Air pressure 10 9 bar 158 psi Gradual changing of the air pressure in steps of 0 2 bar 3 psi Minimum air pressure 7 bar 102 psi Maximum air pressure 12 bar 174 psi Info Never adjust the air pressure to a value outside the stated range Disconnect the fork airpump from the left fork leg When disconnecting excess pres...

Page 45: ...17 clicks Info Turn clockwise to increase damping turn counterclock wise to reduce damping during compression 10 15 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior F03633 10 Turn adjuster 1 clockwise all the way to the stop Info Adjuster 1 is located at the lower end of the right fork leg Turn counterclockwise by the number of cl...

Page 46: ...able position for the rider Info In addition the handlebar can be mounted rigidly or on a rubber bearing 10 17 Adjusting the handlebar position Warning Danger of accidents A repaired handlebar poses a safety risk If the handlebar is bent or straightened the material becomes fatigued The handlebar may break as a result Change the handlebar if the handlebar is damaged or bent Info The handlebar can ...

Page 47: ...ings 4 and 5 Place the handlebar support in the required position Info The handlebar support is longer and higher on one side Mount and tighten the screws 7 with bushing 6 Guideline Screw handle bar support M10 40 Nm 29 5 lbf ft Loctite 243 Position the handlebar Info Make sure the cables and wiring are positioned cor rectly Position handlebar clamp 2 Mount screws 1 but do not tighten yet First bo...

Page 48: ... 5 lbf ft Loctite 243 Rigid handlebar support bushing A46001038010 The conical side of bushing faces downwards Position the handlebar Info Make sure the cables and wiring are positioned cor rectly Position handlebar clamp 2 Mount screws 1 but do not tighten yet First bolt the handlebar clamp with screws 1 onto the longer higher side of the handlebar supports so that both parts touch Tighten screws...

Page 49: ...ound 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 vehicle are designed only for the weight of the vehicle Park the vehicle on a firm and level surface Ensure that no...

Page 50: ...s remove dust and coarse dirt particles from the inside fork tubes Over time dirt can accumu late behind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when nec essary Clean and oil the...

Page 51: ...ove screws 3 and take off the right fork protector 11 6 Installing the fork protector F03656 11 Main work Position the fork protector on left fork leg Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line and the clamp Mount and tighten screws 2 Position the fork protector on the right fork leg Mount and tighten screws 3 Guideline Remaining screw...

Page 52: ...11 Position the engine guard on the frame Mount screws 1 but do not tighten yet Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount screws 2 with bushings but do not tighten yet Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft The engine guard is directed evenly toward the front Tighten all the screws of the engine guard Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 53: ...crews 4 Remove the right fork leg 11 10 Installing the fork legs F03665 11 Main work Position the fork legs Air bleeder 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 ...

Page 54: ...e with a lift stand p 47 Remove the front wheel p 93 Remove the fork legs p 51 Remove the start number plate p 56 Remove front fender p 57 Take off the handlebar cushion F03659 10 Main work Remove screw 1 Detach the wiring harness Remove screw 2 Remove screw 3 Take off the upper triple clamp with the handlebar and place to one side Info Cover the components to protect them against damage Do not ki...

Page 55: ...mp and handlebar Mount screw 2 but do not tighten it yet Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft F03764 10 Position the fork legs Air bleeder screw 3 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 uppe...

Page 56: ...03664 11 Using a plastic hammer tap lightly on the upper triple clamp to avoid stresses Tighten screws 6 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Secure the wiring harness with cable holder on the left Mount and tighten screw 7 F03657 12 Position the brake caliper Mount and tighten screws 8 Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Position the brake line an...

Page 57: ...e bearing seats in the frame can become damaged over time Preparatory work Raise the motorcycle with a lift stand p 47 H01167 01 Main work Move the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel Play should not be detectable on the steering head bearing If there is detectable play Adjust the steering head bearing play p 55 Move the handlebar to an...

Page 58: ...uideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Check the steering head bearing for play p 55 Finishing work Mount the handlebar cushion Remove the motorcycle from the lift stand p 47 11 15 Lubricating the steering head bearing H02387 01 Remove the lower triple clamp p 52 Install the lower triple clamp p 53 Info The steering head bearing is cleaned and lubricated in the course of removal and ...

Page 59: ... 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 56 F03675 10 Main work Remove screws 1 and 2 Take off front fender ...

Page 60: ...er plate p 57 11 20 Removing the shock absorber Preparatory work Remove main silencer p 67 Raise the motorcycle with a lift stand p 47 H05029 10 Main work Remove the cable ties Remove screws 1 with the washers Take off the left frame protector Push the right frame protector to the front and take off at the bottom F03700 10 Remove screw 2 Remove fitting 3 Info Raise the swingarm slightly to be able...

Page 61: ...e H05031 10 Remove nut 5 and the swingarm pivot Push the link fork back and secure it against falling over H05032 10 Hold the shock absorber and remove screw 6 Remove the shock absorber carefully at the bottom 11 21 Installing the shock absorber F03769 10 Main work Carefully position the shock absorber into the vehicle from the bottom Mount and tighten screw 1 Guideline Screw top shock absorber M1...

Page 62: ... 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 F03704 10 Position the angle lever and linkage lever Mount and tighten fitting 6 Guideline Nut linkage lever on angle lever M16x1 5 60 Nm 44 3 lbf ft Info Pay attention to flat area B Mou...

Page 63: ...ft Mount the new cable ties Finishing work Check the free travel of the foot brake lever p 87 Remove the motorcycle from the lift stand p 47 Install the main silencer p 67 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 H05035 10 Remove screw 1 H05036 10 Raise seat pul...

Page 64: ...recesses at the back Make sure the seat is latched in place correctly H05035 10 Mount and tighten screw 1 Guideline Screw seat fixing M6 8 Nm 5 9 lbf ft 11 24 Removing the air filter box cover F03770 10 Condition The air filter box cover is secured Remove screw 1 H05038 11 Pull off the air filter box cover in area A and push it side ways and forward Take off the air filter box cover ...

Page 65: ... filter box cover 11 25 Installing the air filter box cover H05039 10 Condition The air filter box cover is secured Insert the air filter box cover in area A and clip it into area B Info An air filter box cover with openings for greater air flow and a more direct response is included F03770 10 Mount and tighten screw 1 Guideline Screw air filter box cover EJOT PT K60x20 Z 3 Nm 2 2 lbf ft ...

Page 66: ...ive effect on the service life of the engine Dust and dirt will enter the engine without an air filter Only operate the vehicle if it is equipped with an air filter 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 Preparatory work Remove the air f...

Page 67: ... substances attack the foam Preparatory work Remove the air filter box cover p 62 Remove the air filter p 64 F03685 01 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 140 Info Only press the air filter to dry it never wring it out Oil the dry air filter with a high grade air filter oil Oil for foam air filter p 140 Clean the air...

Page 68: ... in bushing B The air filter is correctly positioned Info The marking on the air filter must face upwards Insert retaining tab 2 Retaining pin 3 is secured by retaining tab 2 Info If the air filter is not mounted correctly dust and dirt may enter the engine and result in damage Finishing work Install the air filter box cover p 63 11 29 Preparing air filter box cover for securing Preparatory work R...

Page 69: ...5042 11 Position the main silencer Mount screws 1 with washers but do not tighten yet Attach spring 2 Spring hook 50305017000C1 Tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 32 Changing the glass fiber yarn filling of 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 before perfor...

Page 70: ...e The fuel in the fuel tank expands when warm and can escape if overfilled Do not fuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and...

Page 71: ...he fuel line clogs the injection valve H05044 10 Disconnect the quick release coupling Info Remaining fuel may flow out of the fuel hose Mount wash cap set 3 Wash cap set 81212016100 Pull the fuel tank breather hose off the fuel tank lid H04983 10 Remove screw 4 with the rubber bushing H04984 10 Remove screws 5 with the collar bushings H04985 10 Pull both spoilers laterally off the radiator and li...

Page 72: ...diately 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 the throttle cable routing p 76 H04984 11 Position the fuel tank and fit the two spoilers latera...

Page 73: ...king for chain dirt accumulation 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 71 11 36 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip Remove lubricants from the tires using a suitable cleaning agent Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep ...

Page 74: ...wear more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Raise the motorcycle with a lift stand p 47 F03680 10 Main work Pull the chain ...

Page 75: ...ycle with a lift stand p 47 Check the chain tension p 72 F03681 10 Main work Loosen nut 1 Loosen nuts 2 Adjust the chain tension by turning adjusting screws 3 left and right Guideline Chain tension 55 58 mm 2 17 2 28 in Turn adjusting screws 3 on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks A The rear wheel is th...

Page 76: ...r 400987 10 Pull on the top section of the chain with the specified weight A Guideline Weight chain wear measure ment 10 15 kg 22 33 lb Measure distance B of 18 chain rollers in the lower chain section Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance B from 18 chain rollers at the longest chain section 272 mm 10 71 in If distanc...

Page 77: ...k fork M6 6 Nm 4 4 lbf ft H05045 10 Check the chain sliding piece for wear If the lower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten screw on the chain sliding piece Guideline Screw chain slid ing piece M8 15 Nm 11 1 lbf ft F03687 10 Check the ch...

Page 78: ...Repairs on the frame are not permitted 11 41 Checking the link fork F03646 01 Check the link fork for damage cracking and deformation If the link fork exhibits damage cracking 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 the throttle cable routing Warning Danger of accidents The thrott...

Page 79: ...l the fuel tank p 70 Mount the seat p 62 11 43 Checking the rubber grips 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 handle tube of the throttle grip on the right The left sleeve is clamped onto the handlebar The rubber grip can only be replaced with the sleeve or the throttle tube If a ...

Page 80: ... Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handle bar Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar The range of adjustment is limited Only turn the adjusting screw by hand and do not use force Do not make any adjustments while riding 11 46 Checking correcting the fluid level of the h...

Page 81: ...kin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children 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 wi...

Page 82: ...filling is possible Info Use water to immediately clean up any brake fluid that has overflowed or spilled Avoid contact between the brake fluid and painted parts Brake fluid corrodes paint Only use clean brake fluid from a sealed container H04932 10 Now press the fluid into the system until it emerges from hole 6 of the master cylinder without bubbles Occasionally extract the fluid from the master...

Page 83: ...f the hand brake lever Preparatory work Check the free travel of the hand brake lever p 81 F03648 12 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 84: ...n 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 th...

Page 85: ...r in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your a...

Page 86: ...brake linings reduce the braking effect Ensure that worn out brake linings are replaced immediately Your authorized KTM workshop will be glad to help F03691 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 brake linings of the front brake p 84 Check the brake linings for damage and cracking If damage or w...

Page 87: ...es 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 and purple in c...

Page 88: ...d cor rectly F03696 10 Insert the new brake linings insert pin 6 and mount cotter pins 5 Info Always change the brake linings in pairs To make it easier to mount the pin push the brake lin ings against the retainer spring Make sure the brake linings and retainer spring are seated correctly F03695 10 Position the brake caliper Mount and tighten screws 4 Guideline Screw front brake caliper M8 25 Nm ...

Page 89: ...e free travel on the foot brake lever in accordance with the specification 402026 10 Disconnect spring 1 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 A 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 ...

Page 90: ...0 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is 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 ...

Page 91: ...ediately 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 Hazard...

Page 92: ... linings of the rear brake Warning Danger of accidents Worn out brake linings reduce the braking effect Ensure that worn out brake linings are replaced immediately Your authorized KTM workshop will be glad to help F03719 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 rear brake linings p 90 Check the br...

Page 93: ...ce schedule Your authorized KTM workshop will be glad to help Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc c...

Page 94: ...ate points in the direction of rotation of the brake disc F03723 10 Insert the new brake linings insert pin 5 and mount cotter pins 4 Info Always change the brake linings in pairs Make sure that decoupling plate 8 is mounted on the piston side brake lining Operate the foot brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point H05051 10 Cor...

Page 95: ...rake pistons H04987 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 H04988 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 front wheel and remove wheel spindle Take the front wheel out of the fork Info Do...

Page 96: ... p 140 Insert the spacer and brake disc guard Clean and lightly grease the wheel spindle Long life grease p 140 Position the front wheel and insert the wheel spindle The brake linings are correctly positioned F03724 01 Position the brake disc guard H04987 11 Mount and tighten screw 2 Guideline Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Operate the hand brake lever several times until the ...

Page 97: ...ly pull out wheel spindle 3 far 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 Info Cover the components to protect them against damage 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 rear wheel and...

Page 98: ... Long life grease p 140 Position rear wheel and insert wheel spindle 2 The brake linings are correctly positioned Mount the chain H04990 10 Position chain adjuster 3 Mount nut 4 but do not tighten it yet Make sure that chain adjusters 3 are fitted correctly on adjusting screws 5 Check the chain tension p 72 Tighten nut 4 Guideline Nut rear wheel spin dle M22x1 5 80 Nm 59 lbf ft Info The wide adjus...

Page 99: ...s embedded objects and other damage If the tires have cuts run in objects or other damage Change the tires H01144 01 Check the tire age Info The tire date of manufacture is usually contained in the tire label and is indicated by the last four digits of the DOT number The first two digits indicate the week of manufacture and the last two digits the year of manu facture KTM recommends that the tires...

Page 100: ... is too low then lateral and radial run out will form in the wheel Other spokes will become looser as a result Check spoke tension regularly and in particular on a new vehicle Your authorized KTM workshop will be glad to help 400694 01 Strike each spoke briefly using a screwdriver blade Info The frequency of the sound depends on the spoke length and spoke diameter If spokes of the same length and ...

Page 101: ...V batteries as household waste Dispose of 12 V batteries at a collection point for used batteries Preparatory work Remove the seat p 61 F03729 10 Main work Disconnect negative cable 1 from the 12 V battery Pull back positive terminal cover 2 and disconnect positive cable 3 from the 12 V battery F03730 10 Remove screw 4 Pull off engine control unit 5 from the holder and hang to the side F03731 10 P...

Page 102: ...and tighten screw 2 Guideline Screw battery sup port bracket M6 6 Nm 4 4 lbf ft Attach the engine control unit 3 to the holder F03732 10 Connect positive cable 4 to the 12 V battery Guideline Screw battery termi nal M5 2 5 Nm 1 84 lbf ft Connect negative cable 5 to the 12 V battery Guideline Screw battery termi nal M5 2 5 Nm 1 84 lbf ft Contact disks A must be mounted under screws 6 and cable sock...

Page 103: ... there is no load on the 12 V battery it discharges steadily each day 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 ...

Page 104: ...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 100 Mount the seat p 62 14 4 Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system Only use fuses with the requ...

Page 105: ...nt the protection caps Mount the starter relay onto the holder and route the cable Finishing work Install the fuel tank p 70 Mount the seat p 62 14 5 Changing the fuse of the fuel pump Warning Fire hazard Incorrect fuses overload the electrical system Only use fuses with the required ampere value Do not bypass or repair fuses Caution Danger of burns The voltage regulator gets very hot when the veh...

Page 106: ...aulty fuse has a burned out fuse wire A Put in the new fuse for the fuel pump Fuse 58011109105 p 133 Check that the electrical system is functioning properly Attach the protection cap Finishing work Mount the seat p 62 14 6 Diagnostics connector A01108 10 Diagnostics connector 1 is located under the seat ...

Page 107: ...r components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is harmful to health 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 wat...

Page 108: ... 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 in If...

Page 109: ...in 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 harmful to health 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 imm...

Page 110: ...e 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 Remove the engine guard p 50...

Page 111: ...COOLING SYSTEM 15 109 Finishing work Install the engine guard p 50 ...

Page 112: ...nal posi tion Adjust the play in the throttle cable p 110 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 ...

Page 113: ...there is play in the throttle cable at the throttle grip Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Tighten nut 2 Slide on sleeve 1 Check the throttle grip for smooth operation Finishing work Check the play in the throttle cable p 110 16 3 Adjusting the characteristic map of the throttle response Info On the throttle grip the characteristic map of the throttle response is changed by chang...

Page 114: ...le valve more slowly The black guide plate opens the throttle valve more quickly The gray guide plate is mounted upon delivery F03744 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 cor rectly Position half shells 3 mount and tighten screws 2 Guideline Screw throttle grip M6 5 Nm 3 7 ...

Page 115: ...peed 4 000 rpm The indicator lamp A lights up STANDARD balanced response Info Traction control can be activated additionally using the TC button 3 F03763 10 Activating ADVANCED mapping Press button 2 Guideline Engine speed 4 000 rpm The indicator lamp B lights up ADVANCED direct response Info Traction control can be activated additionally using the TC button 3 16 5 Adjusting the idle speed Warning...

Page 116: ...raises the idle speed 16 6 Programming the throttle valve position Info If the control unit detects that the throttle valve position at idle speed needs to be reprogrammed then the malfunction 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 117: ...en shift lever and upper edge of boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the basic position of the shift lever p 115 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 p...

Page 118: ...ted 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 F03792 10 Clean quick release coupling 1 thoroughly with compresse...

Page 119: ... oil level The engine oil reaches the middle of level viewer A If the engine oil does not reach the middle of the level viewer Add engine oil p 120 Condition The engine is at operating temperature Check the engine oil level Info After switching off the engine wait one minute before checking the level The engine oil level is between the middle of the level viewer A and the upper edge of the level v...

Page 120: ... motorcycle on a level surface Remove the engine guard p 50 F03774 10 Main work Position an appropriate container under the engine Remove oil drain plug 1 with the magnet and seal ring F03775 10 Remove screw plug 2 with the O ring Info Do not remove screw A H05063 10 Remove screw plug 3 with long oil screen 4 and the O rings Allow the engine oil to drain completely Thoroughly clean the parts and t...

Page 121: ...deline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft H05066 10 Remove screws 5 Take off the oil filter cover with the O ring H05067 10 Pull oil filter 6 out of the oil filter housing Lock ring plier 51012011000 Allow the engine oil to drain completely Thoroughly clean the parts and the sealing surfaces H05068 10 Lay the motorcycle on its side and fill the oil filter housing to about full wi...

Page 122: ...r leaks Finishing work Install the engine guard p 50 Check the engine oil level p 117 17 4 Adding engine oil Info Too little engine oil or poor quality engine oil will result in premature wear of the engine 401955 10 Remove filler plug 1 with the O ring Add the same engine oil used when the last oil change was carried out Engine oil SAE 10W 50 p 138 Info For optimal performance of the engine oil d...

Page 123: ...SERVICE WORK ON THE ENGINE 17 121 Start the engine and check for leaks ...

Page 124: ...arly Avoid direct sunshine when cleaning the motorcycle 401061 01 Close off exhaust system to keep water from entering Remove loose dirt first with a soft jet of water Spray the heavily soiled parts with a normal commercial motor cycle cleaner and clean using a brush Motorcycle cleaner p 140 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner t...

Page 125: ... 71 Treat bare metal except for brake discs and the exhaust sys tem with a corrosion inhibitor Preserving materials for paints metal and rubber p 140 Treat all plastic parts and powder coated parts with a mild cleaning and care product Special cleaner for glossy and matte paint finishes metal and plastic surfaces p 141 ...

Page 126: ...e 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 140 Refuel p 32 Clean the motorcycle p 122 Change the engine oil and the oil filter cl...

Page 127: ...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 100 Remove the motorcycle from the lift stand p 47 Perform checks and maintenance measures when preparing for use p 25 Make a test ride ...

Page 128: ...g harness visual check Check the electrical system Malfunction in the electronic fuel injection Read out the fault memory using the KTM diagnostics tool Engine does not speed up Malfunction 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 p 65 Fuel filter is very di...

Page 129: ...ption 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 117 Engine oil too thin low viscosi ty Change the engine oil and the oil filter clean the oil screens p 117 Piston or cylinder worn Measure the piston cylinder mounting clearance 12 V battery discharged 12 V battery is not charging Check the charging voltag...

Page 130: ...gnal too low Blink code for malfunction indicator lamp 12 Malfunction indicator lamp flashes 1x long 2x short Error level condition Coolant temperature sensor input signal too high 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 input signal too high ...

Page 131: ...cuit 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 Fuel pump controller short circuit to plus Blink code for malfunction indicator lamp 65 Malfunction indicator lamp flashes 6x long 5x short Error level condition EEPROM malfunction Blink code for malfunction indi...

Page 132: ...Slide bearing Piston pin bearing Bearing bush Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with 2 trochoidal pumps Primary transmission 29 72 Clutch Multidisc clutch in oil bath hydraulically activated Gearbox 5 gear transmission claw shifted Transmission ratio first gear 14 28 second gear 16 26 third gear 18 24 f...

Page 133: ...01 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 balancer shaft fastening to water pump cover M6 10 Nm 7 4 lbf ft Loctite 222 Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch slave cylinder 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 lb...

Page 134: ... Nm 8 9 lbf ft Screw cylinder head M10x1 25 1st stage 10 Nm 7 4 lbf ft 2nd stage 30 Nm 22 1 lbf ft 3rd stage 50 Nm 36 9 lbf ft Collar and thread oiled 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 Screw plug crankcase M16x1 5 15 Nm 11 1 lbf ft Nut inner clutch hub M18x1 5 100 Nm 73 8 lbf ft Nut primary gear wheel M18LHx1 5 120 ...

Page 135: ... 1 0 bar 15 psi Secondary ratio 13 51 Chain 5 8 x 1 4 Rear sprockets available 47 48 49 50 51 52 Steering head angle 63 9 Wheelbase 1 493 10 mm 58 78 0 39 in Ground clearance unloaded 343 mm 13 5 in Seat height unloaded 958 mm 37 72 in Weight without fuel approx 103 5 kg 228 2 lb Maximum permissible front axle load 145 kg 320 lb Maximum permissible rear axle load 190 kg 419 lb Maximum permissible ...

Page 136: ...ks Sport 17 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 Oil capacity external mechanism right 230 10 50 ml 7 78 0 34 1 69 fl oz Fork oil SAE 4 48601166S1 p 139 Oil capacity external mechanism left 230 10 50 ml 7 78 0 34 1 69 fl oz Fork oil SAE 4 48601166S1 p 139 Oil capacity right cartridge 380 ml 12 85 fl oz ...

Page 137: ...x18 T20 0 7 Nm 0 52 lbf ft Screw radiator hoses clip 2 4 Nm 1 77 lbf ft Screw seat fixing EJOT EJOFORM PT K60x23 18 2 5 Nm 1 84 lbf ft Screw start stop button EJOT PT K50x18 T20 2 Nm 1 5 lbf ft Screw fixed grip M4 5 Nm 3 7 lbf ft Loctite 243 Screw throttle valve body hose clamp M4 5 Nm 3 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 n...

Page 138: ... foot brake lever stop M8 20 Nm 14 8 lbf ft Nut rear sprocket screw M8 35 Nm 25 8 lbf ft Loctite 2701 Nut rim lock M8 12 Nm 8 9 lbf ft Remaining nuts chassis M8 25 Nm 18 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft Screw bottom triple clamp M8 12 Nm 8 9 lbf ft Screw chain sliding piece M8 15 Nm 11 1 lbf ft Screw engine sprocket cover M8 15 Nm 11 1 lbf ft Screw fork stub M8 15 Nm 11 1 lbf...

Page 139: ...60 Nm 44 3 lbf ft Nut fork pivot M16x1 5 100 Nm 73 8 lbf ft Nut frame on linkage lever M16x1 5 60 Nm 44 3 lbf ft Nut linkage lever on angle lever M16x1 5 60 Nm 44 3 lbf ft Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Nut rear wheel spindle M22x1 5 80 Nm 59 lbf ft Screw in fitting cooling system M24x1 5 7 5 Nm 5 53 lbf ft ...

Page 140: ...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 141: ...on SAE p 142 SAE 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 Standard classification DIN EN 228 ROZ 95 Guideline Only use super unleaded fuel that matches or is equivalent to the specified standard Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do ...

Page 142: ...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 143: ...pray Special cleaner for glossy 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 144: ...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 145: ...a standing position OBD On board diagnosis Vehicle system which monitors the specified parame ters of the vehicle electronics Quickshifter Function of the engine electronics for shifting up with out clutch actuation TC Traction Control Auxiliary function of the motor control that reduces engine torque with spinning rear wheel ...

Page 146: ...27 LIST OF ABBREVIATIONS 144 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 147: ...ion control is activated and the speed limiter intervenes TC indicator lamp lights up orange TC is enabled or is currently intervening The TC indica tor lamp flashes if launch control is activated 28 2 Green and blue symbols Green and blue symbols reflect information QS indicator lamp lights up blue The quickshifter is activated The QS indicator lamp flashes when the quickshifter is being programm...

Page 148: ...07 108 132 engine oil 120 132 fuel 32 132 Chain checking 74 cleaning 71 Chain guide checking 74 Chain tension adjusting 73 checking 72 Characteristic map of the throttle response adjusting 111 Clutch fluid level checking correcting 78 fluid changing 79 Clutch lever 14 basic position adjusting 78 Cold start button 17 Combination instrument 16 Compression damping fork adjusting 43 Coolant antifreeze...

Page 149: ... main fuse changing 102 of the fuel pump changing 103 H Hand brake lever 14 basic position adjusting 81 free travel checking 81 Handlebar position 44 adjusting 44 High speed compression damping shock absorber adjusting 36 I Idle speed adjusting 113 Idle speed adjusting screw 18 Implied warranty 9 Indicator lamps overview 15 Intended use 6 L Launch control activating 26 Link fork checking 76 Lithiu...

Page 150: ... speed compression damping adjusting 36 rebound damping adjusting 37 removing 58 riding sag checking 39 spring preload adjusting 39 static sag checking 38 Shock absorber article number 13 Spare parts 9 Spoke tension checking 98 Start button 15 Start number plate installing 57 removing 56 Starting 25 Starting power lithium ion batteries at low temperatures 21 Steering head bearing lubricating 56 St...

Page 151: ...INDEX 149 V Vehicle identification number 12 View of vehicle front left 10 rear right 11 W Work rules 8 ...

Page 152: ... 3214419en 3214419en 03 2022 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria KTM COM Photo Mitterbauer KISKA KTM ...

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KTM 450 SX-F, Owner'S Manual

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