OWNER'S MANUAL 2017

250 SX-F
250 XC‑F
Art. no. 3213472en
 DEAR KTM CUSTOMER 1

Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
DEAR KTM CUSTOMER

give you enormous pleasure if you service and maintain it properly.

We hope you enjoy your new vehicle!

Enter the serial numbers of your vehicle below.

Chassis number ( p. 11) Dealer's stamp

Engine number ( p. 11)

The Owner's Manual contained the latest information for this model series at the time of going to print. Minor differences due to develop-
ments in design cannot be ruled out completely.

All specifications are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical specifications,
prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to
local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, devi-
ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not
belong to the regular scope of supply.

© 2016 KTM Sportmotorcycle GmbH, Mattighofen Austria

All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÜV Management Service

KTM Sportmotorcycle GmbH

5230 Mattighofen, Austria

This document is valid for the following models:

250 SX‑F EU (F8101Q5)
250 SX‑F US (F8175Q5)
250 XC‑F US (F8175Q0)

*3213472en*
3213472en

04/2016
TABLE OF CONTENTS 2

8 RIDING INSTRUCTIONS............................................. 22
TABLE OF CONTENTS

1 MEANS OF REPRESENTATION ..................................... 4

1.1 Symbols used ................................................... 4 8.1 Checks and maintenance before putting into
1.2 Formats used.................................................... 4 operation........................................................ 22
2 SAFETY ADVICE........................................................... 5 8.2 Starting.......................................................... 22
2.1 Use definition – intended use............................. 5 8.3 Activating Launch Control ................................ 23
2.2 Safety advice.................................................... 5 8.4 Activating traction control ................................ 23
2.3 Degrees of risk and symbols ............................... 5 8.5 Starting off..................................................... 24
2.4 Tampering warning............................................ 5 8.6 Shifting, riding ............................................... 24
2.5 Safe operation .................................................. 6 8.7 Applying the brakes......................................... 24
2.6 Protective clothing ............................................ 6 8.8 Stopping, parking............................................ 25
2.7 Work rules........................................................ 6 8.9 Transport ....................................................... 25
2.8 Environment..................................................... 6 8.10 Refueling ....................................................... 26
2.9 Owner's Manual ................................................ 7 9 SERVICE SCHEDULE ................................................. 27
3 IMPORTANT NOTES..................................................... 8 9.1 Additional information ..................................... 27
3.1 Manufacturer and implied warranty..................... 8 9.2 Required work ................................................ 27
3.2 Operating and auxiliary substances ..................... 8 9.3 Recommended work ........................................ 28
3.3 Spare parts, accessories .................................... 8 10 TUNING THE CHASSIS .............................................. 29
3.4 Service ............................................................ 8 10.1 Checking the basic chassis setting with the
3.5 Figures ............................................................ 8 rider's weight.................................................. 29
3.6 Customer service............................................... 8 10.2 Air suspension AER 48.................................... 29
4 VIEW OF VEHICLE ....................................................... 9 10.3 Compression damping of the shock absorber...... 29
4.1 View of vehicle, front left (example) .................... 9 10.4 Adjusting the low-speed compression damping
of the shock absorber ...................................... 30
4.2 View of vehicle, rear right (example) ................. 10
10.5 Adjusting the high-speed compression
5 SERIAL NUMBERS .................................................... 11
damping of the shock absorber......................... 30
5.1 Chassis number .............................................. 11
10.6 Adjusting the rebound damping of the shock
5.2 Type label ...................................................... 11 absorber......................................................... 31
5.3 Engine number ............................................... 11 10.7 Measuring rear wheel sag unloaded................... 32
5.4 Fork part number ............................................ 11 10.8 Checking the static sag of the shock absorber .... 32
5.5 Shock absorber article number ......................... 11 10.9 Checking the riding sag of the shock absorber.... 33
6 CONTROLS................................................................ 12 10.10 Adjusting the spring preload of the shock
6.1 Clutch lever.................................................... 12 absorber ..................................................... 33
6.2 Hand brake lever............................................. 12 10.11 Adjusting the riding sag ............................... 34
6.3 Throttle grip ................................................... 12 10.12 Checking the basic setting of the fork ............... 34
6.4 Kill switch...................................................... 12 10.13 Adjusting the fork air pressure.......................... 35
6.5 Electric starter button...................................... 12 10.14 Adjusting the compression damping of the
6.6 Combination switch......................................... 13 fork ............................................................... 36
6.7 Overview of indicator lamps ............................. 13 10.15 Adjusting the rebound damping of the fork ........ 36
6.8 Service hour counter ....................................... 13 10.16 Handlebar position.......................................... 37
6.9 Opening the filler cap...................................... 13 10.17 Adjusting the handlebar position ................... 37
6.10 Closing the filler cap ....................................... 14 11 SERVICE WORK ON THE CHASSIS.............................. 38
6.11 Cold start button............................................. 15 11.1 Raising the motorcycle with a lift stand............. 38
6.12 Idle speed adjusting screw ............................... 15 11.2 Removing the motorcycle from the lift stand...... 38
6.13 Shift lever ...................................................... 15 11.3 Bleeding the fork legs...................................... 38
6.14 Foot brake lever .............................................. 16 11.4 Cleaning the dust boots of the fork legs............. 39
6.15 Plug-in stand (All SX‑F models) ........................ 16 11.5 Removing the fork protector ............................. 39
6.16 Side stand (XC‑F US) ...................................... 16 11.6 Installing the fork protector.............................. 39
7 PREPARING FOR USE................................................ 18 11.7 Removing the fork legs ................................. 40
7.1 Advice on first use .......................................... 18 11.8 Installing the fork legs ................................. 40
7.2 Running in the engine ..................................... 19 11.9 Removing the lower triple clamp ................... 41
7.3 Starting power of lithium-ion batteries at low 11.10 Installing the lower triple clamp .................... 41
temperatures .................................................. 19 11.11 Checking the steering head bearing play............ 43
7.4 Preparing the vehicle for difficult riding 11.12 Adjusting the steering head bearing play ........ 43
conditions ...................................................... 19 11.13 Greasing the steering head bearing ................ 44
7.5 Preparing for rides on dry sand ......................... 20 11.14 Removing the start number plate ...................... 44
7.6 Preparing for rides on wet sand ........................ 20 11.15 Installing the start number plate....................... 44
7.7 Preparing for rides on wet and muddy 11.16 Removing the front fender ............................... 45
surfaces ......................................................... 21
11.17 Installing the front fender ................................ 45
7.8 Preparing for rides at high temperatures and
11.18 Removing the shock absorber ....................... 45
low speeds ..................................................... 21
11.19 Installing the shock absorber ........................ 46
7.9 Preparing for rides at low temperature and in
snow.............................................................. 21 11.20 Removing the seat .......................................... 48
11.21 Mounting the seat ........................................... 48
TABLE OF CONTENTS 3

11.22 Removing the air filter box cover ...................... 48 15.4 Draining the coolant .................................... 83
11.23 Installing the air filter box cover ....................... 49 15.5 Refilling coolant .......................................... 84
11.24 Removing the air filter ................................. 50 16 TUNING THE ENGINE................................................ 85
11.25 Cleaning the air filter and air filter box .......... 50 16.1 Checking the play in the throttle cable .............. 85
11.26 Installing the air filter .................................. 51 16.2 Adjusting the play in the throttle cable .......... 85
11.27 Securing the air filter box cover .................... 51 16.3 Setting the characteristic map of the throttle
11.28 Sealing the air filter box ............................... 52 response ..................................................... 86
11.29 Removing the main silencer ............................. 52 16.4 Changing the mapping..................................... 87
11.30 Installing the main silencer.............................. 52 16.5 Adjusting the idle speed ............................... 87
11.31 Changing the glass fiber yarn filling of the 16.6 Teaching the throttle valve position................... 88
main silencer .............................................. 53 16.7 Checking the basic position of the shift lever ..... 88
11.32 Removing the fuel tank ................................ 53 16.8 Adjusting the basic position of the shift
11.33 Installing the fuel tank ................................. 55 lever ........................................................... 89
11.34 Checking for chain dirt accumulation ................ 56 17 SERVICE WORK ON THE ENGINE ............................... 90
11.35 Cleaning the chain .......................................... 57 17.1 Changing the fuel screen .............................. 90
11.36 Checking the chain tension .............................. 57 17.2 Checking the engine oil level............................ 91
11.37 Adjusting the chain tension.............................. 58 17.3 Changing the engine oil and oil filter, cleaning
11.38 Checking the chain, rear sprocket, engine the oil screen .............................................. 92
sprocket, and chain guide ................................ 58 17.4 Adding engine oil ............................................ 94
11.39 Checking the frame ..................................... 60 18 CLEANING, CARE ...................................................... 95
11.40 Checking the swingarm ................................ 60 18.1 Cleaning the motorcycle .................................. 95
11.41 Checking the throttle cable routing ................... 60 19 STORAGE .................................................................. 96
11.42 Checking the rubber grips ................................ 61 19.1 Storage .......................................................... 96
11.43 Adjusting the basic position of the clutch 19.2 Putting into operation after storage ................... 97
lever .............................................................. 61 20 TROUBLESHOOTING ................................................. 98
11.44 Checking/correcting the fluid level of the 21 TECHNICAL DATA.................................................... 100
hydraulic clutch.............................................. 62 21.1 Engine ......................................................... 100
11.45 Changing the hydraulic clutch fluid ............... 62 21.2 Engine tightening torques .............................. 101
12 BRAKE SYSTEM ........................................................ 64 21.3 Capacities .................................................... 102
12.1 Checking the free travel of the hand brake 21.3.1 Engine oil ................................................ 102
lever .............................................................. 64 21.3.2 Coolant .................................................... 102
12.2 Adjusting the basic position of the hand brake 21.3.3 Fuel ........................................................ 102
lever .............................................................. 64
21.4 Chassis ........................................................ 102
12.3 Checking the brake discs ................................. 64
21.5 Electrical system........................................... 103
12.4 Checking the front brake fluid level .................. 65
21.6 Tires ............................................................ 103
12.5 Adding front brake fluid ............................... 65
21.7 Fork............................................................. 103
12.6 Checking the front brake linings ....................... 66
21.7.1 SX‑F EU................................................... 103
12.7 Changing the front brake linings ................... 67
21.7.2 SX‑F US................................................... 104
12.8 Checking the free travel of foot brake lever ........ 68
21.7.3 XC‑F US................................................... 104
12.9 Adjusting the basic position of the foot brake
21.8 Shock absorber ............................................. 105
lever ........................................................... 69
21.8.1 SX‑F EU................................................... 105
12.10 Checking the rear brake fluid level.................... 69
21.8.2 SX‑F US................................................... 105
12.11 Adding rear brake fluid ................................ 70
21.8.3 XC‑F US................................................... 106
12.12 Checking the rear brake linings ........................ 70
21.9 Chassis tightening torques ............................. 106
12.13 Changing the rear brake linings ..................... 71
22 SUBSTANCES ......................................................... 108
13 WHEELS, TIRES ........................................................ 73
23 AUXILIARY SUBSTANCES ........................................ 110
13.1 Removing the front wheel ............................. 73
24 STANDARDS ........................................................... 111
13.2 Installing the front wheel ............................. 73
25 INDEX OF SPECIAL TERMS ...................................... 112
13.3 Removing the rear wheel .............................. 74
26 LIST OF ABBREVIATIONS......................................... 113
13.4 Installing the rear wheel ............................... 75
27 LIST OF SYMBOLS................................................... 114
13.5 Checking the tire condition .............................. 76
27.1 Yellow and orange symbols............................. 114
13.6 Checking the tire air pressure........................... 76
INDEX ............................................................................ 115
13.7 Checking spoke tension ................................... 76
14 ELECTRICAL SYSTEM ................................................ 78
14.1 Removing the battery ................................... 78
14.2 Installing the battery .................................... 78
14.3 Recharging the battery ................................. 79
14.4 Changing the main fuse ................................... 80
15 COOLING SYSTEM ..................................................... 82
15.1 Cooling system ............................................... 82
15.2 Checking the antifreeze and coolant level .......... 82
15.3 Checking the coolant level ............................... 83
1 MEANS OF REPRESENTATION 4

1.1 Symbols used

The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).

Indicates an unexpected reaction (e.g. of a work step or a function).

All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of
your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be opti-
mally cared for by specially trained experts using the specialist tools required.

Indicates a page reference (more information is provided on the specified page).

Indicates information with more details or tips.

Indicates the result of a testing step.

1.2 Formats used

The typographical formats used in this document are explained below.
Specific name Identifies a proprietary name.

Name® Identifies a protected name.

Brand™ Identifies a brand available on the open market.

Underlined terms Refer to technical details of the vehicle or indicate technical terms that are explained in
the glossary.
2 SAFETY ADVICE 5

2.1 Use definition – intended use

(All SX‑F models)
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles
comply with currently valid regulations and categories of the top international motorsport organizations.

Info
The motorcycle may only be used in closed off areas remote from public road traffic.

(XC‑F US)
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles
comply with currently valid regulations and categories of the top international motorsport organizations.

Info
This motorcycle is designed for use in offroad endurance competition and not primarily for use in Motocross.

2.2 Safety advice

A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety
instructions are highlighted in the text and are referred to at the relevant passages.

Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If
they are missing, you or others may not recognize dangers and may therefore be injured.

2.3 Degrees of risk and symbols

Danger
Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are
not taken.

Warning
Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Caution
Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.

Note
Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Warning
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.

2.4 Tampering warning

Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:

1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device
or element of design incorporated into any new vehicle for the purpose of 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 silencer, baffles, header pipes or any other components which conduct exhaust gases.
2 Removal or puncturing of parts of the intake system.
3 Lack of proper maintenance.
4 Replacing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manu-
facturer.
2 SAFETY ADVICE 6

2.5 Safe operation

Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
– Do not operate the vehicle 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 an effective exhaust extraction system when starting or running the engine in an enclosed space.

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 brake system before the vehicle
parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.

Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmen-
tally compatible manner.
The vehicle should only be used by trained persons.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.

2.6 Protective clothing

Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all
rides.
– Always wear protective clothing that is in good condition and meets the legal regulations.

In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.

2.7 Work rules

Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren-
theses. E.g.: bearing puller (15112017000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.

2.8 Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcy-
cle sport, make sure that you use your motorcycle legally, display environmental consciousness, 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
pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.
2 SAFETY ADVICE 7

2.9 Owner's Manual

It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains
useful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to cus-
tomize the vehicle ideally for your own use and how you can protect yourself from injury.
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed.
If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.
The Owner's Manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold.
3 IMPORTANT NOTES 8

3.1 Manufacturer and implied warranty

The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the
Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage
caused by tampering with and/or conversions on the vehicle are not covered by the warranty.
Additional information on the manufacturer or implied warranty and the procedures involved can be found in the Service & Warranty
Booklet.

3.2 Operating and auxiliary substances

Warning
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.

Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.

3.3 Spare parts, accessories

For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them
installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your 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 and tuning of the engine and chassis can
lead to damage and breakage of components.
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 components. For this reason, it may be necessary to inspect or
replace parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a
much longer service life for your motorcycle.

3.5 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to dis-
assemble the component to perform the activity in question. Please follow the instructions in the text.

3.6 Customer service

Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.

A list of authorized KTM dealers can be found on the KTM website.

International KTM Website: http://www.ktm.com
4 VIEW OF VEHICLE 9

4.1 View of vehicle, front left (example)

S01190-10

1 Hand brake lever ( p. 12)

2 Clutch lever ( p. 12)
3 Filler cap
4 Air filter box cover
5 Cold start button ( p. 15)
6 Engine number ( p. 11)
7 Shift lever ( p. 15)
4 VIEW OF VEHICLE 10

4.2 View of vehicle, rear right (example)

S01191-10

1 Shock absorber compression adjustment

2 Combination switch ( p. 13)
3 Kill switch ( p. 12)
4 Electric starter button ( p. 12)
5 Throttle grip ( p. 12)
6 Type label ( p. 11)
7 Fork part number ( p. 11)
8 Idle speed adjusting screw ( p. 15)
9 Foot brake lever ( p. 16)
10 Engine oil level viewer
11 Shock absorber rebound adjustment
12 Shock absorber article number ( p. 11)
5 SERIAL NUMBERS 11

5.1 Chassis number

The chassis number 1 is stamped on the right side of the steering head.

401945-10

5.2 Type label

The type label 1 is fixed to the front of the steering head.

401946-10

5.3 Engine number

Engine number 1 is located on the left side of the engine over the engine sprocket.

H01047-10

5.4 Fork part number

The fork part number 1 is stamped on the inner side of the axle clamp.

401947-10

5.5 Shock absorber article number

Shock absorber article number 1 is stamped on the top of the shock absorber above
the adjusting ring towards the engine side.

1
0

401948-10
6 CONTROLS 12

6.1 Clutch lever

The clutch lever 1is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.

S01192-10

6.2 Hand brake lever

Hand brake lever 1 is fitted on the right side of the handlebar.
The front brake is engaged using the hand brake lever.

S01193-10

6.3 Throttle grip

The throttle grip 1 is fitted on the right side of the handlebar.

S01193-11

6.4 Kill switch

Kill switch 1 is fitted on the left side of the handlebar.
Possible states
• Kill switch in the basic position – In this position, the ignition circuit is closed
and the engine can be started.
• Kill switch pressed – In this position, the ignition circuit is interrupted, a run-
ning engine stops, and a non-running engine will not start.

S01194-10

6.5 Electric starter button

The electric starter button 1 is fitted on the right side of the handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button pressed – In this position, the electric starter is actuated.

S01195-10
6 CONTROLS 13

6.6 Combination switch

The combination switch is fitted on the left side of the handlebar.
Possible states
1 STANDARD – STANDARD mapping is activated when LED 1 lights up.
1TC STANDARD with TC – STANDARD mapping with traction control is acti-
vated when LED 1 and TC light up.
2 ADVANCED – ADVANCED mapping is activated, when LED 2 lights up.
2TC ADVANCED with TC – ADVANCED mapping with traction control is acti-
vated 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 via the combination
switch.

H01181-10

6.7 Overview of indicator lamps

Possible states
FI warning lamp (MIL) lights up/flashes orange – The OBD has detected
an emission- or safety-critical fault.
FI warning lamp (MIL) flashes fast in orange – The Launch Control is acti-
vated.

(XC‑F US)
The low fuel warning lamp lights up orange – The fuel level has
reached the reserve mark.
S01196-10

6.8 Service hour counter

Service hour counter 1is fitted in front of the handlebar.
It shows the total number of service hours of the engine.
The service hour counter begins counting when the engine is started and stops when
the engine is switched off.

Info
The value indicated by the service hour counter cannot be cleared or adjusted.

S01257-10

6.9 Opening the filler cap

Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.

– Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
6 CONTROLS 14

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.
– Keep fuels correctly in a suitable canister, and out of the reach of children.

Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.

(All SX‑F models)

– Turn filler cap 1 counterclockwise and lift it off.

S01197-10

(XC‑F US)
– Press release button 1, turn the filler cap counterclockwise, and lift it off.

S01265-10

6.10 Closing the filler cap

(All SX‑F models)
– Mount filler cap 1 and turn it clockwise until the fuel tank is tightly closed.
Info
Route fuel tank breather hose 2 without kinks.

S01198-10

(XC‑F US)
– Replace the filler cap and turn clockwise until release button 1 locks in
place.

Info
Route fuel tank breather hose 2 without kinks.

S01266-10
6 CONTROLS 15

6.11 Cold start button

Cold start button 1 is fitted on the bottom of the throttle valve body.
The injection system extends the injection time if the engine is cold and the outside
temperature is low. To help the engine burn the increased amount of fuel, 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 turn-
ing the throttle grip towards the front, the cold start button returns to its original posi-
tion.

Info
Check whether the cold start button has returned to its basic position.

Possible states
• The cold start button is activated – The cold start button is pushed in all the way.
• The cold start button is deactivated – The cold start button is in its basic position.

S01200-10

6.12 Idle speed adjusting screw

The idle setting of the throttle valve body has a big influence on the vehicle's starting
behavior, on stable idling, and on vehicle response when the throttle is opened.
An engine with a correctly set idle speed is easier to start than an engine with the idle
speed set incorrectly.
The idle speed is adjusted with 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.

S01199-10

6.13 Shift lever

Shift lever 1 is mounted on the left side of the engine.

401950-10
6 CONTROLS 16

(All SX‑F models)

The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.

401950-13

(XC‑F US)
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.

401950-11

6.14 Foot brake lever

Foot brake lever 1 is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.

401956-10

6.15 Plug-in stand (All SX‑F models)

Support for plug-in stand 1 is the left side of the wheel spindle.
The plug-in stand is used to park the motorcycle.

Info
Remove the plug-in stand before riding.

1
0
402001-10

6.16 Side stand (XC‑F US)

The side stand 1 is on the left side of the vehicle.

401943-10
6 CONTROLS 17

The side stand is used to park the motorcycle.

Info
When you are riding, side stand 1 must be folded up and secured with rubber
band 2
.

401944-10
7 PREPARING FOR USE 18

7.1 Advice on first use

Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
– Do not operate the vehicle if you are physically or mentally impaired.
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all
rides.
– Always wear protective clothing that is in good condition and meets the legal regulations.
Warning
Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling characteristic.
Different tire tread patterns can make the vehicle significantly more difficult to control.

– Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.
Warning
Danger 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 continuously.

– Take your foot off the foot brake lever when you are not braking.
Warning
Danger of accidents Total weight and axle loads influence the handling characteristic.
– Do not exceed the maximum permissible overall weight or the axle loads.

Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running.
– Protect the vehicle against access by unauthorized persons.

Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.

– Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.
You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.
– Before your first trip, read the entire Owner's Manual carefully.
– Get to know the controls.
– Adjust the basic position of the clutch lever. ( p. 61)
– Adjust the basic position of the hand brake lever. ( p. 64)
– Adjust the basic position of the foot brake lever. ( p. 69)
– Adjust the basic position of the shift lever. ( p. 89)
– Get used to handling the motorcycle on a suitable piece of land before undertaking a more challenging trip.

Info
Your motorcycle is not approved for use on public roads.
When off road, it is recommended that you are accompanied by another person on another vehicle so that you can help
each other.
7 PREPARING FOR USE 19

– Try also to ride as slowly as possible and in a standing position to get a better feeling for the motorcycle.
– Do not make 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 take luggage along.
(XC‑F US)
– If you carry luggage, make sure you secure it firmly as close as possible to the center of the vehicle and ensure even weight
distribution between the front and rear wheels.

Info
Motorcycles react sensitively to any changes of weight distribution.

– Do not exceed the maximum permissible weight and the maximum permissible axle loads.
Guideline
Maximum permissible overall weight 335 kg (739 lb.)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
– Run in the engine. ( p. 19)

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 temperatures

Lithium-ion batteries are far lighter than lead batteries, have a low self-discharge rate,
and have more starting power at temperatures over 15 °C (60 °F). At low temperatures,
however, the starting power of lithium-ion batteries drops to below that of lead batter-
ies.
Multiple starting attempts may be needed. Press the electric starter button for 5 sec-
onds, and wait 30 seconds between attempts. The pauses are necessary so that the
created heat can distribute through the lithium-ion battery and the battery is not dam-
aged.
If the charged lithium-ion battery does not or only weakly turns over the electric starter
when temperatures are below 15 °C (60 °F), then the battery is not faulty, but needs to
402555-01
be warmed up internally to increase its starting power (current output).
The starting power increases as the battery warms 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 components. For this reason, it may be neces-
sary to inspect or replace parts before the next scheduled service.

– Use the specified engine oil when riding under difficult conditions and to enhance performance, as recommended by KTM.
Engine oil (SAE 10W/60) (00062010035) ( p. 108)
– Clean the air filter and air filter box. ( p. 50)

Info
Check the air filter approx. every 30 minutes.

– Seal the air filter box. ( p. 52)

– Secure the air filter box cover. ( p. 51)
7 PREPARING FOR USE 20

– 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 riding conditions are:
– Rides on dry sand. ( p. 20)
– Rides on wet sand. ( p. 20)
– Rides on wet and muddy surfaces. ( p. 21)
– Rides at high temperatures and low speeds. ( p. 21)
– Riding at low temperature and in snow. ( p. 21)

7.5 Preparing for rides on dry sand

– Fit a dust cover on the air filter.
Dust protection device for air filter (79006920000)

Info
See the KTM PowerParts fitting instructions.

102136-01

– Fit a sand cover on the air filter.

Sand protection device for air filter (79006922000)

Info
See the KTM PowerParts fitting instructions.

102138-01

– Clean the chain.

Chain cleaner ( p. 110)
– Fit the steel sprocket.

Tip
Do not grease the chain.

– Clean the radiator fins.

600868-01 – Straighten bent radiator fins carefully.
Condition
Regular use in sand
– Change the piston every 20 operating hours.

7.6 Preparing for rides on wet sand

– Fit a waterproofing device on the air filter.
Waterproofing device for air filter (79006921000)

Info
See the KTM PowerParts fitting instructions.

102137-01
7 PREPARING FOR USE 21

– Clean the chain.

Chain cleaner ( p. 110)
– Fit the steel sprocket.

Tip
Do not grease the chain.

– Clean the radiator fins.

600868-01 – Straighten bent radiator fins carefully.
Condition
Regular use in sand
– Change the piston every 20 operating hours.

7.7 Preparing for rides on wet and muddy surfaces

– Fit a waterproofing device on the air filter.
Waterproofing device for air filter (79006921000)

Info
See the KTM PowerParts fitting instructions.

102137-01

– Fit the steel sprocket.

– Clean the motorcycle. ( p. 95)
– Straighten bent radiator fins carefully.

600868-01

7.8 Preparing for rides at high temperatures and low speeds

– Adjust the secondary drive to the road conditions.

Info
The engine oil quickly gets hot if the clutch has to be operated very often
due to an excessively high secondary drive.

– Clean the chain.

Chain cleaner ( p. 110)
– Clean the radiator fins.
600868-01
– Straighten bent radiator fins carefully.
– Check the coolant level. ( p. 83)

7.9 Preparing for rides at low temperature and in snow

– Fit a waterproofing device on the air filter.
Waterproofing device for air filter (79006921000)

Info
See the KTM PowerParts fitting instructions.

102137-01
8 RIDING INSTRUCTIONS 22

8.1 Checks and maintenance before putting into operation

Info
Before every trip, check the condition of the vehicle and ensure that it is safe to operate.
The vehicle must be in perfect technical condition when used.

– Check the engine oil level. ( p. 91)

– Check the front brake fluid level. ( p. 65)
– Check the rear brake fluid level. ( p. 69)
– Check the front brake linings. ( p. 66)
– Check the rear brake linings. ( p. 70)
– Check that the brake system is functioning properly.
– Check the coolant level. ( p. 83)
– Check for chain dirt accumulation. ( p. 56)
– Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 58)
– Check the chain tension. ( p. 57)
– Check the tire condition. ( p. 76)
– Check the tire air pressure. ( p. 76)
– Check the spoke tension. ( p. 76)
– Clean the dust boots of the fork legs. ( p. 39)
– Bleed the fork legs. ( p. 38)
– Check the air filter.
– Check the settings of all controls and ensure that they can be operated smoothly.
– Check all screws, nuts and hose clamps regularly for tightness.
– Check the fuel reserves.

8.2 Starting

Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

Note
Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.
– Always run the engine warm at a low speed.

(All SX‑F models)

– Remove plug-in stand 1.

1
0
402001-10

(XC‑F US)
– Take the motorcycle off the side stand 1 and secure the side stand with the
rubber band 2
.
– Shift the transmission to idle.
Condition
Ambient temperature: < 20 °C (< 68 °F)
– Push the cold start button in all the way.

401944-10
8 RIDING INSTRUCTIONS 23

– Press the electric starter button .

Info
Press the electric starter button for a maximum of 5 seconds. Wait for 30
seconds before a further attempt at starting.
At temperatures below 15 °C (60 °F), several attempts at starting may be
necessary to warm-up the lithium-ion battery and thereby increase the start-
ing power.
When starting FI warning lamp lights up briefly as a function check.
400733-01

8.3 Activating Launch Control

Info
The Launch Control assists the rider to optimally accelerate the motorcycle at the beginning of a race. The maximum speed of
the engine with the throttle valve fully opened (full throttle) is reduced. After the start, it is gradually increased up to the max-
imum engine speed. The rider opens the throttle fully throughout this procedure. The clutch must be activated exactly as it
would be without an active Launch Control.

Condition
The motorcycle is stationary.
The engine is running at idle speed.
The transmission is in neutral.
– Press and hold MAP and TC buttons simultaneously.
FI warning lamp flashes orange rapidly.

Info
Several seconds after the vehicle starts, Launch Control is deactivated auto-
matically.
The Launch Control is deactivated in the following cases (FI warning lamp no
longer flashes): After full throttle, the throttle valve was closed by more than
1/3 of the way and/or there is no start within 3 minutes.
H01179-10 To reactivate Launch Control, the engine must first be switched off for at
least 10 seconds for safety reasons. This must occur regardless of whether
the engine was started or not.

8.4 Activating traction control

Info
The traction control reduces excessive slip on the rear wheel in favor of more control and propulsion, particularly in wet condi-
tions.
When traction control is switched off, the rear wheel may spin more during high acceleration and on surfaces with low grip.
Traction control can be switched on or off during the ride.
The setting most recently selected is activated again when restarting.

– Press button TC to switch the traction control on or off.

Guideline
Engine speed ≤ 4,000 rpm
The TC LED lights up when the traction control is activated.

H01179-11
8 RIDING INSTRUCTIONS 24

8.5 Starting off

– Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.

8.6 Shifting, riding

Warning
Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine races.
– Do not change into a low gear at high engine speed.

Info
If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.
First gear is used for starting off and for steep inclines.

– Shift into a higher gear when conditions allow (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 you pushed the cold start button while starting, open the throttle briefly and release the throttle grip or turn the throttle grip for-
ward.
The cold start button goes to the basic position.
– After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This will barely reduce the
speed but fuel consumption will be considerably lower.
– Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel consumption.
– To shift down, apply the brakes and close the throttle at the same time.
– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and either open the throttle or shift again.
– Switch off the engine if running at idle or standing for a long time.
Guideline
≥ 1 min
– Avoid frequent and longer slipping of the clutch. As a result the engine oil, engine and cooling system heat up.
– Ride at a low engine speed instead of at a high engine speed with a slipping clutch.

8.7 Applying the brakes

Warning
Danger of accidents Excessively forceful application of the brakes blocks the wheels.
– Adjust application of the brakes to the respective riding situation and riding surface conditions.
Warning
Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency.
– 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 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 the rear brake.

– Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
– On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine.
In this way, you have to apply the brakes far less frequently and the brake system does not overheat.
8 RIDING INSTRUCTIONS 25

8.8 Stopping, parking

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 brake system before the vehicle
parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
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.

– Brake the motorcycle.

– Shift the transmission to idle.
– Press and hold the kill switch while the engine is idling until the engine stops.
– Park the motorcycle on firm ground.

8.9 Transport

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.

– Switch off the engine.

– Use tension belts or other suitable devices to secure the motorcycle against acci-
dents or falling over.

401475-01
8 RIDING INSTRUCTIONS 26

8.10 Refueling

Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.

– Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– 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
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 that meets the specified standards. (Your authorized KTM workshop will be glad to help.)

Warning
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 filler cap. ( p. 13)
– Fill the fuel tank with fuel up to measurement A.
Guideline
A Measurement of A 35 mm (1.38 in)

Total fuel tank 7 l (1.8 US gal) Super unleaded (ROZ 95/RON 95/PON
capacity, approx. 91) ( p. 109)
(All SX‑F models)
Total fuel tank 8.5 l Super unleaded (ROZ 95/RON 95/PON
capacity, approx. (2.25 US gal) 91) ( p. 109)
401522-10
(XC‑F US)
– Close the filler cap. ( p. 14)
9 SERVICE SCHEDULE 27

9.1 Additional information

Any further work that results from the required work or from the recommended work must be ordered separately and can be invoiced
separately.

9.2 Required work

Every 30 operating hours
Every 20 operating hours
Every 10 operating hours/after every race
Once after 1 operating hour
Read out the fault memory using the KTM diagnostics tool. ○ ● ● ●
Check and charge the battery. ● ● ●
Check the front brake linings. ( p. 66) ● ● ●
Check the rear brake linings. ( p. 70) ● ● ●
Check the brake discs. ( p. 64) ● ● ●
Check the brake lines for damage and leakage. ● ● ●
Check the rear brake fluid level. ( p. 69) ● ● ●
Check the free travel of the foot brake lever. ( p. 68) ● ● ●
Check the frame and swingarm. ● ● ●
Check the swingarm bearing for play. ●
Check the heim joints at the top of the shock absorber. ● ● ●
Check the shock absorber linkage. ● ● ●
Check the tire condition. ( p. 76) ○ ● ● ●
Check the tire air pressure. ( p. 76) ○ ● ● ●
Check the wheel bearing for play. ● ● ●
Check the wheel hubs. ● ● ●
Check the rim run-out. ○ ● ● ●
Check the spoke tension. ( p. 76) ○ ● ● ●
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 58) ● ● ●
Check the chain tension. ( p. 57) ○ ● ● ●
Grease all moving parts (e.g., hand lever, chain, ...) and check for smooth operation. ● ● ●
Check/correct the fluid level of the hydraulic clutch. ( p. 62) ● ● ●
Check the front brake fluid level. ( p. 65) ● ● ●
Check the free travel of the hand brake lever. ( p. 64) ● ● ●
Check the steering head bearing play. ( p. 43) ○ ● ● ●
Check the valve clearance. ○ ●
Check the clutch. ●
Change the cover seal and shaft seal rings of the water pump. ●
Change the engine oil and oil filter, clean the oil screen. ( p. 92) ○ ● ● ●
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and incorrect rout- ○ ● ● ●
ing.
Check the antifreeze and coolant level. ( p. 82) ○ ● ● ●
Check the cables for damage and routing without sharp bends. ● ● ●
Check that the throttle cables are undamaged, routed without sharp bends, and set correctly. ○ ● ● ●
Clean the air filter and air filter box. ( p. 50) ● ● ●
Change the glass fiber yarn filling of the main silencer. ( p. 53) ●
Check the screws and nuts for tightness. ○ ● ● ●
Change the fuel screen. ( p. 90) ○ ● ● ●
Check the fuel pressure. ● ● ●
Check idle. ○ ● ● ●
Final check: Check the vehicle for safe operation and take a test ride. ○ ● ● ●
Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ●
Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ ● ● ●
9 SERVICE SCHEDULE 28

○ One-time interval
● Periodic interval

9.3 Recommended work

Annually
Every 100 operating hours
Every 50 operating hours
Every 40 operating hours
Once after 20 operating hours
Once after 10 operating hours
Change the front brake fluid. ●
Change the rear brake fluid. ●
Change the hydraulic clutch fluid. ( p. 62) ●
Grease the steering head bearing. ( p. 44) ●
Service the fork. ○ ●
Service the shock absorber. ○ ●
Change the fuel filter. ●
Perform minor engine service including removing and installing engine. (Change spark plug and ● ●
spark plug connector. Change piston, check and measure cylinder; check cylinder head. Check
camshaft and cam lever. Check timing assembly. Change intake flange.)
Perform major engine service including removing and installing engine. (Change valves, valve ●
springs, valve spring seats and valve spring retainers. Change the connecting rod, conrod bearing,
and crank pin. Check the transmission and shift mechanism. Check the oil pressure regulator valve.
Change the suction pump. Check the force pump and lubrication system. Change timing chain.
Change all engine bearings. Change freewheel.)
○ One-time interval
● Periodic interval
10 TUNING THE CHASSIS 29

10.1 Checking the basic chassis setting with the rider's weight

Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.

– For optimal motorcycle riding characteristics and to avoid damage to forks, shock
absorbers, swingarm and frame, the basic settings of the suspension components
must match the rider's weight.
– As delivered, KTM offroad motorcycles are adjusted for an average rider's weight
(with full protective clothing).
Guideline
Standard rider weight 75… 85 kg (165… 187 lb.)
– If the rider's weight is above or below this range, the basic setting of the suspen-
sion components must be adjusted accordingly.
– Small weight differences can be compensated by adjusting the spring preload, but
in the case of large weight differences, the springs must be replaced.

401030-01

10.2 Air suspension AER 48

Air suspension WP Performance Systems AER 48 is used in the fork.
In this system, suspension is located in the left fork leg and damping 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 signifi-
cantly improved.
In normal driving mode, suspension is provided exclusively by an air cushion. A steel
spring is located in the left fork leg as an end stop.

Info
If the fork is frequently overloaded, then the air pressure in the fork must be
increased to avoid damage to the fork and frame.

The air pressure in the fork can be quickly adjusted for the rider's weight, surface
conditions and the rider's preference using a fork pump. The fork does not have to
be detached. The time consuming mounting of harder or softer fork springs is not
required.
If the air chamber loses air due to a damaged seal, the fork will still not sag. In this
case the air is retained in the fork. The suspension travel is maintained as far as possi-
ble. The damping becomes harder and the riding comfort reduces.
As with a conventional fork, the damping can be adjusted in rebound and compression
M01110-01 stages.
The rebound adjuster is located at the lower end of the right fork leg.
The compression adjuster is located at the upper end of the right fork leg.

10.3 Compression damping of the shock absorber

The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.
High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.
The high-speed setting, for example, has an effect on the landing after a jump: the rear wheel suspension compresses quickly.
The low-speed setting, for example, has an effect when riding over long ground swells: the rear wheel suspension compresses slowly.
These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, changes in
the high-speed range affect the compression damping in the low-speed range and vice versa.
10 TUNING THE CHASSIS 30

10.4 Adjusting the low-speed compression damping of the shock absorber

Caution
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly.
The shock absorber is filled with highly compressed nitrogen.

– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)

Info
The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber.

– Turn adjusting screw 1 clockwise with a screwdriver up to the last perceptible

click.

Info
Do not loosen fitting 2!
– Turn counterclockwise by the number of clicks corresponding to the shock absorber
type.
Guideline
S01201-10 Compression damping, low-speed (SX‑F EU)
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Compression damping, low-speed (SX‑F US)
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Compression damping, low-speed (XC‑F US)
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks

Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.

10.5 Adjusting the high-speed compression damping of the shock absorber

Caution
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly.
The shock absorber is filled with highly compressed nitrogen.

– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)

Info
The effect of the high-speed setting can be seen in fast compression of the shock absorber.

– Turn adjusting screw 1 all the way clockwise with a socket wrench.
Info
Do not loosen fitting 2!
– Turn counterclockwise by the number of turns corresponding to the shock absorber
type.

S01202-10
10 TUNING THE CHASSIS 31

Guideline
Compression damping, high-speed (SX‑F EU)
Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns
Compression damping, high-speed (SX‑F US)
Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns
Compression damping, high-speed (XC‑F US)
Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns

Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.

10.6 Adjusting the rebound damping of the shock absorber

Caution
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly.
The shock absorber is filled with highly compressed nitrogen.

– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)

– Turn adjusting screw 1 clockwise up to the last perceptible click.

– Turn counterclockwise by the number of clicks corresponding to the shock absorber
type.
Guideline
Rebound damping (SX‑F EU)
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
S01203-10
Rebound damping (SX‑F US)
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Rebound damping (XC‑F US)
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks

Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
10 TUNING THE CHASSIS 32

10.7 Measuring rear wheel sag unloaded

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 38)
Main work
– Position the sag gauge in the rear axle and measure the distance to marking SAG on
the rear fender.
Sag gauge (00029090000)
Pin for sag gauge (00029990010)
– Note down the value as dimension A.

402415-10

Finishing work
– Remove the motorcycle from the lift stand. ( p. 38)

10.8 Checking the static sag of the shock absorber

– Measure distance A of rear wheel unloaded. ( p. 32)
– Hold the motorcycle upright with the aid of an assistant.
– Again measure the distance between the rear axle and marking SAG on the rear
fender using the sag gauge.
– Note down the value as dimension 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)

» If the static sag is less or more than the specified value:
– Adjust the spring preload of the shock absorber. ( p. 33)

402416-10
10 TUNING THE CHASSIS 33

10.9 Checking the riding sag of the shock absorber

– Measure distance A of rear wheel unloaded. ( p. 32)
– With another person holding the motorcycle, the rider, wearing full protective cloth-
ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up
and down a few times.
The rear wheel suspension levels out.
– Another person again measures the distance between the rear axle and
marking SAG on the rear fender using the sag gauge.
– Note down the value as dimension C.
Info
The riding sag is the difference between measurements A and C.
– Check the riding sag.
Riding sag (SX‑F EU) 105 mm (4.13 in)

Riding sag (SX‑F US) 105 mm (4.13 in)

Riding sag (XC‑F US) 105 mm (4.13 in)

» If the riding sag differs from the specified measurement:
402417-10
– Adjust the riding sag. ( p. 34)

10.10 Adjusting the spring preload of the shock absorber

Caution
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly.
The shock absorber is filled with highly compressed nitrogen.

– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)

Info
Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 38)
– Remove the shock absorber. ( p. 45)
– After removing the shock absorber, clean it thoroughly.
Main work
– Loosen screw 1.
– Turn adjusting ring 2 until the spring is no longer under tension.
Hook wrench (T106S)
– Measure the overall spring length while the spring is not under tension.
– Tighten the spring by turning adjusting ring 2 to measurement A.
Guideline
Spring preload (SX‑F EU) 8 mm (0.31 in)
Spring preload (SX‑F US) 6 mm (0.24 in)
Spring preload (XC‑F US) 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
402659-10 Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft)
Finishing work
– Install the shock absorber. ( p. 46)
10 TUNING THE CHASSIS 34

– Check the free travel of the foot brake lever. ( p. 68)

– Remove the motorcycle from the lift stand. ( p. 38)

10.11 Adjusting the riding sag

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 38)
– Remove the shock absorber. ( p. 45)
– After removing the shock absorber, clean it thoroughly.
Main work
– Choose and mount a suitable spring.
Guideline
Spring rate (SX‑F EU)
Weight of rider: 65… 75 kg (143… 39 N/mm (223 lb/in)
165 lb.)
Weight of rider: 75… 85 kg (165… 42 N/mm (240 lb/in)
187 lb.)
B00292-10 Weight of rider: 85… 95 kg (187… 45 N/mm (257 lb/in)
209 lb.)
Spring rate (SX‑F US)
Weight of rider: 65… 75 kg (143… 39 N/mm (223 lb/in)
165 lb.)
Weight of rider: 75… 85 kg (165… 42 N/mm (240 lb/in)
187 lb.)
Weight of rider: 85… 95 kg (187… 45 N/mm (257 lb/in)
209 lb.)
Spring rate (XC‑F US)
Weight of rider: 65… 75 kg (143… 39 N/mm (223 lb/in)
165 lb.)
Weight of rider: 75… 85 kg (165… 42 N/mm (240 lb/in)
187 lb.)
Weight of rider: 85… 95 kg (187… 45 N/mm (257 lb/in)
209 lb.)

Info
The spring rate is shown on the outside of the spring.

Finishing work
– Install the shock absorber. ( p. 46)
– Check the free travel of the foot brake lever. ( p. 68)
– Check the static sag of the shock absorber. ( p. 32)
– Check the riding sag of the shock absorber. ( p. 33)
– Adjust the rebound damping of the shock absorber. ( p. 31)
– Remove the motorcycle from the lift stand. ( p. 38)

10.12 Checking the basic setting of the fork

Info
For various reasons, no exact riding sag can be determined for the fork.

– Smaller differences in the rider's weight can be compensated for by the fork air
pressure.
– However, if the fork frequently bottoms out (hard end stop on compression), the
fork air pressure 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 operation, the fork legs
need to be bled.

401000-01
10 TUNING THE CHASSIS 35

10.13 Adjusting the fork air pressure

Warning
Danger of accident Modifications to the suspension setting may seriously alter the handling characteristic.
Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic 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 suspension is located in the left fork leg. The pressure and rebound damping is located in the right fork leg.

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 38)
Main work
– Remove protection cap 1.
– Push fork pump 2 together fully.
Fork pump (79412966000)

Info
The fork pump is included as part of the motorcycle's separate enclosure.

S01204-10 – Connect the fork pump to the left fork leg.

The fork pump indicator switches on automatically.
A little air escapes from the fork leg when connecting.

Info
This is due to the volume of the hose and not due to a defect in the fork
pump or the fork.
Read the accompanying KTM PowerParts instructions.

– Adjust the air pressure as specified.

Guideline
Air pressure (SX‑F EU) 10.6 bar (154 psi)
Air pressure (SX‑F US) 10.6 bar (154 psi)
Air pressure (XC‑F US) 9.8 bar (142 psi)
Gradual changing of the air pressure in 0.2 bar (3 psi)
steps of
Minimum air pressure 7 bar (102 psi)
Maximum air pressure 15 bar (218 psi)

Info
Never set the air pressure to a value outside the stated range.

– Disconnect the fork pump 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 pump indicator switches off automatically after 80 seconds.
– Mount the protection cap.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 38)
10 TUNING THE CHASSIS 36

10.14 Adjusting the compression damping of the fork

Info
The hydraulic compression damping determines the fork suspension behavior.

– Turn adjusting screw 1 clockwise all the way.

Info
Adjusting screw 1 is located at the upper end of the right fork leg.
– Turn counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping (SX‑F EU)
Comfort 15 clicks
S01205-10
Standard 12 clicks
Sport 9 clicks
Compression damping (SX‑F US)
Comfort 20 clicks
Standard 17 clicks
Sport 12 clicks
Compression damping (XC‑F US)
Comfort 15 clicks
Standard 12 clicks
Sport 10 clicks

Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.

10.15 Adjusting the rebound damping of the fork

Info
The hydraulic rebound damping determines the fork suspension behavior.

– Remove protection cap 1.

– Turn adjusting screw 2 clockwise all the way.
Info
Adjusting screw 2 is located at the lower end of the right fork leg.
– Turn counterclockwise by the number of clicks corresponding to the fork type.
Guideline

M01100-10
Rebound damping (SX‑F EU)
Comfort 20 clicks
Standard 17 clicks
Sport 14 clicks
Rebound damping (SX‑F US)
Comfort 20 clicks
Standard 17 clicks
Sport 12 clicks
Rebound damping (XC‑F US)
Comfort 15 clicks
Standard 12 clicks
Sport 10 clicks
10 TUNING THE CHASSIS 37

Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.

– Mount protection cap 1.

10.16 Handlebar position
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 mounted in 2 different positions. In this way, the handlebar can
be mounted in the most comfortable position for the rider.

H01188-10

10.17 Adjusting the handlebar position

Preparatory work
– Remove the handlebar cushion.
Main work
– Remove screws 1. Remove the handlebar clamp. Remove the handlebar and lay it
to one side.

Info
Cover the components to protect them against damage.
Do not kink the cables and lines.

– Remove screws 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, handlebar support M10 40 Nm Loctite® 243™
(29.5 lbf ft)
H01189-10
– Position the handlebar.

Info
Make sure the cables and wiring are positioned correctly.

– Position the handlebar clamp.

– 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 1 evenly.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
Finishing work
– Mount the handlebar cushion.
11 SERVICE WORK ON THE CHASSIS 38

11.1 Raising the motorcycle with a lift stand

Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.

– Raise 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.

401942-01

11.2 Removing the motorcycle from the lift stand

Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.

(All SX‑F models)

– Remove the motorcycle from the lift stand.
– Remove the lift stand.
– To park the motorcycle, insert plug-in stand 1 into the left side of the wheel
spindle.

Info
1
0 Remove the plug-in stand before starting on a trip.

402001-10

(XC‑F US)
– Remove the motorcycle from the lift stand.
– Remove the lift stand.
– To park the motorcycle, press side stand 1 to the ground with your foot and
lean the motorcycle on it.

Info
When you are riding, the side stand must be folded up and secured with
the rubber band.
401943-10

11.3 Bleeding the fork legs

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 38)
Main work
– Release bleeder screws 1.
Any excess pressure escapes from the interior of the fork.
– Tighten the bleeder screws.

H01182-12

Finishing work
– Remove the motorcycle from the lift stand. ( p. 38)
11 SERVICE WORK ON THE CHASSIS 39

11.4 Cleaning the dust boots of the fork legs

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 38)
– Remove the fork protector. ( p. 39)
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 accumulate behind the dust boots. If this dirt is
not removed, the oil seals behind can start to leak.

Warning
S01207-10 Danger of accidents Oil or grease on the brake discs reduces the braking
effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.

– Clean and oil the dust boots and inner fork tubes of both fork legs.
Universal oil spray ( p. 110)
– Press the dust boots back into their installation position.
– Remove excess oil.
Finishing work
– Install the fork protector. ( p. 39)
– Remove the motorcycle from the lift stand. ( p. 38)

11.5 Removing the fork protector

– Remove screws 1 and take off the clamp.
– Remove screws 2 and take off the left fork protector.
– Remove screws 3 and take off the right fork protector.

S01208-10

11.6 Installing the fork protector

– Position the fork protector 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.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
S01208-11
11 SERVICE WORK ON THE CHASSIS 40

11.7 Removing the fork legs

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 38)
– Remove the front wheel. ( p. 73)
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 tension-free to the side.

Info
Do not pull the hand brake lever when the front wheel is removed.

S01209-10

– Loosen screws 3. Take out the left fork leg.

– Unscrew screws 4. Take out the right fork leg.

S01210-10

11.8 Installing the fork legs

Main work
– Position the fork legs.
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 sec-
ond milled groove (from the top) must be flush with the top edge of the
upper triple clamp.
H01182-10
The air suspension is located in the left fork leg. The pressure and rebound
damping is located in the right fork leg.

– Tighten screws 2.
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
– Tighten screws 3.
Guideline
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
S01210-11

– Position the brake caliper. Mount and tighten screws 4.

Guideline
Screw, front brake caliper M8 25 Nm Loctite® 243™
(18.4 lbf ft)
– Position the brake line and clamp. Mount and tighten screws 5.

S01209-11

Finishing work
– Install the front wheel. ( p. 73)
11 SERVICE WORK ON THE CHASSIS 41

11.9 Removing the lower triple clamp

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 38)
– Remove the front wheel. ( p. 73)
– Remove the fork legs. ( p. 40)
– Remove the start number plate. ( p. 44)
– Remove the front fender. ( p. 45)
– Remove the handlebar cushion.
Main work
– Remove the holder with FI warning lamp.
– Open cable holder 1 on the left and detach the wiring harness.
– Remove screw 2.
– Remove screw 3.
– Remove the upper triple clamp with the handlebar and set aside.

Info
S01211-10 Cover the components to protect them against damage.
Do not kink the cables and lines.

– Remove O-ring 4. Remove protective ring 5.

– Remove the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.

S01212-10

11.10 Installing the lower triple clamp

Main work
– Clean the bearing and sealing elements, check for damage, and grease.
High viscosity grease ( p. 110)
– Insert the lower triple clamp with the steering stem. Mount the upper steering head
bearing.
– Check whether upper steering head seal1 is correctly positioned.
– Slide on protective ring 2 and O-ring 3.

102146-10
11 SERVICE WORK ON THE CHASSIS 42

– Position the upper triple clamp with the handlebar.

– Mount screw 4 but do not tighten yet.

S01213-10

– Position the fork legs.

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 sec-
ond milled groove (from the top) must be flush with the top edge of the
upper triple clamp.
The air suspension is located in the left fork leg. The pressure and rebound
H01182-11 damping is located in the right fork leg.

– Tighten screws 6.
Guideline
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)

S01214-10

– Tighten screw 4.
Guideline
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft)

S01215-10

– Mount and tighten screw 7.

Guideline
Screw, top steering stem M8 20 Nm Loctite® 243™
(14.8 lbf ft)

S01216-10

– Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.
– Tighten screws 8.
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
– Secure the wiring harness with cable holder 9 on the left.
– Mount the holder with FI warning lamp.
S01214-11 Guideline
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft)
11 SERVICE WORK ON THE CHASSIS 43

– Position the brake caliper. Mount and tighten screws bk.

Guideline
Screw, front brake caliper M8 25 Nm Loctite® 243™
(18.4 lbf ft)
– Position the brake line and clamp. Mount and tighten screws bl.

S01209-12

Finishing work
– Install the front fender. ( p. 45)
– Mount the handlebar cushion.
– Install the start number plate. ( p. 44)
– Install the front wheel. ( p. 73)
– Check that the wiring harness, throttle cables, and brake and clutch lines can move
freely and are routed correctly.
– Check the steering head bearing play. ( p. 43)
– Remove the motorcycle from the lift stand. ( p. 38)

11.11 Checking the steering head bearing play

Warning
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components.
– Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.)

Info
If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam-
aged over time.

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 38)
Main work
– Move the handlebar to the straight-ahead position. Move the fork legs to and fro in
the direction of travel.
No play should be noticeable in the steering head bearing.
» If there is noticeable play present:
– Adjust the steering head bearing play. ( p. 43)
– Move the handlebar to and fro over the entire steering range.

H01167-01 The handlebar must be able to move easily over the entire steering range. No
resting locations should be noticeable.
» If click positions are noticeable:
– Adjust the steering head bearing play. ( p. 43)
– Check the steering head bearing and change if necessary.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 38)

11.12 Adjusting the steering head bearing play

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 38)
– Remove the handlebar cushion.
11 SERVICE WORK ON THE CHASSIS 44

Main work
– Loosen screws 1.
– Remove screw 2.
– Loosen and retighten screw 3.
Guideline
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft)
– Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.
S01217-10 – Tighten screws 1.
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
– Mount and tighten screw 2.
Guideline
Screw, top steering stem M8 20 Nm Loctite® 243™
(14.8 lbf ft)
Finishing work
– Check the steering head bearing play. ( p. 43)
– Remove the motorcycle from the lift stand. ( p. 38)
– Mount the handlebar cushion.

11.13 Greasing the steering head bearing

– Remove the lower triple clamp. ( p. 41)
– Install the lower triple clamp. ( p. 41)

800010-10

11.14 Removing the start number plate

– Remove screw 1.
– Unhook the start number plate from the brake line and remove it.

S01234-10

11.15 Installing the start number plate

– Position the brake line in holdersA on the start number plate.
– Position the start number plate. Mount and tighten screw 1.
The holding lugs engage in the fender.

S01235-10
11 SERVICE WORK ON THE CHASSIS 45

11.16 Removing the front fender

Preparatory work
– Remove the start number plate. ( p. 44)
Main work
– Remove screws 1 and 2. Remove the front fender.

S01218-10

11.17 Installing the front fender

Main work
– Position the front fender. Mount and tighten screws 1 and 2.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

S01218-10

Finishing work
– Install the start number plate. ( p. 44)

11.18 Removing the shock absorber

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 38)
Main work
– Remove the cable ties.
– Remove screws 1 with the washers.
– Remove screws 2.
– Remove the frame protectors on the left and right.

S01219-10
11 SERVICE WORK ON THE CHASSIS 46

– Remove screw 3.
– Remove fitting 4.

Info
Raise the wheel slightly to be able to remove the screws more easily.

S01220-10

– Remove screws 5.
– Pull off foot brake cylinder from the push rod.

S01221-10

– Remove the connecting link of the chain.

– Take off the chain.

S01222-10

– Remove nut 6 and pull out the swingarm pivot.

– Push the swingarm back and secure it against falling over.

S01223-10

– Remove screw 7.
– Remove the shock absorber carefully at the bottom.

S01258-10

11.19 Installing the shock absorber

Main work
– Carefully position the shock absorber into the vehicle from the bottom.
– Mount and tighten screw 1.
Guideline
Screw, top shock absorber M10 60 Nm Loctite® 2701™
(44.3 lbf ft)

S01226-10
11 SERVICE WORK ON THE CHASSIS 47

– Position the swingarm and mount the swingarm pivot.

Info
Pay attention to flat area A.
– Mount and tighten nut 2.
Guideline
Nut, swingarm pivot M16x1.5 100 Nm
(73.8 lbf ft)
S01227-10

– Mount the chain.

– Connect the chain with connecting link 3.
Guideline
The closed side of the chain joint lock must face in the direction of travel.

S01222-11

– 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

S01228-10
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

– Position the angle lever and linkage lever.

– Mount and tighten fitting 6.
Guideline
Nut, linkage lever to angle lever M14x1.5 80 Nm (59 lbf ft)

Info
Pay attention to flat area B.
S01229-10 – Mount and tighten screw 7.
Guideline
Screw, bottom shock M10 60 Nm Loctite® 2701™
absorber (44.3 lbf ft)

Info
Raise the wheel slightly to be able to mount the screw more easily.

– Position the frame protectors on the left and right.

– Mount and tighten screws 8 with the washers.
Guideline
Screw, frame protector M5 3 Nm (2.2 lbf ft)
– Mount and tighten screws 9.
Guideline
Screw, frame protector M5 3 Nm (2.2 lbf ft)
S01219-11
– Mount the new cable ties.
Finishing work
– Check the free travel of the foot brake lever. ( p. 68)
– Remove the motorcycle from the lift stand. ( p. 38)
11 SERVICE WORK ON THE CHASSIS 48

11.20 Removing the seat

– Remove screws 1.

S01230-10

– Raise the rear of the seat, pull the seat back, and lift it off.

S01231-01

11.21 Mounting the seat

– Mount the front of the seat on the collar bushing of the fuel tank, lower the seat at
the rear, and push the seat forward.

S01231-11

– Mount and tighten screws 1.

Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

S01230-10

11.22 Removing the air filter box cover

(All SX‑F models)
Condition
The air filter box cover is secured.
– Remove screw 1.

S01232-10
11 SERVICE WORK ON THE CHASSIS 49

– Pull off the air filter box cover in area A sideways and remove it toward the
front.

S01233-10

(XC‑F US)
Condition
The air filter box cover is secured.
– Remove screw 1.

S01253-10

– Pull off the air filter box cover in area A sideways and remove it toward the
front.

S01254-10

11.23 Installing the air filter box cover

(All SX‑F models)
– Insert the air filter box cover in area A and clip it into area B.

S01233-11

Condition
The air filter box cover is secured.
– Mount and tighten screw 1.
Guideline
Screw, air filter box cover EJOT PT® 3 Nm
K60x20-Z (2.2 lbf ft)

S01232-10

(XC‑F US)
– Insert the air filter box cover in area A and clip it into area B.

S01254-11
11 SERVICE WORK ON THE CHASSIS 50

Condition
The air filter box cover is secured.
– Mount and tighten screw 1.
Guideline
Screw, air filter box cover EJOT PT® 3 Nm
K60x20-Z (2.2 lbf ft)

S01253-10

11.24 Removing the air filter

Note
Engine damage Unfiltered intake air has a negative effect on the service life of the engine.
Dust and dirt will enter the engine without an air filter.

– Never start to use the vehicle without an air filter.

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu-
lations.

Preparatory work
– Remove the air filter box cover. ( p. 48)
Main work
(All SX‑F models)
– Detach retaining tab 1. Remove air filter with air filter support.
– Take off air filter from air filter support.

S01236-10

(XC‑F US)
– Detach retaining tab 1. Remove air filter with air filter support.
– Take off air filter from air filter support.

S01252-10

11.25 Cleaning the air filter and air filter box

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu-
lations.

Info
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. 48)
– Remove the air filter. ( p. 50)
11 SERVICE WORK ON THE CHASSIS 51

Main work
– Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.
Air filter cleaner ( p. 110)

Info
Only press the air filter to dry it, never wring it out.

– Oil the dry air filter with a high quality filter oil.

102191-01 Oil for foam air filter ( p. 110)

– Clean the air filter box.
– Clean the intake flange and check it for damage and tightness.
Finishing work
– Install the air filter. ( p. 51)
– Install the air filter box cover. ( p. 49)

11.26 Installing the air filter

Main work
– Mount the clean air filter on the air filter support.
– Grease the air filter in area A.
Long-life grease ( p. 110)

102178-10

(All SX‑F models)

– Insert air filter and position retaining pin 1 in bushing B.
The air filter is correctly positioned.
– Insert retaining tab2.
Retaining pin 3 is secured by retaining tab 2.

Info
If the air filter is not mounted correctly, dust and dirt may enter the
S01237-10 engine and result in damage.

(XC‑F US)
– Insert air filter and position retaining pin 1 in bushing B.
The air filter is correctly positioned.
– Insert retaining tab2.
Retaining pin 3 is secured by retaining tab 2.

Info
If the air filter is not mounted correctly, dust and dirt may enter the
S01256-10 engine and result in damage.

Finishing work
– Install the air filter box cover. ( p. 49)

11.27 Securing the air filter box cover

Preparatory work
– Remove the air filter box cover. ( p. 48)
11 SERVICE WORK ON THE CHASSIS 52

Main work
– Drill a hole at the marking A.
Guideline
Diameter 6 mm (0.24 in)

S00846-10

Finishing work
– Install the air filter box cover. ( p. 49)

11.28 Sealing the air filter box

Preparatory work
– Remove the air filter box cover. ( p. 48)
Main work
– Seal the air filter box in the marked area A.

S00847-10

Finishing work
– Install the air filter box cover. ( p. 49)

11.29 Removing the main silencer

Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.

– Disconnect spring 1.
Spring hook (50305017000)
– Remove screws 2 and take off the main silencer.

S01238-10

11.30 Installing the main silencer

– Position the main silencer.
– Mount screws 1, but do not tighten yet.
– Attach spring 2.
Spring hook (50305017000)
– Tighten screws 1.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
S01238-11
11 SERVICE WORK ON THE CHASSIS 53

11.31 Changing the glass fiber yarn filling of the main silencer

Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.

Info
Over time, the fibers of the glass fiber yarn escape and the damper "burns" out.
Not only is the noise level higher, the performance characteristic changes.

Preparatory work
– Remove the main silencer. ( p. 52)
Main work
– Remove all screws on the main silencer.
– Take off silencer cap 1 and O-ring 2.
– Take off outer tube 3 and O-ring 4.
– Pull glass fiber yarn filling 5 off of inner tube 6.
– Clean the parts that need to be reinstalled and check for damage.
– 5 on inner tube 6.
Mount new glass fiber yarn filling
– 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 the main silencer M5 7 Nm (5.2 lbf ft)

311691-10

Finishing work
– Install the main silencer. ( p. 52)

11.32 Removing the fuel tank

Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.

– Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.

Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– 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.
– Keep fuels correctly in a suitable canister, and out of the reach of children.

Preparatory work
– Remove the seat. ( p. 48)
11 SERVICE WORK ON THE CHASSIS 54

Main work
(All SX‑F models)
– Unplug connector 1 of the fuel pump.
– Clean plug-in connection 2 of the fuel line thoroughly with compressed air.

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

S01239-10

– 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)
– Pull the fuel tank breather hose off the tank lid.
S01240-10

– Remove screw 4 with the rubber bushing.

S01242-10

(XC‑F US)
– Unplug connector 1 of the fuel pump.
– Clean plug-in connection 2 of the fuel line thoroughly with compressed air.

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

S01246-10

– 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)
– Pull the fuel tank breather hose off the tank lid.
S01247-10

– Remove screw 4 with the rubber bushing.

S01248-10
11 SERVICE WORK ON THE CHASSIS 55

– Remove screws 5 with the collar bushings.

S01241-10

– Pull both spoilers off the sides of the radiator bracket and lift off the fuel tank.

S01245-10

11.33 Installing the fuel tank

Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.

– Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.

Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– 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 the throttle cable routing. ( p. 60)
– Position the fuel tank and fit the two spoilers to the sides of the radiator bracket.
– Make sure that no cables or throttle cables are trapped or damaged.
– Attach the hose to the fuel tank breather on the tank lid.
– Mount and tighten screws 1 with the collar bushings.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

S01241-11
11 SERVICE WORK ON THE CHASSIS 56

(All SX‑F models)

– Mount and tighten screw 2 with the rubber bushing.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)

S01242-11

– 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 circumstances should dirt enter into the fuel line. Dirt in the
fuel line clogs the injection valve!

– Lubricate the O-ring and connect plug-in connection 4 for the fuel line.
S01239-11
Info
Route the cable and fuel line at a safe distance from the exhaust sys-
tem.

(XC‑F US)
– Mount and tighten screw 2 with the rubber bushing.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)

S01248-11

– 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 circumstances should dirt enter into the fuel line. Dirt in the
fuel line clogs the injection valve!

– Lubricate the O-ring and connect plug-in connection 4 for the fuel line.
S01246-11
Info
Route the cable and fuel line at a safe distance from the exhaust sys-
tem.

Finishing work
– Mount the seat. ( p. 48)

11.34 Checking for chain dirt accumulation

– Check the chain for coarse dirt accumulation.
» If the chain is very dirty:
– Clean the chain. ( p. 57)

400678-01
11 SERVICE WORK ON THE CHASSIS 57

11.35 Cleaning the chain

Warning
Danger of accidents Oil or grease on the tires reduces the road grip.
– Remove the lubricant 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 the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu-
lations.

Info
The service life of the chain depends largely on its maintenance.

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 38)
Main work
– Clean the chain regularly and then treat with chain spray.
Chain cleaner ( p. 110)
Off-road chain spray ( p. 110)

400725-01

Finishing work
– Remove the motorcycle from the lift stand. ( p. 38)

11.36 Checking the chain tension

Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more
quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel locks or
the engine will be damaged.

– Check the chain tension regularly.

– Set the chain tension in accordance with the specification.

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 38)
Main work
– Pull the chain at the end of the chain sliding component upwards to measure chain
tension A.

Info
The lower chain section 1 must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.

S01243-10 Chain tension 55… 58 mm (2.17… 2.28 in)

11 SERVICE WORK ON THE CHASSIS 58

» If the chain tension does not meet specifications:

– Adjust the chain tension. ( p. 58)
Finishing work
– Remove the motorcycle from the lift stand. ( p. 38)

11.37 Adjusting the chain tension

Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more
quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel locks or
the engine will be damaged.

– Check the chain tension regularly.

– Set the chain tension in accordance with the specification.

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 38)
– Check the chain tension. ( p. 57)
Main work
– Loosen nut 1.
– Loosen nuts 2.
– Adjust the chain tension by turning the 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 then correctly aligned.
– Tighten nuts 2.
– Make sure that chain adjusters 4 are fitted correctly on adjusting screws 3.
– Tighten nut 1.
Guideline
Nut, rear wheel spindle M25x1.5 80 Nm (59 lbf ft)

Info
The wide adjustment range of the chain adjusters (32 mm (1.26 in))
F00167-10
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. 38)

11.38 Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 38)
Main work
– Shift the transmission to idle.
– Check the rear sprocket and engine sprocket for wear.
» If the rear sprocket or engine sprocket is worn:
– Change the drivetrain kit.

Info
The engine sprocket, rear sprocket, and chain should always be
replaced together.
400227-01
11 SERVICE WORK ON THE CHASSIS 59

– Pull at the top part of the chain with the specified weight A.
Guideline
Weight, chain wear measurement 10… 15 kg (22… 33 lb.)

0
A – 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 at the longest 272 mm (10.71 in)

chain section
» If distance B is greater than the specified measurement:
– Change the drivetrain kit.
B
0 Info
When the chain is replaced, the rear sprocket and engine sprocket
should also be changed.
1 2 3 16 17 18 New chains wear out faster on an old, worn rear sprocket or engine
400987-10 sprocket.

– Check the chain sliding guard for wear.

» If the lower edge of the chain pins is in line with or below the chain sliding
guard:
– Change the chain sliding guard.
– Check that the chain sliding guard is firmly seated.
» If the chain sliding guard is loose:
– Tighten the screws on the chain sliding guard.
Guideline
Screw, chain sliding M6 6 Nm Loctite® 243™
guard (4.4 lbf ft)

S01249-01

– 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 the screw on the chain sliding piece.
Guideline
Screw, chain sliding piece M8 15 Nm
(11.1 lbf ft)

S01250-01
11 SERVICE WORK ON THE CHASSIS 60

– Check the chain guide with a slide gauge for dimension C.

Minimum thickness C of the chain 6 mm (0.24 in)
guide
» If the measured value is less than the specification:
– Change the chain guide.

402421-10

– Check that the chain guide is firmly seated.

» If the chain guide is loose:
– Tighten the screws on the chain guide.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)

M00049-01

Finishing work
– Remove the motorcycle from the lift stand. ( p. 38)

11.39 Checking the frame

– Check the frame for cracks and deformation.
» If the frame exhibits cracks or deformation due to a mechanical impact:
– Change the frame.

Info
Always replace a frame that has been damaged due to a mechanical
impact. Repair of the frame is not authorized by KTM.

S00867-01

11.40 Checking the swingarm

– Check the swingarm for damage, cracking, and deformation.
» If the swingarm shows signs of damage, cracking, or deformation:
– Change the swingarm.

Info
Always change a damaged swingarm. Repair of the swingarm is not
authorized by KTM.

401520-01

11.41 Checking the throttle cable routing

Preparatory work
– Remove the seat. ( p. 48)
– Remove the fuel tank. ( p. 53)
11 SERVICE WORK ON THE CHASSIS 61

Main work
– Check the throttle cable routing.
Both throttle cables must be routed, side by side, on the back of the handlebars
and above the fuel tank bracket, to the throttle valve body. Both throttle cables
must be secured behind the fuel tank contact area rubber band.
» If the throttle cable is not routed as specified:
– Correct the throttle cable routing.

S01244-10

Finishing work
– Install the fuel tank. ( p. 55)
– Mount the seat. ( p. 48)

11.42 Checking the rubber grips

– Check the rubber grips on the handlebar for damage, wear, and looseness.

Info
The rubber grips are vulcanized onto a sleeve on the left and onto the han-
dle tube of the throttle grip on the right. The left sleeve is clamped onto the
handlebar.
The rubber grip can only be replaced with the sleeve or the throttle tube.

» If a rubber grip is damaged or worn:

401197-01
– Change the rubber grip.

– Check that screw 1 is firmly seated.

Guideline
Screw, fixed grip M4 5 Nm Loctite® 243™
(3.7 lbf ft)

Diamond A must be located at the top.

F00156-10

11.43 Adjusting the basic position of the clutch lever

– Adjust the basic setting 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 lever and the handlebar.
Turn the adjusting screw clockwise to increase the distance between the
clutch lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
F00157-10
Do not make any adjustments while riding!
11 SERVICE WORK ON THE CHASSIS 62

11.44 Checking/correcting the fluid level of the hydraulic clutch

Warning
Skin 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 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.

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.

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws1.
– Remove cover 2 with membrane 3.
– Check the fluid level.
Fluid level below container rim 4 mm (0.16 in)
» If the fluid level does not meet specifications:
– Correct the fluid level of the hydraulic clutch.
F00158-10
Brake fluid DOT 4 / DOT 5.1 ( p. 108)
– Position the cover with the membrane. Mount and tighten the screws.

Info
Clean up overflowed or spilled brake fluid immediately with water.

11.45 Changing the hydraulic clutch fluid

Warning
Skin 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 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
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu-
lations.
11 SERVICE WORK ON THE CHASSIS 63

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws1.
– Remove cover 2 with membrane 3.

F00158-10

– Fill bleeding syringe 4 with the appropriate hydraulic fluid.

Bleed syringe (50329050000)
Brake fluid DOT 4 / DOT 5.1 ( p. 108)
– Mount bleeding syringe 4 on bleeder screw 5 using a fitting section of hose.
– Only loosen bleeder screw 5 on the clutch slave cylinder to the point where filling
is possible.

Info
F00151-10
Clean up overflowed or spilled brake fluid immediately with water.
Avoid contact between brake fluid and painted parts. Brake fluid attacks
paint.
Only use clean brake fluid from a sealed container.

– Now inject the liquid into the system until it emerges from drill hole 6 of the
master cylinder without bubbles.
– Now and then, extract fluid from the master cylinder reservoir to prevent overflow.
– Tighten the bleeder screw and remove the bleeding syringe with the hose.
– Correct the fluid level of the hydraulic clutch.
Guideline
Fluid level below container rim 4 mm (0.16 in)
– Position the cover with the membrane. Mount and tighten the screws.
F00166-10
12 BRAKE SYSTEM 64

12.1 Checking the free travel of the hand brake lever

Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit.

– Set the free travel on the hand brake lever in accordance with the specification.

– Push the hand brake lever forward and check free travel A.
Free travel of hand brake lever ≥ 3 mm (≥ 0.12 in)
» If the free travel does not meet specifications:
– Adjust the basic position of the hand brake lever. ( p. 64)

F00153-11

12.2 Adjusting the basic position of the hand brake lever

Preparatory work
– Check the free travel of the hand brake lever. ( p. 64)
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 handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the hand brake lever and the handlebar.
The range of adjustment is limited.
F00153-10
Only turn the adjusting screw by hand, and do not use force.
Do not make any adjustments while riding.

12.3 Checking the brake discs

Warning
Danger of accidents Worn-out brake discs reduce the braking effect.
– Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.)

– Check the thickness of the front and rear brake discs at multiple points on each
brake disc to ensure it is at least thickness .A
Info
A Wear reduces the thickness of the brake disc around the area used by the
brake linings.

Brake discs - wear limit

Front 2.5 mm (0.098 in)
402404-10 Rear 3.5 mm (0.138 in)
» If the brake disc thickness is less than the specified value:
– Change the front brake discs.
– Change the rear brake disc.
– Check the front and rear brake discs for damage, cracking, and deformation.
» If the brake disc exhibits damage, cracking, or deformation:
– Change the front brake discs.
– Change the rear brake disc.
12 BRAKE SYSTEM 65

12.4 Checking the front 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 lin-
ings are worn down.

– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be
glad to help.)

Warning
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 autho-
rized KTM workshop will be glad to help.)

Preparatory work
– Check the front brake linings. ( p. 66)
Main work
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Check the brake fluid level in level viewer 1.
» If the brake fluid has dropped below marking A:
– Add front brake fluid. ( p. 65)

F00150-10

12.5 Adding front brake fluid

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 lin-
ings are worn down.

– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be
glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable 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.
– 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 autho-
rized KTM workshop will be glad to help.)

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu-
lations.
12 BRAKE SYSTEM 66

Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.

Preparatory work
– Check the front brake linings. ( p. 66)
Main work
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws1.
– Remove cover 2 with membrane 3.

F00149-10

– Add brake fluid to level A.

Guideline
Level A (brake fluid level below reser- 5 mm (0.2 in)
voir rim)

Brake fluid DOT 4 / DOT 5.1 ( p. 108)

400379-12

– Position cover 2 with membrane 3. Mount and tighten screws 1.

Info
Clean up overflowed or spilled brake fluid immediately with water.

F00149-10

12.6 Checking the front brake linings

Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.)

– 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. 67)
– Check the brake linings for damage and cracking.
» If damage or cracking is visible:
– Change the front brake linings. ( p. 67)
H01333-10
12 BRAKE SYSTEM 67

12.7 Changing the front brake linings

Warning
Danger of accidents Incorrect maintenance will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable 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.
– 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 autho-
rized KTM workshop will be glad to help.)

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu-
lations.

Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake 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.

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws1.
– Remove cover 2 with membrane 3.

F00149-10

– Manually press the brake caliper toward the brake disc to push back the brake pis-
tons. Ensure that brake fluid does not flow out of the brake fluid reservoir, if neces-
sary extract excess.

Info
Make sure that you do not press the brake caliper against the spokes when
pushing back the brake pistons.

– Remove cotter pins 4, pull out pin 5, and remove the brake linings.
F00142-11 – Clean the brake caliper and brake caliper support.
12 BRAKE SYSTEM 68

– Check that leaf spring 6

in the brake caliper and sliding plate 7 in the brake
caliper support are seated correctly.

100397-01

– Insert the new brake linings, 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 linings are in contact with
the brake disc and there is a pressure point.

F00154-10

– Add brake fluid up to level A.

Guideline
Level A (brake fluid level below reser- 5 mm (0.2 in)
voir rim)

Brake fluid DOT 4 / DOT 5.1 ( p. 108)

– 2 with membrane 3.
Position cover
– Mount and tighten screws 1.

Info
Clean up overflowed or spilled brake fluid immediately with water.

F00148-10

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.

– 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. ( p. 69)
– Reconnect spring 1.
402026-10
12 BRAKE SYSTEM 69

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.

– Detach spring 1.
– Loosen nut 4 and, with push rod 5, turn it back until you have maximum free
travel.
– To adjust the basic position of the foot brake lever to individual requirements,
loosen nut 2and turn screw 3
accordingly.

Info
The range of adjustment is limited.

– Turn push rod 5

accordingly until you have free travel A. 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 5 and tighten nut 4.
Guideline
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft)
– Hold screw 3 and tighten nut 2.
F00147-10 Guideline
Nut, foot brake lever stop M8 20 Nm
(14.8 lbf ft)
– Attach spring 1.
12.10 Checking the rear brake fluid level

Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin-
ings are worn down.

– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be
glad to help.)

Warning
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 autho-
rized KTM workshop will be glad to help.)

Preparatory work
– Check the rear brake linings. ( p. 70)
Main work
– Stand the vehicle upright.
– Check the brake fluid level in level viewer 1.
» If the brake fluid has dropped below marking A:
– Add rear brake fluid. ( p. 70)

F00146-10
12 BRAKE SYSTEM 70

12.11 Adding rear brake fluid

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 lin-
ings are worn down.

– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be
glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable 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.
– 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 autho-
rized KTM workshop will be glad to help.)

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu-
lations.

Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake 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.

Preparatory work
– Check the rear brake linings. ( p. 70)
Main work
– Stand the vehicle upright.
– Remove screw cap 1 with membrane 2 and the O-ring.
– Add brake fluid to level A.
Brake fluid DOT 4 / DOT 5.1 ( p. 108)
– Mount and tighten the screw cap with the membrane and O-ring.

Info
F00144-10
Clean up overflowed or spilled brake fluid immediately with water.

12.12 Checking the rear brake linings

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.)
12 BRAKE SYSTEM 71

– 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. 71)
– Check the brake linings for damage and cracking.
» If damage or cracking is visible:
– Change the rear brake linings. ( p. 71)
M01180-10

12.13 Changing the rear brake linings

Warning
Danger of accidents Incorrect maintenance will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable 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.
– 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 autho-
rized KTM workshop will be glad to help.)

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu-
lations.

Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake 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.

– Stand the vehicle upright.

– Remove screw cap 1 with membrane 2 and the O-ring.

F00145-10
12 BRAKE SYSTEM 72

– Manually press the brake caliper to the brake disc to push back the brake piston.
Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it
by suction if it does.

Info
Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.

– Remove cotter pins 3, pull out pin 4, and remove the brake linings.
F00155-10 – Clean the brake caliper and brake caliper support.

– Check that leaf spring 5 in the brake caliper and sliding plate 6 in the brake
caliper support are seated correctly.

Info
The arrow on the leaf spring points in the rotation direction of the brake
disc.

S01251-10

– Insert the new brake linings, insert pin 4, and mount cotter pins 3.
Info
Always change the brake linings in pairs.
Make sure that decoupling plate 7
is mounted on the piston side brake
lining.

– Operate the foot brake lever repeatedly until the brake linings are in contact with
the brake disc and there is a pressure point.
M01181-10

– Add brake fluid to level A.

Brake fluid DOT 4 / DOT 5.1 ( p. 108)
– Mount and tighten screw cap 1 with membrane 2 and the O-ring.
Info
Clean up overflowed or spilled brake fluid immediately with water.

F00144-10
13 WHEELS, TIRES 73

13.1 Removing the front wheel

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 38)
Main work
– Press the brake caliper onto the brake disc by hand in order to push back the brake
pistons.

Info
Make sure that you do not press the brake caliper against the spokes when
pushing back the brake pistons.

F00142-10

– 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.

F00141-10

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 dam-
aged.

– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.

Info
F00140-10
Do not pull the hand brake lever when the front wheel is removed.

– Remove spacers 3.

H00934-10

13.2 Installing the front wheel

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.

– Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:
– Change the front wheel bearing.
– Clean and grease shaft seal rings 1 and contact surface A of the spacers.
Long-life grease ( p. 110)
– Insert the spacers.

H00935-10
13 WHEELS, TIRES 74

– Position the front wheel and insert the wheel spindle.

The brake linings are correctly positioned.
– 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 brake linings are seated cor-
rectly against the brake disc.
– Remove the motorcycle from the lift stand. ( p. 38)
– Operate the front brake and compress the fork a few times firmly.
F00141-11
The fork legs straighten.
– 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. 38)
Main work
– Press the brake caliper onto the brake disc by hand in order to push back the brake
piston.

Info
Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.

– Remove nut 1.
– Remove chain adjuster 2 . Withdraw wheel spindle 3 only enough to allow the
rear wheel to be pushed forward.
– Push the rear wheel forward as far as possible. Remove the chain from the rear
sprocket.

Info
Cover the components to protect them against damage.

Warning
Danger of accidents Damaged brake discs reduce the braking effect.
F00143-10 – Always lay the wheel down in such a way that the brake disc is not dam-
aged.

– Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of the
swingarm.

Info
Do not operate the foot brake lever when the rear wheel is removed.

– Remove spacers 4.

H00936-10
13 WHEELS, TIRES 75

13.4 Installing the rear wheel

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.

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 surface A of the spacers.
Long-life grease ( p. 110)
– Insert the spacers.
H00937-10

– Position the rear wheel and insert wheel spindle 2.

The brake linings are correctly positioned.
– Mount the chain.

F00139-10

– Position chain adjuster3. 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. 57)
– Tighten nut 4.
Guideline
Nut, rear wheel spindle M25x1.5 80 Nm (59 lbf ft)

Info
The wide adjustment range of the chain adjusters (32 mm (1.26 in))
enables different secondary ratios with the same chain length.
Chain adjusters 3 can be turned by 180°.

– Operate the foot brake lever repeatedly until the brake linings are in contact with
the brake disc and there is a pressure point.

F00137-10

Finishing work
– Remove the motorcycle from the lift stand. ( p. 38)
13 WHEELS, TIRES 76

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 air pressure of the tires all have a major impact on the handling of the motorcycle.
The tires mounted on the front and rear wheels must have a similar profile.
Worn tires have a negative effect on handling characteristics, especially on wet surfaces.

– Check the front and rear tires for cuts, run-in objects, and other damage.
» If the tires have cuts, run-in objects, or other damage:
– Change the tires.
– Check the tread depth.

Info
Adhere to the legally required minimum tread depth.

Minimum tread depth ≥ 2 mm (≥ 0.08 in)

400602-10
» If the tread depth is less than the minimum tread depth:
– Change the tires.
– 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 indi-
cate the week of manufacture and the last two digits the year of manufac-
ture.
KTM recommends that the tires be changed after 5 years at the latest,
regardless of the actual state of wear.
H01144-01 » If the tires are more than 5 years old:
– Change the tires.

13.6 Checking the tire air pressure

Info
Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.

– Remove the protection cap.

– Check the tire air pressure when the tires are cold.
Tire air pressure, offroad
Front 1.0 bar (15 psi)
Rear 1.0 bar (15 psi)
» If the tire pressure does not meet specifications:
– Correct the tire pressure.
400695-01 – Mount the protection cap.

13.7 Checking spoke tension

Warning
Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage.
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes 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.)
13 WHEELS, TIRES 77

– Strike each spoke briefly using a screwdriver blade.

Info
The frequency of the sound depends on the spoke length and spoke diame-
ter.
If you hear different tone frequencies from different spokes of equal length
and diameter, this is an indication of different spoke tensions.

You should hear a high note.

400694-01 » If the spoke tension differs:
– Correct the spoke tension.
– Check the spoke torque.
Guideline
Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft)
Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft)

Torque wrench with various accessories in set (58429094000)

14 ELECTRICAL SYSTEM 78

14.1 Removing the battery

Warning
Risk of injury Batteries contain harmful substances.
– Keep batteries out of the reach of children.
– Keep sparks and open flames away from the batteries.
– Only charge batteries in well-ventilated rooms.
– Maintain a minimum clearance from inflammable materials when charging batteries.
Minimum clearance 1 m (3 ft)
– Do not charge deeply discharged batteries if charge is already below the minimum voltage.
Minimum voltage before the start of the charge 9V
– Dispose of batteries with less than the minimum voltage correctly.

Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 48)
Main work
– Disconnect negative cable 1 from the battery.
– Pull back positive terminal cover 2 and disconnect the positive cable from the
battery.
– Remove screw 3.
– Pull holding bracket 4 forward and remove battery toward the top.

F00138-10

14.2 Installing the battery

Main work
– Insert the battery into the battery compartment with the terminals facing forward
and secure with holding bracket . 1
(All SX‑F models)
Battery (C22S) ( p. 103)
(XC‑F US)
Battery (HJTZ5S-FP) ( p. 103)
– Mount and tighten screw 2.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
– Connect positive cable 3 to the battery.
Guideline
Screw, battery terminal M5 2.5 Nm
(1.84 lbf ft)
– Connect negative cable 4 to the battery.
Guideline
H00386-10
Screw, battery terminal M5 2.5 Nm
(1.84 lbf ft)

Contact disks A must be mounted under screws 5 and cable sockets 6 with
the claws toward the battery terminal.
– Slide positive terminal cover 7 over the positive terminal.
Finishing work
– Mount the seat. ( p. 48)
14 ELECTRICAL SYSTEM 79

14.3 Recharging the battery

Warning
Risk of injury Batteries contain harmful substances.
– Keep batteries out of the reach of children.
– Keep sparks and open flames away from the batteries.
– Only charge batteries in well-ventilated rooms.
– Maintain a minimum clearance from inflammable materials when charging batteries.
Minimum clearance 1 m (3 ft)
– Do not charge deeply discharged batteries if charge is already below the minimum voltage.
Minimum voltage before the start of the charge 9V
– Dispose of batteries with less than the minimum voltage correctly.
Warning
Environmental hazard The battery contains elements that are harmful to the environment.
– Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner.
Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries.

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu-
lations.

Info
Even when there is no load on the battery, it discharges steadily.
The charging level and the method of charging are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, or charging time are exceeded, the battery will be destroyed.
If the battery is depleted by repeated starting, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfated, destroying the
battery.
The battery is maintenance-free.

Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 48)
– Remove the battery. ( p. 78)
Main work
(All SX‑F models)
– Check the battery voltage.
» Battery voltage: < 9 V
– Do not charge the battery.
– Replace the battery and dispose of the old battery properly.
» If the specifications have been met:
Battery voltage: ≥ 9 V
102223-10 – Recharge the battery.
Guideline
The charging current, charging voltage, and charging time must not
be exceeded.
Maximum charging voltage 14.4 V
Maximum charging current 3.0 A
Charge the battery regularly when 6 months
the motorcycle is not in use

Info
Never remove cover 1.
14 ELECTRICAL SYSTEM 80

– Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test the open-circuit voltage and start
potential of the battery, and to test the alternator. With this device, you cannot
overcharge the battery. The charging time may be longer at low temperatures.
– Switch off the battery charger after charging and disconnect from the battery.
(XC‑F US)
– Check the battery voltage.
» Battery voltage: < 9 V
– Do not charge the battery.
– Replace the battery and dispose of the old battery properly.
» If the specifications have been met:
Battery voltage: ≥ 9 V
– Recharge the battery.
S00863-10 Guideline
The charging current, charging voltage, and charging time must not
be exceeded.
Maximum charging voltage 14.4 V
Maximum charging current 3.0 A
Charge the battery regularly when 6 months
the motorcycle is not in use

Info
Never remove cover 1.
– Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test the open-circuit voltage and start
potential of the battery, and to test the alternator. With this device, you cannot
overcharge the battery. The charging time may be longer at low temperatures.
– Switch off the battery charger after charging and disconnect from the battery.
Finishing work
– Install the battery. ( p. 78)
– Mount the seat. ( p. 48)

14.4 Changing the main fuse

Warning
Fire hazard Incorrect fuses overload the electrical system.
– Only use fuses with the required ampere value.
– Do not bypass or repair fuses.

Info
The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the seat.

Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 48)
Main work
(All SX‑F models)
– Pull starter relay 1 from the holder.

F00136-10
14 ELECTRICAL SYSTEM 81

– 2.
Take off protection caps
– Remove faulty main fuse 3.

Info
You can recognize a defective fuse by a burned-out fuse wire A.
A spare fuse 4
is located in the starter relay.

– Install a new main fuse.

Fuse (58011109110) ( p. 103)
– Check that the electrical equipment 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.

F00135-10

(XC‑F US)
– Pull starter relay 1 from the holder.

F00161-10

– Take off protection caps 2.

– Remove faulty main fuse 3.
Info
You can recognize a defective fuse by a burned-out fuse wire A.
A spare fuse 4
is located in the starter relay.

– Install a new main fuse.

Fuse (58011109110) ( p. 103)
– Check that the electrical equipment 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.

F00162-10

Finishing work
– Mount the seat. ( p. 48)
15 COOLING SYSTEM 82

15.1 Cooling system

Water pump 1
in the engine circulates the coolant.
The pressure resulting from the warming of the cooling system is regulated by a valve
in radiator cap 2. This ensures that operating the vehicle at the specified coolant
temperature will not result in a risk of malfunctions.
120 °C (248 °F)
Cooling is effected by the air stream.
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cool-
ing effect.
F00133-11

15.2 Checking the antifreeze and coolant level

Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at
operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components
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 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.
– Stand the motorcycle upright on a horizontal surface.
– Remove the radiator cap.
– Check the antifreeze in the coolant.
−25… −45 °C (−13… −49 °F)
» If the antifreeze in the coolant does not match the specified value:
– Correct the antifreeze in the coolant.
– Check the coolant level in the radiator.
400243-10 10 mm (0.39 in)
Coolant level A above the radiator
fins
» If the coolant level does not match the specified value:
– Correct the coolant level.
Coolant ( p. 108)
– Mount the radiator cap.
15 COOLING SYSTEM 83

15.3 Checking the coolant level

Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at
operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components
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 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.
– 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 10 mm (0.39 in)

fins
» If the coolant level does not match the specified value:
– Correct the coolant level.
400243-10 Coolant ( p. 108)
– Mount the radiator cap.

15.4 Draining the coolant

Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at
operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components
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 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.
15 COOLING SYSTEM 84

– Position the motorcycle upright.

– Place a suitable container under the water pump cover.
– Remove screw 1. Take off radiator cap 2.
– 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)
F00133-10

15.5 Refilling 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.
– 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.

– Make sure that screw 1 is tightened.

– Position the motorcycle upright.
– Pour coolant in up to measurement A above the radiator fins.
Guideline
Dimension A over the radiator fins 10 mm (0.39 in)

Coolant 0.95 l (1 qt.) Coolant ( p. 108)

– Mount the radiator cap.
F00134-10
– Take a short test ride.
– Check the coolant level. ( p. 83)
16 TUNING THE ENGINE 85

16.1 Checking the play in the throttle cable

– Check the throttle grip for smooth operation.
– Move the handlebar to the straight-ahead position. Turn the throttle grip back and
forth slightly and determine the play in throttle cable . A
Throttle cable play 3… 5 mm (0.12… 0.2 in)
» If the throttle cable play does not meet the specified value:
– Adjust the play in the throttle cable. ( p. 85)
– Push the cold start button in all the way.
400192-11 When the throttle grip is turned forward, the cold start button returns to its origi-
nal position.
» If the cold start button does not return to its original position:
– Adjust the play in the throttle cable. ( p. 85)

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 an effective exhaust extraction system when starting or running the
engine in an enclosed space.

– Start the engine and let it run idle. Move the handlebar to and fro over the entire
steering range.
The idle speed must not change.
» If the idle speed changes:
– Adjust the play in the throttle cable. ( p. 85)

16.2 Adjusting the play in the throttle cable

Info
If the correct routing of the throttle cables has already been secured, the fuel tank does not need to be removed.

Preparatory work
– Remove the seat. ( p. 48)
– Remove the fuel tank. ( p. 53)
– Check the throttle cable routing. ( p. 60)
Main work
(All SX‑F models)
– 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 .
– 6 all the way to the stop.
Push cold start button
– Turn adjusting screw 5 so that the cold start button moves to the basic posi-
tion when the throttle grip is turned to the front.
– Tighten nut 4.
– Turn adjusting screw 3 so that there is play in the throttle cable at the throt-
tle grip.
Guideline
Throttle cable play 3… 5 mm (0.12… 0.2 in)
– Tighten nut 2.
F00164-10 – Slide on sleeve 1.
16 TUNING THE ENGINE 86

– Check the throttle grip for smooth operation.

(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 posi-
tion when the throttle grip is turned to the front.
– Tighten nut 4.
– Turn adjusting screw 3 so that there is play in the throttle cable at the throt-
tle grip.
Guideline
Throttle cable play 3… 5 mm (0.12… 0.2 in)
– Tighten nut 2.
– Slide on sleeve 1.
F00163-10 – Check the throttle grip for smooth operation.
Finishing work
– Check the play in the throttle cable. ( p. 85)

16.3 Setting the characteristic map of the throttle response

Info
On the throttle grip, the characteristic map of the throttle response is changed by changing the guide plate.
A guide plate with a different characteristic map is supplied.

Main work
– Push back sleeve 1.
– Remove screws 2 and half-shells 3.
– Detach the throttle cables and take off the grip tube.

F00130-10

– Remove guide plate 4 from handle tube 5.

– Position the required guide plate on the grip tube.
Guideline
The label OUTSIDE must be visible. Marking A must be positioned at mark-
ingB .
Alternative 1
Grey guide plate (79002014000)
Alternative 2
Black guide plate (79002014100)

Info
The gray guide plate opens the throttle valve more slowly.
The black guide plate opens the throttle valve more quickly.
The black guide plate is already mounted when the vehicle is delivered.

102246-10
16 TUNING THE ENGINE 87

– Clean the outside of the handlebar and the inside of the grip tube. Mount the grip
tube on the handlebar.
– Attach the throttle cables to the guide plate and route correctly.
– Position half-shells 3, mount and tighten screws 2.
Guideline
Screw, throttle grip M6 5 Nm (3.7 lbf ft)
– Slide on sleeve 1 and check the throttle grip for ease of movement.
F00131-10

Finishing work
– Check the play in the throttle cable. ( p. 85)

16.4 Changing the mapping

Info
The desired engine characteristic can be activated via the MAP button on the combination switch.
The setting most recently selected is activated again when restarting.
The traction control can also be activated in each mapping using the TC button.
The mapping can also be changed during the ride.

Activating STANDARD mapping:

– Press button MAP until LED 1 lights up.
Guideline
Engine speed < 4,000 rpm
STANDARD – balanced response

H01180-10

Activating ADVANCED mapping:

– Press button MAP until LED 2 lights up.
Guideline
Engine speed < 4,000 rpm
ADVANCED – direct response

H01180-11

16.5 Adjusting the idle speed

Warning
Danger of accidents The engine may go out spontaneously if the idle speed is set too low.
– Set the idle speed to the specified value. (Your authorized KTM workshop will be glad to help.)
16 TUNING THE ENGINE 88

– Run the engine until warm.

The cold start button is deactivated – The cold start button is in its basic posi-
tion. ( p. 15)

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 an effective exhaust extraction system when starting or running the
engine in an enclosed space.

– Set the idle speed by turning idle speed adjusting screw 1.

Guideline
Idle speed 2,250… 2,350 rpm

Tachometer (45129075000)

Info
S01199-10
Turning counterclockwise lowers the idle speed.
Turning clockwise raises the idle speed.

16.6 Teaching the throttle valve position

Info
If the control unit detects that the throttle valve idle position needs to be retaught, then the MIL flashes 2x per second.

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 an effective exhaust extraction system when starting or running the engine in an enclosed space.

– Allow the vehicle to idle.

The MIL stops flashing once teaching is completed.

Info
If the engine becomes too hot, perform a cool-down ride at medium revs.
Then do not switch off the engine after this, but leave it running at idle speed until teaching is completed.

16.7 Checking the basic position of the shift lever

Info
When driving, the shift lever must not touch the rider's boot when in the basic position.
When the shift lever keeps touching the boot, the transmission will be subject to an excessive load.

– Sit on the vehicle in the riding position and determine distance A between the
upper edge of your boot and the shift lever.
Distance between shift lever and upper 10… 20 mm (0.39… 0.79 in)
edge of boot
» If the distance does not meet specifications:

0 – Adjust the basic position of the shift lever. ( p. 89)

400692-10
16 TUNING THE ENGINE 89

16.8 Adjusting the basic position of the shift lever

– Remove screw 1 with washers and take off shift lever 2.

401950-12

– 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 the
gearing.

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

401951-10 – Mount and tighten screw 1 with the washers.

Guideline
Screw, shift lever M6 14 Nm Loctite® 243™
(10.3 lbf ft)
17 SERVICE WORK ON THE ENGINE 90

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 refuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– 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.

Warning
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.

(All SX‑F models)

– Clean plug-in connection 1 of the fuel line thoroughly with compressed air.
Info
Under no circumstances should dirt enter into the fuel line. Dirt in the
fuel line clogs the injection valve!

– Disconnect the plug-in connection of the fuel line.

Info
Remaining fuel may flow out of the fuel hose.

– Pull fuel screen 2 out of the connecting piece.

– Insert the new fuel screen all the way into the connecting piece.
– Lubricate the O-ring and connect plug-in connection of the fuel line.

Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may
result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the
F00128-10 engine.
– Use an effective exhaust extraction system when starting or running
the engine in an enclosed space.

– Start the engine and check the response.

17 SERVICE WORK ON THE ENGINE 91

(XC‑F US)
– Clean plug-in connection 1 of the fuel line thoroughly with compressed air.
Info
Under no circumstances should dirt enter into the fuel line. Dirt in the
fuel line clogs the injection valve!

– Disconnect the plug-in connection of the fuel line.

Info
Remaining fuel may flow out of the fuel hose.

– Pull fuel screen 2 out of the connecting piece.

– Insert the new fuel screen all the way into the connecting piece.
– Lubricate the O-ring and connect plug-in connection of the fuel line.

Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may
result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the
F00159-10 engine.
– Use an effective exhaust extraction system when starting or running
the engine in an enclosed space.

– Start the engine and check the response.

17.2 Checking the engine oil level

Info
The engine oil level can be checked when the engine is cold or warm.

Preparatory work
– Stand the motorcycle upright on a horizontal surface.
Condition
The engine is cold.
– Check the engine 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. 94)
Condition
The engine is at operating temperature.
F00127-10
– 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 viewer B .
» If the engine oil does not reach the middle of level viewer A:
– Add engine oil. ( p. 94)
17 SERVICE WORK ON THE ENGINE 92

17.3 Changing the engine oil and oil filter, cleaning the oil screen

Warning
Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden.
– Wear suitable protective clothing and safety gloves.
– In the event of scalding, rinse the area affected immediately with lukewarm water.

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu-
lations.

Info
Drain the engine oil while the engine is at operating temperature.

Preparatory work
– Park the motorcycle on a level surface.
Main work
– Place a suitable container under the engine.
– Remove oil drain plug 1 with the magnet and seal ring.
Info
Do not remove screws 2 on both sides.

F00124-10

– Remove screw plug 3 with oil screen 4 and the O-rings.

– Completely drain the engine oil.
– Thoroughly clean the parts and sealing surfaces.

F00125-10

– Position oil screen 4 with the O-rings on a pin wrench.

– Position the pin wrench through the drilled hole of the screw plug in the opposite
section of the engine case.
– Push the oil screen all the way into the engine case.

F00126-10

– Mount and tighten screw plug 3 with the O-ring.

Guideline
Screw plug, oil screen M20x1.5 15 Nm
(11.1 lbf ft)
– Mount and tighten oil drain plug 1 with the magnet and a new seal ring.
Guideline
Oil drain plug with magnet M12x1.5 20 Nm
(14.8 lbf ft)
F00123-10
17 SERVICE WORK ON THE ENGINE 93

– Remove screws 5. Remove the oil filter cover with the O-ring.

F00121-11

– Pull oil filter 6 out of the oil filter housing.

Circlip pliers reverse (51012011000)
– Completely drain the engine oil.
– Thoroughly clean the parts and sealing surfaces.

F00122-10

– Lay the motorcycle on its side and fill the oil filter housing to about ⅓ full with
engine oil.
– Fill the oil filter with engine oil and position the oil filter in the housing.
– Oil the O-ring of the oil filter cover and mount it with oil filter cover 7.
– Mount and tighten the screws.
Guideline
Screw, oil filter cover M6 10 Nm (7.4 lbf ft)
– Stand the motorcycle upright.
F00121-10

– Remove filler plug 8 with the O-ring from the clutch cover and fill up with engine
oil.
Engine oil 1.0 l (1.1 qt.) Engine oil (SAE 10W/50) ( p. 108)
Alternative engine Engine oil
oil for harsh oper- (SAE 10W/60)
ating conditions (00062010035)
and increased per- ( p. 108)
formance
401955-12
Info
Too little engine oil or poor-quality engine oil results in premature wear of
the engine.

– Install and tighten the oil filler plug with O-ring.

Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result
in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the
engine.
– Use an effective exhaust extraction system when starting or running the
engine in an enclosed space.

– Start the engine and check that it is oil-tight.

Finishing work
– Check the engine oil level. ( p. 91)
17 SERVICE WORK ON THE ENGINE 94

17.4 Adding engine oil

Info
Too little engine oil or poor-quality engine oil results in premature wear of the engine.

– Remove oil filler plug 1 with the O-ring from the clutch cover.
–
0 Add the same engine oil used when the last oil change was carried out.
Engine oil (SAE 10W/50) ( p. 108)
Alternative 1
Engine oil (SAE 10W/60) (00062010035) ( p. 108)

Info
401955-10
For optimal performance of the engine oil, do not mix different types of
engine oil.
We recommended changing the engine oil when necessary.

– Install and tighten the oil filler plug with O-ring.

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 an effective exhaust extraction system when starting or running the
engine in an enclosed space.

– Start the engine and check that it is oil-tight.

18 CLEANING, CARE 95

18.1 Cleaning the motorcycle

Note
Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly.
The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc.
Pressure which is too high causes malfunctions and destroys components.

– Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
– Maintain a minimum distance between the nozzle of the pressure cleaner and the component.
Minimum clearance 60 cm (23.6 in)

Warning
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regu-
lations.

Info
If you clean the motorcycle regularly, its value and appearance will be maintained over a long period.
Avoid direct sunshine on the motorcycle during cleaning.

– Close off the exhaust system to keep 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. 110)

Info
Use warm water containing normal motorcycle cleaner and a soft sponge.
401061-01 Never apply motorcycle cleaner to a dry vehicle; always rinse the vehicle
with water first.

– After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly.
– Remove the closure of the exhaust system.

Warning
Danger of accidents 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.

– After cleaning, ride a short distance until the engine reaches operating tempera-
ture.

Info
The heat produced causes water at inaccessible locations in the engine and
on the brake system to evaporate.

– Push back the protection caps of the handlebar controls to allow any water that has
penetrated to evaporate.
– After the motorcycle has cooled off, lubricate all moving parts and bearings.
– Clean the chain. ( p. 57)
– Treat bare metal parts (except for brake discs and the exhaust system) with a corro-
sion inhibitor.
Preserving materials for paints, metal and rubber ( p. 110)
– 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. 110)
19 STORAGE 96

19.1 Storage

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.
– Keep fuels correctly in a suitable canister, and out of the reach of children.

Info
If you plan to garage the motorcycle for a longer period, perform the following steps or have them performed.
Before storing the motorcycle, check all parts for function and wear. If service, 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.

– When refueling for the last time before taking the motorcycle out of service, add
fuel additive.
Fuel additive ( p. 110)
– Refuel. ( p. 26)
– Clean the motorcycle. ( p. 95)
– Change the engine oil and oil filter, clean the oil screen. ( p. 92)
– Check the antifreeze and coolant level. ( p. 82)
401058-01
– Check the tire air pressure. ( p. 76)
– Remove the battery. ( p. 78)
– Recharge the battery. ( p. 79)
Guideline
Storage temperature of battery without 0… 35 °C (32… 95 °F)
direct sunshine
– Store the vehicle in a dry location that is not subject to large fluctuations in tem-
perature.

Info
KTM recommends jacking up the motorcycle.

– Raise the motorcycle with a lift stand. ( p. 38)

– Cover the vehicle with a tarp or similar cover that is permeable to air.

Info
Do not use non-porous materials since they prevent humidity from escaping,
thus causing corrosion.
Avoid running the engine for a short time 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 STORAGE 97

19.2 Putting into operation after storage

– Install the battery. ( p. 78)
– Remove the motorcycle from the lift stand. ( p. 38)
– Perform checks and maintenance steps before putting into operation. ( p. 22)
– Take a test ride.

401059-01
20 TROUBLESHOOTING 98

Faults Possible cause Action

The engine does not turn when the Operating error – Carry out the start procedure. ( p. 22)
electric starter button is pressed Battery discharged – Recharge the battery. ( p. 79)
– Check the charging voltage.
– Check the open-circuit current.
– Check the stator winding of the alternator.
Main fuse blown – Change the main fuse. ( p. 80)
Faulty starter relay – Check the starter relay.
Faulty starter motor – Check the starter motor.
Engine turns but does not start The plug-in connection of the fuel – Connect the plug-in connection of the fuel line.
line is not connected
Fuel screen in the fuel hose connec- – Change the fuel screen. ( p. 90)
tion is clogged
Idle speed is not set correctly – Adjust the idle speed. ( p. 87)
Spark plug oily or wet – Clean and dry the spark plug, or change it if
necessary.
Electrode distance (plug gap) of spark – Adjust the plug gap.
plug too wide Guideline
Spark plug electrode gap
0.8 mm (0.031 in)
Short circuit cable in wiring harness – Check the wiring harness. (visual check)
frayed, kill switch defective – Check the electrical system.
Defect in fuel injection system – Read out the fault memory using the KTM diag-
nostics tool.
Engine does not speed up Defect in fuel injection system – Read out the fault memory using the KTM diag-
nostics tool.
Engine has too little power Air filter is very dirty – Clean the air filter and air filter box.
( p. 50)
Fuel filter is very dirty – Change the fuel filter.
Defect in fuel injection system – Read out the fault memory using the KTM diag-
nostics tool.
Exhaust system leaky, deformed or – Check exhaust system for damage.
too little glass fiber yarn filling in – Change the glass fiber yarn filling of the main
main silencer silencer. ( p. 53)
Valve clearance too little – Adjust the valve clearance.
Engine dies during the trip Lack of fuel – Refuel. ( p. 26)
Engine overheats Too little coolant in cooling system – Check the cooling system for leakage.
– Check the coolant level. ( p. 83)
Too little air stream – Switch off the engine when standing.
Radiator fins very dirty – Clean the radiator fins.
Foam formation in cooling system – Drain the coolant. ( p. 83)
– Refill the coolant. ( p. 84)
Bent radiator hose – Change the radiator hose.
FI warning lamp (MIL) lights Defect in fuel injection system – Stop the motorcycle and identify the faulty part
up/flashes using the blink code.
– Check the cabling for damage and the electri-
cal plug-in connections for corrosion and dam-
age.
– Read out the fault memory using the KTM diag-
nostics tool.
High oil consumption 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. 91)
Engine oil too thin (low viscosity) – Change the engine oil and oil filter, clean the
oil screen. ( p. 92)
Piston or cylinder worn – Measure the piston/cylinder mounting clear-
ance.
20 TROUBLESHOOTING 99

Faults Possible cause Action

Battery discharged Battery is not charging – Check the charging voltage.
– Check the stator winding of the alternator.
Unwanted power consumer – Check the open-circuit current.
21 TECHNICAL DATA 100

21.1 Engine
Design 1-cylinder 4-stroke engine, water-cooled
Displacement 249.91 cm³ (15.2505 cu in)
Stroke 52.3 mm (2.059 in)
Bore 78 mm (3.07 in)
Compression ratio 14.4:1
Idle speed 2,250… 2,350 rpm
Control DOHC, four valves controlled via cam lever, drive via timing
chain
Valve diameter, intake 32.5 mm (1.28 in)
Valve diameter, exhaust 26.5 mm (1.043 in)
Valve clearance
Intake at: 20 °C (68 °F) 0.10… 0.15 mm (0.0039… 0.0059 in)
Exhaust at: 20 °C (68 °F) 0.13… 0.18 mm (0.0051… 0.0071 in)
Crankshaft bearing 2 cylinder bearings
Conrod bearing 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 two Eaton pumps
Primary transmission 24:73
Clutch Multidisc clutch in oil bath/hydraulically activated
Gearbox (All SX‑F models) 5-gear, claw shifted
Gearbox (XC‑F US) 6-gear, claw shifted
Transmission ratio (All SX‑F models)
First gear 13:32
Second gear 16:32
Third gear 17:28
Fourth gear 19:26
Fifth gear 21:25
Transmission ratio (XC‑F US)
First gear 13:32
Second gear 16:30
Third gear 16:24
Fourth gear 23:28
Fifth gear 23:23
Sixth gear 26:20
Alternator 12 V, 70 W
Ignition Contactless controlled fully electronic ignition with digital igni-
tion adjustment
Spark plug NGK LMAR9AI-8
Spark plug electrode gap 0.8 mm (0.031 in)
Cooling Water cooling, permanent circulation of coolant by water pump
Starting aid Electric starter
21 TECHNICAL DATA 101

21.2 Engine tightening torques

Nozzle, crank chamber ventilation M4 2 Nm (1.5 lbf ft) Loctite® 243™
Oil nozzle for alternator cooling M4 2 Nm (1.5 lbf ft) Loctite® 243™
Oil nozzle for balancer shaft lubrication M4 2 Nm (1.5 lbf ft) Loctite® 243™
Oil nozzle for clutch lubrication M4 2 Nm (1.5 lbf ft) Loctite® 243™
Oil nozzle for conrod bearing lubrica- M4 2 Nm (1.5 lbf ft) Loctite® 243™
tion
Screw, oil nozzle for piston cooling M4 2 Nm (1.5 lbf ft) Loctite® 243™
Locking screw for bearing M5 6 Nm (4.4 lbf ft) Loctite® 243™
Oil channel screw plug in alternator M5 1.2 Nm (0.89 lbf ft) Loctite® 648™
cover
Oil nozzle for cam lever lubrication M5 3 Nm (2.2 lbf ft) Loctite® 243™
Oil nozzle, piston cooling M5 2 Nm (1.5 lbf ft) Loctite® 243™
Screw, bearing bolt, oil pump idler M5 6 Nm (4.4 lbf ft) Loctite® 243™
gear
Screw, crankshaft position sensor M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, gear position sensor M5 5 Nm (3.7 lbf ft) Loctite® 243™
Screw, locking lever M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, oil pump cover M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, stator M5 6 Nm (4.4 lbf ft) Loctite® 243™
Nut, cylinder head M6 10 Nm (7.4 lbf ft) Lubricated with engine oil
Nut, water-pump wheel M6 5 Nm (3.7 lbf ft) Loctite® 243™
Screw, alternator cover M6 10 Nm (7.4 lbf ft) –
Screw, clutch cover M6 10 Nm (7.4 lbf ft) –
Screw, clutch slave cylinder M6 10 Nm (7.4 lbf ft) –
Screw, clutch spring M6 10 Nm (7.4 lbf ft) –
Screw, engine case M6 10 Nm (7.4 lbf ft) –
Screw, exhaust flange M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, oil filter cover M6 10 Nm (7.4 lbf ft) –
Screw, shift drum locating M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, shift lever M6 14 Nm (10.3 lbf ft) Loctite® 243™
Screw, starter motor M6 10 Nm (7.4 lbf ft) –
Screw, timing chain guide rail M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, timing chain securing guide M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, valve cover M6 8 Nm (5.9 lbf ft) –
Screw, water pump cover M6 10 Nm (7.4 lbf ft) –
Stud, cylinder head M6 10 Nm (7.4 lbf ft) –
Screw, camshaft bearing bridge M7x1 14 Nm (10.3 lbf ft) Lubricated with engine oil
Screw plug, crankshaft location M8 10 Nm (7.4 lbf ft) –
Screw, timing chain tensioning rail M8 15 Nm (11.1 lbf ft) Loctite® 243™
Screw, engine sprocket M10 60 Nm (44.3 lbf ft) Loctite® 2701™
Plug, oil channel M10x1 15 Nm (11.1 lbf ft) Loctite® 243™
Rotor screw M10x1 70 Nm (51.6 lbf ft) Thread, oiled with engine
oil/cone degreased
Screw plug, cam lever axis M10x1 10 Nm (7.4 lbf ft) –
Screw, unlocking of timing chain ten- M10x1 8 Nm (5.9 lbf ft) –
sioner
Spark plug M10x1 10… 12 Nm (7.4… –
8.9 lbf ft)
Engine coolant temperature sensor M10x1.25 12 Nm (8.9 lbf ft) –
21 TECHNICAL DATA 102

Nut, cylinder head M10x1.25 Tightening sequence: Thread, oiled with engine
Tighten diagonally. oil/cone greased
1st tightening stage
10 Nm (7.4 lbf ft)
2nd tightening stage
30 Nm (22.1 lbf ft)
3rd tightening stage
50 Nm (36.9 lbf ft)
Stud, cylinder head M10x1.25 20 Nm (14.8 lbf ft) Loctite® 243™
Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –
Plug, oil pressure regulator valve M12x1.5 20 Nm (14.8 lbf ft) –
Oil drain plug M14x1.5 15 Nm (11.1 lbf ft) –
Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft) Loctite® 243™
Nut, primary gear M18LHx1.5 100 Nm (73.8 lbf ft) Loctite® 243™
Screw plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) –
Plug, timing chain tensioner M24x1.5 40 Nm (29.5 lbf ft) –
Screw, alternator cover M24x1.5 18 Nm (13.3 lbf ft) –

21.3 Capacities
21.3.1 Engine oil
Engine oil 1.0 l (1.1 qt.) Engine oil (SAE 10W/50) ( p. 108)
Alternative engine oil for harsh Engine oil (SAE 10W/60)
operating conditions and (00062010035) ( p. 108)
increased performance

21.3.2 Coolant
Coolant 0.95 l (1 qt.) Coolant ( p. 108)

21.3.3 Fuel
Total fuel tank capacity, 7 l (1.8 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 109)
approx. (All SX‑F models)
Total fuel tank capacity, 8.5 l (2.25 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 109)
approx. (XC‑F US)

Fuel reserve, approx. (XC‑F US) 1.5 l (1.6 qt.)

21.4 Chassis
Frame Central tube frame made of chrome molybdenum steel tubing
Fork WP Performance Systems Upside down AER 48
Suspension travel
Front 310 mm (12.2 in)
Rear 300 mm (11.81 in)
Fork offset 22 mm (0.87 in)
Shock absorber (SX‑F EU) WP Performance Systems 5018 DCC Link
Shock absorber (SX‑F US) WP Performance Systems 5018 DCC Link
Shock absorber (XC‑F US) WP Performance Systems 5018 DCC Link
Brake system Disc brakes, brake calipers on floating bearings
Brake discs - diameter
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)
Tire air pressure, offroad
21 TECHNICAL DATA 103

Front 1.0 bar (15 psi)

Rear 1.0 bar (15 psi)
Secondary ratio (All SX‑F models) 2:51 PM
Secondary ratio (XC‑F US) 1:50 PM
Chain 5/8 x 1/4"
Available rear sprockets 48, 50, 51, 52
Steering head angle 63.9°
Wheelbase 1,485±10 mm (58.46±0.39 in)
Seat height, unloaded 960 mm (37.8 in)
Ground clearance, unloaded 370 mm (14.57 in)
Weight without fuel, approx. (SX‑F EU) 98.2 kg (216.5 lb.)
Weight without fuel, approx. (SX‑F US) 98.2 kg (216.5 lb.)
Weight without fuel, approx. (XC‑F US) 99.2 kg (218.7 lb.)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
Maximum permissible overall weight 335 kg (739 lb.)

21.5 Electrical system

Battery (All SX‑F models) C22S Lithium-ion battery
Battery voltage: 12 V
Nominal capacity: 2.2 Ah
maintenance-free
Battery (XC‑F US) HJTZ5S-FP Lithium-ion battery
Battery voltage: 12 V
Nominal capacity: 2.0 Ah
maintenance-free
Fuse 58011109110 10 A
FI warning lamp LED
Remaining indicator lamps (XC‑F US) W2.3W/socket W2x4.6d 12 V
2.3 W

21.6 Tires
Validity Front tires Rear tires
(All SX‑F models) 80/100 - 21 51M TT 110/90 - 19 62M TT
Dunlop GEOMAX MX3S Dunlop GEOMAX MX3S
(XC‑F US) 90/90 - 21 54M TT 110/100 - 18 64M TT
Dunlop GEOMAX AT81F Dunlop GEOMAX AT81
Additional information is available in the Service section under:
http://www.ktm.com

21.7 Fork
21.7.1 SX‑F EU
Fork part number 34.18.8Q.05
Fork WP Performance Systems Upside down AER 48
Compression damping
Comfort 15 clicks
Standard 12 clicks
Sport 9 clicks
Rebound damping
Comfort 20 clicks
Standard 17 clicks
Sport 14 clicks
Air pressure 10.6 bar (154 psi)
21 TECHNICAL DATA 104

Fork length 950 mm (37.4 in)

Oil capacity external mecha- 200+40

−20 ml (6.76−0.68 fl. oz.)
+1.35
Fork oil (SAE 4) (48601166S1) ( p. 108)
nism right
Oil capacity external mecha- 200+40
−20 ml (6.76−0.68 fl. oz.)
+1.35
Fork oil (SAE 4) (48601166S1) ( p. 108)
nism left
Oil capacity, right cartridge 380 ml (12.85 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 108)
Grease capacity, left cartridge 11 ml (0.37 fl. oz.) Multi-purpose grease (00062010051) ( p. 109)

21.7.2 SX‑F US
Fork part number 34.18.8Q.55
Fork WP Performance Systems Upside down AER 48
Compression damping
Comfort 20 clicks
Standard 17 clicks
Sport 12 clicks
Rebound damping
Comfort 20 clicks
Standard 17 clicks
Sport 12 clicks
Air pressure 10.6 bar (154 psi)
Fork length 950 mm (37.4 in)

Oil capacity external mecha- 200+40

−20 ml (6.76−0.68 fl. oz.)
+1.35
Fork oil (SAE 4) (48601166S1) ( p. 108)
nism right
Oil capacity external mecha- 200+40
−20 ml (6.76−0.68 fl. oz.)
+1.35
Fork oil (SAE 4) (48601166S1) ( p. 108)
nism left
Oil capacity, right cartridge 380 ml (12.85 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 108)
Grease capacity, left cartridge 11 ml (0.37 fl. oz.) Multi-purpose grease (00062010051) ( p. 109)

21.7.3 XC‑F US
Fork part number 34.18.8Q.75
Fork WP Performance Systems Upside down AER 48
Compression damping
Comfort 15 clicks
Standard 12 clicks
Sport 10 clicks
Rebound damping
Comfort 15 clicks
Standard 12 clicks
Sport 10 clicks
Air pressure 9.8 bar (142 psi)
Fork length 950 mm (37.4 in)

Oil capacity external mecha- 200+40

−20 ml (6.76−0.68 fl. oz.)
+1.35
Fork oil (SAE 4) (48601166S1) ( p. 108)
nism right
Oil capacity external mecha- 200+40
−20 ml (6.76−0.68 fl. oz.)
+1.35
Fork oil (SAE 4) (48601166S1) ( p. 108)
nism left
Oil capacity, right cartridge 380 ml (12.85 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 108)
Grease capacity, left cartridge 11 ml (0.37 fl. oz.) Multi-purpose grease (00062010051) ( p. 109)
21 TECHNICAL DATA 105

21.8 Shock absorber

21.8.1 SX‑F EU
Shock absorber article number 18.18.7Q.05
Shock absorber WP Performance Systems 5018 DCC Link
Compression damping, low-speed
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Compression damping, high-speed
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.) 39 N/mm (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 247 mm (9.72 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. 109)

21.8.2 SX‑F US
Shock absorber article number 18.18.7Q.55
Shock absorber WP Performance Systems 5018 DCC Link
Compression damping, low-speed
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Compression damping, high-speed
Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns
Rebound damping
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Spring preload 6 mm (0.24 in)
Spring rate
Weight of rider: 65… 75 kg (143… 165 lb.) 39 N/mm (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 247 mm (9.72 in)
Gas pressure 10 bar (145 psi)
21 TECHNICAL DATA 106

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. 109)

21.8.3 XC‑F US
Shock absorber article number 18.18.7Q.75
Shock absorber WP Performance Systems 5018 DCC Link
Compression damping, low-speed
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Compression damping, high-speed
Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns
Rebound damping
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Spring preload 7 mm (0.28 in)
Spring rate
Weight of rider: 65… 75 kg (143… 165 lb.) 39 N/mm (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 247 mm (9.72 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. 109)

21.9 Chassis tightening torques

Screw, air filter box cover EJOT PT® K60x20-Z 3 Nm (2.2 lbf ft) –
Screw, combination switch EJOT PT® K50x18 3 Nm (2.2 lbf ft) –
Screw, intake air temperature sensor EJOT DELTA PT® 45x12‑Z 1 Nm (0.7 lbf ft) –
Screw, pressure regulator EJOT PT® K60x25‑Z 3 Nm (2.2 lbf ft) –
Screw, fixed grip 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) –
Nut, electric starter cable connection M6 4 Nm (3 lbf ft) –
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft) –
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –
Screw, ball joint of push rod on foot M6 10 Nm (7.4 lbf ft) Loctite® 243™
brake cylinder
21 TECHNICAL DATA 107

Screw, chain sliding guard M6 6 Nm (4.4 lbf ft) Loctite® 243™

Screw, front brake disc M6 14 Nm (10.3 lbf ft) Loctite® 243™
Screw, rear brake disc M6 14 Nm (10.3 lbf ft) Loctite® 243™
Screw, throttle grip M6 5 Nm (3.7 lbf ft) –
Fuel connection on fuel tank M8 10 Nm (7.4 lbf ft) –
Nut, 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 side stand attachment M8 35 Nm (25.8 lbf ft) Loctite® 2701™
(XC‑F US)
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft) –
Screw, chain sliding piece M8 15 Nm (11.1 lbf ft) –
Screw, engine brace M8 25 Nm (18.4 lbf ft) Loctite® 243™
Screw, fork stub M8 15 Nm (11.1 lbf ft) –
Screw, front brake caliper M8 25 Nm (18.4 lbf ft) Loctite® 243™
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –
Screw, subframe M8 35 Nm (25.8 lbf ft) Loctite® 2701™
Screw, top steering stem M8 20 Nm (14.8 lbf ft) Loctite® 243™
Screw, top triple clamp M8 17 Nm (12.5 lbf ft) –
Engine carrying screw M10 60 Nm (44.3 lbf ft) –
Remaining nuts, chassis M10 45 Nm (33.2 lbf ft) –
Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –
Screw, bottom shock absorber M10 60 Nm (44.3 lbf ft) Loctite® 2701™
Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite® 243™
Screw, top shock absorber M10 60 Nm (44.3 lbf ft) Loctite® 2701™
Nut, fuel pump M12 15 Nm (11.1 lbf ft) –
Nut, frame to linkage lever M14x1.5 80 Nm (59 lbf ft) –
Nut, linkage lever on swingarm M14x1.5 80 Nm (59 lbf ft) –
Nut, linkage lever to angle lever M14x1.5 80 Nm (59 lbf ft) –
Nut, swingarm pivot M16x1.5 100 Nm (73.8 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) –
Screw-in nozzles, cooling system M20x1.5 12 Nm (8.9 lbf ft) Loctite® 243™
Nut, rear wheel spindle M25x1.5 80 Nm (59 lbf ft) –
22 SUBSTANCES 108

Brake fluid DOT 4 / DOT 5.1

Standard/classification
– DOT
Guideline
– Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corre-
sponding properties.
Recommended supplier
Castrol
– RESPONSE BRAKE FLUID SUPER DOT 4
Motorex®
– Brake Fluid DOT 5.1

Coolant
Guideline
– Only use high quality coolant with corrosion inhibitor for aluminum motors (even in countries with high temperatures). Using infe-
rior antifreeze can result in corrosion and foaming.
Mixture ratio
Antifreeze protection: −25… −45 °C (−13… anti-corrosion/antifreeze
−49 °F) distilled water
Recommended supplier
Motorex®
– COOLANT M3.0

Engine oil (SAE 10W/60) (00062010035)

Standard/classification
– JASO T903 MA ( p. 111)
– SAE ( p. 111) (SAE 10W/60)
– KTM LC4 2007+
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre-
sponding properties.
Synthetic engine oil
Recommended supplier
Motorex®
– Cross Power 4T

Engine oil (SAE 10W/50)

Standard/classification
– JASO T903 MA ( p. 111)
– SAE ( p. 111) (SAE 10W/50)
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre-
sponding properties.
Synthetic engine oil
Recommended supplier
Motorex®
– Cross Power 4T

Fork oil (SAE 4) (48601166S1)

Standard/classification
– SAE ( p. 111) (SAE 4)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding
properties.
22 SUBSTANCES 109

Multi-purpose grease (00062010051)

Recommended supplier
Klüber Lubrication®
– CENTOPLEX 2 EP

Shock absorber fluid (SAE 2.5) (50180751S1)

Standard/classification
– SAE ( p. 111) (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/RON 95/PON 91)

Standard/classification
– DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
– Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
– Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.

Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).
23 AUXILIARY SUBSTANCES 110

Air filter cleaner

Recommended supplier
Motorex®
– Racing Bio Dirt Remover

Chain cleaner
Recommended supplier
Motorex®
– Chain Clean

Fuel additive
Recommended supplier
Motorex®
– Fuel Stabilizer

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®
– Moto Protect

Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
Recommended supplier
Motorex®
– Quick Cleaner

Universal oil spray

Recommended supplier
Motorex®
– Joker 440 Synthetic
24 STANDARDS 111

JASO T903 MA
Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear-
lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi-
cation. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the fore-
ground for motorcycle engines. In most motorcycles, the gearbox and the clutch are lubricated with the same oil as the engine. The
JASO MA Standard meets these special requirements.

SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis-
cosity. The viscosity describes only one property of oil and says nothing about quality.
25 INDEX OF SPECIAL TERMS 112

MIL Malfunction indicator lamp Indicator lamp that supports vehicle diagnostics through flash
codes
OBD On-board diagnosis Vehicle system that monitors emission- and safety-related values
26 LIST OF ABBREVIATIONS 113

Art. no. Article number

ca. circa
cf. compare
e.g. for example
etc. et cetera
i.a. inter alia
no. number
poss. possibly
27 LIST OF SYMBOLS 114

27.1 Yellow and orange symbols

Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by
yellow or orange symbols.
FI warning lamp (MIL) lights up/flashes orange – The OBD has detected an emission- or safety-critical fault.

The low fuel warning lamp lights up orange – The fuel level has reached the reserve mark.
INDEX 115

Clutch
INDEX

A fluid level, checking/correcting . . . . . . . . . . . . . . . . . . 62

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 fluid, changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Air filter Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 61
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Cold start button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Compression damping
Air filter box fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Compression damping, high-speed
sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 30
Air filter box cover
Compression damping, low-speed
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 30
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Coolant
antifreeze and coolant level, checking . . . . . . . . . . . . . 82
Air suspension AER 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Antifreeze level, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Auxiliary substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
B Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Basic chassis setting D

checking with rider's weight . . . . . . . . . . . . . . . . . . . . 29 Difficult riding conditions . . . . . . . . . . . . . . . . . . . . . . . . . 19
Battery dry sand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
installing . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . 78 high temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . 21
recharging . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . 79 low speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
removing . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . 78 low temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
starting power ... . . . . . . . . . . . . . . . . . . . . . . . . . . 19 muddy surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Brake discs snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 wet sand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
wet surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Brake fluid
front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 65 E
rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Electric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Brake fluid level Engine
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 65 running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 69 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Brake linings Engine oil
front brake, checking . .. . . . . . . . . . . . . . . . . . . . . . 66 adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
of front brake, changing . . . . . . . . . . . . . . . . . . . . . . 67 changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
rear brake, changing . . .. . . . . . . . . . . . . . . . . . . . . . 71
Engine oil level
rear brake, checking . . .. . . . . . . . . . . . . . . . . . . . . . 70
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
C
Engine sprocket
Capacity checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84, 102 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93, 102
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26, 102 F
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chain
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Filler cap
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chain guide
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Foot brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 69
Chain tension
free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 68
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Fork legs
air pressure, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 35
Characteristic map of the throttle response
basic setting, checking . . . . . . . . . . . . . . . . . . . . . . . 34
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 compression damping, adjusting . . . . . . . . . . . . . . . . . 36
INDEX 116

dust boots, cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 39 O

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Oil filter
rebound damping, adjusting . . . . . . . . . . . . . . . . . . . . 36
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Oil screen
Fork protector
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Operating substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Overview of indicator lamps . . . . . . . . . . . . . . . . . . . . . . . 13
Frame
Owner's Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Front fender P
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Plug-in stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Preparing for use
Front wheel advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . 18
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Protective clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Putting into operation
Fuel screen after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 checks and maintenance before putting into operation . . 22
Fuel tank R
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Rear sprocket
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fuse
Rear wheel
main fuse, changing . . . . . . . . . . . . . . . . . . . . . . . . . 80
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
H removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Rebound damping
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 64 fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 64 shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 31
Handlebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Refueling
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
I Riding sag
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Idle speed
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Rubber grips
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Idle speed adjusting screw . . . . . . . . . . . . . . . . . . . . . . . . 15
Implied warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 S
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
K Seat
Kill switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
L
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Launch Control Service hour counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
activating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-28
Lower triple clamp Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 89
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 basic position, checking . . . . . . . . . . . . . . . . . . . . . . 88
M Shock absorber
Main fuse compression damping, general . . . . . . . . . . . . . . . . . . 29
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 high-speed compression damping, adjusting . . . . . . . . . 30
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Main silencer
low-speed compression damping, adjusting . . . . . . . . . 30
glass fiber yarn filling, changing . . . . . . . . . . . . . . . . . 53
rebound damping, adjusting . . . . . . . . . . . . . . . . . . . . 31
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
riding sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 33
Mapping spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . . 33
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 static sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 32
Motorcycle Shock absorber article number . . . . . . . . . . . . . . . . . . . . . 11
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
raising with lift stand . . . . . . . . . . . . . . . . . . . . . . . . 38
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
removing from lift stand . . . . . . . . . . . . . . . . . . . . . . 38
INDEX 117

Spoke tension
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Start number plate
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Starting power of lithium-ion batteries at low temperatures . . . 19
Steering head bearing
greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Steering head bearing play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Swingarm
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
T
Technical data
capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
chassis tightening torques . . . . . . . . . . . . . . . . . . . . 106
electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . 103
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
engine tightening torques . . . . . . . . . . . . . . . . . . . . 101
fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Throttle cable play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Throttle cable routing
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Throttle grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Throttle valve position
teaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Tire air pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Traction control
activating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98-99
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
U
Use definition ................................. 5
V
View of vehicle
front left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
rear right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Work rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
*3213472en*
3213472en

04/2016

KTM Sportmotorcycle GmbH

5230 Mattighofen/Austria Photo: Mitterbauer/KTM
http://www.ktm.com