KTM 350 SF-X 2012 Owner's manual
OWNER'S MANUAL 2012
350 SX‑F EU
350 SX‑F USA
350 XC-F USA
Art. no. 3211716en
DEAR KTM CUSTOMER 1
DEARKTM CUSTOMER
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you enormous pleasure if you service and maintain it accordingly.
We wish you a lot of enjoyment in riding this vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( p. 9) Dealer's stamp
Engine number ( p. 9)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing
development and design can, however, not be completely excluded.
All specifications are non-binding. KTM Sportmotorcycle AG 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, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery.
© 2011 KTM-Sportmotorcycle AG, 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 AG
5230 Mattighofen, Austria
TABLE OF CONTENTS 2
TABLEOF CONTENTS
MEANS OF REPRESENTATION ............................................ 4
IMPORTANT INFORMATION ................................................ 5
VIEW OF VEHICLE............................................................... 7
View of vehicle, front left (example)................................... 7
View of vehicle, rear right (example) .................................. 8
SERIAL NUMBERS.............................................................. 9
Chassis number............................................................... 9
Type label....................................................................... 9
Engine number................................................................ 9
Fork part number............................................................. 9
Shock absorber part number ............................................. 9
CONTROLS....................................................................... 10
Clutch lever .................................................................. 10
Hand brake lever ........................................................... 10
Throttle grip.................................................................. 10
Kill switch .................................................................... 10
Electric starter button .................................................... 10
Overview of indicator lamps ............................................ 11
Opening the filler cap .................................................... 11
Closing the filler cap...................................................... 11
Idle speed adjusting screw ............................................. 12
Shift lever..................................................................... 12
Kick starter (XC‑F) ......................................................... 12
Foot brake lever............................................................. 13
Plug-in stand (All SX‑F models) ...................................... 13
Side stand (XC‑F) .......................................................... 13
PREPARING FOR USE ....................................................... 14
Advice on first use ......................................................... 14
Running in the engine.................................................... 15
Preparing vehicle for difficult riding conditions................. 15
Preparing for rides on dry sand ....................................... 15
Preparing for rides on wet sand....................................... 16
Preparing for rides on wet and muddy surfaces................. 16
Preparing for rides at high temperature and slow speed ..... 17
Preparing for rides at low temperatures or in snow ............ 17
RIDING INSTRUCTIONS .................................................... 18
Checks and maintenance work when preparing for use ...... 18
Starting ........................................................................ 18
Starting off ................................................................... 19
Shifting, riding.............................................................. 19
Applying the brakes ....................................................... 19
Stopping, parking .......................................................... 19
Refueling...................................................................... 20
SERVICE SCHEDULE......................................................... 21
Service schedule ........................................................... 21
Service work (as additional order).................................... 22
TUNING THE CHASSIS...................................................... 23
Checking the basic chassis setting with the rider's
weight .......................................................................... 23
Compression damping of the shock absorber .................... 23
Adjusting the low-speed compression damping of the
shock absorber .............................................................. 23
Adjusting the high-speed compression damping of the
shock absorber .............................................................. 24
Adjusting the rebound damping of the shock absorber....... 25
Measuring rear wheel sag unloaded ................................. 25
Checking the static sag of the shock absorber .................. 26
Checking the riding sag of the shock absorber .................. 26
Adjusting the spring preload of the shock absorber x ...... 26
Adjusting the riding sag x............................................. 27
Checking the basic setting of the fork.............................. 28
Adjusting the compression damping of the fork ................ 28
Adjusting the rebound damping of the fork....................... 28
Handlebar position ........................................................ 29
Adjusting the handlebar position x................................ 29
SERVICE WORK ON THE CHASSIS ..................................... 31
Raising the motorcycle with the lift stand ........................ 31
Removing the motorcycle from the lift stand .................... 31
Bleeding the fork legs .................................................... 31
Cleaning the dust boots of the fork legs ........................... 32
Loosening the fork protection.......................................... 32
Positioning the fork protection ........................................ 32
Removing the fork legs x.............................................. 32
Installing the fork legs x............................................... 33
Removing the fork protector x....................................... 33
Installing the fork protector x ....................................... 34
Removing the lower triple clamp x ................................ 34
Installing the lower triple clamp x................................. 34
Checking the steering head bearing play .......................... 36
Adjusting the play of the steering head bearing x............ 36
Greasing the steering head bearing x............................. 37
Removing the start number plate .................................... 37
Installing the start number plate ..................................... 37
Removing the front fender .............................................. 37
Installing the front fender............................................... 37
Removing the shock absorber x..................................... 38
Installing the shock absorber x ..................................... 38
Removing the seat ......................................................... 39
Mounting the seat ......................................................... 39
Removing the air filter box lid......................................... 39
Installing the air filter box lid.......................................... 40
Removing the air filter x............................................... 40
Installing the air filter x ............................................... 40
Cleaning the air filter and air filter box x........................ 41
Removing the main silencer............................................ 41
Installing the main silencer ............................................ 41
Changing the glass fiber yarn filling of the main
silencer x ................................................................... 42
Removing the fuel tank x ............................................. 42
Installing the fuel tank x .............................................. 43
Checking for chain dirt accumulation .............................. 44
Cleaning the chain......................................................... 44
Checking the chain tension ............................................ 45
Adjusting the chain tension ............................................ 45
Checking the chain, rear sprocket, engine sprocket and
chain guide................................................................... 46
Adjusting the chain guide x.......................................... 48
Checking the frame x................................................... 48
Checking the swingarm x ............................................. 48
Checking the throttle cable routing.................................. 48
Checking the rubber grip ................................................ 49
Additionally securing the rubber grip ............................... 49
Adjusting the basic position of the clutch lever................. 49
Checking the fluid level of the hydraulic clutch ................ 49
Changing the hydraulic clutch fluid x ............................ 50
BRAKES........................................................................... 51
Checking the free travel of the hand brake lever ............... 51
Adjusting the basic position of the hand brake lever.......... 51
Checking the brake discs................................................ 51
Checking the front brake fluid level ................................. 52
Adding front brake fluid x ............................................ 52
Checking the front brake linings...................................... 53
Changing the front brake linings x................................. 53
TABLE OF CONTENTS 3
Checking the free travel of foot brake lever....................... 55
Adjusting the basic position of the foot brake lever x ...... 55
Checking the rear brake fluid level .................................. 56
Adding rear brake fluid x.............................................. 56
Checking the rear brake linings ....................................... 57
Changing the rear brake linings x.................................. 57
WHEELS, TIRES ............................................................... 59
Removing the front wheel x .......................................... 59
Installing the front wheel x........................................... 59
Removing the rear wheel x ........................................... 60
Installing the rear wheel x ............................................ 60
Checking the tire condition............................................. 61
Checking the tire air pressure ......................................... 62
Checking the spoke tension ............................................ 62
ELECTRICAL SYSTEM ....................................................... 63
Removing the battery x ................................................ 63
Installing the battery x................................................. 63
Charging the battery x.................................................. 63
Changing the main fuse ................................................. 64
COOLING SYSTEM ............................................................ 66
Cooling system .............................................................. 66
Checking the antifreeze and coolant level ........................ 66
Checking the coolant level.............................................. 66
Draining the coolant x.................................................. 67
Refilling coolant x ....................................................... 68
TUNING THE ENGINE ....................................................... 69
Checking the play in the throttle cable............................. 69
Adjusting the play in the throttle cable x ....................... 69
Adjusting the idle speed x............................................ 69
Checking the basic position of the shift lever.................... 70
Adjusting the basic position of the shift lever x .............. 70
SERVICE WORK ON THE ENGINE ...................................... 71
Checking the engine oil level .......................................... 71
Changing the engine oil and oil filter, cleaning the oil
screen x ..................................................................... 71
Adding engine oil .......................................................... 73
CLEANING, CARE ............................................................. 74
Cleaning the motorcycle ................................................. 74
STORAGE ......................................................................... 75
Storage......................................................................... 75
Preparing for use after storage ........................................ 75
TROUBLESHOOTING......................................................... 76
BLINK CODE .................................................................... 78
TECHNICAL DATA - ENGINE .............................................. 79
Capacity - engine oil ...................................................... 80
Capacity - coolant.......................................................... 80
TECHNICAL DATA - ENGINE TIGHTENING TORQUES .......... 81
TECHNICAL DATA - CHASSIS ............................................ 83
Lighting equipment ....................................................... 83
Tires ............................................................................ 84
Capacity - fuel............................................................... 84
TECHNICAL DATA - FORK.................................................. 85
SX‑F EU ....................................................................... 85
SX‑F USA ..................................................................... 85
XC‑F............................................................................. 86
TECHNICAL DATA - SHOCK ABSORBER ............................. 87
SX‑F EU ....................................................................... 87
SX‑F USA ..................................................................... 87
XC‑F............................................................................. 88
TECHNICAL DATA - TIGHTENING TORQUES FOR
CHASSIS .......................................................................... 89
SUBSTANCES................................................................... 90
AUXILIARY SUBSTANCES.................................................. 92
STANDARDS..................................................................... 94
INDEX .............................................................................. 95
MEANS OF REPRESENTATION 4
Symbols used
The symbols used are explained in the following.
Identifies an expected reaction (e.g. to a work step or a function).
Identifies an unexpected reaction (e.g. to 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 done in an authorized KTM workshop! There, your motorcycle will be serviced
optimally by specially trained experts using the specialist tools required.
Identifies a page reference (more information is provided on the specified page).
Formats used
The following typographical formats are used.
Specific name Identifies a proprietary name.
®
Name
Brand™ Identifies a brand available on the open market.
Identifies a protected name.
IMPORTANT INFORMATION 5
Use definition
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.
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. Poor adjustment and tuning of the engine and chassis can lead to
damage and breakage of components.
Using the vehicle in difficult conditions such as on sand or very muddy or wet terrain can lead to above-average wear of components
such as the drive train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in
the service schedule is reached.
Pay careful attention to the prescribed running-in period and service intervals. If you observe these exactly, you will ensure a much
longer service life for your motorcycle.
Warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage
resulting from manipulations and/or alterations to the vehicle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
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 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
Work rules
Special tools are required for some work. These are not part of the vehicle standard equipment, but they can be ordered with the item
number stated in parentheses. Ex.: bearing puller (15112017000)
When the vehicle is assembled, non-reusable parts (e.g., self-locking screws and nuts, gaskets, seal rings, O-rings, splints, lock washers) must be replaced with new parts.
Where thread lockers are used on screw connections (e.g., Loctite®), follow the instructions for use from the manufacturer.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or worn parts.
After you complete the repair or maintenance work, check the roadworthiness of the vehicle.
Transport
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from
being run. Always let the vehicle cool first.
– Switch off the engine.
– Use straps or other suitable devices to secure the motorcycle against accidents or falling over.
IMPORTANT INFORMATION 6
Environment
Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the
environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
Notes/warnings
Pay close attention to the notes/warnings.
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing, you or others may not recognize potential hazards and may therefore be injured.
Grades of risks
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Owner's manual
– It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful infor-
mation and many tips on how to operate and handle your motorcycle. Only then will you learn how to best customize the motorcycle for your own use and to protect yourself from injury. The owner's manual also contains important information on servicing the
motorcycle.
– The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is
sold.
VIEW OF VEHICLE 7
3.1View of vehicle, front left (example)
1 Hand brake lever ( p. 10)
2 Clutch lever ( p. 10)
3 Filler cap
4 Plug-in stand ( p. 13)
5 Air filter box lid
6 Engine number ( p. 9)
7 Shift lever ( p. 12)
8 Idle speed adjusting screw ( p. 12)
101273-10
VIEW OF VEHICLE 8
3.2View of vehicle, rear right (example)
1 Kill switch ( p. 10)
2 Electric starter button ( p. 10)
3 Fork compression adjustment
4 Fork rebound adjustment
5 Foot brake lever ( p. 13)
6 Level viewer, engine oil
7 Shock absorber compression adjustment
8 Level viewer for brake fluid, rear
9 Shock absorber rebound adjustment
101274-10
SERIAL NUMBERS 9
4.1Chassis number
The chassis number is stamped on the right side of the steering head.
B00262-10
4.2Type label
The type label is fixed to the front of the steering head.
4.3Engine number
4.4Fork part number
B00262-20
The engine number is stamped on the left side of the engine under the engine
sprocket.
B00263-10
The fork part number is stamped on the inner side of the axle clamp.
4.5Shock absorber part number
B00265-01
The shock absorber part number is stamped on the top of the shock absorber above
the adjusting ring on the engine side.
B00264-10
CONTROLS 10
5.1Clutch lever
The clutch lever is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
B00371-10
5.2Hand brake lever
Hand brake lever is located on the right side of the handlebar.
The hand brake lever is used to activate the front brake.
5.3Throttle grip
5.4Kill switch
B00369-10
The throttle grip is fitted on the right side of the handlebar.
B00368-10
Kill switch is fitted on the left side of the handlebar.
Possible states
• Kill switch in basic position – In this position, the ignition circuit is closed and
the engine can be started.
• Kill switch pressed – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.
5.5Electric starter button
B00373-10
Electric starter button 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.
B00374-10
CONTROLS 11
5.6Overview of indicator lamps
Possible states
FI warning lamp (MIL) lights up/flashes orange – The OBD (on-board
diagnosis) has detected an emission- or safety-critical error.
(XC‑F)
The fuel level warning lamp lights up orange – The fuel level has
reached the reserve mark.
101081-10
5.7Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
– Press release button , turn the filler cap counterclockwise and lift it free.
B00277-10
5.8Closing the filler cap
– Replace the filler cap and turn clockwise until the release button locks in place.
Info
Run the fuel tank breather hose without kinks.
B00278-10
CONTROLS 12
5.9Idle speed adjusting screw
Idle speed adjusting screw is located on the throttle valve body at the top left.
The idle speed adjusting screw has two functions.
Turning it controls the idle speed.
Pulling it out all the way raises the idle speed during a cold start.
Possible states
• RPM increase activated – Idle speed adjusting screw is pulled out all the way.
• RPM increase deactivated – Idle speed adjusting screw is pushed in all the way.
401096-10
5.10Shift lever
Shift lever is mounted on the left side of the engine.
5.11Kick starter (XC‑F)
B00280-10
(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.
B00281-10
(XC‑F)
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
B00281-11
The kick starter is fitted on the right side of the engine.
The upper part of the kick starter can be folded in.
B00601-10
Info
Before riding, fold the upper part of the kick starter toward the engine.
CONTROLS 13
5.12Foot brake lever
Foot brake lever is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.
B00282-10
5.13Plug-in stand (All SX‑F models)
The holder for the plug-in stand is the left side of the wheel spindle.
The plug-in stand is used to park the motorcycle.
Info
Remove the plug-in stand before starting on a trip.
5.14Side stand (XC‑F)
B00283-10
The side stand is on the left side of the vehicle.
B00602-10
The side stand is used to park the motorcycle.
Info
When you are riding, side stand must be folded up and secured with rubber
band .
B00603-10
PREPARING FOR USE 14
6.1Advice on first use
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally
impaired.
Warning
Risk of injury Missing or poor protective clothing present an increased safety risk.
– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always
wear protective clothing, which must be undamaged and meet legal requirements.
Warning
Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidents Critical riding behavior due to inappropriate riding.
– Adapt your riding speed to the road conditions and your riding ability.
Warning
Danger of accidents Accident risk caused by presence of a passenger.
– Your vehicle is not designed to carry passengers. Do not ride with a passenger.
Warning
Danger of accidents Unstable riding behavior.
– Do not exceed the maximum permissible weight and axle loads.
Warning
Risk of misappropriation Usage by unauthorized persons.
– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.
Info
When using your motorcycle, remember that 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 record at vehicle handover.
– Before your first trip, read the entire operating instructions carefully.
– Get to know the controls.
– Adjust the basic position of the clutch lever. ( p. 49)
– Adjust the basic position of the hand brake lever. ( p. 51)
–
Adjust the basic position of the foot brake lever. x ( p. 55)
– Get used to handling the motorcycle on a suitable piece of land before making a longer trip.
Info
Your motorcycle is not authorized for riding on public roads.
Offroad, you should be accompanied by another person on another machine so that you can help each other.
– Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.
– Do not make any offroad trips that over-stress 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 transport luggage.
(XC‑F)
– If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight
distribution between the front and rear wheels.
Info
Motorcycles react sensitively to any changes of weight distribution.
PREPARING FOR USE 15
– Do not exceed the overall maximum permitted weight and the 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. 15)
6.2Running 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 service hours ≤ 75 %
– Avoid fully opening the throttle!
6.3Preparing vehicle for difficult riding conditions
Info
Using a motorcycle in difficult conditions can lead to excessive wear of components such as the power train or brakes. For this
reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached.
– KTM recommends that you use the specified engine oil for difficult riding conditions and to increase performance.
Engine oil (SAE 10W/60) (00062010035) ( p. 90)
–
Seal the air filter box. x
Tip
Seal the air filter box at the edges against dirt.
–
Clean the air filter and air filter box. x ( p. 41)
Info
Check the air filter approx. every 30 minutes.
– Additionally secure the rubber grip. ( p. 49)
– 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. 15)
– Rides on wet sand. ( p. 16)
– Rides on wet and muddy surfaces. ( p. 16)
– Rides at high temperature and slow speed. ( p. 17)
– Rides at low temperatures or in snow. ( p. 17)
6.4Preparing for rides on dry sand
B00435-01
– Fit a dust protection device on the air filter.
Dust protection device for air filter (77206920000)
Info
See the KTM PowerParts fitting instructions.
PREPARING FOR USE 16
– Fit a sand protection device on the air filter.
Sand protection device for air filter (77206922000)
Info
See the KTM PowerParts fitting instructions.
B00436-01
– Clean the chain.
Chain cleaner ( p. 92)
– Fit the steel sprocket.
Tip
Do not grease the chain.
– Clean radiator fins.
600868-01
– Straighten bent radiator fins carefully.
– If used in sand regularly, replace the piston every 20 operating hours.
6.5Preparing for rides on wet sand
– Fit a waterproofing device on the air filter.
Waterproofing device for air filter (77206921000)
B00437-01
– Clean the chain.
Chain cleaner ( p. 92)
– Fit the steel sprocket.
– Clean radiator fins.
600868-01
– Straighten bent radiator fins carefully.
– If used in sand regularly, replace the piston every 20 operating hours.
6.6Preparing for rides on wet and muddy surfaces
– Fit a waterproofing device on the air filter.
Info
See the KTM PowerParts fitting instructions.
Tip
Do not grease the chain.
B00437-01
Waterproofing device for air filter (77206921000)
Info
See the KTM PowerParts fitting instructions.
PREPARING FOR USE 17
– Fit the steel sprocket.
– Clean the motorcycle. ( p. 74)
– Straighten bent radiator fins carefully.
600868-01
6.7Preparing for rides at high temperature and slow speed
– 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. 92)
600868-01
– Clean radiator fins.
– Straighten bent radiator fins carefully.
– Check the coolant level. ( p. 66)
6.8Preparing for rides at low temperatures or in snow
– Fit a waterproofing device on the air filter.
Waterproofing device for air filter (77206921000)
B00437-01
Info
See the KTM PowerParts fitting instructions.
RIDING INSTRUCTIONS 18
7.1Checks and maintenance work when preparing for use
Info
Before riding the vehicle, always check its condition and operating safety.
The vehicle must be in perfect technical condition when used.
– Check the engine oil level. ( p. 71)
– Check the front brake fluid level. ( p. 52)
– Check the rear brake fluid level. ( p. 56)
– Check the front brake linings. ( p. 53)
– Check the rear brake linings. ( p. 57)
– Check that the brake system is functioning properly.
– Check the coolant level. ( p. 66)
– Check for chain dirt accumulation. ( p. 44)
– Check the chain, rear sprocket, engine sprocket and chain guide. ( p. 46)
– Check the chain tension. ( p. 45)
– Check the tire condition. ( p. 61)
– Check the tire air pressure. ( p. 62)
– Check the spoke tension. ( p. 62)
– Clean the dust boots of the fork legs. ( p. 32)
– Bleed the fork legs. ( p. 31)
– Check the air filter.
– Check the settings of all controls and ensure that they can be operated smoothly.
– Check all screws, nuts and hose clamps regularly for tightness.
– Check the fuel supply.
7.2Starting
Danger
Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
– Always warm up the engine at low engine speeds.
(All SX‑F models)
– Remove the plug-in stand.
(XC‑F)
– Raise the motorcycle off of the stand and secure the stand with the rubber
band.
– Shift gear to neutral.
Condition
Ambient temperature: < 20 °C (< 68 °F)
400733-01
– Pull the idle speed adjusting screw all the way out.
– Press the electric starter button or press the kick starter robustly through its full
range.
Info
Press the electric starter button for at most 5 seconds. Wait for a least 5
seconds before trying again.
Warning lamp FI lights up briefly as a functional control when starting.
RIDING INSTRUCTIONS 19
7.3Starting off
– Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.
7.4Shifting, riding
Warning
Danger of accidents If you change down at high engine speed, the rear wheel can lock up.
– Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up.
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 or for steep inclines.
– When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simulta-
neously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.
– If you raised the idle speed to start the vehicle, push the idle speed adjusting screw in all the way after the engine warms up.
– 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, brake and close the throttle at the same time.
– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again.
– Switch off the engine if you expect to be standing for a long time.
Guideline
≥ 1 min
– Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and the cooling system.
– Ride with a lower engine speed instead of with a high engine speed and a slipping clutch.
7.5Applying the brakes
Warning
Danger of accidents If you brake too hard, the wheels can lock.
– Adapt your braking to the traffic situation and the road conditions.
Warning
Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake.
– Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Reduced braking efficiency due to wet or dirty brakes.
– Clean or dry dirty or wet brakes by riding and braking gently.
– On sandy, wet or slippery surfaces, use the rear brake.
– Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
– On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine.
In this way, you have to brake far less and the brakes do not overheat.
7.6Stopping, parking
Warning
Risk of misappropriation Usage by unauthorized persons.
– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these compo-
nents to cool down before starting work on them.
Note
Danger of damage The parked vehicle may roll away or fall over.
RIDING INSTRUCTIONS 20
AA
– Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from
being run. Always let the vehicle cool first.
– Brake the motorcycle.
– Shift gear to neutral.
– Press and hold the kill switch while the engine is idling until the engine stops.
– Park the motorcycle on firm ground.
7.7Refueling
Danger
Fire hazard Fuel is highly flammable.
– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
Note
Material damage Premature clogging of the fuel filter.
– In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with
the fuel system. (Your authorized KTM workshop will be glad to help.)
– Only refuel with clean fuel that meets the specified standards.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
– Switch off the engine.
– Open the filler cap. ( p. 11)
– Fill the fuel tank with fuel up to measurement .
Guideline
Measurement of 35 mm (1.38 in)
401226-10
Total fuel tank
capacity, approx.
(All SX‑F models)
Total fuel tank
capacity, approx.
(XC‑F)
– Close the filler cap. ( p. 11)
7.5 l
(1.98 US gal)
9.5 l
(2.51 US gal)
Super unleaded (ROZ 95/RON 95/PON
91) ( p. 91)
Super unleaded (ROZ 95/RON 95/PON
91) ( p. 91)
SERVICE SCHEDULE 21
8.1Service schedule
S1N S10A S20A S30A
Read out the fault memory using the KTM diagnostics tool. x
Check and charge the battery. x
Change the engine oil and oil filter, clean the oil screen. x ( p. 71)
Check the front brake linings. ( p. 53) • • •
Check the rear brake linings. ( p. 57) • • •
Check the brake discs. ( p. 51) • • •
Check the brake lines for damage and leakage. • • •
Check the rear brake fluid level. ( p. 56) • • •
Check the free travel of the foot brake lever. ( p. 55) • • •
Check the frame and swingarm. x
Check the swingarm bearing. x
Check the shock absorber linkage. x
Conduct a minor fork service. x
Conduct a major fork service. x
Check the tire condition. ( p. 61) • • • •
Check the tire air pressure. ( p. 62) • • • •
Check the wheel bearing for play. x
Check the wheel hubs. x
Check the rim run-out. x
Check the spoke tension. ( p. 62) • • • •
Check the chain, rear sprocket, engine sprocket and chain guide. ( p. 46) • • •
Check the chain tension. ( p. 45) • • • •
Grease all moving parts (e.g., hand lever, chain, ...) and check for smooth operation. x
Check the fluid level of the hydraulic clutch. ( p. 49) • • •
Check the front brake fluid level. ( p. 52) • • •
Check the free travel of the hand brake lever. ( p. 51) • • •
Check the steering head bearing play. ( p. 36) • • • •
Check the valve clearance. x
Check the clutch. x
Change the shaft seal rings of the water pump. x
Check the fuel pressure. x
Check all hoses (e. g. fuel, cooling, bleeding, drainage) and sleeves for tearing, leaks and
incorrect routing. x
Check the antifreeze and coolant level. ( p. 66) • • • •
Check the cables for damage and routing without sharp bends. x
Check that the cables are undamaged, routed without sharp bends and set correctly. • • • •
Clean the air filter and air filter box. x ( p. 41)
Change the glass fiber yarn filling of the main silencer. x ( p. 42)
Check the screws and nuts for tightness. x
Check idle. • • • •
Final check: Check the vehicle for safe operation and take a test ride. • • • •
Read out the fault memory using the KTM diagnostics tool after a test ride. x
Make the service entry in KTM DEALER.NET and in the service record. x
• • • •
• • •
• • • •
• • •
•
• • •
• • •
•
• • •
• • •
• • • •
• • •
• •
•
•
• • •
• • • •
• • •
• • •
• • •
• • • •
• • • •
• • • •
S1N: Once after 1 service hour - corresponds to about 7 liters of fuel (1.8 US gal)
S10A: Every 10 service hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race
S20A: Every 20 service hours - corresponds to about 140 liters of fuel (37 US gal)
S30A: Every 30 service hours - corresponds to about 210 liters of fuel (55.5 US gal)
SERVICE SCHEDULE 22
8.2Service work (as additional order)
S20N S40A S50A S100A J1A
Change the front brake fluid. x
Change the rear brake fluid. x
Change the hydraulic clutch fluid. x ( p. 50)
Grease the steering head bearing. x ( p. 37)
Service the shock absorber. x
Change the suction flange. x
Change the spark plug and spark plug connector. x
Change the piston. x
Check/measure the cylinder. x
Check the cylinder head. x
Change the valves, valve springs and valve spring seats. x
Check the camshaft and cam lever. x
Change the connecting rod, conrod bearing and crank pin. x
Check the transmission and shift mechanism. x
Check the oil pressure regulator valve. x
Change the suction oil pump. x
Check the oil pumps and lubrication system. x
Replace the timing chain. x
Check the timing assembly. x
Change all engine bearings. x
• •
• •
•
• •
• •
• •
•
• •
• •
• •
• •
•
• •
•
• •
•
•
•
•
•
S20N: Once after 20 service hours - corresponds to about 140 liters of fuel (37 US gal)
S40A: Every 40 service hours - corresponds to about 280 liters of fuel (74 US gal)
S50A: Every 50 service hours - corresponds to about 350 liters of fuel (92.5 US gal)
S100A: Every 100 service hours - corresponds to about 700 liters of fuel (185 US gal)
J1A: Annually
TUNING THE CHASSIS 23
9.1Checking 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
9.2Compression 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 more quickly.
The low-speed setting, for example, has an effect when riding over long ground swells: the rear wheel suspension compresses more
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.
9.3Adjusting the low-speed compression damping of the shock absorber
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop
will be glad to help.)
Info
The low-speed setting can be seen during the slow to normal compression of the shock absorber.
– Turn adjusting screw clockwise with a screwdriver up to the last perceptible
click.
B00290-10
Info
Do not loosen nut !
– Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
TUNING THE CHASSIS 24
Guideline
Compression damping, low-speed (SX‑F EU)
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Compression damping, low-speed (SX‑F USA)
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Compression damping, low-speed (XC‑F)
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
9.4Adjusting the high-speed compression damping of the shock absorber
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop
will be glad to help.)
Info
The high-speed setting can be seen during the fast compression of the shock absorber.
– Turn adjusting screw all the way clockwise with a socket wrench.
Info
Do not loosen nut !
– Turn back counterclockwise by the number of turns corresponding to the shock
absorber type.
Guideline
Compression damping, high-speed (SX‑F EU)
B00289-10
Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns
Compression damping, high-speed (SX‑F USA)
Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns
Compression damping, high-speed (XC‑F)
Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
TUNING THE CHASSIS 25
00AA
9.5Adjusting the rebound damping of the shock absorber
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop
will be glad to help.)
– Turn adjusting screw clockwise up to the last perceptible click.
– Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Rebound damping (SX‑F EU)
Comfort 17 clicks
Standard 15 clicks
B00291-10
Sport 13 clicks
Rebound damping (SX‑F USA)
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Rebound damping (XC‑F)
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
9.6Measuring rear wheel sag unloaded
400988-10
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
– Raise the motorcycle with the lift stand. ( p. 31)
– Measure the vertical distance between the rear axle and a fixed point such as a
marking on the side cover.
– Note down the value as dimension .
– Remove the motorcycle from the lift stand. ( p. 31)
TUNING THE CHASSIS 26
00AA
0
0
BB
00AA
0
0
CC
9.7Checking the static sag of the shock absorber
– Measure distance of rear wheel unloaded. ( p. 25)
– Hold the motorcycle upright with the aid of an assistant.
– Measure the distance between the rear axle and the fixed point again.
– Note down the value as dimension .
Info
The static sag is the difference between measurements and .
– Check the static sag.
Static sag (SX‑F EU) 30 mm (1.18 in)
Static sag (SX‑F USA) 34 mm (1.34 in)
Static sag (XC‑F) 34 mm (1.34 in)
» If the static sag is less or more than the specified value:
–
Adjust the spring preload of the shock absorber. x ( p. 26)
400989-10
9.8Checking the riding sag of the shock absorber
– Measure distance of rear wheel unloaded. ( p. 25)
– 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 now measures the distance between the rear axle and a fixed point.
– Note down the value as dimension .
Info
The riding sag is the difference between measurements and .
– Check the riding sag.
Riding sag (SX‑F EU) 90 mm (3.54 in)
Riding sag (SX‑F USA) 100 mm (3.94 in)
Riding sag (XC‑F) 100 mm (3.94 in)
» If the riding sag differs from the specified measurement:
–
400990-10
9.9Adjusting the spring preload of the shock absorber x
Adjust the riding sag. x ( p. 27)
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop
will be glad to help.)
Info
Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
–
Remove the shock absorber. x ( p. 38)
– After removing the shock absorber, clean it thoroughly.
TUNING THE CHASSIS 27
– Loosen screw .
– Turn adjusting ring 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 to measurement .
Guideline
Spring preload (SX‑F EU) 15 mm (0.59 in)
Spring preload (SX‑F USA) 12 mm (0.47 in)
Spring preload (XC‑F) 12 mm (0.47 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 .
Guideline
Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft)
401025-10
9.10Adjusting the riding sag x
B00292-10
–
Install the shock absorber. x ( p. 38)
–
Remove the shock absorber. x ( p. 38)
– After removing the shock absorber, clean it thoroughly.
– Choose and mount a suitable spring.
Guideline
Spring rate (SX‑F EU)
Weight of rider: 65… 75 kg (143…
51 N/mm (291 lb/in)
165 lb.)
Weight of rider: 75… 85 kg (165…
54 N/mm (308 lb/in)
187 lb.)
Weight of rider: 85… 95 kg (187…
57 N/mm (325 lb/in)
209 lb.)
Spring rate (SX‑F USA)
Weight of rider: 65… 75 kg (143…
54 N/mm (308 lb/in)
165 lb.)
Weight of rider: 75… 85 kg (165…
57 N/mm (325 lb/in)
187 lb.)
Weight of rider: 85… 95 kg (187…
60 N/mm (343 lb/in)
209 lb.)
Spring rate (XC‑F)
Weight of rider: 65… 75 kg (143…
51 N/mm (291 lb/in)
165 lb.)
Weight of rider: 75… 85 kg (165…
54 N/mm (308 lb/in)
187 lb.)
Weight of rider: 85… 95 kg (187…
57 N/mm (325 lb/in)
209 lb.)
Info
The spring rate is shown on the outside of the spring.
–
Install the shock absorber. x ( p. 38)
– Raise the motorcycle with the lift stand. ( p. 31)
– Check the riding sag of the shock absorber. ( p. 26)
– Adjust the rebound damping of the shock absorber. ( p. 25)
TUNING THE CHASSIS 28
9.11Checking the basic setting of the fork
Info
For various reasons, no exact riding sag can be determined for the forks.
– As with the shock absorber, smaller differences in the rider's weight can be com-
pensated by the spring preload.
– However, if the fork is often overloaded (hard end stop on compression), harder
springs must be fit to avoid damage to the fork and frame.
401000-01
9.12Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
– Turn adjusting screws clockwise all the way.
101275-10
Info
Adjusting screws are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
– Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping (SX‑F EU)
Comfort 14 clicks
Standard 12 clicks
Sport 10 clicks
Compression damping (SX‑F USA)
Comfort 14 clicks
Standard 12 clicks
Sport 10 clicks
Compression damping (XC‑F)
Comfort 14 clicks
Standard 12 clicks
Sport 10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
9.13Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
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