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1. Manuals
2. Brands
3. KTM Manuals
4. Motorcycle
5. 350 SX-F Cairoli replica
6. Owner’s manual

• Contents

• Table of Contents

• Troubleshooting

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Summary of Contents for KTM 350 SX-F

This manual is also suitable for:

350 sc-f

Page: 1

DEAR KTM CUSTOMER 1
*3213640en*
3213640en
03/2017
DEAR KTM 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 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. However, minor differences due to
further developments 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.
© 2017 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:
350 SX‑F EU (F8201R5)
350 SX‑F US (F8275R5)
350 XC‑F US (F8275R0)

Page: 2

TABLE OF CONTENTS 2
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ………………………………. 4
1.1 Symbols used …………………………………………… 4
1.2 Formats used……………………………………………. 4
2 SAFETY ADVICE………………………………………………….. 5
2.1 Use definition – intended use……………………….. 5
2.2 Misuse……………………………………………………. 5
2.3 Safety advice……………………………………………. 5
2.4 Degrees of risk and symbols…………………………. 5
2.5 Tampering warning…………………………………….. 5
2.6 Safe operation ………………………………………….. 6
2.7 Protective clothing …………………………………….. 6
2.8 Work rules……………………………………………….. 6
2.9 Environment…………………………………………….. 6
2.10 Owner’s Manual ………………………………………… 7
3 IMPORTANT NOTES…………………………………………….. 8
3.1 Manufacturer and implied warranty………………… 8
3.2 Operating and auxiliary substances ………………… 8
3.3 Spare parts, accessories ……………………………… 8
3.4 Service …………………………………………………… 8
3.5 Figures …………………………………………………… 8
3.6 Customer service……………………………………….. 8
4 VIEW OF VEHICLE ………………………………………………. 9
4.1 View of vehicle, front left (example) ……………….. 9
4.2 View of vehicle, rear right (example) …………….. 10
5 SERIAL NUMBERS ……………………………………………. 11
5.1 Chassis number ………………………………………. 11
5.2 Type label ……………………………………………… 11
5.3 Engine number ……………………………………….. 11
5.4 Fork part number …………………………………….. 11
5.5 Shock absorber article number ……………………. 11
6 CONTROLS………………………………………………………. 12
6.1 Clutch lever……………………………………………. 12
6.2 Hand brake lever……………………………………… 12
6.3 Throttle grip …………………………………………… 12
6.4 Kill switch……………………………………………… 12
6.5 Electric starter button……………………………….. 12
6.6 Combination switch………………………………….. 13
6.7 Overview of indicator lamps ……………………….. 13
6.8 Service hour counter ………………………………… 13
6.9 Opening the filler cap……………………………….. 13
6.10 Closing the filler cap ………………………………… 14
6.11 Cold start button……………………………………… 15
6.12 Idle speed adjusting screw…………………………. 16
6.13 Shift lever ……………………………………………… 16
6.14 Foot brake lever ………………………………………. 17
6.15 Plug-in stand (All SX‑F models)…………………… 17
6.16 Side stand (XC‑F US) ……………………………….. 17
7 PREPARING FOR USE………………………………………… 18
7.1 Advice on first use …………………………………… 18
7.2 Running in the engine ………………………………. 19
7.3 Starting power of lithium-ion batteries at low
temperatures ………………………………………….. 19
7.4 Preparing the vehicle for difficult riding
conditions ……………………………………………… 19
7.5 Preparing for rides on dry sand……………………. 20
7.6 Preparing for rides on wet sand …………………… 20
7.7 Preparing for rides on wet and muddy
surfaces ………………………………………………… 21
7.8 Preparing for rides at high temperature and
slow speed …………………………………………….. 21
7.9 Preparing for rides at low temperature and in
snow…………………………………………………….. 21
8 RIDING INSTRUCTIONS……………………………………… 22
8.1 Checks and maintenance measures when
preparing for use……………………………………… 22
8.2 Starting…………………………………………………. 22
8.3 Activating launch control …………………………… 23
8.4 Activating traction control………………………….. 23
8.5 Starting off…………………………………………….. 24
8.6 Shifting, riding ……………………………………….. 24
8.7 Applying the brakes………………………………….. 24
8.8 Stopping, parking…………………………………….. 25
8.9 Transport ………………………………………………. 25
8.10 Refueling ………………………………………………. 26
9 SERVICE SCHEDULE …………………………………………. 27
9.1 Additional information………………………………. 27
9.2 Required work ………………………………………… 27
9.3 Recommended work…………………………………. 28
10 TUNING THE CHASSIS ………………………………………. 29
10.1 Checking the basic chassis setting with the
rider’s weight………………………………………….. 29
10.2 Air suspension AER 48……………………………… 29
10.3 Compression damping of the shock absorber…… 29
10.4 Adjusting the low-speed compression damping
of the shock absorber ……………………………….. 30
10.5 Adjusting the high-speed compression
damping of the shock absorber……………………. 30
10.6 Adjusting the rebound damping of the shock
absorber………………………………………………… 31
10.7 Measuring rear wheel sag unloaded………………. 32
10.8 Checking the static sag of the shock absorber…. 32
10.9 Checking the riding sag of the shock absorber…. 33
10.10 Adjusting the spring pretension of the shock
absorber …………………………………………….. 33
10.11 Adjusting the riding sag …………………………. 34
10.12 Checking the basic setting of the fork …………… 34
10.13 Adjusting the fork air pressure…………………….. 35
10.14 Adjusting the compression damping of the
fork ……………………………………………………… 36
10.15 Adjusting the rebound damping of the fork …….. 36
10.16 Handlebar position…………………………………… 37
10.17 Adjusting the handlebar position ………………. 37
11 SERVICE WORK ON THE CHASSIS………………………… 39
11.1 Raising the motorcycle with a lift stand…………. 39
11.2 Removing the motorcycle from the lift stand…… 39
11.3 Bleeding the fork legs……………………………….. 40
11.4 Cleaning the dust boots of the fork legs…………. 40
11.5 Removing the fork protector ……………………….. 40
11.6 Installing the fork protector………………………… 41
11.7 Removing the fork legs …………………………… 41
11.8 Installing the fork legs …………………………… 41
11.9 Removing the lower triple clamp ………………. 42
11.10 Installing the lower triple clamp ……………….. 43
11.11 Checking the steering head bearing play………… 44
11.12 Adjusting the steering head bearing play …….. 45
11.13 Greasing the steering head bearing ……………. 45
11.14 Removing the start number plate…………………. 46
11.15 Installing the start number plate………………….. 46
11.16 Removing the front fender …………………………. 46
11.17 Installing the front fender ………………………….. 47
11.18 Removing the shock absorber ………………….. 47
11.19 Installing the shock absorber …………………… 48
11.20 Removing the seat …………………………………… 49
11.21 Mounting the seat……………………………………. 50

Page: 3

TABLE OF CONTENTS 3
11.22 Removing the air filter box cover …………………. 50
11.23 Installing the air filter box cover ………………….. 50
11.24 Removing the air filter …………………………… 51
11.25 Cleaning the air filter and air filter box ………. 51
11.26 Installing the air filter ……………………………. 52
11.27 Securing the air filter box cover ……………….. 52
11.28 Sealing the air filter box …………………………. 52
11.29 Removing the main silencer ……………………….. 53
11.30 Installing the main silencer………………………… 53
11.31 Changing the glass fiber yarn filling of the
main silencer ………………………………………. 53
11.32 Removing the fuel tank ………………………….. 54
11.33 Installing the fuel tank …………………………… 56
11.34 Checking for chain dirt accumulation……………. 57
11.35 Cleaning the chain …………………………………… 57
11.36 Checking the chain tension………………………… 58
11.37 Adjusting the chain tension………………………… 59
11.38 Checking the chain, rear sprocket, engine
sprocket, and chain guide………………………….. 59
11.39 Checking the frame ………………………………. 61
11.40 Checking the swingarm ………………………….. 61
11.41 Checking the throttle cable routing ………………. 61
11.42 Checking the rubber grips………………………….. 62
11.43 Adjusting the basic position of the clutch
lever …………………………………………………….. 62
11.44 Checking/correcting the fluid level of the
hydraulic clutch………………………………………. 63
11.45 Changing the hydraulic clutch fluid …………… 63
12 BRAKE SYSTEM ……………………………………………….. 65
12.1 Checking the free travel of the hand brake
lever …………………………………………………….. 65
12.2 Adjusting the basic position of the hand brake
lever …………………………………………………….. 65
12.3 Checking the brake discs …………………………… 65
12.4 Checking the brake fluid level of the front
brake ……………………………………………………. 66
12.5 Adding front brake fluid …………………………. 66
12.6 Checking the front brake linings ………………….. 67
12.7 Changing the front brake linings ………………. 68
12.8 Checking the free travel of foot brake lever …….. 69
12.9 Adjusting the basic position of the foot brake
lever ………………………………………………….. 70
12.10 Checking the rear brake fluid level……………….. 70
12.11 Adding rear brake fluid ………………………….. 71
12.12 Checking the rear brake linings …………………… 71
12.13 Changing the rear brake linings ………………… 72
13 WHEELS, TIRES ……………………………………………….. 74
13.1 Removing the front wheel ……………………….. 74
13.2 Installing the front wheel ……………………….. 74
13.3 Removing the rear wheel ………………………… 75
13.4 Installing the rear wheel …………………………. 76
13.5 Checking the tire condition ………………………… 77
13.6 Checking the tire air pressure……………………… 77
13.7 Checking spoke tension …………………………….. 77
14 ELECTRICAL SYSTEM ………………………………………… 79
14.1 Removing the battery …………………………….. 79
14.2 Installing the battery ……………………………… 79
14.3 Recharging the battery …………………………… 80
14.4 Changing the main fuse…………………………….. 81
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
15.4 Draining the coolant ……………………………… 83
15.5 Refilling coolant …………………………………… 84
16 TUNING THE ENGINE………………………………………… 85
16.1 Checking the play in the throttle cable ………….. 85
16.2 Adjusting the play in the throttle cable ………. 85
16.3 Setting the characteristic map of the throttle
response …………………………………………….. 86
16.4 Changing the mapping………………………………. 87
16.5 Adjusting the idle speed …………………………. 87
16.6 Teaching the throttle valve position………………. 88
16.7 Checking the basic position of the shift lever ….. 88
16.8 Adjusting the basic position of the shift
lever ………………………………………………….. 89
17 SERVICE WORK ON THE ENGINE …………………………. 90
17.1 Changing the fuel screen ………………………… 90
17.2 Checking the engine oil level………………………. 91
17.3 Changing the engine oil and oil filter, cleaning
the oil screen ………………………………………. 92
17.4 Adding engine oil…………………………………….. 94
18 CLEANING, CARE ……………………………………………… 95
18.1 Cleaning the motorcycle ……………………………. 95
19 STORAGE………………………………………………………… 96
19.1 Storage …………………………………………………. 96
19.2 Preparing for use after storage…………………….. 97
20 TROUBLESHOOTING …………………………………………. 98
21 TECHNICAL DATA……………………………………………. 100
21.1 Engine ………………………………………………… 100
21.2 Engine tightening torques ………………………… 101
21.3 Capacities ……………………………………………. 102
21.3.1 Engine oil ………………………………………… 102
21.3.2 Coolant……………………………………………. 102
21.3.3 Fuel ……………………………………………….. 102
21.4 Chassis ……………………………………………….. 102
21.5 Electrical system……………………………………. 103
21.6 Tires…………………………………………………… 103
21.7 Fork……………………………………………………. 103
21.7.1 SX‑F EU…………………………………………… 103
21.7.2 SX‑F US…………………………………………… 104
21.7.3 XC‑F US…………………………………………… 104
21.8 Shock absorber……………………………………… 104
21.8.1 SX‑F EU…………………………………………… 104
21.8.2 SX‑F US…………………………………………… 105
21.8.3 XC‑F US…………………………………………… 105
21.9 Chassis tightening torques ……………………….. 106
22 SUBSTANCES ………………………………………………… 108
23 AUXILIARY SUBSTANCES …………………………………. 110
24 STANDARDS ………………………………………………….. 112
25 INDEX OF SPECIAL TERMS ……………………………….. 113
26 LIST OF ABBREVIATIONS………………………………….. 114
27 LIST OF SYMBOLS…………………………………………… 115
27.1 Yellow and orange symbols……………………….. 115
INDEX …………………………………………………………………. 116

Page: 4

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.

Page: 5

2 SAFETY ADVICE 5
2.1 Use definition – intended use
(All SX‑F models)
This vehicle is designed and built to withstand the normal stresses and strains of competitive use. This vehicle complies with the
currently valid regulations and categories of the top international motorsport organizations.
Info
Only operate this vehicle in closed-off areas remote from public road traffic.
(XC‑F US)
This vehicle is designed and built to withstand the normal stresses and strains of competitive use. This vehicle complies with the
currently valid regulations and categories of the top international motorsport organizations.
Info
Only operate this vehicle in closed-off areas remote from public road traffic.
This vehicle is designed for use in offroad endurance competition, and not primarily for use in motocross.
2.2 Misuse
The vehicle must only be used as intended.
Dangers can arise for people, property and the environment through use not as intended.
Any use of the vehicle beyond the intended and defined use constitutes misuse.
Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respective use.
2.3 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.
2.4 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.
2.5 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:

Page: 6

2 SAFETY ADVICE 6
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.
2.6 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.
2.7 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.
2.8 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.
2.9 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.

Page: 7

2 SAFETY ADVICE 7
2.10 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 must be handed over to the new owner if the vehicle is sold.

Page: 8

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

Page: 9

4 VIEW OF VEHICLE 9
4.1 View of vehicle, front left (example)
F01018-10
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. 16)

Page: 10

4 VIEW OF VEHICLE 10
4.2 View of vehicle, rear right (example)
F01019-10
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 Chassis number ( p. 11)
6 Type label ( p. 11)
7 Fork part number ( p. 11)
8 Idle speed adjusting screw ( p. 16)
9 Foot brake lever ( p. 17)
10 Engine oil level viewer
11 Shock absorber rebound adjustment
12 Shock absorber article number ( p. 11)

Page: 11

5 SERIAL NUMBERS 11
5.1 Chassis number
401945-10
The chassis number 1 is stamped on the right side of the steering head.
5.2 Type label
401946-10
The type label 1 is fixed to the front of the steering head.
5.3 Engine number
H01047-10
Engine number 1 is located on the left side of the engine over the engine sprocket.
5.4 Fork part number
401947-10
The fork part number 1 is stamped on the inner side of the axle clamp.
5.5 Shock absorber article number
0
0
1
1
401948-10
Shock absorber article number 1 is stamped on the top of the shock absorber above
the adjusting ring towards the engine side.

Page: 12

6 CONTROLS 12
6.1 Clutch lever
S01192-10
The clutch lever 1 is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
6.2 Hand brake lever
S01193-10
Hand brake lever 1 is fitted on the right side of the handlebar.
The front brake is engaged using the hand brake lever.
6.3 Throttle grip
S01193-11
The throttle grip 1 is fitted on the right side of the handlebar.
6.4 Kill switch
S01194-10
Kill switch 1 is fitted on the left side of the handlebar.
Possible states
• Kill switch in basic position – In this position, the ignition circuit is closed and
the engine can be started.
• Kill switch pressed – In this position, the ignition circuit is interrupted, a run-
ning engine stops, and a non-running engine will not start.
6.5 Electric starter button
S01195-10
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.

Page: 13

6 CONTROLS 13
6.6 Combination switch
H01181-10
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 using the combination
switch.
6.7 Overview of indicator lamps
S01196-10
Possible states
Malfunction indicator lamp lights up/flashes orange – The OBD has
detected an emission- or safety-critical fault.
Malfunction indicator lamp flashes orange rapidly – Launch control is
activated.
(XC‑F US)
Fuel level warning lamp lights up orange – The fuel level has
reached the reserve mark.
6.8 Service hour counter
S01257-10
Service hour counter 1 is 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.
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.

Page: 14

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.
S01197-10
(All SX‑F models)
– Turn filler cap 1 counterclockwise and lift it off.
S01265-10
(XC‑F US)
– Press release button 1, turn the filler cap counterclockwise, and lift it free.
6.10 Closing the filler cap
S01198-10
(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.
S01266-10
(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.

Page: 15

6 CONTROLS 15
6.11 Cold start button
F01032-10
(All SX‑F models)
Cold start button 1 is fitted on the bottom of the throttle valve body.
F01021-10
(XC‑F US)
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.

Page: 16

6 CONTROLS 16
6.12 Idle speed adjusting screw
F01020-10
The idle setting of the throttle valve body has a big influence on the vehicle’s starting
behavior, on stable idling, and on vehicle response when the throttle is opened.
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.
6.13 Shift lever
401950-10
Shift lever 1 is mounted on the left side of the engine.
401950-13
(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.
401950-11
(XC‑F US)
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.

Page: 17

6 CONTROLS 17
6.14 Foot brake lever
401956-10
Foot brake lever 1 is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.
6.15 Plug-in stand (All SX‑F models)
0
0
1
1
402001-10
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.
6.16 Side stand (XC‑F US)
401943-10
The side stand 1 is on the left side of the vehicle.
401944-10
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.

Page: 18

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. 62)
– Adjust the basic position of the hand brake lever. ( p. 65)
– Adjust the basic position of the foot brake lever. ( p. 70)
– Adjust the basic position of the shift lever. ( p. 89)
– Get used to handling the motorcycle on a suitable surface 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.

Page: 19

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
402555-01
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
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. 51)
Info
Check the air filter approx. every 30 minutes.
– Seal the air filter box. ( p. 52)
– Secure the air filter box cover. ( p. 52)

Page: 20

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 temperature and slow speed. ( p. 21)
– Riding at low temperature and in snow. ( p. 21)
7.5 Preparing for rides on dry sand
102136-01
– Fit a dust cover on the air filter.
Dust cover for air filter (79006920000)
Info
See the KTM PowerParts fitting instructions.
102138-01
– Fit a sand cover on the air filter.
Sand cover for air filter (79006922000)
Info
See the KTM PowerParts fitting instructions.
600868-01
– Clean the chain.
Chain cleaner ( p. 110)
– Fit the steel sprocket.
Tip
Do not grease the chain.
– Clean the radiator fins.
– Straighten bent radiator fins carefully.
7.6 Preparing for rides on wet sand
102137-01
– Fit a rain cover on the air filter.
Waterproofing device for air filter (79006921000)
Info
See the KTM PowerParts fitting instructions.

Page: 21

7 PREPARING FOR USE 21
600868-01
– Clean the chain.
Chain cleaner ( p. 110)
– Fit the steel sprocket.
Tip
Do not grease the chain.
– Clean the radiator fins.
– Straighten bent radiator fins carefully.
7.7 Preparing for rides on wet and muddy surfaces
102137-01
– Fit a waterproofing device on the air filter.
Waterproofing device for air filter (79006921000)
Info
See the KTM PowerParts fitting instructions.
600868-01
– Fit the steel sprocket.
– Clean the motorcycle. ( p. 95)
– Straighten bent radiator fins carefully.
7.8 Preparing for rides at high temperature and slow speed
600868-01
– Adjust the secondary drive to the road conditions.
Info
The engine oil quickly gets hot if the clutch has to be operated very often
due to an excessively high secondary drive.
– Clean the chain.
Chain cleaner ( p. 110)
– Clean radiator fins.
– Straighten bent radiator fins carefully.
– Check the coolant level. ( p. 83)
7.9 Preparing for rides at low temperature and in snow
102137-01
– Fit a waterproofing device on the air filter.
Waterproofing device for air filter (79006921000)
Info
See the KTM PowerParts fitting instructions.

Page: 22

8 RIDING INSTRUCTIONS 22
8.1 Checks and maintenance measures when preparing for use
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 it is being operated.
H02217-01
– Check the engine oil level. ( p. 91)
– Check the brake fluid level of the front brake. ( p. 66)
– Check the rear brake fluid level. ( p. 70)
– Check the front brake linings. ( p. 67)
– Check the rear brake linings. ( p. 71)
– Check that the brake system is functioning properly.
– Check the coolant level. ( p. 83)
– Check for chain dirt accumulation. ( p. 57)
– Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 59)
– Check the chain tension. ( p. 58)
– Check the tire condition. ( p. 77)
– Check the tire air pressure. ( p. 77)
– Check the spoke tension. ( p. 77)
Info
The spoke tension must be checked regularly as incorrect spoke tension will
strongly impair riding safety.
– Clean the dust boots of the fork legs. ( p. 40)
– Bleed the fork legs. ( p. 40)
– 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 level.
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.
0
0
1
1
402001-10
(All SX‑F models)
– Remove plug-in stand 1.

Page: 23

8 RIDING INSTRUCTIONS 23
401944-10
(XC‑F US)
– Take the motorcycle off side stand 1 and secure the side stand with rubber
band 2.
– Shift the transmission to idle.
Condition
Ambient temperature: < 20 °C (< 68 °F)
– Push the cold start button in all the way.
400733-01
– 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.
During starting, the warning lamp lights up briefly as a function check.
8.3 Activating launch control
Info
The launch control helps the rider to generate optimum motorcycle acceleration at the beginning of a race. The maximum
speed of the engine with the throttle valve fully opened (full throttle) is reduced. After the start, it is gradually increased up to
the maximum engine speed. The rider opens the throttle fully throughout this procedure. The clutch must be operated exactly
as it would be without launch control activated.
Condition
The motorcycle is stationary.
The engine is running at idle speed.
The transmission is in neutral.
H01179-10
– Press and hold the MAP and TC buttons simultaneously.
Malfunction indicator lamp flashes orange rapidly.
Info
The launch control is deactivated automatically a few seconds after the
vehicle has started.
The launch control is also deactivated in the following cases (malfunction
indicator lamp no longer flashes): if the throttle valve is closed more than
1/3 of the way after full throttle, and/or if there is no start within 3 minutes.
For safety reasons, the engine must be switched off for at least 10 seconds
before the launch control can be activated again, regardless of whether the
vehicle has been 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.

Page: 24

8 RIDING INSTRUCTIONS 24
H01179-11
– 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.
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.

Page: 25

8 RIDING INSTRUCTIONS 25
– 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.
8.8 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
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
– Park the vehicle on a firm and level surface.
– Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
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.
– Apply the brakes on 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.
401475-01
– Switch off the engine.
– Use tension belts or other suitable devices to secure the motorcycle against acci-
dents or falling over.

Page: 26

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)
A
A
401522-10
– Fill the fuel tank with fuel up to measurement A.
Guideline
Measurement of A 35 mm (1.38 in)
Total fuel tank
capacity, approx.
(All SX‑F models)
7 l (1.8 US gal) Super unleaded (ROZ 95/RON 95/PON
91) ( p. 109)
Total fuel tank
capacity, approx.
(XC‑F US)
8.5 l
(2.25 US gal)
Super unleaded (ROZ 95/RON 95/PON
91) ( p. 109)
– Close the filler cap. ( p. 14)

Page: 27

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.
Different service intervals may apply in your country, depending on the local operating conditions.
9.2 Required work
Every 40 operating hours
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 charging the battery. ● ● ● ●
Check the front brake linings. ( p. 67) ● ● ● ●
Check the rear brake linings. ( p. 71) ● ● ● ●
Check the brake discs. ( p. 65) ● ● ● ●
Check the brake lines for damage and leakage. ● ● ● ●
Check the rear brake fluid level. ( p. 70) ● ● ● ●
Check the free travel of the foot brake lever. ( p. 69) ● ● ● ●
Check the frame. ( p. 61) ● ● ● ●
Check the swingarm. ( p. 61) ● ● ● ●
Check the swingarm bearing for play. ● ●
Check the heim joint for play. ● ● ● ●
Check the shock absorber linkage. ● ● ● ●
Check the tire condition. ( p. 77) ○ ● ● ● ●
Check the tire air pressure. ( p. 77) ○ ● ● ● ●
Check the wheel bearing for play. ● ● ● ●
Check the wheel hubs. ● ● ● ●
Check the rim run-out. ○ ● ● ● ●
Check the spoke tension. ( p. 77) ○ ● ● ● ●
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 59) ● ● ● ●
Check the chain tension. ( p. 58) ○ ● ● ● ●
Grease all moving parts (e.g., hand lever, chain, …) and check for smooth operation. ● ● ● ●
Check/correct the fluid level of the hydraulic clutch. ( p. 63) ● ● ● ●
Check the brake fluid level of the front brake. ( p. 66) ● ● ● ●
Check the free travel of the hand brake lever. ( p. 65) ● ● ● ●
Check the steering head bearing play. ( p. 44) ○ ● ● ● ●
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, coolant, bleeder, drainage, etc.) and sleeves for cracking, leaks, and incorrect
routing.
○ ● ● ● ●
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. 51) ● ● ● ●
Change the glass fiber yarn filling of the main silencer. ( p. 53) ● ●
Service the fork. ●
Service the shock absorber. ●
Check the screws and nuts for tightness. ○ ● ● ● ●
Change the fuel screen. ( p. 90) ○ ● ● ● ●

Page: 28

9 SERVICE SCHEDULE 28
Every 40 operating hours
Every 30 operating hours
Every 20 operating hours
Every 10 operating hours/after every race
Once after 1 operating hour
Check the fuel pressure. ● ● ● ●
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. ○ ● ● ● ●
Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ ● ● ● ●
○ One-time interval
● Periodic interval
9.3 Recommended work
Annually
Every 100 operating hours
Every 50 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. 63) ●
Grease the steering head bearing. ( p. 45) ●
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

Page: 29

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.
401030-01
– 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.
10.2 Air suspension AER 48
M01110-01
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
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.

Page: 30

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.
S01201-10
– 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
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.
S01202-10
– 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.

Page: 31

10 TUNING THE CHASSIS 31
Guideline
Compression damping, high-speed (SX‑F EU)
Comfort 2 turns
Standard 1.5 turns
Sport 1 turn
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.)
S01203-10
– 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
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.

Page: 32

10 TUNING THE CHASSIS 32
10.7 Measuring rear wheel sag unloaded
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 39)
402415-10
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.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 39)
10.8 Checking the static sag of the shock absorber
402416-10
– 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 pretension of the shock absorber. ( p. 33)

Page: 33

10 TUNING THE CHASSIS 33
10.9 Checking the riding sag of the shock absorber
402417-10
– 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:
– Adjust the riding sag. ( p. 34)
10.10 Adjusting the spring pretension 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 pretension, 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. 39)
– Remove the shock absorber. ( p. 47)
– After removing the shock absorber, clean it thoroughly.
402659-10
Main work
– Loosen screw 1.
– Turn adjusting ring 2 until the spring is no longer under tension.
Hook wrench (90129051000)
– 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) 10 mm (0.39 in)
Spring preload (SX‑F US) 5 mm (0.2 in)
Spring preload (XC‑F US) 10 mm (0.39 in)
Info
Depending on the static sag and/or the riding sag, it may be necessary to
increase or decrease the spring pretension.
– Tighten screw 1.
Guideline
Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft)
Finishing work
– Install the shock absorber. ( p. 48)

Page: 34

10 TUNING THE CHASSIS 34
– Check the free travel of the foot brake lever. ( p. 69)
– Remove the motorcycle from the lift stand. ( p. 39)
10.11 Adjusting the riding sag
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 39)
– Remove the shock absorber. ( p. 47)
– After removing the shock absorber, clean it thoroughly.
B00292-10
Main work
– Choose and mount a suitable spring.
Guideline
Spring rate (SX‑F EU)
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 rate (SX‑F US)
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 rate (XC‑F US)
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)
Info
The spring rate is shown on the outside of the spring.
Finishing work
– Install the shock absorber. ( p. 48)
– Check the free travel of the foot brake lever. ( p. 69)
– 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. 39)
10.12 Checking the basic setting of the fork
Info
For various reasons, no exact riding sag can be determined for the fork.
401000-01
– 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.

Page: 35

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. 39)
S01204-10
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.
– 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) 10.7 bar (155 psi)
Air pressure (SX‑F US) 10.7 bar (155 psi)
Air pressure (XC‑F US) 9.6 bar (139 psi)
Gradual changing of the air pressure in
steps of
0.2 bar (3 psi)
Minimum air pressure 7 bar (102 psi)
Maximum air pressure 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. 39)

Page: 36

10 TUNING THE CHASSIS 36
10.14 Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
S01205-10
– 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 17 clicks
Standard 12 clicks
Sport 7 clicks
Compression damping (SX‑F US)
Comfort 17 clicks
Standard 12 clicks
Sport 7 clicks
Compression damping (XC‑F US)
Comfort 17 clicks
Standard 12 clicks
Sport 7 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.
M01100-10
– 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
Rebound damping (SX‑F EU)
Comfort 17 clicks
Standard 12 clicks
Sport 7 clicks
Rebound damping (SX‑F US)
Comfort 17 clicks
Standard 12 clicks
Sport 7 clicks
Rebound damping (XC‑F US)
Comfort 17 clicks
Standard 12 clicks
Sport 7 clicks

Page: 37

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
H01188-10
The holes on the handlebar supports are placed at a distance of A from the center.
Hole distance A 3.5 mm (0.138 in)
The handlebar can be mounted in 2 different positions. In this way, the handlebar can
be mounted in the most comfortable position for the rider.
10.17 Adjusting the handlebar position
Warning
Danger of accidents A repaired handlebar poses a safety risk.
If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result.
– Change the handlebar if the handlebar is damaged or bent.
Preparatory work
– Remove the handlebar cushion.
H01189-10
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
(29.5 lbf ft)
Loctite® 243™
– 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)

Page: 38

10 TUNING THE CHASSIS 38
Finishing work
– Mount the handlebar cushion.

Page: 39

11 SERVICE WORK ON THE CHASSIS 39
11.1 Raising the motorcycle with a lift stand
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
– Park the vehicle on a firm and level surface.
– Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
401942-01
– 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.
11.2 Removing the motorcycle from the lift stand
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
– Park the vehicle on a firm and level surface.
– Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
0
0
1
1
402001-10
(All SX‑F models)
– Remove the motorcycle from the lift stand.
– Remove the lift stand.
– To park the motorcycle, insert plug-in stand 1 into the left side of the wheel
spindle.
Info
Remove the plug-in stand before riding.
401943-10
(XC‑F US)
– Remove the motorcycle from the lift stand.
– Remove the lift stand.
– To park the motorcycle, press side stand 1 to the ground with your foot and
lean the motorcycle on it.
Info
While riding, the side stand must be folded up and secured with the
rubber band.

Page: 40

11 SERVICE WORK ON THE CHASSIS 40
11.3 Bleeding the fork legs
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 39)
H01182-12
Main work
– Release bleeder screws 1.
Any excess pressure escapes from the interior of the fork.
– Tighten the bleeder screws.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 39)
11.4 Cleaning the dust boots of the fork legs
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 39)
– Remove the fork protector. ( p. 40)
S01207-10
Main work
– Push dust boots 1 of both fork legs downward.
Info
The dust boots remove dust and coarse dirt particles from the inside fork
tubes. Over time, dirt can accumulate behind the dust boots. If this dirt is
not removed, the oil seals behind can start to leak.
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking
effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
– Clean and oil the dust boots and inner fork tubes of both fork legs.
Universal oil spray ( p. 111)
– Press the dust boots back into their installation position.
– Remove excess oil.
Finishing work
– Install the fork protector. ( p. 41)
– Remove the motorcycle from the lift stand. ( p. 39)
11.5 Removing the fork protector
S01208-10
– 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.

Page: 41

11 SERVICE WORK ON THE CHASSIS 41
11.6 Installing the fork protector
S01208-11
– Position the fork protection on the left fork leg. Mount and tighten screws 1.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
– Position the brake line and clamp. Mount and tighten screws 2.
– Position the fork protector on the right fork leg. Mount and tighten screws 3.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
11.7 Removing the fork legs
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 39)
– Remove the front wheel. ( p. 74)
S01267-10
Main work
– Remove screws 1 and take off the clamp.
– Remove screws 2 and take off the brake caliper.
– Allow the brake caliper and brake line to hang tension-free to the side.
Info
Do not pull the hand brake lever if the front wheel has been removed.
S01210-10
– Loosen screws 3. Take out the left fork leg.
– Unscrew screws 4. Take out the right fork leg.
11.8 Installing the fork legs
H01182-10
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.
The air suspension is located in the left fork leg. The pressure and rebound
damping is located in the right fork leg.
S01210-11
– 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)

Page: 42

11 SERVICE WORK ON THE CHASSIS 42
S01267-11
– Position the brake caliper. Mount and tighten screws 4.
Guideline
Screw, front brake caliper M8 25 Nm
(18.4 lbf ft)
Loctite® 243™
– Position the brake line and clamp. Mount and tighten screws 5.
Finishing work
– Install the front wheel. ( p. 74)
11.9 Removing the lower triple clamp
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 39)
– Remove the front wheel. ( p. 74)
– Remove the fork legs. ( p. 41)
– Remove the start number plate. ( p. 46)
– Remove the front fender. ( p. 46)
– Remove the handlebar cushion.
S01211-10
Main work
– Remove the indicator lamp bracket.
– 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
Cover the components to protect them against damage.
Do not kink the cables and lines.
S01212-10
– Remove O-ring 4. Remove protective ring 5.
– Take out the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.

Page: 43

11 SERVICE WORK ON THE CHASSIS 43
11.10 Installing the lower triple clamp
102146-10
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 seal 1 is correctly positioned.
– Slide on protective ring 2 and O-ring 3.
S01213-10
– Position the upper triple clamp with the handlebar.
– Mount screw 4 but do not tighten yet.
H01182-11
– 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
damping is located in the right fork leg.
S01214-10
– Tighten screws 6.
Guideline
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
S01215-10
– Tighten screw 4.
Guideline
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft)

Page: 44

11 SERVICE WORK ON THE CHASSIS 44
S01216-10
– Mount and tighten screw 7.
Guideline
Screw, top steering stem M8 20 Nm
(14.8 lbf ft)
Loctite® 243™
S01214-11
– 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 indicator lamp bracket.
Guideline
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft)
S01267-12
– Position the brake caliper. Mount and tighten screws bk.
Guideline
Screw, front brake caliper M8 25 Nm
(18.4 lbf ft)
Loctite® 243™
– Position the brake line and clamp. Mount and tighten screws bl.
Finishing work
– Install the front fender. ( p. 47)
– Mount the handlebar cushion.
– Install the start number plate. ( p. 46)
– Install the front wheel. ( p. 74)
– 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. 44)
– Remove the motorcycle from the lift stand. ( p. 39)
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. 39)

Page: 45

11 SERVICE WORK ON THE CHASSIS 45
H01167-01
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. 45)
– Move the handlebar to and fro over the entire steering range.
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. 45)
– Check the steering head bearing and change if necessary.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 39)
11.12 Adjusting the steering head bearing play
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 39)
– Remove the handlebar cushion.
S01217-10
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.
– Mount and tighten screw 2.
Guideline
Screw, top steering stem M8 20 Nm
(14.8 lbf ft)
Loctite® 243™
– Tighten screws 1.
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
– Check the steering head bearing play. ( p. 44)
Finishing work
– Mount the handlebar cushion.
– Remove the motorcycle from the lift stand. ( p. 39)
11.13 Greasing the steering head bearing
800010-10
– Remove the lower triple clamp. ( p. 42)
– Install the lower triple clamp. ( p. 43)

Page: 46

11 SERVICE WORK ON THE CHASSIS 46
11.14 Removing the start number plate
S01234-10
– Remove screw 1.
– Unhook the start number plate from the brake line and remove it.
11.15 Installing the start number plate
S01235-10
– Position the brake line in holders A on the start number plate.
– Position the start number plate. Mount and tighten screw 1.
The holding lugs engage in the fender.
11.16 Removing the front fender
Preparatory work
– Remove the start number plate. ( p. 46)
S01218-10
Main work
– Remove screws 1 and 2. Remove the front fender.

Page: 47

11 SERVICE WORK ON THE CHASSIS 47
11.17 Installing the front fender
S01218-10
Main work
– Position the front fender. Mount and tighten screws 1 and 2.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Finishing work
– Install the start number plate. ( p. 46)
11.18 Removing the shock absorber
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 39)
F01022-10
Main work
– Remove the cable ties.
– Remove screws 1 with the washers.
– Remove screws 2.
– Remove the frame protectors on the left and right.
S01220-10
– Remove screw 3.
– Remove fitting 4.
Info
Raise the wheel slightly to be able to remove the screws more easily.
S01221-10
– Remove screws 5.
– Pull off foot brake cylinder from the push rod.

Page: 48

11 SERVICE WORK ON THE CHASSIS 48
S01222-10
– Remove the connecting link of the chain.
– Take off the chain.
S01223-10
– Remove nut 6 and pull out the swingarm pivot.
– Push the swingarm back and secure it against falling over.
F01024-10
– Remove screw 7.
– Remove the shock absorber carefully at the bottom.
11.19 Installing the shock absorber
F01023-10
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
(44.3 lbf ft)
Loctite® 2701™
S01227-10
– 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)
S01222-11
– 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.

Page: 49

11 SERVICE WORK ON THE CHASSIS 49
S01228-10
– Position the foot brake cylinder.
Push rod 4 engages in the foot brake cylinder.
Info
Ensure that the dust boot is correctly seated.
– Mount and tighten screws 5.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
S01229-10
– Position the angle lever and linkage lever.
– Mount and tighten fitting 6.
Guideline
Nut, linkage lever to angle lever M14x1.5 80 Nm (59 lbf ft)
Info
Pay attention to flat area B.
– Mount and tighten screw 7.
Guideline
Screw, bottom shock
absorber
M10 60 Nm
(44.3 lbf ft)
Loctite® 2701™
Info
Raise the wheel slightly to be able to mount the screw more easily.
F01022-11
– 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)
– Mount the new cable ties.
Finishing work
– Check the free travel of the foot brake lever. ( p. 69)
– Remove the motorcycle from the lift stand. ( p. 39)
11.20 Removing the seat
S01230-10
– Remove screws 1.
H02218-10
– Raise the rear of the seat, pull the seat back, and lift it off.

Page: 50

11 SERVICE WORK ON THE CHASSIS 50
11.21 Mounting the seat
H02218-11
– 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.
S01230-10
– Mount and tighten screws 1.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
11.22 Removing the air filter box cover
F01025-10
Condition
The air filter box cover is secured.
– Remove screw 1.
F01025-11
– Pull off the air filter box cover in area A sideways and remove it toward the front.
11.23 Installing the air filter box cover
F01025-12
– Insert the air filter box cover in area A and clip it into area B.