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KTM 450 EXC-F 2020 Setup Instructions
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KTM 450 EXC-F 2020 Setup Instructions

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SETUP INSTRUCTIONS
2020
450 EXC‑F
450 EXC‑F Six Days
500 EXC‑F
500 EXC‑F Six Days
500 XCF‑W
Art. no. 3214148en

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Summary of Contents for KTM 450 EXC-F 2020

  • Page 1 SETUP INSTRUCTIONS 2020 450 EXC‑F 450 EXC‑F Six Days 500 EXC‑F 500 EXC‑F Six Days 500 XCF‑W Art. no. 3214148en...
  • Page 3 KTM accepts no liability for delivery options, deviations from fig- ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Means Of Representation

    1 MEANS OF REPRESENTATION 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). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips.
  • Page 5 To operate the vehicle, the vehicle electronics must be enabled. This process is conducted during initial setup in KTM Dealer.net. Enabling ensures that the initial setup in KTM Dealer.net is docu- mented. Enabling can be performed either temporarily, e.g. for a test ride, or permanently for vehicle handover.
  • Page 6 2 SETUP – Position turn signal indicator lamp in the combination instrument rack. H01768-10 Condition Packaging V12 – Remove the box and the plastic packaging. Info An assistant prevents the motorcycle from falling over. To avoid damaging the motorcycle during the setup, leave the protective film on the vehicle until you E00850-10 have finished.
  • Page 7 SETUP 2 – Position the connector board and combination instrument on the upper triple clamp. – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Route the clutch line with the clutch master cylinder toward the front between the upper and lower triple 402736-10 clamps.
  • Page 8 2 SETUP Info The markings on the handlebar should be at the center of the handlebar clamps. Keep the installed gap widths equal when tighten- ing. (EXC‑F Six Days) – Remove screws and take off the handlebar supports. – Move the handlebar supports to the desired position and mount and tighten screws Guideline Screw, handle-...
  • Page 9 SETUP 2 Info The markings on the handlebar should be at the center of the handlebar clamps. Keep the installed gap widths equal when tighten- ing. (All EU models) – Position the controls on the right half of the handlebar. S03665-01 (500 EXC‑F US, 500 EXC‑F Six Days US) –...
  • Page 10 2 SETUP (500 EXC‑F US, 500 EXC‑F Six Days US) – Position the controls on the left handlebar half. S01410-01 (XCF‑W) – Position the controls on the left handlebar half. S03666-01 (EXC‑F Six Days EU, XCF‑W) Warning Voiding of the government approval for road use and the insurance coverage If the combination switch is mounted, the vehicle’s road permit, if any, expires.
  • Page 11 SETUP 2 (All EU models) – Mount the turn signal switch. 402390-01 Condition Packaging V12 (All EU models, EXC‑F Six Days, 500 EXC‑F US) – Join all plug-in connectors to the connector board. – Route the cables without tension and secure with the cable ties.
  • Page 12 2 SETUP – Route the cable without tension and secure with cable ties and cable holders. S01412-10 – Mount the mirror clamps on both sides. H01060-01 – Mount both rear mirrors with the adapter. E00474-01...
  • Page 13 SETUP 2 – Preassemble the hand guards on the left and right. E00852-01 – Mount the left hand guard. – Mount the right hand guard. F01077-10 – Secure the handlebar cushion with two cable ties. – Install front fender. ( p.
  • Page 14 2 SETUP (All EU models) – Remove connector from the bracket and join with turn signal wiring harness. V01884-10 – Insert the black and violet cables of bulb included in the separate enclosure into the socket and position it in the turn signal indicator lamp.
  • Page 15 SETUP 2 – Disconnect tail light plug-in connector on the wiring harness. V01863-10 – Remove screws – Remove screws – Remove license plate holder with tail light. Info Pay attention to the cable of the tail light. – Lead the cable between the fairing parts. V01864-10 –...
  • Page 16 2 SETUP – Position the turn signal on both sides on the license plate holder, mount nuts with washers and tighten. – Position license plate lamp on the license plate holder, and mount and tighten screws – Mount reflector on license plate holder. V01866-10 –...
  • Page 17 SETUP 2 – Mount and tighten screws V01865-10 – Mount and tighten screw Guideline Remaining screws, EJOT PT ® 2 Nm (1.5 lbf ft) chassis K60x25‑Z V01867-10 – Lead the wiring harnesses through the opening. – Position the license plate holder on the rear. S03684-01 –...
  • Page 18 2 SETUP – Join the plug-in connectors of tail light and turn signal wiring harness with the wiring harness. Info Pay attention to routing of the wiring harnesses. – Install the rear left side cover. ( p. 33) – Install the air filter box cover. ( p.
  • Page 19 SETUP 2 – Mount the washer and splint V01874-10 – Position the left footrest and pin. Info Only insert the pin to the extent that the spring can still be mounted. S01398-10 – Position spring as shown. Spring engages in area V01875-10 –...
  • Page 20 Mount the cable ties. (XCF‑W, EXC‑F Six Days) – Install the engine guard. ( p. 33) – Unpack and mount the KTM PowerParts included in the deliv- ery (optional). Info Read the accompanying KTM PowerParts fitting instruc- tions. – Attach the stickers included in the scope of supply (optional).
  • Page 21 WORK 3 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (78129955100) Neither wheel is in contact with the ground.
  • Page 22 3 WORK (All EU models, EXC‑F Six Days, 500 EXC‑F US) – Detach plug-in connectors and take off the headlight mask with the headlight. S01328-10 (XCF‑W) – Disconnect plug-in connector and take off the head- light mask together with the headlight. V01802-10 Installing the headlight mask with the headlight Main work...
  • Page 23 WORK 3 Checking the headlight setting – Position the vehicle upright on a horizontal surface in front of a light wall and make a marking at the height of the center of the low beam headlight. – Make another mark at a distance under the first marking.
  • Page 24 3 WORK Installing the shock absorber Main work – Push splash protector to the side and position the shock absorber. Mount and tighten screw Guideline Screw, top 80 Nm (59 lbf ft) Loctite ® 2701™ shock absorber – Mount and tighten screw Guideline K01337-11 Screw, bottom...
  • Page 25 WORK 3 (EXC‑F Six Days) – Position the fork legs. Bleeder screws are positioned toward the front. Info The rebound damping is located in right fork leg REB (red adjusting screw). The compression damping is located in left fork leg COM (white adjusting screw).
  • Page 26 3 WORK – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change front wheel bearing. – Clean and grease shaft seal rings and contact surface of the spacers. Long-life grease ( p.
  • Page 27 WORK 3 (EXC‑F Six Days) – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis K00576-10 – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis S01321-10 Finishing work –...

  • Page 28: Mounting The Seat

    3 WORK 3.12 Mounting the seat – Mount the front of the seat on the collar bushings of the fuel tank, lower the seat at the rear, and push the seat forward. – Make sure the seat is locked in correctly. H02218-11 –...
  • Page 29 WORK 3 3.14 Connecting the negative cable of the 12-V battery Main work – Connect negative cable of the 12-V battery. Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) Contact disk must be mounted under screw cable lug with the claws toward the battery terminal. T02638-10 Finishing work –...
  • Page 30 3 WORK Main work – Disconnect negative cable from the 12-V battery. – Pull back positive terminal cover and disconnect the posi- tive cable from the 12-V battery. V01776-10 – Pull off starter relay and fuse box from the battery compartment and hang to the side.
  • Page 31 WORK 3 – Mount relays and attach wiring harness V01778-11 – Mount starter relay and fuse box V01777-11 – Connect the positive cable to the 12-V battery. Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) Info Contact disk must be mounted under screw cable lug with the claws toward the battery termi- nal.

  • Page 32: Charging The 12-V Battery

    3 WORK 3.17 Charging the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V batteries. – Only charge 12 V batteries in well-ventilated rooms. –...
  • Page 33 WORK 3 Main work – Connect a battery charger to the 12-V battery. Adjust the bat- tery charger. EU battery charger XCharge‑professional (00029095050) Alternative 1 US battery charger XCharge‑professional (00029095051) Alternative 2 311910-10 UK battery charger XCharge‑professional (00029095052) Alternative 3 CH battery charger XCharge‑professional (00029095053) Info...
  • Page 34 3 WORK – Pull off the air filter box cover in area laterally and take it off at the front. V01759-11 Condition The air filter box cover is not secured. – Pull off the air filter box cover in area laterally and take it off at the front.
  • Page 35 WORK 3 3.20 Removing the rear left side cover – Remove screw and take off fairing part to the front. V01870-10 3.21 Installing the rear left side cover – Position side cover and hook it in in areas – Mount and tighten screw Guideline Screw, sub- 35 Nm (25.8 lbf ft)
  • Page 36 3 WORK 3.23 Opening fuel tank 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. –...
  • Page 37 WORK 3 3.25 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.
  • Page 38 3 WORK 3.26 Setting the kilometers or miles Info If you change the unit, the value ODO is retained and converted accordingly. The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed. Condition The motorcycle is stationary.
  • Page 39 WORK 3 Activating the function – Press the button The symbol continues to appear in the display and the next function appears. Deactivating a function – Press the button The symbol disappears in the display and the next function appears. 3.28 Setting the clock Condition...

  • Page 40: Technical Data

    4 TECHNICAL DATA Chassis tightening torques EJOT PT Remaining screws, chassis ® K60x25‑Z 2 Nm (1.5 lbf ft) EJOT PT Screw, combination switch ® K50x18 2 Nm (1.5 lbf ft) (EXC‑F Six Days EU, XCF‑W) EJOT DELTA PT Screw, intake air temperature sen- ®...
  • Page 41 TECHNICAL DATA 4 Screw, engine brace on frame M8x15 25 Nm (18.4 lbf ft) Loctite ® 2701™ Screw, fork stub 15 Nm (11.1 lbf ft) Screw, front brake caliper 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, handlebar clamp 20 Nm (14.8 lbf ft) Screw, manifold 15 Nm (11.1 lbf ft)
  • Page 42 5 SUBSTANCES Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification – DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e.

  • Page 43: Auxiliary Substances

    AUXILIARY SUBSTANCES 6 Long-life grease Recommended supplier MOTOREX ® – Bike Grease 2000...
  • Page 44 *3214148en* 3214148en 07/2019 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

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