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KTM 450 EXC-F 2022 Setup Instructions
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KTM 450 EXC-F 2022 Setup Instructions

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SETUP INSTRUCTIONS
2022
450 EXC‑F
450 EXC‑F SIX DAYS
500 EXC‑F
500 EXC‑F SIX DAYS
500 XCF‑W
Art. no. 3214520en

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Summary of Contents for KTM 450 EXC-F 2022

  • Page 1 SETUP INSTRUCTIONS 2022 450 EXC‑F 450 EXC‑F SIX DAYS 500 EXC‑F 500 EXC‑F SIX DAYS 500 XCF‑W Art. no. 3214520en...
  • 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 Info An assistant prevents the motorcycle from falling over. – Together with an assistant, take the vehicle off the pallet. – Position the vehicle on a lift stand. – Check the vehicle for transport damage. Info The procedure in the event of transport damage is described in the Customer Service Manual.
  • Page 7 SETUP 2 – Together with an assistant, take the vehicle off the pallet. – Position the vehicle on a lift stand. – Check the vehicle and components for transport damage. Info The procedure in the event of transport damage is described in the Customer Service Manual.
  • Page 8 2 SETUP Warning Danger of accidents A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the mate- rial becomes fatigued. The handlebar may break as a result. – Change the handlebar if the handlebar is dam- E00483-01 aged or bent.
  • Page 9 SETUP 2 Warning Danger of accidents A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the mate- rial becomes fatigued. The handlebar may break as a result. – Change the handlebar if the handlebar is dam- S01413-01 aged or bent.
  • Page 10 2 SETUP (XCF‑W) – Position the controls on the right half of the handlebar. S03667-01 (All EU models) – Position the controls on the left handlebar half. S01423-01 (500 EXC‑F US, 500 EXC‑F SIX DAYS US) – Position the controls on the left handlebar half. S01410-01 (XCF‑W) –...
  • Page 11 SETUP 2 Info The figure shows a possible installation position of the left side combination switch. (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. –...
  • Page 12 2 SETUP (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. – Only operate the vehicle in closed-off areas remote from public road traffic if the combina- S01411-01 tion switch is installed.
  • 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 US models) – Install the headlight mask with the headlight. ( p. 20) – Install the 12-V battery. ( p. 28) (All EU models) – Remove connector from the bracket and join with turn signal wiring harness. V01884-10 –...
  • Page 15 SETUP 2 – Disconnect tail light plug-in connector on the wiring harness. V01863-10 – Remove screws – Remove screws – Remove the license plate holder with the tail light. Info Pay attention to the cable of the tail light. – Feed the cable between the fairing parts.
  • Page 16 2 SETUP – Position the turn signal on both sides on the license plate holder, mount nuts with washers and tighten. – Position the license plate lamp on the license plate holder, and mount and tighten screws – Mount reflector on license plate holder.
  • 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 – Feed 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 cable 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 (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 (All EU models, EXC‑F Six Days, 500 EXC‑F US) – Join plug-in connectors S01328-11 (XCF‑W) –...
  • 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 surfaces 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 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 – Pull off starter relay and fuse box from the battery compartment and hang to the side. V01777-10 – Detach wiring harness , disconnect relays and hang them to the side. V01778-10 – Remove screw and detach the battery compartment. –...
  • Page 31 WORK 3 – 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 3 WORK Note Environmental hazard 12 V batteries contain environmentally hazardous materials. – Do not dispose of 12 V batteries as household waste. – Dispose of 12 V batteries at a collection point for used batteries. Note Environmental hazard Hazardous substances cause environmental damage. –...
  • Page 33 WORK 3 3.18 Removing the air filter box cover Condition The air filter box cover is secured. – Remove the seat. ( p. 25) – Remove screw V01759-10 – Pull off the air filter box cover in area laterally and take it off at the front.
  • Page 34 3 WORK – Mount and tighten screw Guideline Screw, air filter box EJOT PT ® 3 Nm (2.2 lbf ft) cover K60x20-Z – Mount the seat. ( p. 26) V01759-10 Condition The air filter box cover is not secured. – Insert the air filter box cover in area and clip it into area...
  • Page 35 WORK 3 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) Loctite ® 2701™ frame top V01879-10 3.22 Installing the engine guard (XCF‑W, EXC‑F Six Days) –...
  • Page 36 3 WORK 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. –...

  • Page 37: Setting Kilometers Or Miles

    WORK 3 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. –...
  • Page 38 3 WORK – Repeatedly press the button briefly until H appears at the bottom right of the display. – Press the button for 2–3 seconds. The Setup menu is displayed and the active functions are shown. – Repeatedly press the button briefly until Km/h/Mph flashes.

  • Page 39: Setting The Clock

    WORK 3 3.28 Setting the clock Condition The motorcycle is stationary. – Repeatedly press the button briefly until CLK appears at the bottom right of the display. – Press the button for 2–3 seconds. The hour display flashes. – Adjust the hour display with the button and/or button –...

  • 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 (EXC‑F ® K50x18 2 Nm (1.5 lbf ft) 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) Standard/classification – DIN EN 228 (ROZ 95) Guideline – Only use super unleaded fuel that matches or is equivalent to the specified standard. – Fuel with an ethanol content of up to 10% (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e.g., M15, M85, M100) or more than 10% ethanol (e.g., E15, E25, E85, E100).

  • Page 43: Auxiliary Substances

    AUXILIARY SUBSTANCES 6 Long-life grease Recommended supplier MOTOREX ® – Bike Grease 2000...
  • Page 44 *3214520en* 3214520en 06/2021 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.COM...

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