KTM 450 EXC-F 2018 Setup Instructions
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KTM 450 EXC-F 2018 Setup Instructions

KTM 450 EXC-F 2018 Setup Instructions

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SETUP INSTRUCTIONS
2018
450 EXC‑F
450 EXC‑F Six Days
500 EXC‑F
500 EXC‑F Six Days
Art. no. 3213713en

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Summary of Contents for KTM 450 EXC-F 2018

  • Page 1 SETUP INSTRUCTIONS 2018 450 EXC‑F 450 EXC‑F Six Days 500 EXC‑F 500 EXC‑F Six Days Art. no. 3213713en...
  • Page 3 KTM accepts no liability for delivery options, deviations from figures 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 2 SETUP Unpacking and setting up the vehicle Condition Packaging V2 – 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 E00851-10 have finished.
  • Page 6 2 SETUP 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 2 SETUP (EXC‑F EU/AU/US) – Take off screws and handlebar supports. – Move the handlebar supports to the desired position and mount and tighten screws Guideline Screw, handle- 40 Nm (29.5 lbf ft) Loctite ® 243™ bar holder Info Position the left and right handlebar supports evenly.

  • Page 8: Remove Screws

    2 SETUP (All EXC‑F Six Days) – Remove screws and handlebar supports. – Move the handlebar supports to the desired position and mount and tighten screws Guideline Screw, handle- 40 Nm (29.5 lbf ft) Loctite ® 243™ bar holder Info Position the left and right handlebar supports evenly.
  • Page 9 2 SETUP – Position the controls on the right half of the handlebar. E00468-01 (EXC‑F EU/AU, EXC‑F Six Days EU) – Position the controls on the left half of the handlebar. S01423-01 (EXC‑F Six Days EU) Warning Voiding of the government approval for road use and the insurance coverage If the combination switch is installed, the vehicle's approval for road use is invalidated.
  • Page 10 2 SETUP (EXC‑F EU/AU, EXC‑F Six Days EU) – Mount the turn signal switch. 402390-01 Condition Packaging V12 – Join all plug-in connectors to the plug-in holder. – Route the cable without tension and secure with cable tie. S01409-10 (EXC‑F Six Days EU) Warning Voiding of the government approval for road use and the insurance coverage If the combination switch...
  • Page 11 2 SETUP – Route the cable without tension and secure with cable ties and cable holder. S01412-10 – Mount the mirror clamps on both sides. H01060-01 – Mount both rear mirrors with the adapter. E00474-01...
  • Page 12 2 SETUP – 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 13 2 SETUP – Position turn signal cable harness. – Insert the indicator lamp with the black and violet cable colors into socket S01393-10 – Position turn signal on the headlight mask on both sides, mount nuts with washers and tighten. –...
  • Page 14 2 SETUP – Detach spring Spring hook (50305017000) – Remove screws with the washers and take off the main silencer. E00487-10 – Pull engine electronics control unit from the holder and hang it to the side. – Disconnect plug-in connector on main wiring harness and take off.
  • Page 15 2 SETUP – Remove screws – Carefully pull the tail light cable out of the frame, paying attention to the plug as you do so. – Take off license plate holder with tail light toward the rear. S01416-10 – Remove screws and hang the tail light to the side.
  • Page 16 2 SETUP – Carefully pass the tail light cable through the frame, pay- ing attention to the plug as you do so. – Position license plate holder on the rear. – Mount and tighten screws E00495-10 – Mount and tighten screw with the collar bushing.
  • Page 17 2 SETUP – Position the main silencer. Mount screws with the washers, but do not tighten yet. – Attach spring Spring hook (50305017000) – Tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis E00487-10 – Attach the side cover in area and engage it in area –...
  • Page 18 2 SETUP – Position the right footrest and pin. Info Only insert the pin to the extent that the spring can still be mounted. D02151-10 – Position spring as shown. Spring engages in area S01395-10 – Press the spring with special tool Pliers for footrest spring (79029083000) The special tool is applied to area on the footrest.
  • Page 19 2 SETUP – 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 S01399-10 – Press the spring with special tool Pliers for footrest spring (79029083000) The special tool is applied to area on the footrest.
  • Page 20 Mount the cable tie(s). (EXC‑F AU, All EXC‑F Six Days) – Install the engine guard. ( p. 34) – Unpack and mount the KTM PowerParts included in the deliv- ery (optional). Info Read the accompanying KTM PowerParts fitting instruc- tions. –...
  • Page 21 3 WORK 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 – Detach plug-in connectors and take off the headlight mask with the headlight. S01328-10 (All US models) – Turn the key in the ignition lock to the position while the engine is idling. – Detach the brake line and wiring harness from the head- light mask.
  • Page 23 3 WORK (All US models) – Connect plug-in connectors V00459-11 – Position the headlight mask and fix it with rubber bands The holding lugs engage in the fender. – Position the brake line and wiring harness in the brake line guide.

  • Page 24: Tighten Screw

    3 WORK Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 21) Main work – Loosen screw – Adjust the headlight range by pivoting the headlight. Guideline The boundary between light and dark must be exactly on the lower marking for a motorcycle with rider (instructions on how to apply the marking: Checking the headlight setting).
  • Page 25 3 WORK Installing the fork legs Main work (EXC‑F EU/AU/US) – 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 COMP (white 402556-10 adjusting screw).

  • Page 26: Tighten Screws 3 . Guideline

    3 WORK – Position the brake caliper, and mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) Loctite ® 243™ brake caliper – Mount the cable tie(s). – Position the brake line, wiring harness, and clamp. Mount and tighten screws K00546-10 Finishing work...
  • Page 27 3 WORK 3.10 Installing front fender Main work (EXC‑F EU/AU/US) – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00340-10 – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00341-10 (All EXC‑F Six Days)

  • Page 28: Mounting The Seat

    3 WORK 3.11 Removing the seat – Remove screws – Raise the rear of the seat, pull the seat back, and lift it off. V00342-10 3.12 Mounting the seat – Mount the front of the seat on the collar bushing of the fuel tank, lower the seat at the rear, and push the seat forward.
  • Page 29 3 WORK Preparatory work (EXC‑F EU/AU, EXC‑F Six Days EU) – Press and hold the kill switch while the engine is idling until the engine stops. (All US models) – Turn the key in the ignition lock to the position while the engine is idling.

  • Page 30: Recharging The Battery

    3 WORK 3.15 Recharging the battery Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batteries. – Only charge batteries in well-ventilated rooms. – Maintain a minimum clearance from inflammable materials when charging batteries.
  • Page 31 3 WORK Alternative 4 Battery charger XCharge-professional CH (00029095053) Info Follow the instructions of the charger and the manual. – Disconnect the battery charger after charging the battery. Guideline The charging current, charging voltage, and charging time must not be exceeded. Charge the battery regularly 3 months when the motorcycle is not...
  • Page 32 3 WORK Main work – Unplug connector of the fuel pump. – Remove the tube from the fuel tank breather. K00555-10 (EXC‑F EU/AU, EXC‑F Six Days EU) – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line.
  • Page 33 3 WORK – Remove screw with the rubber bushing. K00556-11 – Pull both spoilers off the sides of the radiator bracket and lift off the fuel tank. K00559-10 3.17 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. –...
  • Page 34 3 WORK – Attach the fuel tank breather hose. – Mount and tighten screw with the rubber bushing. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis K00556-10 – Position the horn with the horn bracket. – Mount and tighten screws with the collar bushings.

  • Page 35: Checking Throttle Cable Routing

    3 WORK Info Route the cable and fuel line at a safe distance from the exhaust system. Finishing work – Mount the seat. ( p. 26) 3.18 Checking throttle cable routing Preparatory work – Remove the seat. ( p. 26) –...
  • Page 36 3 WORK (All US models) – Check throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars and above the fuel tank bracket, to the throttle valve body. Both throttle cables must be secured behind the fuel tank contact area rubber band.
  • Page 37 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 38 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 39 3 WORK Setting the Mph – Press the button – Wait 3 - 5 seconds. The settings are stored. Info If no button is pressed for 10 -12 seconds, or if an impulse comes from the wheel speed sensor, the settings are automatically saved and the setup menu is closed.

  • Page 40: Setting The Clock

    3 WORK 3.25 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. – Set the hour display with the button and/or button –...

  • Page 41: Technical Data

    4 TECHNICAL DATA Chassis tightening torques EJOT PT Remaining screws, chassis ® K60x25‑Z 2 Nm (1.5 lbf ft) Screw, active carbon filter (All US 5 Nm (3.7 lbf ft) models) EJOT PT Screw, pressure regulator ® K60x25‑Z 2 Nm (1.5 lbf ft) EJOT EJOFORM PT ®...
  • Page 42 4 TECHNICAL DATA Screw, engine brace 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) Screw, side stand attachment...
  • Page 43 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 44: Auxiliary Substances

    6 AUXILIARY SUBSTANCES Long-life grease Recommended supplier Motorex ® – Bike Grease 2000...
  • Page 45 *3213713en* 3213713en 04/2017 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

This manual is also suitable for:

450 exc-fsix days 2018500 exc-f 2018500 exc-f six days 2018

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