KTM 450 EXC-F Six Days 2019 Setup Instructions
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KTM 450 EXC-F Six Days 2019 Setup Instructions

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SETUP INSTRUCTIONS
2019
450 EXC‑F
450 EXC‑F Six Days
500 EXC‑F
500 EXC‑F Six Days
Art. no. 3213970en

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Summary of Contents for KTM 450 EXC-F Six Days 2019

  • Page 1 SETUP INSTRUCTIONS 2019 450 EXC‑F 450 EXC‑F Six Days 500 EXC‑F 500 EXC‑F Six Days Art. no. 3213970en...
  • 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 SETUP 2 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 SETUP 2 (EXC‑F EU/AU/US) – Remove screws and take off 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 2 SETUP (All EXC‑F Six Days) – Remove screws and take off 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 SETUP 2 – 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 connector board. – Route the cable without tension and secure with a cable tie. S01409-10 (EXC‑F Six Days EU) Warning Voiding of the government approval for road use and...
  • Page 11 SETUP 2 – Mount the mirror clamps on both sides. H01060-01 – Mount both rear mirrors with the adapter. E00474-01 – Preassemble the hand guards on the left and right. E00852-01...
  • Page 12 2 SETUP – Mount the left hand guard. – Mount the right hand guard. F01077-10 – Secure the handlebar cushion with two cable ties. – Install front fender. ( p. 24) – Install the front wheel. ( p. 24) – Remove the battery.
  • Page 13 SETUP 2 – Connect plug-in connector of the headlight. – Connect plug-in connector of the turn signal switch. – Secure turn signal relay with a cable tie and plug in the connector. – Install the headlight mask with the headlight. ( p.
  • Page 14 2 SETUP – Remove screw with the collar bushing. – Remove screw – Remove screw with negative cable and contact disk. E00489-10 – Remove screws – Carefully pull the tail light cable out of the frame, paying attention to the plug as you do so. –...
  • Page 15 SETUP 2 – Route the turn signal cable harness toward the rear and pass through the frame paying attention to the plugs as you do so. – Route turn signal cable harness on the license plate holder and pass turn signal cable harness through the drill hole. –...
  • Page 16 2 SETUP – Mount and tighten screw with the collar bushing. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Mount and tighten screw with negative cable and con- tact disk.
  • Page 17 SETUP 2 – Position turn signal on both sides, mount nuts with wash- ers and tighten. – Position license plate lamp on the license plate holder, and mount and tighten screws – Mount reflector on license plate holder. – Pass cable through the license plate holder. E00496-10 –...
  • Page 18 2 SETUP – Press the spring with special tool Footrest spring plier (79029083000) The special tool is applied to area on the footrest. – Mount pin S01396-10 – Mount the washer and splint S01397-10 – Position the left footrest and pin. Info Only insert the pin to the extent that the spring can still be mounted.
  • Page 19 Mount the cable tie. (All EXC‑F Six Days, EXC‑F AU) – Install the engine guard. ( p. 35) – Unpack and mount the KTM PowerParts included in the deliv- ery (optional). Info Read the accompanying KTM PowerParts fitting instruc- tions. –...
  • Page 20 2 SETUP Info Transport mode must be deactivated to be able to start the motorcycle.
  • 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 US models) – Turn the ignition 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. – Loosen rubber straps . Slide the headlight mask up and swing it forward.
  • Page 23 WORK 3 – Position the headlight mask and secure it with rubber straps The holding lugs engage in the fender. – Position the brake line and wiring harness in the brake line guide. V00469-11 Finishing work – Check the headlight setting. ( p.

  • Page 24: Tighten Screw

    3 WORK Info A change in weight on the vehicle may require a correc- tion of the headlight range. – Tighten screw 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)
  • Page 25 WORK 3 – Tighten screws Guideline Screw, top triple 20 Nm clamp (14.8 lbf ft) – Tighten screws Guideline Screw, bottom 15 Nm triple clamp (11.1 lbf ft) V00452-11 (All EXC‑F Six Days) – Position the fork legs. Bleeder screws are positioned toward the front.

  • Page 26: Tighten Screws 3 . Guideline

    3 WORK Installing the front wheel 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. –...

  • Page 27: Remove Screws

    WORK 3 – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis V00341-10 (All 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,...
  • Page 28 3 WORK 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. – Make sure that the seat is correctly locked in. V00343-10 –...
  • Page 29 WORK 3 3.14 Connecting the negative cable of the battery Main work – Connect negative cable of the battery. Guideline Screw, battery termi- 2.5 Nm (1.84 lbf ft) Contact disks must be mounted under the screw the cable lug with the claws toward the battery terminal. T02638-10 Finishing work –...
  • Page 30 3 WORK Main work – Disconnect negative cable from the battery. – Pull back positive terminal cover and disconnect the posi- tive cable from the battery. – Remove screw – Pull holding bracket forward and remove battery toward the top. F00138-10 3.16 Installing the battery...

  • Page 31: Recharging The Battery

    WORK 3 3.17 Recharging the 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 32 3 WORK Main work – Connect the battery charger to the battery. Adjust the battery 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 Follow the instructions of the charger and the manual.
  • Page 33 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 34 3 WORK Wash cap set (81212016100) – Remove screws with the collar bushings. – Hang the horn and horn bracket to one side. K00558-10 – Remove screw with the rubber bushing. K00556-11 – Pull both spoilers off the sides of the radiator bracket and lift off the fuel tank.

  • Page 35: Mount And Tighten Screws

    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 36: Checking Throttle Cable Routing

    3 WORK (All US models) – Plug in connector for the fuel pump. – Remove the wash cap set. – 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 37 WORK 3 (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 rubber strap of the fuel tank sup- port.
  • 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 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 40 3 WORK – 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 41: Setting The Clock

    WORK 3 3.27 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 42: 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) EJOT PT Screw, pressure regulator ® K60x25‑Z 2 Nm (1.5 lbf ft) EJOT EJOFORM PT...
  • Page 43 TECHNICAL DATA 4 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 35 Nm (25.8 lbf ft) Loctite 2701™...
  • Page 44 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 45: Auxiliary Substances

    AUXILIARY SUBSTANCES 6 Long-life grease Recommended supplier MOTOREX ® – Bike Grease 2000...
  • Page 46 *3213970en* 3213970en 06/2018 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

This manual is also suitable for:

450 exc-f 2019500 exc-f 2019500 exc-f six days 2019

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