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Summary of Contents for KTM 450 EXC-F 2024
- Page 1 SETUP INSTRUCTIONS 2024 450 EXC‑F 450 EXC‑F SIX DAYS 450 XCF‑W 500 EXC‑F 500 EXC‑F SIX DAYS 500 XW-F Art. no. 3214917en...
- 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.
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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 – 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 (All except SIX DAYS) – Remove screws and take off the handlebar support. – Move the handlebar support in the desired position and mount and tighten screws Guideline Screw, handle- 40 Nm (29.5 lbf ft) bar holder Loctite ®...
- Page 8 2 SETUP Info Make sure the cables and wiring are positioned cor- rectly. – Position the handlebar clamp. Mount and tighten the screws evenly. Guideline Screw, handlebar 20 Nm (14.8 lbf ft) clamp Info The markings on the handlebar should be at the center of the handlebar clamp.
- Page 9 SETUP 2 (XCF-W, XW-F) – Position the controls on the left handlebar half. W00388-10 (SIX DAYS EU and CN) Caution 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 10 2 SETUP (All EU models) – Join all plug-in connectors to the connector board. – Route the cable without tension and secure with quick release. W00390-10 (XCF‑W) – Join all plug-in connectors to the connector board. – Route the cable without tension and secure with quick release.
- Page 11 SETUP 2 – Mount both rear mirrors with the adapter. E00474-01 – Preassemble the hand guards on the left and right. E00852-01 – Mount the left hand guard. – Mount the right hand guard. F01077-10...
- Page 12 2 SETUP – Fix the handlebar cushion to the handlebar clamp. – Install the front fender. ( p. 20) – Remove the seat. ( p. 20) – Remove the 12-V battery. ( p. 27) – Charge the 12-V battery. ( p.
- Page 13 SETUP 2 – Position the turn signal on the headlight mask on both sides, mount nuts with washers and tighten. – Join plug-in connector of the left turn signal using the violet and brown cable colors of the turn signal cable har- ness.
- Page 14 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 – Connect the plug-in connections of the turn signals and the license plate lamp with the wiring harness.
- Page 15 SETUP 2 (EXC‑F SIX DAYS, All EU models, EXC‑F EU/US) – Position the tail light together with the license plate holder on the license plate bracket. Info Ensure that the cables are routed correctly. – Position the fender on the license plate holder. W00400-10 –...
- Page 16 2 SETUP (EXC‑F SIX DAYS, All EU models, EXC‑F EU/US) – Slide license plate holder onto tail section and position. Info Ensure that the cables are routed correctly. – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) W00397-10 chassis –...
- Page 17 Install the frame protector. ( p. 31) (EXC‑F SIX DAYS, XCF-W, XW-F) – Install the engine guard. ( p. 31) – Unpack and mount the KTM PowerParts included in the deliv- ery (optional). Info W00574-11 Read the accompanying KTM PowerParts fitting instruc- tions. –...
- Page 18 2 SETUP Info Transport mode must be deactivated to be able to start the motorcycle.
- Page 19 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 20 3 WORK (XCF-W, XW-F) – Disconnect plug-in connector and take off the head- light mask together with the headlight. W00351-10 Installing the headlight mask with the headlight Main work (EXC‑F SIX DAYS, All EU models, EXC‑F EU/US) – Join plug-in connectors W00350-11 (XCF-W, XW-F) –...
- Page 21 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 22 3 WORK Installing the front fender Main work – Position the 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 Finishing work...
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Page 23: Mounting The Seat
WORK 3 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 to the rear. The holding lugs engage in the recesses at the back. –... - Page 24 3 WORK Warning Danger of poisoning Fuel is harmful to health. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – Rinse the affected area immediately with plenty of water in the event of contact with the skin. –...
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Page 25: Installing The Fuel Tank
WORK 3 (XCF-W, XW-F) – Remove screws W00347-10 – Pull both spoilers laterally off the radiator and lift off the fuel tank. W00345-10 3.11 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 26 3 WORK – Position the fuel tank and fit the two spoilers to the sides in front of the radiator bracket. – Make sure that no cables or throttle cables are trapped or dam- aged. W00345-11 – Attach the fuel tank breather hose. –...
- Page 27 WORK 3 Info Route the cable and fuel line at a safe distance from the exhaust system. Finishing work – Mount the seat. ( p. 21) 3.12 Checking the throttle cable routing Warning Danger of accidents The throttle cable can become kinked, trapped or blocked if it is not routed cor- rectly.
- Page 28 3 WORK (All EXC-F US) – Check the 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 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. E03231-10 Finishing work –...
- Page 30 3 WORK Main work Warning Risk of injury 12 V batteries contain harmful sub- stances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V bat- teries. – Only charge 12 V batteries in well-ventilated W00356-10 rooms.
- Page 31 WORK 3 3.16 Installing the 12-V battery Main work – Pull up battery holding bracket , insert the 12-V battery into the battery compartment with the terminals facing upward and secure with battery holding bracket Info Ensure that the cable is routed correctly. W00358-11 –...
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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 Alternative 2 UK battery charger XCharge‑professional (00029095052) Info Follow the instructions of the charger and the manual. – Disconnect the battery charger after charging the 12-V battery. Guideline The charging current, charging voltage, and charging time must not be exceeded. Recharge the 12-V battery 3 months regularly when the motorcy-...
- Page 34 3 WORK 3.20 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 fuel the vehicle in the vicinity of open flames or lit cigarettes. –...
- Page 35 WORK 3 3.22 Refueling Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. – Switch off the engine for refueling.
- Page 36 3 WORK 3.23 Setting 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 37 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. 3.25 Setting the clock Condition...
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Page 38: Technical Specifications
4 TECHNICAL SPECIFICATIONS Chassis tightening torques EJOT PT License plate holder screw US ® K60x20-Z 2 Nm (1.5 lbf ft) EJOT PT Remaining screws, chassis ® K60x25‑Z 2 Nm (1.5 lbf ft) EJOT PT ® Screw, combination switch (SIX K50x18 2 Nm (1.5 lbf ft) DAYS EU and CN, XCF‑W) Screw, emergency OFF switch... - Page 39 TECHNICAL SPECIFICATIONS 4 Screw, rear brake disc 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, seat fixing 8 Nm (5.9 lbf ft) Screw, starter cable to starter relay 6 Nm (4.4 lbf ft) Screw, throttle grip 5 Nm (3.7 lbf ft) Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite...
- Page 40 4 TECHNICAL SPECIFICATIONS Nut, wheel spindle, rear 80 Nm (59 lbf ft) Screw-in fitting, cooling system M24x1.5 7.5 Nm (5.53 lbf ft) Loctite ® 243™...
- Page 41 SUBSTANCES 5 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).
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Page 42: Auxiliary Substances
6 AUXILIARY SUBSTANCES Silicone spray Recommended supplier MOTOREX ® – Silicone Spray... - Page 43 *3214917en* 3214917en 23.10.2023 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM KTM.COM...
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