KTM 450 EXC-F 2022 Manual

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

INTRODUCTION
*3214520en*
3214520en
06/2021
INTRODUCTION
Perform the work described in these setup instructions before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make
changes in the interest of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop
are not specified here. It is assumed that the work will be performed by a fully trained mechanic.
All specifications contained herein are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right
to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc.,
without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop produc-
tion of a particular model without prior notice. 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.
© 2021 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission
of the copyright owner.
ISO 9001(12 100 6061)
KTM applies quality assurance processes that lead to the highest possible product quality as
defined in the ISO 9001 international quality management standard.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
450 EXC‑F EU (F8403V9)
450 EXC‑F SIX DAYS EU (F8403V2)
500 EXC‑F EU (F8503V9)
500 EXC‑F US (F8575V9)
500 EXC‑F SIX DAYS EU (F8503V2)
500 EXC‑F SIX DAYS US (F8575V2)
500 XCF-W US (F8575V1)

1 MEANS OF REPRESENTATION
2
1.1 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.
Indicates the result of a testing step.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates a resistance measurement.
Indicates the end of an activity including potential rework.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name®Indicates a protected name.
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
are explained in the glossary.

SETUP 2
3
2.1 Transport mode
H02712-01
This vehicle was blocked for transport in the software.
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.
Info
Make sure that the vehicle is permanently enabled before
handing it over to the customer.
2.2 Diagnostics connector
H00933-12
Diagnostics connector 1is located under the seat.
2.3 Unpacking and setting up the vehicle
E00851-10
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
have finished.
–Remove the separate enclosure and unpack it. Check that
the scope of supply is complete using the enclosed pack-
ing list.
Info
The procedure for missing components is described
in the Customer Service Manual.
–Have a lift stand available.
Lift stand (78129955100)
–Carefully loosen and remove the tension belt of the footrest
mount.

2 SETUP
4
Info
An assistant prevents the motorcycle from falling
over.
402050-01
–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.
–Remove the headlight mask with the headlight. ( p. 19)
H01768-10
–Position turn signal indicator lamp 1in the combination
instrument rack.
E00850-10
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
have finished.
–Remove and unpack the separate enclosure and compo-
nents. Check that the scope of supply is complete using
the enclosed packing list.
Info
The procedure for missing components is described
in the Customer Service Manual.
–Have a lift stand available.
Lift stand (78129955100)
–Remove the two cable ties on the triple clamp.

SETUP 2
5
402051-01
–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.
–Install the shock absorber. ( p. 22)
H01768-10
–Position turn signal indicator lamp 1in the combination
instrument rack.
402736-10
–Position the connector board and combination instrument
on the upper triple clamp.
–Mount and tighten screws 2.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Route the clutch line with the clutch master cylinder
toward the front between the upper and lower triple
clamps.
–Install the fork legs. ( p. 22)
S01414-10
(EXC‑F EU/US, XCF‑W)
–Remove screws 3and take off the handlebar supports.
–Move the handlebar supports to the desired position and
mount and tighten screws 3.
Guideline
Screw, handle-
bar holder
M10 40 Nm (29.5 lbf ft)
Loctite®243™
Info
Position the left and right handlebar supports
evenly.

2 SETUP
6
E00483-01
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-
aged or bent.
–Position the handlebar.
Info
Make sure the cables and wiring are positioned cor-
rectly.
–Position the handlebar clamps. Mount and tighten the
screws evenly.
Guideline
Screw, handlebar
clamp
M8 20 Nm
(14.8 lbf ft)
Info
The markings on the handlebar should be at the
center of the handlebar clamps.
Keep the installed gap widths equal when tighten-
ing.
S01415-10
(EXC‑F Six Days)
–Remove screws 3and take off the handlebar supports.
–Move the handlebar supports to the desired position and
mount and tighten screws 3.
Guideline
Screw, handle-
bar holder
M10 40 Nm (29.5 lbf ft)
Loctite®243™
Info
Position the left and right handlebar supports
evenly.

SETUP 2
7
S01413-01
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-
aged or bent.
–Position the handlebar.
Info
Make sure the cables and wiring are positioned cor-
rectly.
–Position the handlebar clamps. Mount and tighten the
screws evenly.
Guideline
Screw, handlebar
clamp
M8 20 Nm
(14.8 lbf ft)
Info
The markings on the handlebar should be at the
center of the handlebar clamps.
Keep the installed gap widths equal when tighten-
ing.
S03665-01
(All EU models)
–Position the controls on the right half of the handlebar.
E01235-01
(500 EXC‑F US, 500 EXC‑F SIX DAYS US)
–Position the controls on the right half of the handlebar.

2 SETUP
8
S03667-01
(XCF‑W)
–Position the controls on the right half of the handlebar.
S01423-01
(All EU models)
–Position the controls on the left handlebar half.
S01410-01
(500 EXC‑F US, 500 EXC‑F SIX DAYS US)
–Position the controls on the left handlebar half.
S03666-01
(XCF‑W)
–Position the controls on the left handlebar half.
S01422-01
(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.
–Only operate the vehicle in closed-off areas
remote from public road traffic if the combina-
tion switch is installed.
–(Optional) Mount combination switch on the left side.

SETUP 2
9
Info
The figure shows a possible installation position of
the left side combination switch.
402390-01
(All EU models)
–Mount the turn signal switch.
V01882-01
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.
V01883-10
(XCF‑W)
–Plug in light switch 4with the yellow and white
cables.
–Join all plug-in connectors to the connector board.
–Route the cables without tension and secure with the
cable ties.

2 SETUP
10
S01411-01
(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.
–Only operate the vehicle in closed-off areas
remote from public road traffic if the combina-
tion switch is installed.
–(Optional) Remove the protection cap and join the plug-in
connector of the left combination switch.
S01412-10
–Route the cable without tension and secure with cable ties and
cable holders.
H01060-01
–Mount the mirror clamps on both sides.
E00474-01
–Mount both rear mirrors with the adapter.

SETUP 2
11
E00852-01
–Preassemble the hand guards on the left and right.
F01077-10
–Mount the left hand guard.
–Mount the right hand guard.
E00482-01
–Secure the handlebar cushion with two cable ties.
–Install front fender. ( p. 24)
–Install the front wheel. ( p. 23)
–Remove the 12-V battery. ( p. 27)
–Charge the 12-V battery. ( p. 29)
Guideline
The 12-V battery must be fully charged before it is handed
over to the customer.
Info
The first charging process may take longer with a new
12-V battery.

2 SETUP
12
(All US models)
–Install the headlight mask with the headlight. ( p. 20)
–Install the 12-V battery. ( p. 28)
V01884-10
(All EU models)
–Remove connector 5from the bracket and join with turn
signal wiring harness.
S03673-01
–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.
V01862-10
–Position the turn signal on the headlight mask on both
sides, mount nuts with washers and tighten.
–Join plug-in connector 6of the left turn signal using the
violet and brown cable colors of the turn signal cable har-
ness.
Info
Pay attention to where the brake line is routed when
doing so.
–Join plug-in connector 7of the right turn signal using
the black and brown cable colors of the turn signal cable
harness.
–Join plug-in connector 8of the headlight.
–Connect plug-in connector 9of the turn signal switch.
–Secure turn signal relay bk with a cable tie and plug in
the connector.
–Install the headlight mask with the headlight. ( p. 20)
–Remove the air filter box cover. ( p. 31)
–Remove the rear left side cover. ( p. 32)

SETUP 2
13
V01863-10
–Disconnect tail light plug-in connector bl on the wiring
harness.
V01864-10
–Remove screws bm.
–Remove screws bn.
–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.
V01865-10
–Remove screws bo on the license plate holder and hang
the tail light to the side.

2 SETUP
14
V01866-10
–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 bp.
–Mount reflector bq on license plate holder.
S03682-01
–Drill a hole at marking Aon the license plate holder to
the size of the marking.
S03683-10
–Position the tail light together with the license plate holder
on the license plate bracket.
Info
Ensure that the cables are routed correctly.

SETUP 2
15
V01865-10
–Mount and tighten screws bo.
V01867-10
–Mount and tighten screw br.
Guideline
Remaining screws,
chassis
EJOT PT®
K60x25‑Z
2 Nm (1.5 lbf ft)
S03684-01
–Feed the wiring harnesses through the opening.
–Position the license plate holder on the rear.
V01868-10
–Mount and tighten screws bm with the collar bushing.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Mount and tighten screws bn.
Guideline
Remaining screws,
chassis
EJOT PT®
K60x25‑Z
2 Nm (1.5 lbf ft)

2 SETUP
16
V01869-10
–Join the plug-in connectors of tail light bs and turn signal
cable harness bt 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. 31)
–Install the 12-V battery. ( p. 28)
D02151-10
–Position the right footrest and pin.
Info
Only insert the pin to the extent that the spring can still
be mounted.
V01872-10
–Position spring as shown.
Spring Bengages in area C.
V01873-10
–Press the spring with special tool ck.
Footrest spring plier (79029083000)
The special tool is applied to area Don the footrest.
–Mount pin cl.

SETUP 2
17
V01874-10
–Mount the washer and splint cm.
S01398-10
–Position the left footrest and pin.
Info
Only insert the pin to the extent that the spring can still
be mounted.
V01875-10
–Position spring as shown.
Spring Eengages in area F.
V01876-10
–Press the spring with special tool ck.
Footrest spring plier (79029083000)
The special tool is applied to area Gon the footrest.
–Mount pin cn.

2 SETUP
18
V01877-10
–Mount the washer and splint co.
V01880-10
–Position the left frame protector.
–Insert the right frame protector from below and push it to the
rear.
–Mount and tighten screws cp with the washers.
Guideline
Screw, frame protec-
tor
M5 3 Nm (2.2 lbf ft)
–Mount and tighten screw cq.
Guideline
Screw, frame protec-
tor
M5 3 Nm (2.2 lbf ft)
–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).
–Set kilometers or miles. ( p. 35)
–Set the combination instrument. ( p. 36)
–Set the clock. ( p. 37)
–Refuel. ( p. 34)
–Position all controls in their exact positions on the handlebar.
Tighten all screws.
–Prepare the vehicle according to the specifications in
KTM Dealer.net for handover to the customer.
Info
Transport mode must be deactivated to be able to start
the motorcycle.