KTM 450 EXC-F Six Days 2017 Manual

SETUP INSTRUCTIONS 2017
450 EXC‑F
450 EXC‑F Six Days
500 EXC‑F
500 EXC‑F Six Days
Art. no. 3213536en

INTRODUCTION 1
*3213536en*
3213536en
08/2016
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 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 production of a particular model without prior notice. KTM accepts no liability for delivery options, devi-
ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not
belong to the regular scope of supply.
© 2016 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)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
5230 Mattighofen, Austria
This document is valid for the following models:
450 EXC‑F EU (F8403Q9)
450 EXC‑F AU (F8460Q9)
450 EXC‑F Six Days EU (F8403Q2)
450 EXC‑F Six Days US (F8475Q2)
500 EXC‑F EU (F8503Q9)
500 EXC‑F AU (F8560Q9)
500 EXC‑F US (F8575Q9)
500 EXC‑F Six Days EU (F8503Q2)

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.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained
in the glossary.

2 SETUP 3
2.1 Unpacking and setting up the vehicle
M00075-10
Condition
Packaging V2
–Remove the box and the plastic packaging.
Info
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 on the basis of the enclosed packing list.
–Have a lift stand available.
Lift stand (78129955100)
–Carefully loosen and remove the tension belt of the footrest mount.
Info
An assistant prevents the motorcycle from falling over.
402050-01
–Together with an assistant, take the vehicle off the palette.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
H01768-10
–Position turn signal indicator lamp {1} in the speedometer bracket.
–Remove the headlight mask with the headlight. ( p. 16)
M00075-11
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 attachments. Check that the
scope of supply is complete on the basis of the enclosed packing list.
–Remove the two cable ties on the triple clamp.
–Have a lift stand available.
Lift stand (78129955100)
402051-01
–Together with an assistant, take the vehicle off the palette.
–Position the vehicle on a lift stand.
–Check the vehicle and attachments for transport damage.
–Install the shock absorber. ( p. 18)

2 SETUP 4
H01768-10
–Position turn signal indicator lamp {2} in the speedometer bracket.
S01408-10
–Mount the connector retainer and speedometer on the upper triple clamp.
–Mount and tighten screws .
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.
S01414-10
(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, handlebar holder M10 40 Nm
(29.5 lbf ft)
Loctite®243™
Info
Position the left and right handlebar supports evenly.
E00483-01
–Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
–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 gap widths equal when tightening.

2 SETUP 5
S01415-10
(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, handlebar holder M10 40 Nm
(29.5 lbf ft)
Loctite®243™
Info
Position the left and right handlebar supports evenly.
S01413-01
–Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
–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 gap widths equal when tightening.
E00468-01
–Position the controls on the right half of the handlebar.
S01423-01
(EXC‑F EU/AU, EXC‑F Six Days EU)
–Position the controls on the left half of the handlebar.

2 SETUP 6
S01422-01
(EXC‑F Six Days EU)
Warning
Voiding of the government approval for road use and the insurance cover-
age If the combination switch is installed, the vehicle's approval for
road use is invalidated.
–Only operate the vehicle in closed-off areas remote from public road
traffic if the combination switch is installed.
–(Optional) Mount the left side combination switch.
Info
The figure shows a possible installation position of the left side combi-
nation switch.
S01410-01
(All US models)
–Position the controls on the left half of the handlebar.
402390-01
(EXC‑F EU/AU, EXC‑F Six Days EU)
–Mount the turn signal switch.
S01409-10
Condition
Packaging V12
–Connect all plug-in connectors to the connector retainer.
–Route the cable without tension and secure with cable tie.

2 SETUP 7
S01411-01
(EXC‑F Six Days EU)
Warning
Voiding of the government approval for road use and the insurance cover-
age If the combination switch is installed, the vehicle's approval for
road use is invalidated.
–Only operate the vehicle in closed-off areas remote from public road
traffic if the combination switch is installed.
–(Optional) Remove the protection cap and join the combination switch plug-in
connector.
S01412-10
–Route the cable without tension and secure with cable ties and cable holder.
E00474-01
–Mount both rear mirrors with the adapter.
E00475-01
–Preassemble the hand guards on the left and right.

2 SETUP 8
E00481-01
–Mount the left hand guard.
–Mount the right hand guard.
E00482-01
–Secure the handlebar cushion with two cable ties.
–Install the front fender. ( p. 19)
–Install the front wheel. ( p. 19)
–Remove the battery. ( p. 21)
–Recharge the battery. ( p. 22)
(All US models)
–Install the headlight mask with the headlight. ( p. 17)
(EXC‑F EU/AU, EXC‑F Six Days EU)
–Remove the fuel tank. ( p. 23)
S01393-10
–Position the turn signal wiring harness.
–Insert the indicator lamp with the black and violet cable colors into socket .
E00484-10
–Position turn signal on the headlight mask on both sides, mount and tighten
nuts with washers.
–Join the plug-in connector of the right turn signal with the black and brown
cables of the turn signal wiring harness.
–Join the plug-in connector of the left turn signal with the violet and brown
cables of the turn signal wiring harness.
Info
Pay attention to the brake lines routing when doing so.
–Join plug-in connector of the headlight.
–Join 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. 17)