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)

2 SETUP 9
S01418-01
–Route the turn signal wiring harness from front to back as far as the battery
compartment.
–Position and secure the turn signal wiring harness under the rubber bands of
the fuel tank contact area on the main wiring harness.
E00494-10
–Remove screw .
–Remove screw .
–Pull off the side cover in area and in area and remove it toward the
rear.
E00487-10
–Detach spring .
Spring hook (50305017000)
–Remove screws with washers and take off main silencer.
S01417-10
–Pull the EFI control unit from the holder and hang it to one side.
–Disconnect and remove plug-in connector  on the main wiring harness.
–Join the plug-in connector of the turn signal wiring harness with the plug-in
connector of the main wiring harness.
E00489-10
–Remove screw  with the collar sleeve.
–Remove screw .
–Remove screw  with negative cable and contact disk.

2 SETUP 10
S01416-10
–Remove screws .
–Carefully remove the tail light cable from the frame and in doing so pay atten-
tion to the connector.
–Remove license plate holder with tail light to the rear.
E00491-10
–Remove screws  and hang the tail light to the side.
–Drill a hole at the marking the size of the marking.
E00492-10
–Route the turn signal wiring harness toward to rear and pass through the frame,
pay attention to the connector when doing so.
–Route the turn signal wiring harness on the license plate holder and pass the
turn signal wiring harness through the hole.
–Position the tail light on the license plate holder and mount and tighten
screws .

2 SETUP 11
E00495-10
–Carefully guide the tail light cable through the frame and in doing so pay atten-
tion to the connector.
–Position license plate holder on the rear.
–Mount and tighten screws .
E00489-10
–Mount and tighten screw  with the collar bushing.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
–Mount and tighten screw .
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
–Mount and tighten screw  with negative cable and contact disk.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
E00498-10
–Join the plug-in connector of the tail light with the plug-in connector of the turn
signal wiring harness.
–Mount EFI control unit on the holder.
Guideline
The wiring harness runs under the control unit.
E00487-10
–Position the main silencer. Mount screws with the washers, but do not
tighten yet.
–Attach spring .
Spring hook (50305017000)
–Tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)

2 SETUP 12
E00494-10
–Attach the side cover in area and engage it in area .
–Mount and tighten screw .
Guideline
Screw, subframe M8 35 Nm
(25.8 lbf ft)
Loctite®2701™
–Mount and tighten screw .
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
–Install the battery. ( p. 21)
–Install the fuel tank. ( p. 24)
E00496-10
–Position turn signal on both sides, mount and tighten nuts with washers.
–Position license plate lamp on the license plate holder, mount and tighten
screws .
–Mount reflector  on the license plate holder.
–Guide cable through the license plate holder.
E00497-10
–Position license plate holder on the license plate bracket.
–Join the plug-in connector of the license plate lamp.
–Join the plug-in connector of the left turn signal which is marked red.
–Join the plug-in connector of the right turn signal which is marked green.
–Mount and tighten screws .
D02151-10
–Position the right footrest and pin.
Info
Only insert the pins to the extent that the spring can still be mounted.

2 SETUP 13
S01395-10
–Position spring as shown.
Spring engages in area .
S01396-10
–Press the spring with special tool .
Pliers for footrest spring (79029083000)
The special tool is applied to area on the footrest.
–Mount pin .
S01397-10
–Mount the washer and split pin .
S01398-10
–Position the left footrest and pin.
Info
Only insert the pins to the extent that the spring can still be mounted.

2 SETUP 14
S01399-10
–Position spring as shown.
Spring engages in area .
S01400-10
–Press the spring with special tool .
Pliers for footrest spring (79029083000)
The special tool is applied to area on the footrest.
–Mount pin .
S01401-10
–Mount the washer and split pin .
S01407-10
–Position the frame protector on both sides.
–Mount and tighten screws .
Guideline
Screw, frame protector M5 3 Nm (2.2 lbf ft)
–Mount and tighten screws  with the washers.
Guideline
Screw, frame protector M5 3 Nm (2.2 lbf ft)
–Mount the cable binder.
(All EXC‑F Six Days, EXC‑F AU)
–Install the engine guard. ( p. 26)
–Unpack and mount the KTM PowerParts included in the delivery (optional).
Info
Read the accompanying KTM PowerParts fitting instructions.
–Apply the label included in the delivery (optional).
–Set kilometers or miles. ( p. 28)
–Set the speedometer functions. ( p. 29)
–Set the clock. ( p. 29)
–Refuel. ( p. 27)

2 SETUP 15
–Position all controls in their exact positions on the handlebar. Tighten all screws.
–Prepare the vehicle according to the specifications in the KTM Dealer.net for han-
dover to the customer.
Info
In order to be able to start the motorcycle, the transport mode must be
deactivated.

3 WORK 16
3.1 Raising the motorcycle with the lift stand
401942-01
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.
–Secure the motorcycle against falling over.
3.2 Removing the motorcycle from 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.
401943-10
–Remove the motorcycle from the lift stand.
–Remove the lift stand.
–To park the motorcycle, press side stand to the ground with your foot and lean
the motorcycle on it.
Info
While riding, the side stand must be folded up and secured with the rubber
band.
3.3 Removing the headlight mask with the headlight
V00458-10
(EXC‑F EU/AU, EXC‑F Six Days EU)
–Switch off all power consumers and switch off the engine.
–Detach the brake line and wiring harness from the headlight mask.
–Release rubber bands . Slide the headlight mask up and swing it forward.
S01328-10
–Detach plug-in connectors and take off the headlight mask with the head-
light.
V00469-10
(All US models)
–Switch off all power consumers and switch off the engine.
–Detach the brake line and wiring harness from the headlight mask.
–Release rubber bands . Slide the headlight mask up and swing it forward.

3 WORK 17
V00459-10
–Detach plug-in connectors and take off the headlight mask with the head-
light.
3.4 Installing the headlight mask with the headlight
S01328-11
Main work
(EXC‑F EU/AU, EXC‑F Six Days EU)
–Connect plug-in connectors .
V00458-11
–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.
V00459-11
(All US models)
–Connect plug-in connectors .
V00469-11
–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.
Finishing work
–Check the headlight setting. ( p. 18)

3 WORK 18
3.5 Checking the headlight setting
400726-10
–Position the vehicle upright on a horizontal surface in front of a light wall and make
a mark at the height of the center of the low beam headlight.
–Make another mark a distance under the first mark.
Guideline
Distance 5 cm (2 in)
–Position the vehicle vertically at a distance away from the wall.
Guideline
Distance 5 m (16 ft)
–The rider now sits down on the motorcycle.
–Switch on the low beam.
–Check the headlight setting.
The boundary between light and dark must be exactly on the lower mark for a
motorcycle with driver.
» If the light-dark border does not meet specifications:
–Adjust the headlight range. ( p. 18)
3.6 Adjusting the headlight range
Preparatory work
–Check the headlight setting. ( p. 18)
V00369-10
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).
Info
A change in weight on the vehicle may require a correction of the headlight
range.
–Tighten screw .
3.7 Installing the shock absorber
E00398-11
Main work
–Push splash protector to the side and position the shock absorber. Mount and
tighten screw .
Guideline
Screw, top shock absorber M12 80 Nm
(59 lbf ft)
Loctite®2701™
–Mount and tighten screw .
Guideline
Screw, bottom shock
absorber
M12 80 Nm
(59 lbf ft)
Loctite®2701™
Info
The heim joint for the shock absorber at the swingarm is Teflon-coated. It
must not be greased with grease or with other lubricants. Lubricants dis-
solve the Teflon coating, thereby drastically reducing the service life.
Finishing work
–Remove the motorcycle from the lift stand. ( p. 16)