KTM 450 EXC-F Six Days 2019 Manual

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

INTRODUCTION
*3213970en*
3213970en
06/2018
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, 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.
© 2018 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 (F8403S9)
450 EXC‑F AU (F8460S9)
450 EXC‑F Six Days EU (F8403S2)
450 EXC‑F Six Days US (F8475S2)
500 EXC‑F EU (F8503S9)
500 EXC‑F AU (F8560S9)
500 EXC‑F US (F8575S9)
500 EXC‑F Six Days EU (F8503S2)

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 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.
–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 pallet.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
–Remove the headlight mask with the headlight. ( p. 19)
H01768-10
–Position turn signal indicator lamp 1in the combination
instrument rack.

2 SETUP
4
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.
–Have a lift stand available.
Lift stand (78129955100)
–Remove the two cable ties on the triple clamp.
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.
–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)

SETUP 2
5
S01414-10
(EXC‑F EU/AU/US)
–Remove screws 3and take off 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.
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 handlebar.
Info
Make sure the cables and wiring are positioned cor-
rectly.
–Position 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.

2 SETUP
6
S01415-10
(All EXC‑F Six Days)
–Remove screws 3and take off 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.
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 handlebar.
Info
Make sure the cables and wiring are positioned cor-
rectly.
–Position 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.

SETUP 2
7
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.
S01422-01
(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.
–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.
Info
The figure shows a possible installation position of
the left side combination switch.
S01410-01
(All US models)
–Position the controls on the left half of the handlebar.

2 SETUP
8
402390-01
(EXC‑F EU/AU, EXC‑F Six Days EU)
–Mount the turn signal switch.
S01409-10
Condition
Packaging V12
–Join all plug-in connectors to the connector board.
–Route the cable without tension and secure with a cable
tie.
S01411-01
(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.
–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.