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.

SETUP 2
9
H01060-01
–Mount the mirror clamps on both sides.
E00474-01
–Mount both rear mirrors with the adapter.
E00852-01
–Preassemble the hand guards on the left and right.

2 SETUP
10
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. 24)
–Remove the battery. ( p. 27)
–Recharge the battery. ( p. 29)
(All US models)
–Install the headlight mask with the headlight. ( p. 20)
–Install the battery. ( p. 28)
(EXC‑F EU/AU, EXC‑F Six Days EU)
–Remove the fuel tank. ( p. 30)
S01393-10
–Position the turn signal cable harness.
–Insert the indicator lamp with the black and violet cable
colors into socket 4.
E00484-10
–Position the turn signal on the headlight mask on both
sides, mount nuts with washers and tighten.
–Connect the plug-in connector of the right turn signal using
the black and brown cables of the turn signal cable har-
ness.
–Connect the plug-in connector of the left turn signal using
the violet and brown cable colors of the turn signal cable
harness.
Info
Pay attention to where the brake line is routed when
doing so.

SETUP 2
11
–Connect plug-in connector of the headlight.
–Connect plug-in connector of the turn signal switch.
–Secure turn signal relay 5with a cable tie and plug in
the connector.
–Install the headlight mask with the headlight. ( p. 20)
S01418-01
–Route the turn signal cable harness from the front to the
rear as far as the battery compartment.
–Position and secure the turn signal cable harness using
cable ties on the main wiring harness under the rubber
straps of fuel tank support.
E00494-10
–Remove screw 6.
–Remove screw 7.
–Pull off the side cover in area Aand area Band remove
it toward the rear.
E00487-10
–Detach spring 8.
Spring hook (5030501700004)
–Remove screws 9with the washers and take off the main
silencer.
S01417-10
–Pull off the engine control unit from the holder and hang to
the side.
–Disconnect plug-in connector bk on main wiring harness
and take off.
–Join the turn signal cable harness plug-in connector to the
main wiring harness plug-in connector.

2 SETUP
12
E00489-10
–Remove screw bl with the collar bushing.
–Remove screw bm.
–Remove screw bn with negative cable and contact disk.
S01416-10
–Remove screws bo.
–Carefully pull the tail light cable out of the frame, paying
attention to the plug as you do so.
–Take off license plate holder with tail light toward the rear.
E00491-10
–Remove screws bp and hang the tail light to the side.
–Drill a hole at marking Cto the size of the marking.

SETUP 2
13
E00492-10
–Route the turn signal cable harness toward the rear and
pass through the frame paying attention to the plugs as
you do so.
–Route turn signal cable harness on the license plate holder
and pass turn signal cable harness through the drill hole.
–Position tail light on license plate holder, and mount and
tighten screws bp.
E00495-10
–Carefully pass the tail light cable through the frame, pay-
ing attention to the plug as you do so.
–Position the license plate holder on the rear.
–Mount and tighten screws bo.

2 SETUP
14
E00489-10
–Mount and tighten screw bl with the collar bushing.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Mount and tighten screw bm.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Mount and tighten screw bn with negative cable and con-
tact disk.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
E00498-10
–Connect the tail light plug-in connector to the main wiring
harness plug-in connector.
–Mount the engine control unit on the holder.
Info
The wiring harness runs under the engine control
unit.
E00487-10
–Position the main silencer. Mount screws 9with the
washers, but do not tighten yet.
–Attach spring 8.
Spring hook (5030501700004)
–Tighten screws 9.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
E00494-10
–Attach the side cover in area Aand engage it in area B.
–Mount and tighten screw 7.
Guideline
Screw, sub-
frame
M8 35 Nm (25.8 lbf ft)
Loctite®2701™
–Mount and tighten screw 6.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Install the battery. ( p. 28)
–Install the fuel tank. ( p. 32)

SETUP 2
15
E00496-10
–Position turn signal on both sides, mount nuts with wash-
ers and tighten.
–Position license plate lamp on the license plate holder,
and mount and tighten screws bq.
–Mount reflector br on license plate holder.
–Pass cable through the license plate holder.
E00497-10
–Position the license plate holder on the license plate sup-
port.
–Join the plug-in connector of the license plate lamp.
–Connect the plug-in connector of the left turn signal which
is marked red.
–Connect the plug-in connector of the right turn signal
which is marked green.
–Mount and tighten screws bo.
D02151-10
–Position the right footrest and pin.
Info
Only insert the pin to the extent that the spring can still
be mounted.
S01395-10
–Position spring as shown.
Spring Dengages in area E.

2 SETUP
16
S01396-10
–Press the spring with special tool bs.
Footrest spring plier (79029083000)
The special tool is applied to area Fon the footrest.
–Mount pin bt.
S01397-10
–Mount the washer and splint ck.
S01398-10
–Position the left footrest and pin.
Info
Only insert the pin to the extent that the spring can still
be mounted.
S01399-10
–Position spring as shown.
Spring Gengages in area H.

SETUP 2
17
F01080-10
–Press the spring with special tool bs.
Footrest spring plier (79029083000)
The special tool is applied to area Ion the footrest.
–Mount pin cl.
F01081-10
–Mount the washer and splint cm.
F01078-10
–Position the frame protectors on both sides.
–Mount and tighten screws cn.
Guideline
Screw, frame protec-
tor
M5 3 Nm (2.2 lbf ft)
–Mount and tighten screws co with the washers.
Guideline
Screw, frame protec-
tor
M5 3 Nm (2.2 lbf ft)
–Mount the cable tie.
(All EXC‑F Six Days, EXC‑F AU)
–Install the engine guard. ( p. 35)
–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 the kilometers or miles. ( p. 37)
–Set the combination instrument. ( p. 38)
–Set the clock. ( p. 39)
–Refuel. ( p. 36)
–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 handover to the customer.

2 SETUP
18
Info
Transport mode must be deactivated to be able to start
the motorcycle.