KTM 450 SMR 2021 Manual

SETUP INSTRUCTIONS 2021
450 SMR
Art. no. 3214385en

INTRODUCTION
*3214385en*
3214385en
03/2021
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 SMR (F8403U0)

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
The diagnostics connector 1is located under the seat below the
EFI control unit.
2.3 Unpacking and setting up the vehicle
F01082-01
–Remove the box and the plastic packaging.
Guideline
To avoid damaging the vehicle while setting it up, do
not remove the protective film on each component until
installing the component, and leave it on the vehicle until
work has been completed.
–Remove the separate enclosure and unpack it. 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)
F03419-10
–Carefully loosen and remove tension belt 1from the footrest
brackets on the left and right.
Info
An assistant prevents the motorcycle from falling over.
–Remove screws 2from the footrest bracket on the left and
right.

2 SETUP
4
H01079-01
–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.
B00375-13
–Remove screws 3. Take off the handlebar clamps.
–Remove screws 4. Take off handlebar supports.
–Place handlebar supports in required position.
Info
The handlebar supports are longer and higher on one
side.
Position the left and right handlebar supports evenly.
–Mount and tighten screws 4.
Guideline
Screw, handle-
bar support
M10 40 Nm (29.5 lbf ft)
Loctite®243™
F03420-01
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 damaged
or bent.
–Position the handlebar.
Info
Make sure the cables and wiring are positioned cor-
rectly.
Do not kink the cables and lines.
–Position the handlebar clamps.
Info
The markings on the handlebar should be at the center
of the handlebar clamps.
–Mount screws 3, but do not tighten yet.
–First bolt the handlebar clamps with screws 3onto the
longer, higher side of the handlebar supports so that both parts
touch.

SETUP 2
5
Guideline
Screw, handlebar
clamp
M8 20 Nm (14.8 lbf ft)
–Tighten screws 3evenly.
Guideline
Screw, handlebar
clamp
M8 20 Nm (14.8 lbf ft)
–Check the handlebar position.
» If the handlebar position is not adjusted as required by the
customer:
–Adjust the handlebar position. ( p. 9)
F01130-01
–Position the controls on the right half of the handlebar.
F03421-10
–Position the controls on the left handlebar half.
–Tighten screw 5.
Guideline
Screw, fixed
grip
M4 5 Nm (3.7 lbf ft)
Loctite®243™
F03422-01
–Mount the left hand guard.
–Mount the right hand guard.
Info
Read the accompanying KTM PowerParts fitting instruc-
tions.

2 SETUP
6
S03029-10
–Remove the start number plate. ( p. 10)
–Route cable 6of the combination switch to the left.
–Remove protection cap and join plug-in connector 7.
F03423-01
–Mount the handlebar cushion.
–Install the start number plate. ( p. 11)
Z01425-10
–Position the new footrest and pin.
Info
Only insert the pin to the extent that the spring can still
be mounted.
F03424-10
–Position spring as shown.
Spring Aengages in area B.

SETUP 2
7
F03425-10
–Press the spring with special tool 8.
Footrest spring plier (79029083000)
The special tool is applied to area Con the footrest.
–Mount pin 9.
F03426-10
–Mount the washer and splint bk.
–Repeat these steps on the opposite side.
F03427-10
–Position the left frame protector.
–Insert the right frame protector from below and push it to the
rear.
–Mount and tighten screws bl with washers.
Guideline
Screw, frame protec-
tor
M5 3 Nm (2.2 lbf ft)
–Mount and tighten screw bm.
Guideline
Screw, frame protec-
tor
M5 3 Nm (2.2 lbf ft)
–Mount the cable ties.
–Charge the 12-V battery. ( p. 14)
–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).
–Refuel. ( p. 17)
–Position all controls in their exact positions on the handlebar.
Tighten all screws.
–Remove the remaining film, padding, the corrugated card-
board, and the other packaging material.
–Prepare the vehicle according to the specifications in
KTM Dealer.net for handover to the customer.

2 SETUP
8
Info
Transport mode must be deactivated to be able to start
the motorcycle.

WORK 3
9
3.1 Raising the motorcycle with a lift stand
Note
Danger of damage The parked vehicle can roll away or fall over.
–Park the vehicle on a firm and level surface.
401942-01
–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
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
–Park the vehicle on a firm and level surface.
–Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
402001-10
–Remove the motorcycle from the lift stand.
–Remove the lift stand.
–To park the motorcycle, insert plug-in stand 1into the left
side of the wheel spindle.
Info
Remove the plug-in stand before riding.
3.3 Adjusting the handlebar position
Preparatory work
–Remove the handlebar cushion.
B00375-10
Main work
–Remove screws 1. Take off the handlebar clamps. Remove
the handlebar and lay it to one side.
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
–Remove screws 2. Take off the handlebar supports.
–Place the handlebar supports in the required position.

3 WORK
10
Info
The handlebar supports are longer and higher on one
side.
Position the left and right handlebar supports evenly.
–Mount and tighten screws 2.
Guideline
Screw, handle-
bar support
M10 40 Nm (29.5 lbf ft)
Loctite®243™
–Position handlebar.
Info
Make sure the cables and wiring are positioned cor-
rectly.
–Position handlebar clamps.
–Mount screws 1but do not tighten yet.
–First bolt the handlebar clamps with screws 1onto the
longer, higher side of the handlebar supports so that both parts
touch.
Guideline
Screw, handlebar
clamp
M8 20 Nm (14.8 lbf ft)
–Tighten screws 1evenly.
Guideline
Screw, handlebar
clamp
M8 20 Nm (14.8 lbf ft)
Finishing work
–Mount the handlebar cushion.
3.4 Removing the start number plate
E01955-10
–Remove screw 1. Swivel the start number plate to one side.
–Unhook the start number plate from the brake line and remove
it.

WORK 3
11
3.5 Installing the start number plate
E01956-10
–Position the brake line in holders on the start number plate.
–Position the start number plate. Mount and tighten screw 1.
The holding lugs engage in the fender.
3.6 Removing the seat
F01533-10
–Remove screw 1.
H02218-10
–Raise the rear of the seat, pull the seat back, and lift it off.
3.7 Mounting the seat
H02218-11
–Mount the front of the seat on the collar bushing of the fuel
tank and the rear in the bracket.
–Push the seat forward.
–Make sure the seat is latched in place correctly.

3 WORK
12
F01533-10
–Mount and tighten screw 1.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
3.8 Removing the 12-V battery
Warning
Risk of injury 12 V batteries contain harmful substances.
–Keep 12 V batteries out of the reach of children.
–Keep sparks and open flames away from 12 V batteries.
–Only charge 12 V batteries in well-ventilated rooms.
–Maintain a minimum clearance from inflammable materials when charging 12 V batteries.
Minimum clearance 1 m (3 ft)
–Do not charge deeply discharged 12 V batteries if the charge is already below the minimum voltage.
Minimum voltage before the start of the charge 9 V
–Dispose of 12 V batteries with less than the minimum voltage correctly.
Preparatory work
–Remove the seat. ( p. 11)
S02336-10
Main work
–Hang the voltage regulator to the side.
–Disconnect negative cable 1from the 12-V battery.
–Pull back positive terminal cover 2and disconnect positive
cable 3from the 12-V battery.
–Remove screw 4.
–Pull holding bracket 5forward and take out the 12 V battery
upwards.

WORK 3
13
3.9 Installing the 12 V battery
H02650-10
Main work
–Position the 12 V battery in the battery compartment with the
terminals facing forward, and secure with holding bracket 1.
12 V battery (HJTZ5S-FP-C)
–Mount and tighten screw 2.
Guideline
Remaining nuts,
chassis
M6 10 Nm (7.4 lbf ft)
Info
Contact disks Amust be mounted under screws 3
and cable sockets 4with the claws toward the battery
terminal.
–Connect positive cable 5to the 12 V battery.
Guideline
Screw, battery termi-
nal
M5 2.5 Nm
(1.84 lbf ft)
–Slide positive terminal cover 6over the positive terminal.
–Connect negative cable 7to the 12 V battery.
Guideline
Screw, battery termi-
nal
M5 2.5 Nm
(1.84 lbf ft)
–Position the voltage regulator.
Finishing work
–Mount the seat. ( p. 11)
3.10 Disconnecting the negative cable of the 12-V battery
Preparatory work
–Remove the seat. ( p. 11)
R01414-10
Main work
–Disconnect negative cable 1from the 12-V battery.

3 WORK
14
3.11 Connecting the negative cable of the 12 V battery
T02638-10
Main work
–Connect negative cable 1of the 12 V battery.
Guideline
Screw, battery termi-
nal
M5 2.5 Nm
(1.84 lbf ft)
Contact disk Amust be mounted under screw 2and
cable lug 3with the claws toward the battery terminal.
Finishing work
–Mount the seat. ( p. 11)
3.12 Charging the 12-V battery
Warning
Risk of injury 12 V batteries contain harmful substances.
–Keep 12 V batteries out of the reach of children.
–Keep sparks and open flames away from 12 V batteries.
–Only charge 12 V batteries in well-ventilated rooms.
–Maintain a minimum clearance from inflammable materials when charging 12 V batteries.
Minimum clearance 1 m (3 ft)
–Do not charge deeply discharged 12 V batteries if the charge is already below the minimum voltage.
Minimum voltage before the start of the charge 9 V
–Dispose of 12 V batteries with less than the minimum voltage correctly.
Note
Environmental hazard 12 V batteries contain environmentally hazardous materials.
–Do not dispose of 12 V batteries as household waste.
–Dispose of 12 V batteries at a collection point for used batteries.
Note
Environmental hazard Hazardous substances cause environmental damage.
–Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

WORK 3
15
Info
Even when there is no load on the 12-V battery, it discharges steadily each day.
The charging level and the method of charging are very important for the service life of the 12-V battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, and charging time are exceeded, the 12-V battery will be
destroyed.
If the 12-V battery is depleted from starting the vehicle repeatedly, the battery must be charged immedi-
ately.
If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged
and suffer a loss of capacity, destroying the battery.
The 12-V battery is maintenance-free.
Preparatory work
–Remove the seat. ( p. 11)
–Disconnect the negative cable of the 12-V battery. ( p. 13)
311910-10
Main work
–Connect a battery charger to the 12-V battery. Adjust the bat-
tery charger.
EU battery charger XCharge‑professional (00029095050)
Alternative 1
US battery charger XCharge‑professional
(00029095051)
Alternative 2
UK battery charger XCharge‑professional
(00029095052)
Info
Follow the instructions of the charger and the manual.
–Disconnect the battery charger after charging the 12-V battery.
Guideline
The charging current, charging voltage, and charging time
must not be exceeded.
Recharge the 12-V battery
regularly when the motorcy-
cle is not being used
3 months
Finishing work
–Connect the negative cable of the 12 V battery. ( p. 14)
–Mount the seat. ( p. 11)

3 WORK
16
3.13 Opening fuel tank filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
–Keep fuels correctly in a suitable canister, and out of the reach of children.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.
E01950-10
–Turn fuel tank filler cap 1counterclockwise and lift it off.
3.14 Closing the fuel tank filler cap
E01950-11
–Mount fuel tank filler cap 1and turn it clockwise until the
fuel tank is tightly closed.
Info
Route fuel tank breather hose 2without kinks.

WORK 3
17
3.15 Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
Note
Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged.
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in
problems with the fuel system.
–Refuel only with clean fuel that meets the specified standards.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.
–Switch off the engine.
–Open fuel tank filler cap. ( p. 16)
401522-10
–Fill the fuel tank with fuel up to measurement A.
Guideline
Measurement of A35 mm (1.38 in)
Super unleaded (ROZ 95) ( p. 20) 6.8 l (1.8 US gal)
–Close the fuel tank filler cap. ( p. 16)

4 TECHNICAL DATA
18
4.1 Chassis tightening torques
Screw, air filter box EJOT PT®K70x25 5 Nm (3.7 lbf ft)
Screw, combination switch EJOT PT®K50x18 2 Nm (1.5 lbf ft)
Screw, intake air temperature sen-
sor
EJOT DELTA PT®45x12‑Z 0.7 Nm (0.52 lbf ft)
Fitting, start button M3 0.4 Nm (0.3 lbf ft)
Fitting, stop button M3 0.4 Nm (0.3 lbf ft)
Fitting, inlet sleeve to throttle
valve body
M4 2.8 Nm (2.07 lbf ft)
Screw, fixed grip M4 5 Nm (3.7 lbf ft)
Loctite®243™
Screw, service hour counter M4 0.8 Nm (0.59 lbf ft)
Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft)
Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft)
Remaining nuts, chassis M5 5 Nm (3.7 lbf ft)
Remaining screws, chassis M5 5 Nm (3.7 lbf ft)
Screw, battery terminal M5 2.5 Nm (1.84 lbf ft)
Screw, frame protector M5 3 Nm (2.2 lbf ft)
Screw, shock absorber adjusting
ring
M5 5 Nm (3.7 lbf ft)
Nut, cable on starter motor M6 4 Nm (3 lbf ft)
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft)
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Screw, ball joint of push rod on
foot brake cylinder
M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, chain sliding guard M6 6 Nm (4.4 lbf ft)
Loctite®243™
Screw, front brake disc M6 14 Nm (10.3 lbf ft)
Loctite®243™
Screw, indicator lamp bracket M6 5 Nm (3.7 lbf ft)
Screw, rear brake disc M6 14 Nm (10.3 lbf ft)
Loctite®243™
Screw, throttle grip M6 5 Nm (3.7 lbf ft)
Fuel connection on fuel tank M8 15 Nm (11.1 lbf ft)
Nut, foot brake lever stop M8 20 Nm (14.8 lbf ft)
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft)
Loctite®2701™
Nut, rim lock M8 12 Nm (8.9 lbf ft)
Remaining nuts, chassis M8 25 Nm (18.4 lbf ft)
Remaining screws, chassis M8 25 Nm (18.4 lbf ft)
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
Screw, chain sliding piece M8 15 Nm (11.1 lbf ft)
Screw, engine brace M8x20 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, engine brace M8x15 25 Nm (18.4 lbf ft)
Loctite®2701™
Screw, fork stub M8 15 Nm (11.1 lbf ft)