KTM 450 SX-F CAIROLI 2020 Manual

SETUP INSTRUCTIONS 2020
450 SX‑F
450 XC-F
450 SX‑F CAIROLI
450 SX‑F Factory Edition
Art. no. 3214142en

INTRODUCTION
*3214142en*
3214142en
11/2019
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.
© 2019 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 SX‑F EU (F8401T5)
450 SX‑F US (F8475T5)
450 XC‑F US (F8475T0)
450 SX‑F CAIROLI EU (F8401T6)
450 SX‑F Factory Edition US (F8475T1)

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
Diagnostics connector 1is located under the seat.
2.3 Unpacking and setting up the vehicle
E00851-10
Package 2
–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.
Info
The procedure in the event of missing components
is described in the customer service manual.
–Remove the cable ties on the rear wheel, take off the front
wheel and the fender.
–Have a lift stand available.
Lift stand (78129955100)
–Carefully loosen and remove the tension belt of the footrest
mount.

2 SETUP
4
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.
Info
The procedure in the event of transport damage is
described in the customer service manual.
F01622-10
–Remove screw 1and take off the start number plate.
E00850-10
Package 12
–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 on the basis of the
enclosed packing list.
Info
The procedure in the event of missing components
is described in the customer service manual.
402051-01
–Have a lift stand available.
Lift stand (78129955100)
–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.

SETUP 2
5
F01629-10
–Remove the cardboard from around the shock absorber.
–Position the angle lever and linkage lever.
–Mount and tighten fitting 1.
Guideline
Nut, linkage lever
on angle lever
M14x1.5 60 Nm
(44.3 lbf ft)
–Mount and tighten screw 2.
Guideline
Screw, bottom
shock absorber
M10 60 Nm (44.3 lbf ft)
Loctite®2701™
Info
Raise the wheel slightly to be able to mount the
screw more easily.
F01623-01
–Route the clutch line with the clutch master cylinder
toward the front between the upper and lower triple
clamps.
F01064-10
–Position the fork legs and tighten the screws of the triple
clamp.
Guideline
Screw, top triple
clamp
M8 17 Nm
(12.5 lbf ft)
Screw, bottom
triple clamp
M8 12 Nm (8.9 lbf ft)
Air bleeder screw 3of the right fork leg is positioned
to the front.
Valve Aof the left fork leg faces the front.
Info
Grooves are milled into the side of the upper end of
the fork legs. The second milled groove (from the
top) must be flush with the upper edge of the upper
triple clamp.
The air suspension is located in the left fork leg.
The pressure and rebound damping is located in
the right fork leg.

2 SETUP
6
S02349-10
–Remove screws 4. Take off handlebar supports 5.
–Position rubber bushings 6and push through nuts 7from
below.
–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™
F01624-10
–Remove cable ties on the side cover and remove film from the
handlebar.
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 clamp.
–Mount screws 8, but do not tighten yet.
–First bolt the handlebar clamp with screws 8onto the longer,
higher side of the handlebar supports so that both parts touch.
–Tighten screws 8evenly.
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.

SETUP 2
7
K00645-10
–Position the controls on the right half of the handlebar.
Guideline
Screw, throttle grip M6 5 Nm (3.7 lbf ft)
K00646-10
–Position the controls on the left handlebar half.
Guideline
Screw, fixed
grip
M4 5 Nm (3.7 lbf ft)
Loctite®243™
F01067-01
(XC‑F US)
–Preassemble the hand guards on the left and right.

2 SETUP
8
F01068-01
–Mount the left hand guard.
–Mount the right hand guard.
F01625-10
(all SX‑F models)
–Join plug-in connector 9.
–Attach cable in the indicator lamp bracket bk.
–Route the cables without tension and secure with the cable
ties.
F01626-10
(XC‑F US)
–Join plug-in connector 9.
–Attach cable in the indicator lamp bracket bk.
–Route the cables without tension and secure with the cable
ties.
–Install the start number plate. ( p. 17)
F01627-01
–Mount the handlebar cushion.
–Install front fender. ( p. 16)

SETUP 2
9
F02598-01
(Factory Edition)
–Mount the Factory‑Start.
Info
Read the accompanying KTM PowerParts instruc-
tions.
F02583-10
(all SX‑F special models)
–Mount the brake disc guard.
Info
Read the accompanying KTM PowerParts instruc-
tions.
Align the brake disc guard so that the distances are
the same size.
–Install the front wheel. ( p. 15)
F01628-10
Condition
Target market excluding USA
–Apply WARNING sticker to the rear fender.
Info
The WARNING sticker must not be applied together
with the COMPETITION ONLY sticker.
Condition
USA target market
–Do not apply the WARNING sticker.
D00674-10
Left and right footrest (all SX‑F models)
–Position the new footrest and pin.
Info
Only insert the pin to the extent that the spring can
still be mounted.

2 SETUP
10
K00621-12
–Position spring as shown.
Spring Bengages in area C.
F01630-10
–Press the spring with special tool bl.
Footrest spring plier (79029083000)
The special tool is applied to area Don the footrest.
–Mount pin bm.
F01631-10
–Mount the washer and splint bn.
–Repeat these steps on the opposite side.
D00674-10
Right footrest (XC‑F US)
–Position the right footrest and pin.
Info
Only insert the pin to the extent that the spring can
still be mounted.

SETUP 2
11
K00621-12
–Position spring as shown.
Spring Bengages in area C.
F01630-10
–Press the spring with special tool bl.
Footrest spring plier (79029083000)
The special tool is applied to area Don the footrest.
–Mount pin bm.
F01631-10
–Mount the washer and splint bn.
R00757-10
Left footrest (XC‑F US)
–Position the left footrest and pin.
Info
Only insert the pin to the extent that the spring can
still be mounted.

2 SETUP
12
K00688-10
–Position spring as shown.
Spring Eengages in area F.
F01632-10
–Press the spring with special tool bl.
Footrest spring plier (79029083000)
The special tool is applied to area Gon the footrest.
–Mount pin bo.
F01633-10
–Mount the washer and splint bp.
F01634-10
–Position the left frame protector.
–Insert the right frame protector from below and push it to the
rear.
–Mount and tighten screws bq with the washers.
Guideline
Screw, frame protec-
tor
M5 3 Nm (2.2 lbf ft)
–Mount and tighten screw br.
Guideline
Screw, frame protec-
tor
M5 3 Nm (2.2 lbf ft)
–Mount the cable ties.

SETUP 2
13
(all SX‑F special models)
–Install the engine guard. ( p. 20)
F01635-10
–Remove the seat. ( p. 17)
–Remove the air filter box cover. ( p. 18)
–Route the diagnostics connector and the positive cable
upwards towards the 12-V battery.
–Position diagnostics connector in holder bs.
–Install the air filter box cover. ( p. 19)
F01636-10
–Connect positive cable bt to the 12-V battery.
Guideline
Screw, battery termi-
nal
M5 2.5 Nm
(1.84 lbf ft)
–Connect negative cable ck to the 12-V battery.
Guideline
Screw, battery termi-
nal
M5 2.5 Nm
(1.84 lbf ft)
Contact disks Hmust be mounted under screws cl and
cable sockets cm with the claws toward the battery termi-
nal.
–Slide positive terminal cover cn over the positive terminal.
–Charge the 12 V battery. ( p. 20)
–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. 24)
–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.
Info
Transport mode must be deactivated to be able to start
the motorcycle.

3 WORK
14
3.1 Raising the motorcycle with a 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.
401942-01
(All SX‑F standard models)
–Remove the plug-in stand and lift up the motorcycle by the
frame underneath the engine.
Lift stand (78129955100)
Neither wheel is in contact with the ground.
(all SX‑F special models)
–Remove the plug-in stand and lift up the motorcycle by the
motor guard underneath the engine.
Lift stand (78129955100)
Neither wheel is in contact with the ground.
(XC‑F US)
–Fold in the side stand and 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.
H02629-10
(all SX‑F models)
–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.
Plug-in stand (79029094000)
Info
The plug-in stand is included.
Remove the plug-in stand before riding.

WORK 3
15
401943-10
(XC‑F US)
–Remove the motorcycle from the lift stand.
–Remove the lift stand.
–To park the motorcycle, press side stand 1to the ground
with your foot and lean the motorcycle on it.
Info
When you are riding, the side stand must be folded
up and secured with rubber strap.
3.3 Installing the front wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
–Always keep the brake discs free of oil and grease.
–Clean the brake discs with brake cleaner when necessary.
H00935-10
(SX‑F EU/US, XC-F US)
–Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
–Change front wheel bearing.
–Clean and grease shaft seal rings 1and contact sur-
faces Aof the spacers.
Long-life grease ( p. 29)
–Insert the spacers.
–Clean and grease the wheel spindle.
Long-life grease ( p. 29)
–Position the front wheel and insert the wheel spindle.
The brake linings are correctly positioned.
S01631-10
(all SX‑F special models)
–Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
–Change front wheel bearing.
–Clean and grease shaft seal rings 1and contact sur-
faces Aof the spacers.
Long-life grease ( p. 29)
–Insert the spacer and brake disc guard.
–Clean and grease the wheel spindle.
Long-life grease ( p. 29)
–Position the front wheel and insert the wheel spindle.
The brake linings are correctly positioned.

3 WORK
16
S01633-10
–Align the brake disc guard so that distance Band Care
equal in size.
F00141-11
–Mount and tighten screw 2.
Guideline
Screw, front wheel
spindle
M20x1.5 35 Nm (25.8 lbf ft)
–Operate the hand brake lever several times until the brake lin-
ings are seated correctly against the brake disc.
–Remove the motorcycle from the lift stand. ( p. 14)
–Operate the front brake and compress the fork a few times
firmly.
The fork legs straighten.
–Tighten screws 3.
Guideline
Screw, fork stub M8 15 Nm (11.1 lbf ft)
3.4 Installing front fender
F01526-10
Main work
–Position front fender. Mount and tighten screws 1and 2.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
Finishing work
–Install the start number plate. ( p. 17)

WORK 3
17
3.5 Installing the start number plate
F01525-10
–Position the brake line in holders Aon 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
Caution
Danger of burns The voltage regulator gets very hot when the vehicle is driven.
–Allow the voltage regulator to cool down before performing any work.
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, lower the seat at the rear, and push the seat forward.
–Make sure the seat is latched in place correctly.

3 WORK
18
F01533-10
–Mount and tighten screw 1.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
3.8 Removing the air filter box cover
Condition
The air filter box cover is secured.
–Remove the seat. ( p. 17)
F01534-10
–Remove screw 1.
F01534-11
–Pull off the air filter box cover in area Asideways and
take off toward the front.
F01535-10
Condition
The air filter box cover is not secured.
–Pull off the air filter box cover in area Alaterally and take
it off at the front.