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)