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450 EXC-F 2019
KTM 450 EXC-F 2019 User Manual
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SERVICE
WORK
ON
THE
CHASSIS
12
75
S01321-10
–
Remove
screws
2
.
Take
off
front
fender.
12.18
Installing
front
fender
V00340-10
Main
work
(EXC
‑
F
EU/AU)
–
Position
front
fender.
Mount
and
tighten
screws
1
.
Guideline
Remaining
screws,
chassis
M6
10
Nm
(7.4
lbf
ft)
V00341-10
–
Mount
and
tighten
screws
2
.
Guideline
Remaining
screws,
chassis
M6
10
Nm
(7.4
lbf
ft)
K00576-10
(EXC
‑
F
Six
Days)
–
Position
front
fender.
Mount
and
tighten
screws
1
.
Guideline
Remaining
screws,
chassis
M6
10
Nm
(7.4
lbf
ft)
S01321-10
–
Mount
and
tighten
screws
2
.
Guideline
Remaining
screws,
chassis
M6
10
Nm
(7.4
lbf
ft)
Finishing
work
–
Install
the
headlight
mask
with
the
headlight.
(
p.
118)
76
78
Table of Contents
Table of Contents
4
Means of Representation
8
Symbols Used
8
Formats Used
8
Safety Advice 2
9
Use Definition - Intended Use
9
Misuse
9
Degrees of Risk and Symbols
9
Tampering Warning
10
Safe Operation
10
Protective Clothing
11
Work Rules
11
Environment
11
Owner's Manual
11
Important Notes
12
Manufacturer and Implied Warranty
12
Operating and Auxiliary Substances
12
Spare Parts, Accessories
12
Service
12
Figures
12
Customer Service
12
View of Vehicle
14
View of Vehicle, Front Left (Example)
14
View of Vehicle, Rear Right (Example)
15
Serial Numbers
16
Chassis Number
16
Type Label
16
Key Number
16
Engine Number
16
Fork Part Number
17
Shock Absorber Article Number
17
Controls
18
Clutch Lever
18
Hand Brake Lever
18
Throttle Grip
18
Kill Switch
18
Horn Button
19
Light Switch
19
Turn Signal Switch
19
Emergency off Switch
19
Electric Starter Button
20
Combination Switch (EXC-F Six Days)
20
Indicator Lamps Overview
20
Opening the Filler Cap
21
Closing the Filler Cap
21
Cold Start Button
22
Idle Speed Adjusting Screw
22
Shift Lever
23
Foot Brake Lever
23
Side Stand
23
Steering Lock
24
Locking the Steering
24
Unlocking the Steering
25
Combination Instrument
26
Combination Instrument Overview
26
Activation and Test
26
Setting the Kilometers or Miles
26
Adjusting the Combination Instrument
27
Setting the Clock
28
Viewing the Lap Time
28
Display Mode SPEED (Speed)
29
Display Mode SPEED/H (Operating Hours)
29
Setup Menu
29
Setting the Unit of Measurement
30
Display Mode SPEED/CLK (Time)
31
Setting the Clock
31
Display Mode SPEED/LAP (Lap Time)
31
Viewing the Lap Time
32
Display Mode SPEED/ODO (Odometer)
32
Display Mode SPEED/TR1 (Trip Master 1)
33
Display Mode SPEED/TR2 (Trip Master 2)
33
Setting TR2 (Trip Master 2)
33
Display Mode SPEED/A1 (Average Speed 1)
34
Display Mode SPEED/A2 (Average Speed 2)
34
Display Mode SPEED/S1 (Stop Watch 1)
35
Display Mode SPEED/S2 (Stop Watch 2)
35
Table of Functions
36
Table of Conditions and Menu Activation
37
Preparing for Use
38
Advice on First Use
38
Running-In the Engine
39
Starting Power of Lithium-Ion Batteries at Low Temperatures
39
Preparing the Vehicle for Difficult Riding Conditions
40
Preparing Vehicle for Rides on Dry Sand
40
Preparing Vehicle for Rides on Wet Sand
41
Preparing Vehicle for Rides on Wet and Muddy Circuits
42
Preparing Vehicle for High Temperatures or Slow Riding
42
Preparing Vehicle for Low Temperatures or Snow
43
Riding Instructions
44
Checks and Maintenance Measures When Preparing for Use
44
Starting the Vehicle
44
Activating Traction Control (EXC-F Six Days)
45
Starting off
46
Shifting, Riding
46
Braking
46
Stopping, Parking
47
Transporting
48
Refueling
48
10 Service Schedule
50
Additional Information
50
Required Work
50
Recommended Work
51
11 Tuning the Chassis
52
Checking the Basic Suspension Setting against the Rider's Weight
52
Compression Damping of the Shock Absorber
52
Adjusting the Low-Speed Compression Damping of the Shock Absorber
52
Adjusting the High-Speed Compression Damping of the Shock Absorber
53
Adjusting the Rebound Damping of the Shock Absorber
54
Measuring the Rear Wheel Dimension Unloaded
54
Checking the Static Sag of the Shock Absorber
55
Checking the Riding Sag of the Shock Absorber
55
Adjusting the Spring Preload of the Shock Absorber
56
Adjusting the Riding Sag
57
Checking the Basic Setting of the Fork
57
Adjusting the Compression Damping of the Fork
58
Adjusting the Rebound Damping of the Fork
59
Adjusting the Spring Preload of the Fork (EXC-F Six Days)
60
Handlebar Position
61
Adjusting the Handlebar Position
61
12 Service Work on the Chassis
64
Raising the Motorcycle with the Lift Stand
64
Removing the Motorcycle from the Lift Stand
64
Bleeding the Fork Legs
64
Cleaning the Dust Boots of the Fork Legs
65
Removing the Fork Protector
65
Installing the Fork Protector
66
Removing the Fork Legs
66
Installing the Fork Legs
67
(Exc-F Eu/Au)
68
Removing the Lower Triple Clamp (EXC-F Six Days)
69
Installing the Lower Triple Clamp (EXC-F EU/AU)
70
Installing the Lower Triple Clamp (EXC-F Six Days)
72
Checking the Play of the Steering Head Bearing
74
Adjusting the Steering Head Bearing Play (EXC-F EU/AU)
74
Adjusting the Steering Head Bearing Play (EXC-F Six Days)
75
Lubricating the Steering Head Bearing
76
Removing Front Fender
76
Installing Front Fender
77
Removing the Shock Absorber
78
Installing the Shock Absorber
78
Removing the Seat
78
Mounting the Seat
79
Removing the Air Filter Box Cover
79
Installing the Air Filter Box Cover
80
Removing the Air Filter
80
Installing the Air Filter
81
Cleaning the Air Filter and Air Filter Box
81
Sealing the Air Filter Box
82
Preparing Air Filter Box Cover for Securing
82
Removing the Main Silencer
82
Installing the Main Silencer
83
Changing the Glass Fiber Yarn Filling in the Main Silencer
83
Removing the Fuel Tank
84
Installing the Fuel Tank
86
Checking for Chain Dirt Accumulation
87
Cleaning the Chain
87
Checking the Chain Tension
88
Adjusting the Chain Tension
89
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide
90
Checking the Frame
92
Checking the Swingarm
92
Checking Throttle Cable Routing
92
Checking the Rubber Grip
93
Adjusting the Basic Position of the Clutch Lever
94
Checking/Correcting the Fluid Level of the Hydraulic Clutch
94
Changing the Hydraulic Clutch Fluid
95
Removing the Engine Guard (EXC-F Six Days, EXC-F AU)
96
Installing the Engine Guard (EXC-F Six Days, EXC-F AU)
96
Brake System 13
97
Checking the Free Travel of the Hand Brake Lever
97
Adjusting Free Travel of Hand Brake Lever
97
Checking the Brake Discs
97
Checking the Front Brake Fluid Level
98
Adding Front Brake Fluid
99
Checking the Front Brake Linings
100
Changing the Front Brake Linings
100
Checking the Free Travel of Foot Brake Lever
102
Adjusting the Basic Position of the Foot Brake Lever
103
Checking the Rear Brake Fluid Level
103
Adding Rear Brake Fluid
104
Checking the Rear Brake Linings
105
Changing the Rear Brake Linings
105
14 Wheels, Tires
108
Removing the Front Wheel
108
Installing the Front Wheel
109
Removing the Rear Wheel
109
Installing the Rear Wheel
110
Checking the Tire Condition
112
Checking the Tire Air Pressure
112
Checking Spoke Tension
113
15 Electrical System
114
Removing the Battery
114
Installing the Battery
114
Recharging the Battery
115
Changing the Main Fuse
117
Changing the Fuses of Individual Power Consumers
118
Removing the Headlight Mask with the Headlight
120
Installing the Headlight Mask with the Headlight
120
Changing the Headlight Bulb
121
Checking the Headlight Setting
121
Adjusting the Headlight Range
122
Changing the Turn Signal Bulb
122
Changing the Combination Instrument
123
Diagnostics Connector
124
Cooling System 16
125
Checking the Antifreeze and Coolant Level
125
Checking the Coolant Level
126
Draining the Coolant
126
Refilling Coolant
127
Tuning the Engine 17
129
Checking the Play in the Throttle Cable
129
Adjusting the Play in the Throttle Cable
129
Adjusting the Characteristic Map of the Throttle Response
130
Changing the Mapping (EXC-F Six Days)
131
Adjusting the Idle Speed
132
Teaching the Throttle Valve Position
133
Checking the Basic Position of the Shift Lever
133
Adjusting the Basic Position of the Shift Lever
134
Service Work on the Engine 18
135
Changing the Fuel Screen
135
Checking the Engine Oil Level
136
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens
136
Adding Engine Oil
139
19 Cleaning, Care
140
Cleaning the Motorcycle
140
Checks and Maintenance Steps for Winter Operation
141
20 Storage
142
Preparing for Use after Storage
143
21 Troubleshooting
144
Blink Code 22
147
Technical Data 23
149
Engine
149
Engine Tightening Torques
150
Capacities
151
Engine Oil
151
Coolant
151
Fuel
151
Chassis
152
Electrical System
153
Tires
153
Fork
153
Exc-F Eu/Au
153
EXC-F Six Days
154
Shock Absorber
154
Chassis Tightening Torques
155
Substances 24
157
Auxiliary Substances 25
159
Standards 26
161
27 Index of Special Terms
162
List of Abbreviations 28
163
29 List of Symbols
164
Yellow and Orange Symbols
164
Green and Blue Symbols
164
Index
165
5
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KTM 450 EXC-F 2019 Specifications
General
Brand
KTM
Model
450 EXC-F 2019
Category
Motorcycle
Language
English
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