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.
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