KTM F8401V5 Manual

SETUP INSTRUCTIONS 2022

450 SX‑F

450 XC-F

Art. no. 3214450en

INTRODUCTION

*3214450en*

3214450en

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 Sportmotorcycle accepts no liability for delivery options, devi-

ations from figures and descriptions, as well as misprints and other errors. The models portrayed partly contain

special equipment that does not belong to the regular scope of supply.

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 (F8401V5)

450 SX‑F US (F8475V5)

450 XC‑F US (F8475V0)

1 MEANS OF REPRESENTATION

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

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 for 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

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 for 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

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

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

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

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. 16)

F01627-01

–Mount the handlebar cushion.

–Install front fender. ( p. 16)

–Install the front wheel. ( p. 15)

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