🏷️ Basic Information

Make:

KTM

Model:

400 EXC, 450 EXC, 530 EXC, 400 XC-W, 450 XC-W, 530 XC-W

Year:

2009

Engine Codes:

LC4, LC4-5F (Specific codes vary by exact displacement, refer to manual for detailed identification)

Chassis Codes:

SX-F, XC-F (Common base platforms, model variations exist. Refer to VIN for precise identification)

👋 Introduction

Vehicle Segment:

High-performance off-road/enduro motorcycles

Target Audience:

Enthusiast riders, mechanics, and owners seeking detailed service information

Competitors:

Yamaha WR series, Honda CRF-X, Husqvarna TE series, Beta RR series

Manual Value Proposition:

Provides factory-level accuracy and detail, enabling efficient and correct repairs, reducing costly mistakes.

Vehicle Strengths:

Renowned for powerful engines, advanced chassis, and competitive off-road performance.

📋 Manual Details

Geographic Coverage:

Global (Factory specifications applicable worldwide)

Model Coverage:

KTM 400 EXC, 450 EXC, 530 EXC, 400 XC-W, 450 XC-W, 530 XC-W

Model Year Coverage:

2009

Estimated Pages:

Approx. 300-500 pages (typical for a comprehensive factory workshop manual)

Type:

Factory Workshop Service Manual

Primary Language:

English

Format Type:

Digital (PDF)

Searchability:

Full text searchable

Printable:

Yes

📖 Manual Coverage

Engine:

Complete engine disassembly, assembly, inspection, repair, and tuning

Transmission:

Gearbox removal, inspection, repair, and reassembly; clutch system

Fuel System:

Carburetor/EFI system servicing, fuel pump, fuel tank, lines

Cooling System:

Radiator, cooling fan, hoses, coolant specifications

Ignition System:

CDI, spark plugs, ignition timing, troubleshooting

Electrical System:

Wiring diagrams, battery, charging system, lighting, starter motor

Chassis:

Frame inspection, steering head, swingarm, linkage

Suspension:

Front forks (WP), rear shock absorber (WP), servicing, adjustments, oil types

Brakes:

Front and rear brake systems (Brembo), hydraulic systems, pad replacement, bleeding

Wheels And Tires:

Wheel bearing service, spoke tension, tire selection and mounting

Bodywork:

Plastic components, seat, handlebars, controls

Exhaust System:

Muffler, header pipe maintenance

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, lubrication

Troubleshooting:

Diagnostic procedures for common starting, running, and electrical issues

Engine Rebuild:

Piston replacement, ring replacement, valve adjustments, bearing replacement, complete engine overhaul

Suspension Servicing:

Fork seal replacement, damper rod servicing, shock absorber rebuild

Brake System Maintenance:

Brake pad replacement, caliper servicing, master cylinder overhaul, brake fluid flush

Electrical Diagnostics:

Fault finding for lighting, charging, and ignition circuits using wiring diagrams

Carburetor Tuning:

Jetting specifications, idle adjustment, mixture screw settings (for carbureted models)

Fuel Injection Servicing:

Throttle body cleaning, sensor checks (for EFI models)

Wheel Truing:

Spoke tension adjustment and wheel alignment

Depth:

Comprehensive; covers basic maintenance to complete engine and chassis overhauls

Diagnostics:

Detailed diagnostic trees and troubleshooting guides

Specifications:

All factory torque specifications, tolerances, clearances, and fluid levels included

Illustrations:

High-quality diagrams, pictures, and illustrations for visual guidance

Component Function:

Explanation of component and system functions

📊 Manual Specifications

File Type:

PDF

Resolution:

High-resolution for clarity of text and diagrams

Print Readability:

Designed for clear printing of all sections and illustrations

Binding Recommendation:

Digital format; user can print and bind as needed (e.g., spiral-bound for lay-flat access)

Paper Recommendation:

Matte finish paper recommended for workshop environment to reduce glare and fingerprints

⚙️ Engine Specifications

Engine Type:

Four-stroke, Liquid-cooled, Single-cylinder (LC4 platform)

Displacement:

400cc, 450cc, 530cc (model dependent)

Bore X Stroke:

Varies by displacement; e.g., 450 EXC approximately 95 mm x 63.4 mm. Refer to manual for exact figures.

Valve Train:

SOHC, 4 valves per cylinder

Compression Ratio:

Varies by displacement; e.g., approx. 11.2:1 - 11.6:1. Refer to manual for exact figures.

Horsepower Estimate:

Approx. 50-60+ HP (Varies significantly by displacement and tuning)

Torque Estimate:

Approx. 35-45+ lb-ft (Varies significantly by displacement and tuning)

Carburetor Models:

Keihin FCR MX (Specific size varies by displacement)

Efi Models:

Keihin EFI (Electronic Fuel Injection) (Likely present on some XC-W variants)

Fuel Type:

Unleaded gasoline, minimum octane rating 95 (RON+MON)/2 (AKI) or 91 (RON)

Oil Type:

Semi-synthetic or fully synthetic motorcycle-specific 4-stroke engine oil, SAE 10W-50 or 10W-60 recommended by KTM for this era.

Oil Capacity:

Approx. 1.1 - 1.3 liters (Refer to manual for exact capacity and filter change quantity)

🔧 Transmission

Type:

6-speed, constant mesh sequential gearbox

Clutch Type:

Hydraulically operated, multi-disc wet clutch

Final Drive:

O-ring sealed chain

Ratios:

Specific ratios vary by model and displacement; detailed in manual.

Transmission Oil Type:

SAE 75W/80 or 80W/90 gear oil, or specialized KTM transmission oil. Refer to manual.

Transmission Oil Capacity:

Approx. 0.8 - 1.0 liters (Refer to manual for exact capacity)

📐 Dimensions

Wheelbase:

Approx. 1470-1520 mm (Varies by model)

Seat Height:

Approx. 960-970 mm (Unladen)

Dry Weight Estimate:

Approx. 110-120 kg (Varies significantly by model and equipment)

Fuel Tank Capacity:

Approx. 9.5 - 11 liters (Depends on specific model variant)

Front Wheel Size:

21 x 1.60

Rear Wheel Size:

18 x 2.15 or 18 x 2.50

Front Tire Size:

Typically 80/100-21

Rear Tire Size:

Typically 110/100-18 or 140/80-18

Bolt Pattern:

Standard off-road spoke pattern. Consult manual for hub details.

🛡️ Safety Features

Safety Certifications:

CE, EPA (where applicable by market)

Braking System:

High-performance Brembo hydraulic disc brakes (front and rear)

Suspension Damping:

Adjustable WP suspension for controlled handling and stability

Frame Construction:

Chromium-molybdenum steel trellis frame for strength and rider feedback

Ergonomics:

Designed for optimal rider control and position in off-road conditions

💡 Technology Features

Infotainment System:

Not applicable; these are pure off-road performance machines with minimal electronic rider aids beyond EFI systems.

Rider Aids:

None (No ABS, traction control, or rider modes on these 2009 models).

Connectivity Features:

Not applicable.

Engine Management:

EFI system on certain models, providing precise fuel and ignition control. Basic CDI on carbureted models.

🔧 Maintenance

Oil Change Interval:

Every 15-20 hours of riding or annually. Refer to manual for precise intervals based on usage type.

Air Filter Cleaning:

After every few rides, or more frequently in dusty conditions. Refer to manual.

Valve Clearance Check:

Typically every 30-50 hours of riding or annually. Critical inspection point.

Chain Lubrication Adjustment:

Regularly, every 500-1000 km or after washing/off-road riding.

Coolant Type:

KTM recommends a specific coolant mix or equivalent quality ethylene glycol-based antifreeze with corrosion inhibitors (typically 50/50 with distilled water).

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Potential Wear Items:

Clutch plates, valve seats and guides, wheel bearings, steering head bearings, swingarm bearings are common wear items in off-road use.

Engine Performance Degradation:

Can be related to valve clearance, ignition timing, or fueling issues if not maintained.

Suspension Leaks:

Fork seals and shock seals can be prone to leaks due to the demanding nature of off-road riding.

📚 Vehicle History

Brand Focus:

KTM is renowned for its 'Ready to Race' philosophy and strong heritage in off-road motorsport, particularly motocross and enduro.

Lc4 Lineage:

The EXC/XC-W line evolved from KTM's successful LC4 single-cylinder engine platform, known for its robust performance and adaptability to various off-road disciplines.

2009 Updates:

The 2009 models often featured refinements to the LC4 engine, chassis, and suspension (WP), building on previous generations' success.

Manufacturing Location:

Austria (KTM's primary manufacturing base)

🏆 Awards & Recognition

Motorsport Success:

KTM EXC/XC-W models have a long history of success in various professional off-road racing series, including enduro championships and the Dakar Rally, underscoring their performance capabilities.

Industry Reviews:

Consistently praised by motorcycle publications for their powerful engines, agile handling, and robust build quality suitable for demanding off-road conditions.