Target Audience:
Owners of KTM 400, 450, and 530 EXC motorcycles from the 2009 model year, including enthusiasts and professional technicians.
Segment:
High-performance Enduro / Off-Road Motorcycles.
Value Proposition:
An inexpensive and efficient way to maintain and repair the vehicle, providing comprehensive factory-level information that avoids costly dealership visits.
Manual Benefits:
Hundreds of photos and illustrations, detailed substeps, notes/cautions/warnings, numbered instructions, bold figure numbers, enlarged insets, and combined troubleshooting/wiring diagrams.
All Major Systems:
Engine top end, fuel system, cooling system, clutch, engine lubrication, crankshaft/transmission, wheels/tires, final drive, brakes, suspension, steering, frame, and electrical system.
Engine Lubrication System:
Detailed coverage of the oil pump, oil filter, oil passages, and oil level checks for optimal engine health.
Crankshaft Transmission:
In-depth procedures for crankshaft inspection, bearing replacement, transmission gear inspection, shifting mechanisms, and clutch assembly.
Wheels Tires:
Information on wheel bearing maintenance, spoke tension, tire mounting/dismounting, and recommended tire pressures.
Final Drive:
Coverage of chain and sprocket inspection, adjustment, lubrication, and replacement. May also include rear hub and sprocket carrier details.
Steering:
Procedures for steering head bearing inspection, adjustment, and replacement, as well as handlebar and control lever adjustments.
Frame:
Guidance on frame inspection for cracks or damage, swingarm pivot bearing maintenance, and linkage system service (if applicable to the specific model variant covered).
Electrical System:
Comprehensive coverage including wiring diagrams, troubleshooting electrical faults, component testing (e.g., stator, rectifier, ignition coil), battery maintenance, and lighting systems.
Repair And Maintenance:
Step-by-step instructions for repair and service, including complete disassembly and reassembly procedures, troubleshooting, and diagnosis.
General Information:
Includes model identification, safety precautions, basic maintenance guidelines, torque specifications, and tool requirements.
Fuel System Repair:
Carburetor (or FI) cleaning, jetting, float level adjustment, fuel pump (if applicable) service, and fuel line replacement.
Cooling System Maintenance:
Radiator inspection and cleaning, coolant flush and replacement, water pump seal inspection and replacement, thermostat testing.
Engine Top End Rebuild:
Cylinder head removal, valve inspection and servicing, piston and ring replacement, cylinder inspection.
Clutch Service:
Clutch plate replacement, spring inspection, pressure plate adjustments, and hydraulic clutch system bleeding.
Engine Removal Installation:
Step-by-step guide for safely removing the engine from the frame and reinstalling it, including connecting all hoses and wiring.
Suspension Service:
Fork seal replacement, fork oil change, internal fork component inspection, shock absorber maintenance (may include seal replacement for non-rebuildable units or instructions for rebuildable units).
Electrical Troubleshooting:
Systematic approach to diagnosing electrical issues, including testing circuits, components, and following wiring diagrams.
Depth Of Information:
Detailed, professional quality, in-depth coverage suitable for both do-it-yourself owners and experienced mechanics.
Diagnostic Capabilities:
Enables in-depth diagnosis of complex issues, from engine performance problems to electrical circuit failures, using provided troubleshooting flowcharts and component tests.
Rebuild Instructions:
Provides complete instructions for major component overhauls, including engine rebuilds, transmission servicing, and suspension overhauls.
Engine Type:
Single-cylinder, four-stroke, liquid-cooled (LC4 engine family)
Displacements Covered:
Approximately 400cc, 450cc, and 530cc. (Specific model designations may vary, e.g., 400 EXC, 450 EXC Six Days, 530 EXC Six Days, etc.)
Engine Family:
KTM LC4 (Liquid Cooled 4-stroke).
Horsepower Range:
Typically ranging from 45-55 HP depending on displacement and specific tuning (actual figures require reference to model-specific data).
Torque Range:
Varies by displacement, but generally strong low-to-mid-range torque characteristic of KTM's LC4 engines.
Fuel Delivery:
Likely Keihin FCR (Flat CR) carburetors or early fuel injection depending on specific model variant, though carburetors were common for this era. Manual covers fuel system components, tuning, and maintenance.
Oil Change Interval:
Recommended oil and filter changes typically every 10-15 engine hours or annually, whichever comes first, for rigorous off-road use. Refer to manual for exact specifications.
Valve Clearance Check:
Periodic valve clearance checks and adjustments are crucial. Intervals typically range from 50-100 engine hours. Manual provides specifications and procedure.
Engine Oil Type And Capacity:
Requires specific high-quality motorcycle engine oil (e.g., Motorex Power Synt 4T 10W-50 or equivalent). Capacity typically around 1.5-1.7 liters. Manual provides exact specs.
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water. Manual specifies type and capacity.
Brake Fluid Type:
DOT 4 hydraulic brake fluid. Manual provides specific type and bleeding procedures.
Fork Oil Type And Level:
Specific viscosity fork oil (e.g., WP Suspension Fluid 5W or equivalent) and precise oil level are critical for proper damping. Manual will specify exact type and quantity.
Common Wear Items:
Clutch plates, piston rings, valve guides/seals, wheel bearings, fork seals, and chain/sprockets are common wear items on performance off-road motorcycles. Manual assists in diagnosing and replacing these.
Electrical Connections:
Off-road vibrations can sometimes loosen electrical connections; the manual's electrical section helps in checking and securing them.
Fuel Pump Reliability:
Early FI models might have had occasional fuel pump issues; manual provides diagnostic steps. Carbureted models generally robust.
