KTM 450 EXC 2009 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: KTM Model: 450 EXC Year: 2009 Engine Variant Covered: 450cc Trim Levels Covered: All Transmission Types Covered: All Codes Chassis Code: Likely specific to 450...

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Type: Motorcycle

Vendor:

Sku: 78330

Tags: 2009 450 EXC KTM Misc Motorcycle Motorcycles

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

450 EXC

Year:

Engine Variant Covered:

450cc

Trim Levels Covered:

Transmission Types Covered:

Codes

Chassis Code:

Likely specific to 450 EXC 2009 variant, manual should detail

👋 Introduction

Market Position

Segment:

High-performance Enduro/Off-road motorcycle

Key Competitors 2009:

Yamaha WR450F, Honda CRF450X, Husqvarna TE450, Beta RR450

Competitive Analysis

Ktm Strengths:

Renowned for potent engines, WP suspension, lightweight chassis, and aggressive off-road performance.

Key Features

Offroad Capability:

Designed for extreme off-road riding, competition, and trail riding.

Engine Type:

Liquid-cooled, four-stroke, single-cylinder (LC4 engine platform evolution)

📋 Manual Details

Coverage Areas

Comprehensive Coverage:

Yes, full workshop, repair, and service

Target Audience:

Professional technicians and DIY enthusiasts

Page Count

Estimated Page Count:

Varies by specific manual edition, but typically 300-500+ pages for a complete workshop manual.

Manual Type

Manual Type:

Workshop Repair Service Manual

Language

Language:

English (standard for most workshop manuals)

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Detailed disassembly, assembly, inspection, and repair of all engine components (cylinder, piston, crankshaft, camshaft, valves, timing chain, lubrication system, cooling system).

Fuel System:

Carburetor (likely Keihin FCR) tuning, cleaning, rebuilding, fuel pump, fuel lines, fuel tank.

Ignition System:

CDI unit, ignition coil, spark plug, wiring diagrams.

Transmission:

Clutch operation, gearbox disassembly, assembly, inspection, gear selection mechanisms, lubrication.

Suspension:

Front forks (WP USD - Upside Down), rear shock absorber (WP Monoshock), linkage systems, seals, oil levels, pressures, adjustments.

Brakes:

Front and rear hydraulic disc brakes, caliper overhaul, master cylinder service, brake fluid bleeding, pad replacement, rotor inspection.

Electrical System:

Wiring diagrams, lighting system, starter motor, battery, charging system, fuses, switches, instrumentation.

Cooling System:

Radiator, coolant, hoses, water pump, thermostat operation.

Exhaust System:

Exhaust pipe, muffler, gasket replacement.

Frame And Bodywork:

Chassis inspection, bearings (steering, swingarm, wheel), body panel removal and installation, seat, fuel tank.

Wheels And Tires:

Wheel bearing replacement, spoke tensioning, tire mounting and balancing, rim specifications.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment and lubrication, air filter cleaning, spark plug checks.

Troubleshooting Guides:

Diagnostic procedures for common symptoms and malfunctions.

Repair Procedures:

Step-by-step instructions for component disassembly, repair, and reassembly.

Overhaul Instructions:

Complete engine and component overhaul guidance.

Technical Specifications Data:

Torque values, clearances, fluid capacities, electrical resistance values.

Special Tool Recommendations:

Identification of necessary special tools for specific procedures.

Technical Depth

Depth:

In-depth, covering complete teardown and rebuilds of major components.

Diagnostic Level:

Advanced diagnostics, including troubleshooting flowcharts and electrical system analysis.

📊 Manual Specifications

File Format

File Type:

Searchability:

Typically searchable text within the PDF for efficient information retrieval.

Print Quality

Print Quality Recommendation:

High-resolution for clear diagrams and text reproduction.

Binding Type

Binding Recommendation:

Spiral-bound for lay-flat use in workshop environments (if printed).

Paper Type

Paper Recommendation:

Durable, grease-resistant paper (if printed).

⚙️ Engine Specifications

Primary Engine

Engine Type:

449.3 cc, liquid-cooled, four-stroke, single-cylinder, SOHC

Bore X Stroke:

Approx. 95.0 mm x 63.4 mm (refer to manual for exact specification)

Compression Ratio:

Approx. 12.0:1 (refer to manual for exact specification)

Performance

Horsepower Estimated:

Around 50-55 HP (peak, depends on tuning and exhaust)

Torque Estimated:

Around 40-45 Nm (peak, depends on tuning and exhaust)

Fuel System

Carburetor Type:

Keihin FCR MX 39mm (common for this era)

Fuel Requirement:

Unleaded gasoline (RON 91 or higher, check manual for specific octane recommendation)

🔧 Transmission

Standard

Transmission Type:

Constant mesh, 6-speed

Clutch Type:

Wet multi-disc clutch, hydraulically operated

Features

Gear Ratios:

Specific gear ratios will be detailed in the manual, crucial for off-road performance tuning.

📐 Dimensions

Exterior

Seat Height:

Approx. 970 mm (38.2 in) - typical for EXC models, check manual for exact

Ground Clearance:

Approx. 355 mm (14.0 in) - typical for EXC models, check manual for exact

Weights

Dry Weight:

Approx. 113 kg (249 lbs) - check manual for exact specification

Fuel Tank Capacity:

Approx. 9.5 liters (2.5 US gal) - check manual for exact specification

🛡️ Safety Features

Ratings

Safety Certification:

N/A (Motorcycle safety is typically based on design and rider skill, not crash ratings like cars).

Active Features

Braking System:

Hydraulic disc brakes front and rear for strong stopping power.

Suspension Performance:

WP components designed for stability and control over rough terrain.

Passive Features

Chassis Construction:

Chromoly steel trellis frame for strength and rigidity.

Ergonomics:

Designed for rider control and agility in demanding conditions.

💡 Technology Features

Infotainment

Display Type:

Basic LCD multi-function display showing time, trip meter, odometer, and basic warning lights.

Driver Assistance

No ABS (Standard for this era's pure off-road models).

Connectivity

Bluetooth:

No Bluetooth or smartphone integration.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 15-20 hours of riding, or as specified in the manual (e.g., every 1000-1500 km).

Air Filter Cleaning:

Frequent cleaning is essential, especially in dusty conditions (e.g., every few rides).

Valve Clearance Check:

Recommended check every 100-150 hours of riding (refer to manual for precise interval).

Fluid Specifications

Engine Oil Type:

High-quality motorcycle specific 4-stroke engine oil, typically SAE 10W-40 or 15W-50, meeting JASO MA/MA2 standards. Manual will specify exact grade and API rating.

Engine Oil Capacity:

Approx. 1.1 - 1.2 liters (without filter change) / 1.3 - 1.4 liters (with filter change) - verify in manual.

Fork Oil Type:

Specific WP suspension oil, typically SAE 5W or 7.5W. Manual will provide exact type and viscosity.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Coolant Type:

Ethylene glycol-based antifreeze coolant, typically a 50/50 mix with distilled water. Manual will specify type and ratio.

Known Issues

Clutch Wear:

Diaphragm spring weakness or clutch plate wear can occur with hard use, requiring replacement as per manual procedures.

Fork Seal Leaks:

WP fork seal leaks are common with extensive off-road use and can be addressed with seal replacement as detailed in the manual.

Carburetor Adjustment:

Carburetor jetting may require adjustment based on altitude and temperature for optimal performance, covered in manual.

Engine Decarbonization:

Periodic decarbonization of the combustion chamber and piston crown can improve performance and longevity, with procedures outlined in the manual.

📚 Vehicle History

Brand Heritage

Ktm Offroad Legacy:

KTM has a dominant history in off-road racing, including Dakar Rally and Motocross/Enduro championships.

Model Evolution

Exc Lineage:

The EXC line has been a cornerstone of KTM's off-road offering, evolving through numerous engine sizes and chassis updates.

Production

Manufacturing Location:

KTM motorcycles are primarily manufactured in Mattighofen, Austria.

🏆 Awards & Recognition

Recognitions

Offroad Reviews 2009:

The 2009 KTM 450 EXC was generally well-received for its power, suspension, and handling, often praised in off-road motorcycle publications for its competitive edge.

Ratings

Durability Perception:

KTM's EXC line is generally considered durable and capable, with proper maintenance crucial for longevity, as supported by the detailed information in this manual.