Segment:
High-performance Enduro Motorcycle
Target Audience:
Enthusiasts, competitive riders, and professional mechanics.
Competitors:
Yamaha WR450F, Honda CRF450X, Husqvarna TE450.
Performance Focus:
Known for its potent engine and capable off-road chassis.
Durability:
Designed for demanding off-road conditions, requiring proper maintenance.
Manual Value:
Essential for maintaining peak performance and longevity.
Engine:
Complete engine assembly, disassembly, inspection, and repair of all internal components.
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel tank, fuel lines.
Ignition System:
Ignition coil, spark plug, ECU (Engine Control Unit) mapping and diagnostics.
Cooling System:
Radiator, coolant hoses, water pump, thermostat, fan operation.
Transmission:
Gearbox operation, clutch assembly, shift mechanism, internal transmission components.
Drivetrain:
Final drive, chain and sprockets maintenance, wheel bearings.
Suspension:
Front fork (WP Suspension) disassembly, servicing, and adjustments; rear shock absorber (WP Suspension) servicing and adjustments.
Brakes:
Front and rear brake caliper maintenance, brake disc inspection, master cylinder servicing, hydraulic system bleeding.
Electrical System:
Wiring diagrams, battery maintenance, starter motor, lighting system, stator, rectifier/regulator, fuses, switches.
Chassis Frame:
Frame inspection, steering head bearing service, subframe maintenance.
Bodywork Plastics:
Removal and installation of fenders, side panels, seat, fuel tank cover.
Troubleshooting:
Diagnostic flowcharts for common issues and system failures.
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug replacement.
Repair:
Detailed step-by-step instructions for component repair and replacement.
Diagnostics:
System-specific diagnostic procedures for identifying faults.
Rebuilds:
Full engine and component rebuild procedures with specifications.
Adjustments:
Valve clearance adjustments, suspension settings, carburetor tuning (if applicable, though likely EFI for '09).
Depth:
Comprehensive from basic maintenance to complete engine disassembly and rebuilding.
Diagnostics Level:
Advanced diagnostic procedures, including electrical system troubleshooting.
Specifications:
Includes all critical torque values, clearances, fluid capacities, and wear limits.
Engine Type:
Single-cylinder, 4-stroke, liquid-cooled, LC4 engine
Displacement:
449.3 cc (approx.)
Bore X Stroke:
Refer to manual for exact specifications
Compression Ratio:
Refer to manual for exact specifications
Horsepower:
Approximately 50-55 HP (stock, varies by market and tuning)
Torque:
Refer to manual for exact specifications
System:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/2 / 87 AKI
Oil Type:
Refer to manual for specific API and JASO specifications (e.g., Motorex Powersynth 4T 10W/50 is common for KTM)
Oil Capacity:
Refer to manual for exact capacity (typically around 1.2-1.5 liters including filter)
Type:
6-speed constant mesh gearbox
Options:
N/A (Standard configuration for EXC models)
Clutch:
Hydraulic wet multi-disc clutch
Final Drive:
Chain drive (520 pitch, sealed O-ring type)
Fluid Type:
Refer to manual for transmission oil specification (often shared with engine oil for wet clutch applications, but check manual)
Capacity:
Refer to manual for exact capacity.
Crash Test Ratings:
N/A (Motorcycle, not typically rated by automotive bodies)
Brakes:
Hydraulic disc brakes front and rear for strong stopping power.
Suspension:
Advanced WP Suspension for superior control and stability over varied terrain.
Frame:
Chromoly steel frame for strength and impact absorption.
Ergonomics:
Designed for rider control and comfort during aggressive off-road riding.
Oil Change:
Refer to manual; typically every 10-15 hours of hard riding or 1000 km, whichever comes first.
Air Filter Cleaning:
Refer to manual; recommended every few rides or as needed based on conditions.
Valve Check:
Refer to manual; typically every 20-30 hours of riding.
Chain Maintenance:
Lubrication and tension adjustment as needed, typically every ride.
Engine Oil:
Refer to manual for exact specification (e.g., SAE 10W/50, API SG/SH/SJ, JASO MA/MA2).
Coolant:
Ethylene glycol-based coolant, mixed with distilled water (50/50 ratio recommended).
Brake Fluid:
DOT 4 hydraulic fluid.
Clutch Slave Cylinder:
Potential for leaks or failure; manual will guide on inspection and replacement.
Cooling System Leaks:
Check hoses and seals regularly for integrity.
Starter Motor Issues:
Ensure battery is well-maintained; manual covers troubleshooting.
Origins:
KTM is an Austrian manufacturer known for its off-road racing pedigree.
Specialization:
Renowned for producing high-performance dirt bikes and adventure motorcycles.
450 Exc Lineage:
The EXC line has a long history of evolution, with the 450 EXC being a popular displacement for enduro competition.
2009 Model Updates:
The 2009 model year saw refinements to the LC4 engine and chassis, building on previous generations.
Manufacturing Location:
Austria
