KTM 450 EXC 2009 Workshop Service Repair Manual

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Type: Motorcycle

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Sku: 75733

Tags: 2009 450 EXC KTM Misc Motorcycle Motorcycles

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Description

The 2009 KTM 450 EXC is a high-performance Enduro/Off-Road Motorcycle, renowned for its potent LC4 engine and capable chassis, making it a formidable machine for competitive riding and demanding off-road conditions. Building on KTM's strong off-road racing heritage, this Austrian-engineered motorcycle offers a blend of power and durability, designed to excel in challenging terrains. Its advanced WP Suspension and hydraulic disc brakes provide superior control and stopping power, essential for navigating varied off-road environments. Proper maintenance is crucial for preserving the inherent quality and longevity of this machine, ensuring it remains a reliable partner for enthusiasts and professional riders alike. This comprehensive workshop service repair manual provides full coverage for the 2009 KTM 450 EXC, detailing everything from routine maintenance procedures like oil changes and filter replacements to complete engine disassembly, rebuilding, and advanced diagnostic troubleshooting. It covers all critical systems, including the engine, fuel system, ignition, cooling, transmission, drivetrain, suspension, brakes, and electrical systems, offering step-by-step instructions and essential technical specifications such as torque values and clearances. This manual is an indispensable resource for owners, mechanics, and technicians seeking to maintain, repair, and optimize the performance and reliability of their 450 EXC.

🏷️ Basic Information

Identification

Make:

Model:

450 EXC

Year:

Type:

Enduro/Off-Road Motorcycle

Codes

Chassis Code:

Refer to manual for specific chassis codes

Engine Code:

👋 Introduction

Market Position

Segment:

High-performance Enduro Motorcycle

Target Audience:

Enthusiasts, competitive riders, and professional mechanics.

Competitive Analysis

Competitors:

Yamaha WR450F, Honda CRF450X, Husqvarna TE450.

Key Features

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.

📋 Manual Details

Coverage Areas

Areas:

Full Workshop Service Repair Coverage

Page Count

Pages:

Hundreds (Specific number not provided, but implies comprehensive coverage)

Manual Type

Type:

Official Factory Service Repair Manual

Language

Language:

English (Assumed based on product description context)

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

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.

Procedures Included

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).

Technical Depth

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.

📊 Manual Specifications

File Format

Format:

Searchable:

Likely searchable text within the PDF for quick information retrieval.

Print Quality

Quality:

High-resolution scans of original factory documentation, suitable for printing.

Binding Type

Type:

N/A (Digital PDF Download)

Paper Type

Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

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

Performance

Horsepower:

Approximately 50-55 HP (stock, varies by market and tuning)

Torque:

Refer to manual for exact specifications

Fuel System

System:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline, minimum 91 octane (RON+MON)/2 / 87 AKI

Lubrication

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)

🔧 Transmission

Standard

Type:

6-speed constant mesh gearbox

Optional

Options:

N/A (Standard configuration for EXC models)

Features

Clutch:

Hydraulic wet multi-disc clutch

Final Drive:

Chain drive (520 pitch, sealed O-ring type)

Fluid Specifications

Fluid Type:

Refer to manual for transmission oil specification (often shared with engine oil for wet clutch applications, but check manual)

Fluid Capacities

Capacity:

Refer to manual for exact capacity.

📐 Dimensions

Exterior

Wheelbase:

Refer to manual for exact specifications

Seat Height:

Refer to manual for exact specifications (typically high for off-road)

Weights

Dry Weight:

Approximately 115-120 kg (unconfirmed, manual will specify)

Fuel Tank Capacity:

Approximately 9.5 liters (standard)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle, not typically rated by automotive bodies)

Active Features

Brakes:

Hydraulic disc brakes front and rear for strong stopping power.

Suspension:

Advanced WP Suspension for superior control and stability over varied terrain.

Passive Features

Frame:

Chromoly steel frame for strength and impact absorption.

Ergonomics:

Designed for rider control and comfort during aggressive off-road riding.

💡 Technology Features

Infotainment

System:

N/A (Basic motorcycle instrumentation: speedometer, odometer, trip meter, engine hour meter).

Driver Assistance

Features:

N/A (Focus is on rider control and mechanical function).

Connectivity

Features:

Engine Management

Electronic Control Unit (ECU) manages fuel injection and ignition timing.

🔧 Maintenance

Service Intervals

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.

Fluid Specifications

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.

Known Issues

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.

📚 Vehicle History

Brand Heritage

Origins:

KTM is an Austrian manufacturer known for its off-road racing pedigree.

Specialization:

Renowned for producing high-performance dirt bikes and adventure motorcycles.

Model Evolution

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.

Production

Manufacturing Location:

Austria

🏆 Awards & Recognition

Recognitions

Racing Success:

KTM EXC models are highly successful in professional enduro racing, indicating inherent design quality.

Ratings

Reliability:

Generally considered reliable when properly maintained, as detailed in the manual.