🏷️ Basic Information

Make:

KTM

Model:

450 EXC SIX DAYS

Year:

2009

Product Type:

Workshop Repair Service Manual

Engine Code Indicator:

Covers All Models/Engines/Trim/Transmi...

👋 Introduction

Segment:

High-performance Enduro/Off-Road Motorcycle.

Target Audience:

Enthusiasts, mechanics, and owners seeking in-depth maintenance and repair knowledge.

Competitors:

Husqvarna TE450, Yamaha WR450F, Honda CRF450X, Suzuki RM-Z450 (Enduro variant).

Vehicle Focus:

Off-road capability, 'Six Days' package often implies factory race modifications and premium components.

Manual Utility:

Provides the essential technical information for maintaining and repairing the specific model year and variant.

📋 Manual Details

Primary Coverage:

Service, Maintenance, Troubleshooting

Estimated Page Count:

N/A (Digital PDF - dynamic)

Type:

Workshop Repair Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Mechanics:

Complete overhaul, piston, rings, cylinder, crankshaft, connecting rod, valves, camshaft, timing, lubrication system, cooling system.

Fuel System:

Carburetor (Mikuni BSR) disassembly, cleaning, adjustment, jetting, fuel pump, fuel lines, fuel tank maintenance.

Ignition System:

CDI unit, ignition coil, spark plug, stator, rotor, wiring diagnostics.

Transmission Drivetrain:

Clutch (hydraulic actuation), gearbox (5-speed), shifting mechanism, final drive (chain), sprockets.

Suspension:

Front forks (WP USD, adjustable), rear shock absorber (WP, adjustable), linkage system, seals, oil changes, damping adjustments.

Brakes:

Front and rear disc brakes, hydraulic calipers (Brembo), master cylinders, brake lines, pads, bleeding procedures, rotor inspection.

Electrical System:

Wiring diagrams, battery, charging system (alternator, rectifier/regulator), lighting (headlight, taillight, indicators), starter motor, fuses, relays.

Chassis Frame:

Frame inspection, subframe, steering head bearings, footpegs, handlebars, controls.

Exhaust System:

Muffler, header pipe, heat shields, sealing.

Wheels Tires:

Spoke tensioning, rim maintenance, tire fitting and removal, tube replacement.

Routine Maintenance:

Oil and filter changes, air filter cleaning/replacement, spark plug checks, chain lubrication and adjustment, brake pad inspection, general bolt torquing.

Troubleshooting:

Diagnostic procedures for starting issues, poor performance, electrical faults, suspension problems, braking system anomalies.

Engine Rebuild:

Step-by-step instructions for complete engine disassembly, inspection, repair, and reassembly, including torque specifications.

Suspension Overhaul:

Fork seal replacement, shock absorber service, fluid level adjustments, valving inspection.

Carburetor Tuning:

Jetting recommendations for various altitudes and conditions, idle speed and mixture adjustments.

Electrical Diagnostics:

Using multimeters for voltage, resistance, and continuity tests, troubleshooting wiring harness issues.

Brake System Service:

Bleeding brake lines, caliper piston service, master cylinder overhaul, pad replacement.

Wheel Bearing Replacement:

Front and rear wheel bearing replacement procedures.

Depth Level:

Comprehensive (from basic maintenance to complete engine and chassis rebuild).

Diagnostics:

Advanced diagnostic procedures, fault finding trees, and troubleshooting guides.

Specifications:

Detailed technical specifications, torque values, tolerances, clearances, fluid capacities, and electrical resistance values.

📊 Manual Specifications

Format Details:

Searchable PDF, printable pages.

Quality:

High-resolution, clear diagrams and text.

Binding:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Single-cylinder, 4-stroke, DOHC.

Displacement:

449.3 cc

Bore X Stroke:

95.0 mm x 63.4 mm

Compression Ratio:

11.1:1

Cooling System:

Liquid-cooled.

Lubrication System:

Wet sump, separate oil circuit for clutch.

Valve Train:

Chain-driven DOHC with 4 valves.

Estimated Horsepower:

Approx. 50-55 HP (Stock, may vary).

Estimated Torque:

Approx. 45-50 Nm (Stock, may vary).

Carburetor Model:

Mikuni BSR40.

Fuel Type:

Unleaded gasoline (95 RON or higher recommended).

🔧 Transmission

Transmission Type:

Constant mesh, 5-speed sequential gearbox.

Clutch Type:

Wet multi-disc clutch, hydraulically operated.

Gear Ratios:

Specific ratios available in manual (e.g., 1st: 2.571, 2nd: 1.750, 3rd: 1.333, 4th: 1.050, 5th: 0.870).

Final Drive:

Chain drive (520 O-ring chain).

Clutch Fluid:

DOT 4 brake fluid (same as brake system).

📐 Dimensions

Wheelbase:

Approx. 1480 mm (58.3 in).

Seat Height:

Approx. 960 mm (37.8 in).

Ground Clearance:

Approx. 355 mm (14.0 in).

Dry Weight:

Approx. 113 kg (249 lbs).

Fuel Tank Capacity:

Approx. 9.5 liters (2.5 gallons).

🛡️ Safety Features

Safety Standards:

N/A (Off-road vehicle - not subject to typical automotive safety ratings like NHTSA/Euro NCAP).

Braking System:

Hydraulic disc brakes front and rear for strong stopping power.

Ergonomics:

Designed for rider control and stability in challenging terrain.

Frame Design:

Chromium-molybdenum steel central double-cradle frame for torsional rigidity and impact resistance.

Lighting:

Headlight, taillight, and optional turn signals for road legality (depending on region and 'Six Days' trim specifics).

💡 Technology Features

Display:

Minimalist digital display showing speed, odometer, trip meter, clock, and basic warning lights.

ABS:

No ABS standard on this model.

Connectivity Features:

None (basic electrical system).

🔧 Maintenance

Engine Oil Change:

Every 15-20 hours of riding, or annually. (Refer to manual for exact specification).

Air Filter Cleaning:

Every 5-10 hours of riding or after dusty conditions.

Spark Plug Check:

Every 20-30 hours of riding.

Chain Lubrication Adjustment:

Every 5-10 hours of riding, or as needed.

Valve Clearance Check:

Every 40-50 hours of riding. (Critical for engine longevity).

Engine Oil:

KTM recommends specific semi-synthetic or fully synthetic motorcycle oils meeting JASO MA/MA2 and API SG/SH/SJ/SL specifications (e.g., Motorex Power Synt 4T 10W-50 or equivalent).

Engine Oil Capacity:

Approx. 1.1 liters (1.2 US qt) for oil change without filter; approx. 1.3 liters (1.4 US qt) with filter change. (Verify in manual).

Coolant:

Mixture of distilled water and antifreeze (ethylene glycol based) with corrosion inhibitors, typically 50/50 ratio. (See manual for specific coolant type).

Brake Fluid:

DOT 4 brake fluid (for both front and rear brakes, and clutch).

Common Wear Items:

Clutch plates, brake pads, wheel bearings, fork seals, exhaust packing (if applicable).

Potential Failures:

Valve seat wear (in some earlier KTM models, though less common in this specific generation), starter solenoid issues, fuel line degradation.

📚 Vehicle History

Brand Focus:

KTM is renowned for its off-road racing pedigree and performance-oriented motorcycles.

Exc Lineage:

The EXC line represents KTM's dedicated enduro competition and recreational off-road models, evolving significantly year-on-year.

Six Days Package:

The 'Six Days' designation commemorates KTM's participation and success in the International Six Days Enduro (ISDE), typically featuring upgraded components like special graphics, often an orange anodized triple clamp, often a different exhaust system, and sometimes upgraded suspension or other performance enhancements compared to the standard EXC model.

Manufacturing Location:

Austria (KTM AG).

🏆 Awards & Recognition

Brand Reputation:

KTM motorcycles, especially the EXC line, are consistently praised in enthusiast reviews and motorsport publications for their performance and off-road capability.

Enthusiast Reviews:

Highly rated for handling, engine power delivery, and robust construction suitable for extreme off-road use.

Emission Standards:

Typically Euro 3 compliant for its model year, depending on specific market regulations.