KTM 450 EXC 2009 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: KTM Model: 450 EXC Year: 2009 Type: Enduro/Off-Road Motorcycle Codes Chassis Code: Refer to manual for specific chassis codes Engine Code: LC4 👋 Introduction Market...

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标签: 2009 450 EXC KTM Misc Motorcycle Motorcycles

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Description

🏷️ 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.