🏷️ Basic Information

Make:

KTM

Model:

450 EXC SIX DAYS

Model Variant:

SIX DAYS

Model Years Covered:

2008, 2009, 2010, 2011

Vehicle Platform Code:

XC-W Series (internal)

👋 Introduction

Segment:

High-Performance Enduro Motorcycle

Target Audience:

Competitive Enduro Riders, Off-Road Enthusiasts

Key Competitors:

Husqvarna TE450, Yamaha WR450F, Honda CRF450X, Suzuki RMX450Z, Kawasaki KLX450R

Vehicle Highlights:

Powerful 4-stroke engine, robust chassis, advanced WP suspension, lightweight construction, purpose-built for extreme off-road conditions, 'SIX DAYS' designation signifies special edition models often equipped with factory upgrades for international enduro competitions.

📋 Manual Details

Primary Focus:

Repair, Maintenance, Servicing, Troubleshooting

Scope:

Comprehensive Workshop Service Manual

Estimated Pages:

300+

Type:

Service Manual / Workshop Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Complete engine overhaul, assembly, disassembly, specifications, tuning, cooling system, lubrication system

Fuel System:

Carburetor (Keihin FCR 41), fuel pump, fuel tank, fuel lines, fuel filter

Ignition System:

Ignition coil, spark plug, CDI unit, timing

Transmission:

Clutch (hydraulic), gearbox, gear shift mechanism, lubrication

Chassis And Frame:

Frame, subframe, steering system, suspension (front and rear), linkages

Suspension Front:

WP USD forks, internal components, damping adjustments, seals, oil specifications

Suspension Rear:

WP PDS shock absorber, linkage system, adjustments, rebuild procedures

Brakes:

Front and rear brake systems (disc brakes), hydraulic lines, calipers, master cylinders, fluid replacement, bleeding procedures

Electrical System:

Wiring diagrams, lighting system, battery, starter motor, charging system, fuses, relays

Cooling System:

Radiator, coolant, hoses, fan operation

Exhaust System:

Exhaust headers, muffler, packing replacement

Wheels And Tires:

Wheel bearings, spoke tension, tire pressure, rim maintenance

Bodywork And Plastics:

Fairings, seat, fenders, graphics

Maintenance:

Scheduled maintenance, oil changes, filter replacements, valve clearance checks, chain adjustment, spark plug replacement, brake fluid replacement

Troubleshooting:

Diagnostic procedures for common problems, fault finding charts

Repair:

Step-by-step repair instructions for all major components and systems

Rebuilds:

Complete engine and transmission rebuild procedures

Adjustments:

Carburetor tuning, suspension adjustments, clutch and brake lever adjustments

Specifications:

Torque specifications, clearances, fluid capacities, electrical resistance values

Level:

Professional Workshop Level (suitable for experienced technicians and knowledgeable DIY enthusiasts)

Detail Level:

In-depth, component-level detail with diagrams and illustrations

📊 Manual Specifications

Digital Format:

PDF (Portable Document Format)

Reproducibility:

High-resolution scans, suitable for printing

Binding:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

Text Search:

Likely text-searchable (depending on PDF creation)

⚙️ Engine Specifications

Type:

4-Stroke Single-Cylinder, SOHC, Liquid-Cooled

Displacement:

449.3 cc

Bore X Stroke:

97.0 mm x 60.8 mm

Compression Ratio:

11.5:1 (Approximate)

Horsepower:

Approximately 50-55 HP (dependent on tuning and specific year)

Torque:

Not officially specified, but robust low-to-mid-range torque

Carburetor:

Keihin FCR 41 MX with accelerator pump

Fuel Type:

Unleaded Premium Gasoline (95 RON or higher recommended)

System:

Integrated oil tank with separate oil circuit for engine and gearbox.

Type:

Liquid Cooling (Engine Coolant)

🔧 Transmission

Type:

6-Speed Constant Mesh

Optional Gearbox:

N/A

Clutch:

Hydraulically Actuated Wet Multi-Plate Clutch (Brembo hydraulic system)

Final Drive:

Chain Drive (520 O-ring chain)

📐 Dimensions

Wheelbase:

1500 mm +/- 10 mm (Approx. 59.1 inches)

Seat Height:

950 mm (Approx. 37.4 inches)

Dry Weight:

113 kg (Approx. 249 lbs)

Gross Weight Limit:

Not specified, typically around 350 kg for off-road use.

Fuel Tank Capacity:

9.0 Liters (Approx. 2.38 US Gallons)

🛡️ Safety Features

Crash Test Ratings:

Not applicable to off-road motorcycles.

Braking System:

Hydraulic Disc Brakes (Front and Rear) with Wave Discs

Throttle Control:

Standard twist throttle with safety cable attachment point.

Handguards:

Standard on SIX DAYS models for hand protection.

Skid Plate:

Often included or available as an accessory for engine protection.

💡 Technology Features

System:

Basic analog/digital dashboard displaying speed, RPM, odometer, trip meter, and essential warning lights. No infotainment features like audio or navigation.

Features:

None. This is a pure performance off-road machine focused on rider input and mechanical feedback.

Features:

N/A

🔧 Maintenance

Engine Oil Change:

Every 10-15 engine operating hours or monthly, whichever comes first (refer to manual for precise intervals based on usage).

Oil Filter Replacement:

Concurrent with engine oil changes.

Air Filter Cleaning:

Frequent cleaning recommended, especially in dusty conditions (every few rides).

Valve Clearance Check:

Every 30-40 engine operating hours.

Spark Plug Replacement:

As needed, typically every 50-70 hours, or based on inspection.

Engine Oil Type:

Fully Synthetic Motorcycle Oil, SAE 10W/50, API SG, JASO MA/MA2 (e.g., Motorex Power Synt 4T 10W/50).

Engine Oil Capacity:

1.1 Liters (1.16 US Quarts) with filter change.

Transmission Oil Type:

Same as engine oil (KTM shares oil between engine and transmission).

Transmission Oil Capacity:

Included in the 1.1L total engine oil capacity.

Coolant Type:

High-quality motorcycle coolant (50% distilled water and 50% antifreeze/anti-corrosion additive), such as Motorex Coolant M5.0.

Brake Fluid Type:

DOT 4 Hydraulic Brake Fluid (e.g., Brembo Brake Fluid Type 4).

Typical Wear Items:

Clutch plates, spark plug, air filter, piston rings, valve seats, wheel bearings, steering head bearings, brake pads, suspension seals.

Common Faults:

Carburetor jetting sensitivity to altitude and temperature, occasional clutch slave cylinder seal leaks, fork seal weepage.

Spark Plug Type:

NGK CR9EKB or equivalent

Valve Clearance Intake:

0.05 - 0.10 mm

Valve Clearance Exhaust:

0.10 - 0.15 mm

Fork Oil Type:

WP Suspension Fluid / SAE 5W (e.g., Motorex Fork Oil SAE 5W)

Fork Oil Level:

Refer to manual for specific model year, typically around 100mm from top of inner tube with spring removed.

Rear Shock Oil Type:

Specific WP PDS shock absorber fluid required.

Chain Slack:

20-30 mm (13-19 mm is often preferred for off-road).

📚 Vehicle History

Ktm Legacy:

KTM is an Austrian manufacturer renowned for its off-road racing prowess, particularly in motocross and enduro. The 'Ready to Race' slogan reflects their commitment to performance and competition.

Exc Series Development:

The EXC line is KTM's flagship enduro range, evolving significantly throughout the 2000s with chassis and engine updates. The 450 EXC became a dominant force in enduro racing.

Manufacturing Location:

Austria

Six Days Origin:

The 'SIX DAYS' moniker refers to the International Six Days Enduro (ISDE), a prestigious team enduro event. KTM typically releases special edition models with enhancements for this competition.

🏆 Awards & Recognition

Motocross Enduro Wins:

KTM motorcycles, including the EXC platform, have a storied history of victories in major off-road racing championships worldwide. The 450 EXC has been a dominant platform in numerous enduro and cross-country events.

Magazine Reviews:

Consistently received high praise from motorcycle publications for its power, handling, and off-road capability during its production years.