KTM 450 EXC SIX DAYS 2008-2011 Workshop Service Manual

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🏷️ Basic Information Identification Make: KTM Model: 450 EXC SIX DAYS Production Years Covered: 2008, 2009, 2010, 2011 Vehicle Type: Dual-Sport Motorcycle Codes Kba Number: Not Applicable (Motorcycle) Vin Code...

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类型: Motorcycle

斯库: 78328

标签: 2008 2009 2010 2011 450 EXC SIX DAYS KTM Misc Motorcycle Motorcycles

产品多属性

Description

🏷️ Basic Information

Identification

Make:

Model:

450 EXC SIX DAYS

Production Years Covered:

2008, 2009, 2010, 2011

Vehicle Type:

Dual-Sport Motorcycle

Codes

Kba Number:

Not Applicable (Motorcycle)

Vin Code Representation:

N/A (VIN specific to individual vehicle)

👋 Introduction

Market Position

Segment:

High-performance Enduro/Off-road Motorcycle

Target Audience:

Enthusiast riders, off-road competitors, dual-sport riders seeking robust performance.

Key Selling Points:

Powerful single-cylinder engine, advanced suspension, lightweight chassis, 'Six Days' trim signifying special editions for International Six Days Enduro.

Competitive Analysis

Competitors:

Yamaha WR450F, Honda CRF450X, Husqvarna TE450, Suzuki RM-Z450 (dual-sport variants).

Key Features

Engine Type:

Liquid-cooled, 4-stroke, SOHC, single-cylinder

Suspension Type:

WP USD Front Forks, WP PDS Rear Shock (or linkage system)

Brake System:

Hydraulic Disc Brakes Front and Rear

Six Days Distinction:

Special graphics, often enhanced components or factory racing support elements.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Manual / Repair Manual

Language:

English (assumed based on product description)

Format:

PDF Download

Page Count

Page Count:

Estimated 300-500 pages (typical for this type of comprehensive manual)

Page Count Notes:

Exact page count not specified in product info, estimated based on scope.

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, top-end, bottom-end, valve adjustment, timing, cooling system, lubrication.

Fuel System:

Carburetor (likely Keihin FCR41) disassembly, cleaning, adjustment, fuel pump, fuel lines, filters.

Ignition System:

CDI unit, spark plug specifications, wiring diagrams, troubleshooting.

Transmission:

Clutch operation, gear shift mechanism, internal transmission components, lubrication, troubleshooting.

Drivetrain:

Chain and sprockets maintenance, chain wear limits, drive sprocket replacement.

Suspension Front:

USD (Upside-Down) forks (likely WP), internal components, oil type and level, seal replacement, adjustments.

Suspension Rear:

Monoshock (likely WP PDS or linkage-based), shock absorber servicing, spring preload, damping adjustments, linkage maintenance.

Brakes Front:

Hydraulic disc brakes, caliper service, master cylinder overhaul, brake pad replacement, fluid type (DOT 4), bleeding procedures, rotor specifications.

Brakes Rear:

Hydraulic disc brakes, caliper service, master cylinder overhaul, brake pad replacement, fluid type (DOT 4), bleeding procedures, rotor specifications.

Electrical System:

Wiring diagrams, lighting systems (headlight, tail light, indicators), battery maintenance, charging system, starter motor, fuses, relays.

Chassis Frame:

Frame inspection, headstock bearings, swingarm pivot bearings, maintenance.

Wheels Tires:

Wheel bearing maintenance, spoke tensioning, tire pressure recommendations, tire sizes.

Bodywork Plastics:

Fairing removal and installation, seat, fuel tank, fenders.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air), chain adjustment, brake checks, fluid level checks.

Troubleshooting:

Diagnostic procedures for common issues, symptom-based troubleshooting guides.

Engine Rebuild:

Complete disassembly, inspection of internal components (pistons, rings, crankshaft, valves), assembly procedures, torque specifications.

Suspension Servicing:

Fork seal replacement, fork oil changes, shock absorber servicing, linkage lubrication.

Brake System Service:

Bleeding procedures, caliper and master cylinder rebuild, pad and rotor replacement.

Electrical Diagnostics:

Wiring diagram interpretation, component testing, fault finding.

Carburetor Tuning:

Jetting adjustments, idle speed settings, mixture screw adjustments.

Technical Depth

Depth Level:

Comprehensive (covers everything from basic maintenance to complete engine and chassis rebuilds)

Diagnostic Capabilities:

Detailed troubleshooting charts and procedures for identifying and resolving mechanical and electrical faults.

Rebuild Instructions:

Step-by-step instructions with torque specifications for major component overhauls.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text (typical for professionally produced PDFs)

Printability:

Printable (allows for paper copies of sections or the entire manual)

Print Quality

Image Resolution:

High resolution (essential for clear diagrams and illustrations)

Diagram Clarity:

Detailed exploded views and schematic diagrams.

Binding Type

Binding:

N/A (Digital Download - PDF)

Paper Type

Paper Type:

N/A (Digital Download - PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

LC4 (Liquid Cooled 4-stroke)

Displacement:

Approx. 449.3 cc

Bore X Stroke:

Approx. 97.0 mm x 60.8 mm

Compression Ratio:

Approx. 12.0:1

Valve Train:

SOHC (Single Overhead Camshaft), 4 valves

Performance

Horsepower:

Approx. 50-55 HP (factory estimates, may vary)

Torque:

Approx. 40-45 Nm (factory estimates, may vary)

Fuel System

Carburetor:

Keihin FCR41 MX (likely with accelerator pump)

Fuel Type:

Unleaded gasoline, minimum 95 RON (Octane Rating)

Cooling System

Cooling Method:

Liquid Cooling

Lubrication

Oil Type:

JASO MA certified, SAE 10W/40 or 10W/50 motorcycle specific synthetic oil.

Oil Capacity:

Approx. 1.2 - 1.4 Liters (check specific model variation)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet multi-disc clutch, hydraulically operated

Features

Gear Ratios:

Specific ratios provided in manual (e.g., 1st: 2.357, 2nd: 1.750, 3rd: 1.333, 4th: 1.050, 5th: 0.880, 6th: 0.750 - illustrative, actual may vary).

Transmission Oil:

SAE 80W/90 gear oil (check manual for specific type and capacity)

📐 Dimensions

Exterior

Overall Length:

Approx. 2200 mm (varies slightly with model year)

Overall Width:

Approx. 820 mm

Seat Height:

Approx. 960 mm

Ground Clearance:

Approx. 350 mm

Weights

Dry Weight:

Approx. 110-115 kg (without fuel)

Fuel Capacity:

Approx. 8.5 - 9.5 Liters

Wheelbase:

Approx. 1475 mm

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycles typically do not have standardized crash test ratings like cars)

Active Features

Braking System:

Powerful hydraulic disc brakes front and rear with good feel and stopping power.

Suspension Design:

Advanced WP suspension provides excellent control and stability off-road.

Passive Features

Frame Construction:

High-strength chromoly steel frame for rigidity and impact absorption.

Handguards:

Standard fitment on Six Days models to protect hands from debris and impacts.

💡 Technology Features

Infotainment

Instrument Cluster:

Digital multifunction display showing speed, RPM, trip meters, clock, and engine hour meter.

Lighting Technology:

Halogen headlight, LED tail light and brake light for visibility.

Driver Assistance

Traction Control:

Not equipped with electronic traction control systems.

Not equipped with Anti-lock Braking System (ABS) on these models.

Connectivity

Connectivity Features:

No integrated Bluetooth or smartphone connectivity features.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 10-15 hours of riding or annually. For street use, every 5000 km or annually.

Air Filter Cleaning:

After every few rides, or more frequently in dusty conditions.

Chain Adjustment Lubrication:

Every 500-1000 km, or as needed. Lubricate before and after washing.

Spark Plug Replacement:

Check and clean every 10-15 hours; replace as needed, typically every 20-30 hours.

Valve Clearance Check:

First check at 50 hours, then every 25-30 hours or annually. Critical for engine longevity.

Fluid Specifications

Engine Oil:

SAE 10W/40 or 10W/50, JASO MA certified, synthetic motorcycle oil. (e.g., Motorex Power Synt 4T 10W/50)

Brake Fluid:

DOT 4 Hydraulic Brake Fluid.

Coolant:

Ethylene glycol-based coolant mixture with distilled water (50/50 ratio). (e.g., Motorex Cool Protect M3.0)

Fork Oil:

Specific WP fork oil, viscosity and quantity detailed in manual (e.g., WP Suspension Fluid 5W or SAE 7.5W).

Transmission Oil:

SAE 80W/90 Gear Oil (check manual for brand recommendations).

Known Issues

Carburetor Performance:

Can require periodic cleaning and jetting adjustments for optimal performance, especially with fuel changes or altitude variations.

Engine Temperature:

Can run warm under sustained high-load conditions; ensure cooling system is in top condition.

Clutch Wear:

Clutch plates can wear over time with aggressive riding; proper maintenance and adjustment are key.

Suspension Seals:

Fork seals and shock seals can degrade over time, especially with off-road use; regular inspection and maintenance are recommended.

📚 Vehicle History

Brand Heritage

Brand Origin:

Austrian manufacturer founded in 1934, known for racing and off-road motorcycles.

Racing Success:

Extensive history and success in motocross, enduro, and rally racing, influencing production models.

Model Evolution

Exc Lineage:

The EXC line has been KTM's flagship off-road and dual-sport platform for decades, evolving through various engine sizes and technologies.

Six Days Designation:

Represents special editions commemorating KTM's participation and success in the International Six Days Enduro (ISDE), often featuring unique graphics and sometimes upgraded components.

Production

Manufacturing Location:

Austria (primarily)

Market Impact:

The 450 EXC series is highly regarded for its performance and off-road capability, making it a popular choice for serious riders.

🏆 Awards & Recognition

Recognitions

Off Road Performance Awards:

KTM EXC series consistently recognized by motorcycle publications and riders for class-leading performance and durability in off-road and enduro competitions.

Six Days Heritage:

The 'Six Days' designation itself is an award, reflecting KTM's historical dominance and commitment to the ISDE.

Ratings

User Reviews:

Generally high ratings for power, handling, suspension, and off-road capability among enthusiasts.

Certifications

Emissions Compliance:

Compliant with relevant emissions standards for its model years and intended markets.