The 450 EXC is a high-performance dual-sport motorcycle renowned for its potent engine, capable suspension, and lightweight chassis, designed for demanding enduro and off-road riding. Building on a strong off-road racing heritage, this 2009 model offers a powerful four-stroke, single-cylinder engine with a displacement of 449.3 cc, delivering impressive power and torque suitable for competitive use. Its robust construction and Austrian manufacturing ensure reliability, while features like adjustable WP suspension and hydraulic disc brakes contribute to its exceptional performance across varied terrains. This comprehensive Service Repair Manual provides detailed instructions for the maintenance and repair of your 2009 450 EXC. It covers all essential systems, including the engine, fuel system, transmission, clutch, suspension, brakes, and electrical system. Within its pages, you will find procedures for scheduled maintenance, tune-ups, component rebuilds, and troubleshooting common issues. The manual's in-depth technical specifications, torque values, and clear, step-by-step guidance are invaluable for owners and technicians alike, enabling efficient upkeep and ensuring the longevity and optimal performance of the motorcycle. 🏷️ Basic Information Identification Make: KTM Model: 450 EXC Year: 2009 Vehicle Type: Dual-Sport Motorcycle Manual Product Name: KTM 450 EXC 2009 Service Repair Manual Manual Product Description: KTM 450 EXC 2009 Service Repair Manual PDF 👋 Introduction Market Position Segment: High-performance off-road/dual-sport motorcycle. Target Audience: Enthusiasts and owners seeking detailed maintenance and repair guidance. Competitive Analysis Competitors: Yamaha WR450F, Honda CRF450X, Suzuki RM-Z450 (off-road variants). Key Features Vehicle Attributes: Powerful engine, capable suspension, lightweight chassis, designed for enduro and off-road riding. Manual Advantage: Provides authoritative, detailed instructions to maintain and repair the 450 EXC efficiently, saving time and money compared to dealer service. 📋 Manual Details Coverage Areas General Coverage: Comprehensive service and repair information for the 2009 KTM 450 EXC. Page Count Estimated Page Count: Varies by specific manual edition, typically 300-500 pages. Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, tuning, and troubleshooting. Fuel System: Carburetor (Mikuni VM40) or Fuel Injection (depending on specific sub-model), fuel pump, fuel lines, and tank maintenance. Transmission: Gearbox inspection, repair, and fluid changes. Clutch: Hydraulic clutch system service and repair. Suspension: Front fork (WP Suspension) and rear shock absorber (WP) maintenance, adjustments, and rebuilds. Brakes: Front and rear brake system inspection, bleeding, pad replacement, and caliper service. Electrical System: Ignition system, lighting, charging system (stator, rectifier, battery), starter motor, and wiring diagrams. Cooling System: Radiator, hoses, coolant, and fan operation. Frame And Bodywork: Chassis inspection, body panel removal/installation, seat, handlebars, and footpegs. Wheels And Tires: Tire changes, spoke tensioning, wheel bearing service. Procedures Included Scheduled Maintenance: Oil changes, filter replacements, chain adjustment, valve clearance checks, spark plug replacement. Troubleshooting: Diagnostic procedures for common starting, running, and electrical issues. Repair Procedures: Detailed step-by-step instructions for component removal, repair, and reinstallation. Tune Up: Carburetor adjustment, ignition timing checks, general performance tuning. Rebuilds: Engine top-end and complete engine rebuild procedures. Technical Depth Depth: In-depth mechanical and electrical repair, including torque specifications, clearances, and diagnostic charts. 📊 Manual Specifications File Format PDF Quality: High-resolution, searchable PDF for easy navigation and printing. Print Quality Printability: Printable pages for workshop use. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, SOHC Displacement: 449.3 cc Bore X Stroke: 95 mm x 63.4 mm Compression Ratio: 11.2:1 Cooling System: Liquid-cooled Performance Horsepower: Approx. 50-55 HP (at crank, model dependent) Torque: Approx. 45-48 Nm (at crank, model dependent) Fuel System Carburetor Type: Mikuni VM40 flat-slide carburetor (common for EXC models of this era) Fuel Capacity: Approx. 8.5 liters (1.9 gallon) Lubrication Oil Type: JASO MA certified 10W-40 or 10W-50 semi-synthetic or fully synthetic motorcycle oil Oil Capacity With Filter: Approx. 1.1 liters 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Hydraulically operated multi-plate wet clutch Features Gear Ratios: Specific ratios detailed within the manual. Final Drive: O-ring sealed chain 📐 Dimensions Exterior Seat Height: Approx. 960 mm (37.8 inches) Ground Clearance: Approx. 350 mm (13.8 inches) Weights Dry Weight: Approx. 110 kg (242.5 lbs) Curb Weight: Approx. 120 kg (264.6 lbs) with fluids 🛡️ Safety Features Ratings Safety Certification: CE, EPA compliant (depending on market and specific configuration) Active Features Braking System: Hydraulic disc brakes, front and rear (Brembo calipers often fitted). Suspension Features: Adjustable front forks and rear shock for varied terrain conditions. Passive Features Lighting: Headlight, taillight, brake light for road legality. 💡 Technology Features Infotainment Display: Basic LCD instrument cluster displaying speed, odometer, trip meter, and time. Driver Assistance ABS: Not typically equipped on this model year for off-road focus. Connectivity Bluetooth Wifi: Not applicable for this model. 🔧 Maintenance Service Intervals Engine Oil Change: Every 15-20 hours of riding or annually. Air Filter Cleaning: Every 5-10 hours of riding, or more frequently in...