🏷️ Basic Information Identification Make: KTM Model: 450 EXC SIX DAYS Year: 2009 Product Type: Workshop Repair Service Manual Codes Engine Code Indicator: Covers All Models/Engines/Trim/Transmi... 👋 Introduction Market Position Segment: High-performance Enduro/Off-Road Motorcycle. Target Audience: Enthusiasts, mechanics, and owners seeking in-depth maintenance and repair knowledge. Competitive Analysis Competitors: Husqvarna TE450, Yamaha WR450F, Honda CRF450X, Suzuki RM-Z450 (Enduro variant). Key Features 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 Coverage Areas Primary Coverage: Service, Maintenance, Troubleshooting Page Count Estimated Page Count: N/A (Digital PDF - dynamic) Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered 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. Procedures Included 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. Technical Depth 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 File Format Format Details: Searchable PDF, printable pages. Print Quality Quality: High-resolution, clear diagrams and text. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine 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. Performance Estimated Horsepower: Approx. 50-55 HP (Stock, may vary). Estimated Torque: Approx. 45-50 Nm (Stock, may vary). Fuel System Carburetor Model: Mikuni BSR40. Fuel Type: Unleaded gasoline (95 RON or higher recommended). 🔧 Transmission Standard Transmission Type: Constant mesh, 5-speed sequential gearbox. Clutch Type: Wet multi-disc clutch, hydraulically operated. Features 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 Exterior Wheelbase: Approx. 1480 mm (58.3 in). Seat Height: Approx. 960 mm (37.8 in). Ground Clearance: Approx. 355 mm (14.0 in). Weights Dry Weight: Approx. 113 kg (249 lbs). Fuel Tank Capacity: Approx. 9.5 liters (2.5 gallons). 🛡️ Safety Features Ratings Safety Standards: N/A (Off-road vehicle - not subject to typical automotive safety ratings like NHTSA/Euro NCAP). Active Features Braking System: Hydraulic disc brakes front and rear for strong stopping power. Ergonomics: Designed for rider control and stability in challenging terrain. Passive Features 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 Infotainment Display: Minimalist digital display showing speed, odometer, trip meter, clock, and basic warning lights. Driver Assistance ABS: No ABS standard on this model. Connectivity Connectivity Features: None (basic electrical system). 🔧 Maintenance Service Intervals 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....