The 450 EXC SIX DAYS, a 2009 model, is a high-performance enduro motorcycle renowned for its exceptional off-road capability and robust construction. Built with a celebrated racing pedigree, this machine is engineered for demanding terrain and competitive riding, often featuring premium components and special graphics associated with the 'Six Days' package. Its powerful 449.3 cc four-stroke engine, coupled with advanced suspension and a strong chassis, delivers exhilarating performance and reliable handling for enthusiasts and professional riders alike. This comprehensive workshop repair service manual provides essential technical information for the maintenance and repair of your 2009 450 EXC SIX DAYS. It covers a wide range of critical systems, including detailed procedures for engine overhaul, fuel system maintenance, ignition system diagnostics, transmission and drivetrain servicing, suspension adjustments, brake system repairs, and electrical system troubleshooting. The manual offers in-depth guidance from routine maintenance tasks to complete engine rebuilds, ensuring owners and technicians can effectively keep this high-performance motorcycle in optimal condition. 🏷️ 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...