The 2009 KTM 450 EXC is a high-performance, liquid-cooled, four-stroke Enduro motorcycle designed for demanding off-road riding and competition. Building on KTM's strong off-road heritage, this model is renowned for its potent 449.3 cc engine, advanced WP suspension components, and lightweight, rigid chromoly steel trellis frame. These features contribute to its exceptional agility, stability, and aggressive off-road performance, making it a competitive choice against other leading models in its segment. The 450 EXC is engineered for riders who prioritize power, handling, and durability in challenging terrain. This comprehensive workshop repair and service manual provides in-depth coverage for all KTM 450 EXC models from 2009, including all trim levels and transmission types. It is intended for both professional technicians and DIY enthusiasts seeking to maintain and repair their vehicle. The manual details routine maintenance, engine and component overhauls, troubleshooting guides, and technical specifications, covering all major systems such as the engine, fuel, ignition, transmission, suspension, brakes, and electrical systems. With step-by-step instructions and diagnostic procedures, this manual ensures proper care and optimal performance of your 450 EXC. 🏷️ Basic Information Identification Make: KTM Model: 450 EXC Year: 2009 Engine Variant Covered: 450cc Trim Levels Covered: All Transmission Types Covered: All Codes Chassis Code: Likely specific to 450 EXC 2009 variant, manual should detail 👋 Introduction Market Position Segment: High-performance Enduro/Off-road motorcycle Key Competitors 2009: Yamaha WR450F, Honda CRF450X, Husqvarna TE450, Beta RR450 Competitive Analysis Ktm Strengths: Renowned for potent engines, WP suspension, lightweight chassis, and aggressive off-road performance. Key Features Offroad Capability: Designed for extreme off-road riding, competition, and trail riding. Engine Type: Liquid-cooled, four-stroke, single-cylinder (LC4 engine platform evolution) 📋 Manual Details Coverage Areas Comprehensive Coverage: Yes, full workshop, repair, and service Target Audience: Professional technicians and DIY enthusiasts Page Count Estimated Page Count: Varies by specific manual edition, but typically 300-500+ pages for a complete workshop manual. Manual Type Manual Type: Workshop Repair Service Manual Language Language: English (standard for most workshop manuals) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed disassembly, assembly, inspection, and repair of all engine components (cylinder, piston, crankshaft, camshaft, valves, timing chain, lubrication system, cooling system). Fuel System: Carburetor (likely Keihin FCR) tuning, cleaning, rebuilding, fuel pump, fuel lines, fuel tank. Ignition System: CDI unit, ignition coil, spark plug, wiring diagrams. Transmission: Clutch operation, gearbox disassembly, assembly, inspection, gear selection mechanisms, lubrication. Suspension: Front forks (WP USD - Upside Down), rear shock absorber (WP Monoshock), linkage systems, seals, oil levels, pressures, adjustments. Brakes: Front and rear hydraulic disc brakes, caliper overhaul, master cylinder service, brake fluid bleeding, pad replacement, rotor inspection. Electrical System: Wiring diagrams, lighting system, starter motor, battery, charging system, fuses, switches, instrumentation. Cooling System: Radiator, coolant, hoses, water pump, thermostat operation. Exhaust System: Exhaust pipe, muffler, gasket replacement. Frame And Bodywork: Chassis inspection, bearings (steering, swingarm, wheel), body panel removal and installation, seat, fuel tank. Wheels And Tires: Wheel bearing replacement, spoke tensioning, tire mounting and balancing, rim specifications. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment and lubrication, air filter cleaning, spark plug checks. Troubleshooting Guides: Diagnostic procedures for common symptoms and malfunctions. Repair Procedures: Step-by-step instructions for component disassembly, repair, and reassembly. Overhaul Instructions: Complete engine and component overhaul guidance. Technical Specifications Data: Torque values, clearances, fluid capacities, electrical resistance values. Special Tool Recommendations: Identification of necessary special tools for specific procedures. Technical Depth Depth: In-depth, covering complete teardown and rebuilds of major components. Diagnostic Level: Advanced diagnostics, including troubleshooting flowcharts and electrical system analysis. 📊 Manual Specifications File Format File Type: PDF Searchability: Typically searchable text within the PDF for efficient information retrieval. Print Quality Print Quality Recommendation: High-resolution for clear diagrams and text reproduction. Binding Type Binding Recommendation: Spiral-bound for lay-flat use in workshop environments (if printed). Paper Type Paper Recommendation: Durable, grease-resistant paper (if printed). ⚙️ Engine Specifications Primary Engine Engine Type: 449.3 cc, liquid-cooled, four-stroke, single-cylinder, SOHC Bore X Stroke: Approx. 95.0 mm x 63.4 mm (refer to manual for exact specification) Compression Ratio: Approx. 12.0:1 (refer to manual for exact specification) Performance Horsepower Estimated: Around 50-55 HP (peak, depends on tuning and exhaust) Torque Estimated: Around 40-45 Nm (peak, depends on tuning and exhaust) Fuel System Carburetor Type: Keihin FCR MX 39mm (common for this era) Fuel Requirement: Unleaded gasoline (RON 91 or higher, check manual for specific octane recommendation) 🔧 Transmission Standard Transmission Type: Constant mesh, 6-speed Clutch Type: Wet multi-disc clutch, hydraulically operated Features Gear Ratios: Specific gear ratios will be detailed in the manual, crucial for off-road performance tuning. 📐 Dimensions Exterior Seat Height: Approx. 970 mm (38.2 in) - typical for EXC models, check manual for exact Ground Clearance: Approx. 355 mm (14.0 in) - typical for EXC models, check manual for exact Weights Dry Weight: Approx. 113 kg (249 lbs) - check manual for...