KTM 450 EXC SIX DAYS 2008-2011 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: KTM Model: 450 EXC Six Days Model Variant: Six Days Model Years Covered: 2008, 2009, 2010, 2011 Codes Chassis Codes: Likely 450 EXC (specific Six Days variant codes may exist but not explicitly stated in product info) Engine Codes: Likely LC4-based 450cc engine 👋 Introduction Market Position Segment: High-performance Enduro/Off-Road Motorcycle Target Audience: Enthusiast off-road riders, enduro competitors, and experienced dual-sport riders. Competitive Analysis Key Competitors: Husqvarna TE450, Beta RR450, Yamaha WR450F, Honda CRF450X, Suzuki RM-Z450 (off-road variants). Key Features Performance Focus: Designed for demanding off-road conditions, trail riding, and competitive enduro events. Six Days Designation: The 'Six Days' trim typically signifies a model equipped with special features and enhancements for the International Six Days Enduro (ISDE) event, often including upgraded components. 📋 Manual Details Coverage Areas Systems Covered: Engine, fuel system, ignition system, cooling system, transmission, clutch, chassis, suspension (front and rear), brakes (front and rear), electrical system, wiring diagrams, bodywork, wheels, tires, troubleshooting, maintenance. Page Count Page Count: Hundreds (exact count not specified, indicative of a comprehensive manual) Manual Type Manual Type: Factory Service Repair Manual Language Language: English (Assumed, standard for international factory manuals) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, inspection, repair, and reassembly of engine components (cylinder, piston, crankshaft, connecting rod, valves, camshafts, etc.). Fuel System: Carburetor (likely Keihin FCR) tuning, cleaning, and overhaul; fuel pump (if applicable for EFI variants); fuel tank and lines. Ignition System: Ignition coil, spark plug, CDI unit troubleshooting and replacement. Cooling System: Radiator, fan, coolant, water pump maintenance and repair. Transmission And Clutch: Gearbox inspection, repair, and lubrication; clutch plate replacement, adjustment, and hydraulic system service. Chassis And Suspension: Frame inspection and repair; front fork (e.g., WP USD) servicing, including oil changes, seal replacement, and adjustments; rear shock absorber (e.g., WP PDS or linkage-based) servicing and adjustment. Brakes: Hydraulic brake system servicing (bleeding, pad replacement, caliper overhaul, master cylinder service) for both front and rear. Electrical System: Complete wiring diagrams, component testing (lights, horn, starter, etc.), battery maintenance, and troubleshooting. Bodywork And Ergonomics: Fairing, seat, fuel tank, handguards, and other body panel removal, installation, and repair. Procedures Included Maintenance Procedures: Routine checks, lubrication points, filter replacements, fluid changes, chain adjustment, and general upkeep. Troubleshooting Guides: Systematic diagnostic procedures for common and uncommon problems, fault finding charts. Overhaul Procedures: Detailed step-by-step instructions for complete engine, transmission, and suspension unit overhauls. Diagnostic Procedures: Methods for identifying component failures and performance issues. Technical Depth Depth Of Information: Comprehensive. Covers basic maintenance to complete engine rebuilds and advanced diagnostics, suitable for both home mechanics and professional technicians. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, designed for clear printing of text and diagrams. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Searchability Searchable Text: Typically yes for factory PDF manuals, enabling quick access to specific information. ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, Single-cylinder, Liquid-cooled, SOHC Displacement: 449.3 cc (approx.) Bore X Stroke: Likely 95 mm x 63.4 mm (common for this generation LC4 450) Compression Ratio: Typically around 11.5:1 to 12.0:1 Performance Horsepower Estimated: Approximately 50-55 HP (at crankshaft, may vary slightly by year/tune) Torque Estimated: Approximately 45-48 Nm (at crankshaft, may vary slightly by year/tune) Fuel System Fuel Delivery: Carburetor (Keihin FCR 39 or similar) Fuel Type: Unleaded gasoline, minimum 91 octane Lubrication Oil Type: JASO MA certified motorcycle-specific 4-stroke engine oil, viscosity typically 10W/40 or 15W/50. Oil Capacity: Approximately 1.1 - 1.3 Liters (check manual for exact specification, often shared with transmission oil). 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet multi-plate clutch, hydraulically operated Features Gear Ratios: Specific ratios would be detailed in the manual, designed for off-road performance. Final Drive: O-ring sealed chain, typically 520 pitch. 📐 Dimensions Exterior Length: Varies, typically around 2100-2200 mm Width: Varies, typically around 800-850 mm (excluding mirrors) Height: Varies, typically around 1200-1300 mm (seat height significantly lower) Seat Height: Approximately 940-960 mm (unladen) Weights Dry Weight: Approximately 110-115 kg (dry) Wet Weight: Approximately 120-125 kg (ready to ride, with fluids) Fuel Capacity: Approximately 8.5 - 9.5 Liters Wheelbase: Approximately 1470-1480 mm 🛡️ Safety Features Ratings Crash Safety Ratings: N/A (Motorcycles typically do not receive automotive crash test ratings) Active Features Braking System: Hydraulic disc brakes front and rear (typically Brembo components), designed for strong stopping power in off-road conditions. Suspension Features: High-quality, adjustable suspension (e.g., WP USD forks, WP PDS or linkage rear shock) for optimal control and impact absorption. Passive Features Lighting System: Headlight, taillight, brake light, turn signals (may be optional or removed for racing configurations). Handguards: Standard on Six Days models for protection against roost, branches, and impacts. 💡 Technology Features Infotainment Display System: Basic LCD display showing speed, odometer, trip meters, and...
Designed for demanding off-road conditions, trail riding, and competitive enduro events.
Six Days Designation:
The 'Six Days' trim typically signifies a model equipped with special features and enhancements for the International Six Days Enduro (ISDE) event, often including upgraded components.
Hundreds (exact count not specified, indicative of a comprehensive manual)
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English (Assumed, standard for international factory manuals)
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete disassembly, inspection, repair, and reassembly of engine components (cylinder, piston, crankshaft, connecting rod, valves, camshafts, etc.).
Fuel System:
Carburetor (likely Keihin FCR) tuning, cleaning, and overhaul; fuel pump (if applicable for EFI variants); fuel tank and lines.
Ignition System:
Ignition coil, spark plug, CDI unit troubleshooting and replacement.
Cooling System:
Radiator, fan, coolant, water pump maintenance and repair.
Transmission And Clutch:
Gearbox inspection, repair, and lubrication; clutch plate replacement, adjustment, and hydraulic system service.
Chassis And Suspension:
Frame inspection and repair; front fork (e.g., WP USD) servicing, including oil changes, seal replacement, and adjustments; rear shock absorber (e.g., WP PDS or linkage-based) servicing and adjustment.
Brakes:
Hydraulic brake system servicing (bleeding, pad replacement, caliper overhaul, master cylinder service) for both front and rear.
Fairing, seat, fuel tank, handguards, and other body panel removal, installation, and repair.
Procedures Included
Maintenance Procedures:
Routine checks, lubrication points, filter replacements, fluid changes, chain adjustment, and general upkeep.
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon problems, fault finding charts.
Overhaul Procedures:
Detailed step-by-step instructions for complete engine, transmission, and suspension unit overhauls.
Diagnostic Procedures:
Methods for identifying component failures and performance issues.
Technical Depth
Depth Of Information:
Comprehensive. Covers basic maintenance to complete engine rebuilds and advanced diagnostics, suitable for both home mechanics and professional technicians.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution, designed for clear printing of text and diagrams.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Searchability
Searchable Text:
Typically yes for factory PDF manuals, enabling quick access to specific information.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, Single-cylinder, Liquid-cooled, SOHC
Displacement:
449.3 cc (approx.)
Bore X Stroke:
Likely 95 mm x 63.4 mm (common for this generation LC4 450)
Compression Ratio:
Typically around 11.5:1 to 12.0:1
Performance
Horsepower Estimated:
Approximately 50-55 HP (at crankshaft, may vary slightly by year/tune)
Torque Estimated:
Approximately 45-48 Nm (at crankshaft, may vary slightly by year/tune)
Fuel System
Fuel Delivery:
Carburetor (Keihin FCR 39 or similar)
Fuel Type:
Unleaded gasoline, minimum 91 octane
Lubrication
Oil Type:
JASO MA certified motorcycle-specific 4-stroke engine oil, viscosity typically 10W/40 or 15W/50.
Oil Capacity:
Approximately 1.1 - 1.3 Liters (check manual for exact specification, often shared with transmission oil).
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet multi-plate clutch, hydraulically operated
Features
Gear Ratios:
Specific ratios would be detailed in the manual, designed for off-road performance.
Final Drive:
O-ring sealed chain, typically 520 pitch.
📐 Dimensions
Exterior
Length:
Varies, typically around 2100-2200 mm
Width:
Varies, typically around 800-850 mm (excluding mirrors)
Height:
Varies, typically around 1200-1300 mm (seat height significantly lower)
Seat Height:
Approximately 940-960 mm (unladen)
Weights
Dry Weight:
Approximately 110-115 kg (dry)
Wet Weight:
Approximately 120-125 kg (ready to ride, with fluids)
Fuel Capacity:
Approximately 8.5 - 9.5 Liters
Wheelbase:
Approximately 1470-1480 mm
🛡️ Safety Features
Ratings
Crash Safety Ratings:
N/A (Motorcycles typically do not receive automotive crash test ratings)
Active Features
Braking System:
Hydraulic disc brakes front and rear (typically Brembo components), designed for strong stopping power in off-road conditions.
Suspension Features:
High-quality, adjustable suspension (e.g., WP USD forks, WP PDS or linkage rear shock) for optimal control and impact absorption.
Passive Features
Lighting System:
Headlight, taillight, brake light, turn signals (may be optional or removed for racing configurations).
Handguards:
Standard on Six Days models for protection against roost, branches, and impacts.
💡 Technology Features
Infotainment
Display System:
Basic LCD display showing speed, odometer, trip meters, and possibly engine hour meter. No advanced infotainment features.
Driver Assistance
Electronic Aids:
Minimal. Primarily focused on mechanical performance. No traction control or advanced electronic rider aids typically found on modern street bikes.
Connectivity
Connectivity Options:
None. Purely mechanical and electrical systems. No Bluetooth, GPS, or smartphone integration.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Recommended every 15-20 operating hours or annually. Specific intervals vary based on riding conditions.
Air Filter Cleaning:
Recommended every 5-10 operating hours, or more frequently in dusty conditions.
Spark Plug Inspection:
Recommended every 15-20 operating hours.
Valve Clearance Check:
Recommended every 20-30 operating hours or annually. Critical for performance and engine longevity.
Chain Adjustment And Lubrication:
Check and adjust tension every 5-10 operating hours. Lubricate after washing or riding in wet conditions.
Suspension Service:
Fork oil change every 50-100 operating hours; full suspension service annually or as needed based on riding intensity.
Fluid Specifications
Coolant Type:
Ethylene glycol based antifreeze, mixed with distilled water at a 50/50 ratio.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Fork Oil Type And Level:
Specific viscosity (e.g., SAE 5W or 7.5W) and level detailed in the manual, crucial for proper suspension function.
Known Issues
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, chain and sprockets, fork seals, exhaust packing (if applicable).
Potential Reliability Points:
Valve seat wear (can be addressed with harder valve seat materials), carburetors can require periodic cleaning/adjustment, some early models had potential issues with stator or voltage regulators.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Austria
Racing Legacy:
KTM has a strong heritage in off-road racing, including enduro, motocross, and rally raid, which heavily influences its production models.
Model Evolution
Exc Lineage:
The EXC line has been KTM's flagship enduro model for decades, continuously evolving with engine technology, chassis design, and suspension.
Engine Development:
The 450 EXC generally utilizes KTM's LC4 engine architecture, which has seen numerous updates and refinements over the years, including improvements in power delivery, reliability, and weight.
Production
Manufacturing Location:
Austria (Primary)
Six Days Context:
The 'Six Days' designation celebrates KTM's success and participation in the International Six Days Enduro, often featuring model-specific graphics and select component upgrades.
🏆 Awards & Recognition
Recognitions
Off Road Performance Awards:
While specific awards for the 2008-2011 model might not be readily cataloged, KTM EXC models consistently receive high praise and wins in various enduro and off-road racing championships worldwide.