This manual covers the 450 EXC SIX DAYS, a high-performance enduro motorcycle produced in 2009. Renowned for its off-road racing pedigree and the 'Ready to Race' philosophy, the 450 EXC SIX DAYS has been engineered for extreme conditions, rally racing, and demanding trail riding. This special edition commemorates the International Six Days Enduro (ISDE) with enhanced features and distinct graphics, emphasizing lightweight construction, a powerful 449.3 cc four-stroke engine, and advanced suspension for competitive off-road use. Its robust chromium-molybdenum steel trellis frame and capable WP suspension ensure stability and control over challenging terrain. This comprehensive workshop manual provides detailed service, repair, and maintenance information for the 2009 450 EXC SIX DAYS. It covers all essential systems, including the engine, transmission, chassis, brakes, and electrical system, with specific guidance on component overhaul, diagnostics, tuning, and troubleshooting. The manual details routine maintenance procedures, fluid specifications, and technical data such as torque values and clearances. With approximately 300-400 pages of high-resolution, searchable content in English, this resource is designed to assist professional mechanics and experienced DIY technicians in maintaining and repairing the vehicle to the highest standards. 🏷️ Basic Information Identification Make: KTM Model: 450 EXC SIX DAYS Year: 2009 👋 Introduction Market Position Segment: High-performance Enduro / Off-road Motorcycle Philosophy: Built for extreme off-road conditions, rally racing, and demanding trail riding. Competitive Analysis Competitors: Yamaha WR450F, Honda CRF450X, Husqvarna TE450, Beta RR450 Key Features Six Days Edition: Special edition commemorating International Six Days Enduro (ISDE) with enhanced features and specific graphics. Performance Focus: Emphasis on lightweight construction, powerful engine, and advanced suspension for competitive off-road use. 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Workshop Page Count Estimated Pages: 300-400 Manual Type Type: Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete overhaul, diagnostics, tuning, fuel system, lubrication system, cooling system Transmission: Clutch, gearbox, final drive, lubrication Chassis: Frame, suspension (front and rear), steering, wheels, bearings Brakes: Hydraulic system, calipers, master cylinders, discs, bleeding procedures Electrical System: Wiring diagrams, ignition system, lighting, charging system, starter, sensors, diagnostics Fuel System: Carburetor (Mikuni TM40-6) or Fuel Injection system (depending on exact specification), fuel pump, filters, lines Procedures Included Maintenance: Routine checks, oil changes, filter replacements, spark plug service, chain adjustment Troubleshooting: Diagnostic flowcharts, common problems and solutions, electrical fault finding Repair: Component disassembly, reassembly, replacement, internal engine work, suspension overhaul Technical Data: Torque specifications, clearances, fluid capacities, electrical specifications Technical Depth Depth: Comprehensive, suitable for professional mechanics and experienced DIY technicians 📊 Manual Specifications File Format Format: PDF Quality: High-resolution, printable, searchable text Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Type: Four-stroke, single-cylinder, OHC, 4 valves Displacement: 449.3 cc Bore X Stroke: 95 mm x 63.4 mm Cooling System: Liquid-cooled Performance Horsepower: Approx. 50-55 HP (Varies by tuning and specific market) Torque: Approx. 45-48 Nm (Varies by tuning and specific market) Fuel System Carburetor Type: Mikuni TM40-6 (common on many EXC models of this era; FI also possible depending on region/specific model variant) Fuel Type: Unleaded gasoline, minimum 91 octane Lubrication System Oil Type: High-performance motorcycle specific 4-stroke engine oil (e.g., Motorex Power Synth 4T 10W-50 or equivalent) Oil Capacity: Approx. 1.1 - 1.2 Liters (check manual for precise value) 🔧 Transmission Standard Type: 6-speed, constant mesh Optional Optional Gearsets: N/A (Standard configuration) Features Clutch Type: Hydraulically operated, multi-disc wet clutch Final Drive: Chain drive (520 pitch, O-ring or X-ring) Lubrication Gearbox Oil Type: Dedicated gearbox oil or engine oil depending on KTM's specifications for this model year (often shared with engine oil) 📐 Dimensions Exterior Length: Approx. 2200 mm (varies slightly) Width: Approx. 820 mm (handlebar width, varies slightly) Height: Approx. 1260 mm (seat height, varies) Weights Dry Weight: Approx. 113 kg (without fuel) Wet Weight: Approx. 123 kg (with fluids, without fuel) Max Load: Typically around 100-120 kg rider and luggage Wheels Tires Front Wheel Size: 21 x 1.60 Front Tire Size: 90/90-21 (or 80/100-21) Rear Wheel Size: 18 x 2.15 Rear Tire Size: 140/80-18 (or 120/90-18) Dimensions Ground Clearance: Approx. 350-360 mm Seat Height: Approx. 945 mm Wheelbase: Approx. 1480 mm 🛡️ Safety Features Ratings Safety Certification: Not applicable in the same manner as street-legal vehicles; designed for off-road use. Compliance with specific racing regulations may apply. Active Features Braking System: Hydraulic disc brakes front and rear (e.g., Brembo components). Suspension Design: Advanced off-road suspension for stability and control over rough terrain (e.g., WP USD forks, PDS rear shock). Passive Features Frame Construction: Chromium-molybdenum steel trellis frame for strength and flexibility. Handguards: Standard for protection of hands and levers. 💡 Technology Features Infotainment Display: Digital multi-function display (speedometer, odometer, trip meter, clock). Navigation: N/A (Designed for off-road; aftermarket GPS typically used) Driver Assistance ABS: N/A (ABS was not standard or typically available on...