This manual covers the 450 EXC SIX DAYS dual-sport motorcycle models produced between 2008 and 2011. Renowned for its powerful liquid-cooled, 4-stroke, SOHC single-cylinder engine and advanced WP suspension, the 450 EXC SIX DAYS is engineered for high-performance off-road and enduro riding. The 'Six Days' designation highlights its special edition status, commemorating extensive success and participation in the International Six Days Enduro. Key features include a lightweight chassis, hydraulic disc brakes front and rear, and a robust construction designed to withstand demanding conditions, making it a top choice for serious off-road enthusiasts. This comprehensive workshop and repair manual provides detailed guidance for owners, mechanics, and technicians. It covers all essential aspects of the 450 EXC SIX DAYS, including routine maintenance, engine overhaul, fuel system servicing, ignition and electrical systems, transmission, drivetrain, suspension, and brake systems. The manual offers in-depth troubleshooting procedures, diagnostic charts, and step-by-step instructions with torque specifications for component rebuilds and repairs. Its scope extends from basic checks and adjustments to complete engine and chassis work, ensuring the vehicle remains in optimal condition and performance. 🏷️ Basic Information Identification Make: KTM Model: 450 EXC SIX DAYS Production Years Covered: 2008, 2009, 2010, 2011 Vehicle Type: Dual-Sport Motorcycle Codes Kba Number: Not Applicable (Motorcycle) Vin Code Representation: N/A (VIN specific to individual vehicle) 👋 Introduction Market Position Segment: High-performance Enduro/Off-road Motorcycle Target Audience: Enthusiast riders, off-road competitors, dual-sport riders seeking robust performance. Key Selling Points: Powerful single-cylinder engine, advanced suspension, lightweight chassis, 'Six Days' trim signifying special editions for International Six Days Enduro. Competitive Analysis Competitors: Yamaha WR450F, Honda CRF450X, Husqvarna TE450, Suzuki RM-Z450 (dual-sport variants). Key Features Engine Type: Liquid-cooled, 4-stroke, SOHC, single-cylinder Suspension Type: WP USD Front Forks, WP PDS Rear Shock (or linkage system) Brake System: Hydraulic Disc Brakes Front and Rear Six Days Distinction: Special graphics, often enhanced components or factory racing support elements. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Manual / Repair Manual Language: English (assumed based on product description) Format: PDF Download Page Count Page Count: Estimated 300-500 pages (typical for this type of comprehensive manual) Page Count Notes: Exact page count not specified in product info, estimated based on scope. 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, top-end, bottom-end, valve adjustment, timing, cooling system, lubrication. Fuel System: Carburetor (likely Keihin FCR41) disassembly, cleaning, adjustment, fuel pump, fuel lines, filters. Ignition System: CDI unit, spark plug specifications, wiring diagrams, troubleshooting. Transmission: Clutch operation, gear shift mechanism, internal transmission components, lubrication, troubleshooting. Drivetrain: Chain and sprockets maintenance, chain wear limits, drive sprocket replacement. Suspension Front: USD (Upside-Down) forks (likely WP), internal components, oil type and level, seal replacement, adjustments. Suspension Rear: Monoshock (likely WP PDS or linkage-based), shock absorber servicing, spring preload, damping adjustments, linkage maintenance. Brakes Front: Hydraulic disc brakes, caliper service, master cylinder overhaul, brake pad replacement, fluid type (DOT 4), bleeding procedures, rotor specifications. Brakes Rear: Hydraulic disc brakes, caliper service, master cylinder overhaul, brake pad replacement, fluid type (DOT 4), bleeding procedures, rotor specifications. Electrical System: Wiring diagrams, lighting systems (headlight, tail light, indicators), battery maintenance, charging system, starter motor, fuses, relays. Chassis Frame: Frame inspection, headstock bearings, swingarm pivot bearings, maintenance. Wheels Tires: Wheel bearing maintenance, spoke tensioning, tire pressure recommendations, tire sizes. Bodywork Plastics: Fairing removal and installation, seat, fuel tank, fenders. Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air), chain adjustment, brake checks, fluid level checks. Troubleshooting: Diagnostic procedures for common issues, symptom-based troubleshooting guides. Engine Rebuild: Complete disassembly, inspection of internal components (pistons, rings, crankshaft, valves), assembly procedures, torque specifications. Suspension Servicing: Fork seal replacement, fork oil changes, shock absorber servicing, linkage lubrication. Brake System Service: Bleeding procedures, caliper and master cylinder rebuild, pad and rotor replacement. Electrical Diagnostics: Wiring diagram interpretation, component testing, fault finding. Carburetor Tuning: Jetting adjustments, idle speed settings, mixture screw adjustments. Technical Depth Depth Level: Comprehensive (covers everything from basic maintenance to complete engine and chassis rebuilds) Diagnostic Capabilities: Detailed troubleshooting charts and procedures for identifying and resolving mechanical and electrical faults. Rebuild Instructions: Step-by-step instructions with torque specifications for major component overhauls. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text (typical for professionally produced PDFs) Printability: Printable (allows for paper copies of sections or the entire manual) Print Quality Image Resolution: High resolution (essential for clear diagrams and illustrations) Diagram Clarity: Detailed exploded views and schematic diagrams. Binding Type Binding: N/A (Digital Download - PDF) Paper Type Paper Type: N/A (Digital Download - PDF) ⚙️ Engine Specifications Primary Engine Engine Type: LC4 (Liquid Cooled 4-stroke) Displacement: Approx. 449.3 cc Bore X Stroke: Approx. 97.0 mm x 60.8 mm Compression Ratio: Approx. 12.0:1 Valve Train: SOHC (Single Overhead Camshaft), 4 valves Performance Horsepower: Approx. 50-55 HP (factory estimates, may vary) Torque: Approx. 40-45 Nm (factory estimates, may vary) Fuel System Carburetor:...