The 2009 KTM 450 EXC is a high-performance Enduro/Off-Road Motorcycle, renowned for its potent LC4 engine and capable chassis, making it a formidable machine for competitive riding and demanding off-road conditions. Building on KTM's strong off-road racing heritage, this Austrian-engineered motorcycle offers a blend of power and durability, designed to excel in challenging terrains. Its advanced WP Suspension and hydraulic disc brakes provide superior control and stopping power, essential for navigating varied off-road environments. Proper maintenance is crucial for preserving the inherent quality and longevity of this machine, ensuring it remains a reliable partner for enthusiasts and professional riders alike. This comprehensive workshop service repair manual provides full coverage for the 2009 KTM 450 EXC, detailing everything from routine maintenance procedures like oil changes and filter replacements to complete engine disassembly, rebuilding, and advanced diagnostic troubleshooting. It covers all critical systems, including the engine, fuel system, ignition, cooling, transmission, drivetrain, suspension, brakes, and electrical systems, offering step-by-step instructions and essential technical specifications such as torque values and clearances. This manual is an indispensable resource for owners, mechanics, and technicians seeking to maintain, repair, and optimize the performance and reliability of their 450 EXC. 🏷️ Basic Information Identification Make: KTM Model: 450 EXC Year: 2009 Type: Enduro/Off-Road Motorcycle Codes Chassis Code: Refer to manual for specific chassis codes Engine Code: LC4 👋 Introduction Market Position Segment: High-performance Enduro Motorcycle Target Audience: Enthusiasts, competitive riders, and professional mechanics. Competitive Analysis Competitors: Yamaha WR450F, Honda CRF450X, Husqvarna TE450. Key Features Performance Focus: Known for its potent engine and capable off-road chassis. Durability: Designed for demanding off-road conditions, requiring proper maintenance. Manual Value: Essential for maintaining peak performance and longevity. 📋 Manual Details Coverage Areas Areas: Full Workshop Service Repair Coverage Page Count Pages: Hundreds (Specific number not provided, but implies comprehensive coverage) Manual Type Type: Official Factory Service Repair Manual Language Language: English (Assumed based on product description context) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine assembly, disassembly, inspection, and repair of all internal components. Fuel System: Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel tank, fuel lines. Ignition System: Ignition coil, spark plug, ECU (Engine Control Unit) mapping and diagnostics. Cooling System: Radiator, coolant hoses, water pump, thermostat, fan operation. Transmission: Gearbox operation, clutch assembly, shift mechanism, internal transmission components. Drivetrain: Final drive, chain and sprockets maintenance, wheel bearings. Suspension: Front fork (WP Suspension) disassembly, servicing, and adjustments; rear shock absorber (WP Suspension) servicing and adjustments. Brakes: Front and rear brake caliper maintenance, brake disc inspection, master cylinder servicing, hydraulic system bleeding. Electrical System: Wiring diagrams, battery maintenance, starter motor, lighting system, stator, rectifier/regulator, fuses, switches. Chassis Frame: Frame inspection, steering head bearing service, subframe maintenance. Bodywork Plastics: Removal and installation of fenders, side panels, seat, fuel tank cover. Troubleshooting: Diagnostic flowcharts for common issues and system failures. Procedures Included Maintenance: Regular scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug replacement. Repair: Detailed step-by-step instructions for component repair and replacement. Diagnostics: System-specific diagnostic procedures for identifying faults. Rebuilds: Full engine and component rebuild procedures with specifications. Adjustments: Valve clearance adjustments, suspension settings, carburetor tuning (if applicable, though likely EFI for '09). Technical Depth Depth: Comprehensive from basic maintenance to complete engine disassembly and rebuilding. Diagnostics Level: Advanced diagnostic procedures, including electrical system troubleshooting. Specifications: Includes all critical torque values, clearances, fluid capacities, and wear limits. 📊 Manual Specifications File Format Format: PDF Searchable: Likely searchable text within the PDF for quick information retrieval. Print Quality Quality: High-resolution scans of original factory documentation, suitable for printing. Binding Type Type: N/A (Digital PDF Download) Paper Type Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, liquid-cooled, LC4 engine Displacement: 449.3 cc (approx.) Bore X Stroke: Refer to manual for exact specifications Compression Ratio: Refer to manual for exact specifications Performance Horsepower: Approximately 50-55 HP (stock, varies by market and tuning) Torque: Refer to manual for exact specifications Fuel System System: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, minimum 91 octane (RON+MON)/2 / 87 AKI Lubrication Oil Type: Refer to manual for specific API and JASO specifications (e.g., Motorex Powersynth 4T 10W/50 is common for KTM) Oil Capacity: Refer to manual for exact capacity (typically around 1.2-1.5 liters including filter) 🔧 Transmission Standard Type: 6-speed constant mesh gearbox Optional Options: N/A (Standard configuration for EXC models) Features Clutch: Hydraulic wet multi-disc clutch Final Drive: Chain drive (520 pitch, sealed O-ring type) Fluid Specifications Fluid Type: Refer to manual for transmission oil specification (often shared with engine oil for wet clutch applications, but check manual) Fluid Capacities Capacity: Refer to manual for exact capacity. 📐 Dimensions Exterior Wheelbase: Refer to manual for exact specifications Seat Height: Refer to manual for exact specifications (typically high for off-road) Weights Dry Weight: Approximately 115-120...