This manual covers the 2009 450 EXC SIX DAYS, a high-performance dual-sport motorcycle renowned for its off-road prowess and rally-raid heritage. As an Austrian manufacturer, the brand is celebrated for its dedication to off-road performance, and the EXC line represents their flagship enduro offerings. The SIX DAYS variant, in particular, is a special edition model that typically features upgraded components and unique styling, honoring the International Six Days Enduro. This motorcycle is engineered for enthusiast riders and competitors seeking a capable machine for challenging terrain and adventurous journeys. This comprehensive workshop service repair manual provides complete service and repair information for the 2009 450 EXC SIX DAYS. It covers a wide array of systems, including general information, fuel and cooling systems, engine top end, clutch, lubrication, crankshaft, transmission, wheels, tires, final drive, brakes, suspension, steering, frame, and electrical systems. The manual details routine maintenance, diagnostic procedures, and step-by-step repair and rebuild instructions, supplemented by hundreds of photos and illustrations. It is designed to assist owners, mechanics, and technicians in effectively maintaining and repairing the vehicle. 🏷️ Basic Information Identification Make: KTM Model: 450 EXC SIX DAYS Year: 2009 Vehicle Type: Dual-Sport Motorcycle Trim: SIX DAYS Codes Chassis Code: Likely based on the EXC platform, specific SIX DAYS designation is cosmetic/package-related Engine Code: LC4-based, specific designation would be internal KTM code 👋 Introduction Market Position Segment: High-performance off-road/dual-sport motorcycle Target Audience: Enthusiast riders, off-road competitors, experienced mechanics, and DIYers Competitive Analysis Competition: Primarily competes with other European and Japanese manufacturers' premium enduro and dual-sport models (e.g., Yamaha WR450F, Honda CRF450X, Husqvarna FE450) Key Features Distinctive Aspects: SIX DAYS edition typically includes special graphics, upgraded components (e.g., special seat, handguards, exhaust), and race-inspired features, highlighting its off-road prowess and rally-raid heritage. Manual Value Proposition: Inexpensive way to keep the vehicle working properly, provides detailed step-by-step instructions for all service and repair procedures. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service and Repair Specific Systems: General Information, Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix Page Count Estimated Pages: Hundreds (exact count not specified but implied to be extensive) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Top End (cylinder head, valves, piston), Lubrication System (oil pump, filter, passages), Clutch (disassembly, inspection, replacement), Crankshaft/Transmission (gearbox, shifting mechanism, bearings) Fuel Delivery: Fuel system (carburetor or fuel injection components, fuel pump, lines) Chassis And Suspension: Frame inspection and repair, Steering system (bearings, linkage), Suspension (forks, rear shock, linkages), Wheels and Tires (mounting, balancing, spoke tension), Final Drive (chain and sprocket maintenance) Braking System: Front and rear brake systems (calipers, master cylinders, lines, pads, rotors, fluid specifications) Electrical System: Wiring diagrams, ignition system, lighting, battery, starter system, troubleshooting procedures Cooling System Cooling Components: Radiator, coolant pump, hoses, thermostat, coolant specifications Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, tire pressure, brake checks, coolant checks Diagnostic Procedures: Troubleshooting steps for common issues, electrical diagnostics Repair And Rebuild: Step-by-step instructions for component disassembly, repair, and reassembly of major vehicle systems Technical Depth Depth: Comprehensive, covering complete disassembly to detailed component repair, suitable for both DIY and professional mechanics Illustrations: Hundreds of photos and illustrations, enlarged inset views for detailed parts examination Guidance: Numbered instructions, detailed substeps, notes, cautions, and warnings 📊 Manual Specifications File Format Format: PDF Compatibility: All PC-based Windows operating systems and Mac Print Quality Printability: Printable without any restriction (entire manual or specific pages) Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Software Requirements Reader: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled (LC4 architecture) Displacement: Approximately 449.3 cc Bore X Stroke: Likely around 95 mm x 63.4 mm (verify with specific KTM documentation) Valve Train: SOHC, 4 valves Performance Horsepower: Typically in the range of 50-55 HP (specific to factory tune and year) Torque: Estimated around 45-50 Nm (verify with specific KTM documentation) Fuel System Fuel Delivery System: Carburetor (e.g., Keihin FCR 41) or potentially early fuel injection depending on market and specific variant. Fuel Type: Unleaded gasoline (minimum 95 RON/91 AKI recommended) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Optional Optional Gearing: N/A (Standard 6-speed) Features Clutch Type: Wet multi-disc clutch (hydraulically actuated) Final Drive: O-ring sealed chain 📐 Dimensions Exterior Seat Height: Approximately 970 mm (38.2 in) - typical for EXC models, SIX DAYS may vary slightly. Ground Clearance: Approximately 355 mm (14 in) - typical for EXC models. Weights Dry Weight: Approximately 119 kg (262 lbs) - actual weight may vary with SIX DAYS components. Fuel Capacity: Approximately 9.5 liters (2.5 US gal) 🛡️ Safety Features Ratings Safety Compliance: Designed for off-road competition and recreational use, street legality...