This manual covers the 400 EXC, 450 EXC, and 530 EXC Enduro Sport/Competition models from the 2009 model year. These high-performance off-road motorcycles are renowned for their powerful four-stroke engines, advanced WP suspension, and lightweight, race-bred chassis, embodying the 'Ready to Race' philosophy. Engineered for demanding off-road terrain and competition, these models offer a potent combination of power, agility, and durability, making them a favored choice among enthusiast riders and professional racers alike. This comprehensive service repair manual provides in-depth information essential for the maintenance, troubleshooting, and repair of your EXC motorcycle. It details procedures for all major systems, including the engine, transmission, fuel injection, electrical systems, suspension, brakes, and chassis. With detailed step-by-step instructions, diagnostic guidance, and technical specifications, this manual serves as an indispensable resource for owners and technicians to ensure optimal performance, reliability, and longevity of these specialized off-road machines. 🏷️ Basic Information Identification Make: KTM Model: 400 EXC, 450 EXC, 530 EXC Model Variant: Enduro Sport/Competition Year: 2009 Codes Chassis Codes: Likely varies by specific model designation (e.g., EXC 400, EXC 450, EXC 530) Engine Codes: Likely varies by specific model designation 👋 Introduction Market Position Segment: High-performance off-road motorcycles, specifically Enduro and Dual-Sport variants. Target Audience: Enthusiast riders, off-road racers, adventure riders, and DIY mechanics seeking in-depth knowledge for maintaining and repairing their KTM motorcycles. Competitive Analysis Competitors: Other European and Japanese manufacturers in the enduro segment (e.g., Husqvarna, Beta, GasGas, Yamaha WR series, Honda CRF-X, Suzuki DR-Z). Key Features Vehicle Focus: Powerful engines, advanced chassis and suspension, lightweight design, off-road capability. Manual Advantage: Provides detailed technical information not readily available in owner's manuals, enabling efficient and accurate maintenance and repair. 📋 Manual Details Coverage Areas Primary Focus: Service, Repair, Maintenance Geographic Coverage: Global (based on KTM's international production) Page Count Estimated Pages: Highly variable depending on the specific manual, but typically 300-600+ pages for comprehensive service manuals. Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Disassembly, assembly, troubleshooting, diagnostics, component identification, torque specifications, timing procedures, cooling system. Transmission: Clutch system, gearbox operation, shifting mechanisms, maintenance, repair, fluid specifications. Fuel System: Fuel injection system (EFI), throttle body, fuel pump, injectors, fuel pressure, troubleshooting fuel delivery. Electrical System: Ignition system, starter motor, battery, charging system, lighting, wiring diagrams, troubleshooting electrical faults, ECU. Suspension: Front forks (WP Suspension), rear shock absorber, linkage systems, adjustments, maintenance, seal replacement, fluid changes. Brakes: Hydraulic brake systems (Brembo typically), front and rear brake calipers, master cylinders, brake lines, pads, rotors, bleeding procedures. Chassis Frame: Frame inspection, fork yokes, swingarm, rear subframe, wheel bearings, steering head bearings. Bodywork: Plastics removal/installation, seat, fuel tank, fenders, fairings (if applicable), graphics. Cooling System: Radiators, hoses, water pump, coolant specifications, bleeding procedure. Procedures Included Maintenance: Routine checks, oil changes, filter replacements, chain adjustment, spark plug replacement, valve clearance checks. Troubleshooting: Diagnostic flowcharts, common problems and solutions for engine, electrical, and mechanical systems. Repair: Detailed step-by-step instructions for component removal, repair, and reassembly across all major vehicle systems. Diagnostics: Fault code interpretation (if applicable to EFI), system testing procedures. Rebuilds: Engine rebuild procedures, carburetor/throttle body overhaul, suspension component rebuilds. Technical Depth Depth: Comprehensive, covering from basic routine maintenance to complex engine and electrical system repairs and diagnostics. Suitable for professional technicians and experienced DIY mechanics. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Typically fully searchable text within the PDF for quick information retrieval. Print Quality: Designed for clear readability and printable pages. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled Engine Displacement 400: Approx. 400cc (specific bore/stroke varies) Engine Displacement 450: Approx. 450cc (specific bore/stroke varies) Engine Displacement 530: Approx. 530cc (specific bore/stroke varies) Valvetrain: SOHC (Single Overhead Camshaft), 4 valves per cylinder Performance Horsepower: Highly dependent on model and tuning, but typically in the 45-60 HP range for this era's 450/530 models. Torque: Dependent on displacement and tuning. Fuel System Induction: Electronic Fuel Injection (EFI) with Keihin throttle body, often 41mm or 42mm. Fuel Type: Unleaded gasoline, minimum 91 octane (RON+MON)/2 Lubrication Oil Type: High-quality synthetic motorcycle oil, typically SAE 10W-50 or 15W-50, meeting JASO MA/MA2 specifications. Oil Capacity: Approximately 1.0 - 1.2 liters (check manual for exact specification per model variant). 🔧 Transmission Standard Transmission Type: 6-speed manual sequential gearbox Optional Clutch Type: Hydraulically operated wet multi-disc clutch Features Gear Ratios: Specific ratios detailed within the manual for each model. Final Drive: Chain drive Transmission Fluid Fluid Type: Typically engine oil (shared sump in many KTMs of this era) or dedicated transmission oil depending on design specifics. Check manual. 📐 Dimensions Exterior Wheelbase: Varies by model, typically around 1470-1500 mm. Seat Height: Varies by model, generally high for off-road performance (e.g., 960-980 mm)....