This manual covers the 400 EXC, 450 EXC, and 530 EXC dual-sport/enduro motorcycles from the 2009 model year. These models are part of the LC4 engine platform, renowned for its robust torque and off-road prowess. Built in Austria, these motorcycles are designed for demanding terrains and offer exceptional performance and durability, making them a popular choice in the enduro community. This comprehensive factory service repair manual provides detailed information essential for maintaining and repairing your EXC motorcycle. It covers a wide array of systems, including the engine, fuel system, cooling system, clutch, brakes, suspension, electrical system, and more. With step-by-step procedures, troubleshooting guides, and technical specifications, this manual is an invaluable resource for owners and technicians seeking to ensure optimal performance and longevity of their vehicle. 🏷️ Basic Information Identification Make: KTM Model: 400 EXC, 450 EXC, 530 EXC Year: 2009 Vehicle Type: Dual-Sport / Enduro Motorcycle Generation Generation Identifier: 2008-2011 (LC4 Engine Platform) 👋 Introduction Market Position Target Audience: KTM 400/450/530 EXC owners, DIY mechanics, professional technicians Competitive Analysis Authenticity: Actual Genuine Repair Service Factory Manuals (Not 3rd party) Key Features Comprehensiveness: Complete official full factory service repair manual covering all styles Cost Savings: Potential to save $50-$60 per hour on labor costs Instructional Quality: Step-by-step guidance, secret techniques used by top mechanics 📋 Manual Details Coverage Areas Engine: 400cc, 450cc, 530cc LC4 Single-Cylinder Chassis: All models, all styles Page Count Estimated Pages: Hundreds (Actual count not specified, but described as 'complete') Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered General Information: Included Fuel System: Included Cooling System: Included Engine Top End: Included Clutch: Included Engine Lubrication System: Included Engine Removal Installation: Included Crankshaft Transmission: Included Wheels Tires: Included Final Drive: Included Brakes: Included Suspension: Included Steering: Included Frame: Included Electrical System: Included Appendix: Included Procedures Included Maintenance: Comprehensive, step-by-step Repair: Detailed diagnostic and repair procedures Troubleshooting: Advanced troubleshooting guide Tuning: Included Wiring Diagrams: Trace and verify Engine Management Systems: Understanding and analyzing different engine management systems covered Diagnostic Techniques: How to diagnose engine fault symptoms, test suspected parts using secret techniques Mechanic Communication: Guidance on how to instruct mechanics and verify their work Preventative Maintenance: Common tips for preventing problems before they escalate Technical Depth Depth: Complete factory level detail, from basic maintenance to full rebuilds 📊 Manual Specifications File Format Format: PDF Compatibility: Works under all PC based Windows operating systems and Mac Print Quality Quality: High resolution, printable Binding Type Type: Digital Download (Printable) Paper Type Type: Not Applicable (Digital) Software Requirements Reader: Adobe PDF Reader Usability Search Functionality: Searchable Printing Options: Print entire manual or select pages ⚙️ Engine Specifications Primary Engine Engine Type: LC4 Single-Cylinder, 4-stroke Displacement: 400cc, 450cc, 530cc (Specific models differ) Cooling: Liquid-cooled Fuel System Injection Type: Likely Keihin FCR or Mikuni carburetor (specific to model variant), or EFI in later models, though 2009 models are often carbureted. Manual will detail exact system. Performance Horsepower: Not specified, but generally in the 40-55 HP range depending on displacement. Torque: Not specified, but significant low-end and mid-range torque typical of LC4 engines. 🔧 Transmission Standard Type: 6-speed constant mesh Features Clutch Type: Wet multi-disc clutch (Hydraulic actuation) Fluid Requirements Type: Refer to manual for specific KTM specification oil (e.g., Motorex) 📐 Dimensions Exterior Wheelbase: Varies by model, typically around 1480 mm (58.3 in) Weights Dry Weight: Varies by model, typically around 115-125 kg (253-275 lbs) 🛡️ Safety Features Active Features Braking System: Hydraulic disc brakes (front and rear), typically Brembo calipers Passive Features Lighting: Headlight, taillight, turn signals (as per street legality) 💡 Technology Features Infotainment Display: Digital instrument cluster providing speed, RPM, odometer, trip meter, clock. Driver Assistance ABS: Not typically standard on off-road focused models of this era, but ABS may have been an option on some street-legal variants. Manual will confirm. Connectivity Features: Limited to basic electrical functions and diagnostics. No advanced connectivity features. 🔧 Maintenance Service Intervals Oil Change: Refer to manual for specific mileage/hour intervals, typically every 10-15 operating hours or 1000-1500 km. Valve Adjustment: Refer to manual for specific intervals, often around 5000-10000 km. Fluid Specifications Engine Oil: KTM recommends specific Motorex oils (e.g., 10W/50, 15W/50) or equivalent JASO MA certified oil. Manual will specify exact grade and capacity. Coolant: Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Manual will specify type and capacity. Brake Fluid: DOT 4 or DOT 5.1, depending on system specification. Manual will specify exact type. Known Issues Common Wear Items: Clutch plates, valve stem seals, cam chain tensioner, wheel bearings, chain and sprockets. Common Issues Starting Issues: Can sometimes be related to carburetor tuning, fuel delivery, or battery health. Manual provides diagnostic steps. Idle Instability: Often related to carburetor adjustment, air leaks, or fuel quality. Manual details proper tuning. 📚...