450 EXC 2009

Once a champion, always a champion. If one bike in the hard-fought E2 class has until now had what it takes to be the series winner, then that bike is the 450 EXC. And so it should stay! Ultra-modern technology is used both in the chassis and also in the ultra-powerful SOHC engine, which further perfects one of the most successful of off-road bikes.

The result is an extremely light, agile and immensely powerful high-tech race bike which once again raises the bar a whole step higher for the opposition.

CHASSIS



FRAME

Sturdy, oversized, oval lateral tubes make the chromemoly EXC frame one of the most stable and lightweight designs on the market. Tough lateral plastic frame guards now efficiently protect the high-quality powder coating. The Subframe with broad profiles is made from high-quality aluminium and guarantees optimum stability at minimum weight.



SWINGARM

The ultralight cast aluminium swingarm with directly connected PDS shock absorber ensures optimum flexibility, and hence enormous traction and comfort.



FORKS

The new 48 mm upside-down forks from WP offer new iner and outer tubes for more homogeneous flexibility, a completely new cartridge unit and an optimized bearing seat for the sliding bush. All that, together with a modified seting for improved response, provides significantly greater comfort and greater damping reserves. Adjustable rebound and compression damping as well as the spring preload, the forks with the new star - shaped adjustment knobs for the rebound damping can be adapted even easier to the course and rider.



PDS SHOCK

The overhauled WP PDS shock absorber with stronger PDS nedle and optimised design of the second piston impresses with its more comfortable damping properties. With a variable rebound damping setting and adjustable high-speed and low-speed compression damping, it can be optimally adapted to different course conditions.



BRAKES

KTM and Brembo set the standards when it comes to brakes. Up front, a floating two-piston brake calliper and at the rear, a single-piston brake calliper grip the ultralight wave-shaped brake discs.



COOLING SYSTEM

The integrated cooling system leads from the cylinder head through the frame triangle and via a T-piece straight to the coolers. That means a simplified radiator installation, better air circulation and more space under the fuel tank.



HANDLEBARS

The tapered Neken handlebar of high-quality aluminium has four different positions, so it can be adjusted to fit the rider.



EXHAUST

In conjunction with its cleverly devised inner workings, the design of the aluminium silencer not only looks good; it also ensures optimum performance at a minimum weight and very low sound level.



BODYWORK

The cool bodywork offers optimum ergonomics and a trendsetting appearance. The 2-component technology for the headlight mask, chainguard and front fender ensures both a top quality appearance and optimum rigidity.



FUEL TANK

The tank layout was designed for optimum ergonomics and the best knee contact. The ducts under the spoilers form part of the KTM Airflow system with which fresh air is guided to the airbox via openings in the spoilers.



FUEL TANK CAP

The fuel tank cap with bayonet fitting and new noreturn valve has an additional twist lock, to prevent unintentional opening, that can be easily unlocked by pressing the orange inner segment.



SEAT

A new seat now has an optimised foam core for improved comfort and even longer service life. In addition, the weight was reduced by 150 grams.



REAR FENDER

A lightweight and extremely durable LED taillight is installed in the modern mono-fender, which can withstand even the rigours of competition. An add-on number plate bracket with license number llumination and indicators can be easily removed for sport and competition.



AIR BOX

The large volume ensures a whole lot of power, while the external contours offer you optimum knee contact. The easy, tool-free accessibility to the Twin-Air air filter makes changing the filter child’s play.



SPOILER

The new spoilers reduce the width at the front end by more than 10 mm to enhance ergonomics. The INMOULD technology guarantees optimum durability for the newly integrate d graphics. The spoiler openings at the front serve as air outlets for the coolers and fresh air is drawn into the airbox through the openings at the rear.



ENGINE



OVERVIEW

The KTM four-strokes have dominated the offroad scene in the E2 and E3 classes for years. The new SOHC engine family has also made a successful appearance on the scene and has now been expanded to include a further member with the new 400cc engine. The modern engine concept with a single overhead cam was specially developed for Enduro sport and impresses in particular with its strong, linear power development and excellent fatigue strength. The 400 cc engine also stands out with its extremely gentle and energy-sparing engine characteristics. It differs from its bigger brothers with a shorter stroke, a new camshaft and an optimized ignition map.



CYLINDER HEAD

An single overhead camshaft operates the four valves (incl. titanium intake valves) using new weight reduced rocker arms and also serves as a centrifuge for the engine ventilation. An optimised auto-decompresion system enhances the starting behaviour. The magnesium cylinder head cover mounted at an angle makes adjustment of the valves child‘s play.



CRANKSHAFT

The compact crankshaft designed for maximum rigidity actuates a very light forged piston. This also powers a balancer shaft; its weights are laterally mounted outside the crank space, which reduces the churning losses.



OIL CIRCUIT

The sensitive performance elements are protected from aggressive clutch abrasion and dirt, thanks to the two separate lubrication circuits – one for the combustion tract and one for the gearbox and clutch.



CARBURETTOR

All EXC four-stroke models breathe via 39 mm Keihin throttle slide carburettors that, with their accelerator pump and slide potentiometer, ensure spontaneous acceleration and optimum performance. An optimised cold start seting now improves starting, particularly at low temperatures.



CLUTCH

The clutch with integrated torque cushion now has an optimised disc packa ge that is supplied with more oil via additional bores in the outer clutch hub. This allows the temperature, and hence the wear, to be reduced under extreme loads. The controllability of the clutch sets the standard, thanks not least to the Brembo hydraulic clutch system.



IGNITION

An optimised ignition curve and a new spark plug improve combustion and ensure even better ridability, particularly at low revs.



ENGINE COVERS

Optimised coating with a new colour and new logo not only looks cool, it also offers improved protection against rocks and rough offroad boots.