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February 5th, 2020, 11:07 AM   #1
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Joined: Jan 2020
From: Tucson, AZ

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I Ride:
my 09 FE450

So like in a previous post, I acquired a '09 FE450. I am doing this post sorta to keep track of things and if anyone notices me doing something stupid, to try and stop me !

The bike has 150-ish hours on it and the ODO reads 3305. The PO added the rear sub-frame tank but never completed the install, did not connect the 2 tanks. The blue plastics are pretty weathered and there are some wiring rat's nests.

I checked the valves, and they were in spec, but on the loose side. Left them there as they tend to tighten, right? Also did the general maintenance items. The bike is currently I pieces as I am waiting on parts to get the wiring sorted and adding the bits needed to ride on the road, blinkers, license plate light, etc.
The KTM dealer close to my work has been super helpful in finding parts and a friend in Germany got me new blue plastics.

Here are some pics.

Oh, mod's please move this if I posted in the wrong area!
Attached Thumbnails
my 09 FE450-20200122_073939.jpg   my 09 FE450-20200131_080307.jpg  
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February 5th, 2020, 01:26 PM   #2
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Joined: Jan 2020
From: Carib

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I Ride: 2010 FX 450
Originally Posted by bokbfok View Post
So like in a previous post, I acquired a '09 FE450. I am doing this post sorta to keep track of things and if anyone notices me doing something stupid, to try and stop me !

The bike has 150-ish hours on it and the ODO reads 3305. The PO added the rear sub-frame tank but never completed the install, did not connect the 2 tanks. The blue plastics are pretty weathered and there are some wiring rat's nests.

I checked the valves, and they were in spec, but on the loose side. Left them there as they tend to tighten, right? Also did the general maintenance items. The bike is currently I pieces as I am waiting on parts to get the wiring sorted and adding the bits needed to ride on the road, blinkers, license plate light, etc.
The KTM dealer close to my work has been super helpful in finding parts and a friend in Germany got me new blue plastics.

Here are some pics.

Oh, mod's please move this if I posted in the wrong area!
Awesome, I too recently picked up a 2010 FE 450, my first motorcycle. I'll definitely be following along your build.
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February 5th, 2020, 01:30 PM   #3
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Joined: Jan 2020
From: Carib

Posts: 22
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I Ride: 2010 FX 450
And thinking about it now your bike seems to be in much better condition :'(
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February 8th, 2020, 01:04 AM   #4
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Joined: Mar 2017
From: TN

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I Ride: '08 Burg FE650,'98 BMWK1200RS, Ducati 619,999,'86 Honda CB700 Nighthawk, '72 Yamaha AT2-125,CT2-175
450 Refubish

I'll be following too. Have a 09 450. abit on the tired side. Would like to add lighting to it. If you have info. for lighting, let me know. Be watching. DJ
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February 10th, 2020, 02:48 AM   #5
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Joined: Nov 2012
From: Sweden

Posts: 599
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I Ride: HB 570 FE
You may want to check the swing arm bearings, as its a weak point.
Check for play, or you may even want to change the bearings anyhow, at least disassemble and grease them up good. If you let them go too long the swing arm will be deformed. I bought mine with swingarm deformed, not an easy fix.
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February 10th, 2020, 03:53 PM   #6
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Joined: Sep 2006
From: Henderson NV

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I Ride: Huskies, KTMs, Berg, and Kaws
Nice find. Will be a fun build. I recently got an 09 FE450 with 50 hours and 1100 miles. I dont think it ever really saw dirt. I see why so many like the 70 deg bikes as dualsport or semi adventure bikes. Comfortable and does just about everything well.
I am looking for a 570 now also. May wait and really hone in on a 2011 thats DOT legal.
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February 13th, 2020, 09:16 AM   #7
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From: Tucson, AZ

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Originally Posted by Phoenix250 View Post
I'll be following too. Have a 09 450. abit on the tired side. Would like to add lighting to it. If you have info. for lighting, let me know. Be watching. DJ
From what I have found the bike has the wiring in it for running lights and the brake switches, which you have to add. I replaced the dash shroud to include a flasher indicator light and high beam indicator light. I will be making my own flasher harness and will be adding a LED flashing unit for led flashers. I found an all in one rear light. Stop, running, license plate and flashes in one unit and will be using hand guard with build in flashers up front. The PO had a handle bar switch unit for operating all the lights and horn so I will just use that. I am also contemplating adding a keyed kill stitch just to make it a tad bit more undesirable to steal.
I will update this as I go along.
Thanks from westerstroming
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March 1st, 2020, 09:44 PM   #8
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From: Carib

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I Ride: 2010 FX 450
any updates?
BusaHusa is offline  
March 2nd, 2020, 11:37 AM   #9
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From: Tucson, AZ

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I Ride:
Sorry, I have been slacking off!

So like I mentioned before, I got an all in one unit for the rear and mounted that up. It sits a bit further back that the factory light as it is bigger. Does not look bad. I have that connecting to the main harness by the battery and have automotive connector if I ever have to disconnect for service. I ran a new harness for the flashers from the battery to behind the front mask. The handle bar switch is from Tusk, I think. Opened that up to figure out the wiring. The switch had the corresponding connector that connects to the main harness behind the mask but the PO made a hack of it. I bought some molex pins and did the re-wiring. I cleaned up the wiring on the front mask and also added a connector for removal if needed. I installed the flasher unit to the harness connector plate and it tucked right in. I mostly followed the wiring diagram that I found on this forum, so that helped a lot!. I did however change all the info(dash) light bulbs to LED so the flasher light had to be wired differently. I got the Tusk hand guards and also got the LED flasher units that go into the hand guards. Had to cut my own slots in the plastic part of the guards as I wanted white and they only have black guards. I wrapped it all up this weekend and all worked except the rear brakes. The brake switch that came with the bike failed, so will get one tomorrow.

I will post some pics later.
Some links:
Rear light
https://www.amazon.com/dp/B0185P9UFC..._52wxEbD4V785W

Flasher unit:
https://www.amazon.com/dp/B00RM26LXO..._G3wxEbMNC1VFB

Guards:
https://www.rockymountainatvmc.com/p...ds-p?s=1157963

LED hand guard lights:.
https://www.rockymountainatvmc.com/p...nal-p?s=213912
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