FE 450

01. Progressive performance

Engine

Advanced engineering techniques are used to build the engine to ensure maximum performance. It is then positioned in the frame to assist with the anti-squat behavior from the chassis, while also helping to centralize mass. Lightweight at just 63.9 lb (29 kg), the FC 450 engine is also easy to maintain thanks to the service markers on the cases.

Cylinder head

The SOHC cylinder head is incredibly compact and lightweight with the camshaft positioned as close to the centre of gravity as possible. A durable, fine-punched cam chain and Diamond-Like Carbon (DLC) coated rocker arm offer optimal efficiency and reliability with a single oil spray jet providing effective cooling. Valve timings are optimised for maximum torque and a smooth power delivery.

Cylinder and piston

The lightweight aluminium cylinder is an engineering masterpiece with a 95 mm bore and a stroke of 63.40 mm. Inside, the forged CP bridged-box-type piston features anodised annular grooves for added durability and extended service intervals. The compression ratio remains unchanged at 12.75:1.

Crankcases

Designed to be low in weight without sacrificing strength or reliability, the crankcases are made using a high-pressure die cast production process to create a thin-wall design. To centralise engine mass, the shaft arrangements are precisely positioned to harness rotating masses at the ideal centre of gravity.

Throttle body

The FE 450 features a 42 mm Keihin throttle body optimised for throttle response. The injector is positioned to ensure the most efficient flow into the combustion chamber with the throttle cable mounted directly without a linkage for an enhanced response.

Exhaust

The exhaust system is expertly designed to deliver class-leading performance at the lowest possible weight with the header pipe manufactured in two pieces. This design allows the header pipe to be removed without having to remove the rear shock. Further innovation allows for a short, compact silencer without increasing sound levels. The silencer is crafted from lightweight aluminium and stylishly finished with a black coating to highlight its premium quality.

Engine

Cylinder head

Cylinder and piston

Crankcases

Throttle body

Exhaust

02. State-of-the-art chassis

Frame

With an optimised distribution of material around the steering head and upper shock mount, the frame delivers confidence-inspiring handling and assured stability when entering corners. To complement the overall look of the machine, the chromium molybdenum chassis is finished with a premium, metallic blue powder coating. The finishing touches are the frame protectors, which not only protect the paintwork, but also provide riders with additional grip, even in the toughest conditions.

Hybrid subframe

Made from 60% polyamide and 40% aluminum, the subframe offers exceptional strength and durability at a low overall weight of just 3.9 lb (1.8 kg). The lower subframe spars and frame mounts are manufactured from cast aluminum for reliability with the upper section made from injection-molded polyamide to enable specific flex characteristics.

Swingarm

The swingarm is manufactured using a die-cast production process and designed with a calculated level of rigidity. To further complement and optimise the flex characteristics of the chassis, a 22 mm rear wheel axle is utilised. A durable chain slider is neatly integrated into the swingarm, ensuring uninterrupted forward momentum through deeply rutted corners.

Bodywork

The ergonomic bodywork was designed to ensure that riders can perform at their best throughout every race. This was achieved through extensive testing, with the smooth contact points in the rider triangle allowing racers to grip the machine tightly with their legs, reducing fatigue. The radiator shrouds, featuring in-mould graphics, contribute to the progressive appearance of the machine, while a tall, wide seat offers unrestricted movement. A high-grip seat cover also helps keep riders securely in place under hard acceleration.

Fueltank

A 2.1 gallon (8.0 liter) fuel tank integrates neatly with the ergonomic bodywork and features a robust rubber cushion beneath it to hold the tank in place and protect the frame from wear. The one-piece fuel pump design and integrated filter allows the tank to be emptied further, which is particularly beneficial during longer events. For durability, the external fuel line is specifically routed to make it less exposed and susceptible to damage.

Frame

Hybrid subframe

Swingarm

Bodywork

Fueltank

03. Innovative advantage

WP XACT front forks

Designed and developed for the rigours of enduro riding, the WP XACT Closed Cartridge spring forks offer consistent damping thanks to their innovative design. Inside each fork leg, lightweight springs with a polished finish enhance performance, while mid-valve pistons optimise oil flow to prevent foaming. A one-piece hydrostop, effective in the last 68 mm of travel, is highly advantageous when landing heavily as it helps to maintain forward momentum. Additionally, riders can alter the compression and rebound settings quickly and easily using the tool-free adjusters found at the top and bottom of each fork leg.

WP XACT rear shock

The WP XACT rear shock features a Computational Fluid Dynamics (CFD) optimised main piston, ensuring superior initial comfort and predictable performance in all conditions. To give riders the option of creating a personalised set-up, rebound, as well as the high and low-speed compression settings, can all be adjusted easily by hand.

Hydraulic brakes

The highest level of performance is guaranteed with the latest Brembo braking systems which are specifically designed for enduro riding. New callipers, new brake pads, new levers, and new brake lines together with the GSK wave discs (260 mm disc front and 220 mm rear) result in a sensitive and progressive feel ensuring enhanced control in all conditions.

Hydraulic clutch

The new, high-performance Brembo hydraulic clutch system delivers even wear, near maintenance-free operation, and perfect feel in every condition. With this hydraulic system, free play is constantly compensated so that the pressure point, and the function of the clutch, remain identical in cold or hot conditions, as well as over time. Countless hours of testing have proven the reliability of the high-quality, Italian-made Brembo hydraulic system.

Wheels and tires

CNC-machined hubs, strong spokes, and high-strength, black-anodized alloy rims are used to assemble the wheels. They are fitted with versatile Dunlop AT82 tires. The front ensures precise cornering, while the rear provides excellent traction across varied terrain.

Cooling system

Manufactured from high-strength aluminum, the radiators are engineered using Computational Fluid Dynamics (CFD). The design channels air efficiently through the radiators, with a fan fitted as standard to maintain engine performance in extreme conditions. A large center tube routed through the frame reduces pressure at this point in the system, ensuring consistent coolant flow, while an internal thermostat further improves reliability. A new threaded radiator cap allows for easy inspection of the coolant level before each ride.

Triple clamps

The black-anodized, CNC-machined triple clamps offer premium quality as standard. They have a carefully calculated 22 mm offset and are expertly crafted using superior techniques and materials for the highest levels of quality and reliability. The handlebar clamp has a large contact surface with the ProTaper bars to help prevent twisting in the event of an impact and offers two mounting options for customizable ergonomics.

WP XACT front forks

WP XACT rear shock

Hydraulic brakes

Hydraulic clutch

Wheels and tires

Cooling system

Triple clamps

04. Technology advanced

LED headlight

The LED headlight provides a remarkably bright light output for excellent visibility at night and is particularly effective when riding through dense woodland. A clever mounting design sees the LED lighting unit fitted inside the headlight mask using a quick-release system that allows it to be replaced quickly and easily if damaged.

Map Select Switch

Designed for easy operation, the Map Select Switch allows riders to easily choose between two EFI maps, activates Traction Control, and engages the Quickshifter. Traction Control can be switched on or off via the Map Select Switch and functions by analysing throttle input from the rider and the rate at which the engine RPM increases. If the RPM increases too quickly, the EMS registers a loss of grip and reduces the amount of power to the rear wheel, ensuring maximum traction. The Quickshifter can also be engaged using the same Map Select Switch and offers seamless upshifts under heavy load.

Quickshift

The Quickshifter can be activated or deactivated via the Map Select Switch. By interrupting the ignition for a fraction of a second, this allows upshifting while the throttle is fully open without the use of the clutch. The Quickshifter is only active from second gear upwards.

Electric start

The proven electric start system uses a compact and lightweight Li-Ion battery, which is 2.2 lb (1 kg) lighter than a conventional battery. With several years of experience in developing and perfecting electric starting, the reliability of the electric start is second to none and ensures a quick and easy starting in any situation. Additionally, the wiring harness and electrical components are safely located below the seat for easy accessibility.

Footrest

Using state-of-the-art computational fluid dynamics, the large footrests are designed for maximum control and to prevent mud from building up. Additionally, the mounting position brings them inwards, which makes them less susceptible to catching on the ground through deep ruts.