KTM 450 EXC XC-W 2008-2011 Service Repair Manual

Precio habitual: $16.99
Precio de venta: $16.99
Precio habitual
Precio unitario: por

22 people are viewing this right now

Tipo: Motorcycle

Proveedor:

SKU: 94214

Etiquetas: 2008 2009 2010 2011 450 EXC 450 XC-W KTM Misc Motorcycle Motorcycles

Variantes de producto

Descripción

This manual covers the 450 EXC and 450 XC-W models produced between 2008 and 2011. These high-performance, liquid-cooled, single-cylinder motorcycles are engineered for demanding off-road competition and enthusiast riding. Renowned for their potent 449.3 cc engines producing over 50 horsepower, robust build quality, and advanced suspension systems, including USD front forks and PDS rear shocks, these models represent dedication to off-road excellence. Their lightweight construction, estimated at 114 kg dry weight, combined with substantial ground clearance and a 9-liter fuel tank, makes them ideal for tackling challenging terrain and long-distance off-road adventures. This comprehensive Service and Repair Manual in English provides detailed guidance for the maintenance, repair, and troubleshooting of your 450 EXC or XC-W. It covers complete engine overhaul, fuel system maintenance including the Keihin FCR carburetor, ignition system diagnosis, cooling system service, transmission and clutch procedures, suspension component rebuilding, and brake system servicing. Additionally, the manual includes routine maintenance schedules, troubleshooting guides for common issues, component rebuilding instructions, suspension tuning advice, precise torque specifications, and detailed electrical wiring diagrams. This resource is essential for owners and technicians seeking to maintain the optimal performance and longevity of these specialized off-road motorcycles.

🏷️ Basic Information

Identification

Make:

Model:

450 XC-W

Production Years Covered:

2008, 2009, 2010, 2011

👋 Introduction

Market Position

Motorcycle Segment:

Enduro / Off-Road Competition

Target Audience:

Enthusiast riders, off-road racers, and professional mechanics working on KTM EXC and XC-W models.

Competitive Analysis

Key Competitors:

Yamaha WR450F, Honda CRF450X, Husqvarna WR450, Suzuki RM-Z450 (off-road variants).

Key Features

Manual Utility:

Provides comprehensive guidance for maintenance, repair, and troubleshooting, essential for keeping these high-performance machines in optimal condition.

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Manual

Language:

English

Format:

📖 Manual Coverage

Systems Covered

Engine Overhaul:

Complete engine disassembly, inspection, repair, and reassembly procedures for the 450cc single-cylinder engine.

Fuel System:

Carburetor (Keihin FCR) tuning, cleaning, and rebuilding; fuel pump and filter service.

Ignition System:

CDI unit testing, spark plug specifications, coil and wiring diagnosis.

Cooling System:

Radiator maintenance, coolant type and capacity, water pump service, fan operation.

Transmission And Clutch:

Gearbox disassembly, inspection, and reassembly; clutch operation, adjustment, and replacement procedures.

Suspension Front:

WP USD (Upside Down) fork service, oil type and level, seal replacement, adjustment procedures.

Suspension Rear:

WP PDS (Progressive Damping System) shock absorber service, nitrogen charging, seal head replacement, linkage bearing service.

Brake System:

Hydraulic brake system bleeding, caliper service, master cylinder overhaul, pad replacement, rotor specifications.

Electrical System:

Wiring diagrams, starter system troubleshooting, lighting circuits, battery maintenance, fuse specifications.

Frame And Bodywork:

Frame inspection, subframe mounting, plastics removal and installation, seat and tank procedures.

Wheels And Tires:

Hub maintenance, spoke tensioning, wheel bearing replacement, tire pressure recommendations, rim lock installation.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter cleaning, chain lubrication and adjustment, spark plug replacement.

Troubleshooting Guides:

Diagnostic charts for common starting, running, and electrical issues.

Component Rebuilding:

Detailed instructions for rebuilding engine components, carburetors, and suspension units.

Suspension Tuning:

Guidance on adjusting suspension settings for various riding conditions and rider weights.

Torque Specifications:

Precise torque values for all critical fasteners throughout the motorcycle.

Special Tools:

Identification and usage of specific tools required for certain procedures.

Technical Depth

Diagnostic Capability:

Advanced diagnostic procedures for electrical and mechanical systems.

Rebuild Level:

Comprehensive engine and component rebuild procedures suitable for experienced mechanics and serious enthusiasts.

Wiring Diagrams:

Detailed and accurate electrical wiring schematics for all model variations.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Searchable text for quick information retrieval.

Printability:

Printable pages for use in a workshop environment.

Print Quality

Image Resolution:

High-resolution images and diagrams ensuring clarity.

Binding Type

Digital Format:

Not applicable (digital PDF)

Paper Type

Digital Format:

Not applicable (digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, single-cylinder, liquid-cooled

Displacement:

449.3 cc

Bore X Stroke:

97 mm x 60.8 mm

Compression Ratio:

Approximately 12.5:1 (varies slightly by year/model)

Performance

Horsepower Approx:

50+ HP (at crank, varies by tuning)

Torque Approx:

45+ Nm (at crank, varies by tuning)

Fuel System

Carburetor Model:

Keihin FCR MX 39

Fuel Type:

Unleaded gasoline, minimum 95 octane (RON)

Lubrication System

Oil Type:

KTM recommends Motorex Power Synt 4T 10W/50 (or equivalent JASO MA approved motorcycle oil)

Oil Capacity Engine Transmission:

1.1 Liters (for engine and transmission combined, dry fill)

🔧 Transmission

Standard

Type:

6-speed, claw-shifted

Clutch Type:

Wet multi-disc clutch, hydraulically operated (Magura)

Features

Gear Ratios:

Specific gear ratios are detailed within the manual, essential for performance tuning.

Fluid Specification

Transmission Oil Type:

Same as engine oil: Motorex Power Synt 4T 10W/50 or equivalent.

📐 Dimensions

Exterior

Seat Height Approx:

970 mm (38.2 inches)

Ground Clearance Approx:

355 mm (14 inches)

Weights

Dry Weight Approx:

114 kg (251 lbs)

Fuel Tank Capacity:

9 Liters (2.38 US gallons)

🛡️ Safety Features

Ratings

Off Road Design:

Designed for off-road competition and recreational use; not street-legal in many configurations without modifications and proper registration.

Active Features

Braking System:

High-performance Brembo hydraulic disc brakes front and rear for superior stopping power.

Passive Features

Frame Construction:

Chromium-molybdenum steel central tube frame for strength and rigidity.

💡 Technology Features

Infotainment

Instrument Cluster:

Digital multifunction meter displaying speed, RPM, trip meters, and other essential information. Specific diagnostic codes can be accessed.

Driver Assistance

Ignition System:

Advanced CDI ignition system for precise fuel and spark timing.

Connectivity

Diagnostic Ports:

While not a modern OBD-II system, basic diagnostic capabilities through wire bridging or specialized KTM tools are sometimes applicable; manual may hint at this.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 10-15 hours of riding, or as recommended in the manual for specific conditions.

Air Filter Cleaning:

After every ride, or more frequently in dusty conditions.

Chain Lubrication Adjustment:

Every 500 km (300 miles) or as needed.

Valve Clearance Check:

Every 20-30 hours of riding (requires detailed inspection).

Fluid Specifications

Coolant Type:

KTM recommends Motorex Coolant M5.0 or equivalent propylene glycol-based coolant.

Brake Fluid Type:

DOT 4

Fork Oil Type:

KTM recommends WP Suspension Fluid (e.g., WP Suspension Fluid 4W or 5W depending on desired damping characteristics). Specific oil level is critical and detailed in the manual.

Known Issues

Clutch Slave Cylinder Seal:

Potential for seal leakage over time, requiring replacement. Manual provides seal kit P/N and replacement procedure.

Carburetor Jetting:

Stock jetting may require adjustment based on altitude and riding conditions. Manual provides baseline jetting and tuning guidance.

Suspension Maintenance:

Regular fork oil and seal maintenance is crucial for optimal performance and longevity. Manual outlines the process.

📚 Vehicle History

Brand Heritage

Ktm Legacy:

KTM has a long and successful history in off-road racing, particularly in enduro and motocross, renowned for its performance-oriented motorcycles.

Model Evolution

Exc Xcw Lineage:

The EXC and XC-W lines represent KTM's dedication to creating potent and capable off-road machines, evolving with advancements in engine technology, suspension, and chassis design.

Production

Manufacturing Location:

Austria (primarily)

🏆 Awards & Recognition

Recognitions

Off Road Performance:

KTM 450 EXC and XC-W models have consistently received accolades and championships in various off-road racing disciplines, attesting to their performance and reliability.