KTM 450 XC-W 2009 Service Repair Manual

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UGS: 94218

Mots clés: 2009 450 XC-W KTM Misc Motorcycle Motorcycles

Variantes de produits

Description

The 450 XC-W, produced in 2009, is a performance-oriented off-road motorcycle engineered for competition enduro and cross-country events. As part of a esteemed lineage, known for its motorsport prowess, this model embodies a potent 449.3 cc single-cylinder, 4-stroke engine, delivering robust power and torque suitable for demanding terrains. Its design prioritizes agility and durability, featuring a chromium-molybdenum steel trellis frame and advanced suspension components, making it a direct competitor in the high-performance off-road segment. This comprehensive Service Repair Manual provides detailed information for the maintenance, troubleshooting, and repair of your 2009 450 XC-W. It covers all essential systems, including the engine, transmission, fuel system, ignition, electrical components, suspension, and brakes, offering step-by-step instructions, torque specifications, and wiring diagrams. The manual is designed to assist owners, mechanics, and technicians in performing everything from routine service and part replacement to complete engine and chassis rebuilds, ensuring optimal performance and longevity of the vehicle.

🏷️ Basic Information

Identification

Make:

Model:

450 XC-W

Year:

Codes

Engine Family:

Chassis Code Indicator:

👋 Introduction

Market Position

Segment:

Competition Enduro / Off-Road

Target User:

Enthusiast riders, mechanics, and owners requiring in-depth service information

Competitive Analysis

Comparison:

Direct competitor to Yamaha WR450F, Honda CRF450X, Kawasaki KX450F (off-road variants)

Key Features

Vehicle Focus:

Performance-oriented off-road machine with a potent 450cc engine

Manual Advantage:

Provides the detailed technical knowledge needed to maintain and repair this high-performance off-road motorcycle effectively.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service and Repair

Secondary Coverage:

Maintenance, Troubleshooting, Diagnostics

Page Count

Estimated Pages:

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Full Engine Overhaul, Internal Components, Cooling System, Lubrication System

Transmission:

Clutch, Gearbox Internals, Shifting Mechanism, Lubrication

Fuel System:

Carburetor Tuning and Rebuild (Keihin FCR), Fuel Pump, Fuel Lines

Ignition System:

CDI Unit, Spark Plug, Ignition Coil, Wiring Diagrams

Electrical System:

Lighting, Battery, Charging System, Starter Motor, Wiring Schematics

Suspension:

Front Fork (WP Suspension), Rear Shock Absorber (WP Suspension), Seals, Bushings, Valving

Brakes:

Front and Rear Calipers, Master Cylinders, Brake Lines, Bleeding Procedures

Cooling System:

Radiator, Cooling Fan, Coolant Types and Capacities

Frame And Bodywork:

Frame Inspection, Seat, Fenders, Plastics, Graphics

Wheel And Tire:

Wheel bearing replacement, spoke tensioning, tire fitting and balancing.

Procedures Included

Maintenance:

Oil Change Intervals, Air Filter Cleaning/Replacement, Spark Plug Replacement, Chain Adjustment

Repair:

Engine Rebuild, Transmission Overhaul, Suspension Servicing, Brake System Repair

Troubleshooting:

Diagnosis of Common Problems, Fault Finding Charts

Diagnostics:

Electrical System Testing, Carburetor Adjustment

Wiring Diagrams:

Complete electrical system wiring diagrams included for troubleshooting and repair.

Torque Specifications:

Detailed torque specifications for all critical fasteners and components.

Technical Depth

Depth:

Comprehensive from routine maintenance to complete engine and chassis rebuilds

Detail Level:

Detailed step-by-step instructions with torque specifications and diagrams

Rebuild Procedures:

Includes procedures for complete engine teardown and reassembly, gearbox rebuilding, and suspension damper servicing.

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text for quick information retrieval

Print Quality:

High-resolution, suitable for printing

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Type:

Single Cylinder, 4-Stroke, Liquid-Cooled, SOHC

Displacement:

449.3 cc

Bore X Stroke:

97.0 mm x 60.8 mm

Compression Ratio:

11.8:1

Performance

Horsepower Estimate:

Approx. 50-55 HP (factory figures may vary)

Torque Estimate:

Approx. 45-50 Nm (factory figures may vary)

Fuel System

Carburetor:

Keihin FCR 41 MX with accelerator pump

Fuel Type:

Unleaded Gasoline (95 RON recommended)

Cooling System

Type:

Liquid Cooling

Lubrication System

Type:

Dry Sump Lubrication

Engine Oil

Capacity:

1.2 Liters (with filter change)

Specification:

SAE 10W-50, API SG or higher, JASO MA

🔧 Transmission

Standard

Type:

6-Speed Constant Mesh

Features

Clutch:

Hydraulically Operated Wet Multi-Plate Clutch

Final Drive:

O-ring sealed chain, 520 pitch

📐 Dimensions

Exterior

Length:

Approx. 2190 mm (86.2 in)

Width:

Approx. 815 mm (32.1 in)

Height:

Approx. 1240 mm (48.8 in)

Weights

Dry Weight:

Approx. 113.5 kg (250.2 lbs)

Fuel Tank Capacity:

9.5 Liters (2.5 US gal)

Chassis

Frame Type:

Chromium-molybdenum steel trellis frame

🛡️ Safety Features

Ratings

Crash Safety:

Not Applicable (Off-road Competition Vehicle)

Active Features

Brakes:

Disc Brakes (Front and Rear), Radial Calipers

Passive Features

Protection:

Handguards, Skid Plate (typically aftermarket or optional)

💡 Technology Features

Infotainment

Features:

None (Pure Off-Road focus)

Driver Assistance

Features:

None (Pure Off-Road focus)

Connectivity

Features:

None (Pure Off-Road focus)

Instrumentation

Features:

Digital display for hour meter, speedometer, odometer, trip meter, and basic warning lights.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 15-20 hours of operation or annually

Air Filter Cleaning:

Every 5-10 hours of operation, or more frequently in dusty conditions

Spark Plug Inspection:

Every 20-30 hours of operation

Valve Clearance Check:

Every 30-40 hours of operation

Fluid Specifications

Coolant:

Pre-mixed 50/50 ethylene glycol based coolant

Brake Fluid:

DOT 4

Clutch Fluid:

DOT 4

Known Issues

Common Wear Items:

Clutch plates, chain and sprockets, wheel bearings, fork seals

Potential Problems:

Carburetor jetting sensitivity to altitude and temperature, occasional starter motor issues (depending on usage)

Filter Part Numbers

Oil Filter:

KTM Part Number: 0005000100

Air Filter:

KTM Part Number: 78106003000

📚 Vehicle History

Brand Heritage

Focus:

KTM has a long and successful history in off-road racing and motorsport, known for performance-oriented motorcycles.

Model Evolution

Lineage:

The XC-W series is KTM's dedicated off-road competition line, evolving from earlier EXC models, emphasizing pure performance for enduro and cross-country events.

Production

Location:

Austria (KTM AG)

🏆 Awards & Recognition

Recognitions

Off Road Performance:

KTM motorcycles, including the XC-W line, have consistently been top performers and winners in various off-road racing disciplines and championships.

Ratings

Industry Perception:

Highly regarded for robust performance, durable engines (when properly maintained), and competitive chassis dynamics in the off-road market.