Segment:
Competition/Off-road Enduro
Target User:
Enthusiasts, mechanics, and service technicians working on KTM 450 XC-W motorcycles.
Key Competitors 2009:
Yamaha WR450F, Honda CRF450X, Husqvarna WR450, Suzuki RM-Z450 (converted for off-road use).
Vehicle Focus:
High-performance off-road motorcycle designed for competitive enduro riding.
Manual Benefit:
Provides the official, factory-level technical information necessary for maintaining and repairing the vehicle.
Primary Coverage:
Complete workshop service and repair for KTM 450 XC-W 2009
Technical Depth:
Comprehensive: from basic maintenance to full engine rebuilds and troubleshooting.
Estimated Pages:
Hundreds (as stated in description)
Type:
Workshop Service Repair Manual
Language:
Likely English (standard for official KTM manuals, though other languages might exist)
Engine:
Complete disassembly, assembly, timing, lubrication, cooling system, fuel system (carburetion), ignition system, exhaust system.
Transmission:
Gearbox operation, removal, installation, clutch operation, maintenance, and adjustment.
Chassis:
Frame, subframe, steering head, suspension (forks, shock absorber), swingarm, wheel bearings.
Brakes:
Hydraulic brake system (front and rear calipers, master cylinders, lines, fluid replacement, bleeding).
Electrical:
Wiring diagrams, lighting, ignition system components, charging system (stator, regulator/rectifier), battery, starter motor, instrumentation.
Fuel System:
Carburetor identification, disassembly, cleaning, adjustment, fuel tank, fuel pump (if applicable), fuel lines.
Cooling System:
Radiator, hoses, coolant specifications, bleeding procedures, fan operation (if equipped).
Bodywork:
Fairings, seat, fuel tank cover, fenders, skid plate removal and installation.
Maintenance:
Regular service intervals, oil changes, filter replacements, chain adjustment, spark plug replacement, valve clearance checks.
Troubleshooting:
Diagnostic flowcharts for common issues (starting problems, poor performance, electrical faults).
Repair:
Step-by-step instructions for component removal, overhaul, and reassembly.
Specifications:
Torque specifications for all fasteners, clearance measurements, fluid capacities.
Diagnostics:
Detailed diagnostic procedures, including fault finding for electrical and mechanical systems.
Rebuilds:
Complete engine and transmission rebuild procedures with detailed component illustrations.
Format Type:
PDF (Portable Document Format)
Searchable Text:
Typically yes, for PDF documents of this nature, allowing easy keyword searches.
Printability:
Designed to be printable, allowing users to select and print specific pages or the entire manual.
Binding:
Not applicable for digital PDF download, but if printed, typically spiral or comb binding for workshop use.
Paper Quality:
Not applicable for digital PDF download, but original manuals are usually on durable, gloss-coated paper.
Engine Type:
LC4, Single-cylinder, 4-stroke, liquid-cooled, DOHC
Displacement:
Approximately 449.3 cc
Bore X Stroke:
Typically around 97.0 mm x 60.8 mm
Horsepower:
Estimated 40-50 HP (specific dyno results vary)
Torque:
Estimated 40-45 Nm (specific dyno results vary)
Carburetor Model:
Keihin FCR MX 39 (common for this model)
Fuel Type:
Unleaded gasoline, minimum 95 RON
Ignition System:
Digital CDI, dual ignition
Oil Capacity Engine Only:
Approx. 0.8 Liters (check manual for exact figure and procedure)
Oil Capacity Total:
Approx. 1.1 Liters (engine + gearbox/clutch, check manual)
Transmission Type:
Constant mesh, 6-speed
Clutch Type:
Hydraulically operated multi-disc wet clutch
Gear Ratios:
Specific ratios available in the manual, critical for performance tuning.
Transmission Fluid:
KTM recommends specific transmission oil (e.g., Motorex Gear Oil 75W/80W or equivalent), check manual for exact specification.
Crash Test Rating:
Not applicable for off-road competition motorcycles. Designed for closed-course use.
Brakes:
Hydraulic disc brakes, front and rear, with performance-oriented calipers and rotors.
Suspension:
WP USD (Upside Down) front forks and WP PDS (Progressive Damping System) rear shock absorber, adjustable for rider preference and terrain.
Frame Construction:
Lightweight chromoly steel trellis frame for strength and rigidity.
Handguards:
Standard on XC-W models to protect hands and levers from impacts.
Display Type:
Digital multi-function display (speedometer, odometer, trip meter, clock).
Traction Control:
Not equipped on this model.
ABS:
Not equipped on this model.
Bluetooth Usb:
Not equipped on this model.
Oil Change Interval:
Every 15-20 operating hours or annually (check manual for exact recommendation based on usage).
Air Filter Cleaning:
After every few rides or more frequently in dusty conditions.
Valve Clearance Check:
Typically every 50-100 operating hours (check manual for precision).
Spark Plug Replacement:
As recommended by KTM, usually between 50-100 operating hours.
Engine Oil Grade:
KTM recommends Motorex Power Synth 4T SAE 10W/50 or equivalent high-quality synthetic motorcycle oil.
Coolant Type:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Use KTM recommended coolant or equivalent.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Fork Oil Type:
Specific viscosity grade (e.g., SAE 5W) and brand recommended by WP/KTM. Check manual.
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, fork seals, exhaust packing, chain and sprockets.
Carburetor Tuning:
Carburetor jetting may require adjustment based on altitude and temperature for optimal performance.
Radiator Fan:
Ensure radiator fan (if equipped) operates correctly to prevent overheating during slow-speed riding.
Ktm Legacy:
KTM is renowned for its off-road racing heritage, particularly in Motocross and Enduro, often referred to as 'Ready to Race'.
Xc-W Lineage:
The XC-W line represents KTM's dedicated enduro competition models, evolving from their motocross platforms with features tailored for longer-distance, trail-based racing.
2009 Updates:
The 2009 model year saw refinements to the LC4 engine, suspension, and chassis based on racing feedback. Specific updates detailed in the manual.
Manufacturing Origin:
Austria
