Vehicle Segment:
Dual-sport / Enduro motorcycle
Target Audience:
Enthusiasts, off-road riders, DIY mechanics seeking in-depth repair knowledge
Competitors 2009:
Yamaha WR450F, Honda CRF450X, Husqvarna TE450, Beta RR4T 400
Manufacturer Reputation:
KTM is renowned for its high-performance off-road motorcycles, often associated with racing heritage and 'Ready to Race' philosophy.
Model Purpose:
The EC-W (Enduro Competition-W) designation signifies a focus on competitive off-road performance, homologated for street use (depending on specific market regulations).
Primary Coverage:
Full service, repair, and maintenance for the 2009 KTM 400 EC-W
Secondary Coverage:
Troubleshooting, diagnostics, component disassembly and reassembly
Estimated Page Count:
300-500
Manual Classification:
Factory Service Manual (FSM)
Language Content:
English
Format Delivery:
Likely PDF or digital format, potentially printable
Engine Systems:
Engine mechanical (cylinder head, piston, crankshaft, camshaft), lubrication system, cooling system, fuel system (carburetor tuning/overhaul), ignition system, exhaust system, engine management (if applicable).
Drivetrain Systems:
Clutch operation and adjustment, transmission internal inspection and repair, gear shift mechanism, final drive (chain/sprocket maintenance).
Chassis Systems:
Frame inspection and repair, suspension (front fork and rear shock absorber servicing, tuning, and seal replacement), steering system (bearings, linkages), wheel and tire maintenance.
Braking Systems:
Hydraulic brake system (master cylinders, calipers, lines, fluid), brake pad replacement, rotor inspection.
Electrical Systems:
Wiring diagrams, lighting system, charging system (stator, regulator/rectifier), ignition coil, starter motor, battery maintenance, switches, and instrumentation.
Bodywork And Controls:
Body panel removal and installation, seat, fuel tank, handlebars, levers, footpegs, and cable routing.
Maintenance Procedures:
Oil and filter changes, air filter cleaning/replacement, spark plug inspection and replacement, chain adjustment and lubrication, tire pressure checks, brake fluid level checks, coolant checks.
Disassembly Assembly:
Step-by-step instructions for removing and reinstalling major components such as the engine, transmission, suspension units, wheels, and body panels.
Repair Procedures:
Detailed instructions for rebuilding engine components, servicing transmissions, repairing electrical faults, and replacing worn or damaged parts.
Troubleshooting Guides:
Diagnostic charts and procedures to identify and resolve common performance issues, starting problems, and system malfunctions.
Diagnostic Capabilities:
Advanced diagnostic procedures, symptom-based troubleshooting, and identification of root causes for mechanical and electrical issues.
Rebuild Level:
Comprehensive, covering complete engine rebuilds, transmission overhauls, and suspension component refurbishment.
Torque Specifications:
Detailed torque values for all critical fasteners and engine components.
Clearances Tolerances:
Specifications for valve clearances, piston ring gaps, bearing clearances, and other critical mechanical tolerances.
Engine Type:
Four-stroke, single-cylinder, liquid-cooled (LC4 engine family)
Displacement:
Approximately 398cc (exact displacement may vary slightly by internal specification)
Bore X Stroke:
Typical: 89mm x 63.7mm (verify with manual for precise figures)
Compression Ratio:
Typically around 12.0:1 (verify with manual)
Horsepower Est:
Approx. 40-45 HP (at crankshaft, stock configuration)
Torque Est:
Approx. 35-40 Nm (at crankshaft, stock configuration)
Fuel Delivery:
Carburetor (likely Keihin FCR MX 39mm or similar)
Fuel Type:
Unleaded gasoline (95 RON or higher recommended)
Ignition System:
Digital CDI (Capacitor Discharge Ignition)
Safety Certification:
Homologated for street use in many markets, typically meeting Euro 3 emissions standards (verify specific market compliance)
Braking System Type:
Hydraulic disc brakes, front and rear
Suspension Damping:
Adjustable front forks (compression, rebound) and rear shock absorber (preload, compression, rebound)
Lighting:
Headlight, taillight, brake lights, turn signals (street legal configuration)
Instrumentation Type:
Digital or analog/digital combination display, including speedometer, tachometer, odometer, trip meter, and essential warning lights.
Traction Control:
N/A (typically not featured on off-road focused models of this era)
ABS:
N/A (typically not featured on off-road focused models of this era)
Oil Change Interval:
Every 20-30 engine hours or annually (refer to manual for precise recommendation based on usage)
Air Filter Cleaning:
Every 10-20 engine hours or as needed based on conditions
Valve Check Interval:
Every 50-100 engine hours or annually
Engine Oil Type:
SAE 10W-50, JASO MA (e.g., Motorex Power Synt 4T 10W-50)
Engine Oil Capacity:
Approximately 1.1 - 1.3 liters (depending on filter change, verify with manual)
Coolant Type:
Ethylene glycol based antifreeze (e.g., Motorex Coolant M3.0)
Clutch Fluid Type:
Mineral oil (e.g., Magura Blood or similar) for hydraulically operated clutch
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, fork seals, spark plug, air filter, chain and sprockets.
Potential Electrical Concerns:
Wiring harness integrity, stator output, regulator/rectifier function can be points of attention over time.
Engine Specifics:
While generally robust, the LC4 can be sensitive to proper maintenance, particularly oil changes and valve adjustments.
Brand Focus:
KTM has a strong heritage in off-road racing, particularly motocross and enduro.
Lc4 Platform Significance:
The LC4 engine platform is a long-standing and versatile engine used across various KTM models, known for its torque and durability.
Ec W Lineup:
The EC-W designation typically represents KTM's competitive enduro line, designed for demanding off-road conditions and often featuring higher specifications than standard Enduro models.
Manufacturing Origin:
Austria (KTM's primary manufacturing base)
