Years Covered:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Product Type:
Workshop Repair Service Manual
Market Position:
The KTM 450 XC-W models from 2000-2007 were positioned as high-performance off-road competition motorcycles, excelling in motocross and enduro disciplines. They were known for their potent engines and agile chassis.
Competitors:
Competed directly with models from Yamaha (YZ450F), Honda (CRF450X), Suzuki (RM-Z450), and Kawasaki (KX450F) during this period.
Key Features:
Powerful 4-stroke engine, advanced WP suspension, lightweight frame, robust build for demanding off-road use.
Engine Systems:
Engine disassembly, assembly, tuning, lubrication, cooling, fuel, ignition, exhaust, piston, cylinder, crankshaft, camshaft.
Transmission Systems:
Clutch operation, gearbox disassembly and assembly, shifting mechanisms, gear oil specifications.
Chassis Systems:
Frame inspection and repair, suspension (front forks, rear shock), steering head bearings, swingarm, linkages.
Electrical Systems:
Wiring diagrams, lighting, ignition system, charging system, battery maintenance, starter motor, component testing.
Braking Systems:
Brake caliper overhaul, master cylinder repair, brake fluid replacement, pad and rotor inspection, bleeding procedures.
Fuel System:
Carburetor disassembly, cleaning, adjustment, fuel pump (if applicable), fuel tank maintenance.
Cooling System:
Radiator service, coolant replacement, water pump inspection, hose checks.
Exhaust System:
Exhaust pipe inspection, muffler maintenance, heat shield checks.
Maintenance Procedures:
Routine maintenance checks, oil changes, filter replacements, chain adjustment, spark plug replacement, valve clearance adjustment.
Troubleshooting Guides:
Diagnostic procedures for common faults and performance issues, error code interpretation (if applicable).
Repair Procedures:
Step-by-step instructions for component removal, repair, and reinstallation.
Overhaul Procedures:
Complete engine and transmission rebuild instructions.
Technical Specifications:
Torque values, clearances, fluid capacities, tolerances, electrical system specifications.
Depth Of Coverage:
Comprehensive. Covers basic maintenance to complete engine rebuilds, including detailed troubleshooting and diagnostic procedures.
Engine Type:
4-stroke, liquid-cooled, single-cylinder, DOHC
Displacement:
Approximately 450cc (specific displacement may vary slightly by year/variant, e.g., 449.7cc or 448cc).
Bore X Stroke:
Typically around 95 mm x 63.4 mm (refer to specific year for exact figures).
Horsepower:
Estimated 50+ HP at peak RPM (figures vary based on year and specific tuning).
Torque:
Strong mid-range torque characteristic of KTM off-road engines.
Fuel Delivery:
Carburetor (e.g., Keihin FCR series - specific model varies by year, often 39mm or 41mm).
Ignition System:
Digital CDI with adjustable ignition timing.
Cooling Method:
Liquid-cooled via radiator and fan.
Oil Capacity:
Approximately 1.1 - 1.3 liters (check manual for exact capacity).
Oil Type:
High-performance synthetic motorcycle oil, SAE 10W-40 or 10W-50 (refer to manual for precise specification).
Wheelbase:
Approximately 1470 mm - 1490 mm (varies by year).
Seat Height:
Approximately 950 mm - 970 mm (unladen, varies by year).
Dry Weight:
Approximately 105 kg - 110 kg (varies by year).
Fuel Tank Capacity:
Typically 7.5 - 9.5 liters (varies by year/tank model).
Safety Standards:
Designed for closed-course competition use; not street legal or subject to typical automotive safety ratings.
Active Safety:
Responsive braking system, predictable handling, powerful engine for performance riding.
Passive Safety:
Frame integrity, handguards (often standard or optional), robust component construction for off-road conditions.
Infotainment Features:
N/A (This is a performance off-road motorcycle, typically lacks infotainment systems.)
Driver Assistance Features:
N/A (Off-road motorcycle, does not feature typical automotive driver assistance systems.)
Connectivity Features:
N/A
Engine Management System:
Digital CDI with basic ignition mapping, often with adjustable timing curves for different conditions. Carburetor dictates fuel management.
Oil Change Interval:
Recommended every 10-15 operating hours or annually, whichever comes first (highly dependent on riding conditions). Check manual.
Air Filter Cleaning:
Recommended every 5-10 operating hours or as needed based on dust levels.
Valve Clearance Check:
Typically every 20-30 operating hours (critical for performance and engine longevity). Refer to manual for exact interval.
Engine Oil Specification:
API SG/SH/SJ or JASO MA certified synthetic motorcycle oil, viscosity SAE 10W-40 or 10W-50. Consult manual for specific OEM recommendation.
Coolant Specification:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Ensure freeze protection.
Brake Fluid Specification:
DOT 4 brake fluid.
Gear Oil Specification:
Refer to manual; often a dedicated gearbox oil or specific motorcycle transmission fluid.
Common Issues:
Valve seat wear (especially on early models), carburetor jetting sensitivity to altitude and temperature, clutch basket wear, occasional ignition coil issues. The manual addresses these with diagnostic and repair procedures.
Part Numbers:
The manual provides detailed part numbers for all components, essential for ordering correct replacement parts.
Brand Heritage:
KTM, founded in Austria, has a long-standing reputation for producing high-performance off-road and racing motorcycles, often referred to as 'Ready to Race'.
Model Evolution 450Xc-W:
The 450 XC-W lineage evolved through these years, incorporating improvements in engine performance, suspension technology (WP), chassis design, and component reliability based on racing feedback.
Production Period:
2000-2007 for this specific generation/engine configuration of the 450 XC-W.
Manufacturing Origin:
Austria
Racing Success:
KTM 450 XC-W models have a strong history in professional off-road racing, including numerous victories in GNCC, Hare and Hound, and other enduro championships. The manual supports owners in maintaining their bikes for similar performance.
Performance Ratings:
Consistently rated highly by off-road publications for power delivery, suspension performance, and handling characteristics.
