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KTM 450 XC-W 2000-2007 Workshop Repair Service Manual PDF Download
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Basic Information Identification Make: KTM Model: 450 XC-W Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Codes Product Type: Workshop Repair Service Manual Introduction Market Position Market Position:...
Typ: Motorcycles
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Art.-Nr: 75498
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| Basic Information | |
| Identification | |
| Make: | KTM |
| Model: | 450 XC-W |
| Years Covered: | 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 |
| Codes | |
| Product Type: | Workshop Repair Service Manual |
| Introduction | |
| Market Position | |
| 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. |
| Competitive Analysis | |
| Competitors: | Competed directly with models from Yamaha (YZ450F), Honda (CRF450X), Suzuki (RM-Z450), and Kawasaki (KX450F) during this period. |
| Key Features | |
| Key Features: | Powerful 4-stroke engine, advanced WP suspension, lightweight frame, robust build for demanding off-road use. |
| Manual Details | |
| Coverage Areas | |
| Primary Coverage: | Repair and overhaul of KTM 450 XC-W models from 2000 to 2007. |
| Page Count | |
| Estimated Page Count: | Varies by specific edition, typically 300-500 pages. |
| Manual Type | |
| Manual Type: | Workshop Manual / Service Manual / Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | PDF Download |
| Manual Coverage | |
| Systems Covered | |
| 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. |
| Procedures Included | |
| 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. |
| Technical Depth | |
| Depth Of Coverage: | Comprehensive. Covers basic maintenance to complete engine rebuilds, including detailed troubleshooting and diagnostic procedures. |
| Manual Specifications | |
| File Format | |
| File Format: | Portable Document Format (PDF) |
| Print Quality | |
| Print Quality: | High-resolution, suitable for digital viewing and printing. |
| Binding Type | |
| Binding Type: | N/A (Digital Download) |
| Paper Type | |
| Paper Type: | N/A (Digital Download) |
| Engine Specifications | |
| Primary Engine | |
| 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). |
| Performance | |
| 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 System | |
| 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 System | |
| Cooling Method: | Liquid-cooled via radiator and fan. |
| Lubrication | |
| 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). |
| Transmission | |
| Standard | |
| Transmission Type: | 5-speed manual synchromesh gearbox. |
| Optional | |
| Clutch Type: | Hydraulically operated multi-plate wet clutch. |
| Features | |
| Gear Ratios: | Specific gear ratios are detailed in the manual and vary slightly across model years. |
| Final Drive: | Chain drive. |
| Dimensions | |
| Exterior | |
| Wheelbase: | Approximately 1470 mm - 1490 mm (varies by year). |
| Seat Height: | Approximately 950 mm - 970 mm (unladen, varies by year). |
| Weights | |
| 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 Features | |
| Ratings | |
| Safety Standards: | Designed for closed-course competition use; not street legal or subject to typical automotive safety ratings. |
| Active Features | |
| Active Safety: | Responsive braking system, predictable handling, powerful engine for performance riding. |
| Passive Features | |
| Passive Safety: | Frame integrity, handguards (often standard or optional), robust component construction for off-road conditions. |
| Technology Features | |
| Infotainment | |
| Infotainment Features: | N/A (This is a performance off-road motorcycle, typically lacks infotainment systems.) |
| Driver Assistance | |
| Driver Assistance Features: | N/A (Off-road motorcycle, does not feature typical automotive driver assistance systems.) |
| Connectivity | |
| Connectivity Features: | N/A |
| Engine Management | |
| Engine Management System: | Digital CDI with basic ignition mapping, often with adjustable timing curves for different conditions. Carburetor dictates fuel management. |
| Maintenance | |
| Service Intervals | |
| 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. |
| Fluid Specifications | |
| 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. |
| Known Issues | |
| 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. |
| Parts Information | |
| Part Numbers: | The manual provides detailed part numbers for all components, essential for ordering correct replacement parts. |
| Vehicle History | |
| Brand Heritage | |
| 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 | |
| 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 | |
| Production Period: | 2000-2007 for this specific generation/engine configuration of the 450 XC-W. |
| Manufacturing Origin: | Austria |
| Awards & Recognition | |
| Recognitions | |
| 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. |
| Ratings | |
| Performance Ratings: | Consistently rated highly by off-road publications for power delivery, suspension performance, and handling characteristics. |