The 450 EXC and 450 XC-W models, produced between 2008 and 2011, represent high-performance off-road motorcycles designed for demanding enduro and cross-country racing environments. These machines are characterized by their powerful 450cc liquid-cooled, single-cylinder engines, robust chromium-molybdenum steel frames, and advanced suspension components, all contributing to their renowned off-road capability and competitive edge. With a focus on performance and rider engagement, the 450 EXC/XC-W is engineered for enthusiasts and racers seeking a reliable and potent off-road experience. This workshop repair service manual provides comprehensive guidance for the maintenance, troubleshooting, and repair of the 450 EXC and 450 XC-W models from 2008 to 2011. It covers all major systems, including the engine, fuel system, transmission, drivetrain, suspension, brakes, cooling system, and electrical system, offering detailed procedures for disassembly, inspection, assembly, and rebuilding. With in-depth technical specifications and diagnostic information, this manual serves as an essential resource for owners, mechanics, and technicians to ensure the optimal performance and longevity of their vehicles. 🏷️ Basic Information Identification Make: KTM Model: 450 EXC XC-W Model Variant: 450 XC-W Codes Chassis Code Range: Varies based on specific model year and sub-model (e.g., EXC vs. XC-W), but generally identified by the VIN. Engine Code Prefix: LC4 (referring to the single-cylinder engine architecture) 👋 Introduction Market Position Vehicle Class: High-performance Off-Road Motorcycle (Enduro / Dual-Sport) Target Audience: Enthusiast riders, off-road racers, adventure riders, and service technicians. Competitive Analysis Key Competitors: Yamaha WR450F, Honda CRF450X, Husqvarna TE450, GasGas EC450F. Key Features Engine Type: Powerful 450cc 4-stroke, liquid-cooled, single-cylinder engine. Suspension Type: High-quality WP (White Power) suspension components, renowned for off-road performance. Chassis Type: Lightweight and robust chromium-molybdenum steel frame. Off Road Capabilities: Designed for extreme off-road conditions, including trails, enduro events, and cross-country racing. Manual Utility: Provides essential information for maintaining peak performance and addressing mechanical issues. 📋 Manual Details Coverage Areas Manual Type: Workshop Repair Service Manual Applicable Years: 2008, 2009, 2010, 2011 Model Coverage: All Model Variants (EXC, XC-W) Page Count Estimated Page Count: Approximately 300-400 pages Format File Format: PDF Download Language Language: English 📖 Manual Coverage Systems Covered Engine: Complete disassembly, inspection, assembly, tuning, and troubleshooting of the 4-stroke single-cylinder engine. Fuel System: Carburetor (Mikuni BSR42/44), fuel pump, fuel lines, and tank servicing. Ignition System: CDI ignition, spark plug specifications, troubleshooting. Transmission: Clutch operation, gearbox disassembly, inspection, and assembly, shift mechanism. Drivetrain: Chain and sprocket maintenance, rear hub and axle. Suspension: Front forks (WP USD), rear shock absorber (WP PDS or similar), seals, oil, and spring adjustments. Includes settings for EXC and XC-W variants. Brakes: Front and rear hydraulic disc brake systems, caliper servicing, pad replacement, bleeding procedures, master cylinders. Cooling System: Radiator, coolant, hoses, water pump, thermostat. Electrical System: Wiring diagrams, battery maintenance, lighting, starter motor, charging system, fuses, switches. Chassis And Frame: Frame inspection, subframe, footpegs, handlebars, controls. Bodywork: Fairings, seat, fuel tank, fenders, graphics. Procedures Included Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, chain adjustments, valve clearance checks. Troubleshooting: Diagnostic procedures for common issues, fault finding charts. Repair: Detailed step-by-step instructions for component repair and replacement. Rebuild: Engine and transmission complete rebuild procedures, including torque specifications and clearances. Assembly Disassembly: Comprehensive instructions for component removal and installation. Technical Depth Depth Of Coverage: Comprehensive - Suitable for professional mechanics and advanced DIY enthusiasts. Diagnostic Capabilities: Advanced diagnostics for engine performance, electrical systems, and mechanical issues. Component Level Detail: Detailed breakdown and specifications for nearly all components. 📊 Manual Specifications File Format File Type: PDF Searchability: Typically searchable text within the PDF. Print Quality Image Resolution: High resolution for clear diagrams and images. Readability: Designed for easy reading on screen or for printing. Binding Type Binding Type Digital: N/A (Digital Download) Paper Type Paper Type Digital: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, single-cylinder, liquid-cooled, DOHC Displacement: 449.4 cc Bore X Stroke: 97 mm x 60.8 mm Compression Ratio: Approximately 12.0:1 Valve Train: DOHC, 4 valves Starter System: Electric Starter Performance Horsepower: Estimated 50-55 HP Torque: Estimated 45-48 Nm Fuel System Carburetor Type: Mikuni BSR42 (or BSR44 on later models/variants) Fuel Delivery: Fuel pump Fuel Type: Unleaded gasoline (95 RON recommended) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Optional Optional Transmission: N/A (Standard 6-speed for these models) Features Clutch Type: Wet multi-disc clutch, hydraulically operated Final Drive: Chain 📐 Dimensions Exterior Length: Approx. 2190 mm Width: Approx. 820 mm Height: Approx. 1240 mm Wheelbase: Approx. 1495 mm Ground Clearance: Approx. 350 mm Weights Dry Weight: Approx. 112-116 kg Wet Weight: Approx. 128-132 kg (with fluids) Cargo Fuel Tank Capacity: 9.5 Liters (approx.) 🛡️ Safety Features Ratings Safety Ratings: N/A (Off-road motorcycles are not typically rated by crash safety organizations like NHTSA or Euro NCAP). Active Features Braking System: Hydraulic disc brakes front and rear with braided steel lines. Tires: Knobby off-road tires (specific sizes detailed in manual)....