This manual covers the 450 EXC and 450 XC-W models produced between 2008 and 2011. These high-performance, liquid-cooled, single-cylinder motorcycles are engineered for demanding off-road competition and enthusiast riding. Renowned for their potent 449.3 cc engines producing over 50 horsepower, robust build quality, and advanced suspension systems, including USD front forks and PDS rear shocks, these models represent dedication to off-road excellence. Their lightweight construction, estimated at 114 kg dry weight, combined with substantial ground clearance and a 9-liter fuel tank, makes them ideal for tackling challenging terrain and long-distance off-road adventures. This comprehensive Service and Repair Manual in English provides detailed guidance for the maintenance, repair, and troubleshooting of your 450 EXC or XC-W. It covers complete engine overhaul, fuel system maintenance including the Keihin FCR carburetor, ignition system diagnosis, cooling system service, transmission and clutch procedures, suspension component rebuilding, and brake system servicing. Additionally, the manual includes routine maintenance schedules, troubleshooting guides for common issues, component rebuilding instructions, suspension tuning advice, precise torque specifications, and detailed electrical wiring diagrams. This resource is essential for owners and technicians seeking to maintain the optimal performance and longevity of these specialized off-road motorcycles. 🏷️ Basic Information Identification Make: KTM Model: 450 XC-W Production Years Covered: 2008, 2009, 2010, 2011 👋 Introduction Market Position Motorcycle Segment: Enduro / Off-Road Competition Target Audience: Enthusiast riders, off-road racers, and professional mechanics working on KTM EXC and XC-W models. Competitive Analysis Key Competitors: Yamaha WR450F, Honda CRF450X, Husqvarna WR450, Suzuki RM-Z450 (off-road variants). Key Features Manual Utility: Provides comprehensive guidance for maintenance, repair, and troubleshooting, essential for keeping these high-performance machines in optimal condition. 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English Format: PDF 📖 Manual Coverage Systems Covered Engine Overhaul: Complete engine disassembly, inspection, repair, and reassembly procedures for the 450cc single-cylinder engine. Fuel System: Carburetor (Keihin FCR) tuning, cleaning, and rebuilding; fuel pump and filter service. Ignition System: CDI unit testing, spark plug specifications, coil and wiring diagnosis. Cooling System: Radiator maintenance, coolant type and capacity, water pump service, fan operation. Transmission And Clutch: Gearbox disassembly, inspection, and reassembly; clutch operation, adjustment, and replacement procedures. Suspension Front: WP USD (Upside Down) fork service, oil type and level, seal replacement, adjustment procedures. Suspension Rear: WP PDS (Progressive Damping System) shock absorber service, nitrogen charging, seal head replacement, linkage bearing service. Brake System: Hydraulic brake system bleeding, caliper service, master cylinder overhaul, pad replacement, rotor specifications. Electrical System: Wiring diagrams, starter system troubleshooting, lighting circuits, battery maintenance, fuse specifications. Frame And Bodywork: Frame inspection, subframe mounting, plastics removal and installation, seat and tank procedures. Wheels And Tires: Hub maintenance, spoke tensioning, wheel bearing replacement, tire pressure recommendations, rim lock installation. Procedures Included Routine Maintenance: Oil and filter changes, air filter cleaning, chain lubrication and adjustment, spark plug replacement. Troubleshooting Guides: Diagnostic charts for common starting, running, and electrical issues. Component Rebuilding: Detailed instructions for rebuilding engine components, carburetors, and suspension units. Suspension Tuning: Guidance on adjusting suspension settings for various riding conditions and rider weights. Torque Specifications: Precise torque values for all critical fasteners throughout the motorcycle. Special Tools: Identification and usage of specific tools required for certain procedures. Technical Depth Diagnostic Capability: Advanced diagnostic procedures for electrical and mechanical systems. Rebuild Level: Comprehensive engine and component rebuild procedures suitable for experienced mechanics and serious enthusiasts. Wiring Diagrams: Detailed and accurate electrical wiring schematics for all model variations. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Searchable text for quick information retrieval. Printability: Printable pages for use in a workshop environment. Print Quality Image Resolution: High-resolution images and diagrams ensuring clarity. Binding Type Digital Format: Not applicable (digital PDF) Paper Type Digital Format: Not applicable (digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, single-cylinder, liquid-cooled Displacement: 449.3 cc Bore X Stroke: 97 mm x 60.8 mm Compression Ratio: Approximately 12.5:1 (varies slightly by year/model) Performance Horsepower Approx: 50+ HP (at crank, varies by tuning) Torque Approx: 45+ Nm (at crank, varies by tuning) Fuel System Carburetor Model: Keihin FCR MX 39 Fuel Type: Unleaded gasoline, minimum 95 octane (RON) Lubrication System Oil Type: KTM recommends Motorex Power Synt 4T 10W/50 (or equivalent JASO MA approved motorcycle oil) Oil Capacity Engine Transmission: 1.1 Liters (for engine and transmission combined, dry fill) 🔧 Transmission Standard Type: 6-speed, claw-shifted Clutch Type: Wet multi-disc clutch, hydraulically operated (Magura) Features Gear Ratios: Specific gear ratios are detailed within the manual, essential for performance tuning. Fluid Specification Transmission Oil Type: Same as engine oil: Motorex Power Synt 4T 10W/50 or equivalent. 📐 Dimensions Exterior Seat Height Approx: 970 mm (38.2 inches) Ground Clearance Approx: 355 mm (14 inches) Weights Dry Weight Approx: 114 kg (251 lbs) Fuel Tank Capacity: 9 Liters (2.38 US gallons) 🛡️ Safety Features Ratings Off Road...