The 450 XC-W, produced in 2009, is a performance-oriented off-road motorcycle engineered for competition enduro and cross-country events. As part of a esteemed lineage, known for its motorsport prowess, this model embodies a potent 449.3 cc single-cylinder, 4-stroke engine, delivering robust power and torque suitable for demanding terrains. Its design prioritizes agility and durability, featuring a chromium-molybdenum steel trellis frame and advanced suspension components, making it a direct competitor in the high-performance off-road segment. This comprehensive Service Repair Manual provides detailed information for the maintenance, troubleshooting, and repair of your 2009 450 XC-W. It covers all essential systems, including the engine, transmission, fuel system, ignition, electrical components, suspension, and brakes, offering step-by-step instructions, torque specifications, and wiring diagrams. The manual is designed to assist owners, mechanics, and technicians in performing everything from routine service and part replacement to complete engine and chassis rebuilds, ensuring optimal performance and longevity of the vehicle. 🏷️ Basic Information Identification Make: KTM Model: 450 XC-W Year: 2009 Codes Engine Family: LC4 Chassis Code Indicator: XC-W 👋 Introduction Market Position Segment: Competition Enduro / Off-Road Target User: Enthusiast riders, mechanics, and owners requiring in-depth service information Competitive Analysis Comparison: Direct competitor to Yamaha WR450F, Honda CRF450X, Kawasaki KX450F (off-road variants) Key Features Vehicle Focus: Performance-oriented off-road machine with a potent 450cc engine Manual Advantage: Provides the detailed technical knowledge needed to maintain and repair this high-performance off-road motorcycle effectively. 📋 Manual Details Coverage Areas Primary Coverage: Service and Repair Secondary Coverage: Maintenance, Troubleshooting, Diagnostics Page Count Estimated Pages: 300+ Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Full Engine Overhaul, Internal Components, Cooling System, Lubrication System Transmission: Clutch, Gearbox Internals, Shifting Mechanism, Lubrication Fuel System: Carburetor Tuning and Rebuild (Keihin FCR), Fuel Pump, Fuel Lines Ignition System: CDI Unit, Spark Plug, Ignition Coil, Wiring Diagrams Electrical System: Lighting, Battery, Charging System, Starter Motor, Wiring Schematics Suspension: Front Fork (WP Suspension), Rear Shock Absorber (WP Suspension), Seals, Bushings, Valving Brakes: Front and Rear Calipers, Master Cylinders, Brake Lines, Bleeding Procedures Cooling System: Radiator, Cooling Fan, Coolant Types and Capacities Frame And Bodywork: Frame Inspection, Seat, Fenders, Plastics, Graphics Wheel And Tire: Wheel bearing replacement, spoke tensioning, tire fitting and balancing. Procedures Included Maintenance: Oil Change Intervals, Air Filter Cleaning/Replacement, Spark Plug Replacement, Chain Adjustment Repair: Engine Rebuild, Transmission Overhaul, Suspension Servicing, Brake System Repair Troubleshooting: Diagnosis of Common Problems, Fault Finding Charts Diagnostics: Electrical System Testing, Carburetor Adjustment Wiring Diagrams: Complete electrical system wiring diagrams included for troubleshooting and repair. Torque Specifications: Detailed torque specifications for all critical fasteners and components. Technical Depth Depth: Comprehensive from routine maintenance to complete engine and chassis rebuilds Detail Level: Detailed step-by-step instructions with torque specifications and diagrams Rebuild Procedures: Includes procedures for complete engine teardown and reassembly, gearbox rebuilding, and suspension damper servicing. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text for quick information retrieval Print Quality: High-resolution, suitable for printing Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Type: Single Cylinder, 4-Stroke, Liquid-Cooled, SOHC Displacement: 449.3 cc Bore X Stroke: 97.0 mm x 60.8 mm Compression Ratio: 11.8:1 Performance Horsepower Estimate: Approx. 50-55 HP (factory figures may vary) Torque Estimate: Approx. 45-50 Nm (factory figures may vary) Fuel System Carburetor: Keihin FCR 41 MX with accelerator pump Fuel Type: Unleaded Gasoline (95 RON recommended) Cooling System Type: Liquid Cooling Lubrication System Type: Dry Sump Lubrication Engine Oil Capacity: 1.2 Liters (with filter change) Specification: SAE 10W-50, API SG or higher, JASO MA 🔧 Transmission Standard Type: 6-Speed Constant Mesh Features Clutch: Hydraulically Operated Wet Multi-Plate Clutch Final Drive: O-ring sealed chain, 520 pitch 📐 Dimensions Exterior Length: Approx. 2190 mm (86.2 in) Width: Approx. 815 mm (32.1 in) Height: Approx. 1240 mm (48.8 in) Weights Dry Weight: Approx. 113.5 kg (250.2 lbs) Fuel Tank Capacity: 9.5 Liters (2.5 US gal) Chassis Frame Type: Chromium-molybdenum steel trellis frame 🛡️ Safety Features Ratings Crash Safety: Not Applicable (Off-road Competition Vehicle) Active Features Brakes: Disc Brakes (Front and Rear), Radial Calipers Passive Features Protection: Handguards, Skid Plate (typically aftermarket or optional) 💡 Technology Features Infotainment Features: None (Pure Off-Road focus) Driver Assistance Features: None (Pure Off-Road focus) Connectivity Features: None (Pure Off-Road focus) Instrumentation Features: Digital display for hour meter, speedometer, odometer, trip meter, and basic warning lights. 🔧 Maintenance Service Intervals Engine Oil Change: Every 15-20 hours of operation or annually Air Filter Cleaning: Every 5-10 hours of operation, or more frequently in dusty conditions Spark Plug Inspection: Every 20-30 hours of operation Valve Clearance Check: Every 30-40 hours of operation Fluid Specifications Coolant: Pre-mixed 50/50 ethylene glycol based coolant Brake Fluid: DOT 4 Clutch Fluid: DOT 4 Known Issues Common Wear Items: Clutch plates, chain and sprockets, wheel bearings,...