This workshop service repair manual covers the 450 EXC 540 EXC XCR motorcycle from 2008. Engineered with renowned off-road racing heritage, these models are celebrated for their high performance and robust construction, competing effectively in the demanding off-road and enduro segments. The EXC series is distinguished by its advanced suspension, powerful engines, and durable chassis, designed to deliver exceptional capability and rider feedback in challenging terrains.
This comprehensive English-language manual provides professional technician-level guidance for all aspects of the vehicle. It details general information, maintenance procedures, troubleshooting, repair procedures, disassembly, assembly, cleaning, and reinstallation across all major systems, including the engine, fuel, cooling, electrical, suspension, brakes, and chassis. With detailed substeps, cautions, warnings, and illustrations, this manual is an essential resource for owners and technicians to ensure the optimal performance, reliability, and longevity of the 450 EXC 540 EXC XCR.
Model Variant:
540 EXC XCR
Chassis Code:
Refer to manual for specific VIN decoding for EXC, EXC-R models.
Segment:
Off-road/Enduro Motorcycle
Competitors:
Competes with other European and Japanese manufacturers in the performance off-road segment (e.g., Yamaha WR, Honda CRF, Husqvarna TE).
Manual Value Proposition:
Provides professional-level diagnostic, repair, and maintenance information, saving significant costs on dealership service.
Manual Origin:
Written by the manufacturer (KTM), identical to manuals used by official service centers.
Digital Advantage:
Instant download, printable sections, no physical wear and tear, easy to search and navigate.
All Models Engines Trim Transmissions:
Yes
Estimated Page Count:
Hundreds of pages (specific count not provided, but stated as comprehensive).
Type:
Workshop Service Repair Manual
Handlebar And Controls:
Yes
Battery And Charging System:
Yes
Storage Compartments:
Yes
Crankshaft And Transmission:
Yes
Suspension System Overall:
Yes
Electrical System Overall:
Yes
Appendix Technical Data:
Yes
Maintenance Procedures:
Yes
Reinstallation Procedures:
Yes
Engine Removal Installation:
Yes
Diagnostic Procedures:
Yes
Electrical Troubleshooting Diagrams:
Yes
Depth:
Professional Technician Level (Comprehensive diagnostics, repair, and maintenance).
Detail Level:
Detailed substeps, notes, cautions, warnings, numbered instructions, bold figure numbers, detailed illustrations/photos, enlarged inset views.
Printability:
Full Printable
Zoom Functionality:
Zoom IN/OUT supported
Binding:
Digital Download (PDF)
Paper Type:
N/A (Digital Format)
Engine Type:
4-stroke (Specific configuration like SOHC/DOHC not detailed in product info, but typical for EXC models of this era).
Displacement Cc:
450cc and 540cc variants covered (specific bore/stroke for each not provided in this description).
Horsepower Hp:
Refer to manual for specific power figures for 450 and 540 models.
Torque Lb-Ft:
Refer to manual for specific torque figures for 450 and 540 models.
Fuel Delivery:
Likely Fuel Injection (FI) or Carbureted depending on specific sub-model/region for 2008 EXC models. Manual will detail.
Fuel Type:
Unleaded gasoline (Refer to manual for octane rating recommendations).
Transmission Type:
Likely 6-speed constant mesh sequential gearbox.
Optional Transmissions:
N/A (Typically single transmission option for a specific model variant).
Clutch Type:
Hydraulically operated multi-disc wet clutch.
Dry Weight Kg:
Refer to manual for specific model weights (typically around 110-120 kg for EXC models of this era).
Wet Weight Kg:
Refer to manual for specific model weights including fluids.
Fuel Capacity Liters:
Typically around 7-9 liters for EXC models of this era. Manual will confirm exact capacity.
Safety Certification:
Off-road motorcycles are typically not subject to the same crash safety ratings as street vehicles. Manual will cover safe operation.
Braking System:
Hydraulic disc brakes front and rear. Manual details caliper, rotor, and fluid specifications.
Frame Construction:
Chromium-molybdenum steel trellis frame for rigidity and rider feedback. Manual covers frame inspection and repair.
Infotainment System:
N/A (Off-road motorcycle, typically lacks advanced infotainment features).
Electronic Aids:
Minimal electronic rider aids for this era; focus is on mechanical performance and rider input. Manual details electrical system for ignition and lighting.
Oil Change Interval:
Refer to manual for specific intervals based on usage (e.g., operating hours or mileage).
Air Filter Cleaning:
Frequent cleaning recommended based on riding conditions. Manual will specify.
Valve Clearance Check:
Refer to manual for recommended intervals, typically based on operating hours.
Engine Oil Type:
Refer to manual for specific viscosity (e.g., Motorex SAE 10W-50 or equivalent JASO MA certified oil).
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors. Manual will specify concentration and type.
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic brake fluid. Manual will specify exact type and replacement intervals.
Common Wear Items:
Chain and sprockets, brake pads, tires, fork seals, and clutch plates are common wear items on off-road motorcycles. Manual will guide inspection and replacement.
Potential Issues:
Overheating under extreme conditions, wear on suspension components, and timely maintenance of the engine's internal components are critical. The manual addresses all these.
Ktm Heritage:
KTM is renowned for its off-road racing heritage, consistently producing high-performance dirt bikes and dual-sports.
Exc Evolution:
The EXC line has evolved significantly, with the 2008 models representing a period of refinement in KTM's successful off-road platform, often featuring advanced suspension and powerful engines.
Manufacturing Location:
KTM motorcycles are primarily manufactured in Austria.
Industry Recognition:
KTM's EXC line is consistently recognized for its class-leading performance and handling in off-road and enduro championships.
