KTM 450 EXC-R SIX DAYS 2008 Factory Service Repair Manual

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Stichworte: 2008 450 EXC-R SIX DAYS KTM Misc Motorcycle Motorcycles

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Beschreibung

The 450 EXC-R SIX DAYS is a high-performance, 4-stroke, single-cylinder enduro motorcycle produced for the 2008 model year. Known for its robust 449.3 cc liquid-cooled engine, the 'SIX DAYS' designation signifies special edition components and graphics, often reflecting its connection to off-road racing. Built with a chromium-molybdenum steel frame and designed for serious off-road riders and racers, this model embodies a heritage in motorsports, offering a potent combination of power and agility. Its engineering prioritizes reliability and performance in demanding enduro conditions. This comprehensive factory service repair manual provides detailed guidance for all aspects of the 2008 450 EXC-R SIX DAYS. It covers complete engine disassembly and assembly, fuel and ignition systems, cooling, transmission, suspension, brakes, and electrical systems. Within its hundreds of pages, you will find routine maintenance procedures, troubleshooting guides for common issues, and in-depth repair instructions for engine rebuilds, suspension service, and electrical diagnostics. This manual is an essential resource for owners, mechanics, and technicians seeking to maintain, diagnose, and repair this specialized off-road machine, ensuring optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Model:

450 EXC-R SIX DAYS

Year:

Codes

Chassis Code:

EGS-R

Generation

Model Generation:

This manual covers the specific 2008 model year of the 450 EXC-R SIX DAYS.

👋 Introduction

Market Position

Segment:

High-performance enduro/off-road motorcycle, specifically the 'Six Days' variant which typically denotes enhanced features and racing-inspired components.

Competitive Analysis

Competitors 2008:

Yamaha WR450F, Honda CRF450X, Husqvarna WR450, Beta RR450, Sherco SE450.

Key Features

Model Variant:

The 'SIX DAYS' designation typically signifies special edition components and graphics, often developed for the International Six Days Enduro (ISDE).

Target Audience:

Serious off-road riders, enduro racers, and enthusiasts who demand performance and reliability from their machines.

📋 Manual Details

Coverage Areas

Coverage Scope:

Complete official factory service repair manual covering all aspects of the 2008 KTM 450 EXC-R SIX DAYS.

Page Count

Estimated Pages:

Hundreds of pages (exact count not specified, but implies comprehensive coverage).

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English (assumed, standard for factory manuals)

Format

Format:

Download PDF

📖 Manual Coverage

Systems Covered

Engine System:

Complete engine disassembly, assembly, inspection, and repair procedures for the 450cc engine.

Fuel System:

Carburetor (likely Keihin FCR MX), fuel pump, fuel lines, and related components.

Ignition System:

CDI ignition, spark plug, wiring diagrams related to ignition.

Cooling System:

Radiator, coolant hoses, water pump, thermostat, coolant specifications.

Transmission System:

Gearbox, clutch (hydraulic actuation), shift mechanism, lubrication, and related components.

Suspension System:

Front forks (WP USD), rear shock absorber (WP PDS or similar), linkage, seals, oil types, and tuning.

Brake System:

Front and rear disc brakes, hydraulic lines, master cylinders, calipers, pad replacement, fluid specifications, bleeding procedures.

Electrical System:

Wiring diagrams, lighting, battery, starter motor, charging system, fuses, switches.

Chassis And Frame:

Frame inspection, subframe, steering head bearings, footpegs, and related components.

Bodywork And Plastics:

Fairings, seat, fenders, fuel tank, graphics, and trim removal/installation.

Wheels And Tires:

Wheel assembly, spoke tensioning, tire installation, wheel bearing maintenance, recommended tire pressures.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning, valve clearance checks.

Troubleshooting:

Diagnostic flowcharts and procedures for common issues and malfunctions.

Engine Rebuilds:

Piston replacement, ring replacement, cylinder inspection, valve jobs, crankshaft and connecting rod service.

Suspension Service:

Fork seal replacement, shock absorber service, spring replacement, oil and gas recharging.

Electrical Diagnostics:

Testing of electrical components, wiring harness continuity checks, stator and rectifier testing.

Brake System Service:

Brake fluid replacement, caliper overhaul, master cylinder rebuild, line bleeding.

Wheel And Tire Service:

Spoke replacement and truing, tubeless tire mounting (if applicable), wheel bearing replacement.

Technical Depth

Depth:

Comprehensive. Covers everything from basic rider maintenance to full engine and chassis teardowns and rebuilds.

📊 Manual Specifications

File Format

Format Type:

Print Quality

Searchable Text:

Yes (typical for factory PDF manuals, allowing for quick searching of terms).

Printable:

Yes, designed to be printed in its entirety or by specific sections.

Binding Type

Binding Recommendation:

Spiral binding is recommended for shop use due to lay-flat pages.

Paper Type

Paper Quality For Print:

Standard print paper (8.5x11 inches or A4) is suitable.

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, single-cylinder

Displacement:

449.3 cc

Bore X Stroke:

95 mm x 63.4 mm (typical for this engine family)

Cooling System:

Liquid-cooled

Valvetrain:

SOHC, 4 valves

Performance

Horsepower Estimate:

Approx. 50-55 HP (at crank, estimated based on similar models)

Torque Estimate:

Approx. 45 Nm (at crank, estimated)

Fuel System

Carburetor Type:

Keihin FCR MX 39

Fuel Type:

Unleaded gasoline, minimum 95 RON (octane)

🔧 Transmission

Standard

Transmission Type:

Constant-mesh, 6-speed

Features

Clutch Type:

Wet multi-disc clutch, hydraulically operated (Brembo hydraulic system typical).

Final Drive:

Chain drive

Gear Ratios:

Specific gear ratios will be detailed within the manual.

Transmission Fluid:

Specific grade and capacity for the gearbox will be provided in the manual (e.g., Motorex Gear Oil).

📐 Dimensions

Exterior

Frame Type:

Chromium-molybdenum steel central-tube frame, with bolted-on aluminum subframe.

Wheelbase:

Approx. 1470 mm (57.9 inches) - typical for this model.

Weights

Dry Weight:

Approx. 111 kg (244.7 lbs) - dry weight.

Fuel Tank Capacity:

Approx. 9.5 liters (2.5 US gallons).

🛡️ Safety Features

Ratings

Safety Certification:

Not applicable in the traditional automotive sense; designed for closed-course off-road use. Compliance with local regulations for street legality may vary and is not covered by this factory service manual.

Active Features

Braking System:

Hydraulic disc brakes (Brembo front and rear calipers with wave rotors).

Passive Features

Protective Gear:

The manual strongly emphasizes the use of appropriate personal protective equipment (PPE) for all maintenance and riding activities.

💡 Technology Features

Infotainment

Infotainment Features:

Not applicable. This is a performance off-road motorcycle with minimal electronic rider aids.

Driver Assistance

Electronic Aids:

No electronic rider aids such as ABS or traction control. Focus is on direct rider control.

Connectivity

Connectivity Features:

Not applicable.

Instrumentation

Dashboard:

Digital odometer, trip meter, clock, and basic warning lights.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual for specific interval, typically every 15-20 hours of riding or annually.

Air Filter Cleaning:

Recommended after every few rides, or as needed based on conditions.

Valve Clearance Check:

Typically every 20-30 hours of riding.

Fluid Specifications

Engine Oil Type:

Full synthetic motorcycle oil, specific viscosity (e.g., 10W-50) and API rating as per manual.

Coolant Type:

Specific coolant mixture (e.g., Motorex Coolant M3.0) as per manual. Do not use plain water or automotive coolant.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Fork Oil Type:

Specific WP suspension oil (e.g., WP Suspension Fluid 5W) and fill levels are crucial and detailed in the manual.

Gearbox Oil Type:

Dedicated gearbox oil (e.g., Motorex Gear Oil 75W/80).

Known Issues

Common Wear Items:

Clutch plates, spark plugs, wheel bearings, steering head bearings, fork seals, chain and sprockets.

Engine Reliability:

Generally robust, but requires diligent adherence to maintenance schedules, especially valve adjustments and oil changes.

📚 Vehicle History

Brand Heritage

Ktm Offroad Focus:

KTM has a long and storied history in off-road motorsports, consistently producing competitive enduro and motocross machines.

Model Evolution

Exc Series Evolution:

The EXC series has evolved significantly, with the 450 EXC-R being a prominent model in KTM's 4-stroke enduro lineup, known for its potent engine and capable chassis.

Production

Manufacturing Location:

Austria (KTM AG)

🏆 Awards & Recognition

Recognitions

Motorsport Success:

KTM motorcycles, including the EXC series, have a significant history of success in various off-road racing disciplines, including enduro championships and the International Six Days Enduro.