KTM 450 XCR-W 2008 Service Repair Manual

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Tipo: Motorcycle

Proveedor:

SKU: 100573

Etiquetas: 2008 450 XCR-W KTM Misc Motorcycle Motorcycles

Variantes de producto

Descripción

This manual covers the 450 XCR-W, a high-performance off-road motorcycle designed for enduro racing and demanding trail riding. Produced in 2008, this model is known for its aggressive power delivery, advanced WP suspension, and lightweight chromium-molybdenum steel trellis frame, making it a competitive choice against other leading off-road brands. The heritage in off-road competition is evident in the 450 XCR-W's engineering, which focuses on delivering exceptional performance and rider control across challenging terrains. This comprehensive service repair manual provides in-depth technical information essential for the maintenance, diagnosis, and repair of your 2008 450 XCR-W. It details procedures for all major systems, including the engine, fuel system, transmission, electrical system, chassis, brakes, and wheels. Coverage includes routine maintenance schedules, troubleshooting common issues, detailed repair instructions, and full overhaul procedures, along with critical technical specifications. This resource is designed to empower owners and technicians to ensure the optimal performance and longevity of the vehicle.

🏷️ Basic Information

Identification

Make:

Model:

450 XCR-W

Year:

Vehicle Type:

Off-road Motorcycle / Enduro

Codes

Vin Code Identifier:

👋 Introduction

Market Position

Market Segment:

High-performance off-road motorcycle, competitive in the enduro racing and extreme trail riding market

Target Audience:

KTM owners and technicians performing maintenance, repair, and restoration

Competitive Analysis

Competitors 2008:

Husaberg, Yamaha WR450F, Honda CRF450X, Kawasaki KX450F, Suzuki RM-Z450 (off-road variants)

Key Features

Vehicle Focus:

Aggressive power delivery, advanced suspension, lightweight chassis, designed for competition and demanding off-road terrain

Manual Benefit:

Provides crucial technical knowledge for maintaining peak performance and ensuring longevity of the KTM 450 XCR-W

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive service and repair for KTM 450 XCR-W 2008

Secondary Coverage:

Maintenance schedules, troubleshooting, diagnostics, technical specifications

Page Count

Estimated Page Count:

300-400 pages (typical for comprehensive service manuals)

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Engine overhaul, top-end rebuild, bottom-end rebuild, valve adjustment, timing, cooling system, lubrication system

Fuel System:

Carburetor (Mikuni BSR42/44 or Keihin FCR41 depending on exact variant) tuning and rebuilding, fuel pump, fuel lines

Transmission:

Gearbox inspection, clutch service, shift mechanism, lubrication

Electrical System:

Ignition system, lighting, starter motor, battery, charging system, wiring diagrams

Chassis:

Frame inspection, suspension (forks, rear shock) service and rebuild, steering head bearings, swingarm, linkage

Brakes:

Hydraulic brake system (front and rear calipers, master cylinders, lines, bleeding procedures), rotor inspection

Wheels And Tires:

Wheel bearing service, spoke tensioning, tire mounting and balancing

Bodywork And Trim:

Fairing removal and installation, seat, fuel tank, fender service

Procedures Included

Maintenance:

Regular service intervals, oil changes, filter replacements, chain adjustment, spark plug replacement

Troubleshooting:

Diagnostic procedures for common performance issues, electrical faults, starting problems

Repair:

Step-by-step instructions for component removal, disassembly, inspection, assembly, and reinstallation

Overhaul:

Complete engine and transmission rebuild procedures

Specifications:

Torque values, clearances, fluid types, capacities, electrical schematics

Technical Depth

Depth:

In-depth mechanical and electrical repair, advanced diagnostics, full engine and transmission rebuilds

📊 Manual Specifications

File Format

File Type:

Digital (PDF)

Searchability:

Likely text-searchable PDF for easy information retrieval

Print Quality

Printability:

Designed for printing, allowing users to create physical copies

Binding Type

Binding Type If Printed:

N/A (PDF format)

Paper Type

Paper Type If Printed:

N/A (PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder, DOHC

Displacement:

449.3 cc (27.4 cubic inches)

Bore X Stroke:

Approx. 95 mm x 63.4 mm (typical for this generation)

Compression Ratio:

Approx. 11.5:1 to 12.0:1

Cooling System:

Liquid-cooled

Performance

Horsepower Estimate:

Approximately 50-55 HP (at crank)

Torque Estimate:

Approximately 45-50 Nm (at crank)

Fuel System

Carburetor Type:

Likely Keihin FCR41 or Mikuni BSR42/44 (specific to region/variant)

Fuel Type:

Unleaded gasoline (min. 91 octane recommended)

🔧 Transmission

Standard

Transmission Type:

6-speed manual

Features

Clutch Type:

Hydraulically operated multi-plate wet clutch

Final Drive:

O-ring sealed chain drive

📐 Dimensions

Exterior

Length:

Approx. 2150 mm (84.6 inches)

Width:

Approx. 800 mm (31.5 inches)

Height:

Approx. 1250 mm (49.2 inches) (to top of handlebars)

Wheelbase:

Approx. 1475 mm (58.1 inches)

Weights

Dry Weight Estimate:

Approx. 112 kg (247 lbs)

Fuel Tank Capacity:

Approx. 9.5 liters (2.5 US gallons)

🛡️ Safety Features

Ratings

Safety Certification:

Not applicable for street-legal certification in many regions; designed for off-road use.

Active Features

Brakes:

Hydraulic disc brakes (front and rear) with performance calipers and rotors

Suspension:

High-performance WP suspension with ample travel for terrain absorption

Passive Features

Frame Construction:

Chromium-molybdenum steel trellis frame for strength and rigidity

💡 Technology Features

Infotainment

Infotainment System:

N/A (basic off-road motorcycle, no infotainment system)

Driver Assistance

Electronic Aids:

None (designed for pure rider control, no ABS or traction control)

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 15-20 hours of operation or annually (refer to manual for precise intervals based on usage)

Air Filter Cleaning:

Clean/replace every 5-10 hours of operation, or as needed based on dust conditions

Valve Adjustment:

Every 40-60 hours of operation (critical for performance)

Chain And Sprockets Inspection:

Check tension and lubrication every 5-10 hours

Fluid Specifications

Engine Oil Type:

JASO MA certified 10W-50 or 10W-40 synthetic motorcycle oil (e.g., Motorex Power Synt 4T)

Engine Oil Capacity:

Approx. 1.2 - 1.4 liters (check dipstick or fill plug level)

Coolant Type:

Ethylene glycol-based coolant mixture (50/50 with distilled water)

Brake Fluid Type:

DOT 4 hydraulic fluid

Known Issues

Common Wear Items:

Clutch plates, piston rings, valve seats, wheel bearings, steering head bearings due to off-road stress

Carburetor Tuning:

Can be sensitive to altitude and temperature changes, requiring periodic jetting adjustments

Suspension Seals:

Fork and shock seals can wear over time, requiring periodic replacement to prevent oil leaks

📚 Vehicle History

Brand Heritage

Brand Focus:

KTM is renowned for its off-road racing pedigree, specializing in motocross, enduro, and rally racing motorcycles.

Model Evolution

Xcr W Lineage:

The XCR-W models represent KTM's commitment to enduro racing, evolving from earlier LC4 and EXC platforms, incorporating advancements in engine technology and chassis design.

Production

Production Period For Model:

The 450 XCR-W was part of KTM's lineup in the mid-2000s, with specific iterations for various years like 2008.

🏆 Awards & Recognition

Recognitions

Racing Success:

KTM models are consistently top performers in enduro and off-road racing championships worldwide.

Ratings

Owner Satisfaction:

Generally high for performance and durability, contingent on proper maintenance.