Category:
High-performance off-road motorcycles with street-legal capabilities (dual-sport).
Target Audience:
Enthusiast riders, off-road racers, adventure tourers, DIY mechanics.
Key Competitors:
Husqvarna TE series, Beta RR series, Yamaha WR series, Honda CRF-X series, Suzuki DR-Z series.
Vehicle Strengths:
Powerful LC4 engine, robust chassis, advanced WP suspension, lightweight design, potent off-road performance.
Manual Value Proposition:
Empowers owners and technicians with the knowledge to maintain, diagnose, and repair their KTM motorcycles, extending lifespan and optimizing performance.
Primary Coverage:
Comprehensive repair, maintenance, and troubleshooting for 2008 KTM 450 EXC-R and 530 EXC-R models.
Secondary Coverage:
Includes electrical diagrams, technical data, specifications, and diagnostic procedures.
Type:
Service Manual / Workshop Manual / Repair Manual
Engine:
Top-end rebuild (cylinder, piston, valves), bottom-end rebuild (crankshaft, connecting rod, bearings), lubrication system, cooling system (radiator, water pump), fuel injection system (throttle body, injectors, sensors), ignition system (stator, CDI), exhaust system.
Transmission:
Clutch assembly (friction plates, steel plates, springs), gearbox (gear shafts, shift drum, shift forks), lubrication.
Chassis:
Frame inspection and repair, suspension (front forks - WP USD, rear shock absorber - WP PDS or Monoshock), steering head bearings, swingarm, linkages.
Brakes:
Front and rear brake systems (hydraulic calipers, master cylinders, brake lines, rotors), brake pad replacement, bleeding procedures.
Electrical:
Wiring diagrams, battery maintenance, charging system (alternator, regulator/rectifier), starter motor, lighting system (headlight, taillight, indicators), instrumentation, diagnostic connector.
Bodywork And Controls:
Fuel tank, seat, fenders, handlebars, levers, footpegs, cable routing, plastics.
Maintenance:
Oil changes, filter replacements (oil, air), spark plug replacement, valve clearance adjustment, chain adjustment, lubrication points, coolant flush.
Troubleshooting:
Diagnostic tables for common starting issues, running problems, electrical faults, and performance complaints.
Repair:
Detailed step-by-step instructions for component disassembly, inspection, repair, and reassembly for all major systems.
Adjustments:
Carburetor/EFI adjustments, suspension settings, cable slack adjustments, throttle stop adjustment.
Depth:
Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds. Includes torque specifications, clearances, and diagnostic procedures.
Engine Type:
4-stroke, liquid-cooled, single-cylinder, OHC, 4 valves (LC4)
450 Displacement:
449.7 cc (approx.)
530 Displacement:
529.8 cc (approx.)
Bore X Stroke 450:
95 mm x 63.4 mm (approx.)
Bore X Stroke 530:
97 mm x 70.8 mm (approx.)
450 Horsepower:
Approx. 50-55 HP (at crankshaft, variant dependent)
530 Horsepower:
Approx. 55-60 HP (at crankshaft, variant dependent)
450 Torque:
Approx. 45-50 Nm (at crankshaft, variant dependent)
530 Torque:
Approx. 50-55 Nm (at crankshaft, variant dependent)
Fuel Delivery:
Electronic Fuel Injection (EFI) - Keihin specific system
Fuel Type:
Unleaded gasoline, minimum 90 octane
Ignition System:
Digital CDI with electronic advance
Transmission Type:
6-speed constant mesh gearbox
Clutch Type:
Wet multi-plate clutch (hydraulic actuation)
Optional Features:
N/A for standard model, specific factory race kits might exist.
Gear Ratios:
Specific ratios detailed in manual, designed for off-road performance.
Final Drive:
Chain drive (O-ring sealed)
Safety Certification:
CE, EPA (depending on market specifications)
Braking System:
Hydraulic disc brakes front and rear (Brembo components often used).
Suspension Features:
High-performance WP suspension with ample travel for off-road capability and shock absorption.
Lighting:
Headlight, taillight, brake light, turn signals (street legal variants).
Instrumentation:
Digital LCD display featuring speed, RPM, odometer, trip meter, clock, and warning lights.
Electronic Features:
Electronic Fuel Injection (EFI) for precise fuel delivery and engine management.
Diagnostic Port:
Service diagnostic connector for connecting diagnostic tools (e.g., KTM diagnostic software).
Oil Change Interval:
Every 10-15 operating hours or annually, whichever comes first. Consult manual for specific recommendations.
Air Filter Cleaning:
Every 5-10 operating hours or as needed in dusty conditions.
Valve Clearance Check:
Every 20-30 operating hours. Crucial for performance and engine longevity.
Spark Plug Replacement:
Every 15-20 operating hours or based on inspection.
Engine Oil Type:
SAE 10W-50 or 15W-50, JASO MA certified (e.g., Motul 5100, Castrol Power 1).
Engine Oil Capacity:
Approx. 1.0 - 1.2 Liters (dry fill), consult manual.
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, typically 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid.
Common Wear Items:
Clutch plates, brake pads, wheel bearings, steering head bearings, chain and sprockets.
Engine Specific Notes:
Regular valve adjustments are critical. Early models of EFI systems may require ECU re-mapping for optimal performance or to address specific fueling issues.
Suspension Maintenance:
Regular fork seal and oil changes, and rear shock servicing are recommended to maintain optimal damping and performance.
Brand Origin:
KTM Sportmotorcycle AG, Austria.
Brand Focus:
Renowned for off-road racing motorcycles (Motocross, Enduro, Dakar Rally).
Lc4 Lineage:
The LC4 engine platform has been a cornerstone of KTM's large-displacement single-cylinder offerings for decades, evolving through various iterations.
2008 Updates:
This generation featured significant updates including improved fuel injection systems, updated chassis geometry, and refinements to the LC4 engine for increased performance and reliability.
Manufacturing Location:
Austria
