Vehicle Segment:
High-performance off-road competition motorcycle (Enduro/Cross-Country).
Target Audience:
Enthusiast riders, off-road racers, and mechanics specializing in KTM off-road motorcycles.
Competitors:
Yamaha WR450F, Honda CRF450X, Suzuki RM-Z450 (off-road variants), Husqvarna WR450.
Engine Type:
Liquid-cooled, four-stroke, single-cylinder engine.
Suspension Type:
High-quality WP USD front forks and WP monoshock rear suspension, offering excellent adjustability and performance.
Chassis Design:
Chromium-molybdenum steel central double-cradle frame for optimal rigidity and rider feedback.
Manual Purpose:
To provide comprehensive guidance for maintaining, troubleshooting, and repairing the KTM 450 XCR-W 2008 model.
Manual Value Proposition:
Empowers owners and technicians with factory-level repair knowledge, reducing reliance on expensive dealership services and ensuring proper maintenance.
Technical Systems:
Engine, Fuel System, Cooling System, Exhaust System, Clutch, Transmission, Chassis, Suspension (Front & Rear), Brakes (Front & Rear), Electrical System, Wiring Diagrams, Bodywork, Troubleshooting
Type:
Service Repair Workshop Manual
Image Resolution:
High-resolution scans or original digital artwork ensuring clarity of diagrams and text.
Physical Binding:
Not applicable for digital format (printable pages)
Physical Paper:
Not applicable for digital format
Engine Mechanical:
Complete engine disassembly, inspection, repair, and reassembly procedures for all internal components (piston, rings, valves, camshaft, crankshaft, etc.).
Fuel System Carburetion:
Carburetor removal, cleaning, adjustment, and overhaul. Fuel tank, fuel line, and fuel filter maintenance.
Cooling System:
Radiator, hoses, water pump, and thermostat inspection and replacement. Coolant specifications and bleeding procedures.
Exhaust System:
Exhaust pipe, muffler, and heat shield inspection and replacement.
Clutch System:
Clutch lever, cable, and clutch pack inspection, adjustment, and replacement procedures. Clutch fluid specifications.
Transmission Drivetrain:
Gearbox disassembly, inspection, repair, and reassembly. Shift mechanism, final drive (chain and sprockets) maintenance and adjustment. Transmission oil specifications.
Chassis Frame:
Frame inspection for damage, head tube bearing replacement, and general chassis component checks.
Suspension Front:
Fork disassembly, seal replacement, oil change and level checks, spring replacement, and adjustment procedures for WP forks.
Suspension Rear:
Monoshock absorber service, linkage system inspection and lubrication, bearing replacement, and adjustment procedures for WP rear shock.
Brakes Front:
Brake caliper, master cylinder, brake lines, and brake disc inspection and replacement. Brake fluid specifications and bleeding procedures. Pad replacement.
Brakes Rear:
Rear brake caliper, master cylinder, brake lines, and brake disc inspection and replacement. Brake fluid specifications and bleeding procedures. Pad replacement.
Electrical System:
Ignition system, lighting, battery, charging system (stator, regulator/rectifier), starter motor, and fuses. Component testing and troubleshooting.
Wiring Diagrams:
Detailed electrical schematics for all vehicle circuits, including color coding and component identification.
Bodywork Plastics:
Fairing, seat, fuel tank cover, fenders, and number plates removal and installation procedures.
Preventative Maintenance:
Routine checks, lubrication, filter replacement, and adjustments as per service intervals.
Troubleshooting Diagnostics:
Step-by-step guides for identifying and resolving common mechanical and electrical issues, including symptom analysis.
Component Overhaul:
Detailed instructions for the complete disassembly, cleaning, inspection, measurement, and reassembly of major components.
Adjustments Settings:
Procedures for adjusting clutch, throttle cables, chain tension, suspension settings, and carburetor idle speed.
Special Tools Usage:
Identification and recommended use of specific KTM special tools required for certain repair procedures.
Depth Level:
Comprehensive, from basic rider maintenance to full engine and transmission rebuilds.
Diagnostic Detail:
In-depth diagnostic trees and fault finding procedures for electrical and mechanical problems.
Rebuild Procedures:
Detailed steps and specifications for complete engine, transmission, and suspension unit rebuilds.
Engine Type:
Single-cylinder, 4-stroke, liquid-cooled
Bore X Stroke:
95 mm x 63.4 mm
Compression Ratio:
12.3:1
Valvetrain:
DOHC, 4 valves
Estimated Horsepower:
Approximately 50-55 HP (manufacturer's specifications may vary).
Estimated Torque:
Not specified, but expected to be strong for its displacement.
Carburetor Model:
Keihin FCR 39 MX
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON + MON / 2).
Fuel Tank Capacity:
Approximately 9.5 liters (2.5 US gallons)
Cooling Type:
Liquid-cooled
Oil Type:
SAE 10W-50, JASO MA certified motorcycle engine oil.
Oil Capacity:
Approximately 1.1 liters (1.2 US quarts) with filter change.
Wheelbase:
Approximately 1480 mm (58.3 inches)
Seat Height:
Approximately 960 mm (37.8 inches)
Ground Clearance:
Approximately 355 mm (14.0 inches)
Dry Weight:
Approximately 114.5 kg (252.4 lbs)
Wet Weight:
Not typically specified by manufacturer for competition bikes.
Front Wheel Size:
21 inches
Rear Wheel Size:
18 inches
Front Tire Size:
80/100-21 (typical) - Specifics in manual
Rear Tire Size:
110/100-18 (typical) - Specifics in manual
Overall Length:
Approximately 2200 mm (86.6 inches)
Overall Width:
Approximately 810 mm (31.9 inches)
Oil Change Frequency:
Every 15-20 hours of riding, or annually. (Specifics in manual).
Air Filter Cleaning:
Every 5-10 hours of riding, or more frequently in dusty conditions.
Spark Plug Inspection:
Every 20-30 hours of riding.
Valve Clearance Check:
Every 30-40 hours of riding.
Chain And Sprocket Inspection:
Regularly, and adjust tension as needed (every 5-10 hours).
Suspension Service:
Fork oil change and seal inspection every 50-60 hours. Rear shock service based on usage and condition.
Engine Oil Spec:
SAE 10W-50, JASO MA
Transmission Oil Spec:
SAE 80W/90, API GL-4
Coolant Spec:
Ethylene glycol-based coolant, mixed 50/50 with distilled water. Specific KTM coolant recommended.
Brake Fluid Spec:
DOT 4 hydraulic brake fluid
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, swingarm bearings, brake pads, sprockets, and chain are typical wear items in off-road use.
Engine Considerations:
Properly maintaining the cooling system is crucial to prevent overheating. Carburetor jetting may need adjustment based on altitude and temperature.
Suspension Maintenance:
Regular fork seal inspection and replacement is important to prevent oil leaks. Linkage bearings require periodic cleaning and greasing.
