Category:
High-performance Enduro/Off-road Motorcycle
Target User:
Enthusiast riders, competitive off-road racers, mechanics specializing in KTM
Key Competitors:
Yamaha WR450F, Honda CRF450X, Husqvarna WR450
Vehicle Focus:
Power, agility, off-road capability, robust construction
Manual Value Proposition:
Provides expert-level guidance for maintaining and repairing the specific 2008 KTM 450 EXC-R model, enabling owners to maximize performance and longevity.
Engine:
Full overhaul, diagnostics, tuning, lubrication, cooling system
Fuel System:
Carburetor (Keihin FCR41, jetting, overhaul), fuel pump, fuel lines
Ignition System:
CDI unit, spark plugs, wiring diagrams
Transmission:
Clutch operation, gear shifting mechanism, transmission case, lubrication
Chassis:
Frame inspection, suspension (forks, shock absorber), swingarm, bearings
Brakes:
Hydraulic brake system (front and rear calipers, master cylinders, brake lines), bleeding procedures
Electrical System:
Wiring harnesses, battery, lighting, starter motor, charging system, fuses, troubleshooting
Bodywork:
Fairings, seat, handlebars, controls, footpegs, plastics
Maintenance:
Oil changes, filter replacements, chain adjustment, valve clearance checks, spark plug replacement
Troubleshooting:
Diagnostic flowcharts, symptom-based problem solving
Repair:
Engine rebuilds, transmission overhaul, suspension service, electrical component replacement
Adjustment:
Carburetor tuning, clutch adjustment, suspension settings
Scope:
Comprehensive, designed for professional mechanics and experienced DIY users
Detail Level:
Detailed torque specifications, component diagrams, measurement specifications, step-by-step instructions
Searchability:
Typically searchable text within the PDF for quick reference
Resolution:
High-resolution, ensuring clarity of diagrams and text
Physical Manual:
N/A (digital format specified)
Physical Manual:
N/A (digital format specified)
Crash Test Results:
N/A (Off-road motorcycle, not subjected to DOT/NHTSA standards)
Brakes:
Hydraulic disc brakes front and rear
Suspension:
WP Extrem Suspension (USD front forks, PDS rear shock) for stability and control
Frame:
Chromoly steel trellis frame for strength and rigidity
Handlebars:
Handlebar pad for impact absorption
System:
N/A (basic analog instrumentation: speedometer, odometer, trip meter, indicator lights)
Features:
N/A (focus on rider control and mechanical feedback)
Suspension Tech:
WP Extrem Suspension (48mm USD fork, PDS shock) offering extensive adjustability for performance tuning.
Engine Management:
Carbureted Keihin FCR-MX 41, requiring manual tuning.
Oil Change:
Every 10-15 hours of riding or as specified in manual (e.g., 2000-3000 km, depending on usage).
Air Filter Cleaning:
After every few rides, or more frequently in dusty conditions.
Valve Clearance Check:
Every 20-30 hours of riding or as per manual.
Spark Plug Replacement:
Every 30-40 hours or as needed based on inspection.
Engine Oil:
SAE 10W-50, API SG/SH/SJ, JASO MA (specific KTM recommendations often available).
Coolant:
Ethylene glycol-based coolant with anti-corrosion additives (typically 50/50 mix with distilled water).
Brake Fluid:
DOT 4 hydraulic brake fluid.
Clutch Fluid:
DOT 4 hydraulic fluid (if hydraulic clutch).
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, chain and sprockets.
Potential Problems:
Carburetor jetting sensitivity to altitude and temperature; occasional issues with starter motor relays or stator windings.
Manufacturer:
KTM AG, Austria
Legacy:
Renowned for off-road racing dominance and 'Ready to Race' philosophy
Exc Lineage:
Part of KTM's long-standing and highly successful EXC series, known for dual-sport and enduro capabilities.
2008 Updates:
The 2008 model typically featured refinements to the engine, suspension, and chassis based on racing feedback.
Manufacturing Location:
Austria
Segment Performance:
Consistently praised in industry reviews for its power delivery, handling, and off-road prowess within the 450cc enduro class.
Rider Satisfaction:
High rider satisfaction due to performance and KTM's build quality reputation.
Emission Standards:
Euro 3 compliant (may vary by market/region)