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KTM 450 EXC-R 2008 Service Repair Workshop Manual

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This manual covers the 2008 450 EXC-R (E), a high-performance four-stroke, single-cylinder enduro motorcycle renowned for its power, agility, and robust off-road capability. Built with a chromoly steel trellis frame...
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KTM 450 EXC-R 2008 Service Repair Workshop Manual
This manual covers the 2008 450 EXC-R (E), a high-performance four-stroke, single-cylinder enduro motorcycle renowned for its power, agility, and robust off-road capability. Built with a chromoly steel trellis frame and featuring WP Extrem Suspension, this Austrian-manufactured machine is designed for enthusiast riders and competitive off-road racers. Its 449.3 cc liquid-cooled engine, equipped with a Keihin FCR-MX 41 carburetor, delivers estimated horsepower of 50-55 HP and torque of 45-50 Nm, making it a formidable contender in its class. The 450 EXC-R is celebrated for its 'Ready to Race' philosophy, inheriting a legacy of off-road racing dominance. This comprehensive Service Repair Workshop Manual, written in English, provides detailed guidance for maintaining and repairing the 2008 450 EXC-R (E). It covers all essential systems, including the engine, fuel, ignition, transmission, chassis, brakes, and electrical systems, offering expert-level insights for professional mechanics and experienced DIY users. Procedures for routine maintenance, such as oil changes and valve clearance checks, along with in-depth repair instructions for engine rebuilds, suspension service, and electrical diagnostics, are clearly outlined. The manual includes crucial technical specifications, torque values, component diagrams, and troubleshooting flowcharts, enabling owners and technicians to optimize performance and ensure the longevity of this high-performance off-road motorcycle.
🏷️ Basic Information
Identification
Make:
KTM
Model:
450 EXC-R
Year:
2008
Model Variant:
E
Codes
Chassis Code Prefix:
LC4
👋 Introduction
Market Position
Category:
High-performance Enduro/Off-road Motorcycle
Target User:
Enthusiast riders, competitive off-road racers, mechanics specializing in KTM
Competitive Analysis
Key Competitors:
Yamaha WR450F, Honda CRF450X, Husqvarna WR450
Key Features
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.
📋 Manual Details
Coverage Areas
Manual Type:
Service Repair Workshop Manual
Language:
English
Format:
Digital (likely PDF, typical for workshop manuals)
Page Count Estimated:
300-500 pages (typical for comprehensive service manuals)
📖 Manual Coverage
Systems Covered
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
Procedures Included
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
Technical Depth
Scope:
Comprehensive, designed for professional mechanics and experienced DIY users
Detail Level:
Detailed torque specifications, component diagrams, measurement specifications, step-by-step instructions
📊 Manual Specifications
File Format
Type:
Likely PDF
Searchability:
Typically searchable text within the PDF for quick reference
Print Quality
Resolution:
High-resolution, ensuring clarity of diagrams and text
Binding Type
Physical Manual:
N/A (digital format specified)
Paper Type
Physical Manual:
N/A (digital format specified)
⚙️ Engine Specifications
Primary Engine
Type:
Four-stroke, single-cylinder, SOHC
Displacement:
449.3 cc
Bore X Stroke:
95 mm x 63.4 mm
Compression Ratio:
11.5:1 (approx.)
Cooling System:
Liquid-cooled
Performance
Horsepower Est:
50-55 HP (estimated, varies with tuning)
Torque Est:
45-50 Nm (estimated)
Fuel System
Carburetor Model:
Keihin FCR-MX 41
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
9.5 Liters (approx.)
🔧 Transmission
Standard
Type:
6-speed constant mesh
Clutch Type:
Wet multi-disc clutch (hydraulically operated)
Optional
Availability:
N/A for this model year
Features
Gear Ratios:
Specific ratios detailed in the manual
📐 Dimensions
Exterior
Length:
Approx. 2200 mm
Width:
Approx. 820 mm
Height:
Approx. 1290 mm
Seat Height:
Approx. 960 mm
Weights
Dry Weight:
Approx. 117 kg
Curb Weight:
Approx. 125 kg (with fluids)
🛡️ Safety Features
Ratings
Crash Test Results:
N/A (Off-road motorcycle, not subjected to DOT/NHTSA standards)
Active Features
Brakes:
Hydraulic disc brakes front and rear
Suspension:
WP Extrem Suspension (USD front forks, PDS rear shock) for stability and control
Passive Features
Frame:
Chromoly steel trellis frame for strength and rigidity
Handlebars:
Handlebar pad for impact absorption
💡 Technology Features
Infotainment
System:
N/A (basic analog instrumentation: speedometer, odometer, trip meter, indicator lights)
Driver Assistance
Features:
N/A (focus on rider control and mechanical feedback)
Connectivity
Features:
N/A
Other Tech
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.
🔧 Maintenance
Service Intervals
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.
Fluid Specifications
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).
Known Issues
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.
📚 Vehicle History
Brand Heritage
Manufacturer:
KTM AG, Austria
Legacy:
Renowned for off-road racing dominance and 'Ready to Race' philosophy
Model Evolution
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.
Production
Manufacturing Location:
Austria
🏆 Awards & Recognition
Recognitions
Segment Performance:
Consistently praised in industry reviews for its power delivery, handling, and off-road prowess within the 450cc enduro class.
Ratings
Rider Satisfaction:
High rider satisfaction due to performance and KTM's build quality reputation.
Certifications
Emission Standards:
Euro 3 compliant (may vary by market/region)
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