KTM 450 EXC-R 2008 Factory Service Repair Manual

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Type: Motorcycle

Vendor:

Sku: 100796

Tags: 2008 450 EXC-R KTM Misc Motorcycle Motorcycles

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Description

The 2008 KTM 450 EXC-R is a high-performance dual-sport motorcycle renowned for its exceptional off-road capability and street-legal versatility. Building on KTM's legacy in off-road racing, this model features a potent 449.3 cc liquid-cooled, four-stroke engine, a capable WP suspension system, and hydraulic disc brakes, all contributing to its agile handling and robust performance. Designed for riders who demand both thrilling trail capability and the ability to transition to street use, the 450 EXC-R offers a potent combination of power and control, making it a distinguished choice in the competitive enduro and dual-sport market. This comprehensive factory service repair manual provides detailed guidance for the maintenance, diagnosis, and repair of the 2008 KTM 450 EXC-R. It covers all essential systems, including the engine, transmission, fuel, ignition, cooling, suspension, brakes, and electrical systems, offering step-by-step instructions for procedures ranging from routine maintenance and fluid changes to complete engine rebuilds. With technical specifications, troubleshooting guides, and information on special tools, this manual serves as an indispensable resource for owners, technicians, and mechanics seeking to ensure the optimal performance and longevity of their motorcycle.

🏷️ Basic Information

Identification

Make:

Model:

450 EXC-R

Year:

Type:

Dual-Sport / Enduro Motorcycle

👋 Introduction

Market Position

Market Segment:

High-performance off-road/enduro motorcycle, dual-sport homologated for street use

Competitive Analysis

Competitors:

Competes with other European and Japanese enduro/dual-sport models like Yamaha WR450F, Honda CRF450X, Husqvarna FE450

Key Features

Off Road Performance:

Renowned for strong off-road capability, powerful engine, and capable suspension

Street Legality:

Equipped for street use (lights, horn, etc.) allowing for dual-sport versatility

Manual Purpose:

Essential for owners and technicians to maintain, diagnose, and repair the vehicle to factory standards

📋 Manual Details

Coverage Areas

Vehicle Coverage:

KTM 450 EXC-R 2008 Model

Page Count

Page Count:

Hundreds of Pages (Exact count not specified, but described as complete)

Manual Type

Manual Type:

Factory Service Repair Manual

Language

Language:

English (Presumed, based on typical factory manuals for this market)

Format

Format:

Download PDF

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, diagnostics, repair, and tuning procedures

Transmission:

Clutch, gearbox, shift mechanism, lubrication, and adjustments

Fuel System:

Carburetor (likely Keihin FCR 41), fuel pump (if applicable for EFI variants, though 2008 EXC-R likely carbureted), fuel lines, filters

Ignition System:

CDI, ignition timing, spark plug specifications, troubleshooting

Cooling System:

Radiator, coolant, water pump, thermostat, fan operation

Suspension:

Front forks (e.g., WP USD), rear shock absorber, linkage, adjustments, seal replacement

Brakes:

Front and rear brake systems, hydraulic lines, calipers, master cylinders, pads, discs, bleeding procedures

Electrical System:

Wiring diagrams, lighting, battery, starter motor, charging system, fuses, relays, switches

Chassis Frame:

Frame inspection, swingarm, steering head bearings, subframe

Wheels Tires:

Wheel balancing, spoke tension, tire fitting, rim maintenance

Exhaust System:

Muffler, header pipe, silencer packing replacement

Bodywork Plastics:

Fairings, seat, fuel tank removal and installation

Procedures Included

Maintenance:

Scheduled maintenance, routine checks, lubrication points

Troubleshooting:

Diagnostic flowcharts for common problems and electrical issues

Repair:

Step-by-step instructions for component replacement and repair

Rebuilds:

Detailed instructions for engine and suspension component rebuilds

Specifications Data:

Torque values, clearances, fluid capacities, electrical specifications

Special Tools:

Identification of required special tools for specific procedures

Technical Depth

Depth:

Comprehensive (Covers everything from basic checks to full engine rebuilds)

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

Printable (designed for full or partial printing)

Binding Type

Binding Type:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

Searchability

Searchability:

Likely text-searchable PDF for quick information retrieval

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder

Displacement:

449.3 cc (approx.)

Bore X Stroke:

97 mm x 60.8 mm (approx.)

Valve Train:

SOHC, 4 valves

Cooling:

Liquid-cooled

Performance

Horsepower:

Estimated 50-55 HP (stock, may vary)

Torque:

Estimated 45-48 Nm (stock, may vary)

Fuel System

Carburetor:

Keihin FCR 41 MX (common for this model)

Fuel Type:

Unleaded gasoline, minimum 95 octane (RON)

Lubrication

Oil Type:

High-performance motorcycle engine oil, SAE 10W/40 or 15W/50 (specific viscosity depends on climate and oil manufacturer recommendations, check manual for exact spec)

Oil Capacity:

Approx. 1.1 - 1.3 Liters (Check manual for precise capacity with filter change)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Optional

Optional Gear Ratios:

N/A (standard gear ratios are specified in the manual)

Features

Clutch Type:

Wet multi-disc clutch

Transmission Oil Type:

Motorcycle-specific transmission oil or engine oil (depending on shared lubrication system - check manual)

📐 Dimensions

Exterior

Seat Height:

Approx. 960 mm (37.8 in)

Ground Clearance:

Approx. 350 mm (13.8 in)

Weights

Dry Weight:

Approx. 114 kg (251.3 lbs) (without fuel)

Fuel Tank Capacity:

Approx. 9.5 Liters (2.5 US gal)

Wheels Tires

Front Tire Size:

80/100-21

Rear Tire Size:

110/100-18 (or similar)

Wheelbase:

Approx. 1475 mm (58.1 in)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycles are not typically rated by consumer safety organizations like NHTSA or IIHS)

Active Features

Braking System:

Hydraulic disc brakes front and rear (usually Brembo)

Lighting:

Headlight, taillight, brake light, turn signals (as per homologation)

Passive Features

Handguards:

Standard on many KTM models for hand protection

💡 Technology Features

Infotainment

Infotainment System:

None (Basic motorcycle instrumentation)

Driver Assistance

Rider Aids:

None (Focus is on rider control and mechanical feedback)

Connectivity

Connectivity Features:

Instrumentation

Dashboard:

Digital trip meter, speedometer, odometer, neutral indicator, high-beam indicator

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 10-15 operating hours or annually (recommendation for off-road use, refer to manual for exact figures)

Air Filter Cleaning:

After every few rides or as needed, especially in dusty conditions

Spark Plug Check:

Every 20-30 operating hours

Valve Clearance Check:

Every 50-75 operating hours (typical for high-performance 4-strokes, consult manual)

Fluid Specifications

Coolant Type:

Ethylene glycol based coolant with corrosion inhibitors, mixed with distilled water (50/50 ratio recommended)

Brake Fluid Type:

DOT 4 hydraulic brake fluid

Known Issues

Common Wear Items:

Clutch plates, piston rings, valve seats, wheel bearings, steering head bearings, fork seals

Cooling System Maintenance:

Regular coolant flushes and water pump seal checks are crucial for longevity

Carburetor Tuning:

Keihin FCR carbs require periodic cleaning and jetting adjustments based on altitude and temperature

📚 Vehicle History

Brand Heritage

Manufacturer:

KTM AG (Austria)

Model Evolution

Exc Series:

The EXC line has a long history of off-road racing dominance, evolving from smaller displacement models to the more powerful 450cc variants.

2008 Updates:

The 2008 model often featured refinements to suspension, engine mapping, and chassis components compared to previous years.

Production

Production Location:

Austria (typically)

🏆 Awards & Recognition

Recognitions

Off Road Awards:

While specific awards for the 2008 450 EXC-R are not detailed here, KTM EXC models consistently receive accolades in off-road and enduro publications for their performance and durability.

Ratings

Editorial Reviews:

Generally praised by enthusiasts and reviewers for its potent engine, agile handling, and excellent suspension performance for its class.