KTM 450 EXC-R 2008 Workshop Service Repair Manual

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Type: Motorcycle

Vendor:

Sku: 98417

Tags: 2008 450 EXC-R KTM Misc Motorcycle Motorcycles

Product variants

Description

The 450 EXC-R is a performance-oriented competition enduro motorcycle renowned for its robust build quality and off-road prowess. Designed for demanding trail riding and racing, this 2008 model features a liquid-cooled, 4-stroke, single-cylinder LC4 engine with an approximate displacement of 449.3 cc, delivering substantial power and torque. Its lightweight Chromoly steel trellis frame provides rigidity and impact absorption, while high-quality WP suspension components ensure optimal handling and stability across varied terrain. The 450 EXC-R represents a dedication to producing highly capable machines for enthusiasts and professional riders in the competitive enduro segment. This workshop service repair manual offers comprehensive guidance for the maintenance and repair of all 2008 450 EXC-R models. It covers essential areas including detailed engine service, transmission and drivetrain repair, suspension and steering maintenance, brake system servicing, and electrical system troubleshooting. The manual also provides step-by-step instructions for disassembly and reassembly, preventative maintenance schedules, critical torque specifications, and diagnostic procedures. Its purpose is to equip owners and technicians with the necessary knowledge to effectively maintain, troubleshoot, and repair the vehicle, ensuring its optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Model:

450 EXC-R

Year:

Codes

Engine Code:

Likely LC4 450 variant (specific code not provided in product info, typical for KTM EXC series)

Chassis Code:

Likely LC4 chassis variant (specific code not provided in product info)

👋 Introduction

Market Position

Segment:

Competition Enduro Motorcycle

Target Audience:

Enthusiasts and professional mechanics seeking comprehensive maintenance and repair information for their KTM 450 EXC-R.

Competitive Analysis

Competitors:

Likely competes with other 450cc enduro bikes from brands like Husqvarna, Beta, Yamaha (WR450F), Honda (CRF450X), and Kawasaki (KLX450R).

Key Features

Performance Oriented:

Designed for off-road performance, racing, and trail riding.

Durability:

Known for KTM's robust build quality and off-road prowess.

📋 Manual Details

Coverage Areas

Covered Models:

All Models/Engines/Trim/Transmissions Types for 2008 KTM 450 EXC-R

Page Count

Page Count:

Unknown (not specified in product information)

Manual Type

Manual Type:

Workshop Service Repair Manual

Language

Language:

English (standard for this type of manual)

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Service:

Detailed procedures for disassembly, inspection, repair, and reassembly of the 450cc engine, including top-end, bottom-end, lubrication system, cooling system, and fuel delivery.

Transmission And Drivetrain:

Service and repair of the gearbox, clutch, and final drive (chain/sprockets), including gear inspection, shift mechanism, and lubrication.

Suspension And Steering:

Maintenance, adjustment, and repair of front forks (e.g., WP Suspension), rear shock absorber, linkage, and steering head bearings.

Brakes:

Service and bleeding procedures for hydraulic brake systems (front and rear), caliper maintenance, pad replacement, and rotor inspection.

Electrical System:

Wiring diagrams, component testing, troubleshooting of lighting, ignition system, charging system (stator/rectifier), starter motor, and battery.

Fuel System:

Carburetor (likely Keihin FCR) disassembly, cleaning, adjustment, and troubleshooting, as well as fuel tank and line maintenance.

Cooling System:

Radiator, hoses, thermostat, and coolant maintenance, leak testing, and fluid specifications.

Chassis And Frame:

Inspection, cleaning, and maintenance of the frame, subframe, swingarm, and associated components.

Wheels And Tires:

Wheel bearing maintenance, spoke tensioning, tire pressure recommendations, and removal/installation procedures.

Procedures Included

Preventative Maintenance:

Detailed schedules and procedures for oil changes, filter replacements, chain lubrication and adjustment, and general inspection.

Troubleshooting Guides:

Systematic diagnostic procedures and flowcharts for common problems and their solutions.

Repair Procedures:

Step-by-step instructions for virtually all repair tasks, from minor adjustments to major component overhauls.

Disassembly And Reassembly:

Comprehensive instructions for dismantling and reassembling all major vehicle systems for servicing or repair.

Torque Specifications:

Essential torque values for critical fasteners throughout the motorcycle, ensuring proper assembly and preventing component damage.

Technical Depth

Diagnostic Capabilities:

Advanced diagnostic information, including symptom-based troubleshooting and component testing procedures.

Rebuild Instructions:

Full rebuild procedures for engine and transmission components, suitable for experienced mechanics.

Calibration And Adjustment:

Detailed instructions for calibrating and adjusting various systems, such as carburetor settings, valve clearances, and suspension damping.

Wiring Diagrams:

Clear and detailed electrical wiring diagrams for easy troubleshooting and component identification.

Special Tool Identification:

Identification and usage instructions for special tools required for specific maintenance and repair procedures.

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format)

Searchability:

Likely text-searchable PDF, allowing for quick information retrieval.

Print Quality

Print Quality:

High-resolution scans suitable for printing clear diagrams and text.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, 4-stroke, liquid-cooled (LC4 engine family)

Displacement:

Approximately 449.3 cc

Bore X Stroke:

Typical for this era: ~95 mm x 63.4 mm (specific to 2008 model)

Performance

Horsepower:

Estimated 50-55 HP at peak (subject to specific tuning and regulations)

Torque:

Estimated 45-50 Nm at peak (subject to specific tuning)

Fuel System

Fuel Delivery:

Carburetor (likely Keihin FCR 39mm or similar)

Ignition System:

Electronic ignition with digital ignition advance

Lubrication System

Oil Type:

KTM recommends specific semi-synthetic or fully synthetic motorcycle oil (e.g., Motorex Power Synt 4T 10W/50 or similar).

Cooling System

Coolant Type:

Ethylene glycol based coolant with corrosion inhibitors (e.g., Motorex Coolant M5.0).

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh gearbox

Clutch Type:

Hydraulically operated multi-disc wet clutch

Features

Gear Ratios:

Specific ratios detailed in the manual (typical ratios for this model are within a range suited for off-road).

Final Drive:

Chain drive (e.g., 520 O-ring chain)

📐 Dimensions

Exterior

Length:

Not specified in product information, but typical for an enduro bike.

Width:

Not specified in product information.

Height:

Not specified in product information.

Weights

Dry Weight:

Approximately 113 kg (249 lbs) (subject to variations).

Fuel Tank Capacity:

Approximately 9.5 liters (2.5 US gallons).

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycles are not subjected to the same crash test ratings as cars).

Active Features

Braking System:

Hydraulic disc brakes, front and rear, often with Brembo calipers and Wave rotors for enhanced stopping power and heat dissipation.

Suspension Performance:

High-quality WP suspension components designed for optimal handling and stability over rough terrain.

Passive Features

Frame Construction:

Strong and lightweight Chromoly steel trellis frame for rigidity and impact absorption.

Ergonomics:

Designed for aggressive off-road riding with a focus on rider control and maneuverability.

💡 Technology Features

Infotainment

Infotainment System:

N/A (This is a competition enduro motorcycle, typically lacking advanced infotainment features).

Driver Assistance

Electronic Aids:

Limited electronic aids; focus is on mechanical performance. May include basic electronic ignition.

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10-15 engine hours or as per manual recommendations, depending on riding conditions.

Air Filter Cleaning:

Recommended after every ride or as needed, especially in dusty conditions.

Chain Adjustment Lubrication:

Regularly, typically every 500-1000 km or as needed based on wear and stretching.

Valve Clearance Check:

Typically every 20-30 engine hours or as specified in the manual for optimal performance.

Fluid Specifications

Engine Oil Capacity:

Approx. 1.2 liters (total system capacity, including filter).

Coolant Capacity:

Approx. 1.0 liters.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Clutch Fluid Type:

DOT 4 hydraulic clutch fluid (if applicable, check specific model).

Known Issues

Common Wear Items:

Clutch plates, brake pads, wheel bearings, chain and sprockets, fork seals, and air filter are common wear items requiring regular inspection and replacement.

Carburetor Tuning:

Carburetor jetting and idle adjustments may require periodic fine-tuning depending on altitude and temperature changes.

Cooling System Maintenance:

Regular inspection of coolant levels and hose condition is crucial to prevent overheating.

📚 Vehicle History

Brand Heritage

Ktm Legacy:

KTM, an Austrian manufacturer, has a strong heritage in off-road motorcycling, including motocross and enduro racing.

Model Evolution

Exc Series:

The EXC line represents KTM's dedicated range of competition enduro motorcycles, known for their performance and off-road capability.

Production

Manufacturing Location:

Typically manufactured in Austria by KTM Sportmotorcycle AG.

🏆 Awards & Recognition

Recognitions

Motocross Enduro Awards:

KTM EXC models historically receive positive reviews and awards in the off-road motorcycle press for their performance and handling.