Market Segment:
High-performance off-road motorcycle, competitive in the enduro racing and extreme trail riding market
Target Audience:
KTM owners and technicians performing maintenance, repair, and restoration
Competitors 2008:
Husaberg, Yamaha WR450F, Honda CRF450X, Kawasaki KX450F, Suzuki RM-Z450 (off-road variants)
Vehicle Focus:
Aggressive power delivery, advanced suspension, lightweight chassis, designed for competition and demanding off-road terrain
Manual Benefit:
Provides crucial technical knowledge for maintaining peak performance and ensuring longevity of the KTM 450 XCR-W
Primary Coverage:
Comprehensive service and repair for KTM 450 XCR-W 2008
Secondary Coverage:
Maintenance schedules, troubleshooting, diagnostics, technical specifications
Estimated Page Count:
300-400 pages (typical for comprehensive service manuals)
Type:
Service Repair Manual
Engine:
Engine overhaul, top-end rebuild, bottom-end rebuild, valve adjustment, timing, cooling system, lubrication system
Fuel System:
Carburetor (Mikuni BSR42/44 or Keihin FCR41 depending on exact variant) tuning and rebuilding, fuel pump, fuel lines
Transmission:
Gearbox inspection, clutch service, shift mechanism, lubrication
Electrical System:
Ignition system, lighting, starter motor, battery, charging system, wiring diagrams
Chassis:
Frame inspection, suspension (forks, rear shock) service and rebuild, steering head bearings, swingarm, linkage
Brakes:
Hydraulic brake system (front and rear calipers, master cylinders, lines, bleeding procedures), rotor inspection
Wheels And Tires:
Wheel bearing service, spoke tensioning, tire mounting and balancing
Bodywork And Trim:
Fairing removal and installation, seat, fuel tank, fender service
Maintenance:
Regular service intervals, oil changes, filter replacements, chain adjustment, spark plug replacement
Troubleshooting:
Diagnostic procedures for common performance issues, electrical faults, starting problems
Repair:
Step-by-step instructions for component removal, disassembly, inspection, assembly, and reinstallation
Overhaul:
Complete engine and transmission rebuild procedures
Specifications:
Torque values, clearances, fluid types, capacities, electrical schematics
Depth:
In-depth mechanical and electrical repair, advanced diagnostics, full engine and transmission rebuilds
Engine Type:
Four-stroke, single-cylinder, DOHC
Displacement:
449.3 cc (27.4 cubic inches)
Bore X Stroke:
Approx. 95 mm x 63.4 mm (typical for this generation)
Compression Ratio:
Approx. 11.5:1 to 12.0:1
Cooling System:
Liquid-cooled
Horsepower Estimate:
Approximately 50-55 HP (at crank)
Torque Estimate:
Approximately 45-50 Nm (at crank)
Carburetor Type:
Likely Keihin FCR41 or Mikuni BSR42/44 (specific to region/variant)
Fuel Type:
Unleaded gasoline (min. 91 octane recommended)
Length:
Approx. 2150 mm (84.6 inches)
Width:
Approx. 800 mm (31.5 inches)
Height:
Approx. 1250 mm (49.2 inches) (to top of handlebars)
Wheelbase:
Approx. 1475 mm (58.1 inches)
Dry Weight Estimate:
Approx. 112 kg (247 lbs)
Fuel Tank Capacity:
Approx. 9.5 liters (2.5 US gallons)
Safety Certification:
Not applicable for street-legal certification in many regions; designed for off-road use.
Brakes:
Hydraulic disc brakes (front and rear) with performance calipers and rotors
Suspension:
High-performance WP suspension with ample travel for terrain absorption
Frame Construction:
Chromium-molybdenum steel trellis frame for strength and rigidity
Oil Change Interval:
Every 15-20 hours of operation or annually (refer to manual for precise intervals based on usage)
Air Filter Cleaning:
Clean/replace every 5-10 hours of operation, or as needed based on dust conditions
Valve Adjustment:
Every 40-60 hours of operation (critical for performance)
Chain And Sprockets Inspection:
Check tension and lubrication every 5-10 hours
Engine Oil Type:
JASO MA certified 10W-50 or 10W-40 synthetic motorcycle oil (e.g., Motorex Power Synt 4T)
Engine Oil Capacity:
Approx. 1.2 - 1.4 liters (check dipstick or fill plug level)
Coolant Type:
Ethylene glycol-based coolant mixture (50/50 with distilled water)
Brake Fluid Type:
DOT 4 hydraulic fluid
Common Wear Items:
Clutch plates, piston rings, valve seats, wheel bearings, steering head bearings due to off-road stress
Carburetor Tuning:
Can be sensitive to altitude and temperature changes, requiring periodic jetting adjustments
Suspension Seals:
Fork and shock seals can wear over time, requiring periodic replacement to prevent oil leaks
Brand Focus:
KTM is renowned for its off-road racing pedigree, specializing in motocross, enduro, and rally racing motorcycles.
Xcr W Lineage:
The XCR-W models represent KTM's commitment to enduro racing, evolving from earlier LC4 and EXC platforms, incorporating advancements in engine technology and chassis design.
Production Period For Model:
The 450 XCR-W was part of KTM's lineup in the mid-2000s, with specific iterations for various years like 2008.
