Category:
Enduro Motorcycle
Target Audience:
Owners and technicians requiring in-depth repair and maintenance information for the 2008 KTM 450 EXC-R SIX DAYS
Competitors 2008:
Husqvarna TE450, Yamaha WR450F, Honda CRF450X, Suzuki RM-Z450 (off-road variants)
Performance Focus:
High-performance off-road capability, specialized for enduro riding and competition
Advantages Over Paper:
Instant accessibility, easy searchability, portability across devices, no physical wear and tear
Engine:
Complete engine overhaul, tuning, diagnostics, lubrication, cooling system, fuel system, ignition system, exhaust system
Transmission:
Clutch operation, gearbox disassembly and assembly, shift mechanism, lubrication, troubleshooting
Chassis:
Frame inspection and repair, suspension (forks and rear shock absorber) disassembly, servicing, and adjustment, steering system, swingarm, wheel bearings
Electrical System:
Wiring diagrams, battery maintenance, lighting system, ignition system troubleshooting, starter motor, charging system, instrument cluster
Brakes:
Hydraulic brake system, caliper overhaul, pad replacement, fluid bleeding, master cylinder service, rear brake system
Fuel System:
Carburetor (Keihin FCR) disassembly, cleaning, adjustment, jetting, fuel tank, fuel lines, fuel pump (if applicable)
Cooling System:
Radiator maintenance, coolant replacement, water pump inspection and seal replacement, thermostat
Exhaust System:
Muffler and header pipe inspection, common repair points
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment and lubrication, valve clearance checks and adjustments, spark plug replacement, air filter cleaning/replacement
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues, fault finding guides for electrical and mechanical problems
Repair:
Detailed instructions for component disassembly, repair, and reassembly, torque specifications for all fasteners, specialized tool requirements
Rebuilds:
Complete engine rebuild procedures, gearbox rebuild, carburetor rebuild
Adjustment:
Carburetor jetting and idle adjustment, suspension sag and damping adjustments, clutch cable adjustment
Depth:
Comprehensive: Covers everything from basic rider maintenance to complete engine and chassis rebuilds. Includes detailed diagrams, exploded views, and troubleshooting trees.
Engine Type:
Four-stroke, single-cylinder
Bore X Stroke:
95.0 mm x 63.4 mm
Engine Cooling:
Liquid-cooled
Valvetrain:
SOHC, 4 valves
Compression Ratio:
11.7:1
Horsepower:
~50 hp (estimated)
Torque:
~40 Nm (estimated)
Carburetor:
Keihin FCR 41 MX
Fuel Type:
Unleaded gasoline, minimum 95 octane
Oil Type:
Fully synthetic motorcycle oil, SAE 10W-50 (refer to manual for specific API/JASO ratings)
Ignition System:
Digital CDI with variable ignition timing
Starter System:
Electric starter
Transmission Type:
Constant-mesh, 6-speed
Clutch:
Wet multi-disc clutch, hydraulically operated
Gear Ratios:
Refer to manual for specific gear ratios (typically close-ratio for performance)
Final Drive:
X-ring chain, 13/48 gearing (typical, may vary)
Transmission Oil Type:
Refer to manual (often shared with engine oil or specific transmission fluid)
Engine Oil Change:
Every 15-20 hours of riding or annually (refer to manual for precise intervals based on usage)
Air Filter Cleaning:
Every 5-10 hours or as needed, depending on dust conditions
Spark Plug Replacement:
Every 30-40 hours or as needed
Valve Clearance Check:
Every 25-30 hours of riding
Chain Lubrication Adjustment:
Every ride or as needed
Engine Oil Capacity:
Approx. 1.1 liters (without filter change), 1.2 liters (with filter change) - Verify in manual
Coolant Type:
Ethylene glycol-based coolant, mixed 50/50 with distilled water (refer to manual for specific type and color)
Brake Fluid Type:
DOT 4 (verify in manual)
Common Wear Items:
Clutch plates, piston and rings, valve seats, suspension seals, wheel bearings, chain and sprockets
Potential Problems:
Carburetor jetting sensitivity to altitude/temperature, potential for stator or regulator failure in older models (check manual for specific bulletins)
Manufacturer Origin:
Austria
Brand Specialty:
Known for high-performance off-road and racing motorcycles
Exc Series:
The EXC line has a long history of competitive enduro machines, evolving through engine sizes and technologies
Six Days Edition:
Special 'Six Days' editions commemorate KTM's participation and success in the International Six Days Enduro (ISDE) and typically feature upgraded components and special graphics.
Production Period:
The 450 EXC-R model was a prominent offering in KTM's enduro lineup during the mid-to-late 2000s.
