2008 KTM 450-540 exc Servcie Repair Manual download
2008 KTM 450 530 EXC-R XCR-W Manual Model Coverage
2008 KTM 450 EXC-R EU
2008 KTM 450 EXC-R AUS/UK
2008 KTM 450 EXC-R SIX DAYS
2008 KTM 450 EXC-R USA
2008 KTM 450 XCR-W USA
2008 KTM 450 XCR-W ZA
2008 KTM 530 EXC-R EU
2008 KTM 530 EXC-R AUS/UK
2008 KTM 530 EXC-R SIX DAYS
2008 KTM 530 EXC-R USA
2008 KTM 530 XCR-W USA
2008 KTM 530 XCR-W ZA
MEANS OF REPRESENTATION
Jacking up the motorcycle
Removing the motorcycle from the work stand
Adjusting spring preload of the fork
Adjusting compression damping of fork
Adjusting rebound damping of fork
Cleaning dust boots of fork legs
Removing the fork legs
Installing the fork legs
Removing the fork protector
Installing the fork protector
Loosening the fork protection
Positioning the fork protection
Removing the lower triple clamp (EXC-R SIX DAYS, XCR-W USA)
Installing the lower triple clamp (EXC-R SIX DAYS, XCR-W USA)
Removing the lower triple clamp (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA)
Installing the lower triple clamp (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA)
Fork offset (EXC-R SIX DAYS, XCR-W USA)
Setting the fork offset (EXC-R SIX DAYS, XCR-W USA)
Checking play of steering head bearing
Adjusting play of steering head bearing
(EXC-R SIX DAYS, XCR-W USA)
Adjusting play of steering head bearing (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA)
Greasing the steering head bearing
Removing the engine sprocket cover
Installing the engine sprocket cover
SHOCK ABSORBER, SWINGARM
Shock absorber part number
Adjusting high-speed compression damping of the shock
Adjusting the low-speed compression damping of the
Adjusting rebound damping of the shock absorber
Measuring rear wheel sag unloaded
Checking static sag of the shock absorber
Checking the riding sag of the shock absorber
Adjusting spring preload of the shock absorber
Adjusting riding sag
Removing the shock absorber
Installing shock absorber
Removing main silencer
Fitting the main silencer
Removing the manifold
Installing the manifold
Dismounting the air filter box lid
Installing the air filter box lid
Removing the air filter
Installing the air filter
Removing the carburetor connection boot
Installing the carburetor connection boot
FUEL TANK, SEAT, TRIM
Dismounting the fuel tank
Installing the fuel tank
Dismounting the front fender
Installing the front fender
Removing headlight mask with headlight (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W ZA)
Refitting the headlight mask with the headlight (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W ZA)
Dismount the start number plate (XCR-W USA)
Fitting the start number plate (XCR-W USA)
Removing front wheel
Checking brake discs
Removing the front brake disc
Installing the front brake disc
Tire condition checking
Checking tire air pressure
Checking spoke tension
Removing the rear brake disc
Installing the rear brake disc
Checking the chain tension when fitting rear wheel
Adjusting chain tension – fitting rear wheel
Checking the chain tension
Adjusting chain tension – after checking
Adjusting the chain tension
Adjusting chain guide
Checking the rear sprocket / engine sprocket for wear
WIRING HARNESS, BATTERY
Removing the battery
Installing the battery
Recharging the battery
Checking the front brake linings
Removing the front brake linings
Installing the front brake linings
Changing the front brake linings
Adjusting basic position of handbrake lever (Every XCR-W motorcycles)
Checking free play of hand brake lever
Adjusting free travel of handbrake lever (Every EXC-R motorcycles)
Checking the front brake fluid level
Add front brake fluid
Changing the front brake fluid
Checking rear brake linings
Removing the rear brake linings
Installing the rear brake linings
Changing the rear brake linings
Checking free play of foot brake lever
Adjusting basic position of footbrake lever
Checking rear brake fluid level
Adding rear brake fluid
Changing the rear brake fluid
LIGHT SYSTEM, INSTRUMENTS
Adjusting speedometer functions
Setting kilometers or miles
Installing the engine
DISASSEMBLING ENGINE
Draining the engine oil
Removing the oil filter
Draining gear oil, cleaning gear oil screen
Removing the starter engine
Removing the valve cover
Removing the shift lever
Removing the spark plug
Removing the generator cover
Setting the engine to ignition top dead center
Removing the timing chain tensioner
Removing the camshaft
Removing the cylinder head
Removing the balance weight
Removing the timing chain guide rail
Removing the timing chain tensioning rail
2008 KTM 450-540 exc Servcie Repair Manual download
2008 KTM 450 530 EXC-R XCR-W Manual Model Coverage
2008 KTM 450 EXC-R EU
2008 KTM 450 EXC-R AUS/UK
2008 KTM 450 EXC-R SIX DAYS
2008 KTM 450 EXC-R USA
2008 KTM 450 XCR-W USA
2008 KTM 450 XCR-W ZA
2008 KTM 530 EXC-R EU
2008 KTM 530 EXC-R AUS/UK
2008 KTM 530 EXC-R SIX DAYS
2008 KTM 530 EXC-R USA
2008 KTM 530 XCR-W USA
2008 KTM 530 XCR-W ZA
MEANS OF REPRESENTATION
Jacking up the motorcycle
Removing the motorcycle from the work stand
Adjusting spring preload of the fork
Adjusting compression damping of fork
Adjusting rebound damping of fork
Cleaning dust boots of fork legs
Removing the fork legs
Installing the fork legs
Removing the fork protector
Installing the fork protector
Loosening the fork protection
Positioning the fork protection
Removing the lower triple clamp (EXC-R SIX DAYS, XCR-W USA)
Installing the lower triple clamp (EXC-R SIX DAYS, XCR-W USA)
Removing the lower triple clamp (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA)
Installing the lower triple clamp (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA)
Fork offset (EXC-R SIX DAYS, XCR-W USA)
Setting the fork offset (EXC-R SIX DAYS, XCR-W USA)
Checking play of steering head bearing
Adjusting play of steering head bearing
(EXC-R SIX DAYS, XCR-W USA)
Adjusting play of steering head bearing (EXC-R EU, EXC-R AUS/UK, EXC-R USA, XCR-W ZA)
Greasing the steering head bearing
Removing the engine sprocket cover
Installing the engine sprocket cover
SHOCK ABSORBER, SWINGARM
Shock absorber part number
Adjusting high-speed compression damping of the shock
Adjusting the low-speed compression damping of the
Adjusting rebound damping of the shock absorber
Measuring rear wheel sag unloaded
Checking static sag of the shock absorber
Checking the riding sag of the shock absorber
Adjusting spring preload of the shock absorber
Adjusting riding sag
Removing the shock absorber
Installing shock absorber
Removing main silencer
Fitting the main silencer
Removing the manifold
Installing the manifold
Dismounting the air filter box lid
Installing the air filter box lid
Removing the air filter
Installing the air filter
Removing the carburetor connection boot
Installing the carburetor connection boot
FUEL TANK, SEAT, TRIM
Dismounting the fuel tank
Installing the fuel tank
Dismounting the front fender
Installing the front fender
Removing headlight mask with headlight (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W ZA)
Refitting the headlight mask with the headlight (EXC-R EU, EXC-R AUS/UK, EXC-R SIX DAYS, EXC-R USA, XCR-W ZA)
Dismount the start number plate (XCR-W USA)
Fitting the start number plate (XCR-W USA)
Removing front wheel
Checking brake discs
Removing the front brake disc
Installing the front brake disc
Tire condition checking
Checking tire air pressure
Checking spoke tension
Removing the rear brake disc
Installing the rear brake disc
Checking the chain tension when fitting rear wheel
Adjusting chain tension – fitting rear wheel
Checking the chain tension
Adjusting chain tension – after checking
Adjusting the chain tension
Adjusting chain guide
Checking the rear sprocket / engine sprocket for wear
WIRING HARNESS, BATTERY
Removing the battery
Installing the battery
Recharging the battery
Checking the front brake linings
Removing the front brake linings
Installing the front brake linings
Changing the front brake linings
Adjusting basic position of handbrake lever (Every XCR-W motorcycles)
Checking free play of hand brake lever
Adjusting free travel of handbrake lever (Every EXC-R motorcycles)
Checking the front brake fluid level
Add front brake fluid
Changing the front brake fluid
Checking rear brake linings
Removing the rear brake linings
Installing the rear brake linings
Changing the rear brake linings
Checking free play of foot brake lever
Adjusting basic position of footbrake lever
Checking rear brake fluid level
Adding rear brake fluid
Changing the rear brake fluid
LIGHT SYSTEM, INSTRUMENTS
Adjusting speedometer functions
Setting kilometers or miles
Installing the engine
DISASSEMBLING ENGINE
Draining the engine oil
Removing the oil filter
Draining gear oil, cleaning gear oil screen
Removing the starter engine
Removing the valve cover
Removing the shift lever
Removing the spark plug
Removing the generator cover
Setting the engine to ignition top dead center
Removing the timing chain tensioner
Removing the camshaft
Removing the cylinder head
Removing the balance weight
Removing the timing chain guide rail
Removing the timing chain tensioning rail
