2008 KTM 450 XC / 525 XC ATV Repair Manual

2008 KTM 450 XC / 525 XC ATV Service Manual

• Built for owners and workshops servicing the 2008 KTM 450 XC ATV and 2008 KTM 525 XC ATV models
• Official KTM publication, Art. No. 3206058en
• Contains over 50 specific chassis torque settings and detailed carburetor adjustment tables
• File delivered as a direct download the moment payment clears
• Indexed PDF search covers every chapter and appendix
• Full-text search finds any part number in seconds
• Laid out for standard letter and A4 printing
• This 2008 manual is the primary reference for the XC series ATV, documenting the engine, electrical, and chassis systems

Manual Organization and Documentation

This 221-page technical reference provides detailed information on the maintenance and mechanical assembly of the 2008 KTM 450 XC ATV and 525 XC ATV. The document is structured into distinct chapters, ranging from vehicle exterior views and serial number locations to detailed engine disassembly. Major sections include what factory workshop documentation is structured for these models, focusing on critical systems such as the fuel tank and trim, the mask and fender assemblies, and the complete braking system for front and rear wheels.

The manual continues with comprehensive engine work, detailing the removal and installation of the powertrain, along with specialized sub-sections for the carburetor, clutch, transmission, and the cooling system. Lubrication and ignition systems are also documented with specific check procedures and reference values for the generator and starter relay, providing a thorough technical base for engine maintenance and system verification.

Specification and Reference Data

Technical data is provided for critical identification and maintenance tasks, including torque values, clearance limits, and fluid specifications. Specific fastener torques for chassis components are listed at 10 Nm for M6 screws and 25 Nm for M8 screws. The service information covers specific settings for outboard maintenance intervals and internal clearances. Rear axle bearing maintenance, piston and cylinder measurements, and valve clearance adjustments are fully documented with corresponding service limits. Brake system maintenance is highlighted with wear limits for discs specified at 3.5 mm (0.138 in). The official 2008 KTM 450 XC / 525 XC ATV workshop manual provides the essential data for servicing the XC series engine, chassis, and electrical components for the 2008 model year.