Vehicle Type:
High-performance Off-Road Motorcycle (Enduro/Cross-Country)
Competitors Of Era:
Honda XR series, Yamaha WR series, Suzuki DR-Z series, Husaberg FE series, Husqvarna TE series.
Engine Configuration:
Powerful single-cylinder, liquid-cooled engine known for strong torque and top-end power.
Suspension Technology:
Advanced WP suspension components designed for aggressive off-road riding, providing excellent damping and adjustability.
Chassis Design:
Lightweight and robust chromoly steel trellis frame for agile handling and durability.
Engine Service:
Detailed engine disassembly, assembly, inspection, adjustment, and repair procedures for the 525cc LC4 engine.
Fuel System Service:
Carburetor (likely Keihin FCR) service, adjustment, cleaning, and troubleshooting, fuel pump, and fuel lines.
Ignition System Service:
CDI ignition system, spark plug inspection and replacement, ignition timing checks.
Transmission Service:
Gearbox inspection, disassembly, assembly, clutch service (hydraulic actuation), and gear shift mechanism.
Suspension Service:
Front fork (WP USD - Upside Down) overhaul, seal replacement, oil level and type, rear shock absorber (WP) service and adjustment.
Brakes Service:
Hydraulic brake system maintenance, bleeding, caliper service, master cylinder overhaul, brake pad replacement, rotor inspection.
Electrical System Service:
Wiring diagrams, lighting systems, starter system, battery maintenance, troubleshooting electrical faults.
Cooling System Service:
Radiator, coolant hoses, thermostat, and coolant type/capacity.
Exhaust System Service:
Exhaust pipe and muffler inspection, gasket replacement.
Frame And Bodywork Service:
Frame inspection, swingarm pivot, linkage system maintenance, body panel removal and installation.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, brake checks, general inspections.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, fault identification.
Disassembly Assembly:
Step-by-step instructions for removing and reinstalling all major and minor components.
Repair Rebuild:
Detailed guidance on repairing or rebuilding worn or damaged components.
Adjustments:
Precise instructions for valve clearance adjustment, carburetor tuning, clutch and brake lever adjustments.
Special Tool Usage:
Identification and application guidance for specialized tools required for specific repair tasks.
Diagnostic Capabilities:
Comprehensive diagnostic flowcharts and troubleshooting trees to identify root causes of problems.
Rebuild Specifications:
Detailed specifications for component measurements, wear limits, and tolerances for rebuilding.
Pictorial Guidance:
Extensive use of illustrations, exploded diagrams, drawings, and photographs to clarify procedures.
Torque Specifications:
Precise torque values for all critical fasteners, essential for safe and reliable assembly.
Factory Specifications:
Includes factory-recommended specifications, adjustments, and maintenance data.
Engine Type:
4-stroke, SOHC, liquid-cooled, single-cylinder (LC4 family)
Displacement:
Approximately 510.4 cc (exact may vary slightly based on specific internal components)
Bore X Stroke:
Typically around 95 mm x 72 mm (confirmation required from manual specifics)
Horsepower Estimated:
Estimated 50-55 HP (at crankshaft, for models of this era)
Torque Estimated:
Strong mid-range and top-end torque, characteristic of the LC4 engine.
Carburetor:
Likely Keihin FCR 39mm or similar performance carburetor.
Fuel Delivery:
Gravity feed from tank to carburetor, with electric fuel pump for priming (if applicable to specific sub-model).
Oil System:
Semi-dry sump lubrication system.
Oil Change Interval:
Typically every 10-15 hours of riding, or as specified in the manual.
Air Filter Cleaning:
Regular cleaning recommended, especially in dusty conditions, often every few rides.
Valve Clearance Check:
Recommended every 20-30 hours of riding, or as specified.
Engine Oil Type:
High-quality synthetic motorcycle oil, typically SAE 10W-50 or 15W-50, meeting JASO MA/MA2 specifications.
Fork Oil Type:
Specific WP fork oil (e.g., WP Suspension Fluid 7.5W or equivalent) with precise level measurements.
Coolant Type:
Ethylene glycol-based antifreeze with corrosion inhibitors, typically a 50/50 mix with distilled water.
Clutch Slave Cylinder:
Early models could sometimes experience issues with the hydraulic clutch slave cylinder, though improvements were made over the years.
Carburetor Tuning:
While generally robust, the FCR carburetor may require periodic fine-tuning based on altitude and riding conditions.
Kickstarter Engagement:
Occasional reports of issues with the kickstarter mechanism, often related to wear or spring fatigue.
Ktm Offroad Legacy:
KTM has a long and distinguished history in off-road motorsports, particularly in enduro and motocross, earning the nickname 'Ready to Race'.
Xcw Exc Lineage:
The XC-W and EXC lines represent KTM's dedicated enduro motorcycles, emphasizing performance, durability, and off-road capability.
Rfs Engine Platform:
The 525cc engine used in this period is part of KTM's highly regarded RFS (Ready For السلندر) engine family, known for its robust performance and reliability in demanding conditions.
Manufacturing Location:
Austria (KTM AG)
