This manual covers the 450 EXC-R, 530 EXC-R, 450 SIX DAYS, 530 SIX DAYS, 450 XCR-W, 530 XCR-W, 450 XEC-W, and 530 XEC-W motorcycles from the 2008 model year. As an Austrian manufacturer with a strong racing heritage, KTM is known for producing high-performance off-road motorcycles. These models, equipped with single-cylinder, 4-stroke LC4 engines in 449.3cc and 510.4cc displacements, offer robust performance for demanding off-road applications, building upon the legacy of previous EXC and RFS models. They feature liquid-cooled engines, fuel injection, electric starters, and 6-speed manual transmissions with hydraulic wet clutches, all contributing to their reputation for engineering quality and reliability in competitive environments.
This comprehensive workshop service repair manual provides factory-level detail essential for the maintenance and repair of your motorcycle. It covers all major systems, including engine overhaul, lubrication, cooling, fuel, ignition, exhaust, starting, and emission controls, as well as transmission, drivetrain, chassis, suspension, electrical systems, and braking. The manual includes detailed procedures for scheduled maintenance, oil changes, filter replacements, fluid checks, and component repairs, alongside in-depth troubleshooting guidance and diagnostic procedures. With clear, step-by-step instructions and zoomable illustrations, this manual is an invaluable resource for owners, professional mechanics, and restoration enthusiasts seeking to maintain their motorcycles in optimal condition.
    
    
    
    
    
        
            Model:
        
        
            450 EXC-R, 530 EXC-R, 450 SIX DAYS, 530 SIX DAYS, 450 XCR-W, 530 XCR-W, 450 XEC-W, 530 XEC-W
        
     
    
    
    
        
            Region Coverage:
        
        
            EU, AUS, UK, ZA
        
     
 
    
    
    
        
            Target Audience:
        
        
            KTM owners performing DIY repairs, professional motorcycle mechanics, restoration enthusiasts
        
     
    
    
        
            Competitor Manuals:
        
        
            This manual rivals factory service manuals in its detail and scope, offering significant cost savings over dealership-only service.
        
     
    
    
        
            Key Selling Points:
        
        
            Comprehensive coverage, clear step-by-step instructions, troubleshooting assistance, professional technician level detail, instant download, cost savings on repairs.
        
     
    
        
            Manual Source:
        
        
            Official factory or workshop produced
        
     
 
    
    
    
        
            Manual Coverage Regions:
        
        
            EU, Australia, United Kingdom, South Africa
        
     
    
    
        
            Estimated Page Count:
        
        
            Variable (Large file size up to 2550 MB indicates comprehensive detail)
        
     
    
    
        
            Manual Type:
        
        
            Workshop Service Repair Manual
        
     
    
    
        
            Language:
        
        
            English (Implied by typical market manuals and description)
        
     
    
    
        
            Digital Format:
        
        
            PDF (Downloadable, potentially zipped)
        
     
 
    
    
    
        
            Engine Systems:
        
        
            Engine overhaul, lubrication, cooling, fuel system, ignition system, exhaust system, starting system, emission control
        
     
    
        
            Transmission Drivetrain:
        
        
            Clutch, gearbox, final drive, chain maintenance
        
     
    
        
            Chassis Suspension:
        
        
            Frame, suspension (front and rear forks, shock absorber), steering system, wheels, tires
        
     
    
        
            Electrical System:
        
        
            Battery, charging system, lighting, instrumentation, wiring diagrams, ignition system diagnostics
        
     
    
        
            Braking System:
        
        
            Hydraulic brake system (front and rear calipers, master cylinders, lines), brake pad replacement, bleeding procedure
        
     
    
        
            Bodywork And Fairings:
        
        
            Body panel removal and installation, seat, fuel tank, fenders
        
     
    
    
        
            Maintenance Procedures:
        
        
            Scheduled maintenance, oil changes, filter replacements, lubrication, bolt torques, fluid checks and changes
        
     
    
        
            Repair Procedures:
        
        
            Engine rebuilds, transmission repairs, suspension servicing, brake system overhaul, electrical component replacement
        
     
    
        
            Troubleshooting:
        
        
            Diagnostic procedures, common fault identification and rectification, error code explanations (if applicable)
        
     
    
        
            Restoration And Rebuilding:
        
        
            Detailed guidance for complete disassembly and reassembly of major components
        
     
    
    
        
            Depth Of Information:
        
        
            Comprehensive factory-level detail, suitable for professional technicians and advanced DIY enthusiasts
        
     
    
        
            Diagnostic Capabilities:
        
        
            In-depth diagnostic procedures, including electrical system analysis and troubleshooting
        
     
    
        
            Component Breakdowns:
        
        
            Detailed exploded views and part breakdowns for all major assemblies and components
        
     
 
    
    
    
    
        
            File Size Potential:
        
        
            Up to 2550 MB
        
     
    
        
            Additional Software Requirements:
        
        
            PDF Reader, ZIP/RAR utility (for unzipping)
        
     
    
    
        
            Printability:
        
        
            Printable on any computer and printer
        
     
    
        
            Illustration Quality:
        
        
            Zoomable illustrations, clear step-by-step instructions
        
     
    
    
        
            Binding Type:
        
        
            Digital Download (Not a physical copy)
        
     
    
    
        
            Paper Type:
        
        
            N/A (Digital file)
        
     
 
    
    
    
        
            Engine Type:
        
        
            Single-cylinder, 4-stroke (LC4 engine family variants)
        
     
    
        
            Bore X Stroke 450:
        
        
            Approx. 95 mm x 63.4 mm
        
     
    
        
            Bore X Stroke 530:
        
        
            Approx. 97 mm x 70.6 mm
        
     
    
        
            Displacement 450:
        
        
            Approx. 449.3 cc
        
     
    
        
            Displacement 530:
        
        
            Approx. 510.4 cc
        
     
    
    
        
            Horsepower Estimated:
        
        
            Approximately 50-60 HP (model dependent, off-road specific tuning)
        
     
    
        
            Torque Estimated:
        
        
            Approximately 45-55 Nm (model dependent)
        
     
    
    
        
            Fuel Delivery:
        
        
            Fuel Injection (Keihin or similar ECU controlled system)
        
     
    
        
            Fuel Type:
        
        
            Unleaded gasoline (Octane rating specified in manual)
        
     
    
    
        
            Cooling Method:
        
        
            Liquid-cooled
        
     
    
    
        
            Oil Type:
        
        
            Semi-synthetic or fully synthetic motorcycle specific engine oil (refer to manual for exact specifications like API, JASO MA/MA2 standards and viscosity)
        
     
    
    
        
            Valve Train:
        
        
            SOHC (Single Overhead Camshaft) with rocker arms
        
     
    
        
            Starter:
        
        
            Electric starter
        
     
 
    
    
    
        
            Transmission Type:
        
        
            6-speed manual transmission
        
     
    
        
            Clutch Type:
        
        
            Hydraulic operated multi-plate wet clutch
        
     
    
    
        
            Gear Ratios:
        
        
            Detailed gear ratios provided in manual for each gear
        
     
    
        
            Transmission Fluid:
        
        
            Specific transmission oil/fluid type and capacity detailed in manual (often shared with engine oil or specific gearbox oil)
        
     
 
    
    
    
        
            Wheelbase:
        
        
            Approximately 1480-1500 mm (model dependent)
        
     
    
    
        
            Dry Weight:
        
        
            Approximately 115-125 kg (model dependent)
        
     
    
        
            Fuel Tank Capacity:
        
        
            Approximately 9.5 - 11.0 Liters (model dependent)
        
     
 
    
    
    
        
            Safety Certification:
        
        
            CE marking (for EU models) and relevant local certifications
        
     
    
    
        
            Braking System Type:
        
        
            Hydraulic disc brakes front and rear
        
     
    
        
            Suspension Type:
        
        
            High-performance WP suspension (USD forks front, Monoshock rear with linkage)
        
     
 
    
    
    
        
            Infotainment Features:
        
        
            Basic instrumentation cluster (speedometer, odometer, tachometer, warning lights). No advanced infotainment systems.
        
     
    
    
        
            Driver Assistance Systems:
        
        
            N/A (Off-road motorcycle designed for rider control).
        
     
    
    
        
            Connectivity Features:
        
        
            N/A
        
     
 
    
    
    
        
            Oil Change Interval:
        
        
            Typically every 50-100 operating hours or annually (refer to specific manual section for precise intervals based on usage)
        
     
    
        
            Air Filter Cleaning:
        
        
            Regularly, depending on riding conditions (frequently in dusty environments)
        
     
    
        
            Valve Clearance Check:
        
        
            Specified interval in operating hours or mileage (e.g., every 100-200 hours)
        
     
    
    
        
            Engine Oil Viscosity:
        
        
            Commonly SAE 10W-50 or 15W-50 (confirm with manual for exact specification)
        
     
    
        
            Coolant Type:
        
        
            Ethylene glycol based coolant with corrosion inhibitors (e.g., Motorex M3.0 or equivalent)
        
     
    
        
            Brake Fluid Type:
        
        
            DOT 4 hydraulic brake fluid
        
     
    
    
        
            Common Wear Items:
        
        
            Clutch plates, piston rings, valve guides, suspension seals, chain and sprockets.
        
     
    
        
            Potential Electrical Concerns:
        
        
            Wiring harness integrity in exposed areas, battery charging system components (stator, regulator) subject to vibration.
        
     
 
    
    
    
        
            Brand Origin:
        
        
            Austrian manufacturer with a strong heritage in off-road and racing motorcycles.
        
     
    
    
        
            Model Lineage:
        
        
            Successor to previous KTM EXC and RFS (Ready For السير) models, evolving the LC4 engine platform.
        
     
    
    
        
            Production Period:
        
        
            2008 model year, part of the second generation of EXC-R models.
        
     
 
    
    
    
        
            Off Road Performance:
        
        
            KTM models of this era are renowned for their off-road prowess and competitive success in various enduro and rally events.