Category:
High-performance dual-sport motorcycle.
Target Audience:
Off-road enthusiasts, enduro riders, adventure riders seeking a capable and robust machine.
Competitors 2008:
Husqvarna TE510, Yamaha WR450F, Honda CRF450X, Suzuki DR-Z400S/E, Kawasaki KLX450R.
Engine Philosophy:
Powerful, torquey single-cylinder engine designed for off-road performance and endurance.
Chassis Design:
Lightweight and agile chassis, premium WP suspension components, robust build quality typical of KTM.
General Coverage:
Comprehensive service, repair, and troubleshooting for the 2008 KTM 530 EXC-R.
Specific Systems Covered:
Engine, fuel system, ignition system, cooling system, exhaust system, transmission, clutch, chassis, suspension (front and rear), brakes (front and rear), electrical system, wiring diagrams, bodywork, maintenance procedures, troubleshooting guides.
Estimated Page Count:
Likely 300-500 pages (typical for comprehensive service manuals of this era).
Type:
Service Repair Workshop Manual
Format:
Likely PDF (digital download) or printed copy.
Engine Mechanical:
Top-end overhaul (cylinder head, valves, piston), bottom-end overhaul (crankshaft, connecting rod, bearings), timing chain, lubrication system.
Fuel System:
Carburetor (likely Keihin FCR MX) or fuel injection system details, fuel pump, fuel filter, fuel lines, injectors.
Ignition System:
Ignition coil, spark plug, CDI unit, stator, troubleshooting ignition faults.
Cooling System:
Radiator, hoses, coolant, thermostat, fan operation.
Exhaust System:
Muffler, header pipe, emissions components.
Transmission Drivetrain:
Gearbox internals, shift mechanism, clutch operation, oil specifications, chain and sprocket maintenance.
Chassis Frame:
Frame inspection, mounting points, subframe.
Suspension Front:
Fork disassembly, seals, oil levels and type, spring rates, damping adjustments (compression and rebound).
Suspension Rear:
Shock absorber service, linkage maintenance, bearing replacement, spring adjustments.
Brakes Front:
Caliper service, master cylinder overhaul, brake pad replacement, fluid type and bleeding procedure, rotor specifications.
Brakes Rear:
Caliper service, master cylinder overhaul, brake pad replacement, fluid type and bleeding procedure, rotor specifications.
Electrical System:
Battery, starter motor, lighting, instrumentation, switches, fuses, relays.
Wiring Diagrams:
Detailed color-coded wiring schematics for all electrical components.
Scheduled Maintenance:
Oil changes, filter replacements, valve clearance checks, spark plug replacement, chain adjustment, brake system inspection.
Repair Procedures:
Step-by-step instructions for disassembly, inspection, repair, and reassembly of all major components.
Troubleshooting:
Diagnostic flowcharts and procedures for identifying and resolving common operational issues.
Torque Specifications:
Precise torque values for critical fasteners throughout the motorcycle.
Depth:
Covers everything from basic maintenance and adjustments to complete engine and transmission rebuilds, as well as in-depth electrical system diagnostics.
Digital Format:
PDF (Portable Document Format) - typically searchable and printable.
Digital Quality:
High-resolution scans or digital creation, ensuring clarity of text and diagrams.
Printed Binding:
If printed: Staple-bound, spiral-bound, or perfect-bound depending on the publisher.
Printed Paper:
If printed: Typically on durable, often coated paper to withstand shop use.
Engine Type:
4-stroke, single-cylinder, liquid-cooled, DOHC
Displacement:
510.6 cc (510.6 cm3)
Bore X Stroke:
95 mm x 72 mm (estimated based on similar models)
Compression Ratio:
11.1:1 (typical for this model)
Horsepower:
Approximately 50-55 HP (stock, estimated)
Torque:
Approximately 45-50 Nm (stock, estimated)
Carburetor Type:
Keihin FCR MX 41 (common for this era and model).
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/2 = 87 AKI.
Length:
Approximately 2200 mm (estimated)
Width:
Approximately 820 mm (estimated)
Height:
Approximately 1260 mm (estimated)
Wheelbase:
Approximately 1480 mm (estimated)
Dry Weight:
Approximately 115 kg (dry, estimated)
Wet Weight:
Approximately 125-130 kg (with all fluids, estimated)
Fuel Tank Capacity:
Approximately 9.5 Liters (standard)
Crash Test Ratings:
Not applicable for off-road motorcycles in the same way as street vehicles.
Braking System:
Hydraulic disc brakes front and rear (typically Brembo components).
ABS:
Not standard on this model.
Lighting:
Headlight, taillight, brake light, turn signals (depending on regional homologation).
Handlebar Design:
Fatbar handlebars with handguards for protection and control.
Engine Oil Change:
Every 15-20 hours of riding or annually (check manual for specific recommendation).
Oil Filter Replacement:
Concurrent with engine oil changes.
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions (e.g., every 5-10 hours).
Valve Clearance Check:
Every 30-40 hours of riding or annually.
Spark Plug Replacement:
Every 30-40 hours of riding or annually.
Engine Oil Type:
API SG or higher, JASO MA certified 10W-50 or 15W-50 motorcycle oil (e.g., Motorex Power Synth 4T 10W-50).
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, mixed 50/50 with distilled water (e.g., Motorex Coolant M3.0).
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, fork seals, chain and sprockets.
Engine Specific Notes:
Proper and frequent oil changes are crucial for the longevity of the LC4 engine. Overheating can lead to premature wear.
Ktm Legacy:
KTM, an Austrian manufacturer, has a long and storied history in off-road motorsport, particularly in motocross and enduro racing, earning the nickname 'Ready to Race'.
Exc Series:
The EXC series represents KTM's flagship enduro offerings, evolving from smaller displacement models to larger, more powerful single-cylinder machines capable of both off-road challenges and street legality (in some configurations).
530Cc Displacement:
The 530cc displacement marked a significant increase in power and torque for KTM's larger enduro line-up, offering a more potent alternative to the 450cc models.
Production Region:
Austria
