Vehicle Segment:
High-Performance Enduro Motorcycle
Target Audience:
Enthusiast riders, off-road racers, DIY mechanics
Key Competitors:
Husqvarna TE510, Beta RR525, Yamaha WR450F, Honda CRF450X
Manual Value:
Comprehensive, detailed, easy-to-understand, essential for maintenance and repair
Vehicle Attributes:
Powerful engine, advanced suspension, lightweight chassis, designed for off-road competition and trail riding
Powertrain:
Engine (Top End, Bottom End, Lubrication, Cooling), Fuel System (Carburetor/Injection, Fuel Pump, Lines), Ignition System, Exhaust System
Chassis:
Frame, Suspension (Front Fork, Rear Shock Absorber), Swingarm, Steering System, Wheels, Tires
Drivetrain:
Clutch, Transmission (Gearbox Internals, Shifting Mechanism), Final Drive (Chain, Sprockets)
Electrical:
Battery, Lighting System, Starter System, Wiring Harness, ECU (Engine Control Unit), Sensors
Braking:
Front and Rear Brake Systems (Hydraulic, Calipers, Master Cylinders, Hoses, Pads)
Bodywork And Controls:
Body Panels, Seat, Handlebars, Levers, Footpegs, Controls
Maintenance:
Oil Changes, Filter Replacements, Chain Adjustments, Spark Plug Service, Air Filter Cleaning/Replacement, Valve Clearance Checks/Adjustments
Repair:
Engine Rebuilds (Top and Bottom End), Transmission Overhaul, Suspension Servicing, Brake System Bleeding and Overhaul, Electrical Component Replacement, Chassis Component Repairs
Diagnostics And Troubleshooting:
Systematic diagnostic procedures, symptom-based troubleshooting, error code interpretation (if applicable)
Adjustments:
Carburetor/Fuel Injection Tuning, Clutch Adjustment, Brake Lever Adjustment, Suspension Sag and Damping Adjustments
Special Tools:
Identification and usage of specialized service tools required for specific procedures
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds)
Detail Level:
Step-by-step procedures, pictorial diagrams, exploded views, technical specifications, torque values, wear limits
Quality:
High Resolution, Readable Text
Searchability:
Likely text-searchable within PDF viewer
Printable:
Yes, all 244 pages are printable
Digital Format:
N/A (PDF)
Digital Format:
N/A (PDF)
Software:
Adobe Reader or compatible PDF viewer
Operating Systems:
Windows, macOS, Linux
Type:
Single-cylinder, 4-stroke
Displacement:
510.4 cc (31.1 cu in)
Bore X Stroke:
97.0 mm x 70.8 mm (3.82 x 2.79 in)
Compression Ratio:
11.5:1 (Typical)
Horsepower:
Approx. 55-60 HP (Estimate, varies by tuning and specific model year)
Torque:
Refer to manual for specific values (typically around 50-55 Nm)
Induction:
Keihin FCR 41 MX Carburetor (Likely, specific model year may vary)
Fuel Type:
Unleaded Gasoline (91+ Octane Recommended)
Type:
Digital CDI with variable ignition timing
System:
Semi-dry sump, separate oil reservoirs for engine and transmission
System:
Liquid-cooled with radiator and fan
Oil Change:
Refer to manual for specific intervals (typically every 15-30 hours of riding or annually)
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions (refer to manual)
Valve Clearance Check:
Refer to manual for specific intervals (e.g., every 50-100 hours)
Engine Oil Capacity:
Refer to manual (typically around 1.1-1.3 liters for engine and transmission combined)
Engine Oil Type:
KTM recommends specific high-quality motorcycle engine oils (e.g., Motorex Power Synt 4T 10W-50 or similar specifications)
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors (refer to manual for specific type and mixture ratio)
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid
Common Wear Items:
Clutch plates, brake pads, wheel bearings, steering head bearings, fork seals, chain and sprockets
Potential Concerns:
Regular maintenance is critical; some units may experience issues with fuel pump reliability or electrical connectors if not properly maintained/protected from elements.
Manufacturer:
KTM AG, Austria
Specialization:
Off-road motorcycles, racing heritage
Predecessors:
KTM 525 EXC, KTM 500 EXC models
Design Philosophy:
Focus on performance, lightweight, and rider feedback for off-road conditions
Manufacturing Location:
Austria (Likely)
