Positioning:
Premium, high-performance off-road motorcycle, targeted at enthusiasts and professional racers.
Competitors:
Husqvarna TE510, Beta RR525, Gas Gas EC515, Yamaha WR450F, Honda CRF450X.
Vehicle Features:
Six Days edition typically includes upgraded components and special graphics, emphasizing off-road racing prowess. Known for powerful engine, strong suspension, and agile handling.
Value:
Empowers owners to perform all maintenance and repairs, saving significant labor costs ($50-$60/hour savings claimed). Provides factory-level knowledge for informed decision-making and effective communication with mechanics.
Regions Covered:
Global (as it's a factory manual, not region-specific)
Estimated Pages:
Hundreds (explicitly stated in product description)
Type:
Factory Service Repair Manual
Authenticity:
Actual Genuine Repair Service Factory Manuals, not third-party.
Delivery Method:
Instant download link provided on the checkout page after payment.
Software Requirements:
Adobe PDF Reader.
Engine Mechanical:
Engine top end, lubrication system, crankshaft, transmission, engine removal/installation
Fuel System:
Fuel system components, tuning, and diagnostics
Cooling System:
Cooling system components and maintenance
Drivetrain:
Clutch, final drive, wheels, tires
Chassis And Suspension:
Brakes, suspension, steering, frame
Electrical System:
Electrical system, wiring diagrams, diagnostics
General Information:
Includes general overview, specifications, and vehicle identification information.
Appendix:
Contains supplementary information, potentially including torque specifications, special tools, or troubleshooting flowcharts.
Maintenance:
Routine servicing, fluid changes, filter replacements, pre-ride checks
Diagnostics:
Engine fault symptom diagnosis, electrical troubleshooting, component testing
Repair:
Step-by-step repair procedures for all covered systems, including major component overhauls
Tuning:
Engine management system analysis and potential tuning advice
Troubleshooting:
Advanced troubleshooting guide for common and uncommon issues
Wiring Diagrams:
Detailed and traceable wiring diagrams are provided for comprehensive electrical system diagnostics and repair.
Depth:
Comprehensive: Covers all aspects from basic maintenance to full engine rebuilds and complex electrical diagnostics, reflecting factory technician knowledge.
Illustrations And Diagrams:
Includes hundreds of illustrations, drawings, and photos to guide procedures. Features enlarged inset views for detailed part examination and clear wiring diagrams.
Troubleshooting Guide:
Advanced troubleshooting guide integrated to help diagnose and rectify any problem encountered.
Printability:
Printable without restriction, high resolution
Binding:
Digital Download (Printable as needed)
Digital Medium:
Downloadable to PC, Mac, or CD-ROM
Type:
4-stroke, single-cylinder, liquid-cooled, DOHC
Bore X Stroke:
95 mm x 72 mm
Compression Ratio:
Likely around 12.0:1 (typical for this performance level)
Horsepower Estimated:
Approximately 55-60 HP (at crankshaft, specific figures often not published for off-road models)
Torque Estimated:
Approximately 50-55 Nm (at crankshaft)
Carburetor:
Keihin FCR 41 MX (or similar performance-oriented carburetor)
Fuel Type:
Unleaded gasoline, minimum 95 octane recommended.
System Type:
Carburetor-based engine management (refer to 'fuel_system' for specific carburetor type).
Type:
6-speed, sequential claw-shifted gearbox
Clutch Type:
Wet multi-disc clutch, hydraulically operated (KTM PowerParts/Brembo often featured)
Gear Ratios:
Specific ratios would be detailed in the manual, but designed for off-road performance.
Wheelbase:
Approximately 1480 mm (58.3 in)
Seat Height:
Approximately 980 mm (38.6 in) (unladen)
Dry Weight Estimated:
Approximately 110 kg (242.5 lbs)
Fuel Tank Capacity:
Approximately 7.5 liters (1.98 US gal), may vary slightly with specific Six Days tank.
Braking System:
Hydraulic disc brakes front and rear, typically with Brembo components. Front: Dual piston caliper. Rear: Single piston caliper.
Frame Design:
Chromium-Molybdenum steel trellis frame, designed for rigidity and impact absorption.
Off Road Protection:
Handguards, skid plate (often standard on Six Days), and robust construction suitable for demanding terrain.
Display:
Minimalist digital instrument cluster displaying speed, trip meters, time, and basic warning lights (e.g., oil pressure, neutral). No complex infotainment systems.
Electronic Aids:
None typical for this era and type of motorcycle. Focus is on rider control and mechanical feedback.
Features:
No onboard connectivity features. Focus is on mechanical function.
Oil Change:
Engine oil and filter change typically every 15-20 hours of riding or annually, whichever comes first. The manual will provide precise intervals.
Air Filter Cleaning:
Frequent cleaning (every few rides) recommended, especially in dusty conditions. Detailed cleaning procedure in manual.
Valve Clearance Check:
Typically every 50-100 hours of riding. Critical for engine longevity and performance. Manual provides specifications and procedure.
Engine Oil:
KTM typically recommends specific semi-synthetic or fully synthetic motorcycle oils meeting JASO MA/MA2 standards. Viscosity: 10W-50 is common. Manual will specify exact grade and capacity (approx. 1.1 - 1.2 liters).
Coolant:
Ethylene glycol based coolant, typically a 50/50 mix with distilled water. Manual will specify capacity.
Brake Fluid:
DOT 4 recommended for hydraulic clutch and brake systems. Manual will confirm.
Common Wear Items:
Clutch plates, piston rings, valve guides, fork seals, wheel bearings, chain and sprockets are common wear items on high-performance off-road bikes.
Potential Failures:
While generally robust, improper maintenance can lead to premature wear on the engine's top end or transmission components. Fueling issues can arise from carburetor tuning in varied conditions.
Heritage:
KTM is renowned for its off-road racing heritage, with a strong history in motocross, enduro, and Dakar Rally. The 'EXC' designation signifies their Enduro line.
Evolution:
The 530 EXC-R replaced earlier 450 and 525 models, offering increased displacement and performance. The 'Six Days' moniker refers to the International Six Days Enduro (ISDE), with special edition models featuring enhancements and specific graphics.
