Workshop Manual KTM 530

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🏷️ Basic Information Identification Make: KTM Model: 530 EXC Model Variant: EXC Applicable Model Years: 2009-2011 Codes Engine Family Code: LC4 👋 Introduction Market Position Segment: Enduro / Off-Road Motorcycle...

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Type: Motorcycle

Vendor:

Sku: 364179

Tags: 530 KTM Motorcycle Motorcycles

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

530 EXC

Model Variant:

Applicable Model Years:

2009-2011

Codes

Engine Family Code:

👋 Introduction

Market Position

Segment:

Enduro / Off-Road Motorcycle

Target User:

Enthusiast riders, mechanics, and technicians performing maintenance and repairs on the KTM 530 EXC.

Competitive Analysis

Competitors:

Yamaha WR450F, Honda CRF450X, Husqvarna TE450, Beta RR450.

Key Features

Vehicle Focus:

Powerful single-cylinder engine, advanced WP suspension, capable off-road performance.

Manual Value Proposition:

Provides essential technical knowledge for maintaining and repairing the KTM 530 EXC, maximizing performance and longevity.

📋 Manual Details

Coverage Areas

Coverage Scope:

Complete Technical Manual

Page Count

Estimated Page Count:

Manual Type

Type:

Workshop Manual / Service Manual / Repair Manual

Language

Language:

Dutch (Compleet technical manual implies a comprehensive Dutch version)

Format

Format:

Digital (PDF assumed for 'Compleet technical manual' product description)

📖 Manual Coverage

Systems Covered

Engine And Powertrain:

Engine assembly, disassembly, tuning, lubrication system, cooling system, fuel injection, ignition system, exhaust system, clutch, gearbox.

Chassis And Suspension:

Frame, swingarm, front forks (WP USD), rear shock absorber (WP), steering system, wheels, bearings.

Brakes:

Brake system components (calipers, master cylinders, lines, discs), bleeding procedures, pad replacement, fluid specifications.

Electrical System:

Wiring diagrams, battery, starter, alternator, lighting, ignition, sensors, ECU, troubleshooting electrical faults.

Bodywork And Controls:

Plastics, seat, handlebars, levers, pedals, footpegs, fuel tank, instrumentation.

Procedures Included

Maintenance And Inspection:

Regular service checks, oil changes, filter replacements, chain adjustment, valve clearance checks, spark plug replacement.

Troubleshooting:

Diagnostic charts for common issues, fault identification, resolution steps.

Repair And Rebuild:

Detailed step-by-step instructions for engine rebuilds, suspension overhaul, brake system repairs, electrical component replacement.

Technical Adjustments:

Carburetor/FI tuning, suspension sag adjustment, chain slack adjustment, ignition timing checks.

Technical Depth

Depth:

Comprehensive: From basic maintenance to full engine and chassis rebuilds, including electrical system diagnostics.

📊 Manual Specifications

File Format

Digital Format:

PDF (Searchable, printable)

Print Quality

Digital Quality:

High-resolution scans or native digital files for clarity of diagrams and text.

Binding Type

Binding:

N/A (Digital format)

Paper Type

Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, single-cylinder, SOHC, 4 valves

Displacement:

510.4 cc (511 cc)

Bore X Stroke:

95 mm x 72 mm

Cooling System:

Liquid-cooled

Performance

Horsepower:

Approx. 55-60 HP (Varies by market and tune)

Torque:

Approx. 55 Nm (Varies by market and tune)

Fuel System

Fuel Delivery:

Keihin FCR 41 MX Pumper carburetor (some models may have EFI variants in later years, but 2009-2011 are typically carbureted EXC models)

Fuel Type:

Unleaded gasoline, minimum 95 RON

Lubrication System

Oil Type:

Synthetic Motorcycle Oil, SAE 10W-50 or 15W-50 (refer to manual for specific KTM specs)

Oil Capacity:

Approx. 1.1 - 1.3 Liters (Check manual for exact amount with filter change)

Ignition System

Ignition Type:

Digital CDI

Engine Codes

Engine Serial Number Location:

Stamped on crankcase.

🔧 Transmission

Standard

Type:

6-speed constant mesh gearbox

Optional

Optional Transmissions:

N/A (Standard for this model)

Features

Clutch Type:

Hydraulically operated, multi-disc wet clutch (Magura HC3)

Transmission Fluid:

Use engine oil (same as lubrication system)

Gear Ratios

Gear Ratios 1-6:

Manual will contain specific ratios, typically optimized for off-road use.

📐 Dimensions

Exterior

Length:

Approx. 2270 mm

Width:

Approx. 820 mm (excluding mirrors)

Height:

Approx. 1265 mm

Seat Height:

Approx. 990 mm

Ground Clearance:

Approx. 355 mm

Weights

Dry Weight:

Approx. 116 kg (without fuel)

Kerb Weight:

Approx. 126 kg (with all fluids, ready to ride)

Max Payload:

Refer to manual for rider and luggage capacity.

Fuel Capacity

Fuel Tank Capacity:

Approx. 8.5 Liters (including reserve)

Wheelbase

Wheelbase:

Approx. 1520 mm

🛡️ Safety Features

Ratings

Safety Certification:

CE certified for road legality in some markets, but primarily designed for off-road competition.

Active Features

Braking System:

Hydraulic disc brakes front and rear (Brembo components typically).

Suspension Performance:

WP USD forks and WP PDS rear shock provide excellent control and bump absorption.

Passive Features

Frame Strength:

Chromoly steel trellis frame for rigidity and impact resistance.

Ergonomics:

Designed for rider control and comfort during aggressive off-road riding.

💡 Technology Features

Infotainment

Instrumentation:

Digital display with tachometer, speedometer, odometer, trip meter, clock, and warning lights.

Driver Assistance

Traction Control:

N/A (No electronic rider aids typically found on this era of EXC models)

Other Features

Lighting System:

Halogen headlight and taillight.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 10-15 hours of riding or annually. (Specific interval in manual)

Air Filter Cleaning:

As needed, depending on riding conditions (frequently in dusty environments).

Valve Clearance Check:

Every 20-30 hours of riding or annually. (Critical for performance and engine health)

Spark Plug Replacement:

Refer to manual; typically every 30-50 hours or annually.

Chain And Sprockets Inspection:

Regularly, adjust tension as needed, replace when worn.

Fluid Specifications

Engine Oil Specification:

SAE 10W-50 or 15W-50 Synthetic Motorcycle Oil (JASO MA/MA2)

Coolant Type:

Ethylene glycol-based coolant (50/50 mix with distilled water)

Brake Fluid Type:

DOT 4 brake fluid

Known Issues

Typical Wear Items:

Clutch plates, wheel bearings, steering head bearings, fork seals, brake pads, chain, sprockets.

Engine Considerations:

Valve clearance drift, potential for cam chain tensioner issues with high mileage (check manual for specific recommendations).

Fuel System Considerations:

Carburetor jetting may need adjustment based on altitude and temperature for optimal performance.

Part Numbers

Oil Filter Part Number:

Refer to manual or KTM parts catalog for specific filter element (e.g., Hiflofiltro HF155 or equivalent OEM part).

📚 Vehicle History

Brand Heritage

Ktm Offroad Focus:

KTM has a long and successful history in off-road racing, including motocross, enduro, and rally raids.

Model Evolution

Lc4 Engine Lineage:

The 530 EXC is part of the evolution of KTM's powerful LC4 engine platform, known for its torque and durability.

Exc Series:

The EXC series represents KTM's commitment to producing high-performance, competition-ready enduro motorcycles.

Production

Production Period:

The 530 EXC designation was used in the late 2000s and early 2010s, evolving from previous 525 and 530 models.

Manufacturing Location:

Austria (KTM is an Austrian manufacturer)

🏆 Awards & Recognition

Recognitions

Offroad Performance Awards:

KTM models frequently win awards and accolades in off-road publications and competitions due to their performance and durability.

Ratings

Industry Reviews:

KTM 530 EXC models generally received positive reviews for their potent engines and superior suspension handling in the competitive enduro segment.

Certifications

Emissions Standards:

Met applicable emissions standards for its model years and intended markets.