Segment Focus:
High-performance off-road motorcycles designed for competition and demanding terrain
Competitors:
Yamaha WR series, Honda CRF-X series, Suzuki RM-Z/RMX series, Husqvarna FE series
Brand Philosophy:
Readiness for racing (READY TO RACE), performance-oriented engineering
Model Strength:
Powerful engines, advanced chassis design, extensive aftermarket support, specialized components for 'Six Days' models.
Covered Models:
450 EXC EU, 450 EXC AUS, 450 EXC SIX DAYS EU, 450 XC-W USA, 500 EXC EU, 500 EXC AUS, 500 EXC SIX DAYS EU, 500 EXC USA, 500 XC-W USA
Type:
Factory Service Manual / Repair Manual
Format:
Printed (Implied by context, factory manuals are typically printed)
Engine:
Complete Engine Overhaul and Repair (450cc and 500cc Single-Cylinder)
Transmission:
Gearbox Repair, Clutch Service, Shifting Mechanism
Fuel System:
Fuel Injection (EFI) System, Fuel Pump, Injectors, Throttle Body
Electrical System:
Ignition System, Lighting, Battery, Starter Motor, Wiring Diagrams, ECU Diagnostics
Chassis:
Frame, Swingarm, Suspension (Front and Rear), Steering Assembly
Brakes:
Brake System Components (Calipers, Master Cylinders, Lines), Bleeding Procedures, Pad Replacement
Cooling System:
Radiator, Cooling Fan, Coolant Flow, Thermostat
Exhaust System:
Exhaust Pipe, Muffler, Sensor Maintenance
Wheels Tires:
Wheel Bearing Service, Tire Installation and Removal
Bodywork:
Panel Removal and Installation, Seat Service
Maintenance:
Scheduled Maintenance, Fluid Changes, Filter Replacements, Chain Adjustment
Troubleshooting:
Fault Diagnosis for all Major Systems, Diagnostic Codes (if applicable to the model year)
Repair:
Component Repair, Reassembly, Calibration
Overhaul:
Complete Engine and Transmission Rebuilds
Technical Specifications:
Torque Values, Clearances, Tolerances, Fluid Capacities, Electrical Specifications
Efficient Repair:
Step-by-step instructions designed for correct and efficient repairs
Depth:
Comprehensive from basic checks to complete engine and chassis rebuilds
Diagrams Illustrations:
Top quality diagrams, pictures, and illustrations for clarity
Component Functionality:
Explanation of component functions included
Avoid Errors:
Aids in avoiding mistakes and ensures proper execution of tasks
Digital Format:
N/A (Likely printed, but if digital, expect PDF)
Text Readability:
Easy-to-read text sections
Visual Quality:
Top quality diagrams, pictures, and illustrations
Binding:
Professional binding (typical for factory manuals)
Paper Quality:
Durable, high-quality paper suitable for workshop use
Scope:
Covers entire bike, engine, and chassis
Engine Type:
Single-Cylinder, 4-Stroke
Displacement 450:
Approximately 449.3 cc (Engine code LC4)
Displacement 500:
Approximately 510.4 cc (Engine code LC4)
Bore Stroke 450:
95 mm x 63.4 mm (Approximate, refer to manual for exact)
Bore Stroke 500:
97 mm x 70.6 mm (Approximate, refer to manual for exact)
Valve Train:
DOHC, 4 Valves
Fuel Delivery:
Electronic Fuel Injection (EFI) - Keihin
Throttle Body Size:
42 mm (Typical for this era)
Safety Certification:
CE certified for EU models
Braking System:
Hydraulic Disc Brakes Front and Rear (High-performance, e.g., Brembo)
Suspension Features:
Adjustable WP Suspension (USD front forks, Monoshock rear) for optimized handling and control.
Oil Change Interval:
15-30 Operating Hours or Annually (Refer to manual for specific conditions)
Air Filter Cleaning:
Every 5-10 Operating Hours (or as needed based on conditions)
Spark Plug Inspection:
Every 15-30 Operating Hours
Engine Oil Type:
JASO MA or MA2, SAE 10W-50 (e.g., Motorex Power Synt SAE 10W/50 or equivalent)
Engine Oil Capacity:
Approx. 1.1 Liters (Refer to manual for exact capacity)
Coolant Type:
Ethylene Glycol Based Coolant (Antifreeze/Summer protection, 50/50 mix with distilled water)
Clutch Fluid Type:
DOT 4 (For hydraulic clutch actuation)
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, brake pads, chain and sprockets.
Engine Considerations:
Regular valve clearance checks are critical for long-term engine health. Ensure proper air filter maintenance to prevent engine wear.
Brand Awards:
KTM frequently wins championships in off-road racing disciplines (Enduro, Rally, Motocross) with their EXC and SX platforms.
Industry Recognition:
KTM EXC models are widely recognized for their performance, durability, and off-road capabilities.
