KTM 530 EXC EU 2010 User Manual

OWNER'S MANUAL 2010
400 EXC EU
400 EXC AUS
400 XC-W USA
450 EXC EU
450 EXC AUS
450 EXC SIX DAYS EU
450 XC-W SIX DAYS USA
450 XC-W ZA
530 EXC EU
530 EXC AUS
530 EXC SIX DAYS EU
530 XC-W SIX DAYS USA
530 XC-W ZA
Art. no. 3211467en

KTM 530 EXC EU 2010 Specifications

General

Engine Type	Single-cylinder, 4-stroke
Displacement	510.4 cc
Bore x Stroke	95 mm x 72 mm
Compression Ratio	11.9:1
Transmission	6-speed
Front Suspension	WP USD 48 mm
Front Brake	260 mm disc
Cooling	Liquid cooled
Front tire	90/90-21
Rear tire	140/80-18
Fuel System	Keihin FCR MX 41
Rear Suspension	WP PDS monoshock
Ignition	Digital
Wheelbase	1485 mm
Starter	Electric
Frame	Chromium molybdenum steel

Summary

Means of Representation

Important Information

Use Definition (All Models)

Describes the intended use and limitations of the motorcycle.

Maintenance and Warranty

Covers maintenance importance and warranty conditions.

Fuel, Oils, and Accessories

Specifies required fluids, oils, and recommended parts.

Work Rules

Outlines general procedures and requirements for service work.

Transport and Environment

Details safe transport practices and environmental considerations.

View of Vehicle

Left Front View

Illustrates and labels components visible from the front-left.

Right Rear View

Illustrates and labels components visible from the rear-right.

Location of Serial Numbers

Chassis, Type, and Key Numbers

Locates chassis, type label, and key numbers.

Engine and Fork Part Numbers

Identifies locations for engine and fork part numbers.

Shock Absorber Part Number

Shows where to find the shock absorber part number.

Controls

Levers and Basic Switches

Covers clutch, hand brake, short circuit, and emergency OFF buttons.

Starting, Lighting, and Horn

Details electric starter, light switch, and horn controls.

Flasher Switch and Indicators

Explains flasher switch and indicator lamp functions.

Speedometer Overview

Basic speedometer functions, activation, and display modes.

Speedometer Modes and Settings

Tripmaster, unit, and clock settings for the speedometer.

Advanced Speedometer Functions

Configuring speedometer displays and querying lap times.

Speed Display Modes (Speed, Hours, Clock, Lap)

Details speed, service hours, clock, and lap time display modes.

Speed Display Modes (Odometer, Trips)

Explains odometer and trip meter display modes.

Speed Display Modes (Average Speed, Stop Watch)

Details average speed and stop watch display modes.

Fuel Tap and Filler Cap

Describes fuel tap operation and filler cap procedures.

Choke Operation

Explains choke usage for engine starting.

Shift Lever, Foot Brake, and Kick Starter

Covers gear shift, rear brake, and kick starter.

Side Stand and Steering Lock

Details parking and steering lock mechanisms.

Unlocking the Steering

Procedure for unlocking the steering mechanism.

General Tips and Hints on Putting into Operation

First Use Advice and Safety

Covers crucial safety precautions for new riders.

Engine Break-in and Riding Preparation

Details engine break-in and prep for varied riding conditions.

Riding Condition Preparations

Specific preparation tips for different terrains and temperatures.

Riding Instructions

Pre-Ride Checks and Starting

Lists essential checks before riding and engine starting.

Riding and Shifting

Explains gear changes, riding techniques, and safety warnings.

Braking, Stopping, and Refueling

Covers braking, parking, and fuel filling procedures.

Service Schedule

Authorized Workshop Maintenance

Lists scheduled maintenance tasks for KTM workshops.

Rider Maintenance Tasks

Details checks and maintenance the owner can perform.

Maintenance Work on Chassis and Engine

Jacking and Basic Suspension Setup

Procedures for lifting the motorcycle and initial suspension adjustment.

Shock Absorber Damping Adjustment

Adjusting high-speed, low-speed compression, and rebound damping.

Suspension Sag Measurement

Measuring static and riding sag for suspension tuning.

Shock Absorber Spring Preload

Adjusting spring preload and related removal/installation.

Fork Adjustment and Basic Settings

Checking fork settings and adjusting damping.

Steering Head Bearing Play

Checking and adjusting steering head bearing play.

Fork Leg and Protector Maintenance

Procedures for removing and installing fork legs and protectors.

Front Fender Maintenance

Steps for removing and installing the front fender.

Headlight Mask and Start Number Plate

Removing/installing headlight mask and start number plate.

Handlebar Position Adjustment

Adjusting handlebar position and clamp settings.

Throttle Cable Adjustment

Checking and adjusting throttle cable play.

Chain Inspection and Cleaning

Checking chain for dirt accumulation and cleaning.

Chain Tension Adjustment

Checking and adjusting chain tension and alignment.

Chain Guide and Brake Disc Checks

Adjusting chain guide and checking brake disc wear.

Hand Brake Lever Adjustment

Checking and adjusting hand brake lever free travel and position.

Front Brake Fluid Maintenance

Checking and topping up front brake fluid level.

Front Brake Lining Maintenance

Checking and changing front brake linings.

Foot Brake Lever and Rear Brake Fluid

Foot brake lever checks and rear brake fluid level.

Rear Brake Fluid Addition

Procedure for adding fluid to the rear brake circuit.

Rear Brake Lining Maintenance

Checking and changing rear brake linings.

Front Wheel Removal and Installation

Procedures for removing and fitting the front wheel.

Rear Wheel Removal and Installation

Procedures for removing and fitting the rear wheel.

Tire Condition Check

Inspecting tires for wear, damage, and age.

Tire Air Pressure and Spoke Tension

Checking tire air pressure and spoke tension.

Battery Maintenance

Removing, installing, and recharging the battery.

Fuse and Battery Charging

Fuse replacement and battery charging procedures.

Headlight Adjustment

Checking and adjusting headlight alignment and beam width.

Seat and Fuel Tank Maintenance

Procedures for removing and installing the seat and fuel tank.

Cooling System Overview

General information on the motorcycle's cooling system.

Coolant Draining and Refilling

Procedures for draining and refilling the coolant.

Anti-freeze and Coolant Level Checks

Checking coolant and anti-freeze levels.

Silencer and Air Filter Box Maintenance

Procedures for main silencer and air filter box.

Air Filter and Clutch Maintenance

Servicing the air filter and hydraulic clutch system.

Hydraulic Clutch Fluid Change

Procedure for changing the hydraulic clutch fluid.

Shift Lever Position

Checking and adjusting the shift lever's basic position.

Carburetor Idle Adjustment

Setting and adjusting the carburetor idle speed.

Carburetor Float Chamber Emptying

Procedure for emptying the carburetor float chamber.

Engine Oil Level and Change

Checking engine oil level and performing oil/filter changes.

Gear Oil Level and Change

Checking and changing gear oil.

Cleaning

Motorcycle Cleaning Procedure

Safe methods for cleaning the motorcycle.

Storage

Storage Preparation and Guidelines

Steps for preparing the motorcycle for long-term storage.

Post-Storage Startup Procedures

Steps for resuming operation after storage.

Technical Data - Engine

Engine Specifications

Details on displacement, bore, stroke, and valve data.

Engine Capacities

Lists capacities for engine oil, gear oil, and coolant.

Technical Data - Engine Tightening Torques

Technical Data - Carburetor

Technical Data - Chassis

Chassis Dimensions and Weights

Covers frame, suspension, dimensions, and load limits.

Lighting and Tire Specifications

Details on lighting equipment and tire types.

Technical Data - Fork

Technical Data - Shock Absorber

Technical Data - Chassis Tightening Torques

Wiring Diagram

EXC Model Wiring Diagram

Electrical schematic for EXC model motorcycles.

XC-W Model Wiring Diagram

Electrical schematic for XC-W model motorcycles.

Substances

Brake Fluid, Coolant, and Oil Specifications

Details on required fluids and their types.

Auxiliary Substances

Cleaning and Maintenance Products

Lists recommended cleaning and maintenance chemicals.

Standards

Industry Standards (JASO, SAE)

Explanation of oil and viscosity standards.