This workshop repair service manual covers a comprehensive range of motorcycles, including the 250 EXC RACING, 400 SX/MXC/XC/EXC/SMR/SXS RACING, 450 SX/MXC/XC/EXC/SMR/SXS RACING, 520 SX/MXC/XC/EXC/SMR RACING, 525 SX/MXC/XC/EXC/SMR RACING, 540 SXS, 560 SMR, and 610 CRATE models produced between 2000 and 2006. These off-road motorcycles are known for their performance and handling in competitive environments, reflecting a strong heritage in motorsports. The manual is designed to provide owners and independent mechanics with the necessary information to maintain and repair these specialized machines, ensuring their continued optimal performance. This manual offers in-depth coverage of all essential systems, including detailed procedures for engine disassembly and assembly, transmission servicing, driveline maintenance, suspension repair, and comprehensive brake system diagnostics. It also details the electrical system, fuel system components, bodywork, and steering. With step-by-step instructions, troubleshooting guides, and clear illustrations, this resource aims to empower users to perform everything from routine maintenance and fluid changes to complex component rebuilds and repairs, facilitating cost-effective upkeep and ensuring the longevity of your motorcycle. 🏷️ Basic Information Identification Make: KTM Model: 250 EXC RACING, 400 SX/MXC/XC/EXC/SMR/SXS RACING, 450 SX/MXC/XC/EXC/SMR/SXS RACING, 520 SX/MXC/XC/EXC/SMR RACING, 525 SX/MXC/XC/EXC/SMR RACING, 540 SXS, 560 SMR, 610 CRATE Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006 Codes Manual Product Code: REPAIRMANUAL2000-2006 👋 Introduction Market Position Target Audience: KTM owners and independent mechanics performing their own maintenance and repairs. Competitive Analysis Value Proposition: Provides comprehensive DIY repair guidance, enabling significant cost savings on professional servicing. Key Features Completeness: 100% complete and intact, covering all aspects from general information to detailed technical specifications. Ease Of Use: Step-by-step instructions and clear illustrations make complex repairs accessible to novices. Accessibility: Instant download format offers immediate access without shipping delays. 📋 Manual Details Coverage Areas Manual Type: Workshop Repair Service Manual Language: English, German, Italian, French, Spanish Format: PDF Page Count Estimated Page Count: Comprehensive (Exact count not specified, but described as covering 'every single detail') 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, servicing, troubleshooting. Transmission: Service, repair, and troubleshooting of the transmission system. Driveline: Coverage of driveline components and maintenance. Suspension: Front and rear suspension servicing and repair, including shocks. Brakes: Comprehensive brake system maintenance, repair, and troubleshooting. Fuel System: Carburetor (or EFI for relevant models) inspection, cleaning, adjustment, and repair. Electrical System: Wiring diagrams, battery and charging systems, lighting, ignition, and instrumentation. Body Frame: Frame and mounting procedures, bodywork removal and installation. Steering: Steering system maintenance and repair. Procedures Included General Maintenance: Periodic maintenance schedules, fluid changes, filter replacements. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues. Repair Procedures: Step-by-step instructions for a wide range of mechanical and electrical repairs. Disassembly Assembly: Detailed procedures for component and major system disassembly and reassembly. Technical Depth Diagnostic Capabilities: Advanced diagnostic information, including troubleshooting charts and likely causes. Rebuild Procedures: Comprehensive instructions for engine and component rebuilds. Illustrations Diagrams: Detailed illustrations, exploded diagrams, and photos for all procedures. 📊 Manual Specifications File Format File Type: PDF Compatibility: All Versions of Windows, Mac, iOS, BB, Android, etc. Accessibility: Viewable on any computer with a PDF Reader. Print Quality Printability: Yes, all pages are printable. Zoom Functionality: Yes, pages can be zoomed. Binding Type Binding: Digital (Instant Download) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Types: Single-cylinder, 4-stroke (specific displacements vary by model: 250cc, 400cc, 450cc, 520cc, 525cc, 540cc, 560cc, 610cc). Performance Horsepower Torque: Specific figures not provided in product description, but manual covers detailed performance tuning and specifications. Fuel System Fuel Delivery: Primarily carburetor-based systems, with potential for early EFI on some models. Manual covers fuel system components, tuning, and troubleshooting. Engine Internal Valve Train: Details on camshafts, valves, and associated components covered for servicing. Engine Cooling Cooling System: Manual includes information on liquid cooling systems (radiator, coolant, pump) and air-cooled components where applicable. 🔧 Transmission Standard Transmission Type: Manual gearbox (specific number of gears varies by model, typically 5 or 6-speed). Optional Clutch Type: Hydraulically actuated multi-plate wet clutch systems are common; manual covers servicing and adjustment. Features Gear Ratios: Manual includes detailed specifications for gear ratios and final drive. 📐 Dimensions Exterior Chassis Type: Steel frame (CrMo steel common for KTM models of this era); manual covers frame inspection and repair. Weights Dry Weight: Specific weight data not in description, but manual likely contains this information for each model variant. 🛡️ Safety Features Ratings Safety Features: Manual covers maintenance and repair of braking systems, which are critical safety components. Active Features Braking System: Hydraulic disc brakes (front and rear) are standard; manual provides detailed servicing procedures. Passive Features Electrical Warnings: Instrumentation and warning systems covered, including potential fault indicators. 💡 Technology Features Infotainment Infotainment Systems: N/A (These are off-road motorcycles, not typically equipped with infotainment systems). Driver Assistance Assistance Systems: N/A (Off-road motorcycles typically do not have electronic driver...