🏷️ Basic Information Identification Make: KTM Model: 400/450/520/525 EXC, MXC, SMR, SX, SXS Engine Engine Type: Internal Combustion, Motorcycle Engine Codes Product Name: KTM SPORTMOTORCYCLES 400 / 450 / 520 / 525 EXC MXC SMR SX SXS Engine Service Repair Manual 2000-2006 Download PDF Generation Production Period Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006 👋 Introduction Market Position Target Audience: KTM motorcycle owners, independent repair shops, DIY mechanics seeking in-depth technical information for their 400-525cc EXC, MXC, SMR, SX, SXS models. Diy Repair Empowerment: Designed to empower owners to perform complex maintenance and repairs themselves, fostering a deeper understanding and connection with their KTM motorcycle. Competitive Analysis Value Proposition: Provides the same level of detail as official dealership manuals at a significantly lower cost. Enables cost savings through self-maintenance and repair. Instant download eliminates shipping delays and costs. Key Features Manual Benefits: Complete coverage, high-quality images and diagrams, detailed procedures, troubleshooting guides, enabling efficient and accurate repairs for all skill levels. Visual Aid Emphasis: Tons of pictures and diagrams are available at your fingertips to guide repairs. 📋 Manual Details Coverage Areas Covered Models And Years: KTM 400 EXC, MXC, SMR, SX, SXS (2000-2006), KTM 450 EXC, MXC, SMR, SX, SXS (2000-2006), KTM 520 EXC, MXC, SMR, SX, SXS (2000-2006), KTM 525 EXC, MXC, SMR, SX, SXS (2000-2006) Related Models Mentioned In Toc: KTM 250 EXC, KTM 400/450 XC, KTM 520/525 XC, KTM 540 SXS, KTM 560 SMR, KTM 610 CRATE (Note: While listed, the primary focus is on 400-525cc engines, with potential for partial applicability to others based on shared architecture.) Page Count Total Pages: 222 Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF Download Digital Convenience: Downloadable PDF format offers immediate access and portability, allowing users to view the manual on various devices or print specific sections for workshop use. Compatibility Operating Systems: Compatible with all versions of Windows & Mac. Delivery Download Method: Instant download upon payment completion. Completeness Quality Assurance: 100% Complete and Intact, no missing/corrupt pages/sections. 📖 Manual Coverage Systems Covered Primary Systems: Engine Removal & Refitting, Engine Disassembly, Individual Component Servicing, Engine Assembly, Electrical System, Fuel System, Troubleshooting Auxiliary Systems: Fuel System (carburetor or injection specifics), Electrical System (including wiring diagrams). Electrical System Components: Includes ignition, lighting (if applicable), charging system components (stator, regulator/rectifier), battery, and starting system. Wiring diagrams are specifically listed. Exhaust System Considerations: While primarily engine-focused, engine service often involves exhaust system removal and refitting. The manual may touch upon gasket replacements and torque values for exhaust header bolts. Procedures Included Repair And Maintenance: Step-by-step instructions for all repair procedures, detailed exploded pictures and diagrams for correct and efficient job completion, diagnosis, and maintenance. Diagnostic Procedures: Trouble shooting section provides guidance on diagnosing common operational faults and mechanical issues. Detailed disassembly and assembly steps aid in pinpointing problems. Engine Rebuild Scope: Covers full engine rebuilds, from top-end overhaul (piston, rings, valves) to bottom-end work (crankshaft, connecting rod, bearings). Technical Depth Scope: Comprehensive coverage enabling users to maintain, service, diagnose, and repair their own motorcycles. Equivalent to dealer/mechanic level documentation. Specific Tool Requirements: While not explicitly stated, comprehensive service manuals often reference specialized tools required for specific procedures (e.g., piston ring compressors, valve spring compressors, torque wrenches). The manual will guide users on these needs. 📊 Manual Specifications File Format File Type: PDF Accessibility Features: Searchable text, Bookmarked chapters, Zoom In/Out functionality Reader Requirement: Adobe PDF Reader. Print Quality Printability: All pages are printable Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Displacements Covered: 400cc, 450cc, 520cc, 525cc (Exact variants and specific bore/stroke may vary by sub-model and year, detailed within the manual). Performance Typical Power Output Range: While not explicitly stated in the product info, these engines typically produced between 40-60 horsepower depending on displacement and specific tuning for their intended use (e.g., Motocross, Enduro). Torque Specifications: The manual will contain detailed torque specifications for all critical engine fasteners, crucial for proper assembly and to prevent damage or component failure. Compression Ratio: The manual will list the specified compression ratios for each engine variant, crucial for diagnosing performance issues and understanding engine health. Fuel System Fueling Method: Likely carbureted for the earlier years, with potential for fuel injection in later models or specific variants. The manual will detail the specific system for each covered model. Carburetor Details: For carbureted models, the manual will provide detailed information on carburetor types (e.g., Keihin, Mikuni), jetting specifications, idle speed adjustment, float bowl levels, and choke operation. Fuel Pump And Filter: For fuel-injected models, the manual will cover the fuel pump, fuel filter, fuel pressure regulator, and injector servicing procedures. Engine Layout Layout Type: Single-cylinder, four-stroke (typical for these KTM models of that era). Engine Configuration: Single-cylinder,...