This manual covers SX, MXC, XC, EXC, SMR, and SXS Racing models manufactured between 2000 and 2007. These Austrian-engineered motorcycles are renowned for their performance-oriented design, catering to motocross, cross-country, enduro, and supermoto disciplines. The engineering quality and reliability of these machines are a hallmark, with a strong heritage in off-road racing, evidenced by numerous championship successes achieved by models within this period. The focus on powerful engines and robust chassis ensures these bikes deliver exceptional performance in demanding conditions. This comprehensive service and repair manual provides detailed guidance for owners and technicians. It covers all aspects of engine mechanicals, including complete disassembly, assembly, and repair, as well as fuel, cooling, ignition, lubrication, and exhaust systems. Routine maintenance procedures, diagnostic troubleshooting, and engine rebuilds are explained step-by-step. The manual also details carburetor overhaul, timing adjustments, and component replacement, offering the technical depth required for professional-level maintenance and repair, ensuring the longevity and optimal performance of your motorcycle. 🏷️ Basic Information Identification Make: KTM Model: SX / MXC / XC / EXC / SMR / SXS Racing Year Range: 2000-2007 Codes Vehicle Platform Codes: Multiple platforms across different models (e.g., SX, EXC, XC series) during this era, generally sharing core engine architecture with variations. 👋 Introduction Market Position Target Audience: Owners and independent repair shops specializing in off-road and performance KTM motorcycles. Value Proposition: Provides essential, in-depth technical information to maintain and repair high-performance KTM engines, ensuring optimal operation and longevity. Competitive Analysis Alternatives: Factory service manuals (often scarce or expensive for older models), generic repair guides (often lack KTM-specific detail). Key Features Comprehensiveness: Covers multiple performance-oriented models and a significant year range, offering broad applicability for enthusiasts and mechanics. Diagnostic Tools: Includes troubleshooting charts and diagnostic procedures crucial for identifying and resolving complex engine issues. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive engine service and repair for KTM SX, MXC, XC, EXC, SMR, and SXS Racing models. Secondary Coverage: Details on chassis, suspension, and electrical systems pertaining to engine operation and maintenance. Page Count Estimated Page Count: High - expected to be comprehensive, likely 400+ pages given the range of models and years. Manual Type Type: Service Repair Manual / Workshop Manual Language Language: English (assumed based on typical market for such manuals) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Full engine disassembly, assembly, inspection, and repair of all internal components (crankshaft, connecting rod, piston, cylinder, cylinder head, valves, camshaft, timing, etc.). Fuel System: Carburetor system (cleaning, adjustment, overhaul), fuel delivery components, fuel tank, petcock, fuel lines. Cooling System: Radiator, coolant hoses, water pump, thermostat operation and maintenance. Ignition System: Spark plug, ignition coil, CDI unit, stator, timing checks and adjustments. Lubrication System: Oil pump, oil filter, oil passages, oil change procedures, oil specifications. Exhaust System: Exhaust pipe, muffler maintenance and inspection. Electrical System Engine Related: Wiring diagrams for engine starting, ignition, and charging systems. Procedures Included Routine Maintenance: Oil and filter changes, air filter cleaning/replacement, spark plug checks, valve clearance adjustment, chain maintenance, carburetor synchronization (where applicable). Diagnostic Troubleshooting: Step-by-step troubleshooting guides for common engine performance issues, starting problems, and system malfunctions. Engine Rebuilds: Detailed procedures for complete engine overhaul, including torque specifications, critical clearances, and component replacement guidelines. Component Replacement: Instructions for replacing specific engine parts like pistons, rings, valves, seals, gaskets, bearings, etc. Carburetor Overhaul: Complete carburetor disassembly, cleaning, inspection, reassembly, and tuning procedures for various jetting configurations. Timing Adjustment: Procedures for checking and adjusting ignition and valve timing. Technical Depth Depth: Comprehensive, suitable for professional technicians and experienced DIY mechanics. Covers everything from basic service to complete engine rebuilds and advanced diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchable: Likely searchable text within the PDF for quick information retrieval. Print Quality Print Readability: High quality, designed for clear printing of diagrams and text. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, liquid-cooled (common across the range, with variations in displacement and specific design). Displacement: Primarily 400cc and 450cc variants. Specific models may include 380cc (2-stroke, though this manual focuses on 4-strokes given the 400/450 designation) or other close displacements depending on the specific model and year within the range. Bore X Stroke: Varies by specific engine (e.g., 400 LC4 models had different dimensions than 450 EXC). Compression Ratio: Varies by specific engine. Valve Train: SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) depending on specific model and year. Typically chain-driven. Performance Horsepower Range: Approx. 45-60 HP, depending on model, tuning, and exhaust system. Torque Range: Approx. 35-45 lb-ft, depending on model and tuning. Fuel System Carburetor Type: Mikuni VM series, Keihin FCR series (common for performance models), or other similar high-performance carburetor brands. Fuel Type: Unleaded gasoline, typically 91-98 RON (equivalent to 87-93...