This service manual covers 4-stroke race bikes produced between 2000 and 2005, encompassing a wide array of models including EXC, SX, MXC, SMR, and SXS variants. The renowned "Ready to Race" philosophy is evident in these high-performance machines, designed for demanding off-road competition. With a strong Austrian heritage in motorsports, these bikes feature robust chromium-molybdenum steel trellis frames, powerful 4-stroke engines in various displacements, and advanced suspension systems, delivering exceptional performance for amateur and professional racers alike. This comprehensive 410-page English-language manual provides factory-level information essential for maintaining and repairing your bike. It details complete engine teardown and rebuild procedures, transmission overhauls, clutch maintenance, and suspension component servicing for both front forks and rear shocks. Coverage extends to brakes, chassis, and electrical systems, with in-depth guidance on scheduled maintenance, troubleshooting common issues, and performing necessary repairs. The manual includes detailed diagrams, torque specifications, and service limits, making it an invaluable resource for owners and technicians. 🏷️ Basic Information Identification Make: KTM Product Type: Service Manual / Repair Manual Codes Model Years Covered: 2000, 2001, 2002, 2003, 2004, 2005 👋 Introduction Market Position Target Audience: KTM owners, amateur and professional racers, independent repair shops Competitive Analysis Value Proposition: Comprehensive, factory-level information for a wide range of KTM 4-stroke race bikes from a specific era, offering significant cost savings over OEM manuals or professional service. Key Features Content Highlights: Full teardown/rebuild, detailed diagrams, torque specs, troubleshooting guides, suspension rebuilds. 📋 Manual Details Coverage Areas Primary Coverage: KTM 4-stroke Race Bikes (EXC, SX, MXC, SMR, SXS variants) Specific Models Covered: 400EXC Racing, 400SX Racing, 520EXC, 520SX, 400E XC, 400MXC Racing, 400EXC Racing, 400SX Racing, 520EXC Racing, 520MXC Racing, 520SX Racing, 250EXC, 400EXC, 400MXC, 400SX, 520EXC, 520MXC, 520SX, 250EXC Racing, 450EXC Racing, 450MXC Racing, 450SX Racing, 525EXC Racing, 525MXC Racing, 525SX Racing, 400LS-E, 400MIL, 450EXC, 450MXC, 450, 450SX, 525EXC, 525MXC, 525SX, 525SMR, 540SXS, SX450SMR, 610 CRATE, MXC525, SX525 Racing, SX525SMR Page Count Total Pages: 410 Manual Type Types: Factory Repair Manual, Owner's Manual, Motor Repair Manual, Rear Shock Rebuild Manual, Front Fork Rebuild Manual Language Primary Language: English Format File Format: PDF Accessibility Features: Clickable chapters, Searchable text Usage Rights: No restrictions on printing or saving 📖 Manual Coverage Systems Covered Engine: Complete engine teardown and rebuild, lubrication, cooling system, fuel system, ignition system, starting system (kickstart) Transmission: Gearbox overhaul, clutch operation and adjustment, maintenance Suspension: Front fork (KYB/WP) rebuild and maintenance, Rear shock (WP) rebuild and maintenance, linkage lubrication and adjustment Brakes: Hydraulic brake system maintenance (front and rear), caliper service, fluid replacement Electrical: Ignition system, charging system, wiring diagrams (implied by general coverage), starter motor (if applicable, though primarily kickstart) Chassis And Bodywork: Frame inspection and repair, body panels, seat, handlebars, wheels, tires, fenders Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, chain adjustment, valve clearance checks Troubleshooting: Diagnostic procedures for common issues, error code interpretation (if applicable), problem identification Repair And Rebuild: Complete engine overhauls, suspension component rebuilds, brake caliper service, gearbox rebuilds, carburetor rebuilds Assembly Disassembly: Detailed step-by-step instructions for complete teardown and reassembly of all major components Technical Depth Depth Level: Comprehensive (covering complete teardown and rebuild) Specific Data Provided: Torque specifications, part diagrams, component identification, service limits 📊 Manual Specifications File Format Digital Format: PDF Print Quality Printability: Printable (no restrictions) Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, single-cylinder (various displacements) Engine Displacements: 250cc, 400cc, 450cc, 520cc, 525cc, 540cc, 610cc (approximate, based on model names) Performance Power Delivery: High-performance, race-oriented power delivery Fuel System Carburetion: Carbureted (e.g., Keihin, Mikuni), with detailed adjustment and rebuild procedures Fuel Injection: Potentially present on later models (e.g., SX450SMR), coverage may vary. Ignition Ignition System: CDI or similar electronic ignition system Lubrication Oil System: Separate oil reservoir and engine oil lubrication (typical for KTM off-road) Maintenance Valve Adjustment Frequency: Refer to manual for specific intervals, typically requires periodic checking and adjustment. Spark Plug Type: Refer to manual for specific recommendations based on model and usage. 🔧 Transmission Standard Gearbox: Constant-mesh 5 or 6-speed sequential gearbox Optional Clutch Type: Hydraulically operated multi-plate wet clutch Features Clutch Maintenance: Includes clutch plate replacement, spring inspection, and hydraulic system service. Specifications Transmission Oil Type: Refer to manual for specific KTM-recommended transmission/clutch fluid. 📐 Dimensions Exterior Frame Type: Chromium-molybdenum steel trellis frame (typical KTM design) Weights Dry Weight: Varies by model, but generally lightweight for performance off-road riding. Seat Height: High seat height, typical for motocross and enduro bikes. Dimensions Wheelbase: Refer to specific model specifications within the manual. Ground Clearance: Generous ground clearance for off-road obstacle clearance. 🛡️ Safety Features Ratings Safety Focus: Designed for off-road competition; safety features primarily relate to robust construction and reliable operation. No crash ratings in the automotive sense. Active Features Braking System: Powerful hydraulic disc brakes...