This comprehensive workshop repair service manual covers a wide range of KTM motorcycle models from the years 2000 to 2006. The manual includes detailed instructions and illustrations for servicing and repairing models such as 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. The manual is organized into various sections, providing a thorough understanding of your motorcycle's inner workings.

Explore detailed information on:

* **General Information**: Find essential information about your motorcycle, including safety precautions and basic operating procedures.
* **Removing and Refitting the Engine**: Learn the proper techniques for removing and reinstalling the engine, ensuring a smooth process.
* **Disassembling and Assembling the Engine**: This section covers the step-by-step process of taking apart and putting together your engine, with clear instructions and diagrams.
* **Servicing Individual Components**: Find comprehensive guidance on maintaining and repairing individual engine components, including the crankshaft, pistons, connecting rods, and more.
* **Electrical System**: This section provides detailed instructions on troubleshooting and repairing electrical components such as the starter, ignition system, and lighting.
* **Fuel System**: Gain a thorough understanding of the fuel system, including troubleshooting carburetor issues, fuel lines, and fuel pumps.
* **Troubleshooting**: This section helps you diagnose and resolve common motorcycle issues, providing valuable insights into identifying potential problems.
* **Technical Specifications**: This section contains detailed specifications for your model, including engine dimensions, torque settings, and fluid capacities.
* **Periodic Maintenance Schedule**: Follow a recommended maintenance schedule to ensure your motorcycle is operating at its best.
* **Wiring Diagrams**: Clear, detailed wiring diagrams help you understand the electrical system and simplify troubleshooting.

This manual will empower you to confidently tackle your own motorcycle repairs, saving you time and money.

The KTM 250 EXC Racing, 400-450 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 encompass a diverse range of KTM motorcycles spanning a significant period from 2000 to 2006. These models represent the pinnacle of off-road and motocross performance during their era, catering to a wide spectrum of riding styles and disciplines. From the nimble and powerful 250 EXC, renowned for its agility and handling, to the mighty 610 CRATE, designed for adventure and long-distance travel, these motorcycles boast a legacy of innovation and performance. Each model is crafted with a focus on lightweight construction, potent engines, and durable components, all meticulously engineered to deliver unmatched riding experiences.

The extensive lineup of these KTM motorcycles embodies the brand's commitment to performance and innovation. The 250 EXC Racing, with its highly tuned engine, offers exceptional track handling, ideal for motocross and enduro competition. The 400-450 SX/MXC/XC/EXC/SMR/SXS Racing models provide an optimal blend of power and agility, making them equally suitable for aggressive trail riding and demanding track conditions. The larger-displacement 520, 525, and 540 models, known for their robust power delivery, cater to riders seeking unmatched performance and off-road prowess. The 560 SMR represents the street-legal version of these powerful machines, bringing the thrill of off-road riding to the urban jungle. Finally, the 610 CRATE, with its long-stroke engine and increased fuel capacity, is a true adventure touring motorcycle, ready to take on any terrain. Each model, regardless of its intended purpose, shares KTM's signature quality build, delivering reliability and durability for years of exhilarating rides.