This manual covers Sportmotorcycle models produced between 2000 and 2006, including EXC, MXC, SMR, SX, and SXS variants. These performance-oriented off-road motorcycles are characterized by their single-cylinder, liquid-cooled, four-stroke engines, with displacements ranging from approximately 400cc to 525cc, reflecting a strong heritage in motorsport. The engineering quality and reliability are a direct result of extensive experience in competitive off-road racing, which has influenced the design and development of these robust machines. This comprehensive service repair manual is your essential guide for maintaining and repairing your Sportmotorcycle. It provides detailed, step-by-step instructions for engine service and repair, general maintenance, electrical systems, and fuel systems, accompanied by highly detailed exploded diagrams and illustrations. The manual covers everything from routine maintenance schedules and fluid specifications to complete engine rebuilds and advanced diagnostics, empowering owners and technicians to keep these high-performance machines in optimal condition. 🏷️ Basic Information Identification Make: KTM Model: Sportmotorcycle (EXC, MXC, SMR, SX, SXS) Production Years: 2000-2006 Codes Engine Variants Covered: 400cc, 450cc, 520cc, 525cc Additional Models Mentioned: 250 EXC, 540 SXS, 560 SMR, 610 CRATE 👋 Introduction Market Position Target Audience: KTM owners, DIY mechanics, restoration specialists seeking comprehensive service information. Competitive Analysis Value Proposition: Provides dealership-level repair and maintenance information for a fraction of the cost, enabling self-sufficiency and cost savings. Key Features Completeness: 100% complete and intact, no missing or corrupt pages/sections. Instructional Detail: Step-by-step instructions complemented by highly detailed exploded pictures and diagrams. 📋 Manual Details Coverage Areas Primary Focus: Engine Service and Repair Secondary Focus: General Maintenance, Troubleshooting, Electrical Systems, Fuel System Page Count Total Pages: 222 Manual Type Type: Official Service Repair Manual Language Language: English Format File Format: PDF (Download) 📖 Manual Coverage Systems Covered Engine: Complete disassembly, assembly, servicing of individual components, engine removal and refitting. Electrical: Wiring diagrams, diagnostics, troubleshooting related to electrical systems. Fuel System: Service and repair of fuel system components. Procedures Included Repair: Detailed step-by-step repair procedures for all covered systems. Maintenance: Periodic maintenance schedules and procedures. Diagnostics: Comprehensive diagnostic procedures and troubleshooting guides. Assembly Disassembly: Detailed instructions for engine and component assembly and disassembly. Technical Depth Depth: Comprehensive; covers everything from basic maintenance to complete engine rebuilds and advanced diagnostics. Documentation Type: Includes exploded diagrams, detailed illustrations, and photos. 📊 Manual Specifications File Format Compatibility: All versions of Windows & Mac Features: Searchable, Zoom in/out capability Print Quality Printability: Fully Printable Binding Type Digital Binding: Bookmarked Paper Type Digital Paper Analogue: High Quality Digital Representation Delivery Method: Instant Download Requirements: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Types: Single-cylinder, liquid-cooled, four-stroke engines. Performance Displacement Range: Approximately 400cc to 525cc (with mention of 250cc, 540cc, 560cc variants). Engine Design: Performance-oriented, racing-derived engine architecture common to KTM's off-road and supermoto lines. Fuel System Carburetion Type: Likely Keihin or Mikuni carburetors (specific models vary by year and displacement, detailed in manual). Technical Specifications General Technical Specifications Chapter: Chapter 10 dedicated to technical specifications. 🔧 Transmission Standard Transmission Type: Likely 6-speed constant mesh sequential gearbox (typical for KTM off-road models of this era). Optional Clutch Type: Hydraulically operated, multi-plate wet clutch. Features Gear Ratios: Detailed gear ratio specifications would be found within the 'Technical Specifications' chapter. 📐 Dimensions Exterior Vehicle Type: Off-road motorcycles (Enduro, Motocross, Supermoto variants). Weights Dry Weight Range: Typically in the range of 100-120 kg (dry), specific to model and configuration. Seat Height Range: Varies by model, typically high for off-road capability. 🛡️ Safety Features Ratings Safety Focus: Primarily focused on rider control and mechanical integrity of the motorcycle. Active Features Braking System: Hydraulic disc brakes (front and rear), specific caliper and rotor sizes detailed in manual. Passive Features Frame Construction: Chromium-molybdenum steel trellis frame (typical KTM construction). 💡 Technology Features Infotainment Features: Minimal to none; these are performance-oriented off-road motorcycles with a focus on function over rider comfort/entertainment technology. Driver Assistance Features: None. Focus is on rider skill and machine capability. Connectivity Features: None. 🔧 Maintenance Service Intervals Schedule Location: Chapter 11: Periodic Maintenance Schedule. Typical Items: Oil changes, filter replacements, valve adjustments, chain maintenance, spark plug inspection/replacement. Fluid Specifications Engine Oil Type: Specific oil viscosity and type (e.g., SAE 10W-50, JASO MA) will be detailed in the manual, typically high-performance synthetic motorcycle oil. Coolant Type: Ethylene glycol-based coolant (pre-mixed or concentrate) as specified by KTM. Brake Fluid Type: DOT 4 hydraulic brake fluid. Known Issues Common Wear Items: While the manual focuses on repair, common off-road wear items include clutch plates, piston rings, valve guides, fork seals, and wheel bearings. Specific diagnostic procedures for these are covered. Technical Specifications Torque Specifications: Crucial torque specifications for engine and chassis fasteners are detailed throughout the manual. 📚 Vehicle History Brand Heritage Ktm Motorsport Focus: KTM has a long and successful history in off-road motorcycle racing (Motocross, Enduro, Dakar Rally), influencing the development of these models. Model...