This manual covers SX, MXC, XC, EXC, SMR, and SXS Racing model variants produced between 2000 and 2007, featuring LC4 and RFS engine families. These high-performance off-road motorcycles are renowned for their lightweight chassis, powerful single-cylinder engines, advanced WP suspension, and race-proven designs, making them ideal for motocross, enduro, supermoto, and aggressive off-road riding. The heritage of success in motorsports is evident in these models, which have consistently been praised for their potent performance and agile handling. This comprehensive factory service and repair workshop manual provides detailed instructions for all aspects of maintenance, repair, and troubleshooting. It covers engine systems, transmission and drivetrain, chassis and suspension, brakes, electrical systems, and bodywork, including routine maintenance, major repairs, and technical adjustments. With clear wiring diagrams, precise torque specifications, and step-by-step procedures, this manual serves as an essential resource for owners, mechanics, and technicians to ensure optimal performance and longevity of their motorcycles. 🏷️ Basic Information Identification Make: KTM Model: SX, MXC, XC, EXC, SMR, SXS Racing Model Variants Covered: All SX, MXC, XC, EXC, SMR, SXS Racing variants Codes Engine Codes Covered: LC4 (various configurations), RFS (Ready For Suspension) engine family 👋 Introduction Market Position Market Position: High-performance off-road and motard motorcycles designed for competition and aggressive riding. Competitive Analysis Competitors: Honda CRF/CR, Yamaha YZ/WR, Suzuki RM/DRZ, Kawasaki KX/KLX, Husqvarna TE/TC, Beta RR/RR-S Key Features Key Features: Lightweight chassis, powerful single-cylinder engines, advanced WP suspension, race-proven design, durability for demanding conditions. Target Audience Target Audience: Motocross racers, enduro riders, supermoto enthusiasts, off-road adventurers, and skilled mechanics seeking in-depth knowledge for maintenance and repair. 📋 Manual Details Coverage Areas Coverage Years: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Page Count Estimated Page Count: Likely 500+ pages (typical for comprehensive factory service manuals covering multiple models) Manual Type Manual Type: Factory Service & Repair Workshop Manual Language Language: English (standard for factory manuals targeting global markets) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine teardown, assembly, tuning, lubrication, cooling system, fuel system (carburetor/injection), ignition system, exhaust system, piston, rings, cylinder, crankshaft, connecting rod, valve train (OHC/DOHC), camshafts, timing chains/belts, oil pump Transmission Drivetrain: Clutch operation and adjustment, gearbox internals, gear selection mechanism, final drive (chain/sprocket), transmission fluid specifications Chassis Suspension: Frame inspection and repair, front fork (WP Suspension, etc.) disassembly, assembly, servicing, seal replacement, damping adjustments, rear shock absorber (WP Suspension, etc.) servicing, linkage kinematics, swingarm inspection and maintenance Brakes: Hydraulic brake systems (front and rear), caliper servicing, piston replacement, master cylinder overhaul, brake pad replacement, rotor inspection, bleeding procedures, brake fluid specifications Electrical Ignition: Wiring diagrams, lighting system, starter system, battery maintenance, charging system (stator/rotor), ignition coil testing, spark plug specifications, component testing (CDI, voltage regulators) Fuel System: Carburetor models (Mikuni, Keihin) disassembly, cleaning, jetting, float height adjustment; Fuel injection system diagnostics and component testing (if applicable to specific models within the range) Bodywork Controls: Fairing removal and installation, seat maintenance, handlebar replacement, lever adjustments, footpeg systems, kickstarter mechanism Carburetor Details: Comprehensive diagrams and procedures for specific carburetor models used (e.g., Keihin FCR 39/41, Mikuni VM series) including jetting charts, needle selection, and idle mixture adjustments. Suspension Technical Data: Specific oil levels, damping settings (compression, rebound), spring rates, and service procedures for WP USD forks (e.g., 4860, 4800 series) and WP PDS or linkage-based rear shocks. Procedures Included Routine Maintenance: Oil changes, oil filter replacement, air filter cleaning/replacement, chain adjustment and lubrication, spark plug inspection, brake pad inspection, tire pressure checks, general bolt torque checks Troubleshooting: Diagnosis of common starting problems, running issues, electrical faults, suspension performance anomalies, braking system irregularities Major Repairs: Engine rebuilds, top-end overhauls (piston, rings, valves), bottom-end rebuilds (crankshaft, bearings), transmission repairs, clutch replacement, fork seal replacement, shock absorber rebuilds Assembly Disassembly: Step-by-step instructions for complete disassembly and reassembly of all major vehicle components Technical Adjustments: Carburetor jetting and tuning, valve clearance adjustment, ignition timing checks, suspension sag and damping adjustments Torque Specifications: Exact torque values for all critical fasteners across engine, chassis, suspension, and braking systems. Technical Depth Technical Depth: Comprehensive, covering everything from basic rider maintenance to full engine and chassis overhauls, suitable for both home mechanics and professional technicians. Wiring Diagrams Quality: Detailed, clear, and often color-coded wiring diagrams are a hallmark of factory manuals, essential for electrical troubleshooting. Engine Rebuild Level: Full engine rebuilds, including crankshaft balancing, rod replacement, bearing clearances, and piston ring end gap specifications. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality: High resolution, suitable for printing detailed diagrams and text Binding Type Binding Type: N/A (Digital PDF download) Paper Type Paper Type: N/A (Digital PDF download) Searchability Searchability: Likely searchable text, allowing for quick navigation to specific topics Additional Features Diagnostic Codes: Likely includes information on basic troubleshooting and potential diagnostic indicators, though dedicated electronic diagnostic tools are less...