This workshop service repair manual covers a wide range of off-road and supermoto motorcycles produced between 2000 and 2007. The manual encompasses models such as the 250 EXC RACING, 400 SX, 450 SX, 400 MXC, 450 MXC, 400 XC, 450 XC, 400 XC-W, 450 XC-W, 400 EXC, 450 EXC, 400 SMR, 450 SMR, 400 SXS RACING, 450 SXS RACING, 520 SX, 525 SX, 520 MXC, 525 MXC, 520 XC, 525 XC, 520 XC-W, 525 XC-W, 520 EXC, 525 EXC, 520 SMR, 525 SMR, 540 SXS, 560 SMR, and 610 CRA. An Austrian manufacturer, is renowned for its strong heritage in off-road racing and a philosophy of performance. These models represent a significant period of development in the four-stroke off-road line, with engine and chassis updates throughout their production years, designed for competition and demanding riding conditions. This comprehensive manual provides essential technical information for the maintenance, repair, and restoration of these motorcycles. It details engine mechanical and electrical systems, drivetrain, chassis, suspension, brakes, and fuel systems, offering step-by-step repair instructions, troubleshooting guides, and diagnostic procedures. The manual includes periodic maintenance schedules, torque values, fluid capacities, and clear, zoomable illustrations, including exploded views and component breakdowns. This resource is invaluable for professional technicians, mechanics, and DIY enthusiasts seeking to ensure the longevity and optimal performance of their off-road and supermoto machines. 🏷️ Basic Information Identification Make: KTM Model: 250 EXC RACING, 400 SX, 450 SX, 400 MXC, 450 MXC, 400 XC, 450 XC, 400 XC-W, 450 XC-W, 400 EXC, 450 EXC, 400 SMR, 450 SMR, 400 SXS RACING, 450 SXS RACING, 520 SX, 525 SX, 520 MXC, 525 MXC, 520 XC, 525 XC, 520 XC-W, 525 XC-W, 520 EXC, 525 EXC, 520 SMR, 525 SMR, 540 SXS, 560 SMR, 610 CRA Product Type: Workshop Service Repair Manual Generation Production Years: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Codes Vehicle Codes: Not specified in provided information 👋 Introduction Market Position Positioning: Essential technical resource for owners and technicians of specific KTM off-road and supermoto models. Competitive Analysis Advantage: Offers comprehensive, factory-level information for a wide range of popular KTM models from a specific era. Key Features Features: Detailed procedures, extensive troubleshooting, clear illustrations, wide model coverage. Value Proposition Value: Enables cost savings through DIY repairs and maintenance, ensures proper servicing for longevity and performance. 📋 Manual Details Coverage Areas Vehicle Coverage: KTM 250 EXC RACING, 400 SX, 450 SX, 400 MXC, 450 MXC, 400 XC, 450 XC, 400 XC-W, 450 XC-W, 400 EXC, 450 EXC, 400 SMR, 450 SMR, 400 SXS RACING, 450 SXS RACING, 520 SX, 525 SX, 520 MXC, 525 MXC, 520 XC, 525 XC, 520 XC-W, 525 XC-W, 520 EXC, 525 EXC, 520 SMR, 525 SMR, 540 SXS, 560 SMR, 610 CRA Model Years Covered: 2000-2007 Page Count Estimated Page Count: Large (up to 5GB file size mentioned, indicating extensive detail) Manual Type Type: Workshop Service Repair Manual Language Language: English (implied by product description and common industry practice for this type of manual) Format Delivery Format: Digital Download (PDF, ZIP, RAR, or EXE) Accessibility: Readable on PC & MAC (Windows 97, 2000, Me, XP, Vista, 7, 10), iPad, Hard Disc Printing Options: Printable on any computer and printer, no restrictions 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, servicing individual components, detailed engine component breakdowns, engine rebuild procedures Engine Electrical: Electrical troubleshooting, wiring diagrams Drivetrain: Transmission (implied by workshop manual scope), power delivery components Chassis Suspension: Frame, suspension systems, swingarm, linkage (implied) Brakes: Brake system maintenance and repair (implied) Fuel System: Fuel delivery and carburetion/injection systems (implied) Cooling System: Radiator, coolant, fan (if applicable) maintenance and repair (implied) Exhaust System: Exhaust components and service (implied) Bodywork Trim: Fairings, plastics, seat, controls (implied) Procedures Included Maintenance: Periodic maintenance schedule, routine servicing, preventative maintenance Troubleshooting: Trouble shooting guides, identifying and fixing problems Repair: Step-by-step repair instructions, component replacement, diagnostics Restoration: Restore, rebuild procedures Diagnostics: Diagnostic procedures for various systems Technical Specifications: Technical specifications, torque values, fluid capacities, clearances Technical Depth Depth: Comprehensive (covers repair, service, restore, maintain, rebuild, diagnose) Illustrations: Illustrated with clear step-by-step instructions, zoomable illustrations, exploded views, component breakdowns Target Audience: Professional technicians, mechanics, and DIY individuals 📊 Manual Specifications File Format Format: PDF, ZIP, RAR, EXE File Size: Potentially very large, up to 5GB Print Quality Print Quality: High quality, suitable for printing Binding Type Binding: Not applicable (Digital Download) Paper Type Paper Type: Not applicable (Digital Download) Software Requirements PDF Reader: Standard PDF reader required Unzipping Software: WinZip or WinRAR (free versions available) for zipped files ⚙️ Engine Specifications Primary Engine Engine Types: Single-cylinder, four-stroke engines (typical for these KTM models, specific variants detailed in manual) Performance Displacement Range: 250cc, 400cc, 450cc, 520cc, 525cc, 540cc, 560cc, 610cc (approximate based on model names) Horsepower Torque: Detailed specifications and ranges for each engine displacement are...