This manual covers a comprehensive range of motorcycles from the 2000 to 2007 model years, including various EXC, SX, MXC, XC, XC-W, SMR, SXS, and CRATE models. These motorcycles, powered by the robust LC4 engine architecture, span displacements from 250cc to 610cc and are renowned for their off-road performance, durability, and 'Ready to Race' heritage. Engineered for demanding conditions, bikes from this era are characterized by their powerful single-cylinder engines, advanced suspension systems, and agile handling, making them a popular choice for both competitive racing and enthusiast riding. This service manual provides in-depth guidance for owners, mechanics, and technicians to effectively maintain and repair these models. It details essential procedures for engine disassembly and assembly, transmission servicing, electrical system diagnostics, and chassis component maintenance. Coverage includes scheduled maintenance, troubleshooting common issues, detailed technical specifications, and step-by-step repair instructions, ensuring that the vehicle's performance and longevity are optimized. The manual is designed to empower users with the knowledge needed for everything from routine oil changes to complete engine overhauls. 🏷️ Basic Information Identification Make: KTM Model: Multiple (EXC, SX, MXC, XC, XC-W, EXC, SMR, SXS, CRATE) Engine Platform: Shared Engine Architecture Generation Production Years: 2000-2007 Codes Engine Codes Indicated: LC4, LC4-E (specific designations may vary by model and year) 👋 Introduction Market Position Target Audience: DIY owners, independent mechanics, workshops, enthusiasts seeking detailed repair and maintenance information. Competitive Analysis Competitor Manuals: OEM service manuals, Haynes, Clymer (though often less detailed than OEM). Key Features Manual Advantage: Comprehensive coverage across multiple engine displacements and model variants within a specific generation, detailed illustrations, direct application to professional technician procedures. Value Proposition: Cost savings through self-maintenance and repair, empowerment of owners with technical knowledge. Manual Format Benefit Digital Accessibility: Instant download, accessible on multiple devices (computer, tablet, etc.), no physical storage limitations. 📋 Manual Details Coverage Areas Covered Model Years: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Covered Motorcycle Models: KTM 250 EXC, KTM 400 SX, KTM 400 MXC, KTM 400 XC, KTM 400 XC-W, KTM 400 EXC, KTM 400 SMR, KTM 400 SXS, KTM 450 SX, KTM 450 MXC, KTM 450 XC, KTM 450 XC-W, KTM 450 EXC, KTM 450 SMR, KTM 450 SXS, KTM 520 SX, KTM 520 MXC, KTM 520 XC, KTM 520 XC-W, KTM 520 EXC, KTM 520 SMR, KTM 525 SX, KTM 525 MXC, KTM 525 XC, KTM 525 XC-W, KTM 525 EXC, KTM 525 SMR, KTM 540 SMR, KTM 610 CRATE Page Count Estimated Page Count: Varies (up to 3000 MB suggests a very comprehensive manual, likely several hundred pages if printed) Manual Type Manual Type: Service Repair Manual / Workshop Manual / Factory Manual Language Language: English Format Delivery Format: Digital Download (PDF, ZIP, RAR, EXE) 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly, assembly, repair, troubleshooting, component servicing, internal lubrication, cooling system, fuel system, ignition system, exhaust system, engine management. Transmission Systems: Gearbox disassembly, assembly, repair, clutch operation and service, gear shift mechanism. Electrical Systems: Wiring diagrams, ignition system components, lighting, starter system, charging system, electronic control units (ECUs), sensor diagnostics. Chassis Systems: Suspension (forks, rear shock), braking system (hydraulic circuits, components), steering, wheels and tires. Bodywork And Frame: Frame inspection, fairings, seat, fuel tank mounting and servicing. Procedures Included Maintenance Procedures: Scheduled maintenance, oil changes, filter replacements, spark plug service, valve clearance adjustment, chain adjustment, brake fluid replacement, coolant replacement. Repair Procedures: Complete engine rebuild, gearbox overhaul, suspension fork service, brake caliper rebuild, carburetor overhaul, electrical component testing and replacement. Troubleshooting Guidance: Systematic diagnosis of common problems, symptom-based troubleshooting charts, error code interpretation (if applicable). Diagnostic Procedures: Checking component functionality, electrical system testing, pressure testing (e.g., fuel pressure). Technical Depth Depth Of Coverage: Comprehensive (from basic maintenance to complete engine and component overhauls, including detailed exploded views). Diagnostic Capabilities: Advanced diagnostics for engine performance and electrical systems. Rebuild Instructions: Detailed step-by-step instructions for engine and major component rebuilds. 📊 Manual Specifications File Format File Type: PDF (commonly), ZIP, RAR, EXE Searchability: Likely text-searchable PDF, depending on origin and scanning quality. Print Quality Printable: Yes, can be printed on any printer. Illustration Quality: Illustrated with clear step-by-step instructions, zoomable illustrations, exploded views. Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) File Size Maximum File Size: Up to 3000 MB ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder (primarily LC4 architecture) Engine Displacements Covered: 250cc, 400cc, 450cc, 520cc, 525cc, 540cc, 610cc Performance Horsepower Range: Varies significantly by displacement and specific model tune (e.g., 30-55+ HP) Torque Range: Varies significantly by displacement and specific model tune (e.g., 30-50+ lb-ft) Fuel System Fuel Delivery Systems: Carburetor (Mikuni VM/TM, Keihin FCR) or Fuel Injection (EFI on later models within the range, though less common for these specific displacements in this period). Fuel Type: Unleaded Gasoline (Octane rating specified in manual)...