🏷️ 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 Evolution Engine Development: These models represent an evolution of KTM's LC4 engine architecture, adapted for various competitive disciplines. Production Manufacturing Location: Austria (KTM headquarters and primary manufacturing). 🏆 Awards & Recognition Recognitions Motorsport Performance: KTM models of this era were highly successful in various professional off-road racing series, indicating inherent design and performance capabilities. Ratings Manual Quality: Described as a 'QUALITY manual', '100 percents COMPLETE and INTACT'.