This manual covers EXC, MXC, SMR, SX, and SXS 4-stroke motorcycles manufactured between 2000 and 2006. It details a wide range of models including the 250 EXC Racing, 400 SX, 450 EXC, 520 SX, 525 MXC, 540 SXS, 560 SMR, and 610 CRATE, among others. is renowned for its off-road racing heritage and commitment to performance, and these models embody that philosophy with their liquid-cooled, single-cylinder, 4-stroke engines, robust steel trellis frames, and advanced suspension systems. Designed for demanding off-road conditions, these motorcycles offer powerful, high-revving engines and are built for competitive use in disciplines such as motocross, enduro, and supermoto. This comprehensive service manual provides detailed instructions for the maintenance, repair, and overhaul of your motorcycle. It covers all essential systems, including engine disassembly and reassembly, fuel system tuning and repair, lubrication, cooling, transmission, drivetrain, suspension, steering, brakes, and electrical systems. Routine maintenance procedures, troubleshooting guides, technical specifications, and torque values are thoroughly explained. This manual is an indispensable resource for owners, mechanics, and technicians, enabling them to perform accurate diagnostics, efficient repairs, and essential upkeep to ensure optimal performance and longevity of their 4-stroke motorcycles. 🏷️ Basic Information Identification Make: KTM Model: EXC, MXC, SMR, SX, SXS (4-Stroke) Product Name: 2000-2006 KTM 250 400 450 520 525 540 560 610 EXC MXC SMR SX SXS Racing Crate 4-Stroke Motorcycle Repair Manual PDF Download Product Type: Downloadable PDF Repair Manual Codes Manufacturer Codes: KTM AG 👋 Introduction Market Position Target Audience: KTM owners, off-road enthusiasts, motocross racers, enduro riders, and independent repair shops. Competitive Analysis Manual Value: Provides critical factory information to reduce reliance on costly dealership service or potentially inaccurate third-party guides. Key Features Diagnostic Tools: Empowers users with the knowledge to perform diagnostics, reducing the need for specialized electronic diagnostic equipment. Cost Savings: Enables DIY maintenance and repairs, leading to significant cost savings over the ownership period. Performance Optimization: Detailed specifications and tuning advice aid in maintaining optimal engine performance and longevity. 📋 Manual Details Coverage Areas Model Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006 Specific Models Covered: 250 EXC Racing, 400 SX, 400 MXC, 400 XC, 400 EXC, 400 SMR, 400 SXS, 450 SX, 450 MXC, 450 XC, 450 EXC, 450 SMR, 450 SXS, 520 SX, 520 MXC, 520 XC, 520 EXC, 520 SMR, 525 SX, 525 MXC, 525 XC, 525 EXC, 525 SMR, 540 SXS, 560 SMR, 610 CRATE Engine Types Covered: 4-Stroke Page Count Estimated Page Count: Varies by model/year, typically 300-600+ pages for full service manuals Manual Type Manual Format: Service Manual / Workshop Manual / Repair Manual Manual Origin: OEM Factory Service Manual Data (as represented by ClassicCirculations.com) Language Language: English Format Download Format: PDF Download 📖 Manual Coverage Systems Covered Engine Overhaul: Complete disassembly, inspection, repair, and reassembly procedures for all covered 4-stroke engines. Fuel System: Carburetor (Keihin, Mikuni) tuning, cleaning, rebuilding; fuel injection system diagnostics and repair for applicable models. Lubrication And Cooling: Oil pump operation, oil cooler service, coolant system bleeding, radiator and hose inspection, water pump repair. Transmission And Drivetrain: Clutch operation and service, gearbox disassembly and inspection, gear ratio information, chain and sprocket maintenance and replacement. Suspension And Steering: Front fork (WP) servicing (oil changes, seal replacement, revalving), rear shock absorber (WP) overhaul and adjustments, steering head bearing service. Brakes: Brake caliper inspection and service, master cylinder overhaul, brake pad replacement, hydraulic system bleeding, rotor inspection. Electrical System: Wiring diagrams, ignition system troubleshooting, lighting circuits, starter motor and battery maintenance, CDI unit diagnostics. Chassis And Bodywork: Frame inspection, seat and plastic panel removal/installation, exhaust system service, kickstand and footpeg maintenance. Procedures Included Routine Maintenance: Oil and filter changes, air filter cleaning/replacement, chain adjustment, spark plug inspection, valve clearance checks. Troubleshooting: Diagnostic flowcharts and symptom-based problem solving for common issues. Rebuilds And Overhauls: Detailed step-by-step instructions for engine, transmission, and suspension component rebuilds. Specifications And Torque Values: All critical torque specifications, clearances, and measurement data for repairs. Technical Depth Diagnostic Capabilities: Advanced diagnostics for ignition, fuel delivery, and electrical systems, often requiring specialized tools (though manual provides theory). Rebuild Level: Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Parts Identification: Detailed component diagrams and part numbers for accurate identification and ordering. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Print Quality Digital Resolution: High-resolution scans suitable for on-screen viewing and printing. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) Features Searchability: Typically searchable text within the PDF for quick information retrieval. Printable Pages: Allows selective printing of specific pages for workshop use. ⚙️ Engine Specifications Primary Engine Engine Configuration: Single-cylinder, 4-stroke (various displacements) Engine Displacements Quoted: 250cc, 400cc, 450cc, 520cc, 525cc, 540cc, 560cc, 610cc Engine Cooling: Liquid-cooled Performance Power Delivery Characteristics: High-revving, focused on off-road performance (motocross, enduro, supermoto). Fuel System Carburetor Types: Keihin FCR (Flat CR),...