🏷️ Basic Information Identification Make: KTM Model: EXC, MXC, SMR, SX, SXS Racing (4-Stroke) Production Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006 Engine Types Covered: 4-Stroke Codes Vin Prefix General: VTR (for Austria-produced KTMs) Engine Code Examples: LC4 (common for larger displacement models), specific codes vary by displacement and model year 👋 Introduction Market Position Segment: High-performance off-road and street-legal motorcycles (Enduro, Motocross, Supermoto) Competitive Analysis Competitors: Yamaha WR/YZ, Honda CRF/XR, Suzuki DR/RM-Z, Kawasaki KX/KLX (4-stroke variants) Key Features Manual Benefits: Instant PDF download, lifetime protection policy against loss/damage, printable pages, accessible on mobile devices for trailside repairs. Vehicle Strengths: Known for powerful engines, aggressive styling, advanced suspension, and off-road prowess. 📋 Manual Details Coverage Areas Primary Coverage: Repair, Maintenance, Troubleshooting, Parts Lookup Specific Models Detailed: 250 EXC Racing, 400 SX, MXC, XC, EXC, SMR, SXS, 450 SX, MXC, XC, EXC, SMR, SXS, 520 SX, MXC, XC, EXC, SMR, 525 SX, MXC, XC, EXC, SMR, 540 SXS, 560 SMR, 610 CRATE Page Count Estimated Page Count: High (indicative of comprehensive coverage, precise count not provided but typical for full service manuals). Manual Type Type: Comprehensive Repair Manual / Workshop Manual / Owner's Manuals / Parts Catalogs (all provided as downloadable PDF) Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Systems: Engine removal/installation, general specifications, lubrication, cooling, fuel system, intake, exhaust. Drivetrain Systems: Transmission, drive chain, sprockets. Chassis Systems: Steering system, shocks, bodywork. Electrical Systems: Complete electrical system diagnostics, wiring diagrams (likely), ignition, lighting, starting systems. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, spark plug service, air filter cleaning/replacement. Major Repairs: Engine rebuilds, transmission overhauls, suspension servicing, carburetor/fuel injection tuning. Troubleshooting: Advanced troubleshooting guides for common and uncommon issues across all covered systems. Technical Depth Depth: Comprehensive from basic owner maintenance to in-depth workshop repair and diagnostics, suitable for both novice and experienced mechanics. 📊 Manual Specifications File Format Format: PDF Print Quality Quality: High-resolution, suitable for printing individual pages or the entire manual. Binding Type Binding: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Displacement Options: 250cc, 400cc, 450cc, 520cc, 525cc, 540cc, 560cc, 610cc Engine Configuration: Single-cylinder, 4-stroke Cooling System: Liquid-cooled Performance Horsepower Range: Typically 40-60+ HP depending on displacement and specific model tuning (factory figures often not officially stated for racing models). Fuel System Fuel Delivery: Carbureted (Mikuni/Keihin) for most models, some later models or specific SXS/SMR variants may have fuel injection. 🔧 Transmission Standard Type: 5-speed or 6-speed constant mesh sequential gearbox Optional Gearbox Variations: Different gear ratios available for specific racing applications (e.g., SX vs. EXC). Features Clutch: Hydraulically operated, multi-plate wet clutch 📐 Dimensions Exterior Wheelbase Typical: Approx. 1460-1480 mm (varies by model) Seat Height Typical: Approx. 960-990 mm (varies by model, often adjustable) Weights Dry Weight Typical: Approx. 105-115 kg (varies significantly by model and displacement) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (motorcycles are not subject to automotive crash test ratings like NHTSA or Euro NCAP) Active Features Braking System: Hydraulic disc brakes (front and rear), typically Brembo components. Suspension System: High-performance, adjustable WP (White Power) upside-down telescopic forks and monoshock rear suspension. Passive Features Frame Construction: Chromium-molybdenum steel trellis frame. 💡 Technology Features Infotainment Features: Minimal by modern standards; primarily focused on essential instrumentation (speedometer, odometer, tachometer, basic warning lights). Driver Assistance Features: N/A (Off-road motorcycles in this era did not feature electronic rider aids like ABS or traction control). Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10-15 hours of riding or annually, depending on riding conditions and manufacturer recommendations. Manual will specify. Valve Clearance Check: Recommended at major service intervals, often around 30-50 hours or annually. Manual will provide exact figures. Fluid Specifications Engine Oil Viscosity: Commonly 10W-50 or 10W-60 synthetic motorcycle oil (refer to manual for exact OEM specification). Coolant Type: Ethylene glycol-based coolant with corrosion inhibitors (typically 50/50 mix with distilled water). Brake Fluid Type: DOT 4 or DOT 5.1 hydraulic brake fluid (check manual for specific requirements). Known Issues Common Wear Items: Clutch plates, brake pads, wheel bearings, steering head bearings, swingarm/linkage bearings, fork seals, exhaust gaskets. Potential Engine Concerns: KTM's 4-stroke engines of this era were generally robust but could be sensitive to oil maintenance. Some early models might have had specific cam chain tensioner or piston ring wear considerations. 📚 Vehicle History Brand Heritage Heritage: KTM is renowned for its 'Ready to Race' philosophy and success in off-road motorsports, particularly enduro and motocross. Model Evolution Evolution 2000-2006: This period saw significant development in KTM's 4-stroke off-road lineup, transitioning from early LC4 designs to more refined and performance-oriented platforms across the EXC, SX, and MXC ranges. Displacement increased, chassis geometry was refined, and suspension technology advanced. Production Manufacturing Location: Austria (primarily) 🏆 Awards & Recognition...