🏷️ Basic Information Identification Make: KTM Model Range: 250 EXC RACING, 400 SX, 400 MXC, 400 XC, 400 XC-W, 400 EXC, 400 SMR, 400 SXS RACING, 450 SX, 450 MXC, 450 XC, 450 XC-W, 450 EXC, 450 SMR, 450 SXS RACING, 520 SX, 520 MXC, 520 XC, 520 XC-W, 520 EXC, 520 SMR, 520 SXS RACING, 525 SX, 525 MXC, 525 XC, 525 XC-W, 525 EXC, 525 SMR, 525 SXS RACING, 540 SXS, 560 SMR, 610 CRATE Year Range: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Codes Manual Type: Engine Service Repair Manual 👋 Introduction Market Position Target Audience: KTM motorcycle owners and independent repair shops seeking detailed engine maintenance and repair guidance. Competitive Analysis Value Proposition: Provides essential, in-depth technical information for self-maintenance and repair, saving costs associated with dealership servicing. Instant download eliminates shipping delays and costs. Key Features Ease Of Use: Step-by-step instructions designed for ease of following, catering to various skill levels. Diagnostic Support: Includes troubleshooting section to aid in identifying and resolving common problems. Technical Data: Offers crucial technical specifications required for accurate repairs and maintenance. 📋 Manual Details Coverage Areas Engine Repair: Comprehensive engine service and repair procedures Component Servicing: Servicing of individual engine components Electrical Systems: Engine-related electrical systems and troubleshooting Troubleshooting: Diagnostic procedures and common issue resolution Maintenance: Periodic maintenance schedules and procedures Page Count Estimated Pages: High - typical for comprehensive engine manuals (specific number not provided, but coverage implies extensive) Manual Type Type: Service Repair Manual Language Language: English Format File Format: PDF Download Compatibility: All Versions of Windows & Mac Requirements Software Requirement: Adobe PDF Reader Accessibility Download Method: Instant download upon payment completion Printability Print Feature: All pages are printable 📖 Manual Coverage Systems Covered Engine Assembly Disassembly: Complete engine disassembly and reassembly procedures Engine Removal Installation: Procedures for removing and refitting the engine Individual Components: Detailed servicing of specific engine components (e.g., cylinder head, pistons, crankshaft, valve train, cooling system, lubrication system) Electrical: Engine electrical systems including ignition, starting, charging, and associated wiring diagrams Procedures Included Diagnostic Procedures: Troubleshooting common engine faults and diagnostic steps Maintenance Tasks: Routine maintenance tasks as per the periodic maintenance schedule Repair Instructions: Step-by-step repair instructions for engine-related issues Diagrams Illustrations: High-quality diagrams and illustrations for clarity Technical Depth Depth Level: Comprehensive, suitable for DIY enthusiasts and professional mechanics 📊 Manual Specifications File Format Document Format: PDF Print Quality Printability: Printable, allowing for workshop use Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Quality: Not Applicable (Digital Download) Source Quality Content Quality: High quality diagrams and instructions ⚙️ Engine Specifications Primary Engine 250 Engine Type 250: Four-stroke, liquid-cooled single-cylinder (likely LC4 variant for EXC models) Displacement 250: Approximately 250cc (exact variant may differ based on specific model year) Primary Engine 400 450 Engine Type 400 450: Four-stroke, liquid-cooled, single-cylinder (LC4 engine family) Displacement 400 450: 400cc to 450cc range (specific models like 400 EXC, 450 SX) Primary Engine 520 525 Engine Type 520 525: Four-stroke, liquid-cooled, single-cylinder (LC4 engine family, often referred to as 525 EXC, 525 SX) Displacement 520 525: 520cc to 525cc range Primary Engine 540 560 Engine Type 540 560: Four-stroke, liquid-cooled, single-cylinder (LC4 engine family, high-performance variants) Displacement 540 560: 540cc to 560cc range Primary Engine 610 Engine Type 610: Four-stroke, liquid-cooled, single-cylinder (likely LC4 engine family, larger displacement variant) Displacement 610: Approximately 610cc Performance Horsepower Range: Varies by displacement and model, typically 40-60+ HP for this era of KTM off-road/supermoto models. Fuel System Fuel Delivery: Carbureted (likely Keihin or Mikuni CV carbs, specific models might transition to EFI later in the range, though manual focuses on engine service implying carburetors are prevalent). Cooling System Cooling Type: Liquid-cooled, with radiator and fan assembly Lubrication System Lubrication Type: Wet sump or semi-dry sump (specific to LC4 architecture) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh (typical for these KTM models) Features Clutch Type: Hydraulically operated multi-plate wet clutch Fluid Requirements Transmission Oil Spec: Typically SAE 10W-50 or 20W-50 motorcycle-specific engine oil (refer to manual for precise grade and capacity). 📐 Dimensions Exterior Vehicle Type: Motocross, Enduro, Supermoto motorcycles Weights Dry Weight Range: Approx. 100-130 kg (220-285 lbs) depending on model and configuration. Manual is engine-focused, so detailed chassis dimensions are not expected but engine weight for removal/installation is covered. 🛡️ Safety Features Ratings Safety Features: Focuses on mechanical safety related to engine operation and integrity. Does not cover chassis or rider safety equipment. 💡 Technology Features Infotainment Infotainment System: N/A (Motorcycle-specific, no infotainment system expected in this context). Driver Assistance Driver Assistance Features: N/A (Motorcycle-specific, no driver assistance features expected). Engine Management Ignition System: Electronic Ignition (CDI or similar electronic control unit for ignition timing). Efi Transition: While this generation primarily uses carburetors, the manual would cover ignition and potentially basic EFI sensor diagnostics if present...