🏷️ Basic Information Identification Make: KTM Model: 250 EXC RACING / 400 SX / 450 SX / MXC / XC / XC-W / EXC / SMR / SXS RACING / 520 SX / 525 SX / MXC / XC / XC-W / EXC / SMR RACING / 540 SXS / 560 SMR / 610 CRATE Engines Model Variants: EXC RACING, SX, MXC, XC, XC-W, SMR, SXS RACING, CRATE Engines Codes Engine Code Family: LC4 (for larger displacements), LC4 4-Stroke (general reference) Generation Model Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006 👋 Introduction Market Position Target Audience: First-time owners, amateur mechanics, professional technicians. Key Features Readability: Easy to read type, providing all necessary information for correct procedure execution. Preventive Maintenance Focus: Emphasizes routine, preventive maintenance to save time and money by preventing premature failure. Ease Of Use: Designed for accessibility, allowing users of varying skill levels to perform maintenance and repairs. Competitive Analysis Market Segment: High-performance off-road, motocross, and supermoto motorcycles competing against brands like Yamaha, Honda, Suzuki, and Husqvarna in their respective categories. 📋 Manual Details Coverage Areas Covered Models: KTM 250 EXC RACING, 400 SX, 450 SX, MXC, XC, XC-W, EXC, SMR, SXS RACING, 520 SX, 525 SX, MXC, XC, XC-W, EXC, SMR RACING, 540 SXS, 560 SMR, 610 CRATE Engines Engine Displacements Covered: 250cc, 400cc, 450cc, 520cc, 525cc, 540cc, 560cc, 610cc Page Count Estimated Page Count: Not specified, but comprehensive based on content listing. Manual Type Manual Type: Workshop Service Repair Manual Digital Format Advantage: PDF format allows for easy searching, bookmarking, and printing of specific sections. Language Language: English Format File Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine removal/refitting, complete disassembly, component servicing, assembly, fuel system, troubleshooting. Electrical Systems: Electrical system diagnostics, wiring diagrams. Engine Components Serviced: Cylinder head, pistons, connecting rods, crankshaft, camshafts, valve train, lubrication system, cooling system (if applicable), clutch, gearbox. Ignition System: Implied coverage through electrical system and troubleshooting sections, focusing on spark plug, CDI unit, and related components. Procedures Included Maintenance Procedures: Periodic maintenance schedule, servicing individual components, fluid checks and changes. Repair Procedures: Engine disassembly and reassembly, component-specific repair guidance, fuel system repair. Troubleshooting Procedures: Dedicated troubleshooting section for identifying and resolving common issues. Assembly Instructions: Detailed step-by-step instructions for reassembling the engine after disassembly. Component Replacement: Guidance on replacing wear-and-tear components and major engine parts. Technical Depth Technical Depth: Comprehensive; covers from basic owner maintenance to professional technician-level repair and diagnostics. Diagnostic Capabilities: Provides troubleshooting guides and technical specifications aiding in diagnostic procedures. Torque Specifications: Crucial torque values for critical engine fasteners are provided, essential for correct assembly and preventing damage. Part Identification: Detailed descriptions and likely diagrams for individual engine components aid in part identification for service or replacement. 📊 Manual Specifications File Format Compatibility: All Versions of Windows & Mac Required Software: Adobe PDF Reader Document Quality: PDF format ensures consistent display and printability across devices. Print Quality Searchable Text: Likely searchable if the PDF is well-created, common for modern service manuals. Binding Type Binding Type: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Families Covered: Multiple KTM single-cylinder engines (LC4 architecture variants). Engine Variants Covered Displacements: 250cc, 400cc, 450cc, 520cc, 525cc, 540cc, 560cc, 610cc. Performance Performance Details: Horsepower and torque figures will vary significantly by specific model and year, detailed within the manual. Fuel System Fuel System Coverage: Covers fuel system components and procedures, likely including carburetor systems for most models in this era. Engine Type Engine Configuration: Predominantly single-cylinder, 4-stroke engines. Cooling System Cooling Method: Liquid-cooled, requiring attention to coolant levels and system integrity. 🔧 Transmission Standard Transmission Types: Likely includes 5-speed and 6-speed sequential manual transmissions, typical for these KTM models. Features Transmission Servicing: Manual provides procedures for transmission disassembly, inspection, repair, and reassembly. 📐 Dimensions Weights Dry Weight Range: Dry weights varied by model, typically ranging from approximately 100-120 kg for 250cc to 130-150+ kg for larger displacement models. Wet Weight Estimation: Wet weights would be significantly higher due to fluids (oil, coolant, fuel). 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle-specific safety ratings like NCAP do not apply. Focus is on rider safety through proper maintenance and component function.) Active Features Braking System Coverage: While primarily an engine manual, it implies understanding of engine impact on chassis dynamics affecting braking, but explicit brake caliper/master cylinder procedures are unlikely. 💡 Technology Features Infotainment Infotainment Systems: N/A (These are performance-oriented off-road/motocross/supermoto motorcycles, typically lacking advanced infotainment features.) Driver Assistance Driver Assistance Features: N/A (No electronic rider aids like ABS or traction control expected on these models from this era.) Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Typically 10-15 operating hours or annually, specific details are in the manual's periodic maintenance schedule. Air Filter Cleaning: Frequent...