This manual provides comprehensive service and repair information for 4-stroke race bikes manufactured between 2000 and 2005. Covering a wide array of models including the EXC, SX, and MXC variants, these Austrian-engineered machines are built for demanding off-road competition. Known for their robust performance and agility, race bikes from this period feature powerful single-cylinder engines ranging from 250cc to 540cc, utilizing either carburetor or electronic fuel injection systems. Their design emphasizes direct rider feedback and exceptional handling, making them a formidable choice for motocross, enduro, and cross-country racing. This detailed workshop manual serves as an essential resource for owners and technicians. It meticulously outlines routine maintenance procedures, such as oil changes and filter replacements, alongside in-depth troubleshooting guidance for common issues like valve wear or suspension leaks. The manual covers all major vehicle systems, including the engine, fuel, ignition, transmission, chassis, brakes, and electrical components, with step-by-step instructions and clear illustrations. Its comprehensive scope facilitates everything from basic adjustments to complete engine rebuilds, ensuring the optimal performance and longevity of your race bike. 🏷️ Basic Information Identification Make: KTM Model: 4-stroke Race Bike (Multiple Variants) Applicable Years: 2000, 2001, 2002, 2003, 2004, 2005 Codes Manual Product Name: KTM 2000 2001 2002 2003 2004 2005 4-stroke race bike Service Repair Manual Download 👋 Introduction Market Position Target Audience: Owners and technicians of KTM 4-stroke race bikes from model years 2000-2005 seeking to perform maintenance, repairs, and diagnostics. Competitive Analysis Manual Type Comparison: This manual is presented as the 'original' and 'factory' manual used by professionals, offering a higher level of detail than generic repair guides. Key Features Features: Step-by-step instructions, clear illustrations, troubleshooting guidance, and comprehensive coverage of multiple KTM race bike models and years. 📋 Manual Details Coverage Areas Covered Models: • 2000 KTM 400 EXC Racing • 2000 KTM 400 SX Racing • 2000 KTM 520 EXC • 2000 KTM 520 SX • 2001 KTM 400 EXC • 2001 KTM 400 EXC Racing • 2001 KTM 400 MXC Racing • 2001 KTM 400 SX Racing • 2001 KTM 520 EXC Racing • 2001 KTM 520 MXC Racing • 2001 KTM 520 SX Racing • 2002 KTM 250 EXC • 2002 KTM 400 EXC • 2002 KTM 400 MXC • 2002 KTM 400 SX • 2002 KTM 520 EXC • 2002 KTM 520 MXC • 2002 KTM 520 SX • 2003 KTM 250 EXC Racing • 2003 KTM 450 EXC Racing • 2003 KTM 450 MXC Racing • 2003 KTM 450 SX Racing • 2003 KTM 525 EXC Racing • 2003 KTM 525 MXC Racing • 2003 KTM 525 SX Racing • 2004 KTM 250 EXC • 2004 KTM 400 EXC • 2004 KTM 400 LS-E • 2004 KTM 400 MIL • 2004 KTM 450 EXC • 2004 KTM 450 MXC • 2004 KTM 450 SX • 2004 KTM 525 EXC • 2004 KTM 525 MXC • 2004 KTM 525 SX • 2004 KTM 525 SMR • 2004 KTM 540 SXS • 2004 KTM SX450SMR • 2005 KTM 250 EXC • 2005 KTM 400 EXC • 2005 KTM 450 EXC • 2005 KTM 450 MXC • 2005 KTM 525 EXC • 2005 KTM 540 SXS • 2005 KTM 610 CRATE • 2005 KTM MXC525 • 2005 KTM SX450SMR • 2005 KTM SX525 Racing • 2005 KTM SX525SMR Page Count Estimated Page Count: High (Specific count not provided, but described as 'detailed file' and 'very large', potentially up to 5GB) Manual Type Type: Service Repair Manual / Workshop Manual / Factory Manual Language Language: English Format Format: Digital Download (PDF, ZIP, RAR, or EXE) 📖 Manual Coverage Systems Covered Major Systems: • Engine (top-end, bottom-end, cooling, lubrication) • Fuel System (carburetor/EFI, fuel pump, injectors) • Ignition System (CDI/ECU, coils, spark plugs) • Transmission (gearbox, clutch, final drive) • Chassis & Suspension (frame, forks, shock absorber, swingarm) • Braking System (front and rear brakes, hydraulics) • Electrical System (wiring diagrams, charging system, lighting) • Wheels & Tires • Bodywork & Plastics • Exhaust System • Controls & Linkages Procedures Included Repair And Maintenance: • Routine Maintenance (oil changes, filter replacements, chain adjustment) • Troubleshooting and Diagnostics (error codes, symptom analysis) • Engine Overhaul and Rebuild • Carburetor/EFI Adjustment and Cleaning • Clutch Service and Replacement • Transmission Inspection and Repair • Suspension Setup and Rebuilding • Brake System Bleeding and Component Replacement • Electrical System Diagnostics and Repair • Wheel Bearing Replacement • Tire Mounting and Balancing • General Component Disassembly and Reassembly Technical Depth Level Of Detail: Comprehensive. Covers everything from basic maintenance to complete engine rebuilds and advanced troubleshooting. Suitable for both DIY enthusiasts and professional technicians. 📊 Manual Specifications File Format Compatibility: Windows, Linux, Mac OS. Readable with any PDF reader. May require WinZip or WinRAR for decompression. Print Quality Printability: Printable on any computer and printer. Binding Type...