This manual covers EXC, MXC, SMR, SX, and SXS Racing Crate models produced between 2000 and 2006, encompassing engine displacements from 250cc to 610cc. These motorcycles, renowned for their Austrian engineering and 'Ready to Race' philosophy, are built for demanding off-road and competitive use, including Enduro, Motocross, and Supermoto disciplines. With a heritage steeped in racing success, motorcycles from this era are celebrated for their robust performance, advanced suspension, and agile handling, making them a favored choice for both professional racers and serious enthusiasts. This comprehensive service, repair, and workshop manual provides factory-level information essential for the maintenance and repair of your motorcycle. It details everything from routine servicing, including oil changes and filter replacements, to in-depth engine overhauls, transmission repairs, and suspension servicing. Coverage extends to the fuel, ignition, electrical, and braking systems, supported by hundreds of detailed photographs and exploded diagrams. The manual also includes crucial troubleshooting guides and wiring diagrams, ensuring owners, mechanics, and technicians have the resources needed for accurate diagnostics and efficient repairs, thereby maximizing the performance and longevity of these high-caliber machines. 🏷️ Basic Information Identification Make: KTM Model: EXC, MXC, SMR, SX, SXS Racing Crate Model Variants: 250, 400, 450, 520, 525, 540, 560, 610 Year Range: 2000, 2001, 2002, 2003, 2004, 2005, 2006 Codes Chassis Codes: Varies by specific model and year (e.g., EXC, SX, MXC designations with internal KTM project codes) Engine Codes: Varies by specific engine displacement (e.g., LC4 variants, specific engine family identifiers) 👋 Introduction Market Position Target Audience: KTM owners, independent repair shops, and professional motorcycle technicians. Value Proposition: Provides comprehensive, factory-level information for maintenance, repair, and troubleshooting, enabling cost savings and proper upkeep. Competitive Analysis Differentiation: Offers complete factory coverage for a wide range of model years and engine displacements within the EXC, MXC, SMR, SX, and SXS series, differentiating from less comprehensive or aftermarket guides. Key Features Coverage Breadth: Covers multiple engine sizes (250cc to 610cc) and competitive disciplines (Enduro, Motocross, Supermoto). Accessibility: Instant digital download for immediate use on multiple devices, with lifetime access. 📋 Manual Details Coverage Areas Coverage Type: Comprehensive Service, Repair, and Workshop Manual Geographic Scope: Global (factory specifications applicable worldwide) Page Count Estimated Page Count: Hundreds of pages (specific number not provided, but described as extensive) Manual Type Type: Factory Service Repair Workshop Manual Language Language: English (implied by typical professional mechanic manuals and product description phrasing) Format Format: PDF Download Access: Instant Download, Life-time Usage, Unlimited Devices 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, overhaul, component replacement (pistons, rings, valves, crankshaft, connecting rods), cylinder head, valve train. Fuel System: Carburetor adjustment and overhaul (if applicable), fuel injection system diagnostics and repair (if applicable), fuel pump, fuel filter, fuel lines. Ignition System: Ignition coil testing, spark plug specifications, CDI unit diagnostics, stator and rotor inspection. Exhaust System: Exhaust pipe inspection, muffler repair and replacement, catalytic converter diagnosis (if equipped). Cooling System: Radiator inspection, coolant flow diagnosis, water pump service, thermostat replacement, cooling fan operation. Transmission And Drivetrain: Clutch adjustment and overhaul, gear selection mechanisms, internal transmission components, chain and sprocket maintenance, final drive inspection. Suspension Front: Fork oil change and service, fork seal replacement, spring replacement, damping adjustment, steering head bearing service. Suspension Rear: Shock absorber service, linkage lubrication, rear shock adjustment (preload, rebound, compression), swingarm bearing inspection. Brakes Front: Brake pad replacement, caliper service, brake line inspection and replacement, master cylinder overhaul, brake fluid specifications and bleeding procedures. Brakes Rear: Brake pad replacement, caliper service, brake line inspection and replacement, master cylinder overhaul, brake fluid specifications and bleeding procedures. Electrical System: Wiring diagrams, battery maintenance and testing, charging system diagnosis (stator, regulator/rectifier), lighting system troubleshooting, starter motor operation, horn, switches. Chassis And Frame: Frame inspection, subframe inspection, footpeg mounting, rider controls (handlebars, levers, pedals). Bodywork And Trim: Fairing removal and installation, seat maintenance, fender replacement, graphics application. Wheels And Tires: Tire pressure specifications, wheel bearing inspection and replacement, spoke tensioning (if applicable), rim maintenance. Procedures Included Routine Maintenance: Oil change intervals, filter replacement, chain lubrication and adjustment, air filter cleaning/replacement, spark plug checks, brake fluid checks, coolant checks. Troubleshooting: Systematic diagnosis of common and uncommon problems, fault finding charts, error code interpretation (if applicable). Repair Procedures: Step-by-step instructions for component removal, installation, and repair for all covered systems. Overhaul Procedures: Detailed instructions for complete engine, transmission, and suspension overhauls. Assembly Instructions: Torque specifications for all fasteners, reassembly sequences, alignment procedures. Wiring Diagrams: Complete and detailed electrical schematics for all models and variants covered. Technical Depth Depth: Professional-level diagnostics, repair, and rebuilding. Suitable for both experienced mechanics and dedicated enthusiasts. Visual Aids: Hundreds of detailed photos and exploded diagrams illustrating procedures and component identification. 📊 Manual Specifications File Format File Type: PDF Searchable: Likely searchable text (typical for professional PDF manuals) Print Quality Printability: Printable (single pages or...