This manual covers a comprehensive range of motorcycles, including the SX, MXC, EXC, SXS, and SMR models produced between 2000 and 2006. These Austrian-engineered machines are renowned for their potent four-stroke engines, available in displacements from 250cc to 610cc, and their robust chassis designed for demanding off-road and dual-sport applications. Known for their competitive edge and durability, bikes from this era often feature advanced WP suspension and are built to perform under rigorous conditions, making them a favored choice for both racing and recreational riding. This Service Repair Manual provides detailed, factory-level information essential for the maintenance, troubleshooting, and repair of your motorcycle. It encompasses a wide array of critical systems, including complete engine overhaul procedures, fuel system servicing, electrical system diagnostics, chassis and suspension maintenance, and brake system repairs. The manual also details preventative maintenance schedules, rebuild procedures, and offers systematic troubleshooting guides to help owners and technicians efficiently resolve issues and ensure optimal performance and longevity of their vehicles. 🏷️ Basic Information Identification Make: KTM Model: Multi-model - SX, MXC, EXC, SXS, SMR Covered Models Detailed: KTM 250 EXC, KTM 400 SX, KTM 400 MXC, KTM 400 XC, KTM 400 EXC, KTM 400 SMR, KTM 400 SXS, KTM 450 SX, KTM 450 MXC, KTM 450 XC, KTM 450 EXC, KTM 450 SMR, KTM 450 SXS, KTM 520 SX, KTM 520 MXC, KTM 520 XC, KTM 520 EXC, KTM 520 SMR, KTM 525 SX, KTM 525 MXC, KTM 525 XC, KTM 525 EXC, KTM 525 SMR, KTM 540 SXS, KTM 560 SMR, KTM 610 CRATE Generation Model Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006 👋 Introduction Market Position Target Audience: KTM owners, independent workshops, DIY mechanics, motorcycle enthusiasts. Value Proposition: Provides essential, manufacturer-approved information for maintaining, troubleshooting, and repairing a wide range of KTM off-road motorcycles, saving on professional labor costs. Competitive Analysis Manual Advantage: Comprehensive coverage across multiple models and engine sizes within a specific production era, offering a singular resource for a diverse fleet. Key Features Feature Highlight 1: Extensive model year and variant coverage in a single manual. Feature Highlight 2: Factory-level detail, including technical specifications and diagrams. Feature Highlight 3: Troubleshooting guide for immediate problem resolution. 📋 Manual Details Coverage Areas Manual Type: Service Repair Manual / Workshop Manual / Factory Manual Language: English (assumed, typical for KTM factory manuals of this era) Format: PDF Download (digital) Delivery Method: Instant download after purchase, email link provided. Page Count: Not explicitly stated, but described as 'detailed' and potentially large (up to 5GB). 📖 Manual Coverage Systems Covered Engine Overhaul: Complete disassembly, inspection, repair, and reassembly of engine components. Fuel System: Carburetor adjustment, cleaning, rebuilding; fuel pump and filter service (if applicable to specific models). Electrical System: Wiring diagrams, ignition system, lighting, starting system, charging system troubleshooting and repair. Chassis And Suspension: Front fork service, rear shock absorber maintenance, bearing checks, frame inspection. Brakes: Brake caliper service, master cylinder maintenance, bleeding procedures, pad replacement. Cooling System: Radiator service, coolant replacement, thermostat inspection (for liquid-cooled models). Procedures Included Preventative Maintenance: Scheduled maintenance tasks, fluid changes, filter replacements, chain adjustment, lubrication. Troubleshooting: Systematic diagnostic procedures for common problems, fault finding guides. Repair Procedures: Detailed, step-by-step instructions for a wide range of repairs, from minor adjustments to major component replacements. Rebuild Procedures: Comprehensive guidance for engine and transmission rebuilds. Technical Depth Depth Of Coverage: Complete factory-level technical information, suitable for professional mechanics and advanced DIY enthusiasts. Illustrations: Illustrated with clear step-by-step instructions, zoomable illustrations, exploded views, and detailed component breakdowns. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Compatibility: Compatible with all operating systems (Windows, Linux, Mac) and any PDF reader. Compression: May be zipped (.zip, .rar) requiring decompression software (WinZip, WinRAR). Print Quality Printable: Yes, the manual can be printed from any computer and printer. Resolution: High quality, suitable for clear viewing and printing of diagrams and text. Binding Type Binding: N/A (Digital Download - no physical binding) Paper Type Paper: N/A (Digital Download - no physical paper) ⚙️ Engine Specifications Primary Engine Engine Type General: Four-stroke, single-cylinder (most models), with various displacements. Engine Displacements Covered: 250cc, 400cc, 450cc, 520cc, 525cc, 540cc, 560cc, 610cc Engine Cooling: Liquid-cooled (common for SX, EXC, MXC models of this era). Performance Horsepower Range Estimated: Typically ranging from 30 HP (250cc) to 50+ HP (560cc/610cc), varies by specific model and tuning. Torque Range Estimated: Varies significantly with displacement, expect strong mid-range and top-end power delivery characteristic of KTM off-road bikes. Fuel System Fuel Delivery: Carburetor (Mikuni or Keihin commonly used on these models). Carburetor Details General: Specific carburetor models and jetting specifications are detailed within the manual. 🔧 Transmission Standard Transmission Type: Manual Number Of Gears: Typically 5 or 6-speed, depending on the specific model variant. Features Clutch Type: Hydraulically operated, multi-plate wet clutch. Transmission Oil Spec General: Specific...