Basic Information Identification Make: KTM Model Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Platform: Off-Road/Dual-Sport Designation: Service Workshop Repair Manual Introduction Market Position Target Audience: Owners and technicians seeking in-depth knowledge for maintenance, repair, and diagnostics of 2000-2007 KTM off-road and dual-sport motorcycles. Key Features Value Proposition: Provides detailed factory-level repair information, enabling cost savings on repairs and a deeper understanding of the vehicle's mechanics. Competitive Analysis Comparable Models: Competes with other premium off-road motorcycles from brands like Yamaha (YZF, WR), Honda (CRF, XR), Kawasaki (KX, KDX), and Suzuki (RM, DR) of the same era. Manual Details Coverage Areas Primary Models: 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 Racing, 525 SX, 525 MXC, 525 XC, 525 XC-W, 525 EXC, 525 SMR Racing, 540 SXS Racing, 560 SMR Racing, 610 Crate Page Count Estimated Page Count: Highly Detailed (Exact count not specified, but implied to be comprehensive) Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format File Format: PDF Manual Coverage Systems Covered Engine Mechanics: Engine Removal, Engine Disassembly, Servicing Individual Components, Engine Assembly Electrical System: Complete Electrical System Diagnostics and Repair, Wiring Diagrams Troubleshooting: Comprehensive Troubleshooting Guides for Common and Complex Issues General Information: General Specifications, Service Information, Motorcycle Identification Chassis Components: Frame, swingarm, handlebars, footpegs, and related components. Wheels Tires: Wheel bearing service, spoke tensioning, tire installation, and pressure recommendations. Bodywork: Fairings, fenders, seat, fuel tank removal and installation. Cooling System: Radiator, hoses, water pump, and thermostat inspection and service. Procedures Included Maintenance: Periodic Maintenance Schedule, Fluid Changes, Component Servicing Repair: Step-by-step repair procedures for all major vehicle systems Disassembly Assembly: Complete motorcycle disassembly and reassembly guidance Troubleshooting Diagnostics: Systematic approach to identifying and resolving mechanical and electrical faults. Technical Depth Depth: Suitable for both DIY enthusiasts and experienced professional mechanics, covering detailed rebuilds. Diagnostic Tools: While not specific to electronic diagnostic tools (which were rudimentary for these models), it details the use of basic mechanical tools for diagnosis. Manual Specifications File Format Quality: High-quality PDF with detailed illustrations and step-by-step instructions. Print Quality Printability: Fully printable, all pages are printable. Binding Type Binding: Digital PDF Download (printable) Paper Type Paper: N/A (Digital) Compatibility Software: Adobe PDF Reader required. Operating Systems: All PC based Windows operating systems and Mac. Features Bookmarking: Bookmarked for easy navigation. Digital Access: Instant download format for immediate access. Engine Specifications Primary Engine Engine Types Covered: Single-cylinder, four-stroke engines of various displacements (250cc, 400cc, 450cc, 520cc, 525cc, 540cc, 560cc, 610cc). Engine Design: Four-stroke, liquid-cooled (typically), single-cylinder engines with various configurations (e.g., SOHC, DOHC depending on displacement). Performance Performance Details: Manual provides specifications for horsepower, torque, and engine performance tuning, though specific figures vary by model and year. Valve Lash Adjustment: Procedure and specifications for valve clearance adjustment, a critical maintenance task. Fuel System Fuel System Details: Covers carburetion systems (e.g., Keihin, Mikuni) for most models, including jetting, float adjustments, and cleaning procedures. Fuel injection may be covered for later models if applicable. Carburetor Details: Detailed settings, cleaning, and synchronization for various carburetor models used across the range. Transmission Standard Transmission Type: Manual (Clutch and Gearbox) Features Gearbox Coverage: Detailed information on clutch operation, gearbox disassembly, inspection, and reassembly, including gear selection and shifting mechanisms. Dimensions Exterior Body Styles: Enduro (EXC), Motocross (SX), Cross-Country (XC/MXC), Supermoto (SMR), Special Edition (SXS). Weights Dry Weight Range: Varies significantly by model, generally ranging from approximately 220 lbs (100 kg) for 250cc models to over 260 lbs (118 kg) for larger displacement models. Specific weights can be found within the manual. Safety Features Ratings Crash Test Information: N/A for off-road motorcycles; focus is on rider safety through proper maintenance and component function. Active Features Braking System: Detailed coverage of hydraulic brake systems (front and rear), including caliper service, piston replacement, brake pad installation, and bleeding procedures. Passive Features Frame Suspension: Information on frame integrity checks, suspension fork and shock absorber servicing, including oil changes, seal replacement, and adjustment procedures. Technology Features Infotainment Electronics Overview: Basic electronic systems, including ignition, lighting, and instrumentation. Advanced infotainment systems are not present on these models. Driver Assistance Rider Aids: N/A. These are performance-focused off-road machines with minimal electronic rider aids beyond ignition and lighting controls. Connectivity Features: N/A. Maintenance Service Intervals Periodic Maintenance: The manual includes a detailed periodic maintenance schedule, outlining recommended checks and services at specific mileage or operating hour intervals (e.g., oil changes, filter replacements, valve adjustments, chain lubrication). Fluid Specifications Engine Oil: Specific engine oil viscosity grades (e.g., SAE 10W-40, SAE 15W-50) and API service classifications are detailed within the manual. Common recommendations include JASO MA...