Model Line:
SX, MXC, EXC, SXS, SMR, XC
Model Years Covered:
2000, 2001, 2002, 2003, 2004, 2005, 2006
Product Name:
2000-2006 KTM 250 400 450 520 525 540 560 610 SX MXC EXC SXS SMR Service Repair Manual Download
Vehicle Platform Codes:
Varies by specific model and engine variant (e.g., EXC models often share platforms with MXC/SX variants of similar displacement)
Target Audience:
Owners of KTM SX, MXC, EXC, SXS, SMR, and XC motorcycles from 2000-2006 seeking to perform maintenance and repairs themselves.
Value Proposition:
Offers comprehensive coverage for a wide range of displacements and model types within a specific generation, providing significant cost savings compared to professional servicing.
Completeness:
Marketed as the 'Most Complete Service Repair Manual ever compiled by mankind' for this range.
Accessibility:
Instant download format eliminates shipping delays and costs.
Primary Models Covered:
KTM 250 EXC, KTM 400 SX/MXC/XC/EXC/SMR/SXS, KTM 450 SX/MXC/XC/EXC/SMR/SXS, KTM 520 SX/MXC/XC/EXC/SMR, KTM 525 SX/MXC/XC/EXC/SMR/SXS, KTM 540 SXS, KTM 560 SMR, KTM 610 CRATE
Manual Type:
Service Repair Manual
File Format:
PDF Download
Software Compatibility:
All Versions of Windows & Mac
Reader Requirement:
Adobe PDF Reader
Engine:
Complete engine disassembly, assembly, inspection, and repair of all internal components (pistons, rings, valves, camshafts, crankshaft, bearings, etc.)
Fuel System:
Carburetor service, adjustment, and troubleshooting; fuel pump and filter service (where applicable for specific models).
Electrical System:
Ignition system, lighting, starter system, charging system, wiring diagrams for all circuits.
Chassis And Suspension:
Front fork service (oil changes, seal replacement), rear shock absorber service, swingarm and linkage maintenance, wheel bearing service.
Braking System:
Brake caliper service, master cylinder service, brake pad replacement, brake fluid flushing and bleeding.
Cooling System:
Radiator service, coolant replacement, water pump inspection and repair.
General Maintenance:
Periodic maintenance schedule, lubrication points, chain adjustment, air filter cleaning/replacement.
Troubleshooting:
Diagnostic procedures for common problems, symptom-based troubleshooting guides.
Engine Removal Refitting:
Detailed steps for removing and reinstalling the engine from the frame.
Engine Disassembly Assembly:
Step-by-step instructions for breaking down and rebuilding the engine.
Component Servicing:
Specific procedures for servicing individual engine and chassis components.
Depth Of Information:
Comprehensive, suitable for both DIY enthusiasts and professional mechanics.
Diagnostic Level:
Includes troubleshooting guides and symptom analysis for diagnosing issues.
Diagrams And Illustrations:
High-quality diagrams and instructions for servicing and repairing.
Engine Types:
Single-cylinder, four-stroke (liquid-cooled, typically with DOHC or SOHC valve actuation depending on displacement).
Displacement Range:
250cc, 400cc, 450cc, 520cc, 525cc, 540cc, 560cc, 610cc
Typical Power Output:
Varies significantly by displacement and model, but generally in the range of 30-60+ horsepower.
Carburetor Models:
Primarily Keihin carburetors (e.g., FCR series) or Mikuni depending on specific model and year. Specific jetting and adjustment procedures will be detailed.
Oil Type:
Requires high-quality motorcycle-specific 4-stroke engine oil, often with JASO MA certification. Specific viscosity grades (e.g., 10W-40, 10W-50) will be detailed in the manual.
Valve Clearance Adjustment:
Crucial maintenance item. Manual will detail procedures for checking and adjusting valve clearances (shims or screw-and-locknut depending on engine design).
Infotainment System:
Basic instrumentation typically includes an odometer, trip meter, and engine hour meter. No advanced infotainment systems are present.
Electronic Aids:
Minimal electronic aids. Some models might feature electronic engine management for ignition timing, but no advanced rider aids like traction control or ABS are present in this era.
Connectivity Features:
N/A (No smartphone or network connectivity features).
Diagnostic Tools:
While not a dedicated diagnostic tool, the manual provides the necessary information (wiring diagrams, specifications) for mechanic's to use multimeters and other basic diagnostic tools.
Oil Change Interval:
Typically every 10-20 engine operating hours or annually, depending on riding conditions. Manual will provide precise recommendations.
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions (e.g., every few rides). Manual will detail cleaning and oiling procedures.
Spark Plug Replacement:
Intervals vary, typically every 50-100 operating hours. Manual will specify the correct plug type and gap.
Fork Oil Type And Level:
Specific fork oil viscosity (e.g., WP Suspension Fork Oil 7.5W) and precise oil levels are critical for proper suspension performance. Manual will detail these.
Coolant Type:
Requires a high-quality ethylene glycol-based coolant. Manual will specify the correct mixture ratio with distilled water and potentially a specific KTM-approved coolant.
Common Wear Items:
In this generation, common wear items include valve train components (especially valve seats and guides), clutch plates, wheel bearings, and suspension seals due to the demanding nature of off-road riding.
Carburetor Tuning:
Carburetor tuning can be sensitive to altitude and temperature changes. Proper jetting and adjustment are crucial for optimal performance and longevity.
Component Identification:
Manual includes diagrams that aid in identifying specific parts for replacement or inspection.
Ktm Focus:
KTM has a strong heritage in off-road and motocross racing, known for performance-oriented, powerful, and durable motorcycles.
Era Characteristics:
This generation of KTMs (2000-2006) represents a period of significant development in their four-stroke off-road lineup, with engines becoming more refined and powerful. The introduction and expansion of the SXS and SMR models indicate a focus on racing homologation and supermoto applications.
Manufacturing Origin:
KTM motorcycles are primarily manufactured in Austria.
