2000-2006 KTM 250 EXC RACING 400 450 SX MXC XC EXC SMR SXS RACING 520 SX MXC XC EXC SMR RACING 525 SX MXC XC EXC SMR RACING 540 SXS 560 SMR 610 CRATE Motorcycle Workshop Repair Service Manua

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🏷️ Basic Information Identification Make: KTM Model: 250 EXC RACING, 400 SX/MXC/XC/EXC/SMR/SXS RACING, 450 SX/MXC/XC/EXC/SMR/SXS RACING, 520 SX/MXC/XC/EXC/SMR RACING, 525 SX/MXC/XC/EXC/SMR RACING, 540 SXS, 560 SMR, 610 CRATE Years Covered:...

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Tipo: Motorcycle

Proveedor:

SKU: 47874

Etiquetas: 2000 2001 2002 2003 2004 2005 2006 250 EXC RACING 400 SX MXC XC EXC SMR SXS RACING 450 SX 450 SX MXC XC EXC SMR SXS RACING 520 SX MXC XC EXC SMR RACING 525 SX MXC XC EXC SMR RACING 540 SXS 560 SMR 610 CRATE ATV KTM Motorcycle Powersports

Variantes de producto

Descripción

🏷️ Basic Information

Identification

Make:

Model:

250 EXC RACING, 400 SX/MXC/XC/EXC/SMR/SXS RACING, 450 SX/MXC/XC/EXC/SMR/SXS RACING, 520 SX/MXC/XC/EXC/SMR RACING, 525 SX/MXC/XC/EXC/SMR RACING, 540 SXS, 560 SMR, 610 CRATE

Years Covered:

2000, 2001, 2002, 2003, 2004, 2005, 2006

Codes

Manual Product Code:

REPAIRMANUAL2000-2006

👋 Introduction

Market Position

Target Audience:

KTM owners and independent mechanics performing their own maintenance and repairs.

Competitive Analysis

Value Proposition:

Provides comprehensive DIY repair guidance, enabling significant cost savings on professional servicing.

Key Features

Completeness:

100% complete and intact, covering all aspects from general information to detailed technical specifications.

Ease Of Use:

Step-by-step instructions and clear illustrations make complex repairs accessible to novices.

Accessibility:

Instant download format offers immediate access without shipping delays.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Repair Service Manual

Language:

English, German, Italian, French, Spanish

Format:

Page Count

Estimated Page Count:

Comprehensive (Exact count not specified, but described as covering 'every single detail')

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, servicing, troubleshooting.

Transmission:

Service, repair, and troubleshooting of the transmission system.

Driveline:

Coverage of driveline components and maintenance.

Suspension:

Front and rear suspension servicing and repair, including shocks.

Brakes:

Comprehensive brake system maintenance, repair, and troubleshooting.

Fuel System:

Carburetor (or EFI for relevant models) inspection, cleaning, adjustment, and repair.

Electrical System:

Wiring diagrams, battery and charging systems, lighting, ignition, and instrumentation.

Body Frame:

Frame and mounting procedures, bodywork removal and installation.

Steering:

Steering system maintenance and repair.

Procedures Included

General Maintenance:

Periodic maintenance schedules, fluid changes, filter replacements.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues.

Repair Procedures:

Step-by-step instructions for a wide range of mechanical and electrical repairs.

Disassembly Assembly:

Detailed procedures for component and major system disassembly and reassembly.

Technical Depth

Diagnostic Capabilities:

Advanced diagnostic information, including troubleshooting charts and likely causes.

Rebuild Procedures:

Comprehensive instructions for engine and component rebuilds.

Illustrations Diagrams:

Detailed illustrations, exploded diagrams, and photos for all procedures.

📊 Manual Specifications

File Format

File Type:

Compatibility:

All Versions of Windows, Mac, iOS, BB, Android, etc.

Accessibility:

Viewable on any computer with a PDF Reader.

Print Quality

Printability:

Yes, all pages are printable.

Zoom Functionality:

Yes, pages can be zoomed.

Binding Type

Binding:

Digital (Instant Download)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Types:

Single-cylinder, 4-stroke (specific displacements vary by model: 250cc, 400cc, 450cc, 520cc, 525cc, 540cc, 560cc, 610cc).

Performance

Horsepower Torque:

Specific figures not provided in product description, but manual covers detailed performance tuning and specifications.

Fuel System

Fuel Delivery:

Primarily carburetor-based systems, with potential for early EFI on some models. Manual covers fuel system components, tuning, and troubleshooting.

Engine Internal

Valve Train:

Details on camshafts, valves, and associated components covered for servicing.

Engine Cooling

Cooling System:

Manual includes information on liquid cooling systems (radiator, coolant, pump) and air-cooled components where applicable.

🔧 Transmission

Standard

Transmission Type:

Manual gearbox (specific number of gears varies by model, typically 5 or 6-speed).

Optional

Clutch Type:

Hydraulically actuated multi-plate wet clutch systems are common; manual covers servicing and adjustment.

Features

Gear Ratios:

Manual includes detailed specifications for gear ratios and final drive.

📐 Dimensions

Exterior

Chassis Type:

Steel frame (CrMo steel common for KTM models of this era); manual covers frame inspection and repair.

Weights

Dry Weight:

Specific weight data not in description, but manual likely contains this information for each model variant.

🛡️ Safety Features

Ratings

Safety Features:

Manual covers maintenance and repair of braking systems, which are critical safety components.

Active Features

Braking System:

Hydraulic disc brakes (front and rear) are standard; manual provides detailed servicing procedures.

Passive Features

Electrical Warnings:

Instrumentation and warning systems covered, including potential fault indicators.

💡 Technology Features

Infotainment

Infotainment Systems:

N/A (These are off-road motorcycles, not typically equipped with infotainment systems).

Driver Assistance

Assistance Systems:

N/A (Off-road motorcycles typically do not have electronic driver assistance systems beyond basic ignition and lighting controls).

Connectivity

Connectivity Features:

N/A (No electronic connectivity features expected).

Instrumentation

Instrument Cluster:

Covers maintenance and repair of the instrument cluster, including speedometers, tachometers, and warning lights.

🔧 Maintenance

Service Intervals

Scheduled Maintenance:

Manual includes a 'PERIODIC MAINTENANCE SCHEDULE' detailing recommended service intervals for various components.

Fluid Specifications

Engine Oil:

While specific oil grades aren't listed in the product description, the manual will specify recommended engine oil type, viscosity, and capacity for each model.

Coolant:

Manual will detail coolant type and mixture for liquid-cooled models.

Brake Fluid:

Manual will specify correct brake fluid type (e.g., DOT 4).

Known Issues

Common Wear Items:

The manual's troubleshooting section and component servicing guides will implicitly cover common wear items and their associated repairs.

Filter Part Numbers

Oil Filter Part Numbers:

Likely included within the manual's parts listings or service section for each model.

📚 Vehicle History

Brand Heritage

Ktm Offroad Focus:

KTM has a strong heritage in off-road motorcycle sports (Motocross, Enduro, Rally), and these models reflect that lineage.

Model Evolution

Racing Heritage:

Models like SX (Motocross), MXC (Cross-Country), XC (Cross-Country), EXC (Enduro), and SXS (Factory 'R' version) represent different off-road disciplines and performance levels within the KTM lineup.

Production

Manufacturing Era:

Covers a significant period of KTM's development in the early 2000s, a time of significant engine and chassis advancements.

🏆 Awards & Recognition

Recognitions

Model Performance:

KTM models from this era are generally well-regarded for their performance and handling in competitive off-road environments. Specific awards for individual models are not detailed in the product description.