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
Model Years Covered:
2000, 2001, 2002, 2003, 2004, 2005, 2006
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.
Manual Advantage:
Comprehensive coverage across multiple models and engine sizes within a specific production era, offering a singular resource for a diverse fleet.
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 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).
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).
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.
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.
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).
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:
N/A (Digital Download - no physical binding)
Paper:
N/A (Digital Download - no physical paper)
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).
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 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 Type:
Manual
Number Of Gears:
Typically 5 or 6-speed, depending on the specific model variant.
Clutch Type:
Hydraulically operated, multi-plate wet clutch.
Transmission Oil Spec General:
Specific KTM-approved transmission oil or equivalent motorcycle-specific gear oil will be recommended in the manual.
Body Style General:
Dual-sport, Motocross, Enduro, Supermoto motorcycles.
Ground Clearance:
Typically high for off-road capability, varies by model (e.g., 12-15 inches).
Dry Weight Estimate:
Ranges from approximately 220 lbs (250 EXC) to 250 lbs (larger displacement models), without fluids.
Infotainment System:
N/A (Designed for off-road performance, typically no complex infotainment systems).
Traction Control:
N/A (Not available on models from this era).
ABS Brakes:
N/A (Anti-lock Braking System was not commonly equipped on KTM off-road models of this period).
Bluetooth Connectivity:
N/A
Usb Charging:
N/A (Optional accessory might be available).
Oil Change Interval Engine General:
Typically every 10-20 engine hours for hard off-road use, or as specified for street use in the manual.
Air Filter Cleaning Interval:
Frequent cleaning required, often after every few rides in dusty conditions, detailed in the manual.
Valve Clearance Check:
Recommended at intervals specified in the manual, typically every 100-200 engine hours, depending on model.
Engine Oil Type General:
High-quality synthetic motorcycle oil, specific viscosity (e.g., 10W-40, 10W-50) and API rating will be detailed in the manual.
Coolant Type General:
Ethylene glycol-based antifreeze/coolant mixture, specific ratio and type (e.g., mineral or organic acid technology) will be stated.
Brake Fluid Type:
DOT 4 or DOT 5.1 brake fluid (check manual for specific recommendation).
Common Wear Items:
Clutch plates, piston rings, valve guides, wheel bearings, steering head bearings are common wear items on high-performance off-road bikes of this era.
Electrical Gremlins:
While generally robust, specific wiring harness issues or stator failures could occur; the manual provides diagnostic paths.
Carburetor Tuning:
Sensitivity to altitude and temperature changes necessitates proper jetting and tuning, covered extensively in the manual.
Manufacturer Origin:
Austria
Brand Focus:
Renowned for high-performance off-road motorcycles (motocross, enduro, rally) and increasingly adventure bikes.
Era Characteristics:
This generation of KTMs is known for its potent engines, robust chassis, and competitive off-road performance, often featuring WP suspension.
Production Period Covered By Manual:
2000-2006
