2000-2006 KTM 250 400 450 520 525 540 560 610 EXC MXC SMR SX SXS Racing Crate 4 Stroke Motorcycle Repair Manual

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UGS: 68170

Mots clés: 2000 2001 2002 2003 2004 2005 2006 250 4 Stroke 400 450 450 SX 520 525 540 560 610 ATV Crate EXC KTM Motorcycle MXC Powersports Racing SMR SX SXS

Variantes de produits

Description

This manual covers EXC, MXC, SMR, SX, and SXS Racing 4-stroke motorcycles produced between 2000 and 2006. These high-performance off-road and street-legal motorcycles are renowned for their powerful engines, advanced suspension systems, and aggressive styling, reflecting a heritage and success in motorsports. The models detailed include a range of displacements from 250cc to 610cc, featuring single-cylinder, liquid-cooled, 4-stroke engines, typically with carbureted fuel systems and 5- or 6-speed gearboxes. Known for their robust build and off-road prowess, these bikes offer a potent combination of performance and durability for enduro, motocross, and supermoto applications. This comprehensive English-language manual provides essential information for the repair, maintenance, and troubleshooting of your motorcycle. It covers a wide array of systems, including engine removal and installation, lubrication, cooling, fuel, intake, exhaust, transmission, drivetrain, chassis, steering, suspension, and the complete electrical system. Detailed procedures for routine maintenance, such as oil changes and filter replacements, as well as major repairs like engine rebuilds and suspension servicing, are included. The manual also offers advanced troubleshooting guides and technical specifications, empowering both owners and professional technicians to effectively maintain and repair these high-performance machines.

🏷️ Basic Information

Identification

Make:

Model:

EXC, MXC, SMR, SX, SXS Racing (4-Stroke)

Production Years Covered:

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

Engine Types Covered:

4-Stroke

Codes

Vin Prefix General:

VTR (for Austria-produced KTMs)

Engine Code Examples:

LC4 (common for larger displacement models), specific codes vary by displacement and model year

👋 Introduction

Market Position

Segment:

High-performance off-road and street-legal motorcycles (Enduro, Motocross, Supermoto)

Competitive Analysis

Competitors:

Yamaha WR/YZ, Honda CRF/XR, Suzuki DR/RM-Z, Kawasaki KX/KLX (4-stroke variants)

Key Features

Manual Benefits:

Instant PDF download, lifetime protection policy against loss/damage, printable pages, accessible on mobile devices for trailside repairs.

Vehicle Strengths:

Known for powerful engines, aggressive styling, advanced suspension, and off-road prowess.

📋 Manual Details

Coverage Areas

Primary Coverage:

Repair, Maintenance, Troubleshooting, Parts Lookup

Specific Models Detailed:

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

Page Count

Estimated Page Count:

High (indicative of comprehensive coverage, precise count not provided but typical for full service manuals).

Manual Type

Type:

Comprehensive Repair Manual / Workshop Manual / Owner's Manuals / Parts Catalogs (all provided as downloadable PDF)

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine removal/installation, general specifications, lubrication, cooling, fuel system, intake, exhaust.

Drivetrain Systems:

Transmission, drive chain, sprockets.

Chassis Systems:

Steering system, shocks, bodywork.

Electrical Systems:

Complete electrical system diagnostics, wiring diagrams (likely), ignition, lighting, starting systems.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug service, air filter cleaning/replacement.

Major Repairs:

Engine rebuilds, transmission overhauls, suspension servicing, carburetor/fuel injection tuning.

Troubleshooting:

Advanced troubleshooting guides for common and uncommon issues across all covered systems.

Technical Depth

Depth:

Comprehensive from basic owner maintenance to in-depth workshop repair and diagnostics, suitable for both novice and experienced mechanics.

📊 Manual Specifications

File Format

Format:

Print Quality

Quality:

High-resolution, suitable for printing individual pages or the entire manual.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Displacement Options:

250cc, 400cc, 450cc, 520cc, 525cc, 540cc, 560cc, 610cc

Engine Configuration:

Single-cylinder, 4-stroke

Cooling System:

Liquid-cooled

Performance

Horsepower Range:

Typically 40-60+ HP depending on displacement and specific model tuning (factory figures often not officially stated for racing models).

Fuel System

Fuel Delivery:

Carbureted (Mikuni/Keihin) for most models, some later models or specific SXS/SMR variants may have fuel injection.

🔧 Transmission

Standard

Type:

5-speed or 6-speed constant mesh sequential gearbox

Optional

Gearbox Variations:

Different gear ratios available for specific racing applications (e.g., SX vs. EXC).

Features

Clutch:

Hydraulically operated, multi-plate wet clutch

📐 Dimensions

Exterior

Wheelbase Typical:

Approx. 1460-1480 mm (varies by model)

Seat Height Typical:

Approx. 960-990 mm (varies by model, often adjustable)

Weights

Dry Weight Typical:

Approx. 105-115 kg (varies significantly by model and displacement)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (motorcycles are not subject to automotive crash test ratings like NHTSA or Euro NCAP)

Active Features

Braking System:

Hydraulic disc brakes (front and rear), typically Brembo components.

Suspension System:

High-performance, adjustable WP (White Power) upside-down telescopic forks and monoshock rear suspension.

Passive Features

Frame Construction:

Chromium-molybdenum steel trellis frame.

💡 Technology Features

Infotainment

Features:

Minimal by modern standards; primarily focused on essential instrumentation (speedometer, odometer, tachometer, basic warning lights).

Driver Assistance

Features:

N/A (Off-road motorcycles in this era did not feature electronic rider aids like ABS or traction control).

Connectivity

Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10-15 hours of riding or annually, depending on riding conditions and manufacturer recommendations. Manual will specify.

Valve Clearance Check:

Recommended at major service intervals, often around 30-50 hours or annually. Manual will provide exact figures.

Fluid Specifications

Engine Oil Viscosity:

Commonly 10W-50 or 10W-60 synthetic motorcycle oil (refer to manual for exact OEM specification).

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors (typically 50/50 mix with distilled water).

Brake Fluid Type:

DOT 4 or DOT 5.1 hydraulic brake fluid (check manual for specific requirements).

Known Issues

Common Wear Items:

Clutch plates, brake pads, wheel bearings, steering head bearings, swingarm/linkage bearings, fork seals, exhaust gaskets.

Potential Engine Concerns:

KTM's 4-stroke engines of this era were generally robust but could be sensitive to oil maintenance. Some early models might have had specific cam chain tensioner or piston ring wear considerations.

📚 Vehicle History

Brand Heritage

Heritage:

KTM is renowned for its 'Ready to Race' philosophy and success in off-road motorsports, particularly enduro and motocross.

Model Evolution

Evolution 2000-2006:

This period saw significant development in KTM's 4-stroke off-road lineup, transitioning from early LC4 designs to more refined and performance-oriented platforms across the EXC, SX, and MXC ranges. Displacement increased, chassis geometry was refined, and suspension technology advanced.

Production

Manufacturing Location:

Austria (primarily)

🏆 Awards & Recognition

Recognitions

Motorsport Success:

KTM models of this era achieved significant success in various off-road racing disciplines, including Erzberg Rodeo, Dakar Rally, and national enduro/motocross championships, validating their performance and durability.

Ratings

Media Reviews Typical:

Generally received positive reviews for their potent engines, advanced suspension, and aggressive handling characteristics, although often noted for demanding maintenance and a firm ride.

Certifications

Emissions Compliance:

Models sold for street use would comply with applicable emissions standards for their respective markets, though racing-focused models were often uncorked or modified.