KTM SPORTMOTORCYCLES 400 / 450 / 520 / 525 EXC MXC SMR SX SXS Engine Service Repair Manual (2000 2001 2002 2003 2004 2005 2006) - Download PDF

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Type: Motorcycle

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Sku: 44523

Tags: 2000 2001 2002 2003 2004 2005 2006 400 EXC 400 MXC 400 SMR 400 SX 400 SXS 450 EXC 450 MXC 450 SMR 450 SX 450 SXS 520 EXC 520 MXC 520 SMR 520 SX 520 SXS 525 EXC 525 MXC 525 SMR 525 SX 525 SXS ATV Featured KTM Motorcycle Powersports

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Description

Owning a KTM Sportmotorcycle (EXC, MXC, SMR, SX, SXS) from 2000-2006 means riding a machine built for performance and endurance. Whether you're tackling trails, dominating motocross, or restoring a classic, this Official Service Repair Manual is your ultimate guide to maintaining peak performance and extending your bike's lifespan.

Designed for DIY mechanics, restoration specialists, and KTM enthusiasts, this 222-page manual delivers dealership-level expertise at a fraction of the cost. With instant digital access, you gain:

Complete engine service: Disassembly, assembly, and component repair for 400cc–525cc engines (including 250 EXC, 540 SXS, and 560 SMR variants)
Step-by-step procedures: From basic maintenance to advanced diagnostics, with torque specs and fluid requirements
Detailed visuals: Exploded diagrams, wiring schematics, and high-quality photos for precision work

Covering fuel systems, electrical diagnostics, and KTM’s racing-derived LC4 architecture, this manual ensures you’re equipped to handle every repair—saving time and costly shop visits. Fully printable and searchable, it’s the definitive reference for keeping your KTM at competition-ready standards.

🏷️ Basic Information

Identification

Make:

Model:

Sportmotorcycle (EXC, MXC, SMR, SX, SXS)

Production Years:

2000-2006

Codes

Engine Variants Covered:

400cc, 450cc, 520cc, 525cc

Additional Models Mentioned:

250 EXC, 540 SXS, 560 SMR, 610 CRATE

👋 Introduction

Market Position

Target Audience:

KTM owners, DIY mechanics, restoration specialists seeking comprehensive service information.

Competitive Analysis

Value Proposition:

Provides dealership-level repair and maintenance information for a fraction of the cost, enabling self-sufficiency and cost savings.

Key Features

Completeness:

100% complete and intact, no missing or corrupt pages/sections.

Instructional Detail:

Step-by-step instructions complemented by highly detailed exploded pictures and diagrams.

📋 Manual Details

Coverage Areas

Primary Focus:

Engine Service and Repair

Secondary Focus:

General Maintenance, Troubleshooting, Electrical Systems, Fuel System

Page Count

Total Pages:

Manual Type

Type:

Official Service Repair Manual

Language

Language:

English

Format

File Format:

PDF (Download)

📖 Manual Coverage

Systems Covered

Engine:

Complete disassembly, assembly, servicing of individual components, engine removal and refitting.

Electrical:

Wiring diagrams, diagnostics, troubleshooting related to electrical systems.

Fuel System:

Service and repair of fuel system components.

Procedures Included

Repair:

Detailed step-by-step repair procedures for all covered systems.

Maintenance:

Periodic maintenance schedules and procedures.

Diagnostics:

Comprehensive diagnostic procedures and troubleshooting guides.

Assembly Disassembly:

Detailed instructions for engine and component assembly and disassembly.

Technical Depth

Depth:

Comprehensive; covers everything from basic maintenance to complete engine rebuilds and advanced diagnostics.

Documentation Type:

Includes exploded diagrams, detailed illustrations, and photos.

📊 Manual Specifications

File Format

Compatibility:

All versions of Windows & Mac

Features:

Searchable, Zoom in/out capability

Print Quality

Printability:

Fully Printable

Binding Type

Digital Binding:

Bookmarked

Paper Type

Digital Paper Analogue:

High Quality Digital Representation

Delivery

Method:

Instant Download

Requirements:

Adobe PDF Reader

⚙️ Engine Specifications

Primary Engine

Engine Types:

Single-cylinder, liquid-cooled, four-stroke engines.

Performance

Displacement Range:

Approximately 400cc to 525cc (with mention of 250cc, 540cc, 560cc variants).

Engine Design:

Performance-oriented, racing-derived engine architecture common to KTM's off-road and supermoto lines.

Fuel System

Carburetion Type:

Likely Keihin or Mikuni carburetors (specific models vary by year and displacement, detailed in manual).

Technical Specifications General

Technical Specifications Chapter:

Chapter 10 dedicated to technical specifications.

🔧 Transmission

Standard

Transmission Type:

Likely 6-speed constant mesh sequential gearbox (typical for KTM off-road models of this era).

Optional

Clutch Type:

Hydraulically operated, multi-plate wet clutch.

Features

Gear Ratios:

Detailed gear ratio specifications would be found within the 'Technical Specifications' chapter.

📐 Dimensions

Exterior

Vehicle Type:

Off-road motorcycles (Enduro, Motocross, Supermoto variants).

Weights

Dry Weight Range:

Typically in the range of 100-120 kg (dry), specific to model and configuration.

Seat Height Range:

Varies by model, typically high for off-road capability.

🛡️ Safety Features

Ratings

Safety Focus:

Primarily focused on rider control and mechanical integrity of the motorcycle.

Active Features

Braking System:

Hydraulic disc brakes (front and rear), specific caliper and rotor sizes detailed in manual.

Passive Features

Frame Construction:

Chromium-molybdenum steel trellis frame (typical KTM construction).

💡 Technology Features

Infotainment

Features:

Minimal to none; these are performance-oriented off-road motorcycles with a focus on function over rider comfort/entertainment technology.

Driver Assistance

Features:

None. Focus is on rider skill and machine capability.

Connectivity

Features:

None.

🔧 Maintenance

Service Intervals

Schedule Location:

Chapter 11: Periodic Maintenance Schedule.

Typical Items:

Oil changes, filter replacements, valve adjustments, chain maintenance, spark plug inspection/replacement.

Fluid Specifications

Engine Oil Type:

Specific oil viscosity and type (e.g., SAE 10W-50, JASO MA) will be detailed in the manual, typically high-performance synthetic motorcycle oil.

Coolant Type:

Ethylene glycol-based coolant (pre-mixed or concentrate) as specified by KTM.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

While the manual focuses on repair, common off-road wear items include clutch plates, piston rings, valve guides, fork seals, and wheel bearings. Specific diagnostic procedures for these are covered.

Technical Specifications

Torque Specifications:

Crucial torque specifications for engine and chassis fasteners are detailed throughout the manual.

📚 Vehicle History

Brand Heritage

Ktm Motorsport Focus:

KTM has a long and successful history in off-road motorcycle racing (Motocross, Enduro, Dakar Rally), influencing the development of these models.

Model Evolution

Engine Development:

These models represent an evolution of KTM's LC4 engine architecture, adapted for various competitive disciplines.

Production

Manufacturing Location:

Austria (KTM headquarters and primary manufacturing).

🏆 Awards & Recognition

Recognitions

Motorsport Performance:

KTM models of this era were highly successful in various professional off-road racing series, indicating inherent design and performance capabilities.

Ratings

Manual Quality:

Described as a 'QUALITY manual', '100 percents COMPLETE and INTACT'.