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

Regular price: $16.99
Sale price: $16.99
Regular price
Unit price: per

15 people are viewing this right now

Type: Motorcycle

Vendor:

Sku: 92107

Tags: 2000 2001 2002 2003 2004 2005 2006 250 EXC 400 EXC 450 EXC 520 EXC 525 EXC 540 EXC 560 560 EXC 610 EXC KTM Motorcycle Motorcycles MXC SMR SX SXS Racing Crate

Product variants

Description

This manual covers EXC, MXC, SMR, SX, and SXS Racing Crate models produced between 2000 and 2006, encompassing engine displacements from 250cc to 610cc. These motorcycles, renowned for their Austrian engineering and 'Ready to Race' philosophy, are built for demanding off-road and competitive use, including Enduro, Motocross, and Supermoto disciplines. With a heritage steeped in racing success, motorcycles from this era are celebrated for their robust performance, advanced suspension, and agile handling, making them a favored choice for both professional racers and serious enthusiasts. This comprehensive service, repair, and workshop manual provides factory-level information essential for the maintenance and repair of your motorcycle. It details everything from routine servicing, including oil changes and filter replacements, to in-depth engine overhauls, transmission repairs, and suspension servicing. Coverage extends to the fuel, ignition, electrical, and braking systems, supported by hundreds of detailed photographs and exploded diagrams. The manual also includes crucial troubleshooting guides and wiring diagrams, ensuring owners, mechanics, and technicians have the resources needed for accurate diagnostics and efficient repairs, thereby maximizing the performance and longevity of these high-caliber machines.

🏷️ Basic Information

Identification

Make:

Model:

EXC, MXC, SMR, SX, SXS Racing Crate

Model Variants:

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

Year Range:

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

Codes

Chassis Codes:

Varies by specific model and year (e.g., EXC, SX, MXC designations with internal KTM project codes)

Engine Codes:

Varies by specific engine displacement (e.g., LC4 variants, specific engine family identifiers)

👋 Introduction

Market Position

Target Audience:

KTM owners, independent repair shops, and professional motorcycle technicians.

Value Proposition:

Provides comprehensive, factory-level information for maintenance, repair, and troubleshooting, enabling cost savings and proper upkeep.

Competitive Analysis

Differentiation:

Offers complete factory coverage for a wide range of model years and engine displacements within the EXC, MXC, SMR, SX, and SXS series, differentiating from less comprehensive or aftermarket guides.

Key Features

Coverage Breadth:

Covers multiple engine sizes (250cc to 610cc) and competitive disciplines (Enduro, Motocross, Supermoto).

Accessibility:

Instant digital download for immediate use on multiple devices, with lifetime access.

📋 Manual Details

Coverage Areas

Coverage Type:

Comprehensive Service, Repair, and Workshop Manual

Geographic Scope:

Global (factory specifications applicable worldwide)

Page Count

Estimated Page Count:

Hundreds of pages (specific number not provided, but described as extensive)

Manual Type

Type:

Factory Service Repair Workshop Manual

Language

Language:

English (implied by typical professional mechanic manuals and product description phrasing)

Format

Format:

PDF Download

Access:

Instant Download, Life-time Usage, Unlimited Devices

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, overhaul, component replacement (pistons, rings, valves, crankshaft, connecting rods), cylinder head, valve train.

Fuel System:

Carburetor adjustment and overhaul (if applicable), fuel injection system diagnostics and repair (if applicable), fuel pump, fuel filter, fuel lines.

Ignition System:

Ignition coil testing, spark plug specifications, CDI unit diagnostics, stator and rotor inspection.

Exhaust System:

Exhaust pipe inspection, muffler repair and replacement, catalytic converter diagnosis (if equipped).

Cooling System:

Radiator inspection, coolant flow diagnosis, water pump service, thermostat replacement, cooling fan operation.

Transmission And Drivetrain:

Clutch adjustment and overhaul, gear selection mechanisms, internal transmission components, chain and sprocket maintenance, final drive inspection.

Suspension Front:

Fork oil change and service, fork seal replacement, spring replacement, damping adjustment, steering head bearing service.

Suspension Rear:

Shock absorber service, linkage lubrication, rear shock adjustment (preload, rebound, compression), swingarm bearing inspection.

Brakes Front:

Brake pad replacement, caliper service, brake line inspection and replacement, master cylinder overhaul, brake fluid specifications and bleeding procedures.

Brakes Rear:

Brake pad replacement, caliper service, brake line inspection and replacement, master cylinder overhaul, brake fluid specifications and bleeding procedures.

Electrical System:

Wiring diagrams, battery maintenance and testing, charging system diagnosis (stator, regulator/rectifier), lighting system troubleshooting, starter motor operation, horn, switches.

Chassis And Frame:

Frame inspection, subframe inspection, footpeg mounting, rider controls (handlebars, levers, pedals).

Bodywork And Trim:

Fairing removal and installation, seat maintenance, fender replacement, graphics application.

Wheels And Tires:

Tire pressure specifications, wheel bearing inspection and replacement, spoke tensioning (if applicable), rim maintenance.

Procedures Included

Routine Maintenance:

Oil change intervals, filter replacement, chain lubrication and adjustment, air filter cleaning/replacement, spark plug checks, brake fluid checks, coolant checks.

Troubleshooting:

Systematic diagnosis of common and uncommon problems, fault finding charts, error code interpretation (if applicable).

Repair Procedures:

Step-by-step instructions for component removal, installation, and repair for all covered systems.

Overhaul Procedures:

Detailed instructions for complete engine, transmission, and suspension overhauls.

Assembly Instructions:

Torque specifications for all fasteners, reassembly sequences, alignment procedures.

Wiring Diagrams:

Complete and detailed electrical schematics for all models and variants covered.

Technical Depth

Depth:

Professional-level diagnostics, repair, and rebuilding. Suitable for both experienced mechanics and dedicated enthusiasts.

Visual Aids:

Hundreds of detailed photos and exploded diagrams illustrating procedures and component identification.

📊 Manual Specifications

File Format

File Type:

Searchable:

Likely searchable text (typical for professional PDF manuals)

Print Quality

Printability:

Printable (single pages or entire manual)

Binding Type

Binding:

Not Applicable (Digital Download)

Paper Type

Paper:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-Stroke (various displacements)

Engine Family:

LC4 (Liquid Cooled, Single Cylinder) and potentially related engines for smaller displacements.

Bore Stroke:

Varies significantly by displacement (e.g., 250, 400, 450, 525, 560, 610cc models).

Performance

Horsepower:

Not specified in product information, but varies by displacement (typically 40-60+ HP for this range).

Torque:

Not specified in product information, but varies by displacement.

Fuel System

Fuel Delivery:

Carbureted (Mikuni, Keihin) or Fuel Injection (EFI) depending on specific model and year.

Fuel Type:

Unleaded gasoline (Octane rating specified in manual).

Lubrication

Oil Type:

JASO MA certified motorcycle-specific 4-stroke engine oil (viscosity varies with temperature, e.g., 10W-40, 15W-50).

Oil Capacity:

Varies by model and oil filter change; typically around 1.5-2.5 liters.

🔧 Transmission

Standard

Transmission Type:

Constant Mesh, Sequential, Foot-Shifted

Number Of Gears:

Typically 5 or 6 speeds, depending on model.

Clutch Type:

Wet Multi-Plate Clutch, Hydraulically Actuated

Features

Gear Ratios:

Specific gear ratios are detailed within the manual for each model and year.

Transmission Oil:

Dedicated transmission oil or shared engine oil (depending on specific KTM design for the period). Manual will specify.

📐 Dimensions

Exterior

Ground Clearance:

Significant ground clearance typical of off-road motorcycles (specifics vary).

Weights

Dry Weight:

Varies by model, typically in the range of 110-135 kg (dry).

Wet Weight:

Varies by model and fluid levels, includes fuel, oil, coolant.

🛡️ Safety Features

Ratings

Safety Certifications:

Not applicable for off-road motorcycles in the same way as passenger vehicles.

Active Features

Braking System:

High-performance hydraulic disc brakes (front and rear) with Brembo components common.

Passive Features

Frame Construction:

Robust steel or aluminum frame designed for off-road abuse.

💡 Technology Features

Infotainment

Dashboard:

Basic digital or analog instrumentation (speedometer, odometer, trip meter, neutral indicator, engine warning light).

Driver Assistance

Not typically equipped on off-road competition models of this era. Manual will confirm.

Connectivity

Electronics:

Focus is on essential engine management, ignition, and lighting systems. No advanced electronic rider aids.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 5-15 hours of riding for competitive use, or based on mileage/time for less strenuous use. Specifics in manual.

Air Filter Cleaning:

Frequent cleaning recommended, especially in dusty conditions. Manual will provide guidelines.

Valve Clearance Check:

Typically every 100-200 hours of riding. Critical for engine longevity. Detailed procedure in manual.

Fluid Specifications

Fork Oil Viscosity:

Commonly SAE 5W, 7.5W, or 10W, depending on model and desired damping characteristics. Manual will specify.

Brake Fluid Type:

DOT 4 or DOT 5.1 (check manual for specific recommendation and any ABS system considerations if applicable).

Coolant Type:

Proprietary KTM coolant or a high-quality ethylene glycol based coolant with corrosion inhibitors. Manual will specify mix ratio.

Known Issues

Common Wear Items:

Clutch plates, wheel bearings, steering head bearings, fork seals, chain and sprockets, brake pads.

Specific Concerns:

Early LC4 engines sometimes had issues with starter clutch durability or cam chain tensioners; later models improved. Manual will detail specific checks for each year/model.

📚 Vehicle History

Brand Heritage

Manufacturer:

KTM Sportmotorcycle AG, Austria.

Brand Focus:

Renowned for off-road racing performance and 'Ready to Race' philosophy.

Model Evolution

Racing Success:

Models in this range have a strong heritage in Enduro and Motocross racing, with numerous championship wins.

Production

Production Era:

These models represent a significant period of development for KTM's four-stroke off-road lineup.

🏆 Awards & Recognition

Recognitions

Racing Titles:

KTM models from this era have secured numerous national and international Enduro and Motocross championships, validating their performance and reliability in competition.

Ratings

Journal Reviews:

Contemporary motorcycle publications widely praised these models for their power, suspension, and handling capabilities in their respective disciplines.