🏷️ Basic Information

Make:

KTM

Model:

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

Product Name:

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

Product Type:

Downloadable PDF Repair Manual

Manufacturer Codes:

KTM AG

👋 Introduction

Target Audience:

KTM owners, off-road enthusiasts, motocross racers, enduro riders, and independent repair shops.

Manual Value:

Provides critical factory information to reduce reliance on costly dealership service or potentially inaccurate third-party guides.

Diagnostic Tools:

Empowers users with the knowledge to perform diagnostics, reducing the need for specialized electronic diagnostic equipment.

Cost Savings:

Enables DIY maintenance and repairs, leading to significant cost savings over the ownership period.

Performance Optimization:

Detailed specifications and tuning advice aid in maintaining optimal engine performance and longevity.

📋 Manual Details

Model Years Covered:

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

Specific Models Covered:

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

Engine Types Covered:

4-Stroke

Estimated Page Count:

Varies by model/year, typically 300-600+ pages for full service manuals

Manual Format:

Service Manual / Workshop Manual / Repair Manual

Manual Origin:

OEM Factory Service Manual Data (as represented by ClassicCirculations.com)

Language:

English

Download Format:

PDF Download

📖 Manual Coverage

Engine Overhaul:

Complete disassembly, inspection, repair, and reassembly procedures for all covered 4-stroke engines.

Fuel System:

Carburetor (Keihin, Mikuni) tuning, cleaning, rebuilding; fuel injection system diagnostics and repair for applicable models.

Lubrication And Cooling:

Oil pump operation, oil cooler service, coolant system bleeding, radiator and hose inspection, water pump repair.

Transmission And Drivetrain:

Clutch operation and service, gearbox disassembly and inspection, gear ratio information, chain and sprocket maintenance and replacement.

Suspension And Steering:

Front fork (WP) servicing (oil changes, seal replacement, revalving), rear shock absorber (WP) overhaul and adjustments, steering head bearing service.

Brakes:

Brake caliper inspection and service, master cylinder overhaul, brake pad replacement, hydraulic system bleeding, rotor inspection.

Electrical System:

Wiring diagrams, ignition system troubleshooting, lighting circuits, starter motor and battery maintenance, CDI unit diagnostics.

Chassis And Bodywork:

Frame inspection, seat and plastic panel removal/installation, exhaust system service, kickstand and footpeg maintenance.

Routine Maintenance:

Oil and filter changes, air filter cleaning/replacement, chain adjustment, spark plug inspection, valve clearance checks.

Troubleshooting:

Diagnostic flowcharts and symptom-based problem solving for common issues.

Rebuilds And Overhauls:

Detailed step-by-step instructions for engine, transmission, and suspension component rebuilds.

Specifications And Torque Values:

All critical torque specifications, clearances, and measurement data for repairs.

Diagnostic Capabilities:

Advanced diagnostics for ignition, fuel delivery, and electrical systems, often requiring specialized tools (though manual provides theory).

Rebuild Level:

Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts.

Parts Identification:

Detailed component diagrams and part numbers for accurate identification and ordering.

📊 Manual Specifications

File Type:

Portable Document Format (PDF)

Digital Resolution:

High-resolution scans suitable for on-screen viewing and printing.

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

Searchability:

Typically searchable text within the PDF for quick information retrieval.

Printable Pages:

Allows selective printing of specific pages for workshop use.

⚙️ Engine Specifications

Engine Configuration:

Single-cylinder, 4-stroke (various displacements)

Engine Displacements Quoted:

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

Engine Cooling:

Liquid-cooled

Power Delivery Characteristics:

High-revving, focused on off-road performance (motocross, enduro, supermoto).

Carburetor Types:

Keihin FCR (Flat CR), Mikuni (specific models)

Fuel Injection Availability:

Some later models in the 2006 range may have featured early EFI systems.

🔧 Transmission

Transmission Type:

Constant mesh, 5 or 6-speed manual

Optional Gearboxes:

N/A (Standard manual transmission)

Clutch Type:

Wet multi-plate clutch (hydraulic actuation)

Final Drive:

O-ring sealed chain

📐 Dimensions

Chassis Type:

Chromium-molybdenum steel trellis frame

Dry Weight Range:

Approximately 105-120 kg (231-265 lbs), depending on model and configuration.

🛡️ Safety Features

Safety Certifications:

Off-road/competition homologation standards (varies by region and model).

Braking System:

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

Frame Strength:

Robust trellis frame designed for extreme off-road conditions.

💡 Technology Features

Instrumentation:

Digital hour meter and basic odometer are standard. Advanced displays are rare for this era's off-road models.

Electronic Aids:

Minimal to none; these are performance-oriented off-road machines focused on rider control.

Connectivity Features:

N/A

🔧 Maintenance

Oil Change Interval:

Typically every 15-20 hours of riding or annually, refer to specific model section for exact figures.

Air Filter Service:

Frequent cleaning/replacement recommended, especially in dusty conditions (often every 5-10 hours).

Valve Adjustment:

Every 30-50 hours, depending on riding style and engine wear.

Engine Oil Type:

Fully synthetic 10W-40 or 10W-50 motorcycle oil meeting JASO MA/MA2 standards. Specific viscosity may vary by temperature and model year.

Coolant Type:

Ethylene glycol-based coolant (e.g., Motorex Coolant M3.0) with corrosion inhibitors.

Fork Oil Viscosity:

WP suspension typically specifies ISO VG 5 or 5W fork oil.

Common Wear Items:

Clutch plates, piston rings, valve guides, wheel bearings, steering head bearings.

Potential Failures:

Water pump seal leaks, stator failures, carburetor jetting issues at altitude.

Spark Plug Recommendation:

NGK iridium spark plugs are often recommended for optimal performance and longevity.

📚 Vehicle History

Brand Focus:

KTM is renowned for its off-road racing heritage and 'Ready to Race' philosophy.

Engine Development:

This era saw significant development in KTM's four-stroke engine technology, moving towards larger displacements and improved power delivery.

Manufacturing Origin:

Austria (primarily)

🏆 Awards & Recognition

Racing Success:

KTM EXC and SX models have a long history of success in various off-road racing disciplines (Enduro, Motocross, Supermoto) globally.

Industry Reputation:

Highly regarded for robust construction, powerful engines, and competitive performance in their respective classes.