🏷️ Basic Information

Make:

KTM

Model:

540 SXS, 560 SMR, 610 CRATE

Years Covered:

2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007

Product Type:

Workshop Service Repair Manual Download

👋 Introduction

Target Audience:

Do-it-yourselfers and Experienced Mechanics

Value Proposition:

Inexpensive way to keep your vehicle working properly, Avoids expensive dealership service

Key Feature 1:

Comprehensive coverage of multiple model years and variations.

Key Feature 2:

Detailed, step-by-step instructions with extensive visual aids.

Key Feature 3:

Combined troubleshooting and electrical service with wiring diagrams.

📋 Manual Details

Primary Coverage:

Complete Service and Repair

Style Coverage:

All Styles Covered

Estimated Pages:

Hundreds of Pages

Type:

Official Factory Service Repair Manual

Language:

English

File Format:

PDF

Delivery Method:

Instant Download

📖 Manual Coverage

Engine Systems:

General Information, Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Crankshaft/Transmission

Chassis Systems:

Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame

Electrical Systems:

Electrical System, Wiring Diagrams

Maintenance:

Scheduled Maintenance, Fluid Checks, Filter Replacements

Diagnostics:

Troubleshooting, Electrical System Diagnosis

Repair:

Complete Disassembly and Reassembly, Component Repair

Installation:

Engine Removal/Installation

Depth:

In-depth, Step-by-step Instructions

Visual Aids:

Hundreds of Photos and Illustrations, Enlarged Insets

Guidance:

Numbered Instructions, Bold Figure Numbers

📊 Manual Specifications

Format Details:

PDF, Compatible with all PC-based Windows Operating Systems and Mac

Printability:

Printable without any restriction, Entire Manual or Specific Pages

Binding:

Digital Download (user prints as needed)

Paper Type:

N/A (Digital)

Software Requirement:

Adobe PDF Reader

⚙️ Engine Specifications

Engine Variants:

540cc, 560cc, 610cc (specific engine details vary by sub-model and year)

Horsepower Torque:

Specific figures would require consulting the manual for each engine variant. Generally high-performance off-road/supermoto configurations.

Fuel Delivery:

Details will vary; likely carbureted or early fuel injection depending on specific model and year. Manual covers full system diagnostics and repair.

🔧 Transmission

Transmission Type:

Manual Gearbox (specific number of speeds to be detailed in the manual)

Optional Transmission:

N/A (Typically performance-oriented motorcycles of this era featured standard transmissions.)

Clutch System:

Manual covers clutch system operation, adjustment, and repair.

Gearbox Overhaul:

Detailed procedures for crankshaft and transmission overhaul are included.

📐 Dimensions

Motorcycle Type:

Motocross (SXS), Supermoto (SMR), potentially dual-sport or enduro variants for the 610 CRATE model.

Dry Weight:

Specific dry weight varies by model variant and year; typically lightweight for performance.

Wet Weight:

Specific wet weight varies by model variant and year.

🛡️ Safety Features

Safety Standards:

Motorcycle-specific safety standards, manual provides guidance on brake system maintenance and handling.

Active Safety:

Brake system, suspension tuning for stability.

Passive Safety:

Frame integrity, component securement.

💡 Technology Features

Infotainment Systems:

N/A (These are performance motorcycles focused on function, not typically equipped with extensive infotainment.)

Electronic Aids:

Limited electronic aids, focus on mechanical performance. Manual covers basic electrical system diagnostics.

Connectivity Features:

N/A

🔧 Maintenance

Typical Intervals:

Manual will detail specific intervals for oil changes, filter replacements, valve checks, chain maintenance, etc., tailored to racing and regular use.

Engine Oil:

Specific oil viscosity grades (e.g., Motorex Power Synt) and capacities will be provided for engine lubrication and transmission.

Coolant:

Type and mixture ratio for the cooling system will be specified.

Brake Fluid:

DOT specification for brake fluid will be detailed.

Common Wear Items:

Manual can help identify and address common wear items like piston rings, valve guides, clutch plates, and chain/sprockets specific to these performance models.

Troubleshooting Guidance:

Provides systematic approaches to diagnosing common performance issues.

📚 Vehicle History

Ktm Heritage:

KTM is renowned for its off-road racing pedigree and 'Ready to Race' philosophy, producing high-performance motorcycles.

Sx Smr Evolution:

The SXS and SMR lines represent KTM's dedication to competitive motocross and supermoto racing platforms, evolving with engine sizes and chassis improvements through the early 2000s.

Production Era:

Covers a significant period of KTM's expansion and refinement of their off-road and Supermoto offerings.

🏆 Awards & Recognition

Brand Reputation:

KTM motorcycles are consistently recognized for their performance, durability in racing environments, and innovative engineering.

Segment Performance:

These models were competitive in their respective motocross and supermoto racing classes during their production years.