🏷️ Basic Information

Make:

KTM

Motorcycle Type:

Off-Road / Dual-Sport / Supermoto

Model Lineup:

EXC, MXC, SMR, SX, SXS, Racing Crate

Engine Types Covered:

4-Stroke

👋 Introduction

Target Audience:

KTM motorcycle owners and independent repair shops performing maintenance and repairs on 2000-2006 4-stroke models.

Value Proposition:

Offers professional-grade repair information at a fraction of the cost of dealership service, empowering owners to perform maintenance and repairs themselves.

Accessibility:

Instant PDF download provides immediate access to repair information without shipping delays.

Lifetime Access:

Customers retain access to the downloaded manual indefinitely.

Content Quality:

Features clear, step-by-step instructions and comprehensive illustrations, mirroring professional workshop manuals.

📋 Manual Details

Years Covered:

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

Specific Models Covered:

250 EXC, 400 EXC, 450 EXC, 520 EXC, 525 EXC, 540 EXC, 560 EXC, 610 EXC, 250 MXC, 400 MXC, 450 MXC, 520 MXC, 525 MXC, 540 MXC, 560 MXC, 610 MXC, 450 SMR, 525 SMR, 560 SMR, 250 SX, 400 SX, 450 SX, 520 SX, 525 SX, 540 SX, 560 SX, 610 SX, 250 SXS, 400 SXS, 450 SXS, 520 SXS, 525 SXS, 540 SXS, 560 SXS, 610 SXS, Racing Crate models (various displacements)

Estimated Page Count:

Comprehensive (exact count not provided, but indicated as extensive for detailed coverage)

Type:

Repair Manual / Service Manual

Language:

English

Delivery Format:

PDF Download

📖 Manual Coverage

Engine Overhaul:

Complete engine removal, disassembly, inspection, repair, and reassembly for all listed 4-stroke displacements.

Fuel System:

Carburetor (Keihin/Mikuni variations), fuel pump, fuel lines, fuel tank, and related components.

Lubrication And Cooling:

Oil pump, oil filter, oil passages, oil change procedures, coolant system, radiator, water pump, thermostat, and coolant hoses.

Transmission And Drivetrain:

Gearbox disassembly and reassembly, clutch operation and service, drive chain adjustment and replacement, sprocket service, and final drive maintenance.

Electrical System:

Ignition system (CDI, coils), starting system (starter motor, battery), lighting system, charging system (alternator/stator), wiring diagrams, troubleshooting electrical faults, and component testing.

Suspension And Steering:

Front forks (WP suspension typically), rear shock absorber service and adjustment, linkage systems, steering head bearings, and handlebar/triple clamp maintenance.

Brakes:

Front and rear brake system service (hydraulic calipers, master cylinders, brake lines, pads, rotors), bleeding procedures, and brake component inspection.

Bodywork And Chassis:

Body panel removal and installation, seat, fuel tank, airbox, frame inspection and maintenance, footpegs, and general chassis components.

Intake And Exhaust:

Air filter service, intake manifold inspection, exhaust system maintenance, and muffler service.

Wheel And Tire:

Wheel bearing service, spoke tension adjustment (if applicable), tire pressure recommendations, and rim maintenance.

Maintenance Tasks:

Routine service checks, oil changes, filter replacements, chain adjustments, brake pad replacement, spark plug service, valve clearance checks.

Diagnostic Procedures:

Troubleshooting common starting issues, engine running problems, electrical faults, and performance issues.

Repair Procedures:

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

Adjustment Procedures:

Carburetor tuning, suspension setup, clutch adjustment, and brake lever adjustments.

Special Tool Requirements:

Identifies and describes necessary special tools for specific repair and maintenance tasks.

Torque Specifications:

Detailed torque specifications for all critical fasteners, including engine components, chassis bolts, and suspension mounts.

Depth:

Comprehensive; suitable for home mechanics to professional technicians. Covers everything from basic pre-ride checks to full engine and transmission rebuilds.

Diagnostic Charts:

Includes diagnostic flowcharts and symptom-based troubleshooting guides for common mechanical and electrical issues.

Illustrations And Diagrams:

Abundant, clear, and detailed illustrations and exploded diagrams of all major components and systems.

📊 Manual Specifications

File Type:

PDF

Print Recommendation:

High-resolution, suitable for clear printing of text and diagrams. Users can print specific sections or the entire manual.

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Device Compatibility:

PC, MAC, Tablet, Smartphone (any device capable of opening PDF files)

⚙️ Engine Specifications

Engine Configuration:

Single-cylinder, 4-stroke (variations across models)

Valve Train:

Typically DOHC (Double Overhead Camshaft) or SOHC (Single Overhead Camshaft), 4 valves per cylinder.

Cooling System:

Liquid-cooled

Horsepower Range:

Varies by displacement, generally in the 30-55 HP range for the covered models. (Specific figures require referencing individual model specifications.)

Torque Range:

Varies by displacement, generally in the 30-50 Nm range. (Specific figures require referencing individual model specifications.)

Fuel Delivery:

Carburetor (Keihin FCR series, Mikuni variations common)

Ignition Type:

Electronic Ignition (CDI)

🔧 Transmission

Gearbox:

Constant mesh, sequential manual gearbox

Number Of Gears:

Typically 6-speed

Clutch Type:

Wet multi-plate clutch

📐 Dimensions

Dry Weight Range:

Approximately 100-120 kg (220-265 lbs) depending on model and year. (Manual provides specific figures.)

🛡️ Safety Features

Safety Compliance:

N/A (Off-road motorcycles are typically not subjected to the same road vehicle safety ratings. Focus is on operational safety.)

Braking System:

Hydraulic disc brakes front and rear, with high-performance calipers and rotors.

Frame Design:

Chromoly steel, perimeter frame designed for torsional rigidity and impact resistance.

💡 Technology Features

Infotainment Features:

N/A (These are performance-oriented off-road motorcycles; infotainment systems are not applicable.)

Rider Aids:

N/A (No electronic rider aids such as ABS or traction control are typically found on these models.)

Connectivity Features:

N/A (No onboard connectivity features.)

🔧 Maintenance

Oil Change Interval:

Typically every 10-15 hours of riding or annually. (Manual provides exact recommendations based on usage.)

Air Filter Cleaning:

Recommended every 5-10 hours of riding, or more frequently in dusty conditions.

Valve Clearance Check:

Typically every 20-30 hours of riding. (Manual details the procedure and correct clearances.)

Engine Oil:

Typically a high-quality synthetic 10W-40 or 10W-50 motorcycle oil meeting JASO MA specifications. (Manual specifies exact viscosity and API rating.)

Coolant:

Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. (Manual specifies type and capacity.)

Brake Fluid:

DOT 4 or DOT 5.1 hydraulic brake fluid. (Manual specifies correct type for front and rear systems.)

Transmission Oil:

Often the same as engine oil, or a dedicated transmission lubricant may be specified. (Manual clarifies requirements.)

Common Wear Items:

Clutch plates, wheel bearings, steering head bearings, suspension seals, and brake pads are common wear items requiring regular inspection and replacement.

Engine Specific Notes:

Valve seat wear and cam chain tensioner reliability have been noted in some models of this era; the manual will guide on inspection and replacement.

📚 Vehicle History

Ktm Heritage:

KTM is renowned for its off-road racing pedigree and performance-oriented motorcycles, often referred to as 'Ready to Race'.

Evolution Summary:

The EXC (Enduro Cross Country), MXC (Motocross), SMR (Supermoto), and SX (Supercross) lines represent KTM's commitment to diverse off-road disciplines. The models covered (2000-2006) showcase the refinement of KTM's 4-stroke engine technology and chassis design during this era.

🏆 Awards & Recognition

Off Road Performance:

KTM motorcycles from this era consistently performed well in enduro, motocross, and supermoto racing, earning numerous championships and accolades.