🏷️ Basic Information

Make:

KTM

Model Range:

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

Year Range:

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

Manual Type:

Engine Service Repair Manual

👋 Introduction

Target Audience:

KTM motorcycle owners and independent repair shops seeking detailed engine maintenance and repair guidance.

Value Proposition:

Provides essential, in-depth technical information for self-maintenance and repair, saving costs associated with dealership servicing. Instant download eliminates shipping delays and costs.

Ease Of Use:

Step-by-step instructions designed for ease of following, catering to various skill levels.

Diagnostic Support:

Includes troubleshooting section to aid in identifying and resolving common problems.

Technical Data:

Offers crucial technical specifications required for accurate repairs and maintenance.

📋 Manual Details

Engine Repair:

Comprehensive engine service and repair procedures

Component Servicing:

Servicing of individual engine components

Electrical Systems:

Engine-related electrical systems and troubleshooting

Troubleshooting:

Diagnostic procedures and common issue resolution

Maintenance:

Periodic maintenance schedules and procedures

Estimated Pages:

High - typical for comprehensive engine manuals (specific number not provided, but coverage implies extensive)

Type:

Service Repair Manual

Language:

English

File Format:

PDF Download

Compatibility:

All Versions of Windows & Mac

Software Requirement:

Adobe PDF Reader

Download Method:

Instant download upon payment completion

Print Feature:

All pages are printable

📖 Manual Coverage

Engine Assembly Disassembly:

Complete engine disassembly and reassembly procedures

Engine Removal Installation:

Procedures for removing and refitting the engine

Individual Components:

Detailed servicing of specific engine components (e.g., cylinder head, pistons, crankshaft, valve train, cooling system, lubrication system)

Electrical:

Engine electrical systems including ignition, starting, charging, and associated wiring diagrams

Diagnostic Procedures:

Troubleshooting common engine faults and diagnostic steps

Maintenance Tasks:

Routine maintenance tasks as per the periodic maintenance schedule

Repair Instructions:

Step-by-step repair instructions for engine-related issues

Diagrams Illustrations:

High-quality diagrams and illustrations for clarity

Depth Level:

Comprehensive, suitable for DIY enthusiasts and professional mechanics

📊 Manual Specifications

Document Format:

PDF

Printability:

Printable, allowing for workshop use

Binding:

Not Applicable (Digital Download)

Paper Quality:

Not Applicable (Digital Download)

Content Quality:

High quality diagrams and instructions

⚙️ Engine Specifications

Engine Type 250:

Four-stroke, liquid-cooled single-cylinder (likely LC4 variant for EXC models)

Displacement 250:

Approximately 250cc (exact variant may differ based on specific model year)

Engine Type 400 450:

Four-stroke, liquid-cooled, single-cylinder (LC4 engine family)

Displacement 400 450:

400cc to 450cc range (specific models like 400 EXC, 450 SX)

Engine Type 520 525:

Four-stroke, liquid-cooled, single-cylinder (LC4 engine family, often referred to as 525 EXC, 525 SX)

Displacement 520 525:

520cc to 525cc range

Engine Type 540 560:

Four-stroke, liquid-cooled, single-cylinder (LC4 engine family, high-performance variants)

Displacement 540 560:

540cc to 560cc range

Engine Type 610:

Four-stroke, liquid-cooled, single-cylinder (likely LC4 engine family, larger displacement variant)

Displacement 610:

Approximately 610cc

Horsepower Range:

Varies by displacement and model, typically 40-60+ HP for this era of KTM off-road/supermoto models.

Fuel Delivery:

Carbureted (likely Keihin or Mikuni CV carbs, specific models might transition to EFI later in the range, though manual focuses on engine service implying carburetors are prevalent).

Cooling Type:

Liquid-cooled, with radiator and fan assembly

Lubrication Type:

Wet sump or semi-dry sump (specific to LC4 architecture)

🔧 Transmission

Transmission Type:

6-speed constant mesh (typical for these KTM models)

Clutch Type:

Hydraulically operated multi-plate wet clutch

Transmission Oil Spec:

Typically SAE 10W-50 or 20W-50 motorcycle-specific engine oil (refer to manual for precise grade and capacity).

📐 Dimensions

Vehicle Type:

Motocross, Enduro, Supermoto motorcycles

Dry Weight Range:

Approx. 100-130 kg (220-285 lbs) depending on model and configuration. Manual is engine-focused, so detailed chassis dimensions are not expected but engine weight for removal/installation is covered.

🛡️ Safety Features

Safety Features:

Focuses on mechanical safety related to engine operation and integrity. Does not cover chassis or rider safety equipment.

💡 Technology Features

Infotainment System:

N/A (Motorcycle-specific, no infotainment system expected in this context).

Driver Assistance Features:

N/A (Motorcycle-specific, no driver assistance features expected).

Ignition System:

Electronic Ignition (CDI or similar electronic control unit for ignition timing).

Efi Transition:

While this generation primarily uses carburetors, the manual would cover ignition and potentially basic EFI sensor diagnostics if present on specific later models within the year range.

🔧 Maintenance

Oil Change Interval:

Typically every 50-100 hours of riding or annually, depending on usage and model. Manual will detail specific intervals.

Valve Clearance Check:

Often recommended every 50-100 hours of riding. Manual will provide specific procedures and tolerances.

Engine Oil Capacity:

Typically around 1.0-1.5 liters (refer to manual for exact capacity based on model and oil level check method).

Coolant Type:

Ethylene glycol-based antifreeze coolant, typically a 50/50 mix with distilled water. Manual will specify type and capacity.

Lc4 Common Points:

Common areas for inspection and potential issues include cam chain tensioner, valve stem seals, clutch slave cylinder, and cooling system components. Manual will guide on preventative checks and repairs.

Spark Plug Recommendation:

Specific spark plug type (e.g., NGK) and gap will be detailed in the manual's technical specifications section.

📚 Vehicle History

Ktm Offroad Legacy:

KTM has a long-standing and dominant history in off-road motorsport, including motocross and enduro racing. The LC4 engine platform has been a cornerstone of their larger-displacement offerings.

Lc4 Development:

The LC4 engine evolved significantly throughout the late 90s and early 2000s, with updates to performance, reliability, and emissions. This manual covers a crucial period of its development.

Manufacturing Region:

Primarily Austria

🏆 Awards & Recognition

Motorsport Achievements:

KTM's LC4-powered models have achieved significant success in various forms of motorsport, including Dakar Rally, Enduro World Championship, and Supermoto championships, attesting to the engine's robust design and performance.