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KTM 560 SMR 2000-2007 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: KTM Model: 560 SMR Model Variant: Supermoto Racing Year Range Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Vehicle Type: Motorcycle Intended Use: Supermoto...
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类型: Motorcycle
厂商:
斯库: 430197
KTM 560 SMR 2000-2007 Workshop Service Manual for Repair
🏷️ Basic Information
Identification
Make:
KTM
Model:
560 SMR
Model Variant:
Supermoto Racing
Year Range Covered:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Vehicle Type:
Motorcycle
Intended Use:
Supermoto Racing / High-Performance Street Use
👋 Introduction
Market Position
Market Segment:
High-performance Supermoto/Motard.
Target Audience:
Enthusiast riders, track day participants, and DIY mechanics specializing in KTM motorcycles.
Competitive Analysis
Competitors:
Other high-performance supermoto motorcycles of the era, such as Ducati Hypermotard, Aprilia SXV, Yamaha WR series.
Key Features
Vehicle Focus:
Agility, power, and track-bred performance adapted for street use.
Manual Value Proposition:
Enables owners to maintain and repair their high-performance motorcycle effectively, reducing reliance on specialized workshops.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Manual for Repair
Language:
English
Page Count:
245
Delivery Method:
Instant Download (Digital)
File Format:
PDF
Printability:
Yes
Compatibility:
Windows, Mac, Linux OS (requires Adobe Reader)
📖 Manual Coverage
Systems Covered
Engine Service:
Complete overhaul, disassembly, assembly, lubrication, cooling system, fuel system, ignition system, exhaust system, tuning.
Transmission Service:
Gearbox removal, disassembly, inspection, assembly, clutch operation, maintenance.
Chassis And Suspension:
Frame inspection, front fork (WP Suspension components) overhaul, rear shock absorber service, swingarm, linkage maintenance.
Braking System:
Front and rear brake caliper service, master cylinder overhaul, brake line replacement, bleeding procedures, pad and disc inspection.
Electrical System:
Wiring diagrams, starter motor, battery maintenance, lighting system, ignition coil troubleshooting, component testing.
Fuel And Air System:
Carburetor (likely Keihin or Mikuni) specifications, jetting, cleaning, fuel tank, fuel pump, air filter service.
Cooling System:
Radiator inspection, coolant replacement, thermostat operation, hose inspection.
Bodywork And Trim:
Fairing removal and installation, seat maintenance, fender replacement.
Procedures Included
Diagnostic Procedures:
Troubleshooting guides, symptom-based diagnostics, electrical system checks.
Maintenance Tasks:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, general inspections.
Disassembly And Assembly:
Step-by-step guides for component removal and reinstallation.
Adjustment Procedures:
Carburetor synchronization, valve clearance adjustment, clutch and throttle cable adjustment.
Repair Procedures:
Detailed instructions for fixing specific components and systems.
Special Tool References:
Identification and usage of specialized service tools required for various tasks.
Technical Depth
Depth Level:
Comprehensive (from basic maintenance to complete engine rebuilds).
Diagnostic Detail:
Detailed diagnostic flowcharts and symptom analysis.
Pictorial Representation:
Pictorial diagrams, exploded views, and detailed illustrations guiding repair procedures.
Specification Data:
Includes critical service data, tolerances, and tightening torques.
📊 Manual Specifications
File Format
File Type:
PDF
Readability:
High-resolution, printable pages.
Searchability:
Likely text-searchable, facilitating quick information retrieval.
Print Quality
Print Resolution:
Suitable for clear printing of text and diagrams.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, single-cylinder, four-stroke.
Displacement:
Approximately 560cc (exact cubic centimeters may vary slightly based on specific internal specifications not detailed in the product info, but the '560' designation is key).
Bore X Stroke:
Specifications not explicitly provided, but typical for KTM single-cylinders of this era would be large bore.
Performance
Horsepower:
Estimated 55-65+ HP (dependent on year and specific tuning).
Torque:
Estimated 50-55+ lb-ft (dependent on year and specific tuning).
Fuel System
Fuel Delivery:
Carburetor (likely Keihin FCR or similar high-performance unit).
Fuel Type:
Unleaded Gasoline (95 RON or higher recommended).
Lubrication
Oil Type:
High-performance motorcycle-specific 4-stroke engine oil, adhering to JASO MA or MA2 specifications. (Manual will specify exact viscosity and API rating).
Cooling System
Cooling Method:
Liquid-cooled.
Ignition System
Ignition Type:
Digital CDI with variable ignition timing.
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh.
Optional
Optional Transmission:
N/A (Standard for this model).
Features
Clutch Type:
Hydraulically operated multi-disc wet clutch.
Final Drive:
Chain drive.
Gear Ratios:
Specific ratios would be detailed in the manual, optimized for performance riding.
Transmission Oil:
Manual will specify specific transmission oil type and capacity.
📐 Dimensions
Exterior
Wheelbase:
Specifications would be detailed in the manual, typically around 57-59 inches.
Seat Height:
Specifications would be detailed in the manual, typically high for supermoto configuration.
Weights
Dry Weight:
Estimated 250-270 lbs (subject to year and specific componentry).
Fuel Tank Capacity:
Approximately 2.5-3.0 gallons.
🛡️ Safety Features
Ratings
Safety Standards:
Designed for off-road and closed-course competition use, may not meet all DOT street-legal requirements without modification/specific regional homologation.
Active Features
Braking System Type:
High-performance hydraulic disc brakes (e.g., Brembo components common on KTMs).
Suspension System:
High-quality adjustable suspension (typically WP Suspension).
💡 Technology Features
Infotainment
Infotainment System:
Minimalist by design, focused on performance. Likely features a basic LCD display for speed, RPM, odometer, trip meter, and potentially basic engine diagnostics.
Driver Assistance
Driver Assistance Features:
None in the modern sense. Focus is on rider control and mechanical feedback.
Connectivity
Connectivity Options:
N/A.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific mileage/time interval (typically 3,000-5,000 km or annually).
Air Filter Cleaning:
Frequent cleaning recommended, especially for off-road use (refer to manual for schedule).
Chain Lubrication Adjustment:
Regular checks and lubrication (every 500-1000 km or after wet riding) and adjustment as needed.
Fluid Specifications
Engine Oil Viscosity:
Likely 10W-50 or 15W-50 (refer to manual for exact specification).
Coolant Type:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. (Manual will confirm type and capacity).
Brake Fluid Type:
DOT 4 or DOT 5.1 (Manual will specify exact type and change interval).
Known Issues
Common Wear Items:
Clutch plates, brake pads and discs, chain and sprockets, fork seals, wheel bearings, piston rings (depending on mileage).
Potential Problems:
Overheating if coolant system is not maintained, premature wear of engine components if oil changes are neglected, carburetor tuning sensitivity.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Austria.
Brand Specialty:
Off-road racing motorcycles, known for performance and innovative design.
Model Evolution
Model Lineage:
Part of KTM's extensive range of performance motorcycles, evolving from their motocross and enduro platforms.
Design Philosophy:
Lightweight, powerful, and agile, designed for aggressive riding and competition.
Production
Production Period:
Covered by the manual: 2000-2007.
🏆 Awards & Recognition
Recognitions
Racing Heritage:
KTM's reputation is built on racing success, and models like the SMR are direct beneficiaries of this development.
Ratings
Owner Satisfaction:
Generally high among performance-oriented riders who appreciate KTM's build quality and performance capabilities.
Certifications
Emission Standards:
Depending on the target market and year, may meet Euro or other regional emission standards. Manual would detail relevant specifications.
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