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2000-2007 Ktm 250 Exc Racing 400/450 Sx mxc xc xc-w exc smr sxs Racing 520/525 Sx mxc xc xc-w exc smr Racing 540 Sxs 560 Smr 610 Crate Workshop Repair Service Manual
2000-2007 Ktm 250 Exc Racing 400/450 Sx mxc xc xc-w exc smr sxs Racing 520/525 Sx mxc xc xc-w exc smr Racing 540 Sxs 560 Smr 610 Crate Workshop Repair Service Manual
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Vehicle data plateRef 64289
- Brand
- Ktm
- Vehicle
- ATV
- Models covered
- 250 Exc Racing, 400/450 Sx/mxc/xc/xc-w/exc/smr/sxs Racing, 450 SX, 520/525 Sx/mxc/xc/xc-w/exc/smr Racing, 540 Sxs, 560 Smr, 610 Crate, KTM
- Years
- 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
- Format
- PDF, searchable, print-ready
- Delivery
- Instant download after checkout
- Language
- English
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What happens after you pay
- Download link opens on the order page immediately
- The same link is emailed to you — re-download any time
- Open on phone, tablet or PC; print only the pages you need
- Not sure it covers your model year? Ask us before you buy
| Basic Information | |
| Identification | |
| Make: | KTM |
| Model Years Covered: | 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 |
| Platform: | Off-Road/Dual-Sport |
| Designation: | Service Workshop Repair Manual |
| Introduction | |
| Market Position | |
| Target Audience: | Owners and technicians seeking in-depth knowledge for maintenance, repair, and diagnostics of 2000-2007 KTM off-road and dual-sport motorcycles. |
| Key Features | |
| Value Proposition: | Provides detailed factory-level repair information, enabling cost savings on repairs and a deeper understanding of the vehicle's mechanics. |
| Competitive Analysis | |
| Comparable Models: | Competes with other premium off-road motorcycles from brands like Yamaha (YZF, WR), Honda (CRF, XR), Kawasaki (KX, KDX), and Suzuki (RM, DR) of the same era. |
| Manual Details | |
| Coverage Areas | |
| Primary Models: | 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 Racing, 525 SX, 525 MXC, 525 XC, 525 XC-W, 525 EXC, 525 SMR Racing, 540 SXS Racing, 560 SMR Racing, 610 Crate |
| Page Count | |
| Estimated Page Count: | Highly Detailed (Exact count not specified, but implied to be comprehensive) |
| Manual Type | |
| Type: | Factory Service Repair Workshop Manual |
| Language | |
| Language: | English |
| Format | |
| File Format: | |
| Manual Coverage | |
| Systems Covered | |
| Engine Mechanics: | Engine Removal, Engine Disassembly, Servicing Individual Components, Engine Assembly |
| Electrical System: | Complete Electrical System Diagnostics and Repair, Wiring Diagrams |
| Troubleshooting: | Comprehensive Troubleshooting Guides for Common and Complex Issues |
| General Information: | General Specifications, Service Information, Motorcycle Identification |
| Chassis Components: | Frame, swingarm, handlebars, footpegs, and related components. |
| Wheels Tires: | Wheel bearing service, spoke tensioning, tire installation, and pressure recommendations. |
| Bodywork: | Fairings, fenders, seat, fuel tank removal and installation. |
| Cooling System: | Radiator, hoses, water pump, and thermostat inspection and service. |
| Procedures Included | |
| Maintenance: | Periodic Maintenance Schedule, Fluid Changes, Component Servicing |
| Repair: | Step-by-step repair procedures for all major vehicle systems |
| Disassembly Assembly: | Complete motorcycle disassembly and reassembly guidance |
| Troubleshooting Diagnostics: | Systematic approach to identifying and resolving mechanical and electrical faults. |
| Technical Depth | |
| Depth: | Suitable for both DIY enthusiasts and experienced professional mechanics, covering detailed rebuilds. |
| Diagnostic Tools: | While not specific to electronic diagnostic tools (which were rudimentary for these models), it details the use of basic mechanical tools for diagnosis. |
| Manual Specifications | |
| File Format | |
| Quality: | High-quality PDF with detailed illustrations and step-by-step instructions. |
| Print Quality | |
| Printability: | Fully printable, all pages are printable. |
| Binding Type | |
| Binding: | Digital PDF Download (printable) |
| Paper Type | |
| Paper: | N/A (Digital) |
| Compatibility | |
| Software: | Adobe PDF Reader required. |
| Operating Systems: | All PC based Windows operating systems and Mac. |
| Features | |
| Bookmarking: | Bookmarked for easy navigation. |
| Digital Access: | Instant download format for immediate access. |
| Engine Specifications | |
| Primary Engine | |
| Engine Types Covered: | Single-cylinder, four-stroke engines of various displacements (250cc, 400cc, 450cc, 520cc, 525cc, 540cc, 560cc, 610cc). |
| Engine Design: | Four-stroke, liquid-cooled (typically), single-cylinder engines with various configurations (e.g., SOHC, DOHC depending on displacement). |
| Performance | |
| Performance Details: | Manual provides specifications for horsepower, torque, and engine performance tuning, though specific figures vary by model and year. |
| Valve Lash Adjustment: | Procedure and specifications for valve clearance adjustment, a critical maintenance task. |
| Fuel System | |
| Fuel System Details: | Covers carburetion systems (e.g., Keihin, Mikuni) for most models, including jetting, float adjustments, and cleaning procedures. Fuel injection may be covered for later models if applicable. |
| Carburetor Details: | Detailed settings, cleaning, and synchronization for various carburetor models used across the range. |
| Transmission | |
| Standard Transmission | |
| Type: | Manual (Clutch and Gearbox) |
| Features | |
| Gearbox Coverage: | Detailed information on clutch operation, gearbox disassembly, inspection, and reassembly, including gear selection and shifting mechanisms. |
| Dimensions | |
| Exterior | |
| Body Styles: | Enduro (EXC), Motocross (SX), Cross-Country (XC/MXC), Supermoto (SMR), Special Edition (SXS). |
| Weights | |
| Dry Weight Range: | Varies significantly by model, generally ranging from approximately 220 lbs (100 kg) for 250cc models to over 260 lbs (118 kg) for larger displacement models. Specific weights can be found within the manual. |
| Safety Features | |
| Ratings | |
| Crash Test Information: | N/A for off-road motorcycles; focus is on rider safety through proper maintenance and component function. |
| Active Features | |
| Braking System: | Detailed coverage of hydraulic brake systems (front and rear), including caliper service, piston replacement, brake pad installation, and bleeding procedures. |
| Passive Features | |
| Frame Suspension: | Information on frame integrity checks, suspension fork and shock absorber servicing, including oil changes, seal replacement, and adjustment procedures. |
| Technology Features | |
| Infotainment | |
| Electronics Overview: | Basic electronic systems, including ignition, lighting, and instrumentation. Advanced infotainment systems are not present on these models. |
| Driver Assistance | |
| Rider Aids: | N/A. These are performance-focused off-road machines with minimal electronic rider aids beyond ignition and lighting controls. |
| Connectivity | |
| Features: | N/A. |
| Maintenance | |
| Service Intervals | |
| Periodic Maintenance: | The manual includes a detailed periodic maintenance schedule, outlining recommended checks and services at specific mileage or operating hour intervals (e.g., oil changes, filter replacements, valve adjustments, chain lubrication). |
| Fluid Specifications | |
| Engine Oil: | Specific engine oil viscosity grades (e.g., SAE 10W-40, SAE 15W-50) and API service classifications are detailed within the manual. Common recommendations include JASO MA certified motorcycle oils. |
| Coolant: | Specifications for coolant type and mixture (e.g., ethylene glycol-based antifreeze) and fill capacities. |
| Brake Fluid: | DOT 4 brake fluid is commonly specified for KTM hydraulic brake systems. |
| Transmission Oil: | Specifications for transmission and clutch lubrication, often separate from engine oil in KTMs of this era. Specific oil grades are detailed. |
| Fork Oil: | Specific weights and volumes for front suspension fork oil. |
| Shock Oil: | Specifications for rear shock absorber oil, if applicable and serviceable by the user. |
| Known Issues | |
| Common Wear Items: | The manual would implicitly cover the diagnosis and replacement of common wear items such as brake pads, clutch plates, sprockets, chains, wheel bearings, fork seals, and piston rings. |
| Vehicle History | |
| Brand Heritage | |
| Brand Focus: | KTM is renowned for its 'Ready to Race' philosophy, specializing in off-road and performance-oriented motorcycles, with a strong heritage in motocross, enduro, and Dakar Rally. |
| Model Evolution | |
| Generation Overview: | The 2000-2007 period saw significant development in KTM's off-road lineup, with refinements in engine technology, chassis design, and suspension components across their various competitive models. |
| Engine Updates: | Period saw evolution from LC4 single-cylinder dominance to specific performance-oriented engines for different disciplines. |
| Production | |
| Manufacturing Location: | Primarily Austria (Mattighofen). |
Delivery & file format
Delivery & file format
This is a digital PDF download, not a printed book. After payment the download link appears on your order confirmation page and is emailed to the address you entered. Files open in any PDF reader on phone, tablet or computer and can be printed.
Check the model year and engine before you buy
Check the model year and engine before you buy
Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.
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2000-2007 Ktm 250 Exc Racing 400/450 Sx mxc xc xc-w exc smr sxs Racing 520/525 Sx mxc xc xc-w exc smr Racing 540 Sxs 560 Smr 610 Crate Workshop Repair Service Manual
Ktm / Motorcycle · PDF · Instant download
$16.99
- Instant download Link on the order page and in your inbox within a minute.
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