2000-2006 KTM Engine Repair Manual: 250 EXC, 400/450 SX, MXC, EXC, SMR, SXS Racing, 520/525 SX, MXC, EXC, SMR Racing, 540 SXS, 560 SMR, 610 CRATE

Inside the 2000–2006 KTM Racing Engine Repair Manual

• Covers the 2000–2006 KTM 250 EXC, 400/450/520/525/540/560/610 Racing engines, including all sub-model variants and crate configurations
• Official OEM publication Art.-Nr. 3.206.033-E, Edition 02/2006
• Features 120 exploded-view component diagrams and 15 torque-specification tables for engine assembly
• Accessible from your device as soon as the order is placed
• Laid out for standard letter and A4 printing
• Full-text search finds any part number in seconds
• Permanent availability in your purchase account — no re-buy required
• OCR text layer lets you jump to a torque spec by keyword
• This 2006 final update consolidates all previous annual engine revisions, serving as the definitive technical reference for the 250–610 KTM engine series

Engine Documentation and Assembly

This KTM engine publication details procedures for disassembling and reassembling the complete 250–610 series racing powerplants. The documentation removing the engine from the frame, stripping the clutch and ignition systems, and internal component inspection. It provides clear guidance on assessing the wear of pistons, cylinder coatings, and transmission gears, alongside specialized instructions for managing the oil circuit and lubrication systems. The content focuses on verifying clearances and component tolerances, including crankshaft and rocker arm assembly requirements.

Technical Specifications and Maintenance Data

This KTM technical resource documents critical reference values for engine assembly and periodic service. Engine oil quantity is specified at 1.25 liters, with requirements for fully synthetic Motorex Power Synt 4T fluids. Tightening torque values are provided for every major casing bolt and internal fixture, such as the 150 Nm torque setting for primary gear nuts. Valve clearance for the 450/525 models is documented at 0.12 mm in the specification tables. Electrical data includes testing procedures for the CDI unit, stator, and starter relay, with resistance values listed for ignition coil primary and secondary circuits. Reference only — always consult a certified technician before performing service on this equipment. An official 222-page KTM OEM workshop manual covering the 2000–2006 250–610 Racing engines, documenting assembly, technical specifications, and maintenance procedures for the entire engine range.