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
This comprehensive workshop manual details repair procedures for KTM 250-610 Racing models, covering engine disassembly and reassembly. PN 3.206.033-E. Essential for mechanics.
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Sample pages from the 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 manual
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Models Covered & Key Technical Specifications
KTM Engine Repair Manual
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
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Model Coverage | KTM Engine Series Folder
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Published Technical Data: 398 cc displaces the engine's standard displacement.
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Measured Output Performance: For optimal operation, 1.25 liters signifies the total engine oil quantity.
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Integral Mass Specs: The crankshaft bearings utilize 2 cylinder roller bearings for structural integrity.
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Operational Capacity Limits: The transmission system is equipped with 6-speed claw shifted gears for versatile power delivery.
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Fundamental Operating Temps: The cooling system operates with a liquid-cooled, permanent rotation of cooling liquid.
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Universal Heat Tolerance: The engine utilizes a multi-disc clutch in an oil bath for consistent performance.
Professional Workshop Service Manual & Technical Specifications
KTM Engine Repair Manual: 250-610 Racing Engine Repair Manual: KTM 250 EXC Racing, 400/450 SX, MXC, EXC, SMR, SXS Racing, 520/525 SX, MXC, EXC, SMR Racing, 540 SXS, 560 SMR, 610 CRATE. (2000-2006) Chassis-Documentation
Year-Coverage: 2000-2006 // Serial-Range: N/A / Engine // Year-Coverage: N/A
| Assessment-Parameter | Parameters | Context |
|---|---|---|
| Engine Type | 4-stroke | Internal combustion engine |
| Displacement | 250-610 cc | Varies by model variation |
| Cooling System | Liquid-cooled | Standard for this engine type |
| Primary Ratio | Spur wheels | Gear-driven mechanism |
| Transmission | 4, 5, or 6-speed | Depending on specific model variant |
| Ignition System | DC-CDI | Electronic ignition system |
Maintenance information covers engine disassembly, component servicing, and reassembly procedures. Key systems documented include the oil circuit, electrical system, and fuel system.
Engine Disassembly Procedures
This manual documents the complete process for disassembling the engine, including detailed steps for removing and refitting the engine, as well as disassembling individual components.
Component Servicing and Reassembly
Detailed instructions are provided for servicing individual engine components, followed by comprehensive steps for reassembling the engine as a whole unit.
Technical Specifications and Troubleshooting
The document includes extensive technical specifications and troubleshooting guides to assist with diagnostics and repairs. This manual documents torque specifications for engine components to ensure proper structural misalignment prevention.
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