2000-2006 KTM 250, 400, 450, 520, 525, 540, 560, 610, EXC, MXC, SMR, SX, SXS, Racing crate repair manual

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Service and maintain your 4-stroke motorcycle with ease by purchasing an instant PDF copy of the KTM factory service manual.

More information: Get/buy your 2000-2006 KTM 250, 400, 450, 520, 525, 540, 560, 610, EXC, MXC, SMR, SX, SXS, Racing crate repair manual here for instant download

Table of Contents:

• Introduction
• Maintenance
• Engine
• Fuel System
• Cooling System
• Clutch
• Transmission
• Suspension
• Brakes
• Wiring Diagrams
• And more

Please note that the following table of contents is a partial overview and does not cover all the sections and topics included in the manual. It provides a glimpse of the manual's content.

This comprehensive manual/handbook is a valuable resource for mechanics, technicians, and owners as it provides detailed information and instructions on repairing and maintaining the 2000-2006 KTM 250, 400, 450, 520, 525, 540, 560, 610, EXC, MXC, SMR, SX, SXS, Racing crate models. From engine and fuel system to wiring diagrams and troubleshooting, this manual covers it all.

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• Simply click the download button to instantly get access to this manual.# Download the Complete 2000-2006 KTM 250, 400, 450, 520, 525, 540, 560, 610, EXC, MXC, SMR, SX, SXS, Racing Crate Manual/Parts Catalog in PDF Format Now!

If you own a KTM bike from the 2000-2006 model years, you need a comprehensive manual or parts catalog to maintain, repair, or customize your bike. This manual covers various KTM models, including the 250, 400, 450, 520, 525, 540, 560, 610, EXC, MXC, SMR, SX, SXS, and Racing Crate, and is available for instant download in PDF format. Here are some of the engine specs and technical specifications for this model:

• The KTM 250 EXC has a liquid-cooled single-cylinder engine with a displacement of 249 cc.
• The engine delivers 43 horsepower and 27 lb-ft of torque.
• The KTM 400 EXC has a liquid-cooled single-cylinder engine with a displacement of 398 cc.
• The engine delivers 43 horsepower and 30 lb-ft of torque.
• The KTM 450 EXC has a liquid-cooled single-cylinder engine with a displacement of 449 cc.
• The engine delivers 49 horsepower and 33 lb-ft of torque.
• The KTM 520 EXC has a liquid-cooled single-cylinder engine with a displacement of 510 cc.
• The engine delivers 55 horsepower and 35 lb-ft of torque.
• The KTM 525 EXC has a liquid-cooled single-cylinder engine with a displacement of 510 cc.
• The engine delivers 56 horsepower and 39 lb-ft of torque.
• The KTM 540 SXS has a liquid-cooled single-cylinder engine with a displacement of 540 cc.
• The engine delivers 65 horsepower and 39 lb-ft of torque.
• The KTM 560 SMR has a liquid-cooled single-cylinder engine with a displacement of 565 cc.
• The engine delivers 62 horsepower and 42 lb-ft of torque.
• The KTM 610 EXC has a liquid-cooled single-cylinder engine with a displacement of 590 cc.
• The engine delivers 53 horsepower and 40 lb-ft of torque.
• All KTM models feature a six-speed manual transmission.
• The KTM SX models have a single-cylinder engine with a displacement ranging from 249 cc to 540 cc.
• The SX models deliver up to 68 horsepower and 47 lb-ft of torque.
• The KTM SMR models have a single-cylinder engine with a displacement of 560 cc.
• The SMR models deliver up to 60 horsepower and 42 lb-ft of torque.
• The KTM Racing Crate has a single-cylinder engine with a displacement of 525 cc.
• The engine delivers 62 horsepower and 39 lb-ft of torque.
• All KTM models come with a liquid cooling system and electric start.
• The KTM EXC models have a fuel tank capacity of 2.5 gallons.
• The KTM MXC models have a fuel tank capacity of 2.64 gallons.
• The KTM SX models have a fuel tank capacity of 2.01 gallons.
• The KTM SMR models have a fuel tank capacity of 2.1 gallons.
• The KTM Racing Crate has a fuel tank capacity of 2.64 gallons.

Interesting Facts and Details:

• The KTM 525 EXC was named "2005 4-Stroke of the Year" by Dirt Rider Magazine.
• The KTM 450 MXC was named "2004 Bike of the Year" by Dirt Rider Magazine.
• The KTM 560 SMR is a supermoto bike designed for racing on pavement and dirt.
• The KTM Racing Crate is a complete engine package that includes the engine, exhaust system, carburetor, ignition system, and airbox.
• The KTM 250 EXC features a compact, lightweight design that makes it ideal for enduro racing and off-road riding.
• The KTM 520 EXC is a versatile bike that can handle everything from off-road riding to street riding.
• The KTM 450 SX is a motocross bike that is designed for high-speed racing and jumps.
• The KTM 610 EXC is a dual-sport bike that can be ridden on both the street and off-road terrain.
• The KTM 525 SX is a motocross bike that is designed for maximum power and agility.
• The KTM 540 SXS is a limited edition bike that features a high-performance engine and top-of-the-line components.

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