2000-2006 KTM 250 400 450 520 525 540 560 610 SX MXC EXC SXS SMR Service Repair Manual 00 01 02 03 04 05 06

Art.NR.: 3.206.033-E REPAIRMANUAL2000-2006 250 EXC RACING 400/450 SX,MXC,XC,EXC,SMR,SXS RACING 520/525 SX,MXC,XC,EXC,SMR RACING 540 SXS, 560 SMR, 610 CRATE REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE RÉPARATION MANUAL DE REPARACIÓN

REPAIRMANUAL2000-2006 250 EXC RACING 400/450 SX,MXC,XC,EXC,SMR,SXS RACING 520/525 SX,MXC,XC,EXC,SMR RACING 540 SXS, 560 SMR, 610 CRATE KTM Group Partner

1 SERVICE-INFORMATIONS 2 GENERAL INFORMATION 3 REMOVING AND REFITTING THE ENGINE 4 DISASSEMBLING THE ENGINE 5 SERVICING INDIVIDUAL COMPONENTS 6 ASSEMBLING THE ENGINE 7 ELECTRICAL 8 FUEL SYSTEM 9 TROUBLE SHOOTING 10 TECHNICAL SPECIFICATIONS 11 PERIODIC MAINTENANCE SCHEDULE 12 WIRING DIAGRAMS 13 14 15 16

Repair manual KTM 250-610 Racing Art.-Nr. 3.206.033-E IMPORTANT INFORMATION/UPDATING INSTRUCTIONS To be able to continue using the existing loose-leaf repair instructions, simply print the following pages and insert them in the existing repair instructions: 1,3,7,9,13,15,19,20,22-25,29-33,35,38-46,48,49,50,56,57,61,62,64,66,67,72-74,81, 84-90,92-95,107,129-133,135,143,146,151,152,158,160-169,171,189-193,210-222 Remove page (s) Replace by page (s) Insert page (s) after page 2-1 2-1 2-4 to 2-5 2-4 to 2-5 2-7 to 2-9 2-7 to 2-10 3-2 to 3-6 3-2 to 3-6 4-1 4-1 4-3 to 4-11 4-3 to 4-11 4-13 4-13 5-1 5-1 5-7 to 5-8 5-7 to 5-8 5-12 to 5-13 5-12 to 5-13 5-15 5-15 5-17 to 5-18 5-17 to 5-18 5-23 to 5-25 5-23 to 5-25 6-4 6-4 6-7 to 6-13 6-7 to 6-13 6-15 to 6-17 6-15 to 6-17 7-1 7-1 8-1 8-1 9-1 to 9-3 9-1 to 9-3 10-1 to 10-2 10-1 to 10-2 10-9 10-9 10-12 10-12 10-17 to 10-18 10-17 to 10-18 10-24 10-24 10-26 to 10-29 10-26 to 10-35 11-1 11-1 11-19 to 11-22 11-18 12-1 12-1 12-17 to 12-20 12-17 to 12-29 KTM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER – Put the index into the binder. – Put the front page of the repair manual (210x297 mm) into the transparent pocket provided for this purpose on the outside of the binder. – Put the spine label (170x45 mm) into the transparent pocket provided for this purpose on the spine of the binder. – Put the summary list of contents (150x297 mm) into the transparent pocket provided for this purpose on the inside of the binder or insert this page at the beginning of the manual. – Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in the right bottom corner of each page. Example: page no. 3-5 3 = chapter 3 5 = page 5 For example: All pages with a page number that begins with the digit 3, must be put under the index heading “Chapter 3“. – Index sheets that have not been marked with a certain chapter are for your personal convenience. The respective headings can be entered in the list of contents.

Repair manual KTM 250-610 Racing Art.-Nr. 3.206.033-E E XPLANATION - U PDATING Edition 02/2006 3.205.85-E Repair Manual 400/520 SX,MXC,EXC RACING 2/2000 Basic version Model year 2000 (Engine number with first digit "0") 3.210.01-E Update of Rep.Manual 3.205.85-E 1/2001 Model year 2001 (Engine number with first digit "1") 3.210.44-E Update of Rep.Manual 3.205.85-E 2/2002 Model year 2002 (Engine number with first digit "2") 3.206.007-E Update of Rep.Manual 3.205.85-E 1/2003 Model year 2003 (Engine number with first digit "3") 3.206.013-E Update of Rep.Manual 3.205.85-E 9/2003 Model year 2004 (Engine number with first digit "4") 3.206.023-E Update of Rep.Manual 3.205.85-E 7/2004 Model year 2005 (Engine number with first digit "5") 3.206.033-E Update of Rep.Manual 3.205.85-E 2/2006 Model year 2006 (Engine number with first digit "6") Modification / Updating: Technical Details Model 2006, Changing the brake fluid, Technical Specifications, tightening torques, Periodic Maintenance Schedule

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2000-2006 KTM 250 400 450 520 525 540 560 610 SX MXC EXC SXS SMR Service Repair Manual 00 01 02 03 04 05 06

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