2000-2006 KTM 250-610 Enduro Service Manual | Complete Off-Road Repair Guide

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Professional Off-Road Documentation

This official factory manual provides the exact same technical specifications and repair procedures used by KTM technicians. Essential for maintaining these championship-winning enduro bikes with the revolutionary RFS (Racing Four Stroke) engine platform.

Important Notice for Off-Road Riders

This manual contains critical safety information for working on high-performance dirt bikes. Certain procedures should only be performed by authorized KTM technicians.

Complete Coverage Includes:

RFS Engine Rebuild: Detailed procedures for the 250-610cc engines including:

Valve adjustment (shim-under-bucket)
Crankcase splitting and reassembly
Counterbalancer service

WP Suspension Setup: Complete service for:

USD fork rebuild
PDS shock maintenance
Spring rate selection guide

Pro Tip: The manual includes the factory-recommended suspension settings for different terrain types and rider weights.

Off-Road Specifics: Special procedures for:

Air filter maintenance in dusty conditions
Skid plate installation
Handguard mounting

Models Covered:

250 EXC

400/450 SX/MXC/EXC

520/525 SX/MXC/EXC

540 SXS

560 SMR

610 Crate

All 2000-2006 models with RFS (Racing Four Stroke) engines.

Key Technical Specifications

Engine: 249-610cc liquid-cooled 4-stroke single
Power: 30-55 HP (varies by model)
Transmission: 5/6-speed wide-ratio
Suspension: WP 48mm USD forks / WP PDS shock
Weight: 240-260 lbs (dry, varies by model)

Special Tool Requirements:

The manual includes KTM's recommended tools for proper servicing:

Valve shim kit
Case splitting tools
Fork seal driver set
Engine balancing tool

Frequently Asked Questions

Q: Does this cover both EXC and SX models?

A: Yes, includes all variants with differences clearly noted.

Q: Are the valve specs different for high-compression models?

A: The manual provides specifications for all factory configurations.

Q: Does it include jetting recommendations for altitude?

A: Yes, complete with the factory carburetor settings chart.

Professional Off-Road Repair Knowledge

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