Description

This Haynes 4629 repair and service manual covers 2000-2007 KTM EXC Enduro, SX Motocross, SMR Supermoto motorcycles with SOHC 4-stroke engines, including the following models:

KTM 250EXC Racing (Europe) 2002-2006
KTM 400EXC Racing (Europe) 2000-2007
KTM 450EXC Racing (Europe) 2003-2007
KTM 520EXC Racing (Europe) 2000-2002
KTM 525EXC Racing (Europe) 2003-2007 (incl. MXC Desert)
KTM 250EXC RFS (US) 2004
KTM 400EXC-G Racing (US) 2000-2002, 2004-2007 (incl. MXC)
KTM 450EXC-G Racing (US) 2003-2007 (incl. MXC/XC)
KTM 520EXC-G Racing (US) 2000-2002
KTM 525EXC-G Racing (US) 2003-2006
KTM 400SX Racing (Motocross) 2000-2002
KTM 450SX Racing (Motocross) 2003-2006
KTM 520SX Racing (Motocross) 2000-2002
KTM 525SX Racing (Motocross) 2003-2006

Main features of the 450/540 SXS and Six Days models included

KTM 450SMR Supermoto 2004-2006
KTM 525SMR Supermoto 2004-2005
KTM 560SMR Supermoto 2006

Book Excerpt: 2000-2007 KTM EXC, SX, SMR Repair Manual ENGINE, CLUTCH AND TRANSMISSION

OIL PUMPS AND PRESSURE RELIEF VALVE Note: This procedure can be carried out with the engine in the frame. If the engine has been removed, ignore the steps which do not apply.
OIL PUMPS

Two oil pumps are fitted. One supplies oil to the engine (right-hand pump) and the other supplies oil to the transmission (left-hand pump). The pumps are driven by a common shaft, via the small pinion on the back of the clutch housing.

To gain access to the left-hand pump, first remove the alternator cover and displace the ignition pick-up coil (see Section 15).

To gain access to the right-hand pump, first remove the clutch (see Section 18).

Before removing the pumps, check the amount of axial freeplay (end-float) in the pump drive shaft as follows.

Working on the right-hand side of the engine, pry off the E-clip and remove the washer, then pull the oil pump gear off the drive shaft and pull the drive pin out of the shaft (see illustrations).

Grasp the end of the drive shaft and try to pull it in-and-out; there should be no discernable freeplay. If available, use a dial gauge to measure any axial play and compare the result with the specification at the beginning of this Chapter (see Tools and Workshop Tips in the Reference section). If play exceeds the specified limit, remove the pump and inspect the components for wear.

BRAKES | GENERAL INFORMATION

All models are fitted with wire-spoked wheels with alloy rims designed for tubed tires only. Brakes are of Brembo manufacture. The front brake is a twin piston, sliding caliper, hydraulically-operated disc brake. The rear brake is a single piston, sliding caliper, hydraulically-operated disc brake. Final drive is by chain and sprockets.

Subject: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 KTM EXC Enduro, SX Motocross, SMR Supermoto SOHC 4-Stroke service, maintenance, repair. ISBN-10: 0857339591 | ISBN-13: 9780857339591 | Haynes 4629

TABLE of CONTENTS: KTM MOTORCYCLE MAINTENANCE