Provides service, repair and maintenance information for 2000-2006 KTM 250-610 Racing 4 Stroke models. This book covers chassis repair and maintenance. It should be purchased with the repair manual.

This owners manual contains the following information:

IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION

SERIAL NUMBER LOCATIONS - Chassis number , Engine number, engine type

OPERATION INSTRUMENTS - Clutch lever, Hot start lever (250 SX-F), Hand decompression lever (450/525 SX) , Hand brake lever, Short circuit button (SX/XC), Combination switch (EXC), Flasher switch, Starter button (EXC) , Emergency OFF switch (EXC Australia), Indicator lamps, Electronic speedometer, Setting the clock, Filler cap, Fuel tap, Choke , Hot start device (450/525 SX), Shift lever , Kickstarter, Foot brake pedal, Side stand , Steering lock , Compression damping of fork, Rebound damping of fork, Damping action during compression of shock absorber (SX) Compression damping of shock absorber (XC, EXC)Rebound damping of shock absorber (SX, XC, EXC)

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE -  Instructions for initial operation, Running in the Racing models

DRIVING INSTRUCTIONS - Check the following before each start, Starting when the engine is cold, Starting when the engine is warm, What to do when the engine is flooded", Starting off, Shifting/Riding, Braking , Stopping and parking, Fuel

PERIODIC MAINTENANCE, MAINTENANCE WORK ON CHASSIS AND ENGINE - Changing the spring preloading of the shock absorber, Pivot bearing , Basic suspension setup for the weight of the driver, Checking the shock absorber and spring, Determining the static sag of the shock absorber, Determining the riding sag of the shock absorber, Checking the basic setup of the telescopic fork, Changing the spring preload on the telescopic fork, (SX models), Changing the spring preload on the telescopic fork (XC/EXC models), Replacing fork springs, Breather plug front fork, Cleaning the dust sleeves of the telescopic fork Checking and adjusting the steering head bearing, Changing the fork offset (caster) (SX) , Checking and adjusting the steering head bearing, Check chain tension , Correct chain tension, Chain maintenance, Chain wear, General information about KTM disc brakes, Adjusting the free travel at the hand brake lever, Checking the brake fluid level - front brake, Refilling the front brake fluid reservoir , Checking the front brake pads , Replacing the front brake pads, Changing the basic position of the foot brake pedal , Checking the rear brake fluid level , Refilling the rear brake fluid reservoir, Checking the rear brake pads, Replacing the rear brake pads , Dismounting and mounting the front wheel, Dismounting and mounting the rear wheel, Checking spoke tension, Tires, air pressure, Check/set distance of the magnetic sensor, Replacing the battery of the digital speedometer , Battery (XC/EXC), Charging the battery , Fuse (XC/EXC), Replacing headlight lamp/parking light lamp, Cooling system , Checking the coolant level, Bleeding the cooling system, Replacing the glass fiber yarn packing of the silencer, Cleaning the spark arrester (XC/EXC USA), Cleaning the air filter, Checking the adjustment of the hand decompression release cable , Adjusting the throttle cables, Changing the original position of the clutch lever Checking the oil level of the hydraulic clutch, Bleeding of the hydraulic clutch, Carburetor - Adjust idling (Keihin-FCRMX 37/39/41), Adjusting the mixture control screw , Checking the float level (float height)Draining the float chamber of the carburetor, Oil circuit, Checking the engine oil, Engine oil, Changing the engine oil, Changing the oil filters

TROUBLESHOOTING

STORAGE, CONSERVATION FOR WINTER OPERATION, USE AFTER A PERIOD OF STORAGE, CLEANING

TECHNICAL DATA - ENGINE, TECHNICAL DATA-CHASSIS, HEAD WORK

INDEX

WIRING DIAGRAM