1998-2003 KTM 625 SXC 660 SMC Service Repair Workshop Manual

This is the COMPLETE Service and Repair Manual for the 1998-2003 KTM 625 SXC 660 SMC Service Repair Workshop Manual. It covers every single detail.

1998-2003 KTM 625 SXC / 660 SMC Service Repair Workshop Manual PDF VEHICLE/EQUIPMENT INTRODUCTION: The KTM 625 SXC and 660 SMC represent the pinnacle of Austrian enduro and supermoto engineering from the late 1990s and early 2000s. Introduced during a transformative era for KTM, these large-displacement single-cylinder motorcycles combined competition-proven Rotax-derived engine architecture with advanced chassis technology. The 625 SXC was designed as a hard-charging enduro machine with long-travel suspension, while the 660 SMC transformed the same fundamental platform into an aggressive supermoto with sticky road tires and powerful brakes. Both models featured KTM signature orange-framed trellis chassis with chromoly tubing, WP upside-down front forks, and a proven wet multiplate clutch system. These motorcycles became favorites among serious off-road enthusiasts and supermoto racers alike. SERVICE & REPAIR SCOPE: - Complete engine disassembly and rebuild procedures - Cylinder head valve service and camshaft inspection - Piston, cylinder and conrod bearing replacement - Clutch assembly overhaul and adjustment - Carburetor Keihin PWK jetting and tuning procedures - Fuel tap and fuel system maintenance - Cooling system flush, water pump inspection and thermostat testing - Transmission gear inspection, shift drum and fork replacement - Primary drive and starter clutch service - Frame inspection and swingarm bearing replacement - WP suspension overhaul, oil change and linkage service - Steering head bearing adjustment and replacement - Brake caliper rebuild, disc inspection and master cylinder service - Electrical system troubleshooting, CDI and ignition coil testing - Stator, regulator-rectifier and wiring harness inspection - Wheel bearing replacement and spoke tension adjustment - Exhaust system inspection and replacement - Complete torque specifications and maintenance schedules TECHNICAL SPECIFICATIONS: - Engine: Liquid-cooled, single-cylinder, 4-stroke, SOHC - Displacement: 625 cc (625 SXC) / 660 cc (660 SMC) - Bore x Stroke: approximately 100 x 80 mm - Compression ratio: varies by model year 9.5:1 to 11.3:1 - Induction: Keihin PWK carburetor 41mm - Transmission: 5-speed or 6-speed constant mesh - Clutch: Wet multiplate, hydraulically actuated - Frame: Chrome-molybdenum steel trellis frame - Front Suspension: WP USD forks, 48mm - Rear Suspension: WP monoshock with linkage - Brakes: Front 300mm+ disc, Rear single disc - Dry Weight: approximately 125-135 kg depending on model DIAGNOSTIC INFORMATION: - Hard starting or no start diagnostics covering compression, spark and fuel delivery - Valve clearance symptoms and adjustment intervals - Overheating causes and cooling system pressure testing - Clutch slipping diagnosis and plate wear inspection - Gear jumping out of selected ratio and shift drum inspection - Excessive chain/sprocket wear and final drive troubleshooting - Abnormal engine noise top-end and bottom-end diagnosis - WP suspension bott

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