This manual covers the SX-EXC Series motorcycles, including 2-stroke and 4-stroke variants from model years 2000 through 2007. These high-performance off-road motorcycles are renowned for their powerful engines, advanced chassis design, and exceptional handling capabilities, making them a dominant force in motocross and enduro racing. Available in displacements such as 250cc, 400cc, 450cc, and 525cc, the SX models are purpose-built for motocross competition, while the EXC variants are designed for the rigors of enduro riding. The reputation for engineering quality, reliability, and a strong racing pedigree are key differentiators for these machines. This comprehensive workshop service and repair manual provides essential technical knowledge for maintaining, diagnosing, and repairing your SX-EXC Series motorcycle. It details procedures for all major systems, including the engine, transmission, chassis, and electrical components, covering everything from routine maintenance and scheduled checks to complete component overhauls and rebuilds. With step-by-step instructions, torque specifications, and diagnostic guides, this manual is an indispensable resource for owners, mechanics, and technicians seeking to keep these high-performance off-road bikes in optimal condition. 🏷️ Basic Information Identification Make: KTM Model: SX-EXC Series (2-stroke and 4-stroke variants) Covered Years: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Engine Displacements Covered: 250cc, 400cc, 450cc, 525cc Model Variants Covered: SX (Motocross), EXC (Enduro) Codes Engine Codes: Varies by specific model and year (e.g., LC4 for larger displacements) 👋 Introduction Market Position Segment: High-performance off-road motorcycles (Motocross and Enduro) Target User: Enthusiast owners, amateur and professional racers, independent repair shops, KTM service centers. Competitive Analysis Competitors: Yamaha YZ/WR series, Honda CR/CRF series, Suzuki RM/DRZ series, Kawasaki KX/KLX series. Key Differentiators: KTM's reputation for powerful engines (especially the LC4 lineage), advanced chassis design, and racing pedigree. Key Features Manual Value: Provides the essential technical knowledge to maintain, diagnose, and repair these high-performance machines effectively, saving time and money on professional servicing. Vehicle Appeal: Known for their aggressive styling, potent engines, and exceptional handling capabilities in their respective classes. 📋 Manual Details Coverage Areas Primary Coverage: Complete Workshop Service and Repair Geographic Relevance: Global (with specific regional differences noted where applicable for parts/fluids) Page Count Estimated Page Count: High (Likely 500+ pages, comprehensive coverage) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital File (likely PDF) 📖 Manual Coverage Systems Covered Engine: Top-end (cylinder, piston, valves), bottom-end (crankshaft, connecting rod, bearings), lubrication system, cooling system (liquid-cooled variants), fuel system (carburetor/injection), ignition system, exhaust system Transmission: Clutch, gearbox (gear selection, ratios), final drive (chain and sprockets) Chassis: Frame inspection and repair, suspension (forks, rear shock absorber, linkage), steering system, wheels, hubs, spokes, braking system (hydraulic front and rear), controls (levers, cables) Electrical: Wiring diagrams, lighting system, ignition system, battery, charging system (alternator/stator), starter system (electric start variants), instrumentation, sensors Bodywork: Body panels, seat, fuel tank, fenders, graphics, ergonomics Procedures Included Maintenance: Scheduled maintenance checks, oil changes, filter replacements, chain adjustment, spark plug replacement, valve clearance adjustment (if applicable), brake pad replacement, fluid flushes Troubleshooting: Diagnostic procedures for common issues, fault finding, symptom-based troubleshooting guides Repair: Component disassembly, inspection, repair, and reassembly for all major systems. Engine rebuild procedures, transmission overhaul, suspension servicing, brake caliper rebuild. Installation: Instructions for installation of common aftermarket or OEM replacement parts. Technical Depth Depth: Comprehensive. Covers basic adjustments to full engine and transmission rebuilds. Includes torque specifications, clearances, and detailed step-by-step instructions with diagrams. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Resolution: High-resolution scans or original digital source, ensuring clarity of text and diagrams. Binding Type Physical Binding: N/A (Digital format) Paper Type Physical Paper: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Type: Four-stroke, single-cylinder, liquid-cooled (common for EXC variants and later SX models in this range); some early models or specific variants might be two-stroke. Bore X Stroke: Varies significantly by displacement (e.g., 450 SX-F would differ from 250 SX-F). Valve Train: DOHC, 4 valves (typical for 4-stroke models) Performance Horsepower: Generous power output for displacement, typically ranging from 45-60+ HP depending on model and tuning. Torque: Strong mid-range and top-end torque delivery, characteristic of KTM off-road engines. Fuel System Carburetor Spec: Keihin flat-slide carburetors (e.g., PWK series) common in early models; Mikuni also used. Fuel Injection Spec: Keihin or Delphi electronic fuel injection (EFI) introduced on some later models within this range. Cooling System Type: Pressurized liquid cooling system with electric fan on some models. 🔧 Transmission Standard Type: Constant mesh, sequential 5 or 6-speed gearbox. Optional Configurations: N/A (Standardized for model type) Features Clutch Type: Hydraulic multi-plate wet clutch. Final Drive: O-ring sealed chain drive. 📐 Dimensions Exterior Seat Height: High, typical for off-road competition bikes (e.g., 37-39 inches). Ground Clearance: Generous, designed for off-road obstacles. Weights Dry Weight: Generally lightweight, aiming for optimal power-to-weight ratio (e.g., 220-250 lbs). Fuel Tank Capacity: Typically around 2-3 gallons. 🛡️ Safety Features Ratings...