🏷️ Basic Information Identification Make: KTM Model: SX, MXC, EXC Year: 2002 Engine Variants Covered: 250cc, 400cc, 450cc, 520cc, 525cc Product Type: Repair Service Manual 👋 Introduction Market Position Target Audience: Owners of KTM 250, 400, 450, 520, 525 SX, MXC, EXC models from 2002, DIY enthusiasts, professional motorcycle technicians Competitive Analysis Manual Comparison: Equivalent to factory service manuals in content and detail; offers advantages of instant accessibility and searchability over traditional paper manuals Key Features Instructional Method: Step-by-step guidance, designed to teach factory-level maintenance and repair procedures Content Value: Empowers owners to make informed decisions regarding vehicle maintenance and repair, fostering self-sufficiency Accessibility: Instant download provides immediate access to critical repair information 📋 Manual Details Coverage Areas Primary Coverage: Maintenance, Repair, Troubleshooting, Overhaul of KTM 250, 400, 450, 520, 525 SX, MXC, EXC motorcycles Secondary Coverage: Electrical Systems, Chassis, Suspension, Drivetrain, Engine Components Page Count Estimated Page Count: Comprehensive (exact count not specified but implied to be extensive) Manual Type Manual Type: Service Manual, Repair Manual, Workshop Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, top-end repair, bottom-end assembly, lubrication, cooling system, fuel system (carburetion), ignition system Drivetrain Systems: Clutch operation and service, transmission disassembly and reassembly, final drive (chain and sprockets) Chassis Suspension: Front fork service (dampers, seals, oil), rear shock absorber overhaul, steering head bearings, swingarm bearings Electrical Systems: Wiring diagrams, component testing (stator, CDI, lights), battery service, starter system Braking Systems: Hydraulic brake system service (master cylinders, calipers, fluid), brake pad replacement, rotor inspection Bodywork Frame: Body panel removal and installation, frame inspection, seat, fuel tank, and handlebar service Procedures Included Maintenance Procedures: Oil and filter changes, air filter cleaning/replacement, spark plug service, chain adjustment and lubrication, brake fluid flush Repair Procedures: Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly Troubleshooting Guidance: Diagnostic charts and procedures for common performance issues, starting problems, and system malfunctions Technical Specifications: Torque values, clearances, fluid capacities, electrical specifications, engine component measurements Technical Depth Depth Of Coverage: Comprehensive, suitable for both DIY mechanics with basic knowledge and professional technicians 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Full Printable Zoom Functionality Zoom In Out: YES Compatibility Operating Systems: All Versions of Windows & Mac Software Requirements Required Software: Adobe PDF Reader & WinZip Delivery Method Delivery: Instant Download Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke (typically LC4 engine family) Engine Displacement 250Cc Variant: Approx. 250cc (specific designation may vary, often derived from a larger platform) 400Cc Variant: Approx. 400cc 450Cc Variant: Approx. 450cc 520Cc Variant: Approx. 520cc 525Cc Variant: Approx. 525cc Performance Horsepower Range: Varies by displacement, generally in the 40-60 HP range depending on model and tune Torque Range: Varies by displacement, providing strong low-end and mid-range power characteristic of KTM off-road bikes Fuel System Fuel Delivery: Carburetor (e.g., Keihin, Mikuni specific to model and year) Ignition System Ignition Type: Digital CDI (Capacitor Discharge Ignition) Cooling System Cooling Method: Liquid-cooled (radiator and fan) 🔧 Transmission Standard Transmission Type: Manual, Constant Mesh Number Of Gears: Typically 6-speed Features Clutch Type: Hydraulic, Wet Multi-plate Clutch Fluid Requirements Transmission Oil Type: Refer to manual for specific viscosity (e.g., SAE 10W/40 or 15W/50, typically motorcycle-specific 4-stroke engine oil) Transmission Oil Capacity: Refer to manual for specific fill quantity 📐 Dimensions Exterior Vehicle Types: Motocross (SX), Enduro Cross-Country (MXC), Dual-Sport/Enduro (EXC) Weights Dry Weight: Varies significantly by model and displacement, generally lightweight for off-road performance (typically 240-280 lbs) Wet Weight: Refer to individual model specifications in the manual 🛡️ Safety Features Ratings Safety Standards: Off-road competition and recreational use focused; no formal road vehicle crash ratings apply Active Features Braking System: Hydraulic disc brakes (front and rear) for effective stopping power Passive Features Frame Construction: Strong chromoly steel frame for durability and rider feedback 💡 Technology Features Infotainment Infotainment System: N/A (Minimal electronics, focus on performance and off-road capability) Driver Assistance Assistance Features: N/A Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual; typically every 15-30 hours of riding or annually, depending on usage severity Air Filter Cleaning: Frequent cleaning recommended, especially in dusty conditions (e.g., every 5-10 hours) Spark Plug Service: Refer to manual; typically inspected at oil changes and replaced as needed Valve Adjustment: Refer to manual; typically every 30-60 hours or annually Fluid Specifications Engine Oil Spec: Refer to manual for specific SAE viscosity (e.g., Motorex or equivalent high-quality motorcycle 4-stroke oil) Coolant Spec: Ethylene glycol-based coolant (e.g., Motorex Coolant M3.0 or equivalent) Brake Fluid Spec: DOT 4 hydraulic brake fluid Known Issues Common Wear Items: Clutch plates, wheel bearings, steering head bearings, fork seals, piston and rings (due to high-performance nature) Maintenance Importance: Regular and thorough...