This manual covers the SX, MXC, and EXC models from 2001, available with 250cc, 400cc, 450cc, 520cc, and 525cc engine variants. These models embody that heritage, offering robust performance and specialized capabilities for competitive racing and demanding off-road riding. Engineered in Austria, these high-performance machines are built for challenging terrains and are a testament to dedication to excellence in the off-road motorcycle segment. This comprehensive repair service manual provides detailed guidance for professional technicians and DIY mechanics. It covers all essential aspects of maintenance, repair, and troubleshooting for the specified models. Within its pages, you will find in-depth procedures for engine mechanicals, fuel and ignition systems, cooling, exhaust, transmission, drivetrain, suspension, brakes, wheels, tires, electrical systems, and frame/bodywork. The manual includes step-by-step instructions for disassembly, assembly, repairs, and routine maintenance, along with critical technical specifications, torque values, and fluid recommendations, empowering users to keep their motorcycles in optimal condition. 🏷️ Basic Information Identification Make: KTM Model: SX, MXC, EXC Year: 2001 Engine Variants Covered: 250cc, 400cc, 450cc, 520cc, 525cc Codes Product Name: KTM 250 400 450 520 525 SX MXC EXC 2001 Repair Service Manual 👋 Introduction Market Position Category: High-Performance Off-Road Motorcycles Positioning: Competitive racing and performance-oriented off-road riding Competitive Analysis Competitors: Yamaha YZ/WR series, Honda CR/XR series, Suzuki RM/DR series, Kawasaki KX/KLX series Key Features Manual Value Proposition: Empowers owners to perform complex maintenance and repairs, saving on professional service costs and downtime. Vehicle Strengths Implied: Robust performance, specialized off-road capabilities across various engine displacements. 📋 Manual Details Coverage Areas Primary Focus: Repair and Maintenance Target Audience: Professional Technicians and DIY Mechanics Page Count Estimated Page Count: Comprehensive (exact count not specified, but implied to be extensive) Manual Type Type: Repair Service Manual, Factory Service Manual, Workshop Manual Language Language: English Format File Format: PDF Delivery Method: Instant Download Compatibility: All Versions of Windows & Mac Requirements Software Requirements: Adobe PDF Reader & WinZip 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, top-end, bottom-end, piston, rings, valves, crankshaft, camshaft, timing Fuel System: Carburetor service (cleaning, adjustment, jetting), fuel pump, fuel lines Ignition System: Spark plugs, ignition coils, CDI unit, timing Cooling System: Radiator, coolant, thermostat, water pump Exhaust System: Exhaust pipe, muffler, heat shields Transmission: Clutch (operation, adjustment, replacement), gearbox, shift mechanism Drivetrain: Chain, sprockets, wheel hub maintenance Suspension Front: Fork (disassembly, oil change, seal replacement, damping adjustments), steering head bearings Suspension Rear: Shock absorber (rebuild, adjustments), linkage system, swingarm bearings Brakes Front: Brake caliper service, master cylinder, brake lines, rotor, pads Brakes Rear: Brake caliper service, master cylinder, brake lines, rotor, pads Wheels Tires: Spoke tensioning, wheel bearing maintenance, tire changes Electrical System: Wiring diagrams, battery, lighting, charging system, troubleshooting electrical faults Frame Bodywork: Chassis inspection, subframe, plastic panels, seat, tank removal and installation Procedures Included Maintenance: Regular service checks, oil changes, filter replacements, lubrication points Disassembly: Step-by-step instructions for removing components Assembly: Step-by-step instructions for reinstalling components Repair: Detailed repair procedures for all major systems Troubleshooting: Diagnostic procedures for common problems and fault finding Cleaning: Proper cleaning methods for various parts Specifications: Torque values, clearances, fluid capacities, electrical values Technical Depth Depth: Comprehensive, covering full rebuilds and advanced diagnostics 📊 Manual Specifications File Format File Format Details: PDF with searchable text and zoom functionality Print Quality Printability: Full Printable Binding Type Binding Type: Digital (N/A for paper binding) Paper Type Paper Type: Digital (N/A for paper type) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke Bore Stroke Ranges: Varies by displacement (e.g., 250cc, 400cc, 450cc, 520cc, 525cc) Performance Horsepower Torque: Specific figures vary by model and displacement; detailed in manual. Fuel System Carburetion: Mikuni Carburetors (common for this era, specific model to be detailed in manual) Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) 🔧 Transmission Standard Transmission Type: 5-speed or 6-speed Manual (specific to model variant) Features Clutch Type: Hydraulically operated multi-plate wet clutch 📐 Dimensions Exterior Wheelbase: Varies by model variant (specific figures in manual) Weights Dry Weight: Varies significantly by model and displacement (e.g., ~230-260 lbs, exact figures in manual) 🛡️ Safety Features Ratings Safety Features: Standard off-road safety features (e.g., robust frame, effective braking systems). No crash ratings applicable to off-road motorcycles in the same way as cars. Active Features Braking System: Hydraulic disc brakes front and rear 💡 Technology Features Infotainment Infotainment Features: Not applicable to these models; focus is on performance and off-road functionality. Driver Assistance Assistance Features: Not applicable; these are pure off-road machines. Connectivity Connectivity Features: Not applicable. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10-20 hours of riding or annually. Specifics in manual. Air Filter Cleaning: Frequent cleaning recommended, especially in dusty conditions. Specific interval in manual. Valve Check Interval: Typically every 20-40 hours of riding. Specific interval in manual. Fluid Specifications Engine Oil: Specific viscosity grade (e.g., SAE 10W-40 or 20W-50) and API...