This manual covers the 2002 SX, MXC, and EXC models, equipped with 250cc, 400cc, 450cc, 520cc, and 525cc engine variants. An Austrian manufacturer renowned for its off-road racing prowess and "Ready to Race" philosophy, designed these motorcycles for demanding off-road disciplines. The 2002 models are part of the successful LC4 platform, celebrated for its robust torque and versatility. These bikes are characterized by their strong chromoly steel frames, hydraulic disc brakes, and typically 6-speed manual transmissions with wet multi-plate clutches. This comprehensive English-language service and repair manual provides detailed instructions for maintenance, repair, and troubleshooting of these motorcycles. It covers essential areas including engine overhaul, drivetrain, chassis, suspension, and electrical systems. The manual offers step-by-step guidance for procedures such as oil changes, brake servicing, and component assembly, alongside diagnostic charts for common issues and essential technical specifications like torque values and fluid capacities. It is designed to empower owners and technicians alike in maintaining the performance and longevity of their vehicles. 🏷️ 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...