🏷️ Basic Information Identification Make: KTM Model: SX, MXC, EXC, EGS, EXC Racing Model Variants: 250, 400, 450, 520, 525 Years Covered: 2000, 2001, 2002, 2003 Generation Generation Identifier: LC4 4-Stroke Era (Early) 👋 Introduction Market Position Target Audience: DIY enthusiasts, home mechanics, and professional technicians working on KTM off-road motorcycles. Competitive Analysis Value Proposition: Provides essential technical information and repair procedures for a range of popular KTM models, enabling cost-effective maintenance and repair. Key Features Manual Benefits: High-quality diagrams, comprehensive coverage, instant download for immediate access, cost savings on postage and packaging. Diagram Quality: Contains high-quality diagrams essential for understanding complex assemblies and procedures. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service and repair for 2000-2003 KTM 4-stroke off-road models. Page Count Estimated Page Count: Varies by specific model and engine size, but generally extensive for a workshop manual. Manual Type Manual Classification: Workshop Service Repair Manual Language Primary Language: English Text Searchability: PDF format typically allows for text searching of keywords. Format Digital Format: PDF File Format Compatibility: Compatible with all versions of Windows & Mac. 📖 Manual Coverage Systems Covered Engine Systems: Engine removal and refitting, disassembly, component servicing, assembly, troubleshooting. Electrical Systems: Wiring diagrams, troubleshooting electrical issues. Chassis Systems: Frame inspection, suspension (front forks, rear shock absorber) service and adjustment, wheel bearing maintenance. Fuel System Components: Carburetor removal, cleaning, adjustment, and troubleshooting. Cooling System: Radiator and hose inspection, coolant replacement, troubleshooting overheating. Procedures Included Maintenance Procedures: Periodic maintenance schedule, fluid changes, filter replacements, general servicing. Repair Procedures: Detailed step-by-step instructions for engine and component repair. Torque Specifications: Crucial torque values for critical fasteners throughout the engine and chassis are provided. Troubleshooting Flowcharts: Likely includes structured troubleshooting guides for common starting, running, and performance issues. Technical Depth Diagnostic Capabilities: Troubleshooting guides for common issues, technical specifications for accurate diagnosis. Rebuild Depth: Complete engine disassembly and reassembly procedures suitable for full rebuilds. 📊 Manual Specifications File Format File Type: PDF Software Requirement: Adobe PDF Reader. Print Quality Printability: All pages are printable. Binding Type Binding Method: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke, Liquid-Cooled Single Cylinder (LC4 engine family) Performance Displacement Range: 250cc, 400cc, 450cc, 520cc, 525cc Bore Stroke Variations: Specific bore and stroke dimensions vary significantly across the 250, 400, 450, 520, and 525cc displacements. Fuel System Fuel Delivery System: Primarily Carbureted (Mikuni or Keihin, specific model dependent), potential for early fuel injection on some late models/variants, though unlikely for this specific year range in this context. Engine Design Valve Train: SOHC or DOHC (depending on specific engine variant within the LC4 family, though SOHC is more prevalent for earlier models in this range). Cooling System: Liquid-cooled via radiator and fan (electric fan on some models/years). 🔧 Transmission Standard Transmission Type: 5-speed or 6-speed manual gearbox (specific to model and year). Optional Clutch Type: Wet, multi-plate clutch (hydraulic actuation common). Features Drive System: Chain drive (rear wheel). Gear Ratios: Gear ratios are specific to each model and engine size and would be detailed within the manual. 📐 Dimensions Exterior Chassis Type: Chromium-molybdenum steel trellis frame. Suspension Type Front: Upside-down (USD) telescopic forks (e.g., WP). Suspension Type Rear: Monoshock with linkage (e.g., WP). Weights Dry Weight Range: Approximately 105-120 kg (231-265 lbs), varies significantly by model and engine size. 🛡️ Safety Features Ratings Safety Standards: N/A (Off-road competition motorcycles, typically not subjected to DOT/NHTSA safety ratings). Active Features Braking System: Hydraulic disc brakes front and rear (Brembo calipers common). Passive Features Frame Integrity: Robust steel trellis frame designed for off-road stress. 💡 Technology Features Infotainment Display System: Basic LCD display showing trip meter, odometer, clock, and neutral indicator. No advanced infotainment. Driver Assistance ABS Availability: ABS was not a standard or commonly available option on these off-road competition models of this era. Connectivity Connectivity Features: N/A. Focus is on mechanical and electrical systems for performance. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10-15 hours of riding or annually, consult manual for specific model recommendations. Air Filter Cleaning: Frequent cleaning/replacement is critical for off-road performance, often every few rides. Fluid Specifications Engine Oil Grade: Recommended API SG or higher, SAE 10W/40 or 15W/50 motorcycle-specific oil (e.g., Motorex Power Synt). Coolant Type: Ethylene glycol-based antifreeze with corrosion inhibitors (e.g., Motorex Coolant M3.0). Transmission Oil Grade: Separate transmission oil, typically SAE 75W/80 or 85W gear oil, or motorcycle-specific 4-stroke gearbox oil. Known Issues Common Wear Items: Clutch plates, valve stem seals, cam chain tensioner, carburetor jets (depending on usage). Electrical Gremlins: Wire chafing in harness, faulty grounds, especially around the headlight/handlebar area. Carburetor Maintenance: Carburetors require regular cleaning and adjustment due to dirt ingress in off-road environments. 📚 Vehicle History Brand Heritage Brand Focus: KTM has a strong heritage in off-road racing (Motocross, Enduro, Rally) and is...