🏷️ Basic Information Identification Make: KTM Model: 250 SX, 400 SX, 450 SX, 525 SX, 250 EXC, 400 EXC, 450 EXC, 525 EXC Codes Model Code Range: SX series (Motocross), EXC series (Enduro) 👋 Introduction Market Position Target Audience: Owners, mechanics, and enthusiasts of KTM SX and EXC models from 2000-2007 for maintenance, repair, and restoration. Competitive Analysis Value Proposition: Provides essential technical data and repair procedures necessary for maintaining and servicing these high-performance off-road motorcycles, saving significant costs compared to professional dealer service. Key Features Content Focus: Detailed step-by-step instructions, exploded views, diagrams, torque values, and diagnostic charts. 📋 Manual Details Coverage Areas Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Page Count Estimated Page Count: Comprehensive (typical workshop manual for this era and range of models is 400-600+ pages, actual may vary based on specific printing/digitalization). Manual Type Manual Type: Complete Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly, assembly, overhaul, top end (cylinder, piston, valves), bottom end (crankshaft, connecting rod, bearings), cooling system (radiator, fan, coolant), lubrication system (oil pump, oil filter, oil passages). Transmission Drivetrain: Gearbox inspection, disassembly, assembly, shift mechanism, clutch (hydraulic or cable), primary drive, chain drive, sprockets. Fuel System: Carburetor (jetting, float bowl, needle, idle speed), fuel pump (if applicable for later models or specific variants), fuel tank, fuel lines, filters. Ignition Electrical: Ignition system (CDI, stator, coil), lighting system (if applicable to EXC models), battery, wiring diagrams, starter motor, troubleshooting electrical faults. Suspension Chassis: Front suspension (forks - disassembly, seals, oil level, valving, spring replacement), rear suspension (shock absorber - rebuild, damping adjustments, linkage system), swingarm, bearings. Brakes: Front and rear brake systems (calipers, master cylinders, brake lines, pads, rotors), bleeding procedure, hydraulic system troubleshooting. Wheels Tires: Wheel bearing inspection and replacement, spoke tension, tire mounting, rim maintenance. Bodywork Frame: Frame inspection, seat, fuel tank removal/installation, plastics, handlebars, controls. Procedures Included Maintenance Tasks: Routine maintenance checks, oil changes, filter replacements, spark plug service, chain adjustment, air filter cleaning/replacement, valve clearance checks. Troubleshooting: Diagnostic procedures for common problems, symptom-based troubleshooting guides, electrical fault finding. Repair Procedures: Detailed step-by-step instructions for component disassembly, repair, and reassembly for all major systems. Technical Data Specs: Torque specifications for all fasteners, fluid capacities, engine timing, electrical resistance values, dimensional data. Technical Depth Depth Of Coverage: Comprehensive rebuilds, advanced diagnostics, detailed component overhauls, troubleshooting of complex issues. 📊 Manual Specifications File Format File Format: PDF Print Quality Resolution: High-resolution scans (typically 300 dpi or higher for clarity). Searchability: Likely text-searchable PDF if OCR was performed, otherwise image-based. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder (LC4 engine family for most, though specific iterations vary) Displacement Options: Approximately 250cc, 400cc, 450cc, 525cc (exact CC may vary slightly by year and specific sub-model). Cooling System: Liquid-cooled Performance Horsepower Range: Varies by displacement; e.g., 250s typically 30-40 HP, 525s 45-55+ HP (peak figures). Torque Range: Varies by displacement; e.g., 250s 20-25 lb-ft, 525s 35-45+ lb-ft. Fuel System Fuel Delivery: Carbureted (e.g., Keihin, Mikuni models depending on year/variant) Recommended Fuel: Unleaded gasoline, octane rating as specified by KTM (typically 91 RON or higher). 🔧 Transmission Standard Transmission Type: 6-speed manual gearbox Features Clutch Type: Hydraulic actuated wet multi-plate clutch Final Drive: Chain drive 📐 Dimensions Exterior Wheelbase: Varies by model, typically around 1470-1500 mm (57.9-59.1 inches). Weights Dry Weight: Varies by model and year, generally between 105-120 kg (231-265 lbs). 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Off-road motorcycles are not subject to standard automotive crash testing. Active Features Braking System: Hydraulic disc brakes front and rear. Passive Features Frame Construction: Chromium-molybdenum steel trellis frame. 💡 Technology Features Infotainment Features: Basic motorcycle instrumentation (speedometer, tachometer, odometer, hour meter). No advanced infotainment systems. Driver Assistance Features: None (Focus is on pure off-road performance). Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10-15 hours of riding or annually, depending on usage severity and model year recommendations. Air Filter Cleaning: Every 5-10 hours of riding or after dusty conditions. Valve Clearance Check: Typically every 20-30 hours of riding for competition use, or as specified in the manual. Fluid Specifications Engine Oil Type: KTM recommends specific motorcycle oils (e.g., Motorex Power Synt SAE 10W/40 or equivalent JASO MA certified synthetic oil). Engine Oil Capacity: Varies by model, typically around 1.0-1.3 liters. Fork Oil Type: KTM recommends specific suspension fluids (e.g., WP Suspension Fluid or SAE 5W/7.5W fork oil). Fork Oil Level: Specific to each fork model, e.g., 100-120 mm from the top of the stanchion with the spring removed and fork compressed. Coolant Type: Ethylene glycol based antifreeze/coolant mixture (50/50). Known Issues Common Wear Items: Clutch wear, piston and ring wear, valve...